DIESEL GENERATOR SETS
PART I -GENERAL
1.01 RELATED DOCUMENTS:
A. Drawings and general provisions of Contract, including General and
Supplementary Conditions and Division-1 Specification sections, apply to
work of this section.
B. Division-16 "Basic Electrical Materials and Methods" and other sections
apply to work specified in this section.
C. Division-16 "Transfer Switches", "Wires and Cables", "Circuit Breakers" and
Earthing" sections are related to work of this section.
D. Division-15 "fuel tanks".
1.02 SUMMARY:
:
A. This section includes diesel generator set work as indicated by drawings;
indicating ratings, locations of equipment and other features of a system.
B. Generator set ancillary work includes the following:
fuel storage and transfer system
combustion air-intake system
engine exhaust system
starting system with batteries and charger
cooling system
instrumentation, protection and control equipment
manually operated overhead hoist
synchronizing and paralleling switch gear for multiple sets.
inter-plant cabling and wiring
grounding to nearest main grounding bar
C. Concrete and grout for engine-driven generator pads, foundations, frames and
bedplates are specified in Division-3 "Concrete" sections. Contractor is to
coordinate work between civil and electrical work for best results.
D. Vibration control for diesel engine-driven generator units including pads,
springs, rails, bases, hangers, and connectors are specified in Division-15
section pertaining to vibration control and isolation. Contractor is to ensure
provision of the appropriate components.
E. Refer to Division-15 sections for fuel tanks, piping and associated accessories
required for installation of diesel engine-generator units; not work of this I
section.
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F. Refer to Division-15 section "Building Management System" for connection
to the BMS.
G. Refer to other Division-16 sections for wires/cables, cabinets, electrical
boxes and fittings, and wiring devices which are required in conjunction with
diesel engine-generator interplant work.
H. Refer to Division-16 "Transfer Switches" for requirements related to enginegenerator
sets.
I. Connection to BMS system, including interface elements detailed in
BMS schedules and/or shown on the drawings.
1.03 SUBMITTALS:
A. Product Data: submit full technical data of equipment for evaluation and
approval including, but not limited to, the following:
general description and characteristics of engine- generating sets, standards
with which components comply, site rating and overload capability, overall
efficiency, and fuel and lubricant consumption at 100%,75%,50% and 25%
of rated load, number of cylinders, bore, stroke, displacement, compression
ratio, piston speed and break mean effective pressure (BMEP).
description and operating criteria of engine; type, model, manufacturer, fuel
and lubricating oil types and specific consumption, starting conditions and
starting periods from cold to full-load pick-up, governor and response
characteristics due to sudden load changes, super-charger, fuel injection
system, cooling system and radiator, air filters, fuel filters, oil filters and
pumps.
description and operating criteria of generator, exciter and voltage regulator,
with loading response and short-circuit characteristics, insulation, cooling
and accessories.
dimensions, weights and forces, mounting methods, vibration protection etc.
battery type, make, charge/discharge characteristics, capacity and
constructional features
battery charger, method of charging, equalizing and trickle charging
fuel tanks, pipes, pumps, level indicators and accessories; materials and
construction
exhaust system and silencers; materials and construction
control instruments, protection, alarms, cut-outs, indicating lamps, indicating
instruments and all other devices or components
calculation for the net site rating of generator after deduction of all auxiliaries
and application of all efficiencies and derating factors including (temperature,
altitude & humidity)
calculated noise levels in dBA at typical points within engine room and at
various locations inside and outside 70dBA form One meter out side the
generator room..
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B. Compliance: submit clause-by-clause compliance statement with the
specification.
C. Warranty: include manufacturer's standard product warranty, for duration of
not less than l-year , for replacement of defective materials and equipment
used in diesel generator systems.
D. Local Representative: provide evidence that proposed equipment
manufacturer has a locally established and authorized organization which can
be called upon for professional advice and maintenance as may be required,
and which can immediately supply spare parts to support day to day and
emergency maintenance requirements. Failure to satisfy the Engineer may
disqualify a manufacturer.
E. Shop Drawings: submit layout drawings of diesel engine-driven generator
units and accessories including, but not limited to, plans and elevations,
automatic transfer switches and inter-cabling, fuel line piping, remote
start-stop stations, and instrumentation, exhaust ducting and fresh-air
ducting. In addition, show diesel generator set units and their spatial
relationship to associated equipment. Allow adequate clearance space for
removal of engine generator elements for maintenance purposes.
F. Wiring Diagrams: submit wiring diagrams for diesel engine- driven generator
units showing connections to electrical power panels, feeders, output or
transfer switch gear, and ancillary equipment. Differentiate between portions
of wiring that are manufacturer-installed and portions that are field-installed.
G. Agreement to Maintain: prior to time of final acceptance, the Contractor shall
submit 4 copies of an agreement for continued service and maintenance of
diesel engine-driven generator sets, for Employer's possible acceptance.
Offer terms and conditions for furnishing parts and providing continued
testing and servicing, including replacement of materials and equipment, for
one-year period with option for renewal of Agreement by Employer.
H. Certifications: provide diesel engine-driven generator sets certified test
record as required under "Source Quality Control" specified under this
Section of the Specification and with no limitation to, is to include the
following final production testing:
1. Single-step load pickup.
2. Transient and steady-state governing.
3. Safety shutdown device testing
4. Voltage regulation.
5. Rated power.
6. Maximum power
I. Spare Parts: provide manufacturer's recommended spare parts for 1000 hours
operation of the standby plant. Provide list of manufacturer's spare parts for
2000 hours operation together with current prices.
J. Tools and Instruments: provide tools and instruments lists required for
normal routine inspection, testing, operation and general maintenance, as
recommended by the manufacturer, together with current prices.
1.04 QUALITY ASSURANCE:
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A. Manufacturer's Qualifications: firms regularly engaged in manufacture of
diesel engine-driven generator units and ancillary equipment, of types,
ratings and characteristics required, whose products have been in satisfactory
use in similar - service for not less than 5 years.
B. Installer's Qualifications: firm with at least 3 years of successful installation
experience on projects with diesel engine-driven generator units similar to
that required for this project.
C. Agreement to Maintain: engage Installer who is willing to execute with the
Owner, required agreement for continued maintenance of diesel
engine-driven generator units.
D. Codes and Standards:
1. Standards: equipment and component parts are to comply with ISO 3046,
ISO 8528 IEC 34, IEC 85 and CISPR, or equivalent Standards and
recommendations of ABGSM (Association of British Set Manufacturers)
where such standards meet with or supersede the ISO and IEC Standards.
2. Electrical Code Compliance: comply .with applicable local/ International
code requirements of the authority having jurisdiction pertaining to
construction and installation of emergency and standby systems.
1.05 DELIVERY STORAGE AND HANDLING:
A. Deliver diesel engine-driven generators properly packaged and mounted on
pallets, or skids to facilitate handling of heavy items Utilize
factory-fabricated type containers or wrappings for engine-generator and
components, which protect equipment from damage
B. Store diesel engine-driven generator equipment in original packaging and
protect from weather and construction traffic. Wherever possible, store
indoors; where. necessary to store outdoors, store above grade and enclose
With watertight wrapping.
C. Handle diesel engine-driven generator equipment carefully to prevent
physical damage to equipment and components. Do not install damaged
equipment; remove from site and replace damaged equipment with new.
PART 2-PRODUCTS
2.01 MANUFACTURERS:
A. Available Manufacturers: subject to compliance with requirements,
specifications, drawings and regulations.
B. For approved manufacturers refer to the recommended manufacturers list.
2.02 DIESEL GENERATOR SETS –GENERAL
A. Generator Set Assembly: compact package type, with all equipment mounted
on one rigid steel bed frame suitable for skidding. Radiator is to be mounted
on the set Design is to permit easy operation, maintenance and repair.
B. Vibration reduction is to be achieved by appropriate design and careful
balancing at factory .Generator Set is to be installed on an inertia base as
described in section 15241 of division 15. The weight of the inertia base is to
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be 1 to 2 times the generator weight. Type, quantity location and arrangement
of the inertia base's spring isolators are to be selected and sized according to
the generator weight, central of gravity and excitation frequency range in
order to ensure a minimum isolation efficiency of 98% at the lowest operating
speed. The springs are to be chosen to have a natural frequency of I/l0 that of
the lowest operating speed under the combined load of the base. and
generator set. Inertia. base is. to be provided with adequate amount of
reinforcing steel bars and with a suitable number of spring isolators in order
to achieve a maximum inertia base depth of 15 cm for the generator located at
the north east room and 20 cm for the other two generators. The inertia base
works are to include all necessary coordination with the generator
manufacturer and with the structural works for the generator's installation and
mounting requirements and locations of the anchoring devices. Inertia base
frame and spring isolators are to be obtained from Kinetics Noise Control of
USA or other equal and approved manufacturers.
C. Noise reduction is to be achieved by approved methods at source of noise,
noise level and treatment shall be an essential factor in generator evaluation.
D. Cold Starting: engine is to be fully equipped to start and pick up initial load
specified at specified minimum ambient temperature. Cold starting aids, such
as engine jacket water heater, lubricating oil heater, lubricating oil circulation
intake-air heater, oversize standby battery and all devices, accessories,
connections, thermostatic switches and off-duty disconnects with pilot lights
and necessary protection, are to be supplemented as recommended by the
manufacturer and approved.
E. Equipment ratings are to be as shown on the Drawings or the next higher
standard ratings provided by the manufacturer. Ratings are to be net
continuous output to consumer, excluding fan and any auxiliaries, auxiliary
drives and losses, delivered at specified frequency, voltage and power factor
and under worst climatic conditions on site.
F. Connection to Building Management System (BMS): coordinate with the
BMS supplier and provide all necessary interface provision, instruments,
transducers, dry contacts etc. for connection of all required points to the BMS
as specified or indicated in BMS schedules.
2.03 DIESEL GENERATOR SET
A. Performance Class: diesel generator set is to be class "G3" to ISO 8528-1.
B. Components: set is to basically consist of diesel engine, brushless
synchronous generator with direct flexible coupling to engine and single or
parallel control cubicle as required and shown on the Drawings.
C. Governing is to be to ISO 3046/IV or BS 5514, using electronic type
governor with limits of speed control as specified.
D. Starting and Stopping: when in the automatic mode the set is to start and stop
.automatically by a signal sensed through an auxiliary contact in the load
transfer r switch gear. The set is to stop, after an adjustable cool- down period
(2- 30 -minutes).
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E. Duty: plant is to reach full speed within 10 seconds from start impulse and
accept immediately 60% of net rated output (load being mixed, steady and
inductive, with motor starting loads as shown on the Drawings). Transient
voltage variation is not to exceed 15% under 60% step-load application for
which the system is intended, up to full rated load, recovering to within +/-2%
within a few cycles.
F. Failure to Start: should engine fail to start following a start impulse, the
system is to come to rest for a few seconds. Two further starting attempts are
to be automatically made with intermediate 20 second maximum periods of
rest. Should the set fail to start after three attempts, an alarm is to sound and a
'start failure' signal illuminate.
G. Hand operation is to be possible for testing or normal operation through a
test/manual/off/auto selector switch.
H. Regular Exercising: while on 'auto', the set is to start regularly and
automatically every week and is to operate for 30 minutes before stopping.
2.04 DIESEL ENGINE AND AUXILIARIES
A. Design: diesel engine is to be designed for type of load and application
required. Engine and governor are to be selected to meet operating
requirements and response specified.
B. Engine Type: compression-ignition type with direct solid-injection, turbocharged,
after cooled for ratings over l00 kW, water cooled, with air-cooled
radiator, 4-stroke cycle, inline or V-type cylinder arrangement, 1500 rpm,
operating on light (No.2) diesel oil, suitable for direct coupling to driven
machine. Flywheel is to be suitably sized for type of service and constraints
specified, and capable of being rotated at 125% of rated speed without failure.
Torsional vibration dampers are to be provided.
C. Generator Ratings: are to be as shown on the drawings or the next higher
standard ratings provided by the manufacturers. Ratings are to be standby
power with limited time running hours (L TP) to ISO 8528-1, net to the
consumer excluding fan, auxiliaries, losses, etc. delivered at specified
voltage, frequency & power factor and under worst climatic conditions on
site.
D. Accessibility: it is to be possible to:
remove rocker-box covers without disturbing fuel injection pipes or other
components.
remove and replace pistons and piston rods, liners, big and small end shells
and caps without dismounting engine.
bar engine over by hand for spill timing check and adjustment.
E. Measuring Instruments: engine mounted instruments are to include, at least,
water temperature gauge, lubricating oil temperature gauge and pressure
gauge, tachometer and running time meter. It is to be possible to measure,
with extra instrumentation, coolant temperature at lower end of radiator, air
depression after air filter, air boost and temperature using methods
recommended by manufacturer. Instrument accesses are to be normally
sealed by threaded blanking caps.
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F. Cooling System: engine is to be water cooled with gear- driven water pumps.
System is to be pressurized, with heavy duty tropical radiator cooled by
reverse flow fan. Fan cowl and hand protection guard are to be fitted. Coolant
temperature is to be controlled by one or more thermostats as determined by
design of system. Radiator is to be sized for continuous performance at 110%
rated load at worst operating ambient conditions with a 15 deg. C temperature
differential. Radiator is to be non-ferrous metal, Incorporating pressure valve,
radiator cap and drain cock and with integral expansion tank. Direct acting
modulating thermostatic diversion valve is to control engine cooling water;
temperature. Under normal operation, by-pass is not to be fully closed.
Treated or fresh cooling water and anti-corrosion and anti-freeze additives are
to be used as recommended by manufacturer for specific conditions of
installation.
G. Cooling Airflow: obstructions in path of cooling air flow (openings, louvers,
grilles, mesh, ducts, bends etc. ) are not to reduce air flow below that needed
at full rated output. Fan and radiator characteristics are to be selected.
accordingly. Advise if additional booster fans are required and provide
necessary control gear for automatic operation.
H. Cylinders: are to have removable liners. Wet type liners are to have witness
hole between liner sealing rings of each cylinder for early detection of coolant
or oil leakage. Each cylinder is to have drilled and tapped hole and valve for
connections of pressure indicator
I. Lubricating Oil System: pressurized circulating type, using two
engine-driven, gear type lubricating oil pumps with full flow filters and
replaceable elements and lubricating oil heat exchanger. Filter system is to
have spring loaded by- pass valve to permit oil circulation if filters become
clogged. Audible and visual alarms are to cut-in when valve starts opening.
Lubricating oil cooler is to be shell and tube heat exchanger with water from
engine radiator as the cooling medium. Direct acting thermostatic diversion
valve is to control oil temperature. Under normal operation by-pass is not to
be fully closed.
J. Fuel system is to have injection pump and injectors that are easily removable
and replaceable for servicing. Engine is to have integral, gear type, engine
driven transfer pump to lift fuel against ahead of 2.5 m and supply it through
filters to injection pump at constant pressure. Fuel filter elements are to be
easily replaceable.
K. Exhaust system is to be complete with flanged, bolted, galvanized, seamless
steel pipe sections, long sweep elbows, flexible expansion sections,
clean-outs, residential silencer, wall thimbles and supporting steelwork.
Silencer is to be independently supported. Indoor hot exhaust parts are to be
insulated with fiber-glass tape, not less than 10 mm thick, with
anti-condensation overlap and sheet metal covers to protect insulation.
Exhaust system is to be designed to reduce back pressure to below maximum
specified by the manufacturer, In l relation to exhaust pipe length shown on
the Drawings.
L. Air Intake System: plant room is to have heavy duty air- filter of the locker
panel, all metal, cleanable, viscous impingement type, complete with duct
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and frame, as shown on the Drawings. Engine air filter is to be either dry filter
with replaceable paper filter elements. Filters are to be capable of removing
particles 10 microns and larger.
M. Electric Starting System: engine starting is to be manual by push-button or
automatic through control system at control panel. System is to consist of
heavy duty 24 V d.c. starter motor, heavy duty battery and battery charger.
Cranking motor and battery are to be rated for cranking the engine when cold
and at lowest temperature recorded. Starting pinion is to automatically
disengage when engine fires.
N. Storage Battery: lead-acid, sealed-in-plastic type, complete with battery rack
and intercell connectors. Battery is to have sufficient capacity to provide
minimum four cranking periods.
O. Battery Charger: to be 25% over-rated, solid state, full-wave rectifier type,
adequate to fully recharge depleted battery in not more than 8 hours and to
automatically control rate of charge (providing a high-charge rate to a
depleted battery and reducing to a trickle-charge rate when battery is fully
charged). Ammeter is to be provided to indicate charging rate, which is to be
adjustable. Battery charger is to be mounted in control cubicle, unless
otherwise approved.
P. Electronic governor is to provide isochronous governing, paralleling and load
sharing of generator sets. Governor is to have zero percent (isochronous)
setting and adjustable droop from zero percent. to 10% droop. System is to
include power supply Unit, magnetic speed pick-up, control module and,
actuator using fast response d.c. motor drive or equally approved alternative.
Governor is to be designed for fast-response and high-precision of speed
(frequency) control, automatic paralleling and load-sharing and is to include
speed adjustment to +1-5% of normal, while running, and with remote control
interface. Frequency deviation under 25% sudden load change is not to
exceed 0.5 Hz, recovering to stable speed condition of +1-0.1 Hz in 0.5
seconds.
Q. Governor over speed trip is to automatically close fuel pump racks in event of
engine over speed. Device is to be separate and independent from governing
mechanism. -
R. Protective system is to comprise automatic engine shut- down and generator
trip with visual and audible alarm in event of over speed, low lubricating oil
pressure, high cooling water temperature and over cranking.
2.05 GENERATOR EXCITER AND VOLTAGE REGULATOR
A. Type: synchronous, low reactance, high efficiency, revolving field type, with
brushless exciter and flexible coupling, sized to pick up effective load
without exceeding transient and steady-state voltage deviation limits
specified up to its full nominal rating and designed for the performance
stipulated in the Specification. Bearings are to be of the sleeve or sealed ball
type.
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B. Leads and Cables: phase leads are to be brought out fully insulated to a
terminal cable box of heavy gauge sheet steel, protection IP 44. Control and
protection cables are to be brought out to a separate terminal box.
C. Maximum voltage difference between the three phases at 100% balanced load
is not to exceed 1 %. With unbalanced load up to 30% on one phase at unity
power factor and zero load on other phases, the line-to-neutral voltages are
not to differ by more than 5%.
D. Characteristics
number of phases : 3
rated voltage, : 380/220 V
frequency, : 50 HZ
net rated output : as shown on the Drawings
rated power factor : 0.8 lagging
winding connection. : reconnectable with ends brought out and fully
insulated
maximum unbalanced load
current, (negative sequence
component of current)
with none of
the phase currents
exceeding rated
current : 8% of the rated current
maintained short circuit : 250% for 3 seconds.
over-speed : 120% for 2 minutes minimum
rotor : salient pole type, incorporating damping grid
excitation : brushless, with rotating armature rectifiers and
discharge resistors
voltage regulator : automatic, with readily accessible controls for
voltage level
insulation : class H for stator class H for rotor and exciter
with class F ( 105 °C) maximum winding
temperature rise
enclosure : drip proof and screen protected (IF 21 to IEC
144)
cooling : built-in centrifugal fans.
E. Voltage Regulation: overall voltage deviation within normal speed variations
is to be within limits specified from no-load to full-load, from hot to cold and
with load power factor from 0.8 lagging to unity. Regulator is to
automatically reduce voltage if load exceeds capacity of generator. Voltage
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build-up is to be positive and rapid even when full load is suddenly applied.
Line-to-line voltage wave-form deviation factor is not to exceed +/-5%. Total
harmonic content is not to exceed 5% and that of one harmonic not to exceed
2%. Radio interference suppression is to be within the limits set by the
Standards, grade (N).
F. Exciter: armature is to be 3-phase, directly mounted to generator shaft and
connected to generator field windings through six solid state, hermetically
sealed, silicon rectifiers, accessible for maintenance or repair. Exciter is to
have field suppression system to eliminate any source of diode failure
resulting from high inductive loads and surges. Exciter field windings are to
be stationary. Exciter-regulator combination is to maintain output voltage
within limits specified for any load up to full generator rating and under any
sudden load changes specified.
G. Voltage Regulator: solid state, volts/Hz type, utilizing silicon semi-conductor
devices in control and power stages, with built-in electro-magnetic
interference suppression and designed for single or parallel operation.
Manual adjustment to +/-5% of regulated voltage level is to be possible by a
potentiometer at control panel. All components are to be sealed, moisture and
heat resistant, with a suitable environmentally protected enclosure. Voltage
regulator is to automatically reduce voltage if load exceeds capacity of
generator and is to sustain a 3-phase short- circuit current at the generator
terminals for the period for which the short-circuit protection operates and at
least for 3 seconds. Voltage regulator power is to be supported by generator
voltage and current to maintain excitation field power.
H. Two position switch is to be provided for selection of manual or automatic
mode of regulated voltage control.
2.06 INSTRUMENTATION, PROTECTION AND CONTROL EQUIPMENT
A. Generating Set Instruments, Protection and Controls: control relays, sensing
equipment, switch gear protective relays and devices and start, stop and
shutdown controls are to be provided as necessary for operation specified.
Generating set, instruments, protection and controls are to be mounted
preferably in one control cubicle. Generator controls, metering and
monitoring are to be carried out via solid state, microprocessor based modular
controller.
B. Instruments and controls are to include at least the following:
1. Line & phase voltage metering on the 3-phases.
2. Current metering on the 3-phases.
3. Frequency metering.
4. Off/test/manual/auto duty switch.
5. Manual start and stop push buttons.
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6. Kilowatt-hour metering.
7. Power factor metering.
8. Service hour running counter.
9. Plant exerciser.
10. Programmable solid state monitoring unit ( s )may provided instead of the
analogue devices, subject to the engineer's approval.
11. Potentiometer for voltage level control.
12. Speed raise/lower device.
13. Cool-down time setting controls.
14. Illuminated indicator panel with LEDs at least for low oil pressure, high
water temperature, over speed, fail-to-start, over-crank, generator on
load, generator over load, battery low charge state.
15. Lamp test push-button
16. Indicating gauge and low level fuel alarm
17. Battery charger, on/off switch, pilot lights
18. D.c. ammeter
19. Alarm sounder and reset controls "'
20. Anti-condensation heater
C. Protective gear is to ensure orderly engine stop or shutdown with reset relays,
as required for safety and operational reliability, and is to include the
following:
output for over-current and external earth fault protection
power air-circuit breaker (PACB) electrically and manually operated with
solid- state trip in accordance with section 16476 (electrically tripped by
shunt trip release).
over-voltage protection with voltage and time lag adjustment
loss-of-field protection negative phase sequence protection
restricted earth fault protection with current adjustable between 0 and 20% of
rated current, and time adjustable setting 0 to 3 seconds.
2.07 CONTROL AND PROTECTIVE GEAR CUBICLES:
A. Generator set mounted instrument and/or control cubicles are to be resiliently
mounted, preventing transmission of vibration to the components. Separately
mounted instrument and control cubicles are to be self-supporting, floor
mounted and free- standing. Cubicles are to be sheet steel construction,
ventilated indoor type, vermin and dust-proof, (IP 42 to IEC 529), with
lockable hinged doors and instrument panels, separate compartments for
control devices, protective relays, circuit breaker(s) and neutral earthing
device. Inner and outer surfaces of steel enclosures are to be cleaned,
phosphatized, primed with heavy duty rust inhibiting primer and finished
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with two coats of enamel. Wiring is to be 600 V, modularly arranged, with
connections made at front terminal blocks with no live conductors exposed.
Wires are to have approved numbered ferrules at each terminal. Printed
circuit plug-in boards, where applicable, are to be of industry standards,
accessible and withdrawable, mounted in standard racks.
B. Relays: front adjustable, electronic, solid state sealed type, with dust-tight
enclosures, removable covers, test terminal blocks and plugs for testing relay
without removal from case. Removal from casing is to automatically shortcircuit
respective current transformer secondary windings.
C. Instruments are to be housed in enameled metal cases for switchboard flush
installation, with scales and markings protected and sealed. Indicating meters
are to be minimum 76 mm square. Accuracy is to be within 2% unless
otherwise specified. Voltmeters and ammeters are to be moving iron type for
a.c. measurements and moving coil type for d.c. measurements.
D. Current Transformers: class 2 for measuring and protection.
E. Voltage Transformers: single phase, dry type, 0.5 accuracy class.
F. KWH Meter: 3-element type for unbalanced 3-phase, 4- wire loads, fitted
with 6-digit cyclometer.
2.08 FUEL STORAGE AND TRANSFER
A. Day tank Construction: closed cylindrical steel, inclined at least 3 degrees
from horizontal and fitted with drain plug, inlet and outlet pipe connectors
and breather pipe.
B. Day tank breather pipe is to have replaceable paper air filter or breather caps
with air filters.
C. Day tank instruments are to include float switch, solenoid valve and dial-type
level indicator to give alarm on over-fill and low-level.
D. 240 minutes fire resistance.
2.09 FUEL STORAGE TANK (FST) & PIPES
A. FST & Piping: refer to Division “15" Fuel Tanks & Piping".
2.10 MISCELLANEOUS REQUIREMENTS
A. Manually Operated Overhead Hoist:( If required) chain operated, self
aligning, low headroom type, comprising trolley with gear mechanism
combined into a compact unit, designed to run on lower flanges of I-beam
runway. Hoist is to have shock resistant suspension, positive action Western
type local brake, lifetime lubricated sealed bearings and load safety hook.
Trolley is to have four alloy cast iron wheels. Safety factor is to be minimum
of 5. Capacity of hoist is to be as indicated on the Drawings, and is to be
tested to 1.5 times rated capacity.
B. Finishes
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1. Indoor Enclosures and Components: manufacturer's standard enamel over
corrosion-resistant pretreatment and primer.
2.11 SOURCE QUALITY CONTROL
A. Factory Tests: include prototype testing and Project-specific equipment tests
(equipment manufactured specifically for this Project).
B. Prototype Testing: performed on a separate engine generator set using the
same engine model, constructed of identical or equivalent components and
equipped with identical or equivalent accessories.
1. Tests: conform to those required as per specifications.
2. Components and Accessories: items furnished with installed unit that are
not identical to those .on tested prototype have been acceptably tested to
demonstrate compatibility and reliability.
C. Project-Specific Equipment Tests: test engine generator set and other system
components and accessories prior to shipment. Test items individually and
assembled and connected as a complete system at the factory in a manner
equivalent to that required at the Project site. Record and report test data.
1. Test Equipment: use instruments calibrated within the previous 12
months.
2. Hydrostatic Test: perform on radiator, heat exchanger, and engine water
jacket.
3. Generator Tests: conform to I.E.C./I.S.O.
4. Complete System Continuous Operation Test: includes nonstop operation
for a minimum of 8 hours, including at least 1 hour each at 1/2,3/4, and
full load. If unit stops during the 8-hour test, repeat the complete test.
Record the following minimum data at the start and end of each load run,
at 15-minute intervals between those times, and at 15-minute intervals
during the balance of the test:
a. Fuel consumption.
b. Exhaust temperature.
c. Jacket water temperature.
d. Lubricating oil temperature and pressure.
e. Generator load current and voltage, each phase.
f. Generator system gross and net output kW.
5. Complete System Performance Tests: include the following to
demonstrate conformance to specified performance requirements:
a. Single-step load pickup.
b. Transient and steady-state governing.
c. Transient and steady-state voltage performance
d. Safety shutdown devices.
6. Observation of Test: provide 2-week advance notice of tests and
opportunity for observation of test by Owner's representatives.
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7. Report test results within 10 days of completion of test.
2.12 SYNCHRONIZING PANEL
Sequence of operation
1- In the normal case each transformers supports the Max. Demand load for
its Buildings.
2- In case of the normal supply shut off for each or all buildings the
synchronizing panel supports the emergency load for each or all buildings
sequentially or random.
3- The synchronizing panel shall be fully integration with all generator set
including all control and devices for satisfy the complete operations.
PART 3-EXECUTION
3.01 INSTALLATION
A. Anchor generator set and other system components on concrete bases
conforming to Division 3 Section "Cast-In-Place Concrete" and as indicated.
Provide anchorage according to manufacturer's recommendations.
B. Field Installation of Piping and Ductwork: as specified in Division 15
Sections "Basic Mechanical Materials and Methods" and "Hydronic Piping."
C. Exhaust Piping Installation: conform to Standards approved for the project."
Use thimbles where indicated
D. Maintain minimum working space around components according to
manufacturer's shop drawings applicable codes.
E. Manufacturer's Field Services: arrange and pay for the services of a factoryauthorized
service representative to supervise the installing, connecting,
testing, and adjusting of the unit.
F. Manufacturer's Field Services: arrange and pay for the services of a factoryauthorized
service representative to supervise the installing, connecting,
pretesting, and adjusting of the unit.
3.02 IDENTIFICATION
A. Identify system components according to Division 15 Section "Mechanical
Identification" and Division 16 Section "Electrical Identification."
3.03 FIELD QUALITY CONTROL
A. Supervised Adjusting and Pretesting: under supervision of factory-authorized
service representative, .pretest all system functions, operations, and
protective features. Provide all Instruments and equipment required for tests.
Adjust to ensure operation is according to Specifications. Load system using
a variable resistive and reactive load bank to be provided during testing only
simulating kW, and power factor of loads for which unit is rated.
15
B. Tests: provide the services of a qualified independent testing agency to
perform the tests listed below according to manufacturer's recommendations
upon completion of installation of system. Use instruments bearing records of
calibration within the last 12 months, traceable to approved standards, and
adequate for making positive observation of test results. Include the
following tests.
1. Insulation Tests: test generator windings using 500 V d.c. for units rated
up to 250 volts and 1000 V d.c. for units rated between 250 and 600 volts.
Verify minimum insulation resistance is 25 megaohms for units up to 250
volts, and 100 megaohms for units 251 to 600 volts. Verify by dielectric
absorption test that polarization index levels are according to
manufacturer's Industry standards approved
2. Battery Tests: measure charging voltage and voltages between available
battery terminals for full-charging and float-charging conditions. Check
electrolyte level and specific gravity under both conditions. Test for
contact integrity of all connectors. Perform an integrity load test and a
capacity load test for the battery. Verify acceptance of charge for each
-element of battery after discharge. Verify measurements are within
manufacturer's specifications.
3. Battery Charger Tests: verify specified rates of charge for both equalizing
and float-charging conditions.
4. System Integrity Tests: methodically verify proper installation,
connection, and integrity of each element of engine generator system
before and during system operation. Check for air, exhaust, and fluid
leaks.
5. Simulation of malfunctions to verify proper operation of local and remote
protective, alarm, and monitoring devices.
6. Load Test: use variable load bank capable of simulating kVA, kW, and
power factor of load for which unit is rated. Run unit at 25, 50, and 75
percent of rated capacity for 30 minutes each, and at .100 percent for 3
hours. Make the 100-percent load run at 80 percent power factor. Record
voltage, frequency, load current, battery-charging current, power output,
oil pressure, and coolant temperature periodically during the test.
7. Vibration Baseline Test: measure amplitude for nominal frequency and
for frequencies 5, 10, 15 and 20 percent above and below nominal at each
main bearing cap. Vibration levels not exceeding those specified in
NEMA MG1, "Motors and Generators," are acceptable.
8. Exhaust System Back-Pressure Test: use a manometer with a scale
exceeding 40 inches of water. Connect to the exhaust line close to the
engine exhaust manifold. Verify that back pressure at full-rated load is
within manufacturer's published allowable limits for the engine.
9. Exhaust Emissions Test: conform to applicable government test criteria.
10. Voltage and Frequency Transient Stability Tests: use recording
oscilloscope to measure voltage and frequency transients for 50-percent
16
and 100-percent step-load increases and decreases and verify that
performance is as specified.
11. Harmonic Content Tests: measure harmonic content of input and output
current under 25 percent and at 100 percent of rated linear load. Verify
that harmonic content is within specified limits.
12. Efficiency Tests: perform at 50 percent, 75 percent, and 100 percent of
rated load.
C. Retest: correct deficiencies identified by tests and observations and retest
until specified requirements are met.
3.04 FACTORY TEST:
1. The Contractor shall be responsible for performing the generators factory
test.
2. The generators factory test shall be performed at the country of origin the
presence of the Client's, Electrical Consultant and Engineer's
representatives team. the team will comprise three representatives all
expenses are to be borne by the Contractor.
3. the contractor shall provide to the engineer a certified factory test report.
3.05 CLEANING
A. Upon completion of installation, inspect system components. Remove
paint splatters and other spots, dirt, and debris. Touch up scratches and
mars of finish to match original finish. Clean components internally using
methods and materials recommended by manufacturer.
3.06 DEMONSTRATION
A. Training: arrange and pay for the services of a factory-authorized service
representative to demonstrate adjustment, operation, and maintenance of
the system and to train Employer's personnel.
B. Conduct a minimum of 8 hours of training as specified under Instructions
to Employer's Staff in the Project Closeout Section of these Specifications.
C. Schedule training with at least 7-day advance notice.
3.07 COMMISSIONING
A. Battery Equalization: equalize charging of battery cells according to
manufacturer’s instructions. Record individual cell voltages.
END OF SECTION 16621
PART I -GENERAL
1.01 RELATED DOCUMENTS:
A. Drawings and general provisions of Contract, including General and
Supplementary Conditions and Division-1 Specification sections, apply to
work of this section.
B. Division-16 "Basic Electrical Materials and Methods" and other sections
apply to work specified in this section.
C. Division-16 "Transfer Switches", "Wires and Cables", "Circuit Breakers" and
Earthing" sections are related to work of this section.
D. Division-15 "fuel tanks".
1.02 SUMMARY:
:
A. This section includes diesel generator set work as indicated by drawings;
indicating ratings, locations of equipment and other features of a system.
B. Generator set ancillary work includes the following:
fuel storage and transfer system
combustion air-intake system
engine exhaust system
starting system with batteries and charger
cooling system
instrumentation, protection and control equipment
manually operated overhead hoist
synchronizing and paralleling switch gear for multiple sets.
inter-plant cabling and wiring
grounding to nearest main grounding bar
C. Concrete and grout for engine-driven generator pads, foundations, frames and
bedplates are specified in Division-3 "Concrete" sections. Contractor is to
coordinate work between civil and electrical work for best results.
D. Vibration control for diesel engine-driven generator units including pads,
springs, rails, bases, hangers, and connectors are specified in Division-15
section pertaining to vibration control and isolation. Contractor is to ensure
provision of the appropriate components.
E. Refer to Division-15 sections for fuel tanks, piping and associated accessories
required for installation of diesel engine-generator units; not work of this I
section.
2
F. Refer to Division-15 section "Building Management System" for connection
to the BMS.
G. Refer to other Division-16 sections for wires/cables, cabinets, electrical
boxes and fittings, and wiring devices which are required in conjunction with
diesel engine-generator interplant work.
H. Refer to Division-16 "Transfer Switches" for requirements related to enginegenerator
sets.
I. Connection to BMS system, including interface elements detailed in
BMS schedules and/or shown on the drawings.
1.03 SUBMITTALS:
A. Product Data: submit full technical data of equipment for evaluation and
approval including, but not limited to, the following:
general description and characteristics of engine- generating sets, standards
with which components comply, site rating and overload capability, overall
efficiency, and fuel and lubricant consumption at 100%,75%,50% and 25%
of rated load, number of cylinders, bore, stroke, displacement, compression
ratio, piston speed and break mean effective pressure (BMEP).
description and operating criteria of engine; type, model, manufacturer, fuel
and lubricating oil types and specific consumption, starting conditions and
starting periods from cold to full-load pick-up, governor and response
characteristics due to sudden load changes, super-charger, fuel injection
system, cooling system and radiator, air filters, fuel filters, oil filters and
pumps.
description and operating criteria of generator, exciter and voltage regulator,
with loading response and short-circuit characteristics, insulation, cooling
and accessories.
dimensions, weights and forces, mounting methods, vibration protection etc.
battery type, make, charge/discharge characteristics, capacity and
constructional features
battery charger, method of charging, equalizing and trickle charging
fuel tanks, pipes, pumps, level indicators and accessories; materials and
construction
exhaust system and silencers; materials and construction
control instruments, protection, alarms, cut-outs, indicating lamps, indicating
instruments and all other devices or components
calculation for the net site rating of generator after deduction of all auxiliaries
and application of all efficiencies and derating factors including (temperature,
altitude & humidity)
calculated noise levels in dBA at typical points within engine room and at
various locations inside and outside 70dBA form One meter out side the
generator room..
3
B. Compliance: submit clause-by-clause compliance statement with the
specification.
C. Warranty: include manufacturer's standard product warranty, for duration of
not less than l-year , for replacement of defective materials and equipment
used in diesel generator systems.
D. Local Representative: provide evidence that proposed equipment
manufacturer has a locally established and authorized organization which can
be called upon for professional advice and maintenance as may be required,
and which can immediately supply spare parts to support day to day and
emergency maintenance requirements. Failure to satisfy the Engineer may
disqualify a manufacturer.
E. Shop Drawings: submit layout drawings of diesel engine-driven generator
units and accessories including, but not limited to, plans and elevations,
automatic transfer switches and inter-cabling, fuel line piping, remote
start-stop stations, and instrumentation, exhaust ducting and fresh-air
ducting. In addition, show diesel generator set units and their spatial
relationship to associated equipment. Allow adequate clearance space for
removal of engine generator elements for maintenance purposes.
F. Wiring Diagrams: submit wiring diagrams for diesel engine- driven generator
units showing connections to electrical power panels, feeders, output or
transfer switch gear, and ancillary equipment. Differentiate between portions
of wiring that are manufacturer-installed and portions that are field-installed.
G. Agreement to Maintain: prior to time of final acceptance, the Contractor shall
submit 4 copies of an agreement for continued service and maintenance of
diesel engine-driven generator sets, for Employer's possible acceptance.
Offer terms and conditions for furnishing parts and providing continued
testing and servicing, including replacement of materials and equipment, for
one-year period with option for renewal of Agreement by Employer.
H. Certifications: provide diesel engine-driven generator sets certified test
record as required under "Source Quality Control" specified under this
Section of the Specification and with no limitation to, is to include the
following final production testing:
1. Single-step load pickup.
2. Transient and steady-state governing.
3. Safety shutdown device testing
4. Voltage regulation.
5. Rated power.
6. Maximum power
I. Spare Parts: provide manufacturer's recommended spare parts for 1000 hours
operation of the standby plant. Provide list of manufacturer's spare parts for
2000 hours operation together with current prices.
J. Tools and Instruments: provide tools and instruments lists required for
normal routine inspection, testing, operation and general maintenance, as
recommended by the manufacturer, together with current prices.
1.04 QUALITY ASSURANCE:
4
A. Manufacturer's Qualifications: firms regularly engaged in manufacture of
diesel engine-driven generator units and ancillary equipment, of types,
ratings and characteristics required, whose products have been in satisfactory
use in similar - service for not less than 5 years.
B. Installer's Qualifications: firm with at least 3 years of successful installation
experience on projects with diesel engine-driven generator units similar to
that required for this project.
C. Agreement to Maintain: engage Installer who is willing to execute with the
Owner, required agreement for continued maintenance of diesel
engine-driven generator units.
D. Codes and Standards:
1. Standards: equipment and component parts are to comply with ISO 3046,
ISO 8528 IEC 34, IEC 85 and CISPR, or equivalent Standards and
recommendations of ABGSM (Association of British Set Manufacturers)
where such standards meet with or supersede the ISO and IEC Standards.
2. Electrical Code Compliance: comply .with applicable local/ International
code requirements of the authority having jurisdiction pertaining to
construction and installation of emergency and standby systems.
1.05 DELIVERY STORAGE AND HANDLING:
A. Deliver diesel engine-driven generators properly packaged and mounted on
pallets, or skids to facilitate handling of heavy items Utilize
factory-fabricated type containers or wrappings for engine-generator and
components, which protect equipment from damage
B. Store diesel engine-driven generator equipment in original packaging and
protect from weather and construction traffic. Wherever possible, store
indoors; where. necessary to store outdoors, store above grade and enclose
With watertight wrapping.
C. Handle diesel engine-driven generator equipment carefully to prevent
physical damage to equipment and components. Do not install damaged
equipment; remove from site and replace damaged equipment with new.
PART 2-PRODUCTS
2.01 MANUFACTURERS:
A. Available Manufacturers: subject to compliance with requirements,
specifications, drawings and regulations.
B. For approved manufacturers refer to the recommended manufacturers list.
2.02 DIESEL GENERATOR SETS –GENERAL
A. Generator Set Assembly: compact package type, with all equipment mounted
on one rigid steel bed frame suitable for skidding. Radiator is to be mounted
on the set Design is to permit easy operation, maintenance and repair.
B. Vibration reduction is to be achieved by appropriate design and careful
balancing at factory .Generator Set is to be installed on an inertia base as
described in section 15241 of division 15. The weight of the inertia base is to
5
be 1 to 2 times the generator weight. Type, quantity location and arrangement
of the inertia base's spring isolators are to be selected and sized according to
the generator weight, central of gravity and excitation frequency range in
order to ensure a minimum isolation efficiency of 98% at the lowest operating
speed. The springs are to be chosen to have a natural frequency of I/l0 that of
the lowest operating speed under the combined load of the base. and
generator set. Inertia. base is. to be provided with adequate amount of
reinforcing steel bars and with a suitable number of spring isolators in order
to achieve a maximum inertia base depth of 15 cm for the generator located at
the north east room and 20 cm for the other two generators. The inertia base
works are to include all necessary coordination with the generator
manufacturer and with the structural works for the generator's installation and
mounting requirements and locations of the anchoring devices. Inertia base
frame and spring isolators are to be obtained from Kinetics Noise Control of
USA or other equal and approved manufacturers.
C. Noise reduction is to be achieved by approved methods at source of noise,
noise level and treatment shall be an essential factor in generator evaluation.
D. Cold Starting: engine is to be fully equipped to start and pick up initial load
specified at specified minimum ambient temperature. Cold starting aids, such
as engine jacket water heater, lubricating oil heater, lubricating oil circulation
intake-air heater, oversize standby battery and all devices, accessories,
connections, thermostatic switches and off-duty disconnects with pilot lights
and necessary protection, are to be supplemented as recommended by the
manufacturer and approved.
E. Equipment ratings are to be as shown on the Drawings or the next higher
standard ratings provided by the manufacturer. Ratings are to be net
continuous output to consumer, excluding fan and any auxiliaries, auxiliary
drives and losses, delivered at specified frequency, voltage and power factor
and under worst climatic conditions on site.
F. Connection to Building Management System (BMS): coordinate with the
BMS supplier and provide all necessary interface provision, instruments,
transducers, dry contacts etc. for connection of all required points to the BMS
as specified or indicated in BMS schedules.
2.03 DIESEL GENERATOR SET
A. Performance Class: diesel generator set is to be class "G3" to ISO 8528-1.
B. Components: set is to basically consist of diesel engine, brushless
synchronous generator with direct flexible coupling to engine and single or
parallel control cubicle as required and shown on the Drawings.
C. Governing is to be to ISO 3046/IV or BS 5514, using electronic type
governor with limits of speed control as specified.
D. Starting and Stopping: when in the automatic mode the set is to start and stop
.automatically by a signal sensed through an auxiliary contact in the load
transfer r switch gear. The set is to stop, after an adjustable cool- down period
(2- 30 -minutes).
6
E. Duty: plant is to reach full speed within 10 seconds from start impulse and
accept immediately 60% of net rated output (load being mixed, steady and
inductive, with motor starting loads as shown on the Drawings). Transient
voltage variation is not to exceed 15% under 60% step-load application for
which the system is intended, up to full rated load, recovering to within +/-2%
within a few cycles.
F. Failure to Start: should engine fail to start following a start impulse, the
system is to come to rest for a few seconds. Two further starting attempts are
to be automatically made with intermediate 20 second maximum periods of
rest. Should the set fail to start after three attempts, an alarm is to sound and a
'start failure' signal illuminate.
G. Hand operation is to be possible for testing or normal operation through a
test/manual/off/auto selector switch.
H. Regular Exercising: while on 'auto', the set is to start regularly and
automatically every week and is to operate for 30 minutes before stopping.
2.04 DIESEL ENGINE AND AUXILIARIES
A. Design: diesel engine is to be designed for type of load and application
required. Engine and governor are to be selected to meet operating
requirements and response specified.
B. Engine Type: compression-ignition type with direct solid-injection, turbocharged,
after cooled for ratings over l00 kW, water cooled, with air-cooled
radiator, 4-stroke cycle, inline or V-type cylinder arrangement, 1500 rpm,
operating on light (No.2) diesel oil, suitable for direct coupling to driven
machine. Flywheel is to be suitably sized for type of service and constraints
specified, and capable of being rotated at 125% of rated speed without failure.
Torsional vibration dampers are to be provided.
C. Generator Ratings: are to be as shown on the drawings or the next higher
standard ratings provided by the manufacturers. Ratings are to be standby
power with limited time running hours (L TP) to ISO 8528-1, net to the
consumer excluding fan, auxiliaries, losses, etc. delivered at specified
voltage, frequency & power factor and under worst climatic conditions on
site.
D. Accessibility: it is to be possible to:
remove rocker-box covers without disturbing fuel injection pipes or other
components.
remove and replace pistons and piston rods, liners, big and small end shells
and caps without dismounting engine.
bar engine over by hand for spill timing check and adjustment.
E. Measuring Instruments: engine mounted instruments are to include, at least,
water temperature gauge, lubricating oil temperature gauge and pressure
gauge, tachometer and running time meter. It is to be possible to measure,
with extra instrumentation, coolant temperature at lower end of radiator, air
depression after air filter, air boost and temperature using methods
recommended by manufacturer. Instrument accesses are to be normally
sealed by threaded blanking caps.
7
F. Cooling System: engine is to be water cooled with gear- driven water pumps.
System is to be pressurized, with heavy duty tropical radiator cooled by
reverse flow fan. Fan cowl and hand protection guard are to be fitted. Coolant
temperature is to be controlled by one or more thermostats as determined by
design of system. Radiator is to be sized for continuous performance at 110%
rated load at worst operating ambient conditions with a 15 deg. C temperature
differential. Radiator is to be non-ferrous metal, Incorporating pressure valve,
radiator cap and drain cock and with integral expansion tank. Direct acting
modulating thermostatic diversion valve is to control engine cooling water;
temperature. Under normal operation, by-pass is not to be fully closed.
Treated or fresh cooling water and anti-corrosion and anti-freeze additives are
to be used as recommended by manufacturer for specific conditions of
installation.
G. Cooling Airflow: obstructions in path of cooling air flow (openings, louvers,
grilles, mesh, ducts, bends etc. ) are not to reduce air flow below that needed
at full rated output. Fan and radiator characteristics are to be selected.
accordingly. Advise if additional booster fans are required and provide
necessary control gear for automatic operation.
H. Cylinders: are to have removable liners. Wet type liners are to have witness
hole between liner sealing rings of each cylinder for early detection of coolant
or oil leakage. Each cylinder is to have drilled and tapped hole and valve for
connections of pressure indicator
I. Lubricating Oil System: pressurized circulating type, using two
engine-driven, gear type lubricating oil pumps with full flow filters and
replaceable elements and lubricating oil heat exchanger. Filter system is to
have spring loaded by- pass valve to permit oil circulation if filters become
clogged. Audible and visual alarms are to cut-in when valve starts opening.
Lubricating oil cooler is to be shell and tube heat exchanger with water from
engine radiator as the cooling medium. Direct acting thermostatic diversion
valve is to control oil temperature. Under normal operation by-pass is not to
be fully closed.
J. Fuel system is to have injection pump and injectors that are easily removable
and replaceable for servicing. Engine is to have integral, gear type, engine
driven transfer pump to lift fuel against ahead of 2.5 m and supply it through
filters to injection pump at constant pressure. Fuel filter elements are to be
easily replaceable.
K. Exhaust system is to be complete with flanged, bolted, galvanized, seamless
steel pipe sections, long sweep elbows, flexible expansion sections,
clean-outs, residential silencer, wall thimbles and supporting steelwork.
Silencer is to be independently supported. Indoor hot exhaust parts are to be
insulated with fiber-glass tape, not less than 10 mm thick, with
anti-condensation overlap and sheet metal covers to protect insulation.
Exhaust system is to be designed to reduce back pressure to below maximum
specified by the manufacturer, In l relation to exhaust pipe length shown on
the Drawings.
L. Air Intake System: plant room is to have heavy duty air- filter of the locker
panel, all metal, cleanable, viscous impingement type, complete with duct
8
and frame, as shown on the Drawings. Engine air filter is to be either dry filter
with replaceable paper filter elements. Filters are to be capable of removing
particles 10 microns and larger.
M. Electric Starting System: engine starting is to be manual by push-button or
automatic through control system at control panel. System is to consist of
heavy duty 24 V d.c. starter motor, heavy duty battery and battery charger.
Cranking motor and battery are to be rated for cranking the engine when cold
and at lowest temperature recorded. Starting pinion is to automatically
disengage when engine fires.
N. Storage Battery: lead-acid, sealed-in-plastic type, complete with battery rack
and intercell connectors. Battery is to have sufficient capacity to provide
minimum four cranking periods.
O. Battery Charger: to be 25% over-rated, solid state, full-wave rectifier type,
adequate to fully recharge depleted battery in not more than 8 hours and to
automatically control rate of charge (providing a high-charge rate to a
depleted battery and reducing to a trickle-charge rate when battery is fully
charged). Ammeter is to be provided to indicate charging rate, which is to be
adjustable. Battery charger is to be mounted in control cubicle, unless
otherwise approved.
P. Electronic governor is to provide isochronous governing, paralleling and load
sharing of generator sets. Governor is to have zero percent (isochronous)
setting and adjustable droop from zero percent. to 10% droop. System is to
include power supply Unit, magnetic speed pick-up, control module and,
actuator using fast response d.c. motor drive or equally approved alternative.
Governor is to be designed for fast-response and high-precision of speed
(frequency) control, automatic paralleling and load-sharing and is to include
speed adjustment to +1-5% of normal, while running, and with remote control
interface. Frequency deviation under 25% sudden load change is not to
exceed 0.5 Hz, recovering to stable speed condition of +1-0.1 Hz in 0.5
seconds.
Q. Governor over speed trip is to automatically close fuel pump racks in event of
engine over speed. Device is to be separate and independent from governing
mechanism. -
R. Protective system is to comprise automatic engine shut- down and generator
trip with visual and audible alarm in event of over speed, low lubricating oil
pressure, high cooling water temperature and over cranking.
2.05 GENERATOR EXCITER AND VOLTAGE REGULATOR
A. Type: synchronous, low reactance, high efficiency, revolving field type, with
brushless exciter and flexible coupling, sized to pick up effective load
without exceeding transient and steady-state voltage deviation limits
specified up to its full nominal rating and designed for the performance
stipulated in the Specification. Bearings are to be of the sleeve or sealed ball
type.
9
B. Leads and Cables: phase leads are to be brought out fully insulated to a
terminal cable box of heavy gauge sheet steel, protection IP 44. Control and
protection cables are to be brought out to a separate terminal box.
C. Maximum voltage difference between the three phases at 100% balanced load
is not to exceed 1 %. With unbalanced load up to 30% on one phase at unity
power factor and zero load on other phases, the line-to-neutral voltages are
not to differ by more than 5%.
D. Characteristics
number of phases : 3
rated voltage, : 380/220 V
frequency, : 50 HZ
net rated output : as shown on the Drawings
rated power factor : 0.8 lagging
winding connection. : reconnectable with ends brought out and fully
insulated
maximum unbalanced load
current, (negative sequence
component of current)
with none of
the phase currents
exceeding rated
current : 8% of the rated current
maintained short circuit : 250% for 3 seconds.
over-speed : 120% for 2 minutes minimum
rotor : salient pole type, incorporating damping grid
excitation : brushless, with rotating armature rectifiers and
discharge resistors
voltage regulator : automatic, with readily accessible controls for
voltage level
insulation : class H for stator class H for rotor and exciter
with class F ( 105 °C) maximum winding
temperature rise
enclosure : drip proof and screen protected (IF 21 to IEC
144)
cooling : built-in centrifugal fans.
E. Voltage Regulation: overall voltage deviation within normal speed variations
is to be within limits specified from no-load to full-load, from hot to cold and
with load power factor from 0.8 lagging to unity. Regulator is to
automatically reduce voltage if load exceeds capacity of generator. Voltage
10
build-up is to be positive and rapid even when full load is suddenly applied.
Line-to-line voltage wave-form deviation factor is not to exceed +/-5%. Total
harmonic content is not to exceed 5% and that of one harmonic not to exceed
2%. Radio interference suppression is to be within the limits set by the
Standards, grade (N).
F. Exciter: armature is to be 3-phase, directly mounted to generator shaft and
connected to generator field windings through six solid state, hermetically
sealed, silicon rectifiers, accessible for maintenance or repair. Exciter is to
have field suppression system to eliminate any source of diode failure
resulting from high inductive loads and surges. Exciter field windings are to
be stationary. Exciter-regulator combination is to maintain output voltage
within limits specified for any load up to full generator rating and under any
sudden load changes specified.
G. Voltage Regulator: solid state, volts/Hz type, utilizing silicon semi-conductor
devices in control and power stages, with built-in electro-magnetic
interference suppression and designed for single or parallel operation.
Manual adjustment to +/-5% of regulated voltage level is to be possible by a
potentiometer at control panel. All components are to be sealed, moisture and
heat resistant, with a suitable environmentally protected enclosure. Voltage
regulator is to automatically reduce voltage if load exceeds capacity of
generator and is to sustain a 3-phase short- circuit current at the generator
terminals for the period for which the short-circuit protection operates and at
least for 3 seconds. Voltage regulator power is to be supported by generator
voltage and current to maintain excitation field power.
H. Two position switch is to be provided for selection of manual or automatic
mode of regulated voltage control.
2.06 INSTRUMENTATION, PROTECTION AND CONTROL EQUIPMENT
A. Generating Set Instruments, Protection and Controls: control relays, sensing
equipment, switch gear protective relays and devices and start, stop and
shutdown controls are to be provided as necessary for operation specified.
Generating set, instruments, protection and controls are to be mounted
preferably in one control cubicle. Generator controls, metering and
monitoring are to be carried out via solid state, microprocessor based modular
controller.
B. Instruments and controls are to include at least the following:
1. Line & phase voltage metering on the 3-phases.
2. Current metering on the 3-phases.
3. Frequency metering.
4. Off/test/manual/auto duty switch.
5. Manual start and stop push buttons.
11
6. Kilowatt-hour metering.
7. Power factor metering.
8. Service hour running counter.
9. Plant exerciser.
10. Programmable solid state monitoring unit ( s )may provided instead of the
analogue devices, subject to the engineer's approval.
11. Potentiometer for voltage level control.
12. Speed raise/lower device.
13. Cool-down time setting controls.
14. Illuminated indicator panel with LEDs at least for low oil pressure, high
water temperature, over speed, fail-to-start, over-crank, generator on
load, generator over load, battery low charge state.
15. Lamp test push-button
16. Indicating gauge and low level fuel alarm
17. Battery charger, on/off switch, pilot lights
18. D.c. ammeter
19. Alarm sounder and reset controls "'
20. Anti-condensation heater
C. Protective gear is to ensure orderly engine stop or shutdown with reset relays,
as required for safety and operational reliability, and is to include the
following:
output for over-current and external earth fault protection
power air-circuit breaker (PACB) electrically and manually operated with
solid- state trip in accordance with section 16476 (electrically tripped by
shunt trip release).
over-voltage protection with voltage and time lag adjustment
loss-of-field protection negative phase sequence protection
restricted earth fault protection with current adjustable between 0 and 20% of
rated current, and time adjustable setting 0 to 3 seconds.
2.07 CONTROL AND PROTECTIVE GEAR CUBICLES:
A. Generator set mounted instrument and/or control cubicles are to be resiliently
mounted, preventing transmission of vibration to the components. Separately
mounted instrument and control cubicles are to be self-supporting, floor
mounted and free- standing. Cubicles are to be sheet steel construction,
ventilated indoor type, vermin and dust-proof, (IP 42 to IEC 529), with
lockable hinged doors and instrument panels, separate compartments for
control devices, protective relays, circuit breaker(s) and neutral earthing
device. Inner and outer surfaces of steel enclosures are to be cleaned,
phosphatized, primed with heavy duty rust inhibiting primer and finished
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with two coats of enamel. Wiring is to be 600 V, modularly arranged, with
connections made at front terminal blocks with no live conductors exposed.
Wires are to have approved numbered ferrules at each terminal. Printed
circuit plug-in boards, where applicable, are to be of industry standards,
accessible and withdrawable, mounted in standard racks.
B. Relays: front adjustable, electronic, solid state sealed type, with dust-tight
enclosures, removable covers, test terminal blocks and plugs for testing relay
without removal from case. Removal from casing is to automatically shortcircuit
respective current transformer secondary windings.
C. Instruments are to be housed in enameled metal cases for switchboard flush
installation, with scales and markings protected and sealed. Indicating meters
are to be minimum 76 mm square. Accuracy is to be within 2% unless
otherwise specified. Voltmeters and ammeters are to be moving iron type for
a.c. measurements and moving coil type for d.c. measurements.
D. Current Transformers: class 2 for measuring and protection.
E. Voltage Transformers: single phase, dry type, 0.5 accuracy class.
F. KWH Meter: 3-element type for unbalanced 3-phase, 4- wire loads, fitted
with 6-digit cyclometer.
2.08 FUEL STORAGE AND TRANSFER
A. Day tank Construction: closed cylindrical steel, inclined at least 3 degrees
from horizontal and fitted with drain plug, inlet and outlet pipe connectors
and breather pipe.
B. Day tank breather pipe is to have replaceable paper air filter or breather caps
with air filters.
C. Day tank instruments are to include float switch, solenoid valve and dial-type
level indicator to give alarm on over-fill and low-level.
D. 240 minutes fire resistance.
2.09 FUEL STORAGE TANK (FST) & PIPES
A. FST & Piping: refer to Division “15" Fuel Tanks & Piping".
2.10 MISCELLANEOUS REQUIREMENTS
A. Manually Operated Overhead Hoist:( If required) chain operated, self
aligning, low headroom type, comprising trolley with gear mechanism
combined into a compact unit, designed to run on lower flanges of I-beam
runway. Hoist is to have shock resistant suspension, positive action Western
type local brake, lifetime lubricated sealed bearings and load safety hook.
Trolley is to have four alloy cast iron wheels. Safety factor is to be minimum
of 5. Capacity of hoist is to be as indicated on the Drawings, and is to be
tested to 1.5 times rated capacity.
B. Finishes
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1. Indoor Enclosures and Components: manufacturer's standard enamel over
corrosion-resistant pretreatment and primer.
2.11 SOURCE QUALITY CONTROL
A. Factory Tests: include prototype testing and Project-specific equipment tests
(equipment manufactured specifically for this Project).
B. Prototype Testing: performed on a separate engine generator set using the
same engine model, constructed of identical or equivalent components and
equipped with identical or equivalent accessories.
1. Tests: conform to those required as per specifications.
2. Components and Accessories: items furnished with installed unit that are
not identical to those .on tested prototype have been acceptably tested to
demonstrate compatibility and reliability.
C. Project-Specific Equipment Tests: test engine generator set and other system
components and accessories prior to shipment. Test items individually and
assembled and connected as a complete system at the factory in a manner
equivalent to that required at the Project site. Record and report test data.
1. Test Equipment: use instruments calibrated within the previous 12
months.
2. Hydrostatic Test: perform on radiator, heat exchanger, and engine water
jacket.
3. Generator Tests: conform to I.E.C./I.S.O.
4. Complete System Continuous Operation Test: includes nonstop operation
for a minimum of 8 hours, including at least 1 hour each at 1/2,3/4, and
full load. If unit stops during the 8-hour test, repeat the complete test.
Record the following minimum data at the start and end of each load run,
at 15-minute intervals between those times, and at 15-minute intervals
during the balance of the test:
a. Fuel consumption.
b. Exhaust temperature.
c. Jacket water temperature.
d. Lubricating oil temperature and pressure.
e. Generator load current and voltage, each phase.
f. Generator system gross and net output kW.
5. Complete System Performance Tests: include the following to
demonstrate conformance to specified performance requirements:
a. Single-step load pickup.
b. Transient and steady-state governing.
c. Transient and steady-state voltage performance
d. Safety shutdown devices.
6. Observation of Test: provide 2-week advance notice of tests and
opportunity for observation of test by Owner's representatives.
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7. Report test results within 10 days of completion of test.
2.12 SYNCHRONIZING PANEL
Sequence of operation
1- In the normal case each transformers supports the Max. Demand load for
its Buildings.
2- In case of the normal supply shut off for each or all buildings the
synchronizing panel supports the emergency load for each or all buildings
sequentially or random.
3- The synchronizing panel shall be fully integration with all generator set
including all control and devices for satisfy the complete operations.
PART 3-EXECUTION
3.01 INSTALLATION
A. Anchor generator set and other system components on concrete bases
conforming to Division 3 Section "Cast-In-Place Concrete" and as indicated.
Provide anchorage according to manufacturer's recommendations.
B. Field Installation of Piping and Ductwork: as specified in Division 15
Sections "Basic Mechanical Materials and Methods" and "Hydronic Piping."
C. Exhaust Piping Installation: conform to Standards approved for the project."
Use thimbles where indicated
D. Maintain minimum working space around components according to
manufacturer's shop drawings applicable codes.
E. Manufacturer's Field Services: arrange and pay for the services of a factoryauthorized
service representative to supervise the installing, connecting,
testing, and adjusting of the unit.
F. Manufacturer's Field Services: arrange and pay for the services of a factoryauthorized
service representative to supervise the installing, connecting,
pretesting, and adjusting of the unit.
3.02 IDENTIFICATION
A. Identify system components according to Division 15 Section "Mechanical
Identification" and Division 16 Section "Electrical Identification."
3.03 FIELD QUALITY CONTROL
A. Supervised Adjusting and Pretesting: under supervision of factory-authorized
service representative, .pretest all system functions, operations, and
protective features. Provide all Instruments and equipment required for tests.
Adjust to ensure operation is according to Specifications. Load system using
a variable resistive and reactive load bank to be provided during testing only
simulating kW, and power factor of loads for which unit is rated.
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B. Tests: provide the services of a qualified independent testing agency to
perform the tests listed below according to manufacturer's recommendations
upon completion of installation of system. Use instruments bearing records of
calibration within the last 12 months, traceable to approved standards, and
adequate for making positive observation of test results. Include the
following tests.
1. Insulation Tests: test generator windings using 500 V d.c. for units rated
up to 250 volts and 1000 V d.c. for units rated between 250 and 600 volts.
Verify minimum insulation resistance is 25 megaohms for units up to 250
volts, and 100 megaohms for units 251 to 600 volts. Verify by dielectric
absorption test that polarization index levels are according to
manufacturer's Industry standards approved
2. Battery Tests: measure charging voltage and voltages between available
battery terminals for full-charging and float-charging conditions. Check
electrolyte level and specific gravity under both conditions. Test for
contact integrity of all connectors. Perform an integrity load test and a
capacity load test for the battery. Verify acceptance of charge for each
-element of battery after discharge. Verify measurements are within
manufacturer's specifications.
3. Battery Charger Tests: verify specified rates of charge for both equalizing
and float-charging conditions.
4. System Integrity Tests: methodically verify proper installation,
connection, and integrity of each element of engine generator system
before and during system operation. Check for air, exhaust, and fluid
leaks.
5. Simulation of malfunctions to verify proper operation of local and remote
protective, alarm, and monitoring devices.
6. Load Test: use variable load bank capable of simulating kVA, kW, and
power factor of load for which unit is rated. Run unit at 25, 50, and 75
percent of rated capacity for 30 minutes each, and at .100 percent for 3
hours. Make the 100-percent load run at 80 percent power factor. Record
voltage, frequency, load current, battery-charging current, power output,
oil pressure, and coolant temperature periodically during the test.
7. Vibration Baseline Test: measure amplitude for nominal frequency and
for frequencies 5, 10, 15 and 20 percent above and below nominal at each
main bearing cap. Vibration levels not exceeding those specified in
NEMA MG1, "Motors and Generators," are acceptable.
8. Exhaust System Back-Pressure Test: use a manometer with a scale
exceeding 40 inches of water. Connect to the exhaust line close to the
engine exhaust manifold. Verify that back pressure at full-rated load is
within manufacturer's published allowable limits for the engine.
9. Exhaust Emissions Test: conform to applicable government test criteria.
10. Voltage and Frequency Transient Stability Tests: use recording
oscilloscope to measure voltage and frequency transients for 50-percent
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and 100-percent step-load increases and decreases and verify that
performance is as specified.
11. Harmonic Content Tests: measure harmonic content of input and output
current under 25 percent and at 100 percent of rated linear load. Verify
that harmonic content is within specified limits.
12. Efficiency Tests: perform at 50 percent, 75 percent, and 100 percent of
rated load.
C. Retest: correct deficiencies identified by tests and observations and retest
until specified requirements are met.
3.04 FACTORY TEST:
1. The Contractor shall be responsible for performing the generators factory
test.
2. The generators factory test shall be performed at the country of origin the
presence of the Client's, Electrical Consultant and Engineer's
representatives team. the team will comprise three representatives all
expenses are to be borne by the Contractor.
3. the contractor shall provide to the engineer a certified factory test report.
3.05 CLEANING
A. Upon completion of installation, inspect system components. Remove
paint splatters and other spots, dirt, and debris. Touch up scratches and
mars of finish to match original finish. Clean components internally using
methods and materials recommended by manufacturer.
3.06 DEMONSTRATION
A. Training: arrange and pay for the services of a factory-authorized service
representative to demonstrate adjustment, operation, and maintenance of
the system and to train Employer's personnel.
B. Conduct a minimum of 8 hours of training as specified under Instructions
to Employer's Staff in the Project Closeout Section of these Specifications.
C. Schedule training with at least 7-day advance notice.
3.07 COMMISSIONING
A. Battery Equalization: equalize charging of battery cells according to
manufacturer’s instructions. Record individual cell voltages.
END OF SECTION 16621
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