200kVA DIESEL GENERATOR SPECIFICATION Spare Parts and Maintenance Facilities NO ITEM REMARKS 1...

OF 43

200kVA DIESEL GENERATOR SPECIFICATION

OF 43

1. DETAIL INDEX

1. DETAIL INDEX .......................................................................................................... 2

2. SECTION 1 - FORMS TO BE COMPLETED BY TENDERER .............................................. 4 2.1 TECHNICAL DETAIL ON EQUIPMENT OFFERED ......................................................................... 4

2.1.1 GENERATOR SET ....................................................................................................................................................................... 4 3. SECTION 2 - MATERIAL QUALITY SPECIFICATION .................................................... 15

3.1 GENERATOR SETS ................................................................................................................... 15 3.1.1 General ................................................................................................................................................................................... 15 3.1.2 Outdoor Enclosure type Sets (Where Applicable) ................................................................................................................... 15 3.1.3 Indoor mounted sets .............................................................................................................................................................. 16 3.1.4 Base frame .............................................................................................................................................................................. 17 3.1.5 Engine ..................................................................................................................................................................................... 17 3.1.6 Engine Rating .......................................................................................................................................................................... 17 3.1.7 Engine De-rating ..................................................................................................................................................................... 18 3.1.8 Engine Starting and Stopping .................................................................................................................................................. 18 3.1.9 Engine Cooling ........................................................................................................................................................................ 18 3.1.10 Engine Lubrication ............................................................................................................................................................. 18 3.1.11 Mechanical Fusible Link ..................................................................................................................................................... 19 3.1.12 Electronic Governor ........................................................................................................................................................... 19 3.1.13 Alternator - General ........................................................................................................................................................... 19 3.1.14 Alternator Performance ..................................................................................................................................................... 20 3.1.15 Alternator Regulation ........................................................................................................................................................ 20 3.1.16 Alternator Coupling ........................................................................................................................................................... 20 3.1.17 Dummy Load (Where applicable)....................................................................................................................................... 21 3.1.18 System Operation .............................................................................................................................................................. 21 3.1.19 Generator Control and Change over Panel ........................................................................................................................ 22 3.1.20 Change over switch gear (Not part of this Scope of Works) ............................................................................................... 25 3.1.21 Starter Batteries ................................................................................................................................................................. 25 3.1.22 Emergency stop ................................................................................................................................................................. 26 3.1.23 Gauges ............................................................................................................................................................................... 26 3.1.24 16 Amp plug ....................................................................................................................................................................... 26 3.1.25 Wiring diagram .................................................................................................................................................................. 26 3.1.26 Siren / Beacon .................................................................................................................................................................... 26 3.1.27 Water Jacket Heater .......................................................................................................................................................... 27 3.1.28 Drip Tray ............................................................................................................................................................................ 27 3.1.29 Diesel Fuel Pumping system .............................................................................................................................................. 27 3.1.30 Diesel Fuel Filtering system (Where applicable) ................................................................................................................ 27 3.1.31 Diesel Fuel Tanks................................................................................................................................................................ 27 3.1.32 Exhaust Silencer system ..................................................................................................................................................... 29 3.1.33 Radiator Cowl and Flashings .............................................................................................................................................. 29 3.1.34 Weatherproof Enclosure .................................................................................................................................................... 30 3.1.35 Fire Extinguishers (not applicable) ..................................................................................................................................... 30 3.1.36 Warning Notices ................................................................................................................................................................ 30 3.1.37 Earthing ............................................................................................................................................................................. 31 3.1.38 Lightning and Surge Protection .......................................................................................................................................... 31 3.1.39 Workshop Drawings ........................................................................................................................................................... 31 3.1.40 Testing of the Generator set .............................................................................................................................................. 31 3.1.41 Operation and Maintenance Manual ................................................................................................................................. 32 3.1.42 Training of Operator .......................................................................................................................................................... 33 3.1.43 Commissioning, Testing and Handing over ........................................................................................................................ 33 3.1.44 Initial Maintenance Contract ............................................................................................................................................. 34 3.1.45 Maintenance Contract after the first 12 Months ............................................................................................................... 36

4. SECTION 3 - PROJECT SPECIFICATION ..................................................................... 38 4.1 200kVA PRIME RATED GENERATOR SET ................................................................................. 38

4.1.1 General ................................................................................................................................................................................... 38 4.1.2 Site Conditions ........................................................................................................................................................................ 38 4.1.3 Generator Requirements ........................................................................................................................................................ 38 4.1.4 Engine ..................................................................................................................................................................................... 39 4.1.5 Alternator ............................................................................................................................................................................... 39 4.1.6 Diesel tank .............................................................................................................................................................................. 39 4.1.7 Cables between Alternator and Generator Control Panels ..................................................................................................... 39 4.1.8 Generator Automatic Change Over and Generator Control panel .......................................................................................... 40 4.1.9 Batteries ................................................................................................................................................................................. 40 4.1.10 Dummy Load ...................................................................................................................................................................... 40 4.1.11 Sound Attenuation ............................................................................................................................................................. 40 4.1.12 Remote Alarm Panel .......................................................................................................................................................... 41 4.1.13 GSM Programmable Telemetry Controller (Provided as optional extra) ............................................................................ 41 4.1.14 Siren / Beacon unit ............................................................................................................................................................ 41 4.1.15 Warning & Safety Signs ...................................................................................................................................................... 42 4.1.16 Submissions with tender .................................................................................................................................................... 43

OF 43

SECTION 1

FORMS TO BE COMPLETED BY TENDERER

OF 43

2. SECTION 1 - FORMS TO BE COMPLETED BY TENDERER

2.1 TECHNICAL DETAIL ON EQUIPMENT OFFERED The manufacture of all equipment included in the tender, whether specified in detail or not, which forms an integral part of the installation, shall be reflected in this schedule. THE COMPLETED SCHEDULE SHALL BE SUBMITTED WITH THE TENDER.

2.1.1 GENERATOR SET

2.1.1.1 Base

NO ITEM EQUIPMENT OFFERED

1 The base is Manufactured from (Specify material)

2 Width

3 Length

4 Height

5 Does the diesel day tank form integral part of base frame

6 Integral budment filled with sand (diesel tank)

7 Type of paint specification (Corrosion protection)

8 Type of Vibration damper

9 Number of Vibration dampers on Engine

10 Number of Vibration dampers on Alternator

OF 43

2.1.1.2 Engine


1 Manufacturer’s Name

2 Country of Origin

3 Manufacturer’s model No.

4 Year of manufacture

5

Continuous sea level rating after allowing for ancillary equipment: a) Gross b.h.p. b) Gross kWm c) Net b.h.p. d) Net kWm

6

Percentage de-rating for site conditions, in accordance with SANS 8528. See site conditions in Section 3. a) For altitude b) For temperature c) For humidity d) Total de-rating

7 % Step load acceptance

8 % Over-Load accepted for 1 hour without overheating

9 Minimum time expected for set to accept full load in seconds

10 Nominal speed in r.p.m

11 Number of cylinders

12 Strokes per working cycle

13 Stroke in mm

14 Cylinder bore in mm

15 Swept volume in cm³

16 Mean piston speed in m/min

17 Compression ratio

18 Fuel consumption of the complete generating set on site in l/h of alternator output at: a) Full load b) ¾ load c) ½ load NOTE: A tolerance of 5% shall be allowed on the above stated value of fuel consumption.

19 Make of fuel injection system

20 Method of starting

OF 43

21 Voltage of starting system

22 Method of cooling

23 Type of radiator

24 Type of heater for warming cylinder heads

25 Capacity of heater in kW

26 Method of protection against high temperature

27 Method of protection against low oil pressure

28 Electronic governor provided?

29 Governor make and model

30 Speed variation in % a. Temporary b. Permanent

31

Recommended interval in running hours for: a. Lubricating oil change b. Oil filter element change c. Decarbonising

32 Can plant be placed on solid concrete floor?

33 Are all accessories and cowls included?

34 Is engine naturally aspirated

35 Are performance curves attached?

36 BMEP (4 stroke) at continuous rating (kPA)

37 Electronic Control Unit

OF 43

2.1.1.3 Exhaust System


1 Diameter of exhaust pipe

2 Material of exhaust / Silencer inside Generator room

3 Material of exhaust / Silencer Outside

4 Type of exhaust end

5 Exhaust flexible piece: Supplier

6 Exhaust flexible piece: Material

7 Exhaust flexible piece: Length

8 Exhaust paint finish and colour

9 Are the entire exhaust pipes and silencer lagged?

10 Noise level in plant room in dB

11 Noise level at tail of exhaust pipe in dB

12 Are exhaust suspended from concrete roof with anti-vibration devises?

2.1.1.4 Alternator


1 Manufacturer's name

2 Manufacturer's model no.

3 Country of Origin and year of manufacture

4 ISO 9001 Quality Assurance

5 Duty classification

6 Insulation class

7 Number of poles

8 IP rating

9 Short circuit current for 10 seconds (Amps)

10 Efficiency at full load (pf: 0,8)

11 Nominal speed in r.p.m.

12 Number of bearings

13 No load Terminal voltage (Volts)

OF 43

14 Number of terminals in connection box

15 Sea level rating kVA at 0,8 power factor

16

De-rating (K Factor) for site conditions

a) Altitude > 1500m b) Ambient temperature at 40℃ c) Power factor at 0,8

17 Input required in kW

18 Method of excitation

19

Efficiency at 0,8 power factor and: a) Full load b) ¾ load c) ½ load

20 Maximum permanent voltage variation in %

21 Transient voltage dip on full load

22 Voltage recovery on full load application in milliseconds

23 Is alternator brushless?

24 Is alternator tropicalised?

25 Type of Coupling

2.1.1.5 Digital Automatic Voltage Regulator


1 Manufacturer's name

2 Manufacturer's model no.

3 Country of Origin and year of manufacture

4 Steady state voltage regulation (±%)

5 Rated overload current – (Amp & Seconds)

OF 43

2.1.1.6 Diesel tanks – Day tank


1 Does it form part of the base frame?

2 Capacity of day tank (litres)

3 Is gauge fitted to tank?

4 Is an electric pump and an electric solenoid provided for filling the day tank from the bulk tank included?

5 Low fuel level alarm: Level switch provided at 25%

6 Engine cut-out level switch: Level switch provided at 5%

7 Fuel level switches: Make and model

2.1.1.7 Generator Control Panel


1 Does the control panel form part of the AMF panel?

2 Digital programmable generator controller provided

3 Digital programmable generator controller: Make

4 Digital programmable generator controller: Model

5 Make of Battery Charger

6 Rating of Battery charger (V) and (Amps)

7 Make of analogue battery voltmeter

8 Make of analogue battery ammeter

9 Make of analogue running hour meter

10 Make of analogue Engine Alternator ammeter

11 Make of analogue Engine Oil Pressure meter

12 Make of analogue Engine Temperature meter

13 Make of analogue fuel level meter

14 Make of key switches

15 Make of Push buttons

16 Make of Emergency stop button

17 Make of Alarm Siren/Beacon

OF 43

18 Siren/Beacon IP rating

19 Siren sound level

20 Surge protection (Class 3): Provide DEHNrail M DR M 2P 255

21 Not used

2.1.1.8 Battery


1 Maker’s Name

2 Country of Origin

3 Type of battery

4 Voltage of battery

5 Number of cells

6 Capacity in cold crank amp

2.1.1.9 Dimensions


1

Overall dimensions of Generator set in mm

1) Width 2) Length 3) Height

2 Overall mass (Engine, Alternator & Diesel)

3

Proposed Inlet louver:

1) Height 2) Length 3) Depth

4

Proposed Outlet louver:

1) Height 2) Length 3) Depth

OF 43

2.1.1.10 Sound Attenuation


1 Sound Attenuation (Splitters) Maker’s Name

2 Dimensions of Splitters: intake

3 Dimensions of Splitters: discharge

4 Acoustic Weather Louvers Maker’s Name

5 Dimensions of Acoustic Weather Louvers: intake

6 Dimensions of Acoustic Weather Louvers: discharge

7 Weather louver material

8 Acoustic Lining Material for Generator room walls: Product name/ description.

9 Noise level outside dBA (7m away)

10 Noise level inside Generator room in dBA

11 Tropical mesh to be provided to prevent insects entering through louvers

2.1.1.11 Other Equipment

NO ITEM REMARKS

1 Type of fusible link over engine (Fuel shut-down system)

2 Drip tray under engine

3 Automatic Diesel filtering system: Supplier

4 Automatic Diesel filtering system: Model

5 GSM Programmable Telemetry unit: Supplier

6 GSM Programmable Telemetry unit: Model

7 Warning notices provided

8 A3 Schematic drawings provided

9 3 sets of Operation & Maintenance Manuals

OF 43

2.1.1.12 Delivery and Testing

NO ITEM REMARKS

1 Expected delivery time from date of order (weeks)

2 Factory test

3 Load test at factory on balanced resistive load

4 Delivery to site, Rigging, Commissioning and testing of the entire Generator system as specified

2.1.1.13 Spare Parts and Maintenance Facilities

NO ITEM REMARKS

1 Approximate value of spares carried in stock for this particular diesel engine and alternator

2 Where are these spares held in stock

3 What facilities exist for the servicing of the equipment Offered

4 Where are these facilities available

OF 43

2.1.1.14 Guarantee

This item must be completed for tender purposes.

NO ITEM REMARKS

1. Guarantee period in months

2. State conditions of guarantee

2.1.1.15 Deviation from the Specification (State briefly)

NO DESCRIPTION

2.1.1.16 Delivery date of Generator Set

State approximate delivery date of Generator Set ……………………………………………

OF 43

SECTION 2 MATERIAL QUALITY SPECIFICATION

OF 43

3. SECTION 2 - MATERIAL QUALITY SPECIFICATION

3.1 GENERATOR SETS

3.1.1 General

(i) This specification covers only general aspects of a Standby Generator set, but does not

describe the work minutely in detail.

(ii) Refer to The Project Specification for all detail and specific requirements for this project. Any deviation from this Standard Specification or additional information will be given in the Project Specification and Annexure A. In case of contradiction between this Specification and the Project specification, the Project specification shall be given preference

(iii) Generator sets must comply SANS 8528 – Parts 1 to 8

(iv) Full particulars, performance curves and illustrations of the equipment offered, must be

submitted with the Tender. Tenderers may quote for their standard equipment, complying as closely as possible with this Specification, but any deviations from the Specification must be fully detailed.

3.1.2 Outdoor Enclosure type Sets (Where Applicable)

(i) The generating set shall be of the containerised type with a duplex base and shall be placed on

a concrete plinth in the designated location.

(ii) The final position of the container shall be determined on Site.

(iii) The supply and installation of the concrete plinth and the interconnecting sleeves to the electrical distribution manhole shall also be the responsibility of the Operator.

(iv) The generator enclosure shall be clad externally with pre-powder coated 3CR12 sheeting and

supporting frame.

(v) The generator supporting base can be manufactured from mild steel (3CR12 for coastal applications) provided:

The base must be provided with anti-vibration dampers

The frame is totally enclosed in the 3CR12 and powder coated to prevent exposure to the elements.

(vi) The enclosure is to be weatherproof with single pitch roof. The completed container shall

have an earth point, which is earthed to general earth. All components of the container shall be bonded to ensure that all parts of the container are at an equipotential.

(vii) Full details of the proposed container construction and finish, as well as the electrical

services and Equipment placement shall be submitted to the Electrical Engineer for approval prior to manufacturing.

OF 43

3.1.2.1 Enclosure Lighting (Where applicable)

(i) The container shall be equipped with internal as well as external lighting, such that

maintenance or repairs may be carried out after dark. The lighting level within the container shall not be less than 360 lux.

(ii) At least three light fittings shall be installed inside the container:

One directly above the control panel and

One on either side of the diesel engine.

(iii) The light fittings in the container shall be fluorescent type rated for IP65 with the following lamps:

above the control panel: 2x 18 Watt T8 fluorescent lamps with 1x lamp on battery backup

either side of the diesel engine: 2x 36 Watt T8 fluorescent lamps with 1x lamp on battery backup

(iv) Battery backup must be provided on all internal light fittings. The battery backup must be of

the maintained type with a minimum battery backup time of at least 60 minutes.

(v) Limit switches shall be fitted inside the container in such a manner that the lights are switched on when a Canopy door is opened and off when all Canopy doors are closed.

(vi) Two external bulkhead luminaires must be installed on either side of the enclosure. Each

luminaire shall be equipped with at least 1x 18 Watt compact fluorescent lamp. The switching of the two external lamps must be done via a photo-cell switch.

3.1.3 Indoor mounted sets

(i) The Engineer shall provide the generator manufacturer with architectural drawings with

detail dimensions of the plant room. The manufacturer must prepare and submit a layout drawing indicating all equipment in detail.

(ii) Sound attenuation must be provided for sets installed in buildings.

(iii) A double door must be provided for easy access. Required signage and notices must be

provided and installed on the door by the generator manufacturer.

(iv) The cables from the alternator to the changeover panel must be supported on heavy duty type galvanised cable ladders.

(v) Piping on the floor must be covered with galvanised covers.

(vi) The siren/beacon unit must be mounted above the door on the outside.

OF 43

3.1.4 Base frame

(i) The engine and alternator shall be mounted on a common vibration attenuation “DUPLEX”

base. (ii) The generator supporting base can be manufactured from mild steel provided:

The complete base must be hot dip galvanised prior to assembly

Or a paint specification must be issued for approval

(i) If a day tank for part of the base frame an abutment must be provided with 110% in which the base is mounted and filled with sand

3.1.5 Engine

(i) The engine must comply with the requirements laid down in SANS 8528 as well as BS 5514

and must be of the solid injection, compression ignition type, running at a speed not exceeding 1 500 rpm.

(ii) The engine must be amply rated for the required electrical output of the set, when running

under the project specified site conditions. The staring period for either manual or automatic switching-on until taking over by the generating set, in one step, of a load equal to the total specified site electrical output, shall not exceed 30 seconds. This must be guaranteed by the Tenderer.

(iii) Turbocharged engines will only be accepted if the Tenderer provides a written guarantee

that the engine can deliver full load within the specified starting period.

(iv) Curves furnished by the engine makers, showing the output of the engine offered against the speed, for both intermittent and continuous operation as well as fuel consumption curves when the engine is used for electric generation, must be submitted with the tender.

(i) All service connections to the engine shall be flexible to allow the free movement of the set

and prevent the transmission of vibration to the building or other structural elements. All engine flexible or rigid piping not heat resistant shall be adequately protected against damage by radiant heat.

(ii) Engine wiring shall be silicone rubber insulated or shall be of the AUTO-WIRE type.

(iii) All moving parts shall be adequately protected against accidental contact.

3.1.6 Engine Rating

(i) The generator set shall be capable of delivering the specified output under the site

conditions, without overheating.

(ii) The engine shall be capable of delivering an output of 110 % of the specified electrical load at the same speed for one (1) hour in any period of 12 hours consecutive running without undue heating of the engine as per SANS 8528.

OF 43

3.1.7 Engine De-rating

(i) The engine must be de-rated for the site conditions as set out in the Detail Specification, of

this document.

(ii) The de-rating of the engine for site conditions shall be strictly in accordance with SANS 8528 as amended to date. Any other methods of de-rating must have the approval of the engineer and must be motivated in detail. Such de-rating must be guaranteed in writing and proved by the successful Tenderer at the site test.

3.1.8 Engine Starting and Stopping

(i) The engine shall be fitted with an electric starter motor and be easily started from cold,

without the use of any special ignition devices under summer as well as winter conditions.

(ii) Tenderers must state what arrangements are provided to ensure easy starting in cold weather. Full details of this equipment must be submitted. In the case of water cooled engines, any electrical heaters shall be thermostatically controlled. The electrical circuit for such heaters shall be taken from the control panel, and must be protected by a suitable circuit breaker.

3.1.9 Engine Cooling

(i) The engine must be of the water-cooled type.

(ii) A built-on heavy duty, tropical type pressurized radiator must be fitted. An electric heater

shall be installed.

(iii) Protection must be provided against running at excessive temperatures. The operation of this protective device must give a visual and audible indication on the switchboard on the control panel.

(iv) A low water cut-out switch, installed in the radiator, to switch the set off in the event of a

loss of coolant. The protection shall operate in the same way as the other cut-outs (e.g. low oil pressure). All air ducts for the cooling of the engine are to be allowed for. The air shall be supplied from the cooling fan cowling/radiator face to air outlet louvers in the plant room wall.

3.1.10 Engine Lubrication

(i) Lubrication of the main bearings and other important moving parts shall be by forced feed

system. An automatic low oil pressure cut-out must be fitted, operating the stop solenoid on the engine and giving a visible and audible indication on the control panel.

OF 43

3.1.11 Mechanical Fusible Link

(i) A mechanical fusible link across the diesel engine will provide fuel shut-off in case of fire.

(ii) The day tank outlet shall be fitted with a 16mm brass ball valve and 8 kg gravity dead-weight

to facilitate the shut-off.

3.1.12 Electronic Governor

(i) An electronic governor, Woodward or Cummins or approved equivalent, must be supplied

and installed to ensure fast step response recovery and accurate speed control of the diesel engine under varying load conditions.

(ii) The permanent speed variation shall not exceed 4.5% of the nominal engine speed.

(iii) The set must be compatible for the continuous supply of power to sensitive UPS equipment.

(iv) The cyclic irregularity of the set must be within the limit laid down in SANS 8528

3.1.13 Alternator - General

(i) The alternator shall be off the self-excited brushless type, with enclosed ventilated drip

proof housing and must be capable of supplying the specified output continuously as per IEC 60034-1.

(ii) The alternator shall be capable of delivering an output of 110% of the specified output, for

one hour in any period of 12 hour in any period of 12 hours in consecutive running.

(iii) The housing shall be made of steel with cast iron flanges & shields. The IP rating of the alternator must be at least IP23 rated.

(iv) Both windings must be fully impregnated for tropical climate and must have an oil resisting

finishing varnish.

(v) This rating shall be attainable at its output terminals, at the specified altitude, environment and in the configuration as specified.

(vi) The alternator terminal box must be easily accessible to the main terminals and AVR unit.

OF 43

3.1.14 Alternator Performance

(i) The excitation system shall be designed to promote rapid voltage recovery following the sudden

application of the load.

(ii) The voltage shall recover to within 5% of the steady state within 300 milliseconds following the application of full load and the transient voltage dip shall not exceed 18%.

(iii) The alternator must sustain a short circuit current of 300% of In for 10 seconds.

3.1.15 Alternator Regulation

(i) The alternator must preferably be self-regulated without the utilization of solid state

elements.

(ii) The inherent voltage regulation must not exceed plus or minus 5% of the nominal voltage specified, at all loads with the power factor between unity and 0,8 lagging and within the driving speed variations of 4,5% between no-load and full load.

(iii) The AVR unit must be encapsulated in resin for optimum resistance to vibration and harsh

atmospheric conditions.

(iv) The unit must be protected for overload, short-circuit and loss of voltage sensing

3.1.16 Alternator Coupling

(i) The alternator shall be mounted on a vibration attenuated, duplex base and otherwise comply

with this specification.

(ii) The engine and alternator must be directly coupled by means of a high quality flexible coupling, equal and similar to the “HOLSET” type.

OF 43

3.1.17 Dummy Load (Where applicable)

(i) Refer to the Project Specification for the detail requirements and sizes.

(ii) The following minimum requirements must be met if a dummy load is required:

The dummy load will consist of 3 steps. The load monitoring circuit shall select the load in any of three steps. Bypass selector switches must also be provided to enable the manual selection of any of the specified load steps.

Dummy load shall constitute 40% of the rated generator output.

The load monitoring circuit shall select the load in any of three steps, 20 %, 10 % and 10% of the rated kW output.

The dummy load will only be connected 5 minutes after start-up.

Three amber indicators (one per bank) labelled “bank X connected” shall be provided.

Preference shall be given to generator systems where the dummy load is an integral part of the radiator cowl and is cooled by the radiator fan.

3.1.18 System Operation

(i) The set is required to supply the lighting and power requirements in the case of a mains

power failure.

(ii) The set shall be fully automatic i.e. it shall start when any one phase of the main supply fails or get switched and shall shut down when the normal supply is re-established. In addition, it shall be possible to manually start and stop the set by means of pushbuttons on the switchboard.

(iii) The automatic control shall make provision for three consecutive starting attempts.

Thereafter the set must be switched off, and the start failure relay on the switchboard must give a visible and audible indication of the fault.

(iv) The changeover unit and panel, from mains (or normal) to emergency power shall form an

integral part of the MLV Distribution Board (Supplied by others).

(v) To prevent the alternator being electrically connected to the mains supply when the mains supply is on and vice versa, a safe and fail proof system of suitably interlocked contactors shall be supplied and fitted to the changeover switchboard.

Important Note: The Tenderer must submit the design of the control system to comply with the requirements for automatic starting, stopping, interlocking and isolation as specified.

OF 43

3.1.18.1 The changeover configurations (General)

These contactors/motorised circuit breakers shall change the supply to the Main Distribution Board from mains to emergency power and vice versa in the following manner:

Failure of a phase or failure of the utility supply to the main distribution board (normal power) shall be detected on the outgoing side of the main bus bar. A phase failure or a failure of the utility supply shall initiate the starting cycle of the generator, after an adjustable 0 to 6 seconds delay. If the mains supply is restored within the set period, the starting cycle shall be aborted and the control system shall reset to the standby mode.

As soon as the emergency supply from the both generators become available and have been fully synchronized, a timing circuit shall be initiated to provide an adjustable 0 to 6 seconds delay between the opening of the mains contactor and the closing of the emergency contactor. Note that the mains contactor shall remain closed during generator start-up and shall not open unless the emergency supply is available and the mains supply is still out.

As soon as the utility supply is restored, a mains return timing circuit shall be initiated to hold the mains contactor open and the emergency contactor closed, for an adjustable period of 0 to 10 minutes. This is required to prevent the changeover from emergency to mains taking place if the restoration of the main supply is only temporary.

At the end of this mains return delay, the emergency contactor shall open and the main contactor shall close. An adjustable delay of 0 to 3 seconds shall be provided between the opening of the emergency and closing of the mains contactors.

After successful reverse changeover, back to mains supply, the engine shall be run on no-load for a pre-set period. A 0 to 6 minutes adjustable timer shall control this period.

At the end of the run-down period, the engine shall be shut down and the control system shall revert to the standby mode.

Should a main failure re-occur during the run-down period, the run-down cycle shall be aborted and the changeover from mains to emergency shall take place as before.

Note: If more than one generator is installed – refer to project specification for further details.

3.1.19 Generator Control and Change over Panel

3.1.19.1 General

(i) The generator control panel shall be manufactured from mild steel, powder coated:

a. Shell - Structured Orange B26 b. Utility supply sections – Structured Orange B26 c. Generator supply sections - Signal Red A11

(ii) Panel shall be weather proof, vermin proof and installed over a trench in the generator room. Separate sections, with full divisions, shall be provided for each power supply section.

(iii) Allowance must be made for cable ladders and support brackets for all cables and wiring

required from the engine/alternator to the control panel. The control panel must be able to accept cable entries from both bottom and top.

(iv) Refer to the Project Specification for position of Panel, supply cables and sleeve positions.

This must be coordinated with the position of the control panel.

OF 43

(v) Microprocessor based control panels would be preferred.

(vi) Suitable surge protection for the control panel must be provided as specified in this

specification.

(vii) The following indication, with a test facility, shall be provided on the generator control panel (incorporated into controller):

Load on normal supply

Load on emergency supply

Mains failure

Engine run down cycle

Genset in standby mode

Water jacket heater failure

Low day fuel tank level

Engine start failure

Auto-start disabled

High engine temperature

Battery charger failure

Engine over speed

Engine under speed

Overvoltage

Under voltage

Low oil pressure

Low water level

Battery voltage low

(viii) For LCD displays a legend card clearly indicating the type of fault must be provided within sight of the display behind a 4 mm Perspex glass.

(ix) All timer relays or electronic timing circuits adjustment devices shall be labelled according to

their function, for ease of maintenance and future modifications.

3.1.19.2 Key switches

(i) Two key operated switches, labelled as follows:

MAINS OPERATIONS

SUPPLY SELECTOR SWITCH

Shall be fitted on the generator control panel. These two key switches may be combined in one switch provided that the full functionality as described below is maintained.

3.1.19.2.1 Mains Operations key switch

This switch shall have four positions:

In the Auto position, the changeover sequence shall operate automatically as described.

In the Gen. Locked Out position, the changeover sequence shall not be initiated if a mains fail situation occurs. Remote alarm indication is required if the switch is in the latter position. This

OF 43

will mean the Generator is “OFF” or out of service temporary until the key switch is re-positioned.

In the Simulate Mains Failure position, a main failure shall be simulated. The changeover sequence shall be initiated if the simulation period exceeds the main failure delay. This function will be used by the operator for testing purposes.

In the Emergency Start position the Generator will bypass the controller. The set will start and the change over to the alternator mains circuit breaker will be initiated.

3.1.19.2.2 Supply Selector key switch

This switch shall have three positions:

In the Auto position the controller will control the changeover operation and sequence.

The following two positions will only be initiated if the Mains Operation switch is in the Emergency Start position. In the Mains position the Mains circuit breaker will be closed and the Alternator circuit breaker will be opened. In the Alternator position the circuit breaker will be closed and the Mains circuit breaker will be opened.

OF 43

3.1.20 Change over switch gear (Not part of this Scope of Works)

(i) A triple pole on-load breaker is to be provided to isolate the mains (may for part of the

changeover system)

(ii) The changeover equipment shall consist of suitably rated motorised circuit breakers.

(iii) The switchgear must be mechanically and electrically interlocked to prevent the paralleling of the mains and emergency supplies. The sensing and change over equipment shall be rated at minimum 25 kA fault level. See the Project Specification and or the Project drawings for the applicable schematic diagram.

(iv) Where a generator set/sets are synchronized with the utility supply, mechanical interlocking

shall not be applicable for the changeover panel.

(v) Allowance must be made for all equipment including on the schematic diagram as well as 20% spare space.

3.1.21 Starter Batteries

(i) The battery voltage shall be 12V or 24V.

(ii) A dual battery system shall be provided with two independent sets parallel connected.

(iii) The set must be supplied a fully charged lead-acid type battery, complete with necessary

electrolyte.

(iv) The battery must have sufficient capacity to provide the starting torque stipulated by the engine makers. The battery capacity shall not be less than 120 Ah and shall be capable of providing three consecutive start attempts from cold and thereafter a fourth attempt under manual control of not less than 20 seconds duration each.

(v) The diesel generator set starting batteries shall be heavy-duty “low maintenance” type Delco

Remy Type 1250 supplied and distributed by Willard Batteries or similar approved. Batteries shall be supplied complete with charger and battery stand as specified.

(vi) The charger shall be internally supplied from emergency power while the set is operational,

(i.e. mains not available). The charger shall be capable to recharge a fully discharged battery under normal operating modes from the mains supply

OF 43

3.1.22 Emergency stop

(i) An emergency stop switch must be provided on the front panel and must be easy accessible

during an emergency.

3.1.23 Gauges

(i) The following “engine” gauges must be installed on the control panel:

Engine water temperature

Engine oil pressure

Alternator charge rate

(ii) VDO type gauges shall take preference for the above. All three gauges shall be provided with engraved labels, indicating the "normal" parameters of each gauge.

(iii) The following electrical meters must be mounted on the control panel:

running hour meter (six-digit type)

battery voltage

battery charge rate

frequency

three phase demand current meter

voltage selector switch and meter

(iv) The use of a digital multi-meter that combines some or all of the above electrical meters may be used if approved by the Engineer.

3.1.24 16 Amp plug

(i) Provision must be made for a 3-pin 16Amp switch socket outlet inside the control panel for

maintenance and cleaning. (To be provided by main contractor)

3.1.25 Wiring diagram

(i) A system schematic diagram (A3 size), indicating the phase failure sensing circuit and the

complete generator change over control circuit, shall be prepared and mounted on the wall behind 4 mm clear Perspex.

3.1.26 Siren / Beacon

(i) A combination siren/beacon unit must be provided. The beacon must sound an alarm of

minimum 110 dB at a distance of 2 metres, and shall be IP55 rated.

(ii) Any alarm condition must sound the alarm. Two push buttons must be provided to control the siren, an ALARM ACCEPT and ALARM RESET button. By activating the alarm accept button only the siren may be silenced. The beacon can only be cleared once the fault is cleared.

OF 43

3.1.27 Water Jacket Heater

(i) An electrical type water jacket heater system shall be provided, complete with thermostat.

3.1.28 Drip Tray

(i) A removable drip tray shall be supplied to collect spillage from the fuel pump and diesel

engine.

3.1.29 Diesel Fuel Pumping system

3.1.29.1 Manually operated & Electrical fuel pump

(i) The electric pump shall be fed from the generator control panel with 220 Volt AC emergency

power. The pump shall be automatically activated by means of the level switches (REMEX type) when the day tank drops below 80 litre. The pump shall also be activated by means of push-button “push to operate” control. This pushbutton shall be installed within sight of the fuel tank visual level indicator.

(ii) An emergency hand operated semi-rotary hand pump shall also be installed to fill the diesel

tank from an outside fuel storage drum or tank. The pump must be able to pump at least 10 litres per 45 strokes. A 25 mm ø 5 m fuel compatible suction hose must be fitted on the pump. A cartridge type fuel filter shall be provided between the above-mentioned hand pump and the day tank.

(iii) Level switches shall be REMEX or approved equivalent

3.1.30 Diesel Fuel Filtering system (Where applicable)

(i) An automatic diesel filtering and water separation system must be installed. An electronic timer

must be provided to set the automatic recycling period. The filtration media must be 5 microns rated, resin impregnated paper element. The water must be drained automatically with no operator intervention

(ii) The system shall be the Duvalco “MFS” Filtration System for day tanks.

(iii) If a Bulk diesel tank is installed the Duvalco “BFS” Filtration System must be installed

3.1.31 Diesel Fuel Tanks

3.1.31.1 General

(i) The contractor on handover of the completed works shall provide a full tank of diesel to the

Client.

3.1.31.2 Day Fuel Tank

(i) A day tank of adequate capacity for 12 running hours at full load shall be manufactured,

supplied and installed in the generator base or loose standing in the space provided. The fuel

OF 43

tank shall be positioned such that free access to the tank may be afforded. The tank will be a double skin steel tank.

(ii) The tank shall be fitted with an inspection hole and cover of suitable size to facilitate the

cleaning of the tank. A fusible valve shall be installed in the fuel line. When a fire breaks out in the substation, a fusible link shall melt and cause the fuel supply to the engine to be cut off.

(iii) The fuel tank shall be fitted with an alarm to provide an audible alarm on the generator

control panel when the fuel level in the tank drops below 25% with a second cut out level switch at 5% to stop the engine before it runs out of fuel.

(iv) The day tank level switch shall switch the 24 VDC solenoid valve at the day tank. Note that a

total of three level switches are required:

empty tank engine cut-out signal.

low fuel alarm

switching the inlet solenoid valve

(v) A dial type fuel level indicator shall be provided to indicate the fuel level on inspection and shall be visible whilst the hand pump is being operated.

(vi) A stopcock shall be fitted on the lowest point of the day tank to withdraw fuel samples.

(vii) The highest level of fuel in the tank shall never be higher than the lowest level of the

generator’s injectors.

3.1.31.3 Bulk Fuel Tank (Not Applicable)

(i) An above ground bulk fuel tank shall be manufactured, supplied and installed in the position

indicated.

(ii) The tank installation shall conform to SANS 0131 and SANS 089 as amended and shall form part of this contract. Special attention to be given to SANS 089 Parts 2 and 3 as amended.

(iii) Piping shall be steel to SANS 62 with allowance for expansion, wrapped with Denso tape,

overlapping 15 mm.

(iv) A drawing indicating the position of the bulk tank must be submitted to the following institutions for approval and certification:

Local Town or City Council

Local Fire Department

(v) The installation may only comments once the drawing is approved.

(vi) The fire department must do site inspections during the installation of the tank. The Fire department must be informed timelessly to do inspections.

(vii) The tank supplier shall be required to issue a certificate when the installation is complete.

OF 43

(viii) Gravity feed lines shall be 22 mm Ø copper tubing with galvanised support brackets and galvanised protective unistrut sections between the bulk and day tanks. Piping shall be steel to SANS 62 with allowance for expansion, wrapped with Denso tape, overlapping 15 mm.

(ix) The bulk tank shall be fitted with an alarm to provide an audible alarm on the generator control

panel when the fuel level in the tank drops to below 25%. All the required connection pipes, valves etc. shall be supplied, installed and connected with the bulk fuel tank.

(x) The bulk tank shall automatic refuel the day tank when the day tank. Fuel transfer pumps shall

be supplied and installed as backup to the gravity feed system. These pumps shall be positive displacement vane pumps. The pumps shall be controlled by means of the day tank level switch.

(xi) The day tank will be fitted with a 32mm overflow outlet piped to the bulk tank with similar

size return line.

(xii) An insulated 16 mm2 earth wire shall be provided to bond the bulk tank to the generator day tank.

(xiii) The bulk storage tank shall be positioned at least 3m away from any building structure.

(xiv) The bulk diesel tank shall be provided with a bund wall to contain any spillage, and shall be

rated to 110% capacity of the diesel storage vessel. (Bund structure typically provided by building contractor if not specified otherwise in the project specification)

3.1.32 Exhaust Silencer system

(i) The exhaust system of the generator shall be residential specification limited to 65dBA.

Sound pollution will be measured after the installation to ensure the required level is provided.

(ii) The exhaust, where exposed to weather, shall be manufactured from 304 stainless steel.

(iii) A flexible stainless steel piece must be installed between the engine manifold and the

exhaust pipe.

(iv) The entire exhaust shall be lagged with heat insulating material so that the cold surface temperatures do not operate at more than 60º C above ambient.

(v) To prevent sound reflection and echo between the buildings, the exhaust shall face away

from the buildings. The exhaust shall be fitted with a drain tap at the lowest point of the exhaust, to allow the draining of water entering the pipe.

(vi) The exhaust shall be supported independently of the container, on a structure supplied and

installed as part of this contract.

(vii) The indoor section of the exhaust if inside a Generator room shall be supported from the roof by means of spring-support units.

3.1.33 Radiator Cowl and Flashings

(i) Radiator cowls and flashings must be installed to connect to the weather louver.

OF 43

(ii) Tenderers shall confirm in their tenders that the Genset position is acceptable for the

generating set requirements.

3.1.34 Weatherproof Enclosure

(i) This generator set will be housed in a self-contained weatherproof (IP54 minimum), sound

attenuated enclosure.

(ii) All steel louvers must be powder coated. The colour must be white but must be confirmed by the Client.

3.1.35 Fire Extinguishers (not applicable)

(i) One 4,5 kg fire extinguisher suitable for extinguishing electrical and fuel fires shall be

supplied and mounted in close proximity of the generator set (10 meter radius).

3.1.36 Warning Notices

The contents of these notices are summarized below.

(a) Unauthorized entry prohibited.

(b) Unauthorized handing of equipment prohibited.

(c) Procedure in case of electric shock.

(d) Procedure in case of fire.

(i) The successful Tenderer must consult the Occupational Health and Safety Act 83 of 1993 or as amended and get approval of the wording from the engineer, prior to ordering the notices.

(ii) Lettering must be black on a yellow background.

(iii) Notices (a) must be installed outside next to the entrance of the plant room and (b-d) inside the plant

room.

(iv) Inside the generator enclosure, a clearly legible and indelible warning notice must be mounted in a conspicuous position. The motive shall be made of a non-corrodible and non-deteriorating material, preferable plastic, and must read as follows:

DANGER: This engine will start without notice.

Turn selector switch on control board to “OFF” before working on the plant.

OF 43

3.1.37 Earthing

(i) The generator control and change-over board, engine, alternator and enclosure shall be

earthed to the main earth system via a 70mm² Bare Copper Earth Wire. This will be done by others.

(ii) The generator manufacturer must allow to bond between the engine, alternator, change

over panel and main earth bar inside the control panel.

3.1.38 Lightning and Surge Protection

(i) Surge arrestors shall be installed between all live and neutral constructions in every

individual panel.

(ii) Lightning/surge arrestors shall be installed on the normal busbars. A DEHNventil TT unit must be used for this purpose, and shall be as accessible as circuit breakers. A set of 315A HRC fuses must be used to connect this unit to the busbar if the fault rating exceeds 5kA.

(iii) A 16Amp, 400Volt DEHNrail 230 3N and 1x DEHN Netzfilter NF10 in series must be installed

in the auxiliary section. All electronic equipment must be supplied through this unit. This will include the battery charger, Power supplies and Generator control unit

(iv) All live connections to the surge arrestors shall be by means of minimum 16mm² insulated

copper conductors.

(v) The surge protection unit shall be solidly bonded to the changeover panel earth bar by means of 16 mm² green insulated copper conductors.

3.1.39 Workshop Drawings

(i) A complete set of workshop drawings must be prepared and issued to the Engineer for

approval. No manufacturing may commence before the approval of these drawings.

(ii) Detail Control and Single line diagrams as well as the Mechanical works must be submitted to the Engineer. Engine, alternator and base details must form part of the mechanical drawings.

(iii) The diesel tank details as well as a fuel diagram must be submitted for review.

(iv) Detail drawings must be provided for the louvers and sound attenuation systems

3.1.40 Testing of the Generator set

3.1.40.1 Workshop Drawings

(i) A complete set of workshop drawings must be prepared and issued to the Engineer for

approval. No manufacturing may commence before the approval of these drawings.

3.1.40.2 Testing

(i) Before delivery to site, the Engineer and a client representative will be invited to witness

tests at the manufacturer's premises. Test shall be carried out in accordance with SANS 8528

OF 43

and BS5514, to prove that the equipment will deliver the specified output. The manufacturer shall submit and forward a proposed detail test procedure the Engineer at least two weeks before the testing.

(ii) Suitable test gear shall be provided at the manufacturer's premises in order to simulate and

prove all aspects of the changeover system as specified.

(iii) All protective devices and systems shall be fully tested. Injection tests shall be performed to check and test all metering equipment.

(iv) The making available of all equipment, plant and instruments required for the testing and

commissioning shall form part of this Contract.

(v) On site, tests shall be a repetition of the above and shall also be performed in the presence of the Engineer or his representative. The contractor shall provide all the test equipment and instruments, which may be necessary. Load tests are to be done on both occasions.

(vi) Copies of the test reports for the above tests shall be submitted to the Engineer, and shall

also be included in the maintenance manuals.

3.1.40.3 Commissioning

(i) All items shall be pre-checked by the contractor, prior to commissioning. Copies of the

results of all pre-checks, as well as a detailed commissioning procedure for each piece of equipment, shall be presented to the Engineer for approval before commissioning takes place. Note that the Engineer will not commission the system or any part thereof on behalf of the contractor. The contractor, to the satisfaction of the Engineer shall perform all commissioning. The Engineer will witness commissioning.

3.1.41 Operation and Maintenance Manual

(i) The contractor shall prepare and provide comprehensive operating and instruction manuals

(three sets of each) for the Genset in its entirety and comprising the following:

3.1.41.1 Pre-start Checks

(i) These checking procedures shall include pre-start-up checks on batteries, fuel pipes, fuel

levels, lubrication oil levels, coolant levels, alarm indicator lamps and settings of key operated switches and timer relays.

3.1.41.2 Operating Instructions

(i) The function of each switch or control device shall be detailed.

(ii) Manual or automatic operation settings and procedures shall be detailed.

3.1.41.3 Alarm Indication

(i) All alarm conditions and remedies to restore these conditions shall be detailed.

3.1.41.4 Fault Finding

(i) Detailed, logical fault finding procedures, together with readings to be expected for all

possible fault conditions, shall be detailed.

OF 43

3.1.41.5 Wiring Diagrams

(i) Detailed wiring diagrams (A3 size) complete with cable wire and core numbering as well as

terminal block and relay numbering shall be provided in the manuals.

3.1.41.6 Engine and Alternator Information

(i) Relevant detail regarding engine and alternator specifications, lubricants required,

recommended service intervals, detailed service procedures, spares lists and dealer network information shall be provided.

3.1.41.7 Test Sheets and Certificates

(i) Copies of all works test sheets and type test certificates for all items shall be provided.

(ii) The contractor's attention is drawn to the following:

A draft Operating and Maintenance manual shall be submitted to the Engineer for approval at least three (3) weeks before the anticipated handing over date.

The Contract will not be regarded as complete until all requirements in this regard have been met.

3.1.41.8 Service interval details

(i) The tenderer shall provide detail on the exact service and maintenance intervals to be done.

3.1.41.9 Spare holding

(i) The tenderer to specify in manual all required spares and items that must be kept on site for

maintenance.

3.1.41.10 Weekly inspections and test run sheets.

(i) Weekly inspection and test run sheets must be provided in the manuals. All findings and

recordings must be recorded on the sheets to keep a detail maintenance record.

3.1.42 Training of Operator

(i) After the installation has been commissioned, the contractor shall train an appointed person

to operate and control the generating set. The cost of training shall be included in the tender price. The training procedures shall be submitted to the Engineer in writing. After completion of the training period, the Engineer will evaluate the trainee.

3.1.43 Commissioning, Testing and Handing over

(i) The contractor shall be responsible for the commissioning and testing of every component of

the entire systems.

(ii) All items are to be pre-checked by the contractor, prior to commissioning. Copies of the results of all pre-checks, as well as a detailed commissioning procedure for each piece of equipment, shall be presented to the Engineer for approval before commissioning takes place. Note that the Engineer will not commission the system or any part thereof on behalf

OF 43

of the contractor. The contractor, to the satisfaction of the Engineer shall perform all commissioning. The Engineer will witness commissioning. The contractor shall confirm in writing that the entire system has been installed according to specification and that it is operational.

(iii) If the Engineer is satisfied that the system complies with the specification, the contractor

shall hand the system over to the Employer in the presence of the Engineer.

(iv) During handover, the contractor shall re-demonstrate the following to the Engineer in the presence of the Employer's representative:

All operational procedures and pre-switch-on checks

Switching on of the system for normal and maintenance purposes

Maintenance procedures, including the replacement of luminaires and lamps; and

All preventative maintenance checks and procedures

(v) After commissioning and successful final inspection of the installation, a certificate of practical completion, co-signed by the principal contractor, contractor, the Engineer and the Employer will be issued. Note that the date of issue of the certificate will represent the actual completion date of the works. Refer to the detailed maintenance requirements in the conditions of contract.

(vi) Even though the installation may consist of various sub-systems, the contractor shall be

responsible to commission and hand over the entire installation simultaneously. No portions will be handed over on a "beneficial occupation" basis. Those sub-systems, which may be complete well before the date of actual completion of the works, shall be safeguarded and maintained until the entire installation may be handed over simultaneously. Any damages, due to any cause whatsoever, will be for the contractor's own account.

(vii) Safety procedures for maintenance personnel as well as road users shall be demonstrated

during the above procedures.

(viii) All the above procedures shall be clearly documented in the manuals.

3.1.44 Initial Maintenance Contract

(i) The successful Tenderer will be required to maintain the plant in good running order for a

period of twelve months after the plant has been taken over by the client.

(ii) The equipment and installation included in this Contract shall be guaranteed and maintained in all respects for a period of twelve months. The maintenance period shall commence from the date of issue of the certificate of completion issued by the Engineer for the principal contract as a whole, including this, as well as the other, selected subcontracts.

(iii) The full costs of this maintenance must be included in the tender price, inclusive of

overheads and travelling fees. A part from the consumables as detailed below, the engineer shall not acknowledge any cost claims additional to this maintenance cost as tendered. The contractor shall, for the full duration of the maintenance period, be responsible for all work and equipment replacements required, including labour, travelling costs, the replacement of lamps and fuses, etc. Renewals or repairs resulting from misuse, however, will not be made at the expense of the contractor. The contractor shall repair/replace faulty equipment within 48-hours of notification.

OF 43

(iv) However, should the Contractor fail to hand over the plant in good working order on expiry of the specified twelve months, the Contractor will be responsible for further monthly maintenance until final delivery is taken.

(v) All guarantees from manufacturers and suppliers shall be transferred to the Employer as

from the date of issue of the final certificate.

(vi) Tenderers shall submit full details of their maintenance and repair service facilities at all times, including statutory holidays, weekends, after hours and normal hours.

(vii) The contractor shall stock the accepted list of spares during the twelve (12) month

guarantee and free maintenance period. All repairs to be made to the installation due to causes not covered by the guarantees (e.g. vehicles colliding with equipment) shall be done utilising the above material.

(viii) The Engineer shall inspect the above materials during handover, on which date it shall be

certified for payment (material and storage only).

(ix) At the end of the maintenance period, the remaining material shall be documented and handed over to the Employer for the ongoing maintenance of the installation.

(x) Under this agreement the Contractor will undertake to arrange once per month for a visit to

the plant by a qualified member of his staff, who shall:

(a) Report to the Officer-in-charge, keeping the maintenance records, and enters into a log book the date of the visit, the tests carried out, the adjustments made, and any further details that may be required.

(b) Grease and oil moving parts, where necessary.

(c) Check the air filters and, when necessary, clean the filters and replace filter oil.

(d) Check the lubricating oil and top-up when necessary.

(e) After the plant has run one oil change for the number of hours stipulated by the

manufacturers, drain the sump and refill with fresh lubricating oil. The reading of the hour meter on the switchboard will be taken to establish the number of hours run by the plant. Under this heading only the cost of the actual oil used, shall be charged as an extra on the monthly account.

(f) Clean the lubricating oil filter and/or replace the filter element at intervals recommended by

the engine manufacturer, the cost of a new filter element to be charged as an extra on the monthly account.

(g) Check and when necessary adjust the valve settings and the fuel injection equipment.

(h) Check the battery and top-up the electrolyte when necessary.

(i) Test-run the plant for 0,5 hour and check the automatic starting with simulated faults on the

mains, the proper working of all parts, including the electrical gear the protective devices with fault indicators, the changeover equipment and the battery charger. Make the necessary adjustments.

(j) Report to the engineer and to the Contractor on any parts that become unserviceable

through fair wear and tear, or damaged by causes beyond the control of the Contractor. The

OF 43

Contractor on receiving the report, shall immediately submit a detailed quotation for the repair or replacement of such parts to the engineer.

(k) Advise the engineer when it has become necessary to decarbonise the engine and submit a

quotation for this service.

(l) Top up the water of the radiator, if applicable.

(m) Clean the plant and its components.

3.1.45 Maintenance Contract after the first 12 Months

(i) The tenderer shall submit with his tender details, of a contract for maintaining the

generating set after the initial full maintenance period of one (1) year has expired. The acceptance of the tender shall not bind the client to accept this maintenance agreement.

(ii) The following minimum information shall be provided:

Price for annual maintenance agreement

Service interval details

Pro-forma maintenance contract

Number of competent personnel available to maintain the system

Spare holding.

Response time.

OF 43

SECTION 3

PROJECT SPECIFICATION

OF 43

4. SECTION 3 - PROJECT SPECIFICATION

4.1 200kVA PRIME RATED GENERATOR SET One 200kVA Prime rated generator set must be provided. There will be one changeover in the MLV Distribution Board. The generator will supply the normal (non-essential) supplies and the Essential/Critical supplies. The generator set is required to start-up and accept the electrical full load within 30s from a utility supply failure. The generator is required to be synchronized with the utility supply for a seamless transfer back to utility supply.

4.1.1 General

(i) The generator must comply with the Material Quality Specification unless otherwise specified in

the Project Specification.

(ii) The generator will be installed outside the LV Room, approximately 10 metres away.

(iii) Detail design drawings must be provided for approval by the electrical consultant.

(iv) The price shall include the Design, Manufacturing, Delivery, Rigging, Commissioning and testing of the system.

(v) See drawing: COE-0070 / COE-EE-001 for the MLV Distribution Board, which is included in the tender.

4.1.2 Site Conditions

Location : Durban, Kwazulu Natal

Altitude : 8 meters above sea level

Temperature Highest recorded : 36 ℃

Temperature Average high : 27 ℃

Temperature Average low : 11 ℃

Temperature Lowest recorded : 6 ℃

Humidity : 73% - 85%

4.1.3 Generator Requirements

Specification : As per Material Quality Specification and Section 1

Size : 1x Prime rated 200 kVA, 400/230 Volt, 50Hz

Type : Outdoor type, Diesel driven

Sound Attenuation : Yes, less than 72dB @7m away

Battery voltage : 24 Volt

OF 43

4.1.4 Engine

Engines shall comply with all requirements stated in this specification. General engine requirements:

Prime rated

“Electronic” engines are preferable

The engine must be water cooled

4.1.5 Alternator

(i) Minimum alternator ratings:

Output 400Volt, 50Hz at 1500 r.p.m

Power ≥ 200kVA at location and environment specified

Duty Continuous duty at 40℃

Insulation Class H / 125℃

Efficiency (pf = 0,8) ≥ 95%

(ii) The alternator terminal box lid must be painted in RED with a warning notice on top of the lid.

4.1.6 Diesel tank

4.1.6.1 General

(i) A day tank for the generator set must be installed (12 hour capacity). The tank will form part of

the generator base and shall be a “double skin” type diesel tank.

(ii) The diesel tank of the 1x 200kVA generator set fuel capacity may not exceed 1000 litres.

(iii) The tank must be provided with a visual fuel gauge.

(iv) A low fuel level alarm must be generated when the day tank reach 25%. The engine must be cut-out when the day tank reaches 5% of its capacity.

(v) First fill must be provided by the Generator manufacturer.

4.1.7 Cables between Alternator and Generator Control Panels

(i) The generator manufacturer must supply, install and terminate the cables between the

Alternator and the Generator Automatic change over circuit breaker.

(ii) The cables shall be installed in a cable trenches which shall be built by the main contractor. Supply cables must be mounted vertically against the trench wall on cable ladders. Mild steel cable clamps shall be used to secure each cable on the cable ladder in 1m intervals.

OF 43

(iii) The cables must be supported at the Alternator to remove strain from the alternator terminal box.

4.1.8 Generator Automatic Change Over and Generator Control panel

(i) The Automatic Change Over will be incorporated into the MLV Distribution Board (supplied

by others).

(ii) The Generator Control panel will be incorporated into the Weatherproof, sound attenuated outdoor generator set.

(iii) The main switchgear shall be Schneider as per the single line drawing. The supplier must

however submit detailed schematic as well as wiring diagrams for the entire system for approval.

(iv) The Auxiliary equipment in the Generator control panel must be protected by Type 3 surge

arrestor units as indicated on the single line diagram.

(v) The class 3 surge protection units shall be the following units:

DEHNrail M (DR M 2P 255)

(vi) The normal operating values of the analogue gauges must be provided on traffolite labels below the meters:

Engine temperature

Engine Oil Pressure

Engine Alternator Amp meter

(vii) The standard replacement Engine oil and Engine Coolant types must be provided on traffolite labels on the engine.

(viii) The tenderer shall include all control cables between the generator sets and the control panel.

4.1.9 Batteries

(i) 24Volt system. Batteries must be 120Ah rated and of the maintenance free type.

(ii) A Deep Sea Electronic 24Volt, 10Amp battery charger must be supplied.

4.1.10 Dummy Load

(i) No dummy load is required.

4.1.11 Sound Attenuation

(i) Sound attenuation shall be designed to limit noise to 72dB at 7m away from the generator

set.

OF 43

4.1.12 Remote Alarm Panel

(i) Not required.

4.1.13 GSM Programmable Telemetry Controller (Provided as optional extra)

(i) An SMS controller unit must be installed to send messages of the Generator status. The unit

must be able to connect to any cellular network via a quad-band GSM cellular engine. The unit must be configured using a Wizard type software program. The unit must be able to connect to a PC via a USB connection. Minor setup operations must be programmable by sending simple SMS messages to the unit.

(ii) The unit must be similar to the Deep Sea DSE890 3G (GSM) / Ethernet Gateway module

complete with antenna and DSE WebNet software.

4.1.14 Siren / Beacon unit

(i) The alarm siren/beacon unit must be mounted on the outside the generator enclosure.

OF 43

4.1.15 Warning & Safety Signs

The following sign E26 must be installed inside the generator enclosure:

To be mounted at Generator set:

OF 43

4.1.16 Submissions with tender

Engine detailed Brochure

Proof that Engine is ISO 8528 compliant and manufactured to ISO 9001

Alternator detailed brochure

Proof that Alternator is IEC 60034-1 compliant and manufactured to ISO 9001

AVR details

Generator control panel details.

Automatic diesel filtering system

Battery details

Sound attenuation details

Weather enclosure details

Other smaller equipment details

Completed Section 1

200kVA DIESEL GENERATOR SPECIFICATION Spare Parts and Maintenance Facilities NO ITEM REMARKS 1...

Documents

Transcript of 200kVA DIESEL GENERATOR SPECIFICATION Spare Parts and Maintenance Facilities NO ITEM REMARKS 1...