19765508 Specification for Generator

7/31/2019 19765508 Specification for Generator

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SECTION 16231

DIESEL ENGINE GENERATOR SYSTEMS

1 PART 1 - GENERAL

Drawings and general provisions of the Contract, including General andSupplementary Conditions and Division 1 Specification Sections, apply to thisSection.

1 1.01 WORK INCLUDED

1 A. This Section includes the supply, installation, testing andcommissioning of two types of generating systems in regard to their application as follows.

1. Generating System Type 1: Includes two (2) emergency generatorsserving the Main Building. The generators are located on the Roof.

The generating system shall comprise of, a factory-built - weather-proof housing including sound attenuators of a sound pressure level 83db @1.0M and 72db @ 7.0M at full load. The two generators shall run inparallel utilizing a master control Panel (synchronization panel),described hereinafter.

2. Generating System Type 2: Includes five (5) emergency generatorsserving the five shelters, one each. The generators are located inindividual rooms in the Basement.

B. Each system shall be complete packaged diesel engine-generators systemhaving the following main components,2 1. Emergency Engine- Generator Sets3 2. Cooling System.4 3. Engine Starting System.5 4. Fuel Oil Supply System consisting the Diesel Oil Fuel Storage

Tank, Tank Fuel Oil Level Indicator Gauges, Fuel Oil Piping, FuelOil Pumping and Filtering Equipment, and Fuel Oil Day Tank.6 5. Engine Exhaust Pipe works.7 6. Fresh Air Intake and Exhaust Air Systems8 7. Transfer switches.9 8. Batteries & Battery Chargers.10 9. Earthing.


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2 1.02 RELATED WORKL Related work to be coordinated and used inconjunction with this specification includes but is not restricted to:

1 A. Section 15070 - Vibration Isolation

2 B. Section 15080 - Piping and Equipment Insulation

C. Section 15081 - Ductwork Insulation

1 D. Section 16120 - Wires and Cables

2 E. Section 16060 - Earthing

3 F. Section 16415 - Transfer Switches4 G. Section 16441 - Switch Boards

2 1.03 SYSTEM DESCRIPTION

1 A. System Includes: Prime-rated automatically started diesel enginecoupled to an a.c. generator unit. Engine and generator are factory-mounted and -aligned on a structural steel skid. Subsystems and auxiliarycomponents and equipment include, but not in a way of limitation,synchronising panel, switchgears and distribution, engine starting

equipment, fuel service tanks, fuel storage tank, engine cooling system,exhaust silencing equipment and lubrication, fuel transfer pumps sets,lifting pumps sets.

2 B. Functional Description: When the mode selector switch on the controland monitoring panel is in the "automatic" position, remote controlcontacts in one or more separate automatic transfer switches initiate thestarting and stopping of the generator set. When the mode selector switchis placed in the "on" position, the generator set starts manually. The "off"position of the same switch initiates shutdown of the generator set. Uponspecific malfunction of the generator set it shall be made to shut down

automatically and initiate alarms. Operation of a remote emergency stopswitch also shuts down the unit.

3 C. The Generator Master Control Panel shall be interfaced with the BASthrough a serial communication link to facilitate full remote monitoring of the Generators, fuel tanks and fuel pumping system. Generator under frequency and overload alarms shall be available at the BAS.


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4 D. In the event of a mains power failure, the following actions shall beinitiated automatically from the BAS: All the major loads that areconnected to the Generator sets shall be set to manual mode, to berestarted only manually by the operator and subsequently transferred toautomatic mode.

E. A BAS software flag shall be available for the operator to select either manualor automatic restart after a power failure for all Low Voltage motors. If Automatic is selected, then these motors shall be started sequentially, oneprocess area at a time. Automatic control sequences

5 and timer-controlled operations shall also be resumed. If the flag is set tomanual then all controls shall be set to manual, and be ready for restartby the operator.

3 1.04 SUBMITTALS: The following submittals, as defined in section 01323 Submittal Procedures, are required:

1 A. Product Data: Include Manufacturers product literature andperformance data, sufficient to verify compliance to specificationrequirements.2 1. A paragraph by paragraph specification compliance statement,

highlighting thereby any deviations whatsoever and indicating theimplications as applicable.

3 2. Dimensioned outline plan and elevation drawings of enginegenerator set and other components specified.

4 3. Thermal damage curve for generator.5 4. Time-current characteristic curves for generator protective

device.

6 B. Shop Drawings: Indicate fabrication details, dimensions, weights, loads,required clearances, method of field assembly, components, and locationand size of each field connection.7 1. Design Calculations: Signed and sealed by a qualified

professional engineer. Calculate requirements for selectingvibration isolators and seismic restraints and for designing vibrationisolation bases.

8 2. Vibration Isolation Base Details: Signed and sealed by a qualifiedprofessional engineer. Detail fabrication, including anchorages andattachments to structure and to supported equipment. Include baseweights.

9 3. Wiring Diagrams: Detail wiring for power and control connectionsand differentiate between factory-installed and field-installed wiring.


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10 C. Field Test and Observation Reports: Indicate and interpret test resultsand inspection records relative to compliance with performancerequirements.

11 D. Certified summary of prototype-unit test report.

12 E. Certified Test Reports: For components and accessories that areequivalent, but not identical, to those tested on prototype unit.

13 F. Certified Summary of Performance Tests: Demonstrate compliance withspecified requirement to meet performance criteria for sensitive loads.

14 G. Factory Test Reports: For units to be shipped for this Project, showingevidence of compliance with specified requirements.

15 H. Exhaust Emissions Test Report: To show compliance with applicableregulations.

16 I. Sound measurement test report.

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J. Certification of Torsional Vibration Compatibility: Comply with NFPA 110.

18 K. Field test report of tests specified in Part 3.

19 L. Maintenance Data: For each packaged engine generator andaccessories to include in maintenance manuals specified in Division 1.Include the following:20 1. List of tools and replacement items recommended to be stored at

the Project for ready access. Include part and drawing numbers,current unit prices, and source of supply.

21 2. Detail operating instructions for both normal and abnormalconditions.

1 1.05 QUALITY ASSURANCE

0 A. QA shall be in accordance with Sections 01000 and 01451 and as

described below.1 B. The engine-generator set shall be the product of a single manufacturer.

2 C. The manufacturer should have a local agent with a proven successfulexperience record in the installation, testing, commissioning andmaintenance of diesel generators of the size specified herein.


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3 D. The agent should have been associated with the manufacturer for aminimum period of five years.

4 E. Source Limitations: Obtain packaged engine generator and auxiliarycomponents specified in this Section through one source from a single

manufacturer regularly engaged in the manufacture of such equipment.5 F. Engine Exhaust Emissions Comply with applicable state and local

government requirements.

6 G. The emergency power supply system and its components shall be suchas may be properly maintained and serviced without the necessity of carrying expensive spare parts stocks, or being subjected to interruptedservice due to the lack of spare parts

7 H. An engine of the same model, bore, stroke and configuration, rated atthe same or higher bhp and rpm shall have performed satisfactorily (i.e.without failures involving a major component, such as crankshaft, valve,cam shafts, piston, injector and the like) for a minimum of 2000 hours of actual operation under average rated load conditions of 75% or greater over a two year period, either at the manufacturer's factory or a stationarypower plant.

8 I. A generator and generator switchgear components of the type to beused in conjunction with the engine shall have had at least 2000 hours of satisfactory service at a minimum average load of 90%.

9 J. Emergency generator set shall be designed to allow easy replacement

of major items subject to wear.10 K. The size of the set shall be the same or next higher standard size

nearest to the rating specified, when operating at specified frequency,voltage, altitude and maximum ambient temperature.

L. Provide factory test, startup by a supplier authorized by themanufacturer, and on-site testing of the system.

11 M. The generator set manufacturer shall warrant all equipment providedunder this section so that there is one source for warranty and productservice. Technicians specifically trained and certified by the manufacturer to support the product and employed by the generator set supplier shallservice the generator sets.


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1 1.06 RELATED STANDARDS

1 A. BS4999; BS5000.

2 B. ISO8528; ISO3041/1.

3 C. BS 2757 - Method for determining the thermal classification of electricalinsulation.

4 D. EN 60034-1(BS) -1998 - Specification for rating and performance.

5 E. EN 60034-2(BS)-1998 - Methods for determining losses and efficiencyfor tests.

6 F. Part 105: (IEC 34-5) -Classification of degrees of protection provided by

enclosures for rotating machines.7 G. EN 60034-6(BS)-1994- Classification of methods of cooling.

8 H. Part 142: (ISO 2373) - Specification for mechanical performancevibration.

9 I. IEC 34-3:1980 - Generators to be driven by reciprocating internalcombustion engines.

10 J. BS 5514 P1: 1996 - Specification for reciprocating internal combustionengines: performance.

11 K. BS 5514, Part 4: (1997) - Specification for RIC engines: Performancespeed governing.

2 1.07 APPROVED MANUFACTURERS:

1 A. Subject to compliance with the requirements of the ContractDocuments furnish products from one of the following manufacturers.2 1. Caterpillar 3 2. Kohler 4 3. Mitsubishi5 4. Onan/Cummins

3 1.08 DELIVERY, STORAGE, AND HANDLING

1 A. Deliver engine generator set and system components to their finallocations in protective wrappings, containers, and other protection that willexclude dirt and moisture and prevent damage from construction


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operations. Remove protection only after equipment is safe from suchhazards.

4 1.09 WARRANTY

1 A. General Warranty: Special warranty specified in this Article shall notdeprive Employer of other rights Employer may have under other provisions of the

1 Contract Documents and shall be in addition to, and run concurrent with,other warranties made by Contractor under requirements of the ContractDocuments.

2 B. Special Warranty: Written warranty, executed by manufacturer agreeingto repair or replace packaged engine generator and auxiliary components

that fail in materials or workmanship within specified warranty period.3 1. Warranty Period: Five years from date of Substantial Completion.

2 1.10 MAINTENANCE SERVICE

1 A. Maintenance: At Substantial Completion, begin 12 months' fullmaintenance by skilled employees of the manufacturer's designatedservice organization. Include quarterly exercising to check for proper,starting, load transfer, and running under load. Include routine preventivemaintenance as recommended by manufacturer and adjusting as requiredfor proper operation. Maintenance agreements shall include parts andsupplies as used in the manufacture and installation of original equipment.

3 1.11 EXTRA MATERIALS

A. Furnish extra materials described below that match products installed andthat are packaged with protective covering for storage and identified withlabels describing contents.1 1. Fuses: One for every ten of each type and rating, but not less

than one of each.2 2. Indicator Lamps: Two for every six of each type used, but not

less than two of each.3 3. Filters: One set each of lubricating oil, fuel, and combustion-air

filters.

4 PART 2 - PRODUCTS


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5 2.01 EMERGENCY GENERATOR SET

1 A. CLASSIFICATION AND RATINGS:2 1. The generator set shall be prime-rated utilized during the

interruption of normal power, 240/415V, 3-phase, 4- wire, 50Hz at0.8 power factor lagging.3 2. The set shall have a power output rating as indicated on the

drawings with capacity as required to operate as a unit at 55C asevidenced by records of prototype testing.

4 3. Efficiency: Not less than 90% at full load.

5 B. CONSTRUCTION:6 1. The engine generator set shall be complete with all necessary

equipments and accessories suitable for the intended services.Battery and battery charger to be provided.

7 2. The set shall operate automatically and shall have all necessaryapparatus and instruments for proper control of the engine andgenerator and for voltage regulation as specified.

8 3. The engine generator unit and accessory equipment shall becomplete, ready for operation after connection to wiring, fuel,exhaust and cooling systems.

9 4. All switches, lamps, and meters in the control system shall be oil-tight and dust-tight, and the enclosure door shall be gasketed.There shall be no exposed points in the control (with the door open)that operate in excess 50 volts.

10 5. The unit shall be mounted on a rigid, structural steel base,suitable for skidding..

11 6. Each major system component is equipped with a conspicuousnameplate of the component manufacturer. Nameplate identifiesmanufacturer of origin and address, and the model and serialnumber .

12 C. PERFORMANCE13 1. Voltage regulation shall be less than % (steady state) and

less than 1% (no load to full load). Random voltage variation withany steady load from no load to full load shall not exceed %.

14 2. Frequency regulation shall be isochronous from steady state noload to steady state rated load. Random frequency variation withany steady load from no load to full load shall not exceed %.

15 3. The diesel engine-generator set shall be capable of single stepload pick up of 100% nameplate kW and power factor, lessapplicable de-rating factors, with the engine-generator set atoperating temperature.

16 4. The generator set shall be capable of sustaining a minimum of 90% of rated no load voltage with the specified kVA load at near zero power factor applied to the generator set.


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17 D. CONNECTIONS18 1. The generator set load connections shall be composed of silver

or tin plated copper bus bars, drilled to accept mechanical or compression terminations of the number and type as shown on thedrawings. Sufficient lug space shall be provided for use with cables

of the number and size as shown on the drawings.

1 2. Power connections to auxiliary devices shall be made at thedevices, with required protection located at a wall-mountedcommon distribution panel.

2 3. Generator set control interfaces to other system componentsshall be made on a common, permanently labeled terminal blockassembly.

3 E. EXCITORS:4 1. Fast response type with a rotating 3-phase full wave bridge

rectifier.

5 F. VOLTAGE REGULATOR:6 1. Hermetically sealed, silicon controlled rectifier type employing a

zener reference to give a voltage stability of 1.5% with allowancefor up to 3% speed variation.

7 2. To provide automatic protection of the unit on 3 phase shortcircuits.

8 3. To include automatic under frequency protection to allow thegenerator to be operated under load, at less than synchronousspeeds, for engine start-up and shutdown procedures. Switchesand/or fuses shall not be used to give this protection.

9 4. Transient variations shall be limited to a maximum 17% for aduration not exceeding 0.25 seconds.

10 G. MANUAL VOLTAGE RHEOSTAT:11 1. To be fitted to control panel for fine adjustments.

2 2.02 ENGINE

1 A. The engine shall be direct injection, four stroke, 1500 RPM, naturallyaspirated or turbocharged diesel engine to BS 5514 prime-rated at site

conditions to provide sufficient output power for the generator.2 B. The engine shall be with integral air cooled radiator and shall include air

filter, fuel and lubricating oil filters, water pump, fuel and lubricating oilpumps, oil cooler, governor, flywheel, starter motor, tachometer, servicehour counter, oil and water gauges, safety devices and all other accessories. The air filter shall be of the oil bath or dry element type. The


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fuel filters shall be suitable for preventing all particles of 10 micron size or larger from passing.

3 C. A pressure type lubricating system with gear type oil pump and filtersshall be fitted to the engine. A graduated dipstick shall be provided,

located in an accessible position.4 D. A heat-exchanger must be fitted in the cooling-water circuit for cooling

the lubricating-oil and shall be capable of keeping lubricating-oiltemperature within safe limits at all conditions of load-requirement s atworst climatic conditions. The drain connection for draining of sump-oilmust be brought on side of the generator base. Method of lubricationshould be fully described in the offer. It is preferable that the camshaft-bearing lubrication be directly fed from the lubricating-oil pump and notthrough the main bearing.

5 E. The governor shall be electronic type, arranged in parallel configurationto maintain an isochronous load sharing, speed sensing and to respond toload

1 changes which minimise speed dip and recovery time. The governor system shall include the following:2 1. Magnetic pick-up3 2. Proportional actuators4 3. Oil pressure switch5 4. Control box

6 F. The engine shall run steadily at any load at its rated speed. Changes inspeed shall comply with B.S.5514 or ISO 8528 Class G2. The engine shallhave safety devices for stopping the engine and giving alarm in cases of high water temperature, low oil pressure and overspeed.

7 G. Drain plugs and cocks for oil, water and fuel shall be provided in readilyaccessible locations.

8 H. Emergency relief diaphragms shall be provided to obviate danger of crank case explosions, fitted on the side remote from the generator.

9 I. Engine mounted wiring shall be by means of MICC cables properly fixedand protected and terminating in a common terminal box mounted on theengine.

10 J. The diesel engine shall be derated according to BS 5514 for operationin Kuwait climatic condition (REFER SECTION- 16010 GENERALPROVISIONS FOR ELECTRICAL INSTALLATIONS). Enginemanufacturer's certificate for engine deration shall be submitted toapproval.


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2 2.03 VIBRATION ISOLATORS

1 A. Provide vibration isolators, spring/pad type, quantity as recommendedby the generator set manufacturer. Isolators shall include seismicrestraints if required by site location.

3 2.04 COOLING SYSTEM

1 A. The diesel engine generator set is cooled with an integral radiator (setmounted). The radiator shall be heavy-duty tropical design withmechanically driven fan of sufficient capacity to maintain safe operation atthe site in worst climatic conditions. Coils shall be of copper alloy tubingwith copper fins.

2 B. The radiator shall be provided with fan guard and shall be connected by

flexible connections to engine water pipes.C.A thermostatically controlled valve shall be provided

1 in the cooling system to assist rapid heating up of the water in the engine jacket when starting from cold. A thermostatically controlled electricheater, suitable for connection to mains supply shall be located in thecooling water circuit with 'ON/OFF' switch in the control panel. The heater shall be capable of maintaining the whole of the cooling water at atemperature of 20oC with an ambient temperature of 0oC. Indicatinglamps in the control panel shall indicate when heater is 'ON'. The heater

shall be switched 'OFF' automatically when the engine starts and switched'ON' when it stops. The heater shall be connected through HRC fuses.Heaters shall be easily removable for replacement.

2 2.05 ENGINE STARTER BATTERIES

1 A. Starting and control batteries shall be made of high performance leadacid, vented type, 24 volt DC, sized as recommended by the enginemanufacturer, complete with battery cables and connectors

2 B. Batteries size shall be heavy duty such that lead acid cells are not

discharged below 75%.

3 C. Batteries output capacity shall be such that if the engine does not startat the first attempt, there is sufficient starting attempts. The minimumnumber of repeat starts required, each of 10sec duration, should be three.

4 D. Batteries charging shall be provided from a suitable full waverectification static-charger with auto trickle-charge enclosed in an


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adequately ventilated sheet steel case and incorporated within the controlpanel with associated instruments and controls mounted on front of panel.

5 E. An ammeter and voltmeter in the control panel shall indicate the stateof the battery and its charging rate.

3 F. The starting batteries of the diesel engines (serving the shelters) shallbe at least dimensioned for at least four start attempts and suitable for sixhours continuous operation in conformity with the General Department of Civil Defence, Manual 2 of May 1998. The battery shall be provided withre-charging equipment.

4 2.06 CONTROL PANEL:

1 A. Each generator control panel shall be electronic modular, generator-mounted type. The control panel shall be environmentally sealed, solid-

state, microprocessor based module for engine control and AC metering.The control panel shall provide the following control and monitoringfeatures:2 1. Automatic/manual start-stop engine control with programmable

safety shut downs and associated flashing LED indicators for lowoil pressure, high coolant temperature, overspeed, overcrank andemergency stop.

3 2. Cycle cranking adjustable 1-60 second crank/rest periods.4 3. Cool down timer, adjustable 0 - 30 minutes.5 4. Energised to run or shutdown fuel control system.6 5. LCD digital read out for: Engine oil pressure, coolant

temperature, engine RPM, system DC volts, engine running hours,generator AC volts, AC amperes and frequency.

7 6. Control system diagnostic codes: Loss of engine speed signal,invalid engine control switch signal, internal circuit fault, loss of coolant temperature signal.

8 7. Engine Control Switch9 8. Voltmeter, ammeter, KWH meter, frequency meter, PF meter.

1 9. Voltmeter Phase Selector Switch

2 10. Emergency Stop Push Buttons3 11. Indicator/Display Test Button4 12. Voltage Adjust Potentiometer 5 13. Provision for interface through RS 232 port.

6 B. The control Panel shall include all interfaces necessary for proper operation with the paralleling equipment provided under this contract. Thegenerator set supplier shall be responsible for complete compliance to all


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specification requirements for both the generator set and the parallelingequipment.

2 2.07 FUEL SUPPLY SYSTEM

1 A. The fuel supply system shall be considered as mechanical supportsystem for the diesel generator set and will be supplied under the scope of HVAC contract and indicated in the relevant HVAC drawings. Refer Division15 related Sections for compliance, unless indicated morestringent here below.The system includes two types of fuel tanks.2 1. Main fuel tank or storage fuel tank.3 2. Transfer fuel tank or day tank.

4 B. MAIN FUEL TANK5 1. Provide, where shown on the Drawings, cylindrical diesel oil

storage tank having the capacity indicated on the Drawings. Thetank shall be constructed in accordance with the requirements of Kuwait National Petroleum Company (KNPC) and the NationalBoard of Fire Underwriters for underground installation and shall beso labelled. The tank shall be provided with the outlets as indicatedon the Drawings plus two spare 63 mm (21/2") plugged tappings.The sizes of all connections shall be extra heavy welded fullcouplings. Provide inside the tanks a welded steel ladder extendingfrom top of the opening to the bottom of the tank. Ladder shall besecurely fastened to the tank by means of structural angles.

6 2. Tank shall be of steel and factory coated with two (2) coats of red

lead paint. Prior to installation in the ground, tank shall receive acoat of black asphalts paint.

7 3. Tank shall be mounted on reinforced concrete pads withconcrete saddles and set pitched on its supporting base.

8 4. Provide all anchor bolts, holding down straps, tie rods and matinserts required for installation of the tanks.

9 C. TANK GAUGES1. Provide as shown on the Drawings liquid level gauges operating on thehydrostatic principle. Each gauge is to be provided with an

310 aluminium case, drain valve and glass front to protect the indicating

tube and scales. Mounted on gauges shall also be a high/low levelalarm switch. The switches shall be designed for a 240 volt system.Provide all contacts and necessary connection as required for monitoring the levels on the BAS.


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1 2. Scales to be calibrated on one side in litres graduated for equallitre units based on actual tank dimensions, on the other side inmillimetre/centimetre graduated for every 6 mm of tank depth.

2 3. Each gauge shall be filled with red indicating fluid having aspecific gravity of not more than 3.0.

3 4. Connections between tank and gauges shall consist of doublecopper tubing encased in flameproof covering. The copper tubingshall be not less than 3 mm (1/8") O.D. and provided with suitableend connections.

4 5. Tank fittings shall be provided with a 38 mm (1 1/2") male pipethread with a stuffing box and stuffing box nut through which 13mm(1/2") pressure pipe extends. The pressure fitting shall be providedwith a 13 mm (1/2") female pipe thread. Tank fittings and pressurefittings shall be made of solid bar stock to prevent leak possibilities

5 D. FUEL OIL PIPING6 1. Provide all diesel fuel oil piping, fill lines, water tight fill boxes,

vents, vent caps, flame arresters to vent pipes as required byKuwait Fire Brigade (KFB), tank foot valves, quick closing springactuated fusible link valves on supply and return and other accessories.

7 2. All piping shall be provided with ground joint unions at piece of apparatus to facilitate connecting and disconnecting.

8 3. All piping, unless otherwise specified, shall be standard weightblack wrought iron pipe with standard galvanised malleable ironfittings. All valves shall be designed for 610 kg/m2 (125 lb/ft2)steam working pressure. Provide relief valves. Underground fuelpiping shall be extra heavy with galvanized malleable iron fittingsand shall be painted with asphaltum.

9 4. Galvanised steel vent pipe lines shall run from the fuel oil storagetanks, carried to the proper height within building construction andterminating with vent fittings. Fittings shall be "Bronze VentilatingBrick" with thickness of 20 mesh bronze wire gauge in front of louvered opening, as manufactured by Preferred Utilities Mfg.Corp., or approved equal.

10 5. Oil suction line piping shall be tested at 625 mm (25") vacuumprior to backfilling.

11 E. DIESEL OIL PUMPING AND STRAINING SET12 1. Provide packaged type duplex fuel oil pumping and straining set

(with one electric pump) with a capacity of two times the total fuelconsumption of engine at full load. Pump sets shall be factoryassembled, piped, wired and tested. Pumps shall be activated by aswitch in the day tank. Provide one manual pump of equal capacityand make necessary piping connections with valves.

13 2. Support base shall be fabricated of not less than 6 mm steelplate with 75 mm side rails continuously welded to form a 25 mm


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high overflow lip, complete with 13 mm drain plug. Strainer andpumps shall be bolted to individual bases, which in turn, are weldedto the support base.

14 3. Piping shall be complete to suction, discharge and return lineconnections. Provide gate valves and unions arranged to permit

removal of either pump while the system is in operation. Installcheck valves and relief valves on pump outlet and gate valves onthe inlet side of pressure gauges.


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1 4. Suction strainer shall be flanged connection, duplex type, one-piece, cast-iron body, ASTM A 48 Class 30, with 1.2 mmperforation brass baskets.

2 5. Oil pump set shall be factory assembled on a structural steelchannel beam base to include pumps, motors, flexible couplings

and guards. Pump set shall be suitable for diesel oil.3 6. Valves4 a. Gate valves to be bronze body, screwed connection, 1378

kPa.5 b. Check valves to be bronze body, angle type, screwed

connection, stamped 413 kPa, adjustable 275 to 550 kPa.

6 F. FUEL DAY TANK7 1. Fuel supply to the engines shall be maintained in auxiliary fuel

tanks or day tanks. A tank is dedicated for each generator. Thetanks shall be welded 2mm thick sheet steel construction treated toresist corrosion, and mounted on suitable angle iron steel structure.Each tank shall be provided with oil strainer, vent pipe, high andlow level control switches, drain valve, engine supply and returnpiping connections, daily tank supply and overflow pipingconnections, dial type level indicator and electrically operatedsolenoid valve with manual reset lever. The engine supplyconnection shall terminate 25mm above bottom of tank andprovided with a valve.

8 2. The day tanks shall be tested at the factory prior to shipment andshall be capable of providing fuel for minimum 8 hours continuousduty. Complete mounting hardware shall be included and shippedto job site with complete installation instructions.

9 3. Upon receiving a signal from control panel indicating a fire in thegenerator room, actuate each solenoid valve to shut down the fuelsupply lines to the engine.

2 2.08 ENGINE EXHAUST SYSTEM Associated engine exhaust system, except the silencers / mufflers assupplied with the diesel engine, will be furnished and installed under thescope of HVAC contract as shown and indicated in the relevant drawing.

1 A. Exhaust pipes shall be of Schedule 40 black steel and of adequate size

to ensure that backpressure does not exceed the value specified by themanufacturer.

2 B. The exhaust pipe shall be connected through airtight flexible coupling tothe engine. Bends in exhaust pipe shall have a radius of not less thanthree times the pipe diameter.


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3 C. Exhaust pipes shall be adequately lagged with 75mm thick (minimum)calcium silicate moulded insulation having a density of 175 kg/m3 (11lb/ft3) and canvassed so that the surface temperature does not exceed60oC. When exhaust pipes pass through walls or roof a suitableweatherproof sleeve or thimble shall be provided to isolate exhaust pipe

from the building. A silencer of heavy-duty residential type shall beprovided in the exhaust system and it shall also be lagged.


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1 D. Exhaust pipes and mufflers shall be supported from the ceiling byspecial vibration isolating hangers and the pipe shall be slanted away fromthe engine and a condense trap fitted at the lowest points. Approved raincaps shall be installed at the discharge end of the exhaust pipes on the

roof.2 E. Exhaust pipes passing thru walls, floor or other space shall pass thru

welded steel thimble or other approved device to isolate structuremembers from exhaust heat.

3 F. Engine exhaust pipe and system aside from being insulated with 3(three) inch calcium silicate moulded aluminium insulation of 11 (eleven)pounds per cubic feet density shall be covered with weather proof masticwhere exposed.

2 2.09 FRESH AIR INTAKE AND EXHAUST AIR SYSTEM

1 A. As part of the supply and installation of the diesel / alternator set, theContractor shall furnish and install the cooling and aspiration air intake.

2 B. The system includes the engine radiator exhaust air system plus that of the generator room ventilation system. These shall be under the scope of HVAC contract as shown and indicated in the relevant drawing.

3 C. The radiator exhaust ductworks shall be acoustically treated inaccordance to standard codes of practice for generating sets.

4 D. The acoustic treatment and ductwork system shall be such as not toreduce the efficiency of the engine or output of the alternator.

3 2.10 GENERATOR SET PARALLELING CONTROL PANELS

1 A. Provide a paralleling control panel for each generator set in theemergency power system. The paralleling control functions may beintegrated with the generator set control functions (with duplicate functionseliminated). Each paralleling control panel shall contain the componentsand devices as described in this section.

4 2.11 FRONT DISPLAY PANEL:

A. The front panel of the paralleling control shall contain the followinginstruments and devices:1 1. 1% accuracy generator set AC output instruments; Ammeter,

Voltmeter, Frequency Meter, Wattmeter, KW-hour meter, Power


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Factor Meter. Selector switches to allow viewing of voltage andamperes for each phase shall be provided. For 3-phase/4-wiresystems the voltmeter shall indicate line to line and line to neutralconditions. Voltmeter and frequency meter shall be analoginstruments. Switches and/or other provisions shall be included to

allow reading of bus voltage and frequency from this metering set.


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0 2. Synchroscope and generator set synchronized indication.Indication may be synchronizing lamps, LED indication, or other provisions, but must be located on the paralleling control panel,adjacent to the paralleling breaker control switches.

1 3. Running Time Meter, Start Counter

2 4. Generator Set Mode Selector Switch: Switch shall provide run,off, and automatic functions for control of the generator set.3 5. Breaker trip/close switch with breaker status indicating lamps.

The switch shall be interlocked with the control system such thatbreaker closure is not possible unless the mode select switch is inthe run position and the generator set is synchronized with thesystem bus.

4 6. Control Reset push-button switch with indicating lamp. Lampshall flash to indicate that generator set is locked out due to a faultcondition.

5 7. Lamp test push-button switch. Operation of this switch shall

cause all lamps on the panel to be simultaneously tested.6 8. The control panel shall be provided with a set of DC-poweredlamps with a switch to allow viewing of all functions on the frontpanel when normal lighting systems are not available.

7 9. Emergency Stop switch. The emergency stop switch shall be ared, mushroom head switch which maintains its position untilmanually reset.

8 10. Precision voltage and frequency adjust raise/lower switches.Switches shall allow the generator set frequency and voltage to beadjusted plus or minus 5% when the generator set is operatingindependently of the system bus. Voltage and frequency

adjustment switches shall be located adjacent to the generator setand bus metering, breaker control switches, synchroscope andmanual paralleling panel, for ease of use by the operator.

9 11. Alarm and status indicating panel to indicate the followingconditions (alarm horn shall be located on master control):

FunctionLamp Color Alarm Hornhutdown Unit

Low DC Voltage Amber *High DC Voltage Amber *Weak Battery Amber *Fail to Sync Amber *Low Oil Pressure Alarm Amber *Low Fuel - daytank Amber *High Engine Temp Alarm Amber *Ground Fault Amber *Overcurrent Alarm Amber *

Breaker FailureRed**Breaker TrippedRed**


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Not in AutoRed**High Engine TempRed**Low Oil PressureRed**OvercurrentRed**Short CircuitRed**

Loss of ExcitationRed**Reverse Power Red**OvercrankRed**OverspeedRed**


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Under FrequencyRedUnder VoltageRed*Over VoltageRed*Phase RotationRed*Low Coolant LevelRed*

AutomaticreenGenerator RunningreenBreaker OpenreenBreaker ClosedreenDemand Mode StandbyreenTiming for StartreenTiming for Shutdownreen

1 12. Provide all other components required, such as properly sizedcurrent transformers, transducers, terminal blocks, etc., for reliablesystem operation, as described herein under SYSTEMOPERATION".

1 2.12 PARALLELING CONTROL PANEL, INTERNAL COMPONENTS:

0 A. Electrically operated power circuit breaker with electronic trip unit (long,and instantaneous trips) in drawout frame. Frame size and trip units shallbe as shown on the project drawings.

1 B. Electronic isochronous kW load sharing control to operate the engine

governors during synchronizing and to provide isochronous load sharingwhen paralleled. The control system shall allow sharing of real kW loadbetween all generator sets in the system to within 5% of equal levels,without introduction of frequency droop into the system. The controlsystem shall include all equipment required for kW load sharing with aninfinite bus, for future application flexibility. The infinite bus governingcontrols shall allow the generator set to synchronize to an infinite bus,parallel, and ramp up to a preset load level on the generator set.

Additional controls shall be provided to cause the generator set to ramp upto a kW load level signaled by the system PLC.

2 C. Load demand governing controls shall be provided to cause thegenerator set to ramp down to zero load when signaled to shut down in aload demand mode. On a signal to re-start, the load demand governingcontrols shall cause the generator set to synchronize to the system bus,close, and ramp up to its proportional share of the total bus load. Theramp rate of the generator set shall be operator-adjustable.

3 D. The isochronous load sharing module and engine governor shall be acoordinated system of a single manufacturer.


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4 E. Electronic isochronous kVAR load sharing control to operate thealternator excitation system while the generator set is paralleled. Thecontrol system shall allow sharing of reactive load between all generator sets in the system to within 5% of equal levels, without introduction of voltage droop into the system. The control system shall include all

equipment required for VAR load sharing with an infinite bus in either aconstant VAR or constant power factor mode for future applicationflexibility. (Mode and adjustments selectable by the operator)


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0 F. Equipment shall be provided to monitor the generator set as it isstarting, and verify that it has reached at least 90% of nominal voltage andfrequency before closing to the bus. The equipment provided shallpositively prevent out-of-phase paralleling if two or more engine-generator

sets reach operating conditions simultaneously by providing a lockoutsignal to disable breaker closure for generator set(s) in the system whichhave not been selected to be the first units to close to the bus. Controls torecognize the failure of the first breaker signaled to close, and allowsystem operation to proceed in spite of this failure shall also be provided(breaker failure alarm). Systems using dead bus relay schemes without adisable signal to positively prevent out-of-phase paralleling shall not beacceptable under this specification.

1 G. Synchronizer to electronically adjust the engine governor to match thevoltage, frequency and phase angle of the bus. Synchronizer shallmaintain the engine-generator voltage within 1% of bus voltage and phaseangle within 20 electrical degrees of the bus for 0.5 seconds before circuitbreaker closing. Each unit shall have its own synchronizer; systems usinga switching scheme to utilize a single system synchronizer will not beapproved. Synchronizers and systems which utilize a motor driven pot for control of AC voltage during the synchronizing process will not beaccepted. The system shall be provided with a fail to synchronize timedelay, which is adjustable from 10-120 seconds. Control logic for fail tosynchronize function shall allow field adjustment of function for either alarm or shutdown of the generator set on failure condition.

2 H. Controls shall include a permissive relay function to assure that thegenerator set does not attempt to close out of phase with the bus, due toerrant operation of the synchronizer.

3 I. Controls shall include a permissive (sync check) function, to be usedwith generator synchronized indicator during manual paralleling, toprevent accidental closure of the breaker with the generator set out of phase with the bus. Provisions to allow manual closure of the firstgenerator set to a de-energized bus shall be included.

4 J. Control equipment shall contain a system of diagnostic LEDs to assistin analyzing proper system function.

5 K. Controls shall include three phase sensing reverse power equipment, toprevent sustained reverse power flow into the generator set. When thereverse power condition exceeds 10% of the generator set kW for 3seconds, the paralleling circuit breaker shall be tripped open and thegenerator shut down.


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6 L. Controls shall be provided to verify generator set and bus phaserotation match prior to closing the paralleling breaker.

7 M. Electronic alternator overcurrent alarm and shutdown protection. Thisprotection is required in addition to the overcurrent trip on the paralleling

breaker. The overcurrent alarm shall be indicated when the load currenton the generator set is more than 110% of rated current for more than 60seconds. The overcurrent shutdown shall matched to the thermal damagecurve of the generator set, and shall not have an instantaneous function.


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1 N. Electronic alternator short circuit protection. This protection is inaddition to the overcurrent trip on the paralleling breaker. The short circuitshall occur when the load current on the generator set is more than 175%of rated current and an aggregate time/current calculation indicates that

the system is approaching the thermal damage point of the alternator. Theequipment used shall not have an instantaneous function.

2 O. Controls shall be provided to sense loss of excitation of the alternator while paralleled to the system bus.

3 P. Generator set start contacts rated 10 amps at 32 VDC.

4 Q. Cool down time delay, adjustable: 0-600 seconds. The control panelshall indicate the time remaining in the time delay period when thegenerator set is timing for shutdown.

5 R. Start time delay, adjustable: 0-300 seconds. The control panel shallindicate the time remaining in the time delay period when the generator set is timing for start.

6 S. The control system shall monitor the paralleling breaker auxiliarycontacts, and initiate a fault signal if the breaker fails to close within anadjustable time delay period after the control has signaled it to close (0.5-15 seconds). Breaker failure alarm shall cause the paralleling breaker totrip open, and lock out until manually reset.

7 T. Controls shall be provided to initiate an alarm condition when generator

set is at 90% of rated frequency for more than 20 seconds.8 U. Controls shall be provided to shut down generator set and initiate alarm

when the generator set is at less than 85% of nominal voltage for morethan 15 seconds, more than 110% of nominal voltage for more than 10seconds, or more than 130% of nominal.

2 2.13 MASTER CONTROL

1 A. Provide a master control to monitor and control the operation of theentire paralleling system. The master control panel shall contain the

components described in this section.

3 2.14 MASTER CONTROL FRONT PANEL METERING

1 A. 1% accuracy RMS digital instruments to monitor total output of bus: Ammeter, Voltmeter, Frequency Meter, Wattmeter, Power Factor Meter,KVA, kVar kW-Hour Meter, kW demand, kVAR hours, kVA hours. Selector


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switches to allow viewing of voltage and amperes for each phase shall beprovided. For 3-phase/4-wire systems the voltmeter shall indicate line toline and line to neutral conditions.

4 2.15 MASTER CONTROL OPERATOR INTERFACE PANEL


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1

A. A touchscreen type operator interface panel shall be provided which allowsthe operator to monitor and control the on site power system. Thetouchscreen shall include the following screens and/or functions:1 1. Main Menu. The Main Menu screen shall include date, time of

day, and a general system status message which indicates system,generator set, and transfer switch status. Pushbuttons on thescreen shall provide access to the following screens:2 a. One line diagram3 b. System controls4 c. Load controls5 d. Alarm summary report6 e. Bus AC metering7 f. Genset control8 g. Load priority set-up9 h. Test/run report10 i. Help

11 2. One Line Diagram Screen. The one-line diagram screen shalldisplay a system message (to advise the operator of needed or optional control operations), and shall also show the system statusby a combination of animation, changing screen color, textmessages, and pop-up indicators. Conditions visible on the screenshall include:12 a. Generator set and bus configuration, with generator set,

parallel breaker and bus energized/de-energized indication(bright color indicating energized, dull color indicating de-energized).

13 b. Generator set designation. (Touching the generator seticon shall cause the system to switch to the generator setcontrol screen.)

14 c. Generator set mode (run/off/auto)15 d. Generator set status (normal/warning/shutdown/load

demand stop)16 e. Paralleling breaker status (open/closed/tripped)17 f. Bus condition (energized or de-energized)18 g. Run time for latest operation19 h. Transfer switch position and warning status (load

shed/transfer inhibit)20 i. Direct access to system control, load control, main menu,

and help screens.21 3. AC Metering. The AC metering screen shall display all critical

functions of the system digital metering set on a single screen. Thescreen shall include individual phase volts and amps, kW, kVA,kVar, power factor, bus frequency, kW-hours, and kW demand. In


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addition, the screen shall allow access to the following functionalscreens:22 a. Real time trend chart, illustrating system kw and volts as a

percent of nominal, and system frequency. The chart shallupdate on 1-second intervals.

23 b. Historical trend chart, illustrating system kw. The systemshall update on 5 minute intervals and have a chart length of 4 hours.

24 c. Access to the one line diagram screen.25 4. Generator Set Control. The generator set control screen shall

provide control over individual generator sets from the systemmaster control panel. The following functions shall be available onthis screen:


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1 a. Generator manual start/stop control (functional whengenerator set mounted control switch is in the AUTOposition).

2 b. Generator set warning alarm reset. When the generator set has no active warning conditions, the screen shall

indicate that the control condition is normal.3 c. Manual paralleling and breaker control. Controls shallallow manual breaker opening and closing (via a permissiverelay), and manual paralleling.

4 d. Direct access to the one line diagram and help screens.5 5. System Control. Functions in the system control screen shall

only be accessible after entering an access code into the systemvia a keypad screen on the operator interface panel. The accesscode shall be the same code which is used for access to generator set control setup and adjustments. The system control screen shallinclude the following functions:

6 a. System test on/off.7 b. Load demand on/off. In the load demand mode thesystem shall monitor the total load on the system bus andcontrol the number of running generator sets to minimize fuelconsumption in the system but retain system reliability at anacceptable level.

8 c. Load demand pickup and dropout set points. Factorysettings shall be: pickup--90%, adjustable down to 40% in5% increments; dropout--20%, adjustable to a maximum of 70% in 5% increments.

9 d. Load demand shut down time delay. Factory setting: 15

minutes, adjustable from 5-95 minutes in 5 minuteincrements.10 e. Load demand shut down sequence.11 f. Direct access to load control and one-line diagram

screens.12 6. Load Control. The load control screen shall provide the operator

with information and control capability to manually add and shedloads from the system. The screen shall include two real time bar graphs which indicate % of available system KW and % of availablesystem amps capacity. Other information and controls on thisscreen shall include:13 a. Under Frequency/Overload reset. When the system

condition is normal, the button for this function shall be dim,and indicate that bus frequency in normal.

14 b. Load shed time delay raise/lower controls (adjustable 0-99seconds, factory set to 3 seconds).

15 c. Load add manual (one for each level). Button shall bebright when action is available, and dim when action is notavailable.


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16 d. Load shed restore (one for each level).17 e. Load shed (one for each level).18 f. Direct access to one-line diagram, system control, and

help screens.19 7. Load Priority Control. Functions in the system control screen

shall only be accessible after entering an access code into thesystem via a keypad screen on the operator interface panel. Theaccess code shall be the same code which is used for access togenerator set control setup and adjustments. The load prioritycontrol screen shall be designed to allow the operator to control thesequence in which specific load add and load shed relays functionto signal load additions as the system is energized


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1 and load shed, as the system is overloaded. The load prioritycontrol screen shall include the following functions:2 a. Assigning a load add sequence to each load add relay.

The operator shall be allowed to designate relay operationwhen a specific number of generator sets have closed to the

system bus.3 b. Direct access to the load control screen, main menu, andhelp screen.

4 c. Assigning a load shed sequence to each load shed relay.The operator shall be given controls for each load shedrelay, so that its operating sequence can be controlled.

5 8. Alarm Summary. The alarm summary screen shall provide a listof the most recent alarm conditions and specific status changeswhich have occurred in the system. The screen shall list the last 64alarm or status condition changes in the system by number, name,time/date of condition, and the date that the condition was

acknowledged. Buttons shall be provided to facilitate easilymoving through the available data log. This data shall be printabledirectly from the system via a serial port on the equipment.

6 9. Run Report. The control system shall automatically loginformation with each signal for the system to start, whether from alocal test signal (initiated through the touchscreen), or a remotesignal. The screen data shall be capable of being printed over thesystem serial printer port. The run report shall include the followinginformation:7 a. Start time and date.8 b. Stop time and date.

9 c. Maximum kW and Amp load on the system during the runperiod.10 d. Individual generator set start and stop time.11 e. Transfer switch operation times.

2 2.16 SOLID STATE SYSTEM STATUS PANEL.

A. System status panel shall be provided and shall include the followingfeatures and functions:1 1. Alarm Silence Push-button Switch2 2. Alarm horn3 3. LED Indicating lamps to indicate the following conditions:

FunctionColor Alarm Horn

Generator Set #1 RunninggreenGenerator Set #2 RunninggreenLoad Demand ModegreenPriority 1 Load Ongreen


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Priority 2 Load OngreenLoad Shed Level 1red*Load Shed Level 2red*

System TestgreenRemote System Startred

Check Generator Set #1red*Controller Malfunctionred*Check Station Batteryred*


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Check Generator Set #2red*

Bus Overloadred*

System Not in AutoMode

red*

1 2.17 INTERNAL CONTROL COMPONENTS

A. The following internal controls shall be provided within the master controlsection:1 1. Programmable controller for interface with touchscreen, and to

provide load demand, load pick-up, and load shed functions.2 2. Load pick-up output contacts, rated 10 A at 600 VAC (3 contacts

per level).3 3. Load shed output contacts, rated 10 A at 600 VAC (3 contacts

per level).4 4. Provide all other components required, such as properly sized

current transformers, transducers, terminal blocks, etc., for reliablesystem operation.

2 2.18 SYSTEM OPERATION:

A. Loss Of Normal Power:1 1. System is given signal to start by receipt of start signal from

automatic transfer switch(es) or other remote device. On receipt of this signal, all generator sets automatically and independently start,accelerate to rated frequency and build up to rated voltage. Thefirst start system monitors this process, and on finding a generator set at 90% of rated voltage and frequency, automatically disablesall other units from closing to the bus, and closes the ready unit tothe bus. At this time first priority transfer switches begin the timedelay transfer sequence, and on it's completion transfer their loadsto the system bus.

2 2. The priority (load add) controls prevent overloading of the systembus by providing inhibit signals to prevent transfer of selected loadsto the emergency system until sufficient generating capacity isavailable on the bus, or until the priority override switch on thetouchscreen control is actuated.

3 3. After the first unit is closed to the bus, the control of theremaining units is switched to the synchronizer in each generator paralleling control, which causes the generator set to synchronizewith the system bus, and then close to it at the proper time.

4 4. As each unit closes to the bus, the unit assumes it's proportionalshare of the total load on the bus.


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5 B. Failure Of A Unit To Start Or Synchronize:6 1. If a unit fails to start, after the overcrank time delay (in the

generator set control) has expired, the unit will be shut down, andan alarm will sound. The priority control will prevent the lowestpriority loads from being added to the system without manual

intervention. The priority override controls on the touchscreen maybe used by an operator to manually add low priority loads to thebus, if he determines that generator capacity is available to servethe loads. Bus overload monitoring shall protect the


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1 first priority loads in the event that the bus is inadvertentlyoverloaded due to operator error.

2 2. If a unit fails to synchronize, after a preset time delay, an alarmwill sound, but the unit will continue to attempt to synchronize untilsignaled to stop by manual operation of the control switches on the

generator set.3 C. Bus Overload:

4 1. If a bus overload occurs for any reason, a load shed signal willbe generated to initiate load shedding in the system.

5 2. If the bus does not return to proper frequency within apredetermined period of time, additional load shed signals will begenerated.

6 D. Load Demand Mode:7 1. When the system running in the emergency mode with the "load

demand" switch on the touchscreen in the "on" position , controlsshall continuously monitor the total load on the bus. If the total loadon the bus falls below preset limits for a period of 15 minutes, thecontroller will automatically shut down generator sets in an operator predetermined order, until the minimum number of generatorsrequired to operate the load remain on the bus. The purpose of thisfunction is to allow the generator sets to operate closer to their rated capacity, thereby decreasing fuel consumption, and reducingwear on the system.

8 2. On sensing that the available bus capacity is being approached,the standby units will automatically be restarted (in the reverseorder of which they were shut down) and paralleled with the bus toassume their proportional share of system load.

9 E. Return of Normal Power 10 1. When all of the system start signals are removed from the

generator sets, the generator set paralleling breakers shall all open,and the generator sets shall operate at no load for a cool downperiod. When the cool down period has been completed, thegenerator sets shall shut down.

11 2. If a system start signal is received during the cool down period,one generator set shall immediately close to the system bus and allother units shall synchronize to it, as described in Loss of NormalPower above.

12 F. Distribution Equipment13 1. Provide emergency feeder distribution breakers of the number

and size as shown on the project drawings.14 2. The breakers provided shall be molded case breakers, motorized

type, with electronic trip units. Breakers shall be provided with lugsof the number and size as shown on the project drawings.


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15 3. The breakers shall be group-mounted in a distribution panelboard which is bus connected to the paralleling equipment. Provideequipment in enclosure with sufficient space for cable connection,and with access as shown on the drawings.


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1 PART 3 - EXECUTION

2 3.01 EXAMINATION

0 A. Examine areas, equipment foundations, and conditions, with Installer present, for compliance with requirements for installation and other conditions affecting packaged engine generator performance.

1 B. Proceed with installation only after unsatisfactory conditions have beencorrected.

2 C. Verify actual locations of connections before packaged enginegenerator installation.

2 3.02 CONCRETE BASES

1 A. Install concrete bases of dimensions indicated for packaged enginegenerators.

3 3.03 INSTALLATION

1 A. Comply with packaged engine generator manufacturers' writteninstallation and alignment instructions.

2 B. Set packaged engine generator set on concrete bases.3 C. Adjust metal supports or wedges until generator is level.

4 D. Install packaged engine generator to provide access for periodicmaintenance, including removal of drivers and accessories.

5 E. Install cooling-system piping, accessories, hangers and supports, andanchors for complete installation.

6 F. Extend drain piping from heat exchangers to point of disposition.

7 G. Install exhaust-system piping for diesel engines. Extend to point of termination outside structure. Size piping according to manufacturerswritten instructions.

8 H. Install condensate drain piping for diesel-engine exhaust system.Extend drain piping from low points of exhaust system and from muffler tocondensate traps and to point of disposition.


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9 I. Electrical Wiring: Install electrical devices furnished by equipmentmanufacturers but not specified to be factory mounted.

10 J. Verify that electrical wiring is installed according to manufacturers'submittal and installation requirements in Division 16 Sections. Proceed

with equipment startup only after wiring installation is satisfactory.

4 3.04 CONNECTIONS

1 A. Electrical wiring and connections are specified elsewhere in Division16.

2 B. Ground equipment as specified elsewhere in Division 16.

3 C. Tighten electrical connectors and terminals according to manufacturer'spublished torque-tightening values. If manufacturer's torque values are not

indicated, use those specified in UL 486A and UL 486B.


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1 3.05 FUEL TANK (MAIN UNDERGROUND STORAGE TANK)

1 A. Paint the fuel tank with a coat of black asphaltum paint prior toinstallation in the ground.

2 B. Tank shall be set pitched on this supporting base.

2 3.06 FUEL OIL PIPEWORK

1 A. Install all fuel oil pipe work as per KNPC standards.

2 B. Oil suction line piping shall be tested at 0.25" vacuum prior tobackfilling. The test shall be witnessed by consultant and EmployersRepresentative.

3 3.07 ENGINE EXHAUST PIPEWORK

1 A. Install all exhaust pipe work, including muffler as per KNPC Standards.

2 B. Install pipe flexible connector under provisions of Section 15070 -Vibration isolation.

4 3.08 PAINTING

1 A. Painting: After fabrication, the entire oil pumping set, except controlcabinet, name plates, valves and gauges, shall receive a finish coat of heavy duty heat resistant aluminium paint. Refer Section 09900 and09910 for general requirements of painting.

5 3.09 IDENTIFICATION

1 A. Identify system components.

6 3.10 TESTING OF THE SET

A. DIESEL ENGINE TEST:1 1. The Diesel Engine shall be tested at the engine manufacturer's

works for its output-power and relevant temperatures. Testcertificate to be submitted for both, engine and complete Generator Set.

2 B. DIESEL ALTERNATOR SET TESTS:


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3 1. Full performance test including speed and voltage regulationsand the test shall include the following to be performed at sitebefore handling over:4 a. Partial load test.5 b. Full load test and run for one hour

6 2. Detailed records of the foregoing tests shall be submitted.7 3. Test at site before taking over and after the sets are completelyinstalled at the site, full performance operation shall be carried outon the set at the worst specified conditions in summer of 3 hrs of continuous running to the


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1 approval. The tests shall be carried out under the full responsibilityof the Contractor and at his own expense. If the works arecompleted when the climatic conditions are not considered theworst conditions in summer then the above tests shall be made atthe time of completion of the installation of works, but a full

operation and performance test shall be carried out to thesatisfaction in the worst climatic conditions in summer and this testshall be carried out by and at the responsibility of the Contractor.

2 4. The commissioning should be carried out by the Diesel EngineManufacturer's engineer or his Authorised Representative.

2 3.11 GUARANTEE & MAINTENANCE

A. OPERATION & MAINTENANCE1 1. The Contractor will be required to do the following:

2 a. Operate and maintain the Diesel Generator Set for twomonths after handover of the works;

3 b. Maintain the Diesel Generator Set for 10 months after completion of Operation & Maintenance period describedabove.

4 2. The Contractor shall be fully responsible for the satisfactoryoperation of D/G installation during the operation and maintenanceperiod and thereafter during the maintenance (defect liability)period. He shall carry out necessary inspection, preventivemaintenance and testing to keep the sets ready all the time. Theset shall function satisfactorily during power failures. TheContractor shall carry out routine testing. The testing shall becarried out in presence of Employer's Representative. TheContractor shall himself provide all electrical and mechanical spareparts, grease, lucubrating oils, touch-up paints, etc., required for themaintenance of the D/G Installation. The Employer shall beresponsible only for providing diesel oil as and when required. TheContractor shall prepare log-books listing full details of maintenance work and each log-book entry shall be counter signedby the Employer's Representative.

5 C. GUARANTEE OF CONTROL SYSTEM OPERATION6 1. All components of control panel for the D/G set, relays, controls

of all systems mentioned in this specification shall be installed in anambient temperature of more than 55C, high relative humidity anddusty atmosphere.

7 2. The Contractor shall enclose with his offer a written assurancefrom the manufacturer for the guarantee that all components of theControl System (relays, diodes, pre-integrated circuits, semi-conductors, etc.) shall withstand, operate continuously and


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effectively without troubles in this high temperatures and climaticconditions.

3 3.12 DEMONSTRATION

1 A. Engage a factory-authorized service representative to train Employer'smaintenance personnel to adjust, operate, and maintain packaged enginegenerators as specified.


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END OF SECTION


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