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SECTION 26 32 13.16

DIESEL GENERATOR PRIME POWER

PART 1 - GENERAL.................................................................................................................31.1 Related Documents....................................................................................................31.2 Description..................................................................................................................31.3 Applicable Codes and Standards...............................................................................31.4 Related Sections........................................................................................................41.5 Coordination...............................................................................................................41.6 Submittals...................................................................................................................41.7 System Description.....................................................................................................61.8 Site Conditions, Diesel...............................................................................................71.9 System Performance General....................................................................................71.10 Quality Assurance......................................................................................................81.11 Delivery Storage And Handling................................................................................11

PART 2 - PRODUCTS............................................................................................................112.1 The Diesel Engine....................................................................................................112.2 Engine Exhaust System...........................................................................................152.3 The Alternator...........................................................................................................152.4 The Electrical System...............................................................................................172.5 Generator Controller.................................................................................................192.6 Generator Control Panel...........................................................................................202.7 Cable Ladders..........................................................................................................212.8 Essential Tools.........................................................................................................212.9 Spare Parts...............................................................................................................21

PART 3 - EXECUTION...........................................................................................................223.1 Instruction Manuals..................................................................................................223.2 Builder’s Work..........................................................................................................223.3 Electricity Supply......................................................................................................223.4 Pre-Delivery Inspection............................................................................................233.5 Installation................................................................................................................233.6 Earthing....................................................................................................................233.7 Generator Plant Layout............................................................................................233.8 Paintwork..................................................................................................................233.9 Name Plates And Notices.........................................................................................233.10 Danger Notices.........................................................................................................243.11 Training Of Operating Staff.......................................................................................243.12 Tests And Comissioning...........................................................................................243.13 Certificate By Contractor..........................................................................................25

Technical Specifications for SITA Works Section 26 32 13.16Revision 0 of 25 Diesel Generator Prime Power

SECTION 26 32 13.16

DIESEL GENERATOR PRIME POWER

PART 1 - GENERAL

1.1 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General Conditions,

Conditions of Particular Application and Division-0l Specification Sections, apply to work of this Section.

1.2 DESCRIPTION A. The diesel generating set shall comply with the Project Specification.

B. The Project Specification will have preference over this Standard Specification in case of contradictions.

C. This contract covers the design, manufacture, supply, delivery, installation on site, testing, commissioning and handing over in proper working order of the complete standby generator installation as specified in the constituent parts of this set of documents including the following:

1. The complete diesel engine and alternator mounted on a common base frame, inside a container, as specified in the Project Specification.

a) The complete exhaust system.b) The complete cooling system.c) The complete fuel system.d) The complete starting system.e) All pipework and cable work to complete the installation.f) All necessary electrical switchgear and control panels.g) All notices as required by the OHS Act 1993.h) All cable ladders or wire ways as indicated on the drawings.i) The diesel generating set shall be suitable for the ambient

temperatures and altitudes of the site where it will be installed. These parameters are stated in the Project Specification.

j) The de-rating of the diesel engine for site conditions shall be strictly according to the latest amendment of BS 5514 ISO / SANS8528.

k) The diesel generating sets supplied under this contract shall be Uptime Institute certified.

l) The plant shall be rated for continuous operation in Tier III Data Centre applications

m) (Data Centre Continuous Rating DCC).

1.3 APPLICABLE CODES AND STANDARDS A. All diesel generator sets shall be performed in strict accordance with the

Specifications, Drawings and the stipulations of SANS, the British Generating Set Manufactures (ABGSM) or other equivalent international standards and Sound Practice.

B. British Standard Specifications BS No. 5514 Reciprocating Internal Combustion Engines Performances / ISO / SANS 8528.

Technical Specifications for SITA Works Section 26 32 13.16Revision 0 Page 3 of 25 Diesel Generator Prime Power

C. The design rating of the engines shall be in accordance with the latest amendment of BS 5514 part 1 to 5 ISO / SANS 8528

D. Alternator designed in accordance with BS 5000 and BS EN 60034.

E. Contractors shall note the additional DCC rating requirement of this specification

1.4 RELATED SECTIONS A. The following sections include requirements which relate to this section:

1. Special conditions of contract.

1.5 COORDINATION This generator will be replacing an existing generator. Close coordination with the Client is required as this is a data centre installation and no disruptions to existing services will be tolerated.

1.6 SUBMITTALS The Contractor shall submit the following in accordance with the Conditions of the Contract and Division-01 Specification Sections:

A. Product Data: Manufacturer produced generator set specification or data sheet identifying make and model of engine and generator and including relevant component design and performance data.1. Engine

a) Type, aspiration, compression ratio, and combustion cycle.b) Bore, stroke, displacement, and number of cylinders.c) Engine lubricating oil capacity.d) Engine coolant capacity without radiator.e) Engine coolant capacity with radiator.f) Coolant pump external resistance (maximum)g) Coolant pump flow at maximum resistance

2. Generatora) Model - Frameb) Insulation class - Number of leads - Weight, totalc) Weight, rotor d) Air flowe) At rated voltage:

1) Efficiency at 0.8 power factor for: (i) 50% load(ii) 75% load(iii) 100% load

f) Time constants, short circuit transient (T'D)g) Time constants, armature short circuit (TA)h) Reactance, sub transient - direct axis (X"D)i) Reactance, transient - saturated (X'D)j) Reactance, synchronous - direct axis (XD)k) Reactance, negative sequence (X2)l) Reactance, zero sequence (XO)m) Fault current, 3 phase symmetricaln) Decrement curve

3. Radiator (remote mounted)a) Model


b) Typec) Fan drive ratiod) Coolant capacity, radiatore) Coolant capacity, radiator and engine - Weight, dryf) Weight Wet

4. Systema) Dimensions: length, width, heightb) Weight, dryc) Weight, wet

5. Performance - based on SAE J1349 standard conditions of 100 kPa (29.61 in Hg) and 25°C; also at conditions of ISO3046/1.

6. Din 6271 and BS 5514. Fuel rates are based on ISO 3046 and on fuel oil of 35 degrees API (16°C) gravity having a LHV of 42780 kJ/kg (18,390 Btu/lb) when used at 29°C and weighing 838.9 g/l.

7. Power rating at 0.8 power factork V A ratingFuel consumption at standard conditions for: 50% load, 75% load, 100% load

8. Combustion air inlet flow rateExhaust gas flow rate

9. Stack temperatureExhaust system backpressure (maximum)Heat rejection to coolant, after cooler, exhaust, atmosphere from engine, atmosphere from generator

10. Transient response of frequency and voltage for the generator set and if units are operating in parallel for the total system when imposing block load changes of:a) 0 - 25% b) 0 - 50% c) 0 - 75%d) 0 - 100% e) 100 - 0%f) 75 - 0%g) 50 - 0% h) 25 - 0%

11. Auxiliary Equipment - Specification or data sheets, including switchgear,

transfer switch, vibration isolators and day tank.

B. Shop Drawings: General dimensions Drawings showing overall generatorset dimensions , mounting location and interconnect point for load leads, fuel, exhaust, cooling and drain lines.

Wiring diagrams, schematics and control panel outline Drawings published by the Manufacturer in Joint Industrial Council (DC) format for controls and switchgear showing interconnected points and logic diagrams for use by Contractor and Owner.

All installation Drawings and wiring diagrams for the generator set, controls and switchgear must conform to a common format.

Service - location and description of Supplier's parts and service facilities including parts inventory and number of qualified generator set service personnel.


C. Compliance with Building Automation System Requirements.

D. Letter confirming DCC certification

1.7 SYSTEM DESCRIPTION A. The electric power generating system shall have a DCC Rating capability of

1800 kW, 2250 kVA 0.80 power factor, 400 Volts, Star (Wye) connected, three (3) phase, 50 Hertz, after relevant deratings.

B. The system shall consist of generator set(s), which includes all controls, protection, wiring and accessories for automatic start-stop operation.

C. The generator set(s) shall include the capability of automatically controlling generator set operation. After starting, the units shall attain rated speed and voltage and accept the rated load in less than 10 seconds. Generator set speed shall be controlled by the engine governor, while generator output voltage regulation shall be a function of the generator automatic voltage regulator. Manual adjustment of generator speed and voltage shall be provided.

D. The generator set shall automatically start, attain rated speed and voltage and accept share load. Starting and stopping sequence can be initiated manually or automatically by closing and opening of a contact.

E. The set shall immediately shutdown in the event of over speed, low oil pressure,

high engine temperature and low water level. Cause of shutdown shall be indicated by a light annunciator. System logic shall prevent restart until the fault is cleared.

F. There shall be a provision for manual shutdown in the event of an emergency.

G. Each generator set shall be capable of paralleling manually and automatically to the system bus. Appropriate monitors and safety devices shall be included to provide system protection while paralleling and operating on the system bus.

H. Automatic operation shall include control devices to compare and adjust oncoming units to frequency and phase of system bus, sense matching within acceptable limits and signal closure of the circuit breaker. Control circuits shall prevent more than one (1) circuit breaker from simultaneously closing onto a dead bus.

I. Load sensing circuits shall compare system requirements with on-bus generator capacity. Generator sets shall automatically be added and removed from the bus according to system load demand.

J. Under-frequency sensing of system bus shall be an indication of overload. Load shed circuits shall initiate removal of selected loads from system bus.

K. The full status and alarm shall be monitored by the Building Automation System (BAS).


1.8 SITE CONDITIONS, DIESEL A. The operating environment of the power generating system shall be:

1. Altitude 1450m2. Engine room temperature maximum 45°C3. Outside temperature, minimum 5°C

1.9 SYSTEM PERFORMANCE GENERAL The power generating system shall conform to the following performance criteria:

A. Rating: Engine brake horsepower shall be sufficient to deliver full rated generator set kW/kVA when operated at rated rpm and equipped with all engine-mounted parasitic and external loads such as radiator fans and power generators.

The rating shall be based on SAE J 1349 conditions of 100 kPa (29.61 in Hg) and 25°C. The rating shall also apply at ISO 3046/1, DIN 6271 and BS 5514 Standard Conditions.

B. Diesel engine shall be able to deliver rated power when operating on NO.2 diesel fuel having 35 degree API 16°C specific gravity.

C. Engines adapted for operation with heavy fuels shall be able to deliver rated power when using fuel meetings the following specifications:

IF 380 IF 700Fuel viscosity at injection pump <20 cSt <2OcStDensity at 15°c, maximum 991 kg/m3 1010 kg/m3Sulphur, maximum percent by weight

5.0% 5.0%

Vanadium, maximum- °C 300 ppm 600 ppmMinimum flash point 60 60Sulphated ash, maximum percent by weight

0.15% 0.2%

Carbon residue on 10% bottom, maximum percent by weight

18% 22%

Water and sediment, maximum percent by weight Asphaltness, maximum percent by weight

12% 15%

Aluminium, maximum 3ppm 3ppmSilicon, maximum 3ppm 3ppm

D. Diesel fuel rates shall be based on fuel having a low heating value (LHV) of 42780 kJ/kg (18, 390 Btu/lb) when used at 29°C (850f') and weighing 838.9 g/l.

E. Start Time and Load Acceptance: Engine shall start, achieve rated voltage and frequency, and be capable of accepting load within ten (10) seconds when properly equipped and maintained.

F. Block Load Acceptance: Transient response shall conform to ISO 8528 requirements.


1.10 QUALITY ASSURANCE A. Product Manufacturer: The complete power generation system including engine,

generator shall be the product of one (1) Manufacturer who shall be regularly engaged in the production of complete generating systems for at least thirty five (35) years. All components shall be designed to achieve optimum physical and performance compatibility and prototype tested to prove integrated design capability. The complete system shall be factory fabricated, assembled and production tested.

The responsibility for performance to this specification shall not be divided among individual sub-contractors of manufacturers but must be assumed solely by the Contractor. This includes generating system design, manufacture, test and having a local Supplier responsible for service, parts, and warranty for the total system.

B. Tests: The system Manufacturer shall perform post production tests on the generator set supplied. A certified report of these tests shall be available at the time of the generator set order.

Each engine, generator and generator set shall be subjected to production performance tests and quality controls to ensure reliable operation. These tests and controls shall include but not be limited to:

Specific observances of engine blow by, slobber, combustion gas leaks, inlet air leaks, excessive vibration and unusual noise.

Special oil additive for specific leak detection.

Fuel system setting confirmation which shall not be altered to rectify non-conformance to established performance specifications.

Retest after any change affecting airflow through the engine, fuel injected into the engine, engine combustion or any reassembly affects mechanical integrity.

Periodic extended tests to confirm baseline data.Recording of:

1. Enginea) Corrected powerb) Full load speedc) Full load torque Corrected fuel rated) Corrected specific fuel consumption Turbo boost - Inlet air restrictione) High idle speedf) Low idle speedg) Jacket water temperatureh) Jacket water in-out temperature differentiali) Separate circuit after cooler water temperature j) Fuel pressurek) Oil pressurel) Fuel system settingm) Response (rpm-time) for run load removal Timingn) Barometric pressure Water vapour pressure Inlet air temperature o) Fuel density


2. Generatora) High potential test, before and after load runs - Voltage gain range at

loadb) Voltage level rangec) Regulation adjustment at 0.8 PFd) Voltage drop range, when applicable Circulating current between

phases Voltage balance between phasese) Residual voltagef) Torsional and linear vibration analysis of generator setg) Individual testing of major componentsh) Individual balancing and weight control of rotating reciprocating

components.

C. Equipment Alternatives: Data for substitute equipment shall include the following:1. Plan Drawing: Verification that substitute equipment shall fit into the space

allocated and allow for removal and service.2. Air flow requirements: Provision for combustion, ventilating and radiator

cooling air.3. Connections: Wiring and piping diagrams describing interconnect changes.4. Load Study: Complete load review to confirm that generating equipment

operates satisfactorily and complies to original specification during all phases of operation, including motor starting and transient loading capabilities.

5. Specification: Specification sheets and support literature to show that alternate equipment is in compliance with all specifications.

6. Certification: List of projects using similar equipment for the last five (5) years.

7. Exceptions: A complete account of all deviations from these specifications.

D. Service and Warranty: The Manufacturer shall have a local authorized Dealer who can provide factory trained servicemen, the required stock of replacement parts, technical assistance and warranty administration.

The Manufacturer's authorized Dealer shall be capable of administering the Manufacturer's and Dealer's warranty for all components supplied.

The Manufacturer's and Dealer's extended warranty shall in no event be for a period of less than five (5) years from date of initial start-up of the system and shall include repair parts, labour, reasonable travel expense necessary for repairs at the jobsite and expendables (lubricating oil, filters, coolant and other service items made unusable by the defect) used during the course of repair. Applicable deductible costs shall be specified in the Manufacturer's warranty. Running hours shall not be a limiting factor for the system warranty by either the Manufacturer or servicing Dealer. Submittals received without written warranties as specified shall be rejected in their entirety.

The generator set Supplier shall have factory trained service representatives and tooling necessary to install, test, maintain and repair all provided equipment.

The generator set Supplier shall have sufficient parts inventory to maintain over the counter availability of at least 90% of any required parts.

The generator set Supplier shall provide a scheduled oil sampling service to monitor engine condition on an on-going basis. The sampling method shall be of


the atomic absorption spectro-photometry method and be accurate to within a fraction of one (1) part per million for the following elements:1. Iron2. Chromium3. Copper4. Aluminium5. Silicon6. Lead7. Water8. Fuel9. Antifreeze

The oil samples shall be analysed at an approved laboratory with fully trained personnel. Immediate notification of critical results shall be provided to the Engineer.

E. Test Reports: Copies of the manufacturer's certified shop test record of the complete engine driven generator. The engine-generator log test sheets and a performance review report shall be signed by the engine tester and certified by the manufacturer. The report shall include brief outlines of all test procedures and shall compare actual test results to the requirements of these specifications by means of calculations, graphs or charts.

F. Submit name and address of nearest factory authorized service and parts facility.

G. Service Manuals and Parts Books:The system Manufacturer's shall furnish five (5) copies of the manuals and books listed below for each unit under this contract.1. Operating Instructions - with description and illustration of all switchgear

controls and indicators and engine and generator controls.2. Parts Books - that illustrates and list all assemblies, subassemblies and

components, except standard fastening hardware (nuts, bolts, washers, etc.).

3. Preventative Maintenance Instructions - on the complete system that cover daily, weekly, monthly, biannual, and annual maintenance requirements and include a complete lubrication chart.

4. Routine Test Procedures - for all electronic and electrical circuits and for the main AC generator.

5. Troubleshooting Chart - covering the complete generator set showing description of trouble, probable cause, and suggested remedy.

6. Recommended Spare Parts List - showing all consumables anticipated to be required during routing maintenance and test.

7. Wiring Diagrams and Schematics - showing function of all electrical components.

H. All manuals and books described above shall be contained in rigid plastic pouches.


1.11 DELIVERY STORAGE AND HANDLING A. Storage: The Contractor shall acknowledge storage conditions at the time of

submitting his Tender. If the equipment 'Will not be operational within 90 days after manufacture, the manufacturer shall crate and prepare the equipment for export transportation and long-term storage. Precautionary measures for prolonged storage shall be provided by the manufacturer at the factory. The Contractor shall be responsible for storage and maintenance of the protective measures as recommended and instructed by the manufacturer while stored at the storage site. The manufacturer's warranty on units held in prolonged storage exceeding three months shall be covered by special agreement reflecting the storage conditions.

B. Packaging: In addition to the protection specified for prolonged storage, the packaging of spare units and spare parts shall be similar to export packing and shall be suitable for long-term storage in a damp location. Each spare item shall be packed separately and shall be completely identified on the outside of the container.

C. Instructions for the servicing of equipment while in long-term or prolonged

storage shall accompany each item of equipment. Advisement of enclosed instructions with each package shall be noted on the exterior of the package in English.

PART 2 - PRODUCTS

2.1 THE DIESEL ENGINE A. General

1. Due to considerations such as the duration of supplying the local industry, the established RSA service network, the current parts distribution network, international reputation for reliability and the number of engines in use on the continent, only diesel engines from reputable European or North American Manufacturers with an uninterrupted manufacturing track record exceeding 35 years, will be accepted. All equipment offered i.e. Engines, Alternators, Controllers etc must be from reputable Suppliers with full representation in RSA. There must be fully equipped workshops and factory trained personnel in RSA to maintain and rectify any problems that may arise on the equipment. Spare parts must be readily available in Gauteng, RSA for all equipment offered. Furthermore all equipment offered must be built in ISO Certified factories (BSEN9001, ISO9001, ISO1400, OHSAS18001 etc.) and must conform to the latest international standards ie. ISO/SANS 8525 – all relevant sections, BS5514, BS5000 etc. Documented proof must be submitted with the Tender”.

2. The design rating of the engines shall be in accordance with the latest amendment of BS 5514 part 1 to 5 and shall drive an alternator designed in accordance with BS 5000 and BS EN 60034. Contractors shall note the additional DCC rating requirement of this specification.

3. The engine shall be of the multi-cylindered, compression ignition, water-cooled, cold starting, four-stroke fuel injected, heavy duty, industrial type.

4. Flywheel design; cyclic irregularity shall be within the BS 5514 limits.5. All auxiliary power requirements for the engines shall be supplied from the

main alternator.


6. The engines shall be sized to drive alternators with minimum alternator outputs as specified in this document.

7. The engine and alternator shall be coupled together and mounted on a common base frame by means of vibration dampers. As generators will be deployed in the building environment, no vibration shall be transferred to the floor structure.

8. The base shall be installed directly on a solid concrete floor in the plant room. No plinths shall be constructed.

9. Removable oil drip trays shall be supplied and installed under each engine.

B. Engine Speed1. The maximum engine speed shall be 1 500 rpm and shall be electronically

governed to BS 5514 Class A to within 1% of steady state speed.2. A direct acting, mechanical speed controller shall be supplied with each

engine. The controller shall stop the engine when the engine speed exceeds the allowed limit. The controller shall act directly on the fuel injection pump and not on the governor or the electric “stop” circuit.

C. Governor1. The engine speed shall be controlled by an electronic governor. The engine

governor shall be designed for class A1 speed governing according to BS 5514, alternatively full Authority Electronic engines may be offered

2. When full load is suddenly switched on or off, the momentary speed variation shall not be more than 4%. Recovery shall be within 8 seconds.

3. External means – such as ports on the engine management unit - must be provided on engines to facilitate adjustment of the nominal speed setting.

4. The governor must be compatible with the new generator control system.

D. Starting1. The engines shall be easily started from cold, without the use of any special

ignition devices, during summer as well as during winter conditions against full load. The “run up” period from switch on until take-over of the full load, shall not exceed 10 seconds

2. A 24V industrial electric starter motor shall be fitted to the engines.3. Starting batteries shall be accommodated in a stainless steel tray. Batteries

shall be of the lead calcium, maintenance free type. Batteries shall be rated for at least six cold cranking start attempts.

4. Starting batteries shall be charged from an industrial 24V, 60 A belt-driven alternator mounted on the engine. While the engine is stationery, an intelligent solid state charger, accommodated inside the local generator control panel shall charge the batteries.

5. Provision must be made on the local control panel for both automatic and manual, starting and stopping of the engine.

6. Note the requirement for a service lock out switch, to prevent both manual or automatic starting.

E. Cooling System1. The engine shall be of the water-cooled type with a circulating water pump,

remote radiator and cooling fan of sufficient capacity to ensure no overheating of the engine even when running at 10% overload for 1 hour.

2. Basement installations may require remote heat exchangers with specifically designed hot coolant pumps and flow alarms. This will be indicated in the Project Specification.


3. The cooling system shall be pressurized and thermostatically controlled.4. To ensure easy starting in cold weather, heaters shall be installed in the

coolant circulation system. Block temperature shall be between 40 and 60 degrees C. The temperature control provided shall be completely automatic.

5. The electrical power for such coolant heater shall be taken from the local generator control switchboard and must be protected by a suitable moulded case circuit breaker.

6. Protection against running at excessive temperatures shall be provided, with visual and audible alarms on the control panel.

F. Lubrication System1. The lubrication of main bearings and major moving parts shall be forced-fed

by means of a mechanically driven oil pump.2. All engines shall be fitted with an automatic low oil pressure cut out device.

Operation of this device shall give a visual and an audible indication on the control panel.

3. The engine shall be installed in such a manner so as to facilitate gravity oil draining. In addition, a manual facility shall be provided for the transfer of crankcase oil intro drums for ease of maintenance.

4. The engine-oil filter set shall be of the rechargeable cellulose element type.

G. Fuel1. The engine shall use no 2 distillate commercial diesel as is readily available

in the Gauteng (inland) area with a sulphur content of 50ppm.2. Engine shall be fitted with a fuel oil/water separator before the fuel filters.3. Water sediment shall be automatically drained4. Braided (armoured) flexible fuel lines shall be used between the supply

point and engine.

H. Fuel Pumping System for Container Unit1. The fuel transfer system shall consist of a pump and filtration system

complete with supply and return lines. The pump shall be fitted with appropriate safety and protection circuits that will shut down the pump in case of fire or leaks.

2. The minimum flow rate shall be 600 litre per hour at a 10m head3. The system shall incorporate an integral fuel management system that

provide fuel polishing and automatic dewatering from the fuel system.4. The system shall be installed at the underground bulk fuel tank bowser

inside a purpose-made IP 65 3CR12 enclosure.

I. Fuel Consumption1. Tenderers shall submit certificates with their tenders giving the fuel

consumption for the engines offered operating at 75% and 100% of the specified full load.

2. The fuel consumption and emission figures submitted with the tender shall be guaranteed by the successful Tenderer in a separate Warranty document.

3. Emissions shall be equal or better than that specified in EPA 2016 standard.


J. Fuel InjectionThe fuel injection equipment shall be suitable for operation with the available diesel fuel.

K. Engine Air Filters1. The engines shall be fitted with inlet air filters of the replaceable dry type

suitable for a polluted atmosphere.2. Filters shall be of the dry element type. The filter enclosure shall have a

differential pressure indicator.3. Turbo engines shall be supplied for all installations above 900 m above sea

level.

L. Diesel Engine Instrumentation1. The following instrument readings, as a minimum shall be available on the

local generator control panel :a) Tachometer in rpmb) Oil pressure close to the oil pump in kPa.c) Oil temperature in °C.d) Coolant temperature in °C at radiator inflow.e) Coolant pressure in kPa.f) Engine running hours to at least one decimal place.

2. Warning systems shall be installed as specified in the electrical part of this specification.

M. Fuel Tank (base (day tank and bulk fuel storage) (containerised generator unit only)

1. A base frame mounted fuel tank shall be supplied for each generator set; also referred to as the “day tank”.

2. The capacity of the day tank shall not exceed 1 000 litre due to municipal fire bylaws.

3. The day tank shall have a drainage point located at a point the furthest away from the engine supply pipe.

4. A diesel conditioning system shall be supplied with the generator. The system inlet shall be connected to the above mentioned tank drainage point.

5. The day fuel tank shall be supplied with the following minimum accessories:a) In-tank sensor for digital fuel level indication on the local generator

control panel.b) Separate electronic fuel sensors for low and high level indication on

the control panel.c) One fuel draw off point to the engine.d) One injector fuel return line.e) Two fuel supply / filler points with caps.f) Note that all the above tank and sensor connection points shall be

mounted on a removable cover plate. The minimum dimensions of the cover plate will be 600 x 800mm.

g) The fuel supply pipework shall be painted and securely clamped and supported to the approval of the Engineer. Diesel fuel piping shall be finished in SANS 1091, colour B33 Middle Buff enamel paint.

h) Provision shall be made to use a manual fuel pump which shall be supplied with the generator set including oil resistant hose to facilitate the ease of filling of the fuel tank from drums and other portable storage devices. The fuel hoses shall be at least 20m long.


2.2 ENGINE EXHAUST SYSTEM A. General

1. A complete insulated, attenuated exhaust system shall be installed for each engine.

2. The exhaust system shall comprise of the pipes, anti vibration couplings, silencers, expansion pipes, supports and spring-hangers, etc, for the installation of the system. Noise levels must conform to Local Municipal Bylaws for residential areas.

B. Exhaust Piping

1. Exhaust piping shall be supplied in flanged lengths manufactured from suitable gauge mild steel steam piping.

2. Flanged connections shall be made with suitable heat-resistant gasket material.

3. The exhaust pipe shall be covered with permanent lagging for its full length; from the manifold bellows up to the plant room or container wall.

4. The lagging shall be protected with polished 316 stainless steel cladding. Touch temperatures shall not exceed 60 degrees under prolonged full load conditions.

C. Silencer

1. Sound attenuation and vibration control shall be provided to limit the noise levels below 75dB(A) @ 7 metres from the exhaust at 10 degrees Celsius ambient at full load operation.

2. The silencers required to meet the noise limitation as specified above, shall be manufactured from mild steel.

3. Primary and secondary silencers shall be installed in a suitable position in the exhaust system.

4. Silencers shall also be insulated; touch temperatures shall not exceed 60 degrees under prolonged full load conditions.

D. Expansion Pipes, Hangers, Supports and Guides1. Expansion sections shall be installed and so designed as to compensate

for all expansion and/or contraction of the exhaust system.2. The exhaust system design shall include spring dampers for the pipe work

and silencers. The pipe guide through the masonry or metal wall shall be such that no vibration is transferred to the structure.

3. Hangers, supports and guides shall be suitably fixed to the structure to allow for any expansion and/or contraction of the exhaust system.

4. Tenderers shall allow for all necessary dampers and support anchor points.5. All exposed exhaust outlets shall be supplied with suitable weather

protective hoods to prevent ingress of moisture.

2.3 THE ALTERNATOR A. General

1. Due to considerations such as the duration of supplying the local industry, the established RSA service network, international reputation for reliability and the number of alternators currently in use on the continent, only alternators from reputable European or North American Manufacturers with a manufacturing track record exceeding 35 years, will be accepted.


2. The alternator shall conform in all respects to the latest revision of BS 5000 and BS EN60034 and shall be as follows:a) Output : 400/230 volt, 3 phase, 50 Hz with neutralb) Rating : as specified in the Project Specification.c) Speed : 1 500 rpmd) Overload Capacity : to suit enginee) Excitation : self-exciting brushless typef) Excitation : self-exciting brushless typeg) Housing : drip proof to IP21/23 h) Ventilation : internal fan cooling

3. The design shall ensure a sinusoidal voltage wave form within the allowable tolerance as specified in BS EN60034 and have a maximum wave form distortion of 5%.

4. The stator windings shall be connected in star formation with all six terminals brought out to the main terminal box.

5. The terminals shall be marked according to BS EN60034 and the phase rotation shall be according to the standard phase rotation of the local Supply Authority.

6. The windings shall be properly wedged to eliminate damage or movement during faults or surges. The stator windings shall be wound with a 2/3 pitch 12-wire system.

7. Class ‘H’ insulating materials shall be provided. Tropical moisture resistance shall be ensured through hot epoxy dipping

8. Windings shall be so arranged as to facilitate the replacement of faulty coils.

9. Non-hygroscopic material shall be used for all spacers, wedges and clamps.

10. The neutral shall be bonded solidly to the main earth system and the alternator shall be connected to the distribution board by means of a four-core cable/busbar.

11. The connecting cables/busbar shall be sized to limit the voltage drop between the alternator output terminals and the distribution board bus bars to less than one volt between phases at the rated output.

12. The alternator bearing shall be of the sealed roller type bearings.13. Radio and television transmission interference shall be less than 2%

B. Voltage Regulation1. The alternator shall be self-regulated and the voltage shall automatically be

regulated within 0.5% of nominal voltage under all load conditions with power factors between unity and 0,8 lagging, between no-load and full-load.

2. The AVR shall utilize a 3-phase full wave bridge rectifier which shall be protected against overvoltage surges.

3. The transient voltage drop on application of the 50 % step load shall not exceed 15 %.

4. The AVR unit shall be compatible with the new generator control system.

C. Alternator Protection1. Tenderers shall ensure that adequate protection is provided for the

equipment offered, whether or not such protection is specified.2. Tenderers shall include any protection in addition to the specified protection

which is regarded by the Tenderers as essential for the safe working of the plant.


3. The following protection shall be supplied:a) Over current protectionb) Earth fault protectionc) Differential protectiond) Over voltage protectione) Reverse power protection

2.4 THE ELECTRICAL SYSTEM

A. General1. The generating set shall automatically start and supply power to the

generator bus in the event of a brown-out or power failure. On restoration of normal power, the set shall automatically shut down following the cool down period.

2. Facilities for manual operation of the generating set for emergency and test purposes shall also be provided.

3. Signals indicating generator available, in auto mode and generator running shall be provided for feeding into a building automation system.

B. Protection and Alarms1. Audible and visual alarms shall be provided for the alarms indicated below.2. Tenderers may provide additional alarms which they consider to be

necessary.3. All alarms shall initiate a clearly legible alpha numeric display and a siren,

on the generator controller display panel.4. An override button shall be provided to silence the audible alarm and a

reset push button shall be provided to cancel the visible alarm. The visible alarm shall only reset when the fault has been cleared. The controller shall store an alarm log of the last 50 alarms time and date stamped.

5. The normally open and normally closed auxiliary contacts of the relay initiating the audible alarm shall be wired to the terminal block in the generator control panel.

6. In addition, the normally open and normally closed auxiliary contacts of all alarm relays shall be wired to the terminal block in the control panel.

7. The local control panel shall support Modbus protocol to communicate with a plant management and building automation system.

8. Provision shall be made for the following alarms and actions:

FAULT ACTION VISIBLE & AUDIBLE ALARM

High water temperature Stop engine YesHigh engine temperature Stop engine YesLow oil pressure Stop engine YesOver speed Stop engine YesUnder speed Stop engine YesOvervoltage Trip circuit breaker if >

110%Yes

Under voltage --- YesReverse Power Trip circuit breaker if >

20%Yes

Engine shut down --- YesEngine start failure --- Yes

Overload Trip circuit breaker if Yes


FAULT ACTION VISIBLE & AUDIBLE ALARM

>110%Earth fault Trip circuit breaker YesLow water level Stop engine YesLow fuel level --- YesLow battery voltage --- YesBattery charger out of order

--- Yes

9. Other Indications

INDICATION ACTION VISIBLE ALARMGenerator running Indication on screen YesGenerator not in Auto Mode

Flashing Display Yes

C. Start and/or Stop Control1. Remote start/stop initiation shall be possible.2. A voltage free contact shall terminate on the above terminal strip and shall

provide an open or closed status.3. The engine starting sequence shall be initiated by a remote “closed”

contact and vice versa.4. Four modes of operation shall be available on the generator controller:

a) OFFb) MANUALc) AUTOMATICd) TEST.

5. The selection shall be lockable in each position and shall function as follows:a) “OFF” Position

In this position starting of the generating set either manually or automatically, is prohibited.

b) “MANUAL” Position:1) In this position the generating set will start once the “start” push

button has been depressed and stop upon pressing the “stop push button.

2) Operation of the set and output contactor will be similar in all aspects to the “auto” situation, except that starting and stopping will be initiated by the push buttons and not the remote contacts.

3) Should a “run-down” period not be necessary, the generating set shall stop immediately upon the depression of the ‘stop” push button.

c) “AUTOMATIC” Position:1) In this position the generating set shall start automatically when

the following conditions are met:(i) The start contact calls for a “start” sequence.(ii) The 0-5 sec adjustable time delay relay between the

“start” contact operating and the initiation of the “start” sequence has elapsed.

2) When the generating set has run-up and nominal voltage can be supplied, (within 10 seconds of the initiation of the “start”


sequence), the output contactor shall automatically close and provide power to the output busbar or terminals.

3) When the normal supply is restored, (signal via the external control contact), a 0-300sec adjustable time delay shall be triggered. The “stop” sequence of the generating set shall start when this time delay has elapsed.

4) Should the generating set fail to start after five successive starting attempts, the start failure relay shall operate and give a visible and audible alarm.

d) “TEST” Position:1) (With the selector switch in this position and the “start” push

button depressed, the generating set will start. The output contactor will be prevented from operating and shall remain in the open position.

2) Should a “run down” period not be necessary, the generating set shall stop immediately upon the depression of the “stop” push button.

3) Should the normal supply fail while the selector switch is in the “test” position the manual start shall be overridden and the generating set will operate automatically.

e) “START” and “STOP” Push Buttons:

1) “Start” and “Stop” push buttons shall be provided and clearly marked on the front of the generating set’s control panel.

2) The “start/stop” push buttons shall only be operative with the “manual” or “test” selected.

2.5 GENERATOR CONTROLLER A. The Advanced Genset Controller, AGC, shall meet the needs for

synchronisation of a multiple genset architecture with advanced power management.

B. The unit shall be, compact, scalable and all-in-one product with no need of extra units to accomplish the required control and monitoring.

C. The AGC shall integrate all necessary functions for genset protection and control, and shall be reliable and operator-friendly, with an emulation facility for testing and commissioning. The unit shall be capable of asymmetric load sharing to ensure optimal load on the genset, to reduce operating costs and emissions.

D. The unit shall be able to initiate temperature-dependent cooling, arresting cooling at pre-programmed cool-down temperatures with automatic priority selection, to select the optimum combination of gensets for optimised fuel consumption.

E. The AGC shall have the have the following functionality:1. Multiple operating modes software selectable2. Synchronisation of multiple breakers in one plant3. Multi-master power management4. Automatic load-dependent start and stop5. Load management


6. Priority selection (manual, relative running hours, absolute running hours, fuel optimisation)

7. User-programmable logic 8. Configurable inputs/outputs9. Engine, generator and load protection10. Voltage measuring 11. J1939 engine communication, different engine brands 12. Readout of engine diagnostics in clear text13. Remote control via high speed TCP/IP, RS-485 Modbus or GSM modem14. High speed USB connection15. Multi-language interface16. IP66 protection17. Logging stored on SD card

2.6 GENERATOR CONTROL PANEL A. The generator control panel shall comply with IEC 61439 parts 1 to 3.

B. The generator control panel shall be situated in the same plant room as the generating set.

C. The section of a distribution board accommodating circuits on generator supply, shall be mechanically and electrically separated from the normal section.

D. Push buttons shall be of robust construction, suitably rated with facilities for interchanging from normally open to normally close contacts. Push button construction shall be suitable for the operating conditions.

E. All indicating lamps shall be led clusters

F. The control panel shall house the following:1. Communication connections; Ethernet and Modbus2. Generator controller and display to display the following:

a) All instrumentationb) All safety interlocksc) All alarms, indicating lights and control selections.d) All incoming and outgoing circuit breakers and contactors.e) All control circuits and metering as specified for the diesel engine.f) All switching circuits for the diesel engine.g) All circuits and meters not specified above but necessary for the

correct and safe operation of the generating set.h) Maximum demand current readings maximum and instantaneous.i) Voltage readings on the alternator side of the contactor phase to

phase and phase to neutral for all phases.j) A power factor readingk) A frequency readingl) A running hour meterm) A voltmeter reading starting battery voltagen) An ammeter reading starting battery charging current


2.7 CABLE LADDERS A. This contract shall include all cable ladders where specified, including all

clamps, fixing materials, deviations, bends, angles, tees, reducers and other components required to make the cable ladders complete and ready for the laying of cables.

B. All materials associated with the cable ladders shall be epoxy powder paint coated. The colour of the cable ladders shall be as specified in the Project Specification.

C. Cable ladders shall be manufactured of sheet metal steel of minimum thickness of 2 mm or as otherwise specified.

D. Minimum shoulder height shall be 76mm for ladders of all widths.

E. Cable ladder supports shall be spaced adequately to avoid sagging between supports. Supports will be fabricated from unistrut or similar material. A vertical unistrut shall be suspended from the structure or attached to a vertical wall. The vertical unistrut shall be sized to support the combined weight of the horizontal unistrut cross-arms, cable ladders and cables. All vertical and horizontal supports will be finished in the same manner as specified above.

F. The wire way design shall be submitted to the Engineer for formal approval.

G. 45° Cornices of adequate size to permit compliance with minimum allowable cable bends shall be provided at all bends, corners, tees and reduction joints. Deviation and vertical bends shall have radii sufficient to permit compliance with minimum cable bends.

2.8 ESSENTIAL TOOLS A. The tender price shall include the supply and delivery of a complete set of tools

required for the normal maintenance, testing and repair of the generating set.

B. A purpose made, wall mounted, lockable 3CR12, 2-door cabinet to contain the essential tools shall be supplied and installed in the generator plant room. Rack space shall allow for the dimensions of an air cleaner element.

2.9 SPARE PARTS A. Tenderers shall submit a list of recommended essential spares and the prices

thereof with the tender.

B. Tenderers shall include all parts considered necessary for the normal maintenance of equipment and ancillary equipment in this list.

C. Prices in this list shall form part of the tender price.

D. The Client reserves the right to order any or none of the spares scheduled in the list at the prices stated during the course of the contract.

E. All spares order from this list shall be packed in separated crates from the rest of the equipment and shall be clearly marked as such.


PART 3 - EXECUTION

3.1 INSTRUCTION MANUALS A. Two preliminary sets of Owner’s instructions as well as the service and

maintenance manuals are to be submitted to the Engineer before installation commences.

B. The manuals shall include the following:1. Full electrical and mechanical operating instructions.2. Diagrams, drawings, etc, to facilitate servicing, maintenance and fault

finding of the complete generating set. 3. Service requirements

C. A complete list of spare parts with descriptions and RSA Suppliers shall be included in the instruction manual.

D. The Generator Contractor shall hand to the Engineer three complete sets of instruction manuals and drawings after commissioning.

E. The installation shall be considered incomplete until such time that all the above requirements regarding documentation are met.

3.2 BUILDER’S WORK

A. The Generator Contractor shall be held responsible for any damage caused by him to buildings and other services.

B. No cutting of structural concrete will be permitted unless the permission of the Engineer has been obtained beforehand in writing. The Generator Contractor will be held responsible for any damage to the building due to non-compliance with the above.

C. The Generator Contractor shall take care that all pipes, wire ways, electrical and mechanical equipment are firmly fixed in position in a manner acceptable to the Engineer.

D. The Generator Contractor shall be responsible for the making good of all chasing and openings in building work, including installation of an approved fire barrier media, after equipment has been positioned and installed.

E. Immediately after acceptance of the tender, the Generator Contractor shall formally inform the Engineer of his requirements for plinths, ventilation openings, louvre specifications and other modifications to the building.

3.3 ELECTRICITY SUPPLY

A. Electricity supply will be made available by the local Supply Authority at the voltage specified herein and the Generator Contractor shall deliver the installation in such a manner that it complies with the Supply Authority’s requirements regarding voltage, current and frequency and with any other requirements which may be imposed by the Supply Authority.


3.4 PRE-DELIVERY INSPECTION A pre-delivery inspection must be performed by the system Manufacturer's local Dealer at the dealer's facility to ensure no damage occurs in transit and all genset components, controls, and switchgear are included as specified herein.

3.5 INSTALLATION The installation shall be performed in accordance with shop drawings, specifications and the Manufacturer's instructions.

3.6 EARTHING A. The entire installation shall be properly and effectively earthed as prescribed in

SANS 10142-1. The entire installation shall be bonded to the main earth bar by means of separate earth conductors.

B. All earthing work shall be executed before any painting commences.

3.7 GENERATOR PLANT LAYOUT A. Tenderers are to ensure and confirm that the space and access routes and

openings provided are sufficient for the installation of their equipment.

B. The Generator Contractor must ensure that the access provided for the off-loading and positioning of his equipment, is adequate.

3.8 PAINTWORK

A. All distribution boards and control panels shall be treated and epoxy powder coated.

B. All boards, cubicles and/or panels associated with the generator installation shall be painted Signal Red, SANS 1091, colour A11.

C. The enclosure, where specified, the engine, the alternator and the base frame may be finished in the colour of the Manufacturer.

D. Surfaces subject to heat shall be painted with paint suitable to withstand the specific conditions.

E. Machined parts and parts constantly in contact with oil shall be left unpainted. After completion of erection, these parts shall be properly cleaned and oiled.

3.9 NAME PLATES AND NOTICES

A. All warning safety notices and name plates shall be in UK English.

B. Name plates shall be to the Engineer’s approval and shall be permanently mounted on all equipment and distribution boards.

C. Name plates shall be manufactured from 3mm stainless steel plate. Letters and diagrams shall be engraved on the plate so that continuous cleaning of name plates will not obliterate any information.


D. Valves, levers, meters, switch and meter panels and other parts of equipment used for the control of the diesel engine shall be supplied with name plates denoting the function and type of equipment.

3.10 DANGER NOTICES A. In addition to all the external and indoor signage requirements of the

Occupational Health and Safety Act, 1993 (Act No. 85 of 1993), specifically the Electrical Machinery Regulations of 2011, Clause 5, additional signage will be required.

B. A clearly legible danger notice in bold red letters on a white background shall be mounted in a prominent position in the plant room. The notice shall be made of a non-corrodible and non-deteriorating material, preferably engraved Aluminium or Perspex and shall read as follows:

DANGERTHIS ENGINE CAN START WITHOUT NOTICE. TURN SELECTOR SWITCH ON CONTROL PANEL TO “OFF”

BEFORE WORKING ON PLANT

3.11 TRAINING OF OPERATING STAFF A. The Generator Contractor shall be required to train the SITA maintenance staff

to be fully competent in safety, maintenance, operation, fault finding and first line repair of the equipment.

B. After completion of the installation, and when the plant is in running order, the Generator Contractor shall be required to instruct an SITA maintenance staff and SITA contractor in the operation of the plant until they are fully conversant with the equipment and the handling thereof.

C. The Generator Contractor shall take full responsibility for the safety of training personnel and for the quality of work produced by such personnel under his supervision.

3.12 TESTS AND COMISSIONING A. The Generator Contractor shall be responsible for arranging all the tests as

specified, at the appropriate time.

B. The entire installation shall be tested after completion in accordance with SANS 10142-1 and any applicable by-laws of local authorities.

C. The Engineer reserves the right to be present for the witnessing of tests and the Generator Contractor shall advise the Engineer timeously of all tests to enable him to be present if he so desires.

D. The Client may request the Contractor to repeat similar tests at any time and the Generator Contractor shall render all assistance and shall provide all tools and instruments which may be required for such proofing tests.


E. The Generator Contractor shall replace any portion of the installation if it does not meet with the requirements of the regulations or this specification, as may be found by test or inspection. Such replacement shall be done at his own cost.

F. The Generator Contractor shall, after he has notified the Engineer at least two

weeks prior to the scheduled testing date, conduct the following tests:

1. At the Manufacturer’s workshop before the generating sets are delivered to the site; tests shall be performed to ascertain that the generating sets comply with the specification and deliver the specified output. These tests shall be carried out in accordance with BS ISO 30146.

2. The starting duration, step load performance, engine temperature rise, protection and alarm devices, must be tested in particular.

3. Upon completion of the installation on site ; the controls, starting, protection and alarm devices shall be re-tested on site.

G. The load and all instruments which may be required for the tests, shall be provided by the Generator Contractor.

H. Copies of the factory and site test reports of the above tests shall be submitted to the Engineer for inclusion in the O&M manuals.

3.13 CERTIFICATE BY CONTRACTOR

A. The work specified in this document shall not be considered to have been completed until a Certificate of Compliance for the electrical installation has been issued by the Generator Contractor.

B. The Client will withhold final payment until such certificate is produced.

.

END OF SECTION 26 32 13.16
