SECTION 3: EMERGENCY DIESEL GENERATOR

1. GENERAL
1.1. The emergency power generating plant shall be rated in accordance with
ISO3046 for the following operating conditions:

Ambient temperature: 400C

Humidity: 100%
Power factor: 0.8
Output voltage : 400 volt, 3 phase, 4 wire,
Frequency: 50 Hz
operating speed: 1500 rpm

1.2. The emergency generators set shall have installed power as design drawing.

1.3. The generator set shall be capable of carrying minimum net continuous ratings as
specified above and shall also satisfy the transient as well as the steady state of
the connected essential load to the generator sets.

1.4. In selecting the ratings, the Sub-Contractor shall take into account all debating
factors due to altitude, ambient temperature, and the like, as recommended by
the generator manufacturer.

1.5. All wiring for the control and protection systems, carried out in suitable heat and
oil resisting cable as approved by the Project Director and shall be wired out to a
suitable cable termination block.

1.6. Earth terminals and conductors for bonding the engine to the earthing system
shall be provided and installed by the Sub-Contractor.

1.7. The engine and generator shall be mounted on a common industrial type heavy
duty mild steel baseplate able to withstand both static and dynamic loads of the
generator set. Mounting faces for the machines shall be accurately machined.

1.8. The underbase shall be mounted on a suitable number of vibration isolators (as
recommended by the manufacturer and approved by the Project Director).

1.9. The standby diesel generator sets shall be constructed so that they can be
conveniently dismounted into units of moderate size and weight for installation,
major maintenance and repair purposes.

1.10. The entire system shall conform to the requirements of the local Fire Services
Department and other government authorities having jurisdiction on generator
installation as well as other relevant local rules.

1.11. Within two months after award of the Sub-Contract and prior to ordering the
equipment, the Sub-Contractor shall furnish the following information to the
Project Director for approval:

 Wiring and control diagrams

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  Manufacturer's shop drawings

 Complete manufacturer's printed catalogues

 Physical dimensions and operating weights

 Mounting and fixing details

 Complete materials specifications

 Performance curves and data

 Sound power ratings in dBA within octave band (including engine,

alternator and radiator)

1.12. All components selected shall be of minimum vibration and noise level during
operation, should these requirements be excessive and outside normal
acceptable standards, the Sub-Contractor shall be responsible for provision of
adequate vibration isolation and sound attenuation and shall submit such
proposal for the approval of the Project Director.

1.13. Operation of the generator set shall comply with local Fire Service Department's
requirement. Whenever a power failure in detected at the main switchboard, the
following starting sequence shall commence:
1.13.1. Within 10 seconds of the start sequence commencing, the generator set shall
be stabilised at its running speed and full load transfer shall take place
automatically.

1.13.2. Should the generator set fail to start after a period of 10 seconds, the sequence
shall be interrupted for a period of 5 seconds and a further attempt to start of
10 seconds duration shall then be made. If it again fails to start, the starting
sequence should be locked out, an audible and visual alarm shall be given at
the local generator control panel and it shall remain in this locked out condition
until manually reset.

1.13.3. Restoration of the mains supply during the starting period shall not interrupt the
starting sequence but shall prevent operation of the load transfer at the main
switchboard.

1.13.4. On the full restoration of normal supply, shutting down of the generator set
shall be done as follows : when the main power is present, after a suitable
delay (0-5 minutes adjustable) will return the load to the source and after the
load is re-energized to the mains, the generator will remain running for a while
(adjustable from 0 - 15 minutes) to allow for equalizing the motor's thermal
characteristics , automatically stops the machine.

2. ENGINE AND ALTERNATOR

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2.1. The complete generator set including engine, alternator, control panel, radiator
shall be supplied from a single manufacturer as approved by the Project Director
and all guarantees, test certificates and the like shall be deemed to apply to the
entire assembly.

2.2. Engine
2.2.1. Engine shall be water-cooled, four stroke, direct injection, naturally aspirated or
pressure charged.

2.2.2. The engine shall be secured to the underbase by means of foundation bolts by
the Sub-Contractor.

2.2.3. The engine water jacket shall be extended to cover the exhaust manifold to
limit the heat rejection to the room.

2.2.4. Filters for aspiration air, fuel oil and lubricating oil shall be provided for the
engine.

2.2.5. The engine shall be provided with the following measurement devices:

 Tachometer

 Cooling water temperature gauge

 Lubricating oil temperature gauge

 Lubricating oil pressure gauge

 Hours run meter

2.2.6. The engine shall be arranged for automatic electric motor starting, the pinion of
which shall engage with a toothed ring on the driving shaft of the engine.
Starter batteries shall be nickel cadmium type of an adequate ampere hour
capacity and shall be mounted adjacent to the engine underbase.

2.2.7. The batteries shall comply with IEC285 suitable for use in tractions and be
capable of providing 4 number 15 seconds consecutive start sequences with a
five seconds interval between without being discharged to levels where
damage. The batteries shall be sustained by an integral DC battery charger
whilst mains is healthy. Upon main fails and generator sets being started up,
the batteries shall be recharged to fill voltage by the generator supply.

2.2.8. Engine Protective Devices

The following protective devices shall be wired to a common terminal box

mounted on the engine underbase:

 High cooling water temperature sensors (two stage alarm and trip)

 Low lubrication oil pressure sensors (two stage alarm and trip)

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  Mechanical overspeed trip and alarm

 Shutdown solenoids

 Centrifugal switches

 Governor control run-up devices

2.2.9. The generator set shall satisfy the following minimum governing requirements:

 Removal of rated load shall result in a transient frequency change not

exceeding 15% recovering to 5% change within 15 seconds.

 Application or rejection of 60% of rated load shall result in a transient

frequency change not exceeding 10% recovering to 3% change within 10
seconds.

 Application or removal of any step of 25% of rated load shall result in a

transient frequency change not exceeding 4% recovering to 1.5% change
within 15 seconds.

 The steady load speed shall not exceed 1% of the rated speed.

2.2.10. The engine shall be equipped with immersion type electric heaters in its
circulating water system complete with a suitable temperature controlling
device to ensure quick starting of the engine on demand by maintaining it at
the "Ready to Start" temperature at all times.

2.3. Alternator
2.3.1. The alternator shall be self-exciting, self- regulating, air cooled, brushless with
continuously rated output as indicated on the Drawing at 0.8 pf 400V 3 phase
4 wire 50Hz when driven at 1500 rpm.

2.3.2. The alternator shall be single bearing type, horizontally flange mounted to the
engine. Alternator shall be drip proof, screen protected and the stator and rotor
windings shall be totally epoxy impregnated and tropicalised with an
overcoating of resilient insulating material.

2.3.3. The alternator characteristics shall be properly matched to the engine torque vs
peed curves and shall meet the requirements of IEC Standards.

2.3.4. The alternator shall be complete with termination boxes mounted on the side of
the stator.

2.3.5. Voltage regulation shall be within ±2.5% of rated voltage (for balanced steady
load between zero and rated load) to be maintained by automatic voltage
regulator. The power factor at any load shall lie between 0.8 to 1.0. On
suddenly applying a step load from zero to 130% of rated alternator ratings, the
initial voltage drop shall not exceed 20% of rated value and shall recover to at
least 97% of rated value within 0.5 sec.The ability to withstand continuous
short circuit shall be not less than 250-300% for a period not more than 10 s.
Specification Page E III- 4
2.3.6. The insulation class shall be of class H in accordance with IEC85 , IP 22.

2.3.7. Facilities for adjustment shall be provided at the control panel for presetting the
speed frequency of the unit which thereafter shall maintain a frequency of 50
Hz ±1% from no load to full load under steady state conditions.

3. COOLING SYSTEM
3.1. The radiator shall be of tropical type heavy duty waterproof units with thermostatic
control of cooling water circuit and by-pass to suction side of water pumps.
Radiator shall be mounted close to the generator set on the same underbase
frame.

3.2. The Sub-Contractor shall ensure that the fan static pressure of the radiator fan
can overcome the additional pressure drop imposed by both the intake and
exhaust silencer as specified in the Specification herein and on the Drawings.

3.3. The cooling water used shall be clean, free from contamination by foreign matter
and treated to ensure that neither corrosion nor scale shall be formed at any point
in the system. Inhibitors shall be added in suitable proportion. The pH value of the
cooling water shall be maintained 8.0.

4. FLUE EXHAUST SYSTEM

4.1. The Sub-Contractor shall install the flue exhaust system in accordance with the
local regulation.

4.2. The flue pipe shall be sufficiently sized to ensure that the exhaust back pressure
shall not exceed the maximum limitation specified by the generator sets
manufacturer.

4.3. Heavy duty industrial grade of silencers shall be provided and positioned as close
to the manifold as possible. The details of the silencers shall be submitted to the
Project Director for approval, including sound power attenuation characteristics
across the octave band.

4.4. The first section of exhaust pipe from the engine manifold shall include flanged
sleeved stainless steel convoluted bellow units to isolate vibration transmitted
from the generator set.

4.5. Thermal insulation shall be provided along the entire exhaust pipework. The
insulation shall comply with the requirements of local Fire Services Department,
as well as relevant IEC Standards. The insulation shall be enclosed externally by
stainless steel cladding and shall be installed in accordance with the
manufacturers' recommendations.

4.6. Where the exhaust pipe passes through walls, sleeves shall be fitted. Cutting of
openings of the opening for installation of the flue pipe shall be provided by the
Main Contractor whilst waterproof sealing of the opening after installation shall be
provided by the Electrical Sub-Contractor.

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4.7. A rain cap and drain trap capable of automatic removal of condensation, are to be
fitted to the exhaust pipe to avoid water accumulation.

5. GENERATOR CONTROL PANEL

5.1. The control cubicle shall be constructed of materials capable of withstanding the
mechanical, electrical and thermal stresses, as well as the effects of humidity,
which are likely to be encountered in normal service.

5.2. Protection against corrosion shall be ensured by use of suitable materials or by

the application of protective coatings as approved by the Project Director to
exposed surfaces, taking into account the intended conditions of use. :
5.2.1. The equipment in the control panel shall be so arranged as to facilitate its
operation, maintenance and at the same time ensure the necessary degree of
safety against unauthorised interference.

5.2.2. The cubicles shall be arranged for front access, top cables / busducts entry,
and floor mounting, with adequate lifting means provided.

5.2.3. Terminal blocks and provision for conduit terminations shall be provided for
outgoing small wiring. All external cable entries shall be from the top of the
control cubicle. All small wiring shall be colour coded to IEC Standard.

5.2.4. The control panel shall consist of all equipment and accessories required to
control the generator operation and shall include but not be limited to the
following for the generator:

+ 1 voltmeter complete with 7 position selector switch

+ 1 frequency meter

+ 1 power factor meter

+ 1 ammeter complete with 7 position selector switch and current

transformers

+ 1 kilowatt meter

+ 1 kilowatt hour meter .

+ 1 hour run meter

+ 1 start-stop and automatic mains monitoring system

+ 1 emergency off push button

+ 1 lamp test switch

+ 1 manual speed adjusting switch and reset switches for overload, alarm
muting and the like

+ Fully automatic trickle battery charger c/w battery voltmeter

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 + Indicating lamps for 'automatic mode', 'manual mode' , 'mains available'
‘mains on load', 'standby available', 'standby on load', 'alarm', 'mains fail'
and the like

+ Duty selector switch for 'off-automatic-test- manual' operation

+ Manual start-stop push button switch

+ Alarm acknowledge switches

+ Alarm reset switches

+ Audio and visual alarm indications showing generator 'fail-to-start' lock

out.

+ Indicating lamps for generator operation status and alarms including 'low
oil pressure trip', high water temperature trip', 'overspeed trip', 'low fuel
level', 'engine running', 'battery low voltage' and the like.

+ Alternator circuit breaker complete with earth current transformers,

overload and fault tripping device.

+ 1 set of signaling cabling to ATS .

+ Instruction labels detailing the manual operation and resetting

procedures on the generator.

6. EARTHING
6.1. The Sub-contractor shall provide all earthing requirements for the Diesel
Generator Installation as shown on the Drawings.

6.2. The system of earthing shall comply with the recommendations stated in the IEC
Standards and where detailed otherwise in the Specification herein and on the
Drawing.

6.3. All exposed conductive parts and extraneous conductive parts shall be bonded to
the earthing system to maintain equipotential zones within generator room.

7. FUEL OIL SYSTEM

Daily oil tank by engine allows machine to run for 8 hours. The daily service
tanks shall be constructed to the requirements of the local Fire Services
Department.
The tank shall have available terminals and an oil level indicator with low oil
level and high oil level alarm.

8. AIR DUCT AND ACCESSORIES

8.1. All exhaust ducts, accessories and materials must conform to the HVAC
standard. Materials, fabrication and installation of metal corrugated iron pipes
must be in accordance with DW142 standards.

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8.2. All ducts must be made of galvanized steel sheet complying with DW142
standard with tolerances of thickness.

9. FIREPROOF MATERIAL
9.1. Soundproof panels and insulation materials shall be non-flammable.

9.2. Fireproof materials must be tested and comply with State standards. 9.3. The
test sample shall not remain open for 8 seconds after the pilot flame has been
removed.

9.3. The test sample shall not remain open for 8 seconds after the pilot flame has
been removed.

9.4. No fire spread outside the burned area of the material.

10. PROTECTION GUARD

10.1. The Sub-Contractor shall provide proper guards to belts, pulleys, chains, gears,
couplings, projecting set, screws, keys, and other rotating and fast moving parts
so that any person can safety come in close proximity of the equipments with
reasonable degree of safety.

10.2. The guards shall be removed, but should be provided so that access to the motor
and the shafts is easy without removing the protective mesh.

11. ACOUSTIC TREATMENT TO GENERATOR SET

11.1. General
11.1.1. Generators and radiator shall be completed with silencers for engine exhaust
fan exhaust and fresh air intake passages. The whole unit shall site on a
floating floor of 200mm thick cast by the Main Contractor.

11.1.2. Flue exhaust silencers shall be industrial grade combination

reactive/absorptive type as required to meet the specified noise limits.

11.1.3. Access doors/openings shall be provided for maintenance and servicing.

11.1.4. The noise levels when generator set is operating at 100% load shall not
exceed 75 dBA at 10m from the intake/exhaust louvres of the generator room.

11.2. Sound-Attenuators for Cooling and Combustion Air

11.2.1. Sound attenuators shall consist of an outer casing, sound absorbing materials
and internal baffles, splitters and supports. Casings shall be tested to 2 kPa
and shall show no more than 2% leakage or distortion in this condition. Seams
shall be lock formed and mastic filled. End flanges shall be made from
galvanized mild steel or rolled steel angle, as approved by the Project Director.
Attenuators shall be fitted to ductwork using neoprene gaskets between bolted
flanges. The geometry of selected attenuators shall not result in requirements
for sharp transformation in adjacent ductwork, shall not interfere with adjacent
services or with reasonable access to services and shall not affect to adversely
the aerodynamic performance of the system or encourage regeneration of
noise local to the attenuator, all details shall be to the satisfaction of the Project
Director.
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11.2.2. Sound absorbing materials shall be fibreglass or mineral wool held in place
with at least 5% compression to prevent voids due to settling. Absorbing
material density shall be minimum 40 kg/cu.m faced with minimum 0.5mm
(26g) perforated galvanized steel sheets.

11.2.3. Detailed calculations shall be submitted by the Sub-Contractor giving the

sound power levels of the generator sets and the proposed silencers. It will be
the responsibility of the Sub-Contractor to provide all necessary acoustic
treatment to ensure the specified noise limits are achieved.

11.3. Wall sound proof for generator room

The sound absorption material must be glass fiber 48 Kg / m³ density and 100
mm thick (wall) 100 mm (ceiling) held in bars made of galvanized steel sheet and
protected by galvanized steel sheets with 0.5 mm thickness. and puncture 23% of
the area. Z bars placed parallel and horizontally shall not be spaced more than
610 mm apart and have a fixed spacing not longer than 1200 mm. The hole plate
shall be mounted on the Z-rod with drawers with a distance not exceeding 610
mm.

12. VIBRATION ISOLATION

12.1. The Sub-Contractor shall be responsible for the supply, installation and
adjustment of spring-type anti vibration mounts for the generator set.

12.2. Spring type vibration isolators shall be constructed from suitably treated and
finished steel or steel alloys. They shall be manufactured with rubber, neoprene
or glass fibre 'acoustic pads' to prevent transmission of high frequencies. The
material of the pad shall be selected to suit the location. Holes shall be provided
for fixing both to the supported machine and the supporting structure.

12.3. The ratio of ‘lateral stiffness/vertical stiffness’ shall be at least 1.2 times the ratio
of ‘static deflection/working height’.

12.4. All connecting pipework and ductwork (including the flue discharge pipeworks)
shall have flexible connections. The first three pipe supports after flexible
connections to have hanger vibration isolators of minimum static deflection 25mm
or one half the static deflection of the mounting system, whichever is the greater.

13. INSTALLATION
13.1. The design, construction, layout and installation details of all apparatus shall be
such as to give maximum safety convenience and simplicity.

13.2. The Sub-Contractor shall provide proper guards to belts, pulleys, chains, gears,
couplings, projecting set, screws, keys, and other rotating and fast moving parts
so that any person can safety come in close proximity of the equipments with
reasonable degree of safety. .

13.3. Surfaces sufficiently hot to cause injury shall also be adequately guarded.

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13.4. Flexible connectors shall be provided for all pipes, ducts and the like at the point
of pipework connection to the vibrating components. Pipeworks shall be
adequately supported on both sides of the flexible connection to eliminate all
lateral forces on the joint except due to vibration only. Any support of the joint
shall be mounted so as not to transmit vibration to the building. All major items of
equipment are to be bonded by adequately rated conductors to a common earth
terminal of adequate rating.

14. STANDARDS OF MATERIALS AND EQUIPMENT USED FOR MEP WORK

GENERATOR

TECHNICAL
STT DESCRIPTION NOTE
CHARACTERISTICS

1 Manufacture: Mitsubishi

2 Origin: China/Asia

3 Type V / In-line

4 Installation location: Indoor

5 Standard: IEC, BS,ISO

6 ALTERNATOR

7 Power(Prime) Follow the drawing

8 Phases 3 phases- 4 wire

9 Frequency 50Hz

10 Voltage 400/230V

11 Insulation level H

12 Protection level IP 2X

13 Voltage regulation level +/- 0.5%

4-pole rotating magnetic field self-
14 Alternator-excitation
excitation
15 Short-circuit capacity 300% on 10 seconds
Ability to withstand
16 2250rpm (50%)
speeding
17 MOTOR Diesel

18 Cycle 4 stroke

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 19 Motor speed 1500 rpm

20 Cooling method Radiator, blower fan.

21 Fuel Diesel
Lubricating oil cooling
22 Water
method
23 Fuel filter type Replaceable

24 Lubricating filter type Replaceable

Electrical,24 VDC ( battery charger
25 Starts motor road import according to the
machine)
26 Motor speed control Electromagnetic

27 Time to start < 10 seconds

28 Cable in/out: Top/Bottom/Left/Right

Maximum temperature
29 40oC
environment
30 Governor Electronic

31 CONTROL PANEL

32 Control panel According to the machine

33 Operation mode AUTO/OFF/MAN

Voltage, current, frequency,
speed, oil pressure, water
temperature, motor speed, battery
34 Display
voltage, operating time,
(KWKVA,KVAR,KWh,KVAh)
power factor
Overheat cooling, low oil pressure,
Protect overload, over voltage, start
protection no more than 3 times
35 MACHINE FRAME
Production at generator factory, in
36 Machine frame
industrial shape steel
Standard anti-vibration with rubber
37 Anti-vibration
/ Anti-vibration springs

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