CONTRACT No :

SA WELLNESS INVESTMENTS (PTY) LTD

PROPOSED MIXED USE COMMERCIAL DEVELOPMENT - BALLITO

PS-SDG : STAND-BY DIESEL GENERATOR – PARTICULAR TECHNICAL PROJECT SPECIFICATIONS

PROJECT TECHNICAL SPECIFICATIONS

A. GENERAL

SDG.1.1 General

Supply, deliver, install, test, commission and maintain and service one emergency diesel generating set at
the New Mixed Use Commercial Development in Ballito in the north Coast, KZN .

This installation must comply fully with all the sections of this specifications and drawings issued with this
document. This technical Specification is supplementary to the Equipment Requirements, Section 2, the
Standard General Specifications included with the tender and must be read together. Where they are at
variance the Technical Specification shall apply.

These generator sets are to be fully enclosed and synchronised during operation.

SDG.1.2 Site Conditions

The following site conditions will be applicable and equipment shall be suitably rated to develop their
assigned rating and duty at these conditions.

a) Height above sea level : 21 meter above sea level ( Ballito )

b) Maximum ambient temperature : 45°C

c) Humidity : Up to 90% - high

SDG.1.3 Output and Voltage

After the de-rating factors for the engine and generator due to site conditions shall be taken into
account, the sets must have a site output and voltage as follows:

No load voltage : 400/230 Volt

Rating : 1 x 200kVA synchronized units ( estimated , final to be calculated
and confirmed by supplier)
Frequency ( Prime ) : 50Hz
Fault Level : 15kA
Load Power Factor : 0.8

The generator build for the New Mixed use Commercial Development in Ballito shall be a silent type diesel
engine close coupled to a brushless alternator, all on a fabricated steel base via anti-vibration mounts and
mounted in a standard canopy ( double skin ) manufactured of 3CR12 to suit the equipment sizes. Sound
attenuation shall be provided for the set and the canopy as the unit will be adjacent a residential
development and the noise levels kept to minimum decibel values.
Due to the unit being installed on the beach, the canopy is to be manufactured from double skinned sheeting
to mitigate corrosion. All fasteners, mounting accessories, bolts, nuts and washers is to be stainless steel.
The unit is to be corrosion resistant due to it being installed in a very corrosive atmosphere.

The diesel engine shall be a Deutz, John Deere, Volvo or Perkins ( in order of preference) or similar and
equal approved. The motor shall be water cooled, direct injection , four cylinder unit with electronic governor.

Page 1 of 19
The tenderer shall obtain prices for all the brands and the final decision as to which unit is to be used will be
decided later depending on prices and availability. The Deutz and John Deere engine shall be quoted on.

The generator output shall suit the starting and run load as per the load estimates below. The estimates may
change slightly depending on the final selected pumps and motors. The load prime power shall be rated at
0.8PF; 400/230V; three phase four wire; 50Hz running at 1500RPM with an overload capacity of 10% per
one hour in every 12 hour running cycle. The main load on the generator shall be the lift ( one off ) , the fire
water pumps , all internal and external lighting, some aircon units= and some sockets and security access
control and camera systems. Where pumps are installed, no two or more pumps will be able start
simultaneously, inter-locking in the MCC or PLC ( where installed ) will be provided to enable this function.

Table A-1 Table of schedule of current load estimates for the New Mixed Use Development

Type of Load Quantity Load Motor Installed Run Load Type of

kW Load kW Load kW kW starting

Lighting 15 15 15

General power 20 10 15

Lift 1 7,5 7,5 7,5 7,5 VSD

Fire Water Pump 1 11 11 11 11 DOL

Aircon units 4 2,2 8,8 8,8 8,8 Inverter

Fire Water 1 2,2 2,2 2,2 2,2 DOL

Jockey Pump

Instrumentation, 10 10 10
IT/Data

Other small 5 5 5
power loads

Total Load 69,5 69,5

The alternator shall be single bearing brushless type with 2/3 pitch winding / class H insulation;
Voltage regulation plus 1.5%; low harmonic distortion with IP 21 degree protection. The alternator
shall be type DINGOL or Leroy Somer or other similar and equal approved. A base fuel tank sized to
operate the full run load for a period of 12 hours continuous running shall be provided with the unit
including fuel gauge, filler cap, dished bottom with drain and plug. The tank is to be hot dipped galvanised
due to the gen-set being installed on the beach in a corrosive environment

A self contained bund to contain any fuel spillages or leaks shall be provided with the tank and be included in
the price. A drain valve shall be installed for the bund drainage. A hand pump with all fittings and hoses shall
be supplied with the unit for filling of the diesel base tank.

Control panel:
The automatic mains failure plant mounted type 3CR12 control panel shall be finished in red baked epoxy. It
shall be equipped with the following:

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 One suitably rated incoming isolator.
 One suitably rated alternator circuit breaker with adjustable thermal and magnetic overloads.
 One set of suitably rated mechanically and electrically interlocked change over system 4 pole switching.
 One set of three current transformers.
 One 3 amp automatic battery charger with short circuit protection.
 One emergency stop button.
 All necessary control circuit breakers and relays all wired to terminals.
 One PLC “DEEP-CEA” type generator control unit with the following features shall be installed:
- Accurate metering and monitoring system with commands to start, change over, and stop the
- Facilities for signals to the remote PLC or telemetry system shall be provided for mains incoming
breaker open/closed, feeder breaker open/closed, generator run/stop, low fuel and fire alarm.
- Two 24V DC fire alarm detectors shall be shall be installed in the canopy and wired to the control
unit and to the remote PLC or telemetry unit.
 The unit shall be fitted with a low fuel level cut-out facility.

The following minimum viewable functions are to be included:

 Battery voltage
 Mains and alternator voltage
 Phase currents and frequency.
 Fuel level

Facilities shall be provided in the PLC to manually and auto-start the generator from the PLC and for
remote starting from the future Monitoring/SCADA/DCS system.

Full wiring diagrams and details of the control panel shall be submitted to the Engineer and Client for
comments and approval prior to manufacture of the unit. Details, general arrangements, specifications and
manufacturer part numbers etc of all components and equipment shall be supplied with the wiring diagrams.

Standard fittings shall include exhaust with residential silencer and maintenance free lead calcium
battery.

The generator canopy shall be fitted with air supply and exhaust louvres or grilles for the generator and
radiator ventilation and cooling. The generator and radiator discharge air louvre and ducting shall be fitted
between the gen-set and the entrance door which shall be louvred. All louvres and ducting shall be stainless
steel, louvres shall be fitted with stainless steel insect mesh or screens. The sizes and dimensions of the
louvres and ducting shall be determined by the gen-set manufacture in conjunction with the drawings
submitted. The final dimensions shall be measured and determined on site prior to manufacture of the
louvres and ducting.
The canopy shall be fitted with vandal proof locking mechanisms on the doors and other access points. The
container shall be painted dark grey, to be confirmed at order stage. Details of the paint specifications shall
be provided later.

Prior to delivery or despatch, a FAT (factory acceptance test) shall be undertaken and the set shall be given
a full load test and a Test Certificate produced and submitted. Prior and sufficient notice shall be given for all
tests. A SAT (site acceptance test) and full testing and commissioning of the gen-set/s shall be undertaken
on site and a Test Certificate issued. These tests and recordings shall be included with the Operator’s and
Maintenance manual. Five hard copies and five soft copies of the O & M manuals shall be supplied on
successful commissioning of the generator set.

Statutory notices and warning signs shall be fitted to the unit to suit the standards and regulations pertaining
to gen-sets.

The set shall be supplied with a full tank of diesel on delivery to site for testing and commissioning.

Full details and technical specifications of the complete generator set with motor, alternator, control panel etc
set shall be provided with the tender or quote for evaluation purposes. The returnable data sheet shall be
submitted with the quotations or tender.

SDG.1.4 Installation

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The gen-set is to be installed in the basement of the building in positions shown on the drawings. Access
will be restricted, so the generator supplier is to take cognisance of this is his tender.

B. TENDER

The generator supplier shall submit tenders or quotations for each generator set as specified.
The tender or quotation shall be in the format of the bill of quantities and accompanied by a company letter
head and the quotation shall be broken down as follows or as itemised in the bill of quantities submitted
with the tender :

 Genset with base, frame, engine, alternator, exhaust etc complete ( double skin canopy )
 Built in fuel tank
 Self contained bund ( corrosion resistant )
 Generator canopy etc complete ( double skin
corrosion resistant )
 Louvres, sound attenuation etc complete
 Control panel complete as specified
 PLC , I/Os etc
 Power cabling
 Instrumentation and control cabling
 Battery set
 Low fuel shut off
 Fire alarm detection system
 Delivery to site, offloading and rigging
 Full tank of fuel
 Testing and commissioning ( including FAT &
SAT)
 Statutory signages and notices
 Hand over & certificates
 Electrical COC
 O & M manuals
 Other

Note : The final tender bill of quantities shall be as per the schedule in the contract tender
documents.

Name of Contractor : ……………………………….

Signature : ………………………………..

Date : …………………………………

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CONTRACT No :

SA WELLNESS INVESTMENTS (PTY) LTD

NEW MIXED USE COMMERCIAL

DEVELOPMENT - BALLITO

DIESEL POWERED GENERATOR SET AND

INSTALLATION

DATA SHEET ( TO BE COMPLETED AND

SUBMITTED BY TENDERER – 1 FOR EACH SET)

SITE …………………………………………….

SET / INSTALLATION No:……………………

DESCRIPTION UNIT SPECIFIED OFFERED

1 GENSET RATINGS

1,1 Supplier Sinabo (

Ultimate
Group)
1,2 Generator continuous power rating kVA Refer load
schedule
1,3 Typical generator power output (COP) kVA
1,4 Typical generator power output (PRP) kVA
1,5 Typical generator power output (LTP) kVA
1,6 Alternator efficiency %
1,7 Load acceptance recovering time
1,8 At 80% continuously power (COP) sec
1,9 At 100% continuously power (COP) sec

2 ENGINE (MOTOR)

2,1 Country of origin

2,2 Country of manufacturing
2,3 Make As specified
2,4 Is serial number traceable to manufacturer Yes / No Yes
2,5 Model - Turbo charged Yes / No Yes
2,6 Model - Natural aspirated Yes / No
2,7 Type
2,8 Cylinders Qty
2,9 Water cooled Yes / No
2.10 Air cooled Yes / No
2,11 Kilowatt - continuously kW
2,12 Kilowatt - prime rated power kW
2,13 Kilowatt - limit kW
2,14 Speed RPM
2,15 Governor - type
2,16 Governor - make
2,17 Over rev alarm and output Yes / No

3 FUEL SYSTEM TYPE - CONSUMPTION AT COP

3,1 25% Load L/hr :gm/kWh

3,2 50% Load L/hr :gm/kWh

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3,3 75% Load L/hr :gm/kWh

3,4 100% Load L/hr :gm/kWh

3,5 Fuel line/pipe - type Black Steel
HDG
3,6 Fuel tank material
3,7 Fuel tank filter type
3,8 Base mounted fuel tank (at least 12 hours) Yes/No Yes
3,9 Fuel tank size
3,10 Litres L
3,11 Height mm
3,12 Length mm
3,13 Width mm
3,14 Hand fuel pump Yes/No Yes
3,15 Self contained bund built with set(to contain leaks) Yes

4 COOLING SYSTEM TYPE

4,1 Cooling volume - engine Litres

4,2 Cooling volume - radiator Litres
4,3 Maximum coolant operating temperature °C
4,4 High temperature alarm at 95% of coolant °C
operating temperate to manufacturer’s spec
4,5 High temperature alarm and cut out switch Yes/No Yes
4,6 Airflow volume through cooling system m³
4,7 Airflow volume through cooling system as per Yes/No Yes
manufacture specification

5 EXHAUST TYPE

5,1 Type of exhaust system Industrial

5,2 Exhaust gas maximum flow at full load (COP)
5,3 Exhaust emission tier level Tier 2
5,4 Material for lagging Stainless Steel 316

DESCRIPTION UNIT SPECIFIED OFFERED

6 ENGINE (ELECTRICS)

6,1 Battery type 12V/24V

6,2 Batteries Qty
6,3 Minimum capacity Ah/battery
6,4 Starter kW
6,5 Alternator A/V
6,6 Coolant pre-heating unit-type
6,7 230 Volt battery charge (with auto trickle charge) - make
6,8 Battery charger volt meter Yes/No
6,9 Manual stop and start ignition Yes/No Yes
6.10 Engine trip reset Yes/No Yes

7 COLD START CAPACITY - TYPE

7,1 Cold start limit temperature with starting aid °C

7,2 Cold start limit temperature without starting aid °C

8 SKID

8,1 Type of vibration pads / mounting for skid

8,2 Type of vibration pads / mounting for engine
8,3 Type of vibration pads / mounting for generator / alternator
8,4 Drawings of frame structure included Yes/No Yes
8,5 Size of skid
8.5. Height mm

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 1
8.5. Length mm
2
8.5. Width mm
3
8,6 Bund for spillage required ( 110% of capacity ) with drain Yes
valve

9 GENERATOR / ALTERNATOR

9,1 Country of origin

9,2 Country of manufacturing
9,3 Make Dingol,
Leroy
Somer or
similar
9,4 Model
9,5 Is serial number traceable to manufacturer Yes/No Yes
9,6 Prime power kVA
9,7 Standby power kVA
9,8 Phase 1 to 3 3
9,9 Supply Voltage V 400
9.10 Supply Frequency Hz 50
9,11 Number of pole alternator circuit breakers 3 or 4 4
9,12 Change over contactors or circuit breaker
9,13 3 Pole main isolator A
9,14 3 Pole air circuit breakers with overload and short A
circuit protection

10 CONTROL PANEL/INDICATION/INSTRUMENTS

10,1 Automatic / Manual

10,2 Remote / Local
10,3 Type of controller
10,4 Make of controller Deep CEA
or similar
10,5 Model of controller
10,6 Remote monitoring Yes/No Yes, interface with MCC
PLC
10,7 Signals wired to PLC ( Run, stop, low fuel shut-off, fuel Yes
level(4-20mA) , fault , fire detection/alarm
10,8 GSM module for SMS alarm notification Yes/No Yes
10,9 AMF incorporated Yes/No Yes
10,1 Synchronized with mains Yes/No Yes
0
10,1 Manufacture, type and model of switchgear
1
10,1 Wiring diagrams and GA to be submitted Yes
2

11 CONTROL PANEL CONSTRUCTION

11,1 Type of material /steel 3CR12

11,2 Epoxy Powder Coated Yes/No Yes
11,3 Size of electric panel
11.3 Height mm
.1
11.3 Length mm
.2
11.3 Width mm
.3

Page 7 of 19
 DESCRIPTION UNIT SPECIFIED OFFERED
12 OPERATING ENVIORNMENT

12,1 Inland/Coastal Coastal

12,2 Inside /Outside Outside
12,3 Ingress Protection IP
12,4 Site Conditions - Altitude m Ballito - Alt : 21 msl : 15-
45deg C ,40-90%RH
12,5 Site Conditions - Min/Max Ambient Temp. °C / °C
12,6 Site Conditions - Min/Max Relative Humidity %/%

13 DUMMY LOADS

13,1 Dummy loads required Yes/No Yes

13,2 Size of Dummy Load % of % %
Generat
or
Capacity
13,3 Positing in cowling Yes/No Yes

14 LOUVRES

14,1 Louvres size according to Manufacturers HXLXW

Requirements
14,2 Type Acoustic
14,3 Material of Construction 304L
14,4 DB level required after acoustics louvres and DB 65
sound proofing

15 GENERAL

15,1 Warranty / guarantee - Engine months 12

15,2 Warranty / guarantee - Generator / Alternator months 12
15,3 Warranty / guarantee - Canopy months 12
15,4 Warranty / guarantee - Control panel months 12
15,5 Delivery time (after official order number received) weeks
15,6 Weight - Complete Generator Set kg
15,7 Largest Motor Load that can be started at once kW
15,8 Additional datasheet from manufacturer included Yes/No Yes
with tender
15,9 Servicing/maintenance Yes/No
15,1 COC required Yes/No Yes
0

16 EXTRAS

16,1 Fuel shut off valve Yes/No Yes

16,2 Fireman switch Yes/No Yes
16,3 Hand fuel pump Yes/No Yes
16,4 Fuel level indicator with output to controller Yes/No Yes
16,5 Fire detector and alarm system with signal to PLC Yes/No Yes
required

Page 8 of 19
 17 CANOPY OR CONTAINER

17,1 Canopy or container required ( double skin) Yes (

double skin
canopy )
17.1 Height mm
.1
17.1 Length mm
.2
17.1 Width mm
.3
17,2 Type of canopy material / steel 3CR12
17,3 Type of paint : epoxy powder coating Yes/No
17,4 No. of access doors and sizes
17,5 No, size and type of air louvres
17,6 No, size and type of filters
17,7 Drawing required of canopy/container with louvres Yes Yes
17,8 Drawing required of exhaust ducting Yes Yes
17,9 Other details

18 SUPPLEMENTARY DETAILS

Regardless of any information provided in this technical data sheet, the equipment to be provided
shall comply with the specified requirements.

Date : ________________________

Name:________________________ Signature:

Name of Contractor / Manufacturer :

Company stamp :

Page 9 of 19
CONTRACT No :

SA WELLNESS INVESTMENTS (PTY) LTD

NEW MIXED USE COMMERCIAL DEVELOPMENT - BALLITO

GS-SDG : STAND-BY DIESEL GENERATOR – GENERAL SPECIFICATIONS

STANDARD GENERAL SPECIFICATIONS

SECTION 1 - GENERAL

PS 1.1 General

In addition to the project specifications, the stand-by generators/s shall comply to the following standard
specifications :

Specification and Documentation

The specification is intended to cover the complete supply and installation of the generator plant. The
minimum equipment requirements are outlined, but do not cover all the details of design and construction.
Such details are recognized as being the exclusive responsibility of the contractor. In all cases where a
device or part of the equipment is referred to in the singular, it is intended that such reference shall apply to
as many devices that are required to complete the installation.

PS 1.2 Scope of Work

Supply, delivery and installation of the complete emergency stand-by diesel generator set as specified in
this document or particular technical specifications. The civil works will be provided by other trades and the
contractor shall ensure that the space allowed is sufficient for the installation of the generator set. The
generators are to start up on receiving an external signal. On completion of the startup and self-check, they
are to synchronize on to a common bus. Once one or both generators are connected then the bus circuit
breaker must close and supply power to the remote changeover system, supplied by others. In addition,
the control panel is to be equipped with a comms and reporting module with a GSM package for alarms
and notification reporting.

The generator build shall be a silent type diesel engine close coupled to a brushless alternator, all on a
fabricated steel base via anti-vibration mounts and mounted in a standard canopy or shipping type
container as specified in the particular technical specifications. The sizes of the canopy or container shall
be determined by the manufacturer. Sound attenuation shall be provided for the set and the shipping
container and the noise levels kept to minimum decibel values.

Standard fittings shall include exhaust with residential type silencer. The shipping container shall be fitted
with air supply and exhaust louvres or grilles for the generator and radiator ventilation and cooling.
The container shall be fitted with vandal proof locking mechanisms on the doors and other access
points. The container shall be painted white to match the existing. Details of the paint specifications
shall be provided later.

PS 1.4 Safety

Allowance must be made in the price for a safety file and for any cost as required for adherence to Safety,
Environmental and on-site administration thereof.

PS 1.5 Co-ordination

The contractor shall co-ordinate his program with the Civil, Structural, Electrical and Building Contractor as
required for installation. Rates shall include for and rigging etc. Any building or civil works to be by others.

Page 10 of 19
PS 1.6 Test Certificates and Inspections

The following tests are to be carried out:

(a) At the supplier’s premises, before the generating set will be delivered to site the Engineer/Consultant
shall be present during the test to satisfy them that the generating set complies with the specification and
delivers the specified output. The test must be carried out in accordance with BSS 5514, Part 2 and 3. The
Engineer/Consultant must be timeously advised of the date for the test.

(b) After completion of the works and before first delivery is taken, a full test shall be carried out on the
installation for a period of sufficient duration to determine the satisfactory working thereof. During this
period the installation shall be inspected, and the contractor shall make good, to the satisfaction of the
Engineer/Consultant, any defects which may arise.

(c) The Contractor shall provide all instruments and equipment required for testing and any water, power
and fuel required for the commissioning and testing of the installation at completion.

(d) Test reports of both tests as specified under (a) and (b) are to be submitted to the
Engineer/Consultant.

PS 1.7 Guarantee and Maintenance

The Contractor shall provide a warrantee for the complete plant for a period of twelve months after final
completion. The plant shall be serviced and maintained free of charge during the 12 months defects liability
period.

If during this period the plant is not in working order, or not working satisfactorily owing to faulty material,
design or workmanship, immediate steps shall be taken to rectify the defects and/or replace the affected
parts on site at his own expense.

Should the Contractor fail to hand over the plant in good working order on the expiry of the specified twelfth
month warrantee period, the Contractor shall be responsible for further monthly maintenance until final
delivery is taken.

During this period, the contractor will undertake to arrange that the plant be inspected at least once per
month by a qualified member of his staff who shall:

A checklist shall be provided with the following items:

(a) Report to the Engineer/Consultant, keeping the maintenance records, and enter into a logbook the
date of the visit, the tests carried out, the adjustments made, and any further details that may be required.

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

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

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

(e) After the plant has run, one oil change for the number of hours stipulated by the manufacturers, drain
the sump and refill with fresh lubricating oil. The reading of the hour meter on the switchboard shall be
taken to establish the number of hours run by the plant.

Under this heading only the cost of the actual oil used, shall be charged as an extra on the monthly
account.

(f) Clean the lubricating oil filter and/or replace the filter element at intervals recommended by the engine
manufacturer, the cost of a new filter element to be charged as an extra on the monthly account.

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

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

Page 11 of 19
(I) Test-run the plant for 0,5 hour and check the automatic starting with simulated Faults on the mains,
the proper working of all parts, including the electrical switchgear, the protective devices with fault
indicators, the changeover equipment and the battery charger. Make any necessary adjustments
necessary.

(j) Report to the Engineer/Consultant any parts that become unserviceable through fair wear and tear, or
damaged by causes beyond the control of the Contractor.

(k) Advise the Engineer/Consultant when it has become necessary to de-carbonize the engine and
submit a quotation for this service.

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

(m) Clean the plant and its components.

PS 1.8 Material and Workmanship

(a) The work throughout shall be executed to the highest standards and to the entire satisfaction of the
Engineer/Consultant who shall interpret the meaning of the Contract Document and shall have the
authority to reject any work and material, which, in his judgement are not in full accordance therewith. All
condemned material and workmanship shall be replaced or rectified as directed and approved by the
Engineer.

(b) All work shall be executed in a first-class manner by a qualified tradesman.

(c) The Contractor shall warrant that the materials and workmanship shall be of the highest quality and
standard, that the equipment shall be installed in a practical and first-class manner in accordance with the
best practices and ready and complete for full operation. It is specifically intended that all material or labour
which is usually provided as part of such equipment as is called for and the Contractor shall thoroughly
acquaint himself with the work involved and shall verify on site all measurements necessary for proper
installation work. The Contractor shall also be prepared to promptly furnish any installation relating to his
own work as may be necessary for the proper installation work and shall co-operate with and co- ordinate
the work with others as may be applicable.

(d) All components and their respective adjustment, which do not form part of the equipment installation
work but influence the optimum and safe operation of the equipment shall be considered to form part of,
and shall be included in the Contract’s scope of works.

(e) All control equipment and serviceable items shall be installed and positioned such that they will be
accessible and maintainable.

(f) The Contractor shall make sure that all safety regulations and measures are applied and enforced
during the installation and guarantee periods to ensure the safety of the User Client.

PS 1.9 Brochures

Detailed brochures of all equipment offered shall be presented together with the tender documents.

PS 1.10 Submittals

The following information must accompany the tender documents

(a) Full particulars, performance curves and illustrations of the equipment offered, must be submitted with
the Tender.

(b) The design of the control system to comply with the requirements for automatic starting, stopping,
interlocking and isolation as specified.

(c) Curves furnished by the engine makers, showing the output of the engine offered against the speed,
for both intermittent and continuous operation as well as fuel consumption curves when the engine is used
for electric generation The successful Tendered must, as soon as possible after receipt of the order, submit

Page 12 of 19
detailed plant and mechanical drawings and wiring diagrams of the plant and the switchgear and control
gear. One diagram shall be contained in a metal pouch on the side of the switchboard.

(d) All civil and building requirements for the generators , container, canopy and step-up or step-down
transformer

SECTION 2 – EQUIPMENT REQUIREMENTS

PS 2.1 Engine

Deutz, Perkins, Cummins, UK or USA, VOLVO or SCANIA diesel engines shall be provided as specified
under the particular technical specifications. Preference will be given to engines that match the existing on
site.

PS 2.1 General

The engine must comply with the requirements as laid down in BS 5514 and must be of the atomised
injection, compression ignition type, running at a speed not exceeding 1500 r.p.m. The engine must be
suitably rated for the required electrical output of the set, when running under the site conditions. The
starting period for either manual or automatic switching-on until the taking over by the generating set, in
one step, of a load equal to the specified site electrical output, shall not exceed 15 seconds. This must be
guaranteed by the Tenderer. Turbo-charged engines will only be accepted if the Tenderer submits a written
guarantee that the engine can deliver full load within the specified starting period.

PS 2.2 Sound attenuation

Sound attenuation is to be supplied to attain a specification of NC 80dB at 10 meters. The colour of louvres
shall to be natural finish to match existing finishes or as specified.

PS 2.3 Rating

The set shall be capable of delivering the specified output continuously under the site conditions, without
overheating. The engine shall be capable of delivering an output of 110 % of the specified output for one
hour in any period of 12 hours consecutive running in accordance with BS 5514.

PS 2.4 De-Rating

The engine must be de-rated for the site conditions as set out in the Technical Specification, Section 3 of
this document. The de-rating of the engine for site conditions shall be strictly in accordance with BS 5514
of 1977 as amended to date. Any other methods of de-rating must have the approval of the
Engineer/Consultant and must be motivated in detail. Such de-rating must be guaranteed in writing and
proved by the successful tenderer at the site test.

PS 2.5 Starting and Stopping

The engine shall be fitted with an electric starter motor and be easily started from cold, without the use of
any special ignition devices under summer as well as winter conditions. Tenderers must state what
arrangements are provided to ensure easy starting in cold weather. Full details of this equipment must be
submitted. In the case of water-cooled engines, any electrical heaters shall be thermostatically controlled.
The electrical circuit for such heaters shall be taken from the control panel and must be protected by a
suitable circuit breaker.

PS 2.6 Starter Battery

The generator set must be supplied with a fully charged maintenance free lead-acid type battery, complete
with the necessary electrolyte. The battery must have sufficient capacity to provide the starting torque
stipulated by the engine makers. The battery capacity shall not be less than 150 Ah and shall be capable of
providing three consecutive start attempts from cold and thereafter a fourth attempt under manual control
of not less than 20 seconds duration each. The battery shall be of the heavy duty “low maintenance” type,
house in a suitable battery box.

PS 2.7 Cooling

Page 13 of 19
The engine may be either of the air or water cooled type. In the case of water-cooling, a built-on heavy
duty, tropical type pressurised radiator must be fitted. Only stand-by sets that are water-cooled shall have
electric heaters.

For either method of cooling, protection must be provided against running at excessive temperatures. The
operation of this protective device must give a visual and audible indication on the switchboard or control
panel. Water-cooled engines shall in addition be fitted with low water cut-out switch, installed in the
radiator, to switch the set off in the event of a loss of coolant. The protection shall operate in the same way
as the other cut-outs (e.g. low oil pressure). All air and cooling ducts for the cooling of the engine are to be
allowed for. The air shall be supplied from the cooling fan cowling/radiator face to air outlet louvers of the
weatherproof enclosure.

PS 2.8 Lubrication

Lubrication of the main engine bearings and other important moving parts shall be by forced feed system.
An automatic low oil pressure cut-out must be fitted, operating the stop solenoid on the engine and giving a
visible and audible indication on the switchboard or control panel.

PS 2.9 Fuel Pump

The fuel injection equipment and fuel pump/s shall be suitable for operation with the commercial brands of
diesel fuel normally available in South Africa.

PS 2.10 Fuel Tank

The base tank shall have sufficient capacity for standby sets to run the engine on full load for a period of 12
hours. Base tank shall be double skinned/self-bunded.

A base fuel tank sized to operate the full run load for a period of 12 hours continuous running shall be
provided with the unit including fuel gauge, filler cap, dished bottom with drain and plug.

A self contained bund to contain any fuel spillages or leaks shall be provided with the tank and be included
in the price. A hand pump with all fittings and hoses shall be supplied with the unit for filling of the diesel
base tank.

PS 2.11 Governor

The permanent speed variation between no load and full load shall not exceed 4,5% of the normal engine
speed and the temporary speed variation shall not exceed 10%. External facilities must be provided on the
engine, to adjust the normal speed setting by ± 5% at all loads, zero and rated load.

PS 2.12 Flywheel

A suitable flywheel must be fitted, so that lights fed from the set will be free from any visible flicker. The
cyclic irregularity of the set must be within the limit laid down in BS 5514 of 1977.

PS 2.13 Exhaust Silencer

It is essential to keep the noise level as low as possible. An effective exhaust silencing system of the
3CR12 residential type must be provided. The exhaust pipe shall be installed in such a way that the
expulsed exhaust fumes will be as directed away. The exhaust pipe must be flexibly connected to the
engine to take up vibrations transmitted from the engine, which may cause breakage.

PS 2.14 Accessories & Manuals

The engine must be supplied complete with all accessories, air and oil filters, 3 sets of instruction operating
and maintenance manuals, spare parts lists, the first fill of all lubricating oils, fuel, etc

Wiring and plant diagrams shall be included in the manuals.

PS 2.15 Alternator

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Alternator make shall be : Dingol, Stamford, Morelli, Motorelli, Engga, Leroy Somer, Marathon or Maccallte.
Preference will be given to alternators that match the existing two generators on site.

NOTE:

The generator is to comply with Tier 2 omissions standards as defined by the United States Environmental
Protection Agency (EPA) or the equivalent European Stage IIA standard. The standby generator shall
comply with all the requirements of BS 5514, BS 4999 and BS5000 part three as applicable

PS 2.16 General

The alternator shall be of the self-excited brush less type, with enclosed ventilated drip proof
housing and must be capable of supplying the specified output continuously with a temperature
rise not exceeding the limits laid down in BS 5000 for rotor and stator windings. The alternator shall
be capable of delivering an output of 110% of the specified output, for one hour in any period of 12
hours consecutive running. Both windings must be fully impregnated for tropical climate and must
have an oil resisting finishing varnish.
The alternator shall be single bearing brushless type with 2/3 pitch winding / class H insulation;
Voltage regulation plus 1.5%; low harmonic distortion with IP 21 degree protection.

PS 2.17 Regulation

The alternator must preferably be self-regulated without the utilisation of solid state elements. The
inherent voltage regulation shall not exceed plus or minus 5% of the nominal voltage specified, at
all loads with the power factor between unity and 0,8 lagging and within the driving speed
variations of 5% between no-load and full load.

PS 2.18 Performance

The excitation system shall be designed to promote rapid voltage recovery following the sudden
application of the load. The voltage shall recover to within 5% of the steady state within 300
milliseconds following the application of full load and the transient voltage dip shall not exceed
18%.

PS 2.19 Synchronizing

The alternator must be fully setup and supplied with all equipment requiring for the synchronizing of
the new and existing units.

PS 2.20 Coupling

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

PS 2.21 Switchboard

PS 2.21.1 General

A switchboard must be supplied and installed to incorporate the equipment for the control and
protection of the generating set and battery charging system.
The switchboard must conform to the specification as set out in the following paragraphs.

PS 2.21.2 Construction

The switchboard shall be a totally enclosed, floor or wall plant mounted unit, fabricated from 3CR12
steel panels, carried on and-substantial angle iron hot dipped galvanised framework.

The board shall be flush fronted and all equipment to be mounted behind the front plate, on
suitable supports.
All equipment, connections and terminals shall be easily accessible from the front. The front

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panels may be either hinged or removable and fixed with studs and chromium-plated cap nuts.
Self tapping screws shall not be used in the construction of the board.

All pushbuttons, pilot lights, control switches, instrument and control fuses, shall be mounted on
hinged panels with the control wires in flexible looms.

The steelwork of the boards must be thoroughly de-rusted, primed with zinc chromate and finished
with two coats of signal red quality enamel, or a baked powder epoxy coating.

Suitably rated terminals must be provided for all main circuits and the control and protection circuits. Where
cable lugs are used, these shall be crimped onto the cable strands. Screw terminals shall be of the type to
prevent spreading of cable strands. All terminals shall be clearly marked.
For the control wiring, each wire shall be fitted with a cable or wire marker of approved type, and

numbering of these markers must be shown on the wiring diagram on the switchboard or control
panel. Control wiring shall be run in PVC trunking. The trunking shall be properly fixed to the
switchboard steelwork. Adhesives shall not be acceptable for the fixing of trunking or looms.

All equipment on the switchboard, such as contactors, isolators, bus bars, etc., shall have ample
current carrying capacity to handle at least 110% of the alternator full load current

PS 2.21.3 Protection and Alarm Devices

All switchboards and control panels shall be equipped with protection and alarm devices as
described below.
A circuit breaker and an adjustable current limiting protection relay shall be installed for protection
of the alternator. The protection relay shall be of the type with inverse time characteristics. The
relay shall cause contactor to isolate the alternator and stop the engine.
Protection must be provided for overload, high engine temperature, low lubricating oil pressure,
over speed, start-failure, and low water level.
The indicators and re-set push buttons must be as described below. GSM and alarm reporting shall be
included.

“OVERLOAD”
“TEMPERATURE HIGH”
“OIL PRESSURE LOW”
“OVER-SPEED”
“START FAILURE”
“LOW WATER LEVEL”
“LOW FUEL LEVEL”
“NO FUEL LEVEL”

PS 2.21.4 Battery charging Equipment

Each switchboard or control panel shall be equipped with battery charging equipment. The charger shall
operate automatically in accordance with the state of the battery and shall generally consist of an air-
cooled transformer, a full wave solid state rectifier, and the necessary automatic control equipment of the
constant voltage system. The charger must be fed from the mains. An engine driven alternator must also
be provided for charging the battery while the set is operational. Failure of this alternator must also activate
the battery charger failure circuit.

PS 2.21.5 Switchboard Instruments

The following controller is preferred:

Deepsea 8610, no other controller will be accepted. All protective circuit breakers/ change over switches
are to be ABB or similar and equal approved. All alternatives shall be approved by the Engineer prior to the
tenders closing.

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PS 2.21.6 Earthing

An earth bar must be fitted in the switchboard or control panel, to which all non-current carrying metal parts
shall
be bonded.
The neutral point of the alternator must be solidly connected to this bar by means of a removable link
labelled “EARTH”. Suitable terminals must be provided on the earth bar for connection of up to three earth
conductors, which will be supplied and installed by others.

PS 2.21.7. Installation

Except for the outgoing feeder cables, the tenderer must include for the complete installation and wiring of
the plant in running order. The connecting of the cable and control cabling to the generator and the control
terminals in the LV board remains the responsibility of the tenderer.

PS 2.22 Warning Notices

Notices, in both official languages, must be installed on the front face of the standby plant. The contents of
these notices are summarised below.

(a) Unauthorised work on equipment prohibited.

(b) Unauthorised handing of equipment prohibited.
(c) Procedure in case of electric shock, electrical danger signage, warning machine starts automatically .
no un-authorised entry signage shall be suppled and installed

The successful tenderer must consult the latest Occupational Health and regarding these waning and
statutory notices. Lettering must be black on a yellow background.

Notices (a) must be installed outside next to the entrance of the standby plant front face adjacent to the
service hatch, this can be discussed in detail during the manufacture and installation stage.

The motive shall be made of a non-corrodible and non-deteriorating material, preferable plastic, and must
read as follows:

DANGER: This engine will start without notice. Turn selector switch on control board to “OFF” before
working on the plant.

PS 2.23 Construction

The engine and alternator of the set shall be built together on a common frame, which must be mounted on
a skid base on anti-vibration mountings. A drip tray must be fitted under the engine. The tray must be large
enough to catch a drip from any part of the engine. The frame must be of the ‘DUPLEX’ type.

The generator enclosures are to be container type steel enclosures with sound attenuation on the air intake
and outlets. Access doors are to be on both sides of the unit allowing access to the control panel.

PS 2.24 Operation

The set shall be fully automatic i.e. it shall start on a signal supplied remotely. In addition, it shall be
possible to manually start and stop the set by means of pushbuttons on the switchboard or control panel.

The automatic control shall make provision for three consecutive starting attempts. Thereafter the set must
be switched off, and the start failure indication on the switchboard must give a visible and audible indication
of the fault.

The units are to synchronize with each other via the common bus. Once both units are connected then the
common bus needs to be connected to the changeover system. To prevent the alternators being
electrically connected to each other in an unsynchronized state, a safe and fail proof system shall be
designed and integrated into the system.

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The DSE Webnet system is to be fully installed and maintained for the duration of the warranty period. The
operational communication system is to be handed over with training to the Plant Operations staff.

PS 2.25 Switchboard/Control Panel Unit

PS 2.25.1 General

All switch- and control gear shall be rated for a fault current level of 15kA.

The switchboard shall be floor standing or plant wall mounted type and shall be supplied in
accordance with clause of Section 2 of this specification, and shall incorporate the following
additional switch gear, accessible through the front panel:

PS 2.25.2 AMF controller

A DSE8610 Remote start synchronising control system shall be provided.

This is also to provide for no-break load testing of the Generator by way of selector switch on the
panel. The AMF shall accept loading within a maximum of 30 second as from a mains failure
condition.

PS 2.25.3 Control panel:

The automatic mains failure plant mounted type 3CR12 panel shall be finished in red baked epoxy. It shall
be equipped with the following as a minimum :

 One suitably rated incoming isolator.

 One suitably rated alternator circuit breaker with adjustable thermal and magnetic overloads.
 One set of suitably rated mechanically and electrically interlocked change over system 4 pole
switching.
 One set of three current transformers.
 One 6 amp automatic battery charger with short circuit protection.
 One emergency stop button.
 All necessary control circuit breakers and relays all wired to terminals.
 One PLC based “DEEP-CEA” type generator control unit with the following features:
- Accurate metering and monitoring system with commands to start, change over, and stop the set.
- Facilities for signals to the remote PLC or telemetry system shall be provided for mains incoming
breaker open/closed, feeder breaker open/closed, generator run/stop, low fuel and fire alarm.
- The unit shall be fitted with a low fuel level cut-out facility.
- Two 24V DC fire alarm detectors shall be installed in the container and wired to the control unit and to
the remote PLC or telemetry unit.
- The following minimum viewable functions are to be included: Battery voltage, mains and alternator
voltage, phase currents and frequency.

Full wiring diagrams and details of the control panel shall be submitted for comments and approval prior to
manufacture of the unit. Details, general arrangements, specifications and manufacturer part numbers etc
of all components and equipment shall be supplied with the wiring diagrams.

PS 2.26 Regulations and Other Requirements

The installation shall be erected and tested in accordance with the following acts and regulations:

a) The latest issue of SABS 0142: “Code of practice for the wiring of premises.”

b) The Occupational Health and Safety Act, 1993 (Act 85 of 1993) as amended.

c) The local Government Ordinance 1939 (Ordinance 17 of 1939) as amended and the Municipal By-
laws and any special requirements of the local supply authority.

d) The Fire Brigade Services Act 1993 Act 99 of 1987 as amended.

e) The National Building Regulations and Buildings Standards Act 1977 (Act 103 of 1977) as amended

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f) The Post Office Act 1958 (Act 44 of 1958) as amended.

g) The Electricity Act 1984 (Act 41 of 1984) as amended.

PS.2.27 Other Requirements

Prior to delivery, a FAT (factory acceptance test) shall be undertaken and the set shall be given a full load
test and a Test Certificate issued. A SAT (site acceptance test) and full testing and commissioning shall be
undertaken on site and a Test Certificate issued. These tests and recordings shall be included with the
Operator’s and Maintenance manual. Four hard copies and three soft copies of the O & M manuals shall
be supplied on successful commissioning of the generator set. An electrical COC for the electrical
installation of the generator set shall be provided by the contractor.

Statutory notices and warning signs shall be fitted to the unit.

A 5kg CO2 fire extinguisher with all necessary signage shall be supplied and installed for each generator
set.

The set shall be supplied with a full tank of diesel on delivery to site.

The generator set shall be guaranteed, maintained and serviced for a period of 12 months after the issue
of the practical completion certificate. Full details of the servicing and maintenance plan shall be submitted
with the tender.

Full details and technical specifications of the complete generator set with motor, alternator, control panel
etc set shall be provided with the tender or quote for evaluation purposes. The returnable data sheet shall
be submitted with the quotations.

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