SECTION 16231 DIESEL ENGINE GENERATOR SYSTEMS 1 PART 1 - GENERAL

Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section. 1 1.01 WORK INCLUDED 1 A. This Section includes the supply, installation, testing and commissioning of two types of generating systems in regard to their application as follows. 1. Generating System Type 1: Includes two (2) emergency generators serving the Main Building. The generators are located on the Roof. The generating system shall comprise of, a factory-built - weather-proof housing including sound attenuators of a sound pressure level 83db @ 1.0M and 72db @ 7.0M at full load. The two generators shall run in parallel utilizing a master control Panel (synchronization panel), described hereinafter. 2. Generating System Type 2: Includes five (5) emergency generators serving the five shelters, one each. The generators are located in individual rooms in the Basement. B. Each system shall be complete packaged diesel engine-generators system having the following main components, 2 1. Emergency Engine- Generator Sets 3 2. Cooling System. 4 3. Engine Starting System. 5 4. Fuel Oil Supply System consisting the Diesel Oil Fuel Storage Tank, Tank Fuel Oil Level Indicator Gauges, Fuel Oil Piping, Fuel Oil Pumping and Filtering Equipment, and Fuel Oil Day Tank. 6 5. Engine Exhaust Pipe works. 7 6. Fresh Air Intake and Exhaust Air Systems 8 7. Transfer switches. 9 8. Batteries & Battery Chargers. 10 9. Earthing.

1.02 RELATED WORKL Related work to be coordinated and used in conjunction with this specification includes but is not restricted to: 1 A. Section 15070 - Vibration Isolation 2 B. Section 15080 - Piping and Equipment Insulation

C. Section 15081 - Ductwork Insulation 1 D. Section 16120 - Wires and Cables 2 E. Section 16060 - Earthing 3 F. Section 16415 - Transfer Switches 4 G. Section 16441 - Switch Boards 2 1.03 SYSTEM DESCRIPTION 1 A. System Includes: Prime-rated automatically started diesel engine coupled to an a.c. generator unit. Engine and generator are factorymounted and -aligned on a structural steel skid. Subsystems and auxiliary components and equipment include, but not in a way of limitation, synchronising panel, switchgears and distribution, engine starting equipment, fuel service tanks, fuel storage tank, engine cooling system, exhaust silencing equipment and lubrication, fuel transfer pumps sets, lifting pumps sets. 2 B. Functional Description: When the mode selector switch on the control and monitoring panel is in the "automatic" position, remote control contacts in one or more separate automatic transfer switches initiate the starting and stopping of the generator set. When the mode selector switch is placed in the "on" position, the generator set starts manually. The "off" position of the same switch initiates shutdown of the generator set. Upon specific malfunction of the generator set it shall be made to shut down automatically and initiate alarms. Operation of a remote emergency stop switch also shuts down the unit. 3 C. The Generator Master Control Panel shall be interfaced with the BAS through a serial communication link to facilitate full remote monitoring of the Generators, fuel tanks and fuel pumping system. Generator under frequency and overload alarms shall be available at the BAS.

4 D. In the event of a mains power failure, the following actions shall be initiated automatically from the BAS: All the major loads that are connected to the Generator sets shall be set to manual mode, to be restarted only manually by the operator and subsequently transferred to automatic mode. E. A BAS software flag shall be available for the operator to select either manual or automatic restart after a power failure for all Low Voltage motors. If Automatic is selected, then these motors shall be started sequentially, one process area at a time. Automatic control sequences 5 and timer-controlled operations shall also be resumed. If the flag is set to manual then all controls shall be set to manual, and be ready for restart by the operator. 3 1.04 SUBMITTALS: The following submittals, as defined in section 01323 Submittal Procedures, are required: 1 A. Product Data: Include Manufacturers product literature and performance data, sufficient to verify compliance to specification requirements. 2 1. A paragraph by paragraph specification compliance statement, highlighting thereby any deviations whatsoever and indicating the implications as applicable. 3 2. Dimensioned outline plan and elevation drawings of engine generator set and other components specified. 4 3. Thermal damage curve for generator. 5 4. Time-current characteristic curves for generator protective device. 6 B. Shop Drawings: Indicate fabrication details, dimensions, weights, loads, required clearances, method of field assembly, components, and location and size of each field connection. 7 1. Design Calculations: Signed and sealed by a qualified professional engineer. Calculate requirements for selecting vibration isolators and seismic restraints and for designing vibration isolation bases. 8 2. Vibration Isolation Base Details: Signed and sealed by a qualified professional engineer. Detail fabrication, including anchorages and attachments to structure and to supported equipment. Include base weights. 9 3. Wiring Diagrams: Detail wiring for power and control connections and differentiate between factory-installed and field-installed wiring.

10 C. Field Test and Observation Reports: Indicate and interpret test results and inspection records relative to compliance with performance requirements. 11 D. Certified summary of prototype-unit test report. 12 E. Certified Test Reports: For components and accessories that are equivalent, but not identical, to those tested on prototype unit. 13 F. Certified Summary of Performance Tests: Demonstrate compliance with specified requirement to meet performance criteria for sensitive loads. 14 G. Factory Test Reports: For units to be shipped for this Project, showing evidence of compliance with specified requirements. 15 H. Exhaust Emissions Test Report: To show compliance with applicable regulations. 16 I. Sound measurement test report. 17 J. Certification of Torsional Vibration Compatibility: Comply with NFPA 110. 18 K. Field test report of tests specified in Part 3. 19 L. Maintenance Data: For each packaged engine generator and accessories to include in maintenance manuals specified in Division 1. Include the following: 20 1. List of tools and replacement items recommended to be stored at the Project for ready access. Include part and drawing numbers, current unit prices, and source of supply. 21 2. Detail operating instructions for both normal and abnormal conditions.

1.05 QUALITY ASSURANCE 0 A. QA shall be in accordance with Sections 01000 and 01451 and as described below. 1 B. The engine-generator set shall be the product of a single manufacturer. 2 C. The manufacturer should have a local agent with a proven successful experience record in the installation, testing, commissioning and maintenance of diesel generators of the size specified herein.

3 D. The agent should have been associated with the manufacturer for a minimum period of five years. 4 E. Source Limitations: Obtain packaged engine generator and auxiliary components specified in this Section through one source from a single manufacturer regularly engaged in the manufacture of such equipment. 5 F. Engine Exhaust Emissions Comply with applicable state and local government requirements. 6 G. The emergency power supply system and its components shall be such as may be properly maintained and serviced without the necessity of carrying expensive spare parts stocks, or being subjected to interrupted service due to the lack of spare parts 7 H. An engine of the same model, bore, stroke and configuration, rated at the same or higher bhp and rpm shall have performed satisfactorily (i.e. without failures involving a major component, such as crankshaft, valve, cam shafts, piston, injector and the like) for a minimum of 2000 hours of actual operation under average rated load conditions of 75% or greater over a two year period, either at the manufacturer's factory or a stationary power plant. 8 I. A generator and generator switchgear components of the type to be used in conjunction with the engine shall have had at least 2000 hours of satisfactory service at a minimum average load of 90%. 9 J. Emergency generator set shall be designed to allow easy replacement of major items subject to wear. 10 K. The size of the set shall be the same or next higher standard size nearest to the rating specified, when operating at specified frequency, voltage, altitude and maximum ambient temperature. L. Provide factory test, startup by a supplier authorized by the manufacturer, and on-site testing of the system. 11 M. The generator set manufacturer shall warrant all equipment provided under this section so that there is one source for warranty and product service. Technicians specifically trained and certified by the manufacturer to support the product and employed by the generator set supplier shall service the generator sets.

1.06 RELATED STANDARDS 1 A. BS4999; BS5000. 2 B. ISO8528; ISO3041/1. 3 C. BS 2757 - Method for determining the thermal classification of electrical insulation. 4 D. EN 60034-1(BS) -1998 - Specification for rating and performance. 5 E. EN 60034-2(BS)-1998 - Methods for determining losses and efficiency for tests. 6 F. Part 105: (IEC 34-5) -Classification of degrees of protection provided by enclosures for rotating machines. 7 G. EN 60034-6(BS)-1994- Classification of methods of cooling. 8 H. Part 142: (ISO 2373) - Specification for mechanical performance vibration. 9 I. IEC 34-3:1980 - Generators to be driven by reciprocating internal combustion engines. 10 J. BS 5514 P1: 1996 - Specification for reciprocating internal combustion engines: performance. 11 K. BS 5514, Part 4: (1997) - Specification for RIC engines: Performance speed governing.

1.07 APPROVED MANUFACTURERS: 1 A. Subject to compliance with the requirements of the Contract Documents furnish products from one of the following manufacturers. 2 1. Caterpillar 3 2. Kohler 4 3. Mitsubishi 5 4. Onan/Cummins

1.08 DELIVERY, STORAGE, AND HANDLING 1 A. Deliver engine generator set and system components to their final locations in protective wrappings, containers, and other protection that will exclude dirt and moisture and prevent damage from construction

operations. Remove protection only after equipment is safe from such hazards. 4 1.09 WARRANTY 1 A. General Warranty: Special warranty specified in this Article shall not deprive Employer of other rights Employer may have under other provisions of the 1 Contract Documents and shall be in addition to, and run concurrent with, other warranties made by Contractor under requirements of the Contract Documents. 2 B. Special Warranty: Written warranty, executed by manufacturer agreeing to repair or replace packaged engine generator and auxiliary components that fail in materials or workmanship within specified warranty period. 3 1. Warranty Period: Five years from date of Substantial Completion. 2 1.10 MAINTENANCE SERVICE 1 A. Maintenance: At Substantial Completion, begin 12 months' full maintenance by skilled employees of the manufacturer's designated service organization. Include quarterly exercising to check for proper, starting, load transfer, and running under load. Include routine preventive maintenance as recommended by manufacturer and adjusting as required for proper operation. Maintenance agreements shall include parts and supplies as used in the manufacture and installation of original equipment. 3 1.11 EXTRA MATERIALS A. Furnish extra materials described below that match products installed and that are packaged with protective covering for storage and identified with labels describing contents. 1 1. Fuses: One for every ten of each type and rating, but not less than one of each. 2 2. Indicator Lamps: Two for every six of each type used, but not less than two of each. 3 3. Filters: One set each of lubricating oil, fuel, and combustion-air filters. 4 PART 2 - PRODUCTS

2.01 EMERGENCY GENERATOR SET 1 A. CLASSIFICATION AND RATINGS: 2 1. The generator set shall be prime-rated utilized during the interruption of normal power, 240/415V, 3-phase, 4- wire, 50Hz at 0.8 power factor lagging. 3 2. The set shall have a power output rating as indicated on the drawings with capacity as required to operate as a unit at 55C as evidenced by records of prototype testing. 4 3. Efficiency: Not less than 90% at full load. 5 B. CONSTRUCTION: 6 1. The engine generator set shall be complete with all necessary equipments and accessories suitable for the intended services. Battery and battery charger to be provided. 7 2. The set shall operate automatically and shall have all necessary apparatus and instruments for proper control of the engine and generator and for voltage regulation as specified. 8 3. The engine generator unit and accessory equipment shall be complete, ready for operation after connection to wiring, fuel, exhaust and cooling systems. 9 4. All switches, lamps, and meters in the control system shall be oiltight and dust-tight, and the enclosure door shall be gasketed. There shall be no exposed points in the control (with the door open) that operate in excess 50 volts. 10 5. The unit shall be mounted on a rigid, structural steel base, suitable for skidding.. 11 6. Each major system component is equipped with a conspicuous nameplate of the component manufacturer. Nameplate identifies manufacturer of origin and address, and the model and serial number. 12 C. PERFORMANCE 13 1. Voltage regulation shall be less than % (steady state) and less than 1% (no load to full load). Random voltage variation with any steady load from no load to full load shall not exceed %. 14 2. Frequency regulation shall be isochronous from steady state no load to steady state rated load. Random frequency variation with any steady load from no load to full load shall not exceed %. 15 3. The diesel engine-generator set shall be capable of single step load pick up of 100% nameplate kW and power factor, less applicable de-rating factors, with the engine-generator set at operating temperature. 16 4. The generator set shall be capable of sustaining a minimum of 90% of rated no load voltage with the specified kVA load at near zero power factor applied to the generator set.

17 D. CONNECTIONS 18 1. The generator set load connections shall be composed of silver or tin plated copper bus bars, drilled to accept mechanical or compression terminations of the number and type as shown on the drawings. Sufficient lug space shall be provided for use with cables of the number and size as shown on the drawings. 1 2 2. Power connections to auxiliary devices shall be made at the devices, with required protection located at a wall-mounted common distribution panel. 3. Generator set control interfaces to other system components shall be made on a common, permanently labeled terminal block assembly.

3 E. EXCITORS: 4 1. Fast response type with a rotating 3-phase full wave bridge rectifier. 5 F. VOLTAGE REGULATOR: 6 1. Hermetically sealed, silicon controlled rectifier type employing a zener reference to give a voltage stability of 1.5% with allowance for up to 3% speed variation. 7 2. To provide automatic protection of the unit on 3 phase short circuits. 8 3. To include automatic under frequency protection to allow the generator to be operated under load, at less than synchronous speeds, for engine start-up and shutdown procedures. Switches and/or fuses shall not be used to give this protection. 9 4. Transient variations shall be limited to a maximum 17% for a duration not exceeding 0.25 seconds. 10 G. MANUAL VOLTAGE RHEOSTAT: 11 1. To be fitted to control panel for fine adjustments. 2 2.02 ENGINE 1 A. The engine shall be direct injection, four stroke, 1500 RPM, naturally aspirated or turbocharged diesel engine to BS 5514 prime-rated at site conditions to provide sufficient output power for the generator. 2 B. The engine shall be with integral air cooled radiator and shall include air filter, fuel and lubricating oil filters, water pump, fuel and lubricating oil pumps, oil cooler, governor, flywheel, starter motor, tachometer, service hour counter, oil and water gauges, safety devices and all other accessories. The air filter shall be of the oil bath or dry element type. The

fuel filters shall be suitable for preventing all particles of 10 micron size or larger from passing. 3 C. A pressure type lubricating system with gear type oil pump and filters shall be fitted to the engine. A graduated dipstick shall be provided, located in an accessible position. 4 D. A heat-exchanger must be fitted in the cooling-water circuit for cooling the lubricating-oil and shall be capable of keeping lubricating-oil temperature within safe limits at all conditions of load-requirement s at worst climatic conditions. The drain connection for draining of sump-oil must be brought on side of the generator base. Method of lubrication should be fully described in the offer. It is preferable that the camshaftbearing lubrication be directly fed from the lubricating-oil pump and not through the main bearing.

5 E. The governor shall be electronic type, arranged in parallel configuration to maintain an isochronous load sharing, speed sensing and to respond to load 1 changes which minimise speed dip and recovery time. The governor system shall include the following: 2 1. Magnetic pick-up 3 2. Proportional actuators 4 3. Oil pressure switch 5 4. Control box 6 F. The engine shall run steadily at any load at its rated speed. Changes in speed shall comply with B.S.5514 or ISO 8528 Class G2. The engine shall have safety devices for stopping the engine and giving alarm in cases of high water temperature, low oil pressure and overspeed. 7 G. Drain plugs and cocks for oil, water and fuel shall be provided in readily accessible locations. 8 H. Emergency relief diaphragms shall be provided to obviate danger of crank case explosions, fitted on the side remote from the generator. 9 I. Engine mounted wiring shall be by means of MICC cables properly fixed and protected and terminating in a common terminal box mounted on the engine. 10 J. The diesel engine shall be derated according to BS 5514 for operation in Kuwait climatic condition (REFER SECTION- 16010 GENERAL PROVISIONS FOR ELECTRICAL INSTALLATIONS). Engine manufacturer's certificate for engine deration shall be submitted to approval.

2.03 VIBRATION ISOLATORS 1 A. Provide vibration isolators, spring/pad type, quantity as recommended by the generator set manufacturer. Isolators shall include seismic restraints if required by site location.

2.04 COOLING SYSTEM 1 A. The diesel engine generator set is cooled with an integral radiator (set mounted). The radiator shall be heavy-duty tropical design with mechanically driven fan of sufficient capacity to maintain safe operation at the site in worst climatic conditions. Coils shall be of copper alloy tubing with copper fins. 2 B. The radiator shall be provided with fan guard and shall be connected by

flexible connections to engine water pipes. C.A thermostatically controlled valve shall be provided 1 in the cooling system to assist rapid heating up of the water in the engine jacket when starting from cold. A thermostatically controlled electric heater, suitable for connection to mains supply shall be located in the cooling water circuit with 'ON/OFF' switch in the control panel. The heater shall be capable of maintaining the whole of the cooling water at a temperature of 20oC with an ambient temperature of 0oC. Indicating lamps in the control panel shall indicate when heater is 'ON'. The heater shall be switched 'OFF' automatically when the engine starts and switched 'ON' when it stops. The heater shall be connected through HRC fuses. Heaters shall be easily removable for replacement. 2 2.05 ENGINE STARTER BATTERIES 1 A. Starting and control batteries shall be made of high performance lead acid, vented type, 24 volt DC, sized as recommended by the engine manufacturer, complete with battery cables and connectors 2 B. Batteries size shall be heavy duty such that lead acid cells are not discharged below 75%. 3 C. Batteries output capacity shall be such that if the engine does not start at the first attempt, there is sufficient starting attempts. The minimum number of repeat starts required, each of 10sec duration, should be three. 4 D. Batteries charging shall be provided from a suitable full wave rectification static-charger with auto trickle-charge enclosed in an

adequately ventilated sheet steel case and incorporated within the control panel with associated instruments and controls mounted on front of panel. 5 E. An ammeter and voltmeter in the control panel shall indicate the state of the battery and its charging rate. 3 F. The starting batteries of the diesel engines (serving the shelters) shall be at least dimensioned for at least four start attempts and suitable for six hours continuous operation in conformity with the General Department of Civil Defence, Manual 2 of May 1998. The battery shall be provided with re-charging equipment. 4 2.06 CONTROL PANEL: 1 A. Each generator control panel shall be electronic modular, generatormounted type. The control panel shall be environmentally sealed, solidstate, microprocessor based module for engine control and AC metering. The control panel shall provide the following control and monitoring features: 2 1. Automatic/manual start-stop engine control with programmable safety shut downs and associated flashing LED indicators for low oil pressure, high coolant temperature, overspeed, overcrank and emergency stop. 3 2. Cycle cranking adjustable 1-60 second crank/rest periods. 4 3. Cool down timer, adjustable 0 - 30 minutes. 5 4. Energised to run or shutdown fuel control system. 6 5. LCD digital read out for: Engine oil pressure, coolant temperature, engine RPM, system DC volts, engine running hours, generator AC volts, AC amperes and frequency. 7 6. Control system diagnostic codes: Loss of engine speed signal, invalid engine control switch signal, internal circuit fault, loss of coolant temperature signal. 8 7. Engine Control Switch 9 8. Voltmeter, ammeter, KWH meter, frequency meter, PF meter.

1 2 3 4 5

9. Voltmeter Phase Selector Switch 10. Emergency Stop Push Buttons 11. Indicator/Display Test Button 12. Voltage Adjust Potentiometer 13. Provision for interface through RS 232 port.

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

specification requirements for both the generator set and the paralleling equipment. 2 2.07 FUEL SUPPLY SYSTEM 1 A. The fuel supply system shall be considered as mechanical support system for the diesel generator set and will be supplied under the scope of HVAC contract and indicated in the relevant HVAC drawings. Refer Division15 related Sections for compliance, unless indicated more stringent here below. The system includes two types of fuel tanks. 2 1. Main fuel tank or storage fuel tank. 3 2. Transfer fuel tank or day tank. 4 B. MAIN FUEL TANK 5 1. Provide, where shown on the Drawings, cylindrical diesel oil storage tank having the capacity indicated on the Drawings. The tank shall be constructed in accordance with the requirements of Kuwait National Petroleum Company (KNPC) and the National Board of Fire Underwriters for underground installation and shall be so labelled. The tank shall be provided with the outlets as indicated on the Drawings plus two spare 63 mm (21/2") plugged tappings. The sizes of all connections shall be extra heavy welded full couplings. Provide inside the tanks a welded steel ladder extending from top of the opening to the bottom of the tank. Ladder shall be securely fastened to the tank by means of structural angles. 6 2. Tank shall be of steel and factory coated with two (2) coats of red lead paint. Prior to installation in the ground, tank shall receive a coat of black asphalts paint. 7 3. Tank shall be mounted on reinforced concrete pads with concrete saddles and set pitched on its supporting base. 8 4. Provide all anchor bolts, holding down straps, tie rods and mat inserts required for installation of the tanks. 9 C. TANK GAUGES 1. Provide as shown on the Drawings liquid level gauges operating on the hydrostatic principle. Each gauge is to be provided with an 3 10 aluminium case, drain valve and glass front to protect the indicating tube and scales. Mounted on gauges shall also be a high/low level alarm switch. The switches shall be designed for a 240 volt system. Provide all contacts and necessary connection as required for monitoring the levels on the BAS.

1 2 3

2. Scales to be calibrated on one side in litres graduated for equal litre units based on actual tank dimensions, on the other side in millimetre/centimetre graduated for every 6 mm of tank depth. 3. Each gauge shall be filled with red indicating fluid having a specific gravity of not more than 3.0. 4. Connections between tank and gauges shall consist of double copper tubing encased in flameproof covering. The copper tubing shall be not less than 3 mm (1/8") O.D. and provided with suitable end connections. 5. Tank fittings shall be provided with a 38 mm (1 1/2") male pipe thread with a stuffing box and stuffing box nut through which 13mm (1/2") pressure pipe extends. The pressure fitting shall be provided with a 13 mm (1/2") female pipe thread. Tank fittings and pressure fittings shall be made of solid bar stock to prevent leak possibilities

5 D. FUEL OIL PIPING 6 1. Provide all diesel fuel oil piping, fill lines, water tight fill boxes, vents, vent caps, flame arresters to vent pipes as required by Kuwait Fire Brigade (KFB), tank foot valves, quick closing spring actuated fusible link valves on supply and return and other accessories. 7 2. All piping shall be provided with ground joint unions at piece of apparatus to facilitate connecting and disconnecting. 8 3. All piping, unless otherwise specified, shall be standard weight black wrought iron pipe with standard galvanised malleable iron fittings. All valves shall be designed for 610 kg/m2 (125 lb/ft2) steam working pressure. Provide relief valves. Underground fuel piping shall be extra heavy with galvanized malleable iron fittings and shall be painted with asphaltum. 9 4. Galvanised steel vent pipe lines shall run from the fuel oil storage tanks, carried to the proper height within building construction and terminating with vent fittings. Fittings shall be "Bronze Ventilating Brick" with thickness of 20 mesh bronze wire gauge in front of louvered opening, as manufactured by Preferred Utilities Mfg. Corp., or approved equal. 10 5. Oil suction line piping shall be tested at 625 mm (25") vacuum prior to backfilling. 11 E. DIESEL OIL PUMPING AND STRAINING SET 12 1. Provide packaged type duplex fuel oil pumping and straining set (with one electric pump) with a capacity of two times the total fuel consumption of engine at full load. Pump sets shall be factory assembled, piped, wired and tested. Pumps shall be activated by a switch in the day tank. Provide one manual pump of equal capacity and make necessary piping connections with valves. 13 2. Support base shall be fabricated of not less than 6 mm steel plate with 75 mm side rails continuously welded to form a 25 mm

14

high overflow lip, complete with 13 mm drain plug. Strainer and pumps shall be bolted to individual bases, which in turn, are welded to the support base. 3. Piping shall be complete to suction, discharge and return line connections. Provide gate valves and unions arranged to permit removal of either pump while the system is in operation. Install check valves and relief valves on pump outlet and gate valves on the inlet side of pressure gauges.

1 2 3

4. Suction strainer shall be flanged connection, duplex type, onepiece, cast-iron body, ASTM A 48 Class 30, with 1.2 mm perforation brass baskets. 5. Oil pump set shall be factory assembled on a structural steel channel beam base to include pumps, motors, flexible couplings and guards. Pump set shall be suitable for diesel oil. 6. Valves 4 a. Gate valves to be bronze body, screwed connection, 1378 kPa. 5 b. Check valves to be bronze body, angle type, screwed connection, stamped 413 kPa, adjustable 275 to 550 kPa.

6 F. FUEL DAY TANK 7 1. Fuel supply to the engines shall be maintained in auxiliary fuel tanks or day tanks. A tank is dedicated for each generator. The tanks shall be welded 2mm thick sheet steel construction treated to resist corrosion, and mounted on suitable angle iron steel structure. Each tank shall be provided with oil strainer, vent pipe, high and low level control switches, drain valve, engine supply and return piping connections, daily tank supply and overflow piping connections, dial type level indicator and electrically operated solenoid valve with manual reset lever. The engine supply connection shall terminate 25mm above bottom of tank and provided with a valve. 8 2. The day tanks shall be tested at the factory prior to shipment and shall be capable of providing fuel for minimum 8 hours continuous duty. Complete mounting hardware shall be included and shipped to job site with complete installation instructions. 9 3. Upon receiving a signal from control panel indicating a fire in the generator room, actuate each solenoid valve to shut down the fuel supply lines to the engine. 2 2.08 ENGINE EXHAUST SYSTEM Associated engine exhaust system, except the silencers / mufflers as supplied with the diesel engine, will be furnished and installed under the scope of HVAC contract as shown and indicated in the relevant drawing. 1 A. Exhaust pipes shall be of Schedule 40 black steel and of adequate size to ensure that backpressure does not exceed the value specified by the manufacturer. 2 B. The exhaust pipe shall be connected through airtight flexible coupling to the engine. Bends in exhaust pipe shall have a radius of not less than three times the pipe diameter.

3 C. Exhaust pipes shall be adequately lagged with 75mm thick (minimum) calcium silicate moulded insulation having a density of 175 kg/m3 (11 lb/ft3) and canvassed so that the surface temperature does not exceed 60oC. When exhaust pipes pass through walls or roof a suitable weatherproof sleeve or thimble shall be provided to isolate exhaust pipe from the building. A silencer of heavy-duty residential type shall be provided in the exhaust system and it shall also be lagged.

1 D. Exhaust pipes and mufflers shall be supported from the ceiling by special vibration isolating hangers and the pipe shall be slanted away from the engine and a condense trap fitted at the lowest points. Approved rain caps shall be installed at the discharge end of the exhaust pipes on the roof. 2 E. Exhaust pipes passing thru walls, floor or other space shall pass thru welded steel thimble or other approved device to isolate structure members from exhaust heat. 3 F. Engine exhaust pipe and system aside from being insulated with 3 (three) inch calcium silicate moulded aluminium insulation of 11 (eleven) pounds per cubic feet density shall be covered with weather proof mastic where exposed. 2 2.09 FRESH AIR INTAKE AND EXHAUST AIR SYSTEM 1 A. As part of the supply and installation of the diesel / alternator set, the Contractor shall furnish and install the cooling and aspiration air intake. 2 B. The system includes the engine radiator exhaust air system plus that of the generator room ventilation system. These shall be under the scope of HVAC contract as shown and indicated in the relevant drawing. 3 C. The radiator exhaust ductworks shall be acoustically treated in accordance to standard codes of practice for generating sets. 4 D. The acoustic treatment and ductwork system shall be such as not to reduce the efficiency of the engine or output of the alternator. 3 2.10 GENERATOR SET PARALLELING CONTROL PANELS 1 A. Provide a paralleling control panel for each generator set in the emergency power system. The paralleling control functions may be integrated with the generator set control functions (with duplicate functions eliminated). Each paralleling control panel shall contain the components and devices as described in this section. 4 2.11 FRONT DISPLAY PANEL: A. The front panel of the paralleling control shall contain the following instruments and devices: 1 1. 1% accuracy generator set AC output instruments; Ammeter, Voltmeter, Frequency Meter, Wattmeter, KW-hour meter, Power

Factor Meter. Selector switches to allow viewing of voltage and amperes for each phase shall be provided. For 3-phase/4-wire systems the voltmeter shall indicate line to line and line to neutral conditions. Voltmeter and frequency meter shall be analog instruments. Switches and/or other provisions shall be included to allow reading of bus voltage and frequency from this metering set.

1 2 3

4 5 6 7 8

9
Shutdown Unit * * * * * * * * * * * * * Alarm Horn

2. Synchroscope and generator set synchronized indication. Indication may be synchronizing lamps, LED indication, or other provisions, but must be located on the paralleling control panel, adjacent to the paralleling breaker control switches. 3. Running Time Meter, Start Counter 4. Generator Set Mode Selector Switch: Switch shall provide run, off, and automatic functions for control of the generator set. 5. Breaker trip/close switch with breaker status indicating lamps. The switch shall be interlocked with the control system such that breaker closure is not possible unless the mode select switch is in the run position and the generator set is synchronized with the system bus. 6. Control Reset push-button switch with indicating lamp. Lamp shall flash to indicate that generator set is locked out due to a fault condition. 7. Lamp test push-button switch. Operation of this switch shall cause all lamps on the panel to be simultaneously tested. 8. The control panel shall be provided with a set of DC-powered lamps with a switch to allow viewing of all functions on the front panel when normal lighting systems are not available. 9. Emergency Stop switch. The emergency stop switch shall be a red, mushroom head switch which maintains its position until manually reset. 10. Precision voltage and frequency adjust raise/lower switches. Switches shall allow the generator set frequency and voltage to be adjusted plus or minus 5% when the generator set is operating independently of the system bus. Voltage and frequency adjustment switches shall be located adjacent to the generator set and bus metering, breaker control switches, synchroscope and manual paralleling panel, for ease of use by the operator. 11. Alarm and status indicating panel to indicate the following conditions (alarm horn shall be located on master control):
Lamp Color Function

Amber Amber Amber Amber Amber Amber Amber Amber Amber

Low DC Voltage High DC Voltage Weak Battery Fail to Sync Low Oil Pressure Alarm Low Fuel - daytank High Engine Temp Alarm Ground Fault Overcurrent Alarm Red Breaker Failure Red Breaker Tripped

* * * * * * * * *

* * * * * * * * *

Red Red Red Red Red Red Red Red Red

Not in Auto High Engine Temp Low Oil Pressure Overcurrent Short Circuit Loss of Excitation Reverse Power Overcrank Overspeed

* Red Under Frequency * * Red Under Voltage * * Red Over Voltage * * Red Phase Rotation * * Red Low Coolant Level Green Automatic Green Generator Running Green Breaker Open Green Breaker Closed Green Demand Mode Standby Green Timing for Start Green Timing for Shutdown

12. Provide all other components required, such as properly sized current transformers, transducers, terminal blocks, etc., for reliable system operation, as described herein under SYSTEM OPERATION".

2.12 PARALLELING CONTROL PANEL, INTERNAL COMPONENTS: 0 A. Electrically operated power circuit breaker with electronic trip unit (long, and instantaneous trips) in drawout frame. Frame size and trip units shall be as shown on the project drawings. 1 B. Electronic isochronous kW load sharing control to operate the engine governors during synchronizing and to provide isochronous load sharing when paralleled. The control system shall allow sharing of real kW load between all generator sets in the system to within 5% of equal levels, without introduction of frequency droop into the system. The control system shall include all equipment required for kW load sharing with an infinite bus, for future application flexibility. The infinite bus governing controls shall allow the generator set to synchronize to an infinite bus, parallel, and ramp up to a preset load level on the generator set. Additional controls shall be provided to cause the generator set to ramp up to a kW load level signaled by the system PLC. 2 C. Load demand governing controls shall be provided to cause the generator set to ramp down to zero load when signaled to shut down in a load demand mode. On a signal to re-start, the load demand governing controls shall cause the generator set to synchronize to the system bus, close, and ramp up to its proportional share of the total bus load. The ramp rate of the generator set shall be operator-adjustable. 3 D. The isochronous load sharing module and engine governor shall be a coordinated system of a single manufacturer.

4 E. Electronic isochronous kVAR load sharing control to operate the alternator excitation system while the generator set is paralleled. The control system shall allow sharing of reactive load between all generator sets in the system to within 5% of equal levels, without introduction of voltage droop into the system. The control system shall include all equipment required for VAR load sharing with an infinite bus in either a constant VAR or constant power factor mode for future application flexibility. (Mode and adjustments selectable by the operator)

0 F. Equipment shall be provided to monitor the generator set as it is starting, and verify that it has reached at least 90% of nominal voltage and frequency before closing to the bus. The equipment provided shall positively prevent out-of-phase paralleling if two or more engine-generator sets reach operating conditions simultaneously by providing a lockout signal to disable breaker closure for generator set(s) in the system which have not been selected to be the first units to close to the bus. Controls to recognize the failure of the first breaker signaled to close, and allow system operation to proceed in spite of this failure shall also be provided (breaker failure alarm). Systems using dead bus relay schemes without a disable signal to positively prevent out-of-phase paralleling shall not be acceptable under this specification. 1 G. Synchronizer to electronically adjust the engine governor to match the voltage, frequency and phase angle of the bus. Synchronizer shall maintain the engine-generator voltage within 1% of bus voltage and phase angle within 20 electrical degrees of the bus for 0.5 seconds before circuit breaker closing. Each unit shall have its own synchronizer; systems using a switching scheme to utilize a single system synchronizer will not be approved. Synchronizers and systems which utilize a motor driven pot for control of AC voltage during the synchronizing process will not be accepted. The system shall be provided with a fail to synchronize time delay, which is adjustable from 10-120 seconds. Control logic for fail to synchronize function shall allow field adjustment of function for either alarm or shutdown of the generator set on failure condition. 2 H. Controls shall include a permissive relay function to assure that the generator set does not attempt to close out of phase with the bus, due to errant operation of the synchronizer. 3 I. Controls shall include a permissive (sync check) function, to be used with generator synchronized indicator during manual paralleling, to prevent accidental closure of the breaker with the generator set out of phase with the bus. Provisions to allow manual closure of the first generator set to a de-energized bus shall be included. 4 J. Control equipment shall contain a system of diagnostic LEDs to assist in analyzing proper system function. 5 K. Controls shall include three phase sensing reverse power equipment, to prevent sustained reverse power flow into the generator set. When the reverse power condition exceeds 10% of the generator set kW for 3 seconds, the paralleling circuit breaker shall be tripped open and the generator shut down.

6 L. Controls shall be provided to verify generator set and bus phase rotation match prior to closing the paralleling breaker. 7 M. Electronic alternator overcurrent alarm and shutdown protection. This protection is required in addition to the overcurrent trip on the paralleling breaker. The overcurrent alarm shall be indicated when the load current on the generator set is more than 110% of rated current for more than 60 seconds. The overcurrent shutdown shall matched to the thermal damage curve of the generator set, and shall not have an instantaneous function.

1 N. Electronic alternator short circuit protection. This protection is in addition to the overcurrent trip on the paralleling breaker. The short circuit shall occur when the load current on the generator set is more than 175% of rated current and an aggregate time/current calculation indicates that the system is approaching the thermal damage point of the alternator. The equipment used shall not have an instantaneous function. 2 O. Controls shall be provided to sense loss of excitation of the alternator while paralleled to the system bus. 3 P. Generator set start contacts rated 10 amps at 32 VDC. 4 Q. Cool down time delay, adjustable: 0-600 seconds. The control panel shall indicate the time remaining in the time delay period when the generator set is timing for shutdown. 5 R. Start time delay, adjustable: 0-300 seconds. The control panel shall indicate the time remaining in the time delay period when the generator set is timing for start. 6 S. The control system shall monitor the paralleling breaker auxiliary contacts, and initiate a fault signal if the breaker fails to close within an adjustable time delay period after the control has signaled it to close (0.515 seconds). Breaker failure alarm shall cause the paralleling breaker to trip open, and lock out until manually reset. 7 T. Controls shall be provided to initiate an alarm condition when generator set is at 90% of rated frequency for more than 20 seconds. 8 U. Controls shall be provided to shut down generator set and initiate alarm when the generator set is at less than 85% of nominal voltage for more than 15 seconds, more than 110% of nominal voltage for more than 10 seconds, or more than 130% of nominal. 2 2.13 MASTER CONTROL 1 A. Provide a master control to monitor and control the operation of the entire paralleling system. The master control panel shall contain the components described in this section. 3 2.14 MASTER CONTROL FRONT PANEL METERING 1 A. 1% accuracy RMS digital instruments to monitor total output of bus: Ammeter, Voltmeter, Frequency Meter, Wattmeter, Power Factor Meter, KVA, kVar kW-Hour Meter, kW demand, kVAR hours, kVA hours. Selector

switches to allow viewing of voltage and amperes for each phase shall be provided. For 3-phase/4-wire systems the voltmeter shall indicate line to line and line to neutral conditions. 4 2.15 MASTER CONTROL OPERATOR INTERFACE PANEL

1 A. A touchscreen type operator interface panel shall be provided which allows the operator to monitor and control the on site power system. The touchscreen shall include the following screens and/or functions: 1 1. Main Menu. The Main Menu screen shall include date, time of day, and a general system status message which indicates system, generator set, and transfer switch status. Pushbuttons on the screen shall provide access to the following screens: 2 a. One line diagram 3 b. System controls 4 c. Load controls 5 d. Alarm summary report 6 e. Bus AC metering 7 f. Genset control 8 g. Load priority set-up 9 h. Test/run report 10 i. Help 11 2. One Line Diagram Screen. The one-line diagram screen shall display a system message (to advise the operator of needed or optional control operations), and shall also show the system status by a combination of animation, changing screen color, text messages, and pop-up indicators. Conditions visible on the screen shall include: 12 a. Generator set and bus configuration, with generator set, parallel breaker and bus energized/de-energized indication (bright color indicating energized, dull color indicating deenergized). 13 b. Generator set designation. (Touching the generator set icon shall cause the system to switch to the generator set control screen.) 14 c. Generator set mode (run/off/auto) 15 d. Generator set status (normal/warning/shutdown/load demand stop) 16 e. Paralleling breaker status (open/closed/tripped) 17 f. Bus condition (energized or de-energized) 18 g. Run time for latest operation 19 h. Transfer switch position and warning status (load shed/transfer inhibit) 20 i. Direct access to system control, load control, main menu, and help screens. 21 3. AC Metering. The AC metering screen shall display all critical functions of the system digital metering set on a single screen. The screen shall include individual phase volts and amps, kW, kVA, kVar, power factor, bus frequency, kW-hours, and kW demand. In

25

addition, the screen shall allow access to the following functional screens: 22 a. Real time trend chart, illustrating system kw and volts as a percent of nominal, and system frequency. The chart shall update on 1-second intervals. 23 b. Historical trend chart, illustrating system kw. The system shall update on 5 minute intervals and have a chart length of 4 hours. 24 c. Access to the one line diagram screen. 4. Generator Set Control. The generator set control screen shall provide control over individual generator sets from the system master control panel. The following functions shall be available on this screen:

12

a. Generator manual start/stop control (functional when generator set mounted control switch is in the AUTO position). 2 b. Generator set warning alarm reset. When the generator set has no active warning conditions, the screen shall indicate that the control condition is normal. 3 c. Manual paralleling and breaker control. Controls shall allow manual breaker opening and closing (via a permissive relay), and manual paralleling. 4 d. Direct access to the one line diagram and help screens. 5. System Control. Functions in the system control screen shall only be accessible after entering an access code into the system via a keypad screen on the operator interface panel. The access code shall be the same code which is used for access to generator set control setup and adjustments. The system control screen shall include the following functions: 6 a. System test on/off. 7 b. Load demand on/off. In the load demand mode the system shall monitor the total load on the system bus and control the number of running generator sets to minimize fuel consumption in the system but retain system reliability at an acceptable level. 8 c. Load demand pickup and dropout set points. Factory settings shall be: pickup--90%, adjustable down to 40% in 5% increments; dropout--20%, adjustable to a maximum of 70% in 5% increments. 9 d. Load demand shut down time delay. Factory setting: 15 minutes, adjustable from 5-95 minutes in 5 minute increments. 10 e. Load demand shut down sequence. 11 f. Direct access to load control and one-line diagram screens. 6. Load Control. The load control screen shall provide the operator with information and control capability to manually add and shed loads from the system. The screen shall include two real time bar graphs which indicate % of available system KW and % of available system amps capacity. Other information and controls on this screen shall include: 13 a. Under Frequency/Overload reset. When the system condition is normal, the button for this function shall be dim, and indicate that bus frequency in normal. 14 b. Load shed time delay raise/lower controls (adjustable 0-99 seconds, factory set to 3 seconds). 15 c. Load add manual (one for each level). Button shall be bright when action is available, and dim when action is not available.

16 17 18 19

d. Load shed restore (one for each level). e. Load shed (one for each level). f. Direct access to one-line diagram, system control, and help screens. 7. Load Priority Control. Functions in the system control screen shall only be accessible after entering an access code into the system via a keypad screen on the operator interface panel. The access code shall be the same code which is used for access to generator set control setup and adjustments. The load priority control screen shall be designed to allow the operator to control the sequence in which specific load add and load shed relays function to signal load additions as the system is energized

and load shed, as the system is overloaded. The load priority control screen shall include the following functions: 2 a. Assigning a load add sequence to each load add relay. The operator shall be allowed to designate relay operation when a specific number of generator sets have closed to the system bus. 3 b. Direct access to the load control screen, main menu, and help screen. 4 c. Assigning a load shed sequence to each load shed relay. The operator shall be given controls for each load shed relay, so that its operating sequence can be controlled. 8. Alarm Summary. The alarm summary screen shall provide a list of the most recent alarm conditions and specific status changes which have occurred in the system. The screen shall list the last 64 alarm or status condition changes in the system by number, name, time/date of condition, and the date that the condition was acknowledged. Buttons shall be provided to facilitate easily moving through the available data log. This data shall be printable directly from the system via a serial port on the equipment. 9. Run Report. The control system shall automatically log information with each signal for the system to start, whether from a local test signal (initiated through the touchscreen), or a remote signal. The screen data shall be capable of being printed over the system serial printer port. The run report shall include the following information: 7 a. Start time and date. 8 b. Stop time and date. 9 c. Maximum kW and Amp load on the system during the run period. 10 d. Individual generator set start and stop time. 11 e. Transfer switch operation times.

2.16 SOLID STATE SYSTEM STATUS PANEL. A. System status panel shall be provided and shall include the following features and functions: 1 1. Alarm Silence Push-button Switch 2 2. Alarm horn 3 3. LED Indicating lamps to indicate the following conditions:

Alarm Horn Color Function green green green green Generator Set #1 Running Generator Set #2 Running Load Demand Mode Priority 1 Load On

green * * green red * * *

Priority 2 Load On red Load Shed Level 1 red Load Shed Level 2 System Test Remote System Start red Check Generator Set #1 red Controller Malfunction red Check Station Battery

* red Check Generator Set #2 * red Bus Overload * red System Not in Auto Mode

2.17 INTERNAL CONTROL COMPONENTS A. The following internal controls shall be provided within the master control section: 1 1. Programmable controller for interface with touchscreen, and to provide load demand, load pick-up, and load shed functions. 2 2. Load pick-up output contacts, rated 10 A at 600 VAC (3 contacts per level). 3 3. Load shed output contacts, rated 10 A at 600 VAC (3 contacts per level). 4 4. Provide all other components required, such as properly sized current transformers, transducers, terminal blocks, etc., for reliable system operation.

2.18 SYSTEM OPERATION: A. Loss Of Normal Power: 1 1. System is given signal to start by receipt of start signal from automatic transfer switch(es) or other remote device. On receipt of this signal, all generator sets automatically and independently start, accelerate to rated frequency and build up to rated voltage. The first start system monitors this process, and on finding a generator set at 90% of rated voltage and frequency, automatically disables all other units from closing to the bus, and closes the ready unit to the bus. At this time first priority transfer switches begin the time delay transfer sequence, and on it's completion transfer their loads to the system bus. 2 2. The priority (load add) controls prevent overloading of the system bus by providing inhibit signals to prevent transfer of selected loads to the emergency system until sufficient generating capacity is available on the bus, or until the priority override switch on the touchscreen control is actuated. 3 3. After the first unit is closed to the bus, the control of the remaining units is switched to the synchronizer in each generator paralleling control, which causes the generator set to synchronize with the system bus, and then close to it at the proper time. 4 4. As each unit closes to the bus, the unit assumes it's proportional share of the total load on the bus.

5 B. Failure Of A Unit To Start Or Synchronize: 6 1. If a unit fails to start, after the overcrank time delay (in the generator set control) has expired, the unit will be shut down, and an alarm will sound. The priority control will prevent the lowest priority loads from being added to the system without manual intervention. The priority override controls on the touchscreen may be used by an operator to manually add low priority loads to the bus, if he determines that generator capacity is available to serve the loads. Bus overload monitoring shall protect the

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first priority loads in the event that the bus is inadvertently overloaded due to operator error. 2. If a unit fails to synchronize, after a preset time delay, an alarm will sound, but the unit will continue to attempt to synchronize until signaled to stop by manual operation of the control switches on the generator set.

3 C. Bus Overload: 4 1. If a bus overload occurs for any reason, a load shed signal will be generated to initiate load shedding in the system. 5 2. If the bus does not return to proper frequency within a predetermined period of time, additional load shed signals will be generated. 6 D. Load Demand Mode: 7 1. When the system running in the emergency mode with the "load demand" switch on the touchscreen in the "on" position , controls shall continuously monitor the total load on the bus. If the total load on the bus falls below preset limits for a period of 15 minutes, the controller will automatically shut down generator sets in an operator predetermined order, until the minimum number of generators required to operate the load remain on the bus. The purpose of this function is to allow the generator sets to operate closer to their rated capacity, thereby decreasing fuel consumption, and reducing wear on the system. 8 2. On sensing that the available bus capacity is being approached, the standby units will automatically be restarted (in the reverse order of which they were shut down) and paralleled with the bus to assume their proportional share of system load. 9 E. Return of Normal Power 10 1. When all of the system start signals are removed from the generator sets, the generator set paralleling breakers shall all open, and the generator sets shall operate at no load for a cool down period. When the cool down period has been completed, the generator sets shall shut down. 11 2. If a system start signal is received during the cool down period, one generator set shall immediately close to the system bus and all other units shall synchronize to it, as described in Loss of Normal Power above. 12 F. Distribution Equipment 13 1. Provide emergency feeder distribution breakers of the number and size as shown on the project drawings. 14 2. The breakers provided shall be molded case breakers, motorized type, with electronic trip units. Breakers shall be provided with lugs of the number and size as shown on the project drawings.

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

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PART 3 - EXECUTION 3.01 EXAMINATION 0 A. Examine areas, equipment foundations, and conditions, with Installer present, for compliance with requirements for installation and other conditions affecting packaged engine generator performance. 1 B. Proceed with installation only after unsatisfactory conditions have been corrected. 2 C. Verify actual locations of connections before packaged engine generator installation.

3.02 CONCRETE BASES 1 A. Install concrete bases of dimensions indicated for packaged engine generators.

3.03 INSTALLATION 1 A. Comply with packaged engine generator manufacturers' written installation and alignment instructions. 2 B. Set packaged engine generator set on concrete bases. 3 C. Adjust metal supports or wedges until generator is level. 4 D. Install packaged engine generator to provide access for periodic maintenance, including removal of drivers and accessories. 5 E. Install cooling-system piping, accessories, hangers and supports, and anchors for complete installation. 6 F. Extend drain piping from heat exchangers to point of disposition. 7 G. Install exhaust-system piping for diesel engines. Extend to point of termination outside structure. Size piping according to manufacturers written instructions. 8 H. Install condensate drain piping for diesel-engine exhaust system. Extend drain piping from low points of exhaust system and from muffler to condensate traps and to point of disposition.

9 I. Electrical Wiring: Install electrical devices furnished by equipment manufacturers but not specified to be factory mounted. 10 J. Verify that electrical wiring is installed according to manufacturers' submittal and installation requirements in Division 16 Sections. Proceed with equipment startup only after wiring installation is satisfactory. 4 3.04 CONNECTIONS 1 A. Electrical wiring and connections are specified elsewhere in Division 16. 2 B. Ground equipment as specified elsewhere in Division 16. 3 C. Tighten electrical connectors and terminals according to manufacturer's published torque-tightening values. If manufacturer's torque values are not indicated, use those specified in UL 486A and UL 486B.

3.05 FUEL TANK (MAIN UNDERGROUND STORAGE TANK) 1 A. Paint the fuel tank with a coat of black asphaltum paint prior to installation in the ground. 2 B. Tank shall be set pitched on this supporting base.

3.06 FUEL OIL PIPEWORK 1 A. Install all fuel oil pipe work as per KNPC standards. 2 B. Oil suction line piping shall be tested at 0.25" vacuum prior to backfilling. The test shall be witnessed by consultant and Employers Representative.

3.07 ENGINE EXHAUST PIPEWORK 1 A. Install all exhaust pipe work, including muffler as per KNPC Standards. 2 B. Install pipe flexible connector under provisions of Section 15070 Vibration isolation.

3.08 PAINTING 1 A. Painting: After fabrication, the entire oil pumping set, except control cabinet, name plates, valves and gauges, shall receive a finish coat of heavy duty heat resistant aluminium paint. Refer Section 09900 and 09910 for general requirements of painting.

3.09 IDENTIFICATION 1 A. Identify system components.

3.10 TESTING OF THE SET A. DIESEL ENGINE TEST: 1 1. The Diesel Engine shall be tested at the engine manufacturer's works for its output-power and relevant temperatures. Test certificate to be submitted for both, engine and complete Generator Set. 2 B. DIESEL ALTERNATOR SET TESTS:

6 7

1. Full performance test including speed and voltage regulations and the test shall include the following to be performed at site before handling over: 4 a. Partial load test. 5 b. Full load test and run for one hour 2. Detailed records of the foregoing tests shall be submitted. 3. Test at site before taking over and after the sets are completely installed at the site, full performance operation shall be carried out on the set at the worst specified conditions in summer of 3 hrs of continuous running to the

approval. The tests shall be carried out under the full responsibility of the Contractor and at his own expense. If the works are completed when the climatic conditions are not considered the worst conditions in summer then the above tests shall be made at the time of completion of the installation of works, but a full operation and performance test shall be carried out to the satisfaction in the worst climatic conditions in summer and this test shall be carried out by and at the responsibility of the Contractor. 4. The commissioning should be carried out by the Diesel Engine Manufacturer's engineer or his Authorised Representative.

3.11 GUARANTEE & MAINTENANCE A. OPERATION & MAINTENANCE 1 1. The Contractor will be required to do the following: 2 a. Operate and maintain the Diesel Generator Set for two months after handover of the works; 3 b. Maintain the Diesel Generator Set for 10 months after completion of Operation & Maintenance period described above. 4 2. The Contractor shall be fully responsible for the satisfactory operation of D/G installation during the operation and maintenance period and thereafter during the maintenance (defect liability) period. He shall carry out necessary inspection, preventive maintenance and testing to keep the sets ready all the time. The set shall function satisfactorily during power failures. The Contractor shall carry out routine testing. The testing shall be carried out in presence of Employer's Representative. The Contractor shall himself provide all electrical and mechanical spare parts, grease, lucubrating oils, touch-up paints, etc., required for the maintenance of the D/G Installation. The Employer shall be responsible only for providing diesel oil as and when required. The Contractor shall prepare log-books listing full details of maintenance work and each log-book entry shall be counter signed by the Employer's Representative. 5 C. GUARANTEE OF CONTROL SYSTEM OPERATION 6 1. All components of control panel for the D/G set, relays, controls of all systems mentioned in this specification shall be installed in an ambient temperature of more than 55C, high relative humidity and dusty atmosphere. 7 2. The Contractor shall enclose with his offer a written assurance from the manufacturer for the guarantee that all components of the Control System (relays, diodes, pre-integrated circuits, semiconductors, etc.) shall withstand, operate continuously and

effectively without troubles in this high temperatures and climatic conditions. 3 3.12 DEMONSTRATION 1 A. Engage a factory-authorized service representative to train Employer's maintenance personnel to adjust, operate, and maintain packaged engine generators as specified.

END OF SECTION