Works Shall Include but Not Limited to the Following

Works Shall Include but Not Limited to the Following

المواصفات الفنية العائدة للمولد الكهربائيوملحقاته

………………لزوم كلية

PART 1 - SUMMARY

Works shall include but not limited to the following:

  1. Supply and install diesel generator with associated auxiliaries, cooling air flow system, starting equipment, fuel-water separator filter, connection to fuel tank, batteries & charger, instrumentation, protection and control equipment, sound proof enclosure,operating and maintenance manual and maintenance schedule for diesel alternator etc...
  1. Supply and install automatic transfer switches (ATS) with electrical and mechanical interlock,metallic coated panel enclosure and all the required accessories for the good operationetc...,
  1. Supply and install load management module able to control up to three power sources,plant cabling and wiring as required for good operation of the Genset systems, all necessary monitoring, control, protection devices for the perfect operation of the system.
  1. All cables, ATS, accessories,fuel system, exhaust connections and installation should be done by the contractor when necessary

01.All equipment and accessories listed below have to be installed for a perfect operation Generating set 180KVA + sound proof

02.Generating set 250KVA + sound proof

03.Generating set 315KVA + sound proof

  1. and to the satisfaction of the technical staff:

04.Generating set70KVA + sound proof

05.Generating set100KVA + sound proof

06.Generating set135KVA + sound proof

07.Generating set150KVA + sound proof

08.ATS with 2 power contactors (3x150A) for Generating set 70 KVA

09.ATS with 2 power contactors (3x200A) for Generating set 100 KVA

10.ATS with 2 power contactors (3x250A)for Generating set 135 KVA

11.ATSwith 2 power contactors (3x250A) for Generating set 150 KVA

12.ATS with 2 power contactors (3x300A) for Generating set 180 KVA

13.ATS with 2 power contactors (3x400A) for Generating set 250 KVA

14.ATSwith 2 power contactors (3x500A) for Generating set 315 KVA

15.Load management module between two generators and all necessary control cables

16.power cables for Generating set 100 KVA

17.power cables for Generating set 135 KVA

18.power cables for Generating set 150 KVA

19.power cables for Generating set 180 KVA

20.power cables for Generating set 250 KVA

21.power cables for Generating set 315 KVA

22.Fuel tank 1000 L

23.Fuel tank 2000 L

24.Fuel tank 3000 L

25.Exhaust pipes 4 inches

26.Exhaust pipes 6 inches

PART 2 - GENERAL

2.1LOCATION

The contractor is committed to site inspection of the generator location.

2.2STANDARDS

Generator shall comply with the latest edition of IEC, unless otherwise indicated.

2.3SPARE PARTS

Provide manufacturer’s recommended list spare parts for 1000 hours operation of thegenerator (lubricating oil, oil and fuel and air filters, …)

2.4QUANTITIES

Quantities of Power + control cables and Exhaust pipes are approximate and will be paid according to the effective executed meters as the required needs(depending on the site conditions) for the good operation of the system.

2.5SUBMITTALS

  1. Contractor should submit operations and maintenance manuals in English, after the finishing of works.
  1. Contractor should submit test form for approval.
  1. Contractor should submit shop drawing for ATSand load management modulefor approval.

2.6WARRANTY

Provide one year full warranty or 1000 working hours (which ever occurs first) for replacing and repairing any equipment or auxiliary specified in this specifications.

PART 3 - PRODUCTS

3.1MANUFACTURER

  1. Engine and alternator should be made in Europe or USA.
  1. Generator could be locally assembled.

3.2 DESCRIPTION OF GENERATOR SET

  1. DIESEL GENERATOR SET
  2. COMPONENTS: Set is to basically consist of diesel engine, Brushless synchronous generator with direct flexible coupling to engine and set mounted control panel.
  3. GOVERNING: Shall complywith ISO 3046/1 or BS 5514, using electronic type governor.
  4. STARTING AND STOPPING: When in the automatic mode the set is to start automatically by a signal sent through an auxiliary contact. The set is to stop, after an adjustable cool-down period20 minutes.
  5. HAND OPERATION: Is to be possible for testing or normal operation through a selector switch.
  6. DUTY: Generator is to reach full speed within 12 seconds of start impulse. Loads are then connected and the generator shall accept immediately 65% of net rated output (load being mixed, steady and inductive, with motor starting). During the process, transient voltage variation is not to exceed 10% under any step-load application for which the system is intended.
  7. FAILURE TO START: If theengine fails to start following a start impulse, the system is to come to rest for a few seconds. Two further starting attempts are to be automatically made with intermediate 20 second maximum periods of rest. If theengine fails to start after three attempts, an alarm is to sound and a start failure signal illuminate.
  8. REGULAR EXERCISING: While on “auto”, the set is to start regularly and automatically every weekly and is to operate for an adjustable time preset 30 minutes before stopping.
  9. VIBRATION REDUCTION: Is to be achieved by appropriate design and careful balancing at factory. Generator Set is to have approved anti-vibration isolators of steel spring or resilient neoprene between rotating equipment and bed-frame, limiting transmission of vibration to building to a maximum of 0.05 mm amplitude throughout the operating vibration frequency range.
  1. DIESEL ENGINE AND AUXILIARIES
  2. ENGINE TYPE: Compression-ignition type with direct solid- injection, turbo-charged after-cooled, in line or V type cylinder arrangement, 1500 rpm, class A diesel oil, suitable for direct coupling to driven machine. Flywheel is to be suitably sized for type of service and constraints specified (should be enough for a load pick-up capability of 65% of the generator’s rating), and capable of being rotated at 125% of rated speed without failure. Torsional vibration dampers are to be provided. Engine to be preheated in order to reach 65% of the load in 12 seconds and 100% of the load in 3 minutes.
  3. COOLING SYSTEM: Engine is to be water cooled with gear-driven water pumps. System is to be pressurized, with heavy-duty tropical radiator cooled by reverse flow fan. Fan coil and hand protection guard are to be fitted. Coolant temperature is to be controlled by one or more thermostats. Radiator is to be sized for continuous performance at 110% rated load at worst operating ambient conditions with a 15 deg. C temperature differential. Radiator is to be non-ferrous metal, incorporating pressure valve, and radiator cap and drain cock and with integral expansion tank.
  4. COOLING AIRFLOW: Obstructions in path of cooling airflow (openings, louvers, grilles, mesh, ducts, bends, etc...) are not to reduce airflow below that needed at full rated output.
  5. FUEL SYSTEM: Is to have injection pump and injectors that are easily removable and replaceable for servicing. Engine is to have integral, gear type engine driven transfer pump to lift fuel against a head of 2.5 m and supply it through filters to injection pump at constant pressure. Fuel filter elements are to be easily replaceable. Fuel /water separator should be provided. Generator should be connected to the external fuel tankthrough steel pipes, valves and all necessary accessories should be dimensioned, supplied and installed by the contractor in such a way to ensure good function of the system.
  6. AIR INTAKE SYSTEM: Engine air filter is to be either dry filter with replaceable paper filter elements or oil-bath filter dipstick and provision for adding oil while engine is running. Filters are to be capable of removing particles 10 microns and larger.
  7. ELECTRIC STARTING SYSTEM: Engine starting shall be manual by push-button or automatic through control system at control panel. System shall consist of heavy duty 24 V D.C. starter motor, heavy duty battery and battery charger. Cranking motor and battery are to be rated for cranking the engine when cold and at lowest temperature recorded. Starting pinion is to automatically disengage when engine fires.
  8. STORAGE BATTERY: Lead-acid, sealed-in-plastic typecompletes with battery rack and inter-cell connectors. Battery is to have sufficient capacity to provide minimum six (6) cranking periods.
  9. BATTERY CHARGER: To be European, Japanese or American made, 25% over-rated, solid state, full-wave rectifier type, adequate to fully recharge depleted battery in not more than 8 hours and to automatically control rate of charge (providing a high-charge rate to a depleted battery and reducing to a trickle-charge rate when battery is fully charged). Ammeter is to be provided to indicate charging rate, which is to be adjustable.
  10. ELECTRONIC GOVERNOR: Governor is to have zero percent (isochronous) setting and adjustable drop from zero percent to 10% drop. System is to include power supply unit, magnetic speed pick-up, control module and actuator using fast response D.C motor drive or equally approved alternative. Governor is to be designed for fast-response and high-precision of speed (frequency) control, and is to include speed adjustment to +/-5% of normal, while running, and with remote control interface. Frequency deviation under 25% sudden load change is not to exceed 1 Hz, recovering to stable speed condition of +/-0.1 Hz in 1 second.
  11. GOVERNOR OVERSPEED TRIP: Is to automatically close fuel pump racks in event of engine overspeed. Device is to be separate and independent from governing mechanism.
  12. EXHAUST SYSTEM: Is to be complete with flanged, bolted, black sheet steel,
  13. Painted with inflammable aluminum coat,seamless steel pipe sections, long sweep elbows, flexible expansion sections, clean-outs, residential silencer, wall thimbles and supporting steelwork, . Exhaust system is to be designed to reduce back pressure to below maximum specified by the manufacturer.Dimensions of all exhaust systems should be on the responsibility of contractor (not less than 4 inches diameter).
  14. PROTECTIVE SYSTEM: Is to comprise automatic engine shutdown and generator trip with visual and audible alarm in event of overspeed, low lubricating oil pressure, high cooling water temperature and over cranking.
  1. GENERATOR (ALTERNATOR)
  2. TYPE: Synchronous, low reactance, high efficiency, revolving field type, with brushless exciter and flexible coupling, sized to pick up effective load without exceeding transient and steady-state voltage deviation limits specified up to its full nominal rating.
  3. MAXIMUM VOLTAGE DIFFERENCE: Between the three phases at 100% balanced load is not to exceed 1%. With unbalanced load up to 30% on one phase at unity power factor and zero loads on other phases, the line-to neutral voltages are not to differ by more than 5%.
  4. CHARACTERISTICS:
  5. Number of phase:3
  6. Rated voltage:380V
  7. Frequency:50Hz
  8. Rated power factor:0.8
  9. Overload:10% nameplate rating for 1 hour every 12 hours

g.Rotor:Salient pole type. Incorporating damping grid.

h.Excitation:Brushless, with rotating Armature rectifiers and discharge resistors.

j.Insulation:class H for stator, class H for Rotor and exciter.

k.Enclosure:drip proof and screen protected (IP 23 to IEC 529)

l.Cooling:built-in centrifugal fans.

  1. VOLTAGE REGULATOR: Solid state, volts/Hz type, utilizing silicon semi-conductor devices in control and power stages, with built-in electro-magnetic interference suppression and designed for singles or parallel operation. Optional manual adjustment to +/-5% of regulated voltage level is to be possible. Voltage regulator is to automatically reduce voltage if load exceeds capacity of generator and is to sustain a 3-phase short-circuit current at the generator terminals for the period for which the short-circuit protection operates and at least for 3 seconds. The voltage regulator has to monitor the 3-phases outputs.Voltage regulator power is to be supported by a permanent magnet to maintain excitation field power (PMG). Overall voltage deviation within normal speed variations is to be within limits specified from no-load to full-load, from hot to cold and with load power factor from 0.8 lagging to unity. Regulator is to automatically reduce voltage if load exceeds capacity of generator. Voltage build-up is to be positive and rapid even when full load is suddenly applied. Line-to-line voltage wave-from deviation factor is not to exceed +/-5%. Total harmonic content is not to exceed 5%.
  1. INSTRUMENTATION, PROTECTION AND CONTROL EQUIPMENT.
  2. GENERATING SET INSTRUMENTS, PROTECTION AND CONTROLS: Control relays, sensing equipment, switchgear protective relays and devices and start, stop and shutdown controls are to be provided as necessary for operationspecified. Generating set, instruments, protection and controls are to be mounted preferably in one control cubicle.
  3. PROTECTIVE GEAR: Is to ensure orderly engine stop or shutdown with reset relays, as required for safety and operational reliability, and is to include the following:
  4. Molded case circuit breaker (MCCB) 3 poles(Schneider, Siemens, ABB, Moeller or similar ...), compatible with the generator rating and must be adjustable.
  5. Over-voltage protection with voltage and time lag adjustment.
  6. Loss-of-field protection.
  1. GENERATOR CONTROL PANEL is to includeat least the following:
  2. Digital indication (LCD):

1)Voltage

2)Current.

3)Frequency.

4)System diagnostic.

5)Oil pressure.

6)RPM.

7)Hour meter.

8)Coolanttemperature.

  1. Indicating lights:

1)Low oil pressure.

2)High coolant temperature.

3)Overspeed.

4)Overcrank.

5)Fault shutdown.

6)Charging fault.

7)3 spare lights.

  1. Controls:

1)Auto, start/stop.

2)Emergency stop.

3)Lamp test.

4)Cool down timer.

5)Cycle crank.

6)Voltage control.

  1. CURRENT TRANSFORMERS: class 1 for measuring and protection.
  2. ENCLOSURE CONSTRUCTION: Is to comply with IEC EN 60439-1.
  3. VOLTAGE TRANSFORMERS: Single phase, dry type, 0.5 accuracy class.

PART 4 - EXECUTION

4.1SOUND PROOF ENCLOSURE

Sound proof enclosure should be designed for 78dB at 1 meter, made of black steel 2to 3 mm (minimum) sand blasted and painted (humal paint) with rockwool insulation 10mm (minimum), access service lockable doors. It should ensure proper ventilation without using of a separate independent ventilator. 4 lifting points and support pads should be provided to carry the whole set. The sound proof ground should be insulated.

4.2LOAD MANAGEMENT

  1. DESCRIPTION:
  2. The load management module should be able to control up to three power sources: MAIN and two generatorsG1 and G2 of different rating. It should be able to measure the voltage and frequency on all three sources as well as the current on the load side. It has four operating modes selectable by the user: OFF, AUTO, MAIN, generator G1, generator G2. The menu gives access to all timers, set points and other parameters relevant to the control and protection of the installation.
  3. Load management system can be installed in ATS-1 in adequate way or in a separate enclosure.
  4. A manual bypass shall be provided in order to ensure the continuity of electricity feeding for the building, if the load management system fails to operate the system for any reason.
  1. FEATURES:
  2. Measurement and display of the voltages and frequency on the three sources.
  3. Measurement and display of the current on the load side.
  4. All three supplies are monitored for over/under voltage, phase presence and sequence.
  5. All three supplies are monitored for frequency.
  6. Load side is monitored for over current when it is not supplied by the main.
  7. Display switches automatically to show the measurements of the source feeding the load.
  8. Automatic switching between the two generators based on the load.
  9. Weekly exerciser function.
  10. Ability to control contactor and motorized circuit breakers.
  11. Menu to provide access to all timers, set points and other parameters.
  12. Over/under frequency alarm and shut down.
  13. Over/under voltage alarm and shut down.
  14. Over current alarm and shut down.
  1. OPERATION:
  2. OFF.
  3. AUTO: On receipt of a start signal signaling loss of power (MAIN), thegenerator G1 shall automatically and independently start then pick up the load, if the load is less than a preset level (will be determined on site) or G1 fails to start the generator G2 start automatically and pick up the load instead of G1. When the load become higher than a preset level, G1 start automatically and pick up the load instead of G2.
  1. MAIN: The module monitors the MAIN supply. The load is fed exclusively from this supply if it is within the acceptable limits. No generator will be started if the MAIN fails.
  2. GeneratorG1: In this mode and regardless of the status of the MAIN supply, the module starts generator1 and engages the load after warm up delay.
  3. GeneratorG2: In this mode and regardless of the status of the MAIN supply, the module starts generator 2 and engages the load after warm up delay.
  4. Final sequence of operation should be coordinated with technical staff.

4.3AUTOMATIC TRANSFER SWITCH (ATS)

  1. Works shall includeSupply and install automatic transfer switches ATSwith all associated auxiliaries, plant cabling and wiring. ATS cabinet shall be made from sheet steel 1.5 mm minimum with continuous welded seams, hinged key locking front door, IP54. All devices and cables should be labeled.
  1. ATS-1 shall receive incoming cables from the generator G1 and the generator G2 and outgoing cables to the ATS-2 and all necessary control cables.
  1. ATS-2 shall receive incoming cables from ATS-1and the MAINsource (EOL)and outgoing cables to the main panel board and all necessary control cables.
  1. ATS contains but not limited the following:
  2. Two power contactors (AC3) (Telemecanique, Siemens, ABB, Moeller or similar ...)
  3. The two contactors should be mechanically and electrically interlocked.
  4. All incoming and outgoing cable sections shall be adequate with the power of generators
  5. All necessary monitoring, control, protection devices for the perfect operation of the system.

4.4CABLES

  1. Cables glands, cables support, lugs and labels shall be used for all cables.
  1. Cables sizes:
  2. Power cablesbetweengenerators G1and G2, ATS-1, ATS-2and the MAINsource shall be adequate with the power of generators
  3. Control cables shall be selected by the contractor for the perfect operation of the system.

4.5TESTING

  1. LOAD TESTS: Are to be carried out at low loads to overload conditions, at various power factors. Measurements are to include voltage and frequency deviations and regulating time under various step-loading conditions, temperature measurements and pressure measurements at various locations, and in accordance with an approved plan under conditions equal to worst site ambient conditions.
  1. TESTS:Are to include at least the following:
  2. Full load test for 8 hours continuous, immediately followed by 10% overload test, without interruption.
  3. Insulation measurement.
  4. Functional tests for voltage sensing, automatic start and stop etc...
  5. Operation of engine shut- down and alarm a signaling and indication, under simulated fault conditions.

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