Atelier Management and Design Consultancy (Vietnam) Co.

, Ltd

SEL6-GE E!A"# G SE"S$%

SECTION 6: GENERATING SETS 6.1 6.1.1 GENERAL Functional description The generator scope of work covers the supply and installation of a standby generating set. The generator is to be fully enclosed in an acoustic enclosure and is to be installed within the main building. They will normally be on standby duty and available for instant start up on receipt of a signal or operate under local manual control for testing purpose. 6.1.2 Cross references General Comply with the General requirements worksection. Related worksections Refer to the following worksections Adhesives, Sealants, Fasteners, Service Trenching, Switchboards, Switchboard Components, Acoustic & Vibration Control, Power Cables, lectrical Commissioning, !echanical Piping, Tan"s & Vessels, !echanical Controls 6.1.! 6.1.# "tandard Referenced document To $" #%%%& '((( 6.1.' )nterpretation Technical *enerating sets to be +R),- R.T-/. For reference the following definitions are used. 0et continuous rated output 0et continuous electrical output available at alternator terminals1 not including the electrical power consumed by the generating set2s dependent and essential au3iliaries. 0et prime rating 0et continuous 4(5 electrical output available at alternator terminals1 not including the electrical power consumed by the generating set2s dependent and essential au3iliaries. 0et short6time rated output 7or stand6by rating8 0et electrical output available from the generating set for 1 hour in every 12 hours at net continuous rated output1 not including electrical power consumed by the generating set2s dependent and essential au3iliaries. "tart response time connection to load. Total elapsed time from receipt of start signal to final

.ll rated output to be designed tropically at minimum temperature #((C. 6.2 !ALIT"

Atelier Management and Design Consultancy (Vietnam) Co., Ltd

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6.2.1

)nspection Notice *ive sufficient notice so that inspections may be made of each complete generating set and associated systems at the manufacturer2s or supplier2s factory before delivery to the site. 0ote the generator and alternator are to be assembled in the manufacturer2s factory.

6.2.2

+re6completion tests #rod$ction tests *enerating sets Carry out acceptance tests to TC90. .lternators Carry out performance tests to TC90.

6.2.!

"ubmissions #rod$ct data "ubmit product data for test1 manual and auto modes1 including the following Technical description and specifications of each generating set1 including output curves for base load and stand6by conditions1 alternator and engine data1 automatic voltage regulator1 synchronising and load sharing modules and au3iliaries. Type test reports as follows . . . *enerating sets To $" #%%%& '((( .lternators To $" #%%%& '((( 0et continuous rated output. 0et short6time rated output. Transient and subtransient reactance of the alternators. 9oltage regulation grade. *enerating set efficiency at '(51 4'5 and 1((5 load. Calculations for performance of acoustic enclosures and silencers. -vidence that the engine type has previously passed cold starting tests at the minimum ambient site temperature. Clarify that the offered generating sets have sufficient immunity to the :+"s1 variable speed drives and miscellaneous solid state drives throughout the facility. Sho% drawin&s "ubmit shop drawings indicating the following ,a3imum mass and overall dimensions of each separable assembly. .ccess clearances for operational maintenance and dismantling. -lectrical single line diagram and general arrangement for the complete

Atelier Management and Design Consultancy (Vietnam) Co., Ltd

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system. Control diagrams. .larms and shutdown annunciator te3t engraving schedule. /etails of foundations and anti6vibration mountings. 9ibration fre;uencies < amplitudes. +hysical layout of generators1 day tanks1 pumps etc

=ocation of control < starting batteries. Certi'( Certify by the manufacturer that the offered generating set will operate as specified in the installation as shown on the drawings. Certify by the manufacturer that the acoustic performance of the generating set in the specified acoustic enclosure. 6.) 6.!.1 CO*#ONENTS *eneral Electrical o$t%$t !>( 91 ! phase1 # wire ? earth1 '( @A1 star connected with neutral terminal. En&ine # stroke cycle watercooled diesel1 on radiator onboard. Generator #er'or+ance )nclude means to ensure ade;uate and reliable voltage build6up on start6up. $e capable of providing stable voltage within 6 percent of the rated values prior to the operation of the changeover devices. Comply with voltage regulation characteristics for Class 9R2.22 as defined in $" #%%%& '(((. The variation in voltage 7r.m.s.8 does not e3ceed 2( percent of the nominal system voltage for the ma3imum load step likely to be imposed when the generator set is in serviceB and within 1( s1 the voltage returns to providing stable voltage within 6 percent of the rated values. The alternating current generator and e3citer shall be continuously rated and capable of supplying the load to which it is connected so that temperature rises will be in accordance with $" #%%%& '((( for the winding materials utiliAed. 6.!.2 .lternators ,olta&e wa-e'or+

Atelier Management and Design Consultancy (Vietnam) Co., Ltd

SEL6-GE E!A"# G SE"S$(

"inusoidal1 with total wave form deviation not e3ceeding ' 5. E.citation +ermanent magnet. O-ers%eed withstand . speed of 1.2 3 unit rated speed for both alternator and engine. Alternator $nders%eed withstand 0ormal operation at net continuous rated output at a speed of (.%' 3 unit rated speed1 without overheating. S$stained short/circ$it withstand .t least 2.' 3 full load steady state short6circuit current1 for at least ' s. N$+0er o' %oles #. Enclos$re classi'ication /rip proof )+221 with screened ventilation openings. Coolin& +ethod classi'ication Class )C (11 to $" #%%%& '(((. Ins$lation classi'ication Class @ with tropicaliAation and anti abrasion to )-C 6((>'. Anti/condensation heaters *eneral +rovide at least 2 anti6condensation heaters within the winding enclosure. Rating Rate heaters to maintain the windings and insulation at least 6 oC above ambient temperature when the alternator is at rest and one heater is in service. =ocation =ocate a heater at each end of alternator windings in a position which allows heat transfer to the winding insulation by convection1 without e3ceeding ma3imum allowable insulation temperature. /o not fi3 heaters to windings. Terminations Connect heaters to separate identified terminals within a separate accessories terminal bo3 which is connected to a permanent supply. Connection diagram +rovide a connection diagram for the heaters. =ocate within the terminal bo3. 1indin& ther+istors *eneral +rovide thermistors to alternator stator windings. "tandard To $" #%%%& '((( Thermistor type +ositive temperature coefficient.

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Thermistor temperatures -ngine shutdown 16(oC. Cinding temperature high pre6alarm 1#(oC. Ter+inal 0o.es Construction +rovide metal terminal bo3es. "iAe to allow the current transformers1 power and control cables and cable lugs to be neatly installed and terminated with necessary clearances between live parts and the bo31 and without placing undue strain on termination points. "upply cable terminal bo3 +rovide removable lid and side covers. Terminals +rovide star connected windings. $ring both ends of each winding out to separate terminals. -stablish a neutral terminal. "ealing +rovide neoprene or bonded cork gaskets between terminal bo3es and their frames and covers. 6.!.! -ngines General -ngine # stroke cycle watercooled diesel engine. "iAing Chen siAing the engine1 take into account the nature of connected loads including au3iliaries1 harmonics and transient operation Continuous rating of the diesel engine shall not be less than ma3imum power demand. ,a3imum power demand is the sum of a. ,a3imum continuous base load rating of the generator at rated speed and design temperature at (.> +F lagging1 !>(91 three phase1 Cye connected1 '(@A as specified. b. Transmission losses 7if any8. c. .u3iliary power take6 off. d. )n addition the diesel unit shall be capable of running at 11(5 of continuous rating for one hour in every twelve hours. The declared continuous nett brake power shall be in accordance with )"D !(#6&1. The "upplier shall calculate any derating for site condition in accordance with )"D !(#6&1. $earings +rovide front and rear main bearings1 so that crankshaft alignment is not affected by dismantling of the alternator. Coolin& s(ste+ The cooling system shall be of the radiator type. -ngine coolant shall be treated water or similar medium. The radiator shall be mounted on a common skid1 with guards to prevent accidental contact of personnel with fan or hot radiator parts. The tubing connecting to the radiator and engine shall be supplied and installed. The fan shall be driven by engine thru a coupling or belt.

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The radiator shall be siAed for operating under the re;uired ma3imum design ambient temperature plus 1(5. 2$el S(ste+ The supplier shall provide a diesel tank for installation. The capacity of the tank shall be sufficient to permit the emergency generators to run at full rated capacity for a continuous 2#6hours period. .dditionally the tank shall be siAed to allow for any additional fuel cooling re;uirements. . calculation sheet shall be provided to confirm storage tank capacity. The diesel storage tank shall be provided with the e;uipment and services listed as follows

-3ternally mounted level gauge with test provision @igh and low level alarms 7note connection to $,"8 9ent to atmosphere /rain valve Dverflow connection /iesel inlet with automatic filling device

The fuel suction filters shall be of the duple3 type with replaceable elements and a changeover facility to permit removal and replacement of either element without need for engine shutdown. Filter mesh siAe shall be specified by the engine manufacture. +rovision shall be made for priming and bleeding the fuel inEection system. Fuel line between inEection pump and inEectors shall be heavy seamless tubing arranged to eliminate irregularity of fuel inEection1 and preferably be of the same length to all cylinders. Fuel lines shall be ade;uately supported and routed to follow the engine contour as closely as possible. L$0rication S(ste+ . pressure lubrication system shall be provided using a gear type1 gear driven lube oil circulation pump. The pump shall be located on the engine crankcase. Dil pressure shall be controlled by a pressure regulator in the pump discharge. The oil filter shall be of the replaceable element type and shall be capable of removing particles 12 microns and larger with a clean pressure drop not e3ceeding (.! barg. The filter shall be of duple3 type with manual changeover facility and shall be e;uipped with relief valves and a differential pressure gauge. +rovide a blow6by gas control for recirculation of vent gases. E.ha$st S(ste+ +rovide the engine e3haust bifurcation piece complete with bellows e3pansion Eoints1 the e3haust silencer complete with a right angled bend transition piece1 integral spark arrester1 spark trap1 specified fittings and stainless steel bellows e3pansion Eoints1 and all interconnecting pipe & ductwork up to the final e3haust termination point on the roof. The e3haust silencer shall be siAed to match the engine re;uirements at 1((5 load. The e3haust system shall be fully insulated for personnel protection. "upport of the complete e3haust system shall be installed.

Atelier Management and Design Consultancy (Vietnam) Co., Ltd

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+rovide pressure drop calculation for actual e3haust pipe. ,a3imum allowable back pressure in the e3haust system shall not be greater than (.(' barg for the total e3haust system. +rovide calculation for pressure drop. Go-ernin& *eneral The engine shall be provided with electronic controlled governors which enable engines to operate continuously at 1'(( r&min from no6load to the ma3imum rated electrical load connected to the alternator. +rovide filters which ensure that harmonics or switching spikes generated by the load do not interfere with the operation of the governor1 overspeed or underspeed cut out devices. *overning accuracy Class .11 of )"D !(#61 +art # *overnor adEustments +rovide adEustment settings for speed droop between ( percent and ' percentB stabilityB ma3imum speedB acceleration rateB and load gain. 6.!.# Dperation General +rovide automatic and manual modes to start and shut down generating. )n automatic mode the generator is to commence operation in the event of power failure and provide power within 2( seconds. 0ote that the generators are re;uired to drive variable speed drives. The generators are to be selected to match the characteristics of these e;uipment. *an$al se3$ence control +rovide controls to manually start and shut6down the generating set. )nclude emergency stop1 meters1 selector switches1 and status indicating lights. A$to+atic start control +rovide for the following :pon receipt of a FstartG signal1 for generating set to start automatically1 come on6line and connect to the load. Connection of alternators. "hut6down of machine. A$to+atic en&ine sh$tdown +rovide for generating set to run to suit the load demand until receipt of the mains FrestoredG signal is received. .t this point the automatic engine shut6down

Atelier Management and Design Consultancy (Vietnam) Co., Ltd

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signal must be activated after an adEustable time delay of ( H !( min. En&ine sh$tdown +rovide a shutdown control system which disconnects the alternator1 and shuts down the engine upon the occurrence of fault conditions1 such that engines cannot be restarted before safety devices have been manually reset and system alarm sensors have returned to the normal stateB the overspeed shutdown acts directly independent of the governorB and to disconnect the fuel supply

the shutdown control system may be reset by the operation of one reset switch1 after safety devices have been manually reset. E+er&enc( and 'a$lt sh$tdown +rovide for the following conditions to register as audible and visible alarms and to cause the generating sets main circuit breaker to open immediately and the generating set to immediately shutdown -mergency stop push6button +ressed. *enerating set Dver voltage. *enerating set protection .ctivated. *enerating set Dver current. -ngine Dverspeed. -ngine oil pressure =ow. Iacket water temperature @igh. A$to+atic s(nchronisin& +rovide synchronising modules which automatically synchronise each incoming alternator supply fre;uency and phase angle to the live busbars1 by the same manufacturer of generator. 6.!.' Control panels General +rovide control panels1 switchgear and controlgear assemblies which accommodate e;uipment operating in parallel and stabilise load sharing between each generating set at all load steps. )nclude reverse power interlock. En&ine local control 0oard +rovide digital microprocessor control with the following Jey operated local engine start&stop control. Controls for auto&off&manual&load test. -mergency manual shutdown. "peed indicator1 kC meter1 fre;uency meter1 ammeter1 kvar meter1 power factor meter1 and hours run meter.

Atelier Management and Design Consultancy (Vietnam) Co., Ltd

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)ndicator showing generating set under local control. Dil pressure indicator. Coolant temperature indicator. :ndervoltage protection delay ( H 1( s. .dEustable down to %(5 rated voltage with time

:nder fre;uency protection with two stages. . . First stage .dEustable #46'( @A with time delay ( H 1( s. "econd stage .dEustable down to #( @A and with instantaneous trip. .utomatic voltage regulator consisting of the following . . "witch to select manual or automatic voltage control. "olid6state type automatic voltage regulator. :nder and overvoltage sensing. +ower transducers. Dver and underspeed sensors. 6.!.6 $atteries and chargers General +rovide separate batteries and charger systems for engine startB and control and alarm functions. Standards -ngine start batteries To TC0 2(K1%>#. $attery chargers To TC0 2(K1%>#. Control and alarm batteries To TC0 2(K1%>#. Control and alar+ 0atteries =ocation "egregate battery and charger e;uipment from generator control e;uipment. Capacity "ufficient to supply full generating set control1 monitoring and alarm functions for a period of #> hours1 and then operate circuit breaker and transfer devices for 1( consecutive open6trip6close cycles with mains supply off and at minimum ambient temperature. Char&ers / control and alar+ 0atteries .larm outputs +rovide the following local audible and visual alarms together with facilities for e3tending them via a common alarm output to a remote location

Atelier Management and Design Consultancy (Vietnam) Co., Ltd SE"S$%-

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,ains off. Dver voltage. Dver current. =ow battery voltage. )nsufficient charge rate. 6.!.4 "tarting Electric startin& *eneral +rovide starter motors1 batteries and chargers1 and associated control e;uipment to automatically start each engine. Ciring Cire starter motors so that starter motor solenoid contacts are on the active side and field windings are at earth potential when the motor is de6 energised. +rovide an interlock1 connected directly to the engine1 to prevent the starter motor operating when the engine is running. "tarting interlock +rovide a starting lock out system which prevents further starting attempts after ! successive unsuccessful attempts. Startin& 0atteries =ocation =ocate in proprietary battery holders attached to the generating set1 or on purpose6built stands ne3t to the set and constructed of timber or other corrosion resistant material. )solate batteries from vibration. Covers +rovide a high6impact resistant transparent cover for each battery. Capacity "ufficient to crank the engine for ! successive attempted starts1 repeated at ' min intervals. )solator +rovide a lockable isolator to prevent accidental starting. Startin& 0atteries char&ers ,ains power Connect chargers to the generating set au3iliary supply so that mains power is maintained when the generator system is in operation. .larm outputs +rovide the following local audible and visual alarms together with facilities for e3tending them via a common alarm output to a remote location ,ains off. Dver voltage. Dver current. =ow battery voltage. )nsufficient charge rate. 6.!.> ,arking Ratin& %lates

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Temperature6rise limits )f temperature6rise limits are achieved by de6rating an oversiAed generator1 state the de6rated value. .lternator mass "tate alternator mass. Ther+istor detector identi'ication and warnin& %lates Thermistors +rovide details of thermistor type classification and reference temperature. Carning +rovide a warning engraved in # mm high lettering as follows FC.R0)0* # $o not appl% more than &'( V across the protection thermistor devicesG. .nti6condensation heater identification and warning =ocate ne3t to heater terminals. "tate the number1 voltage and power rating of the heaters1 and the following separate warning engraved in red letters on a white background FC.R0)0* 6 .nti6condensation heater. Circuit is live when the set is offG. A$.iliar( wirin& +rovide ferrules to wiring ends identifying each conductor. En&ine direction o' rotation *eneral )f driving shafts or associated rotating parts are accessible1 clearly and permanently mark the direction of rotation on an adEacent fi3ed surface. Rotation identification +rovide a label within the supply cable terminal bo3 identifying the relationship between the direction of rotation and the marking of terminals. Char&er enclos$re +arkin&s *eneral +rovide enclosure with main nameplate engraved in 1( mm high letteringB minor nameplates engraved in # mm high lettering to interior and e3terior componentsB manufacturer2s rating platesB and markings to ." #(##. +late material "tainless steel. 6.4 6.#.1 INSTALLATION *eneral *o$ntin& The engine and alternator units are to be mounted in the manufacturer2s factory on a common structural steel frame to support the generating set assembly and the engine local control board. #linths

Atelier Management and Design Consultancy (Vietnam) Co., Ltd SE"S$%&

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+rovide reinforced concrete plinths for floor mounted e;uipment1 siAed to suit e;uipment footprints. Resilient +o$nts +rovide at least 6 resilient mounting blocks between the frame and the plinth. Co$%lin& /irectly couple the engine and generator shafts with a self6aligning type coupling1 capable of transmitting the engine ma3imum output tor;ue under operating conditions1 including starting and overload. Si&ns Carning +rovide the following on each side of each generating set F)A*+,+G- This set ma% start at an% time without notice.G =ettering '( mm high1 red on white background. 5ri% tra(s *eneral +rovide removable drip trays under those parts of the assembly where fuel or lubricant leakage may occur. +rovide overflow outlet pipes taken to a point where a receptacle can be fitted under the pipe outlet. Capacity .t least 1.' times the oil capacity of the engine sump. /rain the drip trays via !2mm copper drain pipes1 through to the basement with a shutoff valve to allow the oil to be dropped into an oil drum there if re;uired E+er&enc( sto% %$sh/0$ttons +rovide 2 push6buttons for the generating set. =ocate one on each side or locate one of the push6buttons in the engine local control board. Type #( mm diameter red1 palm operated type mounted in a metal wall bo3 fi3ed to a free standing F:G channel pedestal. Cire to disconnect the generator and immediately shut down the engine when the controls are in the automatic or manual mode. 2$el connections Fuel piping and associated au3iliary e;uipment "top valves +rovide stop valves on the inlet to1 and outlets from1 the daily service tank. 6.#.2 .coustic enclosures General +rovide weatherproof acoustic enclosures to surround the generating set1 including inlet and outlet sound attenuators by the same manufacturer of generator. So$nd %ress$re le-el li+it >' d$7.8 at 12 locations 1 m from the enclosure e3terior surface1 at 1.' m above

Atelier Management and Design Consultancy (Vietnam) Co., Ltd SE"S$%'

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floor or roof levels1 measured with the generating set operating at constant ma3imum rated full load output1 with doors closed and service penetrations sealed. 5i+ensions "iAe enclosures to accommodate diesel engine inlet and outlet attenuators and permit an unobstructed walkway at least 6(( mm wide between the generating set and internal face of the enclosure. #linths +rovide reinforced concrete plinths siAed to suit footprints of acoustic enclosures1 to serve as the walkway surface. 5oors +rovide doors of same material as the enclosure. +rovide door stays to each door. ,entilation +rovide ventilation to the enclosure so that Cith generating set running at full rated output the enclosure temperature6 rise does not e3ceed 1(oC @aAardous concentrations of to3ic or e3plosive fumes and gases are prevented. Li&hts +rovide internal lighting to !(( lu3. Si&ns Fit the following signs to single doors1 and the left hand leafs of double doors F)ear hearing conservation protection., to AS /0/1' 2)A*+,+G- This machine ma% start at an% time without notice G1 in red lettering on white background. 6.#.! -ngine cooling General *eneral +rovide a cooling system consisting of radiators1 fans and pumps. Cooling air ductwork Connect the cooling air outlet of generator to generator room cooling air outlet. +rovide pressore drop calculation on actual outlet duct. 6.#.# -ngine air intake General +rovide dry type air intake filters of sufficient capacity to permit continuous engine operation for 11((( hours before filter servicing becomes necessary.

Atelier Management and Design Consultancy (Vietnam) Co., Ltd SE"S$%(

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+rovide dirty filter indicators. 6.#.' -3haust system General *eneral +rovide e3haust piping from the engine complete with silencers1 piping1 ductwork1 supports and e3pansion devices. "ilencer Residential type. -3haust piping *rade !21 "tainless steel. $iameter ,atch engine e3haust manifold connection. Connections +rovide flanged connections to silencers and pipe interconnections. 9ibration isolation +rovide a stainless steel fle3ible connection to the engine. -3pansion Eoints +rovide stainless steel e3pansion Eoints in riser. -nsure that e3haust system matches engine configuration1 and that e3haust manifolds combine to a single silencer if necessary to meet noise re;uirements. 1eather%roo'in& +rovide weatherproof flashing1 sleeves and acoustic seals where the e3haust system penetrates the roof or e3ternal walls. E.ha$st draina&e *rade the e3haust line away from the engine to drainage pockets1 or connect to a suitable valved drainage outlet. La&&in& *eneral =ag internal e3haust piping and ductwork with calcium silicate insulation sheathed with Ainc6coated steel sheet. =agging =ag with 2((mm rockwool plus 1(mm calcium silicate board1 sealed with fire rated putty. 6.6 6.'.1 6.'.2 CO*#LETION *eneral "pares +rovide the recommended spare parts for the e;uipment as follows "tart6up1 commissioning and one years operating spares to be purchased with the base e;uipment. +rovide the recommended spare parts list < costs for the e;uipment as follows 2 years operational spares. The spare parts lists shall give all manufacturer2s part numbers in addition to any numbers used by the "upplier. .ll spare parts furnished by the "upplier shall be wrapped and packaged to preserve original as6new condition under conditions of storage. .ll spare parts shall be properly tagged and coded so that later identification as to their intended

Atelier Management and Design Consultancy (Vietnam) Co., Ltd SE"S$%)

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e;uipment usage will be facilitated. .ll items supplied shall be packaged separately and clearly marked as F"pare +artsG and shipped with the e;uipment in accordance with the instructions from +urchaser. +acking lists shall be furnished complete and in detail. 6.'.! Tools . Tool bo3 with all necessary tools for daily check1 routine maintenance shall be supplied. . tool list also need to be submitted for approval. 6.'.# Completion test Acce%tance tests &enerall( Follow re;uirements of manufacturer. Check tightness of connections and securing devices' 9erify correctness of operation of protection devices and systems including sensor settings. "imulate actual conditions as far as possible1 in order to test responses to faults imposed. Cold start with the engine having been at rest for the previous 2# hours1 timed from receipt of mains failure signal to acceptance of full rated load in ! load steps to within the limits of output voltage and fre;uency. Continuous operational trial consisting of . . . # hours at 1((5 rated power. !( min at 4'5 rated power. !( min at '(5 rated power. Record fuel consumption for each step of the continuous trial. "ample engine oil from engine sump before and after tests. +erform laboratory analysis and submit a report on each oil sample. Continuous operational trial /uring the trial1 measure the following at ma3imum intervals of !( minutes . . . . . . *enerator kC and kvar output. *enerator output voltage. *enerator output current. *enerator output fre;uency. +ower factor. Dil pressure and water temperature.

. -lectrical power re;uirements of continuously running electric motor driven ancillaries. . . -ach battery charger current and voltage readings. 0oise level.

Te+%orar( test loads

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+rovide 1((5 resistive load banks for load testing. 2inal tests "ubmit reports from manufacturers or suppliers verifying the performance of safety and control functions of each system. 6.'.' ,aintenance General .llow for servicing during the first year of service or up to 1((( hours1 whichever occurs first1 by the manufacturer. Call o$t Respond to call outs for breakdowns or other faults re;uiring corrective maintenance. .ttend on site within 2# hours of notification. Rectify faults and replace faulty materials and e;uipment Cons$+a0les Replace all oil and air filters after acceptance tests. +rovide all consumables 7filters1 oil1 fuses1 lamps etc8 for the defect liability period. Replace all oil and air filters at the conclusion of the defects liability period.