DC PRO Engineering

SECTION 16232
DIESEL ENGINE GENERATOR

PART 1 - GENERAL
1.1 SUMMARY
A.Section Includes:
Performance.
Engine.
Generator.
Fuel system.
1.2 SYSTEM DESCRIPTION
A complete functioning system with six (6) x 2600 KVA, Water Cooled (HEX) (Continuous duty), 0 %
tolerance, 50 Hz, 1450 RPM, 3,300 Volt generator, and three (3) x 2000 KVA, Radiator Cooled
(Continuous duty), 0 % tolerance, 50 Hz, 1450 RPM, 415 Volt generator, auxiliary controls and starting
equipment, capable of starting and delivering power to connected loads within 10 seconds from instant of
start command or power failure. There will be six (6) 3,300 Volt diesel generators running in parallel.
Synchronization control panels consisting of all required components for synchronization and load sharing
and load shedding shall be provided, installed and commissioned. The remaining three (3) 415 Volt
Generators shall each include a MCCB & Trip unit mounted on the generator for isolation and shall be
connected directly to the basement MCC’s via mechanical/electrical interlocks. Generators shall run on a
designed power factor of 0.94.

REFERENCES
Prime Movers
ISO 3046 (BS 5514) – Specification for reciprocating internal combustion engines, parts 1 to 6.
ISO 8528 – Reciprocating internal combustion engine driven alternating current generating sets, parts
1 to 10.
The engine and its auxiliaries shall be manufactured and/or controlled under a registered quality
control system approved to ISO 9001.
Generators.
IEC 34-1 – Rotating electrical machines.
BS2615 – The Electrical Performance of Rotating Electrical Machinery.
BS 4999 (IEC 341) – General requirements for rotating electrical machines.
BS 5000 (IEC 341) – Rotating electrical machines of particular types or for particular applications.
NEMA MG1: Motors and Generators.
EN 50081 (BS EN 500812) – Electromagnetic compatibility. Generic immunity standard.
EN 50082 (BS EN 500822) – Electromagnetic compatibility. Generic immunity standard.
The generator and its control system shall be manufactured under a registered quality control system
approved to ISO 9001.

1.3 SUBMITTALS
A. Comply with the Tender Invitation for Submittal Procedures.
B. Product Data:
1. Manufacturer's standard catalog sheets for engine generator set with complete listing of accessories
including the following.
a. Dimensioned outline drawings of complete engine generator sets locating connections and
indicating weights.
b. Engine specifications with complete listing of accessories.
c. Certified horsepower, fuel rate, and altitude derating curves at specified continuous rating.
d. Complete description of vibration damping mounts.
e. Alternator (generator) specifications including voltage regulator and exciter specifications.
f. Detailed drawing of oversized radiator.
g. Data to be submitted detailing pressure drop values.

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h.Detailed drawing of load terminal compartment and method of connection.

i.Detailed drawing of control panel identifying devices.
j.Detailed drawing of remote alarm annunciator.
k.Battery and battery charger specifications.
l.Day tank specifications.
m.Silencer specifications.
n.Engine/governor performance including; droop, drift, horsepower, heat rejection, combustion and
cooling air flow rates, and fuel rates.
o. Alternator/regulator performance including; KW, KVA, drift, transient response and volt drop vs
time as per load step sequence.
p. Complete attached data sheet.
2. Project specific shop drawings for this project including:
a. Wiring Diagrams:
1) Complete wiring diagrams for indicator, control, alarm, fuel and battery charging systems.
b. Components and schematic diagrams indicating minimum and maximum values for fuel system,
cooling system, exhaust system, and starting system.
3. Calculations:
a. Motor starting calculations for this project supporting the performance requirements listed herein.
C. Statement of Compliance
1. This specification details specific requirements. The EPC shall provide a detailed point by point list of
exceptions or planned deviations to this specification. Where no deviation is noted, full compliance
with the specification will be expected.
D. Operation & Maintenance Manuals:
1. Product data as previously described
2. Wiring diagrams as previously described
3. Shop drawings as previously described
4. Operating, maintenance and testing information, including preventative maintenance instructions,
replacement parts lists, fuel specifications, lubricating oil and grease specifications, and literature
describing the function of the unit and each piece of accessory equipment. Name and address of
factory authorized service organization.
E. Test Reports:
1. Source Quality Control submittals as specified in Part 2 of the Section.
2. Field Quality Control submittals as specified in Part 3 of this Section.
3. Complete detail information of Hazardous Air Pollutants (HAP's) and Volatile Organic Chemicals
(VOC's) emitted by engine as required for registration and permits.
F. Manufacturer's Warranty:
1. Certificate as further described below.
G. Personnel Operating Instructions:
1. Letter report identifying personnel attending and date of completion.
H. Owner's Stock:
1. Letter report identifying materials, quantities, date of delivery and Owner's representative receiving.
1.4 DELIVERY, STORAGE, AND HANDLING
A. Deliver products in their original packaging with legible manufacturer's identification.
B. Store materials in accordance with manufacturer's recommendations.
1.5 QUALITY ASSURANCE
A.The factory authorized and certified distributor (agency or firm) shall observe the installation of the
system, until its acceptance by the Owner, and perform certain other services and meet certain other
qualifications, indicated. The factory authorized distributor shall be located within 160 km of the site.
B.The distributor shall show evidence of his factory certification of qualifications, to perform the services
here indicated, in the form of a factory "Certificate of Factory Training in Power Generation".
C.The distributor shall test the system and instruct the Owner's personnel in its use as described under
FIELD QUALITY CONTROL and DEMONSTRATIONS.

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D.A factory authorized Maintenance Agency shall specifically warranty maintenance of the system, as
described under SPECIAL WARRANTIES.
E.A factory authorized Maintenance Agency shall regularly stock replacement parts for this system over
the life expectancy of the equipment.
F.A factory authorized Maintenance Agency shall be located within 320km of the site and shall, during the
warranty period, start non-scheduled maintenance services by no later than noon of the day following a
request for such services.
1.6 WARRANTY
A.Special Warranty
B.Provide warranty service for work specified in the Tender Invitation. The warranty period shall be 24
months from the date of commissioning and acceptance by the Owner, following installation completion
and a successful demonstration of the system performance to the Owner. Warranty service shall include
all material, labor, travel and living expenses for the replacement of parts found defective due to defective
material or workmanship and the correction of developing defects due to faulty design or installation.
C.Provide emergency services as often as needed on a 24 hour basis including weekends and legal
holidays. Such service shall respond to an emergency situation within four hours of notification. Provide a
24 hour telephone number including weekends and legal holidays. Calls shall be handled immediately by
personnel who are full time employees of the service company.
D.Problems encountered and solutions applied shall be documented and turned over to the Owner within
30 days of each service call.
E.Provide certification from engine generator system manufacturer that the final installation is proper and
in no way voids equipment warranty.
F.The Extended Service Warranty, as referred to in the unit prices, shall provide full coverage for major
repairs/replacement of unit, provided the manufacturers required maintenance has been performed as
recommended.
1.7 MAINTENANCE
A.Maintenance Service
1. Provide maintenance service for work specified in this Section for one year beginning on the day
mutually agreed to by the Owner and the contractor following completion of a successful
demonstration and acceptance of the system to the Owner.
2. Perform on-site maintenance when necessary and requested by the Owner, including not less than
two (2) scheduled service calls at approximate six (6) month intervals, without additional cost to the
Owner. Service calls shall include system inspections and testing with written reports to the Owner.
3. Maintenance tests performed, and routine maintenance accomplished shall be documented and
turned over to the Owner within thirty (30) calendar days of each service call.
4. Provide sixteen (16) spare oil filters, two spare air filters and sixteen (16) spare fuel filters of each
size.

PART 2 - PRODUCTS
2.1 MANUFACTURERS
A.Acceptable Manufacturers: Caterpillar; Cummins, MTU (Germany).
B.Certain products may be identified by manufacturer and/or model, in the following paragraphs.
C.Supplying distributor must have permanent stock and parts facility within 160 km of the site.
2.2 ENGINE GENERATOR - PERFORMANCE
A.The unit is to be continuous rated at 3-phase, 3-wire, 50Hz, for operation at not less than 0.94 power
factor. The capacity of the unit shall be sufficient to provide the minimum performance values described
below. Submit factory calculations supporting the selected unit rating.
1. Unit performance values shall be met with the inclusion of specified or required unit modifications, at
project altitude and at 50 degrees C radiator inlet and combustion air temperature.
2. The unit is to support process loading requirements as per loading steps.

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B.Under steady state conditions, output frequency shall be maintained within plus or minus 0.5 percent
(1.0 percent total) of nominal between no load and full specified load (droop) and within plus or minus 0.25
percent (0.5 percent total) of nominal at any given load (drift).
C.Under steady state conditions, output voltage shall be maintained within plus or minus 1.0 percent (2.0
percent total) of nominal between no load and full specified load (droop) and within plus or minus .5
percent (1.0 percent total) of nominal at any given load (drift).
D.Upon the single step assumption or volt drop of either the chiller load or any other process loading step,
the unit shall limit the instantaneous voltage drop to a maximum of 15 percent of nominal and shall
recover its specified droop within 24 cycles (0.4 seconds).
E.The permanent magnet excitation system shall derive excitation current from a pilot exciter mounted on
the rotor shaft. It shall enable the generator to sustain 300 percent of rated current for ten seconds during
a fault condition.
F.Construction and performance of engine generator set to comply with requirements of NFPA 110.

2.3 ENGINE
A.Engine: Water cooled for the 3.3 KV and radiator cooled for 0.415 KV engine, 1500 RPM, four cycle
diesel (two cycle is not acceptable), using commercial grade diesel fuel, mounted on a welded structural
steel base with its radiator and alternator, forming a semi-portable unit.
B.Governor: Solid state Isochronous type with adjustable droop factory-set regulating frequency to 50 Hz
plus 1/2 Hz at steady state load conditions from full load to no load generator output, with frequency at
constant load remaining within steady state bandwidth of ±0.25 percent of rated frequency and with
frequency modulation less than 1 cycle per second, and shall include load sharing as well as load
shedding features
1.Acceptable manufacturers:
a.Woodward or equal.
C.Sensors monitoring lube oil pressure; high coolant temperature, and low coolant temperature.
D.Two-Stage Safety Switches: Automatic resetting, controlled by low lube oil pressure, high engine
coolant temperature, and to work with automatic control system. First stage to provide "Pre-Shutdown"
signal.
E.Lubrication System: With gear driven oil pump, full flow replaceable element oil filter(s). Provide a
duplex oil filter system with transfer device to allow replacement of an oil filter without an engine shut
down and shall include an external electric Pre-Lube auxiliary oil pump with TEFC motor.
F.Air Cleaner: Heavy duty dry type suitable for use in extreme dust conditions.
G.Coolant Pump: Engine mounted, gear or belt driven.
H.Terminal blocks for wiring connections made to engine mounted devices.
I.Water jacket heater.
2.4 ALTERNATOR
A.Alternator shall be a rated for continuous duty @ 2600KVA (3,3KV) & 2000KVA (415V), 1500 RPM, 50
Hz and capable of running at 0.94 power factor.
B.A minimum Class "H" insulation system. Temperature rise to be rated for Class F. Alternator shall be
suitable for continuous operation at ambient temperatures of 50°C.
C.Exciter: Brushless type with rotating rectifier bridge. The exciter shall develop its own power for
excitation and be isolated from harmonic distortions and irregularities on the generator output.
D.Voltage Regulator: Solid-state, volts-per-hertz type with screwdriver operated voltage adjustment, cross
current compensation and internal protection against excessive field currents and alternator output
voltage;
E.Waveform Quality: Not exceeding NEMA values for telephone influence factor (TIF) and with a
waveform deviation factor less than ten percent line to line.

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F.Generator Terminals: Clearly identified and housed in a separate terminal compartment.

G.Generator shall be rated to serve up to 60 percent non-linear loads based on its stand-by rating.
H.Space heaters to be included.
I.RTD’s, x2 RTD’s per winding phase to be installed. x1 bearing RTD to be installed.
2.5 CONTROL PANEL
A.Enclosure: Dust proof NEMA 4X or IP 56 as a minimum of the manufacturer's standard design and; if
generator mounted, with control components and devices suitable for the vibrations encountered,
continuous operation at ambient temperatures of 122°F or 50°C and equipped with:
1. AC ammeter with scale indicating generator full load current, required current transformers, minimum
3" meter size; 1 percent of full scale meter accuracy (digital type meters with ½ percent accuracy are
acceptable).
2. Ammeter phase selector switch; four positions; OFF, A, B, and C phases.
3. AC voltmeter with scale indicating generator line-to-line voltage; minimum 3" meter size; 1 percent of
full scale meter accuracy (digital type meters with ½ percent accuracy are acceptable).
4. Voltmeter phase selector switch; four positions; OFF, A-B, B-C, and C-A phases.
5. Frequency meter indicating 57-63 Hertz.
6. Running time meter indicating 0 to 9999.9 hours.
7. Gauges indicating engine lube oil pressure and engine coolant temperature.
8. Separate Alarm Indicating Pilot Lamps for low lube oil pressure (shutdown and pre-shutdown), high
coolant temperature (shutdown and pre-shutdown), engine overspeed, engine overcrank, low coolant
temperature (below 20 degrees C), fuel tank high or low level, high or low battery voltage and unit
selector switch in OFF or RUN positions.
9. Common Remote Audible Alarm: Battery powered bell / horn to sound continuously when any alarm
sensor trips. Install this bell in the operations room as directed by the Owner. Separate form C
contacts for two remote group alarm indications; UNIT TROUBLE (high and low coolant temperature
and low oil pressure pre-alarm's, high and low fuel level, high and low battery voltage and starting
control selector in OFF or RUN position); and UNIT FAIL (high coolant temperature, low oil pressure,
overspeed, and overcrank shutdown).
10. Automatic Engine Shutdown: Low lube oil pressure, high coolant temperature, overcrank and
overspeed cause shutdown and prevent engine start-up until manual reset is activated. Shutdown to
operate fuel shut-off, and move governor to no-fuel position.
11. Automatic starting control system, described below.
12. Terminal strips for wiring connections in panel with conductors identified.
B. Load sharing and Load Shedding; All six (6) 3,3KV generators shall be equipped with a fully functional
load sharing and load shedding unit. Together with the synchronization unit, all six (6) 3,3KV generators
shall be able to synchronize and perform load shedding/sharing when connected in parallel.
2.6 STARTING SYSTEM
A.Storage Battery: 24 volt DC, lead-acid heavy duty station type with 15 to 20 year life expectancy,
mounted in an acid resistant, seismic rated rack with power capacity necessary to successfully complete
testing indicated but not less than the power required to provide a minimum of 4 sequential 30 second
each cranking operations while driving accessory equipment. Varta bloc type, no substitute.
B.Battery Charger: Automatic float type, internally protected from engine starting surge, with charge rate
capable of recharging batteries within 24 hours after 60 seconds of continuous cranking; charge rate
ammeter and voltage relays to alarm high and low battery voltage.
1. Provide fused battery connections.
2. Provide battery charger indication ‘Healthy’ or ‘Faulty’.
C.Automatic Starting Controls: With relays enclosed in a dust tight housing or with individual dust tight
covers; key-operated selector switch with positions marked "Run-Off-Automatic"; contacts for remote
"overcrank" alarm indication; adjustable timer limiting each automatic cranking cycle to 30 seconds crank
with 10 seconds rest; after four (4) cranking cycles starting system locks out, indicates "Overcrank" and
must be manually reset.
1. With selector switch in auto and pilot starting contacts in auto transfer switch closed, engine starts
automatically and runs continuously until start contacts open unless engine is shutdown by safety
devices.

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2.7 REMOTE ANNUNCIATOR

A.Power from control panel with audible and visual signals as listed on engine generator set control panel;
an additional visual only signal indicating engine generator set carrying load; a labeled alarm silence
switch, and a labeled lamp-test pushbutton, sense engine generator carrying a load condition using a
relay connection to the load terminal of engine generator main circuit breaker. Locate this annunciator in
the control room , or as directed by the Owner.
2.8 FUEL SYSTEM
A. Fuel storage tanks, piping and accessories as needed
B. Solenoid Valves: Direct acting valves not using hydraulic line pressure to close valve seat.
C. Day Tanks: one day tank to be provided by manufacturer to cater for all generators with sufficient
capacity to run each generator set at full load for not less than 6 hours, and equipped with required fittings,
valves, piping, and float switches.
1.Double wall containment.
2.Supplied with radiator fan for return fuel cooling.
3.Comply with UL 142.
4.Float switch to activate for high level alarm and low level alarm.
5.Float switch to control fuel transfer pump.
6.Wall mounting brackets or floor stand as required.
D. Bulk Storage tank: outside vertical mounted storage tank shall be provided by engine supplier to cater
for all generators with sufficient capacity to run each generator set at full load for not less than 72 hours (3
days), and equipped with required fittings, valves, piping, and float switches.
1.Comply with UL 142.
2.Float switch to activate for high level alarm and low level alarm.
3.Float switch to control fuel transfer pump.
4.Wall mounting brackets or floor stand as required.
E. Tank control:
1.On/Off/Emergency run switch.
2.Test/Reset switch.
3.Indicator lamps and shutdowns.
a.Power available.
b.High fuel alarm and shutdown.
c.Low fuel alarm.
d.Low fuel shutdown.
e.Overflow to basin alarm and shutdown.
f.Pump running.
4.Provide manual pump in the event of the motorized pump been faulty.
F.Provide manual pump in the event of the motorized pump been faulty.
G. Provide main fuel storage tank, fuel oil pump, piping and certain accessories, i.e. leak detection
system.
2.9 COOLING SYSTEM
A.All 3.3 KV generators shall be water cooled type with cooling towers entering & leaving water
temperatures of 42 Deg. C & 43 Deg. C respectively. expansion tank, and flange for direct duct
connection. All 0.415 KV generators shall be radiator cooled with radiator capacity sufficient to provide the
engine cooling and heat dissipation from the engine-generator to atmosphere at 8 Deg. C temperature
rise. The engine cooling water system shall consist of three separate circuits:
1. One flat plate heat exchanger circuit cools the lubricating oil, jacket water and after cooler using cooling
tower water.
2. One Totally Enclosed Air Water Cooled (TEWAC) heat exchanger cools the generator using cooling
tower water.

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B. A thermostatic bypass valve shall provide fast warm up and maintain engine operating temperature.
Coolant temperature shall be internally regulated to disconnect external cooling systems until
operating temperature is achieved. The generator cooling shall be controlled by a separate control
valve system.
C. Coolant shall consist of clean water/glycol solution with a rust inhibitor.
D. Redundant jacket water heater(s) in different water circuits shall be provided to work with the
thermostatic bypass to maintain coolant temperature of 86 degrees F (min.) while the engine is off. An
electric immersion heater (230VAC volt, single phase rated) and thermostatic control shall maintain the
coolant in the engine jacket at not less than 30 degrees C.
E. Isolation valves shall be installed on both sides of the heater element to facilitate servicing.
F. Heat exchangers shall be provided with temperature, pressure gauges, service valves, at both the inlet
and outlet connections, vent and drain connections.
2.10 EXHAUST SYSTEM
A.Silencer: Designed for "Residential" silencing with drain fitting at outlet end and bolted flange
connections at inlets and outlets. Silencer to have side inlet and opposite end vertical outlet except as
detailed. Maxim, Nelson, or approved equal.
B.Flexible Connection: Stainless steel, flexible, seamless pipe(s), with mechanical connections for
attachment to exhaust manifold and silencer.
Installation of the exhaust piping, flexible connection, flashing, and silencer. Provide a stainless steel
roof/wall thimble for the exhaust pipe.

2.11 ENGINE-GENERATOR ROOM VENTILATION

A Air circulation requirements for room ventilation will be roof centrifugal fans that will operate when the
engine starts.
B. The air filtration system shall comprise of 50 mm thick cleanable Aluminum filters in sturdy aluminum
frames, having an arrestance of no less than 70% based on ASHRAE 52-76. The filter elements shall be
supported by rigid heavy duty holding frames of galvanized steel, and held in place by quick release fixed
fasteners.
2.12 EMERGENCY OFF SWITCH
A.Provide a key lockable ‘mushroom’ type switch and connection to the control panel to shut down engine
when actuated, manual reset.
2.13 SOURCE QUALITY CONTROL
A.Tests: Test engine generator set under rated load and 0.94 power factor utilizing reactive load banks.

PART 3 - EXECUTION
3.1 EXAMINATION
A.Examine areas and conditions under which Work is to be performed and identify conditions detrimental
to proper or timely completion. Do not proceed until unsatisfactory conditions have been corrected.
3.2 INSTALLATION - GENERAL
A.Verify concrete base is provided in compliance with Division 3.
B.Comply with manufacturer's recommendations.

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C.Install engine generator systems indicated with necessary equipment, support and control systems, and
building construction features (e.g., concrete pads). Dimensions indicated are limiting dimensions for
project and must be verified with actual equipment used. Equipment with dimensions or weights
exceeding those indicated may only be used if approved and related additional costs borne by Contractor.
Equipment requiring additional mechanical services (e.g., exhaust, cooling air or liquid) or electrical
services (e.g., suppression filters, circuit wiring or over current protection) may only be used if approved
and related additional costs borne by Contractor.
D.Ground non-current carrying conductive parts of engine generator sets to main service ground via
conduit raceway systems unless indicated otherwise. Bonding generator neutrals to generator housings
is not acceptable
E.Verify that generator phase sequence matches system phase sequence and correct if necessary.
F.Install storage batteries in racks with required cables to engine and to battery charger.
1. Anchor battery rack to floor.
2. Wall mount battery charger adjacent to engine generator set.
G.Install fuel tank assembly per manufacturer's recommendations and at height recommended by
generator manufacturer.
1. Anchor fuel tank assembly to floor.
2. Do NOT support fuel tank from generator assembly.
H.Coordinate the installation of fuel and exhaust lines, including flex connectors and exhaust silencer, fuel
tank fill and vent lines and radiator discharge duct.
I.Connect unit control wiring. Identify wires to match manufacturer's designations.
1. Identify wires using conductor color coding and Brady (or other) numbered identification tape with
identification corresponding to wiring schematic submitted with Shop Drawings.
2. Connect battery charger alarms to unit control panel to indicate high and low battery voltage.
3. Connect fuel tank float switches to unit control panel, to indicate high and low fuel levels, and to the
fuel oil pump controls.
4. Install and connect remote audible alarm where shown.
5. Interconnect engine start, load bank shunt trip and transfer controls between the engine control panel
and each of the transfer switches and the fire pump controller.
6. Extend auxiliary control power circuit to location shown. Auxiliary control devices and wiring are
described in Plant Controls.
7. Connect emergency off switch into control panel.
8. Interconnect the inlet solenoid and safety valves to operate when float switch is actuated.
Interconnect the high level float switch to close safety valve when actuated and open when level
drops.
J.Coordinate connection of auxiliary devices, remote monitoring and fuel transfer pump control as
described in Plant Controls.
K.Field adjust voltage regulator and governor, and tune engine at site for optimum system performance.
Verify lubricating oil, engine coolant, and storage battery cells are full. Fill as required.
3.3 FUEL SYSTEM
A.Day Tank:
1. Install plumb using shims and bolt to floor with using concrete inserts.
2. Install level switches per manufacturer’s recommendations and adjust switch actions for the specified
elevations above the floor.
3. Provide temporary drain piping between day tank drain and overflow.
4. Simulate actual operating conditions to prove proper operation of controls.
B.Make electrical connections under this Division, including pumps and starters, float switches, solenoid
valves, etc.
1. Solenoid valves: Make electrical connections under this Division and control as recommended by
engine generator set suppliers.
2. Day tank: Make electrical connections to float switches.
3. Fuel transfer pump: Make electrical connections and control with float switches in day tank.
4. Storage tank: Connect low supply alarm float switch to control panel.

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3.4 COOLING SYSTEM

A.Connect engine jacket immersion heater to a 240 volt, 2 pole dedicated normal circuit.
B.Coordinate plenum connection from radiator to exhaust louver opening and damper installation.
3.5 EXHAUST SYSTEM
A.Lightning Protection: Clamp #3/0 bare copper wire to exhaust pipe near silencer and route it to two 5/8
inch by 10 foot ground rods located as indicated.

3.6 ENGINE GENERATOR FACTORY TESTING

A.Provide for factory tests performed on the actual generator sets to be supplied.
B.Factory test procedures shall include the following:
1. Generator sets to be warmed up at synchronous speed with .94 PF electrical load.
2. Final high idle speed adjustment, voltage level adjustments and voltage gain adjustments to be made.
3. After adjustments, calculate and/or record the following during the factory load test:
4. Generator set speed.
5. Frequency.
6. Power measurements.
7. All line to line voltages.
8. Average voltage.
9. All (3) line currents.
10. Frequency stability.
11. Voltage stability.
12. Overshoot.
13. Generator efficiency at test speed and .80 PF.
14. Fuel density.
15. Inlet air temperature.
16. Inlet air pressure.
17. Inlet air restriction.
18. Fuel temperature.
19. Injection pump housing.
20. Total running time.
C.Subject each engine generator set to a sequence of loading to 100% load in four equal steps of 25%
load, to determine the transient response characteristics as follows:
1. Voltage dip: Fifteen (15) Percent of instantaneous voltage drop on addition of load to the generator
set.
2. Voltage overshoot: Five (5) Percent of instantaneous voltage rise on subtraction of load from the
generator set.
3. Frequency dip: Five (5) Percent of instantaneous frequency drop on addition of load to the generator
set.
4. Frequency overshoot: Five (5) Percent or instantaneous frequency rise on subtraction or load from
the generator set.
5. Recovery time: Twenty (20) seconds Time necessary for the generator set to achieve its steady state
voltage and frequency after sudden additions or subtraction's of load.
D.Performance:
1. The complete engine generator train shall be tested at the factory to full load. Full load generating
capacity, fuel consumption and efficiencies shall be recorded. Appropriate correction factors shall be
applied to demonstrate performance at site conditions.
2. The minimum acceptable net electric generating capacity at site conditions (after deducting consumed
power for engine auxiliaries as oil pumps and coolant circulating pumps), shall not be less than 2444
KW (3,3KV @ 2,600KVA 0.94 pf) & 1880KW (415V @ 2000KVA 0,94 pf) .
3. A penalty of US $ 500.00 per KW will apply for any deficit below 2444 KW (3,3KV @ 2,600KVA 0.94
pf) & 1880KW (415V @ 2000KVA 0,94 pf) .
4. KW capacity at site conditions.

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5. The minimum electric and overall efficiency acceptable shall not be less than 37,5 %. This efficiency
based on the net electric power output and low heating value of diesel fuel energy equivalent
consumed when engine operates at site conditions.
6. A penalty clause of US $ 30,000 will apply for every 1 % deficit in the efficiency for the generator
continuous 2444 KW (3,3KV @ 2,600KVA 0.94 pf) & 1880KW (415V @ 2000KVA 0,94 pf) ratings.
7. The above stated values shall be guaranteed by the engine manufacturer through testing at 0 %
tolerance.
E.Test reports: Upon completion of the standard test procedures, submit three sets certified test report
demonstrating compliance to these test procedures with all data recorded as required. In addition, an oil
sample will be taken during the test at full and partial load, thereafter analyzed for signs of unusual wear.
All testing shall be performed on the actual serial number generator sets assigned for delivery to the job
site for this project.
3.7 FIELD QUALITY CONTROL
A.Refer to General Requirements for responsibilities of Field Quality Control Requirements.
B.Coordinate testing date with Owner and Architect to determine date acceptable to all. Provide for engine
generator set manufacturer's authorized personnel to operate equipment during this testing and to verify
details of the installation.
C.Before start-up and loading of the unit, check and correct the following:
1. Alignment of engine and generator shafts.
2. Adjustments of voltage regulator and governor.
3. Fluid levels for lubricating oil, engine coolant, and storage battery cells.
4. Match of generator phase sequence with the main distribution system.
D.After all equipment has been installed at the job site, and after all pre-start checks and procedures have
been completed, a full system test shall be performed to demonstrate operational capability. This shall
include the following:
1. Paralleling of all generator sets on their associated bus segments to demonstrate load sharing and
generator set capacity for a minimum of 6 hours at rated load. After all bus segments have been
tested, the tie breakers (if applicable) will be closed and the segments shall be connected and tested
with full load. At this point all operational modes of the generator switchgear shall be demonstrated.
Load shall be provided by the Plant load or by the use of load banks for a minimum of one week
during mode of operation testing. Provide cabling for load banks as required.
2. During the field operation and load test the appropriate data and information will be documented as
noted below:
a. Upon completion of field testing, the dealer shall submit (5) copies of certification of installation
and testing in compliance with the specifications and manufacturer's guidelines.
E.Field test each engine generator set after final installation and under the total specified steady-state
load. Building loads normally connected to the system, temporary connections to other utility building
loads or portable load banks shall be used to bring the total test load on the engine generator set to its
design value for not less than four hours, or longer as required, to verify the stability of operation of
components in the system. Do not begin test until engine generator set has been inoperative for at least
24 hours and verify the ten second start time in the preheated condition.
1. Record volts and amperes on each phase, hertz, room temperature (two locations), and engine
operating temperature and oil pressure every 15 minutes during test run.
2. Demonstrate the proper operation of all indicators, instruments, devices and system functions for the
equipment specified. Coordinate this work with the installing contractor. Make all corrections required
to achieve proper equipment operation.
F.After successful completion of each unit's steady-state load test, perform two successful tests: one "test
without load" and one "test with load" both of which will require synchronizing (with other Generators).
Record seconds to synchronization of each unit, volts amps, and hertz. Each test shall be no shorter than
30 minutes in duration. Demonstrate load sharing capability.
G.After successful completion of system testing under parallel operation (with other Generators), test the
entire system by simulating a peak-shaving start. Record the synchronization times, volts, amps, and
hertz on each unit. Each test shall be no shorter than 20 minutes in duration.

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H.With the engine at standby temperature, perform a battery test consisting of four (4) cranking cycles of
twenty seconds "on" and ten seconds "off" with engine fuel system disabled. Verify battery storage
capacity is adequate for 4 cycles of 30 second minimum cranking.
I. Repeat until satisfactory conclusion.
1. Replace batteries if they do not recharge to full value after test.
J.In addition, provide and verify the following load tests, namely
1. Bring three (3) generators to running speed in order to start one (1) chiller pair.
2. Bring six (6) generators to running speed in order to start the third (3) chiller pair. This test shall be
done while chiller pairs 1 & 2 are running 100%.
3. Bring all six (6) generators to running speed in order to start the four (4) chiller pairs.
Chiller loads might need to be reduced in order to successfully complete this test. Once initial starting
conditions have passed, chillers can be loaded once again.

Upon completion of the tests, a general inspection shall be made for leaks in the engine, piping, etc.
Remove a minimum of two oil filters and oil (within filter assembly) and examine for metal and abrasive
foreign particles. Oil analysis shall be completed by an independent test lab. If such particles are found,
supplier shall change oil and filters and run engine under load for a period of eight additional hours. Re-
examine oil and filter as specified above, and make all corrective measures as required until oil remains
free of such contaminants. Engine oil analysis shall be completed again one month prior to end of first
year warranty.
K.Provide or replace all fuel and oil used in testing.
L.Submit test results to Owner and Engineer.
3.8 DEMONSTRATION
A.The dealer shall provide five sets of the following documentation (at least 2 weeks prior to scheduled
Owner training):
1. Engine operation manual:
a. Service manual.
b. Spare parts books.
c. Generator operation and maintenance manual.
d. Copy of approved submittals including catalog cut sheets on all components.
e. As-built engine generator set drawings.
f. As-built control system schematics and wiring diagrams.
g. Warranty statement.
B.The dealer shall provide training to provide operating personnel with operational knowledge and
complete preventative maintenance capability of the system. This shall include, as a minimum, one week
classroom job site training by factory certified instructors and switchgear manufacturer's engineers. Topics
to be addressed shall include:
1. System operation in all modes.
2. Individual component operation and maintenance.
3. System preventative maintenance procedures.
4. Component preventative maintenance procedures.
5. System test procedures.
6. Component test procedures.
7. Reading of control schematics and trouble shooting.
C.Training shall be held at the job site and classroom training at the local dealer's facilities. During the first
year of operation, the dealer and a representative of the switchgear manufacturer shall return to perform
follow-up training at the convenience of operating personnel.
D.Demonstrate actual starting of chiller, as previously described, and record all data. Testing and starting
of chiller shall be accomplished after chillers, pumps, fans, etc. are installed and fully operational. The
chiller starting tests shall be completed after, and separate from, the engine generator paralleling tests as
previously discussed.
E.Demonstrate operation and maintenance procedures to Owner.

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3.9 OWNER’S STOCK

A.Provide all special tools and appliances necessary for routine maintenance and minor repairs.
B.Provide all special maintenance materials and tools required for the Top End and Major Overall
procedures. Also provide a complete listing of materials recommended to be stored on site for
intermediate maintenance. List item pricing as a separate line item.
C.Provide all special maintenance materials as previously mentioned above.
D.Provide one hydrometer with a scale divided into two point increments suitable for batteries specified on
this project..
E.Provide wall hung maintenance cabinet with lockable hinged cover and large enough to contain all the
parts and accessories as previously specified and required including maintenance manuals.
3.10 MAINTENANCE
A.Perform maintenance for engine generator units as described above.
3.11 DELIVERY.
Delivery of equipment and materials shall include the cost of freight and handling from the manufacturer’s
plant to the job site. All rigging and unloading shall be by the contractor

END OF SECTION

Al Sowwah Island Specifications Diesel Engine Generator

Concept Design 16232- Page 12 of 12 February 2010