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TECHNICAL SPECIFICATIONS FOR 150KVA STANDBY DIESEL GENERATOR

SET FOR RAROTONGA HOSPITAL

PREAMBLE:

The scope of work includes the supply and installation of 1x 150kVA Diesel Generator
(DG) set mounted inside the Rarotonga Hospital’s existing generator building and
associated works. The outgoing cables shall be sized to suit the DG output.

1.0 GENERAL
This specification covers the turnkey installation of 1 x 150kVA standby diesel
generating system covering the diesel engine, alternator, engine control panel,
associated accessories, cooling system, ventilation system, fuel and exhaust
system, acoustic enclosure and switchgear etc.

The contractor shall assume full responsibility of co-ordinating the work with
various sub-vendors and other contracting agencies at site and execute the
work to the total satisfaction of the clients and statutory agencies.

2.0 SITE CONDITIONS:


Temperature : Maximum 35 deg C
Minimum 15 deg C
Humidity : 60-100%
Rainfall : 2000mm per annum
Altitude : 300ft AMSL

3.0 ELECTRICAL SUPPLY SPECIFICATIONS

Nominal voltage : 415V + 6%


No. of Phases : 3 + Neutral
Frequency : 50Hz + 2.5%
Neutral earthing : Solidly Grounded
Control supply : 24V, 2-wire DC

4.0 SCOPE OF WORK & EXCLUSIONS


4.1 The scope of work shall include but not be limited to the supply, installation,
testing and commissioning of the following items. The supplier shall study the
requirements stipulated in the specification and also to suit the site conditions
and offer a complete system with guaranteed performance under the severest
operating conditions specified.

a. 1 off 415V, 3-phase + Neutral, 150kVA 1500 RPM, DG set with accessories
as specified.
b. Set mounted microprocessor based engine control panel.

c. Radiator cooling system.

d. Exhaust piping including supports.

e. Thermal insulation for exhaust piping.

f. Exhaust stacks with steel supporting system.

g. Preparation of related schematic and GA drawings for DG installation,


exhaust piping, ventilation system, etc.

h. Co-ordination with Ministry of Health (MOH) to ensure timely completion.

i. Obtaining Diesel Engine manufacturer’s approval of the installation with


specific emphasis on alignment, exhaust & fuel piping and ventilation before
commissioning.

j. Testing and commissioning of the installation.

k. House keeping during the installation work and removal of debris and
unwanted materials on a day to day basis and clearing the site on
completion.

l. Any related work covering supply of installation materials, consumables, etc.


whether specified or not, to render the system fully functional and
conforming to the best engineering standards. This shall include battery
charging.

m. The winning tenderer shall work with the MOH personnel in all civil
construction works for making the foundation for DG set including other
works as required.

5.0 DIESEL ENGINE & ACCESSORIES

5.1 ENGINE

a. The diesel engines shall be of approved make, direct injection, four


stroke, multi cylinder, water cooled radiator type, turbo charged,
operating at a nominal speed of 1500 R.P.M and capable of developing
requisite Brake Horse Power (BHP).

b. The engine and the governing system shall be suitable for standby and
Automatic Mains Failure (AMF) duty power generating application and
shall conform to BS5514 / ISO3046. The unit shall be suitable for
operation on high speed diesel oil available in the Cook Islands.

c. The engine shall be electric start and shall be suitable for battery assisted
manual / auto starting.

d. The governing system of the engine shall be electronic type and suitable
to control frequency variation within + 2.5% whenever a load of 100 -
150kW is switched in or thrown off.
e. The engine fittings shall include but not be limited to the following:

i) Closed coupling and flywheel with guard.

ii) Dry type air filter with clogged condition indicator.

iii) Cooling radiator.

iv) Fuel pump.

v) Electronic governor.

vi) Dual fuel filter with online filter changing provision.

vii) Lube oil pump, oil cooler and filter.

viii) Turbo charger.

ix) 24V DC starter & battery charging alternator.

x) Engine mounted microprocessor based control panel to display the


following minimum engine and electrical parameters:

a. Lube oil pressure indicator and temperature gauge.

b. Tacho meter for speed indication with hour meter.

c. Battery charging Ammeter.

d. Starting switch with key.

e. Over speed stop switch with contacts.

f. Low lube oil pressure switch.

g. High water temperature alarm & trip

xi) Wiring harness using temperature resistant insulation and flexible


copper conductor wires. The wiring should be clamped at regular
intervals and terminated using lugs and terminals.

xii) Stainless steel flexible for engine exhaust.

xiii) Stop solenoid.

f. The engine speed shall be regulated through an electronic governing


system which shall also provide the overspeed protection. The governor
shall ensure that the speed of the set is regulated within 1% of the
nominal speed under normal operating conditions.

h. The DG set shall be capable of handling step load up to 70% of the


capacity without dropping other loads due to voltage dips. Further the
engine shall be capable of taking full load within 10 seconds of starting.
i. All moving parts of the engine and other associated equipment shall be
provided with guards to prevent accidental contact. The guard shall be
designed to facilitate easy removal and reinstallation.

j. The engine supplied with first filling of oil of required quantity as


recommended by the manufacturer.

5.2 ACCESSORIES

The following accessories shall be supplied with the DG set.

a. Common base frame for the engine and alternator.

b. Antivibration mounts of requisite capacity.

c. Residential silencer.

d. Protective guards for all rotating parts.

e. Electric driven lube oil priming pump complete with hosepipes and
couplers.

f. Diesel tank with capacity to last 12 hours on 100% load. Capacity


fabricated out of 1.5-3mm thick sheet steel including first filling of
diesel. The tank shall be further complete with overflow pipe, drain pipe,
fuel level indicator, valves, low level contact and alarm.

g. Galvanized sheet steel trays beneath the engine and day tank to collect
the leakage oil.

h. Batteries

The batteries shall be of heavy duty, high performance lead acid type of
Exide make or equivalent. Each battery shall be rated 24V. The number
and AH capacity shall be selected to suit the engine requirements.

Battery shall be suitable for six successive starting attempts each of 10


seconds duration with a gap of 5 seconds between successive starts.

The battery shall be supplied complete with electrolyte and accessories.


The accessories shall include battery stand, battery leads with terminal
ends acrylic top cover and inter battery connectors.

The charger shall allow the battery to be charged when the set is not
running. The charger shall get disconnected from the mains when the
generator set is running.

i. Control Panel

The DG shall be supplied with an engine mounted Microprocessor based


control panel. The control panel shall display all the engine, alternator &
battery parameters. It shall not only display faults but also keep a
record of faults. An emergency stop push button will be provided to stop
the DG during emergency. For Engine faults, the set will be stopped in
emergency mode & for electrical faults it shall be stopped with a time
delay for cooling down. An audible alarm shall be provided in the main
panel to announce tripping of DG.

j. Alarms

The following alarms shall be provided in the DG control Panel to


indicate & protect against abnormal operations.

Condition Status Function


Low Oil Pressure 2 stage Alarm Engine Stop
High Water Temperature 2 stage Alarm Engine Stop
Over Speed Alarm Engine Stop
Low Fuel Level Day tank Alarm
High Fuel Level Day tank Alarm
Earth fault on Alternator Alarm Engine Stop
Fail to start Alarm
Battery charger fault Alarm

6.0 ALTERNATOR

1500 RPM, 415V, 3-Phase, 150 kVA, star-connected, 50Hz, 0.8 P.F, horizontal
foot mounted, double bearing, self excited, self-regulated, brushless, screen
protected drip proof, continuous duty alternator with class “H” insulation in
IP22 enclosure incorporating the following.

a. Continuous damper winding.

b. One anti-condensation heater wired to a separate terminal box.

c. Pilot exciter.

d. 3 Phase sensing AVR with + 0.5% voltage regulation.

e. A neutral CT of adequate ratio and class for REF relay for DG Protection.

6.1 The Alternator shall further meet the following specifications:

a. The alternator shall conform to BS2613.

b. The alternator shall be suitable for 20% over speed for two minutes.

c. The alternator shall be capable of carrying 50% overload for a duration of


one minute.

d. The alternator shall be capable of carrying 10% overloading for one hour
in any period of 12 hrs running.

e. The inertia constant shall be 0.26 second or above.

f. The alternator terminal voltage for any load variation should be


maintained within + 5%.

g. The prime mover response should be such that with 150kW load throw
OFF / ON for the generator both transient and steady state frequency
variation should be within + 3%. The generator terminal voltage for this
load variation should be maintained with + 5%.

h. The field coil terminals shall be wired to terminal box for external speed
control.

i. Both ends of each phase winding shall be brought to the terminal box.

j. The alternator shall withstand a 3-phase short circuit at the terminals for
a period of 3 seconds.

k. The total harmonic distortion shall not exceed 3% and the design shall
permit up to 30% unbalance between phases while in operation.

6.2 Performance

Under normal operating conditions, the sound pressure levels when measured
at a distance of one (1) metre outside the DG building shall be not more than
70 dB.

6.3 Painting

The entire system shall be coated with grey oxide paint.

After erection rust preventive painting must be essential.

After erection one coat of Dark Green color synthetic enamel must be
applied.

7.0 DIMENSIONS

Refer to layout of Generator building.

8.0 SPARES

The DG set will be supplied with the following spares, which shall be handed
over at the time of commissioning.

2 sets of renewable parts of oil, fuel & air filters


2 Nos. fan belts
5 Nos. spare fuses of each type & size used
5 spare relays of each type
1 set of fuel injectors
1 No. Operators manual
1 No. Service manual

9.0 INSTALLATION
The bidder shall undertake the installation work at site. The general scope of
installation work shall include but not be limited to the following:
9.1 Diesel Generator Set
a. The assembled DG set shall be installed on anti-vibration mounts. The unit
shall be visually inspected for any transit damage.
b. The contractor shall arrange for the inspection of the set by the diesel engine
manufacturer’s authorized representative and obtain his approval before
rolling the set.
c. The fuel oil day tank shall be installed over the drip tray at the location
indicated.
d. The batteries shall be fully charged, installed, and connected.
e. The battery charger shall be heavy duty.

9.2 Exhaust Piping


a. The exhaust piping shall be fabricated from 1.5-3mm thick mild steel
pipes.
b. The exhaust piping and the silencers shall be insulated using 50mm thick
mineral wool inside the container & up to the exhaust stack. The
insulation shall be cladded with 24G aluminium sheet.
c. The exhaust pipe shall be supported using spring suspension supports.
d. The shipping sections of the stack shall be welded at site and erected over
the mild steel frame work. The entire length including flanges, bolts and
washers shall be aluminised inside and outside to inhibit corrosion. A
weather cowl shall be provided on top.
e. All tools and tackles used for the erection shall have valid safety
certification.
9.3 Electrical Installation
a. The electrical power cabling from alternator to the panel will be carried out
by the Ministry of Health (MOH) personnel. However the DG control
cabling from the DG to the DG Panel will be carried out by the DG vendor.
b. The contractor shall appoint an experienced full time engineer throughout
the installation period till the set is handed over. Three month
maintenance from the date of commissioning shall be carried out by the
DG vender.
c. The contractor shall carry out the control cabling from the engine control
panel to the breakers in the main panel.
d. Connecting block with wiring diagram shall be provided in the DG Panel for
integrating with our local power utility Te Aponga Uira’s (TAU) Panel.

10.0 TESTING

10.1 At Manufacturer’s works


The routine tests and full load test on Engine, and Alternator shall be carried
out at the manufacturer’s work in accordance with applicable New Zealand,
Australian or British standards. All test results must be forwarded to the MOH,
Rarotonga, Cook Islands.

The following tests shall be conducted:


a. Full load testing for 8 hours with load bank.
b. Overload testing at 10% overload for one hour immediately after the full
load test.
c. Operation of protective devices.
10.2 Site Testing
Following tests shall be conducted at site in the presence of the MOH’s
representative before energisation. The contractor shall provide all testing
equipment, labour and consumables required for the testing.

a. Checking the alignment by engine manufacturer’s representative and


obtaining approval.
b. Insulation resistance test on alternator, control panel and cabling / bus
bar trunking.
c. Checking the Automatic Mains Failure (AMF) operation both on auto and
manual mode.
d. Checking the engine safeties for satisfactory operation.
e. Checking vibration levels.
f. Testing of individual protective devices on engine and alternator and
ensuring that the wiring is carried out properly.
g. Full load running for 8 hours continuously. All the readings shall be logged
to evaluate the fuel consumption, lube oil pressure, water & oil
temperature vis-à-vis the electrical load.
h. One hour overload testing at 110% load shall be carried out at the end of
the full load trial.
i. The guaranteed specific fuel consumption shall not exceed 150 grams /
BHP. HR with a tolerance of + 2.5 %. The same shall be proved during the
load trial.
j. The noise level at 1m from the enclosure and the temperature rise inside
the enclosure shall be measured.
k. Any deviation from the guaranteed parameters shall be made good and
these performance parameters should be measured once again till the
required results are achieved.
l. The DG set shall be deemed to be commissioned after satisfactory
performance of all associated equipment.

11.0 TAKING OVER


The Ministry of Health (MOH) will take over the DG set for operation on
completion of the following:

a. DG set are installed, tested and commissioned as per the specifications.


b. Original test certificates are furnished for engine, alternator, acoustic
enclosure, centrifuge and all other bought out items.
c. Load trials are successfully conducted including the performance of
acoustic protection and ventilation fans.
d. 2 sets of AS BUILT documentation, spare parts list, maintenance chart and
operation and maintenance manual are to be submitted.
e. The set shall be handed over with first fill of lube oil and day tanks full of
diesel oil along with spares mentioned.

12.0 GUARANTEE

12.1 Diesel Generator Set


The DG set and accessories shall be guaranteed for satisfactory operation for
a period of 24 months from the date of commissioning or 5000 running hours
from the date of supply whichever is earlier. Any defects noticed during this
period shall be rectified free of cost.

The supplier shall indicate the type of records to be maintained so that the
warranty claims if any are honoured by the manufacturer.
13.0 MAINTENANCE

13.1 The bidder shall be required to maintain the installation at no extra cost to
the owner for a period of two year from the date of commissioning. During
this period, the contractor shall make good any defects caused due to faulty
design, bad workmanship and poor quality of materials.

13.2 The response time to attend any reported break down shall not be more than
1 hour. This response do not mean to physically be on site.

13.3 During the guarantee period, the bidder shall carry out regular servicing of
the unit at regular intervals as recommended by the manufacturer. The
consumables required for this will be made available by the Ministry of Health.

14.0 DOCUMENTATION

As a part of the equipment supply, following documentation shall be furnished:

a. General arrangement plan of DG set.

b. Exhaust fabrication drawing.

c. Layout of exhaust piping.

d. Engine wiring diagram.

e. Test certificate for engine and alternator.

f. Installation, operation and maintenance instructions for diesel engine and


alternator.

g. Spare parts list.

15.0 PREFERED MAKES

In case the Tenderer proposes to supply any make other than in the approved list,
then the Tenderer should submit:
1. Full technical specifications
2. The proposed model should have been installed in at least 3 locations around
New Zealand or Australia. Completion certificate and performance certificate
should be submitted in the technical bid. It may be noted that this criteria is
in addition to the eligibility criteria mentioned in the tender notice.)

15.1 Diesel engine with residential: Caterpillar / Cummins / Perkins / Deutz or


Silencer equivalent

15.2 Alternator : Stamford / Newage or equivalent

15.3 Anti-vibration mounts : Dunlop – S class or equivalent

15.4 Battery : Exide or equivalent


15.5 DG Panel : Microprocessor based engine mounted as
per the DG Manufacturer instructions

15.6 Motors : Crompton / Siemens or equivalent

15.7 Pipes : Mild/Galvanized steel

15.8 Starters : 24V system

16.0 SCHEDULE OF TECHNICAL PARTICULARS

16.1 All the installation shall fully conform to the requirement stipulated and the
tests shall be carried out as stipulated. Deviations if any, shall be clearly
brought out in the tender.

17.0 STANDARDS
The following Standards apply:

BS5000 Part 3: 2006 - Generators to be driven by Reciprocating Internal


Combustion Engines

BS5514 Parts 1 – 6 (ISO3046) -Specification for Reciprocating Internal


Combustion Engines

BS5486 (IEC60439) -Factory Built assemblies of Low Voltage Switchgear and


Control Gear

BS4999 Parts 103, 140, 141 & 145 (IEC34-1) - General requirements for
Rotating Electrical Machines
TECHNICAL SCHEDULE – STANDBY RATED DIESEL GENERATOR 150kVA

Particulars
Ref. Description Units
As Specified As offered
1 Diesel Engine
1.1 Manufacturer's Name
1.2 Country of Origin
1.3 ISO rating kW brake
1.4 Site rating at 26°C kW brake
1.5 Brake mean effective pressure at Bar
site rating
1.6 Number of cylinders
1.7 Bore mm
1.8 Stroke mm
1.9 Speed rpm
Type of Aspiration
1.10 Year this type was put in service
1.11 Drop in frequency/speed when
engine response to 100% load
injection
Fuel consumption at 100% Prime l/hr
rated load is
less than
1.12 Radiator
Applicable standard Clause 17
Manufacturer's Name
Manufacturer's Type No.
Fan tip speed m/s
Fan power required kW
Cooling airflow m3/min
Cooling surface area - water m2
Cooling surface area - oil m2
1.13 Cooling water system
Applicable standard
Water temperature ˚C
Water pressure Bar
System capacity litre
Thermostat bypass valve type
Low water level switch type
1.14 Lubricating oil system
Applicable standard
Oil pressure Bar
Oil temperature ˚C
Grade of oil
Sump capacity litre
Oil consumption/100 hr. litre
Recommended oil change hrs
1.15 Engine alarms
Applicable standard Clause 17
Low oil pressure setting Bar
Low water level setting as % of %
total cooling
Water capacity
Overspeed setting rpm
High water temperature setting ˚C
High oil pressure setting Bar
1.16 Exhaust system
Applicable standard
Silencer manufacturer's name
Type of silencer (residential or
standard)
Exhaust temperature gauge range ˚C
1.17 Engine governor
Applicable standard Clause 17
Manufacturer's name
Class of governing
1.18 Base Fuel tank
Mounted integrally with engine bed Yes
plate
Capacity
Fitted with level gauge Yes
1.19 Emission Standard
(a) HC (Hydro Carbon) gr/kWh
(b) CO gr/kWh
(c) NOx gr/kWh

2 A.C. Generator
2.1 Manufacturer's name
2.2 Type
2.3 Country of Origin
2.4 Rated output KVA
At site rating
2.5 Terminal voltage V
2.6 Power factor Cos Ö 0.8
2.7 Frequency Hz 50
2.8 Winding Connection Star
2.9 Weight of complete alternator Kg
2.10 Weight of name of heaviest single Kg
item for erection
2.11 Applicable standard Clause 17
2.12 Generator mechanical protection IP23
class
2.13 Short circuit ratio
2.14 Stator insulation class
2.15 Stator d.c. resistance per phase at Ohm
75°C
2.16 Type of rotor bearings
2.17 Number of rotor bearings
2.18 Method of protection against shaft
currents
2.19 Rotor critical speed (s) rpm
2.20 Rotor inertia kg m2
2.21 Weight of rotor kg
2.22 Rotor winding resistance at 75°C ohm
2.23 Generator response for 100% load
change at a low
Power factor :-
A. Instantaneous values when at :-
(i) Minimum excitation
%V
(ii) Maximum excitation %A
%V
%A
B. After 10 Hz when initially at :-
(i) Minimum excitation
%V
(ii) Maximum excitation %A
%V
%A
2.24 State whether stator windings are Yes
protected with embedded
thermistor overloads
2.25 State whether thermostatically Yes
controlled anti- condensation
heaters are fitted in the generator
2.26 Wattage of the heaters W

3 Generator Exciter
3.1 Applicable standard Clause 17
3.2 Manufacturer's name
3.3 Field winding insulation
3.4 Field winding resistance at 75°C ohm
3.5 Exciter winding insulation class
3.6 Exciter winding resistance per
ohm
phase at 75°C
3.7 Number of diodes
3.8 Type of diodes
3.9 Diode rated current A
3.10 Diode rated voltage V
3.11 Exciter full load current in d.c. amp A
3.12 State what provision has been
made to suppress the
field when the main circuit opens
under fault
conditions

4 Generator Automatic Voltage


Regulator
4.1 Applicable standard Clause 17
4.2 Manufacturer's name
4.3 Type
4.4 Range of manual voltage control V

5 Generator Circuit Breaker


5.1 Applicable standard Clause 17
5.2 Manufacturer's Name
5.3 Type
5.4 Country of origin
5.5 Rated current A
5.6 Rated voltage V 415
5.7 Breaking capacity (mini. 35kA)
5.8 Inherent protections provided
Short circuit Yes
Overcurrent Yes
Range of adjustment of ....% to ....%
overcurrent
Range of adjustment for under …..%
voltage

6 Battery
6.1 Manufacturer's name
6.2 Type
6.3 Electrolyte
6.4 Voltage V
6.5 Capacity at 10 hour rate Ah
6.6 Number of cells
6.7 Voltage per cell V
6.8 Normal charging rate A
6.9 Maximum charging rate A
6.10 Ampere-hour efficiency at 10 hour %
rate
6.11 Ampere-hour efficiency at 1 hour %
rate
6.12 Dimensions of cells mm
6.13 Dimensions of battery complete mm
6.14 Weight of cell complete with Kg
electrolyte
6.15 Total weight of battery complete Kg
6.16 Internal resistance per cell Ohm
when fully charged
6.17 Battery voltage at end of the duty V
cycle

7 Charger
7.1 Manufacturer's name
7.2 Type
7.3 AC input to charger kVA
7.4 DC output of charger kW
7.5 Type of d.c. voltage control
7.6 Range of d.c. voltage control V
7.7 Regulation %
7.8 Overall dimensions mm
7.9 Total weight kg

8 Maximum allowable Noise Level of


the Generator Set
8.1 At 1m distance dB 70
8.2 At 10m distance dB 60