MV Generator

(11kV) Specification for the

Bel Air Minig Project

APPROVAL

E. de Leeuw DRA Electrical Engineer

C. Badenhorst DRA Project Manager

J. Booyse Alufer Project Manager

DRA MINERAL PROJECTS (PTY) LTD

 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

REVISION RECORD
Page Revision Description Date

| 2 of
DRA-C8396-ECI-SPC-059
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

ABBREVIATIONS
The definitions and abbreviations as per SANS ISO 8528 applies, additional abbreviations and acronyms listed
below.
Abbreviation or Acronym Definition
 Ohm
C Degrees Centigrade
ac Alternating current
Ah Ampere hours
dc Direct current
Hz Hertz
kA Kilo-amperes
kPa Kilopascals
kVA Kilo-volt Amperes
kVAr Kilovolt Amperes reactive
kW Kilo-watts
l Litre
LED Light Emitting Diode
LV Low voltage
M Mega-ohm
mm Milli-metres
MV Medium voltage
NiCd Nickel Cadmium
rpm Revolutions per Minute
s Seconds

| 3 of
DRA-C8396-ECI-SPC-059
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

REFERENCES
The following documents are applicable:
Document Title Document Number
Model for Quality Assurance in Design, Development, Production, Installation
ISO 9001: 1994
and Services
Occupational Health and Safety Act OSHACT
Direct Acting Indicating Analogue Electrical Measuring Instruments and their
IEC 60051
Accessories - Parts 1 – 3
Internal Combustion Engines ISO 3046 / SANS 8528
Reciprocating Internal Combustion Engine Driven Alternating Current
ISO 8528 / SANS 8528
Generating Sets
Vented Type Prismatic Nickel-Cadmium Cells and Batteries SANS 1632
Battery chargers - industrial type SANS 1652
National Colour Standards for Paint - Amendment No. 2: May 1989 SANS 1091
Symbolic Safety Signs - Amendment No. 1 May 1993 SANS 1186: 1993
Degrees of Protection Provided by Enclosures IEC 60529
The Measurement and Rating of Environmental Noise with respect to
Annoyance and Speech Communications - Amendment No. 2: November SANS 0103
1992.
The Storage and Handling of Liquid Fuel - Amendment No. 2: August 1989 SANS 0131
Rotating Electrical Machines - Part 1: Rating and Performance SANS 8528-1, IEC 34-1
Rotating Electrical Machines - Part 8: Terminal Markings and Direction of
SANS IEC 34-8
Rotation of Rotating Machines
Rotating Electrical Machines – Part 9: Noise Limits SANS IEC 34-9
Rotating Electrical Machines – Part 11: Built-in Thermal Protection SANS IEC 34-11
Low-voltage Switchgear and Control gear
Part 4:Contactors and Motor-starters IEC 947-4-1
Section One - Electromechanical Contactors and Motor-starters
Low-voltage Switchgear and Control gear
- Part 6: Multiple Function Equipment IEC 947-6 1
Section 1 - Automatic Transfer Switching Equipment.
Low-voltage Switchgear and Control gear
- Part 7: Ancillary equipment. IEC 947-7 1
Section 1 - Terminal Blocks for Copper Conductors.
Low Voltage Switchgear and Control gear Assemblies – Part 3: Particular
SANS IEC 439-3
Requirements for Low Voltage Switchgear – Distribution Boards
Automotive Diesel Fuel SANS 342
Electric Cables with Extruded Solid Dielectric Insulation for Fixed Installations
SANS 1507
(300/500 V to 1 900/3 300 V)
The installation, inspection and maintenance of equipment used in explosive
SANS 10089-Parts 1 to 3
atmospheres – Part 1,2 and 3

| 4 of
DRA-C8396-ECI-SPC-059
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

TABLE OF CONTENTS

1. INTRODUCTION.........................................................................................................................
2. SCOPE OF WORKS...................................................................................................................
3. GENERAL...................................................................................................................................
4. GENERATOR............................................................................................................................ 12
5. MECHANICAL BUILD............................................................................................................... 26
6. NAMEPLATES AND PRODUCT MARKING.............................................................................29
7. PREPARATION FOR DELIVERY.............................................................................................34

| 5 of
DRA-C8396-ECI-SPC-059
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

1. INTRODUCTION

This specification covers the design, manufacture, assembly, factory acceptance testing
at works, supply, delivery to site, on-site erection and commissioning of one continuous
power (COP – constant load: unlimited running hours). The sets will be installed at
Asanko Gold Mine, Ghana.

2. SCOPE OF WORKS

The scope of work includes the furnishing of all labour, material and services for the
design, supply, manufacture, testing and inspection at works, delivery to site, offloading,
bush clearing, erection, testing and rectification of defects developing during the
warranty period for equipment as specified below.
The Diesel Generators shall be built in accordance with the latest revisions of SANS ISO
8528 (all parts) except where deviations are specified in this document and its
accompanying Schedule AB.
Where conflicts exist between this document, its accompanying Schedule AB and SANS
ISO 8528, the preference sequence is as follows: accompanying Schedule AB, this
document and SANS ISO 8528.

2.1 WORK TO BE INCLUDED

The work includes, but shall not be limited to the items listed below. Note this section to
be read in conjunction with the supplied scope of works section in the tender document.
Containerised 2.5MW Diesel Generator (COP), 11kVac, 50Hz, fully functional modular
unit, including 11kV Switchgear (mounted in its own container with the Generator Set,
including their own 3-phase Bus VT) and BTU fitted with Surge Protection. Units to be
supplied with complete Local Control Panels, fitted with ComAp Controllers and ComAp
HMIs. Surge Protection also to be installed on all control panels.
All necessary power, instrumentation, control and communication cables as per attached
drawings and specifications.

2.2 WORK TO BE EXCLUDED

Refer to the scope of works document included in the tender for exclusions applicable to
this contract.

3. GENERAL

The Diesel Generators shall be built in accordance with the latest revisions of SANS ISO
8528 (all parts) except where deviations are specified in this document and its
accompanying Schedule AB

3.1 APPLICATION AND OPERATING PHILOSOPHY

| 6 of
DRA-C8396-ECI-SPC-059
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

The diesel generator specified shall be used for co – generation with the main utility
power supply and utilized as a backup system (under power failure conditions).

3.2 SITE CONDITIONS

The diesel generators shall be designed for use on land. Other environmental data such
as humidity, ambient temperatures and humidity values are given in Schedule AB.

3.3 RATINGS AND PERFORMANCE

The power ratings, for all output requirements are given in Schedule AB. The Contractor
shall provide an additional 10% engine power for governing purposes. This additional
engine power shall not be identical to the RIC (Reciprocating internal combustion
Engine) overload power.
The required COP (Continuous Power), PRP (Prime Power) and LTP (Limited-time
running power) as defined in ISO 8528-1 are provided in Schedule AB.
The required Performance Class as defined in ISO 8528 and load type is given in
Schedule AB. If no performance class is specified a G3 class shall be assumed.

3.4 RELIABILITY

The Diesel Generator System shall be designed for an operating life of as per
manufacture specification (operating hours) under the operating conditions specified in
Schedule AB.

3.5 MAINTAINABILITY

The Diesel Generator System shall be designed to minimize the need for maintenance,
whether preventative or predictive. Where maintenance is required, the design shall
provide for good ergonomics in order to make it as easy as possible, with due
consideration given to personnel safety. The design shall allow for modular replacement
of assemblies and components to a level as low as possible.
The time to isolate a faulty component shall be reduced by making extensive use of built-
in test facilities. Component conditions that may lead to a failure shall be monitored, and
an alarm condition generated.

3.6 TRANSPORTABILITY

The Diesel Generator System shall be designed such that it can be transported as a fully
assembled system by road.

3.7 SYSTEM DEFINITION

The Diesel Generator System includes the subsystems and/or components indicated in
Schedule AB.

| 7 of
DRA-C8396-ECI-SPC-059
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

Table 3.7.1: DIESEL GENERATOR SUBSYSTEMS AND COMPONENTS

Diesel Generator System
Diesel Engine, including: Generator, including: Mechanical Build, including:
- Cooling - Control System - Coupling
- Starting system - Protection, Alarms and - Exhaust system
Instrumentation
- Governor - Internal wiring and cabling - Base Frame
- Fuel system including storing - Earthing system - Enclosure
and transfer
- Protection, Alarms and - Dummy Load
Instrumentation (Where applicable)
- Internal wiring and cabling

3.7.1 General

The system shall be designed to run free of excessive vibration and noise under all
conditions of load and speed, and shall comply with the requirements of SANS: IEC
34-9.
The engine and generator combination shall be torsionally analysed and the design
guaranteed.
All moving and rotating parts shall comply with the requirements of the Occupational
Health and Safety Act (OHSA 85 of 1993) and Mines Health and Safety Act 29 of 1996
and Regulations (as amended).

3.7.2 Diesel Engine

3.7.2.1 General
The diesel engine shall be of the diesel fuelled, cold starting, compression ignition, direct
injection industrial type, water-cooled or air-cooled, speed-governed type.
Turbocharged engines, where agreed to, shall have a run-down time as stated in
Schedule AB.
The diesel engine shall be earthed as specified in section 4.7 of this document.
The engine exhaust shall comply with the requirements as set out Schedule AB
The supplier shall state in Schedule AB in Appendix A, the guaranteed specific fuel
consumption of the complete set with all auxiliary equipment at full load, 3/4 load and 1/2
load to an accuracy within 5%. The fuel consumption shall be determined in accordance
with ISO 3046-1, and given in litres per kilowatt hour (l/kWh).
The type of service is specified in the Schedule AB, with the relevant required operating
times.

| 8 of
DRA-C8396-ECI-SPC-059
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

3.7.2.2 Rating
The engine shall be suitably rated to provide the required power output from the
generator, even under impact loading when all pre-impact loads are connected. The
engine shall deliver full load in accordance with ISO 3046-1, within the starting period,
and under the specified environmental conditions. De-rating shall be in accordance with
ISO 3046-1.
Refer to Schedule AB for the required performance class, loading profile, continuous
Power (COP), Prime Power, and (PRP) and Limited Time Running Power (LTP).
The Power rating shall be expressed in kilowatts at rated frequency and a power factor
of 0.8 lagging unless otherwise stated in Schedule AB. It shall be possible to operate the
Diesel Generator with a lagging Power Factor from 0.8 up to 1.0, depending on the
active power demand unless otherwise stated in the Schedule AB.
The Contractor shall supply all technical data with de-rating graphs on altitude of all
engines supplied with the tender which shall form part of the engine sizing.
The output of the engine under the specified site conditions shall be the nett available
output power after allowance for all auxiliary equipment, including Air Filter, radiator fan,
oil pump, water pump, battery charger alternator, governor etc. has been made.
Turbo chargers shall only be acceptable where the Contractor provides written
guarantee that engine can deliver the specified step load and service load within the
specified starting period.

3.7.2.3 Cooling
The engine shall be cooled by a pressurized radiator and shall be entirely self-contained.
The chemical composition of the available water shall be in accordance with ISO 8528-1.
Unless otherwise specified, fans of engines that are installed in the generator container
shall draw the air through the container and exhaust it externally. The Contractor shall
indicate the driving method of the fan i.e. whether it is driven by electric motor or
mechanically coupled to the engine.
A heating element operating at either 230 Vac single-phase or 400 Vac three-phase
shall be fitted in the engine water jacket to maintain the engine at a temperature suitable
for cold starting. The element terminals shall be brought out separately, such that both
terminals of each heater element are available externally. The element wiring shall be
terminated on a separate external terminal strip. The power to the heater element shall
be thermostatically controlled to adequately regulate the engine temperature. An alarm
shall be issued if the heater element is non-operational.

3.7.2.4 Starting system

Refer to the Schedule AB for the preferred starting method.
a) Battery starting
If battery starting has been specified an electric starter motor that operates from a NiCad
battery shall be used. On initiation of the start command, the engine starter shall make
three consecutive start attempts of maximum duration 10 s each, with rest periods of not
more than 10 s between attempts. If the third start attempt is unsuccessful, the indication
‘Start Failure’ (red) shall be activated on the control panel.
b) Batteries

| 9 of
DRA-C8396-ECI-SPC-059
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

NiCad batteries shall be used, and shall be adequate for a rate of discharge class X that
complies with SABS 1632. They shall be rated for the voltage and currents of the starting
motors and the control equipment, and for the time requirements of the alarm system
specified. Details of the batteries offered shall be provided.
The starting battery discharge capacity at 25 C shall be such that the full cranking
current can be drawn for 30 s, and that the final discharge voltage does not fall below
the value as specified in SABS 1632.
During engine operation, the starter battery shall be charged from a charging generator,
or by means of a battery charger mounted on the control panel.
The battery shall be mounted separately from the vibrating part of the set, preferably in a
clean and cool environment.
The battery mounting shall be protected against corrosion, and shall include a spill tray
and a transparent cover over the battery.
The starter battery mounting shall be as close as possible to the starter motor, and shall
be arranged in a position permitting easy access for maintenance.
c) Battery charger
Equipment shall be provided in the control panel for charging the starter battery from the
mains. Battery chargers shall comply with the requirements of SABS 1652, and shall be
of the constant voltage, current limited type. Their performance characteristics shall
comply with the recommendations of the battery manufacturer.

3.7.2.5 Governor
The engine shall be fitted with a governor to provide speed control in accordance with
the requirements of ISO 3046-4 and ISO 8528-2. To make parallel operation possible
the governor shall also be able to operate as a proportional governor where either a
proportional integral or proportional differential type governor is used.

3.7.2.6 Speed
An engine operating nominal speed below 1500rpm is preferred except where it is
otherwise stated in the Schedule AB in Appendix A.

3.7.2.7 Fuel system

The fuel system design and installation shall comply with the requirements of the local
authority, e.g. fire department, and of the OHSA 85 of 1993.
Galvanized materials or materials that contain zinc shall not be used in the fuel system.
In order to filter the input fuel to the Generator a water and fuel separator shall be fitted
before the supply pump. The water fuel water filter drain shall be connected to an
external outlet. A water level alarm system shall be provided to monitor the water level in
the water fuel separator. The Alarm system shall have two alarms levels namely: Water
level High and water Level very High.
a) Fuel injection system
The engine shall be equipped with a means of priming the fuel system to the injectors.
A continuously-rated fail-safe engine-stop solenoid shall be provided on the fuel pump
control rack. The main fuel line shall be equipped with a fire resistant shut down valve,
| 10
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

operated by a fuse or similar type fire detector that closes of the main fuel supply in case
of a fire.
b) Fuel transfer system
The location of the bulk fuel tanks shall be as shown on the drawings.
A return line from the engine for surplus fuel shall lead to the bulk fuel tank. The
Contractor shall provide the facility for others to connect the bulk fuel tank to the return
line.
All fuel lines shall be interconnected with high-pressure, fuel-resistant, flexible hoses. All
necessary non-return valves or shut-off valves, or both, shall be supplied with the set.
c) Diesel fuel
The fuel injection equipment offered shall use diesel fuel that complies with the
requirements of SABS 342.

3.7.2.8 Lubrication
The engine shall be supplied with a force feed lubrication system rated to supply the
circulating lubrication oil to all the bearings, gear trains and other moving parts. An oil
pressure gauge and an oil pressure sensor shall be so mounted downstream of the oil
filter that the engine lubricating oil pressure is readily indicated on the engine or on the
control panel (or on both), as specified. The safety range and the danger zones shall be
indicated on the gauge. The oil pressure sensor shall be connected to the control
system, to give an alarm and to stop the engine if low oil pressure occurs.
The oil filter shall have adequate capacity of at least 250 hours continuous operation.
Duplex oil filters, with blocked filter indication, shall be fitted on large engines. It shall be
possible to switch from one filter to the other while the engine is running. Oil filters shall
be readily accessible.
All bearings and continuously rotating moving parts that are not pressure lubricated shall
be fitted with sealed ball, roller or needle bearings.
If so specified in the Schedule AB, a lubrication oil make-up tank shall be supplied. The
make-up oil shall be gravity fed into the engine sump.
A semi-rotary hand-operated sump drain pump shall be fitted, and so positioned as to
facilitate drainage.
If a motor-driven lubricating oil priming pump is provided, this shall be stated in the
Schedule AB.
A label indicating the grade of oil to use the frequency of oil changes and the volume of
oil shall be affixed to the engine.
Any need for separate oil cooler or an auxiliary oil heater or both for cold starting shall be
stated in the Schedule AB, together with the power requirements for any auxiliary oil
heater.
Extended service periods shall be as indicated in the Schedule AB.

3.7.2.9 Aspiration and cooling air intake

The engine air filter shall be either an oil-bath type or a dry type as appropriate for the
site conditions.

| 11
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

The air intake shall be so mounted that the intake of dust or other particles is minimized.
The air intake shall be screened to prevent vermin or birds from entering the intake.
If water has entered the intake, it shall be possible to drain the water from a low-lying
collection point.
The air filter construction shall be such that the filter element can be readily cleaned or
replaced. A “differential pressure high” switch shall be provided to indicate a dirty filter
element condition.

3.7.2.10 Instrumentation
The minimum required instrumentation is specified. Sufficient information shall be
provided on the control panel to allow an operator to operate the installation in a safe
manner, and to do test and routine maintenance.
If the supplier is of the opinion that additional instrumentation is required, details of this
additional instrumentation shall be provided.

3.7.2.11 Finishing
 The engine cooling fan and blades are to be painted orange,
 All silencers, fittings etc. shall be painted before lagging with heat resistant
aluminium,
 Exhaust cowling shall be manufactured of galvanized sheet steel,
 Rubber hoses and belts shall not be painted,
 All fuel lines before the cut off valve shall be fire proof,

The external exhaust system shall be manufactured from stainless steel.

4. GENERATOR

4.1 GENERAL

4.1.1 Type

The generator shall be a brushless type that complies with the relevant requirements of
SANS IEC 34-9, SANS IEC 34-1, SANS IEC 34-8 and ISO 8528-3, and with the
additional requirements specified.

4.1.2 Excitation

The generator shall have an excitation system independent from any external power
sources. The method of excitation, the excitation voltage range and the maximum field
control current shall be provided.

4.1.3 Heaters

| 12
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

The alternator shall be fitted with one or more anti-condensation heater elements to
protect those components that can be adversely affected by moisture. The heater’s
voltage and power requirements must be stated by the supplier.

4.1.4 Labels

All labels shall comply with Asanko Gold Specifications as per Annexure A4.

4.2 PERFORMANCE

4.2.1 Power Output

The required power output in kilovolt amperes (kVA) shall be as specified, and the
short-circuit current shall be provided, if a limit is not specified. The guaranteed net
continuous site rating and the power factor at that rating shall be provided.
The generator shall comply with the requirements of section 5.2 of ISO 8528-3 in respect
of short-circuits.
The alternator’s efficiency at full load, 3/4 load, 1/2 load and 1/4 load at unity and at 0.8
lag power factors shall be stated Schedule AB.
The continuous current capabilities and the regulation percentages shall be stated.

4.2.2 Loading

Linear and non-linear loads shall be started as per the Starting Sequence detailed in the
Schedule AB, and according to the time intervals quoted by the manufacturer.
The alternator shall be suitable for supplying the following types of loads:
 Linear loads, such as lighting circuits and motors;

 Non-linear loads, such as saturable-reactor controlled rectifiers, 6-pulse or 12-pulse

controlled thyristors, or stop/start control systems; and

 Defined or specified impact loads when large motors are being started.

4.2.3 Voltage and frequency

The nominal voltage and frequency, including tolerances, shall be as stated in the
Schedule AB in Appendix A.
The terminal voltage shall be adjustable over the specified range.
The alternator shall be designed to withstand as stated in Schedule AB.
The generator voltage shall remain within the limits specified from no-load to full-load at
unity, and at 0.8 lag power factors, inclusive of diesel engine speed droop of 4.5% and
temperature drift.
The maximum permissible voltage drop and frequency variation for the maximum load
step in kilovolt amperes (kVA) must be maintained within the specified limits.

| 13
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

4.3 PROTECTION

4.3.1 Voltage transformers

Voltage transformers shall be provided in accordance with IEC 60044-2, and shall
comply with the requirements specified in the Schedule AB in Appendix A.
Standard voltage transformer secondary voltages are 110 V phase to phase, or 63.5 V
phase to neutral. All voltage transformers shall be of three phase type.

4.3.2 Current transformers

Current transformers shall be provided in accordance with IEC 60044-1, and shall
comply with the requirements specified in Schedule AB. Standard current transformer
secondary currents shall be 1 A.
The over-current and earth fault protection requirements, and the number and details of
protection Current Transformers and Voltage Transformers required per phase, shall be
provided. Where necessary, the specified instrumentation current transformer and
voltage transformer requirements shall also be provided. Instrumentation current
transformers and voltage transformers shall comply with Asanko Gold Specifications.

4.4 TYPE OF CONSTRUCTION

 Details of the bearings offered shall be provided.

 The generator shall be air-cooled.
 The generator insulation class for its different parts shall be as specified.

4.5 CONTROL SYSTEM

The control system shall comply with the requirements of ISO 8528-4, and shall be
electrically fail-safe.
The control system shall be capable of operating on an alarm-only basis or alarm and
shut down, if so required.
Where transducers are used in the control circuitry, the failure of a transducer shall be
indicated.

4.5.1 Control panels

a) Control panels shall comply with the requirements of SANS IEC 439-3, and shall:
 be IP55 rated, as per SANS 60529;
 meet colour requirements, as per Asanko Gold Specification;
 have 20% of component mounting space and wire ways available for future
additions;
 include ‘closed cell’ neoprene seals throughout;
 have an easy means of access to the underside of the gland plates from above
floor level;
 have bottom cable entry;
 have removable, cadmium-plated, hot-dip galvanized or white painted, steel
equipment-mounting panels or chassis, of thickness at least 2 mm;
 Include suitable rigging facilities (i.e. eyebolts, lifting brackets, etc.). There shall be
no protrusions beyond the bounds of the cubicles;
| 14
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

 have sufficiently large doors, stiffened if necessary, to permit easy and complete
access to the interior. In addition, the doors shall have:
 one padlockable locking mechanism on doors of height less than 600 mm;
 two padlockable locking mechanisms on doors of height in the range 600 to
1 200 mm
 three lockable mechanisms in doors of height exceeding 1 200 mm, one of which
is padlockable
 keepers, if necessary, to keep the door open
 corrosion-resistant hinges and handles.

b) Components shall be:

 mounted in the compartments on the equipment-mounting plates or chassis, using
bolts screwed into tapped holes or hank nuts that engage at least three full
threads. A DIN mounting rail shall be fixed to the mounting plate or chassis in a
similar manner. Self-tapping screws or bolts with loose nuts shall not be used;
 spaced at least 50 mm apart when components are dissimilar;
 intended for flush mounting on front doors or covers. Equipment manufactured for
surface mounting shall not be modified for flush mounting; and
 labelled exactly in accordance with the drawing or the wiring diagram.

c) Fuse bases shall be labelled with the rating of the fuse link that should be fitted into
them.

d) Control transformers shall:

 be double-wound isolating transformers with an earth screen between the primary
and secondary windings;
 have one leg of the secondary winding earthed; and
 include at least 25 % spare output capacity.

e) Wiring in the assemblies shall be:

 run in covered trunking that is filled to not more than 80% of its capacity,
 protected against chafing, with grommets, where it passes through the panel work;
 loomed with spiral wrap or alternative protection and arranged for minimal twisting
rather than a bending action where it crosses door hinges and other areas that can
move relative to one another;
 thermo-plastic insulated or thermosetting insulated, multi-stranded copper wire.
Solid conductors shall not be used;
 of cross-sectional area at least 1.5 mm2, except for current transformer circuits
where it shall be at least 2.5 mm2 and shall be 600/1 000 V grade in accordance
with SABS 1507;
 identified at each end with an indelibly marked, interlocking, slip-on identification
ferrule. The number on the ferrule shall be shown on the wiring diagram. Adhesive
wrap-on type ferrules shall not be used;
 terminated at each end with pre-insulated crimp lugs. Lugs shall be crimped on
with ratchet type crimping tools that do not release until the crimp is complete;
 colour-coded in accordance with SABS 1091 and Asanko Gold specification;
 free from joints or splices.
| 15
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

f) Control panels may be mounted on the main frame of a duplex frame or on the
inner frame, but control panels on the inner frame shall be mounted on suitable
anti-vibration mountings. These panels are to be manufactured from 2mm thick, 316
stainless steel.

g) Panels containing a rectifier and/or inverter shall be fitted with removable filters that
prevent the ingress of dust. The air-flow to air-cooled components shall be arranged
so that it cannot be impeded accidentally in any way.

h) All terminals should, as far as possible, be at the front of the control panel, and shall
be accessible without wiring having to be disturbed or components having to be
removed.

i) All metal work, including the cabinet, shall be electrically bonded to the earth
connection with 2 separate conductors of nominal cross-sectional area at least 35
mm2.

4.5.2 Control equipment

Programmable Logic Controller

Programmable Logic Controllers shall be utilized to realise the Control System. The PLC
where required will be supplied by DRA (or if logistically not viable, at least specified by
DRA to conform to the controllers used on the rest of the process plant). Test points
shall be provided for fault-finding, and details of the equipment shall be stated in the
Schedule AB.

The Programmable Logic Controller shall:

 Be capable of operation in an ambient temperature of up to 55 ºC;
 Be capable of withstanding mechanical and electrical interference;
 be protected against memory loss during power failure;
 have all inputs, outputs and logic scanned, within a period of sufficiently short
duration, to ensure fail-safe operation of all control and indication features of the
Programmable Logic Controller program;
 have software properly documented down to the annotated ladder diagram level or
equivalent if ladder logic is not used. If so specified, this documentation shall be
provided as part of the system documentation;
 not be coded until a detailed flow chart of the proposed functionality, in which all
possible plant occurrences shall be taken into account, has been submitted and
approved;
 after coding, have their program thoroughly tested at the supplier's works before it
is loaded into the Programmable Logic Controller at site. The program shall then
be tested on site after connection of all cables; and

| 16
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

 have a hard-wired manual override facility to permit operation of the diesel

generator set in the event of a Programmable Logic Controller failure.
 DRA is to be involved in the programming of the controller.

Modular Gen-set Controllers

Modular gen-set controllers shall be utilized for complete automatic generator control.
The types of controller to be used shall be stated in the Schedule AB. The system
architecture can be viewed in Figure 4.5.2 - Generator Control Communication
Interface below.

The gen-set controllers shall:

 Be capable of operation in an ambient temperature of up to 55 ºC;
 Be capable of withstanding mechanical and electrical interference;
 Be protected against memory loss during power failure;
 Be capable of generator automatic synchronisation to grid;
 Be capable of generator protection;
 Be capable of interfacing with power management system;
 DRA is to be involved in the programming of the controller and commissioning of
controllers;

| 17
DRA-C8396-ECI-SPC-059 of
34
Figure 4.5.2 – GENERATOR CONTROL / COMMUNICATION INTERFACE
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

4.5.3 Control System Functionality

Emergency stop
An emergency stop push-button shall be provided both on the engine and on the control
panel. These push-buttons shall be of the self-latching, twist-to-release type, red in
colour, and at least 25 mm in diameter. Directly above each push-button, there shall be
a red label indicating the function of the push-button. The button shall Open the diesel
Generator Main Breaker and shut the diesel engine down by cutting the fuel.

Automatic Voltage Regulator

The automatic voltage regulator shall control the generator output voltage by
three-phase sensing.

Load sequencing demand on diesel generator

Diesel engines have limited capacity for step-load acceptance. The nominal rating of the
set shall be determined, based on anticipated load steps and sequencing requirements
as specified in the Schedule AB.
The supplier shall provide a diesel engine sizing calculation based on these load steps.

Control functions
The vendor must supply information for the required control philosophy, Functions,
Alarming and Tripping.

4.5.4 Alarms and indications

Alarm system
The following are general requirements for the alarm system:
a) Each alarm shall register and maintain the alarm indication until manually cancelled,
even if the signal that initiated the alarm has ceased.
b) Each alarm shall be displayed in the front of the alarm panel by an indicating lamp or
Light-emitting Diode (LED). A Liquid Crystal Display may be used, but it shall comply
with a) above.
c) A common ‘Alarm Reset’ push-button shall be provided to restore the control circuit
to its original state, once the alarm conditions have been noted and rectified.
d) All alarm lamps or LED shall have a Lamp Test facility to test whether they are
operational; this facility shall be operated by a single push-button.
e) Each alarm shall be duplicated at a potential-free changeover contact. Both positions
(three wires) must be wired to outgoing terminals.

Engine alarms, status indications and controls

The following engine alarms, status indications and control requirements shall be
provided:
a) Low oil pressure (Analogue Sensor):

| 19
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

If, with the set in operation, the oil pressure falls below the supplier's prescribed
minimum oil pressure level, the set shall stop automatically. The indication ‘Low Oil
Pressure’ (red) shall be activated on the control panel.
b) High engine temperature (Analogue Sensor):
If the engine cylinder head coolant temperature or the lubricating oil temperature
rises above the supplier's prescribed maximum temperatures, the generator
circuit-breaker shall trip automatically and the set shall continue to run off-load for a
period not exceeding 3 minutes before it stops. The indication ‘High Engine
Temperature’ (red) shall be activated on the control panel.
c) High bearing temperature (Analogue Sensor):
If the bearing temperature exceeds the supplier's prescribed maximum, the set shall
stop automatically. The indication ‘High Engine Bearing Temperature’ (red) shall be
activated on the control panel.
d) Low coolant/water level (Analogue Sensor):
In the case of low coolant/water level, the set shall stop automatically and, if the set
is in standby mode, the pre-heating equipment, if fitted, shall switch off. The
indication ‘Low Coolant/Water Level’ (red) shall be activated on the control panel.
e) Engine overspeed (Analogue Sensor):
If the engine speed rises above the supplier's prescribed overspeed limit, the set
shall stop automatically. The engine's combustion air shall also shut off immediately
(if such a shut-off device is fitted). The indication ‘Engine Overspeed’ (red) shall be
activated on the control panel.
f) Engine underspeed (Analogue Sensor):
If the engine’s speed falls below the supplier's prescribed underspeed limit, the set
shall stop automatically. The indication ‘Engine Underspeed’ (red) shall be activated
on the control panel.
g) Engine start failure (Potential Free Contact):
An engine start failure alarm shall be generated after the sixth/tenth start attempt
fails (depending on the starting system in use).
h) Engine running (Potential Free Contact):
A green indication shall be activated whenever the engine is running, whether
on-load or off-load.
i) Engine running hours:
A running hour’s recorder shall record the time during which the engine is running.
The smallest indication shall record 0.1 hour.
j) Other alarms, etc.:
Any additional indications that may be required, such as crankcase blow-by, coolant
pressure or low battery voltage shall be as recommended and detailed in the
‘Provided’ column in the Table of Compliance.
k) Duty selection:
Feedback shall be provided as to which duty the diesel generator has been set to
i.e.: Automatic Local, Remote and Off.

| 20
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

Generator alarms, status indications and controls

The following generator alarms, status indications and control requirements shall be
provided:
 voltage output
 current output
 over-current and short-circuit;
 winding temperature (analogue output);
 high winding temperature;
 very high winding temperature;
 over-/under-voltage;
 phase unbalance;
 frequency (analogue output);
 over-frequency and under-frequency;
 definite time earth fault;
 bearing temperature (analogue output);
 high bearing temperature;
 load unbalance;
 Reverse power.
 Switch On To Standstill
 Mains Voltage

Fuel system alarms

The following alarms shall be provided for the fuel system on the control panel and
duplicated for remote indication:

a) A fuel tank low fuel level (analogue and switch sensor):

Activates a ‘Low Fuel Level’ (amber) alarm indication when the fuel level in the day
fuel tank drops to a set level; and

4.6 AUTOMATIC SYNCHRONIZING SYSTEM

An automatic synchronizing shall be done by the specified COMAP controllers as

specified in the Schedule AB.

The automatic synchronizing unit shall measure the difference in frequency, voltage and
phase coincidence, and shall adjust outputs to synchronize the diesel generator set with
either the module transformer or alternative supply. The unit shall provide a signal in
order to close the generator circuit-breaker (supplied by others) when the frequency,
voltage and phase angle are within set limits.
The synchronizer shall consist of two separate channels. Both are required to operate to
close the breaker (two-out-of-two system).
The automatic synchronizer shall be provided with speed matching units with adjustment
for maximum slip, breaker operating time compensation and speed control pulse length.
The automatic synchronizer shall be provided with voltage matching units with
adjustment for zero voltage, voltage difference and voltage control pulse length.

| 21
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

The synchronizer incoming voltages and outgoing signals shall be selectable so that it is
possible to either synchronize with the module transformer or alternative supply.

4.7 EARTHING SYSTEM

4.7.1 General requirements

Earthing shall be provided to meet the system protection and safety requirements for the
diesel generator set power circuits. The minimum earth fault current dictates the
generator protection settings for correct operation.
The maximum earth fault current and its duration determine the cross-sectional area of
the earth conductors to be used.
Independent earthing is required in order to eliminate electromagnetic disturbances in
control circuitry, and also to prevent mechanical damage to the shaft and bearings in the
set, caused by induced and stray currents.

4.7.2 Generator neutral earthing

Neutral earthing implies interconnection of the generator’s neutral and the power
system’s neutral, which is generally earthed.
Multiple earth connections can cause neutral circulating currents between parallel
systems. In order to avoid this phenomenon and the consequent unnecessary operation
of the protection, the star point of the generator must be earthed as follows:
The generator shall be earthed through a circuit-breaker in series with an earthing
resistance of 63.5  and 300 A at 11kV (line voltage). Both the circuit-breaker and the
resistor shall be located adjacent to the generator (by Vendor)
The circuit-breaker must be rated in such a way that it can withstand the full earth-fault
current of the generator without any damage.
The neutral connector shall be able to carry the full earth-fault current of the generator,
but shall in any case not be less than 200 mm2 in cross-section.
The supplier shall provide protection of the generator against internal earth faults, and
details of such protection must be supplied.

4.7.3 Earth bonding of components

General
Each main component of equipment shall be earthed direct to a solid copper earth bar,
which shall be connected to the earth system at a point as specified.
As a general rule, the earth continuity conductor shall be of a nominal cross-sectional
area at least half that of the largest phase conductor, but not more than 70 mm2.
Earth conductors may be bare copper, or insulated with a green/yellow cover.

Programmable Logic Controller

The armour and screen of screened cables covered with insulating sheaths shall be
earthed to an insulated earth bar at the Programmable Logic Controller unit. Screens
shall be earthed at the Programmable Logic Controller end only. The earth bar shall be

| 22
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

connected by means of a bolted removable conductor to the enclosed chassis of the

Programmable Logic Controller unit, which should be mounted inside the control panel.

Batteries and battery chargers

The negative pole shall be earthed to the frame of the set.

Frame
The frame of the diesel/generator set shall be flexibly earthed to the earth continuity
conductor with due regard to the magnitude and duration of possible local earth faults.
Electrolytic corrosion shall be avoided. A suitable earthing facility shall be provided on
the frame. If so recommended, bypass earthing of insulated bearings shall be carried out
by means of an earthed brush, to prevent damage caused by induced shaft currents.

Junction boxes
Junction boxes shall be fitted with an earth terminal. The earthing conductor shall be of
suitable cross-sectional area to withstand any earth fault currents.
Junction boxes enclosures shall be rated IP54 as per IEC 60529.

Enclosures earthing
A stud shall be provided for earth connections from inside and outside the enclosure.
Where studs are not welded to the plate, flat washers shall be used as the final mating
surface in the case
of a conductive gland plate. A bolt and nut arrangement may also be used (where the
bolt is welded to the plate as indicated in
earthingWhere the plate is coated with non-conductive covering, studs shall be welded
to the plate after the coating is removed.
An earth bar shall be provided. The earth bar shall be connected to the earth stud inside
the enclosure by the shortest possible path. All earth connections shall follow the
shortest path, and no ‘pigtails’ (wire coils for neatening purposes) are permissible. The
connection between the earth stud and the earth bar shall be made using not less than
35 mm2 stranded cable, and shall be appropriately lugged for the purpose.
Gland plates shall be fabricated from a conductive material, and shall be protectively
coated against corrosion using a conductive coating, such as cadmium. The gland plate
shall be bolted to the enclosure in at least four places, in such a manner that galvanic
continuity between the plate and the enclosure is ensured.
Doors shall be bonded to the enclosure using earth studs. Doors greater than 0.5 m in
length shall be bonded in at least two different locations, with 0.5 m spacing between
each bond. Bonds shall be made using braided copper strapping not less than 10 mm
wide and having a width to thickness ratio greater than 5:1.

| 23
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

G
Discrete equipment
piece Discrete
equipment piece

B
C H
F

D D
A

Figure 4.7.3.1: Enclosure earthing

| 24
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

Figure 4.7.3.2: Earthing attachment fixation to enclosure

4.8 TERMINALS, WIRING AND CABLING

Terminals for control wiring or for cabling shall be of the ‘line-up’ type fitted on DIN or
similar rails. Conductors of nominal cross-sectional area less than 70 mm2 may be
terminated in clamp-type terminals. Conductors of nominal cross-sectional area
exceeding 95 mm2 shall be terminated with crimped-on cable lugs on bus-bar type
terminals, or direct to the bus-bars.
Power and control cables shall be separated at terminations. If these cables run in the
same channel, the control cables shall be insulated to the higher voltage.
Neutral conductors, when looped, shall be so crimped together and inserted into a
common lug, that the neutral connection is not broken when the termination is removed
from an instrument, etc.
External wiring for low voltage control, interlocking, alarm, measuring, and dc circuits
shall terminate on numbered wiring terminals that comply with the requirements of IEC
947-7-1. Terminals for internal circuits shall not be mixed with terminals for external
circuits. A special shorting type terminal shall be provided for the secondary windings of
current transformers. The supplier shall provide details of the terminals offered.
Internal wiring should, as far as possible, be confined to the front portions of switchgear
and control gear, for ease of access.
Unless otherwise agreed upon, all terminals shall be marked in accordance with SANS
IEC 34-8. The position of the terminal boxes, if of importance, shall be as specified.
Each control terminal strip shall contain the specified number of spare terminals.
Where the switchgear or control gear consists of separate sections, the control wiring
that passes between sections shall be so terminated on strips in each section that the
control wiring can be readily re-instated when the switchgear is being reassembled.
In general, the supply to all equipment shall be arranged at the top, and the load
connections at the bottom.
Any equipment that has a current rating that exceeds that for 70 mm 2 conductors shall
be connected to the main bus-bars using copper droppers. When more than two
outgoing circuits are to be supplied from the main bus-bar, copper droppers shall be
used.
All conductors that terminate on meters, fuse holders, indicators and other equipment
fitted with screw terminals, shall be fitted with soldered or crimped lugs, and identified
with cable marking ferrules.
Conductor colours shall be:

| 25
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

a. The colour of the supply phase for that circuit;

b. black for neutral;
c. green/yellow for earth unless bare - copper is used; and
d. grey for control.

Where heat-generating equipment is present and the internal temperature of the

switchgear is likely to exceed 50 ºC, heat-resistant insulation shall be used on stranded
conductors. The supplier shall state where such insulation is used.
Definite cable type requirements shall be as specified, otherwise the type offered shall
be provided.
Cables connected to incoming or outgoing circuits shall be glanded on a gland plate and
terminated on suitably sized terminals. Internal connection to the equipment shall be
made with cables that are similarly connected to the terminal.

All power cables of nominal cross-sectional area exceeding 70 mm2 shall terminate on
busbars that are connected to the associated equipment. Parallel incoming or outgoing
cables shall be connected to a collector bus bar without crossing of phase conductors.
Where screened cables are specified, the screening shall be earthed in the switchgear
or control gear only. Screened cables that enter control boxes shall terminate in
compression glands. Conductors shall, as far as possible, remain inside the screening at
terminations. Where conductors have to be separated from the screen, the braiding shall
be separated and the conductors shall be drawn through the braid without damage to
the braiding. The conductors shall then be connected to their respective terminals, and
the screening shall be smoothed and connected to an earth terminal.

4.9 SWITCHGEAR

Switchgear shall comply with the following standards:

Low voltage switchgear

Low voltage switchgear shall comply with the requirements of SANS IEC 439-3.
Contactors shall comply with the requirements of IEC 947-4-1.

Instruments, meters, and similar equipment

Instruments shall comply with the requirements of the relevant parts of IEC 60051, and
shall be flush mounted on the front of the control panel. They shall be similar to the other
instruments in the control panel.
Protective relays, where used, shall be flush mounted on the front of the control panel, or
on separate protective relay panels.
Meters for recording kilowatt-hours, kilovar-hours or kilovolt ampere-hours (kWh, kVArh,
or kVAh) shall comply with the requirements of IEC 60051. They may be mounted on a
separate panel, and shall be so clearly labelled that an operator standing in front of the
panel can see all the labels.
Digital instruments shall have red numerals of height at least 10 mm, and shall be
readable over an arc of at least 90.
| 26
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

Digital instruments shall have at least one decimal digit, and shall have an accuracy of
0.5% of the maximum range, or better.
Analogue instruments shall have linear scales from zero to at least 120% of the nominal
ratings, and shall be scaled in accordance with the recommendations of IEC 60051 for
the appropriate accuracy class.
Analogue instruments shall indicate to an accuracy of 1.5%, or better

5. MECHANICAL BUILD

5.1 COUPLING METHODS

The generator and engine may be coupled direct with a flange adapter ring or a bell
housing within which a shock absorbing flexible coupling is fitted. The method shall be
fully described by the supplier. In the case of large diesel generator sets, the generator
and engine may be coupled directly.
If the generator is offered with double bearings, it shall be coupled to the engine with a
flexible coupling designed to take up any angular misalignment, and to transmit the drive
torque smoothly.

5.2 BASE FRAMES

Diesel generator sets shall be mounted on a simplex frame. The overall dimensions of
the frame shall be provided.
Lifting provisions on the base shall be provided to lift the complete set, including any
canopy or enclosure, if fitted. The maximum overall mass of the diesel generator set and
its frame shall be provided, to enable the purchaser to provide suitable equipment to lift
the complete set, without decoupling.
The base shall be so constructed as to allow for an oil drip tray, and to allow space for
draining the engine oil from the sump.

5.3 VIBRATION DAMPING

The system shall comply with the requirements of ISO 8528-5:1993. Vibration damping
mounting details shall be provided.

5.4 ENCLOSURES (E.G. HOUSINGS AND CANOPIES)

The generator enclosure shall provide a degree of protection of at least IP55 in

accordance with IEC 60529.
The sound-reducing enclosure shall be completely lined with soundproofing material.
The maximum noise level generated by the set under any load condition, shall comply
with SANS 0103.
The enclosure shall be designed to allow easy access to all equipment for operating and
maintenance purposes. The overall dimensions and mass of the enclosure shall be
| 27
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

provided, and the purchaser shall approve the layout of the proposed construction
before manufacture starts.
Provision for the storage of one set of documentation and spares shall be made inside
the enclosure.

5.5 EXHAUST SYSTEM

5.5.1 General

The exhaust line diameter must be adequate for the length of the exhaust line.
The exhaust shall have an effective silencer that reduces the noise level to not more
than that allowed by local noise regulations.
The exhaust system shall have a low-lying collection point provided with a drain plug, to
enable any condensation to be removed.
Exhaust gases shall be released at a location that complies with the local and national
regulations, and shall not be drawn into the engine or ventilation intake. The position of
the exhaust shall not hinder operation and maintenance.
The exhaust pipe shall be so arranged as to prevent the ingress of rain.

5.5.2 Materials

The exhaust system, with the exception of expansion bellows and flexible joints, shall be
constructed from mild steel.
Expansion bellows shall be fabricated from stainless steel and shall be of the type,
length and diameter recommended by the supplier.
Leak-tight flexible joints shall allow for expansion and contraction without straining the
system.

5.5.3 Lagging

Adequate lagging, of non-asbestos material, shall be provided. The type of lagging and
the thermal capabilities of the lagging offered shall be provided.
Expansion bellows shall not be lagged. Flexible joints shall be lagged.
The piping outside the plant room shall not be lagged. Non-lagged piping shall be
painted with heat-resistant paint.

5.5.4 Safety guards

Safety guards to prevent accidental contact shall be provided over all exposed exhaust
pipes and bellows.

5.5.5 Exhaust system supports

Suitable flexibility shall be built into the system to isolate the exhaust system from the
structure, and to prevent any stresses on the engine flanges. Relative movement of the
engine and surrounding structure shall be considered.

| 28
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

Hangers, supports and guides shall be designed to allow for expansion and contraction,
and to allow necessary access to the set.

5.5.6 Accessory and documentation storage

A lockable steel cabinet shall be provided with all diesel generator sets, to contain the
spares and special tools as agreed between the purchaser and supplier. The cabinet
shall include a separate compartment for storage of the documentation, drawings and
manuals.

5.5.7 Corrosion protection and finish

All metal and surface preparation, painting and coating processes must comply with the
requirements of document number 003428-28, Corrosion Protection of Electrical and
Instrumentation Equipment.

5.5.8 Fire protection

The room where the Diesel Generator shall be installed shall have an automatic water
spray fire suppression system.
The Diesel Generator and auxiliary systems should have enclosures type IP55 to avoid
water damage.
The fuel supply line must be fitted with a fire valve. For this purpose, a suitably designed
fused-link system shall be provided to cut-off the fuel to the engine in the event of fire.
The capacity of day fuel tank shall be limited to 1 000 litres. No farm tank can be used
for fuel storage.

6. NAMEPLATES AND PRODUCT MARKING

6.1 MARKING

All water pipes for external cooling circuits shall be clearly and permanently marked at all
connection points to indicate the direction of flow.
All drain plugs shall be clearly marked with an identifying colour.
Battery and dc circuit terminals shall be clearly marked to indicate their polarity.
All timers shall be marked or labelled to indicate their time control range.
Earth connections shall be labelled with the following standard earth symbol in black on
a yellow background.

6.2 LABELLING

Labels shall be in English, or in pictorial form in accordance with SANS 1186.

Labels shall be indelibly and permanently marked, and shall be securely attached to the
equipment.
A label indicating the grade of oil shall be attached to the diesel engine.
All printed-circuit cards shall be clearly identified.

| 29
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

All instruments shall be clearly labelled to indicate their function, and all alarm indicators
shall be clearly labelled to indicate the alarm they represent.
Statutory labels required to be attached to building doors, etc., shall be provided, and
fitted when applicable.
Labels that have red letters on a white background, the lettering being of height at least
10 mm, shall be affixed to all places where danger can exist owing to automatic start-up.
These labels shall read:
DANGER
THIS MACHINE SHALL START WITHOUT NOTICE. BEFORE WORKING ON THE
MACHINE LOCK THE CONTROL SWITCH ON THE CONTROL PANEL IN THE OFF
POSITION
A label shall be attached adjacent to each terminal to indicate its function and
designation in accordance with the relevant circuit diagram.
A graphic diagram with an electric flash in accordance with type designation WW7 of
SABS 1186, and a label indicating the voltage shall be placed near all mains terminals.
Labels may be engraved on sandwich plastic material that is suitable for tropical outdoor
use.
Warning and danger labels shall be in red on a white background.
Information and instruction labels shall be in black on a white background.
Devices fitted to the set shall be labelled in accordance with the relevant circuit diagram.
Components shall not be labelled on the component, but on the chassis or printed circuit
board adjacent to the component.
Electronic modules shall be labelled to identify them, and the rear connectors shall be
keyed to prevent incorrect positioning.

6.3 RATING PLATES

All major items of plant shall be provided with corrosion-resistant rating plates that
comply with the requirements of the IEC standards. The following details shall be clearly,
legibly and indelibly marked on the plates:
a) the manufacturer's name;
b) the manufacturer's type number;
c) the manufacturer's serial number;
d) the year of manufacture;
e) the rated values. These values shall include the engine speed, power, operating
altitude, voltage, power factor, frequency, etc., depending on the item of plant; and
f) the short-time withstand current, in kA, for the maximum time, in seconds, before the
protection operates.
g) Neutral Earthing method,
h) Performance Class,
i) Load Acceptance,
j) Type of fuel used,

| 30
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

Rating plates shall be permanently fixed in a prominent position on the equipment.

6.4 TESTING OF THE DIESEL GENERATOR

In order to test the Diesel Generator, it shall be synchronized with the Mains and
adequately loaded. The Contractor shall provide the minimum testing frequency and
loading in the Schedule AB in Appendix A.

6.5 SAFETY

The plant and all its equipment and installation must comply with the regulations of the
Occupational Health and Safety Act, OHSACT.

6.6 DOCUMENTATION

The following documentation shall be delivered with the Diesel Generator System over
and above the requirements of the Employers VDSS (Vendor Submittal Schedule):
a) As-built drawings of the plant, showing all the main dimensions.
b) Complete set of the as-built system schematic drawings.
c) Electrical drawings in accordance with the drawing standards and symbols as
specified.
d) Drawings of fluid systems with the symbols in accordance with ISO 1219-1.
e) Installation instructions;
f) Operating and Maintenance Manual, consisting of:
g) operating instructions of all equipment in the supply;
h) routine maintenance instructions, including fault-finding and repair procedures, for all
major items of equipment in the supply;
i) a set of circuit diagrams clearly identifying all components and wire numbers; and
j) a set of circuit and layout drawings of all modular equipment.

k) Two hard copies and two electronic copies of a spare parts list for all major items of
equipment, that contains the following information:
 A description of the part;
 the manufacturer's name;
 the manufacturer's part number;
 the NATO reference code, when applicable; and
 the rating and tolerance of the part, when applicable.

l) Type tests certificates.

Manufacturer’s works test certificates of the following:
 the diesel engine (manufacturer's standard test);

| 31
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

 the generator (manufacturer's standard test); and

 control panel - simulated functional operation.

6.7 LOGISTICS

6.7.1 Spares and special tools

6.7.1.1 Spares
A list of recommended spare parts to allow for normal operation over a period of 12
months shall be provided.
All spare parts shall be guaranteed to be available for a period of 10 years from the time
of delivery.
All spares, where more than one item is enclosed in a package, shall be packed in
sealed and re-sealable packaging, which is clearly marked with the item and its part
number, and the quantity within the packaging.
6.7.1.2 Special tools
Any special tools required for the installation and maintenance of the set shall be
provided.

6.7.2 Responsibility for Tests

The manufacturer is responsible for all tests. Test shall be performed in accordance with
SABS ISO 8528-6 and this section of the specification.

6.7.3 Type Tests

Type tests shall either be performed after the first unit has been completed, or the
results of type tests on identical equipment shall be submitted with the tender
documents. In the former case, the purchaser or his representative shall be a witness to
the tests, and shall certify the equipment if it passes all the tests to his satisfaction. The
tests shall be in accordance with ISO 8528-6.

6.7.4 Insulation-resistance Test

An insulation-resistance test shall be applied to all circuits that do not contain

components such as semiconductor devices, electronic modules and printed-circuit
cards. Printed-circuit cards shall be removed from the connectors prior to testing of
circuits. This test shall be performed in an atmosphere where the relative humidity is not
higher than 85%, and shall consist of the following:
 a test voltage of 2 kV (r.m.s) applied for 1 minute for all ac circuits below 1 000 V,
between the conductors and any earthed components;

 a dc test voltage of 500 V applied for 2 minutes between two separate circuits, using
a 500 V resistance tester. The resistance recorded must exceed 50 M;
| 32
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

 a test voltage as in b) above, but between all circuits connected together and the
frame;

 a test voltage of 1 kV (r.m.s) applied for 1 minute to all dc circuits.

6.7.5 Operational Works Test

The following tests shall be performed:

 A full functional test of all control and operating systems.
 A full load test, at unity power factor of the generator, for a period of at least 1 hour.
This test should be followed immediately by any overload capacity test as specified.
During this test, the following shall be recorded at 10 minute intervals:

a. engine temperature;
b. engine oil pressure;
c. generator voltage;
d. generator frequency; and
e. generator current.
f. A step load acceptance test with a cold engine. Where it is impractical to perform
tests at the supplier's works, the supplier shall provide the purchaser with copies of:
g. The engine manufacturer's test results, clearly indicating the specified performance;
and
h. The generator manufacturer's test results, clearly indicating the specified
performance.
i. A pressure test of the air receiver of the compressed-air starter system.
j. A pressure and functional test of the air valves included in the compressed-air starter
system.
The supplier shall perform a simulated function test of the control panel.
Test results shall indicate that the performance at the specified site altitude meets the
requirements of ISO 3046: 1975.

6.7.6 Commissioning Tests

On completion of the installation, the following tests shall be performed:

a. A full functional test and Acceptance test of all control and operating conditions;

b. a load test utilizing the available site load and under the load parameters given, for a
period of at least 1 hour. During this test, the following shall be recorded at 10
minute intervals:
c. engine temperature;

d. engine oil pressure;

| 33
DRA-C8396-ECI-SPC-059 of
34
 MV Generator
(11kV) Specification

Rev. A Date. 18.08.2014

e. generator voltage;

f. generator frequency; and

g. generator current.

This test shall be continued until it is established that the engine temperature is stable
for at least 20 minutes. The equipment shall perform in accordance with the
requirements as specified; and the noise produced by the engine/generator set shall be
measured in accordance with SABS 0103, and shall comply with the noise levels as
specified.
h. Battery discharge test.
i. Battery charger test.

6.7.7 Tests on Painted or Coated Surfaces

All tests to be carried out on painted/coated surfaces shall be in accordance with the
requirements of Document No. 003428-28 (Corrosion Protection of Electrical and
Instrumentation Equipment).

6.7.8 Special Tests

If any special testing is required, details shall be specified.

7. PREPARATION FOR DELIVERY

7.1 PACKING

The system shall be suitable packed to prevent damage to the system or any
components during transportation to site, and to allow for outdoor storage on site before
installation.

7.2 SHIPPING

The Diesel Generator System may be shipped as a unit or dismantled (however the
system will be preferably shipped as complete as possible to minimise works on site).
When the set is to be shipped dismantled, all dowel pins and shims used for alignment
shall be marked to facilitate identification, and shall be suitably packed and shipped with
the set.

7.3 PERMISSIONS

The Contractor shall ensure that all requirements of permissions, granted by the
following organisations, are met:
7.3.1 The Ghanaian transport / roads authority
7.3.2 Gridco / ECG / VRA or other relevant power authority
7.3.3 Any relevant local authority

| 34
DRA-C8396-ECI-SPC-059 of
34