SPECIFICATION P-161:81

(UDC 621.313. 322-84)

DIESEL GENERATING SETS (250, 625 & 1250 KVA)

PAKISTAN
WATER AND POWER DEVELOPMENT AUTHORITY DESIGN DEPARTMENT (T&G) POWER

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 0 FORWARD

0.1 This specification has been prepared by the Standards and Research Directorate of
the Design Department (Power) WAPDA.

0.2 This specification is subject to revision as and when required.

0.3 This specification is intended for procurement of material and does not include
provisions of contract.

1 SCOPE

1.1 This specification is for skid mounted Diesel Generating Sets for use in power plants
supplying electric power to isolated rural areas.

2 DEFINITIOINS

2.1 Cyclic Irregularity

The ratio of the total variation in speed (instantaneous angular velocity) at the
flywheel during one engine cycle to the mean speed when the engine is running at
any load upto and including rated load and at rated speed. This is conveniently
expressed as follows:

Maximum speed – Minimum speed

Mean speed

2.2 Steady Load Speed Band.

The maximum total variation in speed, (Rev/min) expressed as a percentage of the

mean speed which may occur while there is no change in external load conditions.

2.3 Speed Droop

Permanent change of governed speed from no load to full rated load, expressed as a
percentage of the nominal speed.

2.4 Horse Power

The horse-power is equivalent to 550 ft. lb/sec. The metric unit, variously known as a
Cheval Vapeure (c.v), Pferdekraft (PK) or Pferdestaerks (PS), is slightly smaller than
the horse-power

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 1. Cheval vapeur, etc. = 0.986 horse-power
2. Horse-power = 1.014 cheval vapeur, etc.

3 STANDARD OPERATING CONDITIONS.

3.1 The standard operating conditions are.

Barometric pressure 749 mm Hg corresponding to an altitude of

Humidity
Air temperature at inlet
Temperature of cooling water at 24 °C
inlet to charge air cooler
Intake air depression
Exhaust back-pressure
Ancillaries
150 meters (above sea-level)
Water vapor pressure of 15 mm Hg (49%
Relative Humidity)
29.4 °C
Equal to that obtaining with air silencer
and/or filter (cleaner) normally fitted to the
engine in service.
Equal to that obtaining with the exhaust
system recommended by the engine
manufacturer.
The engine shall be driving all continuously
running ancillaries which are in service
mechanically connected to it, and which are
necessary to its operation, such as collant and
lubricant circulating pumps, scavenge or
super-charging blowers.

4 SITE OPERATING CONDITIONS

4.1 Atmospheric Conditions

Pakistan has three distinct seasons namely, summer, winter and the rainy season.
The period for the seasons vary in different parts of Pakistan but generally summer
weather remains from March to middle of June, when the rains start and continue
upto middle of October, when the winter begins. The climate is mostly mild except
for the mountains in the North and some desert areas in the middle and south of
Pakistan. During the rainy season moderately high temperatures are combined with
high humidity. Dust storms with very heavy dust concentration are common in
creating parts of Pakistan .The dust can be of very fine particles even upto 3 micron
in size.

4.2 Altitude

The altitude in Pakistan varies from upto 100 meters for the plains to 2000 meters
and even above for the mountain areas.

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 4.3 Ambient Temperature

The following ambient temperature may be considered for the operation of the
Diesel Generating Sets.

- Maximum in shade 50 °C
- Maximum mean over 24 hours 45 °C
- Minimum temperature -10°C

5 TYPE OF POERTION

5.1 The diesel generating sets shall be designed for continuous operation for long periods
without any interruption except for overhaul or the abnormal repair.

6 GENERAL
6.1 The Diesel Generating Sets shall be skid mounted complete with the diesel engine,
coupling, generator, control panel, piping for fuel water and air circuits and electric
cables from generator to the control panel. The generator control panel shall be
capable of being installed separately upto 8-meters away from the diesel generating
set. The diesel engine and generator shall be directly coupled and mounted on the
skid. Suitable foundation blots shall be provided in the skid mounting.

6.2 Provision shall be made for providing lifting books on the diesel generating set as a
complete unit, diesel engine & generator as separate units and the control panel to
facilitate lifting.

6.3 The engine, generating set, accessories and parts shall be brand new and NOT
reconditioned.

7 DIESEL ENGINE

7.1 General

7.1.1 The Diesel Engine shall have 1500, 1000 & 750 rpm for sets of 250, 625 & 1250
kVA respectively, heavy duty, solid injection, compression ignition, exhaust gas
turbocharged with intercooler, water-cooled closed circuit with radiator, electric
starting, four stoke, multi –cylinder forced lubrication with lubricating oil cooler,
mechanical/hydraulic governor, suitable flywheel for flicker-free operation and
exhaust silencer with necessary piping etc. All parts shall be easily accessible for
inspection and repairs.

7.1.2 The engine shall be suitable to run on fuel as per grade No. 2D of ASTM D975-78
for 250 & 625 kVA sets and as per grade No.4D for 1250 kVA sets.

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 7.2 Scope of Supply

7.2.1 Engine Components and Accessories

1. Starting battery
2. Battery charger with arrangement for trickle and boost charge
3. Turbo-charger
4. Inter-cooler
5. Extra heavy duty inlet air filter
6. Cooling water circulating pump
7. Radiator and fan
8. Fuel oil daily service tank
9. Fuel oil hand pump
10. Fuel oil transfer pump (230 volts A.C)
11. Fuel oil filters (No.1 & 2)
12. Fuel feed pump
13. Fuel injection pump
14. Governor
15. Lubricating oil cooler
16. Double oil filters with automatic by pass
17. Lubricating oil pump
18. Flywheel
19. Exhaust silencer
20. Control panel accessories as per clause 9.2

7.2.2 Tools

The following tools shall be provided:

1. Crank deflection guage

2. Thickness guage
3. Nozzle tester with pressure guage
4. Torque wrench
5. Cylinder max, pressure indicator
6. Complete set of tools for maintenance and overhauling engine and its
accessories

7.3 Rated and Nominal Power Output & Speed

7.3.1 The standard rating of the engine is the net output, in brake horse power, which
the engine is capable of delivering continuously at the rated rpm under the
conditions specified in clause-3, provided the fuel as per clause 7.1.2 and the
lubricating oil approved by the manufacturer, are used. Nominal value of such
rating shall be 372, 931 & 1862 HP for generating sets of 250, 625 & 1250 KVA
respectively.

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 7.3.2 The engine shall be capable of satisfactorily providing an output 10 percent in
excess of the standard rating at the same speed for one hour in any 12 hours
consecutive running.

7.4 Governing

7.4.1 The governor shall be of the mechanical or hydraulic type. It shall not use any
electronic parts.

7.4.2 The engine shall run steadily at any load within its rated load to the standards of
governing given below:

S r. a) Load variation at rated b) Max. change of c) Max.

No . speed speed as a %age recover
time
(Seconds)

1. On suddenly taking off the rated Temporary change=10 15

load Permanent
change=4.5

2. On suddenly throwing on the Temporary change=10 15

rated load of engines having a Permanent
rating of not more than 10.56 change=4.5
kg/Cm2 b.m.e.p (Brake mean
effective pressure)
3. On suddenly throwing on 70% of Temporary change=10 15
the rated load of engines having a Permanent
rating between 10.56 and 17.59 change=4.5
Kg.Cm2 b.m.e.p.
4. On a change of load, both on and Temporary change=10 5
off, by any step of 20% of the Permanent
rated load change=4.5

7.4.3 When the engine is delivering between 10 percent and 100 percent of the rated
power output, the steady load speed band shall not exceed 1 percent of the rated
speed.

7.4.4 The maximum recovery time form temporary disturbance to within the steady
load speed band at the new load, shall not exceed that given in column (c) for the
specified conditions.

7.4.5 An external means of adjustment of the nominal speed setting by plus or minus
5% at all loads between zero and rated load shall be provided.

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 7.4.6 The secure satisfactory parallel operation and load sharing with other sets, the
total governor speed drop shall be, or shall be readily adjustable to be between
3.5 percent and 4.5 percent of the nominal speed.

7.4.7 The cyclic irregularity is independent of the number of poles of the generator, and
refers to the angular velocity at the rotor of the electrical machine. The cyclic
irregularity shall not be worse than the following values:

Engine impulses per second Cyclic irregularity not worse than

Less than 10 , 1/150

10-20 Engine impulses per second divided
by 1500

7.5 Declared Fuel Consumption

7.5.1 The manufacturer shall declare the fuel consumption of the engine at standard
rated power output as specified in clause 7.3 with operating conditions specified
in clause 3 and also at three-quarters and half of this power output. Fuel
consumption shall be stated in grams of fuel consumed per brake horse-power
hour. A tolerance of 5 percent shall be allowed above the declared value of the
fuel consumption.
He statement shall be based on the use of diesel fuel oil as per clause 7.1.2.

7.6 Starting

7.6.1 Electric starting of the engine shall be provided and shall include all equipment
necessary to start and run the diesel engine without any external source of
power, at all ambient temperatures. The diesel generating set shall be supplied
complete with its own battery and battery charging system.

7.7 Cooling System

7.7.1 The diesel engine shall be water cooled by means of a closed circuit cooling
system. Proper inhibitors shall be added in the cooling water to protect the
cooling system against corrosion & sludge. The cooling water shall be circulated
by a centrifugal pump filled on the engine. The heated up cooling water shall be
cool by a fan driven from the engine. The radiator shall be rated for a maximum
ambient temperature of 50°C and approximate coolant temperature of 82°C.

7.7.2 The radiator shall be provided with a thermostat and bypass line between the
thermostat and the cylinder block to reduce warm up time and to avoid
overheating of the cylinder head.

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 7.7.3 The radiator may also be provided with a thermostatically controlled automatic
shutter system to vary quantity of air flow to the radiator, to maintain engine
temperature within design limits at all ambient temperatures specified in clause 4
irrespective of load.

7.8 Fuel Oil System

7.8.1 The fuel service tank shall have capacity for at least 12 hours operation at full load
and shall be fitted with an electrically operated pump (230 v.a.c) with provision
for manual operation for refueling from Reservoir tank. The service tank shall be
properly calibrated and equipped with fuel level indicator.

7.8.2 The fuel oil from service tank shall be supplied by gravity feed or food pump to
the injection pumps through two fuel filters with replaceable filtering elements.

7.9 Lubricating Oil System

7.9.1 The lubrication oil system shall be closed circuit, forced feed type with double oil
filters with as automatic by pass to avoid stoppage of oil circulation. The system
shall be complete with oil filters of replaceable element type, oil cooler, oil
pressure indicator and low oil pressure alarm.

7.9.2 All parts requiring lubrication must be suitably protected from ingress of dust.

7.10 Combustion Air System.

7.10.1 The combustion air –take system shall be complete with extra heavy duty air
filters, necessary piping, fixtures etc., to supply clean air to the inlet manifold
even under conditions of storms heavily charged with fine dust. The air filters
should be re-useable after cleaning. The charge intake shall be exhaust gas turbo-
charged and intercooled.

7.11 Exhaust System.

7.11.1 The exhaust system shall include exhaust muffler silencer, exhaust manifold,
expansion joints, flexible coupling etc.

7.12 Torsional Critical Speeds.

The manufacturer shall be responsible for ensuring that the torsional vibration
conditions of the dynamic system comprising engine and generator are
satisfactory. The combined system of the set shall be such that torsional
vibration stresses and vibration amplitudes resulting from torsional critical
speeds in the generator shall not exceed any maximum permissible limits laid
down by the generator manufacturer.

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 7.13 Angular Deviation of Alternating Current Generators in Parallel

The combined inertia of the flywheel and the alternator rotating system shall
be such that the angular deviation in either direction from the position of
uniform rotation (calculated on the assumption that the torque of the
alternator, i.e. the torque opposing the motion of the engine, is uniform
torque opposing the motion of the engine, is uniform throughout the engine
cycle) shall not at any time exceed 2.5 electrical degrees.

8 GENERATOR

8.1 General

8.1.1 The a.c. generator shall be constant voltage, 50 Hz, three phase internally air
cooled, self excited type with a power factor of 0.8. Damper windings shall be
uniformly distributed round the periphery. The generator shall be suitable for
parallel operation and shall be capable of supplying unsymmetrical load.

8.1.2 The voltage regulation shall be within ± 2.5% at any load within 0 to 100% of rated
load .This shall be achieved by incorporating automatic voltage regulator.

* An electric degree is 1/360 of a complete electrical cycle. If P=number of poles

of an alternator, the number of electrical cycles in a revelation is p/2, so that 360
mechanical degrees correspond to p/2x360 electrical degrees, or one mechanical
degree = p/2

8.1.3 The generator shall be designed to withstand the speed of 1.2 times the rated
speed.

8.1.4 The degree of protection provided by the enclosure for the generator shall be IP-
23 as per IEC-34-5.

8.1.5 The generator shall be continuous running duty type (SI) as per IEC-34-1 (Clause
4.1).

8.1.6 The generator body and control panel shall have provision for earthing.

8.2 Type of Insulation

8.2.1 Type of insulation shall be class-B for stator and class-F for rotor as per IEC-34-1.

8.3 Ratings

8.3.1 The generator shall have the following ratings:

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 Outpur 250, 625 or 1250 kVA for 372,931 & 1862H.P
engines respectively
Voltage 415 Volts
Phases 3-phase, 4-wire, grounded neutral
Frequency 50 Hz
Power factor 0.8 lagging
Speed 1500, 1000 & 750 rpm for units of 250, 625 &
1250 kVA respectively.

8.4 Over-load

8.4.1 The generator shall be capable of supplying as over-load of 10% at least for one
hour and 50% overload for 2 minutes.

8.5 Temperature Rise

8.5.1 Temperature rise of the windings shall not be more than 70°C for class-B and 90°C
for class-F insulation with an ambient of 50°C under rated conditions.

8.5.2 Thermal sensors shall be provided in the stator windings to operate the trip relay
for excess temperature rise.

8.6 Unbalance Load

8.6.1 The generator shall be capable of continuously operating on as unbalance system

such that, with none of the phase currents exceeding the rated current, the ratio
of the negative sequence component of the system of current to the rated
current does not exceed the following values:

8.7 Short-Circuit Current.

8.7.1 The generator shall be capable to withstand a peak value of short circuit current
on all phases during operation at rated voltage upto 15 times the peak value or 21
times the rms value of the rated current for 3-seconds.

8.8 Vibration

8.8.1 The rotor shall be dynamically balanced to avoid vibration. The shaft current shall
be eliminated to avoid damage to rotor bearings. If it is not possible to eliminate
the shaft current the rotor bearings may be housed in electrically insulated
housing.

8.8.2 The rotor should not resonate with the engine. In case the engine and generator
are manufactured by different manufacturers the design of rotor and the engine
should be checked by the main suppliers to assure that the resonance does not
occur.

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 9 CONTROL PANELS

9.1. Generator Control Panel

9.1.1 Self supporting, sheet steel clad generator control panel shall be capable for
mounting on the ground 8-meters away from the Diesel Generating set.
Generator control panel shall be with following special requirements.

9.1.2 Circuit Breakers

9.1.2.1 Air break circuit breakers shall meet the following requirements.

The continuous current ratings shall be as given below:

Generator Circuit Breaker

Ratings Ratings
(KVA) (Amps)
--------- ---------------------
250 500
625 1250
1250 2500

9.1.2.2 Ratings

i) Rated voltage 415 Volts

ii) Rated frequency 50 Hz
iii) Rated nominal current 500,1250 & 2500 Amps
iv) Rated symmetrical braking
capacities shall be as under:

Rated Current Symmetrical breaking

(Amps) Capacity (Amps)
500
1250 10,000
2500 36,000
85,000
v) Rated making capacities shall be as under:
Rated Current Making Capacity
(Amps) (Amps)
----------- ---------------------
500 25,000
1250 92,000
2500 200,000
vi) One minute power frequency 2500 Volts
withstand voltage

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 9.1.2.3 Trippings

9.1.2.3.1 Each circuit breaker shall be equipped with two direct operating adjustable
over-current releases. One shall be of Thermal type and the other shall be of
magnetic type.

9.1.2.3.2 The thermal release, when carrying 120% of rated current shall operate and
open the breaker within 120 minutes starting from the hot state, i.e. with the
release at the working temperature corresponding to the current setting.

9.1.2.3.3 The magnetic release shall be of the instantaneous type and shall operate
within 20 milliseconds of energizing.

9.1.2.3.4 The calibration setting shall be base on an ambient temperature of 40°C.

9.1.3 Sufficiently sized copper bus bars shall be provided.

9.1.4 Sufficiently sized connecting copper cables shall be provided with vermin
proof entry into the panel.

9.1.5 The neutral shall have provision for earthing.

9.1.5.1 The control panel shall be provided with:

1 Nos. Constant voltage excitation equipment

1 Nos. Circuit Breaker 500, 1250 or 2500 amps rating for
generators of 250, 625 or 1250 kVA rating
respectively.
1 Nos. Stator winding overheat trip relay (to trip the circuit
breaker in conjunction with thermal sensors in the
stator winding).
3 Nos. Ammeters.
1 Nos. Voltmeter 0-600 volts
1 Nos. Voltmeter selector switch.
1 Nos. Frequency meter.
3 Nos. Current transformers accuracy class-1
1 Nos. 3-phase, 4-wire, KWH meter suitable for unbalanced
loads.
1 Nos. 3-phase, 4-wire, Wattmeter for unbalanced load.
3 Nos. Control Fuses
1 Se t . Indicating lamps (for Breaker “ON” and Stator winding
overheat relay “operated”).
1 Se t . Lamps for illumination (normal and emergency)
1 Nos. Manual voltage control
1 Se t Test terminals

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 9.2 Engine Control Panel

9.2.1 Engine control panel shall be suitable for mounting on the engine or it may be
integrated in the main control panel and shall include following:

1 No. Oil pressure gauge

1 No. Low oil pressure indication and tripping devices.
1 No. Water temperature gauge
1 No. High water temperature indication and tripping
devices.
1 No. Tachometer
1 No. Engine over speed indication and tripping devices.
1 No. 10% overload alarm
1 No. Battery charge rate Ammeter
1 No. Start/stop push button
1 No. Manual speed control
1 Se t . Indicator lamps
1 Se t . Lamps for illumination (normal and emergency)

9.3 Synchronizing Equipment for Parallel Operation

Generators are required for parallel operation .Synchronizing equipment as below

shall be provided.

9.3.1 Synchronizing Panel

1 No. Double voltmeter

1 No. Double Frequency Meter
1 No. Synchronoscope

9.3.2 Main Control Panel

1 No. Synchronizing switch

1 No. Reverse power relay
1 No. Miniature circuit breaker/fuses (for instrument protection)

10 CONTROL WIRING AND TERMINATIONS.

10.1 General

10.1.1. The control cable, generator and switch board wiring cable shall be 1100 V
grade PVC insulated and PVC sheathed cable.

10.1.2 The conductor shall be of stranded tinned annealed copper wire of

conductivity equal to 100 percent IACS. The minimum size for voltage and
current circuits shall be 2.5 sq.mm and 4 sq.mm respectively.

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 10.1.3 The following coloured wires may be used to identify

Colour of Wire Circuit Particulars

Red Red phase connections

Yellow Yellow phase connections
Blue Blue phase connections
Green Neutral connections whether
Earthed or un earthes.
Black Connection in ac circuits
Grey Connection in dc circuits
White Connection in alarm and
indication circuits

10.2 Terminations

10.2.1 Each conductor of control cable, generator and switch board wiring shall be
terminated at each end in terminal block with a pressure connector or spade type
terminals. The terminals shall be tinned copper and may be crimped or
compression applied.

10.2.2 The end of each wire shall be identified by machine lettered permanent fiber or
plastic identification identifications devices .The same letters shall be designated
to the terminal blocks with which they are associated.

10.2.3 A cable terminating box of suitable dimensions shall be provided on the

generator. The box shall be vermin and dust proof. The marking of terminals in
the generator box (intended for use with control panel) shall be the same as
those of terminals of the control panel in which they are to be connected through
separate cables. The length of control and wiring cables for connection between
the generator and the control panel shall not be less than 15 meters.

11 TESTS

11.1 Tests for Engine

11.1.1 Routine Tests

The following routine tests shall be carried out on all diesel engines, supplied
under this specification:

a) Standard Test
b) Measurement of fuel consumption
c) Governor tests
d) Functional testing of all control and safety devices.

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 11.1.2 Type Tests

The following type tests shall be carried out on one representative diesel engine
out of the engines of the same design and rating:

a) Standard test
b) Measurement of fuel consumption
c) Governor tests
d) Continuous heat running test
e) Overspeed tests

11.2 Tests for Generator

11.2.1 Routine Tests

The following type tests shall be carried out on one representative generator out
of the generators of the same design and rating:

a) Dielectric test
b) Functional testing of all control and safety devices.

11.2.2 Type Tests

The following type tests shall be carried out on one representative generator out
of the generators of the same design and rating:

a) Temperature rise test

b) Dielectric test
c) Determination of losses and efficiency

12 TEST METHODS

12.1 General Test Conditions

12.1.1 Place

The tests shall be carried out at the manufacturer’s works and necessary testing
facilities equipment and material shall be provided by the manufacturer free of
cost.

12.1.2 Auxiliaries

Any super charger with its after cooler, oil and water cooler, fan, radiator,
charging generator and circulating water pump to be supplied with the engine
shall be coupled up and running throughout the tests.

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 12.1.3 Fuel and Lubricating Oil

The tests shall be carried out with fuel conforming to clause 7.1.2. Lubricating oil
for tests shall be of the type approved by the manufacturer.

12.1.4 Nature of Load

The full load for the test shall be the standard rating, defined in clause 7.3,
adjusted to the operating conditions at the test bed. For the purpose of providing
the load the engine may be coupled to a dynamometer (the calibration constant
of which shall be verifiable by the purchaser) or to the generator itself. In the
latter case the efficiency of the generator must be determined at the power
factor of the load current under test condition and used for determining the test
loading. Test certificates for the generator shall be available.

12.1.5 Measurement of shaft outputs

The dynamometer used to measure the output of the engine shall be accurate
within two percent of the reading at full load output of the test.

12.1.6 Running-in

Before the start of the tests, the engine shall be run as desired by the
manufacturer for a sufficient length of time to ensure that steady working
conditions have been reached.

12.2 Tests for Engine

12.2.1 Standard Test

The test shall include a period of running at rated full load, to be followed
immediately by one hour at 10% overload, sufficient to demonstrate that the
engine is mechanically sound and capable of sustaining the standard rating as
defined in clause 7.3.

12.2.2 Measurement of Fuel Consumption

12.2.2.1 The fuel consumption at full load, and at three quarters and half of this load,
shall be measured over a minimum period of 30 minutes for each load. During
the above period the load shall be maintained as nearly as possible at the test
figure. The weight of fuel used shall be accurately determined by an agreed
method, any specific gravity figures or other constants being obtained from
samples of the actual consignments of fuel used for the test.

12.2.2.2 The measured fuel consumption shall conform to the declared fuel
consumption as per clause 7.5.

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 12.2.2.3 If the load is provided by the generator, the total energy output during the
test period shall be measured by the kilowatt hour meter which is suitable for
measuring unbalanced loads in case of poly-phase circuits.

12.2.3 Governor Tests

Tests to ensure compliance with clause 7.4 of this standard shall be made when
the engine is coupled to the generator .The steady load speed band shall be
measured, over a period of not less than two and not more than five minutes.

12.2.4 Continuous Heat Running Test

12.2.4.1 The test shall be carried out by putting the engine in a permanent temperature
closed door hall of approximate dimensions 10, 000 x 7000 x5000 mm. The
temperature of the hall shall be set and controlled at 45± 2°C. by using
suitable heaters and adjusting the inlet and exhaust air. The measurement of
temperature shall be made by thermo-electric couple senser .Exhaust gas
from the engine shall be discharged directly outdoors .The engine shall be run
continuously for 12 hours at full load with 25 measurements at 30 min.
intervals. The measurements shall include lubricating oil consumption,
lubricating oil temperature, cooling water consumption, cooling water
temperature, exhaust gas temperature, load, speed, fuel consumption and
lubricating oil pressure.
Further, the state of exhaust colour, presence of knocking, misfiring, running
condition, vibration, excessive noise and leakages of gas, water and oil shall be
observed and recorded.

12.2.4.2 The measurements made above shall not exceed any specified values. No
adjustment on engine besides for maintaining the load constant shall be
permitted in this test. Re-run shall be permissible only in case the engine is
stopped for other reasons than engine trouble during the test.

12.2.5 Overspeed Test

12.2.5.1 The engine shall be operated for a period of one to three minutes at the
speed of 110 percent of normal speed.

12.2.5.2 There shall not be occurrence of resonant vibration in generator and engine
common bed, and abnormal temperature rise indication or damage to any
part.

12.3 Tests for Generator.

12.3.1 Temperature Rise Test

The temperature rise test for stator and rotor windings of the generator shall be
carried out as per clauses 14 & 15 of IEC 34-1 following Resistance method. The

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 temperature rise measured shall not be more than specified in clause 8.5.1 of this
specification.

12.3.2 Dielectric Test

The high voltage test shall be carried out as per clause 17 of IEC-43-1. The test
voltage shall be 2000 volts.

12.3.3 Determination of Losses and Efficiency

The total losses shall be worked out at 25%, 50 %,75 %, 100% and 110% of load by
summation of various component losses determined from various tests as per
section-4 of IEC-43-2. The efficiency figures calculated form the total losses shall
be as per the manufacturer’s specified figures after allowing the tolerances
mentioned in section 9 of IEC-34-1.

13 MARKING

13.1 The following markings on a suitable name plate shall be fixed on the Diesel
Engine, Generator and Control Panel separately.

13.2 Diesel Engine

1. Name of the Manufacturer

2. Wapda Purchase Order No. and date
3. Year of manufacture
4. Rated B.H.P (as per clause 7.3)
5. R.P.M
6. Fuel tank capacity in litres (if built in type)
7. Weight of diesel engine
8. Weight of diesel engine and generator as a complete unit
9. Wapda specification Number.

13.3 Generator.

1. Name of the manufacturer

2. Wapda P.O. No. and date
3. Year of manufacture
4. Name of the machine
5. No. of phases
6. Rated output KVA
7. Power factor
8. Frequency
9. No. OF poles
10. R.M.P
11. Rated armature voltage
12. Excitation voltage

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 13. Class of insulation
14. Weight of generator
15. Weight of diesel engine and generator as a complete unit
16. Wapda specification No.

13.4 Control Panel

1. Name of the manufacturer

2. Wapda P.O No. and Date
3. Year of manufacturer
4. Rated voltage
5. Interrupting rating of Main Breaker
6. Thermal settings of main breaker
7. D.C. voltage
8. Weight of panel
9. Wapda Specification No.

14 INSPECTION

14.1 Routine tests will be carried out by Wapda’s Inspectors on all the Diesel
Generating sets and its accessories supplied to Wapda. All the facilities for
carrying out supplied to Wapda. All the facilities for carrying out the tests
including material (consumable & non-consumable) will be provided free of
cost by the manufacturer.

14.2 In case the Diesel generating sets and its accessories do not come up to these
specification, Wapda has the right to reject the generating sets or its
accessories at manufacturer/supplier’s risk and cost.

14.3 WAPDA’s inspectors may carry out any stage inspection during the
manufacture of the Diesel Generating sets ordered.

14.4 The type tests if required will be carried out to the satisfaction of WAPDA. All
facilities for these tests will be provided free of cost by the manufacturer/
supplier.

14.5 Certified type test report on identical units from independent testing agencies
may be accepted in lieu of the actual tests.

15 PACKING

15.1 In case of imported diesel generating sets sea-worthy packing suitable for
storage in open condition will be provided by the manufacturer at their own
cost .The address and marking required on the packages will be provided by
the manufacturer at their own cost. The address and marking required on the
packages will be intimated with the purchase order. Generally the marking
will contain the following information.

This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
 1. Purchase Order and Date
2. Address of the consignee
3. Manufacturer’s name and address
4. Package number and total number of packages
5. Weight of the package in kilograms
6. Instructions for handling
7. Packing load fixed in a suitable enclosure

16 SPARE PARTS

16.1 General

16.1.1 The recommended spare parts for engine and generator have been listed in
clause 16.5 and shall be procured alongwith the purchase of diesel generating
sets. The manufacturer shall attach to this list:

i) A list with the prices of the supplementary spare parts, which he deems
necessary to stock.
ii) A list with prices of the spare parts necessary when alternatives are offered.
While preparing the list of the supplementary spare parts, the Bidder shall
keep the contents of clause 16.2 in view.

16.1.2 All spare parts shall be new, unused and strictly interchangeable with the parts by
which they are intended to be replaced, and shall strictly conform to the relevant
specifications.

16.1.3 The unit prices of spare parts shall b e quoted in Unit Prices Schedule.

16.2. Estimation of Requirements

16.2.1 The quantity of each spare part shall be recommended by the manufacturer
keeping in view the following:

i). Replacement required in due course of time due to wear and tear of the
equipment under normal working conditions.

ii) Replacement required due to accidents, mal-functioning of the equipment

or any other emergencies.
iii) Replacement of the heat sensitive parts such as gaskets, due to severe
climatic conditions.

16.3. Spare Parts Book

16.3.1 For each separate piece of equipment the Contractor shall give a spare parts book.
This spare parts book shall contain an assembly drawing of the equipment which

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 shall show all parts of the equipment separately marked, designated and referenced.
The material of the part shall also be indicated. These sketches and lists of parts shall
be cress-indexed with the assembly drawings. The spare parts book shall present
information in a simple manner so that non-technical personnel may be able to
indent these spare parts. The lists of spare parts required shall be made with
reference to the spare parts book.

16.4 Packing

16.4.1 The spare parts shall be treated and packed for long storage under the climate
conditions specified in clause-4. Each spare part shall be clearly marked or labeled
on the outside of its packing with its description and purpose, and , when more
than one spare parts are packed in a single case or container, a general description
of its contents shall be shown on the outside of such case or container and a
detailed list enclosed . All cases, containers or other packages shall be marked and
numbered in an approved manner for purposes of identification.

16.4.2 All cases, containers or other packages are liable to be opened for examination and
packing shall be designed to facilitate opening and thereafter repacking.

16.5 List of Spares

16.5.1 Engine

1. Cylinder liners
2. Seal rings for cylinder liners
3. Piston rings
4. Piston complete
5. Oil ring
6. Fuel nozzle
7. Engine gasket
8. Working parts for fuel injection pump
9. Big-end bearings
10. Big-end bolts
11. Intake valve
12. Exhaust valve
13. Cylinder head
14. Various springs
15. Thermostat elements
16. Lubrication oil filter elements
17. Fuel filter elements
18. V-Belts for dynamo
19. V-Belts for cooling fan
20. Repair set for water pump
21. Set of gaskets for radiators
22. Radiator filler cap
23. Thermostat for the radiator

This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
 24. Coolant pump
25. Gaskets & bearing for the pump
26. Air filter elements

16.5.2 Generator and Control Panel

1. Carbon brushes (for slip-ring type generators)

2. Brush holders (for slip-ring type generators)
3. Bearings
4. Rectifiers
5. Condensers
6. Indicating lamps
7. Protection fuses
8. Diodes
9. Printed circuit plates if any

17 TECHNICAL DATA AND DRAINGS

17.1 Literature and Drawings with Bid

The following literature and drawings shall be supplied with each bid. The
literature and technical information shall be in English language, and all units
shown in the metric system.

1. Wiring diagrams of generator control panel

2. Assembly drawing of generator control panel
3. Wiring diagram of synchronizing unit
4. Outline drawing of generating set with major dimensions
5. Foundation design drawings/layout arrangement of plant
6. Recommended list of spare parts with price of each part as per clause 16.
7. Instruction manual describing erection, operation and maintenance
8. Reports of tests carried out
9. Details of components and accessories of the engine
10. A list of engine driven ancillaries for which the power requirement is to
be deducted from the nominal rating of the engine, and individual power
requirements of these ancillaries.
11. Engine control panel components.

17.2 Approval Drawings

The supplier/manufacturer shall be required to supply the following

information and drawings for each type of generating set for approval by
WAPDA:

1. Wiring diagrams of generator and control panel

2. Assembly drawing of generator and control panel

This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
 3. Wiring diagram of synchronizing unit
4. Foundation design drawings/layout arrangement of plant room
5. List of spare parts as per clause 16.

17.3 Final Manufacture’s Data

The following literature and drawings shall be supplied with each generating
set being supplied:

1. Wiring diagram of generator and control panel

2. Assembly drawing of generator and control panel
3. Wiring diagram of synchronizing unit
4. Outline drawing of generating set with major dimensions
5. Foundation design drawings/layout arrangement of plant room
6. Instruction manual describing erection operation and maintenance (ten
copies)
7. Layout of cable trenches and pipe connection
8. Spare parts book as per clause 16.3

17.4 Data Schedule

The following information, as applicable, shall be furnished with the bid for
each type of generating set:

17.4.1 Diesel Engine

1. Name of manufacturer
2. Manufacturer’s type designation
3. Continuous rating under standard conditions of clause 3, HP
4. Revolutions per minute
5. Direction of rotation*
6. Number and arrangement of cylinders
7. Cylinder bore, mm
8. Piston stroke, mm
9. Piston speed, m/s
10. Brake meaqn effective pressure, kg/cm2
11. Max. Cylinder pressure, kg/cm2
12. Compression ratio
13. Governor type
14. Governing characteristics as per clause 7.4

*The quoted direction of rotation should be that of the coupling to the driven
machine. It should be stated as clockwise or anti-clock-wise looking from the
engine towards the driven machine.
15. Type of fuel recommended
16. Fuel consumption, grams per brake-horse-power hour at the standard rating
as per clause 3 and at three quarter and half of the standard rating.

This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
 17. Type of grade of lubricating oil recommended
18. Lubricating oil consumption in grams per hour at the rated output.
19. Method of starting
20. Method of cooling
21. De-rating calculations/curves for radiator under varying ambient upto and
including extreme conditions as per clause 4.
22. Intercooler performance under varying ambient temperatures
23. De-rating calculations/ curves for engine
24. Weight of engine complete and dry, dg.
25. Maximum permissible water temperature, °C
26. Minimum permissible oil pressure, kg/cm2
27. Exhaust gas temperature at full rated output at the outlet of the silencer.

17.4.2 Generator

1. Name of manufacturer
2. Manufacturer’s type designation
3. Voltage regulation
4. Overspeed capability
5. Degree of protection by enclosure ( clause 8.1.4)
6. Insulation class for stator and rotor windings
7. Steady value of temperature rise in the windings
8. Rated output under standard conditions, KVA
9. De-rated output at 50°C ambient and 200m
10. Rated voltage, volts
11. Frequency, Hz
12. Power factor
13. Speed, RPM
14. Direction of rotation
15. Overload capacity
16. Excitation system with excitation voltage and power
17. Short circuit withstand capability
18. Capability to operate continuously on unbalanced
19. Rotor type
20. Losses and efficiency at 25%, 50%, 75%, 100% and 110% of laod

This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.
This document is property of Design NTDC. No Part of this can be modified or used for any purpose other than its designated purpose.