COPY CONTROLLED No.

MAIPO ALTO HYDROELECTRIC PROJECT

CONTRACTS AM-CO630

HYDROMECHANICAL AND ELECTRICAL DESIGN SERVICES

6305-EL-ETP-7080-A00
POWER AND LIGHTING SYSTEMS - MAITENES
DISCHARGE ZONE
EMERGENCY GENERATOR DIESEL SETS
TECHNICAL SPECIFICATION

REV PREPARATION STRABAG STRABAG

REVIEW PYRY PYRY APPROVAL
PYRY REVIEW APPROVAL
NAME SIGN. NAME SIGN. NAME SIGN. DATE NAME SIGN. NAME SIGN.

A00 SZE MGM FUP 15-03-17

AES GENER APPROVAL NAME SIGNATURE DATE

Modifications:
 6305-EL-ETP-7080-A00
POWER AND LIGHTING SYSTEMS
EMERGENCY DIESEL GENERATOR SETS
TECHNICAL SPECIFICATION

Table of Contents
1. INTRODUCTION .................................................................................................. 3
2. SCOPE ................................................................................................................. 3
3. STANDARDS........................................................................................................ 3
4. SERVICE CONDITIONS....................................................................................... 4
5. EMERGENCY GENERATOR ............................................................................... 4
5.1 DESIGN AND CONSTRUCTIONAL DETAILS: .......................................... 4
5.1.1 Plates : ........................................................................................... 4
1.1 Scope ......................................................................................................... 4
1.2 Functions, Layout, Performance ................................................................. 5
1.3 Design Requirements ................................................................................. 5
1.3.1 General .......................................................................................... 5
1.3.2 Diesel Engine ................................................................................. 5
1.3.3 Governor ........................................................................................ 6
1.3.4 Cooling System .............................................................................. 6
1.3.5 Fuel Oil System .............................................................................. 6
1.3.6 Lubricating Oil System ................................................................... 7
1.3.7 Combustion Air System.................................................................. 7
1.3.8 Exhaust System ............................................................................. 7
1.3.9 Noise Level .................................................................................... 7
1.3.10 Generator ....................................................................................... 7
1.3.11 Control Panels ............................................................................... 9
1.3.12 Battery Starting System ............................................................... 10
1.4 Control and Monitoring ............................................................................. 10
1.5 Tests ......................................................................................................... 10
1.5.1 Workshop Tests ........................................................................... 10
1.5.2 Site Tests ..................................................................................... 11
1.6 Spare Parts and Special Tools ................................................................. 11
1.6.1 Spare Parts .................................................................................. 11
1.6.2 Tools ............................................................................................ 12
1.7 Documents and Drawings ......................................................................... 12

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 6305-EL-ETP-7080-A00
POWER AND LIGHTING SYSTEMS
EMERGENCY DIESEL GENERATOR SETS
TECHNICAL SPECIFICATION

1. INTRODUCTION

The electrical auxiliary systems shall be of a quality commensurate with the

performance, reliability and availability requirements of the Electrical Equipment shall
be in accordance with all the relevant standards shall satisfy the requirements
specified herein and shall be designed to operate in the environmental conditions
specified in the relevant sections of this specification.

The electrical station systems shall be required to provide the voltage classes
indicated in Table 1.1. for operation of various plant equipment operating
mechanisms, plants, control and communication systems:

Table 1.1 Voltage classes

Nominal Frequency Neutral

Tolerance Phases Wires
Voltage Hz or DC Connection
400 10 % 50 5 % 3 4 Solidly earthed
220 10 % 50 5 % 1 2 Solidly earthed

2. SCOPE
This specification covers manufacture, assembly and testing at manufacturers
works, supply and delivery on site of the Emergency Generator Diesel for the
Discharge Chanel Modification loads belonging to the Surface Works Las Lajas.

a) One (1) Emergency Diesel Generator, 75 kVA, for emergency.

b) One (1) lot of special devices, tools, maintenance equipment etc., required for
installation, testing, commissioning and maintenance of the Diesel Generator.
c) One (1) lot of spare parts.
The scope shall include all components and other systems which are required for
performance, durability and satisfactory operation of the equipment even though not
individually or specifically stated in these specifications.

3. STANDARDS

The equipment shall comply in all respects with the latest edition of relevant Indian
Standard Specifications and IEC except for the modifications specified herein. A
Photo copy of such standards in English shall be enclosed with the offer.

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POWER AND LIGHTING SYSTEMS
EMERGENCY DIESEL GENERATOR SETS
TECHNICAL SPECIFICATION

4. SERVICE CONDITIONS

The ambient environmental conditions for the transmission lines are as follows.

Altitude : 800 to 2 500 m (above sea level)

Temperature Maximum : 40C
Temperature Average : 30C
Temperature Minimum : - 10C
Humidity Relative : 15-100 %
Maximum Wind : 130 km/h
Ice : 12 mm
Ceraunic Level : 60 storm/km-year

5. EMERGENCY GENERATOR

5.1 DESIGN AND CONSTRUCTIONAL DETAILS:

5.1.1 Plates :

1.1 Scope
a) One (1) 75 kVA (60 kW) standby Diesel generator set connected to
the 400 VAC distribution system of the diversion weir (power intake)
including fuel storage tank of 1,000 liters;
All including:
The combustion and cooling air supply and exhaust system;
The battery starting system;
The fuel oil system;
The generator and engine control, excitation, protection and
monitoring equipment;
All necessary accessories, wiring and cabling, cubicles, etc. to make
it a complete system;
The fuel oil and all consumable products for the tests and the first
filling of the fuel oil main storage tanks after the tests;
The spare parts and special tools.

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 6305-EL-ETP-7080-A00
POWER AND LIGHTING SYSTEMS
EMERGENCY DIESEL GENERATOR SETS
TECHNICAL SPECIFICATION

1.2 Functions, Layout, Performance

The 75 kVA generating unit of the diversion weir will be installed on the
right river bank at the power intake area and shall be connected to the
diversion weir 400 VAC distribution board (see drawing 6305-EL-PLA-
7010).
The emergency diesel generator units shall supply automatically the
auxiliary equipment in the event of failure of the normal 400 VAC
sources. Manual mode of starting and shut down shall also be provided.
The emergency Diesel generator units shall be designed for black-start
capability without external auxiliary voltage supply. For exceptional cases
when black-start is required and the powerhouse emergency Diesel is
not available, the Diesel generating unit at the diversion weir or at the
residence house may be connected via 12 kV system to the non-
essential loads busbar of the powerhouse main distribution board to
enable the start of one main unit.
Provisions for a test run under full load in parallel with the 400 VAC
distribution system shall be provided.
The diesel engine and the generator shall be directly coupled and
mounted on a skid. Provision shall be made to avoid transmission of
dangerous vibrations to the supporting structures.

1.3 Design Requirements

1.3.1 General
The equipment shall comply with the following standards:
ISO 3046/II and III: Diesel engines;
DIN 25467: Emergency generating stations with Diesel engines;
design; safety requirements;
IEC 60034.1 and 60034.5 for Generator.
The standby Diesel generator units shall be designed for continuous
operation and for long periods of standstill.
The diesel Generator units shall be provided to start/operate/stop in
complete autonomy with their own automatic/manual starting systems
and with independent ventilation and cooling systems.

1.3.2 Diesel Engine

The Diesel engine shall be of heavy duty type to continuously drive the
electric generator at the speed of 1,800 rpm maximum, solid injection,
compression ignition, exhaust gas turbo charged with inter-cooler, water-

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POWER AND LIGHTING SYSTEMS
EMERGENCY DIESEL GENERATOR SETS
TECHNICAL SPECIFICATION

cooled closed circuit with radiator, battery starting, four stroke, multi-
cylinder with changeable cylinder liners, forced oil lubrication with cooler,
mechanical or hydraulic governor, suitable flywheel for flicker-free
operation, exhaust silencer with necessary piping.

1.3.3 Governor
Between 10 and 100% of the rated output, the steady load speed band
shall not exceed 1% of the rated speed.
External means of adjustment of the nominal speed setting by 5% at all
loads between 0 and 100% load shall be provided.

1.3.4 Cooling System

The Diesel engine shall be water cooled by means of a closed water
cooling system. Proper inhibitors shall be added in the water to protect
the cooling system against corrosion and sludge.
The water shall be boosted by a centrifugal pump fitted on the engine, it
shall be cooled by a fan directly driven by the engine. The radiator shall
be rated for a maximum ambient temperature of 50 C (standard cooling
package). At site the maximum ambient temperature will be 20 oC.

1.3.5 Fuel Oil System

The capacity of the main storage tanks shall be:
for the 75 kVA (60 kW) Diesel generator set: 1,000 liters
The capacity of the daily tanks shall be at least:
for the 75 kVA (60 kW) Diesel generator set: 60 liters
The daily tanks shall be filled from the storage tanks by electrical pump
with automatic and manual operation modes. One hand pump shall be
also provided with valves to by-pass the electrical pump circuit.
Each tank shall be equipped at least with the following:
One level gauge;
High and low level limit switches;
Necessary connections for filing, emptying, drainage, with aeration
valves, rupture discs, etc.;
Necessary shut-off valves, isolating valves, drainage valve, etc.;
One special connection for fuel oil sampling;
Lifting lugs.

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POWER AND LIGHTING SYSTEMS
EMERGENCY DIESEL GENERATOR SETS
TECHNICAL SPECIFICATION

A manhole dia. 500 mm minimum shall be provided in each main storage

tank.

1.3.6 Lubricating Oil System

The lubricating oil system with closed forced circuit, duplex oil filters with
replaceable elements and with an automatic bypass as to not stop the oil
circulation. It shall include:
An automatic preheating system of the oil and water;
One oil pressure gauge;
Too high and too low oil temperature protections;
One oil tank mounted on a trolley, with one hand pump and
necessary fittings for filling the diesel engine.

1.3.7 Combustion Air System

The combustion air intake system shall be complete with extra heavy
duty air filters for fine dust of 3, necessary piping and fittings.
The air filters shall be re-useable after cleaning.

1.3.8 Exhaust System

The exhaust system shall include the silencer, manifold, expansion
joints, flexible couplings, the pipe insulation, a drainage pipe and all
fittings.

1.3.9 Noise Level

The noise level from the Diesel generator plant complete, including
exhaust system, fan units, shall not exceed 75 dB (A) at full load and at
10 m distance from the Diesel set.

1.3.10 Generator

1.3.10.1 General
The AC generator shall be of constant voltage, 60 Hz, three-phase, air
cooled, self-excited type. Damper windings shall be uniformly distributed
around the rotor.
The star-point of the generator shall be grounded through a contactor.
The contactor must be opened during test run in parallel operation with
the normal AC supply system (star-point grounded) for preventing flow of
third harmonic currents. During isolated operation of the Diesel unit the
contactor must be closed. The same procedure is also valid for the

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POWER AND LIGHTING SYSTEMS
EMERGENCY DIESEL GENERATOR SETS
TECHNICAL SPECIFICATION

emergency Diesel at the diversion weir (power intake) and residence

house (ranch).
Further requirements:

Voltage variation between 0 and 100% of rated load: < 2.5% of rated
voltage;
The generator shall be able to withstand 1.2 times the rated speed;
Protection index of the enclosure: IP56 (weather protective
enclosure);
Type of duty : continuous running duty type S1 as per IEC 60034-1.

1.3.10.2 Insulation and Temperature Rise

The insulation shall be of class F. During normal operation the winding
temperature rise under rated conditions and ambient temperature of 50
C (standard cooling package) shall not exceed class B.
Thermal sensors shall be installed in the stator windings.

1.3.10.3 Ratings
Diversion weir

Output 75 (60) kVA

(kW)

Voltage 400 V

Phases 3-phase, 4
wire

Neutral solidly
grounded via
contactor

Frequency 60 Hz

Power 0.8 lagging

factor

Speed 1,800 rpm

The final rating shall be verified during detail design.

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POWER AND LIGHTING SYSTEMS
EMERGENCY DIESEL GENERATOR SETS
TECHNICAL SPECIFICATION

1.3.10.4 Excitation System

Excitation shall be of the brushless type with rotating diodes.

1.3.11 Control Panels

The control panel(s) shall include all necessary switchgear and
equipment for the control, protection and monitoring of the Diesel
generator unit and its auxiliaries, in particular:
The generator protection;
The current transformers and voltage transformers;
The circuit breakers and contactors for the auxiliaries (fuel oil pump,
preheating, etc.);
The protection and auxiliary relays for the Diesel engine;
The Automatic Voltage Regulator;
The synchronizing equipment;
The selector switch for local/remote operation of the Diesel generator
unit;
The selector switch for manual/automatic test run modes;
The push-button switches for starting/stopping the unit and
auxiliaries;
The electrical indicators for current, voltage, frequency and power;
The indicators for the Diesel engine: oil pressure, temperatures,
speed, etc.;
The operation and fault signaling lights;
The protection relays as follows:
low battery charge,
no starting (3 starting trials without results),
fuel oil pump fault,
daily tank low oil level,
daily tank high oil level,
water flow fault,
preheating fault,
high water temperature,
low oil pressure,
high oil pressure,

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POWER AND LIGHTING SYSTEMS
EMERGENCY DIESEL GENERATOR SETS
TECHNICAL SPECIFICATION

oil temperature low,

oil temperature high,
Diesel engine overspeed,
generator winding temperature high,
overcurrent,
under and over voltage,
min. and max. frequency,
generator overload.
The operation of each protection shall be indicated by a flashing light on
the local control panel and a sound alarm.

1.3.12 Battery Starting System

The Diesel generator sets shall be provided with their own DC source for
start-up including one battery charger assembly. The battery system
shall be designed to allow at least three consecutive starting cycles.

1.4 Control and Monitoring

The emergency Diesel generator units will be supplied with their own
control, protection and monitoring system. Signal exchange with the
power plant control and monitoring system as well as the main
distribution board, diversion weir distribution board and residence house
distribution board, respectively, has to ensure for control and interlocking
purposes.
The generator protection shall trip the associated circuit breaker in the
respective distribution board. Protection circuits must be hardwired.

1.5 Tests

1.5.1 Workshop Tests

1) Diesel Engine
The test shall include a period of running at rated full load, to be
followed immediately by one hour at 10% overload.
2) Fuel Consumption
The fuel consumption at full load, three quarters and half of this load,
shall be measured over a minimum period of 30 minutes for each
load.
3) Governor Tests

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POWER AND LIGHTING SYSTEMS
EMERGENCY DIESEL GENERATOR SETS
TECHNICAL SPECIFICATION

4) Overspeed Test
The engine shall be operated for a period of three minutes at 110% of
the normal speed.
5) Generator
Temperature rise test;
Dielectric test;
Determination of losses and efficiency;
AVR tests to determine the performances of the voltage regulator.

1.5.2 Site Tests

After installation and prior to putting the systems into operation, at least
the following tests shall be done:
Dielectric tests;
Resistance measuring of all major circuits and grounding;
Functional and operational tests of all control circuits including full
verification of the interlocking scheme;
Adjustment and functional tests of the protection equipment;
Starting time test;
Load test;
Vibration test.

1.6 Spare Parts and Special Tools

The following spare parts and tools shall be supplied for each Diesel
generator unit.

1.6.1 Spare Parts

a) For the engine and its auxiliaries:
One (1) set of injection nozzles (100% of installed parts);
One (1) set of cylinder liners;
Two (2) pistons with rings and all fittings;
Two (2) rocker arms;
Two (2) sets of any kind of filters (fuel oil, lubricating oil, air,
water);
Two (2) sets of belts;

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EMERGENCY DIESEL GENERATOR SETS
TECHNICAL SPECIFICATION

Two (2) sets of seals;

One (1) detector/sensor of each type.
b) For the generator:
One (1) set of diodes;
One (1) set of spares for the AVR;
One (1) detector/sensor of each type.
c) For the control, protection and monitoring equipment:
Two (2) circuit breakers, miniature circuit breakers, contactors,
switches, protection devices, relays, indicating instruments, etc. of
each type.

1.6.2 Tools
A complete set of tools for maintenance and overhauling the engine and
its accessories shall be supplied, in particular:
Crank deflection gauges;
Thickness gauges;
Nozzle tester with pressure gauges;
Torque wrenches;
Cylinder maximum pressure indicator.

1.7 Documents and Drawings

The documents and drawings to be provided are listed hereafter and in
section 24. Both lists together form integral part of supply.
A: for approval
I: for information

Material / equipment specifications A

Component lists I
Outline drawings A
Arrangement and layout drawings A
Installation drawings A
Foundation drawings A
Foundation load calculations A

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EMERGENCY DIESEL GENERATOR SETS
TECHNICAL SPECIFICATION

Loading drawings A
Stress analysis for main components A
Electrical calculations and characteristics A
Design drawings and assembly drawings A
Diagrams, lists and schedules:
single line diagrams A
circuit diagrams A
terminal diagrams I
block diagrams A
logic diagrams A
protection coordination diagrams A
instrumentation diagrams A
consumer schedules I
feeder data schedules I
signal lists I
setting and alarm list A
P&I diagrams A
cable lists I
Lists of tools and appliances A
Spare part lists A
List of EDS identification numbers I
Specification for rating plates and labels, including list of A
inscriptions

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