SECTION 3 - STANDBY GENERATOR SET

1. Scope

This Specification covers the supply, delivery, installation, testing and

commissioning of a complete standby generating set, control panel
connecting cables, battery unit, fuel tank and other necessary associated
accessories and works.

2. General

The generating set shall comprise a vertically mounted, water-cooled, four

strokes, compression, ignition diesel engine driving a brushless, self-exciting,
self-regulating alternator complete with fuel tank, control cubicle and
auxiliary equipment.

The generating set shall be designed for fully automatic operation on mains
failure and is robust constructed, factory tested and assembled to ensure
perfect alignment of engine and alternator constructed of rolled steel sections
and complete with anti-vibration resilient mountings, and to ensure that there
is no transfer of vibration from the generator set to the structural and casing
the in bond structural noise. All the equipment shall be fully tropicalized and
suitable for use in a hot humid atmosphere having an ambient temperature of
about 40C.

3. Standards

The generating set shall generally be designed, manufactured and tested in

accordance with the relevant British Standards and their latest amendments:-

BS 649/58 : Diesel engine

BS 2869/20 : Fuel oil

BS 5000/Part 99/73 : Alternator

BS 833/70 : Radio Interference

4. Diesel Engine

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 The engine shall be of the industrial type, water cooled and designed for
continuous operation and shall be in accordance with BS 649/58 and/or SAE
85F, 29”Hg. The engine shall be suitable for running on fuel oil specified in
BS 2869/70 and shall be sufficiently silenced to reduce the noise to a
minimum. A running hour counter shall be provided for the engine to record
the number of hours of operation.

5. Starting

Starting shall be by means of a totally-enclosed axial type electric starter with

heavy duty 24 volt lead acid batteries.

6. Cooling

Engine cooling water shall be circulated by a engine driven centrifugal pump

through a tropical duty radiator cooled by a axial blower fan. Automatic
shutdown of the generating set through overheating must be incorporated. A
failure warning light shall be provided on the control panel to indicate the
generating set has shut down due to overheating of the coolant. The warning
light shall be left on until it is reset manually. Water temperature gauge shall
be provided to indicate the water temperature.

7. Lubrication

Lubrication shall be pressure lubricating oil system with engine driven oil
pump throughout the whole engine in conjunction with the built-in-oil to
coolant heat exchanger. Full flow filters with removable elements to be
provided with easy access. Automatic shut down of the generating set
through low lubricating oil pressure must be incorporated. A failure indicate
the generating set has shut down due to low lubricant pressure. Oil pressure
gauge shall be provided. The warning light shall be left on until it is reset
manually.

8. Governor

The governor shall be of the Woodward hydraulic SGX type, and suitable for
maintaining constant engine speeds within the limits specified in BSS 639/58
Class ‘A2’. A speedometer must be provided and automatic shut down of the
engine through overspeed must be incorporated.

9. Exhaust

A residential silencer must be supplied in the exhaust piping system. The

silencer and exhaust piping shall be wrapped with rockwool and/or calcium

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 silicate and the outside shall be neatly wrapped with asbestos cloth sewn with
asbestos string.

10. Daily Service Tank

The fuel tank shall have a capacity capable of storing sufficient fuel to run the
generating set continuously for twelve (12) hours under normal operating
conditions and shall be fitted with a plastic gauge complete with shut of
cocks to indicate the level of fuel in the tank.

11. Fuel Storage Tank

A day tank of suitable capacity for 48 hours operation at full load and of
approved design shall be supplied with each generator set. The tank should
be supplied protected against corrosion externally and internally. A suitable
mechanically protected glass-tube level gauge shall be provided to indicate
fuel level in the tank. Suitable pipework and pumpset for connection to the
service tank shall be provided.

12. Pipe Works

All pipe work for water, lubricating oil, fuel oil and exhaust shall be designed
to suit the standard arrangement for a radiator cool system mounted on anti-
vibration mountings. Piping between the engine and the dairy service fuel
tank for fuel line and fuel overflow shall be copper with braided flexible
connection at the engine.

Flexible connection shall be provided to allow for a 30 mm displacement in

all directions.

A pre-cleaner and multi-disc or felt type main filter with replaceable cartridge
shall be provided in the fuel line to the engine.

The Sub-Contractor shall take care to keep all dirt, grease, water and similar
foreign matter out of the fuel lines and equipment.

13. Pumps

An electric fuel transformer pump, fuel piping and float switch shall be
supplied and fitted for the daily service fuel tank to enable replenishment of
the tank from the storage fuel tank.

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 A suitable semi-rotary hand pump and sufficient length of flexible hose with a
quick action coupling shall be supplied for filling the storage fuel tank from
fuel oil drums.

14. Battery and charger

A set of 24 Volts high performance plated Nickel Cadmium type batteries

complete with floor standing battery rack, necessary cables and clamps shall
be provided for the starting of the generating set. The batteries shall be of
sufficient capacity to provided for six thirty seconds cranking time without
recharging. The Tenderer shall submit full calculation of the battery capacity
in his Tender.

An automatic charger shall be connected to the mains 240Volts supply to

provide trickle charging to the charger set. The charger shall be designed and
set to pass the correct trickle charge current to keep the cells in a fully-
charged condition. A manual boost charge facilities shall be incorporated.

The charger shall include a fused AC input, transformer, silicon diode or

thyristor full wave rectifier, voltage surge diverter DC voltmeter and
ammeter. In additional, a low battery volts and critically low battery volts
alarm complete with indicating lights shall be provided.

15. Alternator Enclosure

The housing shall be screened protected and drip proof in accordance with
BS 5000 : Part 99/73.

16. Insulation

The insulation shall be Class ‘F’ and shall be fully impregnated for use in
tropical climate with humid atmosphere of ambient temperature 40C. The
stator and rotor windings of the alternator and exciter shall have oil resistant
finishing varnish.

17. Bearings

It shall have one or two bearings arrangement to ensure perfect alignment

under all conditions. The bearings shall be pre-packed with lubricant for life.

18. Voltage Regulator

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 A rapid response voltage regulator shall be provided to regulate the
generated voltage. The overall voltage regulator from no load to full load,
including cold to hot variations and load power factor 0.8 lagging to unity
shall be within 2% of the nominal voltage. The excitation system shall be
designed to promote rapid voltage recovery following sudden application or
disconnection of load. The voltage shall recover to within 3% steady state
value within 0.35 second after application or disconnection of load. The
transient voltage dip on application of full load shall be less than 20%.

19. Short-Circuit Capacity

The alternator shall withstand 3 phase short circuit conditions without

damage.

20. Temperature Rise

The temperature rise shall be in accordance with BS 5000 Part 99/73 for
appropriate insulation class in a 40C ambient temperature.

21. Radio Interference

Radio interference suppression shall be in accordance with BS 833/70.

22. Waveform

The line to line voltage waveform shall be in accordance with BS 5000 Part
99/73.

23. Automatic Features

The plant shall be incorporated with the following automatic features

complete with indicating lamps.

23.1 Shut down of the machine due to high coolant temperature.

23.2 Shut down of the machine due to overspeed.

23.3 Shut down of the machine due to low lubricating oil pressure.

23.4 Shut down of the machine due to earth fault.

23.5 Shut down of the machine due to overload on any or all the phases.

23.6 Audible and visible alarm on the control panel to indicate that it has
shut down due to any of the abovementioned causes.

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23.7 Main voltage monitoring - the mains voltage shall be monitored on
all three phases. Failure on all/or any on phase will initiate starting
of the generating set after ensuring the lock-out on mains supply.

23.8 Repeat starting - a triple repetition of the starting process shall be

incorporated in the generating set.

23.9 False start - if the engine fails to start up after the prescribed
number of attempted starts, the generating set which is incorporated
with an automatic system shall be prevented against any further
starting and at the same time sets up an audible and visual alarm
indicating that the plant has shut down as prescribed in items 23.1
to 23.5 above.

23.10 Taking over the load - the load shall only be transferred to the
generating set when the alternator have reached the rated voltage
after approximately 10 seconds from starting of engine.

23.11 Monitoring the alternator voltage - the voltage of the alternator

shall be continuously monitored on three phases. If the voltage
drops below the 10% value, the alternator breaker shall be opened
and an alternator fault indicated both visually and audibly.
Automatic re-energisation of the alternator shall be blocked. A
visual signal alter-nator shall be blocked. A visual signal indicating
that the alternator is in operation shall also be incorporated.

23.12 Mains resumption - immediately the mains supply is restored, the

standby contactor is tripped and the main contactor is engaged
automatically to disconnect the generator output and reconnect the
mains supply to the load.

23.13 Delayed return - an adjustable time delay (0-30 mins) to prevent the
set from shutting down in the event of a momentary mains return
must be provided in the system.

23.14 Slowing down - after reconnection of the load to the main supply,
the unloaded generating set shall continue to run for about 5
minutes before stopping.

23.15 Emergency shutdown - an emergency push button to disconnect the

entire standby generating plant, shut down the generating set and
block the automatic system shall be incorporated in the plant.

23.16 Operation selector switch - a selector switch shall be provided for

the following modes of operation:-

23.16.1 Manual starting/stopping of the engine - intended for

commissioning and maintenance of the set.

23.16.2 Automatic operation.

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 23.16.3 No load test - to test the functioning of the standby
generating set without connection to the load. The
test duration shall be terminated automatically by a
timer and adjustable over 15 minutes. Any failure, or
abnormalities that would arise from this test would
bring on the alarm as indicated in items 23.1 to 23.5
above.

23.17 Earth fault protection - the generator shall be provided with an

earth fault protection system c/w indicating lamps showing shut
down of the machine due to earth fault.

24. Control Cubicle

The control panel shall be designed for fully automatic operation upon mains
failure and shall contain the following equipment:-

24.1 100 mm dial, hermetically sealed, voltmeter c/w 3 position selector

switch.

24.2 100 mm dial ammeter, hermetically sealed c/w current transformers

and phase selector switch.

24.3 100 mm dial frequency meter, hermetically sealed.

24.4 Moulded case circuit breaker.

24.5 Overload current transformers.

24.6 Earth fault relay and associated equipment.

24.7 Automatic battery charger c/w ammeter.

24.8 Automatic starting equipment.

24.9 Mains voltage sensing relays and associated equipment.

24.10 Alternator voltage sensing relays and associated equipment.

24.11 Repeat starting relays and associated equipment.

24.12 Manual testing relays and associated equipment

24.13 Local manual engine “start” and “stop” controls and shut down
equipment for low lubricating oil pressure, high coolant
temperature, over speed, overload, earth fault with indicating
lamps, audible bulks and terminal connections for remote indication
“ON”, “ON LOAD” and “FAILURES”.

24.14 Panel lamps.

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 24.15 HRC fuses for control circuits and instruments.

24.16 Overload indicator lamp with reset push button.

24.17 Duty selector switch for “Manual” , “Auto” , “Off” and “Test”.

25. Operation

The mains sensing relays shall not only detect a complete mains failure but a
drop of 10% more in the mains voltage. When either of these circumstances
occur, they must trip the mains contactor and this action shall start the engine
and close the alternator contactors. Sensing wiring to the Lift Motor Room
shall also be provided.

26. Installation

The generating set shall be installed on concrete plinths. The whole

installation, including the exhaust system shall not transmit any vibration to
the building under normal operating conditions.

27. Cable & Boxes

The Contract shall include the supply and installation of cables and boxes for
incoming and outgoing cables.

28. Cable Installation

The Contract shall included the supply and installation of underground cables
from the generator set to the control cubicle. The cables shall be laid in the
existing cable trench and supported by cable tray if necessary to avoid loose
dangling.

29. Earthing of Generating Set

29.1 The generating set shall be earthed by separate earthing electrodes

to be installed outside the generator room.

29.2 The earth electrode system shall be made-up of copper-clad steel

core rode, 15 mm diameter x 6 m, (such as ‘Copperweld’,
‘Blackburn’ or approved equivalent acceptable by JBE/TNB) driven

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 into the ground and complete with phosphor bronze clamping bolts,
phosphor bronze couplings, nuts and concrete inspection cover pit
fitted with removable inspection cover.

29.3 The earthing conductor shall be 25 mm x 3 mm hard drawn copper

tape lay under the ground at 0.5 m deep.

29.4 The earth resistance shall not exceed 1 ohm.

30. Standard Tools & Spares

Six (6) copies of the operation, maintenance and spare parts manuals and one
set of standard tools shall be provided for the generating set. Assurance that
all spare parts shall always be available ex-stock locally must also be given.

31. Drawings

Three sets of the followings shall be provided:-

31.1 Complete circuit diagram of the control cubicle with details of

circuit components. 1 set of drawings shall be framed up in the
generator room.

31.2 complete installation drawing with details of hole openings.

32. Guarantee

The Contractor shall guarantee that within 18 months period from the date of
commissioning and acceptance the generating sets, any defects which may
develop shall be rectified promptly at no extra charge to the Employer
whether for materials supplied or labour or both. The form “Guarantee for
Plant & Equipment and Plant Performance” is attached.

33. Specialist Maintenance During Guarantee Period

The Tender shall include for the comprehensive service and maintenance
required during the 18 months defects liability period on all plant and
equipment supplied under the Contract.

The Sub-Contractor shall supply all necessary lubricating oil, battery water,
coolant, grease, etc. for topping up during the test run and routine
maintenance.

Should any parts, equipment or material become defective or faulty, the

Contractor shall replace and rectify such defects and faults at his own cost.

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34. Exhaust Piping

Exhaust piping, expansion joints, supports and insulation shall be provided

and installed to manufacturer’s recommendation of the generator set and to
meet the requirements of Local Authorities.

35. Noise Isolation Installation

The standby generator shall be installed on a rigid baseframe suitable for

point mounting of isolators. The isolators shall be unhoused steel springs in
series with two layers of 8 mm thick neoprene waffle pads of 50 mm
minimum static deflection. The makes of isolators are acceptable:-

(a) Kinetics

(b) Korfund

(c) Mason

(d) VMC
There shall be no rigid ties to structure. All conduits and pipework are to be
looped or flexible. limit stops or restraints are to be fitted to the base to limit
transient movements during stops/starts.

36. Test In Work

Acceptance tests shall be carried out at the works of manufacturer to

establish that the generating set complies with the Specifications and is
entirely suitable for its intended purpose.

All tests shall be made in a manner prescribed in the relevant British Standard
Specification.

It shall be the responsibility of the manufacturer to define the extent of and

carry out the tests which include:-

1. For Engine

(a) Test measurement of the following:-

(i) Cooling water temperature

(ii) Lubricating oil temperature and pressure

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 (iii) Exhaust gas temperature

(iv) Fuel and lubricating oil consumption

(v) Protection circuits settings(e.g. over-speed trip,

lubricating oil pressure trip, cooling water
temperature trip)

(vi) Brake horse power

(b) Functional checks to demonstrate:-

(i) The ability of all malfunction and protection and

warning devices to respond correctly to conditions in
which they should operate

(ii) The dynamic and steady state characteristics of the

governing system

(iii) The ability of the staring system to perform in

accordance with the Contract

2. For Alternator

(a) Test measurement of:-

(i) Temperature rise of alternator and excitor windings

(ii) Coil resistance of alternator and excitor windings

(iii) Insulation resistance of alternator and excitor

windings

(b) Functional checks to demonstrate:-

(i) Withstand flash test for 1 minute

(ii) Voltage regulation with automatic voltage regulator

and manual control (if fitted)

(iii) A full load test of sufficient duration for the

alternator to reach its final steady operating
temperature followed by one hour at 110% load.

The manufacturer shall provide a test report embodying the results of all tests
carried out, after completion of the tests. The test report shall contain:-

(i) A description and identification of the equipment tested including

fabrication, block and production numbers

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 (ii) The name, address and contract or order number of the Sub-
Contractor ordering the equipment

(iii) Date, place and time of test

(iv) The properties tested and the source of the parameters for such
properties, i.e. British Standards

(v) The results of the test and any divergence from the Specification

No item of equipment subject to inspection and test shall be dispatched from

the works of the manufacture until the Consulting Engineer has received and
approved in writing the results of the tests.

Acceptance of test reports and approval of tests by the Consulting Engineer

of any equipment shall not relieve the Sub-Contractor from an obligation to
supply the complete equipment in accordance with the Contract
Specifications and suitable for the purpose intended.

37. Test On Site

37.1 General

The Sub-Contractor shall arrange with the Consulting Engineer for all tests at
least 7 working days in advance. He shall supply all necessary instruments,
apparatus, consumable stores, fuel, connections, skilled and unskilled labour
and services with proper, reasonable and safe facilities required for the tests.
Any cost which may be involved in the tests shall be included in the lump sum
tender by the Sub-Contractor. The Sub-Contractor to be used for any tests
are adequate as regards accuracy and calibration for the tests to be
undertaken.
A complete written record shall be made by the Sub-Contractor of all
inspections and tests. These records shall be made at the time of the tests and
shall be countersigned by the Consulting Engineer or his representative as a
true record. A copy of each record sheet shall be included with the operation
and maintenance manual.

Inspection or approval of tests and acceptance of test certificates by the

Consulting Engineer of any equipment, works or installation shall not relieve
the Sub-Contractor from the obligation to supply the complete equipment,
and complete work and installations in accordance with the Contract
Specifications and suitable for the purpose intended.

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 Three copies of certificate of test shall be submitted to the Consulting
Engineer within 14 days of completion of tests.

Certificates of test shall contain or have attached to them the following

information:-

(a) The name of Contract and Contract No. as designed by the

Consulting Engineer

(b) A description of equipment system or installation tested including any

fabrication, block or production numbers

(c) The name and address of the Sub-Contractor

(d) Date and time of the test

(e) Environmental conditions

(f) The testing party of and the signature of the Sub-Contractor’s testing
engineer

(g) The results of the tests and any divergence from Specifications and
Drawings

(h) Signature and stamp of the Sub-Contractor’s testing engineer

Any faults or defects revealed by the inspection or testing shall be made good
and re-testing shall be made, all at the expense of the Sub-Contractor.

37.2 Generating Plant

A 4-hour load running test for the generating plant shall also be carried out
by the Sub-Contractor on site. The load shall be slowly increased by steps of
25% of the rated load to full load and then to 110% of full load. Then the
rated load shall be suddenly taken off and taken on again. Finally the load
shall be slowly decreased by steps of 25% of rated load to no load. Between
load changes, a sufficient duration shall be allowed for the generating plant to
reach steady state conditions. The speed and voltage variations, recovery
times, oil and water temperature and pressures shall be recorded.

The operating function of the control panel, with particular attention to any
timing sequences and protection circuits shall be checked and verified.

Tests shall also be conducted on the automatic operation of the plant on

simulated normal supply failure or up to 20% voltage drop on any phase of
the normal supply.

The performance of the starting equipment and the ability of the set to start
and take up load within specified time shall be checked.

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37.3 Control Panel

The control panel shall be subjected to a pressure test of 2 kV for 1 minute,

with all control circuits disconnected but with all MCCBs, MCBs and
contactors closed.

The Sub-Contractor shall install a glass framed single line diagram of the
main circuit, changeover and supply scheme, and control circuit diagram in
the generator plantroom.

A first aid chart shall also be provided and displayed.

The Sub-Contractor shall provide a 900 mm wide by 6 mm thick rubber mat,

extending the length of the control panel, placed in front of the control panel.

38. Ventilation of Plantroom

The Sub-Contractor shall countercheck and ensure that the required intake
air supply for engine combustion and air flow cooling of the generating plant
are adequately provided by the supply air ventilation system provided by
others.

The hot air from the engine radiator fan shall be discharged through ducts
fabricated from aluminium sheets of minimum 1.2 mm thickness, and
provided with appropriate stiffeners. A hot air discharge attenuator shall be
incorporated. The duct outlet shall be covered with aluminium lourves and
galvanized steel wire mesh.

It shall be the responsibility of the Sub-Contractor to ensure that the

ductwork, intake and discharge outlets are correctly sized and located for
proper ventilation.

The Contractor shall connect the ventilation fans to the control panel so that
the fans will operate when the generating set is running.

The Contractor shall arrange with the main building contractor for the
provision and making good of all wall openings for hot air discharge.

39. Fuel

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 Before handing over the completed works, the Sub-Contractor shall provide
sufficient diesel fuel to fill up fully the daily service fuel tank and 500 litres of
spare fuel for the storage fuel tank.

APPENDIX

RESIDENTIAL CLASS EXHAUST SILENCERS FOR DIESEL

GENERATOR

Specifications

1. The primary exhaust silencers shall be installed within the equipment room as
close as practicable to exhaust outlets of the diesel engines.

2. The primary silencer shall be a multiple chamber reactive type designed for
low frequency noise and exhaust pulsation control. The silencers shall be of
welded sheet steel construction, all components shall be stiffened and braced
to minimize vibration, and shall be finished with high quality heat resistant
paint for surface temperature of up to 540C. All silencers are to be thermally
insulated to minimize heat losses.

3. The minimum insertion loss required for the primary exhaust silencers are:-

Octave Band Frequency in dB

31.5 63 125 250 500 1k 2k

Insertion Loss in dB

6 18 28 30 28 25 22

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4. The tenderer shall submit insertion loss data of the silencers offered for
evaluation.

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