Ordnance Wharf

Phase 3 Moorland and Phase 4 Grafton

Standby Generating Equipment Specification

TENDER KF August 2000

REV DESCRIPTION PREPARED BY DATE AUTHORISED DATE

WORD PROCESSING REF DOCUMENT NUMBER REV

K:/40233/SPEC/ST GEN EQ SPEC 40233//KF/LS/19024
INDEX

PART 1 GENERAL REQUIREMENTS

1.01 Related Documents

1.02 Statutory and Other Regulations
1.03 Compliance with British Standards
1.04 Definitions
1.05 Deviations
1.06 Storage of Materials
1.07 Condition and Quality of New Material
1.08 Protection of New Materials
1.09 Scaffolding
1.10 Dimensions
1.11 Temporary Lighting and Power
1.12 Interference Suppression
1.13 Working Drawings
1.14 Builderswork Drawings
1.15 "As Fitted" Drawings
1.16 Factory Visits

PART 2 SPECIFIC REQUIREMENTS

2.1 EMERGENCY GENERATOR AND CONTROLS

2.1.1 Nature and Extent of Work and Approved Supplier
2.1.2 Condition or Quality of materials
2.1.3 Protection of new Materials
2.1.4 Schedule of Details of Plant Offered
2.1.5 Electric Wiring Diagrams
2.1.6 Interference Suppression
2.1.7 Output of Sets
2.1.8 Engine
2.1.9 Generator
2.1.10 Main Control Panel
2.1.11 General
2.1.12 Works Tests
2.1.13 Commissioning
2.1.14 Information to be supplied with Tender
2.1.15 Painting and Finishes : Generator Plant
2.1.16 Head Sets
2.1.17 Spare Parts
1.00 GENERAL REQUIREMENTS

1.01 RELATED DOCUMENTS

This Specification shall be read in conjunction with any schedules, supplementary specifications,
drawings and other documents issued with it and enumerated in the Invitation to Tender. In the
event of a contradiction between this specification and a specified requirement on any drawing
becoming apparent either before or after tendering then the Contract Administrator shall be
immediately informed.

The requirements of this Specification are in addition to those of the other documents listed
above.

1.02 STATUTORY AND OTHER REGULATIONS

(1) The Health and Safety at Work, et. Act 1974

(2) Regulations under the Electricity Acts.
(3) The Building Regulations 1972 et seq.
(4) Any special requirements of the Local Electricity, Gas or Water
undertakings.
(5) The I.E.E. Regulations for the Electrical Equipment of Buildings (16th Edition)
BS7671.
(6) Regulations under the Factories Act, 1961.

The Tender shall be based on the regulations current on the date for return of tenders. If these
regulations are amended or new regulations enacted after that date the Contract Administrator
shall be immediately informed.

1.03 COMPLIANCE WITH BRITISH STANDARDS

The equipment and/or installations shall conform to the relevant British Standards and Codes of
Practice current three months prior to the date for return of tenders, except where a specific date
of issue is sated. A certificate of compliance with the relevant British Standard shall be provided
to the Contract Administrator at his request. In the event of a contradiction between this
specification and any B.S. or C.P. the Contract Administrator shall immediately be informed.

1.04 DEFINITIONS

For the purpose of this specification the following definitions apply:

(1) Commissioning

The advancement of an installation from the stage of physical completion to full working
order to specified requirements. Commissioning includes the setting to work and
regulations of an installation.

(a) Setting to Work. The process of setting a physically completed system into a
fully operational state.

(b) Regulation. The process of adjusting the output of apparatus or plant

in distribution systems within specified tolerances.

(2) Performed Testing

The evaluation of the performance of a commissioned installation.

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 (3) Approved

(and words derived therefrom) means approval in writing by the Contract

Administrator unless otherwise stated. All systems or equipment designs shall have
operated successfully for not less than two years under conditions generally similar to
those required by this Contract. Facilities shall be given at the tender stage, if required
by the Contract Administrator to enable him to evaluate the features and performance of
equipment offered in the tender. The approval of a design or piece of equipment shall be
without prejudice to the site tests required after installation.

(4) Size. When related to cables, conduit, cable tray and cable trunking means
nominal size in accordance with the recognised methods of sizing these components.

(5) The words "complete installation" shall mean not only the major items of plant
and equipment conveyed by this specification, but all the incidental sundry components
necessary for the complete execution of the works and for the proper operation of the
installation, with their labour charges, whether or not these sundry components are
mentioned in detail in the tender documents issued in connection with the contract.

1.05 DEVIATIONS

Unless deviations are fully detailed all things offered in the tender shall be deemed to comply with
the Specification(s) and/or Drawing(s).

The Lift Specialist's attention is drawn to the Appendices to be completed in respect both of the
materials included in the tender which must comply, in all respects with the Specification and the
Schedules of Alternative materials which are offered as an alternative in place of those specified.

1.06 STORAGE OF MATERIALS

Storage of materials shall be as detailed in the Preliminaries.

1.07 CONDITION AND QUALITY OF NEW MATERIALS

All plant and materials shall be new and the Electrical Contractor shall ensure no materials or
equipment is fitted showing any sign of corrosion, or faults or damage in any way.

1.08 PROTECTION OF NEW MATERIALS

The Lift Specialist shall provide adequate and safe storage and protection for all new materials,
plant and equipment.

Conduits, cable tray and trunking shall be adequately supported and stored on properly made
racks to prevent bending and distortion and the ends shall be closed and protected by means of
caps.
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 Where materials cannot be stored in suitable buildings, they shall be raised clear of the ground
and protected by means of waterproof covers.

Machined and bright surfaces shall be protected by paint, tallow or grease. On completion,
surfaces so protected shall be cleaned and where appropriate polished.

All plant and equipment is to be left in a condition ready for painting, where painting is specified
either as part of the Trade Contract or by others. Parts liable to corrode are to be painted
immediately after removal of the temporary protection.

1.09 SCAFFOLDING

Scaffolding shall be provided as detailed in the Preliminary Bill.

1.10 DIMENSIONS

The Lift Specialist shall take his own dimensions from the site for the setting out of all plant and
equipment, and shall be responsible for the accuracy of those dimensions.

1.11 TEMPORARY LIGHTING AND POWER

The provision of any temporary lighting and power to be supplied as detailed in the Preliminary
Bill.

1.12 INTERFERENCE SUPPRESSION

All equipment used by the Electrical Contractor shall be suppressed to comply with BS 800 so as
to cause no interference with radio or television.

1.13 WORKING DRAWINGS

(a) The Electrical Contractor shall provide 4 copies of all plant manufacturing,
arrangement and wiring drawings for approval prior to manufacture.

(b) The Electrical Contractor shall, in addition, prepare all necessary installation
drawings, diagrams and schedules as may be required for the following purposes:-

( i) To illustrate in detail the arrangements of the various services

and sections of the works and to identify and describe the various components.

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 (ii) To illustrate that detailed designs of the various services and
sections of the works have been properly integrated by the Electrical Contractor
with the detail of the building and with the work of other Trades.

(c) Such drawings and documents shall be made available as requested and in good
time to comply with the requirements and the Contract Administrators Construction
Programme and to enable other interested parties to make full use of the information and
discharge their own responsibilities.

(d) Wiring diagrams shall be fully comprehensive and shall co-ordinate the
Manufacturer's data in respect of individual items of equipment, so far as to present as a
whole, the complete information for any interconnected groups of such items. The
Electrical Contractor shall be responsible for the accuracy of such diagrams.

(e) All drawings, diagrams and schedules called for in this Clause shall be
submitted to the Contract Administrator for approval prior to issue for construction and
installation purposes.

1.14 BUILDER’S WORK DRAWINGS

(a) The Electrical Contractor shall provide all the necessary information to enable
the incidental builder’s work to be executed, either by the provision of drawings or
schedules, or by setting out his requirements on Site.

(b) The methods to be adopted shall be agreed with all interested Parties, but in
general, will be applied as follows:-

( i) Where builder’s work is to be formed, drawings shall be provided.

(ii) Where builder’s work is to be cut, it shall be marked on Site for

verification and thereafter cut by the Main Contractor.

1.15 "AS FITTED" DRAWINGS

The requirements for "As Fitted" Drawings are detailed under separate section.

1.16 FACTORY VISITS

The relevant manufacturers shall allow for at least two factory visits during the manufacturing
phase for inspection, quality checks and testing.

The factory visits shall be by four client representatives and costs shall be met by the Electrical
Contractor including travel and subsistence costs for all parties.

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2.0 SPECIFIC REQUIREMENTS

2.1 EMERGENCY GENERATOR AND CONTROLS

2.1.1 Nature and Extent of Work and Approved Supplier

The work to be undertaken in this Section covers the supply and installation of a new diesel
engined generator set, complete with all controls and exhaust systems to be located within the
brick built enclosure located in the car park. All equipment in this Section to be supplied by Dale
Electric, F.G. Wilson, Country Generators, Autodiesels or approved equal.

The Electrical Contractor to supply, deliver, off-load, store, erect on prepared foundations and
shall install completely, test, commission along with Manufacturer's Specialist Engineers, and
maintain for a period of twelve months one diesel engine driven automatic standby generator set
to the following basic requirements and in accordance with this Specification and associated
drawings.

The generator set c/w control panel, day and bulk fuel tanks, acoustic louvres and exhaust
system shall be able to be installed within the space allocated on the contract drawings and
comply with all relevant regulations.

2.1.2 Condition or Quality of materials

All plant and materials shall be new and no materials or equipment shall be fitted showing any
sign of corrosion, faults or damage in any way.

2.1.3 Protection of new Materials

Machined bright surfaces shall be protected by paint, tallow or grease.

2.1.4 Schedule of Details of Plant Offered

The details of the plant offered shall be in accordance with the Appendices at the back of the
Document.

2.1.5 Electric Wiring Diagrams

Duplicate copies of wiring diagrams for all plant and controls for the Services Engineer's
approval shall be supplied and after approval, 2 copies of the approved diagrams for site use
shall be provided.

2.1.6 Interference Suppression

All equipment used shall be suppressed to comply with BS.800 so as to cause no interference
with radio, television or electronic apparatus in use in the building.

2.1.7 Output of Sets

The set to have an electrical output of 415/240 volts, 3 phase, 50 Hertz with a continuous output
rating of 70 kVA, 56kW at 0.8 lagging power factor.

2.1.8 Engine

2.1.8.1 Type and Design

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 Vertical type multi-cylinder four stroke diesel engine turbo-charged complete with all necessary
ancillary equipment and drives, constructed to comply with BS.5514 and suitable for running
continuously on oil engine fuel to BS.2869, Class "A".

It shall be possible to start, operate on load or stop the unit independently of any automatic
features.

2.1.8.2 Rating

The rating shall be continuous as defined in BS.5514.

2.1.8.3 Speed and Governing

The normal speed of the engine shall be 1500 revolutions per minute. Speed governing shall be
to BS.5514, Class "A.2" and overspeed protection shall be provided.

2.1.8.4 Time of Run-Up Speed

From the initial operation of the starting switch the engine shall start, run up to normal speed and
be capable of accepting 70% of full/load with a minimum time of 10 seconds/and full load within
a further 10 seconds, in accordance with BS.5514.

2.1.8.5 Cooling

Engine cooling shall be by water jacket, with water circulating pump and heavy duty radiator
with electrically or mechanically driven fan. The radiator shall be fitted with flanges or other
suitable arrangement to enable ventilating ductwork to be attached with airtight joints. The fan
rating shall be adequate allowing for the additional resistance to air flow of ductwork, louvres
and silencers fitted, all as detailed on the Generator Layout Drawings.

The cooling equipment shall be composite with the engine and fitted with Feed and Expansion
Tank and pipework, where necessary.

A thermostatically controlled valve shall be provided in the cooling system to assist rapid heating
up of the water in the engine jacket when starting from cold and to control its temperature when
the engine is running. Where necessary to limit the oil temperature rise, a water cooled
lubricating oil temperature stabiliser, complying with BS.3274 shall be incorporated in the engine
cooling system. Sufficient inhibitor shall be added to the cooling water to protect the cooling
system from internal corrosion.

2.1.8.6 Engine Starting

Engine starting shall be by electric starter motor, complete with automatic starting and
sequencing control equipment and starter cut-out switch. The starter motor shall be of adequate
power for its duty and of the "non hold-on" type in which the pinion is moved axially to engage
within a gearing on the engine fly wheel before the starter motor is fully energised. The pinion
shall positively disengage when the engine starts or when the motor is de-energised.

2.1.8.7 Fail to Start Protection

The starting equipment shall incorporate a fail to start device for automatically disconnecting the
starter motor if the engine fails to start within a reasonable time (e.g. 10-12 seconds), so as to
avoid undue discharge of the battery.

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2.1.8.8 Engine Safeguards

Safeguards shall be provided and arranged to stop the engine automatically by de-energising a
solenoid coupled to stop lever on the fuel injection pump rack. The operation of this safeguard
shall at the same time give individual warning of the failure by illuminating an appropriate visual
indicator and sounding audible alarm(s) as specified hereafter.

The safeguards shall operate when any of the following conditions occur, irrespective of whether
the set is on automatic or manual control:

Engine Overspeed

High Cooling Water Temperature

Low Lubricating Oil Pressure

2.1.8.9 Oil Dipstick

A lubricating oil level dipstick suitably graduated shall be provided and located in an accessible
position.

2.1.8.10 Starting Handle or Barring Handle

Suitable means shall be provided for turning by hand the engine main shaft and the associated
generator to facilitate inspection and overhaul.

2.1.8.11 Starter Battery

The starter battery shall be 24 volts "Plante" cell type of adequate size, suitable for charging and
rapid recharging after use.

The type, voltage and ampere/hours capacity of the battery shall be stated in the appropriate
schedule. The battery shall be supplied in a fully charged state ready for use and shall be
complete with hydrometer for testing the electrolyte.

The Tender Price shall be based on the provision of a "Plante" cell type battery.

A floor mounting stand to be provided having corrosion resisting outer cover.

2.1.8.12 Engine Instruments

The following dial type engine instruments shall be provided for the set:

1 - Lubricating Oil Pressure Gauge

1 - Lubricating Oil Thermometer

1 - Cooling Water Thermometer

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 The instruments may be mounted on a suitable panel fixed to the engine or may be incorporated
in a free standing main control panel.

2.1.8.13 Exhaust Systems and Silencing

The exhaust systems shall be manufactured in heavy quality steel tubing to BS.1387, fitted with
well supported stainless steel bellows piece close to the engine to allow engine movement and to
reduce the transmission of engine vibration to the remainder of the exhaust system and the
surroundings. Bends shall have a minimum radius of three times the diameter of the tube. As far
as possible flexible sections shall be vertical, free from bends and have sufficient length of slack
to allow free movement without damage. To be complete with expansion bellows.

Silencers shall be 2 heavy duty baffle and absorption residential type, so designed and installed as
to reduce noise to the minimum practicable level without appreciably impairing the working
efficiency of the engine.

The silencers and exhaust pipework shall be properly and adequately supported clear of fuel tank
and feed pipes, and shall be provided with suitable non-asbestos insulation to protect Personnel,
plant and buildings from excessive heat with outer covering of aluminium sheeting throughout.

The pipework shall drain away from the exhaust manifold and drain cocks shall be fitted in the
lower parts of the system to enable condensate readily to be removed.

The system shall be so constructed as to enable it to be readily dismantled for maintenance.

Bolts, washers and nuts shall be greased with graphite grease or other suitable heat resisting
lubricant during assembly.

The finish of all exhaust pipework and silencers exposed to the open air shall be sprayed metallic
aluminium by a process complying with BS.2569, part 2, Process A.

The complete length of exhaust pipework detailed on the Drawings to be allowed with all
necessary bends, gaskets, couplings, flexible bellows, flexible piping, lagging and fittings, plus
silencers and brackets.

The Electrical Contractor shall also include for all necessary secondary steelwork required in
connection with the generator exhaust system.

Before erecting of this steelwork, details and/or drawings of the proposed support system shall be
submitted for approval.

2.1.8.14 Turbo-Chargers

Turbo-charger units shall be mounted direct on the exhaust manifolds adequately supported and
provided with all necessary instruments.

Special consideration shall be given to the minimising of noise from the turbo-chargers.

2.1.8.15 Intake air Cleaner

A suitable and efficient air cleaner/silencer of an approved type shall be fitted on the air intake
manifold, as defined in BS.1701.

2.1.8.16 Drain Plugs and Cocks

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 Drain plugs and cocks, as appropriate shall be fitted adequately to drain the engine of lubricating
oil, water and fuel. They shall be designed and constructed as to be free from leaks and so
positioned as to be readily accessible and allow draining to be undertaken without need for
special receptacles.

2.1.8.17 Fuel and Lubricating Oil Filters

Suitable and efficient oil filters of an approved type and construction, having replaceable filter
elements, shall be provided in the fuel oil and engine lubricating systems. The oil filters shall be
readily accessible and allow the elements to be changed without difficulty. The fuel oil filter shall
be located as close as possible to the fuel pump manifold.

2.1.8.18 Cooling Water Heater(s)

Thermostatically controlled electric immersion heater(s) of an approved type and suitable for
operating on the mains supply shall be installed and connected in the cooling water circuit in both
the engine jacket and radiator with suitable "On"/"Off" control switch(es) mounted on the main
panel.

The heater(s) shall be capable of maintaining the whole of the cooling water at a minimum
temperature of 10C (50F) with an ambient temperature of 0C (32F), Visual indicators shall
be provided on the main control panel and be illuminated when the immersion heater control
switches are in the "On" position.

Each heater shall be connected to the control panel by an HRC fuse and neutral terminal. The
heater(s) shall be easily removable for replacement.

2.1.8.19 Wiring on Engine/Generator Unit

The electrical wiring on the engine/generator unit shall be carried out with "Metalflex" or MICC
cable having a conductor minimum cross section of 2.5mm² (0.003 sq.in) for single core cables
and 1.5mm² (.002 sq.in) for multicore cables.

All wiring shall be adequately supported and protected from accidental damage and properly
installed and terminated in suitable terminal boxes with flexible connections, all in accordance
with the Manufacturer's recommendations. Special arrangement shall be made where wiring is
subject to movement and vibration.

Mains voltage circuits and extra-low voltage circuits shall be segregated as far as practicable.

2.1.8.20 Fuel Tank and Connections

An integral 8 hour daily service tank within the generator base skid shall be supplied and filled as
part of this Contract.

The piping from the inlet to the generator enclosure shall be supplied and installed by the
Electrical Contractor.

The service tank shall be clearly lettered to indicate the type of oil to be used and the capacity of
the tank in litres and gallons, and shall be provided with the following:

(i) Fillings orifice, oil strainer, filling pipe extension and filler cap.

(ii) Vent pipe to atmosphere

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 (iii) Dial type contents level indicator with adequate size scale clearly marked
proportional part content i.e. empty, quarter, half, three quarters and full.

(iv) Connections for the engine leak-off return pipe (where necessary).

(v) Drain valve and drain hose connection.

(vi) Pipework shall be extended to a coupling on the outer edge of container for
connection to 25mm external pipework provided by others.

2.1.8.21 Fuel Tank Filling

Fuel shall be transferred from the tanker to the service tank by transfer pump, the filling to be
controlled by a manually operated push button operating a solenoid valve and float switches. The
push button, valve and float switches shall be supplied as part of this contract.

2.1.8.22 Coupling to Generator

The engine shall be coupled to the generator in an approved manner in a monobloc arrangement
or by a suitable shaft coupling and satisfactorily guarded to comply with BS.5514.

The method of coupling proposed shall be stated.

2.1.8.23 Noise Level Limit

The noise level from the engine and generator set shall comply with the Local Authority/Building
Control recommendations - maximum 85 dBA at 1.0m.

Acoustic silencing shall be incorporated into the intake and exhaust air louvres.

2.1.8.24 Engine Driven Auxiliaries

Any pumps or fans which are driven by V-belts shall be provided with at least two belts and the
drive shall be capable of transmitting full load with one belt removed.

2.1.8.25 Lubricating Oil System

The engine shall be totally enclosed with forced lubrication from an engine driven pump having
on the suction side a coarse strainer and on the delivery side a full flow fine filter having a
replaceable element and fitted with a bypass relief valve so that oil flow to the engine is
maintained if the filter should choke. The capacity of the lubricating oil system shall be sufficient
to enable the engine to run continuously for 5 days at any load without replenishment.

2.1.8.26 Engine Fuel System

The fuel system shall be so arranged as to be self-venting and fuel spill from injectors shall be
returned directly to the fuel tank or suction side of the fuel pump(s). A full flow fine filter having
a replaceable element shall be fitted in the fuel line immediately before the pump(s). It shall not
be possible for leakage of fuel from any part of the system leading to the injectors to enter the
engine sump.

2.1.9 Generator

2.1.9.1 Type
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 The generator shall be continuously rated 3 phase, 4 wire star connected, alternating current
machine of the brushless excitation, screen protected fan ventilated, rotating field self-excited
type, direct coupled to the diesel engine prime mover, the whole being designed and constructed to
operate as one unit, suitable for solid earthing of the neutral.

The generator shall be complete with all necessary controls and instruments and shall comply in
all respects with BS.5000, Part 99, Class "E" insulation.

The generator shall be capable of running at 10% overload for a period of one hour and of
supplying an unbalanced load, where the current in any one phase exceeds that in any other by up
to 40% of the rated phase current.

2.1.9.2 Three Phase voltage Regulation

The output voltage of the generator shall be automatically maintained within 2½% of the nominal
or specified voltage, from no-load to full-load at any power factor between unity and 0.8 lagging,
by a suitable voltage regulator mounted in the alternator control box. The accuracy of the
voltage control provided by the regulator shall not be impaired by temperature change in itself, in
the generator, or in any associated equipment.

Provision shall be made for adjusting the generator voltage within plus or minus 5%.

After any change of load the voltage shall not vary by more than + 15% of the rated voltage and
shall return to within ± 3% within 3 seconds and to within ± 2½% within 15 seconds.

On starting, the overshoot shall not exceed 15% and shall return to within 3% in not more than 3
seconds.

Out of balance is stated in Paragraph 16.9.1 where the current in any one phase exceeds that in
any other by up to 40% of the rated phase current, and all relays and sensing devices must be
capable of taking this out of balance.

2.1.9.3 Voltage Wave Form

The voltage wave form of the generator shall be a sine wave shape within the permitted limits of
BS.4999.

2.1.9.4 Terminals

The main auxiliary and earthing terminals shall be of robust construction, or an approved pattern
adequate in size for the current to be carried and properly, securely mounted and protected.
Means shall be provided for preventing the terminals from working loose after connections have
been made.

2.1.10 Main Control Panel

2.1.10.1 Type and Construction

The mains control panel shall comprise a totally enclosed metalclad cabinet of ample size to
accommodate the required switchgear, contactors, relays and other equipment to form a complete
automatic control unit for the standby set.

The cabinet panel shall be a heavy gauge sheet metal, either steel, having a matt zinc or other
suitable corrosion resisting coating, or other approved material and be mounted in a substantial
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 and rigid metal framework with the panel edges recessed to give a smooth flush finish suitable for
floor or set mounting.

The corners shall be formed by the framework and be rounded and smooth. Panels not designed
to be removable shall be secured from the inside of the cabinet. Fixing studs and screws shall fit
into properly tapped holes or if the metal is of insufficient thickness to give adequate thread
length for the material used, tapped hank bushes shall be inserted. Self-tapping screws shall not
be used.

External access doors shall each be fitted with locking handles. The locks shall be of the same
pattern throughout, so that one key will operate all the locks. Duplicate keys shall be supplied.
Removable plates of adequate thickness shall be provided for cable and conduit entries to the
cabinet and shall be drilled and tapped as required either before or after delivery to site.

The complete cabinet shall be painted overall with two priming and two finishing coats of best
quality air dry enamel paint. Colour to be selected later.

The design of the enclosure shall be such as to give satisfactory access to all parts for
examination and maintenance. Suitable protection shall be provided for parts at mains potential
to minimise the risk of electric shock when work is carried out within the unit.

All covers both internal and external, which are removable to allow access to components which
operate at potentials exceeding 240 volts shall be inscribed "DANGER" and the maximum
voltage marked clearly thereon.

A schematic wiring diagram on durable material shall be permanently fixed to the inside of the
panel door.

All equipment shall be suitable for front access only.

2.1.10.2 Panel Equipment

All main switches and contactors shall be three pole and shall be complete with operating relays,
time delay devices, generator overload protection and relays. As an alternative to relays the use
of electronic components and micro processors will be acceptable. Contactors shall comply
generally with BS.775, Class UR, Category A.1 and shall be capable of satisfying the making
and breaking test with an inductive load having a power factor of 0.8 lagging.

Relays shall be of the plug-in type enclosed in dust-tight covers and shall have high grade
contacts throughout and comply generally with an appropriate P.O. or other specification.

If printed circuits are employed, the relays shall be mounted on high quality glass fibre printed
circuit boards. The boards shall be screen printed for identification of components.

One spare relay of each pattern used shall be provided and mounted in a suitable holder in a
convenient and accessible position within the cabinet.

2.1.10.3 Generator Isolating Circuit Breaker

A TP&N moulded case air circuit breaker with adjustable over-current protection shall be
provided to isolate the generator supply from the contactor assembly to the main switchboard.

2.1.10.4 Control Selector Switch

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 The controls shall include a suitable three position rotary selector switch giving "Automatic"
"Manual" and "Off" positions, with "Engine Switched Off" warning light in the latter position.
With the switch in the "Off" position, it shall not be possible to start the engine in any way
whatever.

2.1.10.5 Generator Contactor and Relays

A contactor shall be provided for generator duty and shall be complete with adjustable time delay
devices, 0-5 secs. for mains failure and 0-30 secs. for mains restoration. Delay relay to allow the
normal supply to stabilise, prior to generator shut-down. Adjustable overload protection for the
Generator and all other ancillary equipment and control necessary for the proper operation of the
Unit.

The mains sensing relays shall have adjustable voltage settings within the range 75-80% of rated
voltage and be designed to operate on the occurrence of sustained low voltage or loss of voltage
on any one or more phases of the supply. They shall also operate in conjunction with the "Mains
Supply Available" indicators hereafter specified.

Provision shall be made for the connection of the sensing relays operating in conjunction with
mains/standby contactors.

2.1.10.6 Auxiliary Contactor

A suitable auxiliary contactor and relay shall be provided for connecting the battery charger to
the mains supply bus bars. The contactor shall be provided with an isolating switch.

2.1.10.7 Generator Sensing Panel

A sensing panel shall be provided as part of the Generator Installation. The panel shall be wall
mounting or free-standing, arranged for front access only.

The mains sensing relays shall have adjustable voltage settings with the range 75-80% of rated
voltage and shall operate on the occurrence of sustained low voltage or loss of voltage on any one
or more phases of each protected incoming feeder from the main switchboard, which supply the
essential service load. The operation of any sensing relay will automatically start the emergency
generator.

Indicator lights shall be provided on the panel front to show "Mains Supply Available" and
"Mains Supply Failure" for each protected feeder and also to show "Generator Running".

The panel shall contain a battery and charger suitably sized and rated for the number of relays
installed.

Sensing relays shall be fitted by the Electrical Contractor in the Gibraltar Electric feeder pillar.
The relays shall utilise split core transformers fitted to the main bus bars.

Alternatively, the sensing panel may form an integral part of the generator control panel itself.

2.1.10.8 Services Maintenance Switch

A services maintenance switch shall be provided, for use in conjunction with the generator
contactor control panel, to enable work to be carried out on the control panels.

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2.1.10.9 Instruments

In addition to the equipment earlier specified, the control panel shall be provided with the
following instruments, fuses, current transformers etc.

Generator voltmeter with phase/phase, neutral/phase selector switch to enable the instrument to
measure either mains or generator voltage.

(a) Three ammeters one per phase

(b) Polyphase kW indicating meter suitable for unbalanced loads
(c) Battery charging ammeter
(d) Earth leakage meter
(e) Switches and lamps for immersion heaters
(f) Hours run meter

As far as practicable, all instruments on the control panel shall be flush mounting, 76mm
diameter, indicator dial and shall comprise a matching set of similar finish.

The pointers and dials shall be designed to give clear readings and the graduations shall be evenly
and widely spaced as possible over the range of the scales and give accurate indications at all
loads.

A label shall be fixed to the panel, in a position immediately under the ammeter(s) showing the
full load current of the generator.

2.1.10.10 Panel Indicator Lamps

Flush type coloured indicators, illuminated by low voltage lamps shall be provided for the
following:

Green Lamps Mains Supply Available - Battery Charger

Cooling Water
Heater(s)

Red Lamps Fail to Start

Engine Overspeed
High Cooling Water Temperature
Low Lubricating Oil Pressure
Generator Failure (Set Running)

The indicators shall each be clearly labelled as to duty. Energised circuits operating normally
shall show Green. Abnormal conditions shall show Red. The "Mains supply Available"
Indicator(s) shall be operated from the mains voltage sensing relays circuit as earlier specified.

Illumination shall be by lamps serviced from the miniature transformer/lamp units from the mains
and generator, as may be appropriate. All indicator lamps shall be replaceable from the front of
the panel and a lamp test facility shall be included as part of the panel.

2.1.10.11 Audible Alarms

An audible alarm of a distinctive type shall be provided and installed in the main control panel
and shall operate on the occurrence of one or more of the following:

(a) Engine not starting or not continuing to run (from any cause) when the sensing
relay has operated following mains failure.
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 (b) Operation of the generator over-load protection or failure of one or more phases
of the generator supply (set continuing to run).

(c) A self re-setting alarm muting switch shall be provided and connected so that its
operation silences the local alarm.

Volt free terminals shall be provided in the control panel for connection of this additional alarm so
that it will operate simultaneously with the local alarm.

2.1.10.12 Engine Control Switch and Push Buttons

Suitable robust control switch and push buttons shall be provided in a convenient position on the
front of the control panel for the following duties:

Spring Return Push Buttons:

Start engine (for testing, servicing etc.) with control selector switch in "Run" Position/"Off"
Position/"Automatic".

Stop Engine
Mains Failure simulation
Switches shall be provided for cooling water heaters
Terminals shall be provided for connecting in a remote engine stop switch

Lamp test facilities shall be provided for verifying the operation of the following indicators:

Fail to Start
Engine Overspeed
High Cooling Water
Low Lubricating Oil Pressure
Generator Failure

2.1.10.13 Engine Shut Down

Means shall be provided for automatically stopping the engine in the event of the operation of any
of the engine safety devices and prevent further starting until reset by hand.

2.1.10.14 Mains Operated Battery Charging Equipment

The battery charger shall be of the static type employing semi-conductor rectifiers, suitable for
charging "Plante" type batteries.

The charger will be incorporated in a suitable removable ventilated enclosure within the main
control cabinet and its associated instruments and controls mounted on the front. As far as
possible the instrument and controls shall match those of the main panel.

The charger shall be connected, via the auxiliary contactor, to a maintained supply via an HRC
fuse and neutral terminal and as earlier specified, shall have an illuminated indicator on the panel
front to show when the charger is switched on.

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 The charger shall be complete with all necessary relays, cut-outs, controls, switches and
instruments, including an ammeter suitably scaled to indicate clearly the charging rate over the
whole range of charge of the battery and shall be connected to the battery in an approved manner.

The equipment to have adequate capacity in relation to battery size and shall at all times monitor
the battery condition and automatically control the charging rate to suit the state of the battery,
maintaining it in a properly charged condition when not in use. The battery charger must be
capable of remaining in operation whilst the engine is started.

2.1.10.15 Equipment and Instrument Fuses

All equipment and instruments incorporated in the control panel shall be protected by suitably
rated HRC cartridge fuses, comply with BS.88, Clause Q.1.

Three replacement fuses shall be provided as spares for each size of fuse used and these shall be
mounted in proper holders located in convenient positions within the panel enclosure. If steel
spring clips are used as holders, they shall be plastic covered to avoid damage to the fuse
cartridge body.

2 - 60 amps - off set tag, type with 734mm fixing centres

80 - 400 amps - central tag type with 111.1m fixing centres

2.1.10.16 Control Panel Wiring

The control panel wiring shall be carried out using LSF insulated cable complying with BS.6231,
or other approved cable. The current carrying capacity of each conductor shall be adequate for
the particular duty required. The minimum size of conductor shall be 1.5mm².

Other than for short termination, the wiring shall be supported and protected by perforated plastic
racks or trunking, spiral plastic shrouding, lacing and strong plastic straps and cleats, or by other
approved means giving the cables proper support and protection.

Particular care shall be taken where cables are subject to movements, such as on hinged doors.
As far as practicable, wiring at extra-low voltage shall be segregated from that at mains voltage.

Conductor and earthing terminations shall be approved type lugs and terminals for all cables
other than small control cables. The latter may be terminated direct in clamp type terminals
having flat or serrated jaws or by other approved means. The use of screw-in type terminal
screws without clamping plates will not be acceptable unless the cables are terminated in suitable
lugs or tags.

Where possible, appropriate colours of insulation shall be used for the different circuits and
phases and wherever necessary, coloured identification sleeves shall be securely fixed to the
cables. Terminal markings shall comply with BS.822.

2.1.10.17 Labelling

The function or duty of each meter, instrument, indicator switch, push, or other device for
external control shall be clearly and neatly defined by engraved and coloured lettering or Ivorine
or other approved type labels, properly and securely fixed on or close to the item to which the
label rates.

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 Any instructions necessary for the proper and safe working of the plant shall be similarly dealt
with and the instructions fixed in a position close to where the operation is carried out.

2.1.10.18 Electrical and Radio Interference Suppression

The plant, when installed shall comply with BS.800.

2.1.11 General

2.1.11.1 Main Engine : Generator Frame

The frame or base upon which the engine generator and ancillaries will be together mounted shall
be of heavy steel construction and be rigid and free from twist to ensure that proper alignment is
maintained under all conditions. All mounting pads for engine and generator shall be machined to
close tolerances. Frames to be stress relieved.

2.1.11.2 Balancing

The rotating system of the engine, generator and ancillaries shall be statically and dynamically
balanced during manufacture to reduce out of balance forces to a minimum.

2.1.11.3 Anti-Vibration Mountings

Robust spring type anti-vibration and shock-absorbing of an approved pattern shall be fitted
between the main frame and the floor upon which the unit shall stand.

They shall have adjusting screws for optimum setting and levelling and be so designed and
installed that no appreciable engine vibration shall be transmitted to the floor or to any
surroundings. The anti-vibration mountings shall have special bases or pads to prevent
movement across the surface of the floor when the engine is running.

2.1.11.4 Flexible Connections

All external electrical and mechanical connections made to the units, including the exhaust
pipework and the water cooling system shall be of an approved flexible type and permit free
movement of the set on its resilient mountings.

2.1.11.5 Guarding of Moving Parts

All exposed moving parts of the engine, generator and ancillaries shall be fully guarded so as to
prevent accidental contact by Personnel. The guards shall be securely fixed and so constructed
as to be readily removable to facilitate inspection and maintenance.

2.1.11.6 Warning Notice

A permanent warning notice size 400mm x 250mm, having a durable transparent finish to its
surface, shall be provided and fixed in a conspicuous position on the engine-generator unit. The
notice shall bear the following wording in letters not less than 13mm (½") high for the heating
and 6mm (¼") for the remainder:

"DANGER : KEEP CLEAR: THIS SET IS REMOTELY CONTROLLED AND MAY

START AT ANY TIME. WRITTEN AUTHORITY MUST BE OBTAINED AND
APPROPRIATE SAFETY PRECAUTIONS TAKEN BEFORE ANY WORK IS
UNDERTAKEN ON THE SET OR ASSOCIATED CONTROL EQUIPMENT".
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2.1.11.7 Drip Trays

Trays shall be provided beneath filters and under every part of the set where drips of fluid are
likely to occur. The trays shall be integral parts of the items they serve and be provided with
readily accessible drain cocks, or shall be constructed of heavy gauge steel, with rounded corners
and smooth reinforced edges and be easily removable for emptying and cleaning.

2.1.11.8 Tools

A complete set of tools shall be provided, including grease and oil guns, necessary for the normal
maintenance of the set and its controls. The tools shall be of the best quality, the spanners being
of chrome-vanadium steel and shall be contained in a suitable robust steel tool box with lid fitted
with a lock and two keys.

2.1.11.9 Installation Instruction, Drawings and Diagrams

Before delivery and installation of the set, all necessary instructions, dimensioned drawings,
diagrams and other information sufficient for the purchaser or persons employed by him to
proceed without delay or hindrance on work associated with the installation of the set shall be
included. The information shall include the correct marking out of all builderswork (i.e. holes
etc.) required in connection with the installation of the set on the prepared foundations.

2.1.11.10 Operating Instructions

Provision shall be made for full operating, servicing the overhaul instructions, diagrams and parts
schedule in order, references for use with the set and its mechanical and electrical controls. The
information shall be properly bound, illustrated manuals, with wall charts and include all
necessary cautionary notices to safeguard operatives.

Two copies of each set of instructions, charts etc. shall be provided.

2.1.11.11 Initial Supplies of fuel and Lubricating Oil, Grease etc

An initial supply of anti-freeze and of all lubricating oils and grease shall be provided.

Additional lubricating oil shall be provided for recharging the engine sump once together with a
supply of lubricating oils and greased to cover the normal use and servicing of the set to cover the
first fill and one subsequent change.

2.1.11.12 Lubrication between Test Runs

If fortnightly test runs are insufficient to prevent the drying out of the bearings, means shall be
provided to ensure that the bearing surfaces are adequately and automatically wetted with
lubrication oil periodically.

2.1.11.13 Drawings

Provision shall be made for one copy of each of the following drawings within the price quoted.

(a) Typical installation drawing based on the drawing issued with the tender
document, showing details of cable entries, pipe entries and ducts required and exhaust
system.

(b) A general arrangement of the diesel engine.

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 (c) A general arrangement of the engine/electrical control panel

(d) A general arrangement of the alternator and exciter showing terminal markings,
polarity and phase rotation.

(e) A schematic and layouts of the engine/electrical control panel

Allowances shall be made for the maintenance of the complete set and associated control
equipment forming the unit for a period of twelve calendar months from the date that the unit is
put into commission and regular use.

During this maintenance period, the following shall be provided free of charge.

(a) Make good any defects in the unit and replace any parts that show signs of
weakness of undue wear in consequence of faulty design, workmanship or materials.

(b) Visit the site and with all diligence attend to any such defect that arises within 48
hours of receiving notification of the defect.

(c) Carry out regular examination and servicing of the unit every three months, the
service and examination to include all necessary adjustments, gearing, oiling, cleaning
changing of lubricating oils (where necessary) to keep the unit in sound and efficient
working order.

(d) Instruct the Facilities Engineering Personnel in the proper operation, care and
maintenance of the set and its equipment.

At the end of the twelve months period of maintenance, (in addition to the normal quarterly
servicing work), a comprehensive examination and test of the set and its auxiliaries, shall be
carried out, including the checking of the operation of controls and safeguards, to ensure that the
unit is in proper working order and in satisfactory condition for handing over to the Facilities
Engineer whose representative shall be present at such examination and test.

2.1.12 Works Tests

The set shall be tested as a unit at the Manufacturer's works (or elsewhere by agreement) for
output and performance generally in accordance with the requirements of BS.5514 and BS.5000,
Part 99. The Services Engineer shall be given adequate notice in writing of the date and time of
the works tests and he, or his representative, shall, if he so desires, be present at such tests and be
given all reasonable facilities for his own inspections during the course of the tests.

Whether or not he attends the test, he shall be furnished with copies of all relevant Test
Certificates.

2.1.13 Commissioning

Allowance shall be made for fully commissioning the set and its control equipment and for the
purpose of the required tests, shall provide all necessary instruments, tools, fuel and lubricating
oil.

The following tests and checks shall be carried out in the presence of the Services Engineer or his
representative. Before and during testing, use should be made of notes and procedures set out in
the appropriate Commissioning Manual for this section of work:

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 (a) Check that the main frame is level in all directions, engine and generator shafts
are in proper alignment and the vibration absorbing devices are properly installed and
located.

(b) Check water and sump oil levels and that the water jacket and radiator heaters
are in working order.

(c) Check the battery electrolyte levels and the specified gravity

(d) Examine the containers in which the fuel and lubricating oils were delivered and
check that the types and grades of oils are as recommended for the unit.

(e) Ensure that sufficient fuel oil is in the fuel tank for a two hour test run.

(f) Check that all radiator and engine block water drain points are free from sludge
and other blockages.

(g) Check engine bolts, main drive couplings, valve clearances, fuel pump settings,
governor settings, pipeline connections, water hose, exhaust couplings, flexible pipework
etc. and where a separate cooling tank is fitted, that the water level is satisfactory and the
ball valve and overflow work.

(h) Check all outgoing connections on the generator and at the control panel. All
lugs for principle connections shall have clean and bright contact surfaces. A suitable
abrasive material shall be used, where necessary.

(i) Check access panels and doors for proper opening and closing and for the
functioning of any interlocks fitted.

(j) With the set isolated from the mains supply and the selector switch in the
"Manual" position, start the engine by means of the "Start" push button and allow it to
run up to normal speed. Check that during the time the engine starter motor is in
operation, the mains battery charger is automatically switched off to avoid its being
overloaded by the reduction in voltage across the battery.

Where a battery charging dynamo is fitted, check that the mains battery charger
is disconnected by the operation of the auxiliary contactor during the time the engine is
running.

(k) Check instruments and gauges for normal operation and response and that the
generator voltage is being maintained within the prescribed limited, making due
allowance for no-load conditions.

(l) Stop engine by turning selector switch to "Off" position and certify that
generator contactor opens at between 95% and 85% normal voltage. Re-check water
and oil levels.

(m) Turn selector switch to "Auto" position. Disconnect the sensing circuit supply
and check that the set starts, the mains contactor opens and the generator contactor
closes in correct order. Re-connect the sensing circuit to verify that the engine stops on
restoration of the mains supply and that the contactors operate correctly. Check voltage
sensing and time delays on each phase in turn and also that the push buttons for mains
failure simulation and engine stopping operate correctly.

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 Running of the engine for any length of time under no-load conditions is
undesirable and tests calling for such operation should be carried out in as short a time
as possible consistent with thoroughness.

(n) Operate the necessary isolators and switches to put the set on standby for the
essential services network with the selector switch in the "auto" position and using the
mains failure simulation push, certify that the set operates correctly with the appropriate
time delay for taking up load and that the carrying of the load and its distribution over
the three phases are satisfactory.

(o) Run the set at various loads for periods totalling at least 30 minutes. Check the
voltage and current in each phase in turn and that the voltage and frequency are being
maintained within the required limits with large alterations of load. Note the rate of
charge on the dynamo ammeter with the engine running (if a dynamo is fitted) and that
rate of charge on the battery charge ammeter with the engine stopped. Check against
manufacturer's recommendations and adjust charging rates, if necessary.

(p) Check the operation of the turbo-charger unit (if fitted) and the colour of the
exhaust gas at various loads.

(q) Check that vibration absorbing devices for proper operation and that the
performance of all flexible connections, both mechanical and electrical is satisfactory.

(r) Check that the various engine safeguards operate satisfactory.

(s) When all tests are satisfactory and agreed with the Services Engineer, the
lubricating oil and water levels shall be finally checked, the fuel oil tank replenished and
the set left in normal operating order.

(t) Carry out a 4 hour continuous run on full load with fuel consumption check.

(u) One hour at 75% and one hour at 50% load at rated speed.

(v) One hour 10% overload test.

(w) Demonstrate correct functioning of protective devices.

(x) Insulation resistance and high voltage tests.

(y) Efficiency tests, short circuit and open circuit characteristics.

(z) Voltage waveform and alternator exciter heat run.

Test (x), (y) and (z) may be performed under the Work's tests with Test Certificates being
forwarded in duplicate.

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2.1.14 Information to be supplied with Tender

The Electrical Contractor shall submit with his tender the following information:

Number of Sets Offered

Delivery Period Required

General Arrangement of Set

A description of the general arrangement of the standby set, its control panel and auxiliaries and
the engine generator coupling, with illustrations and drawings, where available.

Diesel Engine:

1. Technical Information

2. Ancillary Equipment

Generator:

In addition, the following shall be stated:

1. Type of Enclosure

2. Type of bearings

3. Overall Efficiency of Generator

4. Limits of Voltage Controls

5. Synchronous Reactance

6. Maximum short circuit current per phase

2.1.15 Painting and Finishes : Generator Plant

All ferrous metal work shall be painted, all surfaces to be painted, must be properly cleaned and
prepared before painting. This work to be carried out by skilled Tradesmen.

External finishes of generator plant to be finished Grey, Brown or Blue.

External finishes of switchboards and control panels to be stove enamel finished to match
Generator Plant.

After commissioning all plant and control panels to be sprayed to erase any scratch or chipped
marks so as to present a complete installation as new.

2.1.16 Head Sets

Supply and install 2 sets of head sets for ear protection, to be used to test the Generator Set.

2.1.17 Spare Parts

The following spare parts are to be supplied for the new machine.
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 (a) One complete set of gaskets, special packings etc.

(b) One set of renewable parts for oil fuel and air inlet filters.

(c) Two complete fuel injectors.

(d) One complete set of brushes for starter motor.

(e) One flexible insertion for each type of couplings.

(f) One automatic voltage regulator.

(g) One set of rotating diodes.

(h) One set of engine control relays.

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