GENERATOR SET INSTALLATION SPECIFICATION

PART 1 – GENERAL
1.1 DESCRIPTION OF WORK
A. Work includes providing all materials, equipment, accessories, services and tests necessary to
complete and make ready for operation, a diesel engine generator set complete with engine
generator batteries, charger, silencer, generator control panel and all required appurtenances
and accessories.
1.2 QUALITY ASSURANCE
A. Manufacturers: Firms regularly engaged in the manufacturer of diesel engine generator sets of
the types and capacities required, whose products have been in satisfactory use in similar
service for not less than 10 years.
B. Standards Compliance: Comply with requirements of applicable local codes, ISO 8528, DIN, VDE,
IES, EN, NEC, UL, NEMA, ANSI and IEEE Standards pertaining to diesel generator set.
C. NFPA Compliance: Comply with applicable requirements of NFPA 37, "Installation and Use of
Stationary Combustion Engines and Gas Turbines;" NFPA 99, "Standard for Health Care
Facilities;" NFPA 101, "Code for Safety to Life from Fire in Buildings and Structures;" and
"Emergency Standby Power Systems".
D. Service: Manufacturer must have a factory warehouse located within 100 Km of the job site, at
which spare parts are stocked and where a field service engineer who is a full-time employee of
the manufacturer permanently resides, and is a factory trained and qualified individual whose
primary duty is field service.
E. Equipment Rating: 230 / 400 V, 3 phase, 4 wire, 60 hz, 1800 rpm, Kw rating as indicated on the
drawings. At 0.8 power factor and capable of continuous operation at rated output for the
duration of any utility power failure up to 24 hours.
Ratings of diesel electric set based on operation of the set at rated generator RPM when
equipped with all necessary operating accessories, such as air cleaners, radiator fan, lubricating
oil pump, fuel transfer pump, fuel injection pump, jacket water pump, governor alternating
current generator and exciter. All ratings must be factory certified.
F. The same manufacturer is to build, test, and ship the whole system (the engine, generator, and
all major items of auxiliary equipment).

1.3 SUBMITTALS
A. Product Data: Submit manufacturer's data for diesel engine driven generator sets and
components, including:
1. Drawing of the diesel generator set.
2. The following data in tabulated form:
a. Make of engine.
b. Number of cylinders.
c. Bore, inches (millimeters).
d. Stroke, inches (millimeters).
e. Piston displacement, cubic inches (liters).
f. Piston speed, feet per minute (liters/min.), at rated RPM.
g. BMEP at rated KW output.
h. Make and type of generator.
i. Generator electrical rating, KVA or KW at .8 power factor.
j. Number and type of bearings.
k. Exciter type.
l. Generator insulation class and temperature rise.
m. Parts and service support.

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n. Engine manufacturer's certified engine BHP curve and certified generator set fuel
consumption curve.
3. Batteries and battery charger.
4. Silencer.
5. Fuel system complete.
6. Cooling system complete.
7. Exhaust system complete.
8. All auxiliaries.
B. Shop Drawings: Submit dimensional layout on architectural background drawings of diesel
engine generator sets.
C. Submit a certified test report showing serial number of the engine, generator and all accessories
furnished, and actual readings taken during a factory-conducted full load test including the
following:
1. Cold start acceleration to rated voltage and frequency within 8 seconds.
2. Full and partial load applications and rejections during the test (at least 2 per hour).
Frequency and voltage stability and transients not to exceed the limits specified herein.
3. 15 minutes 1/4 load, or function warm up, 1/2 hour 1/2 load, 1/2 hour 3/4 load, and 2 hours
full load; plus 2 hours overload at 110%. Test shall be conducted at 0.8 power factor.
4. Demonstrate that all applicable safety shutdowns function along with their respective audio
and visual alarms.
D. Ten working days written notice shall be given prior to factory tests being carried out and all
necessary facilities shall be made available for the consultant to witness such tests.
E. A complete set of tools and portable instruments for the operation and equipment shall be
provided, together with suitable means of identification, storage and securing.
1.4 SEQUENCING AND SCHEDULING DELIVERY, STORAGE, AND HANDLING
A. Obtain all necessary permits prior to delivery.
B. Delivery and rigging shall be fully coordinated with, and approved by the consultant.
C. Upon delivery, inspect for physical damage and compare nameplate rating of unit with this
specification.
D. Prior to installation, engine-generator controls and all associated electrical equipment shall be
stored indoors, fully protected from weather, dust and dirt.
E. Extreme care shall be exercised to prevent bumping or dropping. All rigging and handling shall
be in full accordance with engine-generator manufacturers' requirements.
Avoid the use of excessive hammering and jarring which would damage the electrical equipment
contained therein.
F. Do not install damaged equipment, remove from site and replace with new equipment.
G. Extreme care shall be taken to assure that all equipment is properly secured and braced for any
overland and vertical travel.
1.5 EQUIPMENT WARRANTY
A. Guarantee equipment furnished under these specifications against defective parts and
workmanship under terms of the manufacturer's and dealers standard warranties for a period of
not less than 1 year from date of initial start-up and Owner acceptance of the system and
include labor and travel time for necessary repairs at the job site. The system warranty not to be
limited by running hours.
1.6 SYSTEM SERVICE CONTRACT
A. The supplier of the diesel engine generator set to provide a service contract for a period of five
years after guarantee period and include, but not be limited to, the following:

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1. Engine manufacturer's recommended procedures for weekly (biweekly) inspection and

maintenance to be done by user.
2. Quarterly inspection by the supplier personnel to review the weekly maintenance records being
kept by user and train any new Owner operating personnel. Inspection to include scheduled oil
sampling for lube oil contaminants as outlined below. Also include a 100% load test run on the
generator set.
3. Annual inspections to include all of items in above paragraph except run the generator set under
system load.
B. Scheduled Oil Sampling
1. In order to forecast and minimize engine downtime, the supplier of the equipment must provide
an oil sampling analysis kit which operating personnel can utilize for Schedule Oil Sampling.
2. Scheduled Oil Sampling of the atomic absorption spectrophotometry method and accurate to
within a fraction of one part per million for the following elements:
a. Iron
b. Chromium
c. Copper
d. Aluminum
e. Silicon
f. Lead
3. In addition, test the sample for the presence of water, fuel dilution, and antifreeze.
4. Provide all equipment needed to take oil samples in a kit at the time of acceptance and include
the following:
a. Sample extraction gun (1).
b. Bottle (10).
c. Postage-paid mailers (10).
d. Written instructions (1).
5. Provide immediate notification to the consultant when analysis shows any critical reading. If
readings are normal, provide a report showing that the equipment is operating within
established parameters.

PART 2 – PRODUCTS

2.1 GENERAL
The Contractor shall supply, install and commission the automatic start diesel generating sets with
all necessary switchgear, control panel and accessories all as either herein specified or shown on the
Drawings.
The size of the set shall be prime rating to the rating shown of the Drawings, when operating at the
specified frequency, voltage, altitude, maximum temperature and humidity.
The Contractor shall be guided by the emergency power room layout details shown on the drawings,
but a final detailed and dimensioned layout suitable for construction shall be submitted to the Engineer
for approval, prior to ordering of equipment.
The Contractor shall indicate the nearest location from which service facilities and spare parts may
be obtained.
The design of the plant and its installation including all ancillary equipment, shall be such as to
minimize noise and vibration.
Materials and workmanship - All materials, equipment, and parts comprising the units specified
herein, shall be new and unused, of current manufacture and highest grade.

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Manufacturer - The unit shall be factory assembled, and tested as complete unit by the engine
manufacturer. It shall be inspected and started at the job site by his authorized dealer having a parts and
service facility in the area.
Warranty - Equipment furnished under this section shall be guaranteed against defective parts or
workmanship under dealer's standard warranty. Warranty period shall in no case be less than one year
of unrestricted service commencing from date of putting the unit into service and not limited to any
fours limitation.
Tests - The generator set shall receive the manufacturer's standard factory load testing. Prior to
acceptance of the installation, equipment shall be tested to show it is free of any defects and be
subjected to full load test.
Start-up and Instructions - On completion of the installation, start-up shall be performed by a
factory-trained dealer service representative. Operating and maintenance instruction books shall be
supplied upon delivery of the unit and procedures explained to operating personnel.
Specifications and Drawings - The bidders shall furnish information showing manufacturer's model
numbers, dimensions and weights for the generator set and major auxiliary equipment.
Proposed deviations from the specifications shall be stated in the bid. The successful bidder shall
submit copies of pertinent drawings and wiring diagrams for approval.
The diesel generator set should have performance class G2 according to ISO 8528.

2.2 OPERATION OF THE SYSTEM

The loss of normal power from the transformer shall automatically cause the generating set to
start through Automatic Transfer Switch.
The Diesel generating set shall have an automatic start facility.
The emergency generating set shall be designed so that it will come up to steady full speed from
cold condition within 10 seconds of the "start" impulse. It shall then be capable of accepting 100% of
its power rating load under power factor variations of 0.8 to unity lagging with maximum transient
voltage over or under 5-7 % maximum transient frequency variation of + 5% with steady frequency +
1/2% of nominal (within 5 sec).
Should the Diesel engine fail to start in 10 seconds following the "start" impulse, it shall come to
rest for 10 seconds. Two further attempts shall be automatically performed with intermediate
periods of rest. Should the set not start after three attempts, an alarm shall sound and signal "start
failure" shall illuminate. It shall be possible to operate the set manually for testing and normal
operation purposes. For this purpose the set shall be provided with a duty selector switch arranged
for OFF/TEST/MANUAL/AUTO. It shall be possible to run the engine with or without operation of the
Emergency Distribution Board circuit breakers.
The Diesel generator set must still be running at 3 - 5 minutes after transfer and after removal of
all load to ensure that a change-over in the event of a repeated mains failure can rapidly be realized
and to obtain a cooling effect to avoid an accumulation of heat.

2.3 EQUIPMENT
A. GENERAL
The engine-generator sets shall be a complete package unit mounted on rigid base suitable
for skidding as indicated in the drawings.
The design of the set shall allow the easy replacement of major items subject to wear.
A flexible coupling shall be fitted between the engine and generator to provide the drive
and absorb the transmission of shock loads, and shall be completely shielded by a coupling ring
and adequate steel guards.

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Complete protection from machine vibration is required for the building and all
instrumentation and control equipment, including engine-mounted instruments. This may be
achieved either by mounting the combined engine/generator unit to a separate sub- frame
resiliently mounted on the main frame, or by mounting the entire main frame on anti-vibration
mountings, and securing the machine instrument panel by its own resilient mounting. The
machine instrument panel by its own resilient mounting. The mountings employed, method of
mounting, and floor structure and thickness shall be approved by the manufacturer and the
Engineer.

2.4 DIESEL ENGINE

The engine shall operate on diesel fuel oil at 1800 R.P.M. including the capacity to withstand
10% overload for one hour in any period of twelve hours. The net power rating of the engine under
worst site conditions shall be such as to deliver the net electric power indicated on the generator
taking into consideration generator efficiency.
The engine shall be of the water-cooled, radiator type with gear driven water pump system shall
be pressurized and equipped with a heavy-duty radiator mounted integrally with the set and cooled
by a refers flow fan. A fan coil and hand protection guard shall be fitted. Coolant temperature shall
be measured and controlled by means of one or more thermostats.
The lubricating oil system shall be of the full pressure circulating type, complete with full flow
lubricating oil filters with replaceable elements and a lubricating oil heat exchanger. Filter system
shall be equipped with a spring loaded by-pass valve as an insurance against stoppage of lubricating
oil circulation in the event the filters become clogged.
Adequate inspection openings per cylinder to provide quick access and inspection of camshafts
and connecting rod.
The fuel system shall be complete and shall be capable of supplying the engine by gravity from a
day fuel tank. It shall be equipped with easily replaceable fuel filter elements. The fuel system shall
be equipped with a built in, gear type, engine driven fuel transfer pump, capable of lifting fuel
against a head of 250 cms. for supplying fuel through the filters to the injection pump at constant
pressure.
The exhaust system shall be insulated complete with dry type exhaust manifold with flanges,
flexible exhaust expansion connections, exhaust pipes and a residential exhaust silencer which shall
be fitted with a drain plug at its lower end to permit evacuation of condensed humidity. The exhaust
piping shall be insulated with asbestos tape with a total thickness not below 10 mm.
The electric starting of the engine shall be possible either manually by means of push button or
automatically by means of the automatic control panel. The starting system shall consist of a 24
volts d.c. starter motor, heavy duty 24 volts lead - acid battery and a suitable automatic trickle
battery charger. The starting pinion shall automatically disengage when the engine.
An isochronous electronic type engine governor with speed control and droop adjustments shall
be provided and shall be capable of providing accurate speed control within 1% of the rated speed.
An automatic shut-down protective system with signalling lights shall be provided to shut down
the engine in the event of engine overspeed, low lubricating oil pressure, and high cooling water
temperature.
Complete shut-down system shall be arranged to energize an alarm system located within the
plant room and to trip the respective generator circuit-breaker.
The following engine mounted instruments shall be provided:
1. Water temperature gauge calibrated in °C
2. Lubricating oil temperature gauge calibrated in °C
3. Lubricating oil pressure gauge.

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4. Tachometer.
5. Operating time meter.
6. Oil filter differential.
7. Jacket water temperature.
8. Fuel pressure.

2.5 GENERATOR
The generator shall be of drip proof construction, in accordance with screen protected,
revolving field, brush less type with adaptor and flexible coupling for direct connection to the engine
at the flywheel end.
Required Generator Characteristics
i. Type Brushless with salient pole field system incorporating rotating exciter and three
phase rectifier system.
ii. No. of phases Three with 4 terminals
iii. Voltage 220
iv. Winding connection Star with grounded neutral
v. Net rated output As indicated on the drawings @ 35 °C ambient temperature.
vi. Power factor 0.8 lagging.
vii. Frequency 60 Hz.
viii. Overload 10% of name plate rating for one hour every 12 hours.
ix. Insulation Class "F" stator class "F" rotor with temperature rise according to class F 105
°C over 40 °C ambient temperature.

The exciter shall be of the static type with a digital voltage regulator forming an integral part
of the alternator.
Overall voltage regulation from no load to full load, including hot to cold, variations and load
power factor between 0.8 lagging and unity shall be within ± 0.5% of nominal voltage.
Voltage buildup shall be in a positive and rapid manner even when the machine is
connected to its load circuit.
The line to line voltage wave form shall be at least to the requirements of VDE 0530 (less
than 5% deviation. The total harmonics content shall not exceed 3%. Radio interference
suppression shall be at least according to degree "N" of VDE 0875 or equivalent.
Engine-Generator Set Control : The control shall have automatic remote start capability. A
panel mounted switch shall stop the engine in the STOP position, start and run the engine in the
RUN position and allow the engine to start and run by closing remote contact, and stop by
opening the remote contact when in the REMOTE position.
a. The control shall include a cycle cranking function. The cranking cycle, nonadjustable, shall
consist of an automatic crank period of approximately 10 seconds duration followed by a rest
period of approximately 10 seconds duration. Cranking shall cease upon engine starting and
running. Two means of cranking termination shall be provided, one as backup to the other.
Failure to start after three cranking cycles shall shut down and lockout the engine, and visually
indicate an over crank shutdown on the panel.
b. The control shall shut down and lock out the engine upon : failing to start after the specified
time (over crank), over-speed, low, lubricating oil pressure, high engine temperature, or
operation of a remote manual stop station.
c. The generator control panel shall have degree of protection IP 54.
d. The control shall provide a twelve light engine monitor on the control panel; one red light for
each of the four shut downs (except the remote manual stop), and one yellow light each for the

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high engine temperature and low engine oil pressure pre-alarms, and one green run light. The
control panel monitor shall include; a flashing red light to indicate the generator set is not in
automatic start mode, a yellow light to indicate low coolant temperature, a yellow light to
indicate low fuel, and two red lights for auxiliary use (for a total of twelve).
A panel mounted switch shall reset the engine monitor and test all the lamps. The engine
generator set starting battery(ies) shall power the monitor. Operation of shut down circuits shall
be independent of indication and pre-alarm circuits. Individual relay signals shall be provided for
each indication for external circuit connections (not to exceed 1/2 amp draw) to a remote
annunciator. A common alarm contact for external connection to an audible alarm shall be
provided.
e. Provide a low coolant level shutdown, which shall be indicated as a high engine temperature
fault.
f. Provide the supervised points as indicated in fire alarm system.
g. Control panel shall be mounted on the generator set with vibration isolators or wall mounted
type as indicated on the drawings. The control shall include surge suppression for protection of
solid state components. A front control panel illumination lamp with On/Off switch shall be
provided. Control panel mounted indicating meters and devices shall include: Engine Oil
Pressure Gauge, Coolant Temperature Gauge, DC Voltmeter, and Running Time Meter (hours);
Voltage adjusting rheostat, locking screwdriver type, to adjust voltage +/- 5% from rated value;
Analog AC Voltmeter scale 0-500 V dual range, 90 degree scale, 2% accuracy; Analog AC
Ammeter, dual range, 90 degree scale, 2% accuracy; Analog Frequency meter, 45-65 Hz, 90
degree scale, +/- 0.6 Hz accuracy; Seven position phase selector switch with OFF position to
allow meter display of current and voltage in each generator phase.
h. Provide exerciser clock (2-week type) to automatically start the generator for 30 minutes.

2.6 BATTERY TRICKLE CHARGER

A battery trickle charger mounted on the generator control panel shall be supplied with the
generator in order to maintain the two battery sets in good condition. It shall be fitted with on-off
switch indicator light, input and output fuses and reverses current protection. Upon operation of the
standby plant the charger shall be disconnected from the battery and from the mains. An ammeter
to indicate rate of charger and battery voltmeter shall be fitted for each set of batteries.

2.7 ENGINE GENERATOR SUPPORT AND ISOLATION SYSTEM

A. Equip the engine and generator set with a suitable common steel base for mounting the engine-
generator unit on a concrete foundation.
B. Spring Isolators: Freestanding and laterally stable rated for seismic areas with housings that
include vertical resilient limit stops to prevent spring extension when weight is removed; the
isolators complete with neoprene acoustical friction pads between the baseplate and supports.
C. All mounting leveling bolts rigidly bolted to the equipment; spring diameters no less than 0.8 of
the compressed height of the spring at rated load; springs to have a minimum additional travel
to solid equal to 50% of the rated deflection.

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2.8 MISCELLANEOUS
The Contractor shall calculate the reinforced concrete foundation block to support the
generating set. Calculation and detailed drawings shall be submitted to the Engineer for approval.
A water pipe shall be installed between the radiator and the engine.
The Contractor shall supply and install all piping cabling and other required accessories and
items for a complete emergency generating set.
The Contractor shall supply all the required standard and special tools for routine maintenance
and normal over hauls, in suitable cupboard.
The spare parts required for normal operation during 1500 operation shall be supplied with the
set, and placed in a suitable cupboard. Priced spare part list shall be supplied with the Tender.
Manuals and Technical literature required for operation maintenance and overhaul shall be
supplied in English in 3 copies.

2.9 EQUIPMENT DATA/SHOP DRAWINGS

The equipment data to be provided by the Contractor prior to ordering any material covered by
this sub-division shall include but not be limited to:
Complete technical data on diesel engine, includes operating characteristics, site rating, fuel and
lubricating consumption, manufacturer's catalogue cuts, dimensions and weights, etc.
- Detailed description of all components of the engine: starting system, super charge, governor,
injector, cooling radiator, air, fuel and lubricating filters etc. with manufacturer's catalogue cuts
and operating characteristics.
- Detailed description of all auxiliaries : batteries and charger, exhaust pipe and silencer.
- Detailed description of engine control, instruments protection, alarms and cut offs, etc.
- Complete technical data on generator and excitation: standards to which it complies, type of
insulation, system of cooling system of excitation voltage regulation, etc.. with manufacturer's
catalogue cuts.
- List of standard and special tools supplied for routine and major overhauls.
- List of spare parts for 1500 hours operation.
- Operator's manuals, maintenance book and drawings.

The Contractor's shop/construction drawings for installation covered by this sub-division shall
include but not be limited to:
Complete drawings of the generating plant in the particular location of the project, with
indication of all components, piping exhaust pipes, power and control cabling, etc.
- Construction drawings of the foundation block with indication of holes for anchoring bolts.
- Schematic diagram for power and control wiring.
- Complete lay-out drawings of piping.
- Shop drawings for all supports, frames, louvers plates.
- Plans and elevations of control panels.

2.10 TESTS
Sets shall be available for visual inspection at works by the consultant before loading for
dispatch to site.
Sets shall be available at works for noise level tests to be made by the consultant before loading
for dispatch to site.
Performance tests shall be made as specified on the Equipment Data Sheets.

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2.11 GENERATOR PROTECTION

The generator shall be protected against all types of excess current that will damage the
generator electrical system.
Earth leakage protection shall be provided by means of a 'core balance' residual current device.
The restricted earth fault protection level shall be capable of being varied over the range 0.3
amps to 10 amps.
The Contractor shall provide all auxiliary equipment necessary for monitoring the electrical
parameters utilized in the protection systems.

PART 3 – EXECUTION

3.1 INSPECTION

A. Examine conditions under which diesel engine-driven generator sets are to be installed and
notify Engineer in writing of conditions detrimental to proper completion of the work. Do not
proceed with the work until unsatisfactory conditions have been corrected.
3.2 INSTALLATION

A. Install diesel engine-driven generator set as indicated, in accordance with manufacturer's

written instructions, requirements of applicable Standards and in accordance with recognized
industry practices to ensure that installation complies with requirements and serves intended
function.
B. Coordinate as necessary to interface installation of engine-generator equipment work with
other work.
C. Lift generator using eyes and other devices provided by the manufacturer.
D. Tighten connectors and terminals, including screws and bolts, in accordance with equipment
manufacturer's published torque tightening values for equipment connectors.
E. Align shafts of engine and generator within tolerances recommended by engine-generator unit
manufacturer.
F. Provide break glass station to shut down engine generator set.
G. Provide equipment grounding connections for diesel engine-driven generator units as required.

3.3 FIELD QUALITY CONTROL

A. Upon completion of installation of diesel engine generator set, test and inspect system to
ensure compliance with requirements. When possible, field correct malfunctioning equipment,
then retest to demonstrate compliance. Replace equipment which cannot be satisfactorily
corrected.
B. At the construction site, provide the services of a competent, factory trained engineer or
technician employed by the manufacturer of the diesel engine generator set to technically
supervise and participate during all of the adjustments and tests for the set and major
auxiliaries. Make adjustments and test in the presence of the Owner.
C. Provide start-up and load test in accordance with NFPA 110 and include the following:
1. A minimum of 3800 liters of fuel oil for testing.
2. Record room temperature and time of beginning of test.
3. Start the units and record the number of seconds it takes each unit to get it started.

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4. Record voltage readings on all phases and also running hour meter reading RPM and
frequency meter reading. Use a hand tachometer to check RPM against frequency meter
reading.
5. Provide load banks for full load rating of generator to test all systems on generator for
minimum of 4 hours.

D. Mechanical Examination
1. Check engine fuel system and water cooling system for possible leaks during the load test. If
any fuel or water leaks are observed, stop the unit and tighten or replace the leaking item as
required, and restart the load test. It is necessary that each unit run for 2 hours at full load
without any leaks or excessive water temperature, low oil pressure, etc., before acceptance.
2. Deliberately speed up the engine by misadjusting the governor and record the speed at
which the engine automatically shuts down.
3. Simulate low oil pressure by shorting the contacts of the oil pressure relay, to test for
automatic engine shutdown on low oil pressure.
4. Simulate high water temperature by shorting the contacts of the water temperature relay to
test for automatic engine shutdown on high water temperature.
5. With engine running under load, during the last half hour of the 2-hour test, measure room
and outdoor ambient temperatures. Room temperature not to exceed the motor-generator
manufacturer's limit for room temperature with outdoor air temperatures at 35 oC design
day.

The Contractor to submit this data to the motor-generator manufacturer for computation of
equivalent room temperature based upon 35 oC day operation. Manufacturer to certify that room
temperature data is consistent with manufacturer's recommended operating limits for a 35 oC
design day.

END OF SPECIFICATION

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