Patimban Port Development Project ( I ) Bidding Documents

Package – 1; Terminal Construction CHAPTER 6, Volume II

The contactor shall have easily removable coils and contacts, and be used to
switch the capacitors in or out of service. The contactor shall comply with IEC
60947-4 or equivalent and shall have a rating suitable for the service required.
All the contactor shall be operated without discernible noise and shall be fitted
with 400 V coils.
The capacitor bank shall be protected by fuses complying with IEC 60269.

6.4.1.5 Installation of Equipment in the Electric Room (SS-AD)

Connection diagrams and general arrangement for each type of electric rooms shall
comply with the drawings.
It is particularly mentioned that the clearance between the equipment and electric room
walls shall be maintained minimum 10 cm for the switchgear equipment and 50 cm for
the power transformers.

6.4.1 STANDBY GENERATORS

6.4.1.1 General
A. This works shall include the designing, manufacturing, testing before shipment,
packing, for export, delivering to the Site and installation, site testing and
commissioning at the site of diesel engine generating set, complete with all
necessary accessories. The diesel engine generating set shall be factory-assembled
unit.
Stand-by generator shall consist of the following equipment and materials:
(1) Diesel Engine facilities include the complete sets for the following:
- Governor System
- Common Bed
- Flywheel
- Cooling System
- Fuel System
- Lubricating System
- Exhaust System
- Air Ventilation System
- Engine Protection System
- Control System
(2) Generator facilities include the complete sets for the following:
- Excitation System
- Voltage Regulating System
- Generator Protection System
- Current Transformer
- Voltage Transformer

The diesel engine generation set shall be designed with following conditions:

Installation place Generator room Remarks

Minimum
Rated continuous output 625kVA (500kW)
Minimum
Required engine power 750PS

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Patimban Port Development Project ( I ) Bidding Documents
Package – 1; Terminal Construction CHAPTER 6, Volume II

Rated frequency 50Hz

Main tank :5,000 liter
Fuel tank capacity
Dayly tank: 490 litter

B. Design and submittal

The complete design with drawings and other relevant data shall be submitted for
approval of the Engineer

Minimum requirement of the design shall be shown:

(a) Technical particular

(b) Equipment layout at Generator room (Plan and Section view),
(c) Piping and instrumentation diagrams,
(d) Common bed design drawings,
(e) Fuel tank design drawings,
(f) Cable schedules
(g) Piping and valve schedules

6.4.1.2 Diesel Engine

A. General
The diesel engine shall consist of diesel engine, governor system, air filter, radiator,
flywheel, DC motor starting system, including battery charger and battery, fuel
supply system, lubricating system, air suction and exhaust system, engine protection
system, and other necessary accessories for complete and satisfactory operation of
the diesel engine.
The diesel engine shall be set on the common bed and coupled directly with the
generator specified in this subsection 2.3. The diesel engine shall be controlled from
the local control panel installed in the generator room. The diesel engine shall be
stopped automatically when any fault happens.

B. Design Requirements
The diesel engine shall be designed for the following conditions:
Type : Vertical or v-type cylinder, single acting, 4-cycle,
direct injection, cold starting, water cooled and
supercharged by exhaust turbo-blower with air cooler.
Overloaded capacity : 110 % for two hours every 12 hours at the power
factor of 0.8
Revolution per minutes : 1,500 rpm
Engine rating : Based on ISO 3046/I standard
Over speed : 120% for one minute
Number of cylinder : to be specified by the Contractor
Fuel to be used : "A" class heavy oil or diesel oil
Direction of rotation : Clockwise looking from exciter end
Starting system : DC motor
Cooling system : Radiator

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Patimban Port Development Project ( I ) Bidding Documents
Package – 1; Terminal Construction CHAPTER 6, Volume II

C. Governor System
The governor for generator speed control shall be digital, use a microprocessor to
carry out all the control functions. The power needed to operate the control of the
governor shall be supplied from the starter system batter. The drop in speed in
relation to the load shall be manually adjustable between 0% to 3% of the rated
speed at full load.
Under constant load, the speed must be kept constant within tolerance of 0.5%. At
variable loads, there must not be any sustained oscillations in the speed or output
power corresponding to a change in load.
The governor shall be fitted with a stop solenoid, powered by the starter system
battery. A solenoid powered by the starter system battery shall be provided for
transfer of the “stop-start-function” of the fuel control equipment, if so required.

D. Common Bed
The diesel engine and generator shall be rigidly secured on a common fabricated
steel bed of substantial design, which shall be set in position and secured on the
concrete foundation. The vibration absorber (springs or other approved type) shall
be provided for the foundation The Contractor shall provide and install the
foundation bolts and nuts with vibration-free materials for the setting of the
common bed.

E. Flywheel
The flywheel coupled directly with the diesel engine and generator shall be
designed not to make a harmful torsion/vibration. The flywheel shall be completely
covered by steel or other metal guards. A flywheel turning device shall be supplied
as accessories for rotating engine to the starting position. The turning device shall
be operated by DC. motor for starting.

F. Cooling System
The cooling system shall be provided with diesel engine generating set. The cooling
system shall be of self-supporting type radiator and mounted on the common bed
with all necessary piping works, valves, air hood between radiator to wall and other
fittings. The radiator fan driven by motor or coupled to the engine shall be operated
automatically.

G. Fuel System
(1) General
Fuel system shall be consisted of a storage tanks and transferring facilities and
fuel feed system to the diesel engine.
(2) Fuel Storage Tanks (Main Tank and Daily Service Tank)
The inside of tank shall be coated completely with anti-oil paint and the outside
shall be embedded with concrete. The tank shall be of water proof and dust
proof, and shall be mounted on the steel structure. The following accessories
shall be provided, but not limited to:
(a) One fill branch
(b) One extra branch (over-flow)
(c) One drain branch
(d) One air vent pipe
(f) One inspection ladder

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Package – 1; Terminal Construction CHAPTER 6, Volume II

(g) Level indicator with contacts to give remote indication of high and low
level alarming.
(h) Grounding terminal
(i) All necessary piping works, valves and fittings
(3) Fuel Transferring Facilities
The contractor shall supply and install one (1) set of fuel transferring facility for
the diesel engine. The facility shall be consisted of one motor driven type
transfer pump with pressure operated relief valves, one manual operated type
transfer pump, washable primary fuel filter, necessary piping works and fittings.

H. Lubricating System
The lubricating system shall be provided for diesel engine. The lubricating system
shall be consisted of a lubricating oil sump tank for draining all lubricating oil
discharged from the engine, oil cooler, priming pump, filter, pressure adjusting
valves, manual pump with necessary connecting branches, valves and fittings.

I. Exhaust System
The exhaust system shall be provided for the diesel engine. The exhaust system
shall be consisted of the corrosion-resistance steel exhaust pipe, silencer and other
necessary accessories.
The exhaust pipe shall be extended to the outside of the generator room and fitted
with an exhaust silencer(less than 90dB). The silencer shall be supported by the
steel supports anchored on the floor or ceiling. The contractor shall furnish all
necessary supports, clips, etc. All exhaust piping inside the generator room shall be
covered with thermal insulation materials. The exhaust piping shall be fitted with a
flexible connection or an expansion joint.

J. Engine Protection System

(1) General
The engine control panel shall be provided for the diesel engine and placed near
or on the common bed. The control panel shall be adequately sized to contain
the necessary switches, meters, gauges and other devices for the reliable and
efficient operation of the diesel engine.
(2) Control and Alarm
(a) Overload control
The engine shall be adequately protected against the operation under the over-
loaded condition. This requirement shall be made on the provision for the fuel
pump control to prevent the engine when the load exceeds the rated output
plus10%.
(b) Temperature control
The temperature of the jacket water of the engine shall be thermostatically
detected and the engine shall be stopped automatically.
(c) Protection and Alarm
The engine shall be stopped and the main circuit breaker shall be opened
automatically and alarm shall be given by bell in the event of. The integrated
alarm for the above shall also be given on the monitoring panel installed in the
control room.
(i) Engine over speed
(ii) Lubricating oil pressure low
(iii)Lubricating oil temperature high

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Patimban Port Development Project ( I ) Bidding Documents
Package – 1; Terminal Construction CHAPTER 6, Volume II

(iv)Jacket cooling water temperature high and cooling water flow low.
Alarm shall be given by buzzer in the event of:
(v) Fuel storage tank level low.
(3) Instruments
The instrument to be mounted on the engine control panel shall be as follows,
but not limited below:
(a) One tachometer
(b) One running hour meter
(c) Each one pressure gauge for:
(i) Lubricating oil at pump outlet,
(ii) Lubricating oil at engine main inlet,
(iii) Jacket water at pump outlet, and fuel at engine inlet.
(d) Tacho-generator
The tacho-generator shall be provided to supply electric power for speed relays
and tachometers, and shall be coupled directly with the exciter shaft of the
alternator.

K. Control System
When the power supply system from PLN grid is interrupted, the diesel engine
generating sets shall be started automatically. Change-over from normal source
breaker to emergency source breaker for utility plants shall be made automatically
in case of the power failure. When PLN grid is recovered, the diesel engine
generating sets would be stopped.
The float switch in the fuel service tank shall operate the fuel transfer pump.

6.4.1.3 Generator

A. General
Alternating current synchronous generator specified herein shall be set on the
common bed and coupled directly with the diesel engine specified in Sub-section
6.4.1.2 "Common Bed". The generator will be operated independently from other
power sources.

B. Design Conditions
The generator shall be designed in accordance with IEC standards for temperature
rise and for the following condition:

Type : Open, self cooled, rotating field type

Electric system
Rated terminal voltage
Rated power factor
Frequency
Inherent voltage regulation
Rated speed
Winding
Class of insulation
with damper winding
: 3-phase, 4-wire
: 400/ 230 V
: 0.8
: 50 Hz
: 40 %
: 1,500 rpm.
: Star (The neutral point of star connected
windings shall be brought out.)
: "F" (Epoxy impregnated).

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Patimban Port Development Project ( I ) Bidding Documents
Package – 1; Terminal Construction CHAPTER 6, Volume II

Excitation system : Solid state static or brushless AC exciter

with rotating silicon rectifier.
Direction of rotation : Clockwise looking from exciter end.

C. Construction
(1) Generator Bases
The generator shall be mounted on the common beds stated in Sub-section
6.4.1.2 "Common Bed".
(2) Stator Frames
The stator frames shall be fabricated of welded thick steel plates to obtain a
sufficient strength and stiffness with enough safety factor to withstand the
mechanical vibration from the driving engine. The generator frames shall be
provided with suitable space heaters to prevent moisture condensation in
generator itself.
(3) Stator Core
High quality silicon-steel shall be used to form complete laminated cores.
(4) Stator Windings
Interchangeable hexagonal or wave winding coils shall be used for stator
windings. The coils shall be impregnated with polyester resin having high
insulating and moisture proof features. Coils shall have enough strength and
supported to withstand the electromagnetic forces even under a short circuit
failure without any harmful deformation.
(5) Field Coils and Insulation
The insulation of field coils shall be of class F with resign, held firmly on each
pole piece to withstand the electrical and mechanical stresses. The coils shall be
in an edge-wise shape pressed with a hydraulic press and applied with high
quality resign.
(6) Mounting of Pole Pieces
Pole pieces shall be secured on the spider by bolts, fastened tightly from the
inside of the rotor.
(7) Damper Windings
Damper windings shall be furnished on the top each pole surface connected
each other by short circuit rings at both ends, to improve the synchronizing
power for stable running even under abrupt fluctuation and unbalance of load
between phases and for normal parallel running with the other generator.

D. Performance Figures
(1) Temperature Rise
Temperature rise of the generator shall not exceed the following figures:
Stator coils : 70 degrees Celsius
Field coils : 80 degrees Celsius
Bearings : 40 degrees Celsius
Note: The temperature of the field coils shall be measured by resistance method,
and other parts shall be measured by thermometers.
(2) Over speed
The generator shall withstand the mechanical forces, without any injury, at
120% of the rated speed for one minute, under the conditions of no-load and
no-excitation.
(3) Overload

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The generator shall be capable of one hour running with the load, 110% of the
rated output, without any mechanical or electrical damage.
(4) Wave-form Deviation
Deviation factor of wave-form shall be within 10% under the condition of no-
load, rated frequency and rated voltage.
(5) Dielectric Strength
The winding of the generator and exciter shall have enough dielectric strength
to withstand the high voltage test as given hereunder:
Armature windings : E x 2 + 1,000 V, one minute.
Field windings : E* x 10, minimum1,500 V, one minute.
Where, E : Rated voltage of the generator
E*: Rated voltage of the exciter

E. Excitation System
Each exciter shall be of the solid state static type of the open-guarded, rotating
armature type, 3-phase alternating current generator with rotating silicon rectifiers
to supply direct current to the main generator fields. The exciter shall be directly
coupled with and driven by the main generator shaft on the opposite end of the
engine.
The exciter shall be continuously rated and have sufficient capacity to supply
sufficient field current to the main generator.
Each excitation control device shall be mounted on the generator control panel of
self-supporting, containing all necessary components, with indicating and control
equipment completely wired and mounted in the panel. The measuring instruments,
automatic voltage regulator, adjusting rheostat, operation switches, contactors and
other necessary accessories to make the complete excitation control shall be
furnished and mounted on the generator control panel.

F. Voltage Regulating System

An automatic voltage regulator shall provide continuous and practically
instantaneous response to any variation of the generator voltage, plus or minus
0.25% for steady state and plus 10% or minus 20% from no load to full load.
An adjustable handle for setting the voltage regulator shall be provided on the
generator control panel for adjusting the generator voltage. The terminal voltage
shall be adjusted within plus or minus 5% of rated voltage. Output voltage complete
recovery time after sudden application or rejection of rated load shall be within 1.0
second.
The regulator shall re-establish stable generator operating conditions in 4 seconds
for any sudden change of the load between no-load and the rated load.

G. Generator Protection System

The engine shall be stopped and the main circuit breaker shall be opened
automatically and alarm is given by bell, in case of:
(1) Operation of over voltage relay, and
(2) Operation of emergency shutdown switch
The main circuit breaker shall be opened automatically and alarm is given by bell,
in case of:
(1) Operation of over current relays, and
(2) Operation of under voltage relay

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Patimban Port Development Project ( I ) Bidding Documents
Package – 1; Terminal Construction CHAPTER 6, Volume II

The integrated alarm for the above shall also be given on the alarm panel installed
in the PLN control room in O & M building

6.4.1.4 Generator Control Panel

A. General
One (1) generator control panel shall be provided for the diesel engine generating
set. The automatic voltage regulator (AVR) shall be incorporated in the generator
control panel.
The devices and instruments to be mounted on the generator control panel shall be
as follows, but not limited to:
- AC Voltmeter, switch change-over switch
- Ammeter, with change-over switch
- Frequency meter
- Running hour meter
- Over current relay
- Over voltage relay
- Over speed relay
- Low speed relay
- Voltage relay
- Automatic voltage regulator (AVR)
- Voltage transformer
- Circuit breaker control switch, on-off
- Indication lamps for circuit breaker, on-off
- Control switch for engine speed setting
- Control switch for voltage setting
- Fault annunciator group
- Alarming bell
- Alarming buzzer
- Reset button for alarming bell and buzzer
- Lamp test button
- Emergency shutdown switch
- Set of complete bus bar
- Grounding bus at bottom
- Exciter Transformer
- Set of test terminal
- Other necessary accessories
The secondary circuits of instrument transformers shall be brought out to the test
blocks.

6.4.2 CABLE AND CABLE LAYING WORKS FOR UTILITY FACILITIES

6.4.2.1 General

A. This works including materials and installation works for cable, conduit pipe,
manhole, handholes and necessary accessories.
B. Following range of conduit and cable laying shall be provided.

From To
LVSB in the Electric Room (SS- Isolators S-TO-AN & S-TO-AE

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