Particular Specification – Part 38
Particular Specification for
Diesel Generator SETS Installation
1. / Scope and Specification of Work1.1 / Installation/System
The scope of this installations includes the design, supply, installation, commissioning, testing and maintenance of the entire diesel generator installation as listed in the Works Orders under this Contract and described in this Particular Specification unless otherwise specified.
1.2 / Design Responsibilities
The Contractor shall employ a specialist sub-contractor from the “List of Approved Suppliers of Materials and Specialist Contractors for Public Works: Diesel Generator Installation” (hereinafter referred to as Specialist Diesel Generator Sub-contractor) to carry out the diesel generator installation as described in this Particular Specification.
1.3 / Compliance with General Specifications
1.3.1 / All materials and workmanship for diesel generator sets installation work shall comply, where applicable with the following current Specifications and Standards, together with any supplements and amendments made thereto: -
(i) / General Specification for Electrical Installation in Government Buildings, the Hong Kong Special Administrative Region, issued by Building Services Branch, Architectural Services Department (hereinafter referred to as the Electrical General Specification).
(ii) / ISO 8528 Reciprocating internal combustion engine driven alternating current generating sets.
(iii) / Codes of Practice and current requirements of F.S.D. on Fire Prevention in Building including relevant Fire Services Department Circular, especially FSD Circular letter on emergency generator.
1.3.2 / The Contractor shall be responsible for all submission to the statutory bodies and allow all costs relating and pay the cost of the statutory inspections and certificates as appropriate and as necessary.
1.4 / Workmanship and Design of Generator Installation
1.4.1 / The equipment shall be new and of up-to-date model (but in general with proven design not less than 2 years) designed for a nominal serviceable life of 15 years. In general, the mechanical and electrical equipment shall be so designed as not to require frequent maintenance attention.
1.4.2 / All items of equipment shall be rated for continuous service at the specified duties under the prevailing atmospheric and operational conditions on site.
1.4.3 / All component parts of the equipment shall be manufactured to a strict system of tolerance limits so that complete interchangeability of similar parts is possible.
1.4.4 / All items of equipment for which spare parts may be required shall have attached to them untarnishable metal plates clearly showing the manufacturer's name, serial numbers and basic information as to rating, etc., in sufficient detail to allow the unit or assembly to be identified in correspondence and when ordering spare parts.
1.4.5 / All parts subject to wear shall be readily accessible for replacement.
1.4.6 / Adequate and, as far as practicable, automatic means of lubrication shall be provided for all moving parts.
1.4.7 / The position of all greasing and oiling points shall be arranged so as to be readily accessible for routine servicing. Where necessary, to achieve this, suitable extension pipes shall be fitted.
1.4.8 / Lubrication grease points shall be hexagon headed nipples except where the lubrication required is to a special nature. In such event they shall be fitted with metal labels to indicate the special lubricant required.
1.4.9 / Where continual grease or oil feeding is required the capacity of the reservoir shall be sufficient for not less than seven days' continuous service with indicators in the form of meters or alarms.
1.4.10 / In accordance with the Electricity Ordinance, all electrical work and electro-mechanical work on site and electrical tests shall be undertaken by registered/competent electrical workers.
1.4.11 / All machined surfaces which are liable to corrosion shall be appropriately wrapped or greased for protection after manufacture. Care shall be taken with the electrical control gear in order that the contacts and mechanisms remain in good working condition.
1.5 / Information to be Provided
The Contractor shall submit all relevant technical information, including sample-board, to the Architect for approval and/or reference within the period as stipulated in this Particular Specification. In general, the Architect will require approximately 4 calendar weeks to approve or comment on the Contractor's submitted items upon the receipt of the said items.
Any late submission made by the Contractor may affect the generator installation work. In this respect, the Contractor shall be therefore fully responsible for any possible consequence which may arise from his late submission of the said technical information.
1.5.1 / Sample Board
The Contractor shall submit a 'Sample-Board' for approval within four calendar weeks after the issue of respective Works Order. The sample-board shall contain samples of all compact sized materials and accessories to be used on the work. Written acceptance of all samples shall be obtained from the Architect and his representative before commencement of any installation work for which these materials are required.
A label in English bearing the name of the Contractor, the title of the Contract, the name of the manufacturer and the specific service for which the material or accessory is to be used, is to be attached adjacent to each item. The sample-board shall be displayed in the Site Office during the whole of the specified period of the respective Works Order.
Additionally, the Contractor shall supply sufficient samples of materials as are required in this part of Specification for testing purposes. This, where required and stated, shall mean testing to destruction.
1.5.2 / Installation/Shop/Manufacturer's Shop Drawings
Within two weeks from the date of issue of respective Works Order, the Contractor shall prepare and submit for acceptance by the Architect, detailed Installation/Shop/Manufacturer's Shop Drawings to demonstrate how he proposes to install the works both in 'Detail' and 'Form' to facilitate the practical installation on Site. These drawings shall be fully dimensioned, fully coordinated and shall be based on the basic intent of the Contract drawings but shall not be simply a copy of them.
Before shop drawings are prepared for any area of works the full final co-ordination as to line, level and sequence of installation shall have been carried out in conjunction with the Contractor's co-ordinator and all other Works involved in the same 'spatial zone'.
Preparation of any shop drawings without prior receipt of full co-ordination details from the Contractor will likely result in abortive drawing work. No extra payment will be made for such abortive work.
The Contractor shall obtain all necessary dimensions and information required and shall be responsible for checking all dimensions taken from the drawings of respective Works Order for use in the preparation of shop drawings. Acceptance of drawings shall not relieve the Contractor from responsibility to provide equipment suitable in dimensions, construction, finish and function for the location in which and purpose for which it is installed.
Should any part of the work, which reasonably and obviously would be inferred to as necessary for the complete, safe and satisfactory operation of the work as a whole, be not specified or expressly described in the Specification and/or the drawings of respective works order, the Contractor, notwithstanding such omission shall provide and execute such work included in the Contract work and shall not be entitled to any extra payment on that account.
The Contractor shall take all dimensions during the progress of the works and submits for acceptance by the Architect, any modifications in details as may be found necessary before proceeding.
In accordance with the provisions of the Specification, the Installation/Shop/Manufacturer's Shop Drawings must incorporate details of the actual items of accepted plant and equipment proposed for installation by the Contractor and agreed by the Architect.
The Contractor's Installation/Shop/Manufacturer's Shop Drawings shall be prepared to such scales that will clearly show all necessary details.
The Installation/Shop/Manufacturer's Shop Drawings shall be prepared to the same sheet sizes and scales as used for the ultimate 'as-fitted' record drawings. Upon Approval by the Architect, six copies of the final drawings shall be handed over to the Architect.
Generally Installation/Shop/Manufacturer's Shop Drawings shall include not less than the following:
(a) General layout drawings of the emergency generator set and control with leading dimensions, weights, foundation details and required Building Works.
(b) Requirements (including all relevant drawings) for fuel pipe connections, as well as oil and water drains.
(c) Complete schematic and wiring diagrams of the electrical system.
The Architect may request the Contractor to submit additional drawings and technical information and/or calculation to clarify any technical aspect regarding the generator installation. In this respect, the Contractor shall submit the relevant drawings to the Architect within 2 calendar weeks after the Architect's written request is made.
1.5.3 / Instruction Manuals
At least 60 calendar days prior to the completion date of the Works Order the Contractor shall, unless otherwise agreed in writing by the Architect, submit to the Architect for his perusal three copies (one of which shall be an original) of the proposed operating and servicing manual for each item of equipment. The manual shall be in English and in S.I. units. They shall refer to the items supplied. Specific requirements for different sections of the manual shall relate to the requirements listed in the corresponding sections of this part of Specification.
The manual shall contain at least the following, written with individual sections for different services and fully indexed:
(a) A brief outline of the operation of the plant.
(b) General arrangement drawings of plant including complete wiring, cabling and control diagrams.
(c) Drawings showing the internal construction of major items, with part lists and reference numbers for spare identification and ordering purpose.
(d) Instructions on how to start and stop the plant, pointing out all safety precaution requirements, and detailed maintenance requirements etc.
(e) Details of all lubricating oil and greases used.
(f) Parts books giving details of each item of plant and ancillaries including the name and address of the manufacturer, and type and model serial number, etc.
(g) Detailed technical literature of electronic parts describing their mode of operation, circuit description of electronic circuitry with printed circuit board layout down to component level, maintenance and calibration procedures.
(h) Comprehensive part and version numbers for all program storage devices e.g. ROM, EPROM (if any), method of generation/duplication of the data in the storage device.
(i) A preventive maintenance programme as recommended by the manufacturer for all individual items of equipment.
(j) Copies of manufacturer's test certificate.
(k) Copies of surveyor certificates of lifting trolley and hoist, daily service tank, fuel storage tank, fuel oil pipework and all accessories of the fuel supply system.
(l) Testing & commissioning reports of the complete generator set installation.
The draft manual may be in photo-copy form with temporary type binding and covers but all photo-copies shall be clear and easily readable including any half-tones. Temporary insertions may be used for items which cannot be finalised until all work are completed and tested.
Within 30 calendar days following the issue of the Certificate of Completion for the Works Order, the Contractor shall provide four copies of the final agreed manual which shall incorporate all amendments, corrections, etc. found necessary during examination of the draft manual.
The final manual shall have pages of A4 size only (or A3 size folded) and shall be encased in durable hard covers with permanent lettering on spine and front.
All manuals shall be bound in such a manner that they will lie flat when open. Should loose leaf ring binders be utilised they must be of the ring type with all holes in sheets reinforced. On completion of final assembly the rings shall be soldered closed to prevent removal of sheets. The number of separate manual volumes required will depend on the size and complexity of the installation concerned. The Architect's agreement is to be obtained on this at the draft manual stage.
1.5.4 / Birth & Test Certificates
Original (and in quadruplicate) official birth certificates, manufacture certificates and official test certificates for major components including engine and alternator of each emergency generator set and all plant equipment shall be submitted to the Architect at least ONE calendar month before the components/equipment depart from the manufacturer's factory and prior to shipment.
1.6 / Site Work Progress
1.6.1 / The Contractor shall observe the overall programme and plan his work in such a way as to meet the programme. Manufacturing and shipment shall be properly scheduled to achieve the completion of the generator set installation and other trades of Works. All works shall be programmed accordingly by working in conjunction with others on Site.
1.6.2 / A programme for all items of work shall be submitted to the Architect within two weeks of the date of issue of respective Works Order.
1.6.3 / Bi-weekly progress reports shall be submitted prior to the date for commencement of site work and weekly progress reports shall be submitted thereafter to show the progress of production, scheduling, any anticipated delivery delay or other relevant information against each activity reference, and the agreed date of completion of the Works shall be confirmed or a detailed explanation shall be given should there be any possibility of delay.
1.7 / Foundation Bolts and Grouting
1.7.1 / Foundation bolts, nuts and lock nuts etc. of adequate strength shall be supplied and fitted by the Contractor.
1.7.2 / Grouting shall not be carried out until final agreement by the Architect is obtained.
1.7.3 / Grout shall be composed of equal parts of cement and fine granular sand mixed with fresh water.
1.8 / Welding
All welding shall be carried out only by welders of the recognised proficiency, and to the satisfaction of the Architect. The welding electrodes, equipment and process shall also be subject to the Architect's approval and in accordance with :-
BS 638-Arc Welding Power Sources, Equipment and Accessories
EN 499 - Electrodes for Manual Arc Welding of Steels
1.9 / Painting
1.9.1 / In general, painting shall be carried out in accordance with the methods recommended in ISO 12944-1 Code of Practice for Protective Coating of Iron and Steel Structures against Corrosion. Brushes, rollers and/or spraying equipment shall be of a grade suitable for the work and shall be kept in a clean condition throughout the work. Equipment shall be thoroughly cleaned if changing from one type of paint to another and/or from one colour to another. Welded joints and surfaces shall receive the same protection which is applied to the parent metal surfaces.
1.9.2 / All steel surface shall be thoroughly cleaned of all dust, oil, grease, scale, rust or other contaminants.
(a) Degreasing
Grease and dirt shall be removed by emulsion cleaners followed by thorough rinsing with water, or by steam-cleaning or by controlled high pressure water jets.
When it is necessary to use turpentine or similar solvents to remove oil and grease, the use of detergent or emulsion cleaner shall follow and then by thorough rinsing with clean fresh water.
Degreasing by washing in solvent shall not be used.
(b)Removal of Scale and Rust
Unless specially specified in the drawings or elsewhere in this Specification, rust and mill-scale must be removed before painting by manual cleaning.
Manual cleaning shall be carried out by a power tool operated carborundum disc followed by steel wire brushing and dusting to remove all loosened material.
Excess burnishing of the metal through prolonged application of rotary wire brushes or carborundum disc shall be avoided. Visible peaks and ridges produced by the use of mechanical cleaning tool shall be removed.
If blast cleaning is required, it shall be carried out in accordance with ISO 8504 – Methods for Surface Preparation. The quality of blast-cleaning shall be to the preparation grade Sa2.5 as given in ISO 8501 unless otherwise specified. The Contractor should select the most appropriate method of blast-cleaning according to the shape and size of the steel work and the type of surface deposit to be removed.
The maximum grade of metallic abrasive permitted shall be as specified in ISO 8501. before reuse. The abrasive used for blasting shall be free from harmful contamination and any recovered material shall be filtered and cleaned
The blast-cleaned surface shall have a small profile size. Blast-cleaned surfaces shall be dusted by brush or vacuum and shall not be touched by hand or other contaminated materials.
1.9.3 / No painting shall be carried out during wet weather, when condensation has occurred or is likely to occur on steel. Paint film shall be free of embedded foreign metallic particles.
1.9.4 / All pipework and surfaces other than plated surfaces including the hangers, supports and brackets etc. shall be painted immediately after installation with at least one coat of rust inhibitive primer or approved equivalent, one undercoat of rust inhibitive alkyd paint and two finishing coats of best quality paint to be approved by the Architect. Colour will be determined on site.