TECHNICAL SPECIFICATION: SHOSHOLOZA MEYL · PDF fileTechnical Specification – Shosholoza Meyl 250kVA Generating sets. Ref: PD–PDC–NAT–SPEC–0367. Classification: External

Copyright © Transnet Limited

Document Name: Technical Specification – Shosholoza Meyl 250kVA

Generating sets. Ref: PD–PDC–NAT–SPEC–0367

Classification: External Use Revision: 0

Document Serial No: 1348 Controlled and Issued by: Configuration Officer (Koedoespoort)

Document Owner: Product Engineering Specialist (Mainline Coaches) Approved by: Product Development Manager (Coaches)

Date: 12 June 2017 Page: 1 of 45

TECHNICAL SPECIFICATION:

SHOSHOLOZA MEYL

(PRASA) POWER CAR

250kVA GENERATING SETS

REVISION 0

DATE RELEASED

12 JUNE 2017

Note: If there is no red “CONTROL COPY” stamp in the bottom right hand corner of this page, then this is

an uncontrolled copy and should be used with caution.

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CONTROLLED








DISTRIBUTION LIST

Name Email Company

Sugen Govender [email protected] Transnet Engineering

Daniel Kraal [email protected] Transnet Engineering

Collin Moopanar [email protected] Transnet Engineering

Jacques Posthumus [email protected] Transnet Engineering

Albert van der Westhuizen

Albert.vanderWesthuizen@transnet. net

Transnet Engineering

Gordon Westwood [email protected] Transnet Engineering

Jan Corna [email protected] Transnet Engineering

Andre Marais [email protected] Transnet Engineering








TABLE OF CONTENTS

1. GENERAL 2. SCOPE 3. TECHNICAL INFORMATION REQUIRED

4. GENERAL REQUIREMENTS 5. WARRANTY AND INHERENT DEFECTS 6. OPERATING ENVIRONMENT 7. TECHNICAL SPECIFICATION 7.1 GENERATOR SET 7.2 DIESEL ENGINES 7.3 EXHAUST SYSTEM 7.4 COOLING SYSTEM 7.5 RADIATOR AIR OUTLET DUCTING 7.6 FUEL SUPPLY

7.7 ALTERNATOR 7.8 AUTOMATIC VOLTAGE REGULATOR 7.9 DUMMY LOAD 7.10 ENGINE INSTRUMENTATION 7.11 ENGINE STARTING BATTERY 7.12 ENGINE MANAGEMENT MODULE 7.13 SYSTEM OPERATION 7.14 ELECTRICAL CONTROL PANEL

7.15 SWITCH GEAR 7.16 CABLES & INSTALLATION 7.17 FUEL TANKS 8. PAINTING 9. QUALITY ASSURANCE & TESTING 10. MANUALS AND CATALOGUES 11. CONSTRUCTION NOTES

ANNEXURE A - SCHEDULE OF REQUIREMENTS (Generating Set offered) ANNEXURE B - DATA SHEET








1.0 GENERAL

The generating set to be provided in conformance with this specification will be used to provide prime power. The load will comprise of mostly inductive loads such as fluorescent and LED lighting, water pumps, air conditioners, refrigerators etc. Particular attention must be given to operating safety, reliability, maintainability and ease of use. The main contractor is as stated in the schedule of requirements. The successful tenderer will therefore work closely with the main contractor concerning all design issues, testing and

installation work.

2.0 SCOPE

2.1 This specification covers:

The supply, fitment and testing of diesel engine driven, three phase, four wire (400V, 50 Hz), 250 kVA generating sets for the prime electrical power supply that will supply power for continuous periods as stated in the schedule of requirements. A generating set will comprise of:

• Diesel engine complete with fuel filter and electrical pump

combination, gauges, radiator, exhaust, starter motor, battery charging alternator and battery.

• Power alternator including voltage regulator.

• Mounting base.

• Engine management system for each generating set

• Electrical control panel combination for two (2) generating sets working in full

redundancy (one generating set in use and the other in standby mode)

• Dummy loads and a cooling fan system

• Power and control cabling.

• Fuel pump.

• Inlet louvers (already fitted to the coach)

• Airflow ducting (in conjunction with the Transnet Engineering)

• Full works testing of the system prior to dispatch from the

contractor’s works.

If any of the above items are excluded from the requirements they will be listed as not required in the schedule of requirements. Fuel tanks will be supplied and installed by Transnet Engineering on the under frame of the vehicle.








3.0 TECHNICAL INFORMATION REQUIRED

3.1 All offers shall be in duplicate and will not be considered unless full

particulars and sufficient literature are provided at the tendering stage to enable the Transnet Engineering technical officers the opportunity to assess each offer properly.

3.2 Tenderers shall complete the relevant questionnaire in full and must

indicate clause by clause whether their offer complies with or does not comply with the content of that clause of the specification.

3.3 Should there be insufficient space for furnishing full details tenderers

shall provide the additional details in their covering letter. The additional details shall be numbered in accordance with the applicable clause specified in the specification.

3.4 The following sections must be completed fully by the tenderer, viz.

• 5.0 Warranty and inherent defects.

• 7.0 Technical Specification

• Annexure A; Schedule of requirements (Generating

set offered)

• Annexure B; Generating set data sheet.

3.5 Failure to complete the above may preclude a tenderer from

consideration. Where a clause cannot be fully complied with, the tenderer may submit full details of exactly how his product differs from what is required.








4.0 GENERAL REQUIREMENTS

4.1 Two complete generating sets will be installed in a power car to

supply power to a train set, one operating and the other always in standby mode.

4.2 The successful tenderer will manufacture, assemble, test and supply a complete diesel generator set including a mounting base for the generating set as described in the schedule of requirements Annexure A.

4.3 The generating sets must fit into the allocated space inside an existing

vehicle as required. The fuel tank (s) will not form part of the engine mounting frame but will be separately mounted on the underframe of the vehicle.

4.4 The design, manufacture, assembly and testing of an engine control panel that will be mounted inside the control room of the power car.

The requirements of SANS 10142 regarding multiple sources of supply in the same panel must be adhered to. The panel will be wall mounted as stated in the schedule of requirements.

4.5 Uncertainties in this specification or any other problems found which are not included in this specification must be clarified or reported to the Transnet Engineering contact person as stated in the schedule of

requirements, Annexure A, attached.

4.6 Tenderers to put forward suggestions as to the method of attaching the generating set base to the floor of the power car, bearing in mind the high forces in the direction of travel and what could happen should the train come to a sudden stop from up to 100 km/h. The orientation of the sets in the power car will be as indicated on drawings.

4.7 The design of this generating system must in all its parts conform to the requirements as stipulated in the Occupational Health and Safety Act of

1993 and all other standards referred to in this act.

NOTE:

Tenderers must indicate, clause by clause, whether their product

complies with or does not comply with the content of that clause. The data sheet for the generating set offered (Annexure B) must

be completed fully by the tenderer. Failure to complete the above

may preclude a tender from consideration. Where a clause cannot

be fully complied with, the tenderer may submit full details of

exactly how his product differs from what is required.








5.0 WARRANTY AND INHERENT DEFECTS

The tenderer must indicate the following in respect of warranties offered by them:

5.1 The warranty offered on the contract as a whole, and the extent and

conditions of such warranty.

_ _ _ _ _ _

_ _ _ _ _ _

_ _ _ _ _ _

_ _ _ _

_ _ _ _ _ _ _ _ _

_ _ _ _ _ _

5.2 Guaranteed time between failure or faults per thousand operating hours.

_ _ _ _ _ _ _ _ _ _

_ _

_ _ _ _ _ _ _ _ _ _

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _

5.3 The expected life of major components in the generating sets and control equipment.

_ _ _ _ _ _ _ _ _ _ _ _

_ _ _ _ _ _ _ _ _ _

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _

5.4 Whether any specific components and/or parts are excluded from the

general warranty and, if so, the details concerned.








_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

5.5 Whether any specific components and/or parts will be warranted for periods in excess of the general warranty and, if so, full details thereof.

5.6 Whether the successful tenderer is prepared to reimburse Transnet Engineering in respect of labour costs arising from the rectification of

makers’ defects and, if so, to what extent and under what conditions.

5.7 If any specific component, that is the same component used on the generating sets, fail more than three times within two years after commissioning of the equipment, Transnet Engineering could, after due consultations with the contractor, declare such a component “inherently defective”. The contractor will then become liable for re-

design, or replacement of the specific component(s) with superior components.

5.8 The warranty of the generating sets to commence on commissioning date and not delivery date.








6.0 OPERATING ENVIRONMENT

6.1 Elevation:

The generating sets are required to work between coastal and inland centers at altitudes varying between sea level and 2095 meters above sea level. The generating set must be capable of delivering its rated capacity without derating at altitudes up to 2095 meters.

6.2 Temperature extremes:

The ambient temperatures under which the power car operate for

considerable periods may be any temperature between -10 ºC to 45 ºC, while the extremes of temperature which might occur can be taken as between -15 ºC and 50 ºC.

6.3 Humidity and environmental conditions:

The vehicles may operate and be stabled in an atmosphere of average

humidity of between 15% and 86%. When operating or stabled inland

extremely dry, dusty and windy conditions will be experienced during most of the year. Tenderers shall note that blockage due to dry leaves and seeds are a common cause of filter and radiator failure. Tenderers shall clearly indicate what precautions they would take to prevent or minimize such failures.

6.4 Forces:

The tenderer must note that acceleration forces in a train can be high. These accelerations can be caused by shunts or in train dynamics. Tenderers shall clearly indicate what precautions they would take to prevent or minimize risk of failures caused by such accelerations.

• Longitudinal 5g

• Lateral 3g

• Vertical 3g

The tenderer must understand that the generating sets will be part of a coach that will be moving at 100 km/h and it will be exposed to all the elements.








REQUIRED DETAILS OF OFFER

(Comply (Yes) /

Do not comply (No))

6.5 Pitch & roll:

The train can be stationary at inclinations e.g. pitch = 1:50 and 1:10 rolling. The diesel engine’s oil system must work satisfactorily in these conditions.

7.0 TECHNICAL SPECIFICATION

7.1 GENERATING SET

7.1.1 The diesel generating sets must be capable of

delivering the continuous output rating, plus a 10% capability of overload for one hour in twelve, at the conditions stated in section 6.0. ……………………

7.1.2 If mounting space restrictions apply, the generating set and mounting frame must conform to the physical restrictions as shown in the vehicle layout.

……………………








* *

*

Mass (dry and wet) Sketches showing overall layout and dimensions. Details of the mounting hardware and

*

vibration isolators. Engine make and model.

* * *

*

Alternator make and model. Voltage regulator make and model. Engine management module make and model. Starting battery capacity, make and model.

…………………….

REQUIRED DETAILS OF

OFFER (Comply (Yes) /

Do not comply (No)

7.1.3 Tenderers shall submit a data sheet (Annexure

B) on the generating set being offered which must include the following information:

7.1.4 Provisions must be made to prevent possible “Brinelling” of bearings when the generating set

is not in use.

……………………

7.1.5

Since the diesel generating sets will be mounted inside a rail vehicle, filter louvre panels in the vehicle side walls are provided for fresh air intake as well as sound attenuation to limit the exterior noise level to a maximum of 85 dBa dBa at

dBA at a distance of 3 meter from the power car as part of its construction. The area of these panels to be sized according to the air movement capability of the radiator fan as well








REQUIRED DETAILS OF


Do not comply (No)

7.1.5 (Cont)

as the fresh air requirements of the engine and the alternator. The filter elements used will filter out all particles greater than 1mm. The tenderer must indicate if these filters can be cleaned and reused or if they need to be replaced when

clogged (reusable filter elements will be preferred). The tenderer will certify that the filter medium and area is sufficient for the proper operation of the generating set under the worst conditions as stated in clause 6 and compliance to act 85 of 1993 and all other standards referred to in this act. ……………………

7.2 DIESEL ENGINE

7.2.1

The diesel engine may either be normally aspirated or turbo charged. It may be oil or

water cooled. The diesel engine must be rated such that it will drive the alternator at its rated output continuously under all possible conditions mentioned in clause 6 at a speed of 1500RPM.

……………………

7.2.2

The diesel engine must be stopped when the following events occur:

11 Over speed

12 Under speed 13 Low oil pressure 14 High engine temperature 15 Low coolant level The tenderer must provide full details of how the above is to be accomplished.

…………………….








REQUIRED DETAILS OF

OFFER

(Comply (Yes) / Do not comply (No)

7.2.3 The engine must be fitted with an engine

mounted belt driven alternator system that will continuously charge the starting battery. ……………………

7.2.4 Full details of the engine performance,

including fuel consumption at idle, specific fuel

consumption at various loads and full details of the degree of de-rating which occurs at the variations in ambient temperature and atmospheric pressure mentioned in clause 6, must be submitted with the tender. The diesel engine must have at least an European emission control of tier 2 or higher. NNNNNNNN..

7.2.5 The tenderer will ensure that enough space is

provided to allow oil drainage and replacement

while the generator set is mounted on the generator mounting frame. All oil and air filters must be removable with the engine mounted on the base frame.

…………………….








REQUIRED DETAILS OF

OFFER

(Comply (Yes) /

Do not comply (No)

7.2.6

The engine should be run at 1500 rpm (turbo

charged models) during start up or shut down

procedures. The supplier will show the

necessary means to automatically isolate the

alternator excitation circuit to protect the

alternator when the diesel engine is idling. necessarnecessary.

When the engine is set to idle, the load will be

removed before the engine speed changes. …………………….

7.2.7

The engine sump drain plug must be removed

and a shut off stop valve fitted that can be

locked in the closed position or the stop valve

must be operated with the use of a tool. The

stop valve must have a spout fitted on the outlet

side in order that a flexible hose to be fitted to

facilitate oil draining in service. ……………………

7.2.8

All rotating parts or parts running at high

temperatures (e.g. Turbo chargers) will have

protective guards fitted to protect against

accidents. …………………….

7.2.9

The engine breather pipe as well as the

radiator overflow pipe must be extended

through the power car floor. This will help to

keep the installation neat and tidy. ……………………

7.2.10

Transnet Engineering will issue a drawing

indicating the interface mounting points of the genset

frame on the coach floor/underframe. The

Tenderer must build these frames to be easily

removable but still be secure enough to

withstand a head-on collision.

……………………








REQUIRED DETAILS OF


Do not comply (No)

7.3 EXHAUST SYSTEM

7.3.1

The engine will be silenced to the degree that combined mechanical and combustion noise is damped to below the levels that is specified in

the Occupational Health and Safety Act 85 of 1993 (85 dBa maximum limit).

……………………

7.3.2

The exhaust gases will be ducted away from any equipment in the vicinity of the generating set and the outlet point will be above the power car roof height as required in the schedule of requirements. All means possible must be explored to prevent the engine from sucking in exhaust gas at the fresh air intake(s). If the

exhaust outlet is above the roof then it will conform to the Moving Vehicle Gauge (drg. no BE 97-02) and the outlet will have a flapping lid to prevent ingress of moisture when it rains. The final arrangement of the exhaust system must be decided through consultation between the tenderer and Transnet Engineering.

…………………….

7.3.3

The silencer must be connected to the engine using a stainless steel exhaust expansion

bellows in order to prevent the vibration from the engine being transferred to the exhaust system.

……………………








REQUIRED DETAILS OF


Do not comply (No)

7.3.4 The exhaust system must be suitably lagged

and clad in order to prevent injury to possible bystanders or maintenance personnel. ……………………

7.3.5 The exhaust system must be suitably attached

to the coach body/roof to ensure that it complies with the forces acting on the power car stated in clause 6.4. ……………………

7.4 COOLING SYSTEM

7.4.1 The tenderer will specifically state the type of cooling system and type of air filtration system that is proposed.

……………………

7.4.2 The tenderer will indicate, in the case of a “water” cooled machine, what water treatment must be used NNNNNNNNNNNNNN.. NNNNNNNNNNNNNNNNNNNNN NNNNNNNNNNNNNNNNNNNNN ……………………

7.5 RADIATOR AIR OUTLET DUCTING

7.5.1 The engine driven radiator fan will be arranged

such that cold air is sucked across the engine and forced through the radiator and ducting to vent out the side of the coach. ……………………

7.5.2 Each generating set will have its own ducting

to divert the hot air from the radiator to the outside of the power car.








REQUIRED DETAILS OF


Do not comply (No)

7.5.2

7.5.2 If required in the schedule of

(cont) requirements then the main contractor will be

responsible for the provision and installation of

the ducting. ……………………

7.5.3

The radiator of the engine will have ducting

fitted to route the hot air to the side of the

power car. This ducting will be hinge mounted

or it will have an inspection opening to allow

maintenance staff full access to the dummy

loads as well as the radiator core. N

……………………….

7.5.4

The ducting outlet opening will have an area

equal or greater than 150% of the radiator area. …………………….

7.5.5

The ducting will have curved fins applied where

the ducting curves to prevent the air from

swirling, which could reduce the radiator’s

cooling ability. …………………….

7.5.6

The fresh air intake filter panels to be situated

such that hot radiator air will not be sucked in

with the fresh air. …………………….








REQUIRED DETAILS OF

OFFER

(Comply (Yes) /

Do not comply (No)

7.6

FUEL SUPPLY

7.6.1

If stated in the schedule of requirements, the

diesel fuel line shall have non return valves. …………………….

7.6.2

The generator set will have a combination

electrical pump and fuel filter mounted on the

engine in the fuel line to facilitate bleeding the

injectors when the fuel lines have been

uncoupled for whatever reason. The fuel filter

grade will be as specified by the engine

supplier. The recommended fuel grade to be

used by the engine must be clearly stated. …………………….

7.6.3

The contractor will include all power and control

cables for connection to the electrical panels.

This shall be included in the electrical section. …………………….

7.6.4

The contractor must fit a fuel filter of the type

that automatically separates and discards water

(Duvalco or similar) between the generator set

and the fuel tank. Care to be taken to install this

filter as per the manufacturer’s specifications. ……………………

7.6.5

The contractor must certify that the fuel pumps

are capable of sucking fuel up from the under

slung fuel tanks to engine level. …………………….

7.6.6

Fueling will be with a “Wiggins” high pressure

system on either side of the coach as well

as a gravity filling system (see clause 3.3.) …………………….








REQUIRED DETAILS OF

OFFER

(Comply (Yes) /

Do not comply (No)

7.7

ALTERNATOR

The alternator must conform to the following

requirements:-

7.7.1

The continuous minimum kVA output rating to

be as required in the schedule of requirements

Annexure A attached. …………………….

7.7.2

Frequency to be 50 Hz adjustable in a range

between 49 and 51Hz. …………………….

7.7.3

Voltage: 400 Volts, 3 Phase plus Neutral

50 Hz unless stated otherwise in the schedule

of requirements Annexure A attached. …………………….

7.7.4

The alternator shall be continuously rated to

meet with the operational requirements at the

coach conditions stated in clause 6. …………………….

7.7.5

The voltage regulation, defined as the

percentage rise in terminal voltage when full

rated load at 0, 8 power factor is thrown off,

irrespective of engine speed fluctuations, shall

not exceed 5%. …………………….

7.7.6

The output Voltage from the alternator shall be

adjustable between plus and minus 10% of the

nominal rating. …………………….








REQUIRED DETAILS OF

OFFER

(Comply (Yes) /

Do not comply (No)

7.7.7

The winding insulation of the alternator shall be

class B or better as given in BS 2757. …………………….

7.7.8

The temperature rise of the windings for

continuous full load operation of the alternator

under rated conditions shall not exceed the

limits laid down in BS5000 part 99. …………………….

7.7.9

The alternator shall be of the screen protected

drip proof type with a shaft mounted centrifugal

fan to provide forced air cooling. The intake

vents to have easily accessed and removable,

generously sized filters fitted to prevent the

ingress of dirt into the alternator. The filter

elements shall be re-usable. The addition of the

filters will not cause any increase in alternator

operating temperature. …………………….

7.7.10

The alternator must be brushless, all steel

constructed and self-excited. The full rated

output must be achieved at not more than

1500RPM. …………………….

7.7.11

The alternator will be direct coupled to the

diesel engine and shall be of the two bearing

type and the bearings will be of the ball and / or

roller type. …………………….

7.7.12

The tenderer will specifically state the type of

alternator and manufacturer and the method of

mounting as well as the flexible coupling that

will be used. …………………….








REQUIRED DETAILS OF


Do not comply (No)

7.7.13 The star point of the alternator must not be

earthed internally. Two resistors in parallel (440 Ohm, 250W each) will be fitted between the star point on the alternator and earth (coach body) to limit the earth fault current to 1 ampere. These two resistances will be located in the alternator connection terminal box as close to the star point as possible. This is a Transnet Freight Rail, Signal department requirement. This arrangement will provide an TN-S earth system (as per SANS 10142) for the train installation. …………………….

7.7.14 All resilient mounting sets must be “bypassed”

with an earth strap of at least 25mm² to earth (body) of the rail vehicle. …………………….

7.7.15 If stated in the schedule of requirements, the

tenderer will provide the means to continuously monitor the amount of earth fault current flowing through the two 440 Ohm resistances. This may be by means of an digital panel read-out on the main electrical control panel inside the power car. An earth leakage device will be provided for each bus line and this facility will

include:








REQUIRED DETAILS OF


Do not comply (No)

7.7.15 (Cont)

Warning at 350mA and disconnection of the supply should the fault current exceed 750mA. …………………….

7.7.16 If stated in the schedule of requirements, the alternator must have temperature sensing devices fitted in the main windings. These to be

suitable for interfacing with the engine control module for the measurement / monitoring of the winding temperature in service. …………………….

7.7.17 Nature of the load: The loads are mostly of an electronic controlled nature with automatic power factor correction and include air conditioners, fluorescent and LED lighting, water pumps, refrigerators and freezers.

…………………….

7.7.18 The tenderer to indicate the worst sustained power factor that this engine /alternator can

supply without detriment to itself. If power factor correction is required it will be applied to the offending load and controlled by the load’s control circuits, so as to avoid ever going into a leading power factor situation. …………………….








REQUIRED DETAILS OF

OFFER

(Comply (Yes) /

Do not comply (No)

7.7.19

The alternator to be rated to withstand over

speeds of up to 2250 RPM. …………………….

7.8

AUTOMATIC VOLTAGE REGULATOR

7.8.1

The alternator must be fitted with an AREP

solid state automatic voltage regulator that will

enable the alternator to supply fault current in

the order of three times full load current for

ten seconds. If the fault current on the

alternator offered is different from this, then the

tenderer will provide the alternator’s impedance

so that the short circuit capability can be

calculated. This is required to properly design

the complete electrical protection scheme on

the train. The voltage regulator offered must be

of a type that will enable the power alternator to

supply fault current. The type where output

voltage falls away during fault conditions is not

acceptable. …………………….

7.8.2

The tenderer to state the protection provided to

the voltage regulator to adequately protect the

output from the voltage regulator under fault

conditions. …………………….

7.8.3

Protection must be provided for the rotating

diodes against surges, spikes and over

voltages. The tenderer shall state exactly what

this protection entails. ……………………








REQUIRED DETAILS OF


Do not comply (No)

7.8.4 Protection must be provided for the rotating

diodes should the diesel engine be required to run at a speed lower than the rated speed (idle

speed) for whatever reason. Tenderers to give details how this will be accomplished.

7.9 DUMMY LOAD

7.9.1 Suitably rated resistive dummy loads and dummy load control must be supplied. The dummy loads should be 25% of the full load.

………………………

7.9.2 The dummy loads must be housed in a purpose

made, generously sized, steel housing,

venting to the outside of the train and forced air

cooled by the use of at least two electric fans that

activate with the dummy load. The outlet of the

dummy load housing to have louvres fitted to direct

hot air down and to protect against the ingress of rain. NNNNNN.

7.9.3 If electrical dummy load fan/s are employed

then a fail safe protection system to be included in the dummy load control circuit. Failure of these fans should disconnect the dummy load. …………………….








REQUIRED DETAILS OF


Do not comply (No)

7.9.4 Although most of the train loads are three phase loads, imbalances can exist at times. The dummy load should be a single step load applied across all the phases. NNNNN.

7.9.5

If the dummy loads have electric fans then the fans must switch on whenever the dummy load is on load.

…………………….

7.9.6

The dummy loads to be switched on when the load drops to 30% of full load and must be

switched off when the load reaches 70% of full load. The dummy loads to be sized accordingly.

…………………….

7.10

ENGINE INSTRUMENTATION

7.10.1

The following engine read-outs for each set should be provided on the engine controller :

• Oil Pressure.

• Water and oil temperature.

• Battery charging current.

• Battery voltage meter.

• Hour meter. (Non-resetable) …………………….








REQUIRED DETAILS OF


Do not comply (No)

7.11 ENGINE STARTING BATTERY

7.11.1

The tenderer to state what Voltage is employed for engine starting and all other low voltage DC equipment. This must be at least 24 V. Other voltages are not acceptable.

…………………….

7.11.2

The engine starting battery shall be a heavy duty Vented Lead Acid type capable of at least three start attempts one directly after the other. Ampere hour rating of the battery to be stated on the data sheet.

…………………….

7.11.3

The engine starting battery must be housed in a corrosion resistant lockable box on the engine mounting frame as close to the starter motor as possible.

…………………….

7.12

ENGINE MANAGEMENT MODULE:

7.12.1

The Automatic Engine Control Module will take care of all engine management functions. It will shut the engine down in case of:

11 High engine temperature 12 Low engine oil pressure 13 Under speed

14 Over speed 15 Low coolant level 16 High alternator temperature

…………………….








REQUIRED DETAILS OF

OFFER

(Comply (Yes) /

Do not comply (No)

7.12.2

Operation of the Automatic Engine Control

Module will be by means of push buttons with

the following functions: STOP, AUTO and

MANUAL. An additional load transfer switch

must be provided to ensure that the load can

be disconnected from the supply for

maintenance purposes. …………………….

7.12.3

The Automatic Engine Control Module must

control the fuel solenoid by cutting the fuel

supply off when the engine is stopped. …………………….

7.12.4

The Automatic Engine Control Module must

control the load transfer. The load must only be

applied after startup when the voltage and

frequency has stabilized. On stopping the

engine, the load must be removed before the

engine is stopped. ……………………

7.12.5

The Automatic Engine Control Module will

attempt to start the engine three times if it does

not start after the first attempt. …………………….

7.12.6

The Automatic Engine Control Module will

indicate operational status as well as fault

conditions. …………………….

7.12.7

The tenderer will provide information regarding

what can be offered as well as the cost

implications, to record and download to a PC,

of events when the generator set is operational.








REQUIRED DETAILS OF


Do not comply (No)

7.12.7 (Cont)

The periodic logging of the following data will be useful for maintenance purposes:

11 Phase to neutral Voltage for each

phase. 12 The phase to phase voltage. 13 The Current in each phase.

14 The power factor. 15 The engine temperature.

16 The alternator main field temperature.

17 Date and time of the measurement.

With regard to the above it is recommended

that a suitable DSE 7300 series controller or equivalent is fitted.

…………………….

7.13 SYSTEM OPERATION

7.13.1

The control system to be designed such as to operate the generating set in the following way:

Change over: An operator will select the bus line to supply power to the train.

…………………….








REQUIRED DETAILS OF


Do not comply (No)

7.14 ELECTRICAL CONTROL PANEL

7.14.1 The contractor will include all control cable. …………………….

7.14.2 The electrical control panel is to be supplied complete by the successful tenderer and will

contain the following:

• Automatic Engine Control Module

with the following readouts:

• Frequency indication.

• Voltage indication. It must

provide the facility to read the Phase to Phase and Phase to Neutral voltages of all phases

• Amperage indication.

Provide the facility to read the current in each phase.

• Main four pole MCCB.

• Change-over switch (four pole

motorised).

• Indication for bus line return

wiring.

• Each busline must be electrically limited to supply 300A maximum.

• Earth leakage devices for each

bus line.

• Selector switch to switch between “off”, “genset 1” and “genset 2”.

• An on/off switch to control power to the Automatic Engine Control Module.








REQUIRED

DETAILS OF


Do not comply (No)

7.14.3

All plug in type relays, circuit cards etc. will

have a retaining mechanism to fix the

component in place to prevent the component from working loose due to vibration.

…………………….

7.14.4

The engine power and control wires will

terminate permanently, no sockets will be

allowed. …………………….

7.15

SWITCH GEAR

7.15.1

Control circuit protection. (low voltage DC)

All low voltage control circuits to be protected

by suitably rated miniature DC circuit breakers.

Fuses will not be accepted. …………………….

7.15.2

Power circuit protection. (400/230V AC)

Preference must be given to locally produced

switchgear, all other factors being equal. …………………….

7.15.3

All miniature circuit breakers will be clip tray

mounting and CBI make is preferred. …………………….

7.15.4

The tripping curves for all circuit breakers to be

supplied as part of the maintenance

documentation. …………………….

7.15.5

All circuit breakers and earth leakage units to

be readily available in the market. …………………….








REQUIRED DETAILS OF


Do not comply (No)

7.15.6 The main circuit breaker protecting the alternator will be rated at not more than the rated output of the alternator. The two circuit

breakers (MCB’s) feeding the two bus lines will

be as stated in the design documentation. These are special circuit breakers that allow for the reduced short circuit capability of the alternator and the impedance of the distribution system. NNNNNNNN..

7.15.7 the control switches / MCB’s / circuits must be marked clearly, indicating function or equipment supplied. Where duplicate equipment is installed they shall be numbered to identify them. The marking system shall be of a permanent type and screw fixed of riveted to the panel. “Dymotape” will not be accepted.

………………….

7.15.8 All switchgear relying on magnetism to hold contacts closed must be mounted at 90

degrees to the direction of travel of the train. This to prevent switchgear from opening or closing due to sharp bumps experienced in service. …………………….

7.15.9 A facility must be provided for a bus-line return

safety loop for protection against accidental disconnection of the load. When the bus-line return loop is activated it must disconnect the applicable bus-line circuit breaker. …………………








REQUIRED DETAILS OF


Do not comply (No)

7.16 CABLES & INSTALLATION

7.16.1 The size of the power cable to be fitted will be

as required in the schedule of requirements. …………………….

7.16.2 The size of the control cabling to be such that

all control circuits will function satisfactorily at a distance of 15m. …………………….

7.16.3 The type of power and control cabling to be as

stated in the schedule of requirements. All control cabling to be of the correct rating. Normal PVC cable (as used in house wiring), must not to be used. …………………….

7.17 FUEL TANKS 7.17.1 Note: The diesel tanks will be manufactured

and installed by Transnet Engineering. The

tanks will be fitted to the underframe of the vehicle. The useable capacity of the tank will be such as to run the diesel engine at maximum load for the length of time as stated in the schedule of requirements (to be noted).

7.17.2 The tank(s) will be of a robust construction as to withstand severe service conditions. Refer to 6.0. (to be noted).

7.17.3 An Earth tag (M8 x 50 Stainless steel bolt) will be provided on the fuel tank for connection








to the fuel supply equipment to prevent the build up of static electricity (An Act 85 requirement).

NNNNNNN

8.0 PAINTING

8.1 Cleaning and painting of the interior and exterior of the generator

mounting frame will be completed prior to the installation of the generating sets.

8.2.1 Painting of the generating set mounting frame and other manufactured

components must be done according to the Spoornet paint specification RS/ME/SP/028. (The colour to be used is “Graphite grey”

except electrical panels which will be painted orange.)

9.0 QUALITY ASSURANCE & TESTING

This specification must be read in conjunction with Transnet Rail Engineering Specification no. PD-PDC-NAT-SD-RS/W 435

9.1 The complete power generating system must be inspected and tested

at the contractor’s works at the contractors cost.

9.2 The first test being the running of each set under full load for one hour

and finally 110% load for one hour to prove the performance of the generating sets. This test will be done at the contractor’s premises at the contractors cost.

9.3 During this test, measurements must be taken down, documented in a

report and supplied to Transnet Engineering with the set of manuals. 9.4 An employee of Transnet Engineering must be present to witness the

testing of the first two generating sets.

9.5 The generating set will also be tested on the actual coach to ensure

that the supply conforms to the requirements.

9.6 Once the generating sets have been installed on a coach but before

connecting the power cables, do the following tests in this sequence:








9.7 Check the power alternator’s insulation resistance (>5 Megohm). The tenderer to state what Megger voltage can be applied for this test and what precautions are necessary for Megger testing.

9.8 Run the engine and measure the voltages from phase to phase and

phase to neutral. The measurements must be verified using a calibrated multi-meter. The no load voltage must be adjusted if necessary to 230 V (phase to Neutral) using a calibrated multi-meter.

The calibration certificate of all measuring instruments must be available.

9.9 The frequency must be checked (50 Hz -0.2 Hz) and adjusted if necessary again with a calibrated instrument.

9.10 If all the above tests are satisfactory and the rest of the installation has

been tested to SANS 10142, then connect the power cables and before applying the load, check the readings of the Volt, Amp and Frequency metering inside the coach on the control panel.

The main contractor is responsible for Electrical installation test

certificates as per SANS 10142. These certificates to also be delivered to the Senior Engineer, Product Development Coaches, Koedoespoort.

9.11 Place the coach on load and verify the Volt drop at each major

appliance / equipment.

9.12 Following these tests, all readings will once again be recorded and the

contractor will issue a report showing these results.

9.13 A full systems check on all the alarm systems will be carried out. All

faults will be simulated.








10 MANUALS AND CATALOGUES

The tenderer will supply full maintenance, spare parts and operating

manuals, drawings etc to the Transnet Engineering to enable the main contractor to compile complete manuals for the vehicle in

question. It is the responsibility of Transnet Engineering to obtain all relevant publications for all equipment installed in a vehicle and to compile this data into maintenance, spare parts and operating manuals as well as “as built” drawings, as described below. All copies of these manuals, catalogues and drawings to be forwarded to the Principal Engineer, Product Development Coaches, Koedoespoort, Pretoria

10.1 Operating Manuals

The tenderer will be required to supply as part of the contract, not later than one week prior to delivery of the generating set, two

approved operating manuals directly and specifically applicable to the equipment being supplied.

10.1.1 The operating manuals must contain broadly the following information

concerning the operation of the power generating equipment:

• General description and data of the equipment.

• Brief description, function of and location of all major

components.

• Description and use of all controls

• Description of all gauges and instruments.

• General description of all automatic protection alarms and

safeguards.

• Preparation for operation.

• Operating procedures.

• Shut down procedures.








10.1.2 Any further information that the contractor considers essential and

desirable for the safe and correct operation of the equipment.

10.1.3 The successful tenderer will be required to submit as soon as possible

but not later than one month after being advised that his offer has been accepted, a draft copy of the manual for review and approval by Transnet Engineering.

10.1.4 A notice board indicating startup, shutdown and alarm reset

procedures will be supplied by the main contractor.

10.2 Maintenance Instruction Manuals

10.2.1 The contractor will be required to supply as part of the contract, not

later than one week prior to the delivery of the first generating set, two

copies of a comprehensive maintenance instruction manual, directly and specifically applicable to the equipment being supplied.

10.2.2 It is imperative that the maintenance manuals be detailed and

complete in respect of all components being supplied and fitted to the installation. They must cover all information concerning inspection, adjustment and maintenance that will be needed on a day to day basis and for light maintenance tasks. This document must include a maintenance schedule for all components of the generating set.

10.2.3 The maintenance instruction manuals shall include complete

schematic and wiring diagrams of the electrical installation (control, alarm and distribution circuits) and a diagram that describes the fuel supply system.

10.2.4 Should the instruction manuals normally furnished be of a type which

refers to different models of different equipment, and which consequently includes instructions and data on equipment not supplied, it will be necessary for such manuals to be suitably marked to clearly and easily distinguish between instructions and data which

are applicable and those which are not applicable.









but not later than one month after being advised that his offer has been accepted, a draft copy/copies for review and approval by Transnet Engineering.

10.2 Spare Parts Catalogues

10.3.1 The main contractor will be required to supply as part of the contract,

not later than one week prior to the delivery of the generating set two copies of a spare parts catalogue, directly and specifically applicable to the equipment being supplied.

10.3.2 It is imperative that the spare parts catalogues supplied, will be

entirely complete and refer to each and every component or part of all

the equipment supplied.

10.3.3 The catalogues must include suitable illustrations of all equipment

from which it will be possible for non-technical personnel to speedily and easily identify all spare parts.

10.3.4 Should the spare parts catalogues normally furnished be of a type which refers to different models of different equipment, and which consequently includes components and parts which are not used on or applicable to the equipment supplied, it will be necessary for such catalogues to be suitably marked to clearly and easily distinguish

between the parts which are applicable and those which are not applicable.


but not later than one month after being advised that his offer has been accepted, a draft copy of the manual for review and approval by Transnet Engineering.

10.3.6 The successful tenderer will be required to submit a list of parts

required for each type of service. A separate list must be submitted of spare parts that the tenderer considers essential for Transnet Engineering to keep in stock for all equipment supplied.








10.3.7 The successful tenderer will be required to submit a list of third party

suppliers of equipment as well as their contact details.

10.4 Design Drawings

The contractor shall submit a complete set of design drawings (Electrical & Mechanical) to Transnet Engineering on completion of the project. Drawings in software format will be considered provided the format is compatible with, or can be converted to software currently in use in Transnet Engineering. Electrical drawings to include:

• Power circuit schematics

• Control circuit schematics

• Engine control schematics

• Conduit and wiring diagrams








11.0 CONSTRUCTION NOTES:

11.1 All exposed unarmoured cabling on the under frame to be suitably

protected against mechanical damage.

11.2 Where unarmoured cable pass through sheet metal it will be protected

by means of conduit or a rubber grommet.

11.3 All power distribution cables must be PVC trailing cable. A separate

25mm² stranded Copper earth cable with Yellow/Green insulation will be used.

11.4 As stipulated in SANS 10142-1, all metal parts must be earthed to the

coach body. Main earth wiring size to be at least 25 mm².

11.5 All wiring in the roof of the vehicle or in close proximity of hot

equipment will be silicon insulated.

11.6 All externally mounted electrical equipment must be rated at least

IP567 for ingress of dust, moisture and protection against mechanical shock. If the equipment does not conform to this rating it may be mounted inside an enclosure that does. Such enclosures to take into account the effects of possible heat rise and to be suitably marked.

11.7 All conduit exposed to the weather or on the under frame will be

galvanised steel.

11.8 Though the successful Tenderer is responsible for the supply of the

generating set complete as per this specification, the main contractor is responsible for the construction of the power car in conformance with all statutory requirements.

11.9 The aim of this specification is to obtain a power supply for trains that is

above all reliable and easy to maintain. It is not the intention to have the latest in “hi tech” equipment.








Annexure A

Schedule of requirements

The following are the specific requirements for the supply of the generating set (Tick applicable options)Contact person: _ _ _ __Telno.:_ _ _ The main contractor is: Transnet Engineering Address: Lynette Str Koedoespoort Contact persons: J. Posthumus Tel:083 266 8588,

(The above address is where the generating sets must be delivered) The generating sets will be complete as per clause 2.1 Y N or the following items are not required (Note: Reasons for not offering these items as part of the standard requirements must be given):

The generating sets will be installed inside a rail vehicle (power car). The number of generating sets per power car = 2 The quantity of generating sets required = 2

The generating sets will operate in automatic change over mode as per clause 7.13

The generating set will be required to run at full load continuously. The engine and alternator will be mounted on a skid type base

The continuous power output rating must be _250_ kVA _ 3_ phase 4_wire 400V, AC 50Hz.








The radiator outlet air ducting to be supplied by the main contractor if the current ducting is deemed unacceptable.

Electrical panels to be wall mounted.

Fuel lines to be fitted with quick connect couplings. Y N

The alternator fields will be fitted with temperature sensors as per clause 7.7.16 Y N

Data logging as per clause 7.12.7 required: Y N Information only. The power cable will be PVC SWA cable (see clause 6.16) rated at the current of the main MCB taking into consideration the length of the cable. A fault current meter to be provided as per clause 7.7.15 Y N

A fault current alarm (350 mA) to be provided as per clause 7.7.15 Y N

A fault current alarm as well as disconnection of mains to be provided as per

clause 7.7.15 Y N








Annexure B

Generator set data sheet

(To be completed by the tenderer) Tenderer’s name:

Company: Address:

_ _

_ _ _ _

Diesel engine data: Engine make: Volvo

Model: TAD734GE or equivalent

Power in kVA: 250

Engine max. torque

at

RPM: 1500

Power alternator: Make: Marelli

Model: MJB 250 or

equivalent kVA Rating: 250 kVA Short circuit capability: 3 x 380 A for 10 seconds

Temperature sensing device fitted: Make: Automatic voltage regulator: Make: AREP

Model:

Type:

Automatic engine management module:Make:

Model:

Starting battery:

Make: _____________ Model: ________________ A/h: ________








Contactors: Make Model

Circuit breakers: Make Model:

0120773

Typewritten Text

0120773

Typewritten Text

CONTROLLED

Documents

TECHNICAL SPECIFICATION: SHOSHOLOZA MEYL · PDF fileTechnical Specification – Shosholoza Meyl 250kVA Generating sets. Ref: PD–PDC–NAT–SPEC–0367. Classification: External