1. PUMP REQUIREMENTS AND SPECIFICATION - … C3.4... · 2016-12-14 · ... Final\5. Part C3 - Scope...

$: 1. PUMP REQUIREMENTS AND SPECIFICATION - … C3.4... · 2016-12-14 · ... Final\5. Part C3 - Scope of Work\C3.4 Fire Pump Specification.doc 1. PUMP REQUIREMENTS AND SPECIFICATION$
TRANSNET PIPELINES CONTRACT NUMBER: PYP/W1/6/21/1739 DESCRIPTION OF THE WORKS: PROVISION OF MECHANICAL INSTALLATION WORKS AT TRANSNET PIPELINES WALTLOO DEPOTPage 1

Kantey & Templer D:\Users\0145949\Desktop\PYP 1739 - Final\5. Part C3 - Scope of Work\C3.4 Fire Pump Specification.doc

1. PUMP REQUIREMENTS AND SPECIFICATION 1.1 Project Specification

1.1.1 Scope

This specification covers the supply, testing, delivery to site, off-loading, commissioning, alignment and handover of the fire fighting pumpsets and ancillary items as described in this specification. The pumpset shall consist of some or all of the following major components:

(a) Pump.

(b) Prime mover (specified in Particular Specification PC).

(c) Coupling.

(d) Gearbox.

(e) Baseplate or frame.

(f) Controls.

(g) Ancillaries as required. The pumpset requirements are detailed on the attached Datasheet No. 14901P-DS-002 and 14901P-DS-003 appended hereto. The defects liability period is for twelve months from date of commissioning and handover. This specification covers clauses that are generally applicable to medium and large scale centrifugal and positive displacement pumps. Variations of this specification, if required, are set out in the Project Specification.

1.1.2 Drawings

Fabrication drawings for the skid are to be provided by the supplier and approved by the Engineer prior to fabrication. This will include general arrangements drawings detailing the piping, equipment and electrical junction box and equipment layouts.

1.1.3 References

The following standards and codes of practice are referred to in this specification: ISO 1940-1973 : Balance Quality of Rotating Rigid Bodies BS 5316 : Part 1 : Class C : Acceptance tests for centrifugal mixed flow and axial pumps SIS : Swedish Standards Institution – SIS 055900 – 1967 Occupational Health and Safety Act (as amended). Only pumps that are supplied by manufacturers who possess ISO 9001 certification will be accepted.



1.1.4 Materials

1.1.4.1 Materials of Construction All parts of the pump shall have a static life of 20 years and working life of 5000 hours. The materials used shall be suitable for both requirements.

All components in contact with the pumped liquids shall be suitable for the intended service.

Wherever necessary, components are to be static free (earthed), e.g. where plastic (insulating) components are employed.

1.1.4.2 External Protection

The following specification (or equal approved) shall be used for pumps:

(i) Solvent clean and wire brush. (ii) Apply twin pack ethyl based inorganic zinc silicate primer (minimum dry film

thickness 75 microns). (iii) Apply polyamide cured high build epoxy undercoat (minimum dry film thickness

60 microns). (iv) Apply twin pack polyurethane enamel finishing coat, colour to be advised

(minimum dry film thickness 35 microns).

Total dry film thickness = 170 microns (minimum).

Base frames shall be hot dip galvanised to SABS 763, passivated, degreased and painted with coats (ii) to (iv) above.

1.1.4.3 Suction and Discharge Flange Sizes

The pumps shall have suction and discharge flange sizes in accordance with the attached datasheets.

1.1.5 Construction

1.1.5.1 Liquid

The pump shall be suitable for use with the liquid(s) detailed in the Datasheet

1.1.5.2 Viscosity, Temperature and Density of Fluid

The most onerous viscosity and temperature of the liquid and the relative density of each liquid are detailed in the Project Specification and datasheets.

1.1.5.3 Type of Pump and Driver

(a) The type of pump is detailed in the Project Specification, and shall be suitable

for use with the liquid(s) described in Clause 1.5.2.

(b) The pump shall be suitable for use with a driver as detailed in the Project Specification.



1.1.5.4 Atmospheric Conditions The applicable atmospheric conditions are as detailed in the Project Specification. 1.1.5.5 Flow Rate and Differential Head The required flow rate and differential head demanded of the pump are detailed in the Project Specification. 1.1.5.6 Suction Conditions (NPSH) The pump shall be capable of operating with suction conditions as detailed in the Project Specification. 1.1.5.7 Direction of Rotation The direction of rotation of the pump shall be clockwise when viewed from the coupling/driver end unless otherwise required in the Project Specification. 1.1.5.8 Dismantling and Assembly The pump shall be so designed that all wearing parts may be easily removed and replaced with the pump in position. 1.1.5.9 Guards All exposed moving parts including any flexible coupling shall be protected by suitable guards which comply with the Occupational Health and Safety Act (as amended) and shall be easily removable for maintenance and inspection. 1.1.5.10 Common Bedplate Horizontally mounted pumps shall be built onto a common baseplate or frame which shall also accommodate the driver and any necessary gearbox or ancillaries. This frame shall be fixed to a skid base. 1.1.5.11 Coupling Arrangements that include only a coupling between the pump and driver will be more favourably considered than those including a gearbox. The flexible coupling shall be of a design that has been proved in such service. The service factor shall be conservatively selected to equal or better the coupling manufacturer's recommended factor for the intended service. Similar considerations prevail if a gearbox is used. 1.1.5.12 Gearbox If a reduction or right angle gearbox is required, it shall be of design that has been proved in such service. The gearbox shall be conservatively selected for the duty bearing in mind the power and torque to be transmitted, the input and output speeds, the friction and windage losses, the requirement to minimise gear noise, the backlash (clearance) for thermal and centrifugal expansion, the prevention of hunting and resonance and other considerations.



Additional requirements, if any, for gearboxes are detailed in the Project Specification. 1.1.5.13 Nameplate

The pump supplier shall provide a nameplate, made of grade 316 L stainless steel (or equivalent), securely fixed to the pump in a prominent position and giving the following information: Make or manufacturer Model Serial number Impeller diameter (mm)

Rated capacity in l/min

Rated discharge head (m) Date of manufacture

1.1.5.14 Seals and Gland Packing

Unless otherwise specified in the Project Specification, all seals shall be of the mechanical type except for duty with water where conventional gland packing shall be used.

Where the latter is employed, the fluid shall be collected and piped to drain external to the building. The piping and specials shall be designed to allow for easy rodding of the pipe system in the event of blockages preventing the effective drainage of the gland.

1.1.5.15 Pressure Gauges

Pressure gauges shall be fitted to both suction (where possible) and discharge manifolds. The ranges shall be as detailed in the Project Specification.

The gauges shall be made of stainless steel (or other approved material), shall have a face at least 150 mm in diameter and shall be glycerine filled to reduce pulsations. Where necessary, gauges shall be mounted in a remote position to avoid the effects of vibration.

1.1.5.16 Bearing Thermometers

1.1.5.17 Pump Control Valve

Where specified in the project specification or on the drawings a pump control valve controlled by a solenoid operated pilot valve shall be fitted to each centrifugal pump to ensure that the pump will start and stop against a closed valve.

A positive displacement pump will start against an open valve (or bypass) to minimise the starting load and shall not be fitted with a pump control valve.

The Contractor shall provide fully detailed drawings and descriptions of the valve including its size and capacity, method of operation, where it is mounted and other pertinent information.

1.1.5.18 Suction Strainers

Details of suction strainers, if required, are detailed in the Project Specification. The mesh size as stated shall be provided.

1.1.5.19 Pump Driver



The pump is to be direct driven by a diesel engine which is to comply with the Particular specifications, PC DIESEL ENGINES AND PSPC DIESEL ENGINES, appended to this project specification. The intermittent power rating of the engine shall not be less than that stated on the pump data sheet 14901P-DS-002. The pump-set speed may be increased providing the speed is within acceptable limits for both engine and pump.

1.1.6 Tolerances

1.1.6.1 Alignment Tolerances

Installation and alignment shall be as per the manufacturer's instructions.

Concrete bases or plinths shall be finished 25 mm below the underside of the bedplate and, in erecting the plate, the Contractor shall set each unit to precise line and level by means of brass shims and steel wedges, and shall grout up the holding down bolts and shall carry out all the grouting and finishing off below, inside and all round each bedplate. Non-shrink grout shall be employed.

The Contractor shall ensure that once all the grouting, pipe connections, etc., have been completed, the alignment of the pump and driver is correct.

1.1.6.2 Balancing

All rotating elements of the pump shall be statically and dynamically balanced. Dynamic imbalance shall not exceed 6,3 mm/sec

2 as defined by G6.3 in ISO 1940.

1.1.6.3 Piping Stresses on Flanges

Since unusual or excessive stresses on the pump flanges may lead to excessive wear and early failure, the pump supplier shall review the drawings and advise the most suitable methods of reducing or removing these stresses. The pumpsets shall not be run until these stresses and distortions are reduced below an acceptable level.

1.1.7 Tests

1.1.7.1 Test Standards Centrifugal pumps shall be tested in accordance with BS. 5316 : Part 1 : Class C : Acceptance tests for centrifugal, mixed flow and axial pumps. 1.1.7.2 Static Tests Before any performance tests are carried out, each pump shall be subjected to an internal static hydraulic test at a pressure not less than that detailed in the Project Specification and the pump shall be watertight under such test. 1.1.7.3 Dynamic Testing 1.7.3.1 Centrifugal Pumps. At least one pump shall be dynamically tested in the presence of an accredited representative of the SABS in the SABS works or in other approved premises, in accordance with BS 5316 : 1976 by Class C methods of measurement. The range of performance tests shall be presented as per Appendix Z of BS 5316. The Contractor shall arrange and pay for this test. The following 3 test curves shall be provided after this test:



(i) Total pumping head (metres) vs discharge (m3/hr or l/min).

(ii) Pump efficiency (%) vs discharge (m

3/hr or l/min).

(iii) Input power (kW) vs discharge (m

3/hr or l/min).

1.7.3.2 Positive Displacement Pumps. Details of an acceptable dynamic test for positive displacement pumps are stated in the Project Specification. 1.1.7.4 Site Commissioning Apart from checking tolerances as per Clause 1.1.6, the pump-set supplier shall check that the direction of rotation is correct and re-align the pumps on site if necessary. The pump-set supplier shall also be present during commissioning to check for faults such as leaking seals, overheating, etc. The costs of commissioning including for all plant, labour, materials and first fill of lubricating oils, shall be included in the rate tendered for the supply. The Contractor shall arrange and ensure that his electrical and control instrumentation sub-contractors are present at the initial start up of the pumpsets. Pre-commissioning is to be completed in the factory prior to shipping the units to site, when the engines are to be test run all controls and alarm systems are to be tested.

1.1.8 Equipment Performance and Maintenance Manuals

Three copies of an operation and maintenance manual(s) shall be provided prior to commissioning. The manuals shall be of an acceptable standard to the Engineer and shall be subject to his approval. The manual shall be in English, easy to use, well indexed, neatly presented and bound between hard plastic covers. The information provided shall be specifically applicable to all aspects of the equipment being installed under this contract. Separate indexed sections shall be included to cover pumps, motors, seals and couplings, etc. In each section the following information shall be provided: 1. Full details of size, model, design duty, performance curves, supplier and

technical information concerning the component equipment. Performance curves for pumps shall include: Head, efficiency, power and NPSH required, all plotted versus flowrate.

2. Step by step details for the initial start up, operation and adjustments, and shut

down procedures if relevant. 3. A comprehensive lubrication schedule with full details of all lubricants, capacities

and lubrication periods. 4. Details of maintenance schedules, adjustments, minimum running periods and

lists of spares. 5. Full technical information covering assembly and disassembly instruction, 6. Fault finding information. All drawings shall be to a scale which ensures that each detail can be clearly identified. The price tendered shall include for all costs associated with the provision of manuals, as described above, to the satisfaction of the Engineer.



1.1.9 Measurement and Payment

The rates tendered shall include for the supply, installation, corrosion protection, testing, delivery to site, off-loading, alignment, testing and commissioning of the pumpset as specified, including anything that may be required for the pump, together with the specified prime mover, to operate successfully as a unit. Interim payments shall be made in accordance with the conditions of contract.

1.1.10 Electrical Standards Control Panels shall comply with the following standards (in order of decreasing precedence):

SANS 10142-1

SANS 1473-1/ SANS 1765, as appropriate

TPL standards o PL101 (Plant & equipment tag numbering standard) o PL631 (Specification for low voltage switchgear and distribution

boards) o PL727 (Cabling, racking, trenching & earthing installation codes of

practice) 1.1.10.1 General Requirements (a) All general assembly drawings, schematic diagrams, termination schedules

and power distribution drawings shall be submitted to the Engineer for approval prior to construction.

1.1.10.2 Contactors

All Contactors shall comply with SANS 60947-4-1. Contactors shall be operated electro-magnetically. A common control voltage shall be used. Contacts shall be capable of carrying 125% of the full load circuit current continuously. The contactors shall be suitable for "intermittent duty" 15 operations per hour (AC3 duty). Contactors shall be protected by appropriately matched circuit breakers but shall be able to withstand the prospective short-circuit current at the point of installation. Unless otherwise stated all Contactors to have a minimum of two normally open and two normally closed auxiliary contacts. 1.1.10.3 Indication Lamps

Indication lights will be cluster LED panel indication lamps and shall follow the following colour guide:

Colour Function

Green ‘Running’ or ‘On’ or ‘Energised’

Red ‘Stopped’ or ‘Off’ or ‘De-Energised’

Amber ‘Alarm’ or ‘Failure’

Blue ‘Status’ or ‘Step’

Others As instructed



1.1.11 Additional Requirements

1.1.11.1 Literature

The tenderer shall supply sufficient literature including performance curves (head, power and NPSH versus flow) with his tender to enable a true and fair assessment of his offer to be made. The literature shall include materials of construction of components and cover not only the pump but also all the ancillary items and components.

1.1.11.2 Drawings

Certified pump baseplate drawings are to be furnished within 2 weeks of the acceptance of tender.



PSPD PUMPS (PROJECT SPECIFICATION PD) The following clauses give further details where required by the Particular Specification PD. The clause numbers refer to those clauses of the Particular Specification PD, but please note that this Project Specification overrides Particular Specification PD. Specific detail requirements for this Contract are provided in the relevant Data Sheets for Pumpsets and Pumps; these amplify this Project Specification. PSPD 1.4.1 Static life : 20 years Working life : 5000 hours PSPD 1.1.4.2 External protection: The pumps shall be prepared and painted as described in

Clause PD 1.1.4.2, alternatively the factory standard external protection will be considered.

PSPD 1.1.4.3 Suction and discharge flanges shall be ASME B16.5 class 150. PSPD 1.1.5.2 Refer to the Data Sheet. PSPC 1.15.4 Design conditions : Maximum air temperature = 45°C Minimum air temperature = -10°C PSPD 1.15.12 A gearbox shall not be employed to drive the water pump, however, a belt drive is to

be employed to drive the foam pump (refer data sheet). PSPD 1.1.5.14 Both fire pumps are to be gland packed as stated on the data sheets. The foam

pumps are to incorporate mechanical seals. PSPD 1.1.5.17 Pump control valves shall not be employed on the contract. The foam pump will start

against system pressure created by the pressure sustaining valve (refer drawings). PSPD 1.1.6.1 After tightening of the foundation bolts securing the pumpsets and grouting in the

baseplate, the coupling alignments are to be checked and recorded. Following at least 1 hour of running, the alignments are to be rechecked and recorded to ensure that the alignment is still within tolerance.

PSPD 1.1.7.3.1 The pump shall be shop performance tested as described in the data sheets, but

witnessed by the Engineer or his representative. PSPD 1.1.7.4 Testing and Commissioning of Pumps Following completion of the initial alignment check described under Clause PSPD 1.1.6.1, the following tests will be performed on the pumpsets: (a) Check the diesel engine driven pumps for direction of rotation by cranking on the starter, but

with the diesel engine disabled and foam pump drive disconnected. (b) Simulate diesel engine alarm conditions and check that the alarms specified in Clause PSPC

5.6 are shown and sounded. (c) Check that the engine and pump are in a state of readiness for operation per the respective

manuals (e.g. coolant, lubrication etc). (d) Set the low flow switch and relief valve on the cooling water system of each engine to

appropriate valves as dictated by the manufacturer of the engine. (e) With the diesel engine / pump coupling connected, start each fire water pumpset in turn. Set

the pressure sustaining valve on the return line to the reservoir to the value as stated on the drawings. Check for hunting or large pressure variations.



(f) Check that each diesel engine can be remotely started from all the designated locations.

With both engines immobilised, check that consecutive 6-start attempts will be performed by each engine in turn, automatically.

(g) Check that batteries have sufficient storage capacity in terms of Clause 5.24 (b) of the

Particular Specification PC, by turning the diesel engines over while disabled. Check that batteries then re-charge as specified.

(h) Connect foam pump by installing “V”-belts and belt tensioner. (These must be installed

strictly as per manufacturer’s instructions.) (i) Perform a 4 hour test on both pumps under full load. Record every 15 minutes: engine oil

pressures, oil temperatures, bearing temperatures, coolant water temperatures and heat exchanger inlet and outlet temperatures.

Costs The cost of commissioning as described above, including all plant, labour and materials required shall be included in the rates tendered for supply, installation and commissioning of pumpsets. PSPD 1.1.8 Equipment Performance and Maintenance Manuals Three copies of an operation and maintenance manual shall be provided prior to commissioning. The manuals shall be of a standard acceptable to the Engineer and shall be subject to this approval. The manual shall be in English, easy to use, well indexed, neatly presented and bound between hard plastic covers. The information provided shall be specifically applicable to all aspects of the equipment being installed under this contract. Separate indexed sections shall be included to cover pumps, gearbox, engines, electrical equipment, transmission equipment and instrumentation. In each section the following information shall be provided: 1. Full details of size, model, design duty, performance curves, supplier and technical

information concerning the component equipment. 2. Step by step details for the initial start up, operation and adjustments, and shut down

procedures if relevant. 3. A comprehensive lubrication schedule with full details of all lubricants, capacities and

lubrication periods. 4. Taking into account that this system will not run continuously, details of maintenance

schedules, adjustments, minimum running periods and lists of recommended spare parts. 5. Full technical information covering assembly and disassembly instructions. 6. Electrical and control instrumentation circuit diagrams. All drawings shall be to a scale which ensures that each detail can be clearly identified. A separate item is provided in the Schedule of Quantities. The rate tendered against this item shall include for all costs associated with the provision of manuals, as described above, to the satisfaction of the Engineer.



KANTEY & TEMPLER

CONSULTING ENGINEERS

PARTICULAR SPECIFICATION

for

CIVIL AND MECHANICAL ENGINEERING CONSTRUCTION

PC : DIESEL ENGINES KANTEY & TEMPLER CONSULTING ENGINEERS P O BOX 3132 CAPE TOWN 8000 (021) 405 9600



Particular Specification PC - Diesel Engines

CONTENTS

1. SCOPE 2. INTERPRETATIONS 2.1 References 2.2 Application 3. MATERIALS 3.1 Materials of Construction 3.2 Atmospheric Protection 3.3 Corrosive Environment 3.4 Location and Constraints 4. PLANT 4.1 General 5. CONSTRUCTION 5.1 Type of Engine 5.2 Atmospheric Conditions 5.3 Power Output and Rotational Speed 5.4 Direction of Rotation 5.5 Derating 5.6 Control Panel and Instruments 5.7 Common Baseplate 5.8 Dismantling and Assembly 5.9 Fuel System 5.10 Governor 5.11 Cooling System 5.12 Air Cleaner 5.13 Starter Motor 5.14 Oil Circulation Pump 5.15 Preheaters 5.16 Exhaust 5.17 Guards 5.18 Alternator 5.19 Nameplate 5.20 Gauges in General 5.21 Oil Pressure and Temperature Gauges 5.22 Oil Filter Pressure Gauges 5.23 Fuel Tank 5.24 Battery Starting 5.25 Battery Chargers 5.26 Compressed Air Starting 5.27 Hydraulic Power Starting 5.28 Start Signal and Sequence 5.29 Crank Termination 5.30 Delayed Loading 5.31 Stop Signal and Sequence 6. TOLERANCES 6.1 Alignment Tolerances 6.2 Balancing 7. TESTS 7.1 Test Standards 7.2 Dynamic Testing 7.3 Site Commissioning 8. MEASUREMENT AND PAYMENT 9. ADDITIONAL REQUIREMENTS 9.1 Data Sheets 9.2 Literature 9.3 Construction Programme 9.4 Operation and Maintenance Manuals



1. SCOPE

This specification covers the requirements for a diesel engine when specified as the prime mover for a pumpset or generator set when the maximum output of the engine exceeds 10 KW. The scope of the contract shall include the supply, delivery to site, installation onto a common baseplate, bedplate or frame which in turn is installed onto prepared foundations, the testing, commissioning and handover of the complete set(s) as described in this contract.

2. INTERPRETATIONS

2.1 References

The following standards and codes of practice are referred to in this specification : BS 5514 : Parts 1 to 6 : Reciprocating Internal Combustion Engines : Performance ISO 1940-1973 : Balance Quality of Rotating Rigid Bodies SIS : Swedish Standards Institution - SIS 055900 - 1967 Machinery and Occupational Safety Act (as amended).

2.2 Application

This specification covers clauses that are generally applicable to high speed diesel engines when used as prime movers for generating sets or pumpsets.

3. MATERIALS

3.1 Materials Of Construction

All parts of the engine shall have a static and working life as detailed in the Project Specification, taking into account the corrosive and atmospheric conditions at the site. These requirements shall not refer to the easily replaceable working parts such as filters, injectors etc.

3.2 Atmospheric Protection

For inland and generally mildly corrosive atmospheres, the vendor's normal external protection will be acceptable. For marine or severely corrosive environments, the following specification (or equal approved) for external protection shall be followed unless modified in the Project Specification.

(a) Sandblast to SIS SA 2½ (near white metal blast). (b) Apply twin pack ethyl based inorganic zinc silicate based primer (minimum

dry film thickness 75 microns). (c) Apply polyamide cured high build epoxy undercoat (minimum dry film

thickness 60 microns). (d) Apply twin pack polyurethane enamel finishing coat (minimum dry film

thickness 35 microns).

Total dry film thickness 170 microns (minimum).



3.3 Corrosive Environment

Details of any corrosive elements present in the atmosphere are detailed in the Project Specification.

3.4 Location And Constraints

The exact location of the pumpset is described in the Project Specification. Any known obstacles or height, width and mass constraints relevant to the transport and installation of the sets are detailed in the Project Specification.

4. PLANT

4.1 General

In general, the tenderer shall satisfy himself that the plant proposed is suitable for the site conditions. Although obvious or unusual constraints will be detailed in the Project Specification, the tenderer shall investigate the following potential problem areas, and shall make due allowance for them in his tender :

(a) Whether the area concerned is suitable for equipment if it is not explosive

proof or intrinsically safe. (b) Whether the surface conditions allow the use of vehicles and other heavy

equipment e.g. cranes that cause high surface loadings. (c) Whether the reach and load carrying capability of any crane is sufficient. (d) Whether the equipment to be provided and installed can be placed in position

through suitable openings. (e) Whether services, such as water, electricity, compressed air, toilets, etc., are

available. 5. CONSTRUCTION

5.1 Type Of Engine

The engine shall be a multicylinder full diesel with cylinders either vertical or inclined. The engine may be either a two-stroke or four-stroke, and may be turbo charged.

5.2 Atmospheric Conditions

The anticipated atmospheric design conditions are summarised in the Project Specification and include the following where applicable :

(a) The maximum air temperature. (b) The minimum air temperature. (c) The minimum air pressure. (d) The maximum relative humidity. (e) Any other relevant factors.



5.3 Power Output And Rotational Speed

The diesel engine shall have sufficient power to drive the pump or alternator continuously during all load conditions that may be encountered in normal operations. The rotational speed of the diesel engine shall match that of the pump or alternator at the operating point and taking into account any interposed gearbox, clutch or mechanism installed to modify the shaft speed between the driver and driven component.

5.4 Direction Of Rotation

Unless otherwise specified in the Project Specification, the direction of rotation of the engine shall be clockwise when viewed from the front of the engine i.e. the end opposite the coupling or flywheel.

5.5 Derating

The maximum ambient air temperature in the vicinity of the engine inlet will rise by the amount specified in the Project Specification, due to heat transfer from the engine to its surroundings while it is operating. The derating of the engine shall be strictly in accordance with BS.5514 as amended.

5.6 Control Panel And Instruments

The engine shall be provided with a control panel incorporating the following :

(a) Tachometer and hour meter.

(b) Water temperature gauge ) ) These gauges shall be red-lined (c) Oil temperature gauge ) to indicate alarm conditions ) (d) Oil pressure gauge )

(e) Battery charger No 1 charging rate ammeter. (f) Battery charger No 2 charging rate ammeter. (g) Alternator charging rate ammeter. (h) A start button. (i) A stop button. (j) A key operated master switch. (k) Alarm lamps for high oil temperature, low oil pressure, high water

temperature, low coolant level (radiator cooled), low coolant flow (heat exchanger cooled), diesel tank low level, battery charger No 1 fail, battery charger No 2 fail, engine failure to start after full six start attempts, under or over speed. Alarm condition signals to be transmitted to the main distribution board shall be stated in the Project Specification



(l) A trip feature to stop the engine in the event of overspeed. The overspeed

trip setting shall be the maximum permitted speed for the engine. (m) Selector switch to select first battery set to be used for starting. (n) If the pumpset incorporates any form of unloading device which involves a

time delay in stopping the engine after the stop button has been activated, an emergency stop button shall also be provided which will stop the engine immediately.

(o) Lamps to indicate pump control valve 'open' or 'closed'. (p) Lamp test button. (q) Reset button.

Where two or more engines are required, each engine shall have the abovementioned instruments and alarms. All instruments and switches shall be labelled with Ivorine engraved identifying labels. The two battery chargers shall be housed within the panel together with all control relays, timers and six start attempt modules. The control panel shall be wall mounted or mounted on a baseplate in a position where vibration and heat is at a minimum. 2 x spare 10A fuse-disconnectors must be provided in the panel from which outgoing 24 VDC supply feeds can easily be terminated. Spare space needs to be allowed for on the glanding plate to accommodate the following: (a) 1 x No.2 IP65 gland (b) 2 x No.1 IP65 gland (c) 2 x No.0 IP65 gland These pre-drilled holes must be fitted with blanks and marked clearly as spare.

5.7 Common Baseplate

The engine shall be mounted on a common baseplate or frame with the pump and gearbox if applicable. This frame shall be fixed to a skid base.

5.8 Dismantling And Assembly

The engine shall be so designed that all the common wearing parts may be easily removed and replaced with the engine in position.

5.9 Fuel System

The fuel injection equipment shall be suitable for operation with the commercial brands of diesel fuel available in South Africa. The filter shall be full flow and of sufficient capacity for the size of the engine. The filter shall incorporate a water trap and a particle filter with a disposable element, for removing particles down to 5 micron in size.



5.10 Governor

The speed of the engine shall be controlled by a governor in accordance with Class A2 of BS 5514. When the full load is suddenly applied or removed, the temporary speed variation shall not exceed 10%. The permanent speed variation shall not exceed 5% of the normal engine speed. The nominal speed setting shall be externally adjustable.

5.11 Cooling System

The cooling system shall be as detailed in the Project Specification. Air cooling shall be limited to engines having an output below 50 KW.

If radiator cooling is specified, the radiator shall be suitably sized for the amount of cooling required, and shall be made of suitable corrosion resisting materials for the location specified. The cooling fan shall be driven off the engine. If heat exchanger cooling is specified, the heat exchanger shall be correctly sized for the duty, and the materials shall be resistant to both atmospheric corrosion and to corrosion by the heat transfer fluids. In both the above cases the cooling water circulation pump shall be driven by the engine. The exhaust manifold and lubricating oil shall be water cooled. Each engine shall be provided with a temperature gauge to indicate the cooling water temperature, as well as a cooling water level sensor to provide low cooling water alarm.

5.12 Air Cleaner

A two stage air cleaner, with the initial stage a precleaner of the cyclonic type shall be provided unless the tenderer qualifies his tender accordingly. The unit should include replacement paper elements and a restriction indicator.

5.13 Starter Motor

The type of starter motor shall be as specified in the Project Specification and may be either electric, pneumatic (air) or hydraulic. The power source for the starter motor shall be specified in the Project Specification.

5.14 Oil Circulation Pump

In addition to the standard oil circulation pump fitted to the engine to circulate oil while the engine is running, an automatically controlled oil priming pump with timer shall be provided to circulate the lubricating oil for approximately 10 minutes every 8 hours. This pump shall be driven off the mains power supply.

5.15 Preheaters

Thermostatically controlled 220 volt heaters shall be fitted to both the cooling water manifold and the oil sump to enable the engine to start and run under load as quickly as possible. The engine shall be easily started from cold against no load without the use of special ignition devices, under both summer and winter conditions. The Contractor shall provide full details of any arrangements to ensure easy starting in cold weather.



Power for the heaters shall be taken from the main supply via the control panel and shall be protected by a suitable circuit breaker.

5.16 Exhaust

Provision shall be made on the exhaust manifold, exhaust piping and the silencer to avoid hazard to all operating personnel or to flammable material adjacent to the engine.

The exhaust pipe shall be flexibly connected to the engine to take up any vibrations that may cause failure. The exhaust piping and silencer shall be manufactured from stainless steel grade 316 L. The piping and silencer shall be suitably lagged to reduce heat and noise transmitted to the building in which the engine is installed. It is required that the noise level be kept to a minimum and an effective silencing system of the residential type shall be provided to limit noise to 85 dBa when measured 1 metre from the engine or exhaust (while only one pump is running).

5.17 Guards

All exposed moving parts including the flexible coupling shall be protected by suitable guards which comply with the Machinery and Occupational Safety Act (as amended) and shall be easily removable for maintenance and inspection.

5.18 Alternator

The engine shall be fitted with a 24 volt alternator having sufficient power to :

(a) Recharge the associated battery system at its maximum charging rate. (b) Run all the instruments and associated control circuitry. (c) Drive the electric fuel booster pump (if fitted). (d) Drive any other items of equipment as specified in the Project Specification.

5.19 Nameplate

The engine supplier shall provide a nameplate made of grade 316 stainless steel (or equivalent), securely fixed to the engine in a prominent position and giving the following information : Make or Manufacturer Model Type Serial Number Rated Power (kN) and Rotational Speed (rpm) Max Torque (Nm) at a stated rotational speed Fuel Consumption at Maximum Load Date of Manufacture

5.20 Gauges In General

All indicating gauges shall be red lined to show alarm levels. The gauges shall be made of stainless steel (or other approved material), shall have a face of at least 150 mm in diameter and pressure gauges shall be glycerine filled to reduce pulsations.



Where necessary gauges shall be mounted in a remote position to avoid the effects of vibration.



5.21 Oil Pressure And Temperature Gauges

Each engine shall be fitted with an oil pressure gauge calibrated in kPa to measure the lubricating oil pressure, and an oil temperature gauge to measure the lubricating oil temperature in degrees Celsius.

5.22 Oil Filter Pressure Gauges

Pressure gauges, calibrated in kPa, shall be fitted to the inlet and outlet of the oil filters.

5.23 Fuel Tank

The number of fuel tanks, their capacity and special features shall be as detailed in the Project Specification.

5.24 Battery Starting

(a) The type of the batteries shall be as described in the Project Specification,

and shall be furnished according to the manufacturers requirements. (b) Each engine shall have two storage battery units. Each battery unit shall

have a capacity, at 4,5ºC, sufficient to maintain the cranking speed recommended by the engine manufacturer through a 3 minute cycle (15 seconds cranking and 15 seconds rest, in 6 consecutive cycles).

The Contractor shall provide a certificate confirming that each battery complies with this requirement.

(c) Storage batteries shall be rack supported above the floor, secured against

displacement, and located where they will not be subject to excessive temperature, vibration, mechanical injury or flooding with water. They shall be readily accessible for servicing.

(d) Two alternative means for recharging storage batteries shall be provided.

The charging system shall be automatically controlled and take power from either an alternating current power source via a distribution board mounted in the pumpstation or an alternator mounted on the diesel engine.

(e) The main battery contactors supplying current to the starter motor shall be

capable of manual mechanical operation in the event of control circuit failure.

The contactors shall be rated for the voltage and amperage required as well as the duty cycle, e.g. inching or AC-3.

5.25 Battery Chargers

(a) The battery charger at its rated voltage shall be capable of recharging a

completely discharged battery at a maximum rate without damaging the battery.

(b) The charger shall be marked with the ampere-hour rating of the largest

capacity battery that it can recharge in compliance with clause 5.25(a). (c) An ammeter with an accuracy of 5 percent of the normal charging rate shall

be furnished to indicate the operation of the charger.



(d) The charger shall be so designed that it will not be damaged or blow fuses

during the cranking of the engine when operated by the automatic or manual controller.

(e) The charger shall automatically charge at the maximum rate whenever

required by the state of the battery.

(f) The charger shall incorporate a failure alarm relay. (g) The battery charger must adjust the charging voltage based on ambient

temperature conditions. (h) Once the battery is charged, the battery charger must float charge the battery

to prevent sulphation and gassing.

5.26 Compressed Air Starting

Details of compressed air starting system, if required, are detailed in the Project Specification.

5.27 Hydraulic Power Starting

Details of the hydraulic power system, if required, are stated in the Project Specification.

5.28 Start Signal And Sequence

The start signal will be generated as described in the Project Specification. Upon receiving a start signal the automatic control shall make provision for 6 x 15 second consecutive start attempts. These shall alternate between the two battery sets i.e. each battery set will provide a 15 second start followed by a 15 second rest, repeated 3 times.

Thereafter the set shall be switched off and the control panel shall give audible and visual indication of the fault (failure to start). The remote start signal (if required) will be by means of one potential free, normally open momentary contact. The start circuit must latch this signal.

5.29 Crank Termination

The starting circuit shall incorporate a device to cease cranking the engine immediately firing commences and the engine runs under its own power.

5.30 Delayed Loading

A device shall ensure that no load is exerted on the engine for approximately 10 seconds after starting and running up to its design speed.

5.31 Stop Signal And Sequence

The source of the stop signal, and the stop sequence that the set shall follow, is detailed in the Project Specification.



5.32 Fuses

A 5 Amp 2-pole 24 Volt DC fused switch, with spare fuses, must be allowed for, in the

panel, to act as a feeder for the remote start circuit.

5.33 Wiring A complete wiring diagram for the engine control panel, according to IFC standards

and generally accepted engineering practices must be submitted to the Engineer for comment, before the manufacturing process begins.

5.34 Vibration The manufacturer shall recommend and / or install devices, if required, that limit engine vibration to be transmitted to any other areas. This can include mountings and couplings.

6. TOLERANCES

6.1 Alignment Tolerances

The radial and axial alignment of the engine, as measured on the outside circumference of the flexible coupling, shall not exceed the coupling manufacturer's recommended tolerances.

6.2 Balancing

A suitable flywheel shall be fitted, and all other engine parts matched and balanced, to limit cyclic irregularity to within the limits specified in BS.5514.

7. TESTS

7.1 Test Standards

The engine shall comply with BS 5514 as amended.

7.2 Dynamic Testing

The Contractor shall provide details of independent testing facilities available to verify dynamic tests on the engine at the manufacturer's premises. Any further dynamic tests, if required, are detailed in the Project Specification.

7.3 Site Commissioning

The site commissioning tests shall include a four hour load test, and any other test if detailed in the Project Specification. The Contractor shall provide at his own cost, all initial fill requirements such as lubricating oils and diesel fuel.

8. MEASUREMENT AND PAYMENT

Measurement and payment for each item provided in the Schedule of Quantities shall include for the supply, installation, testing and commissioning of the diesel engine as specified. Interim payments may be made at the discretion of the Engineer.

9. ADDITIONAL REQUIREMENTS

9.1 Vendor Data Sheets



The tenderer shall complete the data sheets as provided in the Appendix.

9.2 Literature

The tenderer shall supply sufficient literature with his tender to enable a true and fair assessment of his offer to be made. The literature shall cover not only the engine but also all the ancillary items and components.

9.3 Construction Programme

The construction programme for the pumpset or genset associated with the diesel engine shall clearly show the major components of the construction programme as detailed below :

(a) Manufacture of engine. (b) Testing at manufacturers works. (c) Transport to site where set is assembled. (d) Assembly. (e) Factory tests. (f) SABS tests. (g) Delivery to site. (h) Installation. (i) Commissioning. (j) Handover.

9.4 Operation And Maintenance Manuals

If required, the scope of the operation and maintenance manuals shall be as described in the Project Specification.

TRANSNET PIPELINES CONTRACT NUMBER: PYP/W1/6/21/1739 DESCRIPTION OF THE WORKS: PROVISION OF MECHANICAL INSTALLATION WORKS AT TRANSNET PIPELINES WALTLOO DEPOT Page 24


TRANSNET PIPELINES TPL

TPL WALTLOO FIREFIGHTING UPGRADE

CONTRACT No. 14091P

APPENDIX TO PARTICULAR SPECIFICATION PC PSPC DIESEL ENGINES (PARTICULAR SPECIFICATION PC) The following clauses give further details where required by the Particular Specification PC. The clause numbers refer to those clauses of the Particular Specification PC. PSPC 3.1 Static life : 20 years Working life : 5000 hours PSPC 3.2 The external protection shall be the engine supplier’s standard paint specification. Materials used in the works shall, wherever possible, be of corrosion resistant

materials. PSPC 3.4 The fire pumpsets will be located within a new pump station. PSPC 5.2 Design conditions : Maximum air temperature = 45°C Minimum air temperature = -10°C PSPC 5.3 Notwithstanding the requirements of Clause 5.3 of Particular Specification

PC, the total power output of the engines shall be no less than the power at all points on the pump performance curve plus 10% (derated for temperature, as applicable, and based on intermittent service). The required speed is approximately 2100rpm or as required to drive the fire pump.

PSPC 5.5 Temperature rise in pumpstation when the diesel engine is operating is to be

taken as 10°C. PSPC 5.6.1 The control panel shall also include engine running and engine stop relays

which shall transmit signals to the main distribution board. The engine running relays shall send a signal to the main distribution board when an engine is running and not when an engine is being turned over by a starter motor.

PSPC 5.6.2 The alarm lamp for low coolant level is not required. An alarm lamp for low

cooling water flow is to be provided. (See PC 5.6 (k)). PSPC 5.6.4 Alarm conditions for the diesel engine to be transmitted to the main

distribution board shall be as follows: 1. Engine failure due to the engine stopping (without depressing stop

button), or failure to start engine after 6 start attempts. 2. Engine fault, for the engine, due to any of the following alarm

conditions, (a common alarm point must be provided on the diesel engine control panel):

Low oil pressure, High coolant water temperature, Engine under or over speed,



Cooling water low flow Note : A time delay (± 10 sec) must be provided to ensure that the

engine fault alarm is not activated on engine start-up.

3. Battery charger failure for either battery charger.

4. Loss of 24 VDC power supply. The engine Control Panel shall be suitably mounted on the non drive end of the base frame, as indicated on the drawings. A rotating strobe light must be provided on the panel and must be activated for any condition stated under PSPC 5.6; part 2.

PSPC 5.6.5 The panel shall be mounted on the engine skid / base frame. PSPC 5.7 A common base between pump and engine is to be provided by way of a

steel frame for mounting on the foundations. PSPC 5.10 The requirements of the Particular Specification, Clause PC 5.10 shall apply,

excepting that the permanent speed variation shall not exceed 2%. PSPC 5.11 Type of cooling system : Heat exchanger utilising water from each bund fire

pump delivery pipe and returning to the water tank. A heat exchanger is to be employed, having cupro nickel core element or otherwise approved materials. The heat exchanger is to be adequately sized having excess heat transfer area of at least 25%. The flowrate of water for cooling purposes is to be stated on the vendor data sheet appended.

A flow switch is to be fitted into the outlet piping from the heat exchanges to

provide the signal for the low flow alarm (See PSC 5.6.2 above). Ancillaries to be provided for the heat exchanges cooling are:

A thermal type flow switch (not paddle type) EGE model SN450/1-A4-GRor equal approved. Isolating gate valves. ‘Y’ strainer (20 mesh). Pressure reducing valve, (per Datasheet No. 14901P-DS-018). Sight glass (with flap). Pressure indicator (0-600 kPa). Pressure relief valve (set at ±450kPa) to suit heat exchanger. Temperature gauge 0-100˚C. The supply and installation and connection of the ancillaries shall be included in the tendered rates for the engines.

PSPC 5.13 Type of starter motor : 24 volt electric Power source : Battery PSPC 5.14 The requirements of Clause 5.14 of PC shall not be applicable to this contract. PSPC 5.15 Preheater: Cooling water jacket heater only is to be provided to control the

water temperature within the range 38° to 49°C (or as required by the manufacturer).



The engine shall be easily started from cold against no load without the use of special ignition devices, under both summer and winter conditions.

PSPC 5.16 The exhaust silencer shall be mounted horizontally, external to the building,

with the tail pipe ending horizontally pointing, at roof height and fitted with a flap. The exhaust piping and silencer shall be constructed of 316 L stainless steel. The mechanical contractor shall allow for any additional stainless steel supports to mount the silencer to the building.

The exhaust shall be of the low noise type of residential type silencer. Noise

shall be limited to 85 dB (A) when measured 5m from the exhaust, outside the building.

PSPC 5.20 The requirements of Clause 5.20 of PC shall be applicable to this contract,

except that gauges may have a face size of 65mm or larger. PSPC 5.23 Fuel tanks: One fuel tank per diesel engine, of sufficient volume to allow the

engine at least 4 hours running at full load. Fittings shall include a vent, low level switch (to operate at ±50% of capacity), filling point, a fuel level dip stick and a mechanical hand operated pump. The fuel tank shall be protected against corrosion. The contractor shall be responsible for the supply of diesel and filling of the diesel fuel tank during the commissioning process as described above. All supply lines between the fuel tanks and diesel engines to be provided with fire pumpset skid assembly by the fire pump supplier. The fuel tank is to be a free standing vertical tank mounted onto the pump skid. The diesel fuel tank is to be fitted with vent, fuel level sight glass, hand pump and water drain.

PSPC 5.24 Type of batteries: 24 Volt lead acid (low maintenance). The batteries are to

be mounted on a rack adjacent to the engine skid / base frame. PSPC 5.25 Number of battery chargers per engine: two PSPC 5.28 Start signal: the source of the start signal shall be a start button on the control

panel or from remote start buttons (see Clause 5.6 (h) of PC). The engine must be able to start via a remote start signal. The remote start signal will be fed from the field via a 24 Volt DC potentially free contact closing, thus instructing the engine to start. Two terminals must be allowed for, in the panel, clearly labelled “REMOTE START” for the external connection of the contact.

PSPC 5.30 The requirements of Clause 5.30 of PC shall not be applicable to this contract. PSPC 5.31 Stop signal: The source of the stop signal shall be a stop button on the

control panel (see PC 5.6 (l). PSPC 5.32 A 5 Amp 2-pole 24 Volt DC fused switch, with spare fuses, must be allowed

for, in the panel, to act as a feeder for the remote start circuit. PSPC 5.33 A complete wiring diagram for the engine control panel, according to IFC

standards and generally accepted engineering practices must be submitted to the Engineer for comment, before the manufacturing process begins.

PSPC 2 Equipment Performance and Maintenance Manuals (PC Clause 9.4)



Three copies of an operation and maintenance manual shall be provided prior to commissioning. The manuals shall be of a standard acceptable to the Engineer and shall be subject to his approval. The manual shall be in English, easy to use, well indexed, neatly presented and bound between hard plastic covers. The information provided shall be specifically applicable to all aspects of the equipment being installed under this contract. Separate indexed sections shall be included to cover pumps, engines, electrical equipment, transmission equipment and instrumentation. In each section the following information shall be provided: 1. Full details of size, model, design duty, performance curves, supplier and technical

information concerning the component equipment. 2. Step by step details for the initial start up, operation and adjustments, and shut down

procedures if relevant. 3. A comprehensive lubrication schedule with full details of all lubricants, capacities and

lubrication periods. 4. Taking into account that this system will not run continuously, details of maintenance

schedules, adjustments, minimum running periods and lists of spares. 5. Full technical information covering assembly and disassembly instructions. 6. Electrical and control instrumentation circuit diagrams. All drawings shall be to a scale which ensures that each detail can be clearly identified. A separate item is provided in the Schedule of Quantities. The rate tendered against this item shall include for all costs associated with the provision of manuals, as described above, to the satisfaction of the Engineer. NOTE: THE VENDOR DATA SHEETS (NOS 1, 2 AND 3) AT THE END OF THIS PROJECT SPECIFICATION ARE TO BE COMPLETED FOR ANY/EACH ALTERNATIVE OFFERED.



DATA SHEET NO. 1 WATER PUMP (FIRE) DATA SHEET FOR CENTRIFUGAL PUMPS Manufacturer ............................................................................................................................................

Place of manufacture ...............................................................................................................................

Model number and type ...........................................................................................................................

Number of stages ....................................................................................................................................

Impeller diameter (mm)............................................................................................................................

Pump speed (rev/min) .............................................................................................................................

Power requirements at:

Shut-off head (kW) ...................................................................................................................................

Specified head and flow (kW) ..................................................................................................................

Max power conditions (kW) .....................................................................................................................

Efficiency at specified head (%)…………………………………..………………………. (guaranteed)

Suction diameter (mm) ............................................................................................................................

Discharge diameter (mm) ........................................................................................................................

Net positive suction head required at specified head and flow (m) …………………………. (guaranteed)

Materials:

(a) Casing .........................................................................................................................................

(b) Impeller(s) ...................................................................................................................................

(c) Shaft ............................................................................................................................................

Mass of pump (kg) ...................................................................................................................................

Flexible coupling model and manufacturer ..............................................................................................

Type of gland sealing...............................................................................................................................

PERFORMANCE CURVES

The Tenderer is required to submit signed performance curves with the Tender indicating head, efficiency, kW and NPSH.

SIGNATURE OF TENDER DATE



DATA SHEET NO 2 DATA SHEET FOR POSITIVE DISPLACEMENT PUMP Manufacturer ............................................................................................................................................

Place of manufacturer..............................................................................................................................

Model number and type ...........................................................................................................................

Progressive cavity pump? ......................................................................................................... (Yes / No)

Pump speed (rev/min) .............................................................................................................................

Power requirements at specified head and flow (kW) .............................................................................

Starting torque (Nm) ................................................................................................................................

Minimum power required for starting? .......................................................................................................

Efficiency at specified head (%) ..............................................................................................................

Suction diameter (mm) ............................................................................................................................

Discharge diameter (mm) ........................................................................................................................

Materials:

(a) Casing .........................................................................................................................................

(b) Impeller(s) ...................................................................................................................................

(c) Shaft ............................................................................................................................................

Mass of pump (kg) ...................................................................................................................................

Type of gland sealing...............................................................................................................................

PERFORMANCE CURVES The Tenderer is required to submit signed performance curves with the Tender indicating head, efficiency and kW.




DATA SHEET NO. 3DIESEL ENGINE (DRIVING WATER PUMP AND FOAM CONCENTRATE PUMP)

Maker’s Name ..........................................................................................................................................

Country of Origin ......................................................................................................................................

Manufacturer’s Type No ..........................................................................................................................

Published intermittent power rating at sea level (kW) .............................................................................

Intermittent power rating after derating for altitude and temperature, and allowing for ancillary equipment (kW) ..................................................................

Nominal Speed (rpm)...............................................................................................................................

No of cylinders .........................................................................................................................................

Strokes per working cycle ........................................................................................................................

Bore x stroke (mm) ..................................................................................................................................

Swept volume (cm³) .................................................................................................................................

Compression ratio ....................................................................................................................................

Is engine turbo charged? .........................................................................................................................

Fuel consumption at full load (kg/hr) .......................................................................................................

Preheater power rating (kW) ...................................................................................................................

Preheater voltage (volt) ...........................................................................................................................

Mass of engine (kg) .................................................................................................................................

Make of fuel pump? .................................................................................................................................

Warranty period .......................................................................................................................................

Location of nearest After Sales Service facility to site .............................................................................

Type of batteries ......................................................................................................................................

Is descriptive literature attached? ............................................................................................................

Are overall dimensions in literature? .......................................................................................................

Are performance curves attached? .........................................................................................................

Are operations/ maintenance Manuals included in tender price? ...........................................................

Are recommended spares and tools lists attached? ...............................................................................

Does engine meet specification? .............................................................................................................

If not, provide details of exceptions .........................................................................................................


1. PUMP REQUIREMENTS AND SPECIFICATION - … C3.4... · 2016-12-14 · ... Final\5. Part C3 - Scope...

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