Guide for genset

INDEX , I Section A Standards Regulations World supplies Formulae Installation questionnaire Section B Foundations and recommended room sizes and layouts for one to four generators with or without sound attenuation Section C Fuel systems Exhaust systems Cooling systems Starting systems Section D Control systems Paralleling Switchgear Cabling Earthing Circuit breakers Automatic transfer systems Section E Health Safety Motor starting Section F Soundproofing Silenced sets Dimensions and weights Section G Technical data on gen sets Air tlows Exhaust flows Fuel consumption Dimensions and weights Conversion tables Full load current tables J.ROGER PRESTON (VIETNAM) CO.,LTD Nguyen Gia Thieu Street (IJNIT 103A) District 3, HCMC,V'ietnarn TEL: 84-8-9306597 FAX:84-S-9306598 E-mail: adrnin - jrp@ jrpvietnam.com.vn GENERAL Section A : Scope , This manual provides an Installation Guide for Cummins Power Generation generator sets This includes the following information:Room Sizes Mounting Recommendations Electricity Council Engineering Recommendations G513 and G59 Factories Act 1961 Electrical Connections Health and Safety at Work Act 1974 Mechanical Connections - IS0 4782 Measurement of Airborne noise emitted by method of construction equipment for outdoor use checking for compliance Health and Safety General Maintenance , : ! ! Technical Data This manual details typical installations only as it is not possible to give specific details to many variables in an application If you should require any further advice or information, please consult: Cummins Power Generation Ltd - - 0- - - 1 Electrical Protective Systems for A.C Plant BS3950 IEE Regulations (15th Edition) BS 159 1957 - Busbars and Busbar Connections Fax : +44 (0) 1843 255902 BS 162 1661 Electrical Power Switchgear and Associated Apparatus - Regulations and Bibliography BS 2757 Insulation The authorities listed below may provide informative sources when planning and implementing an installation BS 4999 General requirements for Rotating Electrical Machines BS 5000 Part 1980 Generators to be driven by reciprocating Internal Combustion Engines - - "For securing the safety of the public and for ensuring a proper and sufficient supply of electrical energy" Distribution units for electricity construction and building sites supplies for BS 5486 (IEC 439) Factory Built assemblies of Low Voltage Switchgear and Control Gear - BS 1649 Guards for Shaft Couplings BS529 - Steel Eye Bolts British Standard (BS) 4363 Regulations for the Electrical Equipment of Buildings EEC Directive 841536lEEC - Noise from construction equipment power generators - BS 476 Part Class of Materials Institute of Electrical Engineers (1966) - Electrical Installations General - Surface spread of Flame Tests - BS 799 Part Oil Storage Tanks British Standard Code of Practice CP321 I Private Electric Generating Plant CP323 Quality Assessment Schedule QAS13420.121 relating to BS5750 Part will apply ABGSM Publication TM3 (Revised 1985) - BS 5424 Part 1977 Contractors Mechanical Equipment Her Majesty's Stationary Offlce (H.M.S.0) i Electrical Tel : +44 (0) 1843 255000 Electricity (Supply) Acts 1882 1936 I Rotating IEC 479 Effects of Current Passing through the Human Body - I of Columbus Avenue, Manston Ramsgate Electrical Supply Regulations 1937 Electrical Equipment The Electrical Performance Machinery BS2615 Manston Park Electrical Installation L BS 4142 IS0 1996 Method of rating industrial noise affecting mixed residential and industrial areas A useful glossary of British Standards applicable t~ electrical components is given at the ' Sectional List of British Standards Institution.' Kent CT12 5BF, UK 'i - - Silencing Asbestos (Licensing) Regulations 1983 (SI 1983 No 1649) and Health and Safety at Work series Booklet H5 (R) 19 A Guide to Asbestos (Licensing ) Regulations 1983 'Code of Practice for Designers, Installers and Users of Generating Sets." BS 2869 1970 Fuel Oils for Oil Engines and Burners for non- marine use - BS 3926 Recommendations for the use of maintenance of Engine Coolant Solutions BS 4675 Part (IS0 2372) reciprocating machinery - Mechanical vibration in GENERAL Section A BS 4959 - Recommendations for Corrosion and Scale Prevention in Engine Cooling Water Systems BS 5117 - Methods of Test for Corrosion Inhibition Performance of Anti-Freeze Solutions - Specification for Reciprocating BS 5514 (IS0 3046) Internal Combustion Engines, Part to Manufacturing and Design Standards The generator and its control system are manufactured under a registered quality control system approved to BS EN I S 9001 (1994) The following regulations are observed where applicable: The Health Safety at work Act 1974 The Control of Substances Hazardous to Health Act 1974, 1988 1989 IEE Wiring Regulations for Electrical Installations (16th Edition) KEY: ' A related, but not equivalent, standard: A BSI publication, the content of which to any extent at all short of complete identity or technical equivalence covers subject matters similar to that covered by a corresponding international standard An identical standard: A BSI publication identical in every detail with a corresponding international standard Regulations Governing Installations Before purchasing a generating set, the advice of the local authority should be obtained with regard to the following requirements:Planning permission for the generator building Regulations governing the following:Storage of fuel Noise levels The Electricity at Work Regulations 1989 The Environmental Protection Act 1990 Air pollution levels The Health Safety at work Regulations 1992 Electrical earthing requirements The EMC Directive 89/336/EEC The LV Directive 73/231EEC The Machinery Directive 89/392/EEC The generator and its control system has been designed, constructed and tested generally in accordance with the following Standards where applicable: BS 4999 (IEC 34') General requirements electrical machines for rotating BS 5000 (IEC 34') electrical machines of Rotating particular types or for particular applications BS 5514 (IS0 30462) Reciprocating internal engines: performance combustion BS 7671 (IEC 364') Requirements for electrical installations IEE Wiring Regulations (sixteenth edition) BS 7698 Reciprocating internal combustion (IS0 85282) engine driven alternating current generating sets BS EN 50081 Electromagnetic compatibility Generic (EN 500812) emission standard BS EN 50082 Electromagnetic compatibility Generic (EN 500822) immunity standard BS EN 60439 Specification for low-voltage (IEC 439') switchgear and control gear (EN 60439) assemblies BS EN 60947 Specification for low (IEC 947') switchgear and control gear (EN 609472) voltage Failure to comply with the local authorities regulations, may result in the generator not being used This type of purchase should be installed correctly using the "best" materials and installation guides to ensure the generator set lasts a lifetime Specialist advice should be sought concerning any part of the building requirements, installation, commissioning etc or any references in this manual from Cummins Power Generation Applications Engineering Group Data compiled in this manual will be continuously improved and therefore subject to change without notice, all rights are reserved GENERAL Section A World Electricity Supplies Country Frequency Supply Voltage (Hz) Levels In Common Use (V) Abu Dhabl (United Arab Emirates) 50 415R50 Atohanistan 50 60 380R20 220 Country Frequency Supply Voltage (Hz) Levels In Common Use (V) Country Frequency (Hz) Cuba 60 Cyprus 50 440/220.2201110 Honduras 60 11 kV, 415R40 Hono" Kono land Kowloon) 50 11 kV 346ROO 200 Hungary 50 20 kV 10 kV 380R20 220 Iceland 50 380R20; 220 Israel 50 22 kV; 12.6 kV; 6.3 kV 4001230; b o w Coast 50 3801220: 220 Jamaica 50 412.3 kV: 2201110 Jordan 50 380~720;220 Kenva 50 4151240: 240 Korea Republic (South) 60 2001100; 100 Kuwait 50 415R40; 240 Laos 50 38OR20 Lebanon 50 380/220; 1901110; 2203 10 Lesotho 50 380/220.220 Liberia 60 12.517.2 kV " kV 3801220.220 Angola 50 380R20.220 Anllcua 60 400R30, 230 Argentma 50 13.2 kV 6.88 kV 3901225 6 kV 4401250 415R40 240 20kV 10kV k V 380R20 220 Austria 50 Bahamas 60 4151240 2401120 2081120 120 Bahraln 50 60 11 kV 400R30 380R20 230 2201110 Bangladesh 50 11 kV, 400R30 230 Barbados Belg~um Bermuda 50 50 60 Dahomey 50 15 kV; 380/220 220 Denmark 50 30 kV 10 kV 380/220.220 Domin~ca (Windward Islands) 50 400R30 Dominican Republic 60 2201110; 110 Dubai (United Arab Emirates) 50 6.6 kV: 3301220220 Ecuador 60 2401120; 2081120; 2201127, 2201110 Egypt (Unlted Arab Republic) 50 11 kV; 6.6 kV; 380/220.220 Eire (Republic 01 Ireland) 50 10 kV; 380R20; 220 El Salvador 14.4 kV; 2.4 kV; 11 kV 3 kV, 2301115.20011 15 15 kV kV 380R20 2201127, 220 Faeroe lslands (Denmark) 50 380/220 Falkland Islands (UK) 50 415R30; 230 1612 kV 400~3012201110 50 2201110.110 220 2201127: 220 Japan Finland Botswana 60 Supply Voltage Levels In Common Use (V) 50 660B80, 500: 380/220.220 France 380R20 220 Flench Polynesia 60 220.100 Bulgaria 50 20 kV, 15 kV, 380R20.220 Gabon 50 3801'290 Burma 50 11 kV: 6.6 kV, 400R30 230 Germany (BRD) 50 2C kV 10 kV kV; 380R20 220 Libyan Arab Republic 50 400R30; 22?1127; 230:127 - Germany (DDR) 50 10 kV kV 660B80 3801220 2201127,220,127 Luxembourg 50 20 kV; 15 kV; 380R20.220 Macao 50 380R20, 2201110 Ghana 50 4401'250 250 Malagassy Republ~c (Madagascar) 50 kV; 3801220; 2201127 Malawi 50 400R30; 230 Malavsia (West) 50 415R40: 240 Burundi (Khmer Republic) 120 Cameroon 50 15 kV 3201220 Canada 60 12.517.2 kV, 600B47 2401120 2081120 600, 480; 240 Canary Islands 50 380R20.230 Caoe Verde Islands 50 3801'220 1271990 Cayman Islands 60 480R40.4801227 2401120 2081120 Central African R e ~ u b l ~50 c Chad 50 Gibraltar 50 415R40 Greece 50 22 kV 20 kV 15 kV 6.6 kV 380R20 Greenland 50 380R20 Grenada (Windward Islands) 50 400R30, 230 Guadeloupe 50.60 380R20 380R20.220 China 50 380R20 50Hz Chile 50 3801'290 990 Colombia 2081120 Guam (Mar~anaIslands) 60 Guatemala 20 kV 380/220 220 13.8 kV kV, 4801277: 480: 24011 20 2071120 60 13.8 kV 2401120 Guyana 50 2201110 Halt1 60 380R20 2301115 230: 220.1 15 Mali Malta 50 41 51240 Manila 60 20 kV; 6.24 kV 3.6 kV; 240fl20 Martinique 50 2201127; 127 Maurilania 50 380R20 Mauritius 50 400R30.230 Mexico 60 13.8 kV; 13.2 kV 480R77; 2201127; 220n20 Monaco 50 380/220: 2201127 220: 127 GENERAL Section A World Electricity Supplies Country - Frequency Supply Voltage (Hz) Levels I n Common Usc IV1 Country Frequency Supply Voltage (Hz) Levels In Common Use l V l Country 50 Togo Montserrat 60 4WR30 230 Sabah Morocco 50 380R20 2201127 Saramk (East Malays~a) 50 415R40.240 4151240 240 Mozamb~que 50 3801220 Saua, Alab~a 60 380R20 2201127 Muscat and Oman 50 415R40.240 Naura 50 415R40 Senegal 50 2201127: 127 Sevchelles 50 41 5R40 Nepal 50 11 kV 400R20, 220 S~erraLeone 50 Netherlands 50 10 kV kV 380R20.220 11 kV, 400R30, 230 Sinoaoore " 50 380R20 2301115 2201127: 2081120 22 kV: 6.6 kV: 400R30; 230 Somali Republ~c 50 Netherlands Antilles 50 60 New Caledonia 50 220 New Zealand 50 11 kV 4151740 400R30 440 240; 230 Nicaragua 60 13.2 kV 7.6 kV 2401120 N~aer 50 380R20.220 Nigeria 50 15 kV; 11 kV, 4001730; 3801220 230.220 ' Frequency Supply Voltage (Hz) Levels In Common Use (Vl Tonga Tfln~dadand Tobago 60 12 kV 400R30 2301115 Uganda 50 11 kV 4151240 240 United Kingdom 50 22 kV; 11 kV: 6.6 kV; 3.3 kV; 400R30, 3801220, Turkey 440I220; 2201110; 3.3 MI, 4331250 400R30; 3801220: 500 220 Southern Yemen (Aden) 50 4001730 S~anishSahara 50 3801720: 110: 127 20 kV 10 kV kV 3801220 230 Srl Lanka (Ceylon) 50 11 kV; 400R30; 230 11 kV:415R40 Uruauav 50 15 kV kV 220 USA 60 4801277 2081120 2401120 USSR 50 380/230.2201127 and higher vollages Venezuela 60 13.8 kV: 12.47 kV 15 kV 3801220; 2081120 220; 120 Norway 50 Pak~slan 50 4001230; 230 St Helena 50 Panama 60 12 kV: 4801227 - 2401120: 2081120 St Kins News Anguilla 50 400R30; 230 St Lucia 50 11 kV; 415R40 740 Vietnam (Republic of) 50 Saint V~ncent 50 3.3 kV; 4001230 230 V~rginIslands (UK) 60 208.120 V~rainIslands (US) 60 1101220 415R40 Papua New Guinea 50 22 kV 11 kV 415R40: 240 Paraguay 50 4401720; 3801220 220 Peru 60 10 kV: kV; 225 Philippines 60 13.8 kV 4.16 kV, 2.4 kV 2201110 Poland 50 15 kV kV 380R20, 220 Portugal 50 15 kV, kV: 380R20: 220 Por'uauese Guinea 50 380R20 Puerto Rtco 60 Sudan 50 415R40.240 Western Samoa 50 Surinam 50: 60 2301115; 2201127 2201110 127: 115 Yemen Democratic (PDR) 50 4401750: 250 Yugoslavia 50 10 kV; 6.6 kV 3801220; 220 Zaire (Republic 01) 50 380R20 220 Zambia 50 400R30.230 Sweden 50 20 kV 10 kV kV 380R20.220 Swiuerland 50 k V ; l l kV;6kV 380R20.220 8.32 kV 4.16 kV 480.2401120 Syrian Arab Republic 50 380R20; 2001115 220.115 Oalar - 50 415R40; 240 Reunion 50 11O Romania 50 20 kV; 10 kV; kV; 380122220- 220 Rwanda 50 15 kV 6.6 MI 380R20 220 ~ lalwan (Republ~c01 China) O Table World Electricity Supplies 60 22.8 kV 11.4 kV 3801220 Republic of) Thailand 50 380R20; 220 GENERAL Section A Supply Voltages A THREE PHASE STAR: 50 Hz, 55(YJZO a4OR54 41M4O FOUR WlRE EARTHED 3&5C?W 390,225 2001115 1901110 NEUTRAL 50 Hz of 60 Hz 44W230 380R20 22M27 W M) HZ only 4601265 s a M n F THREE PHASE DELTA THREE WIRE 50 Hz 2tC 60 Hz 230,240.460 575 G THREE PHASE DELTA: FOUR WIRE EAATHED MID POINT OF PHASE: THREE PHASE STAR THREE WIRE Yi Hz 30W220 60 Hz 22W127 4161240 P C THREE PHASE STAR: THREE WIREEARTHED NEUTRAL POINT THREE PHASE OPEN DELTA FOUR WIRE: EAFVHED MID POINT OF PHASE: 50 HZ W 2 O 60 HZ ~ l m K SINGLE PHASE THREE WIRE EARTHED MID POINT - i, - One Iq Lins Volts cenrre tapped A-SAC 170 175 C-SAC 90 95 100 104 105 110 115 120 125 170 175 180 ET~zEN~ PHASE: 8-SAC 156 164 173 180 182 190 199 207 216 , 294 294 312 A-SAC 185 180 195 200 205 208 210 215 220 225 230 250 C-SAC 185 190 195 200 205 208 210 215 220 225 230 SO or 60 H.I ~(xY~w 2 M l O 230nls 6a HZ 210110s ZUYlZO OF 50 Hz 200 225 250 50 cd 60 H2 100 110 115 120 127 220 230, 240 50 Hz 2201127 JBM20.4OM30.41Y240 Special delta 50 Hz 2a, L SINGLE PHASE' M SINGLE PHASE W WlRE EARTHED NEUTRAL: I 60 Hz 21W105 2201110, M J THREE PHASE OPEN i- E TWO PHASE STAR THREE WIRE EARTHED NEUTRAL 50 Hz 2WllOO 230/11S 60Hz 4801277 DELTA : FOUR WIRE: EARTH JUNCTION OF PHASE: D THREE PHASE STAR FOUR WIRE: NON EARTHED NEUTRAL: 50 Hz 22W110 4401220 5W60 Hz 23W115 60 Hz 240112C.2r012io ~ ~ ~ t d4 Wire 240 Line l o Naurral A-N B-N C-N 1M 110 110 120 121 127 133 139 250 144 A-B B-C C-A 180 190 200 208 210 220 230 60 Hz 120 I F GENERAL Section A k I y Formulae for Obtaining kW, kVA, Reactive kVA, BHP and Amperes Equivalents and Formulae Equivalents horsepower = 746watts horsepower = 0.746kW horsepower = 33,000R Iblrnin ft Iblrnin horsepower = 550ft Iblsec horsepower = 2546Btulhr horsepower = 42.4Btulrnin kW = 000watts kW = 1.3415hp kW = 56.8ft Iblmin kW = 738ft Iblsec kW = 3412Btulhr To Obta~n Single Phase AC VxAxPF KW1000 KVA= Btu = 9340in Ib Btu = 778.3ft Ib Btu =.0002930kWhr Btu = 1.05506kJ I f t Ib = kWhr = Direct Current kVA x PF VxA 1000 1000 1000 kVA x - PF' kVAx 1-PF' BHP (Output) = V x A xi~en Eff X PF 1.73xdVx~xEff.X PF VxAxGen Eff 746 x 1000 746 x 1000 746 x 1000 A (when BHP is known) = BHP x 746 x 100 BHP x 746 x 100 BHP x 746 x 100 A (when kW is known) = KW x 1000 kW x 1000 kW x 1000 V x P F x 1732 V V x PF therrn = 100,000Btu 12,000Btu = Ton (air conditioning) A (when KVA is known) = KVA x 1000 792,000 x BHP HZ = BMEP = (for 4-cycle) No of poles x RPM No of poles x RPM 120 120 rprn x cubic inch dis~lacernent KW Brake Horsepower (BHP) HP = BMEP x cubic inch displacement x rprrl BHP = (for 4-cycle) 792,000 Torque 5250 x BHP Torque (ft Ib) = r Prn Temperature (OF - 32) "F=("Cx1.8)+32 1.8 Power Factor kVA kVA KVA = kW PF "1 Misc Brake Mean Effective Pressure (BMEP) I WAX1000 Formulae kW 746 x 1000 ft Ib = 1.35582Nrn ft Iblsec = 0.001355kW ft Iblsec = 0.001818hp PF = s BHP (Input) = kW Btulrnin = 17.57watts Btulrnin = 0.0176kW Btulrnin = 0.0236hp Btulhr = 0.293watts Temp ("C) = "Ir V x A x 1.732 VxA 1000 Reactive kVA = Three Phase AC - 0.746 x Gen ~ff.icienc~ 0.746 x Gen Efficiency Where;kW = Kilowatts V = Line to Line Voltage A = Line Current PF = Power Factor HZ = Frequency HP = Horse Power I I ... - "For securing the safety of the public and for ensuring a proper and sufficient supply of electrical energy" Distribution units for electricity construction and building sites supplies for. .. (R) 19 A Guide to Asbestos (Licensing ) Regulations 1983 'Code of Practice for Designers, Installers and Users of Generating Sets." BS 2869 1970 Fuel Oils for Oil Engines and Burners for non-... Section A : Scope , This manual provides an Installation Guide for Cummins Power Generation generator sets This includes the following information:Room Sizes Mounting Recommendations Electricity