140211 KIUMA Electrical Proposal(S)

140211 KIUMA Electr ical Proposal(S).docx 0 03 April 2014

Prepared by: Mobile Missions Maintenance (South Africa)

2014

KIUMA: Tanzania Report: Electrical Installation of Kiuma Complex

Barry Thomas (Rev) (NDip Electrical Engineering – T3 Heavy Current)

Neil Eichstadt (Rev) (NDip Electrical – N6)

140211 KIUMA Electrical Proposal(S).docx 24 March 2014

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Contents

1. General Overview of Ministry ......................................................................................................... 3

2. Client brief .......................................................................................................................................... 5

3. MMMSA General Observations ...................................................................................................... 5

4. MMMSA Visual Site Evaluations ..................................................................................................... 6

4.1 Generator Room and Equipment ........................................................................................... 6

4.2 Battery Room and Batteries.................................................................................................... 8

4.3 Solar Panel Array..................................................................................................................... 10

4.4 Borehole Pump No.1 .............................................................................................................. 10

4.5 Carpentry and Joinery Workshop ........................................................................................ 12

4.6 Motor Mechanic Workshop .................................................................................................. 12

4.7 Welding Workshop ................................................................................................................. 13

4.8 Overhead Reticulation Network........................................................................................... 13

4.9 Milling Plant ............................................................................................................................. 15

4.10 Hospital..................................................................................................................................... 15

4.11 General Site ............................................................................................................................. 16

5. MMMSA “General Impressions” ................................................................................................... 18

5.1 “Good practices” ..................................................................................................................... 18

5.2 “Bad practices”........................................................................................................................ 18

5.3 Safety (Electrical installation and machinery) .................................................................... 19

6. Loading Table (Including Loading Assumptions) ........................................................................ 21

7. MMMSA Recommendations.......................................................................................................... 25

7.1 Essential 1 - Generator Room Upgrade............................................................................... 25

7.2 Essential 2 - Battery Room Upgrade .................................................................................... 28

7.3 Essential 3 - Main Solar Array Maintenance ...................................................................... 29

7.4 Essential 4 - Hospital Standby Generator Room ................................................................ 29

7.5 Power supply ordering:.......................................................................................................... 29

8. MMMSA Suggested Options .......................................................................................................... 30

8.1 Option 1 – Status Quo ............................................................................................................ 30

8.2 Option 2 - Upgrade Overhead Backbone System only ..................................................... 31

8.3 Option 3 - Teachers Training Centre Generator Room ..................................................... 32

8.4 Option 4 - Eastern Generator Room + Western Generator Room ................................ 33


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8.5 Option 4a – two distinctly separated systems. .................................................................. 34

8.6 Option 4b – both an independent system as well as a linked system. .......................... 34

8.7 Option 5 – 1 x 500kVA 3Ø Central Generator .................................................................... 35

9. Conclusion ........................................................................................................................................ 35

10. Disclaimer ......................................................................................................................................... 36

11. Appendix A........................................................................................................................................ 37

12. Drawings ........................................................................................................................................... 40

12.1 General Existing Layout (Supplied by Wortundat) ............................................................ 40

12.2 Single Line Diagram ................................................................................................................ 41

12.3 Site Layout – (Detailing Future Extensions) ........................................................................ 42

12.4 Overhead Reticulation Upgrade incorporating the Teachers Training Centre

GeneratorRoom / Eastern Generator Room + Western Generator Room.................... 43

140211 KIUMA Electr ical Proposal(S).docx 24 March 2014

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1. GENERAL OVERVIEW OF MINISTRY

The KIUMA Ministry Complex is located in Southern Tanzania. It is a Christian based

organisation with a German heritage and so is currently receiving major financial backing from

the “wortundtat mission” based in Essen, Germany. There are currently approximately 1000

people housed on the site and this is expected to increase to 1500 in the future.

The ministry facilitates many outreach programmes and so utilises many various building

facilities:

• School

• School Hostel (boys & girls)

• Hospital (Patients and Training)

• 160 beds

• Operating Theatre

• Laboratory

Site

Ministry Location

Southern Tanzania

10°45’50.85” S

37°57’37.25” E


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• Nurses Training Centre

• Nurse Accommodation Block

• Vocational Training Centre

• Welding

• Motor Mechanics

• Tailors

• Woodwork

• Brick Laying

• Church Building (+- 1000 seats)

• Conference Centre (+-2500 seats)

• Teachers Training Centre (Currently under construction so included in report)

• Dormitories

• Laboratories

• Lecture Rooms

• Dining hall

• Guesthouse (20 rooms)

• Directors House

• Staff Housing

• Administration Block

• Finance Block

• General buildings

When looking at the entire complex and the existing work already done by KIUMA, a huge

amount of progress has been achieved to date. It is never easy to establish and then run a

ministry successfully, especially, when the site is in a very rural area far away from resources

such as people, equipment and utilities. The impact KIUMA is making extends far beyond its

local physical boundaries.

However, due to the nature and magnitude of this complex it requires a fairly large and stable

electrical supply but with the increase in the ministry’s footprint and programmes the Electrical

Network Capabilities and Functionality are not at optimum utilisation.

As this electrical network needs “fine tuning” wortundtat mission contacted Operation

Mobilisation (OM) in Germany for assistance and so Mobile Mission Maintenance South Africa

Trust (MMMSAT) were contacted to carry out a site inspection with a view to proposing some

simple solutions to the existing problems.


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2. CLIENT BRIEF

The MMMSA Field Technical staff are to carry out a simple visual (non-intrusive) inspection of

the existing Electrical Network – this will include:

• Overhead Network

• Generator Room and related equipment

• Battery Room and related equipment

• Solar Panel Array

• General Inspection of Buildings, Equipment and (where possible) loading

On completion of the inspection, MMMSA is to provide a report / proposal that would see the

Electrical Network being used correctly, with equipment operating as expected and the loading

problems being addressed.

This report will be written – with both MMMSA and KIUMA – realising that the report will be for

information only and will not be a detailed operational directive nor a detailed plan / costing

proposal that is ready for immediate implementation.

Should KIUMA decide to utilise the MMMSA proposals then a detailed programme / costing /

implementation plan should be drawn up by a recognised, qualified planner / designer – this will

then be used as the “blueprint” for further upgrades or refurbishment of existing or future

equipment.

KIUMA would provide MMMSA with all necessary technical specifications, unlimited access to

all sites / equipment and where possible a “site technical assistant” who would be able to give

reasonable answers to network related questions raised by the MMMSA team. This assistant

should have a reasonable knowledge of the complex Electrical Network and the related “end

users”.

3. MMMSA GENERAL OBSERVATIONS

Overall observations are that the electrical network has both minor and major flaws in the way it

is constructed, utilised and maintained.

Minor flaws are generally directed towards simple installation procedures. It would appear is if

there are no STANDARD PROCEDURES or INSTALLATION DIRECTIVES for the internal

wiring of buildings nor are there any drawings available for any of the installations.


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Major flaws are directed towards overhead construction, generator usage, battery usage and

general cable / overhead lengths of line to end user point. These long lines result in volt drops

that are critical to the optimal running capacity of the O/H lines - which can also result in

damage to sensitive equipment – especially those that are near the end of such O/H runs.

Both of these “general observations” are discussed in point 6 “MMMSA General Impressions”

4. MMMSA VISUAL SITE EVALUATIONS

4.1 GENERATOR ROOM AND EQUIPMENT

Site is untidy – used as a storage facility

Site has poor lighting for safe working conditions

Site has exposed wiring and exposed contacts on contactors / switches

Contactors / switches are not labelled and have no interlocking protective devices –

this means that they can be operated out of correct sequence – possibly paralleling

units that cannot electrically be paralleled – this can cause personal injury through

accidental contact or “flashing”


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Site has decommissioned wiring still connected to equipment which can lead to a

serious accident should it be energised accidently. This extraneous wiring makes it

very difficult to determine how the control gear works and makes fault finding even

more difficult

No labels are fitted to the equipment

Frequency meter reading incorrect Generation frequency (reading 47Hz yet should be

50Hz) – this could either be a calibration problem or a genuine under-frequency fault.

Under-frequency generation can lead to numerous faults / issues on the system

especially for frequency sensitive equipment (computers etc)

Load balancing of network is not correct: (readings taken with “clip-on” induction type

ammeter)

• IRØ = 55A This current fluctuated up to 70A which leads to the imbalance current (In) in the Neutral

• IWØ = 34A

• IBØ = 35A

• N = 25A Problem – no current should flow in the Neutral if system is correctly balanced.

This Imbalance Current (In) can result in severe damage to the equipment supplied by

the network. This is generally a current which creates high temperatures which in turn

damage insulation and windings. It was realised when registering this current that the

Generators do not have Negative Phase Sequence protection (Inps) nor Imbalance

Current protection (In) – it is a recommendation that this be installed.

(Note: The Control Panel Mounted Ammeter does not work and so discrepancies in

Current Flow cannot be detected)


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4.2 BATTERY ROOM AND BATTERIES

Inadequate safety standards / precautions (see Point 6.iii – Safety)

Battery Room dirty

Main cable connections to battery bank poorly run and poorly connected

The 220Vac input to the inverter is faulty – needs to be repaired

Batteries not maintained – cells physically dirty which can lead to Leakage Current

(Ileak) which can damage batteries or cause a “flash” to other equipment or to

personnel operating on the batteries.

No hydrometer available to ensure correct Specific Gravity (SG) readings – this

monitors the Acid / Water mixture to ensure correct delivery of battery as well as help

manage a prolonged useful lifespan of the cells and the bank.

Discarded / de-commissioned batteries left in battery area

Discarded / de-commissioned Invertor Unit left in battery area

Exposed wiring is outside of the building and is “live’ – this is a serious hazard


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Control gear is not labelled

Inadequate lighting to carry out maintenance or repairs safely

No drawings detailing the following:

• Charging circuits – how the battery bank is charged

• Outgoing connections – where the outgoing circuits go

• How the bank actually integrates with the rest of the system

It can be expected that the output voltage of the bank is “low” due to a number of cells

being decommissioned

(Note: It is the personal opinion of the writer that the batteries are nearing the end of

their useful lifespan due to negligence in maintenance and loading. A new bank

should be sourced ASAP and prepared to be installed. The new installation should be

done by a DC Battery Installation Professional so that all necessary safety and

operational standards are met)

It should also be noted that the Battery bank should only be utilised as a “back up”

system and not a regular supplier of power to end users. Generally it is the main

power feed that supplies the end users while simultaneously “trickle” charging the

bank. The bank only comes into operation should the main power supply fail. This

continual charge / discharge can harm the cells.


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4.3 SOLAR PANEL ARRAY

The array appears to be in relatively good condition however it could not be

determined if the array actually “follows the sun” and if it has the facility- “does the

function actually still work” – this should be determined, as the function will increase

the arrays efficiency by having more “sun time”

4.4 BOREHOLE PUMP NO.1

Readings taken while pump running

1Ø Voltage Readings 3Ø Voltage Readings Phase Currents

Voltage Swing Voltage Swing Current Swing

RØ - N 229V – 236V RØ – WØ 395V – 408V RØ 16.8A – 17.1A

WØ - N 227V – 234V RØ - BØ 394V – 405V WØ 16.5A – 16.7A

BØ - N 229V – 237V WØ - BØ 392V – 403V BØ 15.9A – 19.9A

Neutral 0.02A – 3.3A

This pump appears to be running well as the nameplate has a running current (Irun) of

18.8A. The voltages supplied from the source generator also appear to be well within

normal accepted values

+- 10% of base line voltage 207V-253V single phase with base = 230V (Ø-N)

360V-440V three phase with base = 400V (Ø-Ø)

When these reading were taken the pump was already running, however, when

looking at the supply cable some problems were noted:


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• The supply cable run is approximately 500m-600m depending on the exact route

• The cable changes size from generator room supply (10 or 16mm2) to the pump supply (6mm2)

• The cable has joints in it (not normally a problem but if not done correctly could create flow problems or leakage)

When a pump starts up – depending on whether it has Direct-on-line (DoL) starting or

Star-Delta (Υ∆) starting – it can draw up to 7x the normal running current (therefore

Istart = Irun x 7 so the start-up current could be as high as 18.8A x 7 = 131.6A and this

raised current flow can last for up to 5 cycles) which means that a cable of this length

– if not sized correctly – could have a very dramatic volt drop (Vdrop) at the pump

connections.

This could lead to two things:

• Generator damage due to the high demand to start the pump (possible cause of existing generator damage)

• Under voltage at the pump which could damage the windings during start-up and ultimately lead to pump failure.

Note: This cable sizing needs to be addressed as a matter of urgency and if

necessary a larger cable needs to be installed or the pump should be supplied with its

own generator at the pump house. What is concerning is that another water supply

tank is currently being built – where will this pump be? If it is to be alongside the

existing pump house then it can be presumed that the pump will be supplied via the

same supply cable / generator connection. Damage is almost certain to occur. It is

recommended then that should this be the future plan that a dedicated generator

supply is provided at the pump house.

Another solution to the starting Volt drop could be to install a Soft Start (SS) system –

this will need to be investigated further.


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4.5 CARPENTRY AND JOINERY WORKSHOP

Insufficient lighting for safe work practices

Distribution boards open and wiring exposed

Generally appears to have sufficient power outlets however due to the distance that

this building is situated from the generator supply room it can be expected that - when

the system is under loaded conditions – this area will have a negative influence on the

total system integrity should numerous cutting machines be activated simultaneously.

4.6 MOTOR MECHANIC WORKSHOP

Insufficient lighting for safe work practices


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4.7 WELDING WORKSHOP

Insufficient lighting for safe working practices

Generally appears to have sufficient outlets however due to the distance that this

building is situated from the generator supply room it can be expected that - when the

system is under loaded conditions – this area will have a negative influence on the

total system integrity should numerous welders be activated simultaneously.

4.8 OVERHEAD RETICULATION NETWORK

Overhead lines use recognised conductor (Airdac) and recognised “manufacturer

tagged” poles.

It would appear too that all poles are buried to correct depths (+- 16% of total pole

length)

Attempts have been made to use a standard on O/H pole-tops with regards “bobbins”

and “tying in”. However there are many instances where the conductor is placed on

the wrong side of the bobbin and so the pressure of the angle is on the “binding wires”

and not on the bobbin as it should be.

Pole Binding Wire

Incorrect

Bobbin

Conductor Correct


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This will result in the binding wire chaffing the conductor insulation and eventually

cause a break down which may result in an Earth fault (IEfault). This IEfault can either

cause a pole top fire or a resulting Negative Phase Sequence fault on the generator

which without the adequate protection could result in

the generator being damaged or destroyed.

However should the fault be of a very low value

Sensitive Earth fault (ISE/F) this could result in

damage to equipment or even a possible death due

to a leakage current that is not detected timeously.

Pole compaction is good

Stay wires are installed on angle poles (however it should be noted that many are

installed at incorrect angles and so the poles are leaning into the stress angle)

Take-offs are not always installed correctly nor are some of the take-offs in use –

however the connections are still on the pole – this can lead to accidental contact

Pole Stay Wires

Incorrect

Conductor

Stress angle

* Sometimes a bisecting

stay may be necessary

to prevent pole toppling

Correct


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In some case no insulators are used to fasten conductors to poles. This can cause

breakdown of insulation and therefore faults that may be very difficult to detect –

especially if there is no protection to detect the fault.

4.9 MILLING PLANT

No safety equipment being used by the operator

De-commissioned equipment still standing in working area

4.10 HOSPITAL

The hospital inspection was very superficial due to the being very limited access to the

site - however there are some minor issues where wires in boxes are exposed to

human contact.


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The battery bank appear to be relatively new and in good condition – this looks to be a

sealed maintenance free lead acid bank

The Solar Array appears to be operating well – supplying the hospital batteries -

however the 220Vac input to the inverter is faulty – needs to be repaired.

4.11 GENERAL SITE

It was noted in the new ‘Finance office” that the main Distribution Board has been

wired incorrectly. The main incoming feeds are fed into the bottom of the breakers

when they should be fed into the top with the load being taken from the bottom. This

means that the breakers may work when detecting a fault but may not work

correctly.

In the new Finance Room – there has been a splitting of phases and a splitting of

protection circuits – the standard / principle used here appears to be very irregular and

should be seen as hazardous – it is the writers recommendation that this buildings

wiring should be removed and re-instituted to acceptable safe standards


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“Teeing” into lines to power a site is often done without the correct procedures or

materials.

Temporary installations are also done without “due diligence” to safety standards or

with regard to correct procedures – these are a hazard to personnel. The sight where

the photo below was taken is currently “standing” however the cables have been left in

position


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5. MMMSA “GENERAL IMPRESSIONS”

5.1 “GOOD PRACTICES”

� Overhead lines use recognised conductor (Airdac) and recognised “tagged”

poles. It would appear too that all poles are buried to correct depths (16% of

pole length)

� Attempts have been made to use a standard on O/H pole-tops with regards

“bobbins” and “tying in”.

� Pole compaction is good

� Stay wire are installed on angle poles (however it should be noted that many

are installed at incorrect “bisecting” angles and so the poles are leaning into

the stress angle)

� Original installations were done to a high standard (however they have since

deteriorated)

� Building electrical installations appear to be safe and well installed (however

standard installation procedures are not consistent over the entire complex)

5.2 “BAD PRACTICES”

x No site “as built” Overhead system electrical drawings are available – detailing

conductor type, size, length or position

x No standards installation procedures are used for domestic installations:

• houses are wired according to each installers own interpretation

• excessive use of materials result in over expenditure at some installations which also leads to redundancy on protection of systems

x Correct phase load balancing is not practised and so it appears as if the RedØ

is excessively loaded while the WhiteØ and BlueØ are under loaded. This has

resulted in a large imbalance on the O/H system as well as the Generator

supply. (See point 5.i)


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x Trees are encroaching on the O/H lines and these can cause the lines to

break under windy conditions

x 3-Phase (3Ø) is used into some houses – this is totally redundant when

looking at loading. This may have been done because of Air Conditioner (A/C)

usage but it would be recommended that A/C units are only installed in

essential areas not domestic or office facilities as this places undue burden on

the Generator set as well as induces imbalance current should the loads not

be connected correctly to allow for Single Phase (1Ø) take-offs.

x Throughout the complex decommissioned wiring is left in place while

telephone and television wiring is running alongside power supply cabling –

this can lead to personal injury if handled by inexperienced or untrained staff

5.3 SAFETY (ELECTRICAL INSTALLATION AND MACHINERY)

� No Safety Standards are in place and staff not trained in these standards

� Staff who monitor equipment are not adequately trained

� Some machinery has exposed moving parts – no guards in place to protect

operators or passers-by

� No standard operating procedures in place for machinery or Electricity

Network operations

� Operators of “noisy” machinery not using ear protection

� Operators of “moving / cutting” machinery not using eye protection

� Welders not using eye protection

� Welding workshop has inadequate lighting for safe working


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� Carpentry / joinery workshop has inadequate lighting for safe working

� Milling room has inadequate lighting for safe working

� Battery room has no eye protection available (full face shield – splashing

Sulphuric Acid H2SO4)

� Battery room has no hand protection available (full leather gloves)

� Battery room has no body protection available (leather apron)

� Battery room has no body cleaning protection available (shower / water

source)

� Carpenters working on machinery not using breathing masks

� Carpenters working on machinery not using eye protection

� Carpenters working on machinery not using gloves

� Carpenters working on machinery not using ear protection

� Metal roofs are not adequately earthed – cannot dissipate faults

� No lightning protection is installed at any of the supply points or end user

points

� No lightning masts are installed around the property to alleviate the possibility

of building strikes

� All fire extinguishers service dates outdated – should a fire occur then these

will be of no use

� There is no central library / storage area for all documentation of manuals for

equipment

� A major concern is around the earthing of the generators and the

reticulation network. Should this earthing be inadequate then the

possibility of serious injury to people of damage to equipment is

multiplied. Earthing is critical to the safe working and electrical integrity

of any system. This needs to be investigated as a matter of urgency.

140211 KIUMA Electr ical Proposal(S).docx 21 03 April 2014

6. LOADING TABLE (INCLUDING LOADING ASSUMPTIONS)


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140211 KIUMA Electrical Proposal(S).docx 25 03 April 2014

7. MMMSA RECOMMENDATIONS

7.1 ESSENTIAL 1 - GENERATOR ROOM UPGRADE

The # 1 JOHN DEERE diesel generator is currently in service supplying both the

complex as a whole and the small water pump alongside the generator room (details

unavailable)

This unit has the power capability of running the

entire complex under a load condition of 54%

diversity (see point 7 - loading table). It is

crucial to the electricity security of the complex

that this generator be serviced so that it is

available at all times to supply KIUMA

The only negative point with regard this unit is that its fuel consumption is high –

15L/hr

The # 2 IVECO AIFO diesel generator is currently out of service and it’s availability

for service could not be determined.

This unit has the power capability of running the

entire complex under a load condition of 35%

diversity (see point 7 - loading table).

Relatively high fuel consumption – 10L/hr

It is also essential that this unit be serviced and made ready for use. It stands as a

“back-up” to the #1 generator should that unit need servicing or repairs.


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The # 3 GREAZZO VICENZA ITALY diesel generator is currently running the water

pump at Borehole #1.

Fuel consumption – 5L/hr

This machine is far under-utilised for its power

delivery capacity and it is recommended that it be

moved to the site of the Borehole #1 pump house

and be used as a dedicated supply for both

Borehole #1 and the future Borehole #2 pump.

The #4 JOHN DEERE diesel generator is currently out-of-service at present and

needs urgent attention. It is also generally used to supply the pump at Borehole #1

when serviceable.

Fuel consumption – 7L/hr

It is also recommended that this generator be moved to the new site alongside the

Borehole #1 pump house. This can be used as a back-up to generator #3 when it is

moved. This will allow the other to be serviced / repaired without any loss of pumping

capacity.


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The generator room is in serious need of maintenance, cleaning and refurbishing (if

possible). There are numerous cables still attached to equipment that is no longer

serviceable or in use. These are a hazard.

It would also be recommended that the building be painted and adequate lighting

installed to ensure safe lit working conditions. The floor can also be painted with a

diesel repellent so as to protect the concrete from becoming corroded – this will also

allow for easier cleaning should a spillage occur.

It is also a recommendation that the main supply boards be removed and cabinet

mounted units be installed. These cabinets should be fitted with the necessary

generator electrical controls, generator protection relays and outgoing line protection.

As both Gen #1 and Gen #2 can / are to be used to supply the reticulation network it is

recommended that the cabinet be wired in such a way that they:

• can work independently of each other (“chop-over” installed)

or

• can be utilised in parallel – HOWEVER this facility needs careful attention as the two units have differing output capacities and should they be running simultaneously under heavy load (above 35% diversity) the load may be distributed between them to the detriment of the smaller Gen#2. Requires

complicated control circuitry.

This cabinet will ensure safer operating conditions for the operating staff as well as

greater efficiency in supplying power to the complex.


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NB! - It is also recommended that a diesel fuel tank (with level indicator) be

installed adjacent to the building that will allow for a gravity feed into both

Generators (+- 500 litre capacity should be sufficient) – this can also be mounted on a

small platform to allow for sufficient “fall”. This tank will allow for at least 40 hours use

by the generators (when running singularly or 20 hours running in parallel). This tank

can be filled from outside of the generator room and so alleviates possible diesel spills

as well as the possibility of fire should the diesel ignite within the building.

7.2 ESSENTIAL 2 - BATTERY ROOM UPGRADE

At present, the battery room is a hazard. Cabling is in disarray, the control board is not

labelled adequately, the lighting is insufficient, the room is dirty and the batteries

themselves are filthy. It is difficult to determine how this system is integrated into the

rest of the network.

It is recommended that the room be painted with a

good white wall coating while the floor is provided with

a good covering that will protect the concrete from

spillage of acid.

The barricade to cordon the batteries off from the rest of the room is a hazard as it can

cause the operator to trip and fall into the batteries possibly cause a short circuit on

contact. This DC short circuit current can run in the hundreds/thousands of Amperes –

this may not be lethal contact but the operator can be severely burnt.

It is also recommended that the battery output be connected to an “insulated” copper

busbar that runs along the wall and is then connected into a control panel fitted to the

wall. This panel will house all the control circuitry and protection necessary to monitor,

control and protect the battery bank and its feed into the network. The capacity of the

bank needs to be calculated correctly - Full load Current (IFL) and No-load current (INL)

needs to be determined and the bank sized accordingly. A DC Battery Bank specialist

is recommended to do this calculation and a recognised installer be utilised to carry

out the necessary battery room upgrades and installations.


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The current invertor has no 220Vac input capability and the spare unit is

unserviceable – these faults need to be corrected as a matter of urgency – again by a

recognised DC specialist.

7.3 ESSENTIAL 3 - MAIN SOLAR ARRAY MAINTENANCE

The suitability of this bank needs to be ascertained by a recognised Solar Energy

Specialist and then if suitable it needs to be serviced – especially with regard “sun

tracking” and cabling. The connection to the battery bank needs to be checked and

corrected. This connection is not labelled nor can it be determined accurately how it

connects into the existing network.

7.4 ESSENTIAL 4 - HOSPITAL STANDBY GENERATOR ROOM

Due to the nature of the work carried out by the hospital it is essential that the hospital

have an “emergency services” supply capability. The power supply to the hospital

needs to be secure and stable . Should the power fail during surgery the resulting

disaster could have far-reaching effects on the KIUMA ministry in Tanzania.

Therefore, it is recommended that the hospital receive its own dedicated generator

supply room.

The hospital currently runs off the existing generator supply which is adequate. A

battery system with Solar Array charging is the standby supply. This system can be

maintained however it does need to be maintained and proper control panels installed

with correct labelling (this system can become back-up No.3). A new generator supply

room should be installed that will become back-up No.2.

7.5 POWER SUPPLY ORDERING:

1st.Main Generator supply

2nd. Hospital Standby Generator

3rd. Battery / Solar Array


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Should the main supply fail and the generator fail to start then the control panel should

engage the battery / solar back-up system. This new arrangement will ensure that the

hospital operating theatres are always supplied with power. The new system also

allows for maintenance for crucial supply units without endangering power supply

security.

KIUMA currently have a suitable generator in storage on site (DIMAGG Listen Petter

diesel 3Ø 180kVA). This unit should be suitable to supply current needs as well as

the future extensions and related power demands. All that is required is the necessary

room, control equipment, fuel supply unit and cabling into the existing supply network

NOTE: This standby unit should not be used to “shore up” the existing power

network as this may have a negative effect on its performance and emergency

status.

The position of the standby room is recommended to be alongside the current Hospital

Solar Array as this allows for minimal cabling into the existing network.

8. MMMSA SUGGESTED OPTIONS

8.1 OPTION 1 – STATUS QUO

This option is available however it comes with many negatives. At present the

electrical system operates but not at optimum capacity.

Should this option be exercised then KIUMA need to understand that the current

problems will not only continue but will in all probability worsen:


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• Loading imbalances become greater

• Overhead backbone system becomes increasingly overloaded

• Overhead backbone system becomes increasingly susceptible to faults and downtime

• Battery capacity diminishes with each loading cycle and will eventually fail

• Solar Array capacity diminishes

• Internal building wiring and security remains without standards or procedures and so becomes a liability to all users and operators

• Fault finding remains a hazard

• The possibility of extended downtime of power supply multiplies as the existing network setup ages.

8.2 OPTION 2 - UPGRADE OVERHEAD BACKBONE SYSTEM ONLY

This option provides for minimal system enhancements at minimum cost. The current

system overheads are running near capacity which means that the effective lifespan is

diminishing due to overloading - as new user points are added the loading increases

and the aging process increases. By upgrading the overhead backbone (main supply)

the loading rate decreases which allows for more end users to be connected. This,

however, cannot provide an unlimited source of supply points and so needs to be

monitored closely – the ability to carry full load for an unlimited time is not possible.

The end users / loadings added will determine the lifespan and capacity of the newly

installed backbone.

It is recommended that the backbone be upgraded to either 25mm2 Aerial Bundle

Conductor (ABC) or 25mm2 Airdac (3 x single phase lines + Neutral). This system

however will need to be determined and calculated by a recognised professional line

designer utilising a power flow / profiling package.

The system should also be fitted with the necessary hardware (poles, bobbins, ties,

stays etc) as well as in-line links to facilitate easier fault finding and system versatility.

Normally Open Points (NOP’s) should also be incorporated into the design to allow for

the network to be “fed via different routes” – this will allow for easier fault finding and

system versatility.


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All take-off points to end users should be via a Pole-top Box (PTB) that incorporates a

protective device (MCB) to protect the overhead line from end user faults. The integrity

of the overhead line is better using these PTB’s.

8.3 OPTION 3 - TEACHERS TRAINING CENTRE GENERATOR ROOM

This option keeps the existing system connected as it is (or allows for the backbone

upgrade) but allows for an additional Generator room to be built at the proposed

Teachers Training Centre (TTC). This will cater for all expansions around this area of

the complex but does not alleviate problems caused by the long supply run to the

Vocational School Workshops fed from the existing generator room – this area does

put a certain drain onto the supply network.

It is also a rather costly exercise as a new generator needs to be purchased and a

room built to house the generator and all its related control and protection circuitry.

It only alleviates a minimal loading problem and should not be seen as a long term

solution to the current electrical system shortcomings.


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8.4 OPTION 4 - EASTERN GENERATOR ROOM + WESTERN GENERATOR ROOM

This option would be the costliest recommendation but will be the best solution to all

the current problems as well as the future loading considerations.

This option relies on the understanding that Essential 1-4 have been carried out.

As well as upgrading the overhead backbone system this option calls for the

installation of an additional Generator Supply Room designated Western Generator

Room (WGR). The existing generator room is designated Eastern generator Room

(EGR).

(Existing Generator Room) (New Generator Room) Eastern Generator Room Western Generator Room

Main Line

Take Offs

These connection parameters can be decided on through optimal routes/loadings

being developed by using a simulation computer programme – this means that exact

areas of supply will need to be clearly defined and implemented.

EGR

This Generator room feeds all

existing network excluding:

• TTC

• Borehole #1 pump house

(self- supplying)

• Vocational School Workshops

WGR

This Generator room feeds:

• TTC

• Vocational School Workshops

• new developments west of

the “old Runway”

NOP


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8.5 OPTION 4A – TWO DISTINCTLY SEPARATED SYSTEMS.

These two generator rooms are coupled in such a way that they run independently of

each other – feeding independent systems – with a Normally Open Point (NoP)

ensuring that they cannot be run in parallel. This means that each generator room is

equipped with two by generators (Main & Standby) that are capable of maintaining a

secure supply to all end users. The NoP is designed in such a way that the two lines

cannot be linked together – how this is achieved will be decided on by the designer

and installer.

8.6 OPTION 4B – BOTH AN INDEPENDENT SYSTEM AS WELL AS A LINKED SYSTEM.

Running in parallel (NoP closed via links) could create problems but with some

expensive protection and control circuitry these problems could be alleviated

(Synchronising relays, phase angle monitors, speed monitoring relays etc).

The two systems are linked together by means of a set of pole mounted links that

have an interlocking system connected to them. This system will only allow the links to

be closed should all the necessary requirements be met by both generator rooms ie

• synchronised speed

• correct phase angle

• correct phasing

• balanced load

(These are not the only criteria and so this system does need to be designed and

installed by a competent recognised person / company)

Running with either of these options - 4a or 4b - allows for a marked increase in

system capability – each has distinct advantages and disadvantages – these will need

to be explored by KIUMA (and the relevant designers) to see which will give maximum

benefit to the complex for least capital outlay (although capital outlay should not be an

exclusion detail).


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• Option 4a will be the cheaper option but will give limited long term benefits.

• Option 4b may be the most expensive yet the long term benefits will support the capital outlay.

(Will the outlay compensate for future expansion and bring a greater return – that

needs to be decided by KIUMA)

8.7 OPTION 5 – 1 X 500KVA 3Ø CENTRAL GENERATOR

A simple solution is to upgrade the existing overhead network and install 1 x 500kVA

generator with all related control circuitry and protection devices. This unit is then

connected to the network which then encompasses the entire complex Eastern area

and Western Area

9. CONCLUSION

The complex appears to be able to cope with the existing loading and design of the electrical

network – however the current situation will not be sufficient for the KIUMA complex to continue

operating well into the near future.

� Equipment is not being maintained,

� New buildings are being added to the loading without the network capacity being upgraded to meet the new requirements

� Standard installation procedures are not being used – this leads to a variety of practices all of which affect the safety, capacity and electrical integrity of the current system (and future system should this not be addressed)

� A variety of “imported” equipment is being used – this does not allow for easy maintenance or for readily available spares to be obtained. Local equipment needs to be utilised or sufficient spares need to be kept on site (this can be a very costly exercise)

� Installation staff are not suitably trained

An intervention is required soon to reduce the drain on the current supply network as well as to

determine a set of compliance standards – should this be delayed then the network is going to

collapse or personnel are going to be injured.

MMMSA is available to continue the investigation process however this will need to be

negotiated as this process will need more time, more equipment and more personnel.


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10. DISCLAIMER

Due to the high-level visual inspection concept applied to this project and the fact that no in-

depth testing or intrusive inspection was done it should be noted that the recommendations of

MMMSA are for guidance and planning purposes only .

Precise and specific recommendations can only be made after:

1. specific load studies are carried out

2. O/H routes and lengths are determined accurately

3. underground cable route, cable sizes and cable lengths are determined accurately

4. detailed reticulation load studies have been carried out

5. future loading expectations have been determined

6. future building plans have been determined

7. existing “out of commission” equipment has been restored to service as this will determine capacity

MMMSA cannot be held responsible should any of its planning recommendations be

implemented without further detailed investigations or designs being carried by qualified

professional persons.


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11. APPENDIX A

Report supplied by wortuntdat (Germany)

– “Current electric report”- Jakob Adolph (Project Manager)

Power supply generators GENERAL

We have two big questions.

1) How can the diesel generators be used best for all the electric power needs in

KIUMA?

2) Knowing that there always be long hours of generator use every day, how can the

solar power and battery banks be designed to cover the generator OFF hours and

emergencies for the hospital and vital administration (directors house) and

communication needs.?

The bottom line

• We need to find a Tanzanian technology provider for each of these questions,

preferably one that can give us qualified answers to both issues. (best use of

generators and solar power)

• We want to provide a reasonable learning and work experience for all staff

and students in KIUMA.

• We want to reduce times when “things cannot be done” because there is no

electric power, yet at the same time we want to maximize the use of electric

power when it is ON.

• We want to have an emergency power system in place, for situations when

the generator power is interrupted, no matter for how long.

The remarks below are not in any order of priority.

• Appropriate sized generators should be chosen for different times of the day.

• The water pump needs to run on the same generator as the general electric

supply. Currently the water pump runs only on an “exclusive” generator #3 or #4. This

is due to water pump failures in the past. The “mix” of pumping water and generating

power for various applications in KIUMA was blamed. Possible reasons for these past

failures could have been the “consumption spike” when various electric motors start up

with the generator. Possibly the max. available power was reached on startups. It must

be assured that the generator in use is powerful enough to start ALL attached electric

motors including the “startup spike”.

Before this new “hookup” is tested it must be assured that there is a “spare” water pump

in KIUMA in case this would not work of other not yet identified reasons for failure.

• A detailed List of electric power consumers must be established. There are too many to

mention here, but the biggest ones are:

-All hospital surgery equipment (high wattage lamps, AC´s etc)

-All lights on the entire compound, especially the high beam in the church and the Aula,

there are approximately 130 different sized buildings, providing housing, schooling

facilities, and general living quarters. There are more than 1100 People on the property,

not counted the inpatients at the hospital, a different sized groups that might come for

various meetings and conferences.


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With the extensions and growth expected in the next 24 month, everything should be planned

for at least 1500 residents.

-Various water heaters (especially in the hostel and the Level “A” housing units

-All carpentry and joinery woodworking machinery

-All welding and fabrication machinery

Schedules need to be made of which equipment can NOT be used at the same times! For

example (not more than 3 electric machines in the woodworking shop at the same time or not

more than 2 electric welding machine in the welding and fabrication workshop etc.) These

schedules need to be based on realistic evaluation of the power needs in KIUMA.

• The current generator times need to be adjusted to the agreed times:

08:30-11:30

19:00-23:00

At least, to raise life quality of all personnel and students, and to increase the time the

water pump is running to increase water quantity.

(A second well and pump might be considered for 2014 to cover the expected growth of

the project and to provide water to the Milonde village)

Also it should be considered to run the generator in the afternoons to give more work

time to the VTC machinery, the hospital and the IT classes.

A completely new schedule might be considered, covering the mornings, afternoons

and evenings.

Battery bank and solar power

• KIUMA has two separated solar panel systems, both with its individual battery bank.

(See attached schematic document)

The system at the hospital is vital and it should be the first priority to have an

independent working system in place.

The system supplying the hostel and the directors house is of secondary priority and it

should be a KIUMA decision on how large this system needs to be and if the

guesthouse really needs a 24/7 power supply.

In both cases the reality is that due to the size and type of electric appliances used,

there will be no meaningful “solar only” solution, but there will always be a need to run

diesel generators for the biggest consumers.

So any new or revamped installation should be taken into account that there is a generator

running a few hours every day anyway. At the same time, for cases of emergency the hospital

needs to be able to run for long periods of time only on battery and solar power.

• It also should be considered to combine all solar panels and battery banks into one

powerful system at the hospital (or at the generator house) with the option of supplying

a small Amp line to the directors house for emergencies (to run the lights, satellite

communications and IT)

• All batteries are quite old and tired (with a small exception of added batteries), a full

replacement needs to be considered.

• It needs to be discussed with the hospital doctors which of the equipment needs to be

running in any power situation to find out what the minimum size of the solar and power

bank system needs to be.


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#1 Generator John Deere, diesel installed 2011 (15Ltr/h)

KVA/KW 23/18

Max KVA/KW 260/208

Volt 400/230

Freq. 50Hz

RPM 1500

Phase 3

Used only when the other generator is in maintenance, due to the higher consumption

Never used to pump water from well.

#2 Generator IVECO AIFO, diesel Installed 2004 (10Ltr/h)

KVA/KW 15/12

Volt 400/230

Freq. 50Hz

RPM 1500

Phase 3

Used most of the time for electric power only, never for pumping water from well

#3 Generator GREAZZO VICENZA ITALY, diesel Installed 2005 (5Ltr/h)

KVA/KW 6/4,8

Volt 110/200/230/400

Freq 50Hz

RPM 1500

Phase 3

Main Generator to pump water from well. Exclusive!

#4 Generator JOHN DEERE, diesel installed 2011 (7Ltr/h)

KVA/KW 6/4,8

Volt 400/230

Freq 50Hz

RPM 1500

Phase 3

Secondary generator exclusive for pumping water from well.

Normal daily current per phase = 75A=17.25 Kw

Daily total current per 3phase=225A=51.75 Kw

These total kilowatt are generated only by #1 and/or #2 generator.

#3 and #4 generators run only the water pump:

Kw 7.50

Volt 400

Amp 18.8

Rpm 2850

Running the waterpump on #1 or #2 generator has led to failure of waterpumps in the past.

A brand-new generator is available in a container:

#5 Generator DIMAGG Listen Petter

KVA/Kw 18.1/14.4

Volt 400

Amp 28.7

RPM 1500

MMMSA Note: KVA rating is 230kVA

KW rating is 180kW


KW rating is 120kW


KW rating is 48kW


KW rating is 48kW


KW rating is 144kW


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12. DRAWINGS

12.1 GENERAL EXISTING LAYOUT (SUPPLIED BY WORTUNDAT)


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12.2 SINGLE LINE DIAGRAM


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12.3 SITE LAYOUT – (DETAILING FUTURE EXTENSIONS)


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12.4 OVERHEAD RETICULATION UPGRADE INCORPORATING THE TEACHERS TRAINING CENTRE GENERATORROOM / EASTERN GENERATOR ROOM + WESTERN GENERATOR ROOM

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140211 KIUMA Electrical Proposal(S)

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