NIOEC-SP-43-12(0)

DOCUMENT CODE NO. OF PAGES: 21

PLAN/PRJ/SUB UNIT PHASE DISCIPLANE DOCUMENT TYPE SERIAL NO. REV. NO. DATE
NIOEC 000 EG PM SP 4312 A0 JULY, 2005

NATIONAL IRANIAN OIL REFINING & DISTRIBUTION COMPANY

NATIONAL IRANIAN OIL ENGINEERING
& CONSTRUCTION COMPANY

NIOEC SPECIFICATION
FOR

EMERGENCY DIESEL GENERATOR

FIRST EDITION

JULY, 2005

THIS SPECIFICATION IS THE PROPERTY OF NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY. IT IS CONFIDENTIAL AND ALL
RIGHTS RESERVED TO THE OWNER. NEITHER WHOLE NOR ANY PART OF THIS DOCUMENT MAY BE DISCLOSED TO ANY THIRD PARTY,
REPRODUCTED, STORED IN ANY RETRIEVAL SYSTEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS WITHOUT THE PRIOR WRITTEN
CONSENT OF THE NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY
JULY, 2005 NIOEC-SP-43-12(0)
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REVISION INDEX
REV. REV. REV. REV.
PAGE 1 2 3 4 5 PAGE
1 2 3 4 5 PAGE 1 2 3 4 5 PAGE 1 2 3 4 5
1 26 51 76
2 27 52 77
3 28 53 78
4 29 54 79
5 30 55 80
6 31 56 81
7 32 57 82
8 33 58 83
9 34 59 84
10 35 60 85
11 36 61 86
12 37 62 87
13 38 63 88
14 39 64 89
15 40 65 90
16 41 66 91
17 42 67 92
18 43 68 93
19 44 69 94
20 45 70 95
21 46 71 96
22 47 72 97
23 48 73 98
24 49 74 99
25 50 75 100

NOTES:
1) THIS SHEET IS A RECORD OF ALL REVISIONS TO THIS SPECIFICATION.
2) REMARKS RELATED TO EACH REVISION SHOW A BRIEF DESCRIPTION. THESE REMARKS SHALL BE
INTERPRETED IN CONJUNCTION WITH THE REVISED TEXT MARKED BY REVISION NUMBERS.
3) WHEN APPROVED EACH REVISION SHALL BE CONSIDERED AS A PART OF THE ORIGINAL
DOCUMENT.
4) NUMBER OF PAGES EXCLUDES THIS SHEET AND THE COVER SHEET.

5
4
3
2
1
0 JULY, 2005 FROUTAN / B.A A.SADEGHILAR M.R.FARZAM M.A.A.SAJEDI
REV. DATE PREPARED CHECKED APPROVED AUTHORIZED
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CONTENTS: PAGE NO.

1. SCOPE ........................................................................................................................................2
2. REFERENCES...........................................................................................................................2
3. UNITS .........................................................................................................................................3
4. DEFINITIONS AND TERMINOLOGY .................................................................................3
5. DESIGN ......................................................................................................................................3
6. INSPECTION AND TEST......................................................................................................15
7. PREPARATION FOR SHIPMENT.......................................................................................17
8. VENDOR’S DATA ..................................................................................................................18

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1. SCOPE

1.1 This specification covers the requirements for emergency diesel generator used in petroleum,
chemical and gas industry.

1.2 Selected diesel generator and accessories shall be, in all respect, well within the range of the
manufacturer’s proven experience.

1.3 Compliance by the manufacturer with the provisions of this specification does not relieve him of
the responsibility of furnishing diesel generator and accessories of proper design, mechanically
suited to meet operating guarantees at the specified service conditions.

1.4 Unless specific exception accompanied by a description of the proposed substitute is recorded
under the heading “Exception” in the manufacturer’s proposal, it shall be mutually understood that
the proposal is based on equipment which complies strictly with the requirements of this
specifications, and such statement of compliance shall be given.

1.5 Where the manufacturer feels it is important to point out his interpretation of the specifications,
these shall be listed under a separate heading “Clarifications”.

1.6 This specification supplements the specification sheets of each individual diesel generator on
which the operating conditions and special requirements are listed in detail. In case of conflict
between data sheet and the documents relating to this specification, the former shall govern.

2. REFERENCES

Throughout this Specification the following dated and undated standards/ codes are referred to. These
referenced documents shall, to the extent specified herein, form a part of this Specification.
For undated references, the latest edition of the referenced document (including any supplements and
amendments) applies. For dated references, the edition cited applies.
The applicability of changes in dated references that occur after the cited date shall mutually be
agreed upon by NIOEC and the Vendor/Contractor.

ISO (INTERNATIONAL STANDARDIZATION ORGANIZATION)

ISO 3046, Reciprocating Internal Combustion Engines.

ISO 8528, Reciprocating Internal Combustion Engine driven Alternating Current Generating
Sets.

IEC (INTERNATIONAL ELECTROTECHNICAL COMMISSION)

IEC 34, Rotating Electrical Machines

API (AMERICAN PETROLEUM INSTITUTE)

ASME (AMERICAN SOCIETY OF MECHANICAL ENGINEERS.)

Boiler and Pressure Vessel Code:

Section II, Pressure casing: design and construction: Material
Section V, Non destructive examination
Section VIII, Division I, Rules for construction of pressure vessels
Section IX, Welding and brazing

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ASTM (American Society for Testing Materials)

BS (British Standard Institute)

BS5514, Reciprocating internal combustion engines.

NIOEC (NIOEC SPECIFICATIONS)

NIOEC-SP-00-10 “NIOEC Specification for Units”
NIOEC-SP-60-02 "General Specification for Motors"

3. UNITS

International system of units (SI) shall be used in accordance with NIOEC-SP-00-10, unless
otherwise specified.

4. DEFINITION & TERMINOLOGY

Employer: National Iranian Oil Engineering and Construction Company (NIOEC).

Contractor: The person, firm, Company or consortium whose tender has been accepted by the
Employer or legal successors in title to such person.

Purchaser: National Iranian Oil Engineering & Construction Company in cases where this
Specification is part of a direct purchase by National Iranian Oil Engineering & Construction

Company: In cases where this Specification is part of Contract Documents, "Purchaser" means the
Contractor.

Vendor: The manufacturer's from which the equipment is to be purchased.

5. DESIGN

5.1 GENERAL

5.1.1 Diesel engine shall complete with all necessary auxiliaries including starting, cooling,
lubricating, combustion air intake, exhaust and fuel systems.

5.1.2 AC synchronous generator shall complete with excitation equipment.

5.1.3 Combined engine-generator control panel shall be furnished with the diesel generator set.

5.1.4 Site condition and the rating of the diesel generator shall be specified by the purchaser on
the specification datasheet. A local control panel shall be required for automatic start. The
service rating of the engine shall be suitable for the generator output in accordance with
the site conditions specified on the specification datasheet.

5.1.5 Diesel generator set shall be mounted on a common baseplate with anti-vibration pads.

5.1.6 The diesel generator shall be automatically started when receiving a breaking off signal on
the normal power supply. The diesel engine shall be designed to reach operating speed and

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full load capability within 15 seconds. The vendor shall provide the automatic start logic
switch schematic.

5.1.7 Design and construction of the diesel generator set shall provide accessibility for all
components requiring routine operational attention and maintenance.

5.1.8 The diesel generator shall be designed and configured to optimize inspection or
maintenance and overhaul activities. Components with weight/mass greater than 25 kgs
shall be provided with lifting lugs. Generators shall have jacking bolts or facilities to lift
the generator with the aid of a mechanical jacking device and jacking bolts or facilitate to
align the generator with the diesel engine.

5.1.9 All material shall be new and unused, and of proven quality. Materials for main
components of the diesel generator shall be specified by the vendor on the specification
datasheet.

5.1.10 The diesel engine noise shall be not more than 102 dB at 1 meter from the equipment
surface.

5.1.11 Vibration isolators shall be provided for mounting the engine and generator on the
fabricated steel supports or sub-base. The torsional natural frequencies of the diesel
generator set, including the couplings and gear units, shall not be within 10% of any
normal operating shaft speed ranges. Critical speed above 120% of the rated speed for
three minutes shall not cause any damage. Automatic over/under speed trip with time
delay element shall be provided.

5.1.12 The voltage dip when starting the largest motor with other loads in operation, shall not
exceed 20% at the motor terminals.

5.1.13 The rating shall be such that the engine shall deliver an output of 10% in excess of the
rating for 2 out of any 24 hours without injurious heating.

5.1.14 The Diesel Generator shall be capable of starting and accelerating to rated speed and to
accept all the loads specified herein. At no time during the loading shall the steady
frequency variation and steady voltage variation be more than 3% of nominal and 5% of
nominal respectively.

5.1.15 All live parts and terminals shall be adequately screened or shrouded, and warning lablels
shall be provided, giving clear instructions regarding live parts and their means of
isolation. All equipment shall be arranged in a logical manner. Where practicable, the
enclosure shall be segregated by compartment to prevent faults in one section from
spreading to other sections.

5.1.16 Reliability in terms of high Mean Time Between Failure (MTBF) factors is essential for
this equipment. To achieve this objective, the Manufacturer shall examine the rating
factors applied to all components used in manufacture, and guarantee that the ratings for
this application will be modified as necessary to ensure long term reliability.

5.1.17 Removable guards for engine flywheel, engine-generator coupling and any other exposed
moving parts shall be furnished for personnel protection. The guards shall be of non-spark
materials.

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5.1.18 The engine shall trip when the generator has tripped on fault or AVR has failed.

5.1.19 A tachometer shall be supplied and mounted on the engine. Speed range shall be 0 to
115% of the rated speed.

5.1.20 Anti-condensation heaters shall be provided for the generator and control panel, within the
enclosures to limit the effect of changes in temperature and humidity. The leads from the
heater shall be brought to an isolator which shall be mounted on the generator baseplate.
Heaters shall be connected to a 230 Volt AC supply.

5.2 ENGINE DESIGN

5.2.1 GENERAL

5.2.1.1 The diesel engine shall be selected from the manufacturer’s standard range of products.
Prototype equipment shall not be acceptable.

5.2.1.2 The rated output for the engine shall meet the requirements noted on the diesel generator
specification sheet. Site condition will be specified by Purchaser.

5.2.1.3 The engine shall be full diesel type. Engine speed shall not exceed 1500 r/min.

5.2.1.4 All bearings shall be capable of withstanding cylinder over a long period. The life of all
bearings shall be no less than 8000 hours.

5.2.1.5 An over speed trip shall be necessary for the engine.

5.2.2 FUEL SYSTEM

5.2.2.1 The fuel system for diesel generator set shall comprise of a day tank, fuel pumps, strainers
or filters, valves and fittings, etc.

5.2.2.2 An engine driven fuel pressure pump shall be provided. The pump shall draw oil from the
day tank to the engine for operation.

5.2.2.3 A day tank with a minimum 8 hours operating capacity shall be supplied with the unit.
This tank shall be provided with all accessories like sight glass, strainers, externally
mounted level guage, filling connection/assembly, nozzles, high/low level alarm switch
with status indication displayed on its local control panel, earthing bosses and nameplate.
The tank shall be of heavy duty welded construction type and shall be vented and drained.
The tank shall be designed to operate under pressure from full vacuum to barometric
pressure and shall be installed indoors.

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5.2.2.4 The fuel oil filter shall be provided and shall be dual, full-flow replaceable cartridge type.

5.2.2.5 A set of fuel oil piping for connection between the fuel oil day tank and the engine
supplied in enough lengths together with all necessary compression type couplings to
complete the service fuel system.

5.2.2.6 In order to fill day tank with oil from outside generator building, suitable set of piping with
relevant accessories shall be foreseen. It should be possible to fill the tank directly from a
truck.

5.2.3 AIR INTAKE AND EXHAUST SYSTEM

5.2.3.1 Air intake system complete with air filter and intake piping shall be required. The
pipework between filter and engine shall be SS316L material. The intake air filter shall be
with replaceable dry elements.

5.2.3.2 Sets of exhaust chromel or alumel thermocouples to give exhaust readings at each cylinder
outlet and at inlet to turbocharger shall be required.

5.2.3.3 An exhaust gas turbocharger with exhaust uptake adaptor shall be required.

5.2.3.4 Sets of charge air ducting for interconnection between the turbocharger and the radiator
shall be furnished with the engine.

5.2.3.5 Exhaust system, with manifold, expansion joint, silencer and any companion flanges,
piping and fittings required shall be furnished. The exhaust outlet from the silencer shall
contain sufficient flexible connections to prevent vibration being transmitted to the
building and arranged to exhaust to the atmosphere at high level and to keep out rain and
dust as far as possible. Exhaust system shall include spark arresters. The exhaust piping
shall be suitable lagged for personnel protection.

5.2.4 LUBRICATING SYSTEM

5.2.4.1 Lubricating oil system complete with engine shaft driven pump, strainers, and necessary
interlocks and instrumentation shall be provided. The system shall include, but not limited
to, oil pump level indicator, oil pressure gauges, jacket water cooled oil-cooler, full flow
filters and lubricating oil pressure switch.

5.2.4.2 Pressure lubricating oil shall be supplied to the main and big end bearing, the small end
bearing and the pistons and also to the camshafts, cam followers and gear drives.

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5.2.4.3 All components shall be installed and mounted on the engine or engine baseplate complete
with piping.

5.2.4.4 A gear type pump driven from the free end of the engine shall supply lubricating oil from
the engine sump through the cooler and fine mesh filters to a main supply rail.

5.2.4.5 The lubricating oil filter shall be replaceable cartridge type with 10 ~ 15 μm filtration
between the lubricating pump and the engine. Filter cartridge materials shall be corrosion
resistant. The clean pressure drop shall not exceed 0.35 Bar at design temperature and
flow. The cartridge collapse pressure shall not be less than 3.5 Bar. The filter shall be
equipped with vent and drain connections.

5.2.4.6 Thermostatically controlled electric immersion heater fitted into the engine sump to heat
the lubricating oil and assist priming and starting of the engine. The heater shall be
operated from the mains supply and the thermostat shall be set to cut out at a constant
value.

5.2.4.7 All components of the oil system shall be of steel construction, 18 Chrome-8 Nickel
stainless steel piping shall be provided downstream of the lube oil filter to the engine and
driver bearings.

5.2.4.8 Carbon steel lube oil piping shall be pickled. Stainless steel tubing and piping shall be
cleaned with suitable solvent.

5.2.5 COOLING SYSTEM

5.2.5.1 Engine jacket water closed cooling system of sufficient capacity to supply cooling water to
engine, oil coolers and charged air coolers and to maintain safe operating temperatures
with an ambient temperature range as specified herein. The system shall include as its
principal features an engine mounted, a closed loop jacket water radiator with expansion
tank, all necessary interconnecting piping, engine mounted blower fan, gear driven jacket
water circulating pump, required thermostats and jacket water temperature switch for
remote high water temperature alarm. The cooling system shall be automatically controlled
and capable of maintaining engine water temperature at 74~80°C at continuous full-load
conditions.

5.2.5.2 A suitable capacity make-up/expansion tank shall be required. The tank shall contains a
level gauge and provision for high and low level alarms. The tank shall be hot dip
galvanized inside and have a loose fitting top cover which enables internal inspection of
the tank.

5.2.5.3 Visual flow indicators shall be supplied. The indicator shall be a hinged flap visible
through a glass window and equivalent device.

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5.2.5.4 Thermostatic controlled electric heater fitted into the engine jacket water system shall be
furnished. The heater shall heat the jacket water and assist automatic starting of the engine
under cold conditions. The heater shall be operated from the mains supply and shall
maintain water temperature in engine between 38~50°C.

5.2.6 STARTING SYSTEM

5.2.6.1 The engine start shall be by motor, battery-powered. The starting system shall be supplied
complete with batteries, starter control, starter contactor and starter overspeed limiting
switch. Starting control shall be integrated with the diesel generator set control system.

5.2.6.2 2×100% Starting batteries shall be provided. Each batteries shall be capable to
automatically start at least 3 times. The battery shall be of the nickel-cadmium
recombination type. The batteries shall be provided with a ventilated, steel-reinforced
plastic battery box mounted on the diesel generator baseplate. The box lid shall be
constructed such that, in case of mechanical damage, the battery terminals will not be
short-circuited. The lid shall also be securable when open as well as when closed. The
battery boxes shall protect the batteries against displacement, excessive temperature,
vibration and mechanical impact. The batteries within their boxes shall be readily
accessible for servicing. The battery shall be charged either by an AC main charger in
engine off condition or by an engine driven alternator in engine running condition. An
automatic changeover system shall also be supplied.

5.3 GENERATOR

5.3.1 GENERAL

5.3.1.1 The rating of the AC Synchronous Generator shall be specified on the specification
datasheet. The generator shall be totally enclosed, direct connected to the diesel engine and
shall be rotating field synchronous type. The governor shall comply with relevant parts of
IEC-34.The generator shall have following characteristics:
Power factor: 0.8
Nominal Voltage 6000 V(3 Phase)
Frequency 50 Hz
Connection Star

5.3.1.2 The Generator shall have a continuous rating and overload rating based on the maximum
site ambient temperature. Calculations shall be submitted to justify the generators chosen,
taking into account the reactance, motor starting capacity and excitation system used. A
listed of proposed connected loads shall also be submitted.

5.3.1.3 The degree of ingress protection of the enclosures for the generator and its auxiliaries in
accordance with IEC34-5 shall be specified on the specification datasheet.

5.3.1.4 The Generator frame and bearing supports shall have sufficient strength and rigidity so that
no distortion or increased vibration occurs as a result of external mechanical forces, e.g.
tightening of anchor bolts. The generator frame and bearing end-shields shall be

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constructed of ferrous metals. All welding shall comply with ASME/AWS D1.1 or the
relevant code.

5.3.1.5 The generator shall be Class F insulation with temperature rise limited to the temperature
class of “B” insulation. The generator stator windings shall have full insulation. The
generator stator windings shall be star connected.

5.3.1.6 The shaft shall be made of one-piece, heat-treated forged steel and shall be capable of
carrying the alternator rotating field system, the D.C. exciter rotor, the rotary three phase
full wave rectifier assembly, etc. The coupling flange shall be integral with the shaft unless
otherwise dictated by the prime-mover coupling requirement. Shafts and/or spiders
subjected to welding shall be post-weld heat treated.

5.3.1.7 The complete rotor assembly shall be securely braced and statically and dynamically
balanced on completion.

5.3.1.8 The direction of rotation shall be clearly and permanently indicated by means of an arrow
on the external surface of the frame at the non-drive end. Painted or adhesive tape method
of indication shall not be acceptable.

5.3.1.9 The terminal box shall be made of steel and may be of Phase Insulated Type. The terminal
box shall be designed so that the products of an electrical breakdown within the terminal
box are relieved through a pressure relief diaphragm to the outside of the terminal box.
Pressure relief shall be located to minimize the potential for injury to personnel. The
terminal box shall be designed to prevent small parts from dropping into the generator
housing. Sufficient space shall be provided for connecting the cables. Gland plates and
glands to be used for single-core cables shall be made of non-magnetic material. Terminal
blocks and bushings shall be made of synthetic resin.

5.3.1.10 The bushings and insulators shall be fully rated for the generator voltage and shall be
capable of withstanding both the dynamic and thermal effects of a short-circuit current for
at least 3 seconds. The distance between bushings and between bushings and earthed parts
of the terminal box shall be based on the applicable distances for an air-insulated
installation.

5.3.1.11 Auxiliary equipment fitted to generator (e.g. temperature detectors, water leakage
detectors, anti-condensation heater and vibration monitors if required) shall be wired to
auxiliary terminal boxes fitted to the side of the generator and shall comply with the above
requirements.

5.3.1.12 The common neutral connection point shall be taken from the star point and brought into
the main terminal box. The copper earth terminal bolt inside the main terminal box shall
have a removable copper link connection with the neutral terminal. Terminal marking of

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auxiliary cable connections shall be in accordance with the relevant generator wiring
diagrams.

5.3.1.13 If bearings are of the grease-lubricated rolling element type, grease nipples and appropriate
grease relief devices shall be fitted. Bearings shall have a minimum greasing interval of
8000 operating hours. The required greasing intervals shall be indicated on the rating plate.
Bearing insulation shall be provided on all bearings unless the generator manufacturer can
demonstrate that rotor stray currents are too low to damage the bearings.

5.3.1.14 Generator shall have at least six(2 per phase), 100 ohm at 20°C spring-loaded, tip-
sensitive, 3 wire element platinum resistance temperature detectors(RTD) in the windings.
RTDs shall be wired to a junction box separated from main terminal box and space heater
or other auxiliary equipment junction box.

5.3.2 EXCITER

5.3.2.1 The generator shall be provided with brushless type solid state excitation system with
Automatic Voltage Regulator. The manufacturer shall submit calculations to justify the
excitation equipment proposed taking into account, the exciter ceiling voltage, exciter
response, the reactances, motor starting requirements, the connected loads and the
excitation equipment parameters.

5.3.2.2 The exciter shall comprise at least the following:

— AC Exciter & Redundant Rotary Rectifiers.
— AVR with Auto/Manual channel with automatic changeover facility.
— Voltage adjuster (rheostat).
— AVR voltage failure relay (alarm).

5.3.2.3 The voltage regulator shall be of the electronic type provided with automatic and manual
control mode. The accuracy of the AVR from no-load to full load shall be such as to
maintain the generator voltage at ±1.0% under site conditions. The equipment shall be
complete with all switches, indicating instruments, fuse lamps and fault protective devices
to ensure that in the event of a component failure, including fuse failure, the control
equipment is tripped automatically from automatic to manual mode.

5.3.2.4 On sudden loss of full load the AVR shall be capable of restoring the voltage to within
±2% of the nominal value within 3 seconds. In manual mode, the AVR shall be capable of
controlling the generator terminal voltage from 70% no-load voltage to 110% of rated
voltage at full load and shall have sufficient fine control for synchronizing. Change over
between auto and manual mode shall be bumpless.

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5.4 BASEPLATE

5.4.1 The diesel engine generator combination shall be mounted on a common baseplate, made
of structural steel beams and with flat top plates, suitable for stationary installation.

5.4.2 The baseplate shall be designed to resist transport and lift conditions. A horizontal force
equal to the total transport weight may be assumed for transport forces in the design of the
package. Consideration shall be given to lifting shock forces.

5.4.3 The baseplate shall be designed to support the mass of the components and resist the
torque reaction imposed by any operating condition.

5.4.4 The baseplate shall be constructed such that it does not interfere with maintenance or
routine servicing of the engine and the generator. No fuel piping shall be concealed within
the baseplate.

5.4.5 The baseplate shall have a drip pan and rim with DN50, Class 150, ASME/ASME B16.5
flanged drain connections in strategic locations.

5.4.6 The manufacturer shall supply suitable anti-vibration mounts to limit the engine vibrations
transmitted to the foundations or surroundings. The baseplate shall be designed to
withstand any dynamic forces arising from action of the anti-vibration mounts. Inertia of
the complete baseplate with the mounted equipment shall be such that stresses in the
rotating components arising from motion of the complete assembly on the anti-vibration
mounts are minimized. The manufacturer shall furnish the principal with calculation of
resonant frequencies and the stresses arising on the rotating components.

5.4.7 Lifting lugs shall be attached to the baseplate. The positioning of the lugs shall take
account of the centre of gravity of the complete assembly and be such that lifting slings,
etc, do not interfere with any equipment mounted on the baseplate. Lifting lugs shall be
designed for a load equal to twice the complete assembly.

5.4.8 Grout holes shall be arranged so that the baseplate with driven equipment and all
auxiliaries mounted in place, can be grouted without removing any componets or piping.
Adequate vent holes shall be provided to insure a complete distribution of grout.

5.5 ROOM VENTILATION AND EQUIPMENT ARRANGEMENT

5.5.1 The manufacturer shall indicate the ventilation requirements in the Generator Room with
his Tender. It shall also be noted that adequate ventilation shall be afforded to the batteries
and the engine intake system requirements, whilst at the same time, restricting the ingress
of sand.

5.5.2 The diesel generator set shall preferably be ventilated by shaft mounted fans. The
ventilation of the generators shall be arranged to avoid recirculation of hot air.

5.5.3 A lift hoist device shall be installed in the room of the diesel generator by the purchaser.

5.5.4 The manufacturer shall provide certified equipment arrangement for the diesel generator,
accessories and hoist, etc.

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5.5.5 Cables and oil pipework shall not be run in the same ducts. Oil pipework shall be provided
by the vendor.

5.6 ELECTRIC MOTOR

5.6.1 Electrical Motor for Auxiliary Systems shall comply with NIOEC-SP-60-02.

5.6.2 Insulation Class of Electrical motor shall be Class F.

5.7 INSTRUMENTATION AND CONTROL

5.7.1 GENERAL

5.7.1.1 The diesel generator set shall be provided with the Local Gauge Panel for monitoring,
control and protection the equipment. The panel shall be of automatic type and all input
and output are directly connected to the necessary instruments.

5.7.1.2 The diesel generator set shall be suitable for fully Automatic Mode of operation, i.e., Fully
Automatic Start, Automatic Power Supply, Load Acceptance and Stop initiated by a Local
or Remote signal.

5.7.1.3 The panel shall be installed indoors. All control & protection equipment shall be installed
in a free standing, self-supporting sheet steel cabinet forming an enclosure. Cabinet shall
be floor mounted type and be provided with eye bolts for lifting. Cabinets shall be
arranged for front access only. The enclosure shall provide a degree of protection of not
less than IP42. The floor shall not be considered as forming part of the enclosure. The
doors shall be fitted with padlocks or other locking devices. The enclosure shall have
facilities for the entry of cables from the top and bottom. Gland plates shall be provided at
top and bottom.

5.7.1.4 Control supply shall be 24V DC.

5.7.1.5 Equipment and components installed within the Panels shall not be mounted directly on
the enclosure walls. The location and grouping of components and auxiliary equipment
shall permit easy identification and access (between AC and DC wiring) for operation and
maintenance. Suitable partitioning between AC power and control sections shall be
provided where necessary to allow adjustment and inspection to be carried out safely.

5.7.1.6 Multiple function elements such as tripping and alarm duties shall have separate operating
contacts for each function and shall be brought out to separate terminals.

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5.7.1.7 A good quality anti_lightning surge suppressor shall be installed into the panel in order to
protect the panel from being destroyed by lightning.

5.7.2 LOCAL GAUGE PANEL

5.7.2.1 The engine shall be supplied complete with engine mounted Local Gauge panel equipped
with a minimum of the following instruments:
— Tachometer indicator
— Engine lubricating oil pressure gauge
— Engine lubricating oil temperature gauge
— Jacket water temperature gauge
— Charge air temperature gauge
— Fuel day tank level gauge
— Battery voltmeter
— Diesel generator stop/start control switch
— Governor control switch
— AVR with manual/auto selector switch
— Raise/Lower Voltage Adjuster
— Voltmeter (with Voltmeter selector switch)
— Ammeters (1 in each phase)
— Wattmeter
— Power factor meter
— Frequency meter
— kWh meter
— Control panel supply voltmeter and ammeter
— Engine running time meter
— Engine RPM indicator
— Battery system status

5.7.2.2 An Alarm with Horn and Accept, Reset and Test Pushbuttons shall be provided in the
control panel. The following Alarms, Interlock protection, and Shutdown shall be provided
as a minimum.
— High/very high jacket water temperature alarm/trip
— Low/very low lubricating oil pressure alarm/trip
— Overspeed shutdown with simultaneous alarm
— High/low level alarm for the day tank
— High/Low water level
— Diesel generator fail to start
— Loss of DC control voltage alarm
— Overcurrent
— Overvoltage
— Underfrequency

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— Overcrank
— Overcrank lockout
— Diesel Generator Earth Fault
— Diesel Generator Failed to Start
— Engine lubricating oil heater automatically start control
— Engine cooling water heater automatically start control
— High generator stator temperature alarms
— High bearing temperature alarms
— Vibration alarms
— Battery charger failure alarms
— Smoke/Fire detection alarms

5.8 NAMEPLATE

5.8.1 The nameplate for diesel engine shall include as following:

— Purchase order number

— Year of manufacture
— Name of manufacture
— Type and Serial Number of the engine
— Primer power
— Revolution speed of the engine

5.8.2 The nameplate for generator shall include as following:

— Purchase order number

— Year of manufacture
— Name of manufacture
— Type and Serial Number of the engine
— Rating power
— IP rating and cooling
— Rating voltage, current and frequency
— Power factor
— Excitation type, voltage and current

5.8.3 The following information shall be inscribed on the Control panel.

— Purchase order number

— Year of manufacture
— Name of manufacture
— Type and Serial Number of the engine

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6. INSPECTION AND TEST

6.1 GENERAL

6.1.1 Each engine shall be tested at manufacturer’s workshop to certify the engine output and
fuel consumption in accordance with the site operating condition specified by purchaser on
the specification datasheet.

6.1.2 All relevant information, drawings pertinent to the testing and test procedure shall be
transmitted to the purchaser in advance of the test date notification.

6.1.3 The purchaser shall call for additional testing if test results are unsatisfactory or marginal.
Any equipment rejected shall be repaired or replaced to the purchaser’s satisfaction and the
tests shall be repeated.

6.1.4 Any unsatisfactory material, equipment, installation, or workmanship shall be replaced or

repaired to the purchaser’s satisfaction at the manufacturer’s cost.

6.1.5 The Engine and Generator shall be tested individually in accordance with relevent
standards specified above.

6.1.6 The completed and individually tested engine and generator shall be assembled onto the
baseplate with all auxiliaries, instruments and controls for a complete test of the generator
set.

6.2 STATIC LOAD TEST

6.2.1 During the test the diesel generator set shall run for at least 6 hours. The test procedure
consists of:

— 30 minutes at 50% rating load

— 30 minutes at 75% rating load
— 4 hours at 100% rating load
— 1 hours at 110% rating load

6.2.2 During the test, all engine and generator parameters shall be recorded. These shall include
but no limited to:

— Generator power output

— Generator voltage
— Generator phase currents
— Generator power factor
— Generator frequency
— Engine oil pressure
— Engine cooling water temperatures
— Fuel consumption
— Noise level

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— Engine speed and variations

— Vibration levels

6.3 DYNAMIC LOAD TEST

The voltage and frequency regulation of the generator set shall be verified against the
specified values. Voltage and frequency variations shall be recorded on oscillograms.
Vendor shall submit its test procedure for approval.

6.4 FUNCTIONAL TEST

6.4.1 The package shall be carried performance test on the complete generator set including the
generator and engine control panel.

6.4.2 The performance test shall be subjected to approval by the purchaser and shall include but
not limited to the following test:

— Engine start-up system, including measurement of the starting time. A

minimum of 2 start and stop tests shall be performed.
— Full Automatic mode, include automatic start-up, automatic power supply, etc.
— For emergency generator sets verification of the time between initiation of a
start command and the full nominal load.
— All alarm and shutdown functions.
— Operation of the battery charger.
— The status/alarm/trip/shutdown indication of the control panel
— Local manual start/stop/emergency stop function
— Remote start/stop/emergency stop function (input signal)
— Operation of AVR
— Operation of the automatic power factor controller
— Calibration of measuring and protective devices

6.5 INSULATION RESISTANCE TEST

These tests shall be performed on the generator, exciter, space heaters, temperature
detectors, control panel and cabling.

6.6 LOAD THROW OFF TEST

Load throw off test shall be performed by manually opening the generator circuit
breaker with the diesel generator set on 50%, 75%, 100% and 110% of the rated output.
The following parameters shall be measured and noted.
— Wattmeter reading

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— Ammeter reading
— Voltage
— Frequency
— Power factor
— Speed
— Excitation voltage
— Excitation current

6.7 ON SITE ACCEPTANCE TEST

Acceptance testing shall include static load test, functional tests and visual inspection as
specified above.

7. PREPARATION FOR SHIPMENT

7.1 The diesel generator set shall be prepared for shipment after all testing and inspections have
been completed.

7.2 Equipment shall be suitably prepared for the type of shipment specified, including restraint
of the rotor when necessary. Restrained rotors shall be identified by means of corrosion
resistant tags attached with stainless steel wire. The preparation shall make the equipment
suitable for 6 months of outdoor storage from the time of shipment, with no disassembly
required before operation, except for inspection of bearings and seals. If storage for a longer
period is contemplated, the purchaser will consult the vendor regarding the recommended
procedures to be followed.

7.3 Manufacturer shall provide the following minimum preparation for shipment and packing
features on all equipment:

7.3.1 Manufacturer’s standard cleaning and painting procedures suitable for the work
temperature and the site conditions specified on the individual data sheets are acceptable.

7.3.2 All equipment shall be packed, securely anchored (skid mounted when required) and
protected for shipment method called for in the purchase order.

7.3.3 Each item shall be identified with its item number. Tags shall be corrosion resistant metal
and impression stamped, “Item No. __” tags shall be attached to each component with
wire. This tag is in addition to the equipment nameplate.

7.3.4 Miscellaneous parts shall be tagged or marked with the tag item number for which they are
intended. All such parts shall be suitably boxed, firmly attached to the main item and
shipped with the unit.

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7.3.5 Duplicate packing lists shall be shipped with crated equipment, one inside and one on the
outside of the shipping container.

7.3.6 All flanged openings shall be protected with metal closure to prevent damage during
shipment. Covers shall be a minimum of 5 mm thick and shall be installed with a full size
gasket using a minimum of 4 full diameter bolts.

7.3.7 Threaded openings shall be provided with steel caps and round head steel plugs in
accordance with ASME B16.11. The caps or plugs shall be of material equal to or better
than of the pressure casing. Nonmetallic caps are not allowed.

7.3.8 All instruments and valves including auxiliary systems must be securely mounted and /or
supported to eliminate damage during shipment, storage, operation and maintenance.

7.3.9 Exposed finished and machined surfaces, including bolting, shall be given a coating of rust
inhibiting compound. Internal metal surfaces shall be sprayed or coated with a suitable oil
soluble rust preventative prior to shipment.

7.3.10 Bearings, bearing housings, and oil systems shall be thoroughly cleaned internally of metal
particles, dirt and debris, and coated internally with a suitable oil soluble rust preventative
prior to shipment.

7.3.11 Equipment containing insulating oil, anti-freeze solutions or other fluids shall be suitably
tagged at openings to indicate the nature of the contents, and shipping and storage
precautions.

7.3.12 One complete set of the installation, operation and maintenance instructions in addition to
the number called for in the purchase order shall be packed in the boxes or crates with the
equipment.

8. VENDOR’S DATA

8.1 PROPOSAL INFORMATION

8.1.1 An individual price and delivery schedule must be quoted for each equipment item
number.

8.1.2 The length of time required for certification of all information, drawings, etc.

8.1.3 Preliminary outline dimension drawing.

8.1.4 Typical cross sectional drawing.

8.1.5 Details of proposed engine auxiliaries, including fuel system, lubricating oil system,
cooling system, starting system, air intake and exhaust systems, and control panel, etc.

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8.1.6 Diesel engine and generator size calculation.

8.1.7 Diesel engine performance curve showing torque, fuel and lube oil comsuption, engine
speed, and power output, etc.

8.1.8 Completed purchaser’s data sheet.

8.1.9 Sizing calculation for engine starting batteries.

8.1.10 Schemetic of the auxiliaries, including fuel circuit, lube oil system, starting system,
cooling system, etc.

8.1.11 Logic procedure diagram of the automatic start of the diesel generator set.

8.1.12 Two years and commissioning priced list of recommended spare parts.

8.1.13 Special hand tools necessary for assembling, disassembling and maintenance of the diesel
generator set.

8.1.14 The delivery data specifying fixed number of calendar days from the receipt of the written
order.

8.2 DOCUMENTS AND DRAWINGS

8.2.1 Approval of drawings shall not relieve manufacturer of any responsibility in meeting the
requirements of specifications nor shall such approval be considered as permitting
deviations from specifications or purchase order requirements, unless specifically agreed
with in writing.

8.2.2 All drawings and data submitted must be identified with the purchaser’s order number and
equipment tag number.

8.2.3 Prior to final drawing submittal, the manufacturer shall add to his drawings notes and data
requested by the purchaser. This is required since these drawings are used by the purchaser
in the field for erection and installation. Also, these drawings are incorporated into the
purchaser’s bound documents for the ultimate users record.

8.2.4 Outline drawings

8.2.4.1 Certified correct dimensional drawings of completely, assembled units, which shall show:
a. Identification data for diesel generator set.
b. Rotation.
c. Weight.
d. Adequate dimensional data to permit the design of foundation, piping and
wiring connection.
e. Location of the control panel.
f. Piping connection identified, with the size, rating, and facing indicated.
g. Clearance required for disassembly and maintenance.

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8.2.4.2 Auxiliary connections listed on the composite outline drawing identified as follows:
a. Not furnished this order.
b. Not drilled this order.
c. Plugged, requires field piping by purchaser.
d. Plugged, not required this order.
e. Piped by manufacturer.

8.2.4.3 Unit outline drawings

Certified correct dimensional drawings of specified components of the diesel generator
set.

8.2.4.4 Cross sectional drawings

A cross sectional drawing (without dimensions) which identifies parts and a listing of
the parts, which agrees with the equipment furnished.

8.2.4.5 Bill of material

a. Bills of material for diesel generator set must include

— Part number
— Names of parts
— Number of parts required
— Metallurgy of part (identified by ASTM number or similar)
— Drawing number which identifies each part as to interchangeability

b. Bills of material must be submitted with each auxiliary system describing in detail
each item of accessory equipment including:

— Manufacturer
— Description of equipment
— Catalog No. Or Part No.
— Materials of construction.
— Electrical, steam and cooling water consumption
— Set point and ranges for instruments and control valves
— Rated pressure, temperature and capacities of auxiliary pumps
— Horsepower and relief valve settings for auxiliary pumps

8.2.4.6 Drawing of furnished piping

A general arrangement and layout of auxiliary piping, to show its approximate location
and routing relation to the major components. A material list must be shown on the
drawing.

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8.2.4.7 Schematic drawings
Schematic drawings of auxiliaries shall include fuel circuit, lube oil system, starting
system, cooling system, etc, and identify all components by make, type, size, capacity,
pressure rating, materials and the like, as applicable.

8.2.4.8 Foundation loading data/details.

8.2.4.9 Schematic drawings for automatically starting of the diesel generator set.

8.2.4.10 Installation, Operation and Maintenance Instructions in English

The instructions shall describe installation, operation and maintenance procedures for
all equipment, auxiliaries and instruments furnished by the manufacturer and any sub-
suppliers.

8.2.4.11 Main and control circuit schematic drawings/diagrams.

8.2.4.12 Interconnection diagrams.

8.2.4.13 Alarm and trip setting list.

8.2.5 Recommended fuel list which include method of application of the fuel, technical
specification of fuel, and any special lubrication precautions, etc.

8.2.6 Recommended lubrication list which include method of application of the lubricant,
technical specification of the lubricant, quantities of the lubricant for initial fill and
any special lubrication precautions, etc.

8.2.7 Parts lists

Parts lists shall include all equipment furnished by the manufacturer and sub-supplier
and shall show pattern, stock or production drawing numbers, materials of
construction and quantities of items required per set.
This list shall completely identify each part so that parts interchangeability with other
equipment furnished by the same manufacturer may be determined. Standard
purchased items shall be identified by the original manufacturer’s numbers.

8.2.8 Recommended spare parts list with prices

This is a supplemental list which includes price and delivery in addition to the
standard data required on the complete parts list.
The list of recommended spares should be sufficient for commissioning and 2 years
operation. This list shall be submitted with quotation.

8.2.9 Test reports

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8.2.10 Completed datasheet.

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