You are on page 1of 43

Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

DGS-MA-004-Rev-2

EMERGENCY GENERATOR

Amendment History

02 Mar-09 AMD-MA-004-002-BECHTEL Clauses 2,4,7,10,11&15 PL/PTD QAM Mar-09

01 Nov-07 AMD-MA-004-001-ETSD Clause 2. PL/PTD QAM Nov-07

No Date Amendment Description Proposed Approved Incorporated

DGS History

2 Mar-09 DGS-MA-004-Rev-2 AMD-MA-004-002-BECHTEL PL/PTD QAM/MAY

1 Nov-07 DGS-MA-004-Rev-1 AMD-MA-004-001-ETSD PL/PTD QAM / MAY

0 Nov-06 DGS-MA-004-Rev-0 Previous Projects PL/DDC ETSDM / EPDM

No Date Description Source Reviewed Approved

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 1 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

Table of Contents

1.0 GENERAL .............................................................................................................................. 3


2.0 CODES AND STANDARDS.................................................................................................... 3
3.0 REFERENCE DOCUMENTS ................................................................................................. 3
4.0 DOCUMENT PRECEDENCE ................................................................................................. 3
5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL..................................................... 3
6.0 QUALITY ASSURANCE/QUALITY CONTROL ...................................................................... 3
7.0 DOCUMENTATION ................................................................................................................ 3
8.0 SUBCONTRACTORS/SUBVENDORS .................................................................................. 3
9.0 HANDLING............................................................................................................................. 3
10.0 GENERAL REQUIREMENTS................................................................................................. 3
11.0 ENGINE REQUIREMENTS.................................................................................................... 3
12.0 MATERIALS ........................................................................................................................... 3
13.0 ENCLOSURE REQUIREMENTS ........................................................................................... 3
14.0 SPECIAL REQUIREMENTS FOR DIFFERENT MODES OF OPERATION............................ 3
15.0 INSPECTION AND TESTING................................................................................................. 3
16.0 PAINTING AND PROTECTIVE COATING.............................................................................. 3
17.0 SPARE PARTS ....................................................................................................................... 3
18.0 SPECIAL TOOLS ................................................................................................................... 3
19.0 PERFORMANCE GUARANTEE ............................................................................................ 3
APPENDIX 1 – DATA SHEET ............................................................................................................... 3
ADDENDUM SHEET ............................................................................................................................ 3

List of Authorized Signatures/ Initials

DGS Discipline Committee Member, ADRD None

DGS Discipline Committee Member, RRD P. T. Daniel (PTD)

DGS Discipline Committee Member Leader, E&PD P. Lobo (PL)

Engineering & Technical Services Manager, E&PD Quazi Abdul Matin (QAM)

Engineering & Projects Division Manager, E&PD Mohamed Al Yabhouni (MAY)

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 2 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

1.0 GENERAL
1.1 INTRODUCTION
This Specification together with the applicable data sheets describes the minimum re-
quirements for Emergency Generators for Abu Dhabi Oil Refining Company (TAKREER)
1.2 PURPOSE
The purpose of this specification is to describe the minimum requirements for the design,
manufacture, testing and supply of Emergency generators.
1.3 DEFINITIONS
For the purposes of this specification, the following definitions shall apply:
CONCESSION REQUEST - A deviation requested by the SUBCONTRACTOR or VEN-
DOR, usually after receiving the contract package or purchase order. Often, it refers to an
authorization to use, repair, recondition, reclaim, or release materials, components or
equipment already in progress or completely manufactured, but which does not meet or
comply with the COMPANY requirements. A CONCESSION REQUEST is subject to
COMPANY approval.
SHALL - Indicates a mandatory requirement.
SHOULD – Denotes an action or requirement which is not mandatory but which is strongly
recommended.
1.4 SCOPE OF EQUIPMENT SUPPLY
The Generators and other auxiliary equipment shall be complete in all respects as defined
in this specification, data sheets and material requisition and shall include as a minimum
the following:
a) Engine complete with all necessary auxiliaries
b) Synchronous AC generator complete with excitation equipment
c) Combined base plate
d) Engine and generator control panel(s)
e) All necessary noise and vibration suppression equipment
f) Engine starting system
g) Engine and generator cooling systems
h) Lubrication system
i) Combustion air intake system
j) Exhaust system
k) Engine fuel system
l) Fuel day tank suitable for 24 hours fuel consumption
m) Couplings and guards
n) All necessary interconnecting pipe work and valves, including drain connections ter-
minating at the edge of the base plate
Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 3 of 43
Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

o) Local gauge panel and instrumentation


p) All CT’s and VT’s (including those for installation in the switchboard)
q) Power supply distribution board for all the auxiliaries on the package
With the exception of the remote control and generator protection panel, the generating
set shall be furnished as a skid mounted unit, consisting of generator, diesel engine driver
and auxiliary systems, assembled on a fabricated steel skid, enclosed in containerized en-
closure.
The MANUFACTURER shall offer standard equipment to perform the duty stated in this
specification, data sheets and associated documents.
Any variations of the MANUFACTURER’S standard package from this specification must
be stated by the MANUFACTURER; otherwise it will be assumed that all equipment of-
fered is in accordance with this specification and associated documents.
Protection and packing of all material supplied shall be suitable for both shipment and pro-
tection on jobsite during long storage prior to erection.
Equipment manufacturing record books, equipment record (data) books and operating and
maintenance manuals are required.
1.5 SERVICE CONDITIONS
The generator package and all individual items forming part of the generator shall be suit-
able for operation in service conditions typical of petrochemical/refinery facility within a de-
sert environment.
The atmosphere is to be considered a salty, sulfurous and dusty with high concentrations
of windborne sand as commonly encountered in petrochemical/refinery installations in the
Middle East. The possibility of condensation, as experienced during large temperature
fluctuations in humid atmosphere, shall be taken into account.
Unless otherwise specified in the requisition, the following site conditions shall apply:
Design Temperature (outdoor) +54oC
Design Temperature (indoor - inside air conditioned building) +40°C
Maximum Ambient Air Temperature - Solar +87oC
Maximum Ambient Temperature – Shade +58oC
Minimum Ambient Air Temperature +5oC
Altitude Not Exceeding +1000m AMSL
o
Maximum Relative Humidity at 43 C 95%
The dedicated remote control, protection and monitoring panel, and the battery charger
shall be installed in a normally air-conditioned electrical substation. Nevertheless the
equipment shall be capable of operation in the absence of the HVAC system in the case of
a power failure.
2.0 CODES AND STANDARDS
It shall be the VENDOR'S responsibility to be, or to become, knowledgeable of the re-
quirements of the referenced Codes and Standards.
Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 4 of 43
Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

The following codes and standards, to the extent specified herein, form a part of this speci-
fication. These shall include any &all the applicable parts of the Standards including any
corrigendums on these published from time to time. The edition in force at the time of
VENDOR’S proposal shall apply.

AMERICAN NATIONAL STANDARDS INSTITUTE(ANSI)


ANSI/AWS D1.1 Structural Welding Code
ANSI/ASME B16.5 Pipe Flanges and Flanged Fittings
AMERICAN SOCIETY OF MECHANICAL ENGINEERS(ASME)
ASME Boiler Pressure Vessel Code, Section VIII, “Rules for Construction
of Pressure Vessels,” and Section IX, “Welding and Brazing Qualifi-
cation”
AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)
ASTM A106/A 106M Standard Specification for Seamless Carbon Steel Pipe for High-
Temperature Service
BRITISH STANDARDS INSTITUTION( B.S.I ):
BS 4999 Part 140. Specification on Voltage Regulation and Parallel Opera-
tion of AC Synchronous Generators
BS PD 5304 Guidance On safe use of Machinery.
BS EN 10204 Metallic Products , Type of Inspection Documents
GERMAN STANDARDS
VDE 0875 Specification for Radio Interference Suppression of Electrical Appli-
ances and Systems
INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)
IEC 60034 Rotating electrical machines
IEC 60044 Instrument transformers
IEC 60051 Direct acting indicating analogue electrical measuring instruments and
their accessories
IEC 60060 High voltage test techniques
IEC 60072 Dimensions and output series for rotating electrical machines

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 5 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

IEC 60079 Electrical apparatus for explosive gas atmospheres


IEC 60085 Electrical insulation – Thermal evaluation & Designation
IEC 60255 Electrical relays
IEC 60317 Specification for particular types of winding wires
IEC 60445 Basic and safety principles for man-machine interface, marking and identi-
fication – Identification of equipment terminals and of terminations of cer-
tain designated conductors, including general rules for an alphanumeric
system
IEC 60529 Degrees of protection provided by enclosures
IEC60617snap Graphical symbols for diagrams
shot
IEC 61000 Electromagnetic compatibility (EMC)
INTERNATIONAL ORGANIZATION FOR STANDARDS (ISO)
ISO 3046 Reciprocating Internal Combustion Engines
ISO 8528 Reciprocating Internal Combustion Engine-driven Alternating Current
Generating Sets
ISO 9001:2000 Quality Management System Requirements
ISO 9004:2000 Quality Management Guidelines for Performance Improvement Sys-
tem
ISO 19011 Guidelines for Quality and/or Environmental System Auditing.
3.0 REFERENCE DOCUMENTS
The following reference documents, to the extent specified herein, form a part of this
specification.
Project Specifications:
DGS-MM-001 Electric Motors Cage Induction and Synchronous
DGS-MU-002 Preservation and Export Packing
DGS-MU-003 Spare Parts
DGS-MU-009 Equipment Noise Control
DGS-MV-003 Diesel Fueled Compression Ignition Engines
DGS-MX-001 Painting

4.0 DOCUMENT PRECEDENCE


It shall be the CONTRACTOR/VENDOR’S responsibility to be, or to become knowledge-
able of the requirements of the referenced Codes and Standards.

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 6 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

The VENDOR shall notify the COMPANY/CONTRACTOR of any apparent conflict be-
tween this specification, the related data sheets, the Codes and Standards and any other
specifications noted herein. Resolution and/or interpretation of precedence shall be ob-
tained from the COMPANY/CONTRACTOR in writing before proceeding with the de-
sign/manufacture.
In case of conflict, the order of precedence shall be:
a) Equipment Data Sheets / Single line diagram / Requisition
b) This Specification
c) Other Specifications and Standards related to the Project
d) Industry Codes and Standards
5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL
Deviations from this specification are only acceptable where the MANUFACTURER has
listed in his quotation the requirements he cannot, nor does not wish to comply with, and
the COMPANY/CONTRACTOR has accepted in writing the deviations before the order is
placed.
In the absence of a list of deviations, it will be assumed that the MANUFACTURER com-
plies fully with this specification.
Any technical deviations to the Purchase Order and its attachments including, but not lim-
ited to, the Data Sheets and Narrative Specifications shall be sought by the VENDOR only
through CONCESSION REQUEST format. CONCESSION REQUESTS require CON-
TRACTOR'S and COMPANY'S review/approval, prior to the proposed technical changes
being implemented. Technical changes implemented prior to COMPANY approval are sub-
ject to rejection.
6.0 QUALITY ASSURANCE/QUALITY CONTROL
The VENDOR shall have in effect at all times, a QA/QC program which meets the re-
quirements of ISO 9001 & 9004, and clearly establishes the authority and responsibility of
those responsible for the quality system. Persons performing quality functions shall have
sufficient and well defined authority to enforce quality requirements that initiate, identify,
recommend and provide solutions to quality problems and verify the effectiveness of the
corrective action.
A copy of the VENDOR'S QA/QC program shall be submitted to the CONTRACTOR with
its quotation for CONTRACTOR'S review and concurrence prior to award. If VENDOR'S
QA/QC program and facility, where the work is to be performed, is ISO 9001:2000 certi-
fied, then only a copy of the VENDOR'S ISO 9001:2000 certificate is required. In addition,
if VENDOR'S facility is ISO certified, CONTRACTOR'S QA audit requirements will be
waived in favor of ISO 9001:2000 registrar audits, unless the CONTRACTOR'S trend
analysis program indicates areas of concern.
The VENDORS shall identify in purchase documents to its SUBVENDORS all applicable
QA/QC requirements imposed by the CONTRACTOR, and shall ensure compliance
thereto. On request, VENDOR shall provide objective evidence of its QA/QC surveillance
of its SUBVENDOR'S activities.
The VENDOR shall submit certified reports of production tests as soon as the tests are
completed satisfactorily.
Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 7 of 43
Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

The COMPANY/CONTRACTOR reserves the right to inspect materials and workmanship


at all stages of manufacture and to witness any or all tests. The VENDOR, 30 days after
award but prior to the pre inspection meeting, shall provide the CONTRACTOR with a
copy of its Manufacturing and Inspection Plan for review and inclusion of any mandatory
COMPANY/CONTRACTOR witness points.
7.0 DOCUMENTATION
VENDOR shall submit the type and quantity of drawings and documentation for CON-
TRACTOR’S authorization or information as listed in the individual Material Requisitions
and Purchase Orders.
Mutual agreement on scheduled submittal of drawings and engineering data shall be an
integral part of any formal Purchase Order.
Drawings and data shall be provided as detailed below and shall be in metric units and
English.
a) Completed data sheets
b) Piping layout
c) Instrument diagram
d) General arrangement drawing of all equipment also showing dry and operating
masses, arrangement of components, cable entry details, minimum space required
for erection and maintenance
e) Schedule and drawing of electrical, instrument and mechanical termination points
f) Foundation design data
g) Base plate construction data
h) Dynamic performance calculations
i) Torsional and lateral vibration data
j) Structural dynamic calculations for generator set vibration, taking account of anti-
vibration mounts
k) Schematic and connection diagrams of main, control, status indication, alarm, meter-
ing, protection, trip, shutdown and auxiliary circuits
l) Alarm and trip setting schedules
m) Material specifications
n) Equipment lists/parts lists
o) Recommended spare parts lists
p) Preservation for shipment procedures
q) Operating manuals incorporating unpacking, depreservation, installation, commis-
sioning, operating and maintenance instructions and fault finding procedures
r) MANUFACTURER’S proposed service and repair support after warranty
s) Test and inspection procedures
t) Testing program
Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 8 of 43
Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

u) Certificates of conformity and declarations of compliance for equipment used in haz-


ardous areas
v) Reports of all tests performed
w) Protection relay settings & calculations.
x) Parameterization of microprocessor relays.
y) Generator performance & capability curves.
z) Battery sizing calculations.
aa) Cable block diagram between skid & Panel for the Complete Emergency generator.
bb) Heat dissipation data for indoor equipment.
cc) Utilities summary.
Descriptive literature for all items together with a full system description shall be provided
as part of the bid documentation.
After order placement, the VENDOR shall submit for approval, all listed drawings: docu-
ments, strictly in accordance with the agreed schedule and program. In addition, the
presentation of drawings shall be such that all components parts of items within the sys-
tem can be located and identified for maintenance purposes.
a) Sectional drawings, part lists
b) Lifting and handling devices, drawings and calculations
c) Auxiliary materials drawings and descriptions/characteristics
d) List of instruments, panels, auxiliary devices with main characteristics
e) Other documents as applicable
In addition to the instructions in standard forms, the MANUFACTURER shall comply with
the following additional requirements for installations, operation and maintenance manu-
als.
a) The front cover, spine and inside page shall state the purchase order number and
MANUFACTURER’S reference number
b) The inside front page shall carry an index listing the contents of each section of the
manual
c) Individual sections shall be complete and shall refer to equipment actually supplied
d) Published data shall also be included, including published data for bought-in items
e) Full details of any special equipment shall be clearly set out in separate sections
f) A punch list of “do’s” and “don’ts” shall be included
g) Full details for installation and setting up shall be included
h) Recommended test data shall be stated, covering initial and also regular testing; i.e.,
values for high voltage, AC. or DC., etc. shall be given
i) Items requiring regular inspection, checking, testing and maintenance shall be listed
and the time scale clearly indicated

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 9 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

j) Important items shall be cross referenced to other parts of the manual as necessary
Quality control, inspection and testing documents
a) Type test certificates and test reports
b) Visual examinations
c) Other documents as applicable
Operating and maintenance manuals shall be submitted by VENDOR to the CONTRAC-
TOR for approval. They shall comprise, as a minimum:
a) Details to permit the installation, commissioning and operation of the equipment
without VENDOR assistance
b) Details of setting/operating range of all instruments
c) Complete parts list and final “as built” drawings
Comments made by CONTRACTOR on drawing submittal shall not relieve VENDOR or
SUBVENDOR’S of any responsibility in meeting the requirements of the specifications.
Such comments shall not be construed as permission to deviate from requirements of the
Purchase Order unless specific and mutual agreement is reached and confirmed in writ-
ing.
Each drawing shall be provided with a title block in the bottom right-hand corner incorpo-
rating the following information:
a) Official trade name of the VENDOR.
b) VENDOR'S drawing number.
c) Drawing title giving the description of contents whereby the drawing can be identi-
fied.
d) A symbol or letter indicating the latest issue or revision.
e) PO number and item tag numbers.
Revisions to drawing shall be identified with symbols adjacent to the alterations, a brief
description in tabular form of each revision shall be given, and if applicable, the authority
and date of the revision shall be listed. The term "Latest Revision" shall not be used.
8.0 SUBCONTRACTORS/SUBVENDORS
The VENDOR shall assume unit responsibility and overall guarantee for the equipment
package and associated equipment.
The VENDOR shall transmit all relevant purchase order documents including specifica-
tions to his SUBVENDORS and SUBCONTRACTORS.
It is the VENDOR'S responsibility to enforce all Purchase Order and Specification re-
quirements on his SUBVENDORS and SUBCONTRACTORS.
The VENDOR shall submit all relevant SUBVENDOR and SUBCONTRACTOR drawings
and engineering data to the CONTRACTOR.
The VENDOR shall obtain and transmit all SUBVENDOR and SUBCONTRACTOR war-
ranties to the CONTRACTOR/COMPANY, in addition to the system warranty.

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 10 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

9.0 HANDLING
9.1 PACKAGING AND SHIPPING
Preparation for shipment shall be in accordance with the VENDOR'S standards and as
noted herein. VENDOR shall be solely responsible for the adequacy of the preparation for
shipment provisions with respect to materials and application, and to provide equipment at
the destination in ex-works condition when handled by commercial carriers.
Adequate protection shall be provided to prevent mechanical damage and atmospheric
corrosion in transit and at the job site.
Preparation for shipment and packing will be subject to inspection and rejection by COM-
PANY'S / CONTRACTOR'S inspectors. All costs occasioned by such rejection shall be to
the account of the VENDOR.
After inspection and test, equipment shall be completely free of water and dry before start
of preparation for shipment.
Equipment shall be packed, securely anchored, and skid mounted when required. Bracing,
supports, and rigging connections shall be provided to prevent damage during transit, lift-
ing, or unloading. All temporary bracing/supports shall be marked "REMOVE BEFORE
EQUIPMENT COMMISSIONING AND STARTUP."
Open ends of tubes and pipe shall be capped for protection. Female threaded connections
shall be plugged with solid metal pipe plugs, and male threaded connections shall be pro-
tected with full metal pipe caps.
Separate, loose, and spare parts shall be completely boxed. Pieces of equipment and
spare parts shall be identified by item number and service and marked with CONTRAC-
TOR’S order number, tag number, and weight, both inside and outside of each individual
package or container. A bill of material shall be enclosed in each package or container of
parts.
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
rust preventative prior to shipment. Openings shall be suitably tagged to indicate the rust
preventative applied.
Mechanical seal assemblies shall be fully protected from rusting and entry of moisture and
dirt.
One complete set of the installation, operation, and maintenance instructions shall be
packed in the boxes or crates with equipment. This is in addition to the number called for
in the Purchase Order.
9.2 PRESERVATION AND STORAGE
Equipment and materials shall be protected to withstand ocean transit and extended pe-
riod of storage at the job site for a minimum period of 18 months. Equipment shall be pro-
tected to safeguard against all adverse environments, such as: humidity, moisture, rain,
dust, dirt, sand, mud, salt air, salt spray, and seawater.
All equipment and material shall be preserved and export packed in accordance with
DGS-MU-002, Preservation and Export Packing.

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 11 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

10.0 GENERAL REQUIREMENTS


The equipment shall be capable of carrying the specified current on a continuous basis of
24 hours per day, without exceeding the permitted temperature. The current rating of the
equipment must be guaranteed at the specified design temperature. Equipment shall be
fully rated and constructed to withstand the specified short circuit duty.
The generator and all individual items, which are a part of the generator package, shall be
designed in accordance with sound engineering practices to provide a minimum service
life of 30 years.
The emergency generator set shall be suitable for continuous full load service, duty type
S1 according to IEC 60034-1, at the rated power and specified ambient conditions.
The rating of the machine offered by the manufacturer shall be based on Class F insula-
tion and to class B temperature rise for all parts of the generator, e.g., stator, rotor and ex-
citer windings, at 54°C ambient temperature.
The emergency generator shall be skid mounted and housed within an enclosure suitable
for outdoor installation, in an unclassified area.
The generating set shall maintain an electrical output in accordance with the parameters
specified on the Data Sheet attached with material requisition.
The rating of the generator shall be selected by the diesel engine manufacturer, in line
with the specified requirements, such that the generator does not limit the output of the
diesel engine over specified operation temperature range.
The generator neutral shall be solidly earthed, unless otherwise specified.
The generator shall be capable of the following operation:
a) In emergency operation, isolated from the normal network,
b) In test condition, in parallel with the network for approximately four hours
When operating in parallel with the electrical network the generator set shall supply power
to the load and network.
The generator shall be designed to have an acceptable wave form and distortion and shall
not exceed more or less 3% at rated frequency under no load condition.
The diesel generator set shall be in a container/enclosure having motorized louvers for air
inlet/outlet suitable for outdoor service conditions - Section 1.5 herein. Forced enclosure
ventilation shall be provided to avoid problems from solar radiation during shutdown condi-
tions. The enclosure shall be supplied with doors or removable panels and internal light-
ing. Suitable Sun shade shall be provided for the Containerized Enclosure.
The enclosure shall be equipped with automatic fire protection system using CO2 as the
extinguishing medium, in addition, local alarm horns and red optical beacons shall be pro-
vided on top of the enclosure. The local fire protection panel shall have isolated dry con-
tacts available for interface to the refinery terminal central fire system. Isolated contacts
shall be provided for fire protection system fault, fire warning, fire detection, and extin-
guishing system activation.
An appropriate temperature monitoring system shall be provided to give a remote alarm if
the temperature of the equipment/components exceed the design limits. The external sur-

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 12 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

faces of generators and other rotating machinery within the enclosure shall have an opera-
tion temperature not more than 80% of the ignition temperature of diesel vapor-air mixture.
The VENDOR’S packaged units shall have provision for glanding and termination of ca-
bles specified.
Cable termination materials, e.g., cable lugs, and other terminating components, are in-
cluded in the VENDOR’S scope.
A remote control, protection and monitoring panel shall be supplied. This panel shall be
equipped with all necessary devices and components to ensure proper operation of the
emergency power generation package and perfect integration with the overall network de-
sign.
Unless otherwise agreed in writing, all electrical equipment required for operation of pack-
aged units shall be supplied, assembled, installed and wired by the supplier. Only external
wiring between the VENDOR’S packaged units standing apart shall be carried out by
CONTRACTOR.
a) Nameplates attached to equipment shall be in English
b) Warning notices shall be in Arabic and in English
10.1 MAIN ELECTRICAL SUPPLY SYSTEM
Voltage : 415V ± 5%, 3 phase,4 wire, neutral solidly earthed.
Frequency: 50 Hz ± 2%.
10.2 DEGREE OF PROTECTION
The degree of protection of equipment shall be:
Generator , Exciter& all electrical enclosures for outdoor location. IP 55
Remote Control Protection and Monitoring Panel IP 41
10.3 PERFORMANCE
The following performance requirements shall be complied with:
10.3.1 Rating
Rating of the Generator shall be as indicated in Single Line Diagram / Data Sheets. The
rating of the generator set shall be the total net output rating at the generator terminals.
The component (e.g. engine, generator, coolers, etc.) with the lowest individual rating shall
provide the limit for defining the net output of the generator set. The rating of any signifi-
cant electrical auxiliaries, such as electric cooling fans, shall be deducted from the output
rating. The generator set shall have a continuous power rating as stated on the requisi-
tion, at a power factor of 0.8 lagging.
The generating set shall maintain an electrical output in accordance with the parameters
specified on the data sheets attached with material requisition. In addition, the generator
shall also be capable of providing the specified rating plus ten percent overload continu-
ously for one hour in a twelve hour period.

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 13 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

10.3.2 Momentary Excess Current


Generators shall be capable, starting from normal operating temperature, of carrying with-
out damage a stator current of 150% of the rated current for a period of at least 15 sec-
onds with voltage not falling below 80% of rated value.
10.3.3 Sustained Overload
Generators shall be capable of carrying a stator current of 110% of the rated current for a
period of at least one hour in a 12 hour period at rated voltage, frequency and power fac-
tor. During this period the temperature of the windings shall not exceed the maximum al-
lowable temperature for Class F.
10.3.4 Voltage Regulation
The automatic voltage regulator shall be of the static type, high speed compounded for
parallel operation. It shall exhibit long term stability and freedom from drift and shall be
provided with a fine voltage adjuster. It shall include frequency sensing circuitry to limit the
ceiling voltage and to prevent damage to components when the generator is driven at re-
duced speeds, such as when starting or when the engine is at idling speed.
The AVR shall be matched to the generator characteristics and shall be of adequate con-
struction and design to fully meet all operational and performance requirements.
The AVR shall be equipped with frequency dependent constant voltage (U=constant down
to 90% rated frequency) and adjustable slope (U/F) facilities.
The AVR shall be installed in the generator control panel unless specified otherwise.
The regulator shall be arranged for both automatic and manual control and shall include
frequency-sensing circuitry to furnish excitation and sustain voltage under short circuit
conditions.
The generator regulator and excitation system shall be capable of sustaining at least 300
percent of rated generator current for 10 seconds when a three phase symmetrical short
circuit is applied at the generator terminals.
10.3.5 Voltage Variation
The steady state voltage variations, at all loads, shall be limited to ±0.5% of the rated volt-
age when operating isolated from the main network.
The generator and excitation system shall be designed for a power factor of 0.8 lagging
(overexcited) at rated output. The output voltage of the generator shall be adjustable be-
tween ±10% of the rated value. Adjustment shall be possible during normal operation.
10.3.6 Unbalanced Loads
The generating unit shall be capable of operating continuously at rated voltage and fre-
quency with an unbalanced load at rated current but containing a 12% negative sequence
component. The VENDOR shall provide details of the I2t.
10.3.7 Subtransient Reactance
The generator shall have a subtransient reactance of approximately 10%. MANUFAC-
TURER shall indicate guaranteed values of transient, subtransient and synchronous reac-
tances with applied tolerances.

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 14 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

10.3.8 Over speed


Rotors shall be subjected to an over speed test at 1.2 times rated speed for a duration of 2
minutes.
Note: The over speed test shall be considered as satisfactory if no permanent abnormal
deformation is apparent. This deformation can be detected if the phase angle of
unbalance has changed after the over speed test. More details are provided in
IEC 60034-1.
10.3.9 Radio Frequency Interference
Production of radio frequency interference voltages shall not exceed suppression grade ‘N’
defined in VDE 0875.
11.0 ENGINE REQUIREMENTS
Diesel Engines shall be furnished in accordance with Project Specification DGS-MV-003,
Diesel Fueled Compression Ignition Engines. Prime power rated engines in accordance
with ISO 8528 are acceptable.
The requirements for the engine driving the generator are described in separate specifica-
tion attached to the material requisition. In general, the engine Supplier will furnish the
engine with all necessary auxiliaries and accessories for operation of the engine. This
section describes the packaging requirements for installation of the engine. This section is
intended for application where these auxiliaries and accessories are not mounted directly
on the engine but require assembly by the VENDOR as part of his scope of work.
Air Intake System
Where an air intake filter has been supplied loose by the engine Supplier, the VENDOR
shall provide the mounting for the air filter and all piping and ductwork between the air filter
and the engine.
Intake ducting or piping shall be properly supported to prevent excessive strains being ap-
plied to the intake nozzle on the engine. Expansion bellow provided by the engine Sup-
plier shall be installed in the locations approved by the engine Supplier. All intake duct-
work shall be swabbed and blown clean of any debris before final assembly.
Exhaust System
Where the engine Supplier has supplied an exhaust silencer the VENDOR shall provide
the mounting for the silencer and all piping and ductwork between the silencer and the en-
gine.
Exhaust ducting or piping shall be properly supported to prevent excessive strains being
applied to the exhaust nozzle on the engine. Due account shall be taken of thermal ex-
pansion and the expansion bellow provided by the engine Supplier shall be installed in the
locations approved by the engine Supplier.
The orientation of the exhaust shall be agreed with the CONTRACTOR, taking account of
the location of adjacent equipment and the prevailing wind.

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 15 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

Fuel System
Shutoff valves for fuel will be supplied loose by the engine Supplier. These valves shall be
installed in locations agreed with the CONTRACTOR, taking account of the hazardous
area classification. The routing and point of emission of all fuel vents shall not infringe the
hazardous area classification.
Cooling System
If the engine Supplier has supplied engine and lube oil coolers loose, these shall be in-
stalled by the VENDOR.
The orientation of the air flow from the cooling fan shall be away from the package. The
VENDOR shall ensure continued adequate cooler performance when the wind is blowing
directly against the cooler with a maximum wind velocity as stated in the requisition. (If
wind data are not available, a maximum velocity of 50 knots shall be used.)
Shaft Couplings
Non lubricated couplings for auxiliaries and accessories shall be supplied by the VENDOR
as required for driving separately mounted accessories.
Frequency Stability
The requirements for isochronous operation, speed droop operation, or single operation
mode shall be stated in the requisition. Unless stated otherwise all emergency generators
shall be suitable for operation in parallel with the system for testing purposes. The dura-
tion may be up to 4 hours.
The total kinetic energy of the rotating train in combination with the governor gain and the
stability adjustment of the total generator set shall provide frequency stability in accor-
dance with governing class A2 as defined in ISO 3046/4 for generators operating in single
mode. The governor shall be of an electronic type.
11.1 GENERATOR
11.1.1 Generator Housing and Frame
The generator frame shall be of heavy duty welded steel construction, suitably braced to
withstand the stresses imposed during handling, transport and due to short circuit when in
service.
Corresponding mounting surfaces shall be in the same plane and within a tolerance of
0.15 mm per meter distance between surfaces.
Generator frame, including bearing supports, shall have sufficient strength and rigidity to
avoid distortion or increased vibration as a result of external mechanical forces, e.g. tight-
ening of fixing bolts. After tightening of one or more of the fixing bolts, the deflection of the
generator feet from the horizontal plane shall be less than 50 micron.
All welding and welding inspection shall comply with international standards and codes,
i.e. ASME IX, Welding and brazing qualifications, ASME VIII and AWS D1.1, Acceptance
Criteria.
Anti-condensation heaters shall be provided and shall be switched “ON” automatically dur-
ing the stand by periods.

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 16 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

The connecting leads of the heater elements shall be brought out to terminals in a sepa-
rate heater terminal box mounted on the generator frame. A prominent warning label shall
be provided:
“Warning circuit may be live!”
The generator and exciter shall be air-to-air self-cooled machine with method of cooling
IC 6A1A1, IEC 60034-6.
Generator frame shall be bonded to the bedplate. The skid shall be provided with two
earthing bosses for connection to the plant earthing grid..
The rotor of the generator shall be balanced at rated speed. Generator and Exciter enclo-
sure shall be fitted with suitable inspection plates and access covers which shall be de-
signed for quick and simple removal. Access covers for the rotating rectifiers shall be
sized to permit easy maintenance by personnel using both hands.
Generator may be of either single or double bearing design. Bearing housing shall be in-
sulated as necessary to prevent circulating shaft currents.
Loads heavier than 25 kg shall have eye bolts, lugs or extension pieces clearly identifiable
to be used for hoisting. Eye bolts shall not be part of the equipment degree of protection.
11.1.2 Windings
Conductors shall be made of high quality enameled copper wire.
The insulation of generator and exciter windings shall be Class F in accordance with IEC
60085. However the temperature rise of all parts shall be limited to that allowable for
Class “B”, at 54°C.
Windings shall be vacuum pressure impregnated and of high quality enameled wire or per-
formed copper bar conductors.
Windings including overhangs and connections to terminals shall be adequately supported
and braced to withstand vibration and the dynamic stresses of external short circuits.
The stator windings shall be fitted with at least six (2 per phase) PT 100 RTD Elements
(100 Ohms at 0oC) in the hottest part of each phase winding. Leads shall be wired to a
separate terminal box mounted on the generator enclosure.
The stator winding shall be star connected. All six windings ends shall be brought out to
terminals and marked U, V, W on the line side of U2, V2, W2 on the star point side. The
alphabetical sequence UVW shall correspond to the time sequence of the voltages in the
required direction of machine rotation.
11.1.3 Terminal Boxes, Bushings and Terminals
Separate terminal boxes shall be provided for:
a) Stator connections
b) Stator star point connections
c) Heater connections
d) Exciter connections
e) RTD connections
f) Other connections
Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 17 of 43
Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

Terminal boxes shall be designed to provide suitable arrangement for the installation of
current transformers required and the connection of the cable type and size specified in
the requisition.
Gland plates and glands to be used for single core cable shall be made of nonmagnetic
material.
Unless otherwise stated in the requisition, the terminal box should be located at the right
hand side or rear side of the generator facing the driven end.
Terminal marking of the main cable connections and the direction of rotation shall be in
accordance with IEC 60034-8.
Terminal marking of auxiliary cable connections shall be in accordance with the relevant
generator wiring diagrams.
Terminal blocks, bushings and/or post insulators shall be made of synthetic resin. The use
or porcelain is not allowed.
Terminal connections shall be constructed in such a way that direct contact between
screws, bolts or nuts and the conductor is avoided.
The bushings and insulators shall be fully rated for the generator voltage and be capable
of withstanding both the dynamic and thermal effects of a through going short circuit cur-
rent for at least 3.0 (three) seconds.
The distance between bushings and, between bushings and earthed parts of the terminal
box shall be based on the applicable distances for air insulated installation.
Clamping devices shall be provided inside the main terminal box of the machine to sepa-
rate and support the cable conductors, thereby ensuring that the ability to withstand the
short circuit current will be maintained after completion of the non compound filled type of
termination. Materials used for clamping devices shall be non hygroscopic.
11.1.4 Excitation System
The excitation system shall be of the brushless type, consisting of a main AC Exciter and a
permanent magnet generator direct coupled and air cooled.
The automatic voltage regulator (AVR) shall be solid state. The parameters shall be read-
ily adjustable. The regulator shall be equipped with a manual control facility.
The AVR electronic control unit shall be mounted within the remote and monitoring panel.
The automatic voltage regulator shall be of the static type, high speed compounded for
parallel operation. It shall exhibit long-term stability and freedom from drift.
Voltage regulation shall be as follows:
a) Steady state conditions - equal or better than Grade 3.11 (VR3) per BS 4999 Pt 140.
b) Transient conditions - equal or better than Grade 2.32 (VR2-32) per BS 4999 Pt 140.
Excitation - Rated Current
The rated excitation current shall be at least 110% of the excitation current at the rated
output of the generator under the most stringent operating conditions.
The excitation system shall be able to cope with any field forcing conditions that the gen-
erator is required to supply, e.g., starting large motors. The field forcing capability shall be
Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 18 of 43
Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

sufficient to enable adequately graded relay settings to be made for system fault current
protection.

Excitation - Rated Voltage


The rated voltage of the excitation system shall be at least 110% of the rotor voltage at the
rated output of the generator under the most stringent conditions. The ceiling voltage shall
be not less than 120% of the rated voltage of the exciter.
The generator reactance and voltage characteristics shall be such that, with the applica-
tion of sudden loads, the generator output voltage shall not fall below 85% of the rated
value. The sudden loads and the generator power factors and loadings at which they are
to be considered to be applied are listed on the data sheets. The maximum reduction in
frequency, and the recovery time to rated frequency, resulting from the application of the
sudden loads shall be stated by the MANUFACTURER.
The generating unit shall be capable of operating continuously at rated voltage and fre-
quency on an unbalanced load at rated current but containing a 12% negative sequence
component. The Supplier shall provide details of the I2t characteristics.
The generating unit shall be capable of withstanding for 15 seconds a current 50% in ex-
cess of its rated output with voltage not falling below 80% of rated value.
The regulator shall incorporate automatic high speed over voltage protection.
The arrangement of the voltage setting rheostats shall be such that loss of the sliding con-
tact shall not interrupt the exciter field current.
The adjustment range on the desired value setting shall provide the facility to control the
generator terminal voltage by + 5%.
The MANUFACTURER shall give details in his quotation of the voltage waveform devia-
tion and the total harmonic factor.
All current transformers, including those required for the operation of the automatic voltage
regulators, shall be supplied by the MANUFACTURER.
11.1.5 Efficiency
The Generator efficiency at nominal load and at power factor of 0.8 shall not be less than
the following:
Rated Output Efficiency
50-100 kVA 90%
125-300 kVA 91%
330-600 kVA 92%
630 kVA & above 93%
Guaranteed values of efficiency shall be given by the VENDOR for 50%, 75% and 100%
of rated output.
11.1.6 Wiring Between Generator and Remote Control Panel

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 19 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

For this purpose multicore control cables, single/multicore power cable shall be used. The
drawings for connection of cables on the generator and on the remote control and monitor-
ing panel and cable details shall be prepared by the VENDOR. The installation on site
shall be by CONTRACTOR.
11.2 FANS, COUPLING AND BEARING
11.2.1 Fans
The external fan, and if applicable the separately mounted internal fans, shall be individu-
ally balanced.
The external fans shall be of non corroding material or shall be treated with a corrosion re-
sistant coating.
11.2.2 Coupling
An integrally flanged shaft end design or a tapered shaft end design with hydraulically fit-
ted hubs is preferred.
MANUFACTURER shall indicate in the quotation the proposed shaft end design.
11.2.3 Bearings
Self or force lubricated sleeve bearings or ball bearings are acceptable for the machines.
MANUFACTURER shall provide, with the quotation, detailed data and drawings regarding
the bearing arrangement. These data shall include but not be limited to:
a) Bearing data, e.g., type, size, clearance
b) Installation instructions
c) Bearing insulation details
d) Minimum permissible lube flow (if applicable)
e) Normal lube flow (if applicable)
Only standard design bearings manufactured by a specialized MANUFACTURER shall be
used.
For generators with ratings up to 5 MVA, self contained bearings with a ring or disc lubri-
cating system are acceptable. The oil change interval for these bearings shall be at least
12 months.
MANUFACTURER shall state in the Quotation the maximum replacement interval of the
lubricating oil based on the most adverse operating conditions.
Generators shall be able to run down with forced lubrication failed or switched off.
All bearings shall be fully insulated from the generator frame and/or bedplate to prevent
the flow or shaft current.
The method of insulation shall be permanent and non deteriorating. VENDOR shall sub-
mit, with the quotation, detailed drawings showing the proposed insulation by any other
connection.
All earthing connection, which shall be removable for test purposes, shall be provided at
the driven end bearing. Care shall be taken not to bridge the insulation by any other con-
nection.

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 20 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

The insulated bearing at the non-driven end of the generator shall bear a prominent warn-
ing label reading:
!! Caution: Bearing Must Be Kept Insulated!!
11.3 OPERATING PRINCIPLE
The mode of operation of the emergency diesel generator shall be based on the following
basic principles.
11.3.1 Automatic Start Mode
Automatic starting will be initiated on loss of normal supply with a time delay relay from the
normal / emergency switchgear.
When the start order is initiated, the diesel starting sequence shall automatically be carried
out followed by tripping of the normal/emergency bus tie circuit breaker and closing of the
emergency supply circuit breakers according to a source transfer sequence to be provided
in the generator control panel.
The generator shall remain in operation until manual shutdown is initiated.
On resumption of normal supply, the normal supply circuit breaker/bus section breaker
shall be manually synchronized & closed onto generator bus bar in order to manually
shutdown the generator without interruption of power supply to the emergency loads.
The diesel generator set shall be completely suitable for safe unattended operation.
11.3.2 Manual Start Mode
Manual starting shall be carried out locally from the generator control panel.
In manual control mode, upon start order, the diesel generator set shall start and run up to
the rated speed. The set shall be manually synchronized to the normal supply and the
emergency generator supply circuit breaker shall be closed. The generator shall then
ramp up to the preset power set point and operate in parallel with the electrical network.
The set shall remain in operation for approximately one hour for testing.
On receipt of a stop signal, if operating in parallel with the network, the set shall gradually
reduce the load until a minimum load is reached and then trip the emergency generator
supply circuit breaker and shutdown.
On receipt of a stop signal, if operating in isolation, the set shall be manually synchronized
to the normal supply before the normal supply circuit breaker is closed. Shutdown will
then be initiated and shall proceed as above.
All necessary systems shall be provided to ensure safe operation of the equipment.
Moreover, it shall be possible in both manual and automatic mode of operation, for safety
reasons, either to inhibit the start of the diesel or to stop it from a remote shutdown signal.
11.4 REMOTE CONTROL, PROTECTION AND MONITORING PANEL
11.4.1 General
The remote control, protection and monitoring panel shall include all control, protective
devices and monitoring units to ensure good operation of the package and integration of
the power generation system with the overall electrical network. Remote control, protec-

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 21 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

tion and monitoring panel shall be powered for control of protection relays from the
24 V DC system.
Control and monitoring units shall be fitted with all necessary equipment and components
to provide the following functions:
a) Control
b) Man/machine interaction
c) Operating assistance
d) Interface with Control Room
Control, sequencing and protection functions as well as detection and annunciation of ab-
normal operating conditions shall be performed.
The following systems shall be provided in the remote control and monitoring panel.
a) Metering panel
b) Supervisory panel
c) Generator protective devices
d) Generator synchronizing unit
e) DC power supply and distribution unit
f) Control relays
g) Temperature monitoring
All necessary switches, push buttons, meters and indicators for operational status and
alarms shall be provided on the front of the generator control panel. They shall include but
not be limited to the specified requirements.
11.4.2 Local Gauge Panel
Local gauge panel for the engine shall be provided on antivibration mounting on the skid
with necessary instruments as detailed in engine data sheets.
11.4.3 Metering Panel
a) Synchroscope
b) Frequency meter
c) Voltmeter (generator, switchgear bus bars) with selector switch.
d) Ammeter with selector switch.
e) Kilowatt meter
f) Cos-phi meter
g) kW-Hr meter
h) kVAR-Hr meter
i) Hour Run counter.
11.4.4 Supervisory Panel
a) Generator ready to start indicator
Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 22 of 43
Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

b) Generator ready to load indicator


c) Generator fail to start indicator
d) Generator stop on fault indicator
e) Generator alarm with shutdown indicator
f) Generator alarm without shutdown indicator
g) Manual/auto voltage regulator switch
h) Manual voltage adjustment
i) On/off synchronizing switch
j) Generator synchronizing lights
k) Speed decrease/increase push buttons
l) Circuit breaker open/closed indicators
m) Circuit breaker open/closed switches
n) Auxiliary system status/alarm indicators
o) Manual/off/auto selector switch
p) Start/stop push buttons
q) Lamp test/reset push buttons
r) Horn silence push buttons
Control Room Interface / IPCS interface: All generator set status and operating data shall
be capable of being displayed on the IPCS screen in the control room. The control panel
supplied for the generator set shall include data communications capability to the control
room via IPCS. The control device for the generator shall support client data coupling as
a node of the DCS control highway. Alternatively a serial data link shall be provided. The
IPCS provides supervisory function only & control of generator shall not be possible from
IPCS. The emergency generator system shall be capable of operating stand alone without
control room/IPCS interface.
11.4.5 Protective Devices
All protective relays shall be of microprocessor type. Protective relays shall be as shown in
the Single Line Diagram.
The following electrical protective relays shall be provided to protect the generator as a
minimum.
a) Time delay voltage restrained over current (51V)
b) Time delay zero sequence over current (51N)
c) Negative phase sequence relay (46)
d) Diode failure/field failure relay ( 40)
e) Stator winding over temperature (49)
f) Reverse Power (32)
g) Synchro check relay (25)
Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 23 of 43
Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

h) Under voltage relay (27)


i) Over voltage relay (59)
j) Under/ over frequency relay (81)
k) Lockout relay (86)
Protective current transformers shall be of accuracy class 5P with a rated secondary cur
rent of 1A. The secondary circuit of all current transformers shall be earthed.
In the event of a main control system failure, a backup relay system shall be provided to
ensure a safe shutdown and avoid engine damage.
11.4.6 Electrical Protection Requirements
The VENDOR shall prepare a proposal for the settings of the protection relays. The final
setting of the relays shall be agreed between VENDOR and CONTRACTOR.
All protection relays shall be of the microprocessor based GE Multilin UR series type or
COMPANY approved equivalent and shall be installed in such a way that they are clearly
visible from the front of the panel .Components requiring inspection or adjustment shall be
accessible from floor level. Protection relays shall be clearly labeled and shall be
equipped with visible flag indicators, e.g. LED’s. Protection relays shall have manual reset
facilities and shall not be sensitive to vibration, shocks or transients. Dustproof flush
mounted protection relays of the removable type and provided with calibrating and testing
facilities, should be provided. For withdrawable protection relays the terminals connected
to CT’s shall be automatically short circuited on withdrawal of the relays. 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. CT’s for over current protec-
tion shall have an appropriate VA rating and accuracy to energize the relays, without caus-
ing damage to the latter, over the range of short circuit current that can arise. Contact rat-
ing and performance shall be in accordance with IEC 60255.
Automatic cranking logic shall provide three start attempts from each battery in turn before
lockout (i.e., six automatic start attempts in total).
For parallel operation with the main power system, loading shall be set-point controlled.
Refer to Control, Protection and Interlocks on single line diagrams.
11.4.7 Auxiliaries Systems
All necessary auxiliary equipment shall be provided to operate the emergency diesel gen-
erator as a stand alone package.
Auxiliary supply shall include:
a) 24V DC supply to feed the electric starting system, complete with dual batteries and
chargers.
b) 415 V AC supply for distribution board for auxiliaries.
Two sets of Ultra Low Maintenance type nickel cadmium batteries shall be provided, sized
for six start attempts each at minimum temperature. The starting system shall be locked
out after three unsuccessful start attempts from each battery in turn.
Batteries shall be housed in a ventilated corrosion proof, splash proof boxes to be located
close to the diesel generator set. Enclosure shall be IP54 minimum.

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 24 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

Automatic battery chargers complete with voltmeter, ammeter and trickle/boost charge fa-
cility shall be provided. The battery charger shall be capable of supplying the standing
loads as well as provide trickle charging for batteries. In addition, the battery charger shall
be capable of restoring a fully discharged battery within a period of 12 hours. The battery
chargers shall form part of the remote control panel.
11.4.8 Remote control, protection and monitoring panel construction requirements:
The remote control and monitoring panel shall be of metal enclosed construction, vertical,
free standing with front access only via hinged, lockable doors.
The remote control and monitoring panel shall be floor mounted with cable access from
below and shall be naturally ventilated.
Internal wiring shall be stranded conductors, with 1000 V flame retarding PVC insulation.
Conductors shall have a minimum cross sectional area of 2.5 sq. mm for control wiring ex-
cept for electronic circuit wiring which shall be as per MANUFACTURER’s standard. Wir-
ing shall be securely and neatly held in position, either loomed or run in trunking. Each
wire shall be identified by numbered ferrules.
Wiring for external connections shall be brought terminals, which shall be arranged for
easy access for cable connections, testing, inspection and fault finding. Not more than 1
wire shall be terminated to each terminal. Terminals shall be clamp type on DIN rails, and
20% spare terminals shall be provided.
The control panel shall be fitted with an earthing terminal for connection to the external
earthing system, and continuity of all parts shall be assured, including doors.
All terminals shall be suitable for termination of internal and specified external cables with
sufficient space provided for looming of termination. Cable lugs and other terminating
components are included in the MANUFACTURER’S scope of supply.
The control panel shall be manufactured to facilitate inspection, cleaning, repair and main-
tenance and to ensure absolute safety during operation, inspection and maintenance.
Similar parts shall be interchangeable wherever practicable.
All doors providing access to control circuitry and the rear of instrument and relays shall
be key locked.
The control panel shall be provided with anti condensation heaters, suitably rated to pre-
vent the formation of harmful condensation inside the enclosure, the heater shall be sup-
plied complete with thermostat and ON/OFF switch.
Self tapping or thread forming screws shall not be used in the construction of the control
panel.
11.4.9 Marking
All external operating, measuring and indicating components shall be clearly identified with
permanent descriptive labels that facilitate easy recognition by the operator. Descriptive
labels shall be white with black lettering.
All components shall be identified by labels inscribed in accordance with the system of
identification as used on the MANUFACTURER’S reference drawings and documents.
All labels shall be of corrosion resistant material (black, white, black 3-ply Traffolyte or ap-
proved equal) with indelible inscriptions in the English language.
Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 25 of 43
Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

Rail-mounted terminals of equipment and components shall be identified by numerical or


alphabetical markings in accordance with the MANUFACTURER’S drawings. Terminals of
input and output supply cables shall be clearly marked to indicate the nominal system
voltage and the phase/polarity of the supply. The identification of terminals shall be in ac-
cordance with IEC 60445.
11.4.10 External Cabling and Terminations
All panels and enclosures shall have facilities for the entry of cables from the top or bottom
as specified on the requisition. Control cables shall be accessible from the front of the en-
closure.
All connection material, cable supporting system and clamping shall be supplied and suit-
able for the size and the number of conductors. Ample space for terminating the external
cables shall be provided. All outgoing cable compartments shall be provided with fully
gasketed removable gland plates for termination using cable glands. A minimum of 25%
spare entries shall be provided. Compression type cable glands suitable for the cables
specified on the requisition shall be included in the scope of supply.
A separate compartment shall be supplied for the terminal strips for all incoming and out-
going cables. Separate sections shall be provided for digital, analogue, pneumatic and
power cables. Interconnecting cables to remotely located equipment shall be installed by
the CONTRACTOR.
11.5 GOVERNOR, ELECTRONIC - LOAD SHARE/SPEED CONTROL
The engine governor shall be a Woodward 1724 or approved equal Electronic Speed Con-
trol and Load Sensor with 24 volt DC Electric Actuator. The governor shall have maximum
speed regulation of 2-2 1/2% through the load range of the generator. Speed droop shall
be externally adjustable from 0 (isochronous) to 10% from no load to full rated load.
Steady state frequency regulation shall be +/- 0.25%. It shall be capable of sharing load
within 5% when paralleled with similarly equipped engines. Speed shall be sensed by a
magnetic pickup off the engine flywheel ring gear. A provision for remote speed adjust-
ment shall be included. In the event of DC power loss, the forward acting actuator will
move to the minimum fuel position.
11.6 RATING PLATES
The rating plates shall be made of Stainless Steel and be fixed to a non-removable part of
the frame.
Information provided on the rating plates shall be in accordance with IEC 60034-1 and
shall include but not be limited to the data stated below. The values provided shall, as far
as possible, be actually measured and shall be based on the specified operating condi-
tions.
On the generator:
a) MANUFACTURER’S name
b) MANUFACTURER’S serial number and year of manufacture
c) Purchase order number
d) Degree of protection of generator and terminal boxes
e) Rated output in kVA

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 26 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

f) Rated voltage and winding connection


g) Rated stator current
h) Rated frequency and number of phases
i) Rated speed
j) Class of insulation and temperature rise
k) Power factor at full load - efficiency at full load
l) Subtransient reactance
m) Transient reactance
On the exciter:
a) MANUFACTURER’S name
b) MANUFACTURER’S serial number and year of manufacture
c) Purchase order number
d) Degree of protection of exciter and terminal boxes
e) Rated output
f) Rated exciter voltage
g) Rated exciter current
h) Rated exciter field current
Bearing information shall be provided on a separate rating plate
a) Bearing type, size, clearance for the DE and NDE bearings
b) Type of lubricant, relubrication interval, minimum and maximum allowable quantity of
lubricant for the DE and NDE bearing
c) Oil pressure required, (for force lubricated bearings)
11.7 VIBRATION
11.7.1 Bearing Vibration Velocity
When free suspended, the bearing vibration of the generator shall not exceed 1.8 mm/s
rms in any direction.
When rigid mounted, the bearing vibration of generators with a rating up to 5 MVA shall
not exceed 2.8 mm/s r m s in any direction.
Maximum allowable vibration levels shall apply to all operating temperatures of the gen-
erator between ambient and maximum operating temperature, to all operating conditions
between no load and full load and max./min. oil viscosity specified for the bearings.
The measurements shall be taken in the direction of the three mutually perpendicular axes
at the bearings and mounting points of the generator. Details regarding the location of the
measuring points are given in IEC 60034-14.
11.7.2 Generator Frame Vibration Velocity
The vibration of the generator frame, including main terminal boxes, shall not cause dam-
age and should be limited to 4.5 mm/s rms.

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 27 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

11.8 NOISE CONTROL


Noise limits.
The noise limits of the total skid (diesel engine and alternator) shall be less than or equal
to 85dB(A) at 1 meter distance.
12.0 MATERIALS
Supplier shall use suitable materials for the fabrication of the generator.
VENDOR shall furnish Material Certificates in accordance with the requirements of BS EN
10204 (formerly DIN 50049). The type of certificate required “A”, “B”, or “C”, is determined
by the inspection class assigned to the type of equipment or material. Component parts of
a piece of equipment may require different types of certificates. For specific requirements,
refer to the individual Material Requisitions and Purchase Order.
13.0 ENCLOSURE REQUIREMENTS
13.1 BASEPLATE
The generator/engine combination shall be mounted on a common baseplate, made of
structural steel beams and with flat top plates, suitable for stationary installation.
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, in particular for offshore
installation.
All welding shall comply with ANSI/AWS D1.1 of the relevant local code. Intermittent
welds or stitch welds are not allowed on any structural part of the skid.
The baseplate shall be designed to support the mass of the components and resist the
torque reaction imposed by any operating condition. It shall also be capable of withstand-
ing the shock loads specified.
The baseplate shall be constructed such that it does not interfere with maintenance or
routing servicing of the engine and the generator. No fuel piping shall be concealed within
the baseplate.
The baseplate shall have a drip pan and rim with DN 50-Class 150 ANSI/ASME B16.5
flanged rain connections in strategic locations.
The VENDOR shall supply suitable antivibration mounts to limit the engine vibrations
transmitted to the foundations or surroundings where a vibration analysis study reveals
that the package requires isolation from the supporting structure. Mounts shall be located
between the baseplate and the supporting structure. Antivibration mounts shall be totally
enclosed design suitable for the environment and possess an isolation efficiency of at
least 90% in respect of all induced vibrations. Full details, including drawings, of the
antivibration mounts shall be submitted together with the frequency and magnitude of any
unbalanced forces and moments that will be transmitted through the mounts into the sup-
porting structure.
The baseplate shall be designed to withstand any dynamic forces arising from action of
the antivibration mounts. Inertias 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 antivibration mounts are minimized. The VENDOR shall furnish the
Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 28 of 43
Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

CONTRACTOR with calculations of resonant frequencies and the stresses arising on the
rotating components.
The VENDOR shall provide earth bonding conductors from the engine, generator and all
other skid mounted equipment to the baseplate. Two earth bosses shall be mounted di-
agonally on the baseplate for external earth bonding by CONTRACTOR.
Lifting lugs shall be attached to the baseplate. The positioning of the lugs shall take ac-
count of the center of gravity of the complete assembly and be such that lifting slings, etc.
do not interfere with any equipment mounted on the baseplate. If a spreader bar is re-
quired to meet this requirement, it shall be supplied by the VENDOR. Lifting lugs shall be
designed for a load equal to twice the complete assembly and shall comply with
ANSI/AWS D1.1 or the relevant local code. The area of material where lifting lugs are to
be welded shall be tested ultrasonically for laminations prior to welding.
13.2 PACKAGE ENCLOSURE
Each diesel generator set shall be in a container/enclosure having motorized louvers for
air inlet/outlet suitable for outdoor service conditions specified. Forced enclosure ventila-
tion shall be provided to avoid problems from solar radiation during shutdown conditions.
The enclosure shall be supplied with doors or removable panels and internal lighting.
Minimum illumination level shall be 200 lux.
The enclosure shall be equipped with automatic fire protection system using CO2 as ex-
tinguishant; in addition, local alarm horns and red optical beacons shall be provided on top
of the enclosure.
Appropriate temperature monitoring system shall be provided to give a remote alarm if the
temperature of the equipment/components exceed the design limits. (NB the external sur-
faces of generators and other rotating machinery within the enclosure shall have an oper-
ating temperature not more than 80% of the ignition temperature of diesel vapor-air mix-
ture.)
A combined baseplate shall be provided secured to steel floor of a purpose built ISO con-
tainer (Housing) via set of spring anti-vibration mounts.
13.3 ELECTRIC MOTORS
Electric motors for auxiliary systems shall comply with specification DGS-MM-001.
13.4 CABLES AND JUNCTION BOXES
Interconnecting cables between the skid mounted equipment shall be supplied and in-
stalled by the VENDOR. The cables shall be 600/1000V grade stranded copper conduc-
tor, XLPE insulated, steel wire armored and overall PVC sheathed. All cable ties used
shall be PVC coated stainless “Band it” or approved equivalent.
Interconnecting cables between the equipment supplied by the VENDOR and those de-
vices furnished by others and those remotely mounted shall be supplied and installed by
the CONTRACTOR. The associated cable glands on the equipment supplied by the VEN-
DOR shall be furnished and fitted by the VENDOR. All glands shall be of brass, double
compression complete with earth tag and PVC shroud. Cable glands shall be CMP,
Hawke, BICC or PEPPERS make.
Power cabling to the generator shall be supplied and installed by the CONTRACTOR and
connected directly to the generator terminal boxes upon installation in the field. The
Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 29 of 43
Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

VENDOR shall provide trays and supports within the confines of the baseplate as neces-
sary to accept these cables. All other electrical equipment supplied by the VENDOR and
requiring external connections shall be wired by the VENDOR to terminal blocks in junc-
tion boxes located at the edge of the baseplate or to terminals in the control panel.
Cabling on the baseplate and the engine cooler assembly shall be flame retardant and oil
resistant type, complete with galvanized steel wire braiding and interwoven copper earth
wires. The insulation level shall be 600/1000 V.
All cabling shall be mounted on the skid/package cable trays. Cable trays shall be heavy
gauge, hot dip galvanized after fabrication and painted with one coat of primer and two
coats of white finish paint suitable for the galvanized surface.
The cable trays shall have equipotential bonding with the baseplate. Cable extensions
from cable trays to equipment shall be supported and protected against mechanical dam-
age. The cables shall be fastened to the cable tray with UV resistant PVC coated
stainless steel ties.
Cables shall be properly marked by stainless steel tags or by Critchley ‘K’ type cable
marks mounted on a carrier strip with ties. Cable markers shall be installed at each gland
at both sides of the gland plate.
All junction boxes shall have a minimum degree of ingress protection of IP 55. Junction
box wire identification, terminal partitions, terminal execution, wire pin requirements, and
spare terminal requirements and earthing provisions shall comply with the provisions of
this specification.
13.5 NAMEPLATES
A list of nameplates, including sizes and character dimensions, shall be submitted to the
CONTRACTOR for approval. Text on the nameplates shall be in English.
The components of the generator set shall have nameplates in accordance with this speci-
fications. The nameplates described herein shall apply to the complete package.
The following information shall be clearly marked on a nondestructible, corrosion-resistant,
indelible name/rating plate attached to a permanent part of the generator control panel:
a) Purchaser order number
b) Year of manufacture
c) Name of VENDOR
d) Type and serial number of the package
e) Nominal output power of the package
13.6 PIPING AND INTERFACE CONNECTIONS
The VENDOR shall supply all on-baseplate piping for fuel, lubricating oil, starting systems
and coolants. Connections to the CONTRACTOR’S piping shall be by appropriately rated
ANSI/ASME B16.5 flanged connections at the baseplate edge. The VENDOR shall pro-
vide flexible elements for all the CONTRACTOR’S piping connections. For fuel piping,
these flexible elements shall be stainless steel convoluted sections with stainless steel re-
inforcing braid.

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 30 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

All package piping shall be carbon steel to ASTM A106 Grade B and shall be pickled,
flushed and passivated after fabrication.
Interconnecting piping between the baseplate edge and remotely installed auxiliaries shall
be supplied and installed by the CONTRACTOR. The VENDOR shall clearly indicate all
piping termination points on the baseplate for separately mounted auxiliaries to be con-
nected by the CONTRACTOR.
13.7 ACOUSTIC ENCLOSURE
If the emitted noise level of the engine generator set exceeds permitted levels at the instal-
lation site, the Package shall provide an acoustic enclosure over all the equipment requir-
ing noise limitation treatment in accordance with DGS-MU-009 which forms part of the
requisition.
The acoustic enclosure shall allow access for routine on-line maintenance and for over-
haul of the enclosed equipment. All doors shall be fitted with emergency opening bars on
the inside. Opening any door for access during generator set operation shall provide an
alarm, but shall not cause a shutdown of the generator set.
If approved by COMPANY a “close fit” acoustic enclosure may be applied for packaged
units with lower ratings. This type of enclosure shall allow easy access for maintenance
by means of maintenance doors. For overhaul of the equipment easy removal of the en-
closure, by the lifting off or taking apart of panels, is required.
Mechanically induced ventilation shall be installed, such as to provide not less than 20
changes of air per hour within the enclosure, or to limit the temperature rise within the en-
closure to not more than 5°C above the ambient air temperature, whichever requires the
greater flow rate. Either failure of the air flow to the enclosure or excessive temperature
rise in the enclosure shall shut down the generator set. Ventilation air shall be filtered by a
two-stage filter comprising an inertial stage followed by a viscous impingement stage.
An enclosure surrounding a diesel fueled engine installed in a non hazardous area shall
have extractor fans maintaining a negative pressure within the enclosure.
The enclosure shall be fitted with two heat detectors above the engine, either of which
shall shut down the engine upon fire detection. Initiation of a shutdown shall cause a re-
lease of extinguishant into the enclosure and simultaneously cause shutting of a damper
in the exhaust air from the enclosure and shutdown of the ventilating fans.
For free access to the enclosure the fire extinguishing system shall be inhibited when us-
ing carbon dioxide or other asphyxiating gases. An alarm shall be provided to indicate that
the system has been inhibited.
An enclosure surroundings a diesel fueled engine shall be fitted with gas detectors on the
ventilation air outlet, utilizing a two out of three voting system to shut down the engine
upon gas detection. The ventilation shall remain in operation and extinguishant shall not
be released upon gas detection.
14.0 SPECIAL REQUIREMENTS FOR DIFFERENT MODES OF OPERATION
14.1 GENERAL

In addition to the requirements specified which apply to generator sets in single operation,
the following requirements apply to other modes of operation. A combination of operation
modes is also possible.
Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 31 of 43
Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

14.2 EMERGENCY GENERATOR SETS


Mode of operation shall be as shown in the single line diagram attached to the requisition.
All low voltage emergency generator sets with 3 phase/4 wire connections shall be capa-
ble of operating continuously with unbalanced load current of up to 20%, or the value
specified in the requisition. The unbalance is defined as:
Imax - Imin
x 100%
Imax
where: I max = maximum phase current
I min = minimum phase current
The maximum time allowed for the emergency generator set to accept the nominal load
after initiation of a start command from cold shall be 10 seconds.
For an emergency generator set in an acoustic enclosure, failure of the ventilating air flow
shall not shut down the set, but shall initiate an alarm.
For an emergency generator set which is periodically tested in a parallel with the main grid
system, the same control and protection requirements shall apply as for parallel operating
generators. If installed, under/over voltage protection and under/over frequency protection
shall be disabled during emergency operation.
14.3 GENERATOR SETS FOR CONTINUOUS OPERATION
The generator set shall run for a minimum of 25,000 hours between major overhauls and
shall have an expected lifetime of at least 30 years.
An indirect cooling system, e.g., air-to-air or air-to-water, for the generator is preferred.
The exact requirements shall be specified in the requisition.
14.4 GENERATOR SETS SUPPLYING LARGE NONLINEAR LOADS
The generator shall operate within its temperature limits under conditions of non-sinusoidal
loads, as specified in IEC 60034-1.
If loads with a large harmonic content, e.g., from rectifiers, need to be supplied the magni-
tude of the individual harmonic currents shall be in the requisition. The generator shall
then operate within its temperature limits under the specified harmonic current conditions.
The distributed system to which the generator is connected shall be designed to limit the
total harmonic voltage distortion of not exceeding 5%.
The maximum acceptable level of voltage wave form distortion for the installation if any will
be indicated in the requisition.
14.5 GENERATOR SETS FOR PARALLEL OPERATION
Generators for parallel operation shall be equipped with a damper winding on the rotor. If
more than one star point of parallel operating generators will be earthed, the Supplier shall
ensure that third harmonic currents circulating through the star point connections are
minimized. The MANUFACTURER shall reduce the third harmonic currents and their mul-
tiples by cording (2/3 pitch stator winding).
Where parallel operation with other generator sets is required, quadrature droop compen-
sation of maximum 5% shall be provided.

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 32 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

For a generator operating in parallel with the main grid system the reactive power gener-
ated shall be controlled by an automatic power factor controller. Either the power factor of
the grid coupling or the power factor of the generator set shall be controlled, as specified
in the requisition.
A droop current transformer and droop rheostat shall be provided.
Manual synchronizing equipment, with check synchronizer and dead bus override, shall be
provided. Automatic (active) synchronizing equipment is only required if specified in the
requisition.
The data regarding the voltage and speed control characteristics of existing generator sets
which are required to operate with the one being purchased will be indicated in the requisi-
tion.
Frequency stability in accordance with governing Class A1, as defined in ISO 3046/4, shall
be provided for the engine.
14.6 GENERATOR SETS FOR HAZARDOUS AREAS
The requirement of the generator set to be suitable for installation in a hazardous area
shall be specified in the requisition.
The generator set and all its accessories shall comply with the recommendations of
IEC 60079.
The requirements for certificate of conformity and declarations of compliance shall be met.
If a generator set provided with an acoustic enclosure is installed in a hazardous area, the
ventilation air intake shall be taken from a safe area.
NOTE: Generator sets shall be installed in a non hazardous area unless this is unavoid-
able. In that case the generator set and its accessories shall be installed in
Zone 2 or 22 locations. Installation in Zone 1 or 21 locations shall not be con-
templated.
15.0 INSPECTION AND TESTING
15.1 GENERAL
All inspection procedures shall have prior approval of the CONTRACTOR. All qualification
test shall be placed under the supervision of the INSPECTION AGENCY.
In the equipment specification shall be listed any special test required at VENDOR’S shop
or at construction site, to test proper performance of equipment. Guaranteed perform-
ances shall be indicated with reference to test procedure. Provisional and final accep-
tance definitions shall be given as necessary.
In addition to performing final inspections and witnessing final simulation tests, the CON-
TRACTOR reserves the right to carry out inspection/expediting visits during the course of
manufacture. Any material, which form the technical design and intent of the CONTRAC-
TOR’S contract with the SUPPLIER without additional cost of the CONTRACTOR.
The VENDOR’S own Quality Control department shall have completed, to their satisfac-
tion, all of the required checks and simulations, before notifying the CONTRACTOR that
the equipment is complete and ready for his inspection.

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 33 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

All proprietary and bought out items/equipment shall be inspected by the CONTRACTOR
or his designated representative, at his discretion, at the MANUFACTURER’S work before
shipment to the VENDOR. This inspection shall only be waived on the written agreement
of the CONTRACTOR.
VENDOR shall prepare and submit for the CONTRACTOR’S approval, not later than six
(6) weeks after order placement, a comprehensive schedule of equipment test. This
schedule shall include sample “test” and “acceptance” forms in addition to the schedule of
tests. The schedule shall include but not be limited to:
a) Quality check of all equipment being supplied
b) Mechanical and physical check of all equipment against standards and detailed re-
quirements in this specification
c) Check of basic operation against the requirements of this specification
d) All Control Room data interface parts shall be tested by connection of hardware with
software to emulate the Control Room host.
VENDOR’S approved drawings, schedules and associated documents, and selected
CONTRACTOR’S documents shall be used as the basis of the aforementioned tests and
inspection. No test or inspection shall be permitted until the schedule and test forms are
approved by the CONTRACTOR.
All drawings and documents used during the inspection/tests shall be “highlighted” and
copies kept for the records.
The VENDOR shall also provide documentation for recording discrepancies, errors, faults,
component failure and changes. Each entry shall be dated and signed by a Senior Mem-
ber of the VENDOR’S Quality Control Department and witnessed by the CONTRACTOR’S
representative. This document shall be attached to the drawings/documents used for the
tests. The degree of re-testing required after a fault/error rectification or component re-
placement shall be at the discretion of the CONTRACTOR’S representative.
All equipment including sub suppliers equipment shall be subject to inspection and witness
of tests at the MANUFACTURER’S works by the CONTRACTOR or his appointed repre-
sentative. The MANUFACTURER shall provide a minimum of ten working days notice of
inspection and test dates.
All equipment shall be subject to shop tests in accordance with applicable engineering
standards and codes. Compliance with the requirements of this specification, the material
requisition and associated documents shall also be demonstrated. The equipment shall
not be dispatched by the MANUFACTURER until material and equipment test certificates
have been approved by the CONTRACTOR at the time of the shop test acceptance.
15.2 GENERATOR
The Generator shall be subjected to the following tests:
a) Insulation resistance tests (on generator, exciter, space heaters, temperature detec-
tors)
b) Dielectric test
c) No-load characteristic
d) Short circuit characteristic
Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 34 of 43
Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

e) Temperature rise at rated voltage, current, power factor and frequency


f) Over speed tests
g) Calculation of efficiency
h) Phase sequence test
i) Insulation test of bearing pedestals
j) Wave form and harmonic analysis
k) Determination of reactances, saturated and unsaturated values
l) Exhaust temperature
15.3 ENGINE/GENERATOR COMBINATION (STATIC LOAD TEST)
The engine/generator unit shall be tested after assembly. The tests shall include as a
minimum one full load run, maintained for 8 hours and be followed with one overload run
(at 110% load) for 1 hour, to demonstrate that the set can deliver the power requirements
as specified.
Where applicable, the following parameters shall be recorded every half hour during the
load run:
a) Generator winding and bearing temperatures
b) Generator power output
c) Generator current
d) Generator voltages
e) Generator frequency
f) Generator power factor
g) Engine oil pressure
h) Lube oil temperature from cooler
i) Lube oil temperature from both generator bearings
j) Engine cooling water to radiator
k) Engine cooling water from radiator
l) Speed
m) Fuel consumption
n) Vibration at engine output shaft
o) Exhaust temperature
The action of the governor shall be tested to demonstrate the specified frequency re-
sponse requirements by application of instantaneous 25%, 50%, 75% and 100% load ac-
ceptance and load rejection. Voltage and frequency variations shall be recorded on oscil-
lograms.
The automatic voltage regulator performance shall also be verified in this test.
Noise level at rated full load of coupled unit shall be verified.
Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 35 of 43
Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

15.4 REMOTE CONTROL PANEL


The panel shall be tested together with its engine/generator combination tests.
Insulation and dielectric tests shall be carried out on the panel before and after the above
combination tests.
15.5 DYNAMIC LOAD TEST
The frequency and voltage regulation of the generator set shall be verified against the re-
quirements specified. Voltage and frequency variations shall be recorded on oscillograms.
The requirement for special dynamic load tests to simulate starting will be indicated in the
requisition.
15.6 FUNCTIONAL TEST
The VENDOR shall perform functional tests on the complete generator set including the
generator and engine control panels. VENDOR shall liaise with IPCS or DCS vendor to
carry out data communication interface testing at MANUFACTURER’s works.
The functional tests to be performed shall include, but not be limited to, the following tests:
a) Engine start-up system, including measurement of the starting time. A minimum of
two start and stop tests shall be performed
b) Automatic start-up system
c) For emergency generator sets verification of the time between initiation of a start
command and acceptance of the nominal load for a cold start
d) All engine alarm and shutdown functions
e) All generator alarm and trip functions, including the verification of protection relay
operation
f) Operation of the battery charger
g) The status/alarm/trip/shutdown indication of the control panels
h) Local manual start/stop/emergency stop functions
i) Remote start/stop/emergency stop functions (input signals)
j) The remote signaling contacts for CONTRACTORS use
k) Operation of the AVR
l) Operation of the AVR automatic transfer system (if provided)
m) Operation of the automatic power factor controller (if provided)
n) Operation of synchronizing equipment (if provided)
o) Calibration of measuring and protective devices
p) Primary & secondary injection tests of electrical protective & metering circuits.
15.7 HYDROSTATIC TESTING
All pressure containing parts, including auxiliaries, shall be tested hydrostatically in accor-
dance with the relevant design codes.

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 36 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

15.8 FINAL INSPECTION


The following inspection and checks shall be performed:
a) Verification against the approved drawings
b) Overall dimensions of the skid and the location of all equipment
c) Location of all piping and electrical interfaces
d) Enclosure degree of protection of all equipment concerned
e) Accessibility of components
f) Lifting arrangement, including spreader bar, if applicable
g) Noninterference of the lifting arrangement
h) Availability of eyebolts for lifting heavy components
i) Terminal and wiring marking
j) Available space for cable termination, the size and number of terminals, the cable
supporting devices
k) Earthing and bonding
l) Marking of components according to the relevant drawings
m) All rating plates of main components
n) Construction materials of auxiliaries such as: baseplate, piping, fittings, coolers, fuel
day tank and control panels
o) Hook-up of local instruments
p) VENDOR’s welding procedures and welder qualifications
q) Welding by nondestructive testing, where specified
r) Weld inspection reports
s) Quality assurance documentation
15.9 ON-SITE ACCEPTANCE TESTING
Acceptance testing shall include static load tests, functional tests and visual inspection as
specified in this specification.
Any defect of the equipment incorporated in the systems shall be rectified and re tested, to
the satisfaction of the CONTRACTOR’S representative, at the VENDOR’S expense, as
part of the acceptance test. A “Fault Log” as detailed above shall be maintained through-
out the testing period. After fault rectification, the decision whether to continue or revert to
the start of testing shall rest entirely with the CONTRACTOR’S representative.
15.10 PROVISIONAL ACCEPTANCE
Final testing for provisional acceptance of the assembled equipment at the SUPPLIER’S
works will be witnessed by CONTRACTOR representative.
Prior to provisional acceptance, VENDOR to make available all design data together with
material certificates for major components.

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 37 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

15.11 FINAL ACCEPTANCE


The VENDOR shall give assistance as required for a final acceptance test after installation
of the equipment/material on the site to ensure correct performance. Test procedure to be
submitted by VENDOR to CONTRACTOR for approval.
16.0 PAINTING AND PROTECTIVE COATING
Equipment shall be delivered fully painted and/or coated as required by the Painting
Specification DGS-MX-001 and this Equipment Specification.
a) Color shade for generator shall be green RAL 6011
b) For the Remote Control Panel, the VENDOR painting process could be used. Color
shade shall be green RAL 6021. The VENDOR painting specification shall be sup-
plied at bid stage.
The engine and generator shall be supplied painted according to the respective specifica-
tions. The control panels, baseplate and auxiliaries shall be painted in accordance with
the VENDOR’S standard for a marine environment, subject to approval by the CON-
TRACTOR/COMPANY. The VENDOR shall submit the painting specification for approval.
The specification shall include surface preparation, paint materials, application, film thick-
ness and the paint Supplier’s data sheets.
17.0 SPARE PARTS
Commissioning and two years operation spare parts shall be provided by the VENDOR.
An itemized list should be provided with the offer.
VENDOR should recommend normal operating spares requirements for two years opera-
tion, on COMPANY supplied SPIR forms. VENDOR shall also include parts manuals,
drawing, data sheets and manual for purchased parts from SUBVENDOR’S.
VENDOR shall ensure that the equipment will be adequately supported by spares
throughout its operational life and major guarantee spares availability for minimum of 10
years after delivery.
VENDOR shall provide list of insurance spare parts, if any.
VENDOR shall supply parts lists also on magnetic media (any commercial software).
18.0 SPECIAL TOOLS
The VENDOR shall provide all necessary special tools and lifting bars/equipment for main-
tenance and erection.
19.0 PERFORMANCE GUARANTEE
MANUFACTURER shall guarantee that the equipment shall meet the performance condi-
tions specified in this specification and the data sheets.

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 38 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

APPENDIX 1 – DATA SHEET

Contract
Item No.
ADNOC Re vision Date:
SYNCHRONOUS GENERATOR By Chk'd: Appr'd:
DATA SHEET ADNOC Date:
P .O. No.
C ritic ality R atin g : I nquiry No.
She e t 1 Of 4

A PP LICA BLE TO:  PROP OSA L  PURCHA SE  A S-BUI LT

1 FOR UNI T
2 SI TE SERIA L NO.
3 SERVI CE NO. REQUIRED
4 MA NUFA CTURER DRI VEN EQUI PMENT / I TEM NO.
5 NOTE:  I NDICA TES INFORMA TION TO BE COMPLETED BY P URCHA SER † BY MA NUFA CTURER
6 DES IGN DATA
7 BAS IC DATA: ELECTRICAL SYSTEM CONDITIONS:
8  VOLTS PHA SE HERTZ  TYP E OF SYSTEM GROUNDI NG  RESISTA NCE
9  NA MEP LA TE, kW KVA PF  REA CTA NCE  EA RTHED  SOLID
10  RPM P OLES EA RTH FA ULT A MPERES
11 SA LI ENT CYLINDRICA L  ELECT. PH. ROTA TION (A BC OR A CB)
12  A RMA TURE (STA TOR) I NSUL. CLA SS / RI SE / MOUNTING:
13  FI ELD (ROTOR) I NSULA TION CLA SS / RISE /  HORIZ.
14  EXCI TER INSULA TI ON CLA SS / RI SE /  BA SEPLA TE FURNISHED BY
15  MI N % OVERSPEED  SOLEPLA TE FURNISHED BY
16  BEA RI NG TYP E: ENCLOSURE:
17  SLEEVE  A NTI FRI CTI ON  OPEN - DRIPP ROOF
18  MA X DRIVEN-EQUI P. VERT. THRUST  WEA THER PROTECTED  TYP E I  TYPE I I
19  TEFC ( I P55 )  CA CA  CA CW
20  DI FF ERENTI A L P ROTECTI ON TO BE A PP LIED  CA CA - TUBES  COPP ER  Cu A LLOY
21 SITE DATA:  A LUMI NUM  STA INLESS STEEL  A l A LLOY
22 A REA CLA SSIF ICA TI ON  A ISI 300 SERIES HA RDWA RE
23  ZONE GROUP  NONCLASS IFIED CACW HEAT EXCHANGER:
24  TEMP ERA TURE CLA SS  TUBE MA TERIA L
25  INDOOR  OUTDOOR  HEA TED  UNHEA TED  TUBE CONSTR.  SINGLE  DOUBLE
26  ROOF OVER  NO ROOF OVER  A IR TEMP . SENSOR  YES  NO
27  NON-MA SSI VE FOUNDA TI ON, DESCRI PTI ON  RTD TYPE  TC TYP E
28  COOLI NG WA TER CONDITI ONS A TTA CHED
29  MA X. SOUND PRESSURE LEVEL dB A @ m  FLOW SENSOR LOCA L INDI CA TOR
30 UNUSUAL CONDITIONS :  OUTER TUBE ON DOUBLE TUBE COOLERS LEA K DETECTION
31  A BRA SIVE DUST DRIVE SYSTEM:
32  EXTERNA L FORCES A ND MOMENTS  DIRECT CONNECTED  GEA R
33  SEI SMIC LOA DING  ROTA TION, F A CING DRIVE END
34  CORROSI VE A GENTS  CW  CCW
35  OTHER
36

37

38
39
40 ACCES SORY EQ UIPMENT
41 WINDING TEMPERATURE DETECTORS : BEARING TEMPERATURE DETECTORS :
42  RTD TYPE NO./P HA SE  PROVISI ON ONLY  PER A PI 670  MFR. STD.
43  RESI STA NCE MA T'L  OHMS  RTD TYPE: MA TERI A L  OHMS
44  3-WI RE  2-WI RE GROUND 1 LEA D  OTHER
45 GROUND 1 LEA D  YES  NO  TERMINA L HEA D OR BOX
46  OTHER  HOUSI NG TEMP. INDICA TOR REQUIRED
47

J :\ 0 4 4 5710 0 \ S HA RE\ 1-TY PEIN \ S TD_ S G EN.WK 4 D o c. N o . D S-

S T D -MA -00001 R e v . A 8/ 96

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 39 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

Contract
Item No.
ADNOC Revision Date:
SYNCHRONOUS GENERATOR By Chk'd: Appr'd:
DATA SHEET P.O. No.
(CONTINUED) Inquiry No.
Sheet 2 Of 4

1 ACCESSORY EQ UIPMENT (CONTINUED)


2 LUBRICATION SYSTEM: MAIN TERMINAL BOX:
3 † SELF LUBE † PRESSURE LUBE  BOX LOC.  OVERSIZED BOX
4  BEA RING OIL RINGS FOR COA STDOWN REQUIRED  MA IN SUPPLY LEA DS: CONDUCTOR SIZE TYPE
5  B EA RI NG CON STA NT-LEV EL SI GHT F EED OI LERS REQUI RED: INSULA TION NO./PHA SE
6 TYPE ENTER FROM:  A BOVE  BELOW  SIDE (R/L)
7  SPECIA L SEA LS FOR GA S PURGE CONDUIT TYPE SIZE NO.
8  LUBE SYSTEM COMMON W/ DRIVE EQUIP. :  CURRENT TRA NSFORMERS FOR PROTECTION:
9 SUPPLIED BY A CCURA CY CLA SS
10  TYPE OF OIL PRESS. MOUNTED BY
11  PRESSURE LUBE SYSTEM QUA NTITY RA TIO
12  PER A PI 614  MFR. STD.  SURGE CA PA CITY  .25µF/PHA SE  .50µF/PHA SE
13  MA IN OIL PUMP REQUIRED MOUNTED BY
14  STA NDBY OIL PUMP REQUIRED  SURGE A RRESTORS:
15  FILTER ELEMENT MOUNTED BY RA TED kV
16 MFR. MODEL NO.  PHA SE CURRENT TRA NSFORMERS:
17  DUPLEX OIL FILTERS REQUIRED A CCURA CY CLA SS
18  OIL COOLER REQUIRED QUA NTITY RA TIO
19  OIL HEA TER REQUIRED VOLTA GE TRA NSFORMERS:
20 VIBRATION DETECTORS: A CCURA CY CLA SS
21  NON-CONTA CTING PROBES MOUNTED BY
22  PROVISIONS ONLY  INSTA LLED QUA NTITY RA TIO
23 PROBE TYPE MODEL FUSES REQUIRED
24  OSCILLA TOR DEMODULA TOR MODEL BUSHING STUDS OR RECEPTA CLES
25 NO. PER BEA RING  TWO  FOUR SPA CE FOR STRESS CONES
26  BEA RING HOUSING SEISMIC SENSORS  THERMA L INSULA TION
27  PROVISIONS ONLY  INSTA LLED  SPA CE HEA TERS
28 SENSOR TYPE MODEL  VOLTS PHA SE HERTZ
29 OUTPUT TRA NSDUCER MODEL  MA X. SHEA TH TEMPERA TURE, °C
30 NO. PER BRG. LOCA TION (H, V, A )  BREA THERS
31  VIBR. SWITCH  MA NUA L RESET  ELEC. RESET  DRA INS
32 SWITCH TYPE MODEL  PA RTIA L DISCHA RGE MEA SUREMENT COUPLERS
33 AIR FILTERS:
34  PROVISIONS ONLY - WPI  REQUIRED - WPI OR WPII  PROVISION FOR PURGING
35 FILTER TYPE  REMOVA BLE LINKS
36  DIFFERENTIA L PRESSURE DEVICE REQUIRED  SILVER-PLA TED BUS J OINTS
37 TYPE  EA RTH BUS
38 BEARING HEATERS :  FA ULT WITHSTA ND
39  TYPE  OTHER
40 VOLTS PHA SE HERTZ
41  OTHER
42

43

44
45

46
47

48
49

50
51

J :\ 0 4 4 5710 0 \ SHA RE\ 1-TY PEIN\ STD_ SGEN.WK4 D o c . N o . D S-

ST D -MA-00001 Re v . A 8/ 96

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 40 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

Contract
Item No.
ADNOC Revision Date:
SYNCHRONOUS GENERATOR By Chk'd: Appr'd:
DATA SHEET P.O. No.
(CONTINUED) Inquiry No.
Sheet 3 Of 4

1 ACCESSORY EQ UIPMENT (CONTINUED)


2 COUPLING: † INTEGRALLY FLANGED PAINTING:
3 † TAPER FIT † CYLINDRICAL FIT  MFR'S STANDARD  EXTRA COAT @ SHIPMENT
4  COUPLING SUPPLIED BY  USER'S SPECIAL PAINT
5  VENDOR MODEL SHIPMENT:
6  COUPLING DATA SHEET NOS.  DOMESTIC  EXPORT
7  MOUNTED BY:  GENERATOR MFR.  EXPORT BOXING REQUIRED
8  ENGINE VENDOR  PURCHASER  OUTDOOR STORAGE FOR MORE THAN 6 MONTHS
9 MISCELLANEOUS:  SPECIAL SHIPPING BEARINGS
10  EPOXY GROUT TYPE  MOUNTED ON SKID
11  NAMEPLATE MATERIAL:  S.S.  MONEL OTHER REQ UIREMENTS:
12  SPECIAL NAMEPLATE FOR ID  VENDOR'S REP. TO BE PRESENT DURING INITIAL EQUIP.
13  QTY. OF SPECIAL TOOLS REQ'D ALIGNMENT CHECK
14  PROOF OF NONSPARKING, CORROSION-RES'T FAN  GUARANTEED EFFICIENCY:
15  SHAFT SEALS (NON-CONDUCTIVE)  OTHER
16  LOC. OF AUX. J UNCTION BOXES
17  SWITCHES W/ CONTACTS RATED FOR DC
18  YES  NO
19 SELLER'S DATA
20 OPERATING CONDITIONS: REACTANCES (%): ( KVA) SAT. UNSAT.
21 † RPM ARMATURE, AMPS † DIRECT-AXIS SYNCH. (Xd)
22 FIELD, AMPS † DIRECT-AXIS TRANS. (X'd)
23 † SPEEDS, RPM: † DIRECT-AXIS SUBTRANS. (X''d)
24 TRIP OVERSPEED † QUADRAT.-AXIS SYNCH. (Xq)
25 1ST CRITICAL 2ND CRITICAL † QUADRAT.-AXIS TRANS. (X'q)
26 † EFFICIENCY(%) AT RATED PF: † QUADRAT.-AXIS SUBTRANS. (X''q)
27 FULL LOAD 3/4 LOAD † NEGATIVE SEQUENCE (Xo)
28 1/2 LOAD 1/4 LOAD † ZERO SEQUENCE (Xo)
29 CHARACTERISTICS: † ARMATURE LEAKAGE (Xl)
30 † SHORT-CIRCUIT RATIO (SCR) COLD WINDING RESISTANCES (20°C):
31 X/R RATIO † ARMATURE (PER PHASE) OHM
32 † TELEPHONE INFLUENCE FACTOR (TIF) † FIELD OHM
33 BALANCED RESIDUAL EXCITATION DATA:
34 † ROTOR SHORT-TIME THERMAL CAPACITY, I2SQT VOLTAGE REGULATOR AND EXCITER CHARACTERISTICS
35 † GENERATOR INERTIA CONSTANT, H (SEC.) PER IEEE COMPUTER REPRESENTATION OF EXCITATION
36 † 3 PH. ARMATURE WIND. CAPACITANCE (µFARADS) SYSTEMS PAS-100, NO. 2, FEB. 1981.
37 † MINIMUM 3-PHASE MOTORING POWER (kW) NOTE: EXCITER AND VOLTAGE REGULATOR
38 TIME CONSTANTS, SECONDS: CONSTANTS TO BE SUPPLIED WITH
39 † DIRECT-AXIS TRANS. OPEN-CIRCUIT (T'do) PROPOSAL.
40 † DIRECT-AXIS TRANS. SHORT-CIRCUIT (T'd) † TYPE (STATIC OR ROT. BRUSHLESS)
41 † DIRECT-AXIS SUBTRANS. OPEN-CIRCUIT (T''do) † POWER SOURCE (PPT OR PMG)
42 † DIRECT-AXIS SUBTRANS. SHORT-CIRCUIT (T''d) † RESPONSE RATIO
43 † QUADRAT.-AXIS TRANS. OPEN-CIRCUIT (T'qo) † MAXIMUM CEILING EXCITATION
44 † QUADRAT.-AXIS TRANS. SHORT-CIRCUIT (T'q) (PER UNIT) AND TIME(S)
45 † QUADRAT.-AXIS SUBTRANS. SHORT-CIRCUIT (T''q) † CURR. / VOLT. AT RATED LOAD (A/V) /
46 † ARMATURE WINDING 3-PH SHORT-CIRCUIT (TA3) † CURR. / VOLT. AT NO LOAD (A/V) /
47 WEIGHTS:
48 † GENERATOR (INCLUDING ROTOR) kg
49 † ROTOR kg

J :\0 4 4 5710 0 \SHA RE\1-TY PEIN\STD_ SGEN.WK4 D o c. N o . D S-

ST D -MA-00001 Re v . A 8/ 96

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 41 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

Contract
Item No.
ADNOC Revision Date:
SYNCHRONOUS GENERATOR By Chk'd: Appr'd:
DATA SHEET P.O. No.
(CONTINUED) Inquiry No.
Sheet 4 Of 4

1 ANALYSIS, SHOP INSPECTION


2 REQUIRED WITNESSED OBSERV ED

3 LATERAL CRITICAL SPEED ANALYSIS BY 


4 DESIGN REVIEWMEETING 
5 TORSIONAL ANALYSIS BY 
6 SHOP INSPECTION 
7 DATA PRESERVATION 
8 MATERIAL CERTIFICATIONS 
9 ASSEMBLY, MAINTENANCE AND RUNNING CLEARANCES 
10 PAINTING DEFERRED 
11 SURFACE & SUBSURFACE INSPECTION OF PARTS   
12 RADIOGRAPHIC TEST PARTS:   
13 ULTRASONIC TEST PARTS:   
14 MAGNETIC PARTICLE TEST PARTS:   
15 LIQUID PENETRANT TEST PARTS:   
16 HARDNESS TEST PARTS: 
17 OPTIONAL ASTM TESTS TO BE PROPOSED BY VENDOR   
18 BALANCE  3 PLANES  VACUUM PIT   
19 CHECK BALANCE WITH HALF COUPLING   
20 INSPECTION FOR CLEANLINESS PER API 614   
21 REVIEWOF QUALITY CONTROL PROGRAM 
22 STATOR INSPECTION PRIOR TO VACUUM-PRESSURE IMPREGNATION   
23 RESIDUAL UNBALANCE TEST   
24 POLARIZATION INDEX VOLTAGE  1000 V  2500 V  5000V   
25 VIBRATION RECORDING   
26 SPECIAL SURGE TEST ON SAMPLE COILS   
27 POWER FACTOR TIP-UP TEST  WOUND STATOR  SACRIFICIAL COILS   
28 SEALED WINDING CONFORMANCE TEST   
29 DC HIGH-POTENTIAL TEST   
30 COMPLETE TEST (IEEE 115)   
31 EFFICIENCY   
32 LOCKED ROTOR   
33 OPEN SHORT-CIRCUIT SATURATION   
34 HEAT RUN   
35 HOT AND COLD VIBRATION   
36 UNBALANCED RESPONSE   
37 MANUFACTURER'S STANDARD SHOP AND ROUTINE TEST   
38 IMMERSION OR SPRAY TEST   
39 RATED ROTOR TEMP. VIBRATION TEST WHEN COMPLETE TEST NOT SPECIFIED   
40 BEARING INSPECTION AT COMPLETION OF TEST   
41 UNBALANCE RESPONSE TEST   
42 BEARING HOUSING NATURAL FREQUENCY TEST   
43 CERTIFIED DATA PRIOR TO SHIPMENT 
44 NOISE LEVEL TEST   
45 OTHER   
46

47
48

49

50
51

J :\ 0 4 4 5710 0 \ SHA RE\ 1-TY PEIN\ STD_ SGEN.WK4 D o c . N o . D S-

ST D -MA-00001 Re v . A 8/ 96

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 42 of 43


Abu Dhabi Oil Refining Company

DGS-MA-004
EMERGENCY GENERATOR
Rev- 2 , Mar 2009

ADDENDUM SHEET
All revisions to this DGS subsequent to the issue of REV zero shall be recorded in this adden-
dum sheet and shall be incorporated into the DGS in the next revision.

Date Proposed Revision Remarks

Nov,2007 AMD-MA-004-001-ETSD: Incorporated


in Rev 1.
In clause 2.0 add the following after the first sentence “These shall include
any & all the applicable parts of the STDs including any corrigendums on
these published from time to time.

Mar-2009 AMD-MA-004-002-BECHTEL: Incorporated


in Rev-2
In clause 2.0 ASTM A106 revised to ASTM A 106/A 106M. Revised title of
BS EN10204 & deleted EN 10204 . Added BS PD 5304. Revised title of
IEC 60085 & revised IEC60617 to ICEC 60617snap shot.
In clause 4.0 added single line diagram. In clause 7.0 added the follow-
ing: protection relay settings & calculations, parameterization of micro-
processor relays, generator performance /capability curves, battery sizing
calculations, cable block diagram, heat dissipation figures & utility sum-
mary.
In clause 10.1 revised voltage variation to plus minus 5 % & frequency
variation to plus minus 2 %.. In 10.2 added outdoor electrical enclosure
degree of protection. In 10.3.3 specified the overload capacity once in a
12 hour period.
In 11.1.1 IC0161 revised to IC6A1A1. In 11.3.1 added how to manually
shut down the generator on normal supply resumption. In 11.3.2 added
manually before “synchronized”. In 11.4.1 deleted pipeline before control
room. In 11.4.3 added selector switch for ammeter & voltmeter & hour run
counter. In 11.4.4 specified interface with IPCS& this interface is for moni-
toring only & the generator to be capable of operating with out IPCS. In
11.4.5 corrected spelling of over current & added relays 40 and 81. In
11.4.6 added relays to be GE Multilin or approved equivalent. & to be in-
stalled in such away they are visible from front of the panel. In 11.4.8 in-
ternal wiring for electronic devices added.
In clause 15.0 added testing of data communication interface & primary
and secondary injection testing.

Takreer DGS-MA-004-Rev-2 Mar-2009 Printed 16-Mar-09 13:48:24 Initials Page 43 of 43