KOC Standard for Generator Sets

KUWAIT OIL COMPANY (K.S.C.
STAYJIARDS PUBLICATION
KOC STANDARD
FOR
GENERATOR SETS
DOC. NO. KOC-E-007
( STANDARDS TEAM 1
DOC. NO. KOC-E-007 I( Page Iof 57 1 REV. 1
KUWAIT OIL COMPANY (K.S.C.)
STANDARDS PUBLICATION
KOC STANDARD
FOR
GENERATOR SETS
STANDARDS TEAM
DOC. NO. KOC-E-007 Page 2 of 57 REV. 1
KOC STANDARD
FOR
GENERATOR SETS
DOC. NO. KOC-E-007

(FORMERLY 015-PH-1904)
ISSUING AUTHORITY:
STANDARDS TEAM
Team Leader Stent.fards

Tel. 61896
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DOC. NO. KOC-E-007 REV. I
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TABLE OF CONTENTS
PAGE NO.
FOREWORD
SCOPE
APPLICATION
TERMINOLOGY
3.1 Definitions
3.2 Abbreviations
REFERENCE CODES & STANDARDS
4.1 Conflicts
4.2 List of Standards and Codes
ENVIRONMENTAL CON DlTlONS
HEALTH, SAFETY AND ENVIRONMENT
SERVICE CONDITIONS
BASIC DESIGN CONSIDERATIONS
OPERATING MODES
9.1 Normal Status

9.2 Automatic Mode
9.3 Manual Mode
9.4 Test Mode
9.5 Shutdown o f Generator Set
9.6 Synchronizing and Parallel Operation
TECHNICAL REQUIREMENTS AND SYSTEM DESCRIPTION
10.1 General
10.2 Generator Set Assembly
GENERATOR
11. I Performance Requirements

11.2 Enclosure
11.3 Bearings and Lubrication
I1.4 Windings
11.5 Excitation
0 Page 4 o f 57 REV. 1
11.6 Terminal Boxes

11-7 Temperature Monitoring
11-8 Anti-Condensation Heaters
11-9 Generator Earthing
11.10 Dynamics
11.11 Rating Plate
DIESEL ENGINE
12.1 Performance Requirements

12.2 Construction Requirements
12.3 Cooling System
12.4 Lubrication System
12.5 Fuel System
12.6 Speed Governing
12.7 Air Intake System
12.8 Exhaust System
12.9 Rearing Temperature Monitoring
12.10 Power Transmission
12.11 Coupling Guards
12.12 Piping and Ancillaries
12.1 3 Engine Maintenance
12.14 Starting System
BATTERY AND BATTERY CHARGER UNITS
CONTROL PANELS
General
Generator Set Control Panel
Transfer/lnterlocklSynchronising Control Panel
Interface with DCS
Control and Protection Equipment
Instruments
Cable Termination
Wiring and Terminals
Anti-Condensation Heaters
DUMMY LOAD RESISTANCE BANK
PANEL EARTHING
NOISE LIMITS
NAMEPLATES AND LABLES
PAINTING
DOC. NO. KOC-E-007 Page 5 of 57
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REV. I
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20.0 INSPECTION AND TESTING
General
Generator Tests
Diesel Engine Tests
Generator Set Performance Tests
Noise Test
Battery Charger Tests
Generator Control Panel Tests
Load Bank Tests
21.O QUALITY ASSURANCE
22.0 PACKING, MARKING AND DOCUMENTATION
22.1 General
22.2 Deliverables
23.0 SPARE PARTS AND MAINTENANCE REQUIRMENTS
24.0 Appendices
Appendix-I Data Sheet for Generator

Appendix-2 Data Sheet for Diesel Engine
ACKNOWLEDGEMENT
FOREWORD
This document "KOC Standard for Generator Sets" (KOC-E-007) is intended to

provide minimum requirements for Generator Sets to be installed at KOC Facilities in
Kuwait.
This Standard has been approved by the Standard Team is consultation with the
Standards Technical Committee (STC), for use throughout the corporate Engineering and
operational functions of Kuwait Oil Company (K.S.C.).
This Standard sets out to achieve the following objectives:
a t o prcvide technical guidance and establish the base document for

developing projectlmaterial specifications for Generator Sets with a view to
achieve uniformity, quality, reliability and efficiency in an economical
mannei;
b) to ma ntain the KOC requirements of safety and protection to plant,

personnel and environment established by KOC's Fire & Safety Regulations,
Health, Safety & Environment Management System (HSEMS) and Health and
Environment (H&E) Guidelines;
c) t o set out minimum features required, Data Sheets have been included
in Appendices 1&2, which will act as a checklist to ensure that all
requirements for design, construction and testing of Generator Sets are
covere.3.
Feed back as well as any comments or suggestions derived from the application of
this Standard at any stage of design, installation or operation are invited and should
be directed to:
Team Leader Standards Team

(Chairman, Standards Technical Committee)
Industrial Services Group, K.O.C.
P.O.Box-9758, Ahmadi- 61 0 0 8
State of Kuwait.
Task Force responsible for this Standard
The preparation of this Standard was entrusted by Standards Technical Committee to

the Task Force (TF-EEIO6) comprising of the following members: -
Mr. Khalid Al-Ahmed Gen. Proj. Team : Task Force Leader Tel No. 61 756
Mr. A.Unnikrishnan Standards Team : Author 1 Member Tel No. 67 633
Mr. Hammad Al-Ajmi Maint. Team (SK) : Member Tel No. 22010
Mr. Gobinda Mishra Design Team : Member Tel No. 61097
Mr. Afeef Kamel Projects Design Team : Member Tel No. 66245
Mr. C.Lazo 0pns.Tech. Svcs. (WK): Member Tel No. 20350
SCOPE
This Standard specifies the minimum requirements for the design,

construction, inspection and testing o f Generator Sets for installation at
various KOC Facilities within Kuwait.
This S;:andard covers the requirements for Generator Sets comprising o f a

Generator and driver. The driver may be a diesel engine, gas engine or gas
turbine.
The Gsrteral requirements for diesel engine drivers are included in this
Standard. For the requirements o f the gas engine driver and the gas turbine
driver, the appropriate project specifications shall be referred in conjunction
w i t h this Standard.
APPLICATION
The design, construction, performance, inspection and testing of Generator

Sets shall fully comply with all the relevant requirements specified in this
Standard and the reference standards / codes mentioned herein.
Any exceptions or deviations from this Standard, along with their merits and
justifications, shall be brought to the attention of KOC's Controlling Team for
their review, consideration and amendment by Standards Team (if required).
Compliance with this KOC Standard does not of itself confer immunity from
legal or statutory obligations.
TERMINOLOGY
Definitions:
For the purposes of this Standard, the following definitions apply.
KOC Controlling Team
Any KOC Team authorized to initiate a request for procurement o f materials

and e q ~ i p m e n for
t KOC.
Packager
Manufacturer of Generator / Driver w h o takes the overall responsibility o f

the entire system including the accessories.
Purchaser
Either KOC or Consultants / Contractors engaged by KOC.

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Abbreviations:
AVR Automatic Voltage Regulator
CT Current Transformer
Db Decibel
DCS Distributed Control System
H&E Health & Environment
HRC High Rupturing Capacity
HSEMS Health, Safety & Environment Management System
HS Hydrogen Sulphide
2
IP Ingress Protection
KOC Kuwait Oil Company (K.S.C)
PT Potential Transformer
PVC Polyvinylchloride
REFERENCE CODES 8 STANDARDS
In the event of conflict between this Standard and the latest edition of
standards / codes referred herein, or other purchase or contractual
requirements, the most stringent requirement shall apply.
List of Standards and Codes
Genera.:or Sets shall conform in design, manufacture, performance and

testing, except where otherwise specified, with the current issues and
amendments of the applicable codes and standards, including but not limited
t o the .'allowing:
Interna-:ional /National Standards
API 5 4 6 Brushless Synchronous Machines-5OOkVA and Larger
API 2 0 0 0 Venting Atmospheric and Low Pressure Storage Tanks-

Non refrigerated and Refrigerated
~.
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DOC. NO. KOC-E-007

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Page 9 of 57
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ASME Section Rules for Construction o f Pressure Vessels

Vlll Div 1
ASME Section V Non- Destructive Examination
ASME 31 6.5 Pipe Flanges and Flanged Fittings NPS% Through NPS 2 4
ASME 3 1 6 . 9 Factory - made Wrought Steel Butt Welding Fittings
ASME B31.3 Process Piping
ASME PTC-17 Reciprocating Internal Combustion Engines-Performance

Test Code
Specification for Fuel Oil for Agricultural, Domestic and

Industrial Engines and Boilers
BS 49S9 General Requirements for Rotating Electrical Machines
BS 5 1 6 9 Fusion Welded Steel Air Receivers
BS PD 5 3 0 4 Safe Use of Machinery
IEC 6 0 0 3 4 Rotating Electrical Machines
IEC 6 0 0 4 4 Instrument Current Transformers
IEC 60051 Recommendation for Direct Acting Indicating Analogue

Electrical Measuring Instruments and their Accessories
IEC 6 0 0 7 2 Dimensions and Output Series for Rotating Electrical

Machines
IEC 6 0 0 8 5 Electrical Insulation-Thermal Classification
IEC 6 0 1 4 6 Semiconductor Converters
IEC 6 0 ' 1 8 6 Voltage Transformers
IEC 60255 Electrical Relays
IEC 60269 Low-Voltage Fuses
IEC 60521 Class 0.5, 1 and 2 Alternating Current Watt-hour Meters
IEC 6 0 5 2 9 Degrees of Protection Provided by Enclosures (1P Code)
IEC 60947 Low-Voltage Switchgear and Controlgear

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NO. KOC-E-007 I Page 10 of 57
Rolling Bearings - Dynamic Load Ratings and Rating Life
Mechanical Vibration of Rotating and Reciprocating

Machinery-Requirements for Instruments for Measuring
Vibration Severity
I S 0 3046 Reciprocating Internal Combustion Engines - Performance
NACE MR 0 1 75 / Petroleum and Natural Gas Industries Materials for Use in

IS0 15156 H,s Containing Environments in Oil and Gas Production
OSHA Occupational Safety and Health Administration

1910.21 9 Machinery Safety
SAE J1349 Engine Power Test Code - Spark Ignition and

Compression Ignition -Net Power Rating
Steel Above ground Tanks for Flammable and

Combustible Liquids
4.2.2 KOC Standards
KOC Standard for Structural Steel Work - Material, Fabrication and

Erection
KOC Standard for High Voltage Switchgear and Control gear
KOC Recommended Practice for Selection, Installation and

Maintenance of Electrical Equipment in Hazardous Areas
KOC Standard for Low Voltage Switchgear
KOC Standard for DC Power Supply Units
KOC Recommended Practice for Electrical Installation on Packaged

Equipment
KOC Standard for Hazardous Area Classifications
KOC Standard for Packing, Marking and Documentation
KOC Standard for Basic Design Data
KOC Standard for Spare Parts and Maintenance Data
KOC Standard for Instrumentation and Control System Design
KOC Standard for Painting and Coating of Metal Surface-New

Construction
r DOC. NO. KOC-E-007
4.2.3 Project Specifications
In addition t o the KOC Standards and Recommended Practices referenced

herein, the Controlling Teams in KOC shall designate other project specifications
as req~lired,for the subjects listed below:
Iilectrical Design, Installation and Testing
Gas Turbine Driver
Gas Engine Driver
General Instruments
Instrumentation for Packaged Equipment
Light Duty Drums
[\Jon Destructive Testing of Welds
Passive Fire Proofing Materials And Applications
Plant / Equipment Noise Control
Pressure Vessels
Special-Purpose Gearboxes
Thermal and Acoustic Insulation
'Nelding Procedure Approval and Welding Quality Requirements
5.0 ENVIRONMENTAL CONDITIONS
5.1 The ervironmental conditions in Kuwait are severe and shall be considered
carefully before selection of Generator Sets. Any equipment for outdoor
installation shall be suitable for continuous operation at a desert location
under high ambient temperature and humidity. The atmosphere shall be
considered to be dusty and corrosive and may contain traces of hydrogen
sulphiae.
5.2 Refer t o "KOC Standard for Basic Design Data" (KOC-G-007), which
provides the detailed design information regarding the environmental, site
and utility supply conditions prevailing throughout the KOC Facilities.
HEALTH, SAFETY AND ENVIRONMENT
All relevant safety requirements of KOCfs Fire & Safety regulation, Health,
Safety & Environmental Management System (HSEMS) and H&E Guidelines
shall be adhered t o while specifying the Generator Set and associated
equipment.
All applicable safety requirements of Occupational Safety and Health

Administration (OSHA) Standard 1910.219 and BS PD 5 3 0 4 shall be
considered in the design, manufacture, and assembly of the equipment
covered by this Standard.
SERVICE CONDITIONS
The Generator Set and associated equipment shall be new and in all
respects suitable for continuous operation at a desert location under high
ambient temperatures and humidity.
Reliability of all components to perform continuously in the service conditions

specified is essential. The manufacturer shall confirm that, Generator Sets
typical of that being supplied shall have been in operational use without
problenls, elsewhere under similar environmental condition as specified in KOC
Standard for Basic Design Data (KOC-G-007) for a minimum period of t w o (2)
years. arototype or unproven equipment not having a well-established record
shall nct be considered.
The ra1:ings of all the electrical equipment shall be their continuous ratings,
after suitably derated for the specified service conditions.
The ingress protection for enclosures of Generator and other electrical

e q u i p r e n t shall be as specified in the Data Sheet. The minimum degree of
protection of Generator and other electrical equipment shall be based on the
following considerations:
a) Generator / other electrical equipment installed in a shelter exposed to

open environment shall have an ingress protection of IP 5 4 in
accordance with IEC 60034-5 1 IEC 60529.
b) Generator / other electrical equipment installed within an enclosed

building suitably constructed to prevent the entry of dust and water
shall have an ingress protection of be I ? 4 2 in accordance with IEC
60034-5 / IEC 60529.
BASIC DESIGN CONSIDERATIONS
The Generator Set shall be suitably rated for supplying under site conditions
the voltage, kVA and other parameters as specified in the Data Sheet.
The Generator shall be in accordance with the requirements of IEC 60034

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The Generator Set shall be designed for continuous unattended operation.

The design shall be suitable for automatic remote start and shall be ready
for service a t all times, without any external power requirement (black
start), ulnless otherwise specified.
The Generator Set shall be capable of accepting the connected loads and
shall maintain the voltage and frequency tolerances specified in this
Standard.
The Generator Set shall be suitable for continuous reliable operation at the
m i n i m ~ mfacility power requirement. Where the driver minimum continuous
output cannot meet this requirement, the use of an automatically connected,
artificial load can be adopted subject to KOC approval.
Electrical components for incorporation into the equipment shall comply w i t h

the relzvant IEC standards. The components shall b e selected to exclude
readily combustible insulating and constructional material. Electrical and
mechanical reliability is of the utmost importance. The components shall
have been type tested to the relevant IEC standards.
OPERATING MODES
Normal Status
Generator Sets shall normally be on standby and available for automatic

start-up and switching of the appropriate circuit breakers o n receipt of a
remote signal or manual control.
When at rest, those parameters which affect its availability to start and
operate shall be continuously monitored and if a malfunction occurs,
suitably alarmed at the Generator control panel situated adjacent t o the
Generator Set, remote Control panel and DCS. Volt free contacts shall be
wired up t o the terminals for remote alarms.
Automatic Mode
In the "Automatic Mode", when a loss of normal power occurs, the

Generator Set shall be started automatically by means o f an undervoltage
signal from the electrical distribution system and result i n an automatic
starting sequence and connection of the Generator supply to the
switchboard.
Upon resumption of normal power, the Generator Set shall stop

a u t o m ~ t i c a l l y after a pre-set time, once the normal supply is transferred
back.
9.3 Manual Mode
In the "Manual Mode", the Generator Set shall be capable of being started
manually by means of a local initiation. When running in this mode, a normal
power failure shall result in an automatic change-over sequence and
connection of the Generator supply to the switchboard.
9.4 Test Mode
9.4.1 In the "Test Mode" starting of the Generator Set shall be by manual means.
This mode shall be used for engine exercising and test running operations.
9.4.2 A test facility shall be provided to simulate the mains failure condition to
ensure the integrity of control circuit and Generator Set starting sequence.
The loading o f the Generator (connections to the switchboard) shall be
inhibited during this testing.
9.5 Shutdown of Generator Set
9.5.1 Manual Shutdown of the Generator Set shall be either from the local
Generator control panel or from remote shutdown switch.
9.5.2 The Generator Set shall automatically shut down on malfunction of its
essential auxiliary systems.
9.5.3 The Generator Set shall be provided with an Emergency shutdown push
button and a facility for mechanical shutdown o f the engine.
9.6 Svnchronirinq and Parallel Operation
9.6.1 The Generator Sets shall be suitable for both standalone operation and
parallel operation with other Generators and shall have adjustable droop
control.^ for both power and reactive load sharing.
9.6.2 Where shown on the single-line diagram, the Generators shall be arranged
for synchronising together for parallel operation. After automatic or manual
starting, the Generator shall automatically synchronise with running
Generators and share the load.
9.6.3 The Generator control panel shall be provided with facility for automatic and
manual control of the Generator voltage and frequency.
9.6.4 Automatic synchronising shall be backed up with check synchronising,

which shall also supervise manual synchronising operations.
Automatic/manual synchronising selector switches shall be provided.
Note: Parallel operation with the "State Grid Supply" is n o t permitted. For more
details on operating philosophy of emergencylstandby Generator Sets, refer
to Project Specification titled "Electrical Design, Installation and Testing".
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TECHNICAL REQUIREMENTS AND SYSTEM DESCRIPTION
Genera!
Each Senerator Set w i t h driver and accessories shall be designed,

manufactured, assembled and supplied as a complete unit as specified in the
Project / Purchase document / Data Sheet, which shall include, but not be
limited to the following:
Generator and auxiliaries including brushless exciter and automatic

tloltage regulator, cooling system etc.
Driver complete with auxiliaries including cooling water system, air

iqtake, engine exhaust / silencer system, lubricating system, starting
system etc.
c1 Power transmission coupling and non-sparking guard.
dl Base frame.
e) Fuel system including fuel storage tank.
fl Control panels, alarm & trip annunciators, battery and charger units.
9 HI1 associated piping, supports and consumable items.
h) Dummy load bank and its associated switchgear.
i) Platforms and ladders for access.
The Packager shall assume total responsibility for the complete Generator
Set package, including the driver and all accessories.
Generator Set Assembly
The Generator Set shall be o f the direct coupled type without gearbox,
unless otherwise recommended by the Manufacturer for better operational
reasons and approved by KOC.
The complete assembly shall be a packaged unit mounted on a common

base frame and shall be furnished w i t h all necessary auxiliary equipment.
The assembly shall be completely pre-wired and piped, requiring only the
connection of utility services at site.
Base Frame
The complete Generator Set shall be mounted on a steel base frame.
The baseframe shall be a fully welded design of rigid construction

suitable to support the weight of the components and withstand any
unbalanced forces that may occur due to the running of the Generator
Set, thermal expansion, forces due to transportation and manoeuvring
during installation. The whole unit shall be fitted with anti-vibration
mounting pads.
-'he baseframe shall be constructed in such a way that it will not

interfere with maintenance and routine servicing of the Generator Set,
and shall be fitted with lifting and pulling lugs t o facilitate installation
and handling. To collect any spillage of oil, a drip pan shall be
provided.
Adequate bonding between the equipment and the baseframe shall be

provided. There shall be t w o diagonally located M I 2 earthing bosses
on the baseplate.
Anti-vibration mounts shall be located under the base frame, Isolators

shall be of totally enclosed design, suitable for the environment, and
possess an isolation efficiency of at least 9 0 % in respect of all
engine-induced vibrations.
GENERATOR
Performance Requirements
The Generator rated voltage and frequency shall be in accordance with that
specified on the single-line diagram / Data Sheet. The voltage waveform
characteristics shall be sinusoidal and in accordance with the requirements
of IEC 50034.
The Generator shall be capable of supplyjng its rated output at rated power
factor for voltage and frequency variation in the voltage range t 6% and
+
frequency range 5 % occurring simultaneously.
The Generator shall be of continuous running duty S1 with continuous

maximum rating in accordance with the requirements of IEC 60034. The
minimum Generator rating when operating at rated voltage, frequency and
power factor and connected to a virtually balanced load shall be as specified
on the Data Sheet / single line diagram.
The Generator shall be capable of accepting load in accordance with the
following:
a) 6 0 % of the Generator full load immediately after reaching full speed

and voltage.
b) The remaining 4 0 % of the Generator full load, 2 seconds after the

application of the first 60% step.
C) Sudden load motor starting duty in accordance with the largest

connected motor load, with all other loads including specified spare
capacity running.
The voltage variation limits for Generator full load acceptance or rejection
shall comply w i t h the following:
a) Voltage +1 5 % of nominal recovering t o + 1% within 3 seconds of

load application.
b) Frequency k 5 % of nominal recovering to c 2 % within 3 seconds.
The Generator shall be capable of carrying an overload of 1 0 % of rated

current for a period of one hour in any 12-hour period of continuous running
at rated voltage, frequency and power factor without exceeding the
temperature limits set in IEC 60034.
The Generator shall be capable of withstanding without damage a 3-phase,

line-to-line, line-to-earth or two-lines-to-earth short circuit for a period of
three (3) seconds when operating at rated speed and w i t h an excitation
corresponding t o 5 % over voltage at no-load.
The Generator shall be capable of operating continuously at rated voltage

and frequency on an unbalanced load, at rated current containing 8 %
negative sequence component, unless otherwise specified.
The maximum level of the total harmonic amplitude shall not exceed 5 % of
the fundamental, while the maximum of any given harmonic shall not
exceed 3 % of the fundamental, unless otherwise specified.
The Generator Set shall be suitably designed t o operate continuously when

supplying harmonic services such as variable speed drive equipment.
Enclosure
The Generator enclosure shall be o f closed air circuit air cooled in

accordance with IEC 60034-6 unless otherwise specified. The classification
shall be IC 41 1 (for less than 750kVA), IC 6 1 1 / IC 61 6 (for larger machines),
unless otherwise specified.
Bearinas and Lubrication
The Generator shall be of the two-bearing, foot-mounted type. The

G e n e r ~ t o rframe and bearing housings shall be fabricated of steel or cast
steel construction and be designed to withstand stresses imposed during
operation and fault conditions.
When ball or roller bearings are used at both the drive and non-drive ends,
suitable provision shall be made to permit differential expansion between the
shaft and frame and thrust loads from the driver.
The L,,, rating life for antifriction bearings shall be in excess of 50,000 hours
and shall be calculated in accordance with I S 0 281. The calculation shall
take into account of the worst aggregate of dimensional tolerances as
obtained during manufacturing.
Bearings shall have a minimum relubrication interval of 4 0 0 0 hours

irrespective of the actual number of running hours.
Bearing housings shall be fully sealed t o prevent ingress of foreign matter,

moisture and loss of grease. Felt-type seals are unacceptable.
The bearing housing shall be designed such that relubrication can be carried
out without stopping the Generator. Grease points shall be conical nipple
type incorporating a check ball and fitted with a protection cap.
A grease relief valve shall be fitted, which makes it possible to displace the
m a x i m ~ mamount of used grease by new grease.
The bearing housing design shall also prevent grease entering the Generator.
Unless otherwise specified, hydrodynamic bearings shall be provided on

Generators rated above 1000 kVA, which shall comply with the following:
a) Each self lubricated bearing housing shall have a constant level oiler
with Pyrex glass bottle. The recommended oil level shall be marked
3n the outside of bearing housings by a cast mark or metal tag.
b) For pressure lubricated systems, where the Generator lubrication

cannot be supplied from the driver lubrication system, an independent
lubrication oil system shall be provided which shall include the
following:
i. Separately driven lubrication pumps, supplying forced oil feed

from a separate system comprising tank, cooler, duplex filters, oil
flow and level indicators including a sight glass.
ii. Means for measuring bearing wear.
iii. Alarms to warn blocked filter.

DOC. NO. KO Page 19 of 57 REV. 1
Bearings shall be electrically insulated t o prevent damage t o bearings by

shaft c,urrents. Provision shall be made to measure the bearing insulation
resistance without disassembling the Generator or removing if from its base.
Vibration monitoring with alarm / trip shall be provided as specified in the

Data Sheet.
Windinqs
The windings shall be using copper conductors provided w i t h "Therma I

Class i5 5 (F)" insulation, limited t o "Thermal Class 1 3 0 (B)" temperature
rise in accordance with IEC 60085.
Stator winding insulation shall be applied by vacuum impregnation. The

process shall thoroughly penetrate the total winding and create a void-free
structure w i t h optimum coil rigidity. The stator winding insulation shalt
provide protection against abrasive materials, moisture, dust and
condensation.
The rotor windings shall be provided w i t h the same protection as the stator
winding and be mechanically designed to withstand the rotational forces.
Excitation
The Generator excitation shall consist of a direct driven rotary brushless AC

exciter, automatic voltage regulators (AVRs), voltage adjustment facility and
fault monitoring system.
The excitation system shall include a permanent magnet generator pilot

exciter The AC exciter shall carry a full-wave rotating rectifier assembly,
complete w i t h surge suppression networks.
The rectifier bridge shall be 3-phase, full-wave bridge, using diodes. Each
bridge arm shall comprise t w o diodes in series. Each diode shall be rated
for at least t w i c e the maximum working voltage and current. All rotating
components shall be proven at values of centrifugal stress under normal
operati 7g levels and fault conditions.
The automatic voltage regulator shall be capable of maintaining the steady

state voltage w i t h k 1 % of the controlled value over the whole load range
of the Generator for power factors between 0 . 8 and 1.0.
The excitation system shall be sufficient t o cover any peak load condition
that the Generator is able to supply. The exciter rating shall be 1 3 0 % of
the excitation current required at the rated output of the Generator.
Diode failure shall be alarmed. On failure of one diode, it shall be possible to
maintain the operation, without adverse effect until the diode is replaced.
The automatic voltage regulators (AVRs) shall be of the dual automatic solid
state, continuously acting type, providing facilities for local and remote
voltage adjustment, unless otherwise specified in the Data Sheet. The
voltage setting range shall be k 5 % of the rated value.
Failure of the operating regulator shall immediately cause the standby

regulator to take over with negligible disturbance to the Generator
operation.
Under sudden load application conditions, the excitation systems shall have
current compound field forcing t o provide voltage recovery. Cross-current
comperisation facilities for parallel operation shall be included.
Terminal Boxes
The terminal boxes shall be of the type as specified in the Data Sheet.
The entls of all the six (6) terminals of the Star Connected Generator stator
winding shall be brought out to the terminal box, unless otherwise specified
in the Data Sheet. The ends of the neutral connections shall be brought out
to a separate terminal box unless otherwise specified in the Data Sheet.
The ter.minal boxes shall have provisions for mounting the required current
transformers in the line and neutral terminals, in accordance with the single-
line diagram.
Terminal boxes shall be sized t o provide ample space to permit unhindered

connection of the cables. Terminal box design shall facilitate mounting and
removal of the power cables without stressing or re-lugging.
Where gaskets are provided, they shall be neoprene, preferably fixed to the
removable part of the terminal box.
Terminal boxes shall be provided with removable undrilled gland plates with
a minimum thickness of 3 mm. Where single-core cables are used, gland
plate shall be of non-magnetic material.
The terminal box design shall enable incoming cable tails t o be taken from
the point of entry t o the connection terminals in such a way that rubbing
against other connections or parts is prevented.
Auxiliary circuits for measuring, control and protection requiring external

connection shall be wired up t o an auxiliary terminal box mounted on the
Generator. Auxiliary terminals and connections shall be continuously rated
to meet the requirements for 110% of the full load current of the Generator.
Temperature Monitorinq
The Generators shall be provided with a minimum of six ( t w o per phase),

embedded resistance temperature detectors in the stator winding with the
connections brought out to a separate terminal box, unless otherwise
specified in the Data Sheet. These shall be the platinum resistance
thermometer elements, three (3) wire type, with a resistance of 1 0 0 ohms
at 0°C.
Generators rated over 1500 kVA shall be provided with local bearing
temperature indicators and t w o thermocouples per bearing to monitor
bearing temperature, unless otherwise specified in the Data Sheet.
AntLCondensation Heaters
Anti-condensation heaters shall be suitable for operation on a 250 V, single-

phase supply.
The arti-condensation heaters shall not exceed or cause any part of the
Generator to exceed the Generator permitted temperature rise. They shall
be suitable for continuous operation and contain no internal switching
devices, i.e., thermostats.
Anti-condensation heaters shall be wired separately to an auxiliary terminal

box fitted with terminals.
Generator Earthing
The Generator terminal boxes shall be provided with M 1 2 external earth

studs.
The Generator frame and base frame shall be provided with M I 2 external
studs.
All metallic non-current-carrying parts that are not inherently bonded

together shall be bonded to the frame earth.
The Generator neutral earthing shall be as specified in the Data Sheet.
Dynamics
All rotor systems within the engine and Generator shall be designed as rigid
shaft assemblies.
The engine-generator combination shall be so designed to ensure that the

torsional conditions of the system are within satisfactory limits.
The maximum individual effective vibration velocity, measured on the
bearing housing of the Generator shall not exceed the limits specified in BS
4999 Part 142.
Rating Plate
Ratins plates shall be made of stainless steel and be screw fixed to a non-
remobable part of the Generator and exciter frames and shall be stamped
with data in accordance with IEC 60034-1 ,which shall include the following:
a) Sub-transient, transient and synchronous reactance of the Generator

in %.
b) Class of insulation and permissible temperature rise.
C) Degree of protection (IP Code).
d) Total weight of machine.
e) Heater rating and voltage.
DIESEL ENGINE
Performance Requirements
Engine performance shall be in accordance with SAE J1349, derated for the
service conditions specified and to provide a continuous power rating at the
site with an overload of 1 0 % for a period of 1 hour, within 1 2 hours of
contiruous running in accordance with IS0 3046.
Rating of the diesel engine shall not be less than the sum of the following:
a) Generator power requirement.
b) Transmission losses (if any).
c) Auxiliary power requirements for engine operation.
Construction Requirements
The engine shall be of multi-cylinder. 4 stroke. heavy-duty type, arranged in

either in-line or V configuration, water cooled.
The engine shall run for a minimum of 2 0 0 0 hours or for 1 year of minimal
use, before requiring any preventative maintenance.
The engine shall be fitted with over speed I abnormal vibration alarm and
shutdown device.
DOC. NO. KOC-E-007
I
I
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REV. 1
_
The engine shall be fitted w i t h the Manufacturer's standard gauges and
control panel. The instruments shall include a tachometer.
Engine speed shall n o t be greater than I500 rpm.
Coolitiq System
The engine shall be provided with a cooling system having sufficient

capacity for cooling the engine, when the diesel Generator Set is delivering
110 % continuous power at the service conditions specified.
The cooling system shall be o f the closed circuit, circulating water type,
which in turn shall be air cooled by an integral skid-mounted radiator w i t h
an engine-driven fan, unless otherwise specified in the Data Sheet. The
cooling system shall be common for both engine and lubricating oil.
The cooling water system shall be fitted w i t h circulation pumps, expansion

tank ~ , n pressure
d relief valve. A n opening shall be provided in the circuit for
filling the system, checking coolant level and adding makeup coolant when
requir3d. All items shall be fully drainable.
The cooling water circuit shall be provided w i t h thermostatic control of the

engine coolant temperature. The temperature control shall be achieved by
bypassing the radiator t o a proportional degree by means of a thermostatic
valve.
Engine-mounted temperature indicators shall be provided t o show the

temperature o f cooling water entering and leaving t h e engine cooling circuit.
Jacket water heater(s) shall be provided to maintain the cooling water at a

suitable temperature for rapid starting and load acceptance. The heaters
shall be thermostatically controlled and arranged to prevent local
overheating. The cooling water heaters shall isolate when the engine
reaches normal operating temperature. Heaters shall be suitable for
connection t o a 250-V, single-phase supply.
The radiator shall b e sized t o dissipate the engine heat rejection t o the water
at If 0% o f the rated load.
Radia1:ors shall b e fitted w i t h an adequately sized expansion tank and be

complete w i t h t h e following as applicable:
a) Level gauge.
b) Low water level switch with alarm contacts.
c) Pressure cap.
7
DOC. NO. KOC-E-007 Page 24 of 57

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I REV. I
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d} Vent,
e) Drain.
f1 Earthing bosses.
g) Ducting for radiator exhaust air between radiator and wall-mounted

louver, as applicable.
h) Access ladder.
The cooling system shall be suitable for the addition of corrosion and scale
inhibitors. Sampling points shall be provided.
For Generator Sets installed within an enclosed building, louvers shall be

provided on the opposite walls for air inlet / outlet. Ducting shall be provided
for the removal of hot air from the radiator, upto the outlet louver. The
louvers shall be motor operated and shall open automatically, when the
Generator Set starts.
Lubrication Svstem
All lubrication points in the engine shall be connected to a pressurised oil

systern with oil sump, strainer, pump, piping, cooler and full-flow duplex oil
filter.
The lubrication system pump shall be of the positive displacement rotary

type, driven from the engine crankshaft unless otherwise specified.
The duplex oil filters shall be of the replaceable element type, rated for the
full flow of lubricating oil, and the elements shall be readily changeable
while the engine is running and without dismantling adjacent engine
components. The absolute particle size after filtration shall not exceed 1 0
microns. Each filter shall be equipped with a differential pressure indicator/
alarm downstream of the filter and a filter change indicator.
The Iubrication oil coolers shall be cooled by the same cooling medium as
that used for the cooling of engine cylinders. The lubrication oil shall be
maintained at a higher pressure than the cooling medium in order to prevent
leakac_leof cooling medium into the oil.
A manually operated lubrication oil pump shall be supplied for priming the
systern and emptying the sump. When the engine requires a pressurised
supply of oil prior to starting, a separately driven electric battery powered
pre-lube oil pump shall be included.
Thermostatically controlled electric sump heater(s) shall be provided,

suitable for a 2 5 0 V, single-phase supply.
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DOC. NO. KOC-E-007 1 Page 25 of 57
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r
12.4.7 In order t o avoid the danger of oil oxidation, the heater surface temperature
shall n o t exceed 150°C or the surface heat flux exceeds 2.3 W/cm2. The
circuits feeding the heaters shall contain miniature circuit breakers
incorporating overload, short-circuit and earth leakage protection.
12.5 Fuel System
12.5.1 General
The engine shal I be supplied with a complete fuel oil system which shall
include, but not be limited t o the following:
Shaft-driven fuel feed pump and fuet injection pump(s), as applicable

with pressure relief valve.
Fuel pump suction and discharge filters of the duplex type with
replaceable cartridge elements and full-ftow transfer valve.
(The filter elements shall be capable of easy removal when the engine
is running without breaking any fuel line connections or allowing the
ingress of air t o the fuel system).
A differential pressure indicator / switch t o indicate pressure drop

across the filter and alarm o n blocked filter condition.
Water and sediment trap with cleanout drain.
Fuel governor.
Low-fuel pressure switch.
A n actuated fuel isolation valve in the fuel line t o the engine arranged
for remote control.
Guards or protection for all exposed fuel lines.
Fuel day tank.
12.5.2 Fuel Day Tank
a) Fuel day tank (Diesel Storage Tank) shall have a minimum capacity t o
supply fuel for 24-hours of continuous operation of the Diesel
Generator Set at rated power.
DOC. NO. KOC-E-007 1 Page 26 of 57 REV. 1
The tank shall be complete with suction and return connections to the
engine fuel system, fill connection, fuel filter, liquid level gauge, vent
pipe with flame arrestor, cleanout, overflow, inlet/outlet and valved
drain connections.
The Diesel Storage Tank shall be designed and constructed in

accordance with the requirements of project specification titled "Light
Duty Drums" and in compliance with UL 142.
The design pressure of the tank in conjunction with the vent size shall
be adequate to handle relieving rates for fire engulfment in
accordance with API 2000.
The Diesel Storage Tank and all appurtenances shall be assembled

and mounted on a skid suitable to be installed on a concrete pad/
structural steel frame work.
The day tank shall be located outside the Generator building at a safe
distance in accordance with the requirements of "KOC Standard for
Hazardous Area Classification" (KOC-G-002).
All instrument / electrical equipment located in the hazardous area

around the tank shall be in accordance with the requirements of KOC
Recommended Practice for the Selection, lnstallation and Maintenance
of Electrical Equipment in Hazardous Areas (KOC-E-004).
The equipment, instruments, piping and wiring shall be installed on

the skid such that piping will terminate at flanges at the edge of the
skid. The electrical / Instrumentation cables shall be pre-wired and
terminated at dedicated junction I terminal boxes at the skid.
All instruments shall be installed as per instrument specifications and

P&ID, Instruments shall be comply with the requirements of project
specification titled "General Instruments" and shall be installed in line
with the requirements of "KOC Standard for Instrument Installation"
(KOC-1-002).
Level switches and level transmitters (certified for use in Zone 1) shall
be provided on the day tank for high and low fuel level to control the
transfer pump from bulk storage tank as applicable. There shall be
provision to alarm the low-level, when the fuel level goes below that
required for three (3) hours operation of the set and to shutdown the
set when the fuel level is less than that required for one (1) hour
operation.
k) To facilitate the flow of diesel oil in the tank, tank shall be slopped
towards the outlet nozzle. The tank shall be vented to a safe location.
The vent pipe shall include a flame arrestor and shall be provided with
an insect screen at the end. The diesel outlet nozzle shall be provided
with stand-up vortex breaker.
1) The package shall include a connection for tank filling from the truck.
Local level indicator, flashing red light I alarm shall be located near
the filling connection.
m) Piping shall be installed as per the piping specifications and P&lD. The
diesel oil supply & return lines and connection for tank filing shall be
provided with flanges located on the edge of the skid.
Speed Governinq
The eqgine shall be provided with a governor with paralleling capabilities to

enable the following operational modes:
a) Operation in parallel with other Generators.
b) Operation in isolation during normal and emergency operation.
The governor shall meet the requirements of I S 0 3 0 4 6 Part 4, and shall be

suitable for isochronous, droop control and local I remote speed adjustment.
Air Intake Svstem
Combustion air shall be drawn from outside the Generator building.
A conlbustion air intake filter shall be provided for each engine, designed to
ensure that the engine condition does not deteriorate due to ingress of sand,
dust or other airborne contaminants under the service conditions specified.
The intake filter unit shall be equipped with a differential pressure indicator
and alarm.
The housing and all structural components of the air filter system shall be
made of type 31 6L stainless steel.
Exhaust Svstem
The exhaust system components shall include the engine exhaust

manifold(s), flexible expansion bellows unit(s), exhaust ducting, silencer,
spark arrestor and heat insulation within the building. The exhaust system
shall terminate outside the Generator building, at a suitable level and
l o c a t i ~ nso as not t o form a dangerous obstruction and I or result in a
dischiwge of exhaust gases directly to persons passing by.
The silencer shall be fitted with flanged, raised-face connections, at each
end.
A spark arrestor shall be fitted to the discharge end of the exhaust system.
The exhaust silencer, spark arrestor and bellow unit(s) shall be

manufactured in 31 6L stainless steel.
Person~ielprotection from hot surfaces above 70°C shall be by metal-clad

mineral wool or better materials.
All steel work and associated materials for supporting the exhaust 1 silencer
system shall be provided.
Bearing Temperature Monitorinq
Thrust and journal bearings on the diesel engine shall be fitted with
thermocouples to monitor bearing temperature.
Power Transmission
12.10.1 The Generator shall be driven via a flywheel and coupling.
12.10.2 The flywheel shall be provided t o prevent resonance of the engine and
Generator and t o provide stable synchronous and momentary parallel
operation with other supply sources.
12, 10.3 The driver, flywheel, coupling and Generator shall be completely coordinated
to prevent torsional vibrations caused by torque impulses of the engine
shaft, coupling etc.
12.10.4 The coupling shall be capable of transmitting 11 5 % of the maximum

transient torque for the driver offered.
12.10.5 I t shal be possible to dismantle and remove the coupling without the
necessity t o move either Generator or driver.
12.1 0.6 It shall be possible to run the driver disconnected and an idling adaptor shall
be provided for this purpose, if necessary.
Coupli~iqGuards
12.1 1 .I The coupling guard shall be of removable type and manufactured from a
non-sparking material.
12.1 7.2 Guards shall be designed to meet the requirements of BS PD 5304.

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DOC. NO. KOC-E-007
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Page 29 of 57 I
Guards shall extend t o within 1 2 m m o f the coupling housing and shall have
sufficient strength t o contain t h e coupling i n the event o f failure and
withstand damage w h e n a force equivalent t o a 1 0 0 K g mass is applied t o
t h e guard.
Pipinq and Ancillaries
All piping, valves and ancillaries shal I be provided as required t o form a

complete engine. Piping shall comply w i t h ASME B 3 1 . 3 and flanges w i t h
ASME B16.5.
All valves, controls and other equipment shall be completely piped and
wired.
The number o f flange joints shall be restricted t o the minimum necessary t o

meet maintainability requirements. Flange bolt holes shall straddle the
vertical and horizontal centre lines.
Where an engine is mounted o n anti-vibration mounts, all connections t o it

shall be via fire-resistant, steel-braided, flexible hoses or stainless steel
bellows.
All flexible hoses shall be fire resistant and shall be externally braided w i t h
stainless steel t y p e 316L, except for short lengths of hose ( n o t greater than
1 0 diarneters or 2 5 0 m m in length, whichever is greater) containing fluids a t
pressures n o t greater than 3 barg. Unbraided hoses shall be arranged t o
minimize t h e likelihood of external mechanical damage.
All terminal points shall terminate w i t h ASME 8 1 6 . 5 raised-face flanges a t

t h e edge o f t h e base frame.
Engine Maintenance
The engine and its auxiliary equipment shall be designed and configured t o
facilitate inspection 1 maintenance and overhaul activities. Equipment and
components o f greater than 15 k g weight shall be provided w i t h lifting lugs
for installation and maintenance.
Provision shall be made for manual turning o f t h e engine during

maintenance. Decompression facilities shall be provided i f necessary. The
engine bar-over facility shall be fully interlocked w i t h any external engine
start station t o ensure operator safety during maintenance. The direction o f
rotation shall be permanently marked on the engine i n a prominent position.
DOC. NO. KOC-E-007
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12.14 start in^ System
The preferred starting system is electric type. Where electrical starting is

limited by Generator rating, alternate type starting methods such as air or
hydraulic starting motors shall be employed w i t h prior approval from KOC.
The total time between mains failure and the connection o f the Generator t o
the switchboard busbars shall not exceed 1 5 seconds (the time setting shall
b e adjustable). If this time is exceeded, an alarm shall be raised o n the
Generator control panel. Provisions shall be made for transmitting the alarm
to remote control room.
12.14.1 Electrical Starting System
a) Electrical engine starting shall be by dual electric 2 4 VDC starter

rnotor and battery system.
b) The automatic start sequence shall be arranged such that there

are six (6) cranking periods o f 1 0 seconds maximum duration,
interspersed with six rest periods. If one battery unit fails during the
start sequence, all the cranking shall automatically be powered from
the other batteries and starter motor combination. The automatic
start sequence shall be locked out after six unsuccessful cranking
periods.
12.1 4 . 2 Air Starting System
a) Air starting systems shall b e complete w i t h an engine-mounted air

motor, electrically driven charging compressor, air receiver, regulator,
controls and safety relief valve. A quick connect coupling shall be
furnished on the air receiver for external air supply to be used for
initial start.
b) The charging compressor shall be sized to fully charge the receiver

I r o m atmospheric pressure within 1 5 minutes.
C) The Air receiver shall comply with t h e Project Specification titled

"Pressure Vessels" and shall be sized to provide, without recharging,
a minimum o f six (6) cranking periods each o f 1 0 seconds duration.
12.1 4.3 Hydraulic Starting System
a) The hydraulic starting system shall be supplied complete with a

separate diesel-engine-driven charging pump, hand-charging pump,
one accumulator pack for each start attempt, hydraulic motor,
necessary manual controls, instrumentation and relief systems.
,\ccumulator packs shall be capable o f being isolated from one
another during start attempts and hand-recharging activities.
DOC. NO. K(X=- REV. 1
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1) The hydraulic starting system shall be capable o f a minimum o f six ( 6 )

cranking periods each of 1 0 seconds duration.
--he engine-driven charging pump shall be sized to completely charge

the accumulator in not more than 1 5 minutes at rated speed.
d) A n alarm shall be provided to annunciate when the accumulator

pressure falls t o a critical level.
BATTERY A N D BATTERY CHARGER UNITS
T w o sets of batteries shall be provided for diesel engines intended for

electric starting. Each battery sets shall be provided w i t h independent
battery charger units.
Batteries shall be o f ultra l o w maintenance type requiring n o topping up o f

electrolyte under normal operation with a life expectancy o f not less than 1 0
years under the service conditions. Plastic cell container material shall be
non-flame propagating, mechanically shock resistant and translucent, to give
a visua indication of electrolyte level.
Inter-cell connections shall be provided and shall be insulated or otherwise

provided w i t h protective covering to prevent inadvertent short circuiting.
B a t t e r i ~ s shall be protected against the effects o f over voltage, under

voltage and overcharging in accordance w i t h the Manufacturer's
recommendations.
Batteries shall b e furnished in a dry condition w i t h electrolyte liquid in

separate container. Electrolyte shall be added at the time the battery is p u t
into service and given a conditioning charge.
The bat:tery enclosure(s) steelwork shall be insulated by means o f plastic or

epoxy coating t o provide suitable protection against the effects of
electrolyte spillage.
The installation o f battery shall be in line with the requirements o f

KOC-G-002.
The battery charger shall be suitable for 250/440V, 5 0 Hz power supply, as

specified in the Data Sheet.
Each battery shall normally be on a continuous float charge, with the

respective chargers maintaining the batteries in a fully charged condition
and at .:he same time supplying any continuous standby quiescent load.
Battery chargers shall be rated for 125% of the maximum expected load
The rms value of the ripple o n the charger DC output voltage, with the
battery connected, shall not exceed 5 % or t h e value recommended by the
Manufacturer, whichever is lower. The charging voltage level shall be
adjustable within + 1 0 % of nominal voltage.
Each charger shall be sized to restore a fully discharged battery t o 1 0 0 %

capacity within eight (8)hours. Battery charging shall be current limited
such tt-at isolation during cranking is not necessary.
Where the Generators are installed inside an enclosed building, the battery
chargers shall be installed in the same building. In case the Generator is
installed in open environment, then the battery chargers shall be installed
inside the substation or other location approved b y KOC.
The battery chargers and their associated distribution equipment shall be

housed in free-standing or wall-mounting sheet steel enclosures with a
degree o f protection as specified in clause 7.4 o f this Standard.
Internally, the units shall be provided w i t h IP2X protection in accordance

w i t h IEC 6 0 9 4 7 .
The enclosure(s) shall be constructed from folded and welded mild steel
sheet not less than 2 m m thick. Cable access shall be via suitably sized, 3-
mm-thick, removable undrilled gland plates.
The enclosure(s) height shall not be greater than 2.2 m. The enclosure shall
be designed t o permit front access only and be equipped w i t h a pair of
removable eye bolts for lifting purposes.
Front access door(s) shall be sufficiently rigid and close fitting t o exclude
dust. Gaskets o f neoprene material shall be used t o provide a seal.
Individual hinged access doors shall be fastened b y means of a T-type key
lockable handle.
The enclosure(s) shall be naturally ventilated.
A mechanical interlock shall be provided between the enclosure door and

the ma'n AC supply isolating switch so that access can only be obtained in
the off position. The main switch operating handle shall be provided w i t h
onloff indication and be padlockable in the off position.
The accessories provided in the charger shall include the following:
a) k C supply onloff switch.
b) Charge indication lamps.

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DOC. NO. KO
DC voltmeter measuring charger output voltage.
DC ammeter w i t h zero at mid-scale, measuring battery current.
DC ammeter measuring charger output current.
Fuses to protect battery charger circuits.
Battery fuse switch unit.
AC supply failure indication / Alarm.
Charger failure / Earth fault indication / Alarm.
Low battery volts indication / Alarm.
Common alarm output.
Engine-driven alternators shall be provided w i t h suitable battery charging

systems to charge the batteries when the engine is running. The system
shall ensure that battery charging is effectively controlled b y diode steering.
The battery 1 charger systems shall be so designed t o cater for the starting
requirements of the engine and continuous load requirements of control
system.
The ampere-hour rating of the batteries shall be suitable for the starting duty
specified in sub-clause 12.14.1 of this Standard and t o cater for the
contin3ous load requirements of control system t o support the standing load
for eight ( 8 ) hours after mains failure and provide control power t o start the
Generator Set after this time, under the minimum ambient temperature
condit-ons.
Where electric starting is not envisaged, the control system battery capacity
shall be adequate to support the standing load for eight ( 8 ) hours after
mains failure and to provide control power to start the Generator Set after
this t i n e .
The battery sizing calculations and load schedule shall be submitted t o KOC
for review and approval.
CONTROL PANELS
General
The Generator control panels shall be of floor-standing type made out of

sheet steel, suitable for front access only.
The Generator Set control systems shall be microprocessor based.
An annunciator system shall be provided for visual and audible display of

alarms and shutdowns.
Generator Set Control Panel
The Generator control panel shall be provided with all Control / Metering /
Indication / Alarm / Shutdown requirements for the proper and safe
operati3n of the Generator Set. The various items shall include, but not
limited to the following:
Contro / Instruments / Metering
Driver start pushbutton.
Driver normal stop pushbutton.
Driver emergency stop pushbutton (red mushroom headed, stay-put

type).
Lockable control mode selector switch - test/off/manual/automatic.
Lockable localiofflremote selector switch for speed and voltage

control.
Speed raisellower control.
Voltage raiseilower control.
Generator emergency trip push button.
RPM meter.
Hours Run meter.
Voltmeter and ammeter for excitation metering.
Generator output voltmeter and 4-position selec switch.
Generator output ammeter and 4-position selector switch.
Generator power factor meter.
Generator kilowatts meter.
Generator frequency meter.

q) AVR controls.
r1 Driver control relay.
S) Switches and indication for test load bank control.
14.2.2 Indication / Alarm / Shutdown
Ready to start indication.
Stopped indication.
Auxiliary drive(s1 running and stopped indications.
Driver coolant heater indication.
Driver lubricating oil heater indication.
Generator Set running indication.
Mains supply available indication.
Load on Mains supply indication.
Generator supply available indication.
Load on Generator supply indication.
Generator anti-condensation heaters on indication.
Fuel oil level low / high (day tank): alarm and indication.
Generator / Driver abnormal vibration Alarm/ Trip.
Generator / Driver bearing temperature indication / alarm "'
Generator fails t o start alarm.
Generator winding temperature indication / alarm "

Driver "Emergency Stopped" alarm.
Electric priming pump failure alarm.
Battery charger alarms.
Driver coolant low-level alarm.
Driver lubricating oil filter blocked alarm.

DOC. NO. KOC-E-007
V) Driver coolant temperature high alarm and shutdown.
W) Driver lubricating oil temperature high alarm and shutdown.
X) Driver lubricating oil pressure low alarm and shutdown.
y) Driver over speed alarm and shutdown.
z) Generator over voltage I under frequency alarm and shutdown.
Stator winding, driver / Generator bearing temperature monitoring unit shall

be provided in the control panel. It shall be of the flush-fronted, door-
m o u n t i i g type with selectable digital readout for each of the temperature
detectors.
T r a n s f e d Interlock / a n c h r o n i s i n g Control Panel
The transfer / interlock / synchronising control panel shall be located in the

substation. The general construction of this remote control panel shall be
similar t o that of the Generator Set control panel.
Mains supply under voltage monitoring and circuit breaker controls together
with automatic check synchronising equipment shall be located in the panel
to provide automatic Generator Set starting, transfer of loads and exercising
of the load bank in accordance with the operational philosophy outlined in
the Project Specification.
Synchronising controls and instruments (twin voltmeters, t w i n frequency

meters, synchroscope), shall be provided, where shown in the single line
diagram I Data Sheet. A Mimic diagram of switchgear incorporating
synchronising selector switches, automatic I check synchronising switches,
circuit breaker controls and indications shall be provided.
In cases where more than one Generator is installed in the same location for
parallel operation, then these controls could be accommodated in a single
panel.
The remote control panel shall be equipped with the following as a

minimum:
a) Voltage sensing relays.
b) Microprocessor based Transfer control system.
c) Speed and Voltage control.
d) Digital Voltage and Frequency displays.
e) Emergency stop button.

DOC. NO. KOC-E-007
I
f1 Repeat o f the alarm / indication of the interface signals provided in
DCS as per clause 1 4 . 4 of this Standard.
14.4 Interface with DCS
14.4.1 The DCS interface signals shall be provided in the form of volt-free
contac1:s for t h e following as a minimum:
Fuel oil high/low level.
Ready t o start.
N o t available t o start.
Failed t o start.
Running.
Engine over speed.
Load accepted.
Common fault.
Common trip.
14.4.2 The DCS interface shall also include the real time analogue signals of the
following as a minimum:
a) Generator voltage.
b) Frequency.
c) Current.
d) Power factor.
e) Kilowatt.
14.5 Control a n d Protection Equipment
14.5.1 All control circuits in the control panels shall be adequately protected b y
means of switches and fuses, double pole for DC circuits.
14.5.2 Circuits to be protected include the mains power supply, power supply
units, small wiring and outgoing circuits.
All circuits shall be protected with fuses including the following:
a) Battery charger circuits,
b) Battery protection fuses (easily accessible and removable) in fuse

switch, w i t h auxiliary alarm contact.
C) Each pole of the voltmeter and alarm relay circuits
Rectifier output and battery circuit fuses shall be in accordance with IEC
60269-2.
Relays shall be provided to give local and remote alarm for the following
fault conditions:
a) Failure of AC supply,
b) Earth-fault o n DC system.
C) Failure of rectifier, detected by loss of voltage from charger.
d) L o w battery voltage: this relay shall be inoperative during heavy

transient load or external fault conditions.
The relays shall be provided with automatic reset indicators and have t w o
volt-free changeover contacts wired out t o terminals for remote alarms.
Pushbuttons, w i t h the exception of stop pushbuttons, shall be of the

shrouded type. Stop pushbuttons shall be mushroom-head, stay-put type.
The pushbuttons shall be provided with a minimum of one normally open
and one normally closed auxiliary contacts.
Instruments
lndicaring instruments shall be of square, flush-type, Class 1 in accordance

with IEC 6 0 0 5 1 .
The irstruments shall be back connected w i t h provision for external zero

adjustment. The minimum scale reading shall not be less than 2 0 % of the
normal or full load reading. All fascias shall be white, w i t h black pointers,
and the scale shall be i n actual values. A red line or adjustable red pointer
t o indicate t h e normal operating point shall be provided.
Indica-tions shall be using LEDs. Digital readouts with status indication and
Mimic Diagram t o show the various status shall also be provided.
Cable Termination
Undrilled removable gland plates shall be provided on cable termination

compartments.
All cable entries shall be from bottom and all connections shall be made
from the front of the panel.
The terminals shall be so arranged that dressing and connection of cables

could be done safely, without exposure to adjacent live functional units.
Inside the compartments, separate terminals or bolts of adequate

dimensions shall be provided for cable armour earthing purpose.
W i r i n ~and Terminals
The internal wiring shall be carried out using a minimum of 1 .5-mm2

stranded copper conductored PVC-insulated 600/1000 V grade wires,
except for CT circuit wiring which shall be of 2.5 mm2 minimum. Wiring
shall be configured so that its insulation shall not be subject to injurious
temperature.
Internal wiring shall be adequately supported by clamping of loomed runs or

installing in plastic trunking.
The supporting arrangements for wiring shall be such that they are not liable
t o cause permanent physical damage or deformation t o the conductor or
insulation. Wiring shall not be bent to a radius less than the permissible
value given by Manufacturers. Trunking fill shall not exceed 7 5 % of its
capacity.
Internal panel wiring shall be identified by heat-shrinkable ferrules at each

end, clearly identifying the appropriate reference numbers as per drawings.
All wiring shall be terminated with approved pin-crimped terminations.
Terminal blocks shall be arranged to facilitate accessibility for cable cores

termination and inspection of terminal identification numbers. Terminals
shall be of the pinch-plate type, Klippon manufacture or KOC approved
equivalent, suitable for a minimum conductor size of 2.5 mm2.
Terminal blocks shall be arranged and installed t o facilitate accessibility for

c a b l e - c ~ r etermination and inspection of terminal identification numbers.
Terminals shall be of Klippon type, suitable for a minimum conductor size of
2.5 mm2.
No more than one wire shall be inserted into any one terminal. Looping
between terminals, when required, shall be carried out using the purpose
made top of block cross connection or comb-type busbar.
DOC. NO. KOC-€407 Page 40 of 57 REV. I
Terminal blocks associated w i t h external current monitoring signal shall be

provided w i t h easily removable shorting plugs.
A t least 300-mm clearance shall be allowed between the gland plate and
any internal equipment t o permit easy cable installation and connection.
Back o f panel wiring shall be so arranged that access to the connecting

stems o f relays I other apparatus and to contacts o f control and other
switchss is n o t impeded.
Wiring looms crossing from fixed to hinged panels shall be mechanically

supported o n both panels, adjacent to the hinged side, by means of saddles
or compression-type supports.
The colour coding for the wiring shall be as follows:
1 4 4 0 VAC Phases I Red, Yellow, Blue I

l p ~ e u t r a l Conductor ] Black
/ Earthing Conductor I GreenIYellow
AC Control Wiring Black
DC Control Wiring Grey
DC Supply Positive Red or Grey Fitted w i t h Red markers
DC Supply Negative Black or Grey Fitted w i t h Black markers
Anti-Condensation Heaters
Space heaters, controlled by thermostats, shall be provided for each

compartment containing electronic components. Heaters w i t h isolating
switch fuse and neutral link shall be suitable for 2 5 0 V single-phase supply
from an external source. Surface temperature o f heaters shall not exceed
160°C.
DUMMY LOAD RESISTANCE BANK
A dummy load resistance bank shall be provided for all emergency 1 standby
diesel Generators, unless otherwise specified in the Data Sheet. The load
bank shall be sufficiently rated to prevent excessive engine carbon deposits
when the unit is exercised for one (1) hour per week, w i t h a minimum rating
of 4 0 % o f the Generator rating.
The load bank shall be forced air cooled, free-standing type and have a
degree of protection in accordance with clause 7 . 4 of this Standard.
The forced air cooling system shall continue operation even after the
shutdown of the Dummy Load for a set time (adjustable).
DOC. NO. KOC-E-007
The resistance elements shall be of the stainless steel grid type, w i t h

supporting insulators rated for at least t w i c e the working voltage. The unit
shall be rated t o withstand the Generator fault level for three (3) seconds.
The load bank shall be provided with power and control switchboard. The
switchboard shall comply with the general requirements of "KOC Standard
for Low-Voltage Switchgear" (KOC-E-009)/ KOC Standard for High Voltage
Switchgear and Controlgear (KOC-E-002) as applicable.
The switchboard shall have a main isolating switch, load bank contactor,
overload protection, switching controls, fan starters and other controls as
required for the safe operation o f the equipment. The protection shall
include interlocking o f the Generator circuit breaker w i t h the load bank
isolatirg switch, interlocking o f the resistance bank contactor w i t h the fans
and high temperature lockout and alarms.
A n errergency trip pushbutton, stay-put type, padlockable in the stopped

position, shall be located adjacent to the load bank.
For eEse o f operation, the "Operation Procedure o f the Dummy Load

R e s i s t ~ n c eBank" shall b e suitably fixed on the switch board.
The unit shall be designed t o include protective measures for preventing

personnel injury by contact with hot surfaces. Necessary Warning notices
shall be provided as required.
PANEL EARTHING
A n earth bar shall be provided along the full length o f each panel enclosure.
All metallic non-current carrying parts shall be bonded together and
connected t o the earth bar. External M I 0 earthing terminals shall be
provided t o facilitate connection o f the enclosures t o the earthing system.
Panel-mounted equipment with exposed metal parts such as pushbuttons,

relays, meters etc, shall be separately earthed.
Provision shall be made for connecting the earth continuity conductors and
cable armouring of all outgoing circuits.
Doors and hinged parts shall be bonded t o the enclosure by means of a

flexible copper connection having a minimum cross-sectional area of 6 mm2,
arranged so that it cannot be trapped as t h e door is opened or closed.
Connections from the main earth bar t o components shall consist of

copper strips or green / yellow PVC-sheathed stranded copper conductors.
Termination lugs shall be o f the compression type.
NOISE LIMITS
The Generator shall be suitably designed I constructed such that the noise
level shall n o t exceed 85 dB (A) at one (1) m from the generator, unless
otherwise specified in the Data Sheet.
The ncise levels for t h e Generator Set package unit shall be as specified in
the Data Sheet. Consideration shall be given for enclosing the entire
generator set including the drive train in a sound reducing enclosure or
provide suitable building to reduce the noise levels within acceptable limits.
NAMEPLATES AND LABELS
Each unit shall have a nameplate clearly and indelibly marked w i t h t h e data
specified in the appropriate IEC standard. Nameplates shall be fixed w i t h
non-corrodible screws or rivets.
Each nit shall have a label on its front at high level showing the unit
designation number.
Warning labels shall b e provided in all locations, where necessary, to warn

personnel of potentially dangerous situations.
All instruments, selector switches, indicators, etc, shall be provided w i t h

descriptive labels.
Solid-state equipment or any other items which can be damaged when

subjected t o high voltage shall be provided w i t h a warning label stating that
they shall n o t be subjected t o high-voltage tests.
Labels shall have black characters on a white background, except warning

labels, which shall have white characters o n a red background.
All labels shall b e engraved on plastic-laminated sandwich material and

secured w i t h non-corrodible screws. Adhesive or self-tapping screws are
unacceptable.
All components incorporated within the unit shall be indelibly marked with
circuit component reference. Handwritten stickers or dyno-tape labels are
unacceptable.
Painting shall be in accordance w i t h the KOC Standard for "Painting and

Coating of Metal Surface - New Construction" (KOC- P-001).
Colour shall be as specified in the Data Sheet

-DOC. NO. KOC-E-007 Page 43 of 57
-.-.-- -
20.0 INSPECTION AND TESTING
20.1 General
20.1 .I All items included in the supply shall be designed, manufactured, inspected
and tested under the control of a documented Quality Assurance system, of
which the general requirements are given in clause 21.0 of this Standard.
20.1.2 Any special reference t o inspection/test referred within this Standard is

additional to and shall not replace or reduce the general QA/QC
requirements.
20.1.3 The manufacturer shall submit the inspection and testing plan to KOC for
approval.
20.2 Generator Tests
The tests shall be carried out on the Generator and exciter, in accordance
with the requirements of IEC 60034, which shall include the following:
Insulation resistance tests.
Dielectric test (after completion of other tests).
rdo-load characteristic up to 1 3 0 % of rated voltage.
Short circuit characteristic up t o 1 2 0 % of rated current.
Temperature rise at rated voltage, current, power factor and

frequency.
Sudden 3-phase short circuit test at 7 0 % of rated voltage.
Measurement of reactance.
Measurement of stator and rotor winding resistance.
Measurement of stator winding capacitance t o earth (per phase).
Calculation of efficiency.
Phase sequence and voltage balance test.
Waveform test.
Response of AVR and frequency with sudden shedding of 25%. 50%.

7 5 % and 1 0 0 % of rated load respectively.
Vibration test a t 1 0 0 % synchronous speed.

o) Response of AVR and frequency with sudden load application of 6 0 %
Generator full load, followed by remaining 40% load, t w o (2) seconds
later.
p) Control panel insulation test.
q) High-voltage test on all auxiliary circuits, heaters, etc.
r Primary and secondary injection test to prove the function of all

current transformers, relays, and instruments.
s) Full functional test of circuits and equipment.
20.3 Diesel Enaine Tests
20.3.1 The hydrostatic test shall be carried out on the diesel engine at the
Manufacturer's Works. All pressure containing parts, including auxiliaries,
shall be tested hydrostatically with water to 1.5 times the maximum
operating pressure. The minimum hydrostatic test pressure for water jackets
shall be 7.5 barg.
Note: Tests shall be maintained for a sufficient period of time to enable the
complete examination of parts under pressure. The hydrostatic test
shall be considered satisfactory when no leakages are observed for a
minimum of t w o (2) hours.
The test gasketing shall be the same as specified for the service
condition. The hydrostatic test medium shall be fresh water with a
biodegradable wetting agent. The test water temperature shall be
within +2" C of the ambient temperature.
20.3.2 The performance tests carried out on the diesel engine at the
Manufacturer's Works shall include the following:
a) The diesel engine shall be tested against a dynamometer to

demonstrate full load power and 1 0 % overload capacity.
b) The diesel engine shall be tested in accordance with SAE J 1349.
C) The functional checks to be carried out shall be as specified in SAE

J1349, which shall include vibration measurement, inspection of
piston / cylinder assembly, bearings etc., chosen at random.
d) The operation of the overspeed protection system shall be

demonstrated mechanically or hydraulically without the use of
electrical power.
t - I - C - .
e) Battery cranking tests shall be carried out to demonstrate compliance

with the specification, using test batteries.
f) All testing shall be carried out using the "job" radiators, filters,
governor and overspeed device.
g) Testing of the control system, simulating the final onsite configuration

shall be demonstrated.
h) Declaration of power, fuel consumption, lubricating oil consumption

as per I S 0 304611.
Generator Set Performance Tests
The complete Generator Set package, including auxiliaries shall be fully

assembled and given a full load performance test for a minimum of eight (8)
hours' duration at the Manufacturer's Works.
Applicable parts of the driver tests may be incorporated in the package

performance test provided the requirements of both tests are satisfied.
The performance test shall include the following as a minimum with the
engine at normal temperature:
a) One (1) hour operation at 1 1 0 % full load power, during the eight (8)
Pour run.
b) Load rejection and acceptance test using the following load steps
(30th directions):
O to 25%, 2 5 % to 50%, 5 0 % to 75%, 7 0 % to l o o % , 0 to 60%,

6 0 % t o 'TOO%, together with simulated starting of largest induction
motor on a normally loaded Generator Set. The permanent and
temporary speed raisellower shall be measured, and the unit shall not
t ~ i p on overspeed during load rejection tests. Generator output
voltage and frequency variations shall be recorded.
c) Six starts including one from cold with measurement of time to when
the Generator could accept full load.
d) Exhaust emission test with analysis.
e) Full functional test on all logic, alarm and trip circuits t o prove
compliance with this specification and operating logic design.
f) Lubricating oil samples shall be analysed before and after the

performance test.
A t an interval of 30 minutes, the following shall be recorded as a minimum:
Generator Set speed.
Driver lubricating oil temperature.
Cooling water temperature.
Vibration at agreed points using an instrument complying with IS0

2954.
Lubricating oil pressure.
Fuel consumption.
Driver exhaust temperature.
Generator voltage and frequency.
Generator kVA output.
Noise Test
During the performance test, noise measurements shall be taken at strategic

locations (typically at 1.0 m distance and at normal operation level) at 0%,
50% and 100% load.
Battery C h a r ~ e Tests
r
The following tests shall be carried out on each battery charger unit at the
Manufacturer's Works:
a) Insulation resistance test of all circuits (except semi-conductor

components).
b) Functional tests of all circuits and all protective relays.
c) Full load test for 48 hour duration t o establish thermal stability of the
unit.
d) The following measurements shall be carried out at zero, 50% and

100% of full load direct current and shall be repeated at plus 10%
and minus 10% of the nominal supply voltage in float-charge and in
the boost charge operating modes.
i. lnput phase voltage and frequency.
ii. Input phase current.

.-.
111, Input power.
iv. DC output voltage.
v. Output voltage ripple.
vi. DC output current.
Generator Control Panel Tests
The following tests shall be carried o u t o n t:he control panel at the

Manufacturer's Works:
a) Insulation resistance test o f all circuits (except any electronic

components).
b) Full simulated functional tests of all circuits and protective relays.
Load Bank Tests
The following tests shall be carried out o n the load bank and its auxiliaries
at t h e Manufacturer's Works:
a) Insulation resistance test on all main and auxiliary control circuits.
b) High Voltage test on load bank main circuits.
c) functional test on all main, control and safety circuits to prove

correct and safe operation.
QUALITY ASSURANCE
The manufacturer shall operate a quality system preferably based o n I S 0

9 0 0 0 series of standards t o satisfy the requirements o f this Standard. The
manufacturer shall demonstrate compliance b y providing a copy of t h e
accredited certificate or the manufacturer's quality manual. Verification o f
the manufacturer's quality system is normally part o f the pre-qualification
p r o c e d ~ r e ,and is therefore not detailed in the core t e x t o f this Standard.
PACKING, MARKING AND DOCUMENTATION
General
All correspondence, drawings, instruction manuals, Data Sheet or any other

written information shall be in English language. In case o f dual language,
one language shall be English.
All dimensions, units of measurement, physical constant etc. shall be in SI

units.
22.1.3 Packing, Marking and Shipping Documentation shall comply w i t h KOC
Standard for "Packing, Marking and Documentation" (KOC-G-004).
22.2 Deliverables
22.2.1 The following documents / drawings shall be provided by the

manufacturer while submitting the offer as a minimum: -
General arrangement drawings showing main dimensions, weights,

arrangement o f components and the minimum space requirement for
installation o f the whole system.
Foundation plan showing location and details of foundation bolts

including static and dynamic loadings.
c) Electrical schematic and wiring diagram.
d1 Supply record for identical Generator Sets.
e Type Test Certificates o f similar machines.
f1 Completed Data Sheets.
22.2.2 The following documents / drawings shall be submitted for KOC's review /
approval, record and use as a minimum:
General arrangement drawings for all equipment and accessories

included in t h e supply, showing dimensions, weights, arrangement of
components, cable termination, piping connection and all other
details.
Floor plan w i t h foundationlfixing details.
Detailed Electrical schematic, wiring and interconnection diagrams.
Data Sheets filled w i t h all details.
Details o f Generator, Battery & Charger units, Load Bank, Control

Panels, CTs, PTs and Driver w i t h all accessories, including sizing
calculations.
Description of the Generator excitation system including AVR

operation together with all necessary diagrams.
Performance Curves of Generatori Driver.
Catalogues, Installation, testing & commissioning, operation &

maintenance instructions for all equipment and accessories included in
the supply.
Parts list w i t h all technical details, Maker's Name, Type, Serial
Number etc.
Paint Specification.
lnspection and Test Plan.
lnspection I Test reports,
List o f Manufacturer's recommended Spare Parts for t w o (2) years

normal operation.
Packing details.
drawing supplied by the manufacturer shall have the following

information as a minimum:-
a) Drawing title.
b) Manufacturer's name and address.
c) Name o f the project.
d) Manufacturer's order or contract number.
e) Purchaser's order number.
f) Manufacturer's drawing number and revision number w i t h dates.
23.0 SPARE PARTS AND MAINTENANCE REQUIREMENTS
23.1 A complete set of special tools and devices necessary for installation,
operation & maintenance o f the Generator Set shall b e provided, housed
inside a lockable cabinet.
23.2 For further details I requirements refer t o KOC Standard for "Spare Parts
and Maintenance Data" (KOC-G-009).
REV. 1
* . . - --Y
DATA SHEET FOR GENEMTOR (Data to be provided by the Purchaser)
F---2
GENERAL-INFORAMTION I DESIGN D A T A
GENERATOR T'! P F
1 PRIME MOVER T*'PE
-
1
-3 INSTALLATION SITF
-
s DESIGN AME~ENTCONDITIONS
5 ALTITUDE
1 B
7
OTHER ENVIRONMENTAL CONDITIONS
AREA CLASSlFlCllTlON
8 K V A RATING KVA
9 VOLTAGE
to FHAG
11F R E ~ U E - ' N ~
12 S Y ~ C H R O N D U SSPEED
'
13 R A T E D FDWER FACTOR
14 STATORCONNECTION
- 15. NO OF STATOR '~.VINDINGTERMINALS
- 16
. INSULATIONCLASS
17 - TEMPERATURE R SE
i s -GCWERATOR EWLOSURE TYPE IP RATING
1 19 OTHERECFCTR'CAL EDUIPMENT IP RATING
20 DUTY TYPF
21 MOUNTING
2 2 -- M l N l N U M SHORT CIRCUIT CURRENT
--
--
23 SUSTAINED
24
--
SUDDEN APPLIED
OVERLOAD
LOAD AND VOLTAGE DROP PERMlTED
--
25 PJEQTRAL-- EARTPING TYPE
28 EXCITATION
27 WINDING TEMPERATURE DETECTION o REfiUIRED n NOT REDWIRED
28 SPACE HEATFRPATING
' I
2 9 SDACE HEATER CABLE SlZElTYPE
30 1 M A I N CABLE TYPE -
31 I RTD
- --- CAB1
--F- TYPE SIZE
32 POWER TERMINAL ROX TYPE PHASE SEGREGATED n PHASE INSULATED
23 ND OF TERMINAL-~UXES REOUlRED
34 SEPARATE NEUTRAL TERMIPJALBOX REL~UIRED n NOT REOUIREO
35 DIFFERENTIAL PROTECTION CT REnUlAED n NOT REQUIRED
36 STAND B Y EARTH FAULT CT REWIRED @ NOT REaUlRED
37 BEARINGTYPE -
38
39
LOCAL BEARING TEMPERATURE INDICATOR
BEARI~JG TEMPEFATUAC DETECTOR
REQUIRED
REQUIRED-_
c NOT REQUIRED
n NOT REOWIRED
-
I
42
ty BEARING VIBRATION OETECTlON
DUMMY LOA0RFSISTANCEBANK
SVNCHRONISING EOPT.
REQUIRED
REaUlRED
tl REQUIRED
fl NOT REQlJlRED
NOT REQUIRED
o NOT REQIJIRED
. 43 AUTOMATtC VOLTAGE REGULATOR CONFIGURATION o DUAL 0 SINGLE -
I
44 DUMMY LOAD VOLTAGE
45 1 BATTERY TYPE
- - I
46 NO. OF BATTERY CHARGERS & SUPPLY VOLTAGE NOS. 250 1 440 VOLTS
47 CONTROL FANEL 4DDITIDNAL REQUIRMENTS
48 RATING OF THE LARGEST MOTOR CONNECTED VOLTS kW
I 43 RATING OF THE L4RGEST EOUloMEMT CONNECTED VOLTS bW
58 GEN. CABLE SIZE 0 1C 0 3C MA?'
1, 51 1 CABLE GLAND TYPE
-5 2
I 1 DIFFERENTIAI- CT RATIO --
1 53 STAND BY EARTH FAULT C T RATIO -
M?&>
1 54
EARTH CABLE SlZElTYPE
DblAI 1M
/ 55 NOISE LEVEL @J
1 56 PAVJTCOLOUR -
57 REMARKS GENERATOR DATA SHEET-
f
Sheet 1 of 3 -
Rel. t)flt~ Prep'

Date Rev. Chkd Allpvd.
No. Sheet No. bv
-
DOC. NO. KOC-E-007 1
I1
Page 51 of 57 REV. I
24.0 APPENDIX-I : (Contd.)
DATA SHEET FOR GENERATOR (Data to be provided by the Manufacturer)

-
1
- --
I MANUFACTURER
-
1 1 I
1, 2
3
WORK ORDER NO.
COMPLINACE WITH SPECIFICATION I DATA SHEET YES n NO {Submit dsrnils 01 deviations. i f any)
1:
.-
4 1 OUTLINE DIMENSIONAL DRAWING NO. I
5 DIMENSIONS Uxbwhl
6 - -
1 6 GE%ERATOR POWER kVA

7 1 GENERATOR POWER k W 1
8 FULL LOAD CURRENT [FLCI AMP
9 DUMMY LOAD RATING kW I
10 ) ROTOR MASS IN KGS I

11 STATOR MASS IN KGS
I 12 ACCESSORIES MASS IN KGS
I
13 NET MASS IN KC-S

14 SHIPPING MASS IN KGS
15 SPEED R PM
16 SPACE HEATER RATING - Volts Wau5-.----
7 MANUFACTURER FOR THE DUMMY LOAD
1
18 I GENERATOR ENCLOSURE TYPE @iIP RATING IP
19 1 TERMINAL BOX IP RATING IP 1
20 DUMMY LOAD IC RATING IP

21 DUMMY LOAD FAULT RATING MVA kA
22 1 GENERATOR INSULATION CLASSflEMPERATURE RISE

23 TERMINAL BOX FAULT RATING
24 BEARING TYPE DEl NDEI
-
BEARING MAKE ?REF. NO.
i I DEI NO3
BEARING LUBRICATION SELF INDEPENDENT
-
LUBRICATION INrEFlVAL I HRS ,-
NOISE LEVEL Db{Al @ 1M

ROTOR AIR GAP MM
MACHINE PARAMETERS:
DIRECT AXIS SY VCHRONOUS REACTANCE
- XdS
0-AXIS SYNCHRONOUS REACTANCE x,%
D-AXIS TRANSIENT REACTANCE Xd'%
QUADRATURE AXIS TRANSIENT REACTANCE Xu'%
DIRECT AXIS SUB TRANSIENT REACTANCE Xd" %
Q-AXIS SUB TRP.NSIENT REACTANCE X,"%
NEGATWE SEOUENCE REACTANCE
-
X2% 1
ZERO SEQUENCE REACTANCE
-
xox [
POSITIVE SE~UEN-ICE
RESISTANCE rl% I
GENERATOR DATA SHEET I
Sheet 2of 3 .
Ref. Data Prep' Chkd. Appvd.
Date Rev.
No. Sheet No.
b y
-
e e o f REV. I
24.0 APPENDIX-I : (Contd.)
DATA SHEET FOR GENERATOR (Data to be provided by the Manufacturer]
j NEGATIVE SEQUENCE RESISTANCE % I

1 k ZERO SEQUENCE RESISTANCE ra%
I ARMATURE SHORT CIRCUIT TIME CONSTANT T,

I. I I
n / D-AXIS TRANSIENT SHORT CIRCUIT TlME CONSTANT T,I - -
o a-AXIS TRANSlENT OPEN CIRCUIT TIME CDNST. T

,
-
p Q-AXIS T RANSIENT SHORT CIRCUIT TIME CONST. T,
D-AXIS SUB-TRANSIENT OPEN CIRCUIT TlME
+
CONSTANT TVr6.
D-AXIS SUB-TRANSIENTSHORT ClRCUlT TlME
CDfUST_ANT T",
Q-AXIS SUB-TRANSIENT OPEN CIRCUIT TIME I
j ' I C13N$TANTTm, 1
I Q-AXIS SUB-TRANSIENT SHORT CIRCUIT TIME I
/ CONSTANT T', 1
1; u
v
SHORT CIRCUIT RATIO [XlRl
I ARMATURE LEAKAGE REACTANCE X%
cv POTIER REACTANCE X, K
x 1 -VE PHASE SEQL'ENCE HEATINO CHARACTERISTIC 1' =XI

I
y INERTIA CONSTANT H
1
I
, 31
32
11 FIRST CRITICAL SPEED lRPMl
EFFICIENCY AT 100% 1 75% 'o150%LOAD 1

I I
EXCITATION SYSTEM RECOVERY TIME FOR SUOOEN secs.
33 LOAD --
34
-
GENERATOR PERFDRMANCE MAXlMUM VOLT. DROP % I
FOR SUDDEN LO40 APPLICATION -
35 VOLTAGE REGULATION
36 GENERATOR SHORT CIRCUIT CURRENT RATING

1
.I 37 BATTERY AMP-HR {AH) CAPAClTY
38 MANUFACTURER FOR THE BATTERIES
39 MANUFACTURER FOR THE BATTERY CHARGER
40 REMARKS
GENERAT~R DATA SHEET
Sheet 3 of 3
Ref. Data !
/
Date Rev. Chkd. Appvd.
No. Sheet No.
I
,
by
-
L
--
--
DOC. NO. KOC-E-007 R Page 53 of S f JI .
REV. I
24.0 APPENDIX-2: DATA SHEET FOR DIESEL ENGINE
1 1
GENERAL INFORMATlON
INL. 1.41.' ATION SlTE I
1
- - 1
I
1/
?
3
4 I
SEEUICE
DRIVEN EDUlPMENT
NOS.REl3UIRED
L
-
5 MANUFACTURER
1 6 MODEL
7 SERIAL TdO
8 DESIRED MIN RATINC
NOTE: o INDICATES {NFORMATION TO BE COMPLETED BY PURCHASER n BY MFR g BY MFR i~ MOT BY PURCHASER
4 0 DUTY. SITE AND UTILITY DATA gl] DESIGN
1
10 DUTY ( ASPIRATION.
11 0 CONTINUOUS 3 STAh'D 8Y I O NAlLJRALLY ASPIRATED O ?VRROCH&RGED
12 0 IWTERMTTAMT START5 .' DAY O SUPERCHARGE0
13 TYPE:
14 LOCATION
-- 0 WJLINE 0 'V'
15 OlND0OR OOUTDOOR NUMBER OF CYLINDERS
- .-
16 OIShPrCEMENT-L COMPRESSION R A I D
17 SITE DATA CYLINDER BORE.- MM CYLINDE!3 STROKE MM
18 ELEVATIOIJ TORSIONAL CRITICAL S K E D S : 15T-.- 2N0 - RPM
/ 19 ENROMETER - BARA MIN SPEED RPM OVER SPEED TRIP RPM
1 20 Ah'BIEPbT TEMPERATURE MAX @C M A X NO LOAD GOVERNOR S E E D P.PM -
2i MtN SPEED WITHOUT PRE-LUW PUMP RPM
22 O WINTERIZATIO k REQ'D Q TROPIC ALIZATION REO'D a F-ERFORMANCE
I 23 CI RATING BASED ON: 0 pr:~:.-
..!I 0 STAt.JD0Y .-.:
23 UNUSUAL CONDITIONS SITE 153 MAXIMUM SITE ,I
75 G DUST 0 SRCl ATMOSPMERE R4TINF RATED RATED CONTINDOUS RCOUIRED!

! 26 0 FUMES - - 0 OTHER KILOWATT
27 TORQUE I W A )
2R ELECTRICAL AREA CLfiSSIRCATlON: -SPEED ( A P M
29 O NOk-HAZARDOUS O HAZARCOU"3ONE GROUP- BUEP !BAA)
, 30 K G A L : K W !HF:
' 31 ELECTRIC POWER AVAILABILITY: PISTON SPEED 1 ~ 1 s ) -
:
;
32
33
VGLTAGE
PHASE
FREQ
-
FUEL RATE IKGiHRI@
1 G3"; LOd 0
75% LOAD
i. _--j
.._
1
, 35 50% LOAD
1 36 COOLING SYSTEM: MAXIMUM TOROUE - N-M @ fiPh1
G SELF COFJTAINED O DN SKID 0 OFF SKID IF!TAKE AIM FLOW RATE ( I S 0 RATE01 - -
-
I'IM.',WR
--
I 37
0 ALLOW. SOUND PRESSUnE LEVEL FOR THE PACKAGE LlNlT
38 r? RADlATOR 0 HEAT EXCHANGER D M @ -.
M
38
$0 EXTERNAL COOLING WATER AVLILCIWLlTv - OR REGULATIONS:
APPL~~E~L~-EEM~5!O_NNCODES
EMISSIONS
-
41 TEMP. ( INLET ! M A X M I N I M A % RETURPJ-
- OC):
42 PRESSURE (BAR VORMAL DES lG PI --- -

-
43
-- MI14 RCTURN M A X ALLOW P lRARl - ---.
44 FLOW IM'!HRI EMISSIONS
46 WATER PlPlNG FLRN. BY 0 VENDOR O OTHERS IVrs, GUARANTEED: ANTICIPATED
-
46 NO, REOUCTION METkOD
47 AIR S U P R Y AVAILABKITY_- CO fiUARAPJTEED: --
ANTICIPATED-
' 48 PREZSURE IBARGI: htlN,MAX - -R EC.lLlCTlO
PARTICULATE EMlSSlOMS: TYPE.
bl WETHO D:
I
49 QUALITY
DIESEL ENGINE
D A T A SHEFT S h ~ a t1 of 3
50 NOTES:
t Dala
Dars Rw. Chkd. Appvd.
NO. Sheet No. Ily
51 REMARKS
-
DOC. NO.-K O C - E - 0 3I REV. I
- -
24.0 APPENDIX-2: DATA SHEET FOR DIESEL ENGINE (Contd.1

-
1
-
STARTING SYSTEM pa OIL SYSTEM IC~NTINUFDI
-- 1
2 /oAIRM.TOP
3 h(FR MODEL
4
5
DNTY FRESSURE - RATING -
PlR TANKS 0 ASME SECT VIII COVE D 5 G N D STAMP mEOD MFR-- . MOD EL
--
SIZE.--
--- 6 hUhWER
SIZE COOLING WATER SYSTEM
. 7
NUMBER OF START5 CAPACITY ENGl'lr 0PI.I Y L
1 B PnF5SURERATIHG BANG - TEMP. RATlNG A
"C RA~IATOR L
- -
3
1 9 AIR COMPRESSOR OTHER - . L

76 idlfR MODEL JACKET WATER W.MP[5> PI TY
-
- 11
- SITE DRIVER - MODEL
'MFR 51ZE
---- 1 Z 0 ELECTRIC MOTOR
$3 NFR MODEL
-
C4PACITV
MATERIALS,
-
CA:
RPM
13 OhlW VOLTAGE CRAhlklRF A M SEAL TYPE-
-
- BATTERY CHARGER
15
16
CAPACITY
W WEB SUPPLY
BATTERY
A M P / HR MODEL & CODE.
DRILER TYPE MFR II,W
117 -VOLTS . PHASE -HZ JACMET WATER HEATERIS) TYPE
P
1 tB O HYDRAULIC MOTOR
1 t9 MFR MOD EL FUEL SYSTEM -
- DAY TANK CAPACtTY L - HOURS

21 OIL SYSTEM DIMGtd510h15 - LDCRTIDM - -
27 OIL PUMP 0 INTEGRAL 0 SEPARATE FUEL, PUMP D W E R 0 DIRECT 0 ELECTRIC U OTHEA -
23
.
7.l.
hlFR MOD EL VFR MOUEL
-SIZE -
2.5 RG
26 MA 1 tWlALh: LAhIIYb MFR MODEL SIZE ImICRON
27 FIOTATIRG ELEMENTS FUEL INJECTORS
2B ] SE4LS FUEL PRESSURE REGULATOA
24 1 DRtUER: TYPE MFR FUEL TYPFISl 'Arrach separate sheet l o r Oirssl Fuel S p e c i l ~ s m o n
INLET A N D EXHAUST
INLET AIR FlLfER MOUPlTlMG 0 ON SKID 0 REMOTE
MFFt MCO EL SIZE
TYPE: 0 DRY O O I L BATH 0 OTHER
hWTER1ALS ELEMENT
INLET PlFl BUCTlhlG ---
1 38 DUTY 2E51GH PRESSURE BARG EXHAUST 0 SILENCER 0 SPARK ARRESTOH
37 SHELL o D. THICKMESS SILENCER M~UNTIRG: o HORIZDNTAL o VERTICA;
38 TUB'EOD. TCIICKWESQ- NO- 5 l L E K E R SUPPCsFlTS O SADDLES - .
OJRURIO~
39 LENGTH SURFACE AREA M' MFFl NDEL - SIZE --
/ 40 -
E?i COUPLING
1 COUPLING TYPE 0 FLEXIBLE
.
11 47
-43
OTHER
-MODEL
1' 44 ' CHATAHEL ., SIZE RATING
' 45 BAFFLES
-- , --
dB G.W. INLET: TEW'EN
~TuRE-'C PRESSURE BANG
47 FLOWREQUIREO - L? PM I
52 1 OIL FLOW METER MFR MODEL I

DIESEL ENGINE
I
1-
55
. I -
1 55 OIL PRESS METER MF,F? MODEL Rat.

56 OIL CAPACITY IL1 SUMP No.
OTHER
1; 53
55' REMARKS
i
--
DOC. NO. KO
24.0 APPENDIX-2: DATA SHEET FOR DIESEL ENGINE (Contd.)
g;t IMSTMUMENTATION AND CORTRQlS

- -
CONSTAUCTION A N 0 MOUNT<RG PLATES LCONTINUED]
2 COV€f$iR TYPE. 0 MECHANICAL 0 HYDRAULIC
-
I
ENCLOSURE REQUIRED FOR : 0 :VEATHER 0 &COUS:IC
. - - 0 ELECTRUVIC 0 OTHER -
- 0 hlOME 0 OTHER
MFR: hmDEL WEIGHT (KO1 ENGlPdE FLYWHEEL
I d SPECIAt. F
--- DRIVEN EOUIPWENT SKID / AGC'5 -
5 I S 0 3QdE TOTAL -- SHlPPlWG _
6 SPEED W w h t ' RPM hlAK FOR ERECTION I
7 MAX FOR MAlNrENAMCE
. - -,.
-
- 0 SPEEQ CHANGER. 0 MANUAL Cl PNEUMATIC flELECTRIC OTHER --
-
9 o OTHER - n a a s SPACE REOUIRE_D ~ r m a !
-
-
-10 TACHOMETER: o MECHANICAL a FLECTMIC LXVIKH
-
-
11 .- TACH GEAR / PICK - UP
p
L
12 ENGINE GAUGE BoAPD FURNISHED WITH:

I
I CDNIYEGTIILIY:
-
'13 D WflCMETER 0 J.W. TEMPERATURE GAUGE NO SIZE RATING FACING LOCATION

I 14 1 TACHOMETEFI 0 FUEL PRESSURE GAUGE -- I I
1 5 OOILPAESSUREGAUGE OAIRPRES~UREGAUGE - AIA INLET
18 0 OIL TEMP GAUGE 0 HOBBS METER STARTING AIR
' ALnwM B SHUTDOWrrl SET POINTS

(Attach Qparata Sheet for A l a r m a n d Shutdown set Pomts]
C.W INLET
c- .w. . OUTLET
- - . -- .
I - I I I I . I
18 I CONTWIC PANEL : 0 INTEGRAL 0 FREE 5TAP.lOlNG 1 OIL INLET I
18 1 LOCATION: OIL OUTLET I
J I I
I
I I
20 1 FUEL INLET I
IC
21 PLATES 1 I 1 I I
22 1 TYPE: 0 SKID 0 OPEN 0 CLB5ED 0 SOLEPLATE 1

za I
31 0 EkGlNE VEPIDOR FURNISHED SUEPLATE5 - . FUNCTIOPIAL TE5T OF CONTROL5 ab

1 32 '
PROTECTIVE DEVICE5
'1 38 S K D CONSTRUCTION: 0 VENDOR 5TD 0 STRUCTURALLY RIGID GO'dERIJOR DVERRPEED 0 I)
$ o omER OVERALL SYSTEM --

a o
1 34 1 MOTES . WTHEAS
1 35 I
1 2s
37 0 PREPARATWN FOR S H I M M T
1 33 EWIWE. AUXILIARY EaUIPMEMT AND $PARE5 PWPARED FOR-
36 0 DOMESTIC 5 H I W E M T 0 EXPORT SHIPMENT
ENGINE PREPAFIED FOR EXTEhlOEa STORAGE -MCjYTHR
1 41 REMARKS SPARES, ACCESSOnIES PREPAHEO FOFl EXTENOEO STOFIPGE
I
1
MONTH5
D A T A SHEET
MESEL Et4QINE
%+el 3
Ref Rw.
Date
Nu. Sheet No. by
- -
Page 56 of 57 REV. 1
--- -
ACKNOWLEDGEMENT
-
This KOC Standard has been approved by the Standards Technical Committee (STC)
consisting of the following:-
M r . Abdul Redha I.Al-Haddad (Standards Team) Chairman

M r . Mohd. Emam (Insp.& Corr. Team-S) Deputy Chairman
Mr. S, Kumar (Standards Team) SecretaryIMember
Mr. Khalid Al-AClmed (Gen. Proj. Team) Member
M r . Henry S. Hill (Opns. Tech. Svcs.Team-S) Member
Mrs. Amina Rajab (Design Team) Member
M r . Khalaf Hamada (Design Team) Member
Mr. N. Ramanathan (Export Facilities Team) Member
Mr. Ali Al-Failakawi (HSE Systems Team) Member
Dr. Modistaba Araghi (Insp.& Corr. Team-N&W) Member
Mr. Daniel Pino (Utilities Team) Member
Mr. Abdul Aziz Akbar (Proj. Mgmt .Team-N) Member
M r . Moataz Khalaf (Information Systems Team) Member
The draft of this Standard has been circulated t o the KOC User Teams for their
review and responses were received from the following:-
OPNS. GROUP (WEST) AHMADI SERVICES GROUP
Team Leader Maintenance Team Leader Proj. Design

Team Leader Opns. Tech. Svcs. Team Leader Utilities
Team Leader Pmj. Engg. & Facilities-DZ
Team Leader Pmd. Opns.
ENGINEERING GROUP INDUSTRIAL SERVICES GROUP
Team Leader Design Team Leader Insp. & Corr. (S&E)
OPNS. GROUP (SOUTH) EXPORT & M-AR!NE OPNS. GROUP
Team Leader Prod. Opns. Team Leader Export Svcs.
MAJOR PROJECTS GROUP DRILLING SERVICES GROUP
Team Leader Proj. Support Team Leader Drilling
HSE G R O H
Team Leader Safety

This KOC Standard for "Generator Sets" (KOC-E-007, Rev. I ) has been prepared by
the Task Force (TF-EE/O6) comprising of the following members:
Mr. Khalid Al-Ahmed Gen. Proj. Team : Task Force Leader Tel No. 61 756
Mr. A.Unnikrist-nan Standards Team : Author / Member Tel No. 61 633
Mr. Hammad A -Ajmi Maint. Team (SK) : Member Tel No. 2201 0
Mr. Gobinda Mishra Design Team : Member Tel No. 61097
Mr. Afeef Kamel Projects Design Team : Member Tel No. 66245
Mr. C.Lazo 0pns.Tech. Svcs. (WK): Member Tel No. 20350

KOC Standard for Generator Sets

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KUWAIT OIL COMPANY (K.S.C.

DOC. NO. KOC-E-007

KUWAIT OIL COMPANY (K.S.C.)

DOC. NO. KOC-E-007

Team Leader Stent.fards

REFERENCE CODES & STANDARDS

ENVIRONMENTAL CON DlTlONS

HEALTH, SAFETY AND ENVIRONMENT

BASIC DESIGN CONSIDERATIONS

9.1 Normal Status

TECHNICAL REQUIREMENTS AND SYSTEM DESCRIPTION

11. I Performance Requirements

11.6 Terminal Boxes

12.1 Performance Requirements

BATTERY AND BATTERY CHARGER UNITS

DUMMY LOAD RESISTANCE BANK

NAMEPLATES AND LABLES

21.O QUALITY ASSURANCE

22.0 PACKING, MARKING AND DOCUMENTATION

23.0 SPARE PARTS AND MAINTENANCE REQUIRMENTS

Appendix-I Data Sheet for Generator

This document "KOC Standard for Generator Sets" (KOC-E-007) is intended to

This Standard sets out to achieve the following objectives:

a t o prcvide technical guidance and establish the base document for

b) to ma ntain the KOC requirements of safety and protection to plant,

Team Leader Standards Team

Task Force responsible for this Standard

The preparation of this Standard was entrusted by Standards Technical Committee to

This Standard specifies the minimum requirements for the design,

This S;:andard covers the requirements for Generator Sets comprising o f a

The design, construction, performance, inspection and testing of Generator

For the purposes of this Standard, the following definitions apply.

KOC Controlling Team

Any KOC Team authorized to initiate a request for procurement o f materials

Manufacturer of Generator / Driver w h o takes the overall responsibility o f

Either KOC or Consultants / Contractors engaged by KOC.

AVR Automatic Voltage Regulator

DCS Distributed Control System

H&E Health & Environment

HRC High Rupturing Capacity

HSEMS Health, Safety & Environment Management System

KOC Kuwait Oil Company (K.S.C)

REFERENCE CODES 8 STANDARDS

List of Standards and Codes

Genera.:or Sets shall conform in design, manufacture, performance and

Interna-:ional /National Standards

API 5 4 6 Brushless Synchronous Machines-5OOkVA and Larger

API 2 0 0 0 Venting Atmospheric and Low Pressure Storage Tanks-

DOC. NO. KOC-E-007

ASME Section Rules for Construction o f Pressure Vessels

ASME Section V Non- Destructive Examination

ASME 3 1 6 . 9 Factory - made Wrought Steel Butt Welding Fittings

ASME B31.3 Process Piping

ASME PTC-17 Reciprocating Internal Combustion Engines-Performance

Specification for Fuel Oil for Agricultural, Domestic and

BS 49S9 General Requirements for Rotating Electrical Machines

BS 5 1 6 9 Fusion Welded Steel Air Receivers

BS PD 5 3 0 4 Safe Use of Machinery

IEC 6 0 0 3 4 Rotating Electrical Machines

IEC 6 0 0 4 4 Instrument Current Transformers

IEC 60051 Recommendation for Direct Acting Indicating Analogue

IEC 6 0 0 7 2 Dimensions and Output Series for Rotating Electrical

IEC 6 0 0 8 5 Electrical Insulation-Thermal Classification