National Oil Corporation: Rev Date Description Checked Approved

NATIONAL OIL CORPORATION
GENERAL ENGINEERING SPECIFICATION
GES L.29
EMERGENCY DIESEL GENERATORS
Rev Date Description Checked Approved

0 1999 Issued for Implementation DL
Compiled by Teknica (UK) Ltd

GENERAL ENGINEERING SPECIFICATION GES L.29
EMERGENCY DIESEL GENERATORS Page 2 of 47
Rev 0 1999
INDEX
SEC TITLE PAGE
1.0 SCOPE OF SPECIFICATION 4
1.1 Introduction 4
1.2 Other NOC Specifications 4
1.3 Data Sheets 5
1.4 Stability Study 5
2.0 DEFINITIONS 5
2.1 Technical 5
2.2 Contractual 7
3.0 DESIGN & PERFORMANCE 8
3.1 Environmental Conditions 8

3.2 Codes and Standards 9
3.3 Voltage and Frequency 10
3.4 Operation and Control 10
3.5 Equipment 12
3.6 Temperature Rise 18
3.7 Surge Arresters and Surge (Capacitor) Suppressors 18
3.8 Vibration 18
3.9 Duty 19
3.10 Alternator Rating, Waveform and Voltage Regulation 20
3.11 Noise 22
3.12 Critical Speeds 22
3.13 Overspeed 22
3.14 Pulsating Stator Current 23
3.15 Parallel Operation 23
4.0 CONSTRUCTION 23
4.1 Type of Alternator 23

4.2 Stator 23
4.3 Stator Windings and Connections 24
4.4 Bearings and Lubrication 26
4.5 Rotor 26
4.6 Rotor Winding 27
4.7 Cooling System 27
4.8 Heat Exchangers 28
4.9 Excitation 28
4.10 Voltage Regulator 29
4.11 Exciter and Field Suppression 30
4.12 Indication 30
4.13 Grounding (Earthing) Terminals 31
4.14 Heaters 31
4.15 Ancillary Equipment 32
4.16 Noise 32
SEC TITLE PAGE

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4.17 Screw Threads 32

4.18 Labelling and Marking 32
4.19 Cabling 32
4.20 Vibration 32
4.21 Coupling Design 33
4.22 Engineering Details and Responsibility 33
4.23 Responsibility 33
4.24 Torsional Analysis 33
4.25 Diesel Engine 33
5.0 NEMA/IEC DIFFERENCES 33
5.1 General 33
5.2 Salient Differences 33
6.0 INSPECTION 35
6.1 Procedures 35
6.2 Scope 35
6.3 Nameplates 36
7.0 TESTING 37
7.1 Statutory Tests 37

7.2 Routine Tests (including String Tests) 37
7.3 Test Procedures 41
7.4 Site Acceptance Test Requirements 41
7.5 Test Certificates 42
7.6 Test Equipment 42
8.0 DOCUMENTATION 42
8.1 Introduction 42
8.2 Schedule and Reports 43
8.3 Data and Calculations 43
8.4 Drawings 43
8.5 Final Records Documents and Manuals 44
9.0 PRIOR TO SHIPMENT 45
9.1 Painting and Coatings 45

9.2 Spares 45
9.3 Packing and Storage 45
9.4 Shipping 45
9.5 Warranty 46
10.0 FIGURES SUB-INDEX 46
Figures 47
DATA SHEETS (2)

Rev 0 1999
1.0 SCOPE OF SPECIFICATION
1.1 Introduction
1.1.1 This specification defines the minimum requirements primarily for the design, construction, inspection and
testing of Diesel Engine Driven Power Generation Units of the brushless type complete with the necessary
automatic voltage regulator (AVR).
For the purpose of this specification, Power Generation Units are defined as three phase low (LV) and
medium voltage (MV), brushless, salient pole alternators and the associated automatic voltage regulator
(AVR) and excitation system for operation on alternating current supplies at voltages not exceeding 2400
volts and ratings up to 5 MVA; for machines in excess of this rating, a separate specification may be
necessary. Note: These machines are for use in non-hazardous (unclassified) areas only.
1.1.2 This specification applies to equipment for refineries, onshore oil & gas installations and processing
facilities, including alternators purchased either directly or as part of a package.
1.1.3 This specification is generally based on ANSI/NEMA standards. The Vendor/Contractor shall comply
fully with the provisions laid down in this specification. Any exception must be authorised in writing by
the Owner as failure to do so shall indicate full compliance; any remedial work then necessary, shall be at
the Vendor/Contractor's expense.
1.1.4 In the event of any conflict between this specification and the Data Sheets, or with any of the applicable
codes and standards, the Vendor/Contractor shall inform the Owner in writing and receive written
clarification before proceeding with the work.
1.1.5 This general specification will form part of the Purchase Order/Contract, together with any Data Sheets,
drawings or other attachments.
This specification is generally based on ANSI/NEMA standards however, where stated on the Data Sheets
or other material requisition attachments, equipment and materials shall comply with IEC/ISO and other
Recommendations, the most important of which are listed in Section 3.2.3.
The salient differences between the ANSI/NEMA and IEC standards are as detailed in Section 5.0 of this
specification, including reference to the units of measurement.
Exclusions
Cylindrical rotor - 2 pole machines are excluded as are machines having ratings in excess of 5 MVA. This
is because at ratings up to 5 MVA the salient pole machines (4 pole upwards) are economically more viable
than the equivalent cylindrical rotor 2 pole machine.
1.2 Other NOC Specifications
The following NOC General Engineering Specifications are an integral part of this specification and any
exceptions shall be approved in advance by the Owner:
GES A.04 Noise Level Criteria and Noise Control of Mechanical Equipment
GES A.06 Site Data
GES L.28 Electrical Requirements for Packaged Units
GES L.34 Electrical Equipment in Contaminated Environments

Rev 0 1999
GES L.35 Electrical Equipment in Hazardous Areas
GES M.01 Diesel Engines
GES X.06 Factory Coatings for Electrical Equipment and Instruments
1.3 Data Sheets
The technical data supplied by the Owner for the equipment is given on Data Sheets which are included at
the end of this specification.
The Vendor/Contractor shall complete the Data Sheets with the remaining information.
1.4 Stability Study
To enable the machine to be 'modelled' in power system stability, load flow and fault calculation studies the
Vendor/Contractor shall provide all of the data requested on the Data Sheets.
2.0 DEFINITIONS
2.1 Technical
The technical terms used in this specification are defined as follows:
Statutory Tests
Statutory tests are those intended to establish compliance with selected, widely applicable requirements of
the National Codes and manufacturing standards.
Critical Speed
A speed at which the amplitude of the vibration of a rotor due to shaft transverse vibration reaches a
maximum value.
Cross-current Compensation
One of two systems which permit generators in parallel, to share the reactive component of the power in
proportion to their rating while maintaining constant output voltage. See also Droop Compensation.
Droop Compensation
A system which permits generators in parallel to share the reactive component of the power in proportion to
their rating. See also Cross Current Compensation.
Dead Band
Dead band is the total magnitude of the change in steady state speed within which there is no resulting
measurable change in the position of the governor controlled valve(s). It is a measure of the speed
governing system insensitivity and is expressed in percent of rated speed.
Flexible Shaft
Rev 0 1999
A shaft which is intended for operation at speeds greater than the first lateral critical speed.
Isochronous Load Sharing
Isochronous load sharing which allows two or more synchronous generator sets operating in parallel to
maintain constant system frequency from zero system load to maximum system load without the need for
any adjustments by operating personnel. This allows each generator set to operate at the same percentage
of its full load rating. Therefore, if the load on the system is 60 percent of the maximum system capacity,
each set in the system will be operating at 60 percent load.
In order for isochronous load sharing to be used, each generator set in the system must have a governor
fitted with the isochronous load sharing feature.
Routine Tests
Routine tests are those tests applied to each individual machine to show that it has been assembled
correctly, is able to withstand the appropriate high-voltage tests and is in sound working order both
electrically and mechanically.
Service Factor - AC Machines
The service factor of a machine is a multiplier which, when applied to the rated output, indicates a
permissible loading which may be carried under the conditions specified for the service factor. It should be
noted that application of the service factor may shorten the anticipated life of the machine.
Service Factor (NEMA)
A multiplier which, when applied to the rated power, indicates the power which may be carried
continuously without exceeding, by more than 50°F (10°C), the rated temperature rise at rated voltage and
frequency. It should be noted that IEC design alternators do not normally have a service factor.
Speed Regulation, Steady State
Speed regulation, expressed as a percentage of rated speed, is the change in sustained speed when the
power output of the driving unit is gradually changed from rated power output to zero power output under
specified steady state conditions.
Stiff Shaft
A shaft which will not be operated during normal circumstances at speeds greater than the first lateral
critical speed.
Telephone Influence Factor (TIF)
The telephone influence factor of a synchronous generator is a measure of the possible effect of harmonics
in the generator voltage wave on telephone circuits.
Type Tests
A test made on a machine which is representative of other machines to demonstrate that these machines
comply with specified requirements not covered by routine tests.
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Note:
A machine is considered to be representative of others if it is fully identical in rating and construction, but
the type test may be also considered valid if it is made on a machine which has minor deviations of rating
or other characteristics. These deviations should be subject to agreement between the Vendor/Contractor
and the Owner.
Utilisation Voltage
The rms "phase to phase" or "phase to neutral" voltage at the line terminals of utilisation equipment.
String Test
Combined works or site test on the diesel engine, alternator and control panels.
Standby Rating
Additional load that the set can produce (above normal full load) for a specified period; normally 10%
overload for 1 hour in 12 hours or 10% overload for 500 hours per year.
2.2 Contractual
The commercial terms used in this specification are defined as follows:
Owner
The oil or gas company, an associate or subsidiary, who is the end user of the equipment.
Vendor/Contractor
The company supplying the equipment.
Contractor
The main contractor for a defined piece of work.
Sub-Contractor
A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.
Inspection Authority
The organisation representing the Owner or Vendor/Contractor that verifies that the equipment has been
designed, constructed, inspected and tested in accordance with the requirements of this specification and
the Purchase Order/Contract.
Inspector
A qualified individual representing the Owner, Vendor/Contractor or assigned Inspection Authority, who
verifies that the equipment has been designed, constructed, inspected and tested in accordance with the
requirements of this specification and the Purchase Order/Contract.
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3.0 DESIGN AND PERFORMANCE
The diesel engine driven alternator sets, covered by this specification, are for emergency standby duty,
feeding an essential services switchboard normally supplied from mains. Transfer to emergency supply
upon mains failure will be automatic and retransfer to mains upon restoration will be manual. The major
components shall comprise:
- engine,
- brushless alternator,
- combined underbase,
- air, oil and fuel filtration,
- Local Engine supervisory panel at set,
- Remote Engine control panel (usually in plant switchroom),
- automatic electric starting equipment and associated battery and battery charging equipment,
- flywheel.
The set shall be complete, with all necessary accessories whether described hereafter or not.
The Vendor/Contractor should include for all equipment on the Engine/Supervisory Local and Remote
Panels all start-up relays, the Alternator Control Panel (which will also contain the alternator electrical
protection relays) and any equipment such that only the outgoing portion of the Essential Services Board
will require adding.
The Remote Engine and Alternator Control Panels will be incorporated with the outgoing portion of the
Essential Services Board as an Integral Unit complete with any necessary Adapter.
3.1 Environmental Conditions
3.1.1 External Environment
These conditions are fully detailed in GES A.06 and cover the principal conditions affecting the electrical
equipment including maximum and minimum ambient temperature, dust, humidity and altitude etc.
3.1.2 Internal Environment
Equipment may be housed in an enclosed, air-conditioned equipment room; full details are given in
GES B.12.
Temporary excursions from these limits e.g. during short term power failure, shall be ignored for the
purposes of equipment rating.
3.2 Codes and Standards
3.2.1 General
In general, the requirements specified herein are based on the ANSI/NEMA and other American Codes and
Standards, the most important of which are listed below. Unless otherwise stated, equipment and materials
shall comply with these Codes and Standards.
Unless specified otherwise in the Purchase Order/Contract, the current editions of the codes and standards
Rev 0 1999
at the time of order shall be used.
The Vendor/Contractor shall operate and supply certification for a Quality System complying with the
requirements of the ASQ Q9000 Series or BS EN ISO 9000, Part 1 (Design), Part 2 (Production) and Part 3
(Test and Inspection).
3.2.2 US Codes and Standards
API 670 Vibration, Axial Position and Bearing Temperature Monitoring Systems
ANSI/FBMA 9 Load Ratings and Fatigue Life for Ball Bearings
ANSI/FBMA 11 Load Ratings and Fatigue Life for Roller Bearings
ANSI/IEEE C57.13 Requirements for Instruments Transformers
ANSI/IEEE 115 Test Procedures for Synchronous Machines
ANSI/IEEE 95 Insulation Testing of Large AC Rotating Machinery with Direct

Voltage. Recommended Practice for,
ANSI/IEEE 433 Large AC Rotating Machinery with High Voltage at Very Low
Frequency, Practice for Insulation Testing of,
ASQ Q9000 Quality Management and Quality Assurance
ASTM D975-92 Specification for Diesel Fuel Oils
NEMA MG-1 Parts 1-30 Motors and Generators
NEMA MG-2 Safety Standard for Construction and Guide for Selection, Installation
and use of Electric Motors and Generators
NEMA MG-3 Sound Level Prediction for Installed Rotating Electrical Machines
NEMA No.250 Enclosures for Electrical Equipment (1000 volts minimum)
NFPA-70 National Electrical Code
3.2.3 IEC and other Recommendations
When appropriate, equivalent International Standards which may be used as alternatives are listed below
and may be used with the prior approval of the Owner. Equipment and materials complying with IEC
Recommendations shall be at least equal to the requirements of this specification. The Vendor/Contractor
shall advise full details of any deviations to these requirements in his offer if IEC based standards are
utilised.
BS 2757 Method for Determining the Thermal Classification of Electrical Insulation
BS 2869 Fuel Oils for Non-Marine Use
BS 3643 Metric Screw Threads
BS 4675 Mechanical Vibration in Rotating Machinery
BS 4999 General Requirements for Rotating Electrical Machines

Rev 0 1999
BS 5000 Specification for Rotating Electrical Machines of particular types for particular
applications
BS 5514 Reciprocating Internal Combustion Engines: Performance
BS EN 60034 Rotating Electrical Machines
EATS 44-5 Testing the Insulation Systems of Stator Coils for Rotating Electrical
machines.
EATS 44-5 Testing the Insulation Systems of Bars (half coils) for Rotating
Electrical Machines of Turbine Driven and Hydro Generator Types.
IEC 34 Rotating Electrical Machines:
IEC 529 Degrees of protection Provided by enclosures (IP Code)
IEC 60072 Dimensions and Output Ratings for Rotating Electrical Machines
ISO 3046/1-7 Reciprocating Internal Combustion Engines: Performance
3.3 Voltage and Frequency
3.3.1 Rating
Alternator rated voltage and frequency shall be as stated on the Data Sheets or attachments to the material
requisition.
3.4 Operation & Control
3.4.1 General
During normal conditions when the 'essential services' are being supplied from AC mains, the alternator set
will be maintained ready for immediate automatic starting. The starting equipment shall be fully charged
with sufficient capacity for nine consecutive start-up attempts, although only three attempts to start are
required after which an automatic relay will lock out the set and sound the alarm.
The lubricating and fuel systems etc., to be in ready condition at all times.
After a supply failure of an adjustable period between 0-10 secs., the set shall automatically start and when
run up to full speed, activate a control circuit so as to close the main circuit breaker on the Essential
Services Switchboard. Normally, the alternator set will not run in parallel with the AC mains. However,
synchronising equipment is required for short time parallel operation of the alternator and the AC mains for
the following conditions:
(a) on load testing of the alternator set,
(b) transfer of load from the alternator set back to the AC mains without interruption of the load
supplies.
As the set will only be paralleled to the mains for short periods, the neutral will be permanently earthed.
For test purposes, the alternator set shall have facilities for running the engine without transferring the
alternator to the bus bars, although means shall be included to place the alternator on load if desired, by
Rev 0 1999
paralleling with the mains for a short time only.
A control system is to be provided for supply monitoring, engine control, plant protection, functioning of
auxiliaries, failure and shut-down, automatic voltage regulation, remote governing and annunciation,
automatic start-up, etc. This equipment will be accommodated at the Control Panel and/or Supervisory
Panel as detailed later.
3.4.2 Automatic
The Hand/Off/Auto/Test switch on the remote engine panel is set to Auto, which places the diesel engine in
the statutory automatic 'ready to start' condition whilst the essential supplies loads are fed from the mains.
Subsequent to a mains failure, the following occurs:
(a) Loss of mains for any reason is sensed by the 3 single phase undervoltage relays (with series
connected contacts) provided by others;
These relays then initiate:
- starting of the diesel engine,

- the closing of the alternator circuit breaker through auxiliary switch interlocks.
(b) Upon receiving the start signal, the diesel engine makes at least three attempts to start after which,
if unsuccessful, the set locks out.
If the attempt is successful, the set runs up to speed ready to take load in 8 to 10 seconds and a
voltage sensing relay then closes the alternator circuit breaker.
(c) As soon as the alternator circuit breaker is closed a Base Load will be present not limited to, but
usually comprising:
- lighting,
- instrumentation,
- public address/fire alarm systems,
- gauge glass lighting,
- control panels,
- induction motors and MOVs.
3.4.3 Manual
The hand/off/auto/test switch on the engine panel is set to Hand so that the diesel engine can be run without
paralleling the alternator with the mains.
3.4.4 Test Start
In this position the set can be test started without closing the alternator ACB, but this will close if a mains
failure is experienced during a test run.
3.5 Equipment
The engine shall generally comply with GES M.01 and the following specific requirements:
3.5.1 Engine
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3.5.1.1 The diesel engine shall be pressure charged, intercooled, vee form, operating on the four stroke cycle, and
shall be suitable for operation on fuel conforming to BS.2869 Class A2 or ASTM 975-92-2D calorific
value 18,400 BTU/1b (10.2) k.Cal/kg), viscosity of 45 secs. maximum, Redwood No 1 at 100°F (37.7°C)
SG = 0.8.
3.5.1.2 The engine shall be continuously rated at site, conditions of 122°F (50°C) maximum and barometric
pressure 29.5 in Hg in accordance with ISO 3046/1, and shall accept 10% overload for one hour in any
period of twelve hours consecutive running at the normal engine speed.
3.5.1.3 The engine shall include the following equipment:
a) Flexible Coupling - Holset (or equal) type.
b) Starting Equipment:
. One - 24 volt DC electric starter motor which engages with a toothed ring on the
flywheel.
. Nickel Cadmium battery complete with automatic trickle and boost charging facilities,
placed adjacent to the set, enclosed in a purpose built container complete with lid.
. All necessary cables between starter motors and battery.
. Auto start pilot equipment to inject Ether into the engine, and which is complete with a
thermostat. This equipment when combined in the heaters (following), allows the set to
accept cold starting conditions down to 15°F (-10°C).
NB Extra Ether canisters to be quoted with the spares.
. Two immersion heaters with thermostat in the engine jacket.
Thermostatic bypass valve in water outlet for quick warm up and even temperature
control.
. Duplicate three attempts to start relays and associated 'failed to start' and 'engine running'
lamps.
These relays are to allow three off, 10 second cranking attempts with a 3 second pause
between attempts.
NB If duplicating the relays (in an attempt to give reliability) increases the complexity of
the system to negate reliability, this feature should be abandoned.
c) Cooling System
. Signal from Engine on start up to automatic louvre in Engine Room Wall.
d) Fuel System
. Fuel injection equipment and hydraulic governor complying with ISO 3046/4.
. Motorised single phase (voltage as on Data Sheets) AC governor speed control unit to
facilitate remote position control of engine speed. A remote push button and YBY
Traffolyte warning label is to be included. Governor to be to ISO 3046/4.
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. Fuel lift pump.
. Fuel tank complete with level gauge, heater, inlet filter, low level float switch and all
necessary connections suitable for 24 hours running; to include filling pipe and non
return valve.
A dead weight fusible link system is to be included, to cut off fuel if a fire occurs.
NB Solenoid valve to be fitted in air intake to prevent uncontrolled Engine Operation

subsequent to an overspeed shut-down, due to intake of atmospheric flammable vapours.
e) Exhaust System
. Dry type, ceramic fibre lagged exhaust system.
. One snubber primary type silencer and a secondary absorption silencer to give residential
grade silencing.
NB Primary unit to be fitted with spark arrester.
. Manufacturer to advise of noise level 3 feet (1 metre) from outlet. In general NR80 db
(A) at one metre is acceptable. The level of noise emission from the set must also be
advised for discussion.
f) Underbase - Mild steel fabricated, one piece underbase to accommodate the complete set plus bolt
on extension piece complete with radiator.
g) Anti Vibration Mountings - All the necessary neoprene anti vibration mountings for insertion
between the steel underbase and the concrete foundations, together with any necessary flexible
engine service connections. Spring steel mountings are acceptable.
h) Automatic Components
. Two stage high water temperature switch.
. Two stage low oil pressure switch.
. Mechanical overspeed trip switch and associated micro-switch.
. Override solenoid for start-up operation of fuel bar.
. Shut-down solenoid de-energised to trip.
. Centrifugal switch to withdraw starter motor from flywheel after start-up. These
components shall all be wired down to a terminal box on the engine frame.
j) Emergency Stop
Emergency stopping of the engine shall be effected by a push button on the Remote Engine Panel;
but a second pushbutton adjacent to the set is also required, and provision is to be made for a third
button, which may or may not be installed in the Control Room.
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k) Overload stop
To be set at an agreed value.
3.5.2 Alternator
a) The alternator shall be of the brushless, revolving field, salient pole rotor self regulating type, with
an output as detailed on the Data Sheets and have class 'F' insulation, limited to class 'B'
temperature rise.
b) It shall be complete with the following equipment:
. rotating brushless exciter with rotating silicon diodes,
. thyristor automatic voltage regulator mounted in the control panel in the Control Room,
. anti-condensation heaters (AC single phase at the supply voltage detailed on the Data
Sheets) automatically connected when the alternator is not running. Heaters to be
connected with separate terminal box from other heaters and equipment,
. ventilation dust filters,
. short pitched windings (to reduce voltage waveform harmonic content to a minimum) are
preferred,
. one main cable box to accommodate (preferably) all 6 winding ends with all neutral ends
linked,
. auto exciter trimmer rheostat for mounting on the control panel in the switchroom. The
switch shall adjust alternator voltage to limits of ± 5%,
. flexible couplings to connect the alternator to the engine,
. manual emergency excitation trimmer.
c) The alternator windings shall be adequately braced to withstand short circuit stresses.
d) The generator voltage must be maintained within ± 1.5% and the frequency to ± 2.5%, for all
balanced loading conditions, between unity and 0.8 lagging power factor. The voltage regulator
shall be set to give maximum speed of response when starting induction motors direct on line, and
the voltage recovery time shall not exceed 0.5 seconds to within ± 1.5% of nominal voltage.
Transient Load Throw shall not cause voltage dips greater than 10% recovering in 0.5 seconds
maximum.
3.5.3 Local Engine Panel (Adjacent to Engine)
This panel shall be of fabricated sheet steel, dust and damp protecting, floor mounting complete with the
following equipment:
- 1 engine tachometer,
- 1 cooling water temperature gauge,
- 1 lubricating oil pressure gauge,
- 1 multi point exhaust pyrometer with selector switch and thermocouples in the exhaust inlets
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before and after the turbo-charger.
NB This panel shall be mounted on the engine or on a cylindrical column adjacent to the engine and shall
(in the latter case) have inlet/exit points for the sensing leads in the column.
3.5.4 Remote Engine Panel (In Control Room Substation)
This panel shall be of fabricated sheet steel, floor mounting, front access only, with top entry cabling from
the engine room (remote control room alarm cabling shall be top entry).
The panel will be integrated with the alternator control panel described in section 3.5.6 and both may be
physically and electrically connected to the outgoing portion of the associated Essential Services
Distribution Board supplied by others.
The panel is to be complete with:
a) Indicator lamps complete with filament test button comprising:
- 1 panel on (white),
- 1 engine running (green),
- 1 battery charger boost charge (red),
- 1 protections healthy (from speed switch) (green),
- 1 battery charger on (white).
b) Alarm/Shutdown Annunciator
The 24 V DC annunciator is to be of the "First Fail" type complete with the following modules
(having black letters on a white background):
- engine failed to start after 3 attempts,

- low cooling water level,
- low fuel oil level,
- high water temperature,
- low lubricating oil pressure,
- engine overspeed,
- control circuit fuse failure,
- battery charger failure,
- fuel solenoid closed,
- 2 spare modules,
- 1 alarm accept and reset feature,
- 1 lamp test feature.
c) Instrumentation
- 1 engine operation hours counter,

- 1 engine starts counter (Hengstler or equal),
- 1 battery charger ammeter,
- 1 battery charger voltmeter.
d) 24 V DC Battery Equipment
- 1 set of Nickel-Cadmium, Alkaline batteries rated to give 9 attempts to start, and also to cover the
continuous drain loads (annunciator etc) for 1 hour subsequent to a total loss of AC supply.
The battery capacity shall be oversized, and the whole unit should be complete with an enclosed,
ventilated container adjacent to the engine.
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- 1 battery charger complete with trickle and boost charge facilities incorporated within the remote
engine panel, rated to recharge the battery from a flat condition within 7 hours.
e) Switches
- 1 manual/off/auto/test switch complete with potential free, normally closed contacts to give remote
indication when set is switched from 'auto' position,
- 1 on/off heater switch and ammeter for each heater except on the engine where the 2 engine heaters
are controlled by one thermostat and can therefore be controlled by one switch,
- 1 battery charger on/off switch,
- 1 test switch for Air Intake Solenoid valve.
NB Boost charge cycle to be automatic.
- 1 set hand/auto/emergency hand excitation switches (plus emergency control unit).
NB Governor switches to be complete with a sliding cover.
f) Push Buttons
- 1 engine start,
- 1 engine stop - "Stay put" type,
- 1 lamp test buttons as required.
g) Start Relays
Duplicate - three attempts to start relays.
NB Only three automatic attempts to start are required, and the duplication of the relays is thought
to guarantee the integrity of the system.
If it is seen that the duplication tends to negate this requirement when the schematics are
developed, then only one relay will be placed in circuit and a spare will be held in reserve.
3.5.5 Contacts
a) Any faults on the equipment within the engine room are to energise alarms on the alternator
control and engine panels and operate a remote alarm in the control room.
The control room alarm contact must be 'potential free' and normally closed (open to alarm); the
terminals associated with this contact are to be adequately shrouded and segregated since they are
incorporated in an intrinsically safe circuit.
b) The hand/off/auto/test switch must also have a 'potential free' contact on each position to actuate
remote indicators in the Control Room. These contacts should be normally closed, open to alarm,
and must be shrouded and segregated.
3.5.6 Remote Alternator Control Panel (In Control Room Substation)
This panel shall be of fabricated sheet steel, floor mounting, front access only, with top entry cabling from
the engine room. The panel will be integrated with the engine panel described in section 3.5.4.
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The panel is to be complete with:
a) Indicator lamps complete with filament test button comprising:
- alternator voltage (red),

- alternator circuit breaker closed (red),
- alternator circuit breaker open (green).
b) Controls
- control selector switch auto/manual/test/off,

- manual restoration to normal supply switch,
- voltmeter switch,
- differential voltmeter initiate pushbutton,
- emergency stop.
c) Protective Relays
- undervoltage relay,
- negative phase sequence current relay,
- earth fault relay at generator neutral (solidly grounded neutral for generators rated 600 V and
below; resistance grounded neutral for generators 601 V and up to 7,200 V), with hand reset flag
and contacts,
- voltage restrained overcurrent relay with hand reset flag and contacts,
- instantaneous differential relay (if such protection is specified).
The above relays are to be complete with the associated protection CTs and are to be flush
mounting draw out pattern.
d) Alarm/Shutdown Annunciator
- alternator protection tripped,

- emergency stop,
- alternator winding temperature high,
- alternator bearing temperature high,
- alternator cooling air temperature high,
- alternator vibration high,
- automatic voltage regulator failure.
e) Metering
- phase L1 Amps,
- phase L2 Amps,
- phase L3 Amps,
- output frequency,
- alternator speed RPM,
- output volts,
- output power,
- output reactive power,
- power factor,
- excitation volts,
- excitation current,
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- synchro voltmeter,
- differential voltmeter.
3.6 Temperature Rise
All alternators shall be designed for a temperature rise of not more than that allowed in the national or
international code or standard for the class of insulation used.
Unless stated otherwise, Class "F" insulation with a Class "B" temperature rise limitation shall be utilised to
NEMA MG 1, Part 22, Section 22.40.
3.7 Surge Arresters and Surge (Capacitor) Suppressors
The Vendor/Contractor shall supply surge arresters to reduce the magnitude of induced voltages due to
lightning strikes, switching surges etc, and surge (capacitor) suppressors to modify the steepness of the
waveform of induced voltages.
Both sets of devices shall be fitted on the line side of the machine by the Vendor/Contractor; the
Vendor/Contractor shall provide full details of these devices with his proposal.
3.8 Vibration
(a) For all alternators, vibration in any direction as measured on the bearing housing, shall not exceed
the limits given in Table 1 overleaf:
Table 1: Vibration Limits
Maximum Permissible Total Amplitude

Synchronous Speed Peak-to-Peak
On Bearing Housing On Shaft
Machine on Machine on Machine on

Elastic Rigid Elastic or
Mounting Mounting Rigid Mounting
rev/min rev/s in mm in mm in mm
< 1500 < 25 0.002 0.051 0.002 0.051 0.0025 0.064
1500 to 2999 25 to 50 0.0015 0.038 0.002 0.051 0.002 0.051
≥ 3000 ≥ 50 0.001 0.025 0.001 0.025 0.002 0.051
(b) The conditions for Table 1 shall be as follows:
- The alternator running uncoupled at no load, at normal voltage and frequency, and at
each speed of its speed range,
- The shaft axis in normal position,
- A half key in the shaft keyway, (or half coupling fitted, if available),
- For alternators having provisions for vibration monitoring systems, vibration shall also be
measured on the shaft adjacent to each bearing housing or through the bearing or
coupling housing where a single bearing machine is used. Vibration as measured shall
not exceed the limits given in Table 1 above.
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- Measurement shall preferably be made with a non-contacting eddy current proximity

probe in accordance API 670. Measurement with a shaft contacting probe may be
proposed for Owner's approval.
- If Vendor/Contractor can demonstrate that `electrical run-out' due to shaft material

anomalies is present in measurements made with proximity probes, this may be added to
the allowable vibration level up to a maximum of 0.25 mils (0.006 mm), provided a hand-
held shaft contacting probe gives results not exceeding the allowable limits.
Reference shall be made to NEMA MG 1, Part 22, Section 22.54 and Part 20, Section 20.54.
3.9 Duty
The alternator and ancillary equipment shall be suitable for operating under the following conditions:
(a) emergency power supply for essential loads when normal supply has failed,
(b) black start ie no auxiliary power available,
(c) stable operation at all loads from zero to rated load,
(d) automatic start on power failure and run up to rated speed within 10 seconds,
(e) supply rated output continuously at 0.8 pf lagging,
(f) synchronising from a remote position,
(g) automatic synchronising and shutdown for multi-unit operation,
(h) automatic loadsharing (kW and kVar) equipment,
(j) the system will have large AC induction cage motors frequently switched, direct on line
(DOL) starting,
These motors typically could be rated in excess of 1 Megawatt (whether as a single rating
or a combination of machines) and the Generator may supply starting currents of such
machines to NEMA MG1 Part 10 - Code Letter D, kVA per horsepower = 4(BS 4999
Part 112, Design D - Column 3, Table 4).
It shall be assumed that the instant of motor switching always gives full offset current in
the same phase, with motor acceleration occupying a period of 15 seconds.
Note:
The busbar voltage drop must not exceed 15% during load application.
(k) the Vendor/Contractor shall assume that the machines are located in an area where the
atmosphere may be corrosive and dusty; the dust may contain a proportion of caliche and
may be conductive,
3.10 Alternator Rating, Waveform and Voltage Regulation
3.10.1 Alternator Rating
(a) Standard ratings shall be in accordance with Table 20.10, Part 20 of MG 1.

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At rated speed, the alternator shall have sufficient capacity to continuously match the full rated output
of the prime mover under both summer and winter extremes of ambient conditions specified, without
exceeding the Insulation Class F total temperature limit (limited to Class B temperature rise).
(b) A Service Factor of 1.0 shall be assumed for the alternator rating and characteristics which shall
comply with the requirement of the latest editions of NEMA MG1, Part 22 (BS 2757, 4999 and 5000)
except where modified by this specification. The complete alternator output characteristic curves
shall be provided with the Tender.
(c) The alternator rated voltage shall be nominal (as on Data Sheets) + 6%. Maximum ground fault
current shall be limited to 25% of the machine's nominal full load current by a high impedance
neutral grounding transformer or resistor as agreed with the Owner.
The Vendor/Contractor shall quote the net alternator output after subtracting all power absorbed by
the alternator, exciter and main shaft driven auxiliaries as well as auxiliaries fed directly from the
machine or exciter. Sustained rated outputs shall also be possible within the stated voltage variations
at rated power factor, in accordance with the requirements of NEMA MG1 (BS 5000 Part 99).
(d) The prospective three-phase fault current infeed from the system to the alternator shall be taken as
equivalent to 25 kA rms symmetrical for MV power systems and to 50kA rms symmetrical for LV
power systems.
(e) Continuous operation over a frequency range of 'nominal, -6% + 2.5% shall be possible at rated stator
current. Below -6% nominal frequency the output voltage may be reduced pro rata with frequency.
(f) The alternator shall have a short circuit ratio of 0.45 unless stated otherwise on the Data Sheets. The
ratio shall be based on the per unit no-load excitation current at rated alternator voltage and the per
unit short-circuit excitation current at rated alternator current.
(g) The tolerance on the stated values of transient and sub-transient reactances shall be + 0.15 per unit of
the stated value.
(h) The Vendor/Contractor shall provide with his proposal a statistical survey of his test results for
machines of the same or similar frame and output showing the distribution of the deviation from the
predicted value. Great importance is attached to the reactance values. The switchgear making duty
often also imposes a constraint on the minimum confirmation and agreement. The dynamic stability
of the system with the potentially low stored energy constants often also imposes limitations on the
maximum transient reactance.
(i) The maximum prospective three phase rating fault making current of LV Switchgear and MV
Switchgear may be at least equivalent to 50 kA and 25 kA rms symmetrical respectively, and shall be
assumed to be of this value for consideration of winding/termination stressing unless stated otherwise
on the Data Sheets.
(j) The constraints imposed by switchgear fault and fault clearing times incur potential dynamic stability
problems which focus attention on the overall machine inertia constants. Subject to confirmation and
agreement, the inertia constant for both engine and generator shall be advised in MJ/MVA.
(k) The design shall take into account the non-natural reactance which may be required (should the frame
size be increased) to maintain the fault current contribution to the switchgear making duty within the
permissible value.
(l) The machine shall be capable of a momentary overload of 150% normal current for 1 minute with the
field set for normal load excitation.
(m) Excitation shall be of the brushless type with a Permanent Magnet Generator (PMG) Voltage Control
Unit, Exciter and rotating diodes as shown in the diagram in Section 10.0.
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The PMG shall have a high excitation field forcing capability to provide good motor starting
characteristics and, for fault clearance, a sustained short circuit capability of three times the normal
full load current for 10 seconds.
(n) The characteristics of the complete alternator including the excitation system shall maintain a steady
state voltage of ±2.5%, between no load and rated load.
(o) The alternator shall be capable of withstanding Negative Phase Sequence Current (I2) up to 10% of
rated stator current (See MG1 Part 22, Section 22.46).
3.10.2 Waveform
The output waveform of the alternator shall be sinusoidal; the allowable degree of distortion shall be
limited to a TIF as detailed in Section 16.43 of MG1 Part 16.
3.10.3 Voltage Regulation
(a) Steady State Conditions
The voltage regulation as measured at the alternator terminals shall either be as stated in Section
16.4.8.2.4, Part 16 of MG1 or shall be a minimum of Grade 3.11 (VR3) to BS 4999 Part 140 which
requires restoration to ±1% of voltage in not more than 10 seconds after a transient disturbance,
whichever is the more onerous.
(b) Transient Conditions
The transient performance shall be better than that stated in Part 16, Section 16.48.2.3 & 4 of MG1
(VR 2.13 of Table 1 'Voltage Regulation Grades' of BS4999 part 140) and shall be at least as follows:
35% Rated Current (at rated voltage) Load Application & 100% Rated Current Load Removal
Maximum recovery time 0.5 seconds to 97% of rated voltage. Overvoltage not more than 38% with
rated kVA at 0.8 pf thrown off, with maximum recovery time to 103% rated voltage not more than 1
second.
Step Load Application
With 35% rated current applied at a power factor between 0.4 and zero lagging, the initial voltage drop
shall be limited to 15% of rated voltage with recovery to 97% of rated voltage in less than 0.5 seconds.
Note:
The Vendor/Contractor shall state the rating of the Code Letter 'D' induction motor as defined in MG1
Part 10, (or combination of motors) that the set is capable of starting without exceeding the maximum
voltage drop of 15% of rated voltage with recovery to 97% of rated voltage in less than 0.5 seconds
and restoration to ±1% of the steady state voltage within 10 seconds.
3.11 Noise
(a) The noise level criteria for the plant shall be as specified in GES A.04.
(b) Reference shall be made to NEMA MG3.
3.12 Critical Speeds

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Alternators shall preferably have a rigid, under-critical (stiff shaft) rotor-bearing system with the first
critical speed not lower than 125% of the synchronous speed.
However, certain machines may have an overcritical (flexible shaft) rotor-bearing system. The first critical
speed shall be lower than 80% of the synchronous speed but should not be lower than 60% of the
synchronous speed. The second critical speed shall not be lower than 125% of the synchronous speed.
The enclosures shall be adequately braced that the critical speeds do not transmit excessive vibration into
the enclosure and components.
3.13 Overspeed
The machine shall be so constructed that in emergency they will withstand without mechanical injury,
overspeeds above the rated synchronous speed of 125% synchronous speed for 2 minutes.
3.14 Pulsating Stator Current
Alternators driven by machines which require a variable torque during each revolution, e.g. Diesel Engines,
shall have sufficient inertia to limit the variations in the open circuit line to line terminal voltage to a value
not exceeding 0.1 as specified in MG1, Part 22, Section 22.42.
The additional inertia necessary to comply with the current variation and speed irregularity requirements,
should be added to the rotating mass of the alternator.
If this requirement cannot be met, approval shall be obtained from the Owner regarding an alternative
design.
3.15 Parallel Operation
(a) The alternator shall be suitable for satisfactory parallel (droop or isochronous) operation with other
machines and systems, however, it shall be suitable for running independently if required.
(b) The speed governor will be provided by the Driving Machine supplier; for the purpose of Electrical
System Design and Operation, it is assumed that it will be a fast acting Electronic Governor with a
maximum speed regulation of 4% droop (Class C to NEMA Standard SM24, Table 3.1).
4.0 CONSTRUCTION
4.1 Type of Alternator
4.1.1 The alternator(s) shall be salient pole rotor type with either Air to Air or Air to Water cooling as detailed
later in Section 4.7.
Open type machines with filter ventilation (pulse filters or other types) are not considered in this
specification.
4.1.2 Class "F" Insulation materials complying with the requirements of MG1 Part 1/IEEE Std.1 (BS 2757 and
BS 4999 Part 144), shall be used as extensively as possible for the alternator and excitation equipment.
The use of other than Class "F" material as a main insulation shall be stated in the Tender. Details of the
insulation shall accompany the tender and shall be supported by evidence of satisfactory experience of a
number of years continuous operation.
4.1.3 The direction of rotation shall be as required by the prime mover and indicated on the Data Sheets.
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4.1.4 The main terminals shall be distinctly and permanently marked and identified to MG1 Part 2 (BS 4999 Part
108).
4.2 Stator
4.2.1 The casing of the stator shall be of fabricated steel construction and the enclosure shall be a minimum of
IP54 to MG1 Part 5 (BS 4999, Part 105) totally enclosed.
4.2.2 All fixings and fastenings on the stator, components, windings and enclosures shall be positively locked to
withstand any vibratory and starting duties imposed on them.
4.2.3 The stator core shall be made up of high permeability, low loss silicon steel laminations suitably braced and
located to ensure true concentricity of the core and to reduce magnetic noise and vibration to a
minimum. No bolts or clamps shall pass through the core and permanently located and robust radial
support fingers shall be provided for the slot teeth.
4.2.4 The stator frame shall be of pressed and welded construction with the core clamped between endplates and
located by keybars. The baseplate shall be of the welded steel box girder type, stress relieved, where
necessary. The completed structure shall be proven to be free from excessive vibration including vibration
from critical speeds.
4.2.5 The ends of the stator frame shall be enclosed by rigid metallic end covers/bells. Rigid baffles shall be
provided to protect the stator end wirings and to control the distribution of the cooling air. Where these
baffles are subject to magnetic fields, they shall be of non-magnetic material. GRP baffles shall be braced
to prevent aerodynamic buffeting. The design shall prevent excessive 100 Hz/120 Hz vibration being
transmitted to the machine foundations, pipes or associated equipment.
4.2.6 The Owner's Inspector may require to check the truth of the stator bore at four positions around the clock-
face at either end and in the centre of the stator 'pack'. Tolerances to be not more than + 20 mil (0.5 mm)
on nominal size.
The core slots shall be of the open type and wedges shall be non-magnetic material such as glass fibre.
4.3 Stator Windings and Connections
4.3.1 The stator winding shall be of diamond involute rectangular strip form wound type coils with short pitched
(chorded) turns. The output voltage waveshape shall be sinusoidal with particular emphasis on minimising
the harmonic components of current generally (And 5th and 7th components in particular) plus the 3rd and
9th components which can flow when the alternator neutral is effectively connected to earth and the
machine is operating in parallel with other machines or the industrial power system.
4.3.2 The conductors shall consist of a number of parallel insulated strips of copper of substantial cross section
transposed as necessary to minimise losses. The general construction of the stator and the bracing of the
winding overhang shall provide adequate cooling and avoid hot spots.
4.3.3 The winding shall be discharge free on a voltage falling to 'nominal' + 6%.
The preferred series of tests on the coils and completed stator is detailed in ANSI/IEEE 95 and 433
(BS 4999 Part 144).
The Vendor/Contractor shall detail in the tender which tests are included. He shall quote an extra price for
each test not included but which he is able to perform.
4.3.4 Anti-corona graphitised tape protection with end grading shall be applied to the slot portion of the insulated
coils with a semi-conducting stress grading tape applied to the end of the corona shield. The insulation
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shall be void free and homogeneous.
4.3.5 The stator winding overhang shall be supported from the frame keybars and adequately braced to prevent
movement under the specified system conditions for motor starting. The bracing shall withstand without
movement the full voltage fault currents associated with a sudden short circuit across the main terminals
with full automatic voltage regulator action when the alternator is connected to the prospect fault level
detailed on the Data Sheets.
4.3.6 One completed machine of any series of similar machines shall undergo 100% rated terminal voltage
sudden short circuit testing, (preferably) with "point on wave" of switching selected to give at least one
shot with full offset in one phase. High speed photography of the end winding is also preferred to
demonstrate the
soundness of the bracing, although physical inspection and a high potential test (after the short circuit) is
acceptable, as is random switching if "point on wave" is not possible.
4.3.7 The windings shall be arranged for star connection with all six ends brought out to Elastimold (or equal)
fully fault tested terminals and clearly permanently identified with phase and sequence. The terminals (bus
bars) shall be suitable for receiving the number and type of cables or bus bars per phase specified on the
Data Sheets, with their appropriate termination.
4.3.8 Contact between adjacent coils between coils and other conductors and between the six winding end tails
shall be avoided by adequate spacing, bracing and support. Suitable insulating spacers are not precluded.
Great care is taken on the industrial system to preclude phase to phase MV faults, by using the appropriate
cabling etc. Similar care is expected of the Vendor/Contractor in the arrangements of the alternator and
connections and full details shall be given in the tender.
4.3.9 The six ends of the winding (Line and Neutral) shall be brought out onto the same side (left hand side
viewing from non drive end) of the machine (on the opposite side to the cooler and lubricating oil
pipework) into a fabricated sheet steel integral Line/Neutral cubicle.
Adequate space shall be provided for the mounting of the following items which are all to be provided by
the Vendor/Contractor:
(a) 1 zero sequence CT (neutral end),
(b) 6 'ring' CT's for differential protection (3 in line and 3 in neutral end) if such protection is fitted,
(c) 3 general protection 'ring' CTs (neutral end),
(d) 2 metering ring CT's (neutral end),
(e) surge suppressors (line end),
(f) surge arresters (line end),
(g) 2 voltage transformers.
Notes:
1. The CT connections shall be brought out to a separate external terminal box to allow access without
opening the main connection chamber.
2. The copperwork shall be adequately sized for the full load current of the machine and be braced for a
50 kA fault level (or as indicated on the Data Sheets).
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3. The tender shall include full details of the proposed method of winding/terminations, which shall be
to the Owner's approval.
4.3.10 Nine off Simplex 3 wire resistance thermometers (6 in use and 3 spare) with platinum elements having a
resistance of 100 ohms at 0°C, shall be equally distributed between the three phases, complete with surge
protection against overvoltages induced from the Stator Winding.
Each element shall be located about the middle of the core and alongside the insulating separator between
the top and bottom coil in the slot. The connections shall be brought out by screened leads (if necessary to
reduce pick up) to a terminal box safely accessible from outside the stator with the machine in service. The
heat run of the completed machine will identify the highest reading elements in each phase and these shall
be marked for use on site for service monitoring of the stator temperature.
4.4 Bearings and Lubrication
Bearings shall be the 'end frame bracket' type.
4.4.1 The oil and lubrication system shall in other respects follow the specification for that of the driving
machine.
4.4.2 Embedded Duplex (PT100) Resistance Temperature Detector for use with a remote Indicator with Temp
Alarm/Trip facilities shall be fitted to each bearing.
4.5 Rotor
4.5.1 The salient pole rotor body shall be of forged steel, preferably comprising one solid forging. The forging
shall be manufactured by an approved forgemaster and shall be subjected to stringent quality control
throughout manufacture.
The Vendor/Contractor shall submit with this offer, full details of the proposed schedule of tests and quality
control together with details of the material and heat treatment to be applied to the forging. The rotor body
shall be thermally stable under all service conditions.
4.5.2 The salient pole rotor shall be machined from a single steel forging.
After rough machining the forging shall be subjected to 100% ultrasonic witnessed examination;
equipment, probes, calibration and sensitivity shall be to the approval of Owner.
4.5.3 The design of the rotor shall give an adequate margin (say 0.2 pu, 20%) between rotor critical speeds and
the normal running speed and shall exceed the overspeed test speed. The critical speeds shall be declared
with the tender and the Vendor/Contractor shall demonstrate that full account has been taken of oil film and
bearing flexibilities.
4.5.4 The maximum permissible error in air gap shall be declared in the tender. This shall be taken into account
when plotting unbalance magnetic forces against stiffness of rotor and stator. The overspeed test on the
completed rotor shall be in accordance with MG1 (BS 4999 Part 143) but shall not be less than 125% of the
normal synchronous speed. The balance shall be checked both before and after the overspeed test to prove
that nothing has been displaced by the test. The Vendor/Contractor shall declare the balancing procedure
used during factory tests and that procedure required on site subject to any maintenance operations.
4.5.5 The vibration level for the complete rotor (with the half coupling fitted), measured at the bearing housings,
vertically, axially and transversely shall be to MG1 or better i.e less than one half of the maximum values
quoted in MG1 (BS 4675 Class IIIB), i.e a limit of 2.25 mm/sec. rms total velocity when tested at the
Vendor/Contractor's works. This test to be performed with the rotor in both unexcited and excited
conditions. As far as possible, all balance weights shall be fitted into the body of the rotor.
4.5.6 All bolts or other fastenings on the rotor shall be positively locked.
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4.5.7 The space required for rotor withdrawal shall be shown on the tender drawings. The proposed method
shall be stated with the instruction manual and any special tools and handling devices included in the
tender.
4.6 Rotor Winding
4.6.1 Deformation of the rotor winding due to "copper-shortening" or phase or earth faults developing either in
the machine or on the connected system shall be avoided by suitable choice of material and rotor design.
The rotor-cooling system shall be entirely suitable to ensure that no hot spots develop and details of the
cooling method shall be included in the Tender.
4.6.2 The rotor winding shall be high conductivity copper strip. All joints between coils shall be adequately
brazed. The winding insulation shall be Class "F" (limited to Class 'B' rise) as detailed in MG1 Part 16,
with the specified cooling air or cooling water temperature.
4.6.3 The field coils are to be of strip on edge construction with interturn insulation cured under heat and
pressure to give fully consolidated units. The coils to be insulated with spools top and bottom and
additional insulation as necessary. The insulated coils to be assembled on the poles and held in place with
bolted on pole shoes and 'V' blocks between the coils where necessary.
4.6.4 The clamping blocks used in the rotor winding shall be approved material and suitable for the high
temperature and mechanical forces which exist in the rotor.
4.6.5 Particular attention shall be given to the insulating and securing of coils to avoid vibration and the possible
failure or slackening of either the connector or its insulation under any condition of service.
4.6.6 The Vendor/Contractor shall supply curves showing permissible single and unbalanced phase loading
against time.
4.7 Cooling System
4.7.1 The cooling system shall be either Totally Enclosed Water-Air cooled (1.26.8, Part 1 of MG1) or Totally
Enclosed Air to Air cooled (1.26.9, Part 1 of MG1) as indicated on the Data Sheets.
4.7.2 The ventilation shall have combined axial and radial flow. Care shall be taken in selecting the combination
of radial ducts to avoid pure tone noise generation. The cooling air flow shall be distributed to cause a
uniform temperature throughout the windings and iron.
4.7.3 A pair of shaft mounted fans shall draw the cool air from the heat exchanger outlets. One fan shall be
mounted at each end of the shaft. Each fan shall be of substantial design with individual blades bolted to
the shaft by two bolts with locking washers. The fan shall be shrouded to prevent unwanted air
recirculation and designed to work at its best efficiency point in conjunction with the cooling system. The
materials of construction shall not be subject to stress corrosion cracking. The fan maximum stress at
overspeed shall not exceed 30% of the elastic limit. The fan design and neutral frequencies of vibration
shall be determined theoretically and practically to avoid resonances and evidence of this shall be produced
before manufacture commences.
4.7.4 The arrangement of the shaft seal shall preclude bearing lubrication oil mist from being induced into the
cooling air circuit by the suction of the alternator cooling fans.
4.7.5 Provision shall be made for ready access into all temperature chambers for inspection and cleaning.
4.7.6 Provision shall be made for measuring the air temperature at the exit from and to the heat exchangers by the
provision of 3 Duplex RTDs externally mounted and also 1 Duplex RTD in Exciter Hot Air Circuit. The
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arrangement shall allow safe replacement of the RTD's whilst the machine is on line.
4.8 Heat Exchangers
4.8.1 Air to Air Cooled
(a) The unit shall preferably be top mounted and of carbon steel with an adequate corrosion allowance
for a 25 year life.
(b) All steel surfaces shall be prepared and adequately painted to GES X.06 to prevent corrosion.
4.9 Excitation
4.9.1 The method of excitation shall be subject to detailed agreement by the Owner, a high speed of response is
required to assist dynamic and system stability, and generally complying with the relevant part of MG1 (BS
5000).
The excitation system shall be brushless including a close coupled permanent magnet generator (PMG).
In the interests of fast response and reliability, no part of the excitation system (compounding CT) shall be
used for another purpose. This excludes the VT which should, however, have double secondaries with 110
V for the AVR and 110 V (or the voltage specified on the Data Sheets) for synchronisation and metering.
4.9.2 The excitation system shall have quick acting field suppression (as well as Field Forcing) and be complete
with:
- 1 thyristor type automatic voltage regulator suitable for controlling the output voltage of the
brushless A.C. generator specified, to within + 0.5% of its nominal rated value when running
singly at rated power factor,
- 1 excitation limits module with current limit CT, PF potentiometer, meter relay and power factor
relay,
- 1 hand control module with auto follow-up and null balance allowing automatic changeover
(without disturbance) from 'AUTO' to 'HAND' Control upon failure of the AVR or field failure as
well as manual transfer from 'HAND' to 'AUTO',
- 1 hand control supply transformer,
- 1 field diode for hand control module,
- 1 resistor for hand control module,
- 1 hand/auto contactor,
- 1 field discharge resistor,
- 1 excitation contactor,
- 1 excitation fault detector,
- 1 diode failure detector with pilot relay and resistor,
- 1 compounding CT (fitted to generator).

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4.9.3 The system offered must have been in service satisfactorily and proven for several years continuous
operation. The proposal shall include an application list of relevant machines of similar frame, together
with full technical details of the proposed system.
4.9.4 All rotating excitation machines shall be integral driven from the main shaft.
4.9.5 The cooling air for shaft driven excitation equipment shall be taken from the main machine air circuit.
Where any return air may be contaminated, filtration shall be provided.
4.9.6 A system of monitoring and alarm shall be provided which indicates when a critical number of diodes have
failed, such as one arm of a bridge, which require the set to be shut down. It is not acceptable to allow the
machines to run until a cascade failure of semi-conductors leads to pole slipping.
4.9.7 All connections between main exciter, any rectifiers and the alternator rotor shall be designed to avoid the
possibility of short circuits and earth faults.
4.9.8 The insulation levels, thermal and voltage ratings of all components in the regulation and excitation system
shall be adequate, and shall also survive pole slipping following system faults or loss of excitation.
4.9.9 Where the main excitation circuit rated voltage does not exceed 500 volts, the rectifiers where fitted and the
main exciter and circuit shall be insulated for a test voltage of 1500 volts. Where the excitation circuit
rated voltage exceeds 500 volts, the insulation level voltage shall be suitable for 4000 V plus twice rated
field voltage. The exciter main circuit and any rectifier assembly shall withstand an insulation high
potential test appropriate to the insulation level voltage, according to the relevant National Standard.
4.9.10 The excitation circuit of the main exciter, including any pilot exciters shall be designed for a working
voltage of 220 volts minimum. The insulation high potential test voltage shall be 1500 volts minimum.
4.9.11 Each bridge arm shall have two fully rated diodes in series and be protected by the Diode Failure Detector.
The peak voltage rating of each semi-conductor arm shall be not less than 10 times the rated DC output
voltage (130 V) of the rectifier circuit.
The current rating of each arm shall be at least 50% greater than the normal rated current of the Semi-
conductor arm.
4.10 Voltage Regulator
4.10.1 The automatic voltage regulator shall be high speed, continuously acting without deadband and
compounded for parallel operation. It shall exhibit long term stability and freedom from drift.
4.10.2 The adjustment range on the desired value setting shall allow the machine to operate on open circuit at the
system voltage specified, and to allow the full reactive lagging capability at 0.8 pf of the alternator frame to
be reached at the system nominal voltage. The desired set point adjustment shall be power operated and
arranged for remote electrical control.
4.10.3 The regulator shall incorporate automatic high speed overvoltage protection reducing the excitation when
the alternator terminal voltage reaches 120% of rated value. The protection shall reduce the terminal
voltage to the rated value.
4.10.4 Preference shall be given to the static amplifier system which is well proven. A regulator sensitive + .005
pu is desired.
4.10.5 The required minimum overall performance is stipulated in section 3.10.3 of this specification.
The regulator shall be suitable for operating from a 110 volt, 50 Hz/60 Hz (or as specified on the Data
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Sheets) voltage transformer output.
4.10.6 The maximum distance between the machine excitation regulator panel and the switchgear that could affect
the accuracy and operation shall be stated. Vendor/Contractor should incorporate a voltage transformer in
the machine, if this is necessary. Details of the design to clarify this point should be included in the
proposal.
Provision shall be made for remote manual control of excitation with the automatic regulator out of service
for maintenance and full details shall be included in the proposal. This should include means of safe
isolation of the automatic voltage regulator for maintenance. The range of manual control shall be at least
that given by the automatic system. Automatic follow up of the manual control system shall be provided,
together with automatic means of bumpless transfer from automatic regulation to manual control of
excitation (null balance meter etc).
4.10.7 The arrangements of any rheostats or adjustable resistances shall be such that loss of sliding contact does
not interrupt the exciter field circuit. They shall be located in the top of cubicles with adequate ventilation
to avoid overheating and heat retention in the cubicles.
4.11 Exciter and Field Suppression
Automatic means shall be provided for suppressing the main exciter and rotor field rapidly on internal
alternator fault and render all modes of operation inoperative. Suppression will be initiated by a signal
from the alternator balance protection on the generator switchgear control/relay panel provided by others.
Where the suppression is not directly on the main field winding, the Vendor/Contractor shall declare the
forcing means provided to obtain rapid suppression.
The exciter fields shall not be damaged by over-voltages during field suppression.
The method of field suppression shall be detailed in the proposal.
The excitation system and AVR shall include the following features:
- single running feature,

- parallel running with automatic load sharing,
- over and under excitation limiter,
- rotating diode failure indication,
- hand voltage adjustment feature (±5%).
4.12 Indication
4.12.1 The requirements for initiating measurement, indication and alarm are as follows;-
(a) Temperature measurement/indication schedule:
Stator winding Simplex points (6 working plus 3 spare, wired out to

terminals),
Cooler air exit (Duplex) 2 points,
Cooler air inlet (Duplex) 1 point,
Exciter air exit (Duplex) 1 point,
Bearing Metal (Duplex), 1 point on each,

Drive End & Non Drive End
Water Leakage Detector (if 2 points.

Rev 0 1999
relevant)
(b) Voltage regulation measurement/indication schedule:
Field ammeter and voltmeter,

Automatic voltage regulator - operative indication,
Automatic voltage regulator - failure indication,
Automatic voltage regulator - balance indication,
Automatic voltage regulator - field raise indication,
Automatic voltage regulator - field lower indication.
c) Alarms schedule:
Cooler exit air high temperature two off,

Cooler air inlet high temperature one off,
Exciter air outlet one off,
Diode failure one off,
Vibration (bearings) four off,
Stator windings six off (plus 3 spare wired out),
Bearing temperature drive end two off,
Bearing temperature non drive end two off.
Note:
Local alarms and indications may be included in this Purchase Order/Contract mounted on the local
supervisory panel in agreed positions.
Remote alarms and indications will be supplied under another contract but the responsibility for the
initiating devices, as specified above and for installing them and connecting them to terminals suitable for
the receipt of the outgoing multicore cable connections is included in the Purchase Order/Contract.
4.13 Grounding (Earthing) Terminals
Two external earth terminals shall be provided on the frame in a visible position. The terminals shall be
rated to carry the full load current of the alternator for 0.4 seconds without exceeding 392°F (200°C)
temperature.
4.14 Heaters
Anti-condensation heaters shall be fitted of a rating adequate to prevent condensation when the machine is
shut down. The rating need not be adequate to dry out the alternator prior to commissioning but shall
maintain the insulation resistance during any prolonged shut down periods.
Heaters shall be metal sheathed type wound for the relevant voltage and frequency indicated on the Data
Sheets, with magnesium oxide (powder) insulation. They shall be arranged so that all live leads and
connections inside the case are fully insulated with heat resisting insulation and all joints shall be brazed.
The leads shall terminate in a separate terminal box readily accessible when the machine is in service. The
box cover shall be labelled "Danger - Isolate Elsewhere".
The rating of heaters (alternator and exciter) shall be declared in the proposal.
4.15 Ancillary Equipment
The Vendor/Contractor shall include all ancillary equipment required for the efficient running of the
alternator mentioned in this specification.
Rev 0 1999
Where any ancillary rotating equipment incorporating AC rotating machines, such as barring gear, or other
drive motors, is provided they shall comply with the Owner's relevant specification.
The recommended spares list shall provide for components included in the ancillary equipment.
4.16 Noise
The noise level generated by the equipment under normal operating conditions when measured shall not
exceed an ISO NR 85 curve when expressed as sound pressure level relative to 0.0029 psi (2 x 10N/m2).
This noise level shall be measured at 3 feet (1m) from the periphery of each item of the equipment.
Directivity effects shall be measured.
The sound power levels shall be calculated and declared if they are likely to be in excess of 100 dBWatt on
the A scale.
The method of measurement shall be that specified in section 7.1.3.
4.17 Screw Threads
Threads shall be imperial, or if relevant, Isometric to BS 3643.
4.18 Labelling & Marking
The terminal boxes, panels and doors giving access to live terminals shall be suitably labelled to warn of
the danger.
Ancillary equipment wiring shall be ferruled completely and every component identified with a reference
keyed to the schematic diagram.
4.19 Cabling
Block wiring diagrams to show the number of cores for each external cable shall be provided within 60
days from the date of the order.
Final wiring diagrams shall be provided in ample time to enable the Vendor/Contractor to programme and
proceed with the installation and connection of the cables.
4.20 Vibration
Vibration limits shall be in accordance with Section 3.8 and the method of measurement shall be in
accordance with either MG1 and MG3 or BS 4999 Part 142, as relevant.
Non contact detectors shall be provided as specified by Owner to match the Driver Vibration Detector
Control Module.
4.21 Coupling Design
(a) The half coupling shall be supplied "rough bored" by the driven equipment Vendor/Contractor for
finish machining and balancing by the alternator Vendor/Contractor.
(b) The coupling design shall be based on the maximum transient torques which can be expected at the
coupling in the case of a two or three phase short circuit.
4.22 Engineering Details & Responsibility

Rev 0 1999
All tapping point values are to be mounted in readily accessible positions, close to the tapping points.
Instrument cases are to be marked on the rear with symbols and numbers.
All temperature measurement points (except windings) shall be replaceable/accessible for test in service.
4.23 Responsibility
The Vendor/Contractor must accept responsibility for checking all electrical and pneumatic signal
connections, and for the correct functioning of the equipment supplied. all instruments shall be tested and
approved and except where agreed to the contrary, they shall also be checked at Site after erection to ensure
that they give accurate indication of the conditions which they are intended to measure.
4.24 Torsional Analysis
The alternator Vendor/Contractor shall supply the information needed for the Driven Equipment
Vendor/Contractor to effect a shaft torsional analysis of the complete installation.
4.25 Diesel Engine
Apart from the brief details in Section 3.0 of this specification, refer to GES M.01 for full construction
details.
5.0 NEMA/IEC DIFFERENCES
5.1 General
This specification is primarily written for machines manufactured in accordance with the American
(NEMA) Standards.
If it is necessary or advantageous to purchase machines in accordance with International (IEC) Standards,

the specification can still be utilised but the salient differences occurring should be noted as detailed below.
5.2 Salient Differences
This section does not attempt to list every difference between American (NEMA) standards and IEC
standards, but covers only those salient differences that could affect the final installation if not properly
addressed during the design phase.
5.2.1 Units - SI Units
The NEMA Standards in many cases utilise imperial units (horsepower, feet, pounds, degrees fahrenheit,
foot candles, etc), whilst the IEC Standards utilise SI units (metres, grammes, degrees celsius etc).
Note:
For electrical equipment, the (American) Institute of Electrical and Electronic Engineers (IEEE) have
recommended that the use of the imperial (British-American) units in use be reduced as rapidly as possible
in favour of the SI units, with certain implementations such as the use of horsepower being phased out first.
Where practicable, both systems have been shown in this standard and on the Electrical Data Sheets since
the transition will take some time to fully implement.
5.2.2 Frame Size : (IEC-72)

Rev 0 1999
The standard frame sizes in MGI will be different to those in IEC 72, however, in either case, the final
frame sizes are normally assigned by the Vendor/Contractor against the required duty.
5.2.3 Ingress Protection (IP) (IEC 34-5) IEC 529
The IEC Code precisely defines the ingress protection offered to the machine by its enclosure against solid
bodies and moisture. The NEMA Code MGI-Part 5, is now similar, and for most refinery installations, an
enclosure of "IP54" (as defined in both codes) should be adequate for most installations.
5.2.4 Hazardous (Classified) Areas (GES L 35)
Full details of the comparison of IEC and American practices are detailed in GES L.35 and are not
reiterated here.
If it is intended to purchase a machine to IEC Standards, reference shall be made to the contract hazardous
area drawing produced from the principles stated in GES L.35 to establish the enclosure type needed.
Note:
The National Electrical Code NFPA 70, Article 500 and API.RP500 cover the American approach to
hazardous (Classified) areas in some detail.
5.2.5 Cooling
The concepts are similar i.e. air or water cooled etc., only the method of identifying them is different.
Provided the requirement is clearly stated in words, it should not be a problem.
5.2.6 Rating (Performance)
Generally, for continuously rated machines, the IEC standards recognise only a continuous maximum
rating (CMR) which relates to a service factor of "1.0".
5.2.7 Testing MG1 (IEC 34-2,9,12,14 and 15)
The principal methods of testing machines and evaluation of performance are covered in the IEC standards
by the parts of IEC-34 detailed above.
The American machines are tested against ANSI/IEEE standards and all differ slightly.
This should not be a problem as the requirements are judged against guarantee figures given at the pre-
order stage by the Vendor/Contractor and if agreed beforehand, either standard would be acceptable for the
test procedures and tolerances to cover the tests required and specified in standard specifications.
5.2.8 Terminal Markings (IEC 34-8)
NEMA MG.1, part 2, gives terminal major markings with a "T" prefix, whereas the IEC code utilises U, V,
W for phases.
5.2.9 Grounding
Concerned with the nature and location of an intentional electrical interconnection between the Electrical
System Conductors and Ground.
In British Practice, the terms "Grounding" and "Ground" are replaced by "Earthing" and "Earth".
6.0 INSPECTION
Rev 0 1999
6.1 Procedures
(a) The Vendor/Contractor shall allow the Inspector free access to all areas of manufacture, construction,
assembly and testing.
(b) The Vendor/Contractor always has the responsibility to provide adequate quality control and
inspection of equipment and materials as defined in ISO 9000. Any inspection by Owner or his
Inspector shall not relieve the Vendor/Contractor of these responsibilities or those under his
guarantees.
(c) Any defects noticed in the course of fabrication shall be brought to the attention of the Inspector who
shall decide if the faulty material or workmanship should be repaired or rejected.
(d) If inspection is waived, the required data shall be forwarded to the Owner. If submission of data is
not requested, all data shall be retained by the Vendor/Contractor for issue to the Owner on demand,
for at least five years.
(e) The Vendor/Contractor shall provide a safe working environment for the Inspector and alert the
Inspector of potential hazards.
6.2 Scope
6.2.1 The inspection requirements are covered by the document "General Conditions of Purchase" which forms
part of the Purchase Order/Contract. Additional requirements are given below.
6.2.2 Inspector shall inspect the diesel generators to ensure that they comply with the requirements of the latest
revision of this specification and Data Sheets, drawings or other attachments to the material requisition, and
the latest revision of the Vendor/Contractor's documentation and data relating to the specific Purchase
Order/Contract.
6.2.3 All shopwork and testing of the diesel generators shall be carried out to the complete satisfaction of the
Inspector, but his approval shall not relieve the Vendor/Contractor of the responsibility for the guarantees
covered in the Purchase Order/Contract.
The diesel engines shall be inspected in accordance with the requirements of GES M.01.
In particular the following shall be checked:
(a) rating plate details,
(b) certification/approvals markings,
(d) terminal box(es) location, size and cable entries,
(e) terminals,
(f) mounting arrangement,
(g) grounding terminal(s) size and location,
(h) accessories including CTs and accessibility for injection testing and accessibility,
(k) equipment tag number,

Rev 0 1999
(l) functional check of all Alarms, Cooling Devices and Tap Changers etc.,
(m) dimensional check particular over length, breadth, height and skid/wheel centres.
Inspector shall ensure that any shortcomings in the Vendor/Contractor's documentation or data are rectified
before any equipment or material is accepted for shipment.
6.3 Nameplates
6.3.1 Information to be given in all cases
Each alternator shall be provided with a rating plate of stainless steel fitted in a visible position, showing
the appropriate items listed overleaf. The entries on the plate shall be indelibly marked (by etching,
engraving or stamping).
(a) continuous overload capability/service factor,
(b) the machine manufacturer's or the bearing manufacturer's identification of all bearings,
(c) for machines with sight feed oilers, information on the setting of the oiler bottle height adjustment
above some convenient reference plane to maintain the proper level of oil in each bearing reservoir,
(d) for machines with unidirectional fans, a separate data plate with rotational arrow,
(e) equipment plant item number,
(f) weight of the machine,
(g) voltage, phases, frequency,
(h) rated current,
(i) connection diagram for multiple connection windings.
Alternator nameplate and data plate material shall be stainless steel and shall be attached by stainless steel
fastenings.
A permanently marked 'direction of rotation' arrow shall be included in the alternator end shield.
7.0 TESTING
7.1 Statutory Tests
Tests shall be performed in accordance with the applicable codes, the requirements of the Data Sheets and
include, as a minimum, the following Routine Tests.
7.2 Routine Tests (including String Tests)
7.2.1 The Vendor/Contractor's basic routine witnessed factory test is required and shall include but not be limited
to the following tests to ensure that the specification for the Emergency Diesel Generator Set has been met
at the rated environmental conditions:
(a) The following will be subjected to official inspection during manufacture.

Rev 0 1999
- shaft material and all non-destructive tests,

- heat exchanger joint technique and construction,
- quality control assurance tests on all windings and construction,
- labelling and packaging.
(b) The alternator shall be subjected to the following Routine Tests witnessed on all machines of a series
covered by the same purchase requisition, except as indicated:
- overspeed test of completed rotor,

- balance test of completed rotor,
- determination of Moment of Inertia (one machine of series only),
- characteristic curve; open and short circuit loss tests to determine efficiency by summation of losses
method, BS 4999 Part 102,
- vibration tests,
- winding high voltage test,
- insulation resistance,
- rotor and stator resistances,
- phase rotation test to (BS 4999 Part 108),
- discharge inception and extinction voltage tests (one machine of series only),
- tan delta test,
- integrated loss energy test,
- wave form tests,
- polarisation Index (before and after winding high voltage test),
- noise level (one machine of series only) to MG1 and MG3 (BS EN 60034-9:1994),
- rated voltage zero p.f. sudden short circuit (s/c) test, followed by examination of the windings to
observe the effects of the s/c (1 machine of series only),
- a temperature rise test with exchangers in operation, at reduced voltage and rated stator and rotor
current at zero power factor over excited.
(c) The excitation equipment shall be subjected to the following Works tests (effected with main
machine).
- overspeed test of rotating equipment, including conductors, where applicable,

- load Saturation curves, heat runs,
- high Potential tests,
- insulation resistances,
- winding resistances,
- noise level,
- rectifier tests, where applicable, to show equipment meets specification.
Note:
During vibration tests, the readings on the machines' vibration probes shall be noted for comparison with
the Vendor/Contractor's vibration test equipment results.
(d) Heat Exchanger (Water Cooled)
Each completed part of the heat exchanger shall be fully tested at room temperature at the
Vendor/Contractor's works.
'In service' cooling, water temperature at the inlet to the heat exchangers to be assumed at the
temperature indicated on the Data Sheets. However, for test purposes, the coolers can be tested at the
fortuitous temperature available. The working pressure will be nominally 5.3 bar (75 psig) and the
water side test pressure shall be 1.5 x Working Pressure (8 bar-120 psig).
Rev 0 1999
The sequence of testing shall be:
(a) a drop in pressure air test applied to each interspace,

(b) any repairs necessary shall be re-expansion of expanded joints by grinding out and rewelding any
welded joint.
The exchanger shall be double pass as a minimum.
The Vendor/Contractor shall declare the method of construction proposed. The fouling margin shall be
stated, together with information on required quantities, predicted exit temperature, total heat rejection,
exchanger rating etc. as required on the data schedule.
(e) Noise
The following noise test procedure shall be followed unless agreement to the contrary is made in
writing, i.e. fully loaded (during zero power factor test), unless otherwise specified, octave band sound
pressure level measurements are to be made as detailed in MG1, MG3, & ANSI/IEEE Publication No.
85 (BS 4999 Part 109).
Note:
Zero P.F. load run accepted, but account must be taken of background noise level by the method
described below.
The set of decibel readings for each active band is to be tabulated and shall not exceed the levels for
Noise Rating 85 dB(A).
The running tests on one set of each rating are to be carried out in the presence of the Owner's
Inspector, who will be responsible for approving the testing arrangements, the location of the sound
measuring equipment and for checking the accuracy of the recorded noise level.
Pure tone
A pure tone is present in a noise when a component in a given octave band is within 10 dB of the total
level in the chosen octave band. Such a pure tone would be detected normally by ear but special
instrumentation is necessary if a quantitative analysis of the tone is required.
Background Noise
The background noise levels when the machine is not on test should be determined using the same
filters and at the same points as for the test. The readings at each point with the machine on test ought
to exceed those due to the background noise alone by at least 10 dB.
When the differences are less than 10 dB, corrections as given below should be applied:
Table 2. Noise Level Correction
Increase in Level Produced by the Amount to be subtracted from the

Machine Measured Value
dB dB
3 3
4-5 2
6-9 1
Rev 0 1999
When corrections are applied, the correct levels should be reported in brackets.
As the increase falls from 3 dB to zero, the significance of measurements vanishes.
The Vendor/Contractor shall confirm that all the above tests will be performed and within the cost of
his proposal. Any other tests deemed advisable by the Vendor/Contractor shall be stated in the
proposal and quoted as and extra cost to the Tender Price.
(f) 'String' Tests
Works 'String' Tests
a) For these tests the requirements of BS 5514 and BS 5000: Part 99 shall be observed and in
addition to the standard engine tests detailed in BS 5514 eg governor tests, etc the set shall be run
as follows:
- ½ hour on ½ full load )

- ½ hour on ¾ full load ) Fuel and oil consumption to be measured at all loads.
- 12 hours on full load )
- Measurement of steady speed band for 2 to 5 minutes during 12 hour test.
Also required are:
'Load Acceptance/Load Rejection' tests at values to be agreed.
Notes:
The Vendor/Contractor's proposal is to include the cost for carrying out all tests on the alternator set.
The set is not to be dispatched by the Vendor/Contractor until test certificates have been approved by
the Owner.
Dismantling
Subsequent to the 'string' tests in section (7.2.f), the following dismantling, at the Vendor/Contractor's
expense, for the purpose of inspection shall be effected:
i) two pistons and two rods,

ii) one cylinder head.
If due to unsatisfactory results, further dismantling is necessary, this will also be effected at the
Vendor/Contractor's expense.
b) Short Circuit Test
The alternator is to have a short circuit applied at 0.8 pf lagging whilst connected to the diesel engine,
so that the effects on the alternator windings and coupling can be observed.
See BS 4999 : Part 104.
The windings must be adequately braced to withstand short circuit stresses.
NB At the end of the short circuit test and upon completion of tests on the set, the alternator end
shields must be removed so that an examination of the windings can be made.
c) Oscillograms
Rev 0 1999
Oscillograms of the load "throw" and short circuit test results are required to check the
voltage/current/transient steady state parameters.
(g) Site Tests
1. Polarisation Index (before and after winding high voltage test).
2. Winding High Voltage Test at reduced (site) voltage levels.
3. Commissioning and functional testing including synchronisation etc.
4. Full load run until temperatures are stabilised, followed by a one hour run.
5. Functional testing required to prove the operations of the associated equipment (engine, cooling
equipment protection, control and excitation cubicles).
6. Excitation and AVR follow up including alternator response and stability tests. This will include
application and removal of full load.
7. Shaft Insulation.
8. Vibration Limits.
9. Load throw with figures in Section 3.7.3 (using UV Recorder) to prove Governor and AVR
response.
10. 'String Test' 6 hour full load run.
Oscillograms
Oscillograms are to be taken during the tests in the works for short circuit and at site to prove voltage,
current and response times and steady state parameters during the tests.
Notes:
1. If vibration probes are specified and are then fitted by the alternator Vendor/Contractor, measurements
of alternator vibration during tests shall be made with those probes installed.
2. Full load heat run, including a minimum running time of four hours at final running temperature.
Temperature rise shall be determined by resistance and by RTD (for alternators so equipped). The
Vendor/Contractor shall keep a continuous test log during the entire heat run, making entries of data
intervals not exceeding one half hour. Data shall include temperature reading of each RTD.
If alternator Vendor/Contractor's test facilities are not capable of making a conventional full load heat
run, the Vendor/Contractor shall submit to the Owner, for approval by the Owner, complete details of
an alternative test that will permit measurement or determination of the machine heating at full load.
This test shall permit measurements of alternator vibration throughout the test for a minimum period of
4 hours with the machine operating at rated speed, and with its rotor at full load temperature.
3. Observation of bearings and mechanical operation of the machine during the full load heat run.
Measurements of vibration shall be made on each bearing housing throughout the entire period of the
heat run. For machines having provisions for vibration monitoring systems, vibration measurements
shall also be made on the alternator shaft at each bearing. Vibration on bearing housings and shaft
shall not exceed limits specified. Heat run test log data shall include amplitude and unfiltered
frequency of vibration at each bearing, and for machines having forced feed lubrication, oil pressures
and inlet and outlet oil temperature at each bearing.
Rev 0 1999
7.3 Test Procedures
7.3.1 In all cases the Vendor/Contractor shall submit his test procedures in writing to the Owner for approval
prior to the start of the testing programme.
7.4 Site Acceptance Test Requirements
7.4.1 Test Schedules
The Vendor/Contractor shall submit a schedule of Site Acceptance Tests that are to be undertaken to
ensure that the Generator is satisfactory.
The test schedules shall be approved by the Owner. There shall be a separate set of acceptance tests for
each Generator supplied.
7.4.2 Initial Acceptance Tests
The initial acceptance tests shall be performed by the Vendor/Contractor when all relevant equipment
has been installed.
7.4.3 Final Acceptance Tests
Fourteen days after the systems have been put into service, or fourteen days after the initial acceptance
tests, whichever is the earliest, the Final Acceptance Tests shall be effected by the Vendor/Contractor,
and be witnessed by the Inspector.
7.5 Test Certificates
7.5.1 Test Certificates
Final acceptance of the system will be given following satisfactory Final Acceptance Tests.
All copies of test certificates shall be furnished with final drawings as called for in documentation
section. The Final Acceptance Tests shall be witnessed by the Inspector who shall retain one copy of
the certified tests.
7.6 Test Equipment
7.6.1 Supply
The Vendor/Contractor shall supply a set of test equipment if it is required.
7.6.2 Test Accessories
All necessary test leads, power cords and ancillaries shall be provided.
Note:
All instrument and apparatus used in the performance of the tests shall have been calibrated to an
agreed standard at a laboratory of National standing within the period of 15 months of the test date.
The cost of carrying out such calibrations shall be borne by the Vendor/Contractor in all cases.
The Vendor/Contractor shall submit his test procedures in writing to the Owner for approval, prior to
the start of the testing programme.
8.0 DOCUMENTATION
Rev 0 1999
8.1 Introduction
8.1.1 This section covers the documentation required for the design, selection, construction, inspection and
testing for all the equipment, components and services to be provided against this specification.
8.1.2 The detailed list of documents that are required is included with the Purchase Order/Contract, however as a
minimum, the following listed documents will be provided by the Vendor/Contractor as and when required
by the Vendor Documentation Requirements (VDR) list:
. General Arrangement,
. Foundation Layout,
. Single Line Diagram,
. Schematic and block wiring diagram.
8.1.3 The documents as listed may be considered as a minimum requirement; all details to confirm compliance
with the relevant specifications, and to allow a full and continued appraisal to be made of the
Vendor/Contractor's proposals and interpretations of the ordered equipment, should be submitted in
accordance with the schedule specified in the Purchase Order/Contract.
8.1.4 Any production or procurement undertaken by the Vendor/Contractor which is prior to the relevant
documentation being submitted and reviewed by the Owner is at the Vendor/Contractor's risk.
8.1.5 On all documentation the Purchase Order/Contract number, equipment title, tag number and project name
shall be quoted.
8.1.6 All documentation shall be checked and signed by the checker before submission.
8.2 Schedules and Reports
8.2.1 The Vendor/Contractor shall submit with his tender a preliminary quality control plan and proposals for
factory acceptance and site acceptance tests.
8.2.2 The Vendor/Contractor shall include with his tender documentation a statement of proposed Sub-
Vendors/Sub-Contractors, a document submission schedule for all documents based on a review of cycle of
three weeks and outline programme for procurement and production activities.
8.2.3 The Vendor/Contractor shall incorporate any revisions agreed with the Owner during the enquiry review
stage.
8.2.4 Monthly reports shall be submitted by the Vendor/Contractor detailing design, procurement, production
and documentation activities, the format of which shall be agreed with the Owner.
8.3 Data and Calculations
8.3.1 The Vendor/Contractor shall supply with his tender completed Data Sheets containing all the relevant
information necessary for appraisal of the design by the Owner.
8.3.2 Project specific instructions will be issued to the Vendor/Contractor with the Purchase Order/Contract,
which describes the data and calculations to be submitted, and the methods of submission.
8.3.3 The Vendor/Contractor shall be responsible for obtaining approvals from the Inspection Authority.
8.3.4 All calculations shall be carried out in clear and logical manner. Where conditions involve the use of
formulae or methods not specified in the Design Code, the source of these formulae or methods shall be
clearly referenced.
Rev 0 1999
8.3.5 Computer calculations will only be acceptable if all input is shown, together with calculated values of
intermediate terms and factors and options chosen, as well as final calculated dimensions, stresses or other
values and the computer program has been validated to the satisfaction of the Owner.
8.3.6 Calculations and drawings that are interdependent, ie, foundation loading and equipment footprint, shall be
presented for appraisal together.
8.4 Drawings
8.4.1 The drawings listed with the Purchase Order/Contract shall be sent by the Vendor/Contractor to the Owner
and/or the Inspection Authority for review and approval.
8.4.2 The components and process to produce the ordered equipment shall be shown in sufficient detail to be
fully appraised eg, outline drawings, components list and schematic diagrams.
8.4.3 General arrangement drawings shall be to scale and show the relative location and main dimensions of all
components including elevations.
8.4.4 Detail drawings which may be included on the general arrangement shall include thicknesses and
dimensions of all components surface finish requirements, gasket and nameplate details etc.
8.4.5 As-built drawings may be the general arrangement drawings marked-up with the actual as-built dimensions.
8.5 Final Records, Documents and Manuals
8.5.1 Two copies of the Data Dossier shall be supplied, and shall be a record of the manufacturing process.
Where stated in the Purchase Order/Contract, besides the electrical documents itemised in Section 8.1.2, it
shall contain the following:
- general arrangement drawing and bill of material,

- the quality control plan,
- material certificates,
- chemical analysis certificates,
- positive material identification certificates,
- Schematic and Wiring diagrams,
- NDT (Non Destructive Testing) procedures and records,
- hazardous area certificates,
- balance certificates,
- performance test procedures, and test certificate,
- non-conformity records,
- approvals by the Independent Inspection Authority,
- certificate of conformity,
- Owner's release certificate.
8.5.2 Six sets of the Installation, Operations and Maintenance Manual (IOM), shall be specifically compiled for
the equipment supplied. A compendium of manufacturer's data for a range of like products is not
acceptable. Where relevant, the IOM shall contain the following:
- a description of the equipment, process and controls philosophy,

- the master document list and certified copies of the key drawings,
- packing, shipping and site preservation instructions,
- step by step installation instructions,
- step by step pre-commissioning procedures,
- step by step commissioning procedures,
- normal start up, operating and shutdown procedures,
- step by step procedures for dismantling and re-assembly,
Rev 0 1999
- normal operating and set point values for all instruments,
- routine operating and set point values for all instruments,
- lubrication, chemicals, consumables schedule,
- spare parts ordering information,
- for PLCs, a copy of the programme and re-programming procedures.
The IOMs shall be presented in A4 format, and be securely bound in heavy duty 4 ring binders.
8.5.3 The Vendor/Contractor shall produce as built documents revised to indicate field changes.
8.5.4 The Vendor/Contractor shall supply one set of mylar original drawings.
8.5.5 Electronic Data Format (EDF)
All documentation (drawings, calculations and Data Sheets etc) shall be produced by the
Vendor/Contractor in electronic format.
The format shall be compatible with that used by the Vendor/Contractor and shall be agreed at the
commencement of the contract.
In addition to the 'hard copies' required under the contract, copies of the electronic records shall be issued
to the purchaser for all approved documentation, this forming part of the Vendor/Contractor's contractual
obligations.
9.0 PRIOR TO SHIPMENT
9.1 Painting and Coatings
All bare surfaces which are exposed during transit or storage shall be given a coat of temporary rust
inhibiting material.
Surface preparation, painting and painting materials shall be in accordance with GES X.06.
9.2 Spares
The Vendor/Contractor shall submit with his proposal, a priced list of recommended spares for start-up and
two years operation for review by the Owner. This list shall include, but not be limited to:
- special tools, if required,

- insulating material,
- gaskets,
- fittings and hardware,
- 1 set bearing liners (drive end),
- 1 set bearing liners (non drive end),
- 1 set of diodes (and fuses if fitted),
- 1 set of surge suppressors (field resistors),
- 5 litres of 'touch up' paint.
9.3 Packing and Storage
This section describes the minimum requirements for the preservation and protection of equipment during
the sea and land transportation and storage prior to installation.
The probable storage period will be specified in the order/enquiry and will extend from the time of
despatch to the time of unpacking at site. If the storage period is not stated, a minimum period of twenty-
four (24) months shall be assumed. Packing to be suitable for sea freight.
Rev 0 1999
(a) After mechanical completion at the works, the equipment shall be left in a clean dry condition.
(b) The Vendor/Contractor shall be responsible for loading and anchoring the item(s) to prevent damage
during shipment.
The Vendor/Contractor shall submit his procedures for packing and preservation for review by the Owner.
9.4 Shipping
Detailed shipping arrangements are covered by the Purchase Order/Contract.
The equipment shall not leave the Vendor/Contractor's works for shipment until the release has been
approved by the Owner's Inspector.
9.5 Warranty
The Vendor/Contractor shall warrant all material and services supplied against any defect for a period of
twelve (12) months after commissioning, or twenty-four (24) months from the date of delivery to site,
whichever is the shorter period, or for the period stipulated in the Order.
Should any item be found defective, the Vendor/Contractor shall be responsible for all costs associated
with restoring the equipment to the standard specified by the Purchase Order/Contract.
10.0 FIGURES SUB-INDEX
Figure 10.1 - Block Diagram of Excitation System

Rev 0 1999
S:\NOC9077\ADMIN\SPECIFICATIONS\L-SERIES\L-29\GESL29RF
DATA SHEET No.
EMERGENCY DIESEL GENERATOR

P.O. / CONTRACT No.
CLIENT
PLANT LOCATION SHEET 1 of 2
SERVICE ITEM No. No. of UNITS
DATA BY OWNER
1 VENDOR / CONTRACTOR
2
3 RATING AND SERVICE CONDITIONS: p.f. LAG/LEAD
4 Output kW kVA Duty Rating:
5 Class of Rating: wire Hz
6 Nominal Voltage: volts phase
7 Neutral:
8 Phase Sequence: Min °F(°C)
9 Ambient Temperature: Max °F(°C)
10 Design Temperature: °F(°C)
11 Ambient Humidity: %
12 Altitude feet (m) above sea level
13 Location: Indoor/Outdoor
14 Site Environment:
15 Noise Limit: dB(A) @ 3 feet (1 metre)
16 Vibration Limit:
17 Cabling:
18
19 Anti-Condensation Heaters Required: Yes/No °F(°C)
20 Cooling Method: Cooling Medium Inlet Temperature:
21 Enclosure Type: Degree of Protection:
22 Insulation Class:
23 Parallel Operation Requirements:
24 Voltage Regulation Grade: (ref. BS 4999 Part 49)
25 Special Requirements:
26
27 ALTERNATOR CONTROL PANEL EQUIPMENT (supply where ticked)
28 Voltmeter Voltmeter Switch Power Factor Indicator
29 Ammeter Ammeter Switch Frequency Indicator
30 Selector Switch: Test/Manual/Automatic/Off R.P.M. Start Button
31 Remote Test Facility Quadrature Droop Switch Hand Voltage Trim
32 Frequency Control Main Contactor Main Circuit Breaker
33 Alternator Overload Protection Battery Charger Battery Charger Ammeter
34 Start Delay Timer 0-30 seconds Shut-down Timer 0-30 mins Panel Light
35 Power Excitation Voltmeter Excitation Ammeter
36 Reactive Power Synchro Voltmeter Differential Voltmeter
37 Tests: i) As called for in specification GES L.29
38 ii) Additional Tests
39
40
41 REMARKS/COMMENTS:
42
43
44
45
Revision No./Date
Prepared by/Date
Authorised by/Date
Purpose
(C) 1999 NATIONAL OIL CORPORATION. The information on this sheet may be used only for the purpose for which it is supplied by NOC.
K:\nocspecs\SPECIFICATIONS\l-series\l-29\dl2901r0.xls Sheet1
DATA SHEET No.
EMERGENCY DIESEL GENERATOR

P.O. / CONTRACT No.
CLIENT
PLANT LOCATION SHEET 2 of 2
SERVICE ITEM No. No. of UNITS
INFORMATION FROM VENDOR / CONTRACTOR
1 VENDOR / CONTRACTOR
2
3 ELECTRICAL DATA:
4
5 Primer Mover Manufacturer:
6 Alternator Manufacturer:
7 Performance:
8 Rating Rated p.f. LAG Unity p.f.
9 Current Eff Current Eff
10 100%
11 75%
12 50%
13
14
15 Speed r.p.m.
16 X"d: p.u.. - Tolerance ±
17 X'd: p.u.. - Tolerance ±
18 Xsd: p.u.. - Tolerance ±
19
20 Short Circuit Ratio:
21 O/C Field Time Constant:
22 Maximum Continuous Negative Phase Sequence Current (I2):
23 I²t Maximum for fault condition:
24 Starting time from initiation to alternator ready to accept load: seconds
25 Voltage drop on instantaneous load change of: on standing load of: = %
26 Time to restore voltage to within 3% of nominal for above condition seconds
27 Frequency Variation: Normal Running %
28 For condition on Line 24: %
29 Stored Energy Constant:
30 Weight of Stator: lbs(kg)
31 Weight of Rotor: lbs(kg)
32 Weight of Complete Unit: lbs(kg)
33 Bearing Type: D.E.:
34 N.D.E.:
35 Direction of Rotation: Clockwise/Anticlockwise (when facing drive end)
36 EXCITATION SYSTEM:
37 Type:
38 Voltage at Rated Output: volts: Current at Rated Output:
39 AVR Type:
40 Voltage Adjustment: ± %
41
42
43
44
45
Revision No./Date
Prepared by/Date
Authorised by/Date
Purpose
(C) 1999 NATIONAL OIL CORPORATION. The information on this sheet may be used only for the purpose for which it is supplied by NOC.
K:\nocspecs\SPECIFICATIONS\l-series\l-29\dl2901r0.xls Sheet2

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NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

EMERGENCY DIESEL GENERATORS

Rev Date Description Checked Approved

Compiled by Teknica (UK) Ltd

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

3.0 DESIGN & PERFORMANCE 8

3.1 Environmental Conditions 8

4.1 Type of Alternator 23

SEC TITLE PAGE

4.17 Screw Threads 32

5.0 NEMA/IEC DIFFERENCES 33

7.1 Statutory Tests 37

9.0 PRIOR TO SHIPMENT 45

9.1 Painting and Coatings 45

10.0 FIGURES SUB-INDEX 46

DATA SHEETS (2)

1.0 SCOPE OF SPECIFICATION

1.2 Other NOC Specifications

GES A.06 Site Data

GES L.28 Electrical Requirements for Packaged Units

GES L.34 Electrical Equipment in Contaminated Environments

GES L.35 Electrical Equipment in Hazardous Areas

GES M.01 Diesel Engines

GES X.06 Factory Coatings for Electrical Equipment and Instruments

1.3 Data Sheets

1.4 Stability Study

The technical terms used in this specification are defined as follows:

Isochronous Load Sharing

Service Factor - AC Machines

Service Factor (NEMA)

Speed Regulation, Steady State

Telephone Influence Factor (TIF)

The commercial terms used in this specification are defined as follows:

The company supplying the equipment.

The main contractor for a defined piece of work.

3.0 DESIGN AND PERFORMANCE

3.1 Environmental Conditions

3.1.1 External Environment

3.1.2 Internal Environment

3.2 Codes and Standards

3.2.2 US Codes and Standards

ANSI/FBMA 9 Load Ratings and Fatigue Life for Ball Bearings

ANSI/FBMA 11 Load Ratings and Fatigue Life for Roller Bearings

ANSI/IEEE C57.13 Requirements for Instruments Transformers

ANSI/IEEE 115 Test Procedures for Synchronous Machines

ANSI/IEEE 95 Insulation Testing of Large AC Rotating Machinery with Direct

ASQ Q9000 Quality Management and Quality Assurance

ASTM D975-92 Specification for Diesel Fuel Oils

NEMA MG-1 Parts 1-30 Motors and Generators

NEMA No.250 Enclosures for Electrical Equipment (1000 volts minimum)

NFPA-70 National Electrical Code

3.2.3 IEC and other Recommendations

BS 2757 Method for Determining the Thermal Classification of Electrical Insulation

BS 2869 Fuel Oils for Non-Marine Use

BS 3643 Metric Screw Threads

BS 4675 Mechanical Vibration in Rotating Machinery

BS 4999 General Requirements for Rotating Electrical Machines

BS 5514 Reciprocating Internal Combustion Engines: Performance

BS EN 60034 Rotating Electrical Machines

IEC 34 Rotating Electrical Machines:

IEC 529 Degrees of protection Provided by enclosures (IP Code)