Materials System Specification

17-SAMSS-518 19 January 2009

Diesel Generator Sets
Motors and Generators Standards Committee Members
Dabbousi, Rami, Chairman
Vouk, Alfred Oswald, Vice Chairman
Hassouneh, Awwad Shaban
Gurouni, Hesham Hamad
Mahfoudhi, Refaat
Dabbousi, Rami Mohammed Osama
Zayir, Zaki Abdulla
As Swaimil, Mohammad Ahmed
Najjar, Elias Mikhael
Asiri, Yahya Ahmad
Qahtani, Naser Hadi
Khairallah, Hussain Ali
Zainaddin, Samir Ahmed

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 2
2 Conflicts and Deviations................................ 2
3 References..................................................... 2
4 Alternative Designs........................................ 3
5 Coordination Responsibility............................ 4
6 Definition of Terms......................................... 4
7 Basic Design.................................................. 5
8 Accessories.................................................. 13
9 Inspection, Testing and
Preparation for Shipment..................... 16
10 Vendors Data
(Non Material Requirements)............... 19

Data Schedule-1................................................. 20

Previous Issue: 10 July 2006 Next Planned Update: 19 January 2014

Revised paragraphs are indicated in the right margin Page 1 of 20
Primary contact: Vouk, Alfred Oswald on 966-3-8747956

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Motors and Generators 17-SAMSS-518
Issue Date: 19 January 2009
Next Planned Update: 19 January 2014 Diesel Generator Sets

1 Scope

1.1 This specification defines mandatory requirements governing the design and
selection of stationary or portable diesel-engine-driven generator sets used for
standby, intermittent (prime), and continuous power generation, rated from
35 kW up to and including 10 MW (at 0.8 p.f.). This specification is not
applicable to shipboard marine installations. Installations in locations classified
as hazardous will require additional features to be specified in the project
specification.

1.2 Diesel generator sets and auxiliary equipment shall be supplied by Vendors
qualified by a minimum of two years of experience in manufacturing units of
comparable rating at the proposed point of manufacture and complying with
ISO 9000 quality standards. Only diesel generator sets which have a proven
satisfactory history of operation for at least two years will be considered. The
Vendor shall also have a local, Saudi Arabian, authorized dealer with parts,
service facilities and engineering support.

2 Conflicts and Deviations

2.1 If there are any conflicts between this Specification and associated purchasing,
project or engineering documents, this specification shall take precedence.

2.2 Direct all requests to deviate from this Specification in writing to the Company or
Buyer Representative, who shall follow internal company waiver procedure.

2.3 The designation “Commentary” is used to label a sub-paragraph that contains

comments that are explanatory or advisory. These comments are not mandatory,
except to the extent that they explain mandatory requirements contained in this
SAMSS.

3 References

The following is a summary of all the documents which have been mentioned within
this Specification. The specific part(s) of these documents which are applicable have
been identified throughout this Specification.

3.1 Saudi Aramco References

Saudi Aramco Engineering Standard

SAES-A-105 Noise Control

Saudi Aramco Product Specification

Code A-888 Diesel

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Saudi Aramco Inspection Requirements

Form 175-170400 Diesel Engine Generator Set

Saudi Aramco Forms and Data Sheets

Form NMR-7908 Nonmaterial Requirements for Diesel Engines
Form NMR-7912 Nonmaterial Requirements for Electric Rotating
Machinery
Form NMR-7923 Nonmaterial Requirements for Control Panels

3.2 Industry Codes and Standards

International Organization for Standardization

ISO 3046-1 Reciprocating Internal Combustion Engines-
Performance
ISO 8528-1 Reciprocating Internal Combustion Engine Driven
Alternating Current Generating Sets - Part 1
ISO 8528-5 Reciprocating Internal Combustion Engine Driven
Alternating Current Generating Sets - Part 5
ISO 9000 Quality Management Systems - Fundamentals and
Vocabulary

National Electrical Manufacturers Association

NEMA MG 1 Synchronous Generators-Salient Pole Type

National Fire Protection Association

NFPA 99 Standard for Health Care Facilities

Institute of Electrical and Electronics Engineers

IEEE C57.13 Requirements for Instrument Transformers

Underwriters Laboratories, Inc.

UL 489 Molded Case Circuit Breakers

4 Alternative Designs

4.1 All deviations from this specification shall be separately listed by the Vendor in
his quotation and shall refer to the relevant paragraph numbers.

4.2 Refer to Section 2 for direction on conflict resolution between documents. For
example, if there are any conflicts between this Specification and associated

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Next Planned Update: 19 January 2014 Diesel Generator Sets

project or engineering documents, this specification shall take precedence.

5 Coordination Responsibility

The Vendor shall be completely responsible for providing the Buyer with all details
necessary for the satisfactory installation and operation of all equipment components
provided as part of the diesel generator set, including sub-vendor items.

6 Definition of Terms

Continuous Service: Service for constant load conditions, where operation exceeds
8000 hours per year with uninterrupted periods of 1000 hours minimum.
Exception:

For annual overhauls, shutdowns for maintenance shall not exceed 24 hours.

Intermittent (Prime) Service: Service for varying load conditions, where operation
exceeds 500 hours per year, but is less than 8000 hours per year.

Standby Service: Operation of the diesel generator set only during failure of the
normal power supply, not to exceed 500 hours per year.

Continuous Power: Maximum effective output which the diesel generator set is
capable of delivering continuously, as defined in ISO 8528-1, including an allowance
for deterioration, with the limit of output being such as to permit overload power as
defined in ISO 3046-1.

Limited-Time Running Power: The maximum power which the generating set is
capable of delivering for up to 500 hours per year, of which a maximum of 300 hours is
continuous running between stated maintenance intervals and under the stated ambient
conditions, the maintenance being carried out as prescribed by the diesel engine
manufacturer, as defined in ISO 8528-1.

Diesel Generator Set Rating: Available generator terminal kilowatts when the diesel
generator set is running under actual site conditions of maximum ambient temperature,
altitude and humidity. All nameplate rating data shall be the site rating.

Portable generator set: Self-contained generator package, usually skid mounted,

containing all the equipment and auxiliaries necessary to deliver power (e.g., fuel tank,
circuit breaker, lube oil system, exhaust system, air intake system, control panel, etc.).
Characterized by the fact that the only connection to the skid package is the primary
power load connection.

Fixed mounted generator: Those generators that do not fit the definition of a
portable generator set.

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Document Responsibility: Motors and Generators 17-SAMSS-518
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Next Planned Update: 19 January 2014 Diesel Generator Sets

7 Basic Design

7.1 General

7.1.1 Terms in bold font are defined within Section 5.

7.1.2 All materials, equipment and parts comprising the units specified
above shall be new, and of current manufacture.

7.1.3 Equipment shall meet all applicable codes, including those listed in
Section 1.5.

7.1.4 The equipment covered by this specification shall be suitable for the
specified operating conditions and shall be designed and constructed
for a minimum service life of 20 years.

7.1.5 Environmental Conditions

The equipment will be installed in a desert area under extreme climatic

conditions, where ambient air temperatures can vary from 0°C to 50°C
and relative humidity from 0 to 100% (condensing). Metal
temperature when exposed to direct sun light can reach 70°C.

Onshore, the normal airborne dust concentration shall be considered as

1 mg/m³. During sand storm conditions, dust concentrations reaching
500 mg/ m³ are encountered and winds may gust to 112 km/hr. 95% of
all dust particles are less than 20 micrometers, and 50% of all particles
are less than 1.5 micrometers in size. Compounds present in the dust
include those of sodium, calcium, magnesium, silicon and aluminum.
When wetted (100% humidity condition), these compounds function as
electrolytes and can result in severe corrosion of materials. Other
pollutants present (ppm in vol/vol in atmosphere, worst case) are H2S
(5 ppm), SO2 (5 ppm), CO (100 ppm), NOx (5 ppm) and hydrocarbons
(50 ppm). All equipment shall be protected from these contaminants to
prevent corrosion and operational failure.

In addition to the above requirements, equipment that is situated

offshore or nearshore (i.e., within ½ km from the shoreline) shall also
be protected against failure due to wind-borne seawater spray and the
accumulation of wetted salt (NaCl).

7.1.6 Diesel generator sets for installation in health care facilities shall
comply with NFPA 99 requirements.

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Next Planned Update: 19 January 2014 Diesel Generator Sets

7.1.7 Noise

Diesel generator sets shall not generate noise in excess of 90 dBA at a

distance of one meter from the enclosure. For a diesel generator set
located inside a dedicated ground floor room within a building, the
enclosure is considered to be immediately outside the walls and ceiling
of the room within which it is installed. For a diesel generator set
located inside a dedicated building the enclosure is considered to be
immediately outside the walls and ceiling of the building. Any
exceptions to this requirement must be requested at the time of
purchase order and must be approved in accordance with paragraph
2.2. Control of the sound pressure level to meet the specified
requirements shall be the sole responsibility of the Vendor. If the
sound pressure level will exceed 90 dBA at 1 meter, the vendor shall
notify the purchaser at the time of quotation and quote the additional
cost for modifications to insure the installed sound pressure level does
not exceed 90 dBA at 1 meter. If the diesel generator set is located
within a building, the vendor shall document the maximum sound
pressure level at 1 meter from the diesel generator set under full load
operating conditions and include this information in the manual. A
“Noise Hazardous Area” sign shall be posted outside all access doors
(as per Saudi Aramco Engineering Standard SAES-A-105) warning
personnel about the excess noise inside the dedicated room or
dedicated building. This sign shall require personnel to wear
appropriate ear protection.

7.2 Rating

The diesel generator set rating shall be derived from the requirements of
paragraphs 7.2.1 through 7.2.4.

7.2.1 For continuous and intermittent (prime) service, the continuous

power at site conditions shall be at least 100% of the maximum
electrical load.

7.2.2 For standby service, the limited-time running power at site

conditions shall be at least 100% of the maximum electrical load.

7.2.3 The diesel generator set shall be capable of single-step load pick-up of
50% nameplate kW at 0.8 pf, and shall be capable of assuming 100%
load within 10 seconds of startup.

7.3 Generator Design

The generator shall be a three-phase, brushless, synchronous type built to

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Next Planned Update: 19 January 2014 Diesel Generator Sets

NEMA MG 1 - 33.

7.3.1 The insulation system, including leads, shall consist of low-

hygroscopic material. The system shall be Class F or Class H
insulation with tropicalization and anti-fungus treatment. The
allowable temperature rise, above an ambient of 50°C, measured by
resistance, shall not exceed that listed in NEMA MG 1 - 33.3.2.1.

7.3.2 The generator frame shall be provided with two ground pads welded to
the skid on diametrically opposite corners.

7.3.3 All current transformers and potential transformers shall be in

accordance with ANSI/IEEE C57.13.

7.3.4 Continuous-duty generators rated 1250 kW and above shall have two
RTDs per phase. RTDs shall be platinum, 100  at 0°C.

7.4 Mechanical Design

7.4.1 Enclosure

When installation outside of a building is specified on Data Schedule-

1, a self-contained enclosure shall be provided for the diesel generator
set. The enclosure shall be manufactured such that all parts are
accessible for inspection and minor maintenance without removal of
the enclosure or enclosure roof. It shall include the following features:
a) The enclosure and all other items shall be designed and built by
the supplier as an integral part of the entire diesel generator set,
and shall perform without overheating in the environment
specified.
b) It shall be constructed of minimum 14-gauge sheet metal,
suitably reinforced to reduce vibration in the operating mode.
c) A minimum of four doors are required. The doors shall be
hinged so that they can be opened to provide complete access to
the equipment inside the enclosure without removing the doors.
d) The side and rear panels shall be completely and simply
removable to permit major service access.
e) Doors shall be lockable.
f) All exterior steel surfaces, including those in contact with the
foundation, shall be epoxy-or epoxy-mastic-coated as a
minimum. Interior surfaces shall have the vendor's standard
finish. All fasteners shall be corrosion-resistant in the

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environment described in paragraph 7.1.5.

g) Batteries shall fit inside the enclosure and alongside the engine
(batteries under the generator are not acceptable).
h) The unit shall have coolant and oil drains piped to the outside
edge of the skid in an accessible location. Each drain line shall
have a valve located near the fluid source.
i) Motorized air intake and radiator-discharge louvers shall be
provided when specified on Data Schedule-1. The louvers shall
be sized to provide sufficient airflow for engine combustion,
engine cooling and generator cooling. The louvers shall open
automatically when the engine receives the start signal and close
when the engine stops. They shall also allow manual over-ride.
j) The air intake and exhaust outlet shall be configured such that
exhaust gas recirculation to the air intake will not occur under
any wind direction.
k) 120 VAC lights, light switch, 120 V receptacles, and an
associated load panel shall be provided. The 120 V source will
be provided by others.

7.4.2 Mounting

7.4.2.1 Unless otherwise specified, the diesel generator set,

including the control panel and radiator, shall be mounted
and shipped on a single steel skid, and shall be provided
with suitable vibration dampers.

7.4.2.2 Units rated below 1000 kW shall have rubber vibration

dampers installed between the engine-generator and the
skid.

7.4.2.3 Units 1000 kW and above shall be supplied with spring-

type vibration dampers, which shall be installed between
the skid and the foundation.

7.4.3 Fuel and Fuel System

7.4.3.1 Using diesel fuel conforming to Saudi Aramco Product

Specification Code A-888, the engine shall be capable of
starting and operating at the minimum site ambient
temperature specified on Data Schedule-1.

7.4.3.2 A day tank and associated fuel piping shall be furnished by

the Vendor. The day tank capacity shall be as specified on

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Data Schedule-1. The day tank shall have a valved drain,

an adequate sized breather vent designed to exclude dust
and water from the tank, and a tank level sight glass. The
fuel system shall incorporate flexible fuel lines between the
day tank and the engine to isolate vibration.

7.4.3.3 Fuel filter(s), a manual or engine-driven fuel priming pump

and a fuel transfer pump shall be provided. When
continuous service is specified on Data Schedule-1, fuel
filters shall be of the duplex, full flow, cartridge type
having a filter mesh not exceeding 10 micrometers. The
duplex filters shall have a cross-over valve.

7.4.3.4 The fuel filter shall be located such that spilled fuel cannot
fall on hot parts of the engine or generator. A cleanable
primary fuel strainer shall be used to collect sediment
between the tank and the main engine fuel filter. A
fuel/water separator shall protect the system from water
damage.

7.4.4 Engine Air Intake

Engine intake air filters shall be a combined heavy duty pre-cleaner

(e.g., inertial separator) and dry filter arrangement with a local
differential pressure indicator. The filters shall be suitable for the
environmental conditions specified in paragraph 7.1.5.

7.4.5 Exhaust System

7.4.5.1 Each diesel engine shall be equipped with an exhaust

silencer of the grade specified on Data Schedule-1. For
engines 600 kW and above, the silencer shall be mounted
such that its weight is not supported by the engine. Exhaust
piping, including silencers and weather caps, shall be sized
such that exhaust back-pressure will not exceed the
maximum limitations specified by the diesel generator set
manufacturer.

7.4.5.2 The Vendor shall supply the complete exhaust system,

including silencer, companion flanges, flexible stainless
steel bellows-type exhaust fittings, and rain cap.

7.4.6 Speed Governing

7.4.6.1 The engine governor shall be selected to meet the steady

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state and transient response requirements of the operating

performance class specified on Data Schedule-1 in
accordance with ISO 8528-5, Table 4.

7.4.6.2 An overspeed device shall be provided which shuts off

either fuel, air, or both, to the diesel engine in the event of
an overspeed condition.

7.4.7 Starting System

7.4.7.1 Capability

The starting system shall include the capability to reliably

start the diesel generator set in cold, dense fog conditions.
This may involve the addition of a starting aid which shall
be provided by the Vendor, if so required.

7.4.7.2 Starting Motor

A DC electric starting system with a positive engagement

drive shall be furnished unless otherwise specified.

7.4.7.3 Alternator

When continuous service is specified, an engine driven

alternator shall be included. Alternator shall provide DC
regulated output to charge batteries.

7.4.7.4 Automatic Controls

When intermittent (prime) or standby service is specified,

fully automatic diesel generator set start-stop controls shall
be provided in the control panel. Crank cycle circuitry for
multiple crank attempts shall be provided by the Vendor.
Automatic starting shall be initiated from a user supplied set
of normally open dry contacts which close to start.

7.4.8 Cooling

7.4.8.1 The engine cooling system shall be a thermostatically

controlled, closed-circuit design. The system shall have
sufficient capacity to maintain stable operating
temperatures at maximum engine output and under the
worst site conditions. The coolant pump shall be integral
with the engine. Unless otherwise specified, a skid-

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mounted radiator with a header make-up tank and a

pressurized filling cap shall be included.

7.4.8.2 The engine cooling fan shall be the blower type. The fan,
fan drive, and fan belts shall be covered with 14-gauge
(minimum) steel mesh guarding, to protect personnel from
injury.

7.4.8.3 A unit-mounted, thermal circulation-type, jacket-water

heater incorporating a thermostatic switch shall be
furnished to maintain engine jacket water at 32.2°C in an
ambient temperature of 0°C. Water heater shall be
positioned to circulate warm water evenly around all
cylinders. AC power for the jacket-water heater shall be as
specified on Data Schedule-1.

7.4.8.4 When continuous service is specified on Data Schedule-1,

the diesel generator set is located indoors and is rated above
500 kW, then either a shell-and-tube heat exchanger shall
be used, or the cooling radiator shall be located outside the
building.

7.4.8.5 Coolant for the engine cooling system shall comply with the
specification requirements of the diesel engine manufacturer.

7.4.9 Lubrication

7.4.9.1 The engine main lube oil pump shall be the positive-
displacement gear-driven type that is integral with the
engine, and shall be easily accessible for maintenance.

7.4.9.2 If the design oil temperature exceeds 120°C, an oil cooler

shall be provided to limit the lube oil temperature in the oil
pan at the oil pump inlet.

7.4.9.3 Lube oil filters shall be located downstream from the lube
oil coolers. When continuous service is specified on Data
Schedule-1 applications, filters shall be the duplex type for
changeover during diesel operation.

7.4.9.4 The diesel generator set shall include an easily accessible

provision for lube oil drainage at the edge of the base or
rails. Inaccessible grease fittings shall be tubed to extend to
the edge of the skid for ease of maintenance.

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7.4.10 Generator Bearings

7.4.10.1 Anti-friction bearings shall have no filling slots. Bearing

race-metal temperature shall not exceed 90°C based on a
maximum ambient temperature of 50°C.

7.4.10.2 Regreasable bearings shall be provided with two NPT-

tapped-and-plugged holes, and fill-in and drainage plugs.
The holes shall be provided with threaded Type 300 Series
stainless steel plugs.
Exception:

Sealed anti-friction bearings may be provided if specified

by Saudi Aramco for units in intermittent or standby
service.

7.4.10.3 Bearings shall be serviceable without moving or

disconnecting the generator.

7.4.10.4 Sleeve-type bearings shall be equipped with split, labyrinth-

type end seals and deflectors where the shaft passes through
the housing. Lip-type seals shall not be used. The sleeve
bearing shell-metal temperature shall not exceed 90C
based on a maximum ambient temperature of 50C.

7.4.10.5 Two-bearing generators shall have interchangeable bearings.

7.4.10.6 Two-bearing generators rated 400 kW (500 kVA) and

above shall have one bearing electrically insulated from the
generator frame or baseplate.

7.4.11 Vibration

The generator set manufacturer shall provide a Torsional Vibration

Analysis for the diesel generator set specified.

7.4.12 Nameplates and Rotation Arrows

7.4.12.1 Nameplates and rotation arrows shall be Type 316 stainless

steel or monel, securely fastened by pins of similar material.
They shall be located such that the information can be read
after the equipment is installed. Entries shall be marked by
etching, engraving or other methods of permanent marking.

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7.4.12.2 The following data is required on the generator nameplate,

in addition to the requirements of NEMA MG 1 - 33 and
ISO 8528-5, and may be on a separate nameplate:
a) Buyer's purchase order number
b) Manufacturer's location
c) Rotor weight
d) Manufacturer's order reference number
e) Insulation system designation

8 Accessories

8.1 Voltage Regulator

8.1.1 Generators shall incorporate an excitation system with an automatic

voltage regulator (AVR). The AVR unit shall maintain generator
terminal voltage within ± 1% of nominal value over the load range, up
to full load. Voltage level adjustment shall be minimum of ± 5%.
When parallel operation is specified on Data Schedule-1, the generator
shall incorporate reactive cross current compensation.

8.1.2 The automatic voltage regulator shall use three-phase sensing and shall
be a temperature-compensated, solid-state design. The solid-state
regulator module shall be shock-mounted and epoxy-encapsulated for
protection against vibration and atmospheric deterioration.

8.1.3 The voltage regulator shall be of an asynchronous, pulse-width-

modulated design that is insensitive to severe load induced wave-shape
distortion from SCR or thyristor loads.

8.2 Control Panels

8.2.1 The generator control panel shall contain all switches, relays, push-
buttons, meters, operational lighting, and pilot lights required for
engine checkout, control, instrumentation, and operation. For portable
generator sets, supplied without rubber vibration dampers installed
between the engine-generator and the skid, the panel shall be mounted
on vibration isolators to prevent engine vibration from damaging the
enclosed equipment. If specified in the Data Schedule-1, control
panels for fixed mounted generators shall be supplied separate from
the generator and shall be suitable for mounting remote from the
generator.

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8.2.2 The control panel shall provide the following controls:

a) Manual- Off- Auto- Reset select. One or more switches can be
used to implement these functions.
b) Voltage “raise/lower” switch
c) Governor “raise/lower” switch (when electronic governors are
supplied)
d) Lamp test switch
e) Ammeter/voltmeter phase select switch or switches with off
position
f) Stop push-button

8.2.3 The control panel shall contain, but not be limited to, the following
readout devices:
a) Engine oil pressure indicator
b) Coolant temperature indicator
c) Voltmeter, 1.5% accuracy
d) Ammeter, 1.5% accuracy
e) Frequency meter, ± 5% accuracy
f) Kilowatt meter
g) Engine tachometer
h) System DC voltmeter
i) Engine running hour meter

8.2.4 The control panel shall provide the following annunciation:

a) Generator on load (status)
b) Low coolant temperature (alarm)
c) Charger failure (alarm)
d) Low battery voltage (alarm)
e) Low fuel level (alarm)
f) High coolant temperature (alarm)
g) High coolant temperature (shutdown)
h) Low oil pressure (alarm)
i) Low oil pressure (shutdown)

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j) Overcrank (shutdown)
k) Overspeed (shutdown)
l) Select switch not in auto position (alarm) (1)
(1)
Note : Not applicable for continuous duty applications.

The annunciator shall contain normally open dry contacts for summary
of the seven alarms and four shutdowns listed above.

8.2.5 In addition to the control panel stop pushbutton, for diesel generator
sets 600 kW and above, an emergency stop pushbutton shall be
mounted at the corner of the skid opposite of the control panel.

8.3 Main Circuit Breaker

For generators rated 480 V and below, and 1200 kVA and below, a readily
accessible molded case circuit breaker shall be installed as an integral part of the
diesel generator set. The circuit breaker shall comply with UL 489 requirements
and shall be the thermal magnetic type. The circuit breaker shall include one set
of normally open dry contacts for status indication.

8.4 Battery and Battery Charger

8.4.1 A lead-acid storage battery set of the heavy-duty diesel starting type
shall be provided. The battery voltage shall be compatible with the
starting system. A corrosion-resistant base-mounted battery rack with
necessary cables and clamps shall be provided. The battery shall be
capable of cranking the engine for a minimum of five 30 second
cranking periods at the minimum rated ambient conditions.

8.4.2 When standby-service or intermittent (prime) service is specified, a

current-limiting, float-equalize, Underwriter Laboratories (UL), or
equivalent, listed charger shall be furnished to automatically recharge
the batteries. The charger shall float at 2.17 volts per cell and equalize
at 2.33 volts per cell. It shall include overload protection, silicon diode
full-wave rectifiers, voltage surge suppressers, a DC ammeter, and
fused DC output. AC input voltage shall be as specified on Data
Schedule-1. Amperage output shall be no less than 5 amperes.

8.5 Space Heaters

Generators shall be supplied with space heaters with a nameplate voltage rating
as given on Data Schedule-1. The heaters shall protect the generator, generator
circuit breaker, and control components from condensing moisture.

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9 Inspection, Testing and Preparation for Shipment

9.1 General

Inspection and testing of the diesel generator set shall be carried out as indicated
on Data Schedule-1 and Saudi Aramco Inspection Requirements Form
175-170400.

9.2 Testing

9.2.1 Factory Standard Shop Tests

Standard shop tests are required for all diesel generator sets with a site
rating of 200 kW (250 kVA) and less. Witnessing shall be required if
specified on Data Schedule-1; otherwise, certificates are sufficient.

9.2.2 Factory Performance Tests

9.2.2.1 Performance tests are required for all diesel generator sets
with a site rating of more than 200 kW (250 kVA). The
Buyer or the Buyer's Representative shall have the option to
witness the performance test.

9.2.2.2 Performance tests shall be conducted only after all

pressures and temperatures have equalized. The tests shall
comprise the following:
a) 30 minutes running at 50% load
b) 30 minutes running at 75% load
c) 4 hours running at 100% load
d) 15 minutes running at 110% load (overload)
(not applicable to standby rated units)
e) Cold start with load step specified in 7.2.4
f) Full load rejection governor response

The following tolerances shall be applied for the full load

test in the evaluation of the performance test results:
a) Generator power shall be within 5% of rating
specified.
b) Fuel consumption shall be within 3% of that quoted
by manufacturer.

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9.2.2.3 The diesel generator set shall be fully equipped with all
components and accessories. Operating conditions (such as
barometric pressure, ambient temperature and humidity)
and the fuel heat value shall be indicated on the
performance certificates.

9.2.3 Factory Additional Tests

The following additional tests are required for all diesel generator sets:
a) Test engine overspeed trip system
b) Test diesel generator set starting system to prove that at least three
consecutive automatic starts and two manual starts can be made.
c) Verify operation of all diesel generator set alarms and shutdowns.
d) Verify operation of the generator circuit breaker.

9.2.4 On-site Testing

9.2.4.1 On-site performance tests, with a load bank supplied by the

vendor if required, are specified for all diesel generator sets
with a site rating of more than 200 kW (250 kVA).

9.2.4.2 On-site performance tests shall be conducted only after all

pressures and temperatures have equalized. The tests shall
comprise the following:
a) 15 minutes running at 50% load
b) 15 minutes running at 75% load
c) 1 hour running at 100% load
d) 15 minutes running at 110% load (overload)
(not applicable to standby rated units)
e) Cold start with load step specified in 7.2.4
f) Full load rejection governor response
g) Test engine overspeed trip system
h) Test diesel generator set starting system to prove that
at least three consecutive automatic starts and two
manual starts can be made
i) Verify operation of all diesel generator set alarms and
shutdowns
j) Verify operation of generator circuit breaker

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Document Responsibility: Motors and Generators 17-SAMSS-518
Issue Date: 19 January 2009
Next Planned Update: 19 January 2014 Diesel Generator Sets

9.3 Preparation for Shipment

9.3.1 Each unit shall be suitably prepared for the type and mode of shipment
specified. The preparation shall be suitable for at least 6 months of
outdoor storage from the time of shipment in a manner requiring no
disassembly prior to operation.

9.3.2 The Vendor shall provide the purchaser with the job site storage
instructions for the diesel generator set.

9.3.3 Unless otherwise specified by Saudi Aramco, preparation for shipment

shall be as specified in paragraphs 9.3.3.1 through 9.3.3.6, as a
minimum.

9.3.3.1 Exterior surfaces, except for machined surfaces, shall be

primed and painted.

9.3.3.2 After having been thoroughly drained and cleaned, internal

areas of bearings and all auxiliary equipment in oil
lubrication systems using carbon steel shall be coated with
suitable oil- soluble rust preventive.

9.3.3.3 Flanged openings shall be provided with metal closures at

least 5 millimeters thick, with synthetic rubber gaskets. At
least four full-diameter bolts shall be used for flanged
openings.

9.3.3.4 The equipment shall be mounted on a rigid skid suitable for

handling by forklift truck or crane.

9.3.3.5 The rotor of sleeve-bearing generators shall be blocked to

prevent axial and radial movement.

9.3.3.6 Space heater leads shall be accessible without disturbing the

shipping package. The leads shall be suitably tagged for
easy identification.

9.3.4 Lifting points or lugs shall be clearly marked.

9.3.5 Each diesel generator set shall be properly identified with item number,
serial number and any other information required by the purchase
order. All material shipped in separate crates shall be suitably
identified with securely affixed, corrosion-resistant metal tags
indicating the item and serial number of the equipment for which it is
intended.

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Document Responsibility: Motors and Generators 17-SAMSS-518
Issue Date: 19 January 2009
Next Planned Update: 19 January 2014 Diesel Generator Sets

9.3.6 The fit-up and assembly of machine-mounted piping and other

equipment shall be completed in the Vendor's shop before shipping.

10 Vendors Data (Non Material Requirements)

10.1 The Vendor shall submit drawings and Documentation as specified on Saudi
Aramco Nonmaterial Requirements forms:
a) NMR-7908 - Diesel Engines
b) NMR-7912 - Electric Rotating Machinery
c) NMR-7923 - Control Panels

10.2 Vendor shall provide installation, operation, and maintenance manuals,

lubrication recommendations, overhaul periods, special tool requirements,
control adjustment procedures and setpoints, and maintenance weights necessary
for the satisfactory installation, operation, troubleshooting, and maintenance
(including major overhaul) of all equipment components provided.

10.3 In addition to fuel consumption data, the Vendor shall also provide ventilation,
combustion and exhaust airflow requirements.

10.4 For indoor installation, the exhaust piping layout and proposed location shall be
submitted to the Buyer for approval.

10.5 The Vendor shall supply, with the bid, an installation list for equipment of a
similar rating and duty to the equipment quoted. The list shall indicate user
company name, installation location, date of installation, and site rating of the
diesel generator set. During bid evaluation, the Vendor shall be prepared to
provide contact names and telephone numbers for installations selected by the
Buyer.

Revision Summary
19 January 2009 Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued
with minor changes.

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Document Responsibility: Motors and Generators 17-SAMSS-518
Issue Date: 19 January 2009
Next Planned Update: 19 January 2014 Diesel Generator Sets

Data Schedule-1

17-SAMSS-518, Diesel Generator Sets

(Supplied by Buyer as part of SAMS Specifications)

ITEM D E S C R I P T I O N DETAILS
1. Buyer's Purchase Order/Quotation Request
Buyer's Budget Item/Job Order Number
Buyer's Line Item Number
2. Installation Area (Offshore/Nearshore/Onshore/Health Facility)
3. Maximum site ambient temperature (°C)
4. Minimum site ambient temperature (°C)
5. Site elevation (feet or meters)
Installation Location (Inside a Building/Outside
6.
will require a Vendor supplied enclosure)
7. Service Condition (Continuous, Intermittent, Standby)
Diesel Generator Set Required Site Rating (kW)
8.
(maximum electrical load)
9. Generator Voltage (3-phase, line-line)
10. Generator Frequency (50Hz, 60Hz) 60 Hz
Operating Performance Class (G1, general purpose; G2,
commercial power grade; G3, severe demands on frequency
11. G2
and voltage waveform characteristics; G4, exceptionally severe
demands on frequency and voltage waveform characteristics)
Motorized Air Intake Louvers Required (Yes/No)
12.
(Applies only to installation outside with Vendor supplied enclosure)
13. Day Tank Capacity (8/12 hour)
Exhaust Silencer Grade
14.
Industrial/Residential/Critical (Health Care Facilities only)
15. Starting System (DC Electric) DC Electric
16. Parallel Operation Required (Yes/No)
17. Generator Space Heater Supply Voltage (120 V, 240 V)
18. Jacket-Water Heater Supply Voltage (120 V, 240 V, 480 V)
Battery Charger Input Voltage (120 V / 240 V / 480 V)
19.
[Applies to standby and intermittent (prime) service applications]
Required Tests; Standard Shop Test (200 kW and less) /
20.
Performance Test (greater than 200 kW)
21. Witness of Tests Required (Yes/No)
22. Sound Pressure Level at 1 meter
Control Panel Mounting for Fixed Mounted Generators
23.
(On Generator/Off Generator)
24. Portable generator set Yes ____No____
25. Additional Requirements

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