SPEC No: FS 4031

Design Division FUNCTIONAL SPECIFICATION

Engineering Services Rev No 0
FOR
ISO – 9001:2000
EMERGENCY GENERATOR Discipline Electrical
PACKAGE
Page 1 of 16

FUNCTIONAL SPECIFICATION
FOR
EMERGENCY GENERATOR PACKAGE

TOTAL
PREPARED / REVIEWED APPROVED
No. OF DATE REV. No.
REVISED BY BY BY
PAGES
16 0

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Design Division FUNCTIONAL SPECIFICATION
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ISO – 9001:2000 DISCIPLINE : Electrical
EG PACKAGE
PAGE No. 2 OF 16

CONTENTS

SECTION

1. SCOPE
2. General
3. DESIGN CRITERIA
4. DESIGN SND CONSTRUCTION
5. PROTECTIVE COATING
6. INSPECTION AND TESTING
7. WARRANTY
8. SPARES
9. TOOLS
10. PACKAGING AND TRANSPORT
11. VENDOR DATA REQUIREMENT
12. ATTACHEMNTS

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ISO – 9001:2000 DISCIPLINE : Electrical
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1.0 SCOPE

This specification defines the minimum requirements for supply of diesel engine generator
set, to be installed on an offshore platform.

2.0 GENERAL

2.1 Purpose

The generator set will be used for emergency power generation and will supply power to
motors, communication equipment, lighting and utility loads on the platform during periods
when the main generating sets are shutdown and during platform start-up.

2.2. Codes and Standards

The following codes and standards (latest edition) are referenced to and made a part of this
specification:

ISO 3046/BS-5514 Reciprocating I.C. Engines, Part-l through VI

ANSI American National Standards Institute
ASTM American society of Testing of Materials
NEC National Electrical Code
NEMA National Electrical Manufacturer’s Association
IEEE Institute of Electrical and Electronic Engineers
IEC International Electra-technical Commission
EEMUA Engineering, Equipment and Material Users’ Association (Publication
No. 107) “Recommendation for the Protection of Diesel Engines
operating in hazardous area.’
API-RP-14C Analysis, design, installation and testing of basic surface, safety
system in offshore production platforms.

2.3 Equipment Furnished

Vendor shall supply all necessary equipment as described hereinafter to make a complete
operating diesel engine generator system. The system shall include but not be limited to the
following:

Diesel Engine and Generator with Coupling and auxiliaries

Intake air manifold/filter
Exhaust manifold with lagging
Turbo charging (if applicable)
Engine starting system (for black start and subsequent start)

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Remote Panels for ‘Generator, Relay, Control and

Synchronising system with synch. Check relay
Remote panel for electronic Automatic voltage regulator
CTs for AVR and Governor operation
Lube Oil System
Fuel System
Engine Cooling System
Governing System & Speed Switch
Engine Control system & Local Control Panel
Any other item(s) required for uninterrupted continuous operation.

2.3.2 All the above components, (except those covered in 2.3.3 below) shall be supported on a
common structural skid with anti-vibration mounting, fully assembled, piped with inlet and
outlet piping terminated at the skid edge with appropriately rated flanges, provided with
readily identifiable piping, wiring and cable connections for the necessary auxiliary
equipment, tested and painted for marine environment.

2.3.3 Items to be supplied loose/on separate skid by the emergency generator vendor (as per this
specification) for location outside the master skid but in the same Emergency Generator
Room shall be indicated separately in the bid proposal.

2.3.4 Vendor shall provide one skid-mounted local engine control panel with manual start/stop
and facility for remote automatic star/stop and manual emergency stop.
2.3.5 Vendor shall provide interface for all utilities required at the skid edge and on the control
panel.

2.3.6 Followings are excluded from Vendor’s scope (to be provided by the Contractor):

i) Motor Control Centre for D.G. Aux. Drives. ,

ii) Power and Control feeder cables form M.C.C. to Aux. Drives.
iii) Interconnecting cable between the following:
a) Generator to remote control panel and switchgear
b) Local control panel to remote control panel and switchgear.

2.4 Acceptance Criteria

Refer clause 4.1.2 of .this specification.

3.0 DESIGN CRITERIA

3.1 Conditions of Service

3.1.1 The equipment shall be designed for continuous duty in indoor location on an offshore
platform with site conditions as detailed in attached functional Specification No. 5006.

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3.2 Utilities

3.2.1 Utilities shall be arranged by contractor.

3.2.2 The Vendor shall specify the utilities required alongwith their rate of consumption in his
bid.

3.3 Safety

3.3.1 ‘It is the intent of the Company that operational hazards be reduced to a minimum. Vendor
shall use sound engineering judgment to complete an installation that will perform the
required process functions without compromising this aim

3.3.2 All electrical devices shall meet the requirements for the area classification in which they
are installed.

3.3.3 All controls shall operate in a fail-safe mode.

3.3.4 All couplings, gears, and exposed rotating parts shall be provided with adequate guards of
non-sparking type. Drive belts, if used, shall be antistatic fire resistance type.

3.3.5 Piping shall be arranged in a manner so as to avoid tripping or headroom problems. Piping
or tubing of insufficient mechanical strength for standing or hanging shall be protected form
personnel traffic.

3.3.6 The requirements of Noise limits and Equipment Vibrations as defined in the attached
Specifications FS 5002 and FS 5004 shall be met. To meet the specified noise level, vendor
shall include in his scope any acoustic treatment either to the DG set or DG set room.

Emergency generator skid shall be located within a weather proof enclosure having
adequate maintenance space and ease of removal of equipment from the enclosure through
proper material handling facilities.

3.4 Conflict

In the event of conflict between this specification and other documents listed herein, the
following order of precedence will govern:

This Specification and attached electrical specifications

Other Specifications of bid

Codes and Standards

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4.0 DESIGN AND CONSTRUCTION

4.1 Diesel Engine

4.1.1 The engine shall be in accordance with these specifications. The design, construction and
rating “of the-diesel engine shall fully meet the requirements of the electric power generator
and the vendor shall be responsible for safe and satisfactory operation of the D.G Set as a
whole.

4.1.2 The offered diesel engine shall be one of the regular production models of the manufacture
for offshore industrial applications and already type tested. The type test report shall be
furnished to the company for review, if desired so. In case the proposed engine model has
not been type tested, vendor shall furnish a reference list of its existing installations and at
least two of these engines should have completed 8000 hours (each) of continuous running
on offshore installation.

4.1.3 The engine shall be diesel fuel operated, water cooled, naturally aspirated or turbo charged
engine.

4.1.4 The engine shall be rated to continuously develop net electrical power equal to the specified
generator continuous rating (in addition to the electrical power requirements for emergency
generator auxiliaries), under the worst site conditions as indicated in the attached Generator
data sheet.

4.1.5 Unless otherwise specified, the site rating of the engine shall be worked out considering
derating in accordance with ISO-3046/BS-5514 plus the power absorbed by all the
auxiliaries.

The applicable standard for diesel engine and its rating at N.T.P.conditions shall be clearly
stated in the bid supported by printed rating curve. Derating calculations as applicable for
site conditions shall also be furnished with the bid. Derating data should be supported by the
manufacturer’s std. Deration curve.

4.1.6 The engine shall be capable of satisfactorily providing an output 10% in excess of the
continuous rating at the same speed for one hour in any period of 12 hours consecutive
running.

4.1.7 The normal power requirement of the engine driven radiator or the coolant pump and other
auxiliaries shall be clearly stated.

4.1.8 The “Cyclic irregularity” of the diesel engine for direct coupling to an electric power
generator “Angular deviation of A.C. Generator” driven by diesel engine for parallel
operation and the “Engine electronic Governor speed droop Characteristics” shall be
restricted to the values specified in the codes and standards.

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4.1.9 Fuel System

a) The engine shall be capable of giving satisfactory performance on diesel fuel.

b) The engine shall have individual mechanical injection valve for each cylinder.
Injection pumps and injection valves shall be of type not requiring adjustment in
service.
c) The fuel system shall have built-in gear-type engine-driven fuel transfer pump to
supply, at constant pressure, fuel through filters to the injection pumps.
d) The diesel to the engine-driven transfer pumps shall be supplied from day tank
mounted off skid. Vendor shall furnish the day tank mounted on the skid with a low
level switch with DPDT contacts and dual conduit entries and self actuated full float
level controller in the fuel oil inlet line to day tank.
e) The diesel day tank with a minimum capacity as defined elsewhere in the bid
package shall be supplied alongwith interconnected piping/hoses, valves, air
breathers, shielded level gauge, strainer, a hand hole of not less than 150mm
diameter, besides the required connections and a drain plug.
f) The inside surface of the day tank shall be coated with Engenamel red or black of
I.C.I or its equivalent and the outside surfaces given two coats of oil resistant primer
paint.
g) Excess fuel to the engine shall be returned to the tank.

4.1.10 Performance Data

The vendor shall furnish fuel and lubricating oil consumption estimates under different load
conditions of engine generator and also give an estimate on requirements of combustion air.
Vendor shall state these in the proposal.

4.1.11 Lubrication

The engine shall have positive displacement, gear type lubrication oil pump for supplying
oil under pressure to main bearing, crank pin bearing, piston pins, timing gear, crankshaft
bearings and valve mechanism etc. effective full flow duplex type lubricating oil filters shall
be provided and so located and connected that lubricating oil is continuously filtered and
cleaned.

Filters shall be accessible and suitable for easy replacement. This system shall have a lube
oil cooler with thermostat. Prelubrication oil pump driven by electric motor shall be
provided with necessary timer.

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4.1.12 a) Intake Air System

The engine shall be provided with engine-mounted, dry-type air cleaners of sufficient
capacity for the intake air, Intake air shall be taken from safe area.

Engine intake air filters shall be suitable for replaceable severe marine environment with
differential pressure indicator. Engine shall be equipped with an automatic air intake
shutoff-device in addition of fuel shut off-valve to prevent engine over speed in case of
combustible environment. This device shall be set to stop the air intake at 10% over speed.

4.1.12 b) Starting

The engine shall be equipped with an air motor starting system. The air starting equipment
shall include valve, strainer and lubricator with valves to allow automatic and manual
starting. Nitrogen cylinder (with 100% standby) shall be provided and connected to the
pneumatic starting system for black start conditions. Diesel engine (with manual start-up)
driven compressor along with suitably sized air receiver shall also be supplied for black start
condition. Start-up shall be automatic in case of sudden complete black out condition
compatible with main power system.

Additionally, the engine shall have hydraulic start system.

4.1.13 Exhaust System

a) Engine shall be equipped with exhaust manifold lagged with solid insulation.
b) The exhaust system shall be furnished with Burgess Manning or equivalent Spark
Arresting type silencer with flexible connector. Exhaust piping in the enclosure shall
be supplied with calcium silicate insulation. A flexible connection for the exhaust
on the engine shall be supplied (Exhaust Ducting to safe location by
CONTRACTOR).
c) The engine exhaust system shall be jacketed and water cooled to ensure that surface
temperatures meet the requirements of EEMUA with engine operating at full load.
The open end of the exhaust pipe shall be fitted with a suitable rain hood.

4.1.14 Cooling

The engine shall be cooled by means of a radiator type cooling system composed of an
engine shaft or motor driven radiator fan and a water pump controlled with full flow bypass.
The radiator shall have Copon-coated core and Carbo Zinc 11 coating on the exterior
housing. Radiator shall have a low water level switch with DPDT contacts wired on the
local control panel. A water level gauge shall also be provided.
4.1.16 Governor

Governor shall be electronic type and suitable for isochronous operation with control
characteristics of maximum _+ 1% of rated speed at steady state. Governor offered shall be

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of a proven make with adequate track record for reliable operation. The mechanical
operation shall be used during operation of engine-generator under black start. The droop
operation shall also be provided for parallel running with other emergency generator of the
complex and for parallel operation with main turbine power also.

4.1.17 Oil Regulator

Engine shall be furnished with Oil level Regulator or equivalent complete with reservoir and
stand.

4.1.18 Instruments and Controls

The engine shall be equipped with instruments, gauges and controls as per this specification.
Vendor shall also include any other safety devices, which are considered necessary for the
protection of ’equipment supplied by him.

4.1.19 Engine Control Panel

a) The engine controls suitable for D.C. Voltage shall be supplied by the vendor,
completely wired, mounted on a panel and the panel installed in a weather proof
enclosure.
b) Wiring of the panel shall be complete and shall include a terminal block for external
to the panel. All relays shall be plug-in type and hermetically sealed with spring
clips.
c) The controls shall include a local ON/OFF/REMOTE switch for energizing the
controls. The ‘ON’ mode shall open a solenoid valve in the fuel line to the engine.
System shut-down/stop (OFF) shall de-energize a solenoid valve to shut off the fuel
REMOTE mode shall allow starting and stopping from a remote location. Automatic
starting shall be provided with lockout after three starts. Engine shut down shall cut
off air supply to the engine.
d) The engine shall shutdown on low oil pressure, high water temperature, excessive
vibration and over-speed. Alarm shall be provided for excessive vibration, low
radiator water level, oil pressure low, high jacket water temperature, over speed, low
diesel fuel level and high oil temperature. Under any of these abnormal conditions, a
visual local indication on the control panel shall be given, and an auxiliary contact
which is closed in healthy condition, shall open to activate a remote annunciator. In
addition, a dry contact will be provided that opens on the successful starting and
running of the engine (to provide remote status indication).

The controls shall prevent cranking of the engine if a shutdown condition exists.

The engine control circuit shall provide terminal contacts for ‘permissive” signal to run/stop
from an external relay contact (by contractor) that will close, shorting the terminals and
allowing the engine to stop/run. This system will be used for gas detection shutdown -

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(furnished by Contractor) lockout on an electrical fault in the switch gear and start signal
from the main generators control panels on lockout and/or shutdown of main generator sets.

Engine control panel shall consist of following:

Hour Meter
Start/Stop Push Buttons
Remote/Local Selector Switch
Running indication
Ammeters for auxiliary motors
Trip/Alarm Indicators (visual only)

4.2 Telemetry

4.2.1 As the generator set will be monitored and controlled from a remote location at later date, it
is necessary that provisions for telemetry inputs and outputs be provided. Any other
parameters considered essential for monitoring the performance by these units, but not
included in the identified list of parameters, shall be included by vendor for remote
telemetry. On the basis of these parameters, the vendor shall include necessary transducer,
auxiliary relays and wired outlet contacts in a separate junction box on each skid.Contacts.
The Contacts, where furnished shall be volt-free.

4.2.2 Supervisory system for telemetry shall be provided by the Company. The analog signal
output for telemetry shall be two wire, totally isolated and powered 4-20mA.D.C. The
contractor shall pick off these output points for remote analog telemetry and other voltage
free contact wired for remote indication/alarm. and remote start and stop actuation from
each junction box which shall be considered as the interface between vendor equipment and
Company’s Supervisory telemetry system.

4.2.3 Control supply of 24 volts DC can be furnished ‘from the platform battery-bank where
required. The vendor shall furnish power requirements if any, for this equipment in this
regard.

4.2.4 Input

Parameter Signal/Contacts required

Remote Start Volt-free momentary contact supplied

by other

Remote stop Volt-free momentary contact supplied

Actuation by others

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4.2.5 Output

Parameter Signal/Contacts required

Diesel level @-20mA D.C. Signal output

in day tank

Lube Oil pressure - do -

Radiator Cooling water - do –

Temperature

Start system Air pressure - do –

Engine status ON/OFF Volt free contact by vendor

4.2.6 Deviations, if any shall be clearly brought out for Company’s consideration.

4.3 Skid

4.3.1 The skid shall be designed and built to ensure that all the equipment along with accessories,
panel and piping are mounted suitably for convenient operation. The skid shall. be designed
and built in accordance with the attached specification 5001-P.

4.4 Piping

The selection, fabrication and installation of piping works shall meet the minimum
requirements defined in the functional Specification No. 2004-A and 2004-B attached
elsewhere in bid package.

4.5 Electrical

4.5.1 The electrical equipment shall be supplied in accordance with the enclosed specifications,
data sheets and Functional Specification No. 4017.

4.5.2 All equipment selected for hazardous area shall be certified by BASEEFA, UL or equivalent
international testing, agency for the service and area in which it is to be used.

4.6 Instrumentation

4.6.1 The selection and installation of instrumentation works shall meet in the relevant
specifications attached elsewhere in bid.

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4.6.2 The controls/indications which are required to be connected to Company’s Remote Control
room shall be terminated in a junction box (.with terminal strip) located at the edge of the
skid.

4.7 Insulation

Insulation shall be provided wherever required for personnel protection/heat conservation, in

accordance with the attached Functional Specification No 2006.

5.0 PROTECTIVE COATING

All carbon steel surfaces, piping, vessels, fittings, supports and structural steel skid shall be
coated in accordance with attached functional specification No. FS 2005.

6.0 INSPECTION AND TESTING

6.1 Vendor shall carry out various tests as per applicable codes/standards. Test certificates shall
be submitted for Company’s approval.

6.2 Company/its authorized representative or certifying agency shall have access to inspect the
equipment at any stage during manufacture. During inspection material certificates, shop
test data, certificates for bought out components and other relevant information shall be
furnished so as to ascertain that the specifications and quality are complied with.

6.3 Tests specified in the specifications shall be carried out in presence of the Company/its
authorized representative or certifying agency. Vendor shall give minimum 15 days’ prior
intimation regarding testing schedules.

6.4 Tests of generator and associated electrical equipment shall be as per attached electrical
specifications.

6.5 String Test -

String Test shall be carried out on complete Diesel Engine Generator set as follows:

I) No Load at rated voltage : 30 minutes

and frequency
ii) One quarter load (approx.) : 30 minutes
a) Reject load in one step
b) Re-apply load in one step
iii)Increase load to approx. 50% : 30 minutes
a) Reject load in one step
b) Re-apply toad in one step
iv) Increased load to approx. 75%: 30 minutes

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Reject load in one step

v) Increased load to 100% Duration until temperatures are stabilized but not to
exceed 2 hours Reject load in one step
vi) Increase load to 110%: 30 minutes
vii) Decrease load to 100%: 5 minutes
viii) Operate at no load: 30 minutes
ix) Test the synchronizing Capacity of D.G by Simulating Operating conditions.
x) Stop unit

NOTES

1) String test shall be carried out by using all job equipment. All parameters e.g.,
voltage, frequency, current, temperature, noise, vibration shall be recorded during
the string test.
2) Functioning of all controls/shut downs shall also be tested during this testing by
simulating the test conditions.

6.6 Site Tests

The complete emergency generator set shall be tested at site in accordance with lEC-46. The
site test programme shall however, include the following:

a) Guaranteed performance test at specified design rating over

a period of not less than 2 hours duration continuous.
b) Demonstrate voltage regulation over the load range.
c) Demonstration of speed response to load changes
d) Demonstrate transient behavior of generator,

6.7 Shop Tests

Shop test shall include the following as a minimum for complete diesel engine generator set;

a) Engine shall be separately tested at engine manufacturer’s shop. As a minimum, tests

as indicated in this specification or elsewhere in the bid package shall be performed.

b) The engine generator set shall be run at synchronous speed non-stop for two (2)
hours, at its rated capacity. Each half-hour the following data shall be recorded:
Ampere
Voltage
Frequency
Power factor
Water Temperature
Oil Pressure
Vibrations
Noise

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c) The operation of protective/safety devices shall be checked during this test.

d) Automatic start of this unit with loss of the prime power.
e) Local control panel and remote control panel shall be functionally tested to check all
safety system and control instruments.
f) In addition to the tests mentioned above, the tests specified in the codes pertaining to
engine and generator shall also be performed.

6.7.2 The required load bank and all interconnecting wiring/cabling required for testing shall be
arranged by the vendor at his own cost. No slave or temporary installed wiring etc. shall be
used on the set during testing.

6.7.3 A detailed schedule of test alongwith test procedures shall be furnished for approval atleast
2 months prior to testing. Vendor shall supply lists of tests to be performed including those
listed above with the proposal.

7.0 WARRANTY

Vendor shall have final and total responsibility for the design and mechanical performance
of all equipment supplied under this specification. Vendor shall warrant the equipment
furnished by him and the performance of the said equipment in accordance with this
specification for a period of 12 months from the date of commissioning.

8.0 SPARES

8.1 Vendor shall recommend and provide spare parts needed for startup and commissioning. In
addition, Vendor shall also furnish a separate itemized priced list of recommended spares
for one (I) year’ normal operation and maintenance. Recommended spares should take into
account related factors of equipment reliability, effect of equipment downtime upon
production or safety, cost of parts, and availability of equipment service facilities. All spares
parts furnished by Vendor should be wrapped and packaged so that they will be preserved in
original as new condition under the normal conditions of storage to be anticipated in India,
and shall be properly tagged and coded so that later identification as to intended equipment
usage will be facilitated They shall be packaged separately clearly marked as “Spare Parts”
and shipped at the same time as the equipment. Packing lists shall be furnished so that the
parts can be handled without uncrating, if desired. Startup spares shall be packed and
identified separately.

9.0 TOOLS

Vendor shall provide two sets of special tools required for operation and maintenance of the
furnished equipment.

10.0 PACKING AND TRANSPORT

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The offered equipment alongwith their accessories shall be shipped packed in wooden
crates. They shall be wrapped with polythene sheets before being placed in the crates to
prevent damage to finish. Crates shall have skid bottom for handling.

11.0 VENDOR DATA REQUlREMENT

11.1 With proposal

Equipment specifications, catalogues, data sheets, deviation schedule and other relevant data
as per attached “Vendor Data Requirement” sheet, to facilitate the Company in evaluating
the equipment selection,

11.2 After Order Placement Drawings and data to be furnished for Company’s review/approval

11.2.1 As built drawings, inspection and test reports, operation manual

and other relevant documents as covered in the attached ‘Vendor
Data Requirement’ sheet shall be submitted as a part of Equipment
Data Book. :

12.0 ATTACHMENT

The following functional specification are referenced to this specification and

attached elsewhere in bid.

12.1 Functional Specifications:

5001-P Skid Mounted Assemblies
2004-A &B Piping
2009 Welding and Weld Inspection
4017 Electrics for Skid Mounted Equipment
2005 Protective Coating
2006 Insulation for Personnel Protection
5002 Equipment. Noise Limits
5006 Site Conditions and Climate
5004 Equipment Vibration
4008 Medium Voltage Motors
5502 F Diesel engine Specification
FS4030 EG and accessories specification
3503 Instruments for equipment package
C-102 Integrated control system

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12.2 Vendor Data Requirement Sheet

Sl. Description With proposal After Order Placement

No.
For Company For Company With
Evaluation Approval/Review Equpt.
Data
Book
1. G.A. of control panels X X
2. Maintenance Clearance diagrams ☼ X X
3. Torsional analysis report for engine ☼ X
and driven equipment
4. Deviation list w.r.t job spec. & codes X ☼
5. One year spares list X
6. Special tools & tackles list X
7. Spare parts catalogue X
8. Installation, operation and X
maintenance manual
9. Inspection reports/Test data X X
10. Reference list of previous X
installations
11. Heat rejection data and radiator data X
12. Other data as per FS-1060 X

X- Means Data required in five copies

☼-Means required at Inspection Stage

12.3 The relevant Data sheets attached elsewhere in bid package is part of this specification.

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
DD/SOF/004B DD/SOP/008 TO 015 02 01 01/08/2006