Primary & Backup Generator Specification

and Testing
EEB/ESD

Feb-2021

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 Primary & Backup Generator
Specification and Testing Standards

Table of Contents
1 Primary & Backup Generator Specification..................................................................................3
1.1 General...................................................................................................................................3
2 Conflict and deviation...................................................................................................................3
2.1 Codes and Standards..............................................................................................................3
2.2 Primary & Backup Generator System....................................................................................4
3 Purpose.........................................................................................................................................4
4 Primary & Backup Generator documents.....................................................................................4
5 Primary & Backup Generator Specification……………………………………………………………………….
……...5
6 Primary & Backup Generator Testing………………………………………………………………………………………
10
7 Installation & Configuration
Requirements…………………………………………………………………………….12
8 Fuel Tank Requirements…………………………………………………………………………………………………………
13
9 ATS Specification and
Testing………………………………………………………………………………………………….15

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1 Primary & Backup Generator Specification and Testing

1.1 General
This standard aims to clarify all the requirements / needs to satisfy the environment for
Primary & Backup Generator Specification and Testing.

2 Conflict and deviation

Any conflicts between this Standard and other applicable SANS Engineering Standards, SANS
Materials System Specifications, SANS Standard Drawings, or industry standards, codes, and forms shall
be referred to SANS for arbitration.
2.1 Codes and Standards
Design of the shelter shall conform to the following standards:

1. SANS Power Configuration Power Manual.

2. NFPA National Fire Protection Association 110 (Standard for Emergency and Standby
Power Systems).
3. IEEE Guide: Test Procedures for Synchronous Machines
4. NEC Requirements for Generators and Standby Power Systems

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2.2 Primary & Backup Generator Systems

2. Scope
This standard contains requirements covering the performance of emergency and standby
power systems providing an alternate source of electrical power to loads in buildings and
facilities in the event that the primary power source fails.
3 Purpose
An emergency power system is an independent source of electrical power that supports
important electrical systems on loss of normal power supply.

4 Primary & Backup Generator Requirements Documents

1- Data sheets of the Primary and Backup
Generator.
2- Shop Drawings.
3- As Built drawings.
4- Electrical drawings.
5- Operation & user manuals.
6- Contractor shall provide a confirmation letter for the proposed product about providing
technical support and spare parts for the equipment's lifetime (10 years).
7- Contractor Provide a complete system's parts list (not only the proposed two years
spare parts list) showing the item's Part Number, item's description item's quantity in
the system, MTBF and item's price).

8- Warranty Certificate.

9- SAT & FAT Procedure

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5 Primary & Backup Generator Specification

Classification of Emergency Power Supply Systems (EPSSs)

General. The EPSS shall provide a source of electrical power of required capacity, reliability, and
quality to loads for a length of time as specified in [Table 2] and within a specified time
following loss or failure of the normal power supply as specified in [Table 1].

Class. The class defines the minimum time, in hours, for which the EPSS is designed to operate
at its rated load without being refueled or recharged. [See Table 2]

Type. The type defines the maximum time, in seconds, that the EPSS will permit the load
terminals of the transfer switch to be without acceptable electrical power. [Table 1] provides
the types defined by this standard.

Level. This standard recognizes two levels of equipment installation, performance, and
maintenance.
Level 1 systems shall be installed where failure of the equipment to perform could result in loss
of human life or serious injuries.
Level 2 systems shall be installed where failure of the EPSS to perform is less critical to human
life and safety.
All equipment shall be permanently installed.
Level 1 and Level 2 systems shall ensure that all loads served by the EPSS are supplied with
alternate power that meets all the following criteria:
(1) Of a quality within the operating limits of the load
(2) For a duration specified for the class as defined in [Table 2]
(3) Within the time specified for the type as defined in [Table 1]

1 2

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Emergency Power Supply (EPS): Energy Sources, Converters, and Accessories

Energy Sources
The liquid petroleum products at atmospheric pressure shall be permitted to be used for the
emergency power supply (EPS) as specified in the appropriate ASTM standards and as
recommended by the engine manufacturer
Exception: For Level 1 installations in locations where the probability of interruption of off-site
fuel supplies is high, on-site storage of an alternate energy source sufficient to allow full output
of the EPSS to be delivered for the class specified shall be required, with the provision for
automatic transfer from the primary energy source to the alternate energy source.
The energy sources listed in NFPA 110 Section 5.1.1 shall be permitted to be used for the EPS
where the primary source of power is by means of on-site energy conversion, provided that
there is separately dedicated energy conversion equipment on-site with a capacity equal to the
power needs of the EPSS.
A public electric utility that has a demonstrated reliability shall be permitted to be used as the
EPS where the primary source is by means of on-site energy conversion.
Energy Converters
 Energy converters shall consist only of rotating driven by diesel cycle
 Level 1 energy converters shall be representative products built from components that have
proven compatibility and reliability and are coordinated to operate as a unit.
 The capability of the energy converter, with its controls and accessories, to survive without
damage from common and abnormal disturbances in actual load circuits shall be
demonstrable by tests on separate prototype models, or by acceptable tests on the system
components as performed by the component suppliers, or by tests performed in the listing
process for the assembly.
 A separate prototype unit shall be permitted to be utilized in a Level 1 or Level 2 installation,
provided that all prototype tests produce no deleterious effects on the unit, and the
authority having jurisdiction, the owner, and the user are informed that the unit is the
prototype test unit.
 The rotating equipment prototype unit shall be tested with all typical prime mover
accessories that affect its power output in place and operating.
 Other types of prime movers and their associated equipment meeting the applicable
performance requirements of this standard shall be permitted, if acceptable to the authority
having jurisdiction.
 Where used for Level 1 applications, the prime mover shall not mechanically drive any
equipment other than its operating accessories and its generator.
 The EPS shall be installed in accordance with NFPA 70, National Electrical Code.

Rotating Equipment

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Prime movers and accessories shall comply with NFPA 37, Standard for the Installation and Use
of Stationary Combustion Engines and Gas Turbines, except as modified in this standard.
Prime Mover Ratings. Proper derating factors, such as altitudes, ambient temperature, fuel
energy content, accessory losses, and site conditions as recommended by the manufacturer of
the generator set shall be used in determining whether or not brake power meets the
connected load requirements.
Prime Mover Starting Equipment
Starting Systems shall be accomplished using either an electric starter or a stored energy
starting system.
 Electric starter systems shall start using a positive shift solenoid to engage the starter
motor and to crank the prime mover for the period specified in NFPA110 section 5.6.4.2
without overheating, at a speed at least equal to that recommended by the
manufacturer of the prime mover and at the lowest ambient temperature anticipated at
the installation site.
 Other types of stored energy starting systems (except pyrotechnic) shall be permitted to
be used where recommended by the manufacturer of the prime mover and subject to
approval of the authority having jurisdiction, under the following conditions:
(1) Where two complete periods of cranking cycles are completed without
replacement of the stored energy
(2) Where a means for automatic restoration from the emergency source of the
stored energy is provided
(3) Where the stored energy system has the cranking capacity specified in NFPA110
section 5.6.4.2.1
(4) Where the stored energy system has a “black start” capability in addition to
normal discharge capability
Otto or Diesel Cycle Prime Movers. For otto or diesel cycle prime movers, the type and duration
of the cranking cycle shall be as specified in NFPA110 Table 5.6.4.2.
 A complete cranking cycle shall consist of an automatic crank period of approximately 15
seconds followed by a rest period of approximately 15 seconds. Upon starting and
running the prime mover, further cranking shall cease.
 Two means of cranking termination shall be utilized so that one serves as backup to
prevent inadvertent starter engagement.
 Otto cycle prime movers of 15 kW and lower and all diesel prime movers shall be
permitted to use continuous cranking methods.

Number of Batteries. Each prime mover shall be provided with both of the following:

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(1) Storage battery units as specified in NFPA110 Table 5.6.4.2

(2) A storage rack for each battery or battery unit
Size of Batteries. The battery unit shall have the capacity to maintain the cranking speed
recommended by the prime mover manufacturer through two complete periods of cranking
limiter time-outs. The manufacturer shall provide installation, operation, and maintenance
instructions and, for batteries shipped dry, electrolyte mixing instructions. All batteries used in
this service shall have been designed for this duty and shall have demonstrable characteristics of
performance and reliability acceptable to the authority having jurisdiction.
Prime Mover Cooling Systems. Cooling systems for prime movers shall be either forced-air or
natural convection, liquid-cooled, or a combination thereof.
 Cooling systems shall prevent overheating of prime movers under conditions of highest
anticipated ambient temperature at the installed elevation (above sea level) when fully
loaded.
 The installed EPS cooling system shall be designed to cool the prime mover at full-rated
load while operating in the particular installation circumstances of each EPS.
 Design of the EPS cooling system shall consider the following factors:
(1) Remote radiator or heat exchanger sizing
(2) Pipe sizing
(3) Pump sizing
(4) Sufficient shutoffs to isolate equipment to facilitate maintenance
(5) The need for and sizing of de-aeration and surge tanks
(6) Drain valves for cleaning and flushing the cooling system
(7) Type of flexible hoses between the prime mover and the cooling system piping

Prime Mover Exhaust Piping. Where applicable, the exhaust system shall include a muffler or
silencer sized for the unit and a flexible exhaust section.
Generators, Exciters, and Voltage Regulators. Genera‐ tors shall comply with Article 445 of
NFPA 70, National Electrical Code, and with the requirements of 5.6.9.1 through 5.6.9.9.
 The generator shall be of drip proof construction and have amortisseur windings.
 The generator shall be suitable for the environmental conditions at the installation
location.
Control Functions.
A control panel shall be provided and shall contain the following:
 Automatic remote start capability
 “Run-off-automatic” switch
 Controls to shut down and lock out the prime mover under any of the following
conditions:
(a) Failing to start after specified cranking time

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(b) Overspeed
(c) Low lubricating-oil pressure
(d) High engine temperature (An automatic engine shutdown device for high
lubricating-oil temperature shall not be required.)
(e) Operation of remote manual stop station
 Individual alarm indication to annunciate any of the conditions listed in NFPA110 table
5.6.5.2 and with the following characteristics:
(a) Battery powered
(b) Visually indicated
(c) Have additional contacts or circuits for a common audible alarm that signals locally
and remotely when any of the itemized conditions occurs
(d) Have a lamp test switch(es) to test the operation of all alarm lamps
 Controls to shut down the prime mover upon removal of the initiating signal or manual
emergency shutdown
Remote Controls and Alarms. A remote, common audible alarm shall be provided as specified in
NFPA 110 Section 5.6.5.2(4). Alarms and annunciation shall be powered by the prime mover
starting battery unless operational constraints make this impracticable. In that circumstance an
alternate source from the EPS, such as a storage battery, UPS, or branch circuit supplied by the
EPSS, shall be permitted. The following annunciation shall be provided at a minimum:
(1) For Level 1 EPS, local annunciation and facility remote annunciation, or local annunciation
and network remote annunciation
(2) For Level 2 EPS, local annunciation
For the purposes of defining the types of annunciation the following shall apply:
(1) Local annunciation is located on the equipment itself or within the same equipment room.
(2) Facility remote annunciation is located on site but not within the room where the
equipment is located.
(3) Network remote annunciation is located off site.
An alarm-silencing means shall be provided, and the panel shall include repetitive alarm
circuitry so that, after the audible alarm has been silenced, it reactivates after the fault
condition has been cleared and has to be restored to its normal position to be silenced again.

Miscellaneous Requirements

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 Where applicable, the prime mover and generator shall be factory mounted on a common
base, rigid enough to maintain the dynamic alignment of the rotating element of the system
prior to shipment to the installation site.
 A certification shall be supplied with the unit that verifies the torsional vibration
compatibility of the rotating element of the prime mover and generator for the intended use
of the energy converter.
 Vibration isolators shall be furnished where necessary to minimize vibration transmission to
the permanent structure.
 The manufacturer of the EPS shall submit complete schematic, wiring, and interconnection
diagrams showing all terminal and destination markings for all EPS equipment, as well as the
functional relationship between all electrical components.
 The energy converter supplier shall stipulate compliance and performance with this
standard for the entire unit when installed.
 Where requested, the short circuit current capability at the generator output terminals shall
be furnished.
6 Primary & Backup Generator Testing
1) Maintenance and testing are critical to the continued reliability of SANS emergency
generator and must be performed in accordance with manufacturer’s recommendations,
instruction manuals, and the minimum requirements of NFPA 110 and the authority having
jurisdiction (AHJ) [see: NFPA 110(10), Section 8.1.1].
2) SANS facility should have at least two sets of instruction manuals for all major generator
components. One set should be kept in a secure, convenient location near the equipment. The
other set should be kept in a different secure location [see: NFPA 110(10), Section 8.2.2]. These
manuals must, at a minimum, contain the following:
a) A detailed explanation of the operation of the emergency power supply system
b) Instructions for routine maintenance
c) Detailed repair instructions
d) An illustrated parts list and part numbers
e) Illustrated and schematic drawings of electrical wiring systems, including operating and
safety devices, control panels, instrumentation, and annunciators Page 2 of 6 June 2016
3) Special tools and testing devices necessary for routine maintenance must be available for use
when needed [see: NFPA 110(10), Sec. 8.2.3].
4) Routine maintenance, inspection and operational testing of the emergency generator and
associated components must be overseen by a properly trained person [see MSFC (15), Sec.
604.6; NFPA 99(12), Sec. 6.4.4.1.1.4(C); NFPA 110(10), Sec. 8.4.8]. Evidence of such training

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should be kept in the designated employees’ personnel file. In the absence of a properly trained
person on-site, an outside vendor may need to be contracted to oversee the performance of all
or part of these services.
5) NFPA 110 does not establish a specific date and time of day for required testing. Those are to
be determined by management and are typically scheduled so as to provide minimum
disruption of facility operations. [see NFPA 110(10), Sections 8.4.2.1 and 8.4.2.4.1]. NFPA 99(12),
Sec. 6.4.4.1.1.4(A), however, requires that generator sets be tested 12 times a year, with testing
intervals of not less than 20 days nor more than 40 days.
Generator Tests
 Insulation resistance
 Dielectric and partial discharge tests
 Tests for short-circuited field turn
 Polarity test of field poles
 Shaft current and bearing insulation
 Phase sequence
 Telephone-influence factor
 Balanced telephone-influence factor
 Residual-component telephone-influence factor
 Line to natural telephone influence factor
 Stator terminal voltage-waveform deviation and distortion factors
 Over speed test
 Line-charging capacitance
 Acoustic noise
 Temperature tests
 Torque test
 Sudden short-circuit test

7 Installation & Configuration Requirements

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 Upon completion of the installation of the EPSS, the EPS shall be tested to ensure
conformity to the requirements of the standard with respect to both power output and
function.
 An on-site acceptance test shall be conducted as a final approval test for all EPSSs.
 For new Level 1 installations, the EPSS shall not be considered as meeting this standard
until the acceptance tests have been conducted and test requirements met.
 The test shall be conducted after completion of the installation with all EPSS accessory
and support equipment in place and operating.
 The authority having jurisdiction shall be given advance notification of the time at which
the acceptance test is to be performed so that the authority can witness the test.
 The EPSS shall perform within the limits specified in this standard.
 When the EPSS consists of paralleled EPSs, the system control function for paralleling
and load shedding shall be verified in accordance with system design documentation.
 Any method recommended by the manufacturer for the cycle crank test shall be utilized
to prevent the prime mover from running.
 The control switch shall be set at “run” to cause the prime mover to crank.
 The battery charge rate shall be recorded at 5- minute intervals for the first 15 minutes
or until charge rate stabilization.
 Items (1) through (4) shall be made available to the authority having jurisdiction at the
time of the acceptance test:
(1) Evidence of the prototype test as specified in NFPA section 5.2.1.2 (for Level 1 systems)
(2) A certified analysis as specified in 5.6.10.2
(3) A letter of compliance as specified in 5.6.10.5
(4) A manufacturer’s certification of a rated load test at rated power factor with the ambient
temperature, altitude, and fuel grade recorded

8 Fuel Tank Requirements

Fuel tanks shall be sized to accommodate the specific EPS class.

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All fuel tanks and systems shall be installed and maintained in accordance with (NFPA 30,
Flammable and Combustible Liquids Code; NFPA 37, Standard for the Installation and Use of
Stationary Combustion Engines and Gas Turbines; NFPA 54, National Fuel Gas Code; and NFPA
58, Liquefied Petroleum Gas Code).
 Fuel system design shall provide for a supply of clean fuel to the prime mover.
 Tanks shall be sized so that the fuel is consumed within the storage life, or provisions
shall be made to remediate fuel that is stale or contaminated or to replace stale or
contaminated fuel with clean fuel.
 Fuel tanks shall be close enough to the prime mover for the fuel lift (suction head) of the
prime mover fuel pump to meet the fuel system requirements, or a fuel transfer pump
and day tank shall be provided.
 If the engine manufacturer's fuel pump static head pressure limits are exceeded when
the level of fuel in the tank is at a maximum, a day tank shall be utilized.
 Fuel piping shall be of compatible metal to minimize electrolysis and shall be properly
sized, with vent and fill pipes located to prevent entry of groundwater or rain into the
tank.
 Galvanized fuel lines shall not be used.
 Approved flexible fuel lines shall be used between the prime mover and the fuel piping.
 Day tanks on diesel systems shall be installed below the engine fuel return elevation.
 The return line to the day tank shall be below the fuel return elevation.
 Gravity fuel oil return lines between the day tank and the main supply tank shall be sized
to handle the potential fuel flow and shall be free of traps so that fuel can flow freely to
the main tank.
 Integral tanks of the following capacities shall be permitted inside or on roofs of
structures, or as approved by the authority having jurisdiction:
(a) Maximum of 2498 L (660 gal) diesel fuel
(b) Maximum of 95 L (25 gal) gasoline fuel
 The fuel supply for gas-fueled and liquid-fueled prime movers shall be installed in
accordance with applicable standards.
 Where the gas supply is connected to the building gas supply system, it shall be
connected on the supply side of the main gas shutoff valve and marked as supplying an
emergency generator.
 The building's main gas shutoff valve shall be marked or tagged to indicate the existence
of the separate EPS shutoff valve.

 The fuel supply for gas-fueled and liquid-fueled prime movers shall be designed to meet
the demands of the prime mover for all of the following factors:

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(a) Sizing of fuel lines

(b) Valves, including manual shutoff
(c) Battery-powered fuel solenoids
(d) Gas regulators
(e) Regulator vent piping
(f) Flexible fuel line section
(g) Fuel line filters
(h) Fuel vaporizers (LP-Gas)
(l) Ambient temperature effect of fuel tank vaporization rates of LP-Gas where
applicable in NFPA 110 Section 7.9.10 The fuel storage and supply lines for an EPSS
shall be in accordance with this standard or with the specific authority having
jurisdiction, or both.
 All manual fuel system valves shall be of the indicating type.
 Listed generator subbase secondary containment fuel tanks of 2498 L (660 gal) capacity
and below shall be permitted to be installed outdoors or indoors without diking or
remote impounding.
 A minimum clearance of 0.9 m (36 in.) shall be maintained on all sides.
 Automatically actuated valves shall not be permitted in the fuel oil supply or fuel oil
return lines.
Filling Mechanism
Bulk cryogenic fluid systems shall include a fill mechanism consisting of the following
components:
(1) A nonremovable product specific fill connection in compliance with CGA V-6,
Standard Cryogenic Liquid Trans‐ fer Connection
(2) A means to cap and secure the fill connection inlet
(3) A check valve to prevent product backflow from the fill inlet
(4) A fill hose purge valve
(5) Supports that hold the fill piping off the ground
(6) A secure connection between the bulk tank and the fill piping
(7) Supports as necessary to hold the fill line in position during all operations associated
with the filling procedure

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9 ATS Specification and Testing

Automatic Transfer Switches (Specifications )
Each engine shall be 2- or 1k -stroke Diesel running at 1500 R.P.M. for 50 Hz and 1800 R.P.M. for
60 Hz generators: liquid- or air-cooled.
STANDARDS. The switch shall comply wih the latest applicable standards of the National
Electrical Manufacturers Association (NEMA), the American National Standards Institute (ANSI),
and shall meet USA National Electrical Code requirements as a minimum. The complete switch
assembly shall be listed under UL-1008 for use on emergency systems.
ENVIRONMENT. The switch and associated devices shall be designed to operate under the
following: a. Temperature 600 Celsius b. RH to 95% c. High dust/sand concentration d. Salt-
laden atmosphere

Automatic Transfer Switches (Testing)

1. Transfer switches are required to be operated monthly [see NFPA 110(10), Sec. 8.4.6; see
also: MSFC (15), Sec. 604.3.3].
2. This monthly test must consist of electrically operating the transfer switch from the
normal/standard position to the alternate position and then a return to the normal/standard
position [see MSFC(15), Sec. 604.4.1; NFPA 110(10), Sec. 8.4.6.1].
a. In many cases, a “Transfer Test” switch or button is provided and can be used to perform this
test. Where this feature does not exist, it may be necessary to manually disconnect normal
power in some fashion to the transfer switch (see “some words of caution on testing” below).
3. Transfer switches must also be inspected on a routine basis (monthly is recommended) to
check connections, check for evidence of overheating or excessive contact erosion (terminals
and connectors are normal color), listen for unusual sounds, to ensure that the switches are
maintained free from accumulated dust and dirt, and ensure that all covers are tight and doors
securely closed [see MSFC (15), Sec. 604.3.3; NFPA 110(10), Sec. 8.3.5].
4. EPSS circuit breakers for Level 1 system usage, including main and feed breakers between the
EPS and the transfer switch load terminals, are required to be exercised annually with the EPS in
the “off” position [see NFPA 110(10), Sec. 8.4.7].
a. Circuit breakers rated in excess of 600 volts for Level 1 system usage are required to be
exercised every 6 months and tested under simulated overload conditions every 2 years [see
NFPA 110(10), Sec. 8.4.7.1].
5.Because they are such a key component in the successful operation of SANS emergency
generator, it is recommended that you consider having infrared testing of SANS transfer
switch(es) conducted annually to check for loose connections.

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NFPA 110 has the following rules stated in terms of Automatic Transfer Switch testing

1. Operational Inspection and Testing.

2. EPSSs, including all components, should be exercised under load at least monthly and
inspected weekly.
3. If the generator set is used for peak load shaving or for standby power, such use should
be recorded and should be allowed to be replaced for scheduled functioning and testing
of the generator set.
4. Transfer switches shall be operated monthly.
5. The periodic test of a transfer switch should constitute of electrically functioning the
transfer switch till the alternate position from the standard position and returning.

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