Koc e 007 - 1
Koc e 007 - 1
STAYJIARDS PUBLICATION
KOC STANDARD
FOR
GENERATOR SETS
( STANDARDS TEAM 1
DOC. NO. KOC-E-007 I( Page Iof 57 1 REV. 1
STANDARDS PUBLICATION
KOC STANDARD
FOR
GENERATOR SETS
STANDARDS TEAM
DOC. NO. KOC-E-007 Page 2 of 57 REV. 1
KOC STANDARD
FOR
GENERATOR SETS
ISSUING AUTHORITY:
STANDARDS TEAM
TABLE OF CONTENTS
PAGE NO.
FOREWORD
SCOPE
APPLICATION
TERMINOLOGY
3.1 Definitions
3.2 Abbreviations
4.1 Conflicts
4.2 List of Standards and Codes
SERVICE CONDITIONS
OPERATING MODES
10.1 General
10.2 Generator Set Assembly
GENERATOR
DIESEL ENGINE
CONTROL PANELS
General
Generator Set Control Panel
Transfer/lnterlocklSynchronising Control Panel
Interface with DCS
Control and Protection Equipment
Instruments
Cable Termination
Wiring and Terminals
Anti-Condensation Heaters
PANEL EARTHING
NOISE LIMITS
PAINTING
DOC. NO. KOC-E-007 Page 5 of 57
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20.0 INSPECTION AND TESTING
General
Generator Tests
Diesel Engine Tests
Generator Set Performance Tests
Noise Test
Battery Charger Tests
Generator Control Panel Tests
Load Bank Tests
22.1 General
22.2 Deliverables
24.0 Appendices
ACKNOWLEDGEMENT
FOREWORD
This Standard has been approved by the Standard Team is consultation with the
Standards Technical Committee (STC), for use throughout the corporate Engineering and
operational functions of Kuwait Oil Company (K.S.C.).
c) t o set out minimum features required, Data Sheets have been included
in Appendices 1&2, which will act as a checklist to ensure that all
requirements for design, construction and testing of Generator Sets are
covere.3.
Feed back as well as any comments or suggestions derived from the application of
this Standard at any stage of design, installation or operation are invited and should
be directed to:
Mr. Khalid Al-Ahmed Gen. Proj. Team : Task Force Leader Tel No. 61 756
Mr. A.Unnikrishnan Standards Team : Author 1 Member Tel No. 67 633
Mr. Hammad Al-Ajmi Maint. Team (SK) : Member Tel No. 22010
Mr. Gobinda Mishra Design Team : Member Tel No. 61097
Mr. Afeef Kamel Projects Design Team : Member Tel No. 66245
Mr. C.Lazo 0pns.Tech. Svcs. (WK): Member Tel No. 20350
SCOPE
The Gsrteral requirements for diesel engine drivers are included in this
Standard. For the requirements o f the gas engine driver and the gas turbine
driver, the appropriate project specifications shall be referred in conjunction
w i t h this Standard.
APPLICATION
Any exceptions or deviations from this Standard, along with their merits and
justifications, shall be brought to the attention of KOC's Controlling Team for
their review, consideration and amendment by Standards Team (if required).
Compliance with this KOC Standard does not of itself confer immunity from
legal or statutory obligations.
TERMINOLOGY
Definitions:
Packager
Purchaser
Abbreviations:
CT Current Transformer
Db Decibel
HS Hydrogen Sulphide
2
IP Ingress Protection
PT Potential Transformer
PVC Polyvinylchloride
In the event of conflict between this Standard and the latest edition of
standards / codes referred herein, or other purchase or contractual
requirements, the most stringent requirement shall apply.
ASME 31 6.5 Pipe Flanges and Flanged Fittings NPS% Through NPS 2 4
General Instruments
Pressure Vessels
Special-Purpose Gearboxes
5.1 The ervironmental conditions in Kuwait are severe and shall be considered
carefully before selection of Generator Sets. Any equipment for outdoor
installation shall be suitable for continuous operation at a desert location
under high ambient temperature and humidity. The atmosphere shall be
considered to be dusty and corrosive and may contain traces of hydrogen
sulphiae.
5.2 Refer t o "KOC Standard for Basic Design Data" (KOC-G-007), which
provides the detailed design information regarding the environmental, site
and utility supply conditions prevailing throughout the KOC Facilities.
HEALTH, SAFETY AND ENVIRONMENT
All relevant safety requirements of KOCfs Fire & Safety regulation, Health,
Safety & Environmental Management System (HSEMS) and H&E Guidelines
shall be adhered t o while specifying the Generator Set and associated
equipment.
SERVICE CONDITIONS
The Generator Set and associated equipment shall be new and in all
respects suitable for continuous operation at a desert location under high
ambient temperatures and humidity.
The ra1:ings of all the electrical equipment shall be their continuous ratings,
after suitably derated for the specified service conditions.
The Generator Set shall be suitably rated for supplying under site conditions
the voltage, kVA and other parameters as specified in the Data Sheet.
The Generator Set shall be capable of accepting the connected loads and
shall maintain the voltage and frequency tolerances specified in this
Standard.
The Generator Set shall be suitable for continuous reliable operation at the
m i n i m ~ mfacility power requirement. Where the driver minimum continuous
output cannot meet this requirement, the use of an automatically connected,
artificial load can be adopted subject to KOC approval.
OPERATING MODES
Normal Status
When at rest, those parameters which affect its availability to start and
operate shall be continuously monitored and if a malfunction occurs,
suitably alarmed at the Generator control panel situated adjacent t o the
Generator Set, remote Control panel and DCS. Volt free contacts shall be
wired up t o the terminals for remote alarms.
Automatic Mode
In the "Manual Mode", the Generator Set shall be capable of being started
manually by means of a local initiation. When running in this mode, a normal
power failure shall result in an automatic change-over sequence and
connection of the Generator supply to the switchboard.
9.4.1 In the "Test Mode" starting of the Generator Set shall be by manual means.
This mode shall be used for engine exercising and test running operations.
9.4.2 A test facility shall be provided to simulate the mains failure condition to
ensure the integrity of control circuit and Generator Set starting sequence.
The loading o f the Generator (connections to the switchboard) shall be
inhibited during this testing.
9.5.1 Manual Shutdown of the Generator Set shall be either from the local
Generator control panel or from remote shutdown switch.
9.5.2 The Generator Set shall automatically shut down on malfunction of its
essential auxiliary systems.
9.5.3 The Generator Set shall be provided with an Emergency shutdown push
button and a facility for mechanical shutdown o f the engine.
9.6.1 The Generator Sets shall be suitable for both standalone operation and
parallel operation with other Generators and shall have adjustable droop
control.^ for both power and reactive load sharing.
9.6.2 Where shown on the single-line diagram, the Generators shall be arranged
for synchronising together for parallel operation. After automatic or manual
starting, the Generator shall automatically synchronise with running
Generators and share the load.
9.6.3 The Generator control panel shall be provided with facility for automatic and
manual control of the Generator voltage and frequency.
Note: Parallel operation with the "State Grid Supply" is n o t permitted. For more
details on operating philosophy of emergencylstandby Generator Sets, refer
to Project Specification titled "Electrical Design, Installation and Testing".
I
DOC. NO. KOC-E-007 Page 15 of 57 REV. 1
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Genera!
dl Base frame.
fl Control panels, alarm & trip annunciators, battery and charger units.
The Packager shall assume total responsibility for the complete Generator
Set package, including the driver and all accessories.
The Generator Set shall be o f the direct coupled type without gearbox,
unless otherwise recommended by the Manufacturer for better operational
reasons and approved by KOC.
The assembly shall be completely pre-wired and piped, requiring only the
connection of utility services at site.
Base Frame
GENERATOR
Performance Requirements
The Generator rated voltage and frequency shall be in accordance with that
specified on the single-line diagram / Data Sheet. The voltage waveform
characteristics shall be sinusoidal and in accordance with the requirements
of IEC 50034.
The Generator shall be capable of supplyjng its rated output at rated power
factor for voltage and frequency variation in the voltage range t 6% and
+
frequency range 5 % occurring simultaneously.
The voltage variation limits for Generator full load acceptance or rejection
shall comply w i t h the following:
The maximum level of the total harmonic amplitude shall not exceed 5 % of
the fundamental, while the maximum of any given harmonic shall not
exceed 3 % of the fundamental, unless otherwise specified.
Enclosure
When ball or roller bearings are used at both the drive and non-drive ends,
suitable provision shall be made to permit differential expansion between the
shaft and frame and thrust loads from the driver.
The L,,, rating life for antifriction bearings shall be in excess of 50,000 hours
and shall be calculated in accordance with I S 0 281. The calculation shall
take into account of the worst aggregate of dimensional tolerances as
obtained during manufacturing.
The bearing housing shall be designed such that relubrication can be carried
out without stopping the Generator. Grease points shall be conical nipple
type incorporating a check ball and fitted with a protection cap.
A grease relief valve shall be fitted, which makes it possible to displace the
m a x i m ~ mamount of used grease by new grease.
The bearing housing design shall also prevent grease entering the Generator.
a) Each self lubricated bearing housing shall have a constant level oiler
with Pyrex glass bottle. The recommended oil level shall be marked
3n the outside of bearing housings by a cast mark or metal tag.
Windinqs
The rotor windings shall be provided w i t h the same protection as the stator
winding and be mechanically designed to withstand the rotational forces.
Excitation
The rectifier bridge shall be 3-phase, full-wave bridge, using diodes. Each
bridge arm shall comprise t w o diodes in series. Each diode shall be rated
for at least t w i c e the maximum working voltage and current. All rotating
components shall be proven at values of centrifugal stress under normal
operati 7g levels and fault conditions.
The excitation system shall be sufficient t o cover any peak load condition
that the Generator is able to supply. The exciter rating shall be 1 3 0 % of
the excitation current required at the rated output of the Generator.
Diode failure shall be alarmed. On failure of one diode, it shall be possible to
maintain the operation, without adverse effect until the diode is replaced.
The automatic voltage regulators (AVRs) shall be of the dual automatic solid
state, continuously acting type, providing facilities for local and remote
voltage adjustment, unless otherwise specified in the Data Sheet. The
voltage setting range shall be k 5 % of the rated value.
Under sudden load application conditions, the excitation systems shall have
current compound field forcing t o provide voltage recovery. Cross-current
comperisation facilities for parallel operation shall be included.
Terminal Boxes
The terminal boxes shall be of the type as specified in the Data Sheet.
The entls of all the six (6) terminals of the Star Connected Generator stator
winding shall be brought out to the terminal box, unless otherwise specified
in the Data Sheet. The ends of the neutral connections shall be brought out
to a separate terminal box unless otherwise specified in the Data Sheet.
The ter.minal boxes shall have provisions for mounting the required current
transformers in the line and neutral terminals, in accordance with the single-
line diagram.
Where gaskets are provided, they shall be neoprene, preferably fixed to the
removable part of the terminal box.
Terminal boxes shall be provided with removable undrilled gland plates with
a minimum thickness of 3 mm. Where single-core cables are used, gland
plate shall be of non-magnetic material.
The terminal box design shall enable incoming cable tails t o be taken from
the point of entry t o the connection terminals in such a way that rubbing
against other connections or parts is prevented.
Generators rated over 1500 kVA shall be provided with local bearing
temperature indicators and t w o thermocouples per bearing to monitor
bearing temperature, unless otherwise specified in the Data Sheet.
AntLCondensation Heaters
The arti-condensation heaters shall not exceed or cause any part of the
Generator to exceed the Generator permitted temperature rise. They shall
be suitable for continuous operation and contain no internal switching
devices, i.e., thermostats.
Generator Earthing
The Generator frame and base frame shall be provided with M I 2 external
studs.
Dynamics
All rotor systems within the engine and Generator shall be designed as rigid
shaft assemblies.
Rating Plate
Ratins plates shall be made of stainless steel and be screw fixed to a non-
remobable part of the Generator and exciter frames and shall be stamped
with data in accordance with IEC 60034-1 ,which shall include the following:
DIESEL ENGINE
Performance Requirements
Engine performance shall be in accordance with SAE J1349, derated for the
service conditions specified and to provide a continuous power rating at the
site with an overload of 1 0 % for a period of 1 hour, within 1 2 hours of
contiruous running in accordance with IS0 3046.
Rating of the diesel engine shall not be less than the sum of the following:
Construction Requirements
The engine shall run for a minimum of 2 0 0 0 hours or for 1 year of minimal
use, before requiring any preventative maintenance.
The engine shall be fitted with over speed I abnormal vibration alarm and
shutdown device.
DOC. NO. KOC-E-007
I
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The engine shall be fitted w i t h the Manufacturer's standard gauges and
control panel. The instruments shall include a tachometer.
Coolitiq System
The cooling system shall be o f the closed circuit, circulating water type,
which in turn shall be air cooled by an integral skid-mounted radiator w i t h
an engine-driven fan, unless otherwise specified in the Data Sheet. The
cooling system shall be common for both engine and lubricating oil.
The radiator shall b e sized t o dissipate the engine heat rejection t o the water
at If 0% o f the rated load.
a) Level gauge.
c) Pressure cap.
7
d} Vent,
e) Drain.
f1 Earthing bosses.
h) Access ladder.
The cooling system shall be suitable for the addition of corrosion and scale
inhibitors. Sampling points shall be provided.
Lubrication Svstem
The duplex oil filters shall be of the replaceable element type, rated for the
full flow of lubricating oil, and the elements shall be readily changeable
while the engine is running and without dismantling adjacent engine
components. The absolute particle size after filtration shall not exceed 1 0
microns. Each filter shall be equipped with a differential pressure indicator/
alarm downstream of the filter and a filter change indicator.
The Iubrication oil coolers shall be cooled by the same cooling medium as
that used for the cooling of engine cylinders. The lubrication oil shall be
maintained at a higher pressure than the cooling medium in order to prevent
leakac_leof cooling medium into the oil.
A manually operated lubrication oil pump shall be supplied for priming the
systern and emptying the sump. When the engine requires a pressurised
supply of oil prior to starting, a separately driven electric battery powered
pre-lube oil pump shall be included.
12.4.7 In order t o avoid the danger of oil oxidation, the heater surface temperature
shall n o t exceed 150°C or the surface heat flux exceeds 2.3 W/cm2. The
circuits feeding the heaters shall contain miniature circuit breakers
incorporating overload, short-circuit and earth leakage protection.
12.5.1 General
The engine shal I be supplied with a complete fuel oil system which shall
include, but not be limited t o the following:
Fuel pump suction and discharge filters of the duplex type with
replaceable cartridge elements and full-ftow transfer valve.
(The filter elements shall be capable of easy removal when the engine
is running without breaking any fuel line connections or allowing the
ingress of air t o the fuel system).
Fuel governor.
A n actuated fuel isolation valve in the fuel line t o the engine arranged
for remote control.
a) Fuel day tank (Diesel Storage Tank) shall have a minimum capacity t o
supply fuel for 24-hours of continuous operation of the Diesel
Generator Set at rated power.
DOC. NO. KOC-E-007 1 Page 26 of 57 REV. 1
The tank shall be complete with suction and return connections to the
engine fuel system, fill connection, fuel filter, liquid level gauge, vent
pipe with flame arrestor, cleanout, overflow, inlet/outlet and valved
drain connections.
The design pressure of the tank in conjunction with the vent size shall
be adequate to handle relieving rates for fire engulfment in
accordance with API 2000.
The day tank shall be located outside the Generator building at a safe
distance in accordance with the requirements of "KOC Standard for
Hazardous Area Classification" (KOC-G-002).
Level switches and level transmitters (certified for use in Zone 1) shall
be provided on the day tank for high and low fuel level to control the
transfer pump from bulk storage tank as applicable. There shall be
provision to alarm the low-level, when the fuel level goes below that
required for three (3) hours operation of the set and to shutdown the
set when the fuel level is less than that required for one (1) hour
operation.
k) To facilitate the flow of diesel oil in the tank, tank shall be slopped
towards the outlet nozzle. The tank shall be vented to a safe location.
The vent pipe shall include a flame arrestor and shall be provided with
an insect screen at the end. The diesel outlet nozzle shall be provided
with stand-up vortex breaker.
1) The package shall include a connection for tank filling from the truck.
Local level indicator, flashing red light I alarm shall be located near
the filling connection.
m) Piping shall be installed as per the piping specifications and P&lD. The
diesel oil supply & return lines and connection for tank filing shall be
provided with flanges located on the edge of the skid.
Speed Governinq
A conlbustion air intake filter shall be provided for each engine, designed to
ensure that the engine condition does not deteriorate due to ingress of sand,
dust or other airborne contaminants under the service conditions specified.
The intake filter unit shall be equipped with a differential pressure indicator
and alarm.
The housing and all structural components of the air filter system shall be
made of type 31 6L stainless steel.
Exhaust Svstem
A spark arrestor shall be fitted to the discharge end of the exhaust system.
All steel work and associated materials for supporting the exhaust 1 silencer
system shall be provided.
Thrust and journal bearings on the diesel engine shall be fitted with
thermocouples to monitor bearing temperature.
Power Transmission
12.10.2 The flywheel shall be provided t o prevent resonance of the engine and
Generator and t o provide stable synchronous and momentary parallel
operation with other supply sources.
12, 10.3 The driver, flywheel, coupling and Generator shall be completely coordinated
to prevent torsional vibrations caused by torque impulses of the engine
shaft, coupling etc.
12.10.5 I t shal be possible to dismantle and remove the coupling without the
necessity t o move either Generator or driver.
12.1 0.6 It shall be possible to run the driver disconnected and an idling adaptor shall
be provided for this purpose, if necessary.
Coupli~iqGuards
12.1 1 .I The coupling guard shall be of removable type and manufactured from a
non-sparking material.
Guards shall extend t o within 1 2 m m o f the coupling housing and shall have
sufficient strength t o contain t h e coupling i n the event o f failure and
withstand damage w h e n a force equivalent t o a 1 0 0 K g mass is applied t o
t h e guard.
All valves, controls and other equipment shall be completely piped and
wired.
All flexible hoses shall be fire resistant and shall be externally braided w i t h
stainless steel t y p e 316L, except for short lengths of hose ( n o t greater than
1 0 diarneters or 2 5 0 m m in length, whichever is greater) containing fluids a t
pressures n o t greater than 3 barg. Unbraided hoses shall be arranged t o
minimize t h e likelihood of external mechanical damage.
Engine Maintenance
The engine and its auxiliary equipment shall be designed and configured t o
facilitate inspection 1 maintenance and overhaul activities. Equipment and
components o f greater than 15 k g weight shall be provided w i t h lifting lugs
for installation and maintenance.
The rms value of the ripple o n the charger DC output voltage, with the
battery connected, shall not exceed 5 % or t h e value recommended by the
Manufacturer, whichever is lower. The charging voltage level shall be
adjustable within + 1 0 % of nominal voltage.
Where the Generators are installed inside an enclosed building, the battery
chargers shall be installed in the same building. In case the Generator is
installed in open environment, then the battery chargers shall be installed
inside the substation or other location approved b y KOC.
The enclosure(s) shall be constructed from folded and welded mild steel
sheet not less than 2 m m thick. Cable access shall be via suitably sized, 3-
mm-thick, removable undrilled gland plates.
The enclosure(s) height shall not be greater than 2.2 m. The enclosure shall
be designed t o permit front access only and be equipped w i t h a pair of
removable eye bolts for lifting purposes.
Front access door(s) shall be sufficiently rigid and close fitting t o exclude
dust. Gaskets o f neoprene material shall be used t o provide a seal.
Individual hinged access doors shall be fastened b y means of a T-type key
lockable handle.
The battery 1 charger systems shall be so designed t o cater for the starting
requirements of the engine and continuous load requirements of control
system.
The ampere-hour rating of the batteries shall be suitable for the starting duty
specified in sub-clause 12.14.1 of this Standard and t o cater for the
contin3ous load requirements of control system t o support the standing load
for eight ( 8 ) hours after mains failure and provide control power t o start the
Generator Set after this time, under the minimum ambient temperature
condit-ons.
Where electric starting is not envisaged, the control system battery capacity
shall be adequate to support the standing load for eight ( 8 ) hours after
mains failure and to provide control power to start the Generator Set after
this t i n e .
The battery sizing calculations and load schedule shall be submitted t o KOC
for review and approval.
CONTROL PANELS
General
The Generator control panel shall be provided with all Control / Metering /
Indication / Alarm / Shutdown requirements for the proper and safe
operati3n of the Generator Set. The various items shall include, but not
limited to the following:
RPM meter.
Stopped indication.
Fuel oil level low / high (day tank): alarm and indication.
Mains supply under voltage monitoring and circuit breaker controls together
with automatic check synchronising equipment shall be located in the panel
to provide automatic Generator Set starting, transfer of loads and exercising
of the load bank in accordance with the operational philosophy outlined in
the Project Specification.
In cases where more than one Generator is installed in the same location for
parallel operation, then these controls could be accommodated in a single
panel.
14.4.1 The DCS interface signals shall be provided in the form of volt-free
contac1:s for t h e following as a minimum:
Ready t o start.
N o t available t o start.
Failed t o start.
Running.
Load accepted.
Common fault.
Common trip.
14.4.2 The DCS interface shall also include the real time analogue signals of the
following as a minimum:
a) Generator voltage.
b) Frequency.
c) Current.
d) Power factor.
e) Kilowatt.
14.5.1 All control circuits in the control panels shall be adequately protected b y
means of switches and fuses, double pole for DC circuits.
14.5.2 Circuits to be protected include the mains power supply, power supply
units, small wiring and outgoing circuits.
All circuits shall be protected with fuses including the following:
Rectifier output and battery circuit fuses shall be in accordance with IEC
60269-2.
Relays shall be provided to give local and remote alarm for the following
fault conditions:
a) Failure of AC supply,
b) Earth-fault o n DC system.
The relays shall be provided with automatic reset indicators and have t w o
volt-free changeover contacts wired out t o terminals for remote alarms.
Instruments
Indica-tions shall be using LEDs. Digital readouts with status indication and
Mimic Diagram t o show the various status shall also be provided.
Cable Termination
All cable entries shall be from bottom and all connections shall be made
from the front of the panel.
W i r i n ~and Terminals
The supporting arrangements for wiring shall be such that they are not liable
t o cause permanent physical damage or deformation t o the conductor or
insulation. Wiring shall not be bent to a radius less than the permissible
value given by Manufacturers. Trunking fill shall not exceed 7 5 % of its
capacity.
No more than one wire shall be inserted into any one terminal. Looping
between terminals, when required, shall be carried out using the purpose
made top of block cross connection or comb-type busbar.
DOC. NO. KOC-€407 Page 40 of 57 REV. I
A t least 300-mm clearance shall be allowed between the gland plate and
any internal equipment t o permit easy cable installation and connection.
Anti-Condensation Heaters
A dummy load resistance bank shall be provided for all emergency 1 standby
diesel Generators, unless otherwise specified in the Data Sheet. The load
bank shall be sufficiently rated to prevent excessive engine carbon deposits
when the unit is exercised for one (1) hour per week, w i t h a minimum rating
of 4 0 % o f the Generator rating.
The load bank shall be forced air cooled, free-standing type and have a
degree of protection in accordance with clause 7 . 4 of this Standard.
The forced air cooling system shall continue operation even after the
shutdown of the Dummy Load for a set time (adjustable).
DOC. NO. KOC-E-007
The load bank shall be provided with power and control switchboard. The
switchboard shall comply with the general requirements of "KOC Standard
for Low-Voltage Switchgear" (KOC-E-009)/ KOC Standard for High Voltage
Switchgear and Controlgear (KOC-E-002) as applicable.
The switchboard shall have a main isolating switch, load bank contactor,
overload protection, switching controls, fan starters and other controls as
required for the safe operation o f the equipment. The protection shall
include interlocking o f the Generator circuit breaker w i t h the load bank
isolatirg switch, interlocking o f the resistance bank contactor w i t h the fans
and high temperature lockout and alarms.
PANEL EARTHING
A n earth bar shall be provided along the full length o f each panel enclosure.
All metallic non-current carrying parts shall be bonded together and
connected t o the earth bar. External M I 0 earthing terminals shall be
provided t o facilitate connection o f the enclosures t o the earthing system.
Provision shall be made for connecting the earth continuity conductors and
cable armouring of all outgoing circuits.
The Generator shall be suitably designed I constructed such that the noise
level shall n o t exceed 85 dB (A) at one (1) m from the generator, unless
otherwise specified in the Data Sheet.
The ncise levels for t h e Generator Set package unit shall be as specified in
the Data Sheet. Consideration shall be given for enclosing the entire
generator set including the drive train in a sound reducing enclosure or
provide suitable building to reduce the noise levels within acceptable limits.
Each unit shall have a nameplate clearly and indelibly marked w i t h t h e data
specified in the appropriate IEC standard. Nameplates shall be fixed w i t h
non-corrodible screws or rivets.
Each nit shall have a label on its front at high level showing the unit
designation number.
All components incorporated within the unit shall be indelibly marked with
circuit component reference. Handwritten stickers or dyno-tape labels are
unacceptable.
20.1 General
20.1 .I All items included in the supply shall be designed, manufactured, inspected
and tested under the control of a documented Quality Assurance system, of
which the general requirements are given in clause 21.0 of this Standard.
20.1.3 The manufacturer shall submit the inspection and testing plan to KOC for
approval.
The tests shall be carried out on the Generator and exciter, in accordance
with the requirements of IEC 60034, which shall include the following:
Measurement of reactance.
Calculation of efficiency.
Waveform test.
20.3.1 The hydrostatic test shall be carried out on the diesel engine at the
Manufacturer's Works. All pressure containing parts, including auxiliaries,
shall be tested hydrostatically with water to 1.5 times the maximum
operating pressure. The minimum hydrostatic test pressure for water jackets
shall be 7.5 barg.
Note: Tests shall be maintained for a sufficient period of time to enable the
complete examination of parts under pressure. The hydrostatic test
shall be considered satisfactory when no leakages are observed for a
minimum of t w o (2) hours.
The test gasketing shall be the same as specified for the service
condition. The hydrostatic test medium shall be fresh water with a
biodegradable wetting agent. The test water temperature shall be
within +2" C of the ambient temperature.
20.3.2 The performance tests carried out on the diesel engine at the
Manufacturer's Works shall include the following:
f) All testing shall be carried out using the "job" radiators, filters,
governor and overspeed device.
The performance test shall include the following as a minimum with the
engine at normal temperature:
a) One (1) hour operation at 1 1 0 % full load power, during the eight (8)
Pour run.
b) Load rejection and acceptance test using the following load steps
(30th directions):
c) Six starts including one from cold with measurement of time to when
the Generator could accept full load.
e) Full functional test on all logic, alarm and trip circuits t o prove
compliance with this specification and operating logic design.
Fuel consumption.
Noise Test
Battery C h a r ~ e Tests
r
The following tests shall be carried out on each battery charger unit at the
Manufacturer's Works:
c) Full load test for 48 hour duration t o establish thermal stability of the
unit.
The following tests shall be carried out o n the load bank and its auxiliaries
at t h e Manufacturer's Works:
QUALITY ASSURANCE
General
22.2 Deliverables
22.2.2 The following documents / drawings shall be submitted for KOC's review /
approval, record and use as a minimum:
Paint Specification.
Packing details.
a) Drawing title.
23.1 A complete set of special tools and devices necessary for installation,
operation & maintenance o f the Generator Set shall b e provided, housed
inside a lockable cabinet.
23.2 For further details I requirements refer t o KOC Standard for "Spare Parts
and Maintenance Data" (KOC-G-009).
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GENERAL-INFORAMTION I DESIGN D A T A
GENERATOR T'! P F
1 PRIME MOVER T*'PE
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1
-3 INSTALLATION SITF
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s DESIGN AME~ENTCONDITIONS
5 ALTITUDE
1 B
7
OTHER ENVIRONMENTAL CONDITIONS
AREA CLASSlFlCllTlON
8 K V A RATING KVA
9 VOLTAGE
to FHAG
11F R E ~ U E - ' N ~
12 S Y ~ C H R O N D U SSPEED
'
13 R A T E D FDWER FACTOR
14 STATORCONNECTION
- 15. NO OF STATOR '~.VINDINGTERMINALS
- 16
. INSULATIONCLASS
17 - TEMPERATURE R SE
i s -GCWERATOR EWLOSURE TYPE IP RATING
1 19 OTHERECFCTR'CAL EDUIPMENT IP RATING
20 DUTY TYPF
21 MOUNTING
2 2 -- M l N l N U M SHORT CIRCUIT CURRENT
--
--
23 SUSTAINED
24
--
SUDDEN APPLIED
OVERLOAD
LOAD AND VOLTAGE DROP PERMlTED
--
25 PJEQTRAL-- EARTPING TYPE
28 EXCITATION
27 WINDING TEMPERATURE DETECTION o REfiUIRED n NOT REDWIRED
28 SPACE HEATFRPATING
' I
2 9 SDACE HEATER CABLE SlZElTYPE
30 1 M A I N CABLE TYPE -
31 I RTD
- --- CAB1
--F- TYPE SIZE
32 POWER TERMINAL ROX TYPE PHASE SEGREGATED n PHASE INSULATED
23 ND OF TERMINAL-~UXES REOUlRED
34 SEPARATE NEUTRAL TERMIPJALBOX REL~UIRED n NOT REOUIREO
35 DIFFERENTIAL PROTECTION CT REnUlAED n NOT REQUIRED
36 STAND B Y EARTH FAULT CT REWIRED @ NOT REaUlRED
37 BEARINGTYPE -
38
39
LOCAL BEARING TEMPERATURE INDICATOR
BEARI~JG TEMPEFATUAC DETECTOR
REQUIRED
REQUIRED-_
c NOT REQUIRED
n NOT REOWIRED
-
I
42
ty BEARING VIBRATION OETECTlON
DUMMY LOA0RFSISTANCEBANK
SVNCHRONISING EOPT.
REQUIRED
REaUlRED
tl REQUIRED
fl NOT REQlJlRED
NOT REQUIRED
o NOT REQIJIRED
. 43 AUTOMATtC VOLTAGE REGULATOR CONFIGURATION o DUAL 0 SINGLE -
I
44 DUMMY LOAD VOLTAGE
45 1 BATTERY TYPE
- - I
46 NO. OF BATTERY CHARGERS & SUPPLY VOLTAGE NOS. 250 1 440 VOLTS
47 CONTROL FANEL 4DDITIDNAL REQUIRMENTS
48 RATING OF THE LARGEST MOTOR CONNECTED VOLTS kW
I 43 RATING OF THE L4RGEST EOUloMEMT CONNECTED VOLTS bW
58 GEN. CABLE SIZE 0 1C 0 3C MA?'
1, 51 1 CABLE GLAND TYPE
-5 2
I 1 DIFFERENTIAI- CT RATIO --
1 53 STAND BY EARTH FAULT C T RATIO -
M?&>
1 54
EARTH CABLE SlZElTYPE
DblAI 1M
/ 55 NOISE LEVEL @J
1 56 PAVJTCOLOUR -
57 REMARKS GENERATOR DATA SHEET-
f
Sheet 1 of 3 -
-
DOC. NO. KOC-E-007 1
I1
Page 51 of 57 REV. I
I MANUFACTURER
-
1 1 I
1, 2
3
WORK ORDER NO.
COMPLINACE WITH SPECIFICATION I DATA SHEET YES n NO {Submit dsrnils 01 deviations. i f any)
1:
.-
4 1 OUTLINE DIMENSIONAL DRAWING NO. I
5 DIMENSIONS Uxbwhl
6 - -
+
CONSTANT TVr6.
D-AXIS SUB-TRANSIENTSHORT ClRCUlT TlME
CDfUST_ANT T",
Q-AXIS SUB-TRANSIENT OPEN CIRCUIT TIME I
j ' I C13N$TANTTm, 1
I Q-AXIS SUB-TRANSIENT SHORT CIRCUIT TIME I
/ CONSTANT T', 1
1; u
v
SHORT CIRCUIT RATIO [XlRl
cv POTIER REACTANCE X, K
y INERTIA CONSTANT H
1
I
, 31
32
11 FIRST CRITICAL SPEED lRPMl
40 REMARKS
GENERAT~R DATA SHEET
Sheet 3 of 3
Ref. Data !
/
Date Rev. Chkd. Appvd.
No. Sheet No.
I
,
by
-
L
--
--
DOC. NO. KOC-E-007 R Page 53 of S f JI .
REV. I
1 1
GENERAL INFORMATlON
INL. 1.41.' ATION SlTE I
1
- - 1
I
1/
?
3
4 I
SEEUICE
DRIVEN EDUlPMENT
NOS.REl3UIRED
L
-
5 MANUFACTURER
1 6 MODEL
7 SERIAL TdO
8 DESIRED MIN RATINC
NOTE: o INDICATES {NFORMATION TO BE COMPLETED BY PURCHASER n BY MFR g BY MFR i~ MOT BY PURCHASER
4 0 DUTY. SITE AND UTILITY DATA gl] DESIGN
1
10 DUTY ( ASPIRATION.
11 0 CONTINUOUS 3 STAh'D 8Y I O NAlLJRALLY ASPIRATED O ?VRROCH&RGED
12 0 IWTERMTTAMT START5 .' DAY O SUPERCHARGE0
13 TYPE:
14 LOCATION
-- 0 WJLINE 0 'V'
15 OlND0OR OOUTDOOR NUMBER OF CYLINDERS
- .-
16 OIShPrCEMENT-L COMPRESSION R A I D
17 SITE DATA CYLINDER BORE.- MM CYLINDE!3 STROKE MM
18 ELEVATIOIJ TORSIONAL CRITICAL S K E D S : 15T-.- 2N0 - RPM
/ 19 ENROMETER - BARA MIN SPEED RPM OVER SPEED TRIP RPM
1 20 Ah'BIEPbT TEMPERATURE MAX @C M A X NO LOAD GOVERNOR S E E D P.PM -
2i MtN SPEED WITHOUT PRE-LUW PUMP RPM
22 O WINTERIZATIO k REQ'D Q TROPIC ALIZATION REO'D a F-ERFORMANCE
I 23 CI RATING BASED ON: 0 pr:~:.-
..!I 0 STAt.JD0Y .-.:
23 UNUSUAL CONDITIONS SITE 153 MAXIMUM SITE ,I
;
32
33
VGLTAGE
PHASE
FREQ
-
FUEL RATE IKGiHRI@
1 G3"; LOd 0
75% LOAD
i. _--j
.._
1
, 35 50% LOAD
1 36 COOLING SYSTEM: MAXIMUM TOROUE - N-M @ fiPh1
G SELF COFJTAINED O DN SKID 0 OFF SKID IF!TAKE AIM FLOW RATE ( I S 0 RATE01 - -
-
I'IM.',WR
--
I 37
0 ALLOW. SOUND PRESSUnE LEVEL FOR THE PACKAGE LlNlT
38 r? RADlATOR 0 HEAT EXCHANGER D M @ -.
M
38
$0 EXTERNAL COOLING WATER AVLILCIWLlTv - OR REGULATIONS:
APPL~~E~L~-EEM~5!O_NNCODES
EMISSIONS
-
41 TEMP. ( INLET ! M A X M I N I M A % RETURPJ-
- OC):
-
46 NO, REOUCTION METkOD
47 AIR S U P R Y AVAILABKITY_- CO fiUARAPJTEED: --
ANTICIPATED-
' 48 PREZSURE IBARGI: htlN,MAX - -R EC.lLlCTlO
PARTICULATE EMlSSlOMS: TYPE.
bl WETHO D:
I
49 QUALITY
DIESEL ENGINE
D A T A SHEFT S h ~ a t1 of 3
50 NOTES:
t Dala
Dars Rw. Chkd. Appvd.
NO. Sheet No. Ily
51 REMARKS
-
DOC. NO.-K O C - E - 0 3I REV. I
- -
--
SIZE.--
--- 6 hUhWER
SIZE COOLING WATER SYSTEM
. 7
NUMBER OF START5 CAPACITY ENGl'lr 0PI.I Y L
1 B PnF5SURERATIHG BANG - TEMP. RATlNG A
"C RA~IATOR L
- -
3
-
- BATTERY CHARGER
15
16
CAPACITY
W WEB SUPPLY
BATTERY
A M P / HR MODEL & CODE.
DRILER TYPE MFR II,W
117 -VOLTS . PHASE -HZ JACMET WATER HEATERIS) TYPE
P
1 tB O HYDRAULIC MOTOR
1 t9 MFR MOD EL FUEL SYSTEM -
2.5 RG
26 MA 1 tWlALh: LAhIIYb MFR MODEL SIZE ImICRON
27 FIOTATIRG ELEMENTS FUEL INJECTORS
2B ] SE4LS FUEL PRESSURE REGULATOA
24 1 DRtUER: TYPE MFR FUEL TYPFISl 'Arrach separate sheet l o r Oirssl Fuel S p e c i l ~ s m o n
INLET A N D EXHAUST
INLET AIR FlLfER MOUPlTlMG 0 ON SKID 0 REMOTE
MFFt MCO EL SIZE
TYPE: 0 DRY O O I L BATH 0 OTHER
hWTER1ALS ELEMENT
INLET PlFl BUCTlhlG ---
1 38 DUTY 2E51GH PRESSURE BARG EXHAUST 0 SILENCER 0 SPARK ARRESTOH
37 SHELL o D. THICKMESS SILENCER M~UNTIRG: o HORIZDNTAL o VERTICA;
38 TUB'EOD. TCIICKWESQ- NO- 5 l L E K E R SUPPCsFlTS O SADDLES - .
OJRURIO~
39 LENGTH SURFACE AREA M' MFFl NDEL - SIZE --
/ 40 -
E?i COUPLING
1 COUPLING TYPE 0 FLEXIBLE
.
11 47
-43
OTHER
-MODEL
1' 44 ' CHATAHEL ., SIZE RATING
' 45 BAFFLES
-- , --
dB G.W. INLET: TEW'EN
~TuRE-'C PRESSURE BANG
47 FLOWREQUIREO - L? PM I
-
9 o OTHER - n a a s SPACE REOUIRE_D ~ r m a !
-
-
-10 TACHOMETER: o MECHANICAL a FLECTMIC LXVIKH
-
-
11 .- TACH GEAR / PICK - UP
p
L
20 1 FUEL INLET I
IC
21 PLATES 1 I 1 I I
I
1
MONTH5
D A T A SHEET
MESEL Et4QINE
%+el 3
Ref Rw.
Date
Nu. Sheet No. by
- -
Page 56 of 57 REV. 1
--- -
ACKNOWLEDGEMENT
-
This KOC Standard has been approved by the Standards Technical Committee (STC)
consisting of the following:-
The draft of this Standard has been circulated t o the KOC User Teams for their
review and responses were received from the following:-
HSE G R O H
This KOC Standard for "Generator Sets" (KOC-E-007, Rev. I ) has been prepared by
the Task Force (TF-EE/O6) comprising of the following members:
Mr. Khalid Al-Ahmed Gen. Proj. Team : Task Force Leader Tel No. 61 756
Mr. A.Unnikrist-nan Standards Team : Author / Member Tel No. 61 633
Mr. Hammad A -Ajmi Maint. Team (SK) : Member Tel No. 2201 0
Mr. Gobinda Mishra Design Team : Member Tel No. 61097
Mr. Afeef Kamel Projects Design Team : Member Tel No. 66245
Mr. C.Lazo 0pns.Tech. Svcs. (WK): Member Tel No. 20350