FPSO - Diesel Engine Generator Set PDF

Shell Deepwater Development Systems, Inc. Doc. No.
: BONGA-SPEC-EE-007
Bonga Project September 1 , 1999
Diesel Engine Generator Set Page 1 of 57
Specification Rev. B
R:\BONGA\CLERICAL\SPECS\EE\BONGAEE007(PACKAGE_GENR).DOC
TABLE OF CONTENTS
SECTION TITLE PAGE
1 SCOPE 2
2 DESIGN AND ENGINEERING PRACTICE DEP 33.65.11.32 3
3 ADDENDUM TO DEP 33.65.11.32 46
APPENDIX A - Technical Data Sheet(s)
APPENDIX B Engine and Generator Performance Data
APPENDIX C Contract Drawings
Shell Deepwater Development Systems, Inc. Doc. No.: BONGA-SPEC-EE-007
1 SCOPE
This specification, together with attachments, covers the requirements for design, construction and testing
of Diesel Engine Generator. It is based on SIOP/SIEP Design and Engineering Practice DEP 33.65.11.32,
October 1994 Packaged Unit AC Generator Sets. Modifications/addendums to the DEP are listed in
Section 3.0. Contractor shall strictly adhere to this specification and shall submit all exceptions to this
document with tender.
2 DESIGN & ENGINEERING PRACTICE DEP 33.65.11.32-Gen.
TECHNICAL SPECIFICATION
PACKAGED UNIT AC GENERATOR SETS
DEP 33.65.11.32-Gen.
October 1994
DESIGN AND ENGINEERING PRACTICE
This document is confidential. Neither thewholenor any part of this document may bedisclosed to any third party without theprior writtenconsent of Shell InternationalePetroleumMaatschappij
B.V., TheHague, theNetherlands. Thecopyright of this document is vested inShell InternationalePetroleumMaatschappij B.V., TheHague, theNetherlands. All rights reserved. Neither the
wholenor any part of this document may bereproduced, stored inany retrieval systemor transmitted inany formor by any means (electronic, mechanical, reprographic, recording or otherwise)
without theprior writtenconsent of thecopyright owner.
PREFACE
DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of:
Shell International Oil Products B.V. (SIOP)
and
Shell International Exploration and Production B.V. (SIEP)
and
Shell International Chemicals B.V. (SIC)
The Hague, The Netherlands,
and other Service Companies.
They are based on the experience acquired during their involvement with the design, construction, operation and maintenance of processing units
and facilities, and they are supplemented with the experience of Group Operating companies. Where appropriate they are based on, or reference
is made to, national and international standards and codes of practice.
The objective is to set the recommended standard for good design and engineering practice applied by Group companies operating an oil
refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such facility, and thereby to achieve maximum
technical and economic benefit from standardization.
The information set forth in these publications is provided to users for their consideration and decision to implement. This is of particular
importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be
sufficiently flexible to allow individual operating companies to adapt the information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs they shall be solely responsible for the quality of work and the attainment of the required
design and engineering standards. In particular, for those requirements not specifically covered, the Principal will expect them to follow those
design and engineering practices which will achieve the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or
Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal or its technical advisor.
The right to use DEPs is granted by SIOP, SIEP or SIC, in most cases under Service Agreements primarily with companies of the Royal
Dutch/Shell Group and other companies receiving technical advice and services from SIOP, SIEP or SIC. Consequently, three categories of
users of DEPs can be distinguished:
1) Operating companies having a Service Agreement with SIOP, SIEP, SIC or other Service Company. The use of DEPs by these
Operating companies is subject in all respects to the terms and conditions of the relevant Service Agreement.
2) Other parties who are authorized to use DEPs subject to appropriate contractual arrangements.
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that
tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, SIOP, SIEP and SIC disclaim any liability of
whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with
the use, application or implementation of any DEP, combination of DEPs or any part thereof. The benefit of this disclaimer shall inure in all
respects to SIOP, SIEP, SIC and/or any company affiliated to these companies that may issue DEPs or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior
written consent of SIOP and SIEP, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the
purpose for which they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users
with the express prior written consent of SIOP and SIEP. The copyright of DEPs vests in SIOP and SIEP. Users shall arrange for DEPs to be held
in safe custody and SIOP or SIEP may at any time require information satisfactory to them in order to ascertain how users implement this
requirement.
All administrative queries should be directed to the DEP Administrator in SIOP.
NOTE: In addition to DEP publications there are Standard Specifications and Draft DEPs for Development (DDDs). DDDs generally introduce
new procedures or techniques that will probably need updating as further experience develops during their use. The above requirements
for distribution and use of DEPs are also applicable to Standard Specifications and DDDs. Standard Specifications and DDDs will
gradually be replaced by DEPs.
TABLE OF CONTENTS
1. INTRODUCTION.........................................................................................................7
1.1 SCOPE.........................................................................................................................7
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS.............7
1.3 PRE-MANUFACTURING MEETING...........................................................................7
1.4 DEFINITIONS..............................................................................................................8
1.5 ABBREVIATIONS.....................................................................................................11
1.6 CROSS-REFERENCES...............................................................................................11
1.7 UNITS........................................................................................................................11
2. BASIC REQUIREMENTS...........................................................................................12
2.1 GENERAL .................................................................................................................12
2.2 SAFETY.....................................................................................................................12
2.3 SERVICE CONDITIONS............................................................................................12
2.4 MATERIALS..............................................................................................................13
2.5 SCOPE OF SUPPLY ...................................................................................................13
3. PERFORMANCE REQUIREMENTS...........................................................................14
3.1 RATING.....................................................................................................................14
3.2 NOISE........................................................................................................................14
3.3 TORSIONAL VIBRATIONS.......................................................................................14
3.4 LATERAL VIBRATIONS...........................................................................................14
4. ENGINE REQUIREMENTS........................................................................................15
4.1 GENERAL .................................................................................................................15
4.2 AIR INTAKE SYSTEM ..............................................................................................15
4.3 EXHAUST SYSTEM..................................................................................................15
4.4 FUEL SYSTEM..........................................................................................................15
4.5 COOLING SYSTEM...................................................................................................15
4.6 SHAFT COUPLINGS..................................................................................................16
4.7 FREQUENCY STABILITY .........................................................................................16
5. GENERATOR REQUIREMENTS ...............................................................................17
5.1 GENERAL .................................................................................................................17
5.2 GENERATOR IMPEDANCES....................................................................................17
5.3 EXCITATION SYSTEM.............................................................................................17
5.4 OUTPUT VOLTAGE VARIATIONS...........................................................................18
5.5 EFFICIENCY .............................................................................................................18
5.6 RADIO FREQUENCY INTERFERENCE.....................................................................18
5.7 GENERATOR COOLING...........................................................................................18
5.8 GENERATOR HOUSING...........................................................................................19
5.9 WINDINGS................................................................................................................19
5.10 BUSHINGS AND TERMINALS..................................................................................19
5.11 BEARINGS................................................................................................................19
6. CONTROL AND PROTECTION EQUIPMENT...........................................................20
6.1 GENERAL .................................................................................................................20
6.2 ENGINE CONTROL PANEL ......................................................................................20
6.3 GENERATOR CONTROL PANEL..............................................................................20
6.4 CONTROL PANEL CONSTRUCTION........................................................................21
7. PACKAGE REQUIREMENTS....................................................................................25
7.1 BASEPLATE..............................................................................................................25
7.2 ROOM VENTILATION..............................................................................................26
7.3 ELECTRIC MOTORS.................................................................................................26
7.4 CABLES AND J UNCTION BOXES............................................................................26
7.5 NAMEPLATES..........................................................................................................26
7.6 PIPING AND INTERFACE CONNECTIONS...............................................................28
7.7 PAINTING.................................................................................................................28
7.8 ACOUSTIC ENCLOSURE..........................................................................................28
8. SPECIAL REQUIREMENTS FOR DIFFERENT MODES OF OPERATION..................30
8.1 GENERAL .................................................................................................................30
8.2 EMERGENCY GENERATOR SETS............................................................................30
8.3 GENERATOR SETS FOR CONTINUOUS OPERATION.............................................30
8.4 GENERATOR SETS SUPPLYING LARGE NON-LINEAR LOADS.............................31
8.5 GENERATOR SETS FOR PARALLEL OPERATION..................................................31
8.6 GENERATOR SETS FOR HAZARDOUS AREAS.......................................................31
9. INSPECTION AND TESTING....................................................................................33
9.1 GENERAL .................................................................................................................33
9.2 WORKS TEST OF THE COMPLETE GENERATOR SET............................................33
9.3 ON-SITE ACCEPTANCE TESTING...........................................................................35
10. PREPARATION FOR SHIPMENT AND STORAGE....................................................36
10.1 GENERAL .................................................................................................................36
10.2 PRESERVATION.......................................................................................................36
10.3 BATTERIES...............................................................................................................37
11. SPECIAL TOOLS.......................................................................................................38
12. DOCUMENTS............................................................................................................39
12.1 GENERAL .................................................................................................................39
12.2 TECHNICAL INFORMATION....................................................................................39
13. REFERENCES............................................................................................................40
APPENDICES
APPENDIX 1 GENERATOR STATUS, ALARM, TRIP AND SHUTDOWN REQUIREMENTS.44
1. INTRODUCTION
1.1 SCOPE
This is a new DEP which gives the minimum requirements for the design, manufacturing, assembly,
inspection and testing of packaged unit AC generator sets, hereafter referred to as generator sets. A
generator set consists of a synchronous AC generator, an engine driving the generator, their control,
protection and relay panels, auxiliary equipment and a baseplate. Drivers applied to these generator sets
may be either gas or diesel engines. The range of applicability intended is from approximately 100 kVA to
1250 kVA. In exceptional circumstances the Principal may approve the application of this DEP to generator
sets outside this range. The applicable technical specification shall be given in the requisitions:
DEP 33.65.11.94-Gen., DEP 31.29.80.93-Gen. and DEP 33.65.11.93-Gen. The type of engine shall be
specified in requisition DEP 33.65.11.94-Gen. The Packager shall provide the information requested by
completing the data sheets.
In the case of conflict between documents the following hierarchy shall apply:
upper level: purchase order and variations thereto
second level: requisition sheets and project specification
third level: this DEP
The extent of equipment and services to be provided against this DEP excludes the supply of:
- civil engineering such as buildings, cable floors, trenches, foundations and protective fences
- cabling between skids
- cable tray systems, except as fitted on the package
- switchboards, including generator circuit breaker
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS
Unless otherwise authorised by SIPM, the distribution of this DEP is confined to companies forming part of
the Royal Dutch/Shell Group or managed by a Group company, and to Contractors and
manufacturers/Suppliers nominated by them (i.e. the distribution code is "F" as described in
DEP 00.00.05.05-Gen.).
This DEP is intended for use in oil refineries, gas plants, chemical plants, oil and gas production facilities
(both onshore and offshore) and supply/marketing installations.
If national and/or local regulations exist in which some of the requirements may be more stringent than in
this DEP the Contractor shall determine by careful scrutiny which of the requirements are the more stringent
and which combination of requirements will be acceptable as regards safety, environmental, economic and
legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements
of this DEP which is considered to be necessary in order to comply with national and/or local regulations.
The Principal may then negotiate with the Authorities concerned with the object of obtaining agreement to
follow this DEP as closely as possible.
1.3 PRE-MANUFACTURING MEETING
If deemed necessary, a pre-manufacturing meeting shall be arranged with all parties concerned. This shall
be stated on the requisition or may be initiated by the Packager.
The purpose of this meeting is to define the scope and parameters of the order and the responsibilities of
each party involved. The final list of deviations to the specification shall be agreed. Agreement shall be
reached with respect to administrative, production and test procedures.
Minutes of the pre-manufacturing meeting shall be made by a mutually agreed party and be sent to the
Principal for approval within 14 days. The final minutes shall be issued within 14 days of notification by the
Principal of approval of the draft.
1.4 DEFINITIONS
1.4.1 General Definitions
The Contractor is the party which carries out all or part of the design, engineering, procurement,
construction, commissioning or management of a project or operation of a facility. The Principal may
undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party which manufactures or supplies equipment and services to
perform the duties specified by the Contractor.
The Packager is the party that designs, manufactures, assembles, inspects and tests the complete generator
set.
The Principal is the party which initiates the project and ultimately pays for its design and construction.
The Principal will generally specify the technical requirements. The Principal may also include an agent or
consultant authorised to act for, and on behalf of, the Principal.
The word shall indicates a requirement.
The word should indicates a recommendation.
1.4.2 Technical definitions
Air to air cooled machine 411-14-24, IEC 50
A closed machine with integral or machine mounted heat exchanger, using air as
the primary and secondary coolant.
Air to water cooled machine 411-14-25, IEC 50
A closed machine with a heat exchanger using air as primary coolant and water
as secondary coolant.
Certificate Document issued by a recognised authority certifying that it has examined a
certain type of apparatus and, if necessary, has tested it and concluded that the
apparatus complies with the relevant standard for such apparatus.
Certificate of conformity Certificate stating that the electrical apparatus complies with the relevant
standards for apparatus for potentially explosive atmospheres.
Declaration of compliance Document issued by the manufacturer stating that the electrical apparatus
complies with the requirements of IEC 79-15.
Hazardous area 423-03-01, IEC 50
An area in which an explosive gas mixture is or may be expected to be present in
a quantity such as to require special precautions for the construction, installation
and use of electrical apparatus.
Land installation An installation located at sufficient distance from open saliferous water to
minimize the effect of a salt-laden atmosphere.
Lifetime
The lifetime of a generator set is the time during which the generator set remains
suitable for the application for which it was made, provided it is regularly
inspected, examined and serviced in accordance with the manufacturer's
instructions, with replacement of lubricants and of parts subject to wear.
Low voltage 601-01-26, IEC 50
A set of voltage levels used for the distribution of electricity and whose upper
limit is 1000 V AC.
Marking Data put on the electrical apparatus by the Manufacturer giving information for
safe use of the apparatus.
Rated value 151-04-03, IEC 50
A quantity value assigned, generally by the Manufacturer, for a specific
operating condition of a component, device or equipment.
Site conditions
The external factors, e.g. altitude, air temperature, wind velocity, vibration,
earthquake, black body temperature and relative humidity, which may influence
the operation of a machine or apparatus.
Test report Document prepared by the Manufacturer indicating in detail the tests and
verifications to which the apparatus has been subjected, and their results.
Vital service A service which, when failing in operation or when failing if called upon, can
cause an unsafe condition of the process and/or electrical installation, jeopardize
life, or cause major damage to the installation.
Voltage deviation 604-01-17, IEC 50
The difference, generally expressed as a percentage, between the value at a given
instant at a point in the system, and a reference voltage such as a nominal
voltage, a mean value of operating voltage or a declared supply voltage.
Zone 1 (In the classification of hazardous gas areas), 426-03-04, IEC 50
An area in which an explosive gas atmosphere is likely to occur in normal
operation.
Zone 2 (In the classification of hazardous gas areas), 426-03-05, IEC 50
An area in which an explosive gas atmosphere is not likely to occur in normal
operation and if it does occurs it will exist for a short period only.
1.4.3 Frequently used Expressions
Emergency generator sets
Generator sets which have an infrequent and relative short duration of operation. They will only operate in
case of a power failure of the main grid system for a relative short period, e.g. 24 hours. When the main grid
system is available the starting ability of these generators will be tested at regular intervals, e.g. once every
week.
Generator sets for continuous operation
Generator sets which provide power to the connected installation and may run in single operation, in
parallel with the main grid system or in parallel with other generators on a continuous basis. The nature of
the operation shall be specified in the requisition.
Generator sets for island operation
Generator sets which are not connected to any supply grid with external generating capacity.
Generator sets for parallel operation
Generator sets with an ability to operate without permanent supervision in parallel with the main grid
system, in parallel with other generators, or both.
Generator sets supplying large non-linear loads
Generator sets with an ability to supply large non-linear loads (e.g. rectifiers), while operating within its
temperature limits.
1.5 ABBREVIATIONS
AC : Alternating current
AISI : American Iron and Steel Institute
ANSI : American National Standards Institute
API : American Petroleum Institute
ASME : American Society of Mechanical Engineers
ASTM : American Society for the Testing of Materials
AVR : Automatic Voltage Regulator
AWS : American Welding Society
BS : British Standard
CT : Current transformer
ESD : Emergency shut down
IEC : International Electrotechnical Commission
IP : The degree of ingress protection of an enclosure
according to IEC 529 (for example: IP 41)
ISO : International Organisation for Standardization
LED : Light emitting diode
SI : International System of Units
VDE : Verbandes Deutscher Elektrotechniker
VT : Voltage transformer
1.6 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section number is shown in
brackets. Other documents referenced in this DEP are listed in (13).
1.7 UNITS
Technical units, quantities etc. are and shall be expressed, used and abbreviated according to the SI system
and DEP 00.00.20.10-Gen.
2. BASIC REQUIREMENTS
2.1 GENERAL
The generator set shall be the product of a Packager regularly engaged in their production. The generator
set shall be of modern design and proven performance. Design and construction of the generator set shall
provide accessibility for all components requiring routine operational attention and maintenance.
The requirements in (2) to (7) apply to all generator sets. The requirements for specific modes of operation
are given in (8).
For certain special applications it may be necessary to deviate from this DEP. Any special requirements
shall be stated in the requisition.
2.2 SAFETY
The generator set shall be designed to minimize any risk of internal short circuits and to ensure personnel
and plant safety under all prescribed conditions of operation, inspection and maintenance.
The generator set shall be designed to withstand the thermal and dynamic stresses and transient mechanical
torques such as those resulting from a short circuit and circuit switching operations. Damage arising from
component failure should be confined to the component concerned.
Products that are persistent or toxic to the environment or are considered potential carcinogens shall not be
used, e.g. polychlorinated biphenyls (PCB's), asbestos, cadmium plating.
All exposed rotating or moving parts shall be protected by guards in accordance with BS 5304 or equivalent
national standard. The guards shall be readily removable for plant maintenance purposes.
Exposed surfaces which attain a temperature in excess of 70 C under normal operation and which are a
potential hazard to personnel shall be screened.
All flexible drive belts shall be of anti-static material to ISO 1813.
2.3 SERVICE CONDITIONS
The equipment shall in all respects be suitable for operation in a saliferous and dusty atmosphere. The
possibility of condensation on equipment surfaces shall be taken into account. The site environmental
conditions shall be given in the requisition.
The generator set shall be suitable for unattended operation.
Unless otherwise specified in the requisition, the following conditions shall apply:
2.3.1 Seismic conditions
Generator sets for installation offshore shall be designed for shock accelerations of 20 m/sec
2
whilst in
operation, without interference to operation.
2.3.2 Hazardous areas
The Principal should install generator sets in a non-hazardous area. However, if the circumstances of the
installation dictate that the installation will be in a hazardous area, it shall be stated in the requisition. All
equipment in the package shall then be suitable for operation in the hazardous area.
See DEP 31.29.90.30-Gen. for gas engine fuel gas systems with respect to hazardous areas.
2.4 MATERIALS
All components shall be of a quality commensurate with the requirements of a secure power supply system.
Component materials shall be flame retardant, moisture and fungus resistant whenever practicable.
Equipment destined for humid tropical environments shall be compatible with these environments.
2.5 SCOPE OF SUPPLY
The generator set shall in general consist of:
- engine complete with all necessary auxiliaries
- synchronous AC generator complete with excitation equipment
- combined baseplate
- engine and generator control panel(s)
- all necessary noise and vibration suppression equipment
- engine starting system
- engine and generator cooling systems
- lubrication system
- combustion air intake system
- exhaust system
- engine fuel system
- fuel day tank (diesel engines)
- couplings and guards
- all necessary interconnecting pipe work and valves, including drain connections
terminating at the edge of the baseplate
- local gauge panel and instrumentation
- all CT's and VT's (incl. those for installation in the switchboard).
The Packager shall advise any deviation from this DEP in his tender.
3. PERFORMANCE REQUIREMENTS
3.1 RATING
The rating of the generator set shall be the total net output rating at the generator terminals. The component
(e.g. engine, generator, coolers, etc.) with the lowest individual rating shall provide the limit for defining the
net output of the generator set. The rating of any significant electrical auxiliaries, such as electric cooling
fans, shall be deducted from the output rating. The generator set shall have a continuous power rating as
stated on the requisition, at a power factor of 0.8 lagging.
3.2 NOISE
Noise control requirements as given in DEP 31.10.00.31-Gen. shall be adhered to. The Principal shall
specify the noise limitations of the generator set, using data sheet DEP 31.10.00.94-Gen., which forms part
of the requisition.
The Packager shall submit guaranteed sound power levels and sound pressure levels of the packaged unit,
together with any other relevant information as requested in DEP 31.10.00.94-Gen. The Packager shall
indicate what special silencing measures, if any, are proposed in order to meet the specified levels.
3.3 TORSIONAL VIBRATIONS
A torsional vibration analysis shall be performed by the Packager. The necessary remedial measures shall
be implemented in accordance with DEP 31.29.90.30-Gen. or DEP 31.29.80.30-Gen.
3.4 LATERAL VIBRATIONS
The lateral vibration severity of the complete generator set shall not exceed 4.5 mm/s RMS as defined in
ISO 2372.
The vibration levels of individual auxiliary low voltage electric motors shall be as per
DEP 33.66.05.31-Gen.
4. ENGINE REQUIREMENTS
4.1 GENERAL
The requirements for the engine driving the generator are be described in either DEP 31.29.80.30-Gen., or
DEP 31.29.90.30-Gen., as specified in the requisition. In general, the engine Supplier will furnish the
engine with all necessary auxiliaries and accessories for operation of the engine. This section describes the
packaging requirements for installation of the engine. This section is intended for application where these
auxiliaries and accessories are not mounted directly on the engine but require assembly by the Packager as
part of his scope of work.
4.2 AIR INTAKE SYSTEM
Where an air intake filter has been supplied loose by the engine Supplier, the Packager shall provide the
mounting for the air filter and all piping and ductwork between the air filter and the engine.
Intake ducting or piping shall be properly supported to prevent excessive strains being applied to the intake
nozzle on the engine. Expansion bellows provided by the engine Supplier shall be installed in the locations
approved by the engine Supplier.
All intake ductwork shall be swabbed and blown clean of any debris before final assembly.
4.3 EXHAUST SYSTEM
Where the engine Supplier has supplied an exhaust silencer the Packager shall provide the mounting for the
silencer and all piping and ductwork between the silencer and the engine.
Exhaust ducting or piping shall be properly supported to prevent excessive strains being applied to the
exhaust nozzle on the engine. Due account shall be taken of thermal expansion and the expansion bellows
provided by the engine Supplier shall be installed in the locations approved by the engine Supplier.
The orientation of the exhaust shall be agreed with the Principal, taking account of the location of adjacent
equipment and the prevailing wind.
4.4 FUEL SYSTEM
Shutoff valves for fuel gas will be supplied loose by the engine Supplier. These valves shall be installed in
locations agreed with the Principal, taking account of the hazardous area classification. The routing and
point of emission of all fuel gas vents shall not infringe the hazardous area classification.
4.5 COOLING SYSTEM
If the engine Supplier has supplied engine and lube oil coolers loose, these shall be installed by the
Packager.
If the cooler location is remote from the engine, e.g. in the wall of an enclosure or free-standing adjacent to
the baseplate, the piping shall be installed by the Principal.
The orientation of the air flow from the cooling fan shall be away from the package. The Packager shall
ensure continued adequate cooler performance when the wind is blowing directly against the cooler with a
maximum wind velocity as stated in the requisition.
NOTE: If wind data are not available, a maximumvelocity of 50 knots shall be used.
If a remotely located cooler has a fan which is mechanically driven from the engine, the Packager shall
provide lineshafting and belt drive as necessary.
4.6 SHAFT COUPLINGS
Non-lubricated couplings for auxiliaries and accessories shall be supplied by the Packager as required for
driving separately mounted accessories.
4.7 FREQUENCY STABILITY
The requirements for isochronous operation, speed droop operation, or single operation mode shall be given
in the requisition.
The total kinetic energy of the rotating train in combination with the governor gain and the stability
adjustment of the total generator set shall provide frequency stability in accordance with governing class A2
as defined in ISO 3046/IV for generators operating in single mode.
The governor shall be of an electronic type.
5. GENERATOR REQUIREMENTS
5.1 GENERAL
The generator shall be designed, manufactured and tested in accordance with DEP 33.65.11.31-Gen.,
except as modified herein.
5.2 GENERATOR IMPEDANCES
The requisition shall specify the requirements for minimum and maximum subtransient and transient
impedances, together with the maximum tolerances.
5.3 EXCITATION SYSTEM
5.3.1 General
The generator shall be self-exciting, i.e. it shall generate its nominal voltage without the use of external
power sources, even after long idle periods or after a short circuit.
The excitation system shall comprise at least the following:
- excitation equipment
- AVR
- voltage adjuster (rheostat)
- AVR voltage failure relay (alarm).
In addition to brushless excitation, static excitation consisting of voltage and current transformer circuits,
where the generator rotor current is supplied via sliprings and brushes, is also acceptable.
The AVR shall be of the electronic type provided with a fine voltage adjuster. It shall include frequency
sensing circuitry to limit the ceiling voltage and to prevent damage to components when the generator is
driven at reduced speeds, such as when starting or when the engine is at idling speed.
Where excitation power is derived from terminal voltage, current boost circuitry shall be included to
provide excitation under short circuit conditions and to maintain a short circuit current greater than 300% of
the nominal current for 3 seconds.
The AVR shall be matched to the generator characteristics and shall be of adequate construction and design
to fully meet all operational and performance requirements.
The AVR shall be equipped with frequency dependent constant voltage (U =constant down to 90% rated
frequency) and adjustable slope (U/f) facilities.
The AVR should be installed in the generator control panel. Installation of the AVR at the generator is
subject to approval by the Principal, or may be specified in the requisition. In this case the AVR shall be
located in a separate housing or in a clearly segregated section of the main terminal box.
For generator sets operating in parallel with other generators, or with a grid system, see (8.5).
5.3.2 Excitation - Rated current
The rated excitation current shall be at least 110% of the excitation current at the rated output of the
generator under the most stringent operating conditions.
The excitation system shall be able to cope with any field forcing conditions that the generator is required to
supply, e.g. starting large motors. The field forcing capability shall be sufficient to enable adequately
graded relay settings to be made for system fault current protection.
5.3.3 Excitation - Rated voltage
The rated voltage of the excitation system shall be at least 110% of the rotor voltage at the rated output of
the generator under the most stringent conditions. The ceiling voltage shall be not less than 120% of the
rated voltage of the exciter.
5.4 OUTPUT VOLTAGE VARIATIONS
The voltage regulation of the generator shall be grade VR2.31 in accordance with BS 4999 Part 140. If a
more stringent voltage regulation is required, as dictated by the connected loads, this shall be specified in
the requisition.
5.5 EFFICIENCY
The generator efficiency at nominal load and a power factor of 0.8 shall be not less than:
Rated output Efficiency
50 - 100 kVA 90%
125 - 300 kVA 91%
330 - 600 kVA 92%
630 -1250 kVA 93%
Guaranteed values for the efficiency shall be given by the Packager for 50%, 75% and 100% of rated
output.
5.6 RADIO FREQUENCY INTERFERENCE
The production of radio frequency interference voltages shall not exceed the value of suppression grade 'N'
as defined in VDE 0875.
5.7 GENERATOR COOLING
The preferred methods of generator cooling are:
- self cooled open-IC 01
- air to air-IC 0141/0151/0161/0166
- air to water-IC W 37 A 81
The designations are in accordance with IEC 34-6.
The required method of cooling shall be specified in the requisition.
5.8 GENERATOR HOUSING
5.8.1 General
The degree of ingress protection of the enclosures for a generator and for its auxiliaries intended for
outdoor installation shall be at least IP 55.
The generator and exciter enclosures shall be fitted with suitable inspection plates and access covers which
shall be designed for quick and simple removal. Access covers to the rotating excitation rectifier equipment
shall be adequately sized to permit easy maintenance by personnel using both hands.
The generator shall be provided with an external earthing terminal bolt, which shall be clearly marked with
the appropriate symbol.
5.8.2 Stator frame
The generator frame and bearing end-shields shall be constructed of ferrous metals.
All welding shall comply with ANSI/AWS D1.1 or the relevant local code.
5.9 WINDINGS
The windings of the generator, and if stalled of the exciter and the pilot exciter, shall be designed in
accordance with DEP 33.66.05.31-Gen.
5.10 BUSHINGS AND TERMINALS
The common neutral connection point shall be taken from the star point and brought into the main terminal
box.
The copper earth terminal bolt inside the main terminal box shall have a removable copper link connection
with the neutral terminal.
5.11 BEARINGS
The bearing design shall be in accordance with DEP 33.66.05.31-Gen.
If bearings are of the grease-lubricated rolling element type, grease nipples and appropriate grease relief
devices shall be fitted. Bearings shall have a minimum greasing interval of 4000 operating hours, but should
have a greasing interval of greater than 8000 operating hours. The required greasing intervals shall be
indicated on the rating plate
.
If sleeve bearings are fitted, a lubricating oil overflow shall be provided which prevents the bearing from
holding an excess of oil while still permitting efficient lubrication when the machine is running. Measures
shall be taken to prevent lubricant from creeping along the shaft or otherwise gaining access to the
insulation of the machine or to any live part thereof.
Bearing insulation shall be provided on all bearings unless the generator Manufacturer can demonstrate that
rotor stray currents are too low to damage the bearings.
6. CONTROL AND PROTECTION EQUIPMENT
6.1 GENERAL
Unless otherwise specified in the requisition, the generator set shall be provided with the following
monitoring, control and protection equipment:
- local gauge panel for the engine
- engine control panel
- generator control panel.
If specified in the requisition, the engine control panel may be combined with the generator control panel
into one freestanding cubicle. Clear physical segregation between engine and generator controls shall be
provided.
6.2 ENGINE CONTROL PANEL
The engine control panel shall be manufactured in accordance with DEP 31.29.80.30-Gen. or
DEP 31.29.90.30-Gen. and the construction requirements of this DEP (6.4).
6.3 GENERATOR CONTROL PANEL
Unless otherwise specified in the requisition, the generator control panel shall comply with the requirements
of (6.3) and (6.4).
6.3.1 Generator control panel features
The generator control panel shall include the following:
- all control and protection devices required for the safe and reliable operation of the generator
- AVR, see (5.3.1)
- complete AC sub-distribution for the generator space heater, panel space heater and any other
generator auxiliary items
- battery backed up DC power supply distribution for the generator protection systems (may be
combined with the engine protection systems)
- raise/lower voltage adjuster (behind the panel door)
- generator status, alarm and trip functions as specified in the requisition, see also Appendix 1
- generator voltage meter (including 7 step selector switch)
- generator line current meters (1 in each phase)
- power meter
- frequency meter
- power factor meter
- kWh meter (*)
- exciter current meter (*)
- exciter voltage meter (*)
- control panel supply voltage meter (*).
NOTE: * If specified in the requisition.
Standard drawing S 67.055 is a single line diagram of the generator protection, control and indication
functions. It shall be considered as typical only; the exact requirements shall be given in the requisition.
The Principal shall provide information regarding the proposed actual lay-out of the generator set and its
auxiliaries, the preferred location of the necessary current and voltage transformers and the location of the
control and protection cubicles.
All meters shall be a minimum of 72 mm square, and to minimum accuracy class 1.5 according to IEC 51.
6.3.2 Electrical protection requirements
The Packager shall prepare a proposal for the settings of the protection relays. The final setting of the relays
shall be agreed between Packager and Principal.
All protection relays shall be of the digital electronic type and shall be installed in such a way that they are
clearly visible. Components requiring inspection or adjustment shall be accessible from floor level.
Protection relays shall be clearly labelled and shall be equipped with visible flag indicators or other means
of indication used on electronic type relays, e.g. LED's. Protection relays shall have manual reset facilities
and shall not be sensitive to vibration, shocks or transients. Dust proof flush mounted protection relays of
the removable type and provided with calibrating and testing facilities, should be provided. For
withdrawable protection relays the terminals connected to CT's shall be automatically short circuited on
withdrawal of the relays. Multiple function elements such as tripping and alarm duties shall have separate
operating contacts for each function and shall be brought out to separate terminals. CT's for overcurrent
protection shall have an appropriate VA rating and accuracy to energise the relays, without causing damage
to the latter, over the range of short circuit currents that can arise. Contact rating and performance shall be
in accordance with IEC 255.
6.4 CONTROL PANEL CONSTRUCTION
6.4.1 Enclosure and accessibility
All control equipment specified in (6.2) and (6.3) shall be installed in a free standing, self-supporting sheet
steel cabinet forming an enclosure. The enclosure shall be suitable for operation and maintenance with its
rear panel against a wall, requiring only front access.
The control panel shall be manufactured from sheet steel not less than 2 mm thick. If specified in the
requisition the panel shall be manufactured from AISI 316L stainless steel, all panel hardware shall then be
stainless steel in compatible grades.
The enclosure shall provide a degree of ingress protection at least equal to IP 41 if the panels are for
installation in an enclosed building. The degree of ingress protection shall be at least IP 55 if the panels are
for installation outdoors under a rain canopy. The installation floor shall not form part of the enclosure.
Internal cooling shall be by natural ventilation. The working temperature of any components shall not have
a detrimental effect on any other component.
Equipment and components installed within the enclosure shall not be mounted directly on the enclosure
walls. The location and grouping of components and auxiliary equipment shall permit easy identification
and access for operation, maintenance and repair. Suitable partitioning between AC power and control
sections shall be provided where necessary to allow adjustment and inspection to be carried out safely.
All live terminals of door-mounted equipment having a maximum voltage greater than 24 V shall be
shrouded or otherwise protected by barriers to a degree of ingress protection of at least equal to IP 30, to
prevent inadvertent contact by personnel when the enclosure door is open. Barriers shall be of rigid
transparent insulating material to enable the screened components to be identified. Any relays which can
cause tripping of the unit shall not be installed on the enclosure door.
To prevent inadvertent contact or short circuit by personnel when performing control circuit adjustments or
when resetting/replacing protective devices, all bare busbars and live terminals of equipment and
components located within the enclosure shall be similarly protected by barriers or shrouds to a degree of
ingress protection of at least IP 20, unless adequately recessed within the enclosure.
NOTE: Outdoor panels shall always be provided with a rain/sun canopy to make access possible under adverse weather
conditions.
6.4.2 Sub-distribution
Each incoming supply to the panel shall have an appropriate padlockable type disconnecting device. Any
sub-distribution shall be via miniature circuit breakers, manufactured in accordance with IEC 898.
Switches, including miniature circuit breakers, shall simultaneously de-energize and isolate all phases and
the neutral.
6.4.3 Anti-condensation heaters
Adequate provisions shall be made to avoid deterioration of the panel interior caused by condensation.
The requirement for anti-condensation heaters shall be indicated in the requisition.
Anti-condensation heaters shall be of a fully insulated design and suitable for 220 - 254 volts single phase
supply, unless otherwise specified. Anti-condensation heaters shall be arranged to provide uniform heating
of the control panel and shall maintain the panel interior at approximately 5 C above ambient temperature.
The surface temperature of the heater elements shall not exceed the limiting temperature specified. The
heater elements shall be protected against accidental touching by personnel performing tasks in the control
panel.
6.4.4 Internal wiring and terminations
Insulated stranded copper conductors shall be used for secondary wiring. The size and type shall be selected
on current carrying capacity, voltage and mechanical strength. Wiring between terminals shall be
continuous and without joints.
Wires shall be held in position by means of insulated tubes, channels, cleats or plastic strips and shall be
routed so as to avoid mechanical damage. Channels, tubes, etc. shall not be filled to more than 75%
capacity during manufacture. Wiring between fixed portions and hinged doors shall in addition to the
electrical insulation have protection against abrasion or entrapment and not be carried over or bent around
sharp edges.
Individual wires or cables terminating at fixed (not plug-in) components shall be identified by means of
ferrules of insulating material marked in accordance with the manufacturer's drawings. Wrap around,
adhesive type markers shall not be used.
Terminals shall be of the non-loosening type and only accept one wire, unless the terminals are specially
designed to accept more than one wire. Terminals shall be constructed in such a way that direct contact
between screws, bolts or nuts and the conductor is prevented. Partitions shall be placed between terminals
of different voltages. Stranded wiring ends which are to be connected into butt type contacts and terminals
shall be provided with compression type pre-insulated wire pins with insulation support.
Terminals to accommodate wiring supplied by the Principal shall be sized to accept minimum 2.5 sq mm
wires for control and minimum 4 sq mm wires for power and current transformer secondaries. A minimum
of 25% spare control terminals shall be provided in each panel.
6.4.5 External cabling and terminations
All panels and enclosures shall have facilities for the entry of cables from the top or bottom as specified on
the requisition. Control cables shall be accessible from the front of the enclosure.
All connection material, cable supporting system and clamping shall be supplied and suitable for the size
and the number of conductors. Ample space for terminating the external cables shall be provided. All
outgoing cable compartments shall be provided with fully gasketed removable gland plates for termination
using cable glands. A minimum of 25% spare entries shall be provided. Compression type cable glands
suitable for the cables specified on the requisition shall be included in the scope of supply.
A separate compartment shall be supplied for the terminal strips for all incoming and outgoing cables.
Separate sections shall be provided for digital, analogue, pneumatic and power cables. Interconnecting
cables to remotely located equipment shall be installed by the Principal.
6.4.6 Earthing
Where a number of electrical components are to be earthed, parallel earthing shall be employed and not
series looping of equipment.
An earth rail with a suitable number of earthing bolts or screws shall be provided in a position close to the
external cable glands to facilitate termination of cable earth braids or armouring. Individual connections for
all earth wires shall be provided.
A threaded brass earth stud of not less than 6 mm diameter, with nuts and spring washers, shall be provided
within the enclosure for termination of a separate single-core earth cable.
Earth conductor connections on equipment which is regularly disconnected for maintenance shall be made
with screw type solderless connectors. All other connections shall be made with crimp type connectors.
Electrical conductivity between the exposed non-current-carrying conductive parts of the control panel
components and the enclosure and between the enclosure and the earth rail and the earth stud shall be such
as to maintain effective continuity of earth circuits.
The minimum size of earth conductors shall be 2.5 sq mm for internal earth connections. Earth connections
shall be yellow/green coloured insulated copper flexible wires.
Removable metal parts, including doors, shall be earthed
.
All electrical connections made for earthing shall be accessible to allow checking of tightness and electrical
contact.
6.4.7 Marking
All external operating, measuring and indicating components shall be clearly identified with permanent
descriptive labels that facilitate easy recognition by the operator. Descriptive labels shall be white with
black lettering.
All components shall be identified by labels inscribed in accordance with the system of identification as
used on the manufacturer's reference drawings and documents.
All labels shall be of corrosion resistant material with indelible inscriptions in the language specified in the
requisition.
Rail-mounted terminals of equipment and components shall be identified by numerical or alphabetical
markings in accordance with the manufacturer's drawings. Terminals of input and output supply cables shall
be clearly marked to indicate the nominal system voltage and the phase/polarity of the supply. The
identification of terminals shall be in accordance with IEC 445.
7. PACKAGE REQUIREMENTS
7.1 BASEPLATE
The generator/engine combination shall be mounted on a common baseplate, made of structural steel beams
and with flat top plates, suitable for stationary installation.
The baseplate shall be designed to resist transport and lift conditions. A horizontal force equal to the total
transport weight may be assumed for transport forces in the design of the package. Consideration shall be
given to lifting shock forces, in particular for offshore installation.
All welding shall comply with ANSI/AWS D1.1 or the relevant local code. Intermittent welds or stitch
welds are not allowed on any structural part of the skid.
The baseplate shall be designed to support the mass of the components and resist the torque reaction
imposed by any operating condition. It shall also be capable of withstanding the shock loads defined in
(2.3.1).
The baseplate shall be constructed such that it does not interfere with maintenance or routine servicing of
the engine and the generator. No fuel piping shall be concealed within the baseplate.
The baseplate shall have a drip pan and rim with DN 50-Class 150 ANSI/ASME B16.5 flanged drain
connections in strategic locations.
The Packager shall supply suitable anti-vibration mounts to limit the engine vibrations transmitted to the
foundations or surroundings where a vibration analysis study reveals that the package requires isolation
from the supporting structure. Mounts shall be located between the baseplate and the supporting structure.
Anti-vibration mounts shall be of a totally enclosed design suitable for the environment and possess an
isolation efficiency of at least 90% in respect of all induced vibrations. Full details, including drawings, of
the anti-vibration mounts shall be submitted together with the frequency and magnitude of any unbalanced
forces and moments that will be transmitted through the mounts into the Principal's supporting structure.
The baseplate shall be designed to withstand any dynamic forces arising from action of the anti-vibration
mounts. Inertias of the complete baseplate with the mounted equipment shall be such that stresses in the
rotating components arising from motion of the complete assembly on the anti-vibration mounts are
minimised. The Packager shall furnish the Principal with calculations of resonant frequencies and the
stresses arising on the rotating components.
The Packager shall provide earth bonding conductors from the engine, generator and all other skid mounted
equipment to the baseplate. Two earth bosses in accordance with standard drawing S 68.004 shall be
mounted diagonally on the baseplate for external earth bonding by others.
Lifting lugs shall be attached to the baseplate. The positioning of the lugs shall take account of the centre of
gravity of the complete assembly and be such that lifting slings, etc. do not interfere with any equipment
mounted on the baseplate. If a spreader bar is required to meet this requirement, it shall be supplied by the
Packager. Lifting lugs shall be designed for a load equal to twice the complete assembly and shall comply
with ANSI/AWS D1.1 or the relevant local code. The area of material where lifting lugs are to be welded
shall be tested ultrasonically for laminations prior to welding.
7.2 ROOM VENTILATION
Unless otherwise specified in the requisition, the ventilation requirements for a generator set installed in a
closed room shall be provided by the Principal. See (4.2) for combustion air and (4.3) exhaust requirements.
See (7.8) for a generator set installed in an acoustic enclosure.
7.3 ELECTRIC MOTORS
Electric motors for auxiliary systems shall comply with DEP 33.66.05.31-Gen.
7.4 CABLES AND J UNCTION BOXES
Interconnecting cables between the equipment supplied by the Packager and those devices furnished by the
Principal shall be supplied and installed by the Principal. The associated cable glands on the equipment
supplied by the Packager shall be furnished and fitted by the Packager. All glands shall be equipped with
shrouds.
Power cabling to the generator and to electric motors shall be supplied and installed by the Principal and
connected directly to the generator and motor terminal boxes upon installation in the field. The Packager
shall provide trays and supports within the confines of the baseplate as necessary to accept these cables. All
other electrical equipment supplied by the Packager and requiring external connections shall be wired by
the Packager to terminal blocks in junction boxes located at the edge of the baseplate or to terminals in the
control panel.
Cabling on the baseplate and the engine cooler assembly shall be flame retardant and oil resistant type,
complete with galvanized steel wire braiding and interwoven copper earth wires. The insulation level shall
be 600/1000 V.
All cabling shall be mounted on ANSI 316L stainless steel cable trays. The cable trays shall be properly
insulated from the steel structure to prevent corrosion caused by dissimilar materials. The cable trays shall
have equipotential bonding with the baseplate. Cable extensions from cable trays to equipment shall be
supported and protected against mechanical damage. The cables shall be fastened to the cable tray with UV
resistant ties.
Cables shall be properly marked by stainless steel tags or by Critchley 'K' type cable markers mounted on a
carrier strip with ties. Cable markers shall be installed at each gland at both sides of the gland plate.
All junction boxes shall have a minimum degree of ingress protection of IP 55. J unction box wire
identification, terminal partitions, terminal execution, wire pin requirements, and spare terminal
requirements and earthing provisions shall comply with (6.4.3) through (6.4.6).
7.5 NAMEPLATES
A list of nameplates, including sizes and character dimensions, shall be submitted to the Principal for
approval. Text on the nameplates shall be in the language specified in the requisition.
The components of the generator set shall have nameplates in accordance with the respective specifications.
The nameplate described herein shall apply to the complete package.
The following information shall be clearly marked on a non-destructible, corrosion-resistant, indelible
name/rating plate attached to a permanent part of the generator control panel:
- purchaser's order number
- year of manufacture
- name of Packager
- type and serial number of the package
- nominal output power of the package.
7.6 PIPING AND INTERFACE CONNECTIONS
The Packager shall supply all on-baseplate piping for fuel, lubricating oil, starting systems and coolants.
Connections to the Principal's piping shall be by appropriately rated ANSI/ASME B16.5 flanged
connections at the baseplate edge. The Packager shall provide flexible elements for all the Principal's piping
connections. For fuel piping, these flexible elements shall be stainless steel convoluted sections with
stainless steel reinforcing braid.
All package piping shall be carbon steel to ASTM A106 Grade B and shall be pickled, flushed and
passivated after fabrication.
If sea water cooling is used, pipework shall conform to a minimum of ANSI Class 150 and shall be
manufactured in duplex stainless steel, UNS S31803 to ASTM A790.
Interconnecting piping between the baseplate edge and remotely installed auxiliaries shall be supplied and
installed by the Principal. The Packager shall clearly indicate all piping termination points on the baseplate
for separately mounted auxiliaries to be connected by the Principal.
Fuel gas piping shall comply with DEP 31.29.90.30-Gen.
7.7 PAINTING
The engine and generator shall be supplied painted according to the respective specifications. The control
panels, baseplate and auxiliaries shall be painted in accordance with the Packager's standard for a marine
environment, subject to approval by the Principal. The Packager shall submit the painting specification for
approval upon request. The specification shall include surface preparation, paint materials, application, film
thickness and the paint Supplier's data sheets. Stainless steel components shall not be painted.
7.8 ACOUSTIC ENCLOSURE
If the emitted noise level of the generator set exceeds permitted levels at the installation site, the Packager
shall provide an acoustic enclosure over all the equipment requiring noise limitation treatment in
accordance with DEP 31.10.00.96-Gen., which forms part of the requisition.
The acoustic enclosure shall allow access for routine on-line maintenance and for overhaul of the enclosed
equipment. All doors shall be fitted with emergency opening bars on the inside. Opening any door for
access during generator set operation shall provide an alarm, but shall not cause a shutdown of the generator
set.
If approved by the Principal a "close fit" acoustic enclosure may be applied for packaged units with lower
ratings. This type of enclosure shall allow easy access for maintenance by means of maintenance doors. For
overhaul of the equipment easy removal of the enclosure, by the lifting off or taking apart of panels, is
required.
Mechanically induced ventilation shall be installed, such as to provide not less than 20 changes of air per
hour within the enclosure, or to limit the temperature rise within the enclosure to not more than 5 C above
the ambient air temperature, whichever requires the greater flow rate. Either failure of the air flow to the
enclosure or excessive temperature rise in the enclosure shall shut down the generator set. Ventilation air
shall be filtered by a two-stage filter comprising an inertial stage followed by a viscous impingement stage.
An enclosure surrounding a gas fuelled engine installed in a non-hazardous area shall have extractor fans
maintaining a negative pressure within the enclosure.
The enclosure shall be fitted with two heat detectors above the engine, either of which shall shut down the
engine upon fire detection. Initiation of a shutdown shall cause a release of extinguishant into the enclosure
and simultaneously cause shutting of a damper in the exhaust air from the enclosure and shutdown of the
ventilating fans.
For free access to the enclosure the fire extinguishing system shall be inhibited when using carbon dioxide
or other asphyxiating gases. An alarm shall be provided to indicate that the system has been inhibited. For
fire extinguishing systems using water fog, inhibition is not required.
An enclosure surrounding a gas fuelled engine shall be fitted with gas detectors on the ventilation air outlet,
utilising a two out of three voting system to shut down the engine upon gas detection. The ventilation shall
remain in operation and extinguishant shall not be released upon gas detection.
8. SPECIAL REQUIREMENTS FOR DIFFERENT MODES OF OPERATION
8.1 GENERAL
In addition to the requirements given in (2) through (7) which apply to generator sets in single operation,
the following requirements apply to other modes of operation. A combination of operation modes is also
possible.
8.2 EMERGENCY GENERATOR SETS
Standard drawing S 67.070 gives single line and schematic diagrams of control circuits; these shall be
regarded as typical only, the exact requirements shall be given in the requisition.
A low voltage emergency generator set with 3 phase/4 wire connections shall be capable of operating
continuously with unbalanced load current of up to 20%, or the value specified in the requisition. The
unbalance is defined as: % 100
max
min max

I
I I
where:
I
max
= maximumphase current
I
min
= minimumphase current
The maximumtime allowed for the emergency generator set to accept the nominal load after initiation of a
start command fromcold shall be 10 seconds.
For an emergency generator set in an acoustic enclosure, failure of the ventilating air flow shall not shut
down the set, but shall initiate an alarm.
For an emergency generator set which is periodically tested in parallel with the main grid system, the same
control and protection requirements shall apply as for parallel operating generators. If installed,
under/overvoltage protection and under/over-frequency protection shall be disabled during emergency
operation.
8.3 GENERATOR SETS FOR CONTINUOUS OPERATION
The generator set shall run for a minimumof 25000 hours between major overhauls and shall have an
expected lifetime of at least 20 years.
The stator winding of the generator shall have 2 embedded temperature detectors per phase for alarmand
trip functions, in accordance with DEP 33.66.05.31-Gen.
An indirect cooling system, e.g. air to air or air to water, for the generator is preferred. The exact
requirements shall be specified in the requisition.
8.4 GENERATOR SETS SUPPLYING LARGE NON-LINEAR LOADS
The generator shall operate within its temperature limits under conditions of non-sinusoidal loads, as
specified in IEC 34-1.
If loads with a large harmonic content, e.g. fromrectifiers, need to be supplied the magnitude of the
individual harmonic currents shall be advised in the requisition. The generator shall then operate within its
temperature limits under the specified harmonic current conditions.
NOTE: The distribution systemto which the generator is connected shall be designed to limit the harmonic voltage to the
values stated in DEP 33.64.10.10-Gen.
The Principal shall indicate the maximumacceptable level of voltage waveformdistortion for the
installation.
8.5 GENERATOR SETS FOR PARALLEL OPERATION
Generators for parallel operation shall be equipped with a damper winding on the rotor. If more than one
star point of parallel operating generators will be earthed, the Supplier shall ensure that third harmonic
currents circulating through the star point connections are minimised. If specified in the requisition, the
Manufacturer shall reduce the third harmonic currents and their multiples by chording (
2
/
3
pitch stator
winding).
Where parallel operation with other generator sets is required, quadrature droop compensation of maximum
5% shall be provided.
For a generator operating in parallel with the main grid systemthe reactive power generated shall be
controlled by an automatic power factor controller. Either the power factor of the grid coupling or the
power factor of the generator set shall be controlled, as specified in the requisition.
A droop current transformer and droop rheostat shall be provided.
Manual synchronising equipment, with check synchroniser and dead bus override, shall be provided.
Automatic (active) synchronising equipment is only required if specified in the requisition.
The Principal shall provide data regarding the voltage and speed control characteristics of existing
generator sets which are required to operate with the one being purchased.
Frequency stability in accordance with governing class A1, as defined in ISO 3046/IV, shall be provided for
the engine.
8.6 GENERATOR SETS FOR HAZARDOUS AREAS
The requirement of the generator set to be suitable for installation in a hazardous area shall be specified in
the requisition.
The generator set and all its accessories shall comply with the recommendations of IEC 79.
The requirements for certificate of conformity and declarations of compliance shall be met in accordance
with DEP 33.64.10.10-Gen.
If a generator set provided with an acoustic enclosure is installed in a hazardous area, the ventilation air
intake shall be taken froma safe area.
NOTE: Generator sets shall be installed in a non-hazardous area unless this is unavoidable. In that case the generator set and
its accessories shall be installed in a zone 2 location. Installation in a zone 1 location shall not be contemplated.
9. INSPECTION AND TESTING
9.1 GENERAL
Inspection and acceptance tests shall be carried out on the complete generator set at the Packager's works
and may be witnessed by the Principal. The Packager shall submit a detailed proposed inspection and
testing schedule to the Principal.
9.2 WORKS TEST OF THE COMPLETE GENERATOR SET
The completed and individually tested engine and generator shall be assembled onto the baseplate with all
auxiliaries, instruments and controls for a complete test of the generator set. The works test shall include, as
a minimum, the tests described in this section.
9.2.1 Static load test
During this test the generator set shall run for at least four hours under the following conditions:
- 30 minutes at 25% rated output
- 30 minutes at 50% rated output
- Two hours at 100% rated output
- One hour at 110% rated output.
During the load test all engine and generator parameters shall be recorded. These shall include, but not be
limited to:
- Generator power output
- Generator phase currents
- Generator voltages and variations
- Generator power factor
- Generator frequency
- Engine oil pressure
- Cooling water temperatures
- Fuel consumption
- Noise level
- Engine speed and variations
- Vibration levels.
9.2.2 Dynamic load test
The frequency and voltage regulation of the generator set shall be verified against the requirements given in
(4.8) and (5.4). Voltage and frequency variations shall be recorded on oscillograms. The requirement for
special dynamic load tests to simulate motor starting will be indicated in the requisition.
9.2.3 Functional test
The Packager shall performfunctional tests on the complete generator set including the generator and
engine control panels.
The functional tests to be performed shall be subject to approval by the Principal and shall include, but not
be limited to, the following tests:
- engine start-up system, including measurement of the starting time. A minimumof two start and stop
tests shall be performed
- automatic start-up system, if provided
- for emergency generator sets verification of the time between initiation of a start command and
acceptance of the nominal load for a cold start
- all engine alarmand shutdown functions (
*
)
- all generator alarmand trip functions, including the verification of protection relay operation (
*
)
- operation of the battery charger
- the status/alarm/trip/shutdown indication of the control panels
- local manual start/stop/emergency stop functions
- remote start/stop/emergency stop functions (input signals)
- the remote signalling contacts for Principal's use
- operation of the AVR
- operation of the AVR automatic transfer system(if provided)
- operation of the automatic power factor controller (if provided)
- operation of synchronising equipment (if provided)
- calibration of measuring and protective devices.
NOTE: (
*
) These functions do not all have to be tested with a running generator set.
9.2.4 Insulation resistance tests
These tests shall be performed on the generator, exciter, space heaters, temperature detectors, control panel
and skid cabling.
9.2.5 Hydrostatic testing
All pressure containing parts, including auxiliaries, shall be tested hydrostatically in accordance with the
relevant design codes.
9.2.6 Final inspection
The following inspection and checks shall be performed:
- verification against the approved drawings
- overall dimensions of the skid and the location of all equipment
- location of all piping and electrical interfaces
- enclosure degree of protection of all equipment concerned
- accessibility of components
- lifting arrangement, including spreader bar, if applicable
- non-interference of the lifting arrangement
- availability of eye bolts for lifting heavy components
- terminal and wiring marking
- available space for cable termination, the size and number of terminals, the cable supporting devices
- earthing and bonding
- marking of components according to the relevant drawings
- all rating plates of main components
- construction materials of auxiliaries, such as: baseplate, piping, fittings, coolers, fuel day tank (for
diesel engines) and control panels
- hook-up of local instruments
- Packager's welding procedures and welder qualifications
- welding by non-destructive testing, where specified
- weld inspection reports
- quality assurance documentation.
9.3 ON-SITE ACCEPTANCE TESTING
Acceptance testing shall include static load tests, functional tests and visual inspection as specified in
(9.2.1), (9.2.3) and (9.2.6).
NOTE: The Packager may be required to assist with the installation and commissioning of the generator set, as specified in the
purchase order.
10. PREPARATION FOR SHIPMENT AND STORAGE
10.1 GENERAL
The generator set shall be prepared for shipment after all testing and inspections have been completed, and
the equipment has been painted.
The generator set shall be prepared for the type of shipment specified, including blocking of rotors where
necessary. Blocked rotors shall be identified by corrosion-resistant tags attached with stainless steel wire.
The preparation shall make the equipment suitable for 6 months (or for a period as stated in the requisition)
outdoor storage fromthe time of shipment, with no disassembly required before operation. If storage for a
longer period is contemplated, the Principal shall consult with the Packager regarding the recommended
preservation procedures to be followed.
Internal bracing or supports for shipping shall be clearly identified, preferably by painting in a distinctive
colour.
Lifting points and the centre of gravity shall be clearly identified on the equipment packages. A
recommended lifting arrangement shall be provided by the Packager.
The equipment shall be identified by itemand serial number. Materials shipped separately shall be
identified by securely attached corrosion-resistant metal tags indicating the itemand serial number of the
equipment for which it is intended. Crated equipment shall be shipped with duplicate packing lists, one
inside and one on the outside of the crate.
10.2 PRESERVATION
The Packager shall provide instructions for maintaining the integrity of the preservation for the period
between arrival at site and startup of the generator set.
Exterior machined surfaces shall be coated with a rust preventative.
The interior of all equipment shall be clean, free fromscale, welding spatter, and foreign objects.
Mechanical equipment shall be sprayed or flushed with a rust preventative that can be removed with
solvent. The rust preventative shall be applied through all openings while the engine is slow-rolled.
Internal steel areas of bearing housings and carbon steel oil systems, auxiliary equipment and piping (except
for cooling water piping) shall be coated with an oil-soluble rust preventative. Preservation agents
containing calciumand/or silicone compounds shall not be used as they cause subsequent foaming of the
lubricating oil.
All coolants shall be drained fromthe engine, coolers and piping. The interior of the coolant systemshall be
preserved by a water soluble film.
All flanged openings shall be closed with metal closures 5 millimetres thick, with elastomer gaskets and at
least four full-diameter bolts. Plastic or wooden plates/closures are not acceptable. All open ends of drains,
vents, instrument tubing and small bore piping connections shall be capped or plugged with metal caps or
plugs, as applicable. Threaded caps or plugs shall be used for threaded connections. Grease fittings shall be
protected with plastic caps. Auxiliary piping connections on the generator set shall be die stamped or
permanently tagged to agree with the Packager's connection table or general arrangement drawing.
Exposed shafts and shaft couplings shall be wrapped with waterproof, mouldable waxed cloth or vapour
phase inhibitor paper. The seams shall be sealed with oil-proof adhesive tape.
If vapour phase inhibitor compounds in bags are inserted into large cavities the bags shall be attached in an
accessible area for ease of removal. Vapour phase inhibitor locations shall be clearly identified by corrosion
resistant tags and metal wire
.
All demountable internal components of control panels shall be separately packed in secure waterproof
crates. Non-demountable equipment shall be braced for transport. External surfaces of the panels shall be
protected fromabrasion during transport. Desiccants shall be inserted where necessary for preservation.
10.3 BATTERIES
Nickel-cadiumbatteries shall be supplied dry and discharged, with the electrolyte packed separately. Lead-
acid recombination type batteries must receive a commissioning charge within a period after leaving the
factory, as specified by the Manufacturer.
11. SPECIAL TOOLS
All special tools necessary for assembly, dismantling and service of the generator set shall be assembled by
the Packager fromall the equipment Suppliers. The special tools shall be supplied in lockable steel
cabinets.
One set of special tools will be necessary for multiple generator sets to be installed on the same site.
A list of the special tools and their application shall be included in the operating manual.
12. DOCUMENTS
12.1 GENERAL
All documents shall be marked in the right-hand bottomcorner with the principal's order and itemnumber
together with the Packager's references. All documents shall be in English and be distributed as specified in
DEP 40.10.01.93-Gen.
12.2 TECHNICAL INFORMATION
The Packager shall submit as a minimumthe following information and data:
- completed data sheets
- piping layout
- instrument diagram
- general arrangement drawing of all equipment also showing dry and operating masses, arrangement of
components, cable entry details, minimumspace required for erection and maintenance
- schedule and drawing of electrical, instrument and mechanical termination points
- foundation design data
- baseplate construction data
- dynamic performance calculations
- torsional and lateral vibration data
- structural dynamic calculations for generator set vibration, taking account of anti-vibration mounts
- schematic and connection diagrams of main, control, status indication, alarm, metering, protection,
trip, shutdown and auxiliary circuits
- alarmand trip setting schedules
- material specifications
- equipment lists/parts lists
- recommended spare parts lists
- preservation for shipment procedures
- operating manuals incorporating unpacking, depreservation, installation, commissioning, operating and
maintenance instructions and fault finding procedures
- manufacturer's proposed service and repair support after warranty
- test and inspection procedures
- testing programme
- certificates of conformity and declarations of compliance for equipment used in hazardous areas
- reports of all tests performed.
13. REFERENCES
In this DEP reference is made to the following publications:
NOTE: Unless specifically designated by date, the latest edition of each publication shall be used, together with any
amendments/supplements/revisions thereto.
SHELL STANDARDS
Index to DEP publications and standard specifications DEP 00.00.05.05-Gen.
Index to standard drawings DEP 00.00.06.06-Gen.
The use of SI quantities and units
(Endorsement of ISO 31 and ISO 1000)
DEP 00.00.20.10-Gen.
Requisitioning (binder) DEP 30.10.01.10-Gen
Noise control DEP 31.10.00.31-Gen.
Data sheet for equipment noise limitation * DEP 31.10.00.94-Gen.
Requisition for rotating equipment acoustic enclosures * DEP 31.10.00.96-Gen.
Diesel fuelled compression ignition engines DEP 31.29.80.30-Gen.
Requisition for internal combustion engines * DEP 31.29.80.93-Gen.
Spark ignited gas fuelled engines DEP 31.29.90.30-Gen.
Electrical engineering guidelines DEP 33.64.10.10-Gen.
Synchronous AC generators 1250 kVA and above DEP 33.65.11.31-Gen.
Requisition for synchronous for AC generators * DEP 33.65.11.93-Gen.
Requisition for packaged unit AC generator sets * DEP 33.65.11.94-Gen.
Electric motors - Cage-induction and synchronous type DEP 33.66.05.31-Gen.
Requisition for engineering documents * DEP 40.10.01.93-Gen.
NOTE:* The latest revisions of data/requisition sheets are identified in DEP binder 30.10.01.10-Gen.
STANDARD DRAWINGS
NOTE: The latest revisions of Standard Drawings are identified in DEP 00.00.06.06-Gen.
Typical HV single line diagram- generator directly
connected (voltage 11kv)
S 67.055
Typical single line and schematic diagramof control
circuits for LV emergency generator
S 67.070
Earthing boss for steel structures, tanks, vessels, etc. S 68.004
AMERICAN STANDARDS
Pipe flanges and flanged fittings ANSI/ASME B16.5
Structural welding code-steel ANSI/AWS D1.1
Issued by:
American National Standards Institute
United Engineering Center
345 East 47th Street
New York, NY 10017
USA.
Carbon steel ASTM A106
Standard specification for seamless and welded
ferritic/austenitic stainless steel pipe
ASTM A790/A790M
Issued by :
American Society for the Testing of Materials
1916 Race Street
Philadelphia
Pa. 19013-1187
USA.
BRITISH STANDARDS
General requirements for rotating electrical machines Part
140. Specification for voltage regulation and parallel
operation of a.c. synchronous generators
BS 4999
Code of practice for safety of machinery BS 5304
Issued by:
British Standards Institution
389 Chiswick High Road
London W4 4AL
England
United Kingdom.
GERMAN STANDARDS
Specification for radio interference suppression of
electrical appliances and systems
VDE 0875
Issued by:
Beuth Verlag GmbH
Burggrafenstrasse 4 - 10
D-1000 Berlin 30
Germany.
INTERNATIONAL STANDARDS
Rotating electrical machines
Part 1: Rating and performance
Part 6: Methods of cooling rotating machinery
IEC 34-1
IEC 34-6
International electrotechnical vocabulary IEC 50
Recommendations for indicating electrical measuring
instruments and their accessories
IEC 51
Electrical apparatus for explosive gas atmospheres IEC 79
Electrical relays IEC 255
Identification of apparatus terminals and general rules for an
uniformsystemof terminal marking, using an alphanumeric
notation
IEC 445
Classification of degrees of protection provided by enclosures IEC 529
Circuit breakers for overcurrent protection for household and
similar installations
IEC 898
Issued by:
Central Office of IEC (sales dept.)
3, Rue de Varemb
1211 Geneva 20
Switzerland.
Copies can also be obtained from national standards
organizations
Antistatic endless V-belts-electrical conductivity -
characteristics and methods of test
ISO 1813
Mechanical vibration of machines with operating speeds from
10 to 200 rev./s.;
Basis for specifying evaluation standards
ISO 2372
Reciprocating internal combustion engines:
Performance
Part 4: Speed governing
ISO 3046/IV
Issued by:
Central Secretariat of International
Organisation for Standarization (ISO)
1, Rue de Varemb
P.O. Box 56
CH-1211 Geneva 20
Switzerland.
Copies can also be obtained from national standards
organizations
APPENDIX 1 GENERATOR STATUS, ALARM, TRIP AND SHUTDOWN REQUIREMENTS
The table below is intended to cover all types of application. It does not imply that all the alarms, trips and
shutdowns listed herein are required on every application. The actual requirements shall be given in the
requisition.
NOTE: The reliability of a generator set may be seriously compromised by improper selection of generator trips and engine
shutdowns.
DESCRIPTION STATUS ALARM TRIP
Overcurrent voltage restraint X
Overcurrent X
Stator earth fault (*1) X (*3)
Differential X (*3)
Under voltage X X
Over voltage X X (*3)
Under frequency X X
Over frequency X X (*3)
Reverse power (*2) X (*3)
Negative phase sequence X
Loss of excitation X
Stator winding temperature - high X X
Diode failure X X
Rotor earth fault X (*3)
Bearing temperature - high X X (*3)
Local ESD X (*3)
Remote ESD X (*3)
AVR failure X
Cooler water leakage (air to water) X
Cooler generator air outlet temperature - high X
Control panel general (including control/trip supply failure) X
Lock-out general X
Generator circuit breaker 'open' (*4) X
Generator circuit breaker 'closed' (*4) X
Control/trip supply 'on' (*4) X
On acoustic enclosures: (*5)
- enclosure door(s) open X
- ventilation air flow-low X (*3)
- ventilation air temperature-high X (*3)
- fire (heat) detection X (*3)
- inhibition of carbon dioxide extinguishing system X
- gas detection on gas fuelled engines X (*3)
NOTES: *1. Where a restricted earth-fault relay is used for generator differential protection the separate stator earth-fault relay
may be omitted.
*2. To be provided only where there is continuous parallel operation with public grid or other generator sets.
*3. Shutdown of engine required in addition to generator trip.
*4. Status indication required on each application.
*5. Mandatory functions.
APPENDIX 2 TYPICAL BLOCK DIAGRAM FOR A PACKAGED UNIT AC GENERATOR SET
3.0 ADDENDUM TO DEP 33.65.11.32
Modifications and clarifications to DEP 33.65.11.32 are listed below. These items take precedence over
those within the DEP. Section numbers correspond to those in DEP 33.65.11.32.

The following are general comments to the DEP and should be applied throughout:

a. References to Shell standard drawings and forms within the DEP are not applicable to the project.
b. References to standard requisition are not applicable, as Bonga has developed its own equipment
data sheet to be used on the project.
c. References to DEPs that have an equivalent BONGA specific specification shall be superceded by
the BONGA specific document. Where applicable Bonga specific specification does not exist, the
referenced DEP shall be used.
The Principal where used shall mean SNEPCO.
1.4.2 TECHNICAL DEFINITIONS
Engine Generator Package The terms Engine Generator package in this DEP shall mean a
complete assembly with all associated equipment and
accessories necessary for a fully functional/operational unit.
2.1 GENERAL
Each Engine Generator shall be a designed, manufactured, and tested assembly consisting of
structural steel base (skid), engine, generator, and control components as defined by the contract
drawings, the data sheets and this DEP.
Based on site conditions, the engine generator shall be capable of starting, coming up to rated power,
voltage, and frequency, and accepting load within 10 seconds when engine jacket water is maintained at
32C (90F). Manufacturer/Supplier shall provide all necessary jacket water and lube oil immersion
heaters and associated controls, as described herein, to allow engine/generator to comply with these
criteria.
2.2 SAFETY
Emergency Shutdown of the unit shall result in closure of the fuel valve and closure of the
aspiration air intake valve.
2.3 SERVICE CONDITIONS
The engine generator package shall be designed for use in a highly humid, salt laden atmosphere.
3.2 NOISE
Noise control requirements shall be per BONGA-SPEC-ME-015 Noise Control.
Add new sections:
3.5 SCR LOAD CONTROL
The Engine Generator shall be able to handle any SCR type loads without requirement for
additional filters or add-on components.
3.6 WAVEFORM AND HARMONIC DISTORTION
Generator output voltage waveformdeviation shall be less than 5%. Total harmonic current
content shall be less than 3%.
3.7 PARALLEL OPERATION
Where so indicated on the data sheets the Engine Generator shall be run in parallel with either an
electrical utility or other facility generators.
4.1 ENGINE GENERAL REQUIREMENTS
Engine shall be furnished by a Manufacturer/Supplier acceptable to the Principal.
Engine horsepower rating shall be the horsepower available at the coupling to the generator, at
rated speed and after derating required for type of service, altitude, ambient temperature, and after
subtracting horsepower required by auxiliary equipment driven fromthe engine shaft.
Unless indicated otherwise, the engine shall be a four cycle, 1800 RPM, compression-ignition,
internal-combustion piston engine; liquid-cooled, diesel fueled, V-type.
The engine furnished under these specifications shall meet the requirements of the appropriate
Regulatory Agencies.
Manufacturer/Supplier shall provide engine ratings for continuous and standby service with his
proposal.
The block shall be of one-piece design and cast of high tensile strength iron in the system
manufacturers own foundry.
The crankshaft shall be a one-piece forging with wear surfaces hardened through heat treat
methods.
Cylinder wear surfaces shall be induction hardened over their entire length with rolled and
burnished edges.
Main and rod bearings shall consist of aluminumcopper-bonded to a steel backing. The wear
surface shall be coated with a lead-tin overlay.
Connecting rods shall be high strength steel with tapered pin bore.
Pistons shall be elliptically ground across the skirt and tapered fromcrown to skirt. Compression
rings shall have integral cast iron ring bands. Top rings shall be keystone sectioned.
Valves shall be stellite-faced with replaceable inserts.
4.2 AIR INTAKE SYSTEMS
Diesel Engine Generator shall be furnished with a complete combustion air systemconsisting of
inlet air filter assembly, turbocharger, aftercooler air circuits, piping and miscellaneous
appurtenances such as fittings described on the data sheets, in these specifications or required for a
complete and operable system.
Engine mounted dry-type air intake filters with replaceable elements shall be provided. Filter
assembly size shall be sufficient for operation of no less than 250 hours before replacement is
required. Elements shall be readily accessible for filter change.
The turbocharger, if so equipped, shall be engine mounted. Turbocharger shall be single stage
only. The turbocharger shall be isolated fromthermal strain and vibration by means of a stainless
steel expansion joint with liner in the exhaust piping and by a flexible sliding sleeve or corrugated
type coupling in the air inlet piping. Connections for monitoring air pressure shall be provided.
Low point drains shall be provided.
After cooler air circuit interior passages shall be coated with a corrosion inhibitor to prevent
oxidation.
Combustion air systemshall include an air damper solenoid or air inlet valve solenoid to block
combustion inlet air to engine.
4.3 EXHAUST SYSTEM
The Diesel Engine Generator shall be furnished with a complete exhaust systemconsisting of
manifolds, outlet, flexible connector, silencer and miscellaneous appurtenances as noted on the
data sheets, as described herein or as required for complete and operable system.
The exhaust manifold shall be the water-cooled type with cooling water supplied fromthe main
engine cooling system. The engine exhaust systemshall be dry type and shall be manifolded
onboard the engine generator skid to a single flanged outlet.
An exhaust silencer shall be provided. Silencer type and mounting shall be as indicated on the data
sheets. Silencer selection shall be by Manufacturer/Supplier and shall provide an acceptable level
of backpressure on the engine including allowance for piping.
A 316 SS seamless flexible exhaust expansion joint shall be provided between the engine and
silencer for the exhaust outlet piping connection to prevent weight transfer due to thermal growth
Exhaust piping and silencer shall be insulated by Manufacturer/Supplier for personnel protection.
The Engine Generator shall submit with their proposal the minimumload required to prevent the blow by
of liquid fuel fromaccumulating in the exhaust systemand becoming a fire hazard when the engine is run
unloaded or lightly loaded.
4.4 FUEL SYSTEM
The Diesel Engine Generator shall be furnished with a complete fuel systemconsisting of fuel
transfer pump, fuel injection pumps, fuel filters, fuel injection nozzles, fuel
control/governor/governor actuator assembly, fuel lines, block valves, shutdown valve or other
suitable means to block fuel flow, and miscellaneous appurtenances such as gauges and fittings as
described herein, as shown on the contract drawings or as required for a complete and operable
system. Provisions for on-board or remote fuel storage tank and associated piping thereto, shall be
as noted on the data sheets. Otherwise, the fuel systemshall be completely contained, mounted,
and piped to connection flanges at the Diesel Engine Generator skid boundary.
The primary systemshall consist of an engine driven positive displacement fuel pump, fuel
regulator, and dual, full flow filters. Provision shall be made for manual priming of the fuel system
to facilitate priming and bleeding air fromthe systemat initial startup or in the occurrence of
unscheduled repairs. The fuel transfer pump shall be capable of nine (9) foot lift fromthe fuel
storage tank, and shall deliver fuel under low pressure to individual injection pumps, one per
cylinder.
Fuel lines between pump and fuel nozzles shall be 316 stainless steel seamless tubing. Pressure
bleed valves and low point drains shall be furnished. Manufacturer/Supplier shall provide 316
stainless steel flexible fuel lines and connections to absorb vibration and relative motion across all
vibration isolators.
Fuel injection pump shall be of the self-lubricating positive displacement type equipped with
pressure relief valve. Fuel injection pumps shall be camshaft driven and controlled simultaneously
by a rack and pinion assembly that is actuated by signals fromthe engine governing system. Fuel
injection pumps shall be variable displacement type to alter volume of fuel delivered based on load
demand.
Dual fuel filters shall be contained in easily accessible steel housings and located upstreamof the fuel
injection pump and/or unit injectors as applicable. Filters shall be valued to allow changing a filter
element without shut down of engine. Filters shall be located to allow for easy removal without removing
skid enclosure. In addition to the standard filter(s), the fuel systemshall be equipped with a primary fuel
filter between the fuel tank and transfer pump to strain large contaminants. Additionally, when called for
on the data sheets, provide a fuel/water separator in the fuel inlet line to the engine to protect the fuel
systemfromwater damage.
A check valve and ball valve shall be installed between the engine driven fuel transfer pump and the
diesel storage tank. The check valve shall be mounted in the vertical position.
When a separate skid base is required by the data sheets, provide a fuel tank in the skid base sized
for either 1) the quantity of fuel, in gallons, as noted on the data sheets or 2) the number of hours
of fully loaded running, as noted on the data sheets. All fuel tank welds are subject to UT testing.
All tank couplings shall be 6000 lbs. All tank nozzles shall be 150#RF (2 and larger). The bottom
of the fuel tank shall be sloped 1/8 per foot to allow for complete drainage. The fuel tank shall be
equipped with a level indicator, high and low fuel level switches, (for alarmand closing of any
storage tank auto-fill valves), level transmitter, fill connection valve for remote fuel supply, drain
connection valve, and engine supply and return connections. The overflow and tank drains shall be
piped to the drain cup. In addition, a vent line shall provided and when appropriate, shall be piped
outside of the enclosure with a goose neck and bug screen mounted on the end.
When called for on the data sheets furnish an electrically operated shutdown valve arranged to shut off all
fuel flow in the event of emergency shutdown by safety devices. This shutdown valve, when required,
shall be a manual reset type and shall be separate and independent of the normal stop function, provided
by the governor control mechanism.
4.5 COOLING SYSTEM
The Diesel Engine Generator shall be furnished with a complete engine cooling systemconsisting
of coolant pump, radiator, fan, 3-way valve, block valves, flexible connections, piping and
miscellaneous appurtenances such as pressure gauges, thermometer, thermowells, alarmand safety
switches, immersion heater, and fittings as noted on the data sheets or contract drawings, as
described herein or as required for a complete and operable system. The cooling systemshall be
either completely contained, mounted and piped on the engine generator skid or, if data sheet
selection of options or contract drawings so require, shall be furnished complete with provisions
for interconnecting piping for off skid devices and equipment.
Coolant systemshall be closed circuit type, designed to use a commercially available corrosion inhibiting
coolant. Coolant systemshall have provisions for filling, draining, expansion and deaeration.
The engine coolant pump shall be gear driven and directly mounted to or integral with the engine.
Any auxiliary cooling pumps required for separate circuit aftercooling shall also be unit
mounted/integral and gear driven. Engine coolant pumps shall be capable of no less than 25 psi
static head.
When data sheets require a radiator as the cooling mechanism, the radiator furnished shall be sized to
adequately cool the engine when operating continuously at full rated kW output under the site conditions
specified. The radiator shall be a folded core design consisting of individually replaceable core
assemblies (modules) sealed between a top and bottomtank and arranged in accordion-like folds. Core
modules shall be replaceable individually at the job site. When data sheets require or allow a water-to-
water exchanger as the cooling mechanism, the exchanger furnished shall be a shell and tube type,
located on or off-skid as indicated on the data sheets.
Coolant systemshall contain a thermostatically controlled 3-way valve for controlling jacket
coolant temperature. This temperature controlled valve shall be full bypass type, mounted on the
engine generator skid, and completely piped and tested before shipment.
When indicated on the data sheets, the engine jacket water circuit shall be equipped with
convection flow, thermostatically controlled water heater to maintain a constant jacket water
temperature at 68F (20C). The heater shall be installed vertically and the temperature sensing
bulb shall be located on the water return side of the heater to minimize cycling. The heater system
shall be provided with features such as overcurrent protection, disconnects, contactors, and control
switches as noted on the data sheets, described herein or as required for a complete and operable
system and shall operate off of a power supply, with features and ratings as noted on the data
sheets. When an enclosed, on-board radiator type of cooling is called for on the data sheets, the
cooling systemshall be provided with a shaft driven radiator fan, which blows air out of the
enclosure. When no enclosure is specified, the cooling fan shall be a blower type to draw air from
the engine side of the core and exhaust it through an opening in a roomwall. A radiator mounted
flange shall be provided to facilitate duct installation. The fan, fan drive and fan belts shall be
covered with 14 gauge punched marine grade aluminumor 316 stainless steel mesh guarding to
protect personnel frominjury. This guarding shall conformto ISO standards.
The cooler heat rejection shall be based on the engines maximumrated horsepower plus a 15%
reserve capacity allowed for fouling.
4.6 FREQUENCY STABILITY
The governor shall be capable of both isochronous and droop operation.
Add new sections:
4.8 LUBRICATION
The Diesel Engine Generator shall be furnished with a complete oil lubrication system. This
systemshall consist of a full pressure oil systemwith oil pump, cooler, suction strainer, full flow
filter, relief valve, alarmand safety switches, block valves and miscellaneous piping and
appurtenances such as pressure gauges, thermometer, thermowells, etc. as described herein or as
required for a complete and operable system. The lube oil systemshall be completely contained,
piped and mounted on the engine generator skid. Low-point drain connections with valve and cap
shall be provided.
Lube oil pump shall be engine driven, positive displacement type, with ample capacity to circulate
the amount of lubricating oil and cooling oil required by the engine. A relief valve shall be
provided at the discharge of the lube oil pump and arranged to relieve pressure back to the
crankcase sump.
The lube oil systemshall contain a jacket water cooled shell and tube type lube oil cooler, engine
mounted. The oil cooler shall maintain lube oil supply temperature at or below
Manufacturer/Suppliers maximumallowable operating temperature for all potential operating
conditions with 15 percent excess surface available. Cooler shall be equipped with vent and drain
connections on oil and water sides.
The lube oil systemshall incorporate a strainer and a full-flow, 10 micron nominal, oil filter. The
filter shall be located downstreamof the cooler. Filter elements shall be readily accessible.
Filtration shall incorporate a bypass valve arrangement to ensure lubrication in the event of
clogging. When indicated on the data sheets furnish a local differential pressure gauge and/or
alarmswitch to indicate clogged filter and bypass valve operation. Bypass valve shall be integral
with the lube oil filter base.
Turbochargers, when provided, shall be lubricated fromthe engine lubrication system.
When indicated on the data sheets, a thermostatically-controlled electrical immersion heater shall
be provided for maintaining lubricating oil temperature at 68F (20C). Heater systemshall be
provided with features such as overcurrent protection, disconnects, contactors, and control
switches as noted on the data sheets, as described herein or as required for a complete and operable
system, and shall operate off of a power supply with features and ratings as noted on the data
sheets. Heater shall be sized to keep the value of watts per square inch at the surface of the
immersion heater elements to a minimumto prevent local lube oil carbonization on the elements.
When required by the data sheets provide a low oil level gauge and/or alarmdevice, complete with fire
safe valves, an impending low oil pressure switch for alarmpurposes, and a low oil pressure switch for
shutdown purposes. Provide block and test valves as necessary to allow periodic testing of alarmand
safety devices.
4.9 STARTING SYSTEM
The engine shall be equipped with starting system(s) of a type as noted on the data sheets. When multiple
starting systems are required, the flywheel housing shall accommodate all starter motors.
Manufacturer/Supplier shall provide equipment and/or make suitable provisions for starting systemtypes
as called for on the data sheets.
When the data sheets require electric starting, provide provisions for engine starting which shall
include starting motor and starter relay. If so noted on the data sheets provide an automatic reset
circuit breaker to protect against starter butt engagement. When the data sheets require
Manufacturer/Supplier to provide cranking batteries, they shall be sized for the number and
duration of engine starts as noted on the data sheets. Batteries shall be sized to allow for no less
than 6 starting cycles. When the data sheets require Manufacturer/Supplier to provide batteries,
they shall be furnished in a vented fiberglass enclosure suitable for outside installation. Batteries
and enclosure shall be located as noted on the data sheets.
When the data sheets require Manufacturer/Supplier to provide a pneumatic air start system, the
pneumatic starting systemshall include an air starter motor suitable for compressed air supply at
the engine generator skid edge as noted on the data sheets. Manufacturer/Supplier shall install a
metal bowl lubricator, Y-type strainer, regulator, shutdown valve, and isolating valves per contract
drawings, or as required for a complete and operable
Any starting systems required by the data sheets shall be independently capable of starting the
engine such that it can be loaded within 45 seconds fromthe initiation of start.
Manufacturer/Supplier shall provide engine air and/or hydraulic starting requirements with quotation to
allow Principal to size the off-skid air and/or hydraulic systemequipment.
4.10 ENGINE SAFETY CONTRL DEVICES
Packager shall provide the engine governor systemconsisting of a controller and an actuator as
noted on the data sheets. The governor shall be capable of both isochronous and droop operation.
The governor shall have fail-safe features such that a loss of signal shall initiate a shutdown and
shall also utilize a redundant and independent overspeed device, which will protect the engine
froma governor failure. When indicated on the data sheets, the governor controller shall be
supplied to Principal for installation off-skid in switchgear/control panel.
The governor shall have the following characteristics:
Steady State Frequency Control - Frequency shall not vary by more than .25 percent of rated
frequency when the load is varied fromno load to rated load (or vice versa) and all transients have
decayed.
Transient Frequency Control - Transient frequency deviation shall not exceed 4 percent of rated
frequency froma stabilized initial condition upon the application of rated full load (or vice versa).
The frequency shall recover to within .25 percent of rated frequency within five seconds of
application of load.
Frequency Drift - The change in frequency shall not exceed .25 percent of rated frequency with
any constant load between no load and rated full load.
Engine speed shall be monitored and controlled by an electronic speed switch of a type noted on
the data sheets, with contacts for overspeed and crank terminate. Speed switch shall be mounted in
switchgear/control panel. Manufacturer/Supplier shall furnish and install on the engine flywheel
housing a magnetic pickup compatible with this electronic speed switch. Magnetic pickup shall be
electrically connected, as shown the contract drawings, to an on-skid termination point.
Automatic shutdown and alarmdevices shall be provided and wired, by Packager, to an on-skid
termination point, as indicated on the data sheets and/or contract drawings. (Note: When data
sheets indicate engine control systemto be off-skid, it shall be Packagers responsibility to wire
alarmand shutdown end devices to an on-skid 316 stainless steel, junction box). All engine
mounted electrical devices shall operate at 24 Volts D.C. unless noted otherwise. Shutdowns shall
be fail safe, i.e., de-energize to trip.
4.11 SKID/SKID BASE
The Diesel Engine Generator shall be furnished complete with a structural steel skid. The skid
shall be a structural steel base that spans the entire distance longitudinally between the engine and
generator supports. Where indicated on the data sheets an additional skid base shall be provided.
The skid and/or the skid base shall be seal welded steel construction designed to maintain
alignment of all components to within Packagers tolerances when lifting. The skid and/or skid
base shall include a continuous drip pan with a minimumslope of 1/8 inch per foot. The drip pan
shall be sloped to a minimum2 diameter drain located, at Principals option, on either the side or
the end of the skid beams to allow for complete drainage of the contents of the pan. The drip pan
shall be constructed of a minimumof 3/16 inch thick plate and shall be seal welded to the skid or
skid base beams. All penetrations through the drip pan shall be seal welded. When an additional
skid base is required by the data sheets, a single drip pan, located in the skid base, is acceptable;
however skid base shall be sufficiently longer and wider than the engine generator skid such that
leakage/spillage fromengine generator components shall be effectively captured by the skid base
drip pan.
Packager shall furnish lifting eyes to provide ease in loading, unloading, and handling. Lift eye
arrangement and placement shall not cause damage to Diesel Engine Generator components by
normal lifting sling arrangements. Lifting provisions shall be provided for engine generator skid,
enclosure and/or overall assembly, as noted on the data sheets. Lifting lugs shall be provided at the
ends of the lifted itemfor a four point vertical lift. At Principals option, Packager shall supply a
spreader bar or frame with package. Packager shall quote spreader bar or frame as a separate line
itemcost.
Provide steel spring isolators installed under the skid or skid. base, as noted on the data sheets, for
connection to the mounting surface. These spring isolators shall be bolted to the skid or skid base.
Waffled or ribbed pads shall also be provided for installation beneath the spring isolators to block
high frequency transmissions through the springs and resist creepage. These pads shall be resistant
to oil, fuel, antifreeze, water, cleaning compounds and heat. They shall also be resistant to
compression with age. Packager shall furnish technical data on the type of isolation proposed, for
the Principals approval.
ADD the following new paragraph(s) at the end of the existing paragraph(s).The generator shall be a
revolving field, 3 phase, 50 HZ, 6 lead, wye-connected synchronous machine complete with amortisseur
windings, arranged for operation at 1800 RPM or other speed as noted on the data sheets. Generator shall
be produced by a Manufacturer/Supplier acceptable to the Principal, as shown on the data sheets.
5.1 GENERATOR REQUIREMENTS GENERAL
The generator shall have kW and voltage output ratings, as indicated on the data sheets, and be capable
of supplying full load at specified site conditions IEC 34-1 whichever is applicable.
The generator shall be capable of starting a motor load as indicated on the data sheets, when
loaded no less than 66% with a maximumallowable dip at the generator terminals of 15%.
Bidders shall provide the following with quotation:
Subtransient Reactance Subtransient Short Circuit Time Constant
Transient Reactance Transient Short Circuit Time Constant
Synchronous Reactance Armature Short Circuit Time Constant
Zero Sequence Reactance
Negative Sequence Reactance
5.3.1 EXCITATION SYSTEM GENERAL
The exciter shall be a brushless type using a rotating rectifier bridge circuit. The 3-phase full wave
rectifying unit shall be mounted on the generator rotor shaft. The exciter shall be capable of supplying the
field excitation current requirements for the generator and delivering 150 percent of its rated current for
one minute without being subject to damage. The complete exciter shall be enclosed and protected by a
removable cover.
5.10 BUSHINGS AND TERMINALS
The main power connections shall be brought out to a terminal box of sufficient size to house field
power wiring connections and any accessories. Copper bus bars shall be furnished and mounted on
suitable stand off insulators with provisions for termination of power conductors fromswitchgear.
Bus bar termination provisions shall be coordinated with the Principal to match switchgear power
conductor requirements. Bus bar arrangement shall have provision (such as removable bus links)
for isolation of generator windings for meggaring and drying without the need of disconnection of
power conductors fromswitchgear or generator. Vendor shall bring six leads of generator into this
terminal box so that a wye connection insulated neutral in the switchgear can be accomplished. Bus
bar, insulators, cable termination (both fromswitchgear and generator) arrangements shall be such
as to minimize disconnection time of switchgear power and control conductors for generator
removal and shall inhibit tracking and arc-over due to accumulated dust and moisture. Provide a
copper ground bus bar, factory installed and bonded to the generator frame and terminal box
frame, with provisions for connecting ground conductors of main power circuits fromswitchgear.
Ground bus bar termination provisions shall be coordinated with the Principal to match switchgear
ground conductor requirements. Placement of terminal box shall not interfere with cooling air flow
in or out of generator.
The terminal box shall be sized to enclose Differential Current Transformers as indicated on data
sheet. Current Transformer secondaries shall be wired to an independent terminal box containing
shorting type terminal blocks.
6.2 ENGINE CONTROL PANEL
In lieu of DEP 31.29.80.30 and DEP 31.29.90.30 the engine control panel shall be as specified
below.
Guage Panel
The Diesel Engine Generator shall be supplied with a vibration resistant gauge panel with
components and gauges as noted on the data sheets, contract drawings and/or as described herein.
The panel shall be supported fromthe engine skid and, when an enclosure is provided, either
bolted and gasketed to the enclosure or located behind a shatter-proof glass or UV resistant acrylic
viewing window such that it is visible fromthe outside of the enclosure. Panel shall be mounted
such that it will not be damaged when removing skid enclosure. Gauges shall be located at a height
between 41 and 70, referenced frombottomof skid or skid base steel, whichever is lower. No
equipment associated with the gauge panel shall require disconnection in order to remove skid
enclosure.
The gauge panel shall be complete with all wiring and tubing connections to the engine and engine
mounted devices. The panel shall have the gauges and control devices indicated on the data sheets.
All gauges shall be constructed with 316 stainless steel trim, be oil filled and corrosion resistant.
Gauge faces shall be marked with red and green color bands to indicate normal working values
(green) and out of tolerance (red) values. Gauges shall be no less than 4 1/2 diameter.
Gauge panel shall be constructed of 316 stainless steel.
Pneumatic/hydraulic gauges shall be equipped with shutoff/test valves.
Control System
The engine control systemassociated with the Diesel Engine Generator shall be furnished and/or
installed by Manufacturer/Supplier and/or others as indicated on the data sheets and contract
drawings. When the data sheets indicate that the engine control systemis to be furnished by
Manufacturer/Supplier, the Manufacturer/Supplier shall provide the following associated with
engine generator controls:
Engine control logic including alarms, shutdowns, and running and starting.
When the data sheets indicate engine control logic is to be provided via a PLC. The engine
generator control panel ladder logic software programshall be approved by Principal.
Manufacturer/Supplier shall work closely with the Principal to ensure a properly working package.
A copy of the PLC programming software, registered in the Principals name, shall be furnished.
Vendor shall provide skid wiring of end devices wired to terminals in either the engine control
panel or in an on-skid junction box as indicated on data sheets.
When the data sheets indicate the engine control systemis to be furnished by Others,
Manufacturer/Supplier shall be responsible for verification and acceptance of control panel
fabricators engine control panel logic. Also, when data sheets indicate engine control systemis to
be located off-skid, Manufacturer/Supplier shall provide that all skid wired end devices be
terminated in a 316 SS, IP56 junction box on-board the skid.
When the data sheets indicate engine control panel is to be located on-skid, Manufacturer/Supplier
shall be responsible for installing the panel and all interconnect wiring between end devices and
the control panel. Control panel shall be mounted on steel spring vibration isolators to minimize
vibration transmitted fromengine/generator. There shall be no rigid connections to the panel.
6.3.1 GENERATOR CONTROL PANEL FEATURES
Add the following:
Raise/Lower voltage adjuster shall be located on front of door.
Control panel supply voltage meter (*).
Synchroscope, Synch.. Lights and Synchronizing switch with removable handle. (If Generator can
be paralleled to other sources) (*).
Circuit Breaker control switch. (*)
Bus voltmeter (Including 4 step selector switch, Off, 1, 2 and 3) (*)
Reverse Power Relay (*)
7.6 PIPING AND INTERFACE CONNECTIONS
All piping connections shall terminate at the edge of the skid with 3000 lb. forged couplings or
ANSI 150#RF flanges per Contract Drawings. All electrical control wiring shall terminate in one
or more 316 stainless steel junction boxes or, if required by the data sheets, generator
switchgear/control panel located within the enclosure.
Unless otherwise noted, piping material, installation and welding shall be in accordance with
BONGA-SPEC-ME-008- Schedule Q Standard Specification for Pipe, Valves, Fittings and
Fabrication.
Fuel piping and valves shall be in accordance with Piping Specification Class, MDA. A stainless
steel flexible connection shall be installed on all lines connecting the engine and the fuel tank. All
exposed fuel lines shall be protected fromdamage. When the regulatory compliance is required,
fuel line from diesel storage to engine shall be equipped with a double-pipe arrangement such
that fuel line rupture can be detected. Provide suitable detection of this condition and wire
corresponding signal to an on-skid termination point. Also, arrange for closing of fuel storage tank
auto-fill valves.
All lube oil piping shall be 316 stainless steel pipe or tubing in accordance with Piping
Specification Class SS.
All piping shall be supported for service and shipment. The support and installation shall be made
to allow piping to be removed without cutting of main structural members. All on-skid piping
(diesel, coolant, oil, vents, etc.) shall be terminated to skid edge with 3000 lb. forged steel
couplings or ANSI 150#RF flanges.
Start air piping shall be in accordance with Piping Specification Class MGA.
7.7 PAINTING
Manufacturer/Supplier shall provide in his base bid the price for his standard coating systemfor
the specified environment. In addition he shall adequately define his coating systemfor
consideration in the bid evaluation. As an alternate, Manufacturer/Supplier shall include with
proposal the differential () cost to coat the equipment per BONGA SPEC-ME-014 Schedule P
Coatings and Markings.
7.8 ACOUSTIC ENCLOSURE
When an overall enclosure is called for on the data sheets, Manufacturer/Supplier shall provide the
Diesel Engine Generator with a removable, marine-grade copper free aluminumenclosure.
Enclosure shall be made of continuously welded 1/8 aluminumplate with 2 fiberglass sound-
proofing insulation held in place by perforated aluminumpaneling. Doors entering the enclosure
shall be formed, made of 1/8 aluminumwith 316 stainless steel hardware and pinned for quick
removal. Doors shall be arranged to ensure accessibility to high maintenance items, fuel filters, air
intake filters, starter, etc. All exterior hardware shall be 316 stainless steel. Care in the isolation of
the aluminumexterior and the steel skid is of the utmost importance. Contact points between the
aluminumenclosure and the steel skid shall be painted with a minimumof three coats and gasketed
using 1/4 neoprene. All bolts shall be provided with plastic washers. The enclosure shall be of
sufficient size to allow all routine maintenance without removal of any part of the enclosure (e.g.
oil change, solenoid replacement, V-belt adjustment, etc.).
Unless otherwise noted, ventilation shall be provided by the engine fan. Maximumpressure drop
across the engine/generator shall be equal to 0.5 inches of water gauge or less, including intake and
exhaust louver losses. Louvers shall have a spring closing device with a pressure trip. When fire
suppression agent is required by the data sheets and is released, the pressure trip shall release and
close the louvers. Louvers must be tightly closed so that fire suppression agent will not escape after
dumping. The louvers and pressure trip device shall be supplied by the Manufacturer/Supplier.
Enclosure design shall be such that disconnection for external or internal piping, tubing, and
electrical devices shall be minimized when removing enclosure.
Lifting eyes for enclosure removal shall be installed and labeled with a sign Caution: Lifting Eyes
For Enclosure Removal Only, yellow with black letters.
The enclosure shall contain no less than three (3) industrial grade, 18 watt U-tube type fluorescent
lighting fixtures, rated for the hazardous area classification that applies. The fixtures shall be wired
to an off/on selector switch mounted in, but not attached to, the enclosure. Provide additional
fixtures where illumination is blocked by components as determined by comparative light meter
readings.
As an option, BIDDER shall provide additional cost, delivery and size impact, if any, for an
enclosure that has sound attenuating insulation and/or features that limit the external noise level to
85 dbA at a height of 3 feet and a distance of 3 feet with louvers open.
The following sign shall be mounted on enclosure doors (yellow with black letters):
CAUTION: EQUIPMENT MAY START AUTOMATICALLY.
8.5 GENERATOR SETS FOR PARALLEL OPERATION
Reverse Power relay protection shall be provided on all units that have the ability to parallel with
other systems.
Shell Deepwater Development Systems Inc. Doc. No.: BONGA-DS-EE-007-___
Bonga Project September 1, 1999
Diesel Engine Generator Page 1 of 10
Data Sheet Rev. B
APPENDIX A - TECHNICAL DATA SHEET
Diesel Engine Generator shall comply with specification BONGA-SPEC-EE-007 and the following:
1.0 Equipment Data
Project:
Equipment Tag No.:
PlatformLocation:
Contract Drawings:
2.0 Site Conditions
Elevation ft above MSL
Temperature C (min) C (max)
Relative Humidity % (min) % (max)
Regulatory J urisdiction
( ) MMS ( ) USCG ( ) Other
Area Classification:
( ) Zone Group Temp. Rating
( ) Non-Hazardous
Degree of Protection
Acceptance Testing by SNEPCO at Equipment Delivery/Installation/Operation location
( ) will ( ) will not be performed
Acceptance Testing by SNEPCO at Equipment Delivery/Installation/Operation location
( ) will ( ) will not require Vendor representatives presence
All electrical equipment, materials and installations on the engine generator set shall be suitable for
installation in hazardous or non-hazardous area as noted above. Where area classification is noted to be
non-hazardous, BIDDER shall submit a separate price to upgrade all electrical equipment to Zone 2.
Data Sheet Rev. B
3.0 Power SystemData
Voltage Volts Frequency HZ
Number of Phases Wires W +G
System/Ground:
( ) Low Resistance ( ) High Resistance ( ) Solid
Short Circuit Data:
Three Phase: Amperes RMS Symmetrical
Peak Amperes RMS Symmetrical
Phase to Ground: Amperes
4.0 Diesel Engine Generator Performance
4.1 Diesel Engine Generator Rating
KW #of Phases
Voltage RPM
AC / DC Power Factor
Hertz Xd (min)
4.2 Motor Starting Capability
( ) 260kW, with 15% Voltage Dip
( ) Other (Describe)
Motor Size (kW) Pre-load on Generator
(KW or % of Full Load)
Starting Method
( ) Full Voltage Start
( ) Reduced Voltage (Autotransformer)
( ) 80% Tap
( ) 65% Tap
( ) 50% Tap
( ) Other (Describe)
Data Sheet Rev. B
4.3 Parallel Operation
Diesel Engine Generator
( ) will
( ) will not be run in parallel
5.0 Skid/Skid Base
5.1 Packaging - Diesel Engine Generator shall be furnished as follows:
( ) Engine and Generator on Common Skid, only
Vibration Isolators under Common Skid
( ) Required
( ) Not Required
( ) Engine and Generator on Common Skid with additional Skid Base below
and Vibration Isolators between Skid and Skid Base
Vibration Isolators under Skid Base
( ) Required
( ) Not Required
Lifting Provisions shall be provided as follows:
( ) on Enclosure *
( ) on Engine Generator Skid **
( ) on Engine Generator Skid Base ***
* Adjacent to Lifting Provisions for enclosure provide warning
sign not to attempt lift of overall assembly fromthese points.
** Adjacent to Lifting Provisions for Engine Generator Skid,
provide warning sign not to attempt lift of overall assembly from
these points.
*** Lift provisions on Engine Generator Skid Base shall be
suitable for lift of entire assembly, including enclosure, engine
generator skid, skid base with fuel storage tank, engine radiator and
lube oil reservoirs full.
Diesel Storage Tank in Skid Base
( ) Required Gallons Capacity or Hours Run Capacity @ Full Load
( ) Not Required
Data Sheet Rev. B
5.2 Enclosure
Weatherproof, marine grade enclosure
Enclosure Features
( ) Required ( ) Removable
( ) Not Required ( ) Non-Removable
Fire Detection Make and Model of Fire Detection Sensor
( ) Required ( ) General Monitor, IR-type, Model FL3002
( ) Not Required ( ) Other
Gas Detection Make and Model of Gas Detector
( ) Required ( ) General Monitor, Model S104 w/LED Display
( ) Not Required ( ) Other
Fire Suppression Type of Fire Suppression
( ) Required ( ) Water Mist Spray, Self Contained
( ) Not Required ( ) Water Mist Spray, Hybrid
( ) Water Mist Spray, Central
( ) FM-200, Self Contained
( ) CO
2
, Self Contained
( ) Other
6.0 Engine
6.1 Acceptable Manufacturer(s)
( ) Caterpillar ( ) Other(s)
6.2 Engine Combustion Features
( ) Naturally Aspirated Only ( ) Turbocharged and Intercooled permitted
( ) Turbocharged Permitted
7.0 Engine Exhaust
7.1 Provide the following type of Exhaust Silencer:
Spark-Arresting Non-Spark-Arresting
( ) Industrial MaximMSA-1 ( ) Industrial MaximM21
( ) Industrial-Commercial MaximMSA 2 ( ) Industrial-Commercial MaximM31
( ) Commercial MaximM41
( ) Residential MaximM51
7.2 Mounting of Exhaust Silencer
( ) Horizontal ( ) on Skid
( ) Vertical ( ) Ship Loose
Data Sheet Rev. B
8.0 Cooling System
8.1 Cooling SystemType
( ) Self-cooled (Radiator) ( ) Water to water
( ) Air to air ( ) Manufacturer Recommendation
( ) Air to water
8.2 J acket Water Immersion Heater
( ) Required
( ) Not Required
When required, arrange J acket Water Immersion Heater as follows:
Power Supply / / / Volts/phase/Hertz/AIC
Power Source
( ) Local (on-Skid)
( ) Remote
Location of Contactor/Overcurrent Protection
( ) Local (on-Skid)
( ) Remote
On-Skid Controls Required
( ) Low Level Switch
( ) Thermostat-Control Voltage on T-Stat Contacts__________ (AC/DC)
( ) Hand-OFF-Automatic Switch
( ) Other(s)
9.0 Lube Oil System
9.1 Fuel/Water Separator
( ) Required
( ) Not Required
9.2 Lube Oil Immersion Heater
( ) Required
( ) Not Required
Data Sheet Rev. B
Where Required, arrange Lube Oil Immersion Heater as follows:
Power Supply / / / Volts/phase/Hertz/AIC
Power Source
( ) Local (on-Skid)
( ) Remote
Location of Contactor/Overcurrent Protection
( ) Local (on-Skid)
( ) Remote
On-Skid Controls Required
( ) Low Level Switch
( ) Thermostat-Control Voltage on T-Stat Contacts____________ (AC/DC)
( ) Temperature Safety High
( ) with Manual Reset Feature
( ) without Manual Reset Feature
( ) Hand-OFF-Automatic Switch
( ) Other(s)
10.0 Starting System
( ) Electric Batteries Located:
Volts DC ( ) On Skid
( ) Inside Skid Enclosure, When provided
Batteries Furnished By: ( ) Outside Skid Enclosure, When provided
( ) Vendor ( ) Off Skid
( ) Others
Battery Charger Furnished By: Battery Charger Located:
( ) Vendor ( ) On-Skid
( ) Others ( ) Off-Skid
Automatic Reset Circuit Breaker
( ) Required
( ) Not Required
Battery Sizing
( ) 6 starting cycles
( ) Other
Number of consecutive starts without battery recharge
Duration, in seconds of each start
( ) Pneumatic Air Pressure at Skid Limits ________ PSIG
( ) Hydraulic Hydraulic Pressure at Skid Limits ________ PSIG
Data Sheet Rev. B
11.0 Engine Safety/Control Devices
Item Alarm Location Furnished By
No. Required Description or S/D Tag (Skid/Remote) Vendor Others
11.1 ( ) Electronic Speed Switch
Type/Cat. No. ___________________
ESS/OSS
11.2 ( ) Magnetic Pickup for Item11.1
Type: __________________________
11.3 ( ) Governor Actuator w/rheostat
Type: __________________________
11.4 ( ) Governor Control
Type: __________________________
11.5 ( ) J acketwater Level Low
Type: __________________________
11.6 ( ) J acketwater Temperature High
Type: __________________________
11.7 ( ) Lube Oil Level Low
Type: __________________________
11.8 ( ) Lube Oil Temperature High
Type: __________________________
11.9 ( ) Lube Oil Pressure Low
Type: __________________________
11.10 ( ) Lube Oil Filter dP High
Type: __________________________
11.11 ( ) Diesel Fuel Level Low
Type: __________________________
11.12 ( ) Diesel Fuel Level High
Type: __________________________
11.13 ( ) Diesel Fuel Filter dP High
Type: __________________________
11.14 ( ) Diesel Fuel Line Rupture
Type: __________________________
11.15 ( ) Cooling Fan Vibration High
Type: __________________________
11.16 ( ) Start Air Pressure Low
Type: __________________________
11.17 ( ) Turbocharger Discharge
Air Pressure High
Type: __________________________
11.18 ( ) Fire Suppression Agent Released
Type: __________________________
11.19 ( ) Emergency Shutdown Pushbutton
Type: __________________________
11.20 ( ) Thermal Fire Sensor
Type: __________________________
11.21 ( ) Infrared Fire Sensor
Type: __________________________
11.22 ( ) Other: __________________________
Type: __________________________
Data Sheet Rev. B
Item Alarm Location Furnished By
No. Required Description or S/D Tag (Skid/Remote) Vendor Others
11.23 ( ) Other: __________________________
Type: __________________________
11.24 ( ) Other: __________________________
Type: __________________________
11.25 ( ) Other: __________________________
Type: __________________________
OPTIONAL EQUIPMENT
11.26 ( ) Governor Load Control Unit
Type: __________________________
11.27 ( ) Governor Automatic Synchronizer
Type: __________________________
11.28 ( ) Other: __________________________
Type: __________________________
11.29 ( ) Other: __________________________
Type: __________________________
12.0 Gauge Panel
Item Range
No. Required Description of Gauge/Meter/Control (Provided by Vendor)
12.1 ( ) Lube Oil Pressure
12.2 ( ) Lube Oil Temperature
12.3 ( ) J acket Water Temperature
12.4 ( ) Inlet Manifold Pressure (Turbo Charged Engines)
12.5 ( ) Lube Oil Filter dP
12.6 ( ) Diesel Fuel Filter dP
12.7 ( ) Start Air Pressure
12.8 ( ) Tachometer (Electronic)
12.9 ( ) Engine Air Intake ESP (Manual Operator) N/A
12.10 ( ) Emergency Shutdown Pushbutton
Type: __________________________
N/A
12.11 ( ) Other: __________________________
Type: __________________________
12.12 ( ) Other: __________________________
Type: __________________________
12.13 ( ) Other: __________________________
Type: __________________________
12.14 ( ) Other: __________________________
Type: __________________________
Data Sheet Rev. B
13.0 Control System
13.1 Type of Engine Control System
( ) Relay Logic ( ) PLC
Indicate Manufacture and Type
13.2 Location of Engine Control System
( ) On-Skid ( ) Off-Skid
( ) In 316 SS Panel
( ) In Switchgear (i.e. No Separate Engine Control Panel)
13.3 Engine Control Systemto be Furnished by:
( ) Vendor
( ) Others
13.4 When utilized, Engine Control Panel features shall include:
( ) Generator Main Circuit Breaker to be included in Engine Control Panel
( ) Type of Main Breaker
( ) Molded Case Thermal Magnetic
( ) Insulated Case
( ) Air Circuit Breaker
( ) Generator Main Circuit Breaker to be Furnished by Others in Remote Switchgear.
14.0 Generator
14.1 Acceptable Manufacturer
( ) KATO ( ) Other
( ) Ideal
14.2 Location of Generator Voltage Regulator
( ) In Engine Control Panel
( ) In Switchgear
14.3 Manual Voltage Regulator
( ) Required
( ) Not Required
Where required, location of Manual Voltage Regulator
( ) In Switchgear
Data Sheet Rev. B
14.4 Additional Generator Excitation/Control Equipment
14.4.1 Equipment
( ) Underfrequency/Overvoltage Control -
( ) UFOV Shunt-Trip Breaker
( ) Voltage Adjusting Rheostat
( ) Cross-Current Compensation Current Transformer
( ) PF/VAR Control Unit-
( ) Other
14.4.2 Location
( ) In Switchgear
14.5 Generator Optional Accessories
( ) Stator RTDs - 100 , Platinum, 3 wire type
( ) Bearing RTD - 100 , Platinum, 3 wire type
( ) RTD Monitor -
Location
( ) In Switchgear
( ) 3-Phase Surge Capacitor (MV Generators Only)
( ) Station Class MOV type Surge Arrestors (MV Generators only)
( ) Vibration Switch -
( ) Vibration Monitor
( ) Current Transformer (for Differential Protection)
15.0 Comments:
Shell Deepwater Development Systems Inc. Attachment B to Doc. No.: BONGA-SPEC-EE-007
Generator Performance Data Sheet Rev. B
APPENDIX B - ENGINE AND GENERATOR PERFORMANCE DATA
1.0 Vendor shall provide the following Engine ratings and performance data:
a. Engine: n. Ambient capacity of radiator C
Make
Model o. Combustion air flow CFM
Bore
Stroke p. Max allowable exhaust
Number of Cylinders backpressure psi
b. Continuous Rating HP q. Exhaust gas flow CFM
c. Intermittent Rating HP r. Exhaust gas stack temp. C
d. MaximumRating HP s. Heat rejection to exhaust KW
e. Displacement cu. in. t. Heat rejection to coolant KW
f. Piston speed fpm u. Heat rejection to atmosphere KW
g. Compression ratio v. Weights-Individual (Dry)
Engine lbs.
h BMEP psi Generator lbs.
Radiator lbs.
i. Speeds Skid lbs.
Skid Base lbs.
Synchronous RPM Enclosure lbs.
Minimum RPM
Recommended Idle RPM w. Recommended alarmand shutdown setpoints of
safety devices-Attach addition sheet(s)
j. Fuel consumption-based on fuel having an LHV of
42,780 kJ /kg when used at 29C and weighing 838.9 x. Exhaust temperatures
g/liter:
25% Load gal/hr 25% Load
k. Lube oil capacity gals y. Exhaust volume at allowable
pressure drop
l. Coolant capacity gals 25% Load CFM
50% Load CFM
m. Required radiator air flow CFM 75% Load CFM
100% Load CFM
Shell Deepwater Development Systems Inc. Attachment B to Doc. No.: BONGA-SPEC-EE-007
Generator Performance Data Sheet Rev. B
2.0 The following Generator ratings and performance data:
a. Frame size h. Voltage
Line to Line
b. Number of poles Line to Neutral
c. .8 pf efficiency i. RMS Current-3 phase @
25% Load full load Amps
50% Load
75% Load j. Voltage adjustment range
100% Load
d. Stator and field resistance at 25C k. Speed regulation accuracy
Stator ohms
Field ohms l. 3% speed change
regulation accuracy
e. Reactances
Subtransient (Xd) % m. Waveformdeviation
Transient (Xd) % percentage line-line @ no
Synchronous(X
d
) % load
Zero Sequence (X
o
) %
Negative Sequence (X
2
) % n. Rotor weight lbs.
f. Short Circuit Time constants o. Stator weight lbs.
Subtransient (Td) secs
Transient (Td) secs p. Heat dissipation at full load KW
Armature (T
a
) secs
q. Air flow requirements CFM
g. Excitation voltage and current at
no load and .8 PF
Current Amps
Voltage Volts
3.0 Torsional Analysis - Certification that torsional vibration analysis has been performed on all prototype
equipment.
4.0 Transient Capability - Manufacturer-published verification of transient load acceptance in compliance
with ISO 8528, DIN 6280, ABGSM TM-3.
5.0 Warranty Statements - Manufacturer published verification.
6.0 Service - Location and description of suppliers, parts and service facility including parts inventory -
Attach additional sheets
REVISION RECORD SHEET
B 1-Sep-99 Issued for Use on Bonga Project MDH MDH MLB
A 23-Aug-99 Initial Issue MDH MDH MLB
Rev. Issue
Date
Description of Revision ENGR
APPR.
PROJ.
APPR.
SHELL
APPR.
Shell Deepwater Development Systems Inc.
Bonga Project
Document Title
Diesel Engine Generator Set
Specification
Document
Number BONGA - SPEC - EE - 007
Rev. No.
B
Page Total
(Excluding this Cover)
69

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