Materials System Specification

17-SAMSS-518 Diesel Generator Sets Motors and Generators Standards Committee Members
Anizi, Thani Salem, Chairman Vouk, Alfred Oswald, Vice Chairman Khairallah, Hussain Ali Hassouneh, Awwad Shaban Mahfoudhi, Refaat Dabbousi, Rami Mohmmed Osama As Swaimil, Mohammad Ahmed Asiri, Yahya Ahmad Najjar, Elias Mikhael Zayir, Zaki Abdulla Zainaddin, Samir Ahmed Gurouni, Hesham Hamad Qahtani, Naser Hadi

13 June 2006

Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 6 7 8 9 Scope............................................................. 2 Conflicts and Deviations................................ 2 References.................................................... 2 Alternative Designs....................................... 3 Coordination Responsibility........................... 4 Definition of Terms......................................... 4 Basic Design.................................................. 5 Accessories.................................................. 13 Inspection, Testing and Preparation for Shipment..................... 16 10 Vendors Data (Non Material Requirements)............... 18

Previous Issue: 29 June 2005 Next Planned Update: 1 March 2008 Revised paragraphs are indicated in the right margin Primary contact: Carlson, Ronald Wayne on 966-3-8746128 CopyrightSaudi Aramco 2005. All rights reserved.

Page 1 of 20

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008

17-SAMSS-518 Diesel Generator Sets

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

Scope 1.1 This specification defines mandatory requirements governing the design and selection of stationary or portable diesel-engine-driven generator sets used for standby, intermittent (prime), and continuous power generation, rated from 35 kW up to and including 2000 kW (at 0.8 p.f.). This specification is not applicable to shipboard marine installations. Installations in locations classified as hazardous will require additional features to be specified in the project specification. Diesel generator sets and auxiliary equipment shall be supplied by Vendors qualified by a minimum of two years of experience in manufacturing units of comparable rating at the proposed point of manufacture and complying with ISO 9000 quality standards. Only diesel generator sets which have a proven satisfactory history of operation for at least two years will be considered. The Vendor shall also have a local, Saudi Arabian, authorized dealer with parts, service facilities and engineering support.

1.2

Conflicts and Deviations 2.1 2.2 2.3 If there are any conflicts between this Specification and associated purchasing, project or engineering documents, this specification shall take precedence. Direct all requests to deviate from this Specification in writing to the Company or Buyer Representative, who shall follow internal company waiver procedure. The designation "Commentary" is used to label a sub-paragraph that contains comments that are explanatory or advisory. These comments are not mandatory, except to the extent that they explain mandatory requirements contained in this SAMSS.

References The following is a summary of all the documents which have been mentioned within this Specification. The specific part(s) of these documents which are applicable have been identified throughout this Specification. 3.1 Saudi Aramco References Saudi Aramco Engineering Standard SAES-A-105 Noise Control Page 2 of 20

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008 Saudi Aramco Product Specification Code A-888 Diesel

17-SAMSS-518 Diesel Generator Sets

Saudi Aramco Inspection Requirements Form 175-170400 Diesel Engine Generator Set

Saudi Aramco Forms and Data Sheets Form NMR-7908 Form NMR-7912 Form NMR-7923 3.2 Industry Codes and Standards International Organization for Standardization ISO 3046 ISO 8528 Reciprocating Internal Combustion EnginesPerformance Reciprocating Internal Combustion Engine Driven Alternating Current Generating Sets Nonmaterial Requirements for Diesel Engines Nonmaterial Requirements for Electric Rotating Machinery Nonmaterial Requirements for Control Panels

National Electrical Manufacturers Association NEMA MG 1-22 Synchronous Generators-Salient Pole Type

National Fire Protection Association NFPA 99 Standard for Health Care Facilities

Institute of Electrical and Electronics Engineers IEEE C57.13 Requirements for Instrument Transformers

Society of Automotive Engineers SAE J1349 Engine Power Test Code - Spark Ignition & Diesel

Underwriters Laboratories, Inc. UL 489 4 Alternative Designs 4.1 All deviations from this specification shall be separately listed by the Vendor in his quotation and shall refer to the relevant paragraph numbers. Molded Case Circuit Breakers

Page 3 of 20

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008 4.2

17-SAMSS-518 Diesel Generator Sets

Refer to Section 2 for direction on conflict resolution between documents. For example, if there are any conflicts between this Specification and associated project or engineering documents, this specification shall take precedence.

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

Definition of Terms Continuous Service: Service for constant load conditions, where operation exceeds 8000 hours per year with uninterrupted periods of 1000 hours minimum.
Exception: For annual overhauls, shutdowns for maintenance shall not exceed 24 hours.

Intermittent (Prime) Service: Service for varying load conditions, where operation exceeds 500 hours per year, but is less than 8000 hours per year. Standby Service: Operation of the diesel generator set only during failure of the normal power supply, not to exceed 500 hours per year. Continuous Power: Maximum effective output which the diesel generator set is capable of delivering continuously, as defined in ISO 8528-1, including an allowance for deterioration, with the limit of output being such as to permit overload power as defined in ISO 3046-1. Limited-Time Running Power: The maximum power which the generating set is capable of delivering for up to 500 hours per year, of which a maximum of 300 hours is continuous running between stated maintenance intervals and under the stated ambient conditions, the maintenance being carried out as prescribed by the diesel engine manufacturer, as defined in ISO 8528-1. Diesel Generator Set Rating: Available generator terminal kilowatts when the diesel generator set is running under actual site conditions of maximum ambient temperature, altitude and humidity. All nameplate rating data shall be the site rating. Portable generator set: Self-contained generator package, usually skid mounted, containing all the equipment and auxiliaries necessary to deliver power (e.g., fuel tank, circuit breaker, lube oil system, exhaust system, air intake system, control panel etc.). Characterized by the fact that the only connection to the skid package is the primary power load connection. Page 4 of 20

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008

17-SAMSS-518 Diesel Generator Sets

Fixed mounted generator: Those generators that do not fit the definition of a portable generator set. 7 Basic Design 7.1 General 7.1.1 7.1.2 7.1.3 7.1.4 Terms in bold font are defined within Section 5 All materials, equipment and parts comprising the units specified above shall be new, and of current manufacture. Equipment shall meet all applicable codes, including those listed in Section 1.5. The equipment covered by this specification shall be suitable for the specified operating conditions and shall be designed and constructed for a minimum service life of 20 years. Environmental Conditions The equipment will be installed in a desert area under extreme climatic conditions, where ambient air temperatures can vary from 0C to 50C and relative humidity from 0 to 100% (condensing). Metal temperature when exposed to direct sun light can reach 70C. Onshore, the normal airborne dust concentration shall be considered as 1 mg/m. During sand storm conditions, dust concentrations reaching 500 mg/ m are encountered and winds may gust to 112 km/hr. 95% of all dust particles are less than 20 micrometers, and 50% of all particles are less than 1.5 micrometers in size. Compounds present in the dust include those of sodium, calcium, magnesium, silicon and aluminum. When wetted (100% humidity condition), these compounds function as electrolytes and can result in severe corrosion of materials. Other pollutants present (ppm in vol/vol in atmosphere, worst case) are H2S (5 ppm), SO2 (5 ppm), CO (100 ppm), NOx (5 ppm) and hydrocarbons (50 ppm). All equipment shall be protected from these contaminants to prevent corrosion and operational failure. In addition to the above requirements, equipment that is situated offshore or nearshore (i.e., within km from the shoreline) shall also be protected against failure due to wind-borne seawater spray and the accumulation of wetted salt (NaCl).

7.1.5

Page 5 of 20

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008 7.1.6 7.1.7

17-SAMSS-518 Diesel Generator Sets

Diesel generator sets for installation in health care facilities shall comply with NFPA 99 requirements. Noise Diesel generator sets shall not generate noise in excess of 90 dBA at a distance of one meter meter from the enclosure. For a diesel generator set located inside a dedicated ground floor room within a building, the enclosure is considered to be immediately outside the walls and ceiling of the room within which it is installed. For a diesel generator set located inside a dedicated building the enclosure is considered to be immediately outside the walls and ceiling of the building. Any exceptions to this requirement must be requested at the time of purchase order and must be approved in accordance with paragraph 2.2. Control of the sound pressure level to meet the specified requirements shall be the sole responsibility of the Vendor. If the sound pressure level will exceed 90 dBA at 1 meter, the vendor shall notify the purchaser at the time of quotation and quote the additional cost for modifications to insure the installed sound pressure level does not exceed 90 dBA at 1 meter. If the diesel generator set is located within a building, the vendor shall document the maximum sound pressure level at 1 meter from the diesel generator set under full load operating conditions and include this information in the manual. A "Noise Hazardous Area" sign shall be posted outside all access doors (as per Saudi Aramco standard SAES-A-105) warning personnel about the excess noise inside the dedicated room or dedicated building. This sign shall require personnel to wear appropriate ear protection.

7.2

Rating The diesel generator set rating shall be derived from the requirements of paragraphs 7.2.1 through 7.2.4. 7.2.1 7.2.2 Derating for site conditions shall be calculated in accordance with SAE J1349. For continuous and intermittent (prime) service, the continuous power at site conditions shall be at least 100% of the maximum electrical load. For standby service, the limited-time running power at site conditions shall be at least 100% of the maximum electrical load.

7.2.3

Page 6 of 20

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008 7.2.4

17-SAMSS-518 Diesel Generator Sets

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

7.3

Generator Design The generator shall be a three-phase, brushless, synchronous type built to NEMA MG 1-22. 7.3.1 The insulation system, including leads, shall consist of lowhygroscopic material. The system shall be Class F or Class H insulation with tropicalization and anti-fungus treatment. The temperature rise, above an ambient of 50C, measured by resistance, shall not exceed 70C for generators with Class F insulation, and 95C for generators with Class H insulation. Balance adjustment shall be made only by addition of weights. Generators shall have provisions for possible future rotor balancing in a maintenance shop by the addition of weights. The generator frame shall be provided with two ground pads welded to the skid on diametrically opposite corners. All current transformers and potential transformers shall be in accordance with ANSI/IEEE C57.13. Continuous-duty generators rated 1250 kW and above shall have two RTDs per phase. RTDs shall be platinum, 100 at 0C.

7.3.2

7.3.3 7.3.4 7.3.5 7.4

Mechanical Design 7.4.1 Enclosure When installation outside of a building is specified on Data Schedule1, a self-contained enclosure shall be provided for the diesel generator set. The enclosure shall be manufactured such that all parts are accessible for inspection and minor maintenance without removal of the enclosure or enclosure roof. It shall include the following features: a) The enclosure and all other items shall be designed and built by the supplier as an integral part of the entire diesel generator set, and shall perform without overheating in the environment specified. It shall be constructed of minimum 14-gauge sheet metal, suitably reinforced to reduce vibration in the operating mode. Page 7 of 20

b)

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008 c)

17-SAMSS-518 Diesel Generator Sets

A minimum of four doors are required. The doors shall be hinged so that they can be opened to provide complete access to the equipment inside the enclosure without removing the doors. The side and rear panels shall be completely and simply removable to permit major service access. Doors shall be lockable. All exterior steel surfaces, including those in contact with the foundation, shall be epoxy-or epoxy-mastic-coated as a minimum. Interior surfaces shall have the vendor's standard finish. All fasteners shall be corrosion-resistant in the environment described in paragraph 7.1.5. Batteries shall fit inside the enclosure and alongside the engine (batteries under the generator are not acceptable). The unit shall have coolant and oil drains piped to the outside edge of the skid in an accessible location. Each drain line shall have a valve located near the fluid source. Motorized air intake and radiator-discharge louvers shall be provided when specified on Data Schedule-1. The louvers shall be sized to provide sufficient airflow for engine combustion, engine cooling and generator cooling. The louvers shall open automatically when the engine receives the start signal and close when the engine stops. They shall also allow manual over-ride. The air intake and exhaust outlet shall be configured such that exhaust gas recirculation to the air intake will not occur under any wind direction. 120 VAC lights, light switch, 120 V receptacles, and an associated load panel shall be provided. The 120 V source will be provided by others.

d) e) f)

g) h)

i)

j)

k)

7.4.2

Mounting 7.4.2.1 Unless otherwise specified, the diesel generator set, including the control panel and radiator, shall be mounted and shipped on a single steel skid, and shall be provided with suitable vibration dampers. Units rated 200 kW and below shall have rubber vibration dampers installed between the engine-generator and the skid.

7.4.2.2

Page 8 of 20

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008 7.4.2.3

17-SAMSS-518 Diesel Generator Sets

Units above 200 kW shall be supplied with spring-type vibration dampers, which shall be installed between the skid and the foundation.

7.4.3

Fuel and Fuel System 7.4.3.1 Using diesel fuel conforming to Saudi Aramco Product Specification Code A-888, the engine shall be capable of starting and operating at the minimum site ambient temperature specified on Data Schedule-1. A day tank and associated fuel piping shall be furnished by the Vendor. The day tank capacity shall be as specified on Data Schedule-1. The day tank shall have a valved drain, an adequate sized breather vent designed to exclude dust and water from the tank, and a tank level sight glass. The fuel system shall incorporate flexible fuel lines between the day tank and the engine to isolate vibration. Fuel filter(s), a manual or engine-driven fuel priming pump and a fuel transfer pump shall be provided. When continuous service is specified on Data Schedule-1, fuel filters shall be of the duplex, full flow, cartridge type having a filter mesh not exceeding 10 micrometers. The duplex filters shall have a cross-over valve. The fuel filter shall be located such that spilled fuel cannot fall on hot parts of the engine or generator. A cleanable primary fuel strainer shall be used to collect sediment between the tank and the main engine fuel filter. A fuel/water separator shall protect the system from water damage.

7.4.3.2

7.4.3.3

7.4.3.4

7.4.4

Engine Air Intake Engine intake air filters shall be a combined heavy duty pre-cleaner (e.g., inertial separator) and dry filter arrangement with a local differential pressure indicator. The filters shall be suitable for the environmental conditions specified in paragraph 7.1.5.

7.4.5

Exhaust System 7.4.5.1 Each diesel engine shall be equipped with an exhaust silencer of the grade specified on Data Schedule-1. For engines 600 kW and above, the silencer shall be mounted Page 9 of 20

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008

17-SAMSS-518 Diesel Generator Sets

such that its weight is not supported by the engine. Exhaust piping, including silencers and weather caps, shall be sized such that exhaust back-pressure will not exceed the maximum limitations specified by the diesel generator set manufacturer. 7.4.5.2 The Vendor shall supply the complete exhaust system, including silencer, companion flanges, flexible stainless steel bellows-type exhaust fittings, and rain cap.

7.4.6

Speed Governing 7.4.6.1 The engine governor shall be selected to meet the steady state and transient response requirements of the operating performance class specified on Data Schedule-1 in accordance with ISO 8528-5, Table 3. For diesel generator sets of 600 kW rating or higher, the governor shall be a Woodward 2301A or Saudi Aramco approved equivalent. An overspeed device shall be provided which shuts off either fuel, air, or both, to the diesel engine in the event of an overspeed condition.

7.4.6.2

7.4.7

Starting System 7.4.7.1 Capability The starting system shall include the capability to reliably start the diesel generator set in cold, dense fog conditions. This may involve the addition of a starting aid which shall be provided by the Vendor, if so required. 7.4.7.2 Starting Motor A DC electric starting system with a positive engagement drive shall be furnished unless otherwise specified. 7.4.7.3 Alternator When continuous service is specified, an engine driven alternator shall be included. Alternator shall provide DC regulated output to charge batteries. 7.4.7.4 Automatic Controls

Page 10 of 20

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008

17-SAMSS-518 Diesel Generator Sets

When intermittent (prime) or standby service is specified, fully automatic diesel generator set start-stop controls shall be provided in the control panel. Crank cycle circuitry for multiple crank attempts shall be provided by the Vendor. Automatic starting shall be initiated from a user supplied set of normally open dry contacts which close to start. 7.4.8 Cooling 7.4.8.1 The engine cooling system shall be a thermostatically controlled, closed-circuit design. The system shall have sufficient capacity to maintain stable operating temperatures at maximum engine output and under the worst site conditions. The coolant pump shall be integral with the engine. Unless otherwise specified, a skidmounted radiator with a header make-up tank and a pressurized filling cap shall be included. The engine cooling fan shall be the blower type. The fan, fan drive, and fan belts shall be covered with 14-gauge (minimum) steel mesh guarding, to protect personnel from injury. A unit-mounted, thermal circulation-type, jacket-water heater incorporating a thermostatic switch shall be furnished to maintain engine jacket water at 32.2C in an ambient temperature of 0C. Water heater shall be positioned to circulate warm water evenly around all cylinders. AC power for the jacket-water heater shall be as specified on Data Schedule-1. When continuous service is specified on Data Schedule-1, the diesel generator set is located indoors and is rated above 500 kW, then either a shell-and-tube heat exchanger shall be used, or the cooling radiator shall be located outside the building. Coolant for the engine cooling system shall comply with the specification requirements of the diesel engine manufacturer.

7.4.8.2

7.4.8.3

7.4.8.4

7.4.8.5

7.4.9

Lubrication

Page 11 of 20

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008 7.4.9.1

17-SAMSS-518 Diesel Generator Sets

The engine main lube oil pump shall be the positivedisplacement gear-driven type that is integral with the engine, and shall be easily accessible for maintenance. If the design oil temperature exceeds 120C, an oil cooler shall be provided to limit the lube oil temperature in the oil pan at the oil pump inlet. Lube oil filters shall be located downstream from the lube oil coolers. When continuous service is specified on Data Schedule-1 applications, filters shall be the duplex type for changeover during diesel operation. The diesel generator set shall include an easily accessible provision for lube oil drainage at the edge of the base or rails. Inaccessible grease fittings shall be tubed to extend to the edge of the skid for ease of maintenance.

7.4.9.2

7.4.9.3

7.4.9.4

7.4.10

Generator Bearings 7.4.10.1 Anti-friction bearings shall have no filling slots. Bearing race-metal temperature shall not exceed 90C based on a maximum ambient temperature of 50C. Regreasable bearings shall be provided with two NPTtapped-and-plugged holes, and fill-in and drainage plugs. The holes shall be provided with threaded Type 300 Series stainless steel plugs.
Exception: Sealed anti-friction bearings may be provided if specified by Saudi Aramco for units in intermittent or standby service.

7.4.10.2

7.4.10.3 7.4.10.4

Bearings shall be serviceable without moving or disconnecting the generator. Sleeve-type bearings shall be equipped with split, labyrinthtype end seals and deflectors where the shaft passes through the housing. Lip-type seals shall not be used. The sleeve bearing shell-metal temperature shall not exceed 90C based on a maximum ambient temperature of 50C.

Page 12 of 20

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008 7.4.10.5 7.4.10.6

17-SAMSS-518 Diesel Generator Sets

Two-bearing generators shall have interchangeable bearings. Two-bearing generators rated 400 kW (500 kVA) and above shall have one bearing electrically insulated from the generator frame or baseplate.

7.4.11

Vibration The generator set manufacturer shall provide a Torsional Vibration Analysis for the diesel generator set specified.

7.4.12

Nameplates and Rotation Arrows 7.4.12.1 Nameplates and rotation arrows shall be Type 316 stainless steel or monel, securely fastened by pins of similar material. They shall be located such that the information can be read after the equipment is installed. Entries shall be marked by etching, engraving or other methods of permanent marking. The following data is required on the generator nameplate, in addition to the requirements of NEMA MG 1-22 and ISO 8528-5, and may be on a separate nameplate: a) b) c) d) e) Buyer's purchase order number Manufacturer's location Rotor weight Manufacturer's order reference number Insulation system designation

7.4.12.2

Accessories 8.1 Voltage Regulator 8.1.1 Generators shall incorporate an excitation system with an automatic voltage regulator (AVR). The AVR unit shall maintain generator terminal voltage within 1% of nominal value over the load range, up to full load. Voltage level adjustment shall be minimum of 5%. When parallel operation is specified on Data Schedule-1, the generator shall incorporate reactive cross current compensation. The automatic voltage regulator shall use three-phase sensing and shall be a temperature-compensated, solid-state design. The solid-state

8.1.2

Page 13 of 20

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008

17-SAMSS-518 Diesel Generator Sets

regulator module shall be shock-mounted and epoxy-encapsulated for protection against vibration and atmospheric deterioration. 8.1.3 The voltage regulator shall be of an asynchronous, pulse-widthmodulated design that is insensitive to severe load induced wave-shape distortion from SCR or thyristor loads.

8.2

Control Panels 8.2.1 The generator control panel shall contain all switches, relays, pushbuttons, meters, operational lighting, and pilot lights required for engine checkout, control, instrumentation, and operation. For portable generator sets, the panel shall be mounted on vibration isolators to prevent engine vibration from damaging the enclosed equipment. If specified, control panels for fixed mounted generators shall be supplied separate from the generator and shall be suitable for mounting remote from the generator. The control panel shall provide the following controls: a) b) c) d) e) f) 8.2.3 Manual- Off- Auto- Reset select. One or more switches can be used to implement these functions. Voltage "raise/lower" switch Governor "raise/lower" switch (when electronic governors are supplied) Lamp test switch Ammeter/voltmeter phase select switch or switches with off position Stop push-button

8.2.2

The control panel shall contain, but not be limited to, the following readout devices: a) b) c) d) e) f) g) Engine oil pressure indicator Coolant temperature indicator Voltmeter, 1.5% accuracy Ammeter, 1.5% accuracy Frequency meter, 5% accuracy Kilowatt meter Engine tachometer Page 14 of 20

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008 h) i) 8.2.4 System DC voltmeter Engine running hour meter

17-SAMSS-518 Diesel Generator Sets

The control panel shall provide the following annunciation: a) b) c) d) e) f) g) h) i) j) k) l) Generator on load (status) Low coolant temperature (alarm) Charger failure (alarm) Low battery voltage (alarm) Low fuel level (alarm) High coolant temperature (alarm) High coolant temperature (shutdown) Low oil pressure (alarm) Low oil pressure (shutdown) Overcrank (shutdown) Overspeed (shutdown) Select switch not in auto position (alarm) (1)

Note (1): Not applicable for continuous duty applications.

The annunciator shall contain normally open dry contacts for summary of the seven alarms and four shutdowns listed above. 8.2.5 In addition to the control panel stop pushbutton, for diesel generator sets 600 kW and above, an emergency stop pushbutton shall be mounted at the corner of the skid opposite of the control panel.

8.3

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

8.4

Battery and Battery Charger 8.4.1 A lead-acid storage battery set of the heavy-duty diesel starting type shall be provided. The battery voltage shall be compatible with the starting system. A corrosion-resistant base-mounted battery rack with Page 15 of 20

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008

17-SAMSS-518 Diesel Generator Sets

necessary cables and clamps shall be provided. The battery shall be capable of cranking the engine for a minimum of five 30 second cranking periods at the minimum rated ambient conditions. 8.4.2 When standby-service or intermittent (prime) service is specified, a current-limiting, float-equalize, Underwriter Laboratories (UL) listed charger shall be furnished to automatically recharge the batteries. The charger shall float at 2.17 volts per cell and equalize at 2.33 volts per cell. It shall include overload protection, silicon diode full-wave rectifiers, voltage surge suppressers, a DC ammeter, and fused DC output. AC input voltage shall be as specified on Data Schedule-1. Amperage output shall be no less than 5 amperes.

8.5

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

Inspection, Testing and Preparation for Shipment 9.1 General Inspection and testing of the diesel generator set shall be carried out as indicated on Data Schedule-1 and Saudi Aramco Inspection Requirements Form 175-170400. 9.2 Testing 9.2.1 Standard Shop Tests Standard shop tests are required for all diesel generator sets with a site rating of 200 kW (250 kVA) and less. Witnessing shall be required if specified on Data Schedule-1; otherwise, certificates are sufficient. 9.2.2 Performance Tests 9.2.2.1 Performance tests are required for all diesel generator sets with a site rating of more than 200 kW (250 kVA). The Buyer or the Buyer's Representative shall have the option to witness the performance test.

Page 16 of 20

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008 9.2.2.2

17-SAMSS-518 Diesel Generator Sets

Performance tests shall be conducted only after all pressures and temperatures have equalized. The tests shall comprise the following: a) b) c) d) e) f) 30 minutes running at 50% load 30 minutes running at 75% load 4 hours running at 100% load 15 minutes running at 110% load (overload) (not applicable to standby rated units) Cold start with load step specified in 6.2.4 Full load rejection governor response

The following tolerances shall be applied for the full load test in the evaluation of the performance test results: a) b) 9.2.2.3 Generator power shall be within 5% of rating specified. Fuel consumption shall be within 3% of that quoted by manufacturer.

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

9.2.3

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

c) d) 9.3

Preparation for Shipment 9.3.1 Each unit shall be suitably prepared for the type and mode of shipment specified. The preparation shall be suitable for at least 6 months of

Page 17 of 20

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008

17-SAMSS-518 Diesel Generator Sets

outdoor storage from the time of shipment in a manner requiring no disassembly prior to operation. 9.3.2 9.3.3 The Vendor shall provide the purchaser with the job site storage instructions for the diesel generator set. Unless otherwise specified by Saudi Aramco, preparation for shipment shall be as specified in paragraphs 9.3.3.1 through 9.3.3.6, as a minimum. 9.3.3.1 9.3.3.2 Exterior surfaces, except for machined surfaces, shall be primed and painted. After having been thoroughly drained and cleaned, internal areas of bearings and all auxiliary equipment in oil lubrication systems using carbon steel shall be coated with suitable oil- soluble rust preventive. Flanged openings shall be provided with metal closures at least 5 millimeters thick, with synthetic rubber gaskets. At least four full-diameter bolts shall be used for flanged openings. The equipment shall be mounted on a rigid skid suitable for handling by forklift truck or crane. The rotor of sleeve-bearing generators shall be blocked to prevent axial and radial movement. Space heater leads shall be accessible without disturbing the shipping package. The leads shall be suitably tagged for easy identification.

9.3.3.3

9.3.3.4 9.3.3.5 9.3.3.6

9.3.4 9.3.5

Lifting points or lugs shall be clearly marked. Each diesel generator set shall be properly identified with item number, serial number and any other information required by the purchase order. All material shipped in separate crates shall be suitably identified with securely affixed, corrosion-resistant metal tags indicating the item and serial number of the equipment for which it is intended. The fit-up and assembly of machine-mounted piping and other equipment shall be completed in the Vendor's shop before shipping.

9.3.6

Page 18 of 20

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008 10 Vendors Data (Non Material Requirements) 10.1

17-SAMSS-518 Diesel Generator Sets

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

10.2

Vendor shall provide installation, operation, and maintenance manuals, lubrication recommendations, overhaul periods, special tool requirements, control adjustment procedures and setpoints, and maintenance weights necessary for the satisfactory installation, operation, troubleshooting, and maintenance (including major overhaul) of all equipment components provided. In addition to fuel consumption data, the Vendor shall also provide ventilation, combustion and exhaust airflow requirements. For indoor installation, the exhaust piping layout and proposed location shall be submitted to the Buyer for approval. The Vendor shall supply, with the bid, an installation list for equipment of a similar rating and duty to the equipment quoted. The list shall indicate user company name, installation location, date of installation, and site rating of the diesel generator set. During bid evaluation, the Vendor shall be prepared to provide contact names and telephone numbers for installations selected by the Buyer.
Revision Summary Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued with minor changes. Minor revision. Editorial revision.

10.3 10.4 10.5

26 February 2003 29 June 2005 13 June 2006

Page 19 of 20

Document Responsibility: Motors and Generators Issue Date: 13 June 2006 Next Planned Update: 1 March 2008

17-SAMSS-518 Diesel Generator Sets

Data Schedule-1 17-SAMSS-518, Diesel Generator Sets (Supplied by Buyer as part of SAMS Specifications)
ITEM 1. D E S C R I P T I O N Buyer's Purchase Order/Quotation Request Buyer's Budget Item/Job Order Number Buyer's Line Item Number Installation Area (Offshore/Nearshore/Onshore/Health Facility) Maximum site ambient temperature (C) Minimum site ambient temperature (C) Site elevation (feet or meters) Installation Location (Inside a Building/Outside will require a Vendor supplied enclosure) Service Condition (Continuous, Intermittent, Standby) Diesel Generator Set Required Site Rating (kW) (maximum electrical load) Generator Voltage (3-phase, line-line) Generator Frequency (50Hz, 60Hz) Operating Performance Class (G1, general purpose; G2, commercial power grade; G3, severe demands on frequency and voltage waveform characteristics; G4, exceptionally severe demands on frequency and voltage waveform characteristics) Motorized Air Intake Louvers Required (Yes/No) (Applies only to installation outside with Vendor supplied enclosure) Day Tank Capacity (8/12 hour) Exhaust Silencer Grade Industrial/Residential/Critical (Health Care Facilities only) Starting System (DC Electric) Parallel Operation Required (Yes/No) Generator Space Heater Supply Voltage (120V, 240V) Jacket-Water Heater Supply Voltage (120V, 240V, 480V) Battery Charger Input Voltage (120V/240V/480V) [Applies to standby and intermittent (prime) service applications] Required Tests; Standard Shop Test (200kW and less) / Performance Test (greater than 200kW) Witness of Tests Required (Yes/No) Sound Pressure Level at 1 meter Portable generator set Additional Requirements DETAILS

2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

60 Hz G2

12. 13. 14. 15. 16. 17. 18. 19.

DC Electric

20. 21. 22. 23. 24.

Yes ____No____

Page 20 of 20