PACKAGED UNIT AC GENERATOR SETS

DEP 33.65.11.32-Gen.

April 2003

DESIGN AND ENGINEERING PRACTICE

This document is restricted. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of Shell Global
Solutions International B.V. and Shell International Exploration and Production B.V., The Netherlands. The copyright of this document is vested in these companies. All
rights reserved. Neither the whole nor any part of this document may be reproduced, stored in any retrieval system or transmitted in any form or by any means
(electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owners.
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PREFACE
DEPs (Design and Engineering Practice) publications reflect the views, at the time of publication, of:
Shell Global Solutions International B.V. (Shell GSI)
and
Shell International Exploration and Production B.V. (SIEP)
and
Shell International Chemicals B.V. (SIC)
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, international, regional, national and industry
standards.
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 Shell GSI, 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
Shell GSI, SIEP, SIC or another Group Service Company. Consequently, three categories of users of DEPs can be
distinguished:
1) Operating companies having a Service Agreement with Shell GSI, 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 (whether as part
of a Service Agreement or otherwise).
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, Shell GSI, 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, even if it is wholly or partly caused by negligence on the part of Shell GSI,
SIEP or other Service Company. The benefit of this disclaimer shall inure in all respects to Shell GSI, 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 Shell GSI 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 Shell GSI, SIEP or SIC. The copyright of DEPs vests in Shell GSI and SIEP. Users shall arrange for DEPs to
be held in safe custody and Shell GSI, SIEP or SIC 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 Shell GSI.
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April 2003Page 3

TABLE OF CONTENTS
1. INTRODUCTION................................................................................................ 5
1.1 SCOPE............................................................................................................... 5
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS. .5
1.3 DEFINITIONS.................................................................................................... 6
1.4 ABBREVIATIONS.............................................................................................. 8
1.5 CROSS-REFERENCES.....................................................................................8
1.6 UNITS................................................................................................................ 8
1.7 CHANGES FROM THE PREVIOUS EDITION...................................................8
1.8 COMMENTS ON THIS DEP..............................................................................8
2. BASIC REQUIREMENTS..................................................................................9
2.1 GENERAL.......................................................................................................... 9
2.2 PRE-MANUFACTURING MEETING..................................................................9
2.3 SAFETY............................................................................................................. 9
2.4 SERVICE CONDITIONS....................................................................................9
2.5 MATERIALS..................................................................................................... 10
2.6 SCOPE OF SUPPLY........................................................................................ 10
3. PERFORMANCE REQUIREMENTS...............................................................11
3.1 RATING............................................................................................................ 11
3.2 NOISE.............................................................................................................. 11
3.3 TORSIONAL VIBRATIONS..............................................................................11
3.4 LATERAL VIBRATIONS...................................................................................11
4. ENGINE REQUIREMENTS..............................................................................12
4.1 GENERAL........................................................................................................ 12
4.2 AIR INTAKE SYSTEM......................................................................................12
4.3 EXHAUST SYSTEM......................................................................................... 12
4.4 FUEL SYSTEM................................................................................................ 12
4.5 COOLING SYSTEM......................................................................................... 12
4.6 SHAFT COUPLINGS.......................................................................................13
4.7 FREQUENCY STABILITY................................................................................13
5. GENERATOR REQUIREMENTS....................................................................14
5.1 GENERAL........................................................................................................ 14
5.2 GENERATOR IMPEDANCES..........................................................................14
5.3 EXCITATION SYSTEM....................................................................................14
5.4 OUTPUT VOLTAGE VARIATIONS..................................................................15
5.5 EFFICIENCY.................................................................................................... 15
5.6 RADIO FREQUENCY INTERFERENCE..........................................................15
5.7 GENERATOR COOLING.................................................................................15
5.8 GENERATOR HOUSING.................................................................................15
5.9 WINDINGS....................................................................................................... 16
5.10 BUSHINGS AND TERMINALS........................................................................16
5.11 BEARINGS....................................................................................................... 16
6. CONTROL AND PROTECTION EQUIPMENT................................................17
6.1 GENERAL........................................................................................................ 17
6.2 ENGINE CONTROL PANEL............................................................................17
6.3 GENERATOR CONTROL PANEL...................................................................17
6.4 CONTROL PANEL CONSTRUCTION.............................................................18
7. PACKAGE REQUIREMENTS.........................................................................21
7.1 BASEPLATE.................................................................................................... 21
7.2 ROOM VENTILATION......................................................................................21
7.3 ELECTRIC MOTORS.......................................................................................22
7.4 CABLES AND JUNCTION BOXES..................................................................22
7.5 NAMEPLATES................................................................................................. 22
7.6 PIPING AND INTERFACE CONNECTIONS....................................................22
7.7 PAINTING........................................................................................................ 23
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7.8 ACOUSTIC ENCLOSURE...............................................................................23

8. SPECIAL REQUIREMENTS FOR DIFFERENT MODES OF OPERATION....24
8.1 GENERAL........................................................................................................ 24
8.2 EMERGENCY GENERATOR SETS................................................................24
8.3 GENERATOR SETS FOR CONTINUOUS OPERATION.................................24
8.4 GENERATOR SETS SUPPLYING LARGE NON-LINEAR LOADS..................25
8.5 GENERATOR SETS FOR PARALLEL OPERATION.......................................25
8.6 GENERATOR SETS FOR HAZARDOUS AREAS...........................................25
9. INSPECTION AND TESTING..........................................................................26
9.1 GENERAL........................................................................................................ 26
9.2 WORKS TEST OF THE COMPLETE GENERATOR SET...............................26
9.3 ON-SITE ACCEPTANCE TESTING.................................................................28
10. PREPARATION FOR SHIPMENT AND STORAGE........................................29
10.1 GENERAL........................................................................................................ 29
10.2 PRESERVATION............................................................................................. 29
10.3 BATTERIES..................................................................................................... 30
11. SPECIAL TOOLS............................................................................................30
12. DOCUMENTS.................................................................................................. 31
12.1 GENERAL........................................................................................................ 31
12.2 TECHNICAL INFORMATION...........................................................................31
13. REFERENCES................................................................................................. 32

APPENDICES
APPENDIX 1 GENERATOR STATUS, ALARM, TRIP AND SHUTDOWN
REQUIREMENTS...................................................................................36
APPENDIX 2 TYPICAL BLOCK DIAGRAM FOR A PACKAGED UNIT AC
GENERATOR SET.................................................................................37
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1. INTRODUCTION

1.1 SCOPE
This DEP specifies 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. Generator sets may be driven by either gas or diesel engines.
This DEP is intended for AC generator sets in the design power range 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 project requirements shall be given in 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 event of conflict between documents the following hierarchy shall apply:
1st priority: purchase order and variations thereto;
2nd priority: requisition sheets and project specification;
3rd priority: this DEP.

The equipment and services to be provided in accordance with 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 the generator circuit breaker.
This DEP is a revision of the publication of the same number and title dated October 1994.
A summary of the major changes from the previous edition is listed in (1.7).

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI and SIEP, 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. When
DEPs are applied, a Management of Change (MOC) process should be implemented. This
is of particular importance when existing facilities are to be modified.
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.
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1.3 DEFINITIONS

1.3.1 General Definitions

The Contractor is the party that 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 that 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 that 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.

1.3.2 Technical definitions

Air to air cooled machine
A closed machine with an integral or machine mounted heat exchanger, using air as the
primary and secondary coolant.
Air to water cooled machine
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 60079-15.
Hazardous area
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
A set of voltage levels used for the distribution of electricity and whose upper limit is
1000 V AC.
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Marking
Data put on the electrical apparatus by the Manufacturer giving information for the safe use
of the apparatus.
Rated value
A quantity value assigned, generally by the Manufacturer, to 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
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)
An area in which an explosive gas atmosphere is likely to occur in normal operation.
Zone 2 (In the classification of hazardous gas areas)
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.

1.3.3 Frequently used expressions

Emergency generator sets
Generator sets that are infrequently operated and for a relatively short duration. They will
only operate in case of a power failure of the main grid system for a relatively 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 that 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 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 their temperature limits.
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1.4 ABBREVIATIONS
AC Alternating Current
AISI American Iron and Steel Institute
AVR Automatic Voltage Regulator
CT Current Transformer
ESD Emergency Shut Down
IP The degree of ingress protection of an enclosure
according to IEC 60529 (for example: IP 41)
LED Light Emitting Diode
RMS Root-Mean-Square
VA Voltage-Ampere
VT Voltage Transformer

1.5 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).

1.6 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.

1.7 CHANGES FROM THE PREVIOUS EDITION

The previous edition of this DEP was dated October 1994. Other than editorial changes, the
following are the major changes to the previous edition.

Old Section New Section Subject

1.3 2.2 Section on pre-manufacturing meeting moved; other
sections in (1) and (2) re-numbered accordingly.
1.3.2 1.3.2 References to IEC standards removed from the
technical definitions.
6.1 6.1 Requirements for combined packaged unit control
panel clarified.
6.3.1 6.3.1 Bearing and winding temperature added.
7.1 7.1 Anti-vibration mounts made mandatory, unless
specified otherwise in the requistion.
8.2 8.2 Maximum time allowed for the emergency generator
to accept the normal load has been revised from 10 s
to 25 s. Also added that starting system and
autonomy to be specified in the requisition.
9.2.1 9.2.1 Exhaust temperature added.

1.8 COMMENTS ON THIS DEP

Comments on this DEP may be sent to the DEP Administrator at standards@shell.com.
Shell staff may also post comments on this DEP on the Surface Global Network (SGN)
under the Standards/DEP 33.65.11.32-Gen. folder. The DEP Administrator and DEP Author
monitor these folders on a regular basis.
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2. BASIC REQUIREMENTS

2.1 GENERAL
The generator set shall be the product of a Packager regularly engaged in the production of
such sets. 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 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. After the Principal has approved the draft
minutes, the final minutes shall be issued within 14 days.

2.3 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 very toxic (see DEP 01.00.01.30-Gen.) shall not be used.
All exposed rotating or moving parts shall be protected by guards in accordance with
BS PD 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 in accordance with ISO 1813.

2.4 SERVICE CONDITIONS

2.4.1 General
The site environmental conditions shall be given in the requisition. 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 generator set shall be suitable for unattended operation.
 DEP 33.65.11.32-Gen.
April 2003Page 10

Unless otherwise specified in the requisition, the following conditions shall apply:

2.4.2 Seismic conditions

Generator sets for installation offshore shall be designed for shock accelerations of 20 m/s2
whilst in operation, without interference to operation.

2.4.3 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.

2.5 MATERIALS
All components shall be of a quality commensurate with the requirements of a secure
power supply system. Component materials shall be flame retardant, and moisture and
fungus resistant whenever practicable. Equipment destined for humid tropical environments
shall be compatible with these environments.

2.6 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 CTs and VTs (incl. those for installation in the switchboard).
The Packager shall advise in its tender any deviation from this DEP.
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3. PERFORMANCE REQUIREMENTS

3.1 RATING
The generator set rating 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 in accordance with 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 in accordance with
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

The Packager shall perform a torsional vibration analysis. 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
in accordance with ISO 10816-1, ISO 10816-5, and ISO 10816-6.
The vibration levels of individual auxiliary low voltage electric motors shall be in accordance
with DEP 33.66.05.31-Gen.
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4. ENGINE REQUIREMENTS

4.1 GENERAL
The requirements for the drive engine are given in DEP 31.29.80.30-Gen. (for diesel fuelled
engines) and DEP 31.29.90.30-Gen. (for gas fuelled engines), as specified in the
requisition. In general, the engine Supplier shall 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 use in
those cases 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

If the engine Supplier supplies an air intake filter loose, 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 engine intake nozzle. 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

If the engine Supplier supplies 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 engine exhaust nozzle. Due consideration shall be paid to 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 shall 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 supplies engine and lube oil coolers loose, the Packager shall install
them.
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 maximum velocity of 50 knots shall be assumed.

If a remotely located cooler has a fan that is mechanically driven from the engine, the
Packager shall provide lineshafting and belt drive as necessary.
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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 3046-4 for generators operating in single mode.
The governor shall be an electronic type.
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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 precision 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.
If 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 s.
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.
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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 (kVA) Efficiency (%)
50 to 100 90
125 to 300 91
330 to 600 92
630 to1250 93

Guaranteed efficiency values 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 DIN 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 60034-6. 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.
 DEP 33.65.11.32-Gen.
April 2003Page 16

5.8.2 Stator frame

The generator frame and bearing end-shields shall be constructed of ferrous metals.
All welding shall comply with AWS D1.1/D1.1M or the relevant local code.

5.9 WINDINGS
The windings of the generator, and if installed, 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
4,000 operating hours, but a greasing interval of greater than 8,000 operating hours is
preferred. 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.
Insulation shall be provided on all bearings unless the generator Manufacturer can
demonstrate that rotor stray currents are too low to damage the bearings.
 DEP 33.65.11.32-Gen.
April 2003Page 17

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.

Unless otherwise specified in the requisition, the engine control panel shall be combined
with the generator control panel in 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 (*);
- bearing and winding temperature (*).

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.
 DEP 33.65.11.32-Gen.
April 2003Page 18

The Principal shall provide information regarding the layout 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 in
accordance with IEC 60051.

6.3.2 Electrical protection requirements

The Packager shall prepare a proposal for the protection relay settings. The final relay
settings shall be agreed between Packager and Principal.
All protection relays shall be of the digital electronic type and shall be installed so 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., LEDs.
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 CTs shall be automatically short circuited on
withdrawal. 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. CTs 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 the
following:
IEC 60255-11;
IEC 60255-12;
IEC 60255-13;
IEC 60255-14;
IEC 60255-15;
IEC 60255-19;
IEC 60255-19-1;
IEC 60255-21-1.

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 freestanding,
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 to be installed 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/sun canopy.
NOTE: Panels installed outdoors shall always be provided with a rain/sun canopy to make access possible
under adverse weather conditions.

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
 DEP 33.65.11.32-Gen.
April 2003Page 19

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 that can cause tripping of the unit shall not be
installed on the enclosure door.
To prevent inadvertent contact or short circuit by personnel performing control circuit
adjustments or 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.

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 60898. 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. If
required, anti-condensation heaters shall be of a fully insulated design and suitable for
220 V to 254 V 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 according to 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 shall not cross or be routed along 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 that 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 mm2 wires for control and minimum 4 mm2 wires for power and current
 DEP 33.65.11.32-Gen.
April 2003Page 20

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.
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.
Separate terminal strips shall be supplied for all incoming and outgoing cables. Separate
sections shall be provided for digital, analogue, pneumatic and power cables. The Principal
shall install interconnecting cables to remotely located equipment.

6.4.6 Earthing
Where a number of electrical components are to be earthed, parallel earthing shall be
employed. Series looping of equipment is not permitted.
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 that 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 mm2 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 60445.
 DEP 33.65.11.32-Gen.
April 2003Page 21

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 withstand 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 AWS D1.1/D1.1 M 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 (2.4.2).
The baseplate shall be constructed so 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 ASME B16.5 flanged
drain connections in strategic locations.
Unless specified otherwise in the requisition, the Packager shall supply suitable anti-
vibration mounts to limit the engine vibrations transmitted to the foundations or
surroundings. 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 for
lifting, the Packager shall supply it. Lifting lugs shall be designed for a load equal to twice
the complete assembly and shall comply with AWS D1.1/D1.1M 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 Principal shall provide the ventilation
requirements for a generator set installed in a closed room. See (4.2) for combustion air
and (4.3) exhaust requirements. See (7.8) for a generator set installed in an acoustic
enclosure.
 DEP 33.65.11.32-Gen.
April 2003Page 22

7.3 ELECTRIC MOTORS

Electric motors for auxiliary systems shall comply with DEP 33.66.05.31-Gen.

7.4 CABLES AND JUNCTION 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, 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 AISI 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. Junction box
wire identification, terminal partitions, terminal execution, wire pin requirements, and spare
terminal requirements and earthing provisions shall comply with (6.4.4) 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:
- Principal'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
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.
 DEP 33.65.11.32-Gen.
April 2003Page 23

All package piping shall be carbon steel to ASTM A 106 Grade B and shall be pickled,
flushed and passivated after fabrication.
If seawater 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 A 790/A 790M.
The Principal shall supply and install interconnecting piping between the baseplate edge
and remotely installed auxiliaries. 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 supplied with the requisition. 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 initiate 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, so 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. Failure of the airflow to the enclosure or excessive temperature rise in the
enclosure shall shut down the generator set. A two-stage filter, comprising an inertial stage
followed by a viscous impingement stage, shall filter ventilation air.
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 the shutting of a damper in the
exhaust air from the enclosure and shutdown of the ventilating fans.
Fire extinguishing systems using carbon dioxide or other asphyxiating gases shall be
inhibited before free access to the enclosure is allowed. 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.
 DEP 33.65.11.32-Gen.
April 2003Page 24

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:

where:
Imax = maximum phase current;

Imin = minimum phase current.

The maximum time allowed for the emergency generator set to accept the nominal load
after initiation of a start command from cold shall be 25 s. The exact requirement for the
emergency generator starting system and the level of autonomy (black start capability) of
auxiliary systems shall be specified in the requistion.
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 that 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/overfrequency protection
shall be disabled during emergency operation.

8.3 GENERATOR SETS FOR CONTINUOUS OPERATION

The generator set shall be designed to operate for a minimum of 25,000 h 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 alarm and 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.
 DEP 33.65.11.32-Gen.
April 2003Page 25

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 60034-1.
If the generator will supply power to loads with a large harmonic content, e.g. rectifiers, 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 system to 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 maximum acceptable level of voltage waveform distortion
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 system, an automatic power factor
controller shall control the reactive power generated. 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 that are required to operate with the one being purchased.
Frequency stability in accordance with governing class A1, as defined in ISO 3046-4, 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 60079-15.
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 from a 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 considered.
 DEP 33.65.11.32-Gen.
April 2003Page 26

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.
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 (9.2).

9.2 WORKS TEST OF THE COMPLETE GENERATOR SET

9.2.1 Static load test

During this test the generator set shall run for at least 4 h under the following conditions:
- 30 min at 25 % rated output;
- 30 min at 50 % rated output;
- 2 h at 100 % rated output;
- 1 h 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;
- exhaust temperature.
9.2.2 Dynamic load test
The frequency and voltage regulation of the generator set shall be verified against the
requirements given in (4.7) 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 perform functional 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 minimum of 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;
 DEP 33.65.11.32-Gen.
April 2003Page 27

- all engine alarm and shutdown functions ( * );

- all generator alarm and 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

Insulation resistance 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.
 DEP 33.65.11.32-Gen.
April 2003Page 28

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.
 DEP 33.65.11.32-Gen.
April 2003Page 29

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. Corrosion-resistant tags attached with stainless steel wire shall
identify blocked rotors. The preparation shall make the equipment suitable for 6 months’ (or
for a period as stated in the requisition) outdoor storage from the 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. The Packager shall provide a recommended lifting arrangement.
The equipment shall be identified by item and serial number. Materials shipped separately
shall be identified by securely attached corrosion-resistant metal tags indicating the item
and 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 start-up of the generator set.
Exterior machined surfaces shall be coated with a rust preventative.
The interior of all equipment shall be clean, free from scale, 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 calcium and/or silicone compounds shall not
be used as they cause subsequent foaming of the lubricating oil.
All coolants shall be drained from the engine, coolers and piping. The interior of the coolant
system shall be preserved by a water soluble film.
All flanged openings shall be closed with metal closures 5 mm 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 packed separately in secure
waterproof crates. Non-demountable equipment shall be braced for transport. External
 DEP 33.65.11.32-Gen.
April 2003Page 30

surfaces of the panels shall be protected from abrasion during transport. Desiccants shall
be inserted where necessary for preservation.

10.3 BATTERIES
Nickel-cadium batteries shall be supplied dry and discharged, with the electrolyte packed
separately. Lead-acid recombination type batteries shall receive a commissioning charge
within a period after leaving the factory, as specified by the Manufacturer.

11. SPECIAL TOOLS

The Packager shall assemble all special tools necessary for assembly, dismantling and
service of the generator set from all 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.
 DEP 33.65.11.32-Gen.
April 2003Page 31

12. DOCUMENTS

12.1 GENERAL
All documents shall be marked in the right-hand bottom corner with the Principal's order
and item number 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 minimum the 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, minimum space 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;
- alarm and 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.
 DEP 33.65.11.32-Gen.
April 2003Page 32

13. REFERENCES

In this DEP, reference is made to the following publications:

NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell users on the SWW (Shell
Wide Web) at http://sww.shell.com/standards.

SHELL STANDARDS
Index to DEP publications and standard DEP 00.00.05.05-Gen.
specifications
Index to standard drawings DEP 00.00.06.06-Gen.
The use of SI quantities and units DEP 00.00.20.10-Gen.
(Endorsement of ISO 31 and ISO 1000)
Definition of temperature, pressure and toxicity levels DEP 01.00.01.30-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 DEP 31.10.00.96-Gen.
enclosures *
Diesel 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 machines (Amendments/ DEP 33.65.11.31-Gen.
Supplements to IEC 60034-1)
Requisition for synchronous for AC machines * DEP 33.65.11.93-Gen.
Requisition for packaged unit AC generator sets * DEP 33.65.11.94-Gen.
Electric machines - Cage-induction types DEP 33.66.05.31-Gen.
(Amendments/Supplements to IEC 60034-1
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 S 67.055

connected (voltage  11kv)
Typical single line and schematic diagram of control S 67.070
circuits for LV emergency generator
Earthing boss for steel structures, tanks, vessels, S 68.004
etc.
 DEP 33.65.11.32-Gen.
April 2003Page 33

AMERICAN STANDARDS
Pipe flanges and flanged fittings NPS ½ through ASME B16.5
NPS 24
Issued by:
American Society of Mechanical Engineers
ASME International
Three Park Avenue, M/S 10E
New York, NY 10016-5990
USA

Structural welding code-steel AWS D1.1/D1.1M

Issued by:
American Welding Society
550 North Lejeune Road
Miami, FL 33136
USA

Standard specification for seamless carbon steel ASTM A 106

pipe for high temperature service
Standard specification for seamless and welded ASTM A 790/A 790M
ferritic/austenitic stainless steel pipe
Issued by:
American Society for the Testing of Materials
100 Barr Harbor Drive,
West Conshohocken,
PA 19428-2959
USA

BRITISH STANDARDS
General requirements for rotating electrical machines BS 4999-140
Part 140. Voltage regulation and parallel operation of
A.C. synchronous generators
Safe use of machinery BS PD 5304
Issued by:
British Standards Institution
389 Chiswick High Road
London W4 4AL
United Kingdom

GERMAN STANDARDS
Radio interference suppression of electrical DIN 0875
appliances and systems
Issued by:
Verband Deutscher Elektrotechniker
Stresemannallee 15
Frankfurt, Germany D-60596

INTERNATIONAL STANDARDS
Rotating electrical machines
Part 1: Rating and performance IEC 60034-1
Part 6: Methods of cooling (IC Code) IEC 60034-6
Direct acting indicating analogue electrical IEC 60051
measuring instruments and their accessories,
Parts 1 through 9
Electrical apparatus for explosive gas atmospheres IEC 60079-15
 DEP 33.65.11.32-Gen.
April 2003Page 34

Electrical relays IEC 60255

Part 11 - Interruptions to and alternating component
(ripple) in d.c. auxiliary energizing quantity of
measuring relays
Part 12 - Directional relays and power relays with
two input energizing quantities
Part 13 - Biased (percentage) differential relays
Part 14 - Endurance test for electrical relay contacts
- preferred values for contact loads
Part 15 - Endurance tests for electrical relay contacts
- specification for the characteristics of test
equipment
Part 19 - Sectional specification: electromechanical
all-or-nothing relays of assessed quality
Part 19-1 - Blank detail specification:
electromechanical all-or-nothing relays of assessed
quality test schedules 1, 2 and 3
Part 21-1 - Vibration, shock, bump and seismic tests
on measuring relays and protection equipment
section one - vibration tests (sinusoidal)
Basic and safety principles for man-machine IEC 60445
interface, marking and identification – Identification
of equipment terminals and of terminations of certain
designated conductors, including general rules for an
alphanumeric system
Degress of protection provided by enclosures (IP IEC 60529
Code)
Circuit breakers for overcurrent protection for IEC 60898
household and similar installations
Issued by:
Central Office of IEC (sales dept.)
3, Rue de Varembé
CH 1211 Geneva 20
Switzerland
Copies can also be obtained from national standards
organizations
Belt-drives – V-ribbed belts, joined v-belts, and V- ISO 1813
belts including wide section belts and hexagonal
belts – Electrical conductivity of antistatic endless V-
belts-electrical conductivity - characteristics and
methods of test
Reciprocating internal combustion engines: ISO 3046-4
Part 4: Speed governing
 DEP 33.65.11.32-Gen.
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Mechanical vibration – Evaluation of machine ISO 10816

vibration by measurements on non-rotating parts
Part 1: General guidelines
Part 5: Machine sets in hydraulic power generating
and pumping plants
Part 6: Reciprocating machines with power ratings
above 100 kw
Issued by:
International Organization for Standardization
Case Postale 56
Geneva 20 Switzerland CH-1211
Copies can also be obtained from national standards
organizations
 DEP 33.65.11.32-Gen.
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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