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SECTION 16220:

GUIDELINE SPECIFICATION FOR

MOTORS AND GENERA TORS

0 31/01/06 I IssuedforUse c=,. ~

REV DATE DESCRIPTION PREPARED BY

KINGDOM
OFSAUDIARABIA ~~~I ~}-l11~!
RoyalCommission
forJubail& Yanbu ~4~~1~1
 SECTION 16220
MOTORS AND GENERATORS

TABLE OF CONTENTS

Item No Title Page No

PART 1 GENERAL............................................................................................................ 1

1.01 DESCRIPTION OF WORK .................................................................................. 1

1.02 SECTION INCLUDES .......................................................................................... 1

1.03 RELATED SECTIONS ......................................................................................... 1

1.04 REFERENCES..................................................................................................... 1

1.05 DEFINITIONS....................................................................................................... 3

1.06 SUBMITTALS....................................................................................................... 4

1.07 QUALITY CONTROL ........................................................................................... 5

1.08 HEALTH AND SAFETY CONSIDERATIONS...................................................... 5

1.09 FACTORY TESTING ........................................................................................... 6

1.10 SERVICE CONDITION ........................................................................................ 6

1.11 DELIVERY, HANDLING AND STORAGE ........................................................... 7

PART 2 PRODUCTS ......................................................................................................... 8

2.01 GENERAL ............................................................................................................ 8

2.02 PACKAGED ENGINE GENERATOR SETS ........................................................ 8

2.03 DIESEL ENGINE................................................................................................ 10

2.04 GENERATOR..................................................................................................... 15

2.05 MOTORS............................................................................................................ 19

PART 3 EXECUTION ...................................................................................................... 26

3.01 GENERAL .......................................................................................................... 26

3.02 INSTALLATIONS ............................................................................................... 26

3.03 TESTING AND COMMISSIONING .................................................................... 29

Rev 0 i Contract No:

 SECTION 16220
MOTORS AND GENERATORS

PART 1 GENERAL

1.01 DESCRIPTION OF WORK

A. This Section specifies minimum technical requirements for designing, manufacturing,

supplying, installing, storing, handling, testing and commissioning of Motors, and
Emergency and Standby Generators as specified and shown on the Contract
Drawings/Documents.

1.02 SECTION INCLUDES

A. Packaged Engine Generator Sets

B. Diesel Engine

C. Generator

D. Motors

1.03 RELATED SECTIONS

A. Section 01320 Construction Progress Documentation

B. Section 01330 Submittal Procedures

C. Section 01410 Regulatory Requirements

D. Section 01450 Quality Control

E. Section 01650 Product Delivery Requirements

F. Section 01660 Product Storage and Handling Requirements

G. Section 02315 Excavation and Fill

H. Section 03310 Structural Concrete

I. Section 15190 Fuel Piping

J. Section 16055 General Provision of Low Voltage Electrical Works

K. Section 16060 Grounding and Bonding

L. Section 16075 Electrical Identifications

1.04 REFERENCES

A. The referred codes and standards are intended to provide an acceptable level of
quality for materials and products. In case of conflict between these standards and
the text of this Specification, the Specification text shall govern.

Rev 0 1 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

B. The latest revision of the referred codes and standards shall be used wherever
applicable. In case of conflict, the Contractor shall propose equipment conforming to
one group of codes and standards.

C. ANSI American National Standards Institute

1. ANSI C50.13 Requirements for Rotating Electrical Machinery

Cylindrical Rotors Synchronous Generators

D. ASTM American Society of Testing Materials

1. ASTM A53M Standard Specification for Pipe, Steel, Black, and

Hot-Dipped. Zinc Coated Welded and Seamless

2. ASTM B88M Standard Specification for Seamless Copper Water

Tube [Metric]

E. IEC International Electrotechnical Commission

1. IEC 60034 Rotating Electrical Machines

2. IEC 60050 International Electrotechnical Vocabulary

3. IEC 60072 Dimension and Output Series for Rotating Electric

Machine

4. IEC 60079 Electrical Apparatus for Explosive Gas Atmospheres

5. IEC 60529 Classification of Degree of Protection Provided by

Enclosure (IP Code)

F. IEEE Institute of Electrical and Electronic Engineers

1. IEEE 43 Recommended Practice for Testing Insulation

Resistance of Rotating Machinery

2. IEEE 112 Standard Test Procedure for Polyphase Induction

Motors and Generators

3. IEEE 114 Standard Test Procedure for Single Phase Induction

Motors

4. IEEE 115 Standard Test Procedure for Synchronous Machines

5. IEEE C37.96 Guide for AC Motor Protection

G. ISO International Standard Organization

1. ISO 3046 Reciprocating Internal Combustion Engines

2. ISO 8528 Reciprocating Internal Combustion Engine Driven

Alternating Current Generating Sets

Rev 0 2 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

H. NEMA National Electrical Manufacturers Association

1. NEMA 250 Enclosure for Electrical Equipment

2. NEMA MG1 Motors and Generators

3. NEMA MG2 Safety Standard for Construction and Guide for

Selection, Installation, and Use of Electric Motors
and Generators

I. NFPA National Fire Protection Association

1. NFPA 70 National Electric Code

2. NFPA 99 Standard for Health Care Facilities

3. NFPA 110 Emergency and Standby Power System

J. UL Underwriter’s Laboratories Inc.

1. UL 674 Electric Motors and Generators for Use in Division 1

Hazardous Locations

1.05 DEFINITIONS

A. code letter: A letter which appears on nameplates of alternating current (ac) motors
to show their locked rotor kilovolt-amperes per horsepower at rated voltage and
frequency.

B. duty: A continuous or short-time rating of a machine.

C. frequency: The number of cycles per second. Alternating current frequency is

expressed in cycles per second, termed as Hertz (Hz).

D. generator: A machine that is used to convert mechanical power into an electric

power.

E. insulation class: A letter or number that designates the temperature rating of an

insulation material or system with respect to thermal endurance.

F. motor: A rotating machine that converts electrical power into mechanical power.

G. poles: The magnetic poles set up inside the machine by the placement and
connection of the windings.

H. power factor: The ratio of watts to volt-amperes of an ac electric circuit.

I. rotor: The rotating element of any motor or generator.

J. rated output: Motor rated output is mechanical power available at the shaft
expressed in watts (w).

Rev 0 3 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

K. slip: The difference between the speed of the rotating magnetic field (which is
always synchronous) and the rotor in a non-synchronous induction motor and is
expressed as a percentage of a synchronous speed. Slip generally increases with an
increase in torque.

L. speed factor: A factor derived by multiplying internal diameter of a bearing in

millimeter (mm) by motor speed in revolution per minute (rpm).

M. stator: The stationary part of a rotating machine. Commonly used to describe the
stationary part of an ac machine that contains the power windings.

N. synchronous speed: A speed of rotating machine element of an ac motor that

matches the speed of the rotating magnetic field created by the armature winding.

O. thermistor: A resistive device used for temperature sensing that is composed of

metal oxides formed into a bead and encapsulated in epoxy or glass.

1.06 SUBMITTALS

A. The Contractor shall submit to the Royal Commission, under the provisions of
SECTION 01330, the following items for review and approval before commencing
Work:

1. Shop Drawings

a) A complete drawing list/index identifying all drawings in the Shop

Drawing package.

b) Legend, symbols and specialized terminology used on the drawings.

c) Layouts showing concrete pad dimensions, conduit entrance and

available space, electrical ratings, nameplate nomenclature.

d) Single line diagram.

e) Schematic diagram.

f) Control schematics.

g) Interconnection wiring diagram.

h) Front, side and rear elevations showing location of all components.

i) Nameplate Schedules.

2. Data Sheets and Specifications.

3. Maintenance Data and Operating Instructions

a) Manufacturer’s catalogs giving description of the equipment and its

components.

Rev 0 4 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

b) Manufacturer’s operating and maintenance instructions manuals.

c) Storage and handling Instructions.

d) Installation instructions.

e) Part list.

f) Illustrations and diagram of components.

g) Recommended list of spare parts along with price list.

h) Factory test report.

4. Quality Program as specified in SECTION 01450.

B. The Contractor shall submit Field Test Report after completion of testing and
commissioning.

1.07 QUALITY CONTROL

A. The Contractor shall be responsible for the quality of work and shall develop and
propose programs and methods of construction and testing to achieve the specified
quality to the approval of the Royal Commission in accordance with
SECTION 01450.

1.08 HEALTH AND SAFETY CONSIDERATIONS

A. All works undertaken in relation to this Specification are to be completed in full

accordance with the respective health and safety requirements established by the
following:

1. Kingdom of Saudi Arabia

a) Legislation, Regulation, Standards and Codes.

2. Royal Commission Regulations

a) Standards, Contractual Conditions, and Health and Safety Systems.

3. Contractor

a) Health and Safety Standards and Systems as accepted by the Royal

Commission.

B. In the absence of any of the above, best accepted industry practice shall be
employed throughout.

Rev 0 5 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

1.09 FACTORY TESTING

A. All equipment/material shall be tested at factory in accordance with latest applicable

codes and standards. All type tests as per applicable codes and standards shall be
performed on first unit of every new design. The Contractor shall notify the Royal
Commission in writing not less than 30 days prior to the scheduled starting date of
the factory tests.

B. The Royal Commission reserves the right of deputing their representative for
witnessing the factory test.

C. Upon completion of factory test and before shipment of the equipment/material, the
Contractor shall submit 5 certified copies of test reports not later than 10 days after
completion of all factory test for review/approval by the Royal Commission.

1.10 SERVICE CONDITION

A. Motors and Diesel Generators installed indoor shall be suitable for continuous
operation under the following service conditions:

1. Ambient Air Temperature

a) A maximum of 40°C.

b) A minimum of 0°C.

c) Average temperature measured over a period of 1 month is 35°C.

2. Average Value of Relative Humidity

a) For a period of 24 hours does not exceed 95%.

b) For a period of 1 month does not exceed 90%.

c) Relative humidity may be temporarily 100%.

B. Motors and Diesel Generators installed outdoors shall be suitable for continuous
operation under the following service conditions:

1. Ambient Air Temperature

a) A maximum of 50°C.

b) A minimum of 0°C.

c) Average temperature measured over a period of 1 month is 45°C.

2. Altitude shall be less than 1000 m, unless a higher altitude is specified in the
Contract Drawings/Documents.

3. Average Value of Relative Humidity

Rev 0 6 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

a) For a period of 24 hours does not exceed 95%.

b) For a period of 1 month does not exceed 90%.

c) Relative humidity may be temporarily 100%.

C. Motors and Generators installed in hazardous locations shall comply with the
relevant requirements of Article 500 of NEC.

1.11 DELIVERY, HANDLING AND STORAGE

A. The Contractor shall deliver, handle and store equipment and material units in
accordance with SECTIONS 01650 and 01660, as well as the following
requirements:

1. Provide marking on each item in accordance with the referenced standards.

Ship each unit securely wrapped, crated and wrapped or packaged and
labeled for safe handling in shipment and to avoid damage or distortion.

2. On arrival at site, the equipment/material shall be checked for completeness

and physical damage.

3. Store equipment in secure and dry storage facility as recommended by

manufacturer.

4. Protect all units from physical damage from work of other trades.

5. The Contractor shall be responsible for any damage occurring during

transportation, handling and storage of the equipment.

Rev 0 7 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

PART 2 PRODUCTS

2.01 GENERAL

A. All goods and products covered by these Specifications shall be procured, when
available, from an in-Kingdom manufacturer. Procurement of all goods and products
manufactured out-of-Kingdom must be approved by the Royal Commission.

B. All parts and materials shall be new, good quality, and shall be selected by the
Contractor and the manufacturer to perform as specified herein.

C. The Equipment Supplied:

1. Shall fully confirm to or exceed the minimum requirements specified in this

Specification.

2. Shall be a product of an original manufacturer.

3. Shall be factory assembled and tested to the extent possible so as to minimize

field erection.

D. Items or components of the equipment not specifically covered herein shall be in

accordance with latest editions of the referenced codes and standards.

E. The components of assembled unit shall be UL listed or approved by a testing

laboratory acceptable to the Royal Commission.

F. Reliability and maximum service continuity shall be the fundamental considerations

of engineering, design, operational functions and material used in the design of
components and manufacturing.

G. The Contractor shall have full responsibility for testing and inspection to ensure that
the equipment provided shall comply with all regulatory codes, standards, and
regulations applicable to the specified service and to the requirements of this
Specification.

2.02 PACKAGED ENGINE GENERATOR SETS

A. The Contractor shall supply factory assembled, completely wired except for the field
components, fully automatic diesel engine-generator system as specified in the
Contract Drawings/Documents and in accordance with related standards specified
in par. 1.04.

B. The unit shall be skid-mounted or mobile, package type consisting of a water-cooled

diesel engine, coupled directly or geared to an alternating current generator. The
mobile generator shall either be provided with wheel or trolley mounted. The unit
shall be furnished complete with all auxiliaries, including starting system, fuel storage
and supply system, cooling system, exhaust system, switching equipment, controls,
protections, alarms, piping and accessories.

C. Steel Skid for Packaged Set

Rev 0 8 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

1. The engine generator set shall be integrally mounted on steel skids fabricated
from channels or I-beams with welded steel cross bracing.

2. The skids shall be of sufficient size and rigidity to support the assembled unit,
to permit moving of the assembly without the addition of wheels or rollers and
to maintain alignment between the engine and generator during all skidding,
transporting, and operating conditions.

3. Holes at the bottom flange of the skid shall be provided for proper alignment
with anchor bolts.

4. Units rated 200 kW and below shall have rubber vibration dampers installed
between the engine-generator and the skid.

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

D. The Diesel Generator set shall be aligned properly after proper coordination of
various components required for such alignment.

E. Couplings, shafts and other moving parts shall be enclosed and guarded. The guard
shall be metal, ruggedly constructed, rigidly fastened and readily removable for
convenient servicing of the equipment without disassembling any pipes and fittings.

F. Technical Characteristic

1. Each unit shall have output rating and other characteristics as specified below:

a) Continuous Output Rating: As specified on the Contract Drawings

b) Rated Voltage: As specified on the Contract Drawings

c) Frequency: 60 Hz

d) No. of Phases: 3-phase, 4-wire

e) Power Factor (pf): 0.8

f) Engine Speed: Not to exceed 1800 rpm

g) Elevation: As specified on the Contract Drawings

2. The unit shall be capable of operating continuously for 2 consecutive hours

within any 24-hour period of operation at 110% of its specified rating without
damage.

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

Rev 0 9 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

2.03 DIESEL ENGINE

A. Diesel Engine Requirements

1. Diesel engine shall be 2 or 4 cycle, water-cooled, cold starting type and shall
be of the size required to produce the power required by the generator at
synchronous speeds after appropriate de-rating adjustments have been made
to compensate for conditions cited above and shall be rated for full load of the
generator for continuous 24-hour duty.

2. Forced feed lubrication system, if required, shall be provided by engine driven

pump at main crank shaft, camshaft bearings and at camshaft chain and gear
drives.

3. The engine/flywheel shall be of a proper design for safe operation at speeds

between ± 10% of synchronous speed.

4. The engine shall drive the generator through a flexible coupling of the torque
limiting type to minimize de-synchronization. The coupling shall be selected to
permit the engine generator assembly to operate free from critical or torsional
vibration within a range of 20% of the normal operating speed.

5. Cylinder heads, exhaust valves, piston and piston rings shall be sufficiently
cooled to prevent overheating at ambient temperatures specified in par. 1.10.

6. There shall be an over-speed shut down with manual reset, overriding the
governor at 115% of the rated speed.

7. The engine supplier shall consider the long periods, the engines will stand idle,
and ensure that engine can meet full-rated load immediately after attaining the
full-rated speed after a cold start.

B. Starting of the Engine

1. The engine shall be provided with a complete automatic electric starting

system, consisting of starting motor, battery charger, voltage regulator, heavy
duty diesel cranking type batteries and associated accessories and wiring to
provide a complete starting system.

2. The starting battery (12 or 24 V as specified on the Contract Drawings), shall

have sufficient capacity to crank the engine for temperatures specified in
par. 1.10 for a minimum of 5 consecutive start trials. The battery charger shall
be adequate to fully recharge the depleted battery within 24 hours.

3. Battery console consisting of floor standing cabinet, battery charger and

battery cells of nickel cadmium or lead-acid type, for 12 or 24 V DC operation.
Charger shall be constant potential, line compensated type, rated volt input,
and shall include a DC voltmeter and ammeter.

4. The motor shall be locked out and an audible alarm shall be initiated if the
engine fails to start after fifth attempt.

5. Extra large engines could have other means of starting, such as compressed

Rev 0 10 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

air. In such cases, the manufacturer shall completely specify the starting
system.

C. Engine Cooling System

1. The engine cooling system shall consist of liquid cooled closed loop
arrangement with a unit mounted or remote radiator as specified on the
Contract Drawing.

2. Cooling capacity of the system shall not be less than the cooling requirements
of the engine-generator set and its lubricating oil while operating continuously
at 110% of its specified rating. The system shall have sufficient capacity to
maintain stable operating temperature under the worst site condition.

3. The engine driven pump used for circulating the coolant shall be centrifugal
type.

4. Appropriate pressure relief valves shall be provided to prevent excessive

pressure increase after the engine stops.

5. Forced air fan driven by engine shaft and controlled by thermostat shall be
provided. The fan shall operate if the temperature of coolant exceeds the value
as determined by manufacturer.

6. A thermostat set shall be provided to initiate coolant circulation at a specified

temperature with a radiator by-pass to control the circulation. The radiator and
fan shall be protected by a heavy duty metal guard.

7. The coolant shall be extended life antifreeze solution of 50% ethylene and
50% soft water. Corrosion inhibitor additive as recommended by the
manufacturer shall be added to the coolant to prevent corrosion.

8. Coolant hoses shall be flexible as per manufacturer's recommendation.

9. Self-contained thermostatic-control valve shall be provided to modulate coolant

flow to maintain optimum constant coolant temperature as recommended by
the engine manufacturer.

10. Drain pipes for the radiator and for the engine block shall be provided at low
points in a system.

11. An engine mounted, thermostatically controlled immersion type engine coolant

heater shall be provided to ensure a minimum coolant temperature of 49°C.
Heater shall be suitable for operation on voltage rating as specified on the
Contract Drawings.

12. An expansion tank shall be located at the highest point in the system and shall
have a minimum volume of 10% of the entire cooling system. The tank shall
be supplied with a visual gage so that the coolant level can be checked without
removing the radiator cap.

13. If certain installations require remote radiator, additional electric motor driven
fan and starter, with protective and interlock controls shall be provided to
prevent engine operation without proper cooling system.

Rev 0 11 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

D. Governor

1. The engine shall be equipped with a hydraulic or electronic type governor

meeting steady state and transient response requirements of the system. The
governor shall provide the following speed regulations:

a) At no load and rated rpm, the periodic variation in speed shall not
exceed 1% above or below the mean rpm.

b) For any constant load between 25% and full load of generator rating,
the governor shall maintain the frequency constant between ± 0.5%.

c) The change in the speed when the generator load is gradually reduced
from 100% rated capacity to no-load, when initially operated at rated
rpm, shall not exceed 3%. For certain installations, such as
telecommunication facilities, governor speed regulation shall be within
± 0.25%.

d) While engine is running, it shall be possible to adjust the speed

manually.

E. Engine Air Intake

1. Engine intake replaceable air filters shall be a combined heavy duty pre-
cleaner and dry filter arrangement with a local differential pressure indicator to
ascertain the dirty condition of the filter. The filter shall be suitable for the worst
site conditions.

F. Exhaust System

1. The exhaust system shall be designed in such a way that the pressure drop in
the complete exhaust system shall be small enough for satisfactory operation
of the engine-generator set while it is delivering 110% of its specified rating.

2. Exhaust pipe size from the engine to the muffler shall be as recommended by
the engine manufacturer. Pipe size from muffler to air discharge shall be
2-pipe sizes larger than engine exhaust pipe.

3. Connections at the engine exhaust outlet shall be made with a flexible exhaust
pipe. Provide bolted type pipe flanges welded to each end of the flexible
section.

4. The muffler shall be designed to keep noise level below allowable limit.
Condensate drain at muffler shall be made with Schedule 40 black steel pipe
through a petcock.

5. Exhaust piping and muffler shall be adequately supported, supplied with

flexible joints to absorb thermal expansion stresses and insulated with 50 mm
thick glass fiber covered with an aluminum jacket of minimum thickness
0.8 mm. The jacket is to be held in place by 0.38 mm thick and 15 mm wide
aluminum bands.

Rev 0 12 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

G. Fuel System

1. The fuel system shall be as shown on the Contract Drawings and shall
incorporate all the necessary pumps, valves, filters, piping, fittings, Day and
Bulk Storage tanks to provide a clean reliable supply of fuel to the engine.

2. The engine fuel pump shall be an engine driven, positive displacement pump
capable of supplying an adequate amount of fuel to the engine under all
operating conditions.

3. Fuel injection system shall operate satisfactorily under load and specified
temperature conditions and shall be provided with injector nozzles of such
designs as to obtain the most efficient fuel distribution.

4. Fuel filtration system shall consist of a primary fuel filter installed in the line
between the fuel Bulk Storage tank and the engine-driven pump and a
secondary replaceable fuel filter, installed integrally with engine ahead of the
injector system.

5. The construction of the secondary filter shall be such as to prevent leakage

when the filter is subjected to the maximum pressure which the fuel pump is
capable of generating when the fuel system becomes completely obstructed.

6. Both primary and secondary filters shall be full-flow type and shall be mounted
so as to prevent injury from shock and vibration throughout the normal life of
the unit.

7. Filter elements shall be replaceable without removing the filter assembly from
the engine. The filters shall entrap and remove water moisture as
recommended by engine manufacturer.

8. The fuel lines shall be designed to withstand pressures developed by the fuel
pump under all conditions and so installed and supported as to prevent strains
and chafing from vibration.

9. A schematic flow diagram shall be provided showing the entire fuel system
including the arrangements and location of the valves.

10. Day Tank

a) The capacity of the day tank shall be sufficient to run the engine for
12 hours at full load and shall not be less than:
1) 190 L (50 gallons) for generator sets specified from 50 to 200 kW.
2) 284 L (75 gallons) for generator sets specified from 201 to
300 kW.
3) 379 L (100 gallons) for generator sets specified over 300 kW.

b) Fuel pipe shall be secured and connected to the tank adequately for
maximum protection from fire hazards, including oil leaks. Removable
drip trays shall be provided for collection of oil leakages and its disposal.

c) The day tank shall have a vent, drain cock, shutoff cocks and gage

Rev 0 13 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

glass.

d) The day tank shall have adequate sized breather vent designed to
exclude dust and water from the tank.

e) A float switch shall be incorporated on the day tank to control the fuel oil
transfer pump and to actuate an alarm in the engine generator control
cubicle when the oil level in the tank drops below the level at which the
transfer pump should start to refill the tank.
1) The float switch contacts, which control the fuel oil transfer pump,
shall be set to energize the pump when the liquid level in the tank
reaches 33% of the total volume of the tank.
2) The float switch contacts, which actuate the low fuel oil day tank
alarm device, shall be set to alarm and energize the second fuel
transfer pump when the liquid level in the tank reaches 25% of the
total volume of the tank.

H. Engine Control Panel

1. The engine control panel shall be mounted integrally with the unit and shall
include, but not necessarily be limited to, the following components:

a) Lubricating oil pressure gage (kPa).

b) Over-speed trip device.

c) Manual push-button starter, in addition to auto cranking circuitry.

d) Water temperature gage (°C).

e) Running time indicator (Hr).

f) Tachometer (rpm).

g) Signal indication or alarm lights shall indicate the following engine

shutdown cases:
1) Low lubricating oil pressure.
2) High coolant temperature.
3) Low coolant flow.
4) Over-speed and over-crank.

h) Indicating lights shall remain on until "abnormal" condition is corrected,

at which time, a "reset" button can be depressed to de-energize the
lamps and alarm bell.

i) Any of the above conditions shall prevent re-starting the engine until
normal start-up condition is restored. Spare contacts of the above
conditions shall be provided for remote alarm or annunciation.

Rev 0 14 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

2.04 GENERATOR

A. Generator shall be rotating armature or rotating field type with built-in exciter,
automatic voltage regulation, and radio shielding, all designed and built to applicable
standards as specified in par. 1.04. Voltage regulation shall be within ± 5% and
frequency regulation within ± 3%.

B. Generator shall be capable of withstanding 20% over-speed without mechanical

damage.

C. Generator rotation shall be dictated by the driver rotation. Phase sequence shall be
1, 2, and 3 with counterclockwise phase rotation.

D. Stator

1. The stator frame shall be of fabricated steel construction with sufficient

strength and rigidity to withstand the stresses to which it may be subjected in
handling, transporting or due to short circuit or other forces while in service.

2. The stator frame shall have easily removable end enclosures and associated
ventilation system.

3. The stator core shall be formed from high permeability, low loss, high grade
steel laminations. Each lamination shall be insulated from adjacent lamination
to reduce eddy currents losses.

4. Spacers shall be provided at intervals along the length of the core to form
radial ventilating ducts to ensure uniform temperature distribution across the
stator winding.

5. The laminations shall be tightly clamped together to reduce noise and

vibrations to a minimum. Design shall prevent excessive vibration being
transmitted to the generator foundations, pipes or associated equipment.

E. Rotor

1. Machine shall have a cylindrical pole rotor of laminated construction. Radial

slots shall be machined in the rotor body to receive the field coils.

2. Generator rotor shall be statically and dynamically balanced.

F. Generator shall have Class H insulation with the temperature rise limited to Class B
(80°C rise by winding RTD) in a 50°C ambient. Generator shall be capable of
continuous operation at the limiting observable temperature rise, as specified in
ANSI C50.13. Generator shall conform to the design requirements specified in
NEMA MG 1.

G. Generator windings shall be suitable for wye or delta connection with both ends of
each winding brought out to terminals, in an accessible location, for further
connections.

H. Machines rated 1000 kW and above shall have the stator windings equipped with
twelve 100 W platinum RTDs, 4 per phase, wired to a terminal strip in a NEMA 4X

Rev 0 15 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

stainless steel or cast iron terminal box. The RTDs shall be 3-wire and shall be
located in each phase where the maximum temperature may be detected. Six of the
RTD’s shall be used for local temperature indication and 6 RTDs shall be used for
protective relaying.

I. For machines rated 1500 kW and above, the lower section of each bearing shall be
provided with two 100 W, platinum RTDs. The RTDs shall be located within 6 mm of
the bearing surface. The RTD’s shall be wired to a separate terminal box.

J. Bearing

1. Antifriction or sleeve type bearing shall be used as recommended by the

manufacturer.

2. Antifriction Bearing

a) Antifriction bearings shall have no filling slots. Bearing race-metal

temperature shall not exceed 90°C based on a maximum ambient
temperature of 50°C.

b) Regreasable bearing shall be provided with 2 Nominal Pipe Thread

(NPT) tapped and plugged holes, fill in and drainage plugs. The holes
shall be provided with threaded Type 300 series stainless steel plugs.

c) The bearings shall be serviceable without moving or disconnecting the

generator.

3. Sleeve Bearing

a) Sleeve type bearings shall be equipped with split, labyrinth type end
seals and deflectors where the shaft passes through the housing.

b) Lip type seals shall not be used.

c) The sleeve bearing shell-metal temperature shall not exceed 90°C

based on a maximum ambient temperature of 50°C.

4. Bearings shall be insulated to prevent shaft current circulation.

K. Generator Control Panel

1. Generator Control Panel shall be dead front and dust tight. The panel shall be
free standing, rack mounted, wall mounted or an integral component of the
generator unit as specified on the Contract Drawings.

2. All meters, control switches etc. shall be mounted on hinged doors and shall
be arranged and identified in accordance with good engineering practice.

3. All metering and controls shall be factory wired. Terminal blocks shall be
supplied at hinge side of doors for internal and remote wiring. All wiring shall
be numbered in accordance with standard practice and in accordance with
wiring diagrams.

4. The generator panelboard shall include the following components:

Rev 0 16 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

a) AC Ammeter with 100° scale, 2% accuracy, and a phase selector

switch.

b) Frequency meter with scale 55 to 65 Hz, vibration reed or dial type with
integral transducer, 100° scale, 2% accuracy.

c) Elapsed operating time meter.

d) Ground fault detector.

e) Generator winding over-temperature.

f) Automatic voltage regulator.

g) Wiring, terminal blocks, miscellaneous relays.

h) Current and potential transformers as required.

i) Energy meter.

j) Proper nameplates shall be provided for all equipment.

k) Synchroscope.

l) Voltmeter with 100° scale and 2% accuracy.

m) Power Factor Meter.

n) Ground Bus.

o) Panel illumination light and duplex receptacle.

L. Automatic Transfer and Controls

1. The automatic transfer switch shall be provided if required and shown on the
Contract Drawings. The transfer switch mechanism shall be quick make quick
break type. The switch shall be electrically operated with positive mechanical
interlock to provide load transfer.

2. Four wire automatic transfer switch shall have fully rated switched neutral.

3. The switch shall be fully enclosed in NEMA 1 enclosure for indoor installations
and NEMA 4 enclosure for outdoor installation. The switch shall be provided
with fully rated switched neutral.

4. Transfer to emergency shall occur when normal supply voltage falls below
70% and to return to normal when normal supply voltage attains 90% of rated
voltage.

5. Transfer control shall include auxiliary engine starting and stopping contacts,
cranking limiter, automatic engine starting controls, 4 position selector switch
(TEST-AUTO-OFF-ENGINE START) with TEST position to simulate failure of
normal power supply.

Rev 0 17 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

6. Automatic operation of generator set for 30 minutes per week without load
shall be provided, except on failure of normal source. A local warning visual
and audible alarm is required prior to cranking the engine.

7. The automatic starting controls shall provide four 5 equal length cranking
cycles before the signal indicating failure to start is initiated.

8. Controls shall include an adjustable 0 to 2 minutes time delay to circumvent

momentary voltage dips and an adjustable time delay from 5 to 25 minutes
against re-transfer to normal. After re-transfer of load back to normal, the
engine shall run for 5 minutes unloaded and then automatically shut down,
ready for immediate operation.

9. A frequency relay shall be provided to prevent transfer from normal to

generator source except when generator frequency is between 58 and 62 Hz.

10. Voltage sensing relay shall prevent transfer to emergency generator except
when generator voltage is within ± 5% of normal voltage.

11. Transfer shall be designed for on-load switching on normal and emergency
sources, at rated voltage and current. Auxiliary contacts shall be provided for
light indication of generator operation.

12. A synchroscope shall be used with adjustments of voltage and frequency to

manually synchronize the generator for testing on loads.

13. The battery console shall be incorporated with automatic transfer switching.
The generator set shall power the charger during unit operation when the
normal source is out.

14. Audible and visual alarm signals shall be transmitted with control cables to
specific areas as shown on the Contract Drawings.

15. All transfer switches complete with relays, timers and associated accessories
shall be listed by UL and approved for use on emergency system.

M. Nameplates

1. Engine and generator shall have a stainless steel nameplate attached by

stainless steel screws or rivets and mounted at approximately eye-level in
such a way that the information can be read after the equipment is installed.

2. Entries shall be marked by etching, engraving or other methods of permanent

markings.

3. Each nameplate shall contain the following performance data:

a) Serial number.

b) Manufacturer’s name and year of manufacture.

c) Voltage.

d) Output kVA.

Rev 0 18 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

e) Output kW.

f) RPM.

g) Frequency.

h) Number of poles.

i) Temperature rise of armature.

j) Temperature rise of field.

k) Number of phases.

l) Power factor.

m) Excitation voltage.

n) Excitation current.

o) Buyer’s purchase order number.

p) Connection Diagram indicating winding terminals.

N. Space Heaters

1. Generator shall be supplied with heaters with a nameplate voltage rating of

twice the supply voltage as specified on the Contract Drawings. The heaters
shall protect the generator, generator circuit breaker and control components
from condensation.

O. Painting

1. Diesel Generator Units could be subject to intense direct sunlight, exposure to

dust and abrasion by sand. Generator shall be given an anti-corrosive primer
coat followed by a hard weather and abrasion resistant high gloss finish, to a
total thickness of 0.13 mm.

2. Surfaces after preparation shall be primed and painted according to

manufacturer's standard. The surface shall be given 1 further coat of epoxy
paint. Metallic flake paint shall not be used on any part.

2.05 MOTORS

A. The Contractor shall supply motors operating at 60 Hz. The voltage rating, number of
phases and type of the motor shall be as specified on Contract Drawings. The motors
shall be supplied as per NEMA MG1.

B. Rated Output

1. Motor rating shall be determined by the intended duty.

Rev 0 19 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

a) The majority of motors shall be employed as continuous duty machine, if

not specified.

b) All the motors which are required to drive load for a period of more than
3 hours shall be specified for continuous duty.

2. Horsepower ratings shall be adequate for operating the connected loads

continuously in the prevailing ambient temperatures in areas where the motors
are installed, without exceeding the NEMA standard temperature rise for the
motor insulation.

C. Motor designs, as indicated by the NEMA code letters, shall be coordinated with the
connected loads to assure adequate starting and running torque.

D. The motors supplied shall be either induction or synchronous motors as follows:

1. Induction Motors

a) Induction motors shall be used for most of the Royal Commission

applications as these motors are robust and simple in construction.

b) Induction motors shall employ a distributed stator winding and cage type
rotors.

2. Synchronous Motors

a) Synchronous motors shall be used for:

1) Low speed and high power applications such as reciprocating
compressor. The synchronous motors are more efficient, smaller
and lighter than equivalent induction motors for such applications.
2) High speed, high power and high inertia applications such as axial
compressor or centrifugal pumps where temperature rise during
starting of the motor is of prime consideration.
3) Installations where supply system cannot meet the lagging
varying requirements of induction motors resulting in excessive
voltage drop.

b) Synchronous motors shall be self-starting, utilizing a 3-phase distributed

stator winding and salient pole rotors. The excitation supplies shall be of
the brushless type employing a rotary brushless exciter and rotating
diodes.

E. Construction

1. Stator

a) Frame and Base Plate

1) The stator frame shall be of fabricated steel construction with
sufficient strength and rigidity to withstand the stresses to which it
may be subjected in handling, transporting or due to short circuit
or other forces when in service.

Rev 0 20 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

2) Bases for motors 185 kW and above shall be provided with

mechanical devices to permit accurate horizontal alignment.
These mechanical devices such as jack screws shall be installed
on the base plate of the frame.

b) Winding
1) Windings shall be treated to withstand tropical conditions and the
corrosive effects of industrial sulfurous atmospheres.
2) Form wound stator coils shall be utilized for the motors with rated
voltage 2.3 kV and above.
3) All motor windings shall be adequately braced to permit
application of voltage at 133% of rated value.

c) Winding Temperature Monitoring

1) Three lead type, 100 ohm, Platinum Resistance Temperature
Detector (RTD), calibrated at 0°C (32°F) shall be utilized for
monitoring stator winding temperature as well as for protective
relaying in accordance with IEEE C37.96. RTDs shall be provided
in slot portion of stator winding coils as follows:
(a) All motors rated 375 to 7500 kW shall be provided with
6 RTDs, two each per phase.
(b) Motors rated 7500 kW and above shall be provided with
9 RTDs, three each per phase. Thermistors shall not be
used in motor windings.

2. Rotor

a) General
1) Induction motors shall have a cylindrical rotor of the squirrel cage
type and synchronous motor shall have salient pole rotor.

b) Rotor Winding
1) The rotor winding of induction machines shall be of the cage type,
formed from copper, copper alloy or aluminum bar.
2) The rotor body of synchronous machines shall be of the salient
pole type with the windings of insulated copper wire or strip,
treated to withstand tropical conditions.
3) On squirrel cage rotors, end ring connections shall be of high
mechanical strength. Filler metals used shall be resistant to attack
by sulfurous gases.

3. Insulation of Stator and Rotor Windings

a) Continuous and intermittent rated motors shall be insulated with Class F

insulation. Use of Class B insulation is not acceptable.

b) The maximum permissible temperature for insulation shall not exceed

when the motor operates at 50°C ambient.

Rev 0 21 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

4. Bearing

a) Bearings may be anti-friction (ball/roller) or sleeve type. The selection of

the bearing system shall be in accordance with speed factor as follows:
1) Anti-friction, grease or oil lubricated bearing shall be used up to
speed factor of 250000.
2) Sleeve type of bearing shall be used for the speed factor between
250000 and 300000.
3) Anti-friction, oil lubricated bearing shall be used for speed factor
above 300000.

b) Anti-friction bearings shall typically have an internal fit in accordance

with Class 3 of the Antifriction Bearing Manufacturers Association
Standards.

c) Ball bearings are preferred to roller, and when provided shall be

manufactured from vacuum degassed steel to motor quality.

d) Sleeve bearings shall be of the journal type horizontally split to facilitate

erection and maintenance. The bearing shell halves shall have a white
metal lining and may be self-aligning permitting the bearing to adjust
themselves to static deflection of the shaft.

e) The anti-friction and sleeve bearing metal temperature shall not exceed
90°C based on a maximum ambient of 50°C.

f) The bearing shall be insulated to prevent circulation of stray currents

induced in rotor shaft which may damage the rotor shaft journal or
bearing.

5. Vibration

a) Motors shall be dynamically balanced. The use of solder or similar

deposits is not acceptable. Parent metal removed to achieve dynamic or
static balance shall be drilled out in a manner which will maintain the
structural integrity of the rotor. Chiseling or sawing is not permitted.

b) All motors shall have provisions for future in-situ balance adjustments by
the buyer.

6. Cooling

a) The stator and rotor of the motor shall be air cooled. For certain design
of motors, secondary cooling system using air cooled heat exchanger
shall be employed, if required.

7. Enclosures

a) Totally Enclosed Fan Cooled (TEFC)

1) This type of the enclosure shall be provided for the motors of
rating up to 11000 kW.

Rev 0 22 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

2) The motor shall be totally enclosed and equipped with external

cooling by means of a fan or fans integral with the machine but
external to the enclosing parts.

b) Totally Enclosed Air to Air Cooled (TEFC/CACA)

1) This type of enclosure shall be provided on larger machines for
effective cooling.
2) The motor shall be totally enclosed and shall be cooled by
circulating external air. It is provided with air to air heat exchanger
for cooling the internal air. The internal air shall be circulated by a
fan integral with the rotor shaft. External air shall be circulated by
separated fan.

c) Weather Protected WPII

1) This type of enclosures shall be used for synchronous motors with
rated output above 11000 kW, where cost advantage over TEFC
type is significant.
2) WPII enclosure shall be provided with access to enable inspection
of stator end windings, cleaning of high voltage connectors or
leads and removal of dust without removal of motor assemblies.

d) Classified Areas
1) Motors in classified areas shall have explosion proof enclosure.
These enclosures shall comply with the requirements of
NEC Article No. 501.8, 502.8 and 503.6.

8. Terminal Boxes

a) The terminal boxes shall meet or exceed the enclosure requirements for
the main machine. Terminal boxes and connectors must withstand the
effects of faults as follows:
1) To contain or relieve the consequences of an internal terminal box
fault without an external detrimental effect to personnel.
2) Terminal box shall be adequately sized for line and neutral end
cable terminations.

9. Nameplates

a) Motors shall have a stainless steel nameplate attached by stainless

steel screws or rivets and mounted in such a way that the information
can be read after the equipment is installed.

b) Entries shall be marked by etching, engraving or other methods of

permanent markings.

c) Motor nameplate shall show all the data required by NEMA MG1. In
addition to this, the following data shall be included on the nameplate.
1) Buyer’s purchase order number.
2) Year of manufacture.

Rev 0 23 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

3) Maximum ambient temperature specified in this Section for which

the motor is specifically designed.

10. Space Heaters

a) Motors shall be supplied with heaters with a nameplate voltage rating of

twice the supply voltage as specified on the Contract Drawings. The
heaters shall protect the motors from condensation during their
prolonged outages.

F. Frame Sizes

1. Frame sizes refer to the set of physical dimensions of motors as established

by NEMA. These dimensions include critical mounting dimensions.

2. The frame sizes for various motors shall be in accordance with NEMA MG1,
Section I, Part 4.

G. Operating Characteristics of Motors

1. Different motors of the same rating can have varying starting current, torque
curve and other variables. The four NEMA design have unique speed-torque
relationships making them suitable for different type of applications:

a) NEMA design A motors shall have:

1) High to medium starting current.
2) Normal locked rotor torque.
3) Maximum slip of 5%.

b) NEMA design B motors shall have:

1) Low starting current.
2) High locked rotor torque.
3) Maximum slip of 5%.

c) NEMA design C motors shall have:

1) Low starting current.
2) High locked rotor torque.
3) Maximum slip 5%.

d) NEMA design D motors shall have:

1) Low starting current.
2) Very high locked rotor torque.
3) Maximum slip varying between 5 to 10%.

2. For various values of starting current and locked rotor torques for different
motor ratings, refer to NEMA MG1, Section II, Part 12.

Rev 0 24 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

H. Speed Control of Motors

1. Multi-speed motor shall be provided if required for particular application as

stated in the Contract Document.

2. The speed of the motor shall be changed by varying the connections. A motor
shall be wound in such a way that by varying the connections at stator, the
speed of the motor shall be changed.

I. Effect of Load Inertia

1. The time required for acceleration or deceleration of the motor depends upon
the inertia of the load to which the motor is connected. The larger the inertia
load, the larger will be the time taken by motor to accelerate or decelerate.

2. For a high performance, load inertia reflected on motor side shall not exceed
the motor inertia by more than 10 times. Further increase in load inertia will
cause unstable system behavior and inefficient power usage.

J. Motor Starters

1. For various types of motor starters, refer to SECTION 16440.

Rev 0 25 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

PART 3 EXECUTION

3.01 GENERAL

A. The Contractor shall provide all materials, equipment and labor as deemed
necessary for complete and proper execution of the work.

B. After the installation is completed and properly adjusted, the Contractor shall conduct
operating tests. The various equipment and systems shall be demonstrated to
operate in accordance with the requirements of the specifications. Tests shall be
performed in the presence of the Royal Commission's representative. The Contractor
shall provide electric power, instruments and personnel necessary for performing the
various tests.

3.02 INSTALLATIONS

A. General

1. All installation details, write up on handling of the equipment, instruction

manuals and latest revised drawings furnished by manufacturer shall be
available at site prior to installation of the equipment. These details shall be
reviewed by Royal Commission’s representative. The details and instructions
furnished in these documents shall be followed carefully during installation of
the equipment.

2. Ensure that all buildings and rooms for the installation of the equipment are
ready, complete and clean. All embedded channels and anchor bolts shall be
in place as per layout drawings.

3. All the facilities required for transportation of electrical equipment from store to
site such as competent manpower, crane and trucks of adequate capacities
shall be supplied by the Contractor.

4. All equipment moved to the site shall be inspected for damage or deterioration
during storage. Tag numbers and nameplates shall be verified with the details
given on the Contract Drawings.

5. Installation of the equipment shall be in accordance with the NEC,

manufacturer’s instructions and as shown on the Contact Drawings.

B. Installations

1. Diesel Generator Sets

a) The engine-generator set shall be mounted on concrete base not less

than 300 mm thick.

b) The base shall be constructed independent of the floor slab of the

generator room. The base shall be isolated from the floor slab with
granulated cork of proper thickness, or other approved material and the
space shall be sealed with an approved expansion joint material.

Rev 0 26 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

c) For excavation, mass structure backfill under bases, unclassified

structure backfill around bases, disposal of surplus and unsuitable
material, refer to SECTION 02315.

d) Any soft, spongy or other unstable ground at a concrete base shall be

removed and replaced with compacted mass structure backfill as
specified in SECTION 02315.

e) Refer to SECTION 03310 for construction of concrete bases.

f) The entire unit shall be aligned and mounted on pad type vibration
isolators as follows:
1) Vibration isolator’s mounting bolts shall be securely anchored to
the base.
2) The base of engine generator set shall be bolted and supported
on vibration isolators.
3) Sufficient number of isolators shall be installed so that the floor
(pad) bearing pressure under each isolator is within the floor (pad)
loading specification.
4) Equal number of isolators shall be installed on each side of the
engine generator set's base.
5) Isolators shall be located for approximately equal load distribution
and deflection per isolator. Base of the engine generator set shall
be drilled at the factory for the isolator bolts.
6) All connections between the engine generator set and exterior
systems, such as fuel lines, electrical connections, engine
exhaust system and air exhaust shroud, shall be flexible.

g) The engine generator set shall be balanced properly so that the

vibration velocity in the horizontal, vertical, and axial directions shall not
exceed 16.25 mm per second peak at any specific frequency. These
limits apply to main structural components such as the engine block and
the generator frame at the bearings.

h) Exhaust Air from Radiator

1) The exhaust air from the radiator shall be discharged through the
opening in masonry wall.
(a) The opening in the wall shall not be less than the
dimension of the radiator.
(b) Noncombustible flexible connections made of 20-ounce
neoprene coated fiberglass fabric shall be provided
between radiator and opening of the wall.
(c) The opening in the wall shall be fitted with a rain guard
louvers.

i) Exhaust Gases from Engine

1) The exhaust pipe work, required for connecting to the exhaust
outlet of the engine for discharging exhaust gases to the

Rev 0 27 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

atmosphere, shall be mounted on an efficient suspension

brackets fitted with an expansion joints between piping and
muffler of the engine.
2) The pipe work shall be insulated with 50 mm thick glass fiber
covered with an aluminum jacket of minimum thickness 0.8 mm.
The jacket is to be held in place by 0.38 mm thick and 15 mm
wide aluminum bands.
3) The pipe work shall be supported in such a way that its weight
should not fall on engine or muffler.
4) The opening through which pipe enters the atmosphere shall be
sealed properly by appropriate sealant.
5) The exhaust outlet shall be protected from any obstruction as well
as falling or infiltration of foreign elements by an appropriate
arrangement.
6) The installation shall be neat, thermally and structurally tight
without sag, neatly finished at all hangers or other penetrations
and shall provide a smooth finish surface.
7) Insulation and jacket shall terminate hard and tight at all anchor
points.

j) All mechanical system shall be installed and connected properly as

shown on the Contract Drawings.

k) All power and control wiring shall be completed as per the Contract
Drawings.

l) Adequate working space/clearances shall be maintained around diesel

generator set as recommended by manufacturer. However the minimum
clearance around the set shall not be less than 1 m from nearest object.

m) Grounding of the diesel generator set shall be carried out as specified in

SECTION 16060.

2. Motors

a) Motor unit shall be mounted on a firm flat concrete base sufficiently rigid
to prevent vibration.

b) The motor foundation must rigidly support all 4 legs in the same plane.
The shims shall be placed under the motor leg as required so that they
will not be pulled out of the plane when mounting bolts are tightened.

c) Any items removed during shipment of the motor shall be reinstalled.

d) Guards shall be provided for all exposed rotating parts to prevent

possible personnel injury.

e) Electrical Connections
1) All power and control wiring to the motor shall be done in
accordance with NEC.

Rev 0 28 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

2) Power connections shall be made to drive the motor in the same

direction as required by driven equipment.
3) Before coupling the driven equipment, the motor shall be
energized momentarily to check that the direction of rotation is
proper.

f) Drive belts and chains shall be tensioned in accordance with supplier

recommendations.

g) Couplings shall be properly aligned and balanced.

h) Grounding of the motor shall be carried out as specified in

SECTION 16060.

3.03 TESTING AND COMMISSIONING

A. General

1. The Contractor shall carry out all site tests in accordance with approved test
procedure to ensure that the equipment and materials comply with the
specifications and operational requirements. All tests are subject to witnessing
by the Royal Commission representatives.

2. At least 4 weeks prior to scheduled tests, the Contractor shall submit to Royal
Commission an outline of the plan and procedures to be used in performing
the site inspection and site tests. This outline shall include a brief description
of the test equipment, connection diagrams, proposed tests and procedures,
test sheets, calculations, reference drawings and minimum/maximum test and
performance values in conformance with applicable standards which will be
used to determine conformance with the specification and acceptability of the
equipment and installation.

3. Upon completion of installation and prior to final acceptance, each component

of each system shall be tested to the complete satisfaction of the Royal
Commission. The various equipment and systems shall be demonstrated to
operate in accordance with the requirements of the specifications.

4. The Contractor shall provide all test instrumentation, equipment and

accessories necessary for demonstration and putting the equipment into
operation.

5. All testing equipment shall be calibrated by approved authorities and

calibration certificate shall be provided to Royal Commission for their review
and approval.

6. Upon completion of all testing, the Contractor shall submit 5 copies of a

certified report attesting that each test has been performed in accordance with
the approved test procedures. The report for each test shall include the name
of the person in charge of test and the date of performance. All factory and
field test reports shall be included in Operation and Maintenance Manuals.

Rev 0 29 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

B. Checking and Testing of Diesel Generator Set

1. The following checks shall be carried out prior to testing the Diesel Generator
set:

a) Check interior and exterior of the equipment for physical damage or

defects, if any.

b) Check the condition of lifting lugs and tightness of all bolt connections.

c) Check for rust spots, if any, and ensure that paint finish has been
restored as required.

d) Field work and terminations completed.

e) Mechanical checkout of prime mover completed.

f) Nameplate ratings on all control and instrument transformers verified.

g) All devices (relays, meters, fuses, etc) installed and set properly as per
the Contract Drawings.

h) Ground bus bar continuity and connections to plant ground grid/bus

verified.

2. The following tests shall be carried out on Diesel Generator sets:

a) Insulation resistance test on:

1) Generator winding.
2) Potential and control transformer primary winding.
3) Power and Control wiring.

b) Proper operation of auxiliary devices, governor, voltage regulator,

excitation supply and tripping of each relay scheme shall be tested.

c) Performance Test shall be conducted at rated voltage and frequency as

stated below:
1) 30 minutes running at 50% load.
2) 30 minutes running at 75% load.
3) 4 hours running at 100% load.
4) 2 hours running at 110% load.
5) Single step load pick-up of 50% nameplate kW rating at 0.8 pf,
and 100% load pick-up within 10 seconds of start-up.
6) The following test data shall be recorded at every 30 minutes
interval while performing above test:
(a) kW.
(b) Voltage on each phase.

Rev 0 30 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

(c) Amperes on each phase.

(d) Engine RPM.
(e) Frequency.
(f) Engine water temperature.
(g) Fuel pressure
(h) Oil pressure.
(i) Outdoor temperature.
(j) Average ambient temperature in the vicinity of the diesel
engine.
(k) Average ambient temperature in the vicinity of the starting
batteries.

d) Battery and Starting System Test

1) Operation of batteries and cranking motor shall be demonstrated
to prove that they are capable of 5 starting attempts of 10 second
cranking each at 10 second intervals with the battery charger
turned off.

e) Panel Test
1) Functional tests on all control circuit shall be performed using
elementary diagram.
2) Engine failure conditions shall be simulated to test the proper
operation of each indicating lamp, alarm device and reset button.

f) Fuel Oil Consumption.

C. Checking and Testing of Motors

1. The following checks shall be carried out prior to testing of motors:

a) Check the outside of the motor carefully for damage with particular
attention to terminal box, fans and covers.

b) Check the tightness of all hardware and accessories which may have
become loose during handling.

c) Check that motor shaft rotates freely by turning it by hand.

d) Check interior and exterior of the equipment for cleanliness and check
that the paint finish has been restored as required.

e) Check all connections are carried out as per elementary wiring diagram.

f) Check ground bus bar continuity and connections to plant ground grid.

2. The following test shall be carried out on motors:

a) Insulation resistance test on winding in accordance with IEEE 43.

Rev 0 31 of 32 Contract No:

 SECTION 16220
MOTORS AND GENERATORS

b) Polarization index test.

c) Functional tests on all control circuits as per elementary wiring diagram.

D. Acceptance and performance testing of synchronous machine shall be in accordance

with IEEE 115.

END OF SECTION

Rev 0 32 of 32 Contract No: