FUNCTIONAL SPEC. No.

FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 1 of 19

FUNCTIONAL SPECIFICATION FOR

FOR
SYNCHRONOUS GENERATOR AND ACCESSORIES

TOTAL
PREPARED / REVIEWED APPROVED
No. OF DATE REV. No.
REVISED BY BY BY
PAGES
HSM 19 14.12.06 0

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 TO 015 02 01 01/08/2006
 FUNCTIONAL SPEC. No. FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 2 of 19

CONTENTS

SECTION PAGE

1.0 SCOPE 3

2.0 CODES AND STANDARDS 3

3.0 SITE CONDITIONS 3

4.0 SCOPE OF SUPPLY 4

5.0 TECHNICAL REQUIREMENTS 5

6.0 TESTING AND INSPECTION 16

7.0 SPARES 18

8.0 WARRANTY 18

9.0 VENDOR DATA REQUIREMENTS 18

10.0 CONFLICT 19

11.0 CERTIFICATION 19

12.0 PACKING AND TRANSPORTATION 19

13.0 ATTACHMENTS 19

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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 FUNCTIONAL SPEC. No. FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 3 of 19

1.0 SCOPE

This specification covers the design, manufacture, testing and supply of Gas
Turbine/Diesel Engine driven, synchronous generators with associated accessories,
as specified in the data sheet, to be installed on offshore platforms.

2.0 CODES AND STANDARDS

2.1 The synchronous generator, associated accessories and various other

components supplied, shall comply with the requirements of latest revisions of
relevant standards of :

ISI : Indian Standards Institution.

IEC : International Electro-technical Commission.

BSI : British Standards Institution.

NEMA : National Electrical Manufacturer’s Association.

NEC : U.S. National Electrical Code.

IEEE : Institute of Electrical & Electronics Engineers.

NFPA : National Fire Protection Association

API : American Petroleum Institute

2.2 Any other international codes or standards may be used in lieu of above
with prior approval of the Company.

3.0 SITE CONDITIONS

The synchronous generators shall be designed and tropicalised to withstand the site
conditions specified in functional Specification (Spec No. FS 5006) and attached
data sheets.

4.0 SCOPE OF SUPPLY

Each generator set shall comprise of the following as a minimum:

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 FUNCTIONAL SPEC. No. FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 4 of 19

4.1 Stator frame with end covers, stator core, stator winding and termination
arrangement.

4.2 Integrally framed rotor body and shaft with retaining ring and rotor windings.

4.3 Pedestal or stator frame mounted bearings.

4.4 Lifting hooks provided on the top half of the frame.

4.5 Brushless excitation system with permanent magnet generator (PMG) , field
breaker, field discharge resistor, AVR etc.

4.6 Suspension device for rotor insertion and withdrawal

4.7 Foundation frame, foundation bolts and base plates.

4.8 Fire detection & fire extinguishing equipments (Integrated with prime mover
requirements)

4.9 Lubricating oil system integral with prime mover oil system

4.10 Closed circuit air cooler (Air-Air) complete with supporting frame, main and
distribution piping with flanges and inlet/outlet valves, air tight door with
inspection windows, manhole sealing and foundation bolts. (If specified in data
sheet)

4.11 Interconnecting cabling for auxiliary

equipments & panels
4.12 Line cubicles
4.13 Phase bus ducts
4.14 Generator Relay, Control, Synchronizing (If specified in data sheet)
and load shedding panels.
4.15 Battery and Battery Charger
4.16 L.T Switchboard for auxiliaries

4.17 CTs required for AVR operation(if items 4.12 & 4.13 are not supplied by vendor)

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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 FUNCTIONAL SPEC. No. FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 5 of 19

Any other part/ accessories although not specifically indicated in this specification
but considered necessary for safe, efficient & reliable operation of the system, shall
be included in the vendor’s scope of supply.

5.0 TECHNICAL REQUIREMENTS

5.1 Performance Requirements of the Generator:

5.1.1 Black Start Facility

Unless otherwise mentioned in the data sheet, black start facility

shall be provided for the generator.
5.1.2 Voltage Adjustment range

The generator voltage shall be adjustable within a range of ± 5% by means of

sensitive reference point selector. The generator shall be able to deliver the rated
KVA for the full voltage range.

5.1.3 Transient Voltage Response

The dip or rise in voltage load variations shall be kept at minimum. When full
load is applied in one step at the rated P.F. to the generator running on no load
at rated speed and voltage, the voltage drop shall not exceed 15% & voltage
shall be restored to atleast 97% value of rated voltage within 0.6 seconds
depending on the size of the machine.

5.1.4 Steady state voltage stability

5.1.4.1 Voltage accuracy shall be limited to + 0.5% for all loads between no load to full
load at rated power factor.
5.1.4.2 Voltage regulator shall be so designed that voltage accuracy of ± 0.5% is
maintained for a load independent of speed variation upto ± 3%.
5.1.4.3 Voltage regulator shall have sufficient power reserve to compensate for the
differing exciter requirements due to variation in resistance between cold and hot
conditions of generator and exciter.

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 TO 015 02 01 01/08/2006
 FUNCTIONAL SPEC. No. FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 6 of 19

5.1.5 Steady State Frequency

5.1.5.1 Generator frequency accuracy shall be limited to + 1%. Suitable governor shall be
provided on the prime mover to achieve the same..
5.1.5.2 Generator shall be suitable for continuous operation at rated load for the frequency
variation of ± 3%.

5.1.6 Wave Form

5.1.6.1 Harmonic Content, distortion factor

The geometric dimensions of the magnetic system shall be designed in such a

way that the harmonic content of the voltage is less than 2.0% in the line to line
voltage wave form obtained with generator running at rated voltage and speed
and on open circuit .

5.1.6.2 Telephone harmonic factor

This shall not exceed the values given in IEC 34-1.

5.1.7 Unbalanced Load

The generator shall be capable of continuously operating on an unbalanced system

such that, with none of the phase currents exceeding the rated current, the ratio of
negative sequence component of current to the rated current doesn’t exceed 8%.
The temperature-rise limits may be exceeded by 5 oC than those specified in clause
5.2.7 of this specification, under this extreme condition.

5.1.8 Overload

The generator unit shall be able to withstand 10% overload for two hours and 50%
overload for one minute with field set for normal rated load excitation. This shall
be based on a 24 hour cycle.

5.1.9 Parallel Operation

Generator sets shall be suitable for parallel operation, (if specified in data sheet)
with other generating sets, at operating voltage and under load conditions upto
rated value, where by the power factor shall be maintained approximately at
rated value by means of automatic reactive load sharing.

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 TO 015 02 01 01/08/2006
 FUNCTIONAL SPEC. No. FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 7 of 19

5.1.10 Short circuit conditions

5.1.10.1 The generator shall be capable of withstanding for 3 seconds without injury, the
maximum short circuit currents due to a terminal fault, when operating at rated
KVA, P.F. & voltage with fixed excitation.

5.1.10.2 Regulator and exciter should sustain 300% current for 10 seconds when
symmetrical short circuit is applied.

5.1.11 Vibration

The generator vibration shall be within limits specified in the functional

Specification “Equipment Vibration”. (Spec. No. FS 5004)

5.1.12 Noise Level

The noise level shall be within limits specified in the functional Specification
“Equipment Noise Limits”. (Spec No. FS 5002)

5.2 Construction Requirements of Generators

5.2.1 Frame

The frame shall be of steel plate with welded construction. It shall be compact,
light weight and with sufficient mechanical rigidity.

5.2.2 Stator Core

The stator core shall be made of low loss high permeability laminated silicon steel
stampings to reduce heat loss and improve electromagnetic efficiency. In addition,
cooling air ducts shall be provided at optimum intervals to ensure uniform
temperature distribution within the stator winding.

5.2.3 Stator Winding

The stator winding shall preferably use thermosetting resin rich mica insulation
conforming to class F . The coils shall be continuously wound type and
manufactured from electrolytic copper strips having high conductivity and creep
resistance. The winding shall be mechanically strong against vibrations, shall resist
heat build up and shall withstand both moisture and chemical attack. Surface of the
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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 FUNCTIONAL SPEC. No. FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 8 of 19

coils shall be protected against corona discharge for all HV Generators.

Resistance type embedded temperature detectors (RTD) suitably distributed in

stator winding shall be provided. Lead wires from these shall be brought to the
control terminal box on generator frame. The RTDs shall be of 3 wire type,
platinum, 100 ohms at 0o C.

5.2.4 Rotor

The rotor shall preferably be of cylindrical construction. It shall be manufactured

from forged alloy steel having high mechanical and superior magnetic properties. It
shall be free from deformity & shall be mechanically & thermally stable.

5.2.5 Field Winding

Rotor coils shall be continuously wound type and manufactured from silver bearing
electrolytic copper strips having high conductivity and creep resistance. Field
winding shall be provided with hardened glass laminate class “F” interturn
insulation with excellent electrical and mechanical properties. The winding shall
electrically form a compact mass capable of withstanding all the mechanical forces
during operation.

5.2.6 Bearings

Bearings shall preferably be pressure lubricated self-aligning journal type and shall
be lined with superior quality white metal. To prevent damage to the journals due to
shaft currents, bearing and oil piping on exciter side shall be insulated from the
foundation frame. RTDs shall be provided for each bearing and lead wires brought
to control terminal box. In all cases, the bearings shall be chosen to provide a
minimum operating life of 40,000 hours. Vibration detectors shall be provided on
bearings on both horizontal & vertical axis and leads brought to control terminal
box.

5.2.7 Temperature Limits

All the windings shall have class “F” insulation with temperature rise limited to
class ‘B’. The maximum temperature of different parts of the generator shall be
limited as per IEC standards.

5.2.8 Cooling System

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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 FUNCTIONAL SPEC. No. FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 9 of 19

The generators shall be designed with closed circuit air cooling system with air to
air heat exchangers or open air cooling system as specified in the data sheet. The
heat exchanger tubes shall be of stainless steel. Filter shall be provided to prevent
the ingress of dust and foreign particles. Air inlet filters shall be self cleaning type.
These shall be easily accessible for replacement. One RTD each shall be provided
on the cooler inlet & outlet and shall be wired to control T.B. The fans shall be
made of bronze, brass, copper free aluminum, mild steel or stainless & shall be
properly treated to make it corrosion resistant. In case of forced air cooling system,
100% redundancy shall be provided for the inlet air fans.

5.2.9 Direction of rotation

The direction of rotation of the rotor of the machine as viewed from the coupling
end, shall be clockwise. A clear indication of the direction of rotation shall be
marked on either end of the machine.

5.2.10 Stator connections and terminal box

The stator windings shall be star connected with all six winding ends brought to the
terminal boxes. Alternatively, the stator winding may be designed for connection in
double star with three phase and six neutral terminals brought to the terminal boxes.
Separate terminal box shall be provided for phase & neutral.

In addition to above, all high voltage generators (3.3 KV & above), the following
shall be adhered to (i) phase terminal box shall segregated type (ii) Bushing type
terminals shall be provided.

All LV generator neutral terminal box shall be large enough to accommodate 3

Nos. differential CT before star point and one No. CT for earth fault detection after
star point.

The terminal boxes shall be of fabricated sheet steel and shall be suitable for
withstanding maximum fault current for 3 secs. They shall also be suitable for
busduct/cable connection as specified in the data sheet. Necessary
clearances/creepage distance shall be provided between live parts and between live
parts to earth.

Live terminals shall be thoroughly insulated from the frame with material resistant
to tracking.

The terminal box shall have double compression type Ni/Cr plated brass cable
glands for cable entry. Appropriate phase markings shall be provided inside the
terminal boxes. The markings shall be non-removable and indelible.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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 FUNCTIONAL SPEC. No. FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 10 of 19

5.2.11 Space Heaters

Suitably rated space heaters shall be installed within the enclosure. Location and
maximum surface temperatures of the heaters shall be such that no damage can be
caused to any insulation. Heaters shall be suitable for operation on a single phase
240V, 50 Hz AC supply. The leads of the heater shall be brought out to a separate
terminal box.

5.2.12 NAME PLATE DETAILS

A SS 316 name plate shall be fixed on the generator frame containing the
following information as minimum , in English language.

- Manufacturer’s name
- Applicable standard / Model
- Serial Number, type & Frame reference
- Rated output in KVA and KW
- Duty
- Rated power factor
- Overload rating
- Rated frequency
- Rated voltage
- No. of Phase / type of connection
- Rated stator current
- Rated speed in Rev/Min
- Direct axis Subtransient, transient & synchronous reactances (in %)
- Class of insulation ( Stator)
- Temp. Rise (Stator)
- Phase Rotation ( CW or CCW ) viewed from DE
- Excitation current & voltage at rated output
- Year of manufacture
- Weights in Kg of rotor and stator
- Bearing type/No (DE/NDE )

5.2.13 Brushless Excitation System

5.2.13.1 Brushless excitation scheme shall consist of an AC exciter, rotary rectifier,

discharge resistors and an automatic voltage regulator. Rotating AC exciter shall
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 FUNCTIONAL SPEC. No. FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 11 of 19

have stationery field circuit which shall be powered by a permanent magnet

generator. AC voltage generated in the AC exciter shall be rectified by the rotary
rectifier assembly and fed to the main field circuit. During faults when the
generator is isolated from the system , field suppression shall be automatically done
by the rotating rectifier and field discharge resistors.

The armature winding of the AC exciter, the rectifier assembly, main field winding
of the generator and other accessories on rotor part shall be rigidly fastened to the
shaft and the connections with different items shall be anti-loosening type.

The exciter capacity shall be atleast 20% more than the maximum requirement at
any time and the rated voltage shall be atleast 110% of the full load machine
excitation voltage.

5.2.13.2 A.C.Exciter

The AC exciter shall be three phase synchronous generator with a rotary

armature type structure. Its stator shall be so constructed that the magnetic poles
are bolted to the magnet frame. The magnetic poles shall be made of laminated,
punched sheet steel.

The AC exciter armature and field windings shall be made of silver bearing
electrolytic copper and electrolytic copper respectively and insulated with class F
insulation material with temperature rise limitation of class B insulation. The
exciter field circuit shall be controlled by the AVR.

5.2.13.3 Rotary Rectifier

The rotary rectifier set shall consist of thyristors, zener diodes, semi-conducting
fuses, surge suppressors other protective devices, etc. Rectifier circuit should be
designed to take care of rectification of AC voltage and for proper field suppression
through discharge resistors. Series diodes shall be used for redundancy. The rating
of the diode bridge and armature shall be such that the full load rated current can be
supplied even if one diode remains inoperative.

All components shall be designed and mounted considering the effects of the
centrifugal forces. The elements built into the rotary rectifier shall offer very high
reliability, long life and trouble-free operation with practically no maintenance
requirements.

5.2.13.4 Pilot Exciter

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 FUNCTIONAL SPEC. No. FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 12 of 19

The pilot exciter shall be a permanent magnet revolving field, A.C generator, which
provides excitation power to the AVR system. The PMG shall be mounted on the
rotor shaft adjacent to the main exciter. The rotor shall consist of a series of
permanent magnet poles with steel strips, bolted to a forged steel hub.

5.2.13.5 Automatic voltage regulator

The automatic solid state voltage regulator shall be provided with following
features; as a minimum-
a. Under frequency protection circuit.
b. Protection against short circuit.
c. Manual voltage regulator with auto follower.
d. Over voltage protection
e. Minimum excitation protection
f. Over excitation protection
g. Stator current limiter
h. Flux limiter
i. Soft start facility (voltage buildup circuit)
j. Quadrature current compensation for parallel operation
k. Null balance indicator
l. Change over to manual control in case of AVR limit crossing
m. Monitoring system for diode failure
n. Voltage & excitation monitor

o. The AVR should operate with following parameters:

+ 0.5% accuracy from no load to full load at steady state,

+ 5% setting range,

Response time of 25 ms,

+15% for full load step change and recovery to at least 97% of
normal voltage within 6.0 secs (with maximum two overshoots).
p. All operating & indicating instruments shall be flush mounted on the door front.
AVR Panel shall house the field breaker, discharge resistors and all other
accessories/ protection devices equipments required for field circuit. Space
heater with adjustable setting thermostat & cubicle illumination lamp suitable
for 240 V AC, single phase supply shall be provided in the AVR Panel.

5.2.14 Special tools and tackles

Each generator shall be provided with set of special tools & spanners required for
maintenance, as a free issue material.

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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 FUNCTIONAL SPEC. No. FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 13 of 19

5.3 Line Cubicles

5.3.1 The cubicles shall be floor mounted, free standing type, dust and vermin proof,
fabricated from 2mm thick cold rolled sheet steel mounted on angle iron frame
work.

5.3.2 The cubicle shall be divided into two sections with a metallic partition. The front
section shall house the PTs, lighting arrestors, surge capacitors and the rear section
shall house the bus bars and CTs (if specified in the data sheet)

5.3.3 The cubicles shall be provided with bolted doors in the rear and hinged doors at the
front.

5.3.4 The bus bar material shall be electrolytic copper sleeved with flame retardant low
smoke insulating material and shall be supported on fibre glass insulators at regular
intervals to withstand the required short circuit force.

5.3.5 The line cubicles shall be provided with suitable flanges to match with bus duct
flange, if specified in data sheet.

5.3.6 The PTs shall be housed in drawout compartments and three different
compartments shall be provided for three single phase PTs with H.V. & L.V fuses.
Each set of PTs shall be housed in separate tiers.

5.3.7 Space heaters with adjustable setting thermostat shall be provided in individual
compartments to avoid condensation of moisture & they shall be suitable for 240V,
50 Hz, 1 phase supply.

5.3.8 The PTs & CTs shall be cast resin insulated type. The VA burden, ratio & accuracy
class shall conform to the specifications given in the data sheet.

5.3.9 A copper earth bus of minimum (50 x 60mm2 ) size shall be run throughout the
length of cubicle and all metallic non-current carrying parts shall be connected to it.

5.3.10 All C.T. & P.T. secondary terminals and space heater terminals shall be brought to
a common marshalling box mounted on the cubicle. Control switches and MCCBs
shall be provided in the marshalling box. 20% spare terminals shall be provided on
the terminal block.

5.3.11 One No. 240V, 5A, 3 pin plug – socket assembly shall be provided in the panel.
If bus duct is specified in data sheet, CT shall be mounted in the bus duct.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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 FUNCTIONAL SPEC. No. FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 14 of 19

5.4 Phase Bus Ducts

5.4.1 The bus ducts shall be of box frame construction of cold rolled sheet steel enclosure
suitably braced to withstand the maximum mechanical and electrodynamics forces.
All joints and covers shall be provided with gaskets. The covers shall be in suitable
lengths for ease of removal and shall be arranged to give complete accessibility to
the bush bars, joints, bends and supports etc.

5.4.2 Necessary flanged opening shall be provided at the terminating ends of bus ducts.
These flanges shall match with corresponding flanges in the equipment to which
they are connected. Proper alignment and co-ordination regarding PHASE
SEQUENCE etc. between bus ducts, generator, line cubicle etc. shall be the
responsibility of the vendor. The bus duct shall be supplied with all the hardware
necessary for terminations. The hardware shall be cadmium plated.

5.4.3 Bus ducts shall be supported from overhead hangers inside the generator room. The
supports shall be provided by the contractor. However, the vendor shall furnish the
details of supports and indicate the intervals at which such supports have to be
provided. The bus bars shall be of electrolytic copper supported on fibre glass
insulators at regulators intervals to withstand the required force due to short circuit
current. Each shipping section shall meet this requirement separately. Expansion
joints shall be provided to take care of expansion due to specified changes in site
temperature. Minimum one expansion joint shall be provided for each 3000 mm
long straight length of bus duct. Bus bar size shall be suitable for maximum
specified continuous and short circuit current ratings at maximum specified site
temperature. Bus ducts for high voltage generators shall be phase segregated type.

5.4.4 The termination of bus bars at the terminating ends shall be done through flexible
joints.

5.4.5 A copper earth bus of minimum 50mm x 6 mm cross section shall be run
throughout the length of bus duct outside the enclosure and all metallic non-current
carrying parts shall be connected to it.

5.4.6 All the bus bars shall be insulated with flame retardant low smoke insulating
material sleeves.

5.4.7 Space heaters with adjustable setting thermostat shall be provided in the bus duct
enclosure at suitable intervals to maintain the temperature of the bus ducts in no
load condition and avoid deposit of moisture. The space heater shall be suitable
for 240V, single phase, A.C supply.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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 FUNCTIONAL SPEC. No. FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 15 of 19

5.4.8 CTs, if provided, shall be cast resin insulated type. The VA burden, ratio &
accuracy class shall conform to the specification given in the data sheet.

5.4.9 C.T secondaries & space heater terminals shall be wired to a marshalling box
located on the bus duct. Shorting links shall be provided in the marshalling box.
Control switches/MCBs shall also be located in the marshalling box. 20% spare
terminals shall be provided in the control terminal box.

5.5 Generator Relay, Control, Synchronising and Load Shedding Panels

The panel shall conform to the bid package specification No. FS 4019 enclosed
elsewhere in bid package.
5.6 Battery & Battery Charger

The battery & charger shall cater for all requirements of prime mover, generator
and control panel as per Specification No. 4023 enclosed elsewhere in bid
package with the exception that battery shall have 1 No. battery pack rated for
100% AH capacity and single charger system.

5.7 LT Switch Boards

Power shall be made available at the incomer of the switch board at 415V, TPN, 50
Hz AC. Necessary outgoing feeders shall be provided to meet the requirements of
all auxiliary supplies of prime mover, generator, control panel, bus ducts, line &
neutral cubicle etc. The switchboard shall meet the requirements given in data sheet
& function specification No. FS 4013 placed elsewhere in bid.

5.8 Cables

All cables supplied shall meet the requirements given in data sheet and bid package
specification No.4011.

5.9 Miscellaneous Requirements

5.9.1 All auxiliary motors shall conform to functional Specification “ Medium voltage
motors”. (Spec. No. FS 4008)
5.9.2 All the equipments shall be painted in conformity with Functional Specification
“Protective Coating”. (Spec No. FS 2005)
5.9.3 Any other item not specifically included in this specification but required for safe,
smooth and trouble-free operation & maintenance, shall be deemed to have been
included by the vendor in his scope of supply.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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 FUNCTIONAL SPEC. No. FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 16 of 19

6.0 TESTING AND INSPECTION

6.1 The generator package with all controls must be assembled and tested to check all
system operation and ensure minimum commissioning time.

6.2 Detailed test procedures along with the facilities available shall be submitted with
the bid.

6.3 Company shall be advised atleast (4) weeks in advance of the scheduled date of
each test and again 20 days prior to the actual test.

6.4 Shop inspection may be required at regular intervals and vendor shall allow
Company’s representative / inspectors to do the same.

6.5 Generator Tests

Generator sets shall be tested and inspected to verify compliance with the
guaranteed technical particulars and for satisfactory performance. Relevant
standards shall be followed as guideline for testing. All the tests shall be witnessed
by Company or its authorized representatives.
The Commissioning tests shall be carried out at site under normal service
conditions.
Following tests, as a minimum, shall be carried out on the generators at Vendor’s
works in accordance with IEC-34 or equivalent international standards.

6.5.1 Insulation resistance tests and determination of polarization index value of :

a) Generator (Before & after dielectric test)
b) Exciter (Before & after dielectric test)
c) Resistance temperature detectors.
d) Bearings.
6.5.2 High voltage Test.
6.5.3 Measurement of open circuit characteristic.
6.5.4 Measurement of short circuit characteristic.
6.5.5 Temperature rise at rated voltage, current, frequency and zero power factor.
6.5.6 Overspeed test at 120% rated speed for 2 minutes.
6.5.7 Vibration tests.
Note
• Vibration tests in the factory to be taken at 100% of synchronous speed and at
120% during overspeed test.
• Vibration tests at site to be taken at 100% of synchronous speed of the complete
generator with its driver.
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 TO 015 02 01 01/08/2006
 FUNCTIONAL SPEC. No. FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 17 of 19

6.5.8 Determination of efficiency by measurement of segregated losses.

6.5.9 Phase sequence/voltage balance/current balance tests.
6.5.10 Determination of reactance and time constants.
6.5.11 Wave form test and harmonic analysis.
6.5.12 Determination of moment of inertia (Type test results are acceptable).
6.5.13 Instantaneous short circuit test (if specified in data sheet)
6.5.14 Noise measurement test.
6.5.15 Response of voltage and frequency with sudden shedding of 25%, 50%, 75%, 100%
and 150% rated load
6.5.16 Response of voltage and frequency with sudden application of 25%, 50%, 75%,
100% and 150% rated load respectively to the generator running at no load.
6.5.17 General dimensional and alignment of windings.
6.5.18 Measurement of DC resistance of windings.
6.5.19 Pressure test on heat exchangers (cooling system)
6.5.20 Inter turn insulation test of stator winding with induced voltage of 130% of value of
exciter.
6.5.21 Measurement of shaft current
6.5.22 Flux test on stator core before and after pressing.
6.5.23 Determination of exciter response and ceiling voltage of exciter.

6.6 Test on line cubicles & bus ducts

6.6.1 Dimensional checks & visual inspection for workmanship.

6.6.2 High voltage test.
6.6.3 Phase to phase & phase to earth insulation resistance measurement.
6.6.4 Phase to phase & phase to earth clearances & creepage distance of insulator
measurement.
6.6.5 Name plate checks for CTs, PTs, LAs & Capacitors etc.
6.6.6 Continuity checks for L.T Circuits & voltage withstand test.

6.7 Test on generator relay, control, synchronising and load shedding panels

All test as listed in bid package functional specification (Spec no. FS 4019) shall
be conducted on the panels.

6.8 Test on battery & battery charger

All tests as listed in bid package specification (Spec no. FS 4023) shall be
conducted on the battery & charger system.

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 TO 015 02 01 01/08/2006
 FUNCTIONAL SPEC. No. FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 18 of 19

6.9 Test on LT Switchboard

All tests as listed in bid package specification (Spec no. FS4013) shall be
conducted on the switchboard.

6.10 Test on cables

All tests as listed in bid package specification (Spec no. 4011) shall be conducted
on the cables.

7.0 SPARES

7.1 Vendor shall provide spare parts needed for start-up. In addition, vendor shall also
furnish a separate priced list of recommended spares for two (2) years of normal
operation and maintenance. Recommended spares shall take into account the
related factors of equipment reliability, effect of equipment downtime upon
production, safety, cost of parts and availability of equipment service facilities.

7.2 All spares furnished by vendor shall be wrapped and packaged so that they shall be
preserved in original as new condition under the normal conditions of storage
prevailing in India and shall be properly tagged and coded to facilitate future
identification. They shall be packaged separately clearly marked as “SPARE
PARTS” and shipped alongwith the main equipment. Packing lists shall be
furnished so that the parts can be handled without uncrating, if required.

8.0 WARRANTY

Vendor shall have final and total responsibility for the design and performance of all the
equipments supplied under this specification. Vendor shall warrant the equipment
furnished by him and their performance of in accordance with this specification and
‘ Specifications Definitions’.( Spec No. 1050)

9.0 VENDOR DATA REQUIREMENTS

Vendor shall furnish the data / information in accordance with this Specification
and vendor data requirement Specification (Spec. No. 1060).

10.0 CONFLICT

In the event of conflict between this specification & other documents listed herein,
the following order of priority shall govern :

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 TO 015 02 01 01/08/2006
 FUNCTIONAL SPEC. No. FS 4040
Design Division SPECIFICATION FOR
SYNCHRONOUS Rev. No. 0
Engineering GENERATOR AND
Services ACCESSORIES Discipline: Electrical
ISO – 9001:2000 PAGE : 19 of 19

i) Electrical Design Criteria, drawings and data sheet (whichever applicable)

ii) This Specification
iii) Codes & Standards

11.0 CERTIFICATION

All offered equipments or equipments of similar design and construction features

manufactured by the same vendor.

shall have been type tested by an authority approved by the Company.

•
shall have been in continuous satisfactory service in offshore for a minimum
•
period of two years.
• shall be having current certification/approval/listing by an approved agency
or UL or FM
12.0 PACKING AND TRANSPORTATION

The offered equipment alongwith their accessories shall be shipped to site packed
in wooden crates. They shall be wrapped with polythene sheets, before being placed
in the crates to prevent damage to finish. Crates shall have skid bottom for
handling.

13.0 ATTACHMENTS

The following specifications and drawing/data sheets shall form part of this
specification :

13.1 Other Functional Specifications.

1060 Definition
2005 Protective-coating
5002 Equipment Noise limits
5006 Site conditions and climate
1060 Vendor data requirements
5004 Equipment Vibrations
4008 Medium Voltage Motors

13.2 Data sheet placed elsewhere in bid package.

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A ODS/SOP/008 TO 015 02 01 01/08/2006