ILF-SPC-SRT-EL-812-0

THE HASHEMITE KINGDOM OF JORDAN

MINISTRY OF ENERGY AND MINERAL
RESOURCES

Amman Strategic Reserve

Terminal for Petroleum Products
EMERGENCY DIESEL GENERATOR
SPECIFICATION
07.11.2013

ILF CONSULTING ENGINEERS

Werner-Eckert-Str. 7, 81829 Munich,

GERMANY
Phone: +49-89-25 55 94 - 0
Fax:
+49-89-25 55 94 - 144
E-mail: info.muc@ilf.com

A m m a n S t r a t e g i c R e s e r ve T e r m i n a l for Petroleum Products

E m e r g e n c y Diesel Generator
Specification

ILF-SPC-SRT-EL-812-0
07.11.2013

REVISION

7.11.2013 Approved

V.S.

P.B.

S. B.

4.10.2013 Issue for Review

V.S.

P.B.

S. B.

5.09.2013 Issue for IDC

V.S.

P.B.

S. B.

Prepared

Checked

Approved

Rev.

Date

Issue, Modification

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Specification

ILF-SPC-SRT-EL-812-0
07.11.2013

TABLE OF CONTENTS
1

GENERAL

1.1

Purpose of the Document

DEFINITION AND ABBREVIATION

2.1

Definition

2.2

Abbreviations

STANDARDS

ENVIRONMENTAL CONDITIONS

GENERAL REQUIREMENTS

5.1

Components and Equipment

5.2

Tagging

5.3

Container

5.4

Engine

5.4.1

Motor

5.4.2

Combustion Air Intake

5.4.3

Cooling

5.4.4

Lubrication System

5.4.5

Starting System

5.5

Generator

5.6

Pipes and Cabling on the EDG Set

5.7

Air Intake and Outlet System

5.8

Exhaust System

10

5.9

Fuel System

10

5.10 Engine Gauge Panel

10

5.11 Control and Monitoring System

11

5.11.1 General 11
5.11.2 Emergency Stop

11

5.11.3 Control Cabinet

11

MODES OF OPERATION

13

WIRING

14

PAINTING

15

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Specification

ILF-SPC-SRT-EL-812-0
07.11.2013

INSTALLATION

15

10

TESTS

15

10.1 Workshop Tests

15

10.2 Type Tests

16

10.3 Site Tests

16

ADDITIONAL INFORMATION

16

11

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E m e r g e n c y Diesel Generator
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GENERAL

1.1

Purpose of the Document

ILF-SPC-SRT-EL-812-0
07.11.2013

This specification contains the requirements for design, construction, installation, testing
and commissioning of low voltage emergency diesel generator (EDG) in the new Amman
Strategic Reserve Terminal for Petroleum Products.

DEFINITION AND ABBREVIATION

2.1

Definition
In the present document the following definitions were used. Their meaning is explained
in the table below.

2.2

Definition

Explanation

Client

MEMR Ministry of Energy and Mineral Resources

Engineer

The engineering company entrusted with the project

management and construction supervision of the project
(ILF Beratende Ingenieure GmbH, Munchen).

Contractor

The company or group of companies entrusted by the

Client with Engineering, Procurement and Construction of
the project.

Terminal

The whole terminal within the limits defined on the Station

Layout Plan.

Abbreviations
Abbreviation

Explanation

BS

British Standard

ATS

Automatic Transfer Switch

EDG

Emergency Diesel Generator

IEC

International Electrotechnical Commission

API

American Petroleum Institute,

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ILF-SPC-SRT-EL-812-0
07.11.2013

STANDARDS
The design, manufacturing, construction, installation, test and commissioning of EDG
sets shall be in accordance with the IEC/API and ISO standards. Cables shall follow British standards.
The following standards shall be applied, at least:
API RP 540

Electrical Installations in Petroleum Processing Plants

NEC,API RP 500

Explosion proof equipment in hazardous areas to suit area

classification.

IEC 60034

Rotating Electrical Machines

IEC 60072

Dimensions and Output Series for Rotating Electrical

Machines

IEC 60896

Stationary Lead Acid Batteries

IEC 60947

Low-Voltage Switchgear and Control gear

ISO 3046

Reciprocating internal Combustion Engines Performance

ISO 8528

Reciprocating internal Combustion

Alternating Current Generating

Engine

driven

As far as the energy provider or permits of other authorities require additional codes and
standards, respectively impose additional requirements, these are also part of the contract.
In the case of the conflict between the various codes, standards and order, the most
stringent of the requirements shall generally govern. The Contractor shall refer any such
conflict and any other matter to the attention of the Engineer and Client, whose interpretation shall be final.
All conflicts between the requirements of this specification, contract documents, data
sheets, or drawings shall be referred to Engineer for clarification before proceeding with
the fabrication of the affected parts.

ENVIRONMENTAL CONDITIONS
The emergency diesel generator sets shall be designed and constructed for continuous
operation at full load under the climatic and environmental conditions as described in the
specification Design and Construction of Power Supply Systems.

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GENERAL REQUIREMENTS

5.1

Components and Equipment

ILF-SPC-SRT-EL-812-0
07.11.2013

Components and equipment of same kind and type shall be selected for equivalent functions. The interchangeability must be guaranteed.
The EDG sets shall consist of the following main parts:

diesel engine,

generator,

starter equipment,

fuel system,

lubrication system,

air intake and exhaust system,

control and monitoring system,

EDG container

Diesel engine and generator shall be skid mounted. The EDG set shall be integrated in
an EDG equipment container.
5.2

Tagging
All components, equipment and installations shall receive the respective tagging plates,
labels, etc., which have to be of extremely durable material resistant against the environmental conditions. Tagging plates or labels on fronts of enclosures shall be fixed with
screws.

5.3

Container
The container shall be a welded steel type and be equipped with adapted arrangements
for lightning protection and grounding. All EDG equipment shall be placed within dedicated compartments within the container.
The bottom of engine room shall be a stainless steel and shall serve as collection pan.
Within the engine compartment and the control compartment galvanized steel grating
plates shall be installed above the collection pan. The front or side wall of the engine
compartment shall be completely removable. For noise and heat insulation partition and
outer walls shall be filled with a non-flammable lining. Doors and opening shall be noise
and heat isolated as well. Noise level inside the container shall be max. 105 dB(A), inside the control compartment the noise level shall be max. 85 dB(A).

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ILF-SPC-SRT-EL-812-0
07.11.2013

The container shall be fully equipped with all electrical installations mainly consisting of
but not limited to the following items:

distribution board

lighting powered by station UPS,

switches, cabling, cable transitions etc.

power socket 16A,

heating,

earthing bus bar.

For equipment details refer to relevant specification or attachment.

5.4

Engine

5.4.1

Motor
The engine shall be equipped with a water cooled, turbo-charged, four-stroke diesel motor suitable for indoor installation.

5.4.2

Combustion Air Intake

The engine shall be provided with heavy-duty, two-stage dry type air cleaners complete
with replaceable paper filter elements. The filter shall be sized to suit engine requirements at 100% of rated full load at the ambient conditions inside the generator room.

5.4.3

Cooling
The engine shall be provided with a closed loop, jacket cooling water system. The system shall be sized for continuous maximum load with ambient temperature. The engine
shall be furnished with a thermostatic control valve in the jacket cooling system to maintain a constant jacket coolant temperature in the engine.
The cooling water heat exchanger shall be of the finned radiator type equipped with a
fan. The radiator shall be mounted on the engine skid. The fan shall be preferably driven
from the engine. For the engine a pre-heating system shall be provided.

5.4.4

Lubrication System
The engine and if necessary the generator shall be fully pressure-lubricated. The main oil
pump shall be gear-driven from the main shaft. The lubrication system shall be equipped
with integral relief valve, twin full flow lubrication oil filters and if necessary, with lube oil
cooler with bypass. Where necessary, suitable periodic lubrication equipment shall be
provided to keep the engine ready to start at any time.

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5.4.5

ILF-SPC-SRT-EL-812-0
07.11.2013

Starting System
For engine start an electrical starting system with 24V starter motor, lead-acid battery set
and battery charger shall be provided. The capacity of the battery shall allow six consecutive starts of the engine within 10 minutes.
After the mentioned number of starts the battery shall have 50 % capacity. The charger
shall be sized for recharging of the batteries within 8 hours.

5.5

Generator
For the EDG unit a 3 phase, air cooled, synchronous type generator with shaft driven
ventilator shall be provided. The generator shall tolerate the sudden application or rejection of 50 % of its rated power without unacceptably high voltage fluctuations in excess of
5 %.
The generator winding shall be according to IEC 60085, class F, the utilization shall not
exceed the figures for class B insulation. Brushless rotating exciter and a solid state type
voltage regulator shall be provided. The voltage regulator shall have automatic and manual control to within a deviation of 0.5 % from no-load to full load at rated frequency.
The stator windings shall be equipped with six Pt 100 temperature sensors, which shall
be wired to a common terminal box.
The excitation and de-excitation control equipment shall be combined with the voltage
regulation equipment and shall be placed inside of generator unit control panel. The
generator shall be equipped with a standstill thermostat regulated heater with automatic
initiation when the generator unit is on stand-by.
A differential protection relay is required to be installed inside control cabinet of the EDG
set.

5.6

Pipes and Cabling on the EDG Set

External pipe connections (air intake, exhaust, fuel, etc.) to the vibrating parts of the unit
shall be made with compensator tubes, flexible connections or hoses. Cables and electrical connections shall be mechanically protected and resistant against oil, heat and vibration.

5.7

Air Intake and Outlet System

For the cooling air, including combustion air the container shall be equipped with weather-proof air filters and motor driven louvers for air intake and for air outlet. The sizing of
filters shall guarantee that the entire waste heat of the engine (with exception of exhaust

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Specification

ILF-SPC-SRT-EL-812-0
07.11.2013

air heat) can be carried off with the cooling fan of engine. Filters to achieve the required
noise dampening to at least 95 dB(A) in 1 m distance shall be provided.
The heat exchanger of cooling system shall be connected with the filter by means of vibration bellows. Louvers shall automatically open during start of generator unit and close
after EDG cooling phase.
For the engine an independent supply air system with air filters and piping shall be provided. The system shall be equipped with weatherproof differential pressure indication.
5.8

Exhaust System
The exhaust system shall be stainless steel and the silencer has to be heat insulated in
the room and in the container wall bushing. Silencers to achieve the required noise
dampening to at least 95 dB(A) in 1 m distance shall be provided.

5.9

Fuel System
For the EDG set a day tank shall be provided, which will be installed within the EDG container. For filling a fuel nozzle outside the container shall be provided. Fuel tanks, incorporated in the base frame are not allowed. The day tank shall be fitted with visual level
indicator and level alarm devices for remote indication.
A flame trap shall protect the ventilation openings of the tank. The engine shall be
equipped with suitable fuel oil filters.
The day tank shall be equipped with all necessary devices to allow the automatic filling
from an external fuel tank.

5.10

Engine Gauge Panel

On the diesel generator set a local panel shall be installed which is vibration isolated
from the engine.
The following instruments shall be provided:

lube oil pressure,

engine cooling water temperature,

lube oil temperature.

The panel shall consist of a stainless steel or aluminum plate with holes for the instruments. For increasing the stability the plate shall be rounded off at all sides.

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5.11

Control and Monitoring System

5.11.1

General

ILF-SPC-SRT-EL-812-0
07.11.2013

The control and monitoring system shall be realized by means of a programmable logic
controller (PLC), which is designed for generator set applications. The system shall protect control, monitoring and operation of the EDG set during startup, operation, load
change and normal shutdown.
For switch over to EDG set supply and back to network supply the LV switchboard will be
equipped with an Automatic Transfer Switch (by EDG manufacturer). Via this device the
normal network will be monitored to initiate the start and stop of the EDG set.
Network synchronization is foreseen for the switch-back to normal network supply, only.
Parallel operation with the network is not allowed.
The link to the station control system, the emergency stop functions and the connection
to the automatic change over device of LV switchboard shall be hardwired.
5.11.2

Emergency Stop
The unit shall be provided with an automatic stop via fail-safe controls. All process criteria and measures initiating emergency stop shall be transferred to the station control system.
The low voltage diesel generator set must be stopped with blocking at least in case of
the following conditions:

stop push button,

over speed,

low lube oil pressure,

and all other abnormal conditions which can be dangerous for the diesel generator unit.
The over speed sensing element and shut down mechanism shall be independent from
the regulator governor apparatus and governor drive. The over speed trip shall act on the
injection pump, preferably.
5.11.3

Control Cabinet
The equipment for the control and monitoring system and the necessary auxiliaries shall
be placed inside of a metal enclosed, self-standing or wall mounted cabinet, located in
the Electrical building.
The control cabinet shall be equipped with the following main parts:

sub distribution panel,

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battery charger,

control unit,

measuring and protective instruments,

display or indicator panel,

switches, push buttons.

ILF-SPC-SRT-EL-812-0
07.11.2013

The cabinet shall also include the facilities for automatic synchronization and
manual/automatic voltage regulation.
The supply voltage for sub-distribution panel, which shall feed standstill heater, battery
charger and ventilator for control cabinet shall be 230/400 V, 50 Hz. The voltage level for
control, protection and monitoring shall be 24 V DC, fed from the internal charger/battery.
On the hinged front door of the control cabinet the following devices shall be installed:
1.

2.

3.

Instruments

operating hour meter,

generator voltage (with selector switch),

battery voltage,

current (all three phases),

frequency,

active power.

Switches, push buttons

selector switch for operating modes (off-manual-test-automatic),

manual/automatic voltage regulation selector switch,

push buttons for voltage regulation,

push button for initiation of automatic synchronization,

push buttons for EDG set unit ON/OFF,

push button for lamp test.

Display or indicator panel with the following indications

day tank empty (20% level),

lube oil low pressure alarm,

lube oil high temperature alarm,

generator windings over temperature alarm,

cooling water high temperature,

high speed alarm,

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generator overload alarm,

generator synchronized to network.

ILF-SPC-SRT-EL-812-0
07.11.2013

For all indications, measuring and alarms the respective sensors shall be installed on the
low voltage diesel generator set and its auxiliaries.
To the station control system the following signals shall be transferred:

day tank empty (20% level),

day tank full,

EDG set running,

EDG set fault,

emergency stop (EDG blocked).

From/to automatic transfer switch device in the LV switchboard the following signals shall
be transferred:

EDG set Start,

EDG set Stop,

reference voltage for synchronization.

From low voltage diesel generator set to ATS:

EDG set not available,

emergency stop,

EDG set ready for taking over of load,

EDG set synchronized to network,

switching over to generator supply/network supply (for test of EDG set).

For all indications, measuring and alarms the respective sensors shall be installed on the
EDG set and its auxiliaries. For all remote signals potential free contacts or the respective coupling relays shall be provided and shall be wired to a separate terminal strip.
The main circuit shall be equipped with differential protection relays and releasers for
generator windings high temperature. The protection facilities shall act on the main circuit
breaker for generator feeder.

MODES OF OPERATION
The selector switch for operation modes shall be lockable. For the EDG set the following
operation modes shall be provided:
1.

Off

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ILF-SPC-SRT-EL-812-0
07.11.2013

The control logic is blocked, all signals will be indicated. A switching into this position
during running engine will initiate a stop command.
2.

Manual

All functions (start/stop, voltage regulations, automatic synchronization, etc.) shall be initiated from the control cabinet. In case of network power failure an automatic switch over
to emergency supply shall not be executed.
3.

Test

The EDG set starts and synchronizes automatically and initiate a signal Switching over
to generator supply to the changeover device. After switching the selector switch to
manual or automatic the EDG set synchronizes and initiate the signal Switching over to
network supply to the changeover device. After this the engine stops with a respective
time delay. If during test run the normal network fails the unit shall switch automatically to
emergency supply (via start signal from ATS).
4.

Automatic

In case of supply network failure all functions (start, synchronizing, etc.) shall be carried
out via signal exchange with the ATS. After return of normal network the synchronization
and stop shall also be initiated from the ATS.
During automatic mode no other commands can be given from the control cabinet of
EDG.

WIRING
The wires shall be selected according to load, insulation level, function and operating requirements. The wires shall be adequately rated and equipped with fuses/circuit breakers
of adequate size.
The wiring shall be carried out solid and safe against damages. Wires shall be bundled
and fixed. The wiring shall be laid inside of wiring trays, with 20 % spare foreseen.
All circuits and auxiliary contacts including not used contacts for disconnecting devices
and relays shall be terminated on terminal strips. Terminal strips shall have 10 % spare
terminals. If wires with different potential will be terminated on one terminal strip the respective terminals shall be separated by means of isolating plates. The termination of
multiple stranded wires has to be carried out by means of multiple core cable ends.

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ILF-SPC-SRT-EL-812-0
07.11.2013

PAINTING
All components and devices shall have a resistant, long term stable, high quality painting. Damages, caused by transport, installation, cabling or commissioning shall be repaired in a way, that the original quality is restored.

INSTALLATION
The delivery, installation and commissioning of the low voltage diesel generator sets
shall include, but not limited to the following items:

transport to location of installation (if necessary storage), and the complete

mounting including all accessories,

cable connections between the different parts of the EDG set and to the accessories,

grounding and potential equalization, including connection with the next

grounding bus bars,

first filling of EDG set with lube oil and cooling water,

first filling of day tank with fuel,

termination of all cables at the parts of EDG set and at the accessories,

commissioning of the functioning EDG sets, including voltage feeding and

adjustment of all relays, protection devices, etc.,

briefing of the operation personnel in operation and maintenance during

commissioning phase and during a training on site.

The required lube oil and cooling water shall be delivered by Contractor. The diesel fuel
will be delivered by the owner of the terminal.
The installation and as well the tests and the commissioning shall be carried out with
Contractor own staff and with own tools and measuring/test devices.

10

TESTS

10.1

Workshop Tests
All components of the low voltage diesel generator sets shall be tested completely and
detailed in manufacturers workshop. All tests required by the codes and standards as
well as all manufactures tests have to be performed.

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ILF-SPC-SRT-EL-812-0
07.11.2013

The test program for the work shop test has to be submitted at least 3 weeks prior to
start of the tests.
The following tests shall be carried out, at least:

full load run with measurement of all output data,

check of all unit data under full load conditions,

vibration check,

mechanical operation test on circuit breakers,

functional tests to prove all alarms, signals, indications, shut downs, etc.,

operation of speed governor, over speed trip and voltage regulator,

test of auxiliary devices.

Detailed test protocols of all tests performed have to be submitted prior to shipment.
10.2

Type Tests
Type tests and verifications according to IEC/ISO shall not be performed, if the Contractor delivers a copy of the certified test results.

10.3

Site Tests
The site tests shall include the following steps:

pre-commissioning (including loop testing),

commissioning and test on completion,

performance test.

The workshop tests described above shall be repeated on site by the Supplier after installation. Special care shall be taken for setting of protection devices, relays. Setting
must be done according to the approved selectivity study.
The aim of the tests is to ensure the proper function of the complete scope of delivery.

11

ADDITIONAL INFORMATION
For documentation requirements, shipping instructions, spare parts policy refer to document: Design and Construction of Power Supply Systems - Specification.

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