NUMBER E07-S01

REV. NO. 2
ENGINEERING STANDARD DATE MAR 2004
PAGE 1 OF 11

Stand-By Diesel Generators, 480 and 4160 V

This document is issued by Engineering Standards Section, SABIC Engineering and Project Management, Kingdom of Saudi Arabia.
The information contained in this document is the confidential property of SABIC. It can not be disclosed, copied or used for any purpose
without prior approval from SABIC. If you are not authorized to possess this document, please destroy it immediately.
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Stand-By Diesel Generators, 480 and 4160 V
DATE MAR 2004
ENGINEERING STANDARD PAGE 2 OF 11

CONTENTS

1. SCOPE ................................................................................................ 3
2. REFERENCES 3
3. GENERAL 3
4. SYSTEM DESCRIPTION .................................................................... 4
5. GENERATOR 4
6. GENERATOR CONTROLS 5
7. ENCLOSURE ...................................................................................... 6
8. CONTROL PANEL 7
9. NAMEPLATES 7
10. INSPECTION AND TESTING ............................................................. 8
10.1 Inspection 8
10.2 Test 9
11. FINISH ............................................................................................... 10
12. DOCUMENTATION 10
12.1 Drawings 10
12.2 Operation and Maintenance Manual ............................................ 10
12.3 Spare Parts 10
13. PREPARATION FOR SHIPMENT 10
13.1 General ........................................................................................ 10
13.2 Internal Preservation 11
13.3 External Preservation ....................................................................11
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DATE MAR 2004
ENGINEERING STANDARD
PAGE 3 OF 11

1. Scope
This specification is for the design, materials, manufacture, testing, and commissioning of packaged
stand-by diesel engine generators intended for permanent installation in industrial plants.

2. References
Reference is made in this specification to the following documents. The latest issues, amendments, and
supplements to these documents shall apply unless otherwise indicated.
SABIC Engineering Standards (SES)
E07-X01 Stand-by Diesel Generators, 480 V and 4160 V - Data Sheet
G10-S01 Diesel Engines
Z01-G04 Measurement Units for Use in SABIC Projects
E09-S01 Motor Control Center 600 V
E09-S02 Medium Voltage Motor Control Center
E19-S01 Packaged Electrical Equipment Requirements
American National Standards Institute (ANSI)
C50.10 Synchronous Machines
C50.12 Synchronous Generators
Institute of Electrical and Electronics Engineers (IEEE)
115 Guide: Test Procedures for Synchronous Machines Part I
National Electrical Manufacturers Association (NEMA)
MG 1 Motors and Generators
National Fire Protection Association (NFPA)
70 National Electrical Code
110 Standard for Emergency and Standby Power Systems (National Fire Codes, vol. 5)

3. General
3.1 The diesel engine generator (DEG) system shall provide the source of standby power for critical
electrical loads when normal electrical power is not available.
3.2 The generator set shall be supplied as a complete package comprising diesel engine, generator,
controls, cooling system, starting system, and diesel day tank. The generator set package shall conform to
NFPA 70 Article 702, NFPA 110, SES G10-S01 and SES E19-S01.
3.3 The generator set shall be supplied in accordance with the electrical one line diagram and
SES E07-X01 which shall indicate the generator kW, output voltage, and the protective relays required for
generator protection. ANSI relay designations shall be utilized.
3.4 The engine shall be diesel and shall meet all requirements of SES G10-S01.
3.5 The engine shall be supplied with all support systems in accordance with SES G10-S01.
3.6 Generator set shall be suitable for operation under the following environmental conditions:
a. Ambient temperature range: 1 °C to 50 °C
b. Metallic surface temperatures reaching 75 °C due to solar radiation
c. Relative humidity: 10 to 100 percent
d. Corrosive desert atmosphere with blowing sand and dust
e. Seismic conditions: UBC Zone 1
3.7 When specified in SES E07-X01 an adequately sized power circuit breaker and controls housed in a
motor control center (MCC) enclosure shall be supplied for 600 V and 4160 V generators, conforming to
SES E09-S01 and E09-S02.
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3.8 Documents shall be provided in units conforming to SES Z01-G04, and shall be written in English
language.
3.9 Any conflict(s) between this specification, SES and industry standards, engineering drawings, and
contract documents shall be resolved at the discretion of SABIC.

4. System Description
4.1 Engine-generator unit and accessories shall be designed for a 20-year life expectancy, and shall be
capable of operating at 105 percent of rated speed without overstressing any part of the engine, generator
or accessories.
4.2 Engine-generator unit shall be capable of continuous operation at all loads up to and including rated
load at the specified operating conditions and at 110 percent of rated load for two (2) hours out of every 24
hours.
4.3 Engine-generator shall start, reach full speed and be ready to pick up load in no more than 15 seconds.
System load shall be picked up immediately after engine is stable. Engine-generator shall be capable of
unattended operation at rated full load or any partial load, while maintaining rated voltage and frequency for
a period not exceeding two (2) days. Engine-generator shall be capable of being started and exercised
under partial or full load for a period of at least two (2) hours per week.
4.4 DEG system shall be capable of accepting 85 percent of rated load or shedding 100 percent load
without exceeding an 8 percent frequency and 10 percent voltage variation at the generator terminals, and
shall be capable of starting the largest motor connected as essential load without exceeding a 2 percent
frequency droop and 15 percent voltage drop. DEG shall be capable of accepting 50 percent of rated load
without exceeding a 5 percent frequency droop.
4.5 Engine-generator set shall be able to start under black-start conditions, that is, without power for the
auxiliary devices on the generator set, using only generator set battery, or the air contained in the starting
air tanks and fuel supplied from the day tanks.
4.6 A constant speed governor shall be supplied for the generator set that has the capability for load
sensing and will maintain isosynchronous speed of the engine at ± 0.25 percent of steady state speed.

5. Generator
5.1 Generator shall be capable of continuous duty service and shall operate successfully at rated kVA,
frequency, and power factor at any voltage not more than 5 percent above or below rated voltage.
5.2 Generator shall be capable of withstanding 20 percent overspeed without mechanical damage.
5.3 Generator rotation shall be dictated by the driver rotation. Phase sequence shall be 1, 2, 3, with
counterclockwise phase rotation.
5.4 Generator shall be designed with limiting values for subtransient reactance and short-circuit ratio. See
SES E07-X01 for specific limiting requirements, if any.
5.5 Generator armature and field winding short-time thermal requirements shall be as specified in
ANSI C50.12.
5.6 The generator rotor short-time thermal requirements for unbalanced faults shall be as specified in
ANSI C50.12.
5.7 In addition to the mechanical requirements for short circuits specified in ANSI C50.12, the generator,
voltage regulator, and exciter system shall be capable of sustaining at least 300 percent rated generator
current for 10 seconds, if a 3-phase, symmetrical short circuit occurs at the generator terminals.
5.8 The requirements for continuous current unbalance of the generator shall be as specified in
ANSI C50.12.
5.9 Generator shall have Class F insulation with the temperature rise limited to Class B (80 °C rise by
winding resistance temperature detector (RTD) in a 50 °C ambient. Generator shall be capable of
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continuous operation at the limiting observable temperature rise, as specified in ANSI C50.12. Generator
shall conform to the design requirements specified in NEMA MG 1.
5.10 The stator frame shall have easily removable end enclosures and associated ventilating system. The
frame shall be of sufficient strength to support the armature laminations and coils.
5.11 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 SABIC’s connection. Either end of the windings shall
be suitable for phase terminals; leads shall be separated and adequately braced. See SES E07-X01 for
specific connection requirements. An oversized terminal box shall be provided to house the neutral ground
current transformer (CT).
5.12 Machines rated 1000 kW and above shall have the stator windings equipped with 12, 100: platinum
RTD’s, four (4) per phase, wired to a terminal strip in a NEMA 4X stainless steel or cast iron terminal box
for continuation wiring by SABIC. The RTDs shall be 3-wire and shall be located in each phase where the
maximum temperature may be detected. Six (6) of the RTD’s shall be used for local temperature indication
and six (6) RTD’s shall be used for protective relaying.
5.13 For machines rated 1500 kW and above, the lower section of each bearing shall be provided with
two (2), 100:, platinum RTD’s. The RTD’s shall be located within 6 mm of the bearing surface. The RTD’s
shall be wired to a separate terminal box.
5.14 The armature laminations shall be constructed of high-grade steel, suitably secured to the stator
frame. Spacers shall be provided at intervals along the length of the core to form radial ventilating ducts.
The laminations and spacers shall be securely clamped together to minimize undue vibration and noise.
5.15 Main armature coils shall be form-wound and exciter armature coil shall be random wound.
5.16 Generator rotor shall be made of steel. Radial slots shall be machined in the rotor body to receive the
field coils.
5.17 Generator shaft shall be accurately finished throughout its entire length, and shall be grounded at
bearing and sealing surfaces and adjacent to the bearing surfaces, to permit vibration measurements.
5.18 Generator rotor shall be statically and dynamically balanced. During the shop test of the assembled
generator while operating at rated speed, the double amplitude of vibration, including mechanical runout in
any plane measured on the shaft adjacent and relative to each radial bearing, shall not exceed 38 Pm
(11/2 mils). A 6 Pm (1/4 mil) maximum shaft electrical runout, as measured on test, may be deducted from
measured vibration. Vibration readings taken on the housings shall not be acceptable. At the overspeed
condition, the double amplitude of vibration shall not exceed 100 Pm (4 mills).
5.19 Bearings shall be insulated to prevent shaft current circulation.
5.20 When required, vibration monitor shall be specified in E07-X01.
5.21 Neutral CT shall be provided for ground fault protection or ground differential protection.
5.22 Generators shall have jacking bolts, or facilities to lift the generator with the aid of mechanical jacking
device, to facilitate alignment of the generator with prime mover.

6. Generator Controls
6.1 Exciter. The exciter shall be of the static, rotating brushless, or comparable self-ventilating type,
mounted on or coupled to the main generator shaft external to the bearing opposite the drive end.
6.2 Voltage Regulator. The voltage regulator shall be a completely solid-state voltage regulator for control
of the generator voltage by control of the exciter field. No vacuum tubes or electromechanical relays shall
be used in the voltage regulator.
6.3 Space Heater. Electric space heaters shall be provided in the generator, exciter housing and control
panel to prevent condensation when not in service. Space heaters shall be rated for 240 V AC, single
phase and shall operate on 120 V AC, single phase.
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6.4 Resistive Load Bank. When specified in SES E07-X01, an adequately sized resistive load bank shall
be supplied for purposes of testing and exercising the generator set. The load bank shall be compact,
portable and fully self-contained, with all metering, controls and test instrumentation.
6.5 Exciter shall be sized to provide 20 percent capacity in excess of that required to supply the field
excitation of the generator when the generator is operated at 5 percent above normal rated kVA output, at
rated power factor, and at normal voltage without exceeding rated temperature rise.
6.6 The main exciter response ratio shall be minimum of 0.5.
6.7 The exciter current rating shall be guaranteed to be at least equal to the actual excitation required by
the generator at rated power factor and load when operating at 5 percent above rated voltage.
6.8 For static excitation systems, a comparable auxiliary pilot excitation system shall be furnished to
facilitate generator operation and startup.
6.9 The rotating brushless exciter, if mounted or coupled to the generator shaft, shall be capable of
withstanding 20 percent overspeed without mechanical damage.
6.10 Generators supplied with rotating brushless excitation shall be furnished with an auxiliary pilot exciter
permanent magnet generator (PMG) type, shaft mounted, outboard of the brushless main exciter.
6.11 Exciters of the rotating brushless type shall be ventilated by means of cooling air received from the
main generator, circulated through the exciter, and returned to the main generator.
6.12 The voltage regulator system shall include voltage transformers and voltages adjusting rheostat, as
required for proper operation.

7. Enclosure
When specified in SES E07-X01, self-contained enclosure shall be provided for the diesel generator
set.The enclosure shall be manufactured such that all part are accessible for inspection and minor
maintenance without removal of the enclosure or enclosure roof. It shall include the following features:
a. The enclosure and all other items shall be designed and built by the supplier as an integral part of
the entire diesel generator set, and shall perform without overheating in the environment specified.
b. It shall be constructed of minimum 14-gauge sheet metal, suitably reinforced to reduce vibration in
the operating mode.
c. A minimum of four doors are required. The doors shall be hinged so that they can be opened to
provide complete access to the equipment inside the enclosure without removing the doors.
d. The side and rear panels shall be completely and simply removable to permit major service access.
e. Doors shall be lockable.
f. All exterior steel surfaces, including those in contact with the foundation, shall be epoxy-or
epoxy-mastic-coated as a minimum. Interior surfaces shall have the vendor’s standard finish. All
fasteners shall be corrosion resistant.
g. Batteries shall fit inside the enclosure and alongside the engine (batteries under the generator are
not acceptable).
h. The unit shall have coolant and oil drains piped to the outside edge of the skid in an accessible
location. Each drain line shall have a valve located near the fluid source.
i. Air Intake louvers shall be sized to provide sufficient airflow for engine combustion, engine cooling
and generator cooling. The louvers shall open automatically when the engine receives the start signal
and close when the engine stops. They shall also allow manual over-ride.
j. The air intake and exhaust outlet shall be configured such that exhaust gas recirculation to the air
intake will not occur under any wind direction.
k. 120 VAC lights, light switch, 120 V receptacles, and an associated load panel shall provided. The
120 V source will be provided by others.
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l. Diesel generator set shall not generate noise in access of 85dba at a distance of 1 meter. If the
sound pressure level will exceed 85 dba, the vendor shall notify the purchaser and additional cost for
modification to ensure the sound pressure does not exceed 90dba at 1 meter. dba shall be specified
in SES E07-X01
7.2 Transport units heavier than 25 kg shall have eyebolts, lugs, or extension pieces clearly identifiable to
be used for hoisting.
7.3 A separate junction box or boxes shall be provided on the generator enclosure for connections to
space heaters, temperature detectors, thermocouples, and humidity detector, if any. SABIC’s leads shall
enter the junction box from below.

8. Control Panel
8.1 Generator control system shall be contained in a single control panel. Instrumentation shall be
supplied by generator manufacturer as outlined in this section. Any instruments to be furnished by the
generator manufacturer beyond normal generator control requirements shall be listed in SES E07-X01.
8.2 The control panel shall include:
a. Voltmeter (2 percent accuracy) and 3 phase switch
b. Ammeter (2 percent accuracy) and 3 phase switch
c. Frequency meter
d. Voltage Adjusting raise/lower, switch/rheostat
e. Voltage regulator
f. Manual off /automatic, Start/stop engine control
g. Alarm panel equipped with first out feature to indicate the following alarms and shutdowns:
(i) Stator winding temperature(s)
(ii) Generator bearing temperatures
(iii) Battery low voltage
(iv) Battery charger Failure
(v) Generator relay trip/lockout
(vi) Over and under frequency
(vii) Emergency stop
8.3 Duplication of instruments between the generator control panel and the engine local instrument panel
shall be mutually agreed upon between SABIC, driver manufacturer and generator manufacturer.
8.4 All safety or protective alarms shall be wired fail-safe, utilizing field alarm and shutdown contacts that
are closed and energized when the generator system is in its normal operation mode.
8.5 Alarm and shutdown switches shall be suitable for operation on both AC and DC systems and shall
have a minimum current rating of 1 A at 125 V DC or 10 A at 120 V AC.

9. Nameplates
9.1 Engine and generator shall have a stainless steel nameplate attached by stainless steel screws or
rivets and mounted at approximately eye-level. Each nameplate shall contain the following performance
data:
a. Serial number
b. Manufacturer’s name
c. SABIC 's equipment item number
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d. Voltage
e. Output kVA
f. Output kW
g. RPM
h. Frequency
i. Temperature rise of armature
j. Temperature rise of field
k. Number of phases
l. Power factor
m. Excitation voltage
n. SABIC purchase order number
9.2 Nameplates shall be provided to identify, for example space heaters, meters, relays, switches, fuses,
breakers, terminal strips and indicating lights. These type of nameplates shall be machine-engraved on
laminated plastic (black letters on white background) in accordance with SES E19-S01.
9.3 Items requiring tagging shall be tagged with their specific item number, which is derived either from the
purchase order or subsequent drawing transmittals. In general, items to be tagged shall be; all
instrumentation; all pre-assembled components, and all components shipped separately that require a field
utility connection.
9.4 Tags shall be corrosion resistant metal, and shall be impression stamped. Tags shall be attached to
each component with a stainless steel strap, wire or hardware.
9.5 See the formal request for quotation (RFQ) and subsequent purchase order for any additional or
special packing or marking instructions.
9.6 Equipment containing insulating oils, antifreeze solutions, and other fluids shall be suitably tagged at
openings to indicate both the nature of the contents and shipping and storage precautions.
9.7 Those openings that require a rust preventative shall be tagged to indicate that a rust preventative has
been applied. The tag shall also show the name, type, and manufacturer of the rust preventative.

10. Inspection and Testing

10.1 Inspection
10.1.1 Equipment covered by this specification shall be subject to inspection and witnessed testing by
SABIC.
10.1.2 SABIC shall be granted access to all parts of manufacturer’s plants or subsupplier’s plants engaged
in the manufacture or testing of SABIC’s equipment.
10.1.3 Manufacturer shall keep the following available for examination upon request by SABIC:
a. Necessary certification of materials, for example mill test reports
b. Purchase specifications of bills of material
c. Hydrostatic and running test data to verify that the requirements of the specifications are being
met
10.1.4 Unless otherwise permitted by SABIC, no surfaces or parts of the furnished equipment shall be
painted until inspection is completed.
10.1.5 Additional inspection requirements, as may be required for special applications, shall be mutually
agreed upon.
10.1.6 Whenever shop inspection by SABIC is required, during the manufacturing schedule, Manufacturer
shall provide sufficient advance notice to SABIC. The extent of the advance notice shall be that as mutually
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agreed upon in the formal PO. It is not the intent of this prior notice requirement to interfere with or delay
normal production. Some tests and many mutually agreed upon inspection hold points may be handled
normally through SABIC ’s regional inspection services.
10.2 Test
10.2.1 Tests required in this specification shall be carried out in the generator manufacturer ’s shop.
SABIC, and the driver manufacturer, reserve the right to witness tests.
10.2.2 Equipment shall be tested in accordance with mutually agreed upon test procedures. The final test
procedures shall be submitted by manufacturer for SABIC’s review at least 60 days before notification of
test.
10.2.3 Electrical test procedures shall conform to IEEE 115.
10.2.4 The following tests shall be performed on the generator, exciter, and auxiliaries:
a. Visual inspection
b. Dimensional checks
c. Generator Performance test
d. Exciter field current
e. Insulation resistance of field and armature
f. Measurement of cold resistance of armature and field windings
g. Measurement of rotor impedance
h. Generator phase-sequence and voltage balance
i. Short-circuit tests at reduced voltage to determine reactance and time constants. These tests, or
certified test reports on a duplicate generator, shall be required
j. Overspeed trip
k. Temperature tests
l. Dielectric tests and polarization index
m. The dielectric tests described in Paragraph 9.3 of ANSI C50.10 shall be performed on the
generator
n. Generator rotor shall be statically and dynamically balanced at a minimum of 600 rpm
o. Exciter rotor shall be balanced in the same manner as the generator rotor
p. Mechanical run of generator and, if applicable, exciter. The generator shall be mechanically run
at rated speed for a minimum of 4 hours.
q. During the machinical operation of all equipment shall function satisfactorily.
r. The job or contract noncontacting probes shall be installed for the test and used to determine the
vibration levels. Supplier shall be expected to prove the compatibility of the probe and test stand
readout equipment.
s. The generator shall be run with the generator unexcited, if possible, at 110 percent and 120
percent of normal operating speed. After the unit has stabilized at these conditions, readings shall be
recorded for vibration, oil pressure, and temperature for each operating condition.
t. Piping shall be hydrostatically tested to 11/2 times the design pressure
u. Load tests including full load test, for 4 hours, with a load bank of adequate capacity
v. Overload test
w. Functional test of control panel
x. Combined operation test
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y. Governor response
10.2.5 See purchase order for additional test requirements.

11. Finish
Finish shall be manufacturer’s standard, suitable for climatic conditions specified in 3.6. Topcoat color shall
be manufacturer’s standard, unless otherwise specified in purchase order.

12. Documentation
12.1 Drawings
12.1.1 Drawings and data shall be provided at the proposal and during the design and manufacturing
stages. SABIC will review and comment on all drawings and data submitted for design review until such
time as the final documents are reviewed without comment.
12.1.2 Shop drawings shall be submitted, showing dimensions, weights, ratings, plan and elevation views
with overall and interconnection point dimensions, fuel consumption rate curves at various loads,
ventilation and combustion air requirements, and electrical diagrams, including schematic and
interconnection diagrams.
12.1.3 Product data shall be submitted, showing installation instructions and general recommendations for
the generator set.
12.1.4 Generator reactive capability curves, generator open-circuit saturation curves, and generator
current decrement curves (or tabulations) shall be submitted. The generator current decrement curves
shall be for a 3-phase short circuit, line-to-line short circuit, and a line-to-ground short circuit.
12.1.5 Exciter and voltage regulator data shall be submitted for SABIC 's system stability studies.
12.2 Operation and Maintenance Manual
12.2.1 Manufacturer shall provide operation and maintenance manuals and as-built drawings in
accordance with purchase order. These documents shall become part of SABIC’s operation and
maintenance manuals for the project.
12.2.2 Manufacturer’s manuals shall include the following information:
a. Procedures for unloading and storage. Storage may be outdoor or indoor for extended periods.
b. Operating instructions, and trouble shooting charts with corrective recommendations
12.3 Spare Parts
The generator and engine manufacturer’s shall provide a list of recommended startup and operating spare
parts to SABIC.

13. Preparation for Shipment

13.1 General
13.1.1 Manufacturer shall suitably prepare each unit for the shipment specified, and for outdoor storage for
a period of at least 6 months, in a manner requiring no disassembly before installation.
13.1.2 Shipment preparation procedures shall require SABIC approval before shipment.
13.1.3 Equipment shall be packed, securely anchored (skid-mounted when required), and weather
protected for the shipment method specified in the purchase order. Separate, loose, or spare parts shall be
boxed, and each part individually protected as required. Each container shall be marked both inside and
outside with the equipment number and service for which the parts are intended.
13.1.4 Each container shall include complete Bills of Material identifying each part. In some instances, for
example instruments, specific tagging shall be required. See Section 9 for specific tagging requirements.
13.1.5 Equipment shall be free from water before shipment preparation.
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13.1.6 Bearing assemblies shall be fully protected from rusting and from entry of moisture and dirt.
13.1.7 One complete set of installation, operation, and maintenance instructions shall be packed with the
equipment.
13.2 Internal Preservation
13.2.1 Internals shall be sprayed or fog machined. They shall be sprayed with a suitable preservative while
the generator rotor is being turned slowly in its bearings thoroughly through all access openings in
sufficient quantity to ensure coverage of all internal parts. Drains shall be left open during spraying to
prevent liquid buildup within the generator.
13.2.2 Internals of bearing housings shall be sprayed with circulating oil. Bearing housing openings shall
be blind flanged or pluged using standard blind flanges and gaskets. Bearing housing sump shall be filled
with circulating oil to a level about 75 mm from the bottom of the sump before installing the bearing
housing cover.
13.2.3 Desiccant bags shall be tied securely to flange covers, to ensure that they are removed when the
cover is removed.
13.3 External Preservation
13.3.1 Immediately upon completion of all tests and inspection, all exposed-machined surfaces including
soleplates and bolting shall be coated with a rust preventative.
13.3.2 To provide a clean epoxy grouting surface, the bottom of all baseplates and soleplates shall be
sandblasted to near white metal and immediately covered with epoxy paint.
13.3.3 Solid steel plugs shall be used instead of plastic plugs for any part that is pressurized during startup
or operation.
13.3.4 Open ends of tubes and pipe shall be capped for protection. Taping shall not be considered
adequate.
13.3.5 Flanged openings shall be provided with full size steel closures of 5 mm minimum thickness with
full-face rubber gaskets and at least 4 full diameter bolts. A rust inhibitor shall be applied to all flange
faces.