STANDARDS FOR CERTIFICATIONNo. 2.10

DET NORSKE VERITAS

Veritasveien 1, N-1322 Høvik, Norway Tel.: +47 67 57 99 00 Fax: +47 67 57 99 11

DIESEL ENGINE DRIVEN POWER PLANTS —CERTIFICATION, TESTING AND INSPECTION

JULY 1991

FOREWORD

DET NORSKE VERITAS is an autonomous and independent Foundation with the objective of safeguarding life, property andthe environment at sea and ashore.

DET NORSKE VERITAS AS is a fully owned subsidiary Society of the Foundation. It undertakes classification and certificationof ships, mobile offshore units, fixed offshore structures, facilities and systems for shipping and other industries. The Societyalso carries out research and development associated with these functions.

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Standards for CertificationStandards for Certification (previously Certification Notes) are publications that contain principles, acceptance criteria and prac-tical information related to the Society's consideration of objects, personnel, organisations, services and operations. Standardsfor Certification also apply as the basis for the issue of certificates and/or declarations that may not necessarily be related to clas-sification.

A list of Standards for Certification is found in the latest edition of the Introduction booklets to the ”Rules for Classification ofShips”, the ”Rules for Classification of Mobile Offshore Units” and the ”Rules for Classification of High Speed and Light Craft”.In “Rules for Classification of Fixed Offshore Installations”, only those Standards for Certification that are relevant for this typeof structure, have been listed.

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Re-issue November 2002This is a re-issue of the version published in July 1991. However, this page has been modified according to current standard. Noother changes have been made except for editorial ones.

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CONTENTS

1. INTRODUCTION .................................................... 52. CERTIFICATION ................................................... 52.1 Documents issued ........................................................52.2 Basis for certification ..................................................52.3 Planning and preparations ...........................................52.4 Records of testing and inspections .............................52.4.1 General ................................................................................. 52.4.2 Tests ..................................................................................... 52.4.3 Inspections ............................................................................ 53. FACTORY TESTING AND INSPECTION ......... 63.1 General.........................................................................6

3.2 Performance tests ....................................................... 63.3 Function tests .............................................................. 63.4 Inspections .................................................................. 64. COMMISSIONING, TESTING AND

INSPECTION .......................................................... 64.1 General ....................................................................... 64.2 Plant performance ...................................................... 64.3 Performance auxiliary machinery .............................. 64.4 Function tests .............................................................. 64.5 Inspections .................................................................. 6

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1. IntroductionThe purpose of this Certification Note for «Certification, Test-ing and Inspection of Diesel Engine Power Plants» is to dem-onstrate and document compliance with performance andfunctional requirements of the given specifications and stand-ards.

The present document outlines and gives the extent of testingand inspection to be carried out at the «Commissioning» and atthe «Factory Testing and Inspection».

The individual tests are assumed carried out according toagreed plans and in accordance with internationally recognizedstandards as agreed, e.g. Relevant ISO Standard, IEC Publica-tions, Veritas Rules or equivalent.

2. Certification

2.1 Documents issuedOn satisfactory completion of all test and inspections a test re-port is issued. As a confirmation of compliance with the givenspecifications, function test and final inspection, a «VeritasCertificate of Conformance» is issued.

2.2 Basis for certificationThe basis for the certification, standard of comparison, may inprinciple be any standard or specification to which the partiesinvolved have agreed to. In practice it will be the plant specifi-cation with its annexes.

It is assumed that the builder has a quality control systemwhich is effective both for the builders own production as wellas for materials and components supplied by vendors.

2.3 Planning and preparationsWell ahead of time a program for testing and inspection, in-cluding procedures and data to be observed, is to be worked outand agreed to by the parties concerned.

Equipment, tools, instruments and manpower are to be identi-fied and listed.

All instruments and systems to be used for measurements andobservations are to be calibrated and checked out as needed.

The program shall list all persons and parties to be present atthe testing, as well as the functions and responsibilities of each.

Arrangement shall be made to record all data and relevant in-formation from the testing.

All test records or copies there off are to be made available tothe Veritas representative directly up on completion of the test-ing. Before leaving the test site he is to countersign and stampeach test sheet to attest (verify) the authenticity of the records.

2.4 Records of testing and inspectionsThe party responsible for executing the testing shall prepare a«Records of Tests and Inspections». The records are to con-tain:

2.4.1 General

— Identification and description of the plant (and compo-nents if factory test) with reference to contract, technicalspecifications and data.

2.4.2 Tests

— Testprogram, with description of each test, procedures,data to be observed, and time, signed by the person respon-sible for the execution of the tests.

— Records of the tests including all observed data, time andambient reference conditions, signed by the person re-sponsible for the execution of the test programs.

— Summary of test results, giving the principle data on stand-ardized form, enabling direct comparison with require-ments and specifications. The performance data to berecorded are to include all parameters necessary to con-firm the typical performance characteristics of the plant.These may e.g. include as follows:

— Specific fuel consumption, gr/kWHr vs Power/cyl,kW

— Engine speed, rpm vs Power/ cyl, kW— Mean indicated press, MIP. Bar vs Power/cyl, kW— Mean effective press, MEP, Bar vs Power/cyl, kW— Max. press, Bar vs Power/cyl, kW— Compr. press. Bar vs Power/cyl, kW— Scavenging air press, Bar vs Power/ cyl, kW— Exhaustgas temperature, cyl outlet ° C vs Power/ cyl,

kW— Exhaustgas temperature, before and after turbo-

charger ° C vs Power/ cyl, kW— Total air excess ratio, ° C vs Power/ cyl, kW— Generator power— Generator current— Generator voltage— Generator frequency (alt. RPM)— Generator temperature rise (normally to be measured

at gen. suppl.)— Generator Cos Phi (not necessary if current, voltage,

power can be measured)— Auxiliary machinery:

- Pumps, power, kW vs massflow/Eng.loadPumps, speed, rpm vs massflow/Eng.loadPumps, pressure in, Bar vs massflow/Eng.loadPumps, pressure out, Bar vs massflow/Eng.load

- Heat exchangers, temperature in/out primary, ° Cvs mass flow/Eng.loadHeat exchangers, temperature in/out secondary, ° Cvs mass flow/Eng.load

Note:From generator factory test, following records shouldbe obtained:

- Voltage wave form- Voltage variations under transient conditions- Measurements of induced shaft voltage.

— Calculations of results, showing all calculations, correc-tions, to be observed to give the final data (e.g. correctionto standard conditions).

— List of instruments and documentations of calibrations,signed by the person responsible for securing these.

2.4.3 Inspections

— Inspection program, outlining items to be subjected to in-spections and the method of inspection, signed by the per-son in charge of the inspection program.

— Records of observations including identification of itemsinspected.

At the «Commissioning» the complete log from the «Factorytests and inspections» is to be available.

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3. Factory testing and inspection

3.1 GeneralConsidering that the units for the final power station may beshipped directly from its manufacturer to the plant site, the fac-tory testing and inspection will often be for the individual com-ponents only. Should the units be assembled on a skid or in acontainer before shipment a number of the tests and inspec-tions normally assigned to the commissioning may be carriedout at an earlier stage. In such case the on site, commissioningtesting and inspection may be limited on agreement betweenthe parties involved.

3.2 Performance testsPerformance test runs are normally to be made at 50%, 75%,90% and 100% of the max cont. rating.

3.3 Function tests

a) Diesel engine:

— An overload test to be made at 110% of the max cont.rating for 1/2 Hrs.

— The speed controller function to be tested with regardto stability and response.

— Control, alarm and safety systems to be function test-ed and all setpoint calibrations checked.

— Number of motor starts with compressed air; state-ment/recording of minimum air pressure.

b) Generator:(Tests specified normally to be carried out at generatorsupplier before fitting to the diesel engine. In most casesnot practical to carry out at the last stage.)

— Temperature rise is to be determined at rated output,voltage and frequency. The temperature test is to becarried out for the duty for which the machine is ratedand marked, and in accordance with IEC 34-1 (V, 14-15).

— Overload capability is to be demonstrated with anoverload of 50% of the rated current and in accord-ance with IEC 34.1 (VII, 18).

— Overspeed test to be carried out at 1.2 times ratedspeed and in accordance with IEC34-1 (VII,21).

— High voltage test to be carried out according to IEC34-1 (VI,17).

— Insulation resistance to be measured between thephases and between each phase and ground.

— Winding resistance to be measured.— Airgap to be measured.— Open circuit voltage characteristics to be determined.— Closed circuit current characteristics to be deter-

mined.— Excitation current at rated current, voltage and power

factor.— Short circuit test (alternatively on other unit of the

same type).

3.4 Inspections

— Alignment of the shaft!ine is to be checked by «clocking»of the Crankshaft while the engine is still at its runningtemperature provided this is a prescribed procedure by theManufacturer to check the alignment.

— Spotcheck of wear exposed parts to be carried out. Allsliding surfaces of at least 1 cylinder, or 1 cylinder sectionin a Vee-engine to be inspected.

— Lub oil samples and lub oil filters to be checked before andafter the test runs.

— Fuel oil sample to be taken of the fuel actually being used,for analysis and heating value determination

4. Commissioning, testing and inspection

4.1 General

— The commissioning testing and inspection are the finalchecks of the plant/unit/equipment before delivery to thefuture owner/operator.

— All installation work, adjustments and the builders owntest runs as well as the initial running in are to have beencompleted (initial running in sufficient to allow «Unlimit-ed operation» without defects/ damages.)

4.2 Plant performancePerformance runs are normally to be made at 50%, 75%, 90%and 100% of max. cont. rating.

Special operating conditions may require runs at additionaland different power levels.

The performance testing is to include a duration test at 100%Maximum Continuous Rating (MCR) for 24 HRS.

Data to be observed are to include all parameters necessary todemonstrate compliance with the requirements to performancegiven by the specification for the plant.

4.3 Performance auxiliary machinery

— Pump systems providing essential auxiliary service. Per-formance measured at 100% plant load.

— Heat exchangers' performance to be measured at 100%plant load and conditions simulating, as closely as possi-ble, the most severe specified ambient conditions with re-gard to plant heat load.

4.4 Function testsThe testing of functions are to include as follows:

— Overload test at 110% of MCR for 1/2 Hrs.— Speed controller stability test.— Speed controller response characteristic at max possible

power drop and increase (to be agreed upon).— Sharing of active and reactive power when running in par-

allel.— Measurement of the equalizing current resulting from har-

monics when different generators are working in parallelor generators are running in parallel on nets, in both caseswith earthed neutral.

— Manual and automatic control systems, including those foressential auxiliary machinery, as well as pressure and tem-perature control systems.

— Automatic safety functions: automatic shut down, load-shedding and return power.

— Alarm systems.— Generator resistance measurements.— Communications systems if more than one command cen-

tral.— Fire alarm and fire extinguishing systems.

Optional measurements include as follows:

— Exhaustgas, soot content, NOX content.— Noise measurements in machinery spaces as well as in the

immediate surroundings.— Vibration measurements and analysis. These measure-

ments and analysis may include torsional, lateral as well asaxial vibrations.

4.5 Inspections

— Lub oil samples and lub oil filters to be checked before andafter the test runs.

— Fuel oil sample to be taken of the fuel actually being used,for analysis and heating value determination.

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— Alignment of the shaftline is to be checked by «clocking»of the Crankshaft while the engine is still at its runningtemperature.

— Spotcheck of wear exposed parts to be carried out. Allsliding surfaces of at least 1 cylinder, or 1 cylinder sectionin a Vee-engine to be inspected.

— Foundation bolt tightness to be checked upon completionof the function test.

— During the test runs as well as after stop, thorough checksare to be made for leaks.

— Piping Systems with valves to be inspected with regard torouting, fastening, tightness and consequences of potentialleaks (e.g. fuels lines – fire hazard).

— Electric cables to be inspected with regard to routing, fas-tening, protection against damage during overhaul worketc.

— Fire detectors and inspection systems to be inspected withregard to positioning of detectors and practicability of theextinguishing systems (ref. local codes and regulations).

— Maintenance Plans should be reviewed with attention to:

- Instruction manuals and procedures- Required availability and timing of maintenance- Manpower requirements- Tools necessary for the planned maintenance as well as

repairs that may be necessary.— Spares system should be reviewed with attention to poten-

tial need, availability, supply lead time, as well as the sys-tem for inventory accounting.

DET NORSKE VERITAS