ECE3

TECHNICAL SPECIFICATION FOR

TRANSPORTABLE ELECTRICITY GENERATOR

SETS, INCLUDING GENERATORS COMBINED
WITH COMPRESSORS

AUGUST 1992
J026 (Rev 11/02)
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CONTENTS

Page

FOREWORD iii

BRIEF HISTORY iv

1. SCOPE AND FIELD OF APPLICATION 1

2. REFERENCES 1

3. DEFINITIONS 1

4. REQUIREMENTS FOR TRANSPORTABLE GENERATOR SETS 1

4.1 Design requirements 1

4.2 Prime mover 2

4.3 Generator 2

4.4 Electrical protection 3

4.5 Socket outlets and switches 3

4.6 Metering 4

5. DOCUMENTATION 4

6. TESTING SCHEDULE FOR GENERATOR SETS 4

6.1 General 4

6.2 Approval tests 4

6.3 Acceptance tests 6

7. VARIANTS 7

TABLE

1 Socket outlets 4

FIGURE

1 Typical circuit diagram for 110 V portable and transportable (CTE) alternators 5

APPENDICES

A LIST OF REFERENCES 9

B INFORMATION TO BE SPECIFIED WHEN ORDERING 11

C SUB-TRANSIENT REACTANCE TESTS 12

D PRO-FORMA TEST CERTIFICATE 16

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FOREWORD

Comments and queries regarding the Technical content of this engineering document should be directed to:

Engineering Policy
Transco
Brick Kiln Street
Off Coventry Road
Hinckley
Leicestershire
LE10 0NA

Further copies of this engineering document can be obtained from Dataform Print Management using the
print requisition form G004 quoting the Form Number of this Transco engineering document (not the
designation) and your cost code.

Transco documents are revised, when necessary, by the issue of new editions. Users should ensure that they
are in possession of the latest edition by referring to the Transco Register of Engineering Documents
available on TransNet.

Compliance with this engineering document does not confer immunity from prosecution for breach of
statutory or other legal obligations.

Contractors and other users external to Transco should direct their requests for further copies of Transco
engineering documents to the department or group responsible for the initial issue of their contract
documentation.

DISCLAIMER

This engineering document is provided for use by Transco and such of its contractors as are obliged by the
terms and conditions of their contracts to comply with this engineering document. Where this engineering
document is used by any other party it is the responsibility of that party to ensure that the engineering
document is correctly applied.

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BRIEF HISTORY

First published as GBE/ECE3 August 1992 August 1992

Amendment No. 1 published January 1993

Editorial update to reflect demerger November 2000 June 2001

Editorial update to reflect merger October 2002 November 2002

© Transco plc.

This engineering document is copyright and must not be reproduced in whole or in part by any means
without the approval in writing of Transco plc.

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TECHNICAL SPECIFICATION FOR

TRANSPORTABLE ELECTRICITY GENERATOR
SETS, INCLUDING GENERATORS COMBINED WITH
COMPRESSORS

1. SCOPE AND FIELD OF APPLICATION

1.1 This Transco Technical Specification* specifies the requirements for transportable generator sets
(primarily for electronically controlled equipment such as electrofusion and butt welding systems) for use in
non-hazardous areas and powered by internal combustion prime movers.
* Hereinafter referred to as 'this specification'.

This specification may be used for the design of generators mounted on compressors or other equipment.

2. REFERENCES
This specification makes reference to the documents listed in Appendix A.

3. DEFINITIONS
For the purposes of this specification the following definitions shall apply:

Contractor: the person, firm or company with whom Transco enters into a contract to which this
specification applies, including the Contractor's personal representatives, successors and permitted assigns.

4. REQUIREMENTS FOR TRANSPORTABLE GENERATOR SETS

4.1 Design requirements
4.1.1 Environmental
The generator set shall be suitable for outdoor operation on rough excavation sites throughout the United
Kingdom without any additional protection and shall be protected to BS 4999: Part 105, IP23S as a
minimum requirement.

4.1.2 Radio interference suppression

Radio interference suppression shall be fitted on the engine and generator where necessary to comply with
BS 833.

4.1.3 Manoeuvrability
Generator sets designed to be carried by two persons shall not be heavier than 75 kg. Where the weight
exceeds 75 kg the construction shall incorporate wheels suitable for travelling over rough construction sites
and suitable means of lifting shall be fitted. All generator sets shall be easily manoeuvrable around the site.

4.1.4 Transportation
Where specified by Transco (see Appendix B), transportable generator sets shall be mounted on a trailer
conforming with the requirements of SI 1986 No.1078, capable of being towed safely on the public
highway. The trailer shall be fitted with rear lights and provision for attachment of a number plate.
Alternatively, provision shall be made for a tailboard with rear lights and number plate supplied by Transco.
The requirements will be specified at the time of ordering.

4.1.5 Identification
A permanent nameplate shall be fitted to the set. This shall state the manufacturer's name, type and serial
number, the electrical output in kW, the full load current, nominal voltage and maximum weight.

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4.1.6 Nameplate
The nameplate shall be so designed and located that it is clearly visible.

4.1.7 Mounting
The sets shall be on resilient mounts to minimize vibration.

4.1.8 Noise level

The noise level shall be in accordance with SI 1985 No.1968.

4.2 Prime mover

4.2.1 Type of fuel
The prime mover shall operate using one of the following fuels as specified by Transco:

a) diesel;
b) petrol;
c) liquefied petroleum gas (LPG).
4.2.2 Fuel reservoir
The fuel reservoir shall be sized to give at least 2 h continuous operation at full load. The type of fuel shall
be marked on the outside of the tank.

Where LPG is the specified fuel, adequate mounting facilities shall be provided for gas bottles.

4.2.3 Operating capability

The prime movers shall be capable of a total of at least 1000 h operation before ma]or overhaul. Continuous
running between maximum and minimum lubricating oil levels shall be at least 25 h for generator sets and
at least 8 h for compressor/generator sets. An oil protection circuit shall be fitted to stop the prime mover
when the lubricating oil pressure is low.

4.2.4 Speed range conditions

The speed range of the prime mover shall not exceed ± 5% under any load condition when the generator is
being used with an ambient temperature range of -10 0 C to 40 0 C and a maximum altitude of 460 m
(1500 ft).

4.3 Generator
4.3.1 Construction
Generators shall be constructed to BS 5000: Part 3 and may be fitted with brushes or be of the brushless
type.

4.3.2 Rated output power

The output shall be based on unity power factor.

4.3.3 Output voltage

Unless otherwise specified (see 4.3.8), the nominal output voltage shall be 110 V ac. The output voltage of
the generator set shall not exceed 120 V and shall not be less than 103 V at any kW loading between no
load and full load.

4.3.4 Output frequency

The generator set output frequency shall be 50 Hz ± 5%.

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4.3.5 Output phase configuration

The output shall be single phase with the mid-point brought out for earthing to the generator frame. A
substantial earthing terminal shall be provided suitable for connection of the mid-point conductor and an
external earth conductor.

4.3.6 Output waveform characteristics

The output voltage waveform of the generator set shall be sinusoidal with a maximum of 20% distortion.
No spurious zero crossovers shall occur on any resistance load within the requirements of 6.2.6.

4.3.7 Sub-transient reactance limits

The generator sub-transient reactance shall not exceed 11 Ω at any angle of rotation of the rotor (see
Appendix C).

4.3.8 Provision of low voltage output

When nominal voltages less than 110 V are required (e.g. 25 V for handlamps), a double-wound
transformer shall be provided having either one pole or centre tap earthed.

Where a dc output is required, a suitable transformer/rectifier unit shall be provided.

4.4 Electrical protection

4.4.1 Over-temperature
Suitable protection against over-temperature of the generator windings shall be provided where necessary.
If protection is by a double-pole miniature circuit breaker (MCB), it shall be rated to trip at not more than
120% of full load current in less than 2 h (see BS 4941: Part 1).

4.4.2 Earth fault protection

An earth current operated residual current circuit breaker (RCCB) to BS 4293, with an integral test facility,
having a 30 mA sensitivity, shall be fitted. The RCCB should be suitably mounted to withstand the
vibration forces set up by the generator and prime mover and be suitable for operation with thyristor-
controlled circuits.

4.4.3 Over-current protection

Over-current protection MCBs shall be fitted to the 16 A outlets only as shown in Figure 1.

4.5 Socket outlets and switches

4.5.1 Specification
The 110 V output shall be provided with yellow socket outlets to BS 4343, as listed in Table 1.

4.5.2 Low voltage outlet

Any low voltage output shall be provided with a 15 A, 2-pole socket outlet to BS 196. Colours shall be in
accordance with BS 196, Figure 10. A label stating the voltage rating shall be fitted.

4.5.3 Circuit diagram

Figure 1 is a typical circuit diagram.

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TABLE 1 - Socket outlets

4.5.4 Marking
A label shall be fitted in the vicinity of the 32 A socket outlet bearing the legend:

WARNING - Use for electrofusion only

4.6 Metering
An hours-run meter shall be provided. An ammeter and/or voltmeter shall be fitted when specified by
Transco. The voltmeter shall have a green band marked on the scale to indicate the output voltage limits
(see 4.3.3).

5. DOCUMENTATION
Following completion of type approval tests, the Contractor shall compile a data folder which shall include
details of all test results and graphs, maintenance requirements, and a set of drawings showing all critical
information, i.e. dimensions, components, circuit diagram, etc. The submission shall be presented in a
manner that clearly indicates compliance with, or variations from, the requirements of this specification and
shall provide for signature of the Transco representative witnessing the tests. Three copies of the data folder
shall be submitted to Transco.

6. TESTING SCHEDULE FOR GENERATOR SETS

6.1 General
The Contractor shall demonstrate compliance with this specification by satisfying the test requirements
specified in 6.2 and 6.3. The equipment will then be granted limited approval and, after a satisfactory six-
month field trial, full type approval will be given.

6.2 Approval tests

6.2.1 Output characteristics
After the machine has run at full load for 15 min, the voltage and frequency shall be measured over the load
range from no load to 110% full load at unity power factor. Measurements shall be taken at the following
approximate % full load (kW):

No load, 10%, 20%, 40%, 60%, 80%, 100% and 110% full load.

A graph of voltage/kW shall be plotted. The equipment shall comply with the requirements of 4.3.3 and
4.3.4.

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FIGURE 1 - Typical circuit diagram for 110V portable and transportable centre tapped earth
alternators

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6.2.2 Measurement requirements

All measurements shall be true root mean square (rms) and be made with calibrated wattmeters and
voltmeters.

6.2.3 Fuel consumption

Fuel consumption shall be measured at full load.

6.2.4 Speed control

The operation of the prime mover speed control shall be checked.

6.2.5 Output waveform distortion

The maximum output waveform distortion between zero and full load at unity power factor shall be
measured and analysed. No spurious zero crossovers shall occur.

6.2.6 Insulation resistance

The insulation resistance of the complete equipment shall be measured at 500 V dc and shall be not less
than 50 M Ω .

6.2.7 Over-temperature protection operation

The operation of the over-temperature protection device shall be checked (see 4.4.1). The test method shall
be agreed with Transco.

6.2.8 Noise level

The noise level shall be measured at no load and full load to ensure that the equipment complies with the
requirements of SI 1985 No.1968.

6.2.9 Temperature limits

A heat run shall be carried out at full load in accordance with BS 4999: Parts 101 and 143. The temperature
rise shall be within the permitted limits.

6.2.10 Sub-transient reactance

The generator sub-transient reactance shall be measured in accordance with Appendix C.

6.2.11 Running hours

The hours-run meter reading shall be recorded after tests have been completed.

6.2.12 Verification of RCCB effectiveness

The effectiveness of the RCCB shall be verified by a test simulating an appropriate fault condition and
independent of the test facility incorporated in the device.

6.2.13 Test certificates

Test certificates covering all the tests specified in 6.2.1 to 6.2.12 inclusive shall be provided by the
Contractor (see Appendix D).

6.3 Acceptance tests

6.3.1 General requirements
The acceptance tests specified in 6.3.2 to 6.3.7 inclusive shall be carried out by the Contractor and
witnessed by Transco, to demonstrate that each piece of equipment meets its performance specification.

In the case of large batches of equipment being offered at any one time, the Transco representative shall
determine the sample size in accordance with BS 6001.

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6.3.2 Output characteristics

The voltage and frequency shall be measured over the load range from no load to full load at unity power
factor to ensure that the equipment complies with the specified requirements of 4.3.3 and 4.3.4.
Measurements shall be taken at the following approximate % full load (kW):

No load, 60%, 100% and 110% full load.

6.3.3 Speed control

The operation of the prime mover speed control shall be checked.

6.3.4 Insulation resistance

The insulation resistance of the complete equipment shall be measured at 500 V dc and shall be not less
than 50 M Ω .

6.3.5 Over-temperature protection operation

The operation of the over-temperature protection device shall be checked (see 4.4.1). The test method shall
be agreed with Transco.

6.3.6 Running hours

The hours-run meter reading shall be recorded after tests have been completed.

6.3.7 Verification of RCCB operation

The operation of the RCCB shall be verified by means of the test facility incorporated in the device.

6.3.8 Test certificates

Test certificates covering tests specified in 6.3.2 to 6.3.7 inclusive shall be provided by the Contractor (see
Appendix D).

7. VARIANTS
A contractor shall only propose amendments to this specification where the text indicates that variants
would be considered by Transco.

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APPENDIX A
LIST OF REFERENCES
This specification makes reference to the documents listed below. Unless otherwise specified the latest
editions of these documents, including all addenda and revisions, shall apply.

British Standards

BS 196 - Specification for protected-type non-reversible plugs, socket-outlets,

cable-couplers and appliance-couplers with earthing contacts for
single phase a.c. circuits up to 250 volts

BS 833 - Specification for radio interference limits and measurements for the
electrical ignition systems of internal combustion engines

BS 3871 - Specification for miniature and moulded case circuit-breakers

BS 4293 - Specification for residual current-operated circuit-breakers

BS 4343 - Specification for industrial plugs, socket-outlets and couplers for a.c.
and d.c. supplies

BS 4941 - Specification for motor starters for voltages up to and including 1000
V a.c. and 1200 V d.c.:
Part 1 - Direct-on-line (full voltage) a.c. starters

BS 4999 - General requirements for rotating electrical machines:

Part 101 - Specification for rating and performance
Part 105 - Classification of degrees of protection provided by
enclosures for rotating machinery
Part 143 - Specification for tests

BS 5000 - Specification for rotating electrical machines of particular types or

for particular applications:
Part 3 - Generators to be driven by reciprocating internal combustion
engines

BS 5750 - Quality systems

BS 6001 - Sampling procedures for inspection by attributes

BS 6004 - Specification for PVC-insulated cables (non-armoured) for electric

power and lighting

Statutes and Regulations

SI 1985 No.1968 - The Construction Plant and Equipment

(Harmonization of Noise Emission Standards)
Regulations 1985

- The Highly Flammable and Liquefied Petroleum Gases Regulations

1972

- The Electricity at Work Regulations 1989

SI 1986 No.1078 - Road Vehicles (Construction and Use) Regulations 1986

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- Health and Safety at Work etc. Act 1974.

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APPENDIX B
INFORMATION TO BE SPECIFIED WHEN ORDERING
Requirements Reference
Mounting on trailer 4.1.4 YES/NO

trailer to be fitted with rear lights* YES/NO

tailboard to be supplied by Transco* YES/NO

* alternative choices

Type of fuel 4.2.1 diesel/petrol/LPG

Rated output power 4.3.2 ………..kW

DC output (if required) 4.3.8 ……..….V

AC low voltage output (if required) 4.3.8 ………...V

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APPENDIX C
SUB-TRANSIENT REACTANCE TESTS (see 4.3.7)
C.1 TEST ARRANGEMENT
The test arrangement for a rotating field machine is detailed on Figure C.1.

C.2 INITIAL TEST CONDITIONS

The test shall be performed initially with the field winding open circuit, i.e. all excitation circuitry, rectifier
bridges, etc., disconnected.

C.3 TEST PROCEDURE: OPEN-CIRCUIT

The field winding shall be held stationary and the alternating current source is adjusted to increase the
current up to a nominal value of 5 A (any value within the region 3 A to 7 A will suffice). The voltmeter
indication should be noted. The current should be reduced to zero before turning the rotor through 10 0 and
repeating the operation for the same current. The process shall be continued until the field winding has
completed a 360 0 turn.

CAUTION - The current should be reduced to zero before moving to and

locking in the next position to avoid any possible danger from the generator
performing as a motor.

C.4 TEST PROCEDURE: SHORT-CIRCUIT

The test procedure described in C.3 shall be repeated but with the field winding short circuited.

The dc resistance of the load winding shall be measured.

NOTES
1. As this test destroys the machine remanence, remagnetization will be necessary.
2. Some machines may have a rotating load winding and a fixed field winding. The test method
is as above, but the load winding is rotated 360 0 .

C.5 RECORDING OF INFORMATION

The following information should be recorded on the test sheet:

Contractor ……………………..

Alternator type ……………………….. Power rating …………………..

Brushless or slip-ring …………………

Rotating field or load winding ………………..

DC resistance of load winding …………………

Temperature ………………….. 0 C

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FIGURE C.1 - Test arrangement for a rotating field machine

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FIGURE C.2 - OPEN-CIRCUIT TEST PROCEDURE SHEET

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FIGURE C.3 - SHORT-CIRCUIT TEST PROCEDURES SHEET

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APPENDIX D
PRO-FORMA TEST CERTIFICATE

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PRO-FORMA TEST CERTIFICATE (Continued)

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PRO-FORMA TEST CERTIFICATE (Continued)

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PRO-FORMA TEST CERTIFICATE (Continued)

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PRO-FORMA TEST CERTIFICATE (Concluded)

CERTIFICATION STATEMENT
1. For Contractor
I certify that the above test results are in accordance with ECE3.

Company ……………………..

Name …………………………

Position ……………………….

Signed ………………………… Date …………………

2. For Transco
I confirm that the above test results are in accordance with ECE3.

Name …………………………

Position ……………………….

Signed ………………………… Date …………………

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