CLASS GUIDELINE

DNV-CG-0565 Edition August 2021

Engine driven generator sets - voluntary

verification scheme

The content of this service document is the subject of intellectual property rights reserved by DNV AS (“DNV”). The user
accepts that it is prohibited by anyone else but DNV and/or its licensees to offer and/or perform classification, certification
and/or verification services, including the issuance of certificates and/or declarations of conformity, wholly or partly, on the
basis of and/or pursuant to this document whether free of charge or chargeable, without DNV’s prior written consent. DNV
is not responsible for the consequences arising from any use of this document by others.

The PDF electronic version of this document available at the DNV website dnv.com is the official version. If there
are any inconsistencies between the PDF version and any other available version, the PDF version shall prevail.

DNV AS
FOREWORD

DNV class guidelines contain methods, technical requirements, principles and acceptance criteria
related to classed objects as referred to from the rules.

© DNV AS August 2021

Any comments may be sent by e-mail to rules@dnv.com

This service document has been prepared based on available knowledge, technology and/or information at the time of issuance of this
document. The use of this document by other parties than DNV is at the user's sole risk. Unless otherwise stated in an applicable contract,
or following from mandatory law, the liability of DNV AS, its parent companies and subsidiaries as well as their officers, directors and
employees (“DNV”) for proved loss or damage arising from or in connection with any act or omission of DNV, whether in contract or in tort
(including negligence), shall be limited to direct losses and under any circumstance be limited to 300,000 USD.
CHANGES – CURRENT

Changes - current
This document supersedes the December 2020 edition of DNVGL-CG-0565.
The numbering and/or title of items containing changes is highlighted in red.

Changes August 2021

Topic Reference Description

Rebranding to DNV All This document has been revised due to the rebranding of DNV
GL to DNV. The following have been updated: the company
name, material and certificate designations, and references to
other documents in the DNV portfolio. Some of the documents
referred to may not yet have been rebranded. If so, please see
the relevant DNV GL document. No technical content has been
changed.

Editorial corrections
In addition to the above stated changes, editorial corrections may have been made.

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CONTENTS

Contents
Changes – current.................................................................................................. 3

Section 1 General.................................................................................................... 5
1 Introduction.........................................................................................5
2 Objective..............................................................................................5
3 Scope................................................................................................... 5
4 Application........................................................................................... 5
5 References........................................................................................... 5
6 Abbreviations....................................................................................... 6

Section 2 Generator sets for DNV GL class............................................................. 7

1 General................................................................................................ 7
2 Workshop testing and inspection........................................................ 8
3 Issuance of generator set compliance document.................................9

Section 3 Generator sets for other purposes than DNV GL class........................... 10

1 General.............................................................................................. 10
2 Workshop testing and inspection.......................................................12
3 Commissioning, testing and inspection..............................................13
4 Issuance of verification statement for generator sets....................... 15
5 Verification of calculations................................................................ 15

Changes – historic................................................................................................ 16

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SECTION 1 GENERAL

Section 1
1 Introduction
Complete generator sets are often assembled and tested at either the engine manufacturer or the generator
set manufacturer.
The manufacturer may request DNV GL to verify that the assembled generator set complies with the
performance and functional requirements of any recognized and relevant specification and/or standard. The
DNV rules is one example of a relevant standard in this respect.

2 Objective
The objective of this class guideline is to describe the verification process during workshop testing of an
assembled generator set when carried out according to DNV rules or other standards.

3 Scope
Relevant verification scope for generator sets depends on whether they are intended for a DNV classed vessel
or not.
Generator sets for DNV class
Sec.2 describes the relevant DNV rules for documentation, component certification, testing and inspection of
the assembled generator set.
Although not required by the DNV rules, a description is given on how underlying documentation may be
applied as basis for issuance of a product certificate.
Generator sets for other purposes than DNV class
Sec.3 describes a verification scope for non-class related verification of a generator set. This could e.g. be
power plant generator sets for on-shore application.
Note that for non-class verification, any agreed rule set, recognized standard or specification may be used as
basis.

4 Application
This guideline applies to all generator sets powered by diesel, dual-fuel and gas-only engines.

5 References
References used in this document are listed in Table 1 and Table 2.

Table 1 DNV references

Document code Title

DNV-RU-SHIP Pt.4 Ch.2 Rotating machinery, general

DNV-RU-SHIP Pt.4 Ch.3 Rotating machinery - drivers

DNV-RU-SHIP Pt.4 Ch.4 Rotating machinery - power transmission

DNV-RU-SHIP Pt.4 Ch.8 Electrical installations

DNV-RU-SHIP Pt.4 Ch.9 Control and monitoring systems

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Table 2 Other references

Section 1
Document code Title

ISO 8528-1 Reciprocating internal combustion engine driven alternating current generating sets
- Part 1: Application, ratings and performance

ISO 8528-3 Reciprocating internal combustion engine driven alternating current generating sets
- Part 3: Alternating current generators for generating sets

ISO 8528-6 Reciprocating internal combustion engine driven alternating current generating sets
- Part 6: Test methods

ISO 3046-1 Reciprocating internal combustion engines - Performance - Part 1: Declarations

of power, fuel and lubricating oil consumptions, and test methods - Additional
requirements for engines for general use

IEC 60034-1 Rotating electrical machines - Part 1: Rating and performance

IEC 60034-4-1 Rotating electrical machines - Part 4-1: Methods for determining electrically excited
synchronous machine quantities from tests

6 Abbreviations
Abbreviations used in this document are listed in Table 3.

Table 3 Abbreviations

Abbreviation Description

AVR automatic voltage regulator

COP continuous power, defined in ISO 8528-1

PRP prime power, defined in ISO 8528-1

LTP limited-time running power, defined in ISO 8528-1

MCR maximum continuos rating

PM particulate matter

NOX nitrogen oxides

HC hydrocarbons

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SECTION 2 GENERATOR SETS FOR DNV GL CLASS

Section 2
1 General

1.1 Introduction
This section covers the voluntary product certification process for assembled generator sets intended for DNV
classed vessels.
Guidance note:
The requirements for shipboard testing as given in DNV-RU-SHIP Pt.4 Ch.3 Sec.1 [9] are applicable, also when a product certificate
is issued according to this guideline for the assembled generator set.

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1.2 Preparations
Prior to the tests and inspections of the assembled generator set, the components and systems shall be
certified as required by DNV GL rules. For conventional generator sets this means:
— The engine shall be approved and certified according to DNV-RU-SHIP Pt.4 Ch.3 Sec.1 Table 2.
— The generator including the automatic voltage regulator (AVR) shall be approved and certified according
to DNV-RU-SHIP Pt.4 Ch.8 Sec.1.
— Control and monitoring system of the engine shall be approved and certified according to DNV-RU-SHIP
Pt.4 Ch.3 Sec.1 Table 9.
— Flexible coupling, if installed, shall be approved and certified according to DNV-RU-SHIP Pt.4 Ch.4 Sec.5
Table 2.
Certification of the engine may be carried out as part of the verification process for the assembled generator
set. If so, the test shall be planned to comply with DNV-RU-SHIP Pt.4 Ch.3 Sec.1 [4.2] and DNV-RU-SHIP
Pt.4 Ch.3 Sec.1 [4.4].

1.3 Documents to be submitted

Prior to the tests, a test program shall be submitted for information, see also [2.2].
Further, the DNV rules require the following documentation to be submitted for approval:
— Torsional vibration calculation according to DNV-RU-SHIP Pt.4 Ch.2 Sec.2 [1.4].
— Shafting arrangement of generator sets with single bearing generators according to DNV-RU-SHIP Pt.4
Ch.4 Sec.1 [1.2.2].
— Schematic layouts for fuel, lubricating oil and cooling water system if not already approved for the engine
according to DNV-RU-SHIP Pt.4 Ch.3 Sec.1 [1.4].
— List of alarms and shutdowns including set points according to DNV-RU-SHIP Pt.4 Ch.3 Sec.1 Table 11.

1.4 Marking of generator sets

The generator set shall be marked with a rating plate including the following information, as a minimum:
— manufacturer’s name or mark
— generator set serial number
— generator set year of manufacture
— rated power, both in [kW] and [KVA] with one of the prefixes COP, PRP or LTP
— rated power factor
— rated frequency [Hz]
— rated voltage [V]

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— rated current [A]

Section 2
— mass [kg].

2 Workshop testing and inspection

2.1 General
Generator sets are normally assembled on a common bedframe and shipped to the yard as one complete
unit. Tests and inspections required in DNV-RU-SHIP Pt.4 Ch.3 Sec.1 [8] and DNV-RU-SHIP Pt.4 Ch.3 Sec.1
[9] shall be carried out and documented.

2.2 Performance tests

2.2.1 General
The performance test of the generator set may be divided into two parts:
— test of engine, see [2.2.3]
— test of the assembled generator set, see [2.2.4].

2.2.2 Records of testing and inspections

All parameters required by DNV-RU-SHIP Pt.4 Ch.3 Sec.1 [4.2.1] and DNV-RU-SHIP Pt.4 Ch.3 Sec.1 [4.2.2]
shall be recorded in addition to the generator specific parameters. This applies during both steady state
operation and transient conditions.
Typical generator specific parameters are:
— power, both in [kW] and [KVA]
— frequency [Hz]
— voltage [V]
— current [A].

2.2.3 Engine load and functional test

The engine shall be tested according to the requirements as specified in DNV-RU-SHIP Pt.4 Ch.3 Sec.1
[4.4.1].
Guidance note:
For engines which is already certified, the testing above may be limited to the load points.

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2.2.4 Generator set transient and function tests

A generator shall keep the frequency and voltage in steady state and in transient operation as required in
DNV-RU-SHIP Pt.4 Ch.2 Sec.5 [1] and DNV-RU-SHIP Pt.4 Ch.8 Sec.5 [2.2].
The testing as specified below may be carried out to demonstrate that the generator set is capable of
supporting the electrical system including the transients it is intended for onboard the vessel:
— Two step on-loading is default for generator sets for auxiliary purpose, 0% to 50% and 50% to 100%
application of load, see DNV-RU-SHIP Pt.4 Ch.2 Sec.5 [1.5].
— Multistep on-loading may be agreed upon prior to the test, e.g. 3, 4 or more steps, see DNV-RU-SHIP Pt.4
Ch.2 Sec.5 [1.6].
— For emergency generator sets, application of load according to DNV-RU-SHIP Pt.4 Ch.2 Sec.5 [1.7].
— Load switch off testing, 100% to 0% sudden reduction of load within requirements in DNV-RU-SHIP Pt.4
Ch.2 Sec.5 [1.1].
The tests shall be carried out with the engine running stable at idle before applying load.

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 Section 2
2.3 Inspections
2.3.1 General
Paragraphs [2.3.2] to [2.3.4] give guidance on relevant items to inspect, as required by DNV rules.

2.3.2 Engine
Inspection of engine after testing shall be carried out according to DNV-RU-SHIP Pt.4 Ch.3 Sec.1 [4.5] if the
engine is not earlier certified.
Guidance note:
The inspection of the engine may be omitted if certification of the engine is not part of agreed scope.

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2.3.3 Generator
Inspection of the generator after testing shall be carried out according to DNV-RU-SHIP Pt.4 Ch.8 Sec.5 [4].
Guidance note:
Inspection of the generator may be omitted if it is already done and documented at the generator manufacturer.

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2.3.4 Generator set

The engine and generator are normally connected with a flexible coupling and it shall be demonstrated that
the alignment is within specified tolerances. The coupling is normally certified at the coupling manufacturer.
Installation of electrical equipment and cabling shall be carried out in accordance with DNV-RU-SHIP Pt.4
Ch.8 Sec.10. Special attention shall be given to routing and fixing of cables, see DNV-RU-SHIP Pt.4 Ch.8
Sec.10 [3.5].

3 Issuance of generator set compliance document

Upon complete and successful testing and inspection according to DNV GL rules, a product certificate for the
generator set may be issued.
For any other agreed scope witnessed, a survey report may be issued stating what has been carried out and
observed during the testing and inspection.

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SECTION 3 GENERATOR SETS FOR OTHER PURPOSES THAN DNV GL

Section 3
CLASS

1 General

1.1 Introduction
This section suggest a voluntary verification process which may be applied to any generator set intended for
other purposes than DNV class.
Considering that individual components may be shipped directly from the respective manufacturers to the
plant site, the factory testing and inspection will often be for the individual components only. Should the units
be assembled on a skid or in a container before shipment, a number of tests and inspections assigned to
the commissioning stage, may be carried out at an earlier stage. In such case, the on site commissioning
testing and inspection may be limited in agreement between the parties involved and verified by the DNV GL
surveyor.

1.2 Scope of verification

The verification scope may be agreed on basis of any relevant standard or specification.
ISO 8528-6 and IEC 60034-1 may be used for guidance as these standards specify relevant matters to
consider. Other examples of possible specifications that may be relevant are DNV rules, other ISO and IEC
standards, customer specifications or other documents that specify testing with acceptance criteria.
The design and function of electrical rotating machines shall generally comply with the requirements of the
IEC 60034-series. Additional testing may be agreed upon if generator set is intended for parallel operation,
see ISO 8528-3.

1.3 Proposal for preparations

Prior to the test, a program for testing and inspection, including procedures and data to be observed, should
be prepared and agreed upon:
— Equipment, tools and instruments should be identified and listed. All instruments and systems to be used
for measurements and observations shall be calibrated and checked out as agreed.
— The test program should list all persons and parties to be present at the testing, as well as the functions
and responsibilities of these.
— The inspection program should outline which items are subjected to inspections and which method to be
used.
— Arrangements shall be made to record all relevant data from the testing.

1.4 Proposal for testing and inspection records

1.4.1 General information
The general information shall include as a minimum the generator set identification and description of the
plant and its components. It shall also include a reference to the contract and its technical specifications.

1.4.2 Test records and inspections

The party responsible for the test should prepare a record of tests and inspections. This record may include,
but not necessarily be limited to, test and inspections as defined in [1.4.1] to [1.4.3]. The person in charge
for the testing and inspections shall sign the test program, inspection program and the final test record.
All test records or copies shall be made available to the DNV representative directly upon completion of
the test. Before leaving the test site, the DNV representative will countersign and stamp each test sheet to
confirm the authenticity of the records.

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1.4.3 Testing

Section 3
All relevant equipment for safety of personnel shall be in operation during the testing.
The test program shall as a minimum contain the following:
— test procedure with description of each test
— data collection to be observed during the test
— time and date
— person responsible for the execution of the test program.

The records of the test shall include all observed data and as a minimum the following:
— Ambient reference conditions:
— air temperature
— air pressure air humidity
— external cooling water temperature
— external cooling water temperature
— fuel and lubricating oil characteristics
— time and date
— Summary and conclusion of the test results, giving the principle data on standardized form, enabling
direct comparison with requirements and specifications.
— Performance data.
— Test records and inspections, see [1.4.2].

The performance data to be recorded shall include all parameters as specified in the applicable standard or
customer specification and shall be recorded at each load point.
Typical data to be recorded are:
— engine power, either as total power [kW], or power pr. cylinder [kW/cyl]
— engine speed [rpm]
— mean indicated pressure, MIP [bar]
— mean effective pressure, MEP [bar]
— maximum cylinder pressure [bar]
— compression pressure [bar]
— specific fuel consumption [g/kWh]
— scavenging air pressure [bar]
— exhaust-gas temperature at cylinder outlet [°C]
— exhaust-gas temperature, before and after turbocharger [°C]
— total air excess ratio []
— generator power [kWe]
— generator current [V]
— generator voltage [A]
— generator frequency (alt. rpm) [Hz]
— generator temperature rise (normally to be measured at generator supplier) [Δ °C]
— generator Cos Phi (not necessary if current, voltage, power can be measured) [-].
For auxiliary machinery, the following data is typically relevant to be recorded:
— Pumps:
— power [kW] vs. massflow [kg/h) /engine load [%]
— rotating speed [rpm] vs. massflow [kg/h) /engine load [%]
— inlet pressure [bar] vs. massflow [kg/h) /engine load [%]
— outlet pressure [bar] vs. massflow [kg/h) /engine load [%].

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— Heat exchangers:

Section 3
— temperature [°C] in and out, both on warm side and cold side for all heat exchangers vs. mass flow/
engine load.
Guidance note:
From generator factory, following records should be obtained:

— voltage wave form

— voltage variations under transient conditions
— measurements of induced shaft voltage.

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2 Workshop testing and inspection

2.1 General
The agreed test verification may include both performance test, functional test and final inspection. ISO
8528-6 may be used as guidance for which tests to consider. Examples of what may be included are given in
paragraph [2.2] to [2.4] below.

2.2 Performance test

Performance test shall be made at 50%, 75%, 90% and 100% of the engine's max continuous rating.

2.3 Functional test

The functional test for the generator set may be separated in two different test groups, one for the engine
and one for the generator.
1) For the engine, the following functional tests may be carried out:
— Overload test at 110% of the max continuos rating for 30 min.
— Speed controller function with regard to stability and response.
— Control, alarm and safety system set point including verification of calibrations.
— Number of engine starts if compressed air is used, including statement/recording of minimum air
pressure and starting air tank volume.
2) For the generator, the following functional test should be carried out in accordance with IEC 60034-1 and
IEC 60034-4-1:
— Temperature rise shall be determined at rated output, voltage and frequency.
— Overload capability with an overload of 50% of the rated current.
— Overspeed at 120% of rated speed.
— Withstand voltage test.
— Insulation resistance shall be measured between the phases and between each phase and ground.
— Winding resistance shall be measured.
— Air gap shall be measured.
— Voltage and current characteristics shall be determined by open-circuit and closed-circuit test.
— Excitation current at rated current, voltage and power factor.
— Short circuit test (alternatively on other unit of the same type).
Guidance note:
Exciter and voltage regulation equipment (automatic voltage regulator) are normally considered as part of the generator.

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 Guidance note:

Section 3
Tests specified shall be carried out at generator manufacturer before fitting to the diesel engine.

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2.4 Inspections
Immediately after the testing as specified in [2.2] and [2.3] are completed and witnessed, inspections of the
generator set shall be carried out according to the agreed inspection program. The records of observations
shall include identification of the inspected items.
As a minimum the following items should be inspected:
— Alignment of the shaftline should be checked by measuring crankshaft deflection while the engine is still at
its running temperature provided this is a prescribed procedure by the engine manufacturer.
— Spot check of wear exposed parts should be carried out. All sliding surfaces of at least 1 cylinder, or 1-
cylinder section in a Vee-engine shall be inspected.
— Lubricating oil samples and lubricating oil filters should be checked before and after the test runs.
— Fuel oil sample of the fuel used shoud be analyzed for heat value determination.
— Generator rating plate and performance data should be as per IEC 60034-1.

3 Commissioning, testing and inspection

3.1 General
Commissioning, testing and inspection may be the final check of the plant, unit or equipment before delivery
to the owner or operator.
All installation work with its adjustments, and the builders own test runs as well as the initial running-in,
should be completed (initial running in sufficiently to allow 'unlimited operation' without defects/damages).
ISO 8528-6 may be used as guidance for what tol considered to be tested.
At the commissioning, the complete log from the factory test and inspections shall be available to the
attending surveyor.

3.2 Plant performance

Performance runs may be carried out at 25%, 50%, 75%, 90% and 100% of maximum continuous rating
(MCR).
Special operating conditions may require test runs at additional and different power levels.
The performance testing may include a duration test at MCR for more hours, e.g. 24 hours for guidance.
Data to be observed should include all parameters necessary to demonstrate compliance with the
requirements to performance given by the specification for the plant.

3.3 Performance of auxiliary systems

The testing of auxiliary systems should include the following:
— Pump systems providing essential auxiliary service should be checked. Performance should be measured
at 100% plant load.
— Heat exchanger's performance should be measured at 100% plant load. Conditions should simulate, as
closely as possible, the most severe specified ambient conditions with regard to plant heat load.

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 Section 3
3.4 Functional test
The testing of functions should include the following:
— overload test at 110% of MCR for 30 min
— 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 parallel
— measurement of the equalizing current resulting from harmonics when different generators are working in
parallel or generators are running in parallel on net, in both cases with if earthed neutral
— manual and automatic control systems, including those for essential auxiliary machinery, as well as
pressure and temperature control systems
— automatic safety functions: automatic shutdown, load shedding and return power
— alarm systems
— generator resistance measurements
— communications systems if more than one command central
— fire alarm and fire extinguishing systems.

3.5 Other measurements

Other measurements may additionally be included in the verification scope. The testing of auxiliary systems
should include the following:
— exhaust-gas mass flow, soot content (PM), NOx content, HC content, etc.
— noise measurements in machinery spaces as well as in the immediate surroundings
— vibration measurements and analysis. These measurements and analysis may include torsional, lateral as
well as axial vibrations.
DNV may upon agreement carry out one or more of the above specified measurements.

3.6 Inspections
The following items should be subject to inspections:
— Lubricating oil samples and lubricating oil filters should be checked before and after the test runs.
— Fuel oil sample should be taken of the fuel being used and sent for analysis and heating value
determination.
— Alignment of the shaftline should be checked by crankshaft deflection while the engine is still at its
running temperature.
— Spot check of wear exposed parts should be carried out. All sliding surfaces of at least 1 cylinder, or 1-
cylinder section in a Vee-engine to be inspected.
— Foundation bolt tightness should be checked upon completion of the function test.
— During the test runs as well as after stop, thorough checks should be made for leaks.
— Piping systems with valves should be inspected of its routing, fastening, tightness and consequences of
potential leaks (e.g. fuels lines - fire hazard).
— Electric cables should be inspected for its routing, fastening, protection against damage during overhaul
work, etc.
— Fire detectors and inspection systems should be inspected for its positioning of detectors and practicability
of the extinguishing systems (see local codes and regulations).

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— Maintenance plans should be reviewed with attention to:

Section 3
— 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 potential need, availability, supply lead time, as
well as the system for inventory accounting.

4 Issuance of verification statement for generator sets

After successful testing and inspection, DNV will issue a verification statement stating that the agreed scope
is complied with.
In case the tests and inspections were not successfully carried out, a survey report may be issued stating
what was carried out and observed.

5 Verification of calculations
DNV GL may offer to verify calculations of performance parameters to standard conditions according to
standards after the test, e.g. ISO 3046-1. Example: Correction of power and fuel consumption.

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CHANGES – HISTORIC

Changes – historic
December 2020 edition
This is a new document.

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 About DNV
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