1. UFC 3-540-07 Operations and Maintenance O&M Generators.pdf

UFC 3-540-07

21 February 2018

Change 1, 5 November 2019

UNIFIED FACILITIES CRITERIA (UFC)

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED

OPERATION AND MAINTENANCE

(O&M): GENERATORS

OPERATION AND MAINTENANCE (O&M): GENERATORS

Any copyrighted material included in this UFC is identified at its point of use.

Use of the copyrighted material apart from this UFC must have the permission of the copyright holder.

Use of the name or mark of any specific manufacturer, commercial product, commodity, or service in this UFC does not imply endorsement by the Department of Defense.

U.S. ARMY CORPS OF ENGINEERS

NAVAL FACILITIES ENGINEERING COMMAND

AIR FORCE CIVIL ENGINEER CENTER (Preparing Activity)

Record of Changes (changes are indicated by \1\ ... /1/)

Change No. Date Location 1 5 Nov 2019 Updated the Summary Sheet, Chapters 1, 2, 3, 5, and 8

(Chap. 8 formerly App. C) and App. A (formerly App. D);

renumbered former Appendices A and B as Appendices B and C. Numerous non-substantive corrections throughout for format, grammar, missing/outdated references, and paragraph numbering; these changes are not marked.

This UFC supersedes Engineering Technical Letter (ETL) 13-4, Standby Generator Design, Maintenance, and Testing Criteria.

FOREWORD

The Unified Facilities Criteria (UFC) system is prescribed by MIL-STD 3007 and provides planning, design, construction, sustainment, restoration, and modernization criteria, and applies to the Military Departments, the Defense Agencies, and the DoD Field Activities in accordance with USD (AT&L) Memorandum dated 29 May 2002. UFC will be used for all DoD projects and work for other customers where appropriate. All construction outside of the United States is also governed by Status of Forces Agreements (SOFA), Host Nation Funded Construction Agreements (HNFA), and, in some instances, Bilateral Infrastructure Agreements (BIA).

Therefore, the acquisition team must ensure compliance with the most stringent of the UFC, the SOFA, the HNFA, and the BIA, as applicable.

UFC are living documents and will be periodically reviewed, updated, and made available to users as part of the Services’ responsibility for providing technical criteria for military construction. Headquarters, U.S. Army Corps of Engineers (HQUSACE), Naval Facilities Engineering Command (NAVFAC), and the Air Force Civil Engineer Center (AFCEC) are responsible for administration of the UFC system. Defense agencies should contact the preparing Service for document interpretation and improvements. Technical content of UFC is the responsibility of the cognizant DoD working group. Recommended changes with supporting rationale should be sent to the respective Service proponent office by the following electronic form: Criteria Change Request. The form is also accessible from the Internet site below.

UFC are effective upon issuance and are distributed only in electronic media from the following source:

• Whole Building Design Guide web site http://dod.wbdg.org/.

Hard copies of UFC printed from electronic media should be checked against the current electronic version prior to use to ensure they are current.

AUTHORIZED BY:

LARRY D. McCALLISTER, PhD, PE, PMP, SES

Chief, Engineering and Construction Directorate of Civil Works U.S. Army Corps of Engineers

JOSEPH E. GOTT, P.E.

Chief Engineer Naval Facilities Engineering Command

EDWIN H. OSHIBA, SES, DAF MICHAEL McANDREW Director Air Force Civil Engineer Center

Deputy Assistant Secretary of Defense (Facilities Investment and Management) Office of the Assistant Secretary of Defense (Energy, Installations, and Environment)

SUMMARY SHEET

Document: UFC 3-540-07, Operation and Maintenance (O&M): Generators

Superseding: Air Force ETL 13-4, Standby Generator Design, Maintenance, and Testing Criteria

Description: UFC 3-540-07 provides guidance for O&M of standby, emergency, and prime power generators.

Reasons for Document: Provide guidance for O&M of generators.

Impact: There are no impacts on design and initial cost, energy savings, or life cycle costs.

\1\ Unification Issues: Air Force-only requirements are in Chapter 8. /1/ i

TABLE OF CONTENTS

CHAPTER 1 INTRODUCTION

1-1 BACKGROUND

1-2 PURPOSE AND SCOPE

1-3 APPLICABILITY

1-4 SAFETY

1-4.1 Minimizing Hazards

1-4.2 Qualifications of Generator and Electrical Workers

1-5 CYBERSECURITY

1-6 PERSONNEL SAFETY

1-7 REFERENCES

1-8 GLOSSARY

CHAPTER 2 GENERATOR CONFIGURATION

2-1 GENERAL REQUIREMENTS

2-2 RECIPROCATING ENGINE PRIME MOVER

2-3 GENERATOR

2-3.1 AC Generator

2-3.2 Mechanical

2-4 FUEL SYSTEM

2-5 LUBRICATING SYSTEMS – RECIPROCATING ENGINES

2-6 ENGINE COOLING SYSTEMS

2-7 INTAKE AIR AND EXHAUST SYSTEMS

2-7.1 Intake Air

2-7.2 Exhaust System

2-8 DC POWER AND CHARGING SYSTEM

2-9 AC POWER DISTRIBUTION SYSTEM

2-10 AUTOMATIC TRANSFER SWITCHES (ATS)

2-11 MANUAL TRANSFER SWITCHES (MTS)

2-12 GROUNDING SYSTEMS

CHAPTER 3 DEVELOPING AN O&M PROGRAM

3-1 O&M MANAGEMENT

3-1.1 Administration and Structure

3-1.2 Quality Assurance Program ii

3-1.3 Contracted Maintenance

3-2 TRAINING

3-2.1 Qualifications of Generator Workers

3-2.2 Safety

3-3 TOOLS AND EQUIPMENT

3-3.1 Electrical Tools and Equipment Standards

3-3.2 Standard Tools and Equipment

3-3.3 Care and Storage of Tools and Equipment

3-3.4 Electrical Inspecting and Testing Equipment

3-3.5 Required Electrical Safety Program

3-4 HAZARDOUS MATERIAL PROCEDURES

3-5 SYSTEM DATA, EQUIPMENT DATA, AND DOCUMENTATION

3-5.1 Operating Procedures

3-5.2 Manufacturer O&M Manuals

3-5.3 Derating

3-5.4 Installation Drawings

3-5.5 Control Diagrams

3-5.6 Maintenance Forms and Records

3-5.7 Spare Parts Lists

3-5.8 Service Contract Documents

CHAPTER 4 OPERATIONS

4-1 OPERATING PROCEDURES

4-1.1 Responsibilities

4-1.2 Fire Emergency

4-2 AIR QUALITY PERMITTING

4-2.1 New Permits and Modifications to Existing Permits

4-2.2 Changes

4-3 COMPLIANCE MONITORING AND INSPECTIONS

4-3.1 OSHA Compliance and Monitoring

4-3.2 Air Quality Compliance

4-3.3 Clean Water Act (CWA) Compliance and Monitoring

4-3.4 Resource Conservation and Recovery Act (RCRA) Compliance Monitoring iii

CHAPTER 5 RELIABILITY MAINTENANCE-CENTERED PRACTICES

5-1 PURPOSE AND SCOPE

5-2 PREVENTIVE MAINTENANCE ELEMENTS (TIME-BASED)

5-2.1 General

5-2.2 Load Bank Optimization

5-2.3 Prime Mover (Engines)

5-2.4 Cooling System

5-2.5 Lubrication System

5-2.6 Fuel System (Including Long-Term Fuel Storage)

5-2.7 Air Intake Systems

5-2.8 Exhaust System

5-2.9 Generator Components

5-2.10 DC Electrical System

5-2.11 AC Electrical System

5-3 PREDICTIVE MAINTENANCE ELEMENTS (CONDITION-BASED)

5-3.1 General

5-3.2 Electrical and Mechanical Systems

5-4 GENERATOR LOAD TESTING

CHAPTER 6 TYPICAL INSPECTION AND MAINTENANCE SCHEDULES

6-1 PURPOSE AND SCOPE

6-2 PREVENTIVE MAINTENANCE (PM) SCHEDULES

6-3 PREDICTIVE MAINTENANCE SCHEDULES

CHAPTER 7 PRIME POWER

7-1 GENERAL REQUIREMENTS

7-2 CERTIFICATION OF GENERATOR WORKERS

7-3 COMBUSTION TURBINE ENGINE

7-4 GASEOUS FUELS

7-5 FUEL OIL

7-6 LUBRICATING SYSTEMS – GAS TURBINE ENGINES

7-6.1 Oil Analysis

7-6.2 Ultrasonic Scanning

7-6.3 Weld Inspection

7-6.4 Steam Turbine System iv

7-7 PRIME COOLING SYSTEMS

7-7.1 Stator Cooling Systems

7-8 INTAKE AIR MAINTENANCE

7-8.1 Gas Turbine Intake Air

7-9 SPECIALTY TOOLS AND EQUIPMENT

7-10 TOOL SAFETY

7-10.1 Energized Lines

7-10.2 Insulating Hydraulic Fluid

7-11 POWR PLANT OPERATIONS

7-11.1 Load Shedding

7-11.2 Methods of Load Shedding

7-11.3 Requirements for Load Reduction

7-11.4 Total Load Reduction

7-11.5 Methods of Load Shedding

7-11.6 Electrical Usage and Criticality

7-11.7 Stable Operation and Overload Capability

7-12 OPERATIONAL CONSIDERATIONS

7-12.1 Isolated Operation

7-12.2 Base Loads

7-12.3 Alternate Energy Sources

7-13 POWER PLANT OPERATIONS

7-13.1 Power Plant Supervisors

7-13.2 Work Schedule

7-13.3 Dead Plant Start-Up

7-13.4 Power Outage

7-13.5 Emergency Plant Shutdown

7-13.6 Micro-Grid Operation

7-14 OPERATIONAL PERMITTING

7-14.1 Wastewater Discharge Permit

7-14.2 FAA Permit

7-14.3 Incidental Take

7-15 PREVENTIVE MAINTENANCE

7-15.1 Corrosion Control v

7-16 BAGHOUSE LEAK DETECTION AND PERFORMANCE

MEASUREMENTS

7-16.1 Inspection

7-16.2 Trial Period

7-17 SPECIALIZED INSPECTIONS (GAS TURBINE ONLY)

7-17.1 Borescope Inspection

7-17.2 Hot Gas Path Inspection

7-17.3 Major Inspection

CHAPTER 8 AIR FORCE REQUIREMENTS

8-1 SUMMARY OF REQUIREMENTS

8-2 DEFINITIONS

8-3 GENERATOR PREVENTIVE MAINTENANCE FREQUENCIES,

MAINTENANCE REQUIREMENTS, AND TESTING

8-3.1 Requirements for Select Mission-Essential Facilities Compliance with Published Guidance

8-3.2 RPIE Generator and Transfer Switch Inspections and Operational Testing Requirements

8-3.3 RPIE POL/Fuels Generator and Transfer Switch Testing

8-3.4 EAID Generator and Transfer Switch Inspections and Operational Testing Requirements

8-3.5 Deployable Generator Inspections and Testing

8-4 MISSION UNINTERRUPTIBLE POWER SUPPLIES (UPS)

8-5 LUBRICATING OILS

8-5.1 Deviation from Manufacturer’s Service Intervals

8-6 FUELS

8-6.1 Fuel Oils

8-6.2 Jet Fuels

8-6.3 Natural Gas, Liquid Petroleum Gas, and Bio-Diesel

8-6.4 Fuel Storage Tank Training

8-6.5 Fuel Tanks of Emergency Generators

8-7 COOLANT

8-7.1 Engine Water Treatment

8-7.2 Cooling System Maintenance

8-8 ACCOUNTING FOR GENERATORS

vi

8-8.1 RPIE Generators

8-8.2 EAID Generators

8-8.3 AFLCMC/WNZEC

8-8.4 Reporting RPIE Generators

APPENDIX A SAMPLE O&M PROCEDURES AND FREQUENCY

A-1 STRUCTURE AND ENCLOSURES

A-1.1 Service Practices

A-2 GENERATOR MAINTENANCE

A-2.1 Service and Troubleshooting

A-2.2 Operational Check

A-2.3 Preventive Maintenance

A-2.4 Troubleshooting

A-3 MEDIUM-VOLTAGE ELEMENTS

A-3.1 Troubleshooting

A-3.2 Switchgear Equipment Troubleshooting

A-3.3 Routine Maintenance

A-3.4 Diesel Engines Long-Term Checklist

A-3.5 Short-Term Checklist for Gas Turbines

A-3.6 Long-Term Checklist for Gas Turbines

A-4 GENERATORS AND EXCITERS

A-4.1 Short-term Checklist

A-4.2 Long-term Checklist

A-4.3 Checklist and Schedule for Solid-state Exciters

A-5 SWITCHGEAR MAINTENANCE

A-5.1 Short-Term Checklist

A-5.2 Long-term Checklist

A-6 OIL MAINTENANCE PROCEDURES

A-7 FUEL AND FUEL STORAGE

A-7.1 Diesel Fuel

A-7.2 Gas Turbine Fuel

A-7.3 Storage

A-7.4 Fuel Storage Maintenance Procedures

A-8 LUBRICATING OIL

vii

A-8.1 Diesel Engine Oil

A-8.2 GAS TURBINE OIL

A-8.3 Coolant

A-8.4 Engine Water Treatment

A-8.5 Cooling System Maintenance

A-9 ATS MAINTENANCE

APPENDIX B REFERENCES

APPENDIX C GLOSSARY

C-1 ACRONYMS AND ABBREVIATIONS

C-2 DEFINITIONS OF TERMS

FIGURES

Figure 3-1 Engine Generator Inspection Checklist Figure 3-2 Generator Set Survey Figure 3-3 Generator Data Record

TABLES

Table 6-1 Typical Generator Maintenance Schedule Table 7-1 Typical Prime Generator Maintenance Schedule Table 8-1 Generator System Inspection and Testing Frequency Requirements viii

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CHAPTER 1 INTRODUCTION

1-1 BACKGROUND.

Proper O&M of generators is essential to ensuring continuous electrical system operation and reliability. A comprehensive O&M program with proven practices and well-performed maintenance prevents downtime and mission loss or delay.

1-2 PURPOSE AND SCOPE.

This UFC provides the minimum guidance and standards for O&M of standby, emergency, and prime power generators and is intended to be used by operations and maintenance personnel. It includes safety requirements, standard operating instructions, maintenance instructions, and test procedures. This UFC is intended to be used with the generator manufacturer's recommended operational procedures and maintenance manuals.

1-3 APPLICABILITY.

The guidance and standards contained within are the minimum requirements acceptable for military installations for efficiency, economy, durability, maintainability, and reliability of generator systems. The provided guidance does not automatically supersede equipment manufacturers’ instructions and requirements. When conflicts exist, follow the most rigorous requirement. The guidance and standards herein are not intended to be retroactively mandatory. Provide, as a minimum, the level of maintenance required to meet critical mission reliability goals.

• Comply with the requirements of 29 CFR 1910, Occupational Safety and Health Standards.

• Comply with the requirements of Title 40 CFR 1 to 1100, Environmental Protection Agency.

• Comply with UFC 3-550-01, Exterior Electrical Power Distribution, for minimum system and component design standards.

• Comply with UFC 3-520-01, Interior Electrical Systems.

• Comply with UFC 3-560-01, O&M: Electrical Safety, for electrical safety requirements applicable to the installation and operation of electrical systems.

• Comply with UFC 3-540-01, Engine-Driven Generator Systems for Backup Power Applications, for backup power applications.

\1\ Note: The Air Force will follow operations, maintenance, and testing requirements outlined in Chapter 8. /1/

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1-4 SAFETY.

1-4.1 Minimizing Hazards.

Before starting maintenance, be aware that a generator can start without warning and cause serious injury or death. Use lockout/tagout (LOTO) procedures and wear appropriate personal protective equipment (PPE). Comply with UFC 3-560-01 for electrical safety requirements.

Apply standard operating procedures (SOP), where available, for reducing/minimizing/eliminating potential hazards with PPE, proper training, and rescue procedures and equipment.

1-4.2 Qualifications of Generator and Electrical Workers.

1-4.2.1 Training.

Generator and electrical workers must be qualified through training and demonstrated skills and knowledge in specific hazards associated with their potential exposure in accordance with OSHA requirements and safety-related practices contained in NFPA 70E, Standard for Electrical Safety in the Workplace, and IEEE C2, National Electrical Safety Code (NESC). Trained and qualified generator and electrical workers must be familiar with the following:

• The skills and techniques necessary to distinguish exposed live parts from other parts of electric equipment.

• The skills and techniques necessary to determine the nominal voltage of exposed live parts.

• The clearances specified in NFPA 70E and IEEE C2.

• Operating (starting, running, shutdown procedures) and maintaining generators, generator synchronizers, generator control system, fuel system, cooling system, exhaust system, and switchgear.

1-4.2.2 Generator Workers and Operators.

Maintain a list of qualified generator operators. The generator operator and worker must have the knowledge to monitor indicating devices that reflect system operation and manipulate controls necessary to properly start, operate, and shut down generator equipment. Ensure the facility manager or others (operators) at the facility are trained to operate and check generator status. It is the responsibility of the facility or mission owner to request annual training from the base civil engineer (BCE)/Public Works as required.

1-5 CYBERSECURITY.

Operate and maintain all generator-related control systems to maintain compliance with the network system authorization as required by DoDI 8500.01, Cybersecurity, and

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DoDI 8510.01, Risk Management Framework (RMF) for DoD Information Technology (IT). See UFC 4-010-06, Cybersecurity of Facility-Related Control Systems, for additional information.

\1\ [Deleted note.] /1/

1-6 PERSONNEL SAFETY.

Generator and electrical workers must wear proper safety clothing in the work area per OSHA 1910.132. Workers must be trained and certified in use and care of PPE, insulating protective equipment (IPE), and LOTO controls. Personnel must follow safety procedures, conduct hazard analyses, and attend job safety briefings in accordance with OSHA and UFC 3-560-01 safety requirements. Proper tools must also be used in accordance with 29 CFR 1926. Electrical gloves must be tested according to ASTM F496, Standard Specification for In-Service Care of Insulating Gloves and Sleeves.

NAVFAC must also follow local specific regulations.

1-7 REFERENCES.

Appendix B contains a list of references used in this document. The publication date of the code or standard is not included in this document. In general, the latest available issuance or edition of the reference is used.

1-8 GLOSSARY.

Appendix C contains acronyms, abbreviations, and terms.

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CHAPTER 2 GENERATOR CONFIGURATION

2-1 GENERAL REQUIREMENTS.

Maintenance of the generator consists of all systems associated with the generator, including cables, prime movers, and ancillary equipment.

Note: There are differences between the EPA and NFPA definitions for an emergency generator and generator operators must ensure they are using the correct reference within each context to avoid misunderstandings.

2-2 RECIPROCATING ENGINE PRIME MOVER.

There are two primary types of reciprocating engines: compression ignition and spark ignition. Compression ignition includes diesel fuel engines. Spark ignition includes gasoline, natural gas, and liquid petroleum gas (LPG) engines.

The major components of reciprocating engine requiring maintenance include:

• Engine block assembly (block, crankshaft, pistons and rings, camshaft, lifters, connecting rods, intake and exhaust valves, and cylinder heads)

• Fuel system

• Cooling system

• Exhaust system

• Lubrication system

• Starting system

• Battery and charging system

• Automatic transfer switch (ATS)

• \1\ Manual transfer switch (MTS) /1/

• Ignition system

• Air intake system

• Control system

• Exercise

2-3 GENERATOR.

2-3.1 AC Generator.

AC generators used are synchronous except for wind turbines.

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2-3.2 Mechanical.

The mechanical portion of a generator system consists of the fuel system, starting system (either pneumatic or electric), lubrication system, cooling system, and intake/exhaust system.

2-4 FUEL SYSTEM.

A common reason for generators not starting is a clogged fuel filter due to old or contaminated fuel; therefore, the fuel filters and fuel must be checked as part of routine maintenance.

2-5 LUBRICATING SYSTEMS – RECIPROCATING ENGINES.

Reciprocating engine lubrication system components requiring maintenance typically include:

• Sump/oil tank

• Lubrication filter

• Lubrication cooler

• Oil pump

• Tubing, hoses, and fittings

On larger size engines, the clean oil tank, waste oil tank, and pre-lubrication pumps are separate and require maintenance.

2-6 ENGINE COOLING SYSTEMS.

Engine water cooling system components typically requiring maintenance include water pumps, radiator, thermostat, cooling fan, hoses, thermostats, and instrumentation.

2-7 INTAKE AIR AND EXHAUST SYSTEMS.

2-7.1 Intake Air.

The intake air system cleans the air entering the generator engine or turbine. Air filtration systems for reciprocating engines typically use weather protection and final filters.

Intake air system components typically requiring maintenance include filters, filter housings and air intake horns, dampers, damper actuators, inertial separators, moisture coalescers, anti-icing systems, and instrumentation.

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2-7.2 Exhaust System.

The exhaust system removes the combustion gases from the engine. Exhaust system components that typically require maintenance include draining the condensate and examining the manifold for leaks and holes.

2-8 DC POWER AND CHARGING SYSTEM.

Two types of batteries are vented cell batteries and sealed cell batteries. The vented, or open, batteries require periodic liquid levels observation and refilling, as necessary.

Lead calcium flooded batteries have typical lifetimes of 20 years. \1\ Sealed cell, valve regulated lead acid (VRLA) batteries generally recommended are versions of sealed wet cell or absorbent glass mat (AGM). /1/ Pure lead versions of these batteries have lifetimes over four years. A lifetime cost analysis must be done to choose what type batteries are required for the application. Maintenance must be included in these calculations. Load test all batteries according to IEEE 450, Recommended Practice for Maintenance, Testing, and replacement of Vented Lead-Acid Batteries for Stationary Applications. According to manufacturers, the top two reasons standby generators fail to automatically start or run are that the generator START switch is in the OFF position instead of AUTO or the starting batteries are dead or insufficiently charged.

2-9 AC POWER DISTRIBUTION SYSTEM.

Refer to UFC 3-550-01 for exterior electrical power distribution.

2-10 AUTOMATIC TRANSFER SWITCHES (ATS).

Most standby and emergency generators will have an associated ATS that requires maintenance. Those systems that do not have an ATS will have switchgear that accomplishes the same result or synchronizes with the utility. The ATS is an integral part of a generator system and must be tested to ensure proper operation. Refer to UFC 3-540-01 for design requirements.

2-11 MANUAL TRANSFER SWITCHES (MTS).

MTSs must be maintained by visually inspecting for rust and corrosion and ensuring moving components are greased with electrically conductive grease. They must also be exercised during generator system testing.

2-12 GROUNDING SYSTEMS.

Grounding systems should be visually inspected during generator inspections and testing for physical continuity for separately derived systems is required every two years (specifically at expeditionary sites).

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CHAPTER 3 DEVELOPING AN O&M PROGRAM

3-1 O&M MANAGEMENT.

3-1.1 Administration and Structure.

The O&M administration structure must include the elements of operations, maintenance, engineering support, training, and administration. Operations is responsible for management and control of operation activities, equipment control and status, and operator knowledge and performance to support safe and reliable operations. Maintenance is responsible for effective management and control of maintenance activities, efficient performance of the work control system, safe conduct of maintenance activities, and maintenance procedures and documentation. Engineering support ensures effective implementation and control of technical support, equipment modifications, equipment performance monitoring, and engineer support of procedures and documentation. The Commanding officer, in conjunction with the generator subject matter expert (SME), must implement and control training activities, general training, maintenance training, operations training, training facilities, and equipment.

Administration plans and implements policies, develops management objectives to improve performance, monitors activities, oversees industrial safety, and ensures personnel are appropriately trained.

Operational testing/operation must be done per the manufacturer’s recommendations.

NFPA 110, Standard for Emergency and Standby Power Systems, also specifies emergency generator testing requirements. This includes full-load generator testing and exercise of circuit breakers and switches.

Note: The Air Force will follow the test requirements in Chapter 8.

3-1.2 Quality Assurance Program.

The O&M quality assurance program must measure the quality or effectiveness of the quality assurance program. Each plant is recommended to have a quality assurance plan to ensure the maintenance program is effective; however, it is not a minimum requirement.

3-1.2.1 Quality Assurance Metrics.

Use the following metrics to measure the quality or effectiveness of the quality assurance program:

• Plant reliability

• Work orders generated and closed out

• Corrective maintenance backlog

• Safety record

• Environmental record

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• Energy use

• Inventory control

• Overtime worked

• Absentee rate

• Staff turnover

3-1.2.2 Base Period.

Track performance metrics on a periodic basis but not less than monthly.

3-1.3 Contracted Maintenance.

During the warranty period, the manufacturer must be contacted for resolution.

Technicians will have documented training/experience on maintaining assigned generators. The contracted maintenance must include a submittal of a preventive maintenance schedule that meets or exceeds the generator manufacturer's recommended requirements.

3-2 TRAINING.

Fully train all personnel to perform O&M on specific installed generators. At a minimum, train personnel on the following:

• O&M of the equipment

• Proper use of tools, protective equipment, and precautionary techniques

• Electrical hazards associated with electrical equipment

• Techniques and skills to practice O&M activities on electrical equipment

• Job planning

• Maintaining a safe work environment

• Familiarization of the one-line electrical connection diagram/control diagrams for specific generator facility connection and layout

3-2.1 Qualifications of Generator Workers.

Personnel must be fully qualified/trained to perform O&M on generators and must follow/obey safety procedures in their work area.

3-2.1.1 Electricians.

Electrical workers must be trained and qualified to operate and maintain the electrical switchgear, including relays and circuit breakers, switchgear control system, transformers, DC power system, and other electrical ancillary equipment.

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3-2.2 Safety.

Safety considerations must be taken into account to maintain the generators in accordance with UFC 3-560-01 and, for the Air Force, AFI 32-1064, Electrical Safe Practices. This involves access to generators, location of generators, tool locations, grouping of equipment, spacing requirements dictated by manufacturer’s instructions, and NEC Article 110.

3-3 TOOLS AND EQUIPMENT.

3-3.1 Electrical Tools and Equipment Standards.

Industry standards describe the requirements for electrical protective equipment and tools. \1\ These standards were developed so tools, equipment, materials, and test methods used by electrical workers will provide protection from electrical hazards. Tool and equipment terminology and in-service maintenance and electrical testing are included in IEEE 935, IEEE Guide on Terminology for Tools and Equipment to Be Used in Live Line Working, and IEEE 516, IEEE Guide for Maintenance Methods on Energized Power Lines, respectively. /1/ UFC 3-560-01 also contains tool and equipment requirements. In case of conflict, always use the most stringent safety requirement.

3-3.2 Standard Tools and Equipment.

For simplicity and convenience, the tools and equipment required for electrical inspection and maintenance are classified as follows:

3-3.2.1 Tools.

Tools include hand tools, digging tools, hot line tools, miscellaneous and special tools, and tackle.

3-3.2.2 Protective Equipment.

Protective equipment includes required PPE, such as eye and hearing protection, helmets, gloves, footwear, and arc flash clothing, and non-PPE items such as LOTO locks, barricades, and warning devices. Follow PPE requirements in UFC 3-560-01 and, for the Air Force, AFI 32-1062, Electrical Systems, Power Plants and Generators.

3-3.2.3 Large Portable and Mobile Equipment.

Large portable and mobile equipment includes relatively large and easily transportable equipment for use in maintenance work, such as line trucks, aerial lift trucks, motor-generator sets, posthole diggers, load banks, and similar apparatus.

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3-3.3 Care and Storage of Tools and Equipment.

Tools and equipment will be kept in proper operating condition and used only for the purpose for which they were designed. If proper and safe tools are unavailable, report tool needs to a supervisor.

Inspect all tools at regular intervals and any tool that develops defects when in use will be taken from service, tagged, and not used again until restored to proper working condition.

3-3.4 Electrical Inspecting and Testing Equipment.

The number and types of testing/inspection devices needed depends on local needs.

When available, follow the manufacturer’s instructions for the care and maintenance of test equipment. Schedules for calibrating and testing instruments and meters are dependent upon the particular installation. When precision is not essential, the period between tests is not critical and may be assigned as convenient. For units provided with built-in diagnostic capabilities, check diagnostics when their associated power apparatus is checked.

3-3.4.1 Maintenance of Instruments, Meters, and Test Equipment.

Only personnel trained and qualified to maintain instruments, meters, and test equipment, or personnel under the immediate supervision of such qualified personnel, are allowed to perform accuracy tests, repairs, calibrations, and adjustments of instruments and meters. When selecting meters, match meter accuracy to the requirements of which the reading and records are being used. Procuring equipment with higher accuracy than requirements dictate must be economically justified.

3-3.4.2 Frequency of Inspections.

If calibration standards and equipment are not available, instruments and meters of nearly the same rating can be checked against each other. When wide discrepancies are noted or the instrument or meter is obviously incorrect, recalibrate and make any needed repairs.

3-3.4.3 Test Instrument Calibrations.

Calibrate instruments according to manufacturer's recommendations and agency requirements.

• Air Force: Perform calibration in accordance with AFI 21-113, Air Force Metrology and Calibration (AFMETCAL) Management, and T.O. 00-20-14, Air Force Metrology and Calibration Program.

• Army: Perform calibration in accordance with U.S. Army Test, Measurement, and Diagnostic Equipment Activity (USATA) requirements, AR 750-43, Army Test, Measurement, and Diagnostic Equipment, and TB

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43-180, Calibration and Repair Requirements for the Maintenance of Army Materiel.

• Navy and Marine Corps: Perform calibration in accordance with the NSWC Corona Measurement Science and Technology Laboratory Measurement and Calibration (METCAL) program.

3-3.5 Required Electrical Safety Program.

Implement and document an overall electrical safety program that directs activity appropriate for the electrical hazards, voltage, energy level, and circuit conditions. Refer to NFPA 70E and UFC 3-560-01.

Note: For the Air Force, see AFMAN 91-203, Air Force Occupational Safety, Fire, and Health Standards, and AFI 32-1064.

3-4 HAZARDOUS MATERIAL PROCEDURES.

Implement a hazard communication program in accordance with 29 CFR 1910.1200 or 29 CFR 1926.59 and DoDI 6050.05, DoD Hazard Communication (HAZCOM) Program, as amended by agency guidance. The major hazardous items to which electrical workers may be exposed are asbestos, polychlorinated biphenyls (PCBs), sulfur hexafluoride (SF6), and some of the chemicals used to control undesirable brush or pests or to preserve wood. For PCBs, comply with 40 CFR 761 and DoD 4715.05-G, Overseas Environmental Baseline Guidance Document (OEBGD).

Note: For the Air Force, see AFMAN 91-203.

3-5 SYSTEM DATA, EQUIPMENT DATA, AND DOCUMENTATION.

3-5.1 Operating Procedures.

Operating procedures must be documented and readily available. Mandatory testing, validation, approval, and review requirements must be kept in a permanent or appropriate record for the various types of generator configurations.

3-5.2 Manufacturer O&M Manuals.

Ensure manufacturer O&M manuals, parts manuals, and technical manuals/orders (if applicable) are always available and in a convenient location for access. Manufacturer manuals provide essential guidance on recommended frequency for inspections and maintenance for generators. Ensure at least one set of O&M manuals are supplied by the generator manufacturer at the time of acquisition.

3-5.3 Derating.

If something has changed on the generator, such as moving it from one location to another, and therefore the altitude, secondary fuel, or environmental conditions change, the generator must be de-rated \1\ by the authority having jurisdiction (AHJ) for each

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Service. This de-rating must be documented in the O&M manuals and properly labeled.

/1/

3-5.4 Installation Drawings.

Ensure at least two sets of installation drawings are provided by the installation contractor and maintained by the shop to give guidance to the operator and maintainer on equipment installation and other related activities. Circuit drawings must be updated with any modifications by the responsible party as required by NFPA 70E and 29 CFR 1910.

3-5.5 Control Diagrams.

Control diagrams are functional representations of the interconnection of the electrical equipment and contain one-lines, schematics, and wiring diagrams. They include the required content, format, and verification process for control diagrams for the operator and maintainer.

3-5.6 Maintenance Forms and Records.

Record maintenance information and test data for generators on Service-approved forms and checklists. Forms serve as an equipment inspection guide or checklist in order to maintain the generators in optimum working condition. Retain records for the Service-defined period of time and make available to the AHJ, as requested. Figures 3- 1, 3-2, and 3-3 are typical maintenance forms to use for generator inspection activities.

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Figure 3-1 Engine Generator Inspection Checklist

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Figure 3-2 Generator Set Survey

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Figure 3-3 Generator Data Record

3-5.7 Spare Parts Lists.

Identify high-rate-of-mortality parts by historical experience. Ensure spare parts for each system of the generator is available for use when there is a need for replacement. Refer to the spare parts lists provided by the equipment manufacturer.

3-5.8 Service Contract Documents.

Describe typical service contract types and contract documents necessary to manage the service contract program if a service contract is utilized.

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CHAPTER 4 OPERATIONS

4-1 OPERATING PROCEDURES.

4-1.1 Responsibilities.

There are levels of approval required for any changes to occur to generators. Know the changes, who/what it impacts, and obtain appropriate approvals before executing.

Know and ask advice from the appropriate SME.

\1\ Note: The Air Force will follow operations, maintenance, and testing requirements in Chapter 8. /1/

4-1.2 Fire Emergency.

Train operators on fire safety procedures. In fire emergencies, call the fire department and identify the specific fire emergency area.

4-2 AIR QUALITY PERMITTING.

Comply with UFC 1-200-01, DoD Building Code (General Building Requirements), and agency-specific environmental regulations, restrictions, and specific applicable environmental guidance. In addition to the listed permitting activities herein, contact state and local environmental and development offices to verify additional permitting requirements. Maintainer/operator must coordinate with the local environmental office to ensure continued compliance with operating permits, especially when changes occur.

Obtain and maintain all required air permitting in accordance with the rules of the Clean Air Act (CAA) regulatory agency (federal or state/local/tribal) with delegated authority over the location of subject operations.

\1\ [Note deleted] /1/

4-2.1 New Permits and Modifications to Existing Permits.

Initial permitting activities are accomplished during the design phase and prior to equipment installation. When changes are made to a unit (e.g., modified, remanufactured, relocated, and/or how it is used/operated), operators will immediately notify the appropriate environmental management office(s) that hold existing permit(s) of these changes and provide them with the necessary system information required to update those permits. This is necessary to ensure continued compliance with applicable federal, state, and local laws.

4-2.2 Changes.

Operational permitting is done during design and installation. Existing standby generators require additional permitting when operating hours exceed the permit.

However, when changes are made to the unit or how it is used, the operators will

Change 1, 5 November 2019 immediately notify their office(s) that holds the existing operating permit(s) of these changes and provide them with the necessary system information required to update the operating permits. This will ensure continued compliance with applicable federal, state, and local laws.

4-3 COMPLIANCE MONITORING AND INSPECTIONS.

4-3.1 OSHA Compliance and Monitoring.

The generator must comply with the requirements and regulations of OSHA for personnel safety, including safe work practices.

4-3.2 Air Quality Compliance.

Generator engines must meet and maintain compliance with the requirements of federal, state, and local regulations and facility-specific permits. Air quality regulations/permits may specify monitoring, recordkeeping, and reporting requirements, as well as O&M frequencies/practices.

\1\ Note: The Air Force will follow operations, maintenance, and testing requirements in Chapter 8. /1/

4-3.3 Clean Water Act (CWA) Compliance and Monitoring.

Generators must comply with CWA regulations to prevent the spill of oil, petroleum, or other contaminants to the water.

4-3.4 Resource Conservation and Recovery Act (RCRA) Compliance Monitoring.

Generators are required by RCRA to properly control and manage hazardous waste.

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CHAPTER 5 RELIABILITY MAINTENANCE-CENTERED PRACTICES

5-1 PURPOSE AND SCOPE.

This chapter provides guidance on typical preventive maintenance practices to keep generators in good performance.

5-2 PREVENTIVE MAINTENANCE ELEMENTS (TIME-BASED).

5-2.1 General.

Refer to manufacturers’ manuals for maintenance and repair requirements, frequencies, and consumables specifications. On standby generators in locations without SCADA or communications links, the self-test alarm is not monitored. For these applications, or applications where there are no self-diagnostics on the relays, the relays should be tested every one to six years. The timespan is based upon the relay installation, atmosphere, debris, temperature, and humidity.

5-2.2 Load Bank Optimization.

Load banks are used for load optimization, allowing the generator to run at a higher load than needed for facility power to prevent engine damage to certain types of prime movers. Use load banks to augment facility load to optimize generator performance when the prime mover is operating at less than the manufacturer's minimum rated load for continuous operation.

5-2.3 Prime Mover (Engines).

Prime mover preventive maintenance activities are mandatory. These activities are required to ensure the prime mover reaches their expected life expectancy as they are an expensive and essential part of the generator set. Maintenance activities include the following:

5-2.3.1 Structures and Enclosures.

Check structures and enclosures for corrosion. For corroded areas, clean, prepare and apply corrosion-control treatment on affected surfaces to avoid further deterioration.

5-2.3.2 Power Takeoff Assemblies and Couplings.

Check for coupling alignment in accordance with manufacturer’s maintenance schedule.

5-2.3.3 Bearing Lubrication.

Inspect and ensure the proper amount of grease on bearings and replace as required by the maintenance schedule.

5-2.3.4 Belt-Driven Equipment Checks.

Check misalignments on belt-driven equipment. Replace belts if damaged, as required.

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5-2.4 Cooling System.

Dust can foul cooling passages, increase operating temperature, and negatively affect the generator’s/engine’s performance. Clean radiators of dust and debris. Use soft brush or cloth. Avoid damaging the fins. Use low-pressure air or water in the reverse direction from normal flow to clean the radiator.

5-2.4.1 Coolant Levels.

• Check the coolant levels during shutdown periods. Premix the coolant in a clean tank when replacing the coolant to an engine.

• Never add antifreeze directly into the engine cooling system.

• Avoid adding coolant to an overheated engine.

• Avoid adding coolant at a rate of more than 10 gallons per minute when filling and emptying the engine cooling system.

• Check heat exchangers. Poor coolant maintenance can result in heat exchanger damage.

5-2.4.2 Coolant.

Engines with wet liners are subject to liner pitting and pumps/seals are subject to failure if the cooling system is not properly maintained. Use the coolant recommended by the engine manufacturer.

The following are unacceptable coolant maintenance practices:

• Use of non-treated (distilled or de-ionized) water.

• Use of water alone as coolant.

• High or low concentrations of supplemental coolant additive (SCA).

• Use of anti-freeze or SCA that are high in silicates or do not meet original equipment manufacturer (OEM) specifications.

• Topping off coolant system without proper SCA.

5-2.4.3 Coolant Maintenance.

Perform the following coolant maintenance:

• Test the coolant a minimum of twice a year for freeze protection, coolant/water percentages, nitrite or SCA level, pH, visual color and appearance, and reserve alkalinity. Use a spectro-chemical test with results reported in parts per million (ppm) and SCA.

• Drain and replace coolant at intervals in accordance with the engine and/or coolant manufacturer’s recommendation or when coolant analysis dictates replacement.

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• When topping off, add coolant until the level is at the radiator cap’s lower sealing surface.

• Store coolants out of direct sunlight and replace when shelf life has expired.

5-2.4.4 Air Intake/Ventilation Systems.

• Check for obstructions to cooling air lines or paths.

• Check for deterioration of cooling air ducts. This deterioration can lead to leakage of airflow, reducing its capacity.

• Check for dust and dirt of cooling air ducts.

• Check for loose or misaligned airline connections.

5-2.4.5 Coolant Pumps.

Inspect and maintain coolant pumps in accordance with maintenance schedule.

5-2.4.6 Engine Water Jacket Heaters.

Inspect engine water jacket heaters while in operation and observe for leaks at hoses, adapters, cylinder heads, pump seals, and block seals. Check for engine water jacket heater damage or deterioration. Inspect and maintain jacket water heaters in accordance with manufacturer’s recommendations.

5-2.4.7 Valve Exercising.

• Verify correct position/alignment on valves.

• Check for leaking seals.

• Verify correct operation of valves.

5-2.4.8 Safety Relief Valve Tests.

• Check for leaks on safety relief valves and replace if leaks continue.

• Check that the safety relief discharge piping is working properly.

• Check that the safety relief valve opens at the acceptable pressure value.

• If the safety relief valve opens at a pressure below the acceptable range, it may indicate that the relief valve is in a deteriorated condition and requires replacement.

• If the safety relief remains closed, do not operate the system until the safety relief valve is completely replaced.

5-2.5 Lubrication System.

Maintain lubrication systems to comply with applicable standards and specifications.

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5-2.5.1 Oil Level.

Ensure generator oil levels comply with the indications presented on the manufacturer’s instruction manuals to keep the generator in good performance. Test the oil quality to determine oil level, conditioning, or replacement. For accurate readings on the dipstick, wait at least 10 minutes after shutting off the engine to allow the oil to drain to the bottom.

5-2.5.2 Oil Change.

• Replace oil according to the recommendations given by the manufacturer.

• Drain oil while warm.

• Test a sample of the drained oil to examine for fuel dilution, acidity, and the presence of solids and contaminants.

• Ensure oil change frequency is in accordance with manufacturer and environmental air quality regulatory requirements.

5-2.5.3 Oil Filter Change.

\1\ Inspect oil filters periodically and replace when an accumulation of sludge or other contaminants is present. /1/ The frequency is shown in Table 6.1.

5-2.5.4 Crankcase Breather.

Check crankcase breather each time the generator is taken down for maintenance to make sure it is not clogged and unusable.

5-2.5.5 Oil Leaks.

Check for oil leaks and follow the instructions of the manufacturer if oil leaks are found.

5-2.5.6 Gauges and Safety Mechanisms.

During maintenance, observe gauges and safety mechanisms and check fuel and temperature gauges to ensure proper operation.

5-2.6 Fuel System (Including Long-Term Fuel Storage).

Inspect and clean fuel systems. Remove contaminants such as dirt and sediments from tanks storing fuel to ensure proper engine operation. Test and analyze a sample of fuel taken from the storage tank to check for the presence of contaminants. One of these samples must include one sample taken from the inside bottom of the tank.

Note: For the Air Force, fuel testing should be coordinated with the Logistics Readiness Squadron (LRS) POL Fuels Lab.

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5-2.6.1 Fuel Additives.

Check the proper levels of fuel additives in the system.

5-2.6.2 Fuel Filters.

Inspect and clean fuel filters as recommended by the manufacturer for identifying contaminants, sediments, or microorganisms.

5-2.6.3 Water/Condensate Removal.

Sample fuel from the fuel tank to detect the presence of water. Fuel and water tend to separate and water will sink to the bottom of the container. Remove water accumulation from storage fuel tanks with the provision and use of drain valves.

5-2.6.4 Fuel System Components.

Check fuel oil components such as fuel hoses, fuel pipes, fuel filters, injector pumps, etc. If damage to these components is encountered, replace following the instructions provided by the manufacturer. Make sure the lines are not rubbing against anything that could cause an eventual failure. Immediately repair any leaks or alter line routing to eliminate wear.

5-2.6.5 Gauges and Safety Mechanisms.

Check for accuracy on fuel level gauges and repair gauges as required.

5-2.6.6 Fuel Pumps.

Fuel pumps must be maintained to deliver sufficient fuel and sustain a satisfactory combustion to operate the generator. Fuel pumps must be cleaned by removing contaminants such as dirt, sand, and water.

5-2.6.7 Fuel Storage Tank Maintenance.

Clean and inspect fuel storage tanks every 10 years in accordance with API Standard 2015, Requirements for Safe Entry and Cleaning of Petroleum Tanks.

Drain tanks of water monthly to minimize corrosion of the inner tank surface. Bacterial growth in diesel fuel will be a problem in warm areas. \1\ Test fuel for contamination and polish as required if fuel is not used within three months. /1/

\1\ [Note deleted.] /1/

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5-2.7 Air Intake Systems.

5-2.7.1 Air Filters.

Prior to removing the intake air filters, remove accumulations of dirt from the air filter housing. Remove air filters and wipe to remove excess dust and dirt. Replace intake air filters per recommendations of the manufacturer.

5-2.7.2 Unlined Expansion Joints.

Inspect unlined expansion joint belts for cuts, worn sections, and cracks. Replace belts that are excessively worn and have cracks. Repair or replace belts with cuts per manufacturer’s instructions. Inspect backing bars, mating flanges and hardware for corrosion. Refer to manufacturer’s instructions for corrosion repair. Check fastener torque and re-torque to manufacturer’s recommendations, as appropriate.

5-2.7.3 Unlined Duct.

Clean duct and check for corrosion and signs of water and air leakage. For paint, corrosion repair, and gasket replacement, refer to manufacturer’s instructions.

5-2.7.4 Silencer Duct.

Clean duct and check for corrosion and signs of water and air leakage. For paint, corrosion repair, and gasket replacement, refer to manufacturer instructions.

Check acoustic insulation lining for water damage, corrosion, and cracking. For repair, refer to manufacturer’s instructions.

5-2.7.5 Acoustically Lined Duct.

Clean duct and check for corrosion and signs of water and air leakage. For paint, corrosion repair, and gasket replacement, refer to manufacturer’s instructions. Check acoustic insulation lining for water damage, corrosion, and cracking. Check access hatches and maintenance ports for air-tight seals. For repair, refer to manufacturer’s instructions.

5-2.7.6 Trash Screens.

Inspect screen and framework for damage, including broken wires and missing screens.

Replace damaged screens and tighten loose wires. Check screen frame and screen holder for corrosion. For repair, refer to manufacturer’s instructions.

Check screen for deflection using hand pressure. If deflection is greater than 4 inches (100 mm), replace screen.

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5-2.7.7 Expansion Joints.

Inspect expansion joint belts for cuts, worn sections, and cracks. Replace belts that are excessively worn and have cracks. Check manufacturer’s repair instructions for cracked belts as this typically indicates a system malfunction or alignment problem. Repair or replace belts with cuts per manufacturer’s instructions.

Inspect backing bars, mating flanges, and hardware for corrosion. Refer to manufacturer’s instructions for corrosion repair. Check fastener torque and re-torque to manufacturer’s recommendations, as appropriate.

5-2.7.8 Inlet Plenum and Cone.

Inspect and repair inlet plenum per manufacturer’s instructions.

5-2.8 Exhaust System.

Exhaust systems need to be maintained to keep the generator in good performance.

Check for leaks at all connections, welds, gaskets, and joints. Make sure the exhaust systems are not heating the surrounding areas more than normal. Check for excessive smoke upon starting; this indicates air quality problems.

5-2.8.1 Air Induction Piping.

Exhaust system piping of generators must have suitable devices to prevent the entry of water from rain.

5-2.8.2 Turbochargers and Blowers.

Clean and maintain turbochargers in accordance with manufacturer’s recommendations.

5-2.8.3 Exhaust Manifolds.

Check exhaust manifolds for rust and corrosion.

5-2.8.4 Emissions System and Controls.

Maintain emissions system controls (e.g., catalytic oxidizers, exhaust particulate filters) and monitoring devices (e.g., continuous emissions monitoring systems) in accordance with manufacturer’s and environmental regulations/requirements. Manufacturer's instructions should be consulted for procedures specific to each model. Contact the environmental compliance office when problems are identified.

5-2.9 Generator Components.

Accomplish generator inspection, maintenance, and service in accordance with manufacturer’s requirements, environmental regulations/requirements, and/or recommendations or applicable technical orders. Listen and look for changes in

Change 1, 5 November 2019 performance or sound. Misfires and changes in oil consumption indicate service will be…