A02 SOW Attachment 1_UFC 3-540-01.pdf

UFC 3-540-01

1 August 2014

Change 3, 26 January 2023

UNIFIED FACILITIES CRITERIA (UFC)

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED

ENGINE-DRIVEN GENERATOR

SYSTEMS FOR PRIME

\1\ AND STANDBY POWER

APPLICATIONS /1/

ENGINE-DRIVEN GENERATOR SYSTEMS FOR PRIME

\1\ AND STANDBY POWER APPLICATIONS /1/

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.

Indicate the preparing activity beside the Service responsible for preparing the document.

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 10/24/17 Chapter 3 added to incorporate prime power applications.

2 11/5/19 Paragraph 2-5.3.2, added a provision for an external bypass design for AF projects that require ATS replacement capability without mission downtime;

paragraph 2-5.3.1, added a requirement for submitting a design approval request to AFCEC/COSM at the 65 percent design mile stone for AF projects, a greater than 50 percent of rated load sizing requirement for all generators and a mission-essential facility load greater than 70 percent of the total facility load for a whole building generator; paragraph 3-3, clarified generator type for CONUS locations.

3 01/26/23 Format changes throughout and minor corrections, clarifications and updated references. AF Appendix G.

Paragraph 1-7 sizing the generator for UPS Paragraph 1-8 facility-related control systems Paragraph 1-9 Reference to Appendix I Paragraph 1-10 Reference to Appendix A Paragraph 2-3 Fuel stored on site for 24-hour or longer Paragraph 2-4.2 References added Paragraph 2-4.5 Parallel operation of Generators Paragraph 2-4.7 Reference to 2-4.7.1 through 2-4.7.4.

Table 2-2 note site-specific analysis Appendix A All references have been updated

This UFC supersedes UFC 3-540-04N, Design: Diesel Electric Generating Plants.

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, its territories, and possessions 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 Military Department’s responsibility for providing technical criteria for military construction. Headquarters, U.S. Army Corps of Engineers (HQUSACE), Naval Facilities Engineering Systems Command (NAVFAC), and Air Force Civil Engineer Center (AFCEC) are responsible for administration of the UFC system. Technical content of UFC is the responsibility of the cognizant DoD working group. Defense Agencies should contact the respective DoD Working Group for document interpretation and improvements. Recommended changes with supporting rationale may be sent to the respective DoD working group by submitting a Criteria Change Request (CCR) via the Internet site listed below.

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

• Whole Building Design Guide website http://www.wbdg.org/ffc/dod.

Refer to UFC 1-200-01, DoD Building Code, for implementation of new issuances on projects.

AUTHORIZED BY:

GEORGE O. LEA, P.E. JOSEPH E. GOTT, P.E.

Chief, Military Engineering Branch Chief Engineer U.S. Army Corps of Engineers Naval Facilities Engineering Command

EDWIN H. OSHIBA, SES, DAF MICHAEL McANDREW Deputy Director of Civil Engineers DCS/Logistics, Engineering & Force Protection

Director, Facilities Investment and Management Office of the Deputy Under Secretary of Defense (Installations and Environment) http://www.wbdg.org/pdfs/ufc_implementation.pdf http://www.wbdg.org/ffc/dod

CHANGE SUMMARY SHEET

Document: 3-540-01, Engine-Driven Generator Systems for Prime and Standby Power Applications

Superseding:

• UFC 3-540-04N, Design: Diesel Electric Generating Plants

Description: This UFC provides criteria for the design and installation of engine generator systems for use as standby and prime power systems.

Reasons for Document:

• Provide technical requirements for design.

• Consolidate design criteria currently located in multiple documents.

• Update the existing material to reflect new and revised industry standards.

Impact: There are minor cost impacts associated with this UFC. However, the following benefits should be realized:

• Standardized criteria has been prepared to assist engineers in the development of the plans, specifications, calculations, and Design / Build Request for Proposals (RFPs).

• Overlap of material with other UFCs has also been eliminated with the issue of this UFC.

• Adopting NFPA 110 as a basis for engine generator design results in additional requirements; however, these requirements are intended to improve the reliability of emergency generator installations.

Unification Issues

None.

i

TABLE OF CONTENTS

CHAPTER 1 INTRODUCTION

1-1 REISSUES AND CANCELS

1-2 PURPOSE AND SCOPE

1-3 APPLICABILITY

1-4 GENERAL BUILDING REQUIREMENTS

1-5 EMI/EMP PROTECTION SYSTEMS

1-6 PROJECT REQUIREMENTS

1-7 MISSION FACILITY SUPPORT REQUIREMENTS

1-8 CYBERSECURITY

1-9 GLOSSARY

1-10 REFERENCES

CHAPTER 2 STANDBY POWER GENERATORS DESIGN CRITERIA

2-1 APPLICATIONS

2-1.1 Design Guidance

2-1.2 NFPA 110 Compliance

2-1.3 NFPA 70 and NFPA 110 Compliance

2-2 AUTHORIZED FUEL TYPES

2-3 ONSITE FUEL STORAGE CAPACITY

2-4 ANALYSIS REQUIREMENTS

2-4.1 Design Analysis

2-4.2 Environmental

2-4.3 Seismic Classification

2-4.4 Fuel Storage Design and Capacity

2-4.5 Utility Requirements for Paralleling

2-4.6 Power Rating Category

2-4.7 Performance Class Transient Limits

2-5 DESIGN CRITERIA

2-5.1 Circuit Wiring for Legally Required and Optional Standby Systems

2-5.2 Automatic Operation

2-5.3 Single Operation Generator Sets

2-5.4 Requirements for Paralleling ii

CHAPTER 3 PRIME POWER GENERATORS /1/

3-1 PRIME POWER GENERATORS

3-1.1 Purpose

3-1.2 Definitions

3-1.3 Renewable Power

3-2 PRIME POWER GENERATOR CLASSIFICATION

3-2.1 Rating Classification

3-2.2 Application Classes

3-2.3 Fuels Classification

3-3 GENERATOR TYPE

3-4 PRIME POWER GENERATOR DESIGN

3-4.1 Reliability, Availability and Maintainability (RAM)

3-4.2 Capacity Factors

3-4.3 General Requirements

3-4.4 Generator Sets

3-4.5 Liquid Fuel Systems

3-4.6 Air Intake System

3-4.7 Lubrication System

3-4.8 Cooling System

3-4.9 Exhaust/Air Emissions Control System

3-4.10 Starting System

3-4.11 Control System

3-4.12 Direct Current (DC) Power System

3-4.13 Paralleling Switchgear

3-4.14 Distribution Switchgear

3-4.15 Split Bus

3-4.16 Black Start Generator

3-4.17 Communications and Alarms

3-5 ENVIRONMENTAL

3-6 COMMISSIONING

3-7 GENERATOR PLANT SECURITY

APPENDIX A REFERENCES

\1\ iii

APPENDIX B EXAMPLES OF SYSTEM CONFIGURATIONS

B-1 INTRODUCTION

B-2 SINGLE GENERATOR SYSTEM CONFIGURATIONS

B-2.1 Single Engine Generator Supply to Essential Loads

B-2.2 Permanently Installed Engine Generator with Portable Connection

B-2.3 Single Engine Generator Configuration for Whole Building Supply

B-2.4 Single Engine Generator Configuration with Multiple ATS

B-2.5 Single Engine Generator with Redundant Utility Supply

B-2.6 Dual Engine Generator with Redundant Utility Supply

B-3 PARALLEL GENERATOR SYSTEM CONFIGURATIONS

B-3.1 Utility Supply

B-3.2 Parallel Generator Control Systems

B-4 AUTOMATIC TRANSFER SWITCH CONFIGURATIONS

APPENDIX C DESIGN CHECKLIST

C-1 INTRODUCTION

C-2 GENERAL

C-3 ELECTRICAL

C-4 MECHANICAL

C-5 CIVIL/STRUCTURAL

C-6 ARCHITECTURAL

APPENDIX D GENERATOR SIZING

D-1 INTRODUCTION

D-2 LOAD EVALUATION

D-2.1 Uninterruptible, Essential, and Nonessential Loads

D-2.2 Conditions of Loading

D-2.3 Nonlinear Loads

D-2.4 Step Loading

D-2.5 Motor Starting Requirements

D-3 GENERATOR RATING

D-3.1 Industry Ratings

D-3.2 Generator Capacity Rating

D-3.3 UPS Systems iv

D-3.4 Power Quality

APPENDIX E CONNECTION METHODS FOR PORTABLE GENERATORS

E-1 INTRODUCTION

E-2 CONNECTION METHODS

E-2.1 MIL-DTL-22992F, Class L, QWLD-Rated Connectors

E-2.2 Single-Pole (Cam-Lok style) Connectors

APPENDIX F FACILITY DESIGN TYPES

APPENDIX G AIR FORCE GENERATOR AUTHORIZATIONS

APPENDIX H POWER PLANT CONSIDERATIONS

H-1 PLANT LOCATION FACTORS

H-2 ACOUSTICAL CONSIDERATIONS

H-3 PRIME POWER PLANTS

H-3.1 Boiler Requirements

H-3.2 Load Requirements

APPENDIX I GLOSSARY

I-1 ACRONYMS

I-2 DEFINITION OF TERMS

FIGURES

Figure B-1 Typical Single Engine Generator Configuration Figure B-2 Configuration for Permanently Installed and Portable Generators ... 34 Figure B-3 Whole Building Generator Supply Configuration Figure B-4 Configuration to Supply Multiple ATS Figure B-5 Selection Between Redundant Utility Supply and Generator Figure B-6 Selection Between Redundant Utility Supply and Dual Generators.. 37 Figure B-7 Parallel Generators with Single Utility Supply Figure B-8 Parallel Generators with Alternate Utility Supply Figure B-9 Parallel Generators with Alternate Utility Supply for UPS Systems .. 38 Figure B-10 Parallel Generator Control System Architecture Figure B-11 Typical Four-Pole ATS Arrangement Figure H-1 Typical Steam and Electric Load Curves Figure H-2 Typical Load Duration Curves v

Figure H-3 Typical Load Duration Curves Figure H-4 Typical Load Duration Curves

TABLES

Table 2-1 Generator Noise Level Regulation

Table 2-2 Performance Class Transient Limits

Table F-1 Naval Facilities Authorized for Standby Power

Table F-2 UFCs Addressing Standby Power Requirements

Table H-1 Power Plant Location Factors

Table H-2 Electrical Load Types

Table H-3 Steam Load Types vi

This Page Intentionally Left Blank

CHAPTER 1 INTRODUCTION

1-1 REISSUES AND CANCELS.

This UFC supersedes UFC 3-540-04N, dated 16 Jan 2004.

1-2 PURPOSE AND SCOPE.

This UFC provides criteria for the design of engine-driven generator systems for standby and prime power applications. Information provided here must be used by engineers in the development of the plans, specifications, calculations, and Design/Build Request for Proposals (RFP) and serves as the minimum design requirements. Project conditions may dictate the need for a design that exceeds these minimum requirements.

1-3 APPLICABILITY.

Compliance with this UFC is mandatory for the design and installation of engine-driven (fossil fueled) generator systems for standby and prime power applications at all DoD installations. Connection of generator systems to a facility is covered by this UFC. It applies to the traditional services customary for Design-Bid-Build construction contracts and for Design-Build construction contracts. Refer to Appendix H regarding generator connection design criteria. This UFC does not apply to tactical engine generators.

1-4 GENERAL BUILDING REQUIREMENTS.

Comply with UFC 1-200-01. UFC 1-200-01 provides applicability of model building codes and government unique criteria for typical design disciplines and building systems, as well as for accessibility, antiterrorism, security, high performance and sustainability requirements, and safety. Use this UFC in addition to UFC 1-200-01 and the UFCs and referenced government criteria. Also, review siting for possible damage from flooding, wind/wind-blown debris, and seismic events.

Modernization of existing systems for the sole purpose of meeting design criteria of this UFC is not required. Upgrades or modifications of existing facilities should consider the design criteria in this UFC, but an entire facility may not require modernization solely because of a minor modification to a part of the facility.

1-5 EMI/EMP PROTECTION SYSTEMS.

Prime power generators and switchgear that serve mission critical, mission essential and Command, Control, Communications, Computers, Intelligence, Surveillance, and Reconnaissance (C4ISR) facilities must be evaluated for protection from electromagnetic interference (EMI) and electromagnetic pulse (EMP) in accordance with TM 5-690, QSTAG 244, Edition 4, MIL-STD-461G and MIL-STD-2169. Operation and maintenance of generator facilities must not introduce unacceptable levels of degradation into EMI/EMP survivability of a system scored to the above criteria. To ensure continued EMI/EMP survivability, a Life Cycle Nuclear Survivability program must be established in accordance with AR 70-75, DoDD 5000.1, and DoDI 3150.09.

1-6 PROJECT REQUIREMENTS.

Provide analyses that document the multi-discipline requirements and impacts of the following:

• Facility features and siting for passive survivability

• System sizing and rating

• System configuration

• System operation and control

• Physical and cybersecurity

• Emissions and permitting

• Noise mitigation

• Seismic classification

• Fuel

• Utility requirements for paralleling

Appendix C provides a checklist of items to consider as part of system planning and design.

1-7 MISSION FACILITY SUPPORT REQUIREMENTS.

Generator design must be based upon the mission’s requirements for transient and steady state loads, startup, and charging of uninterruptable power supply (UPS). \3\ For the Air Force, sizing the generator for UPS load will be based on maintaining a minimum float charge rather than a deep discharge or the full capacity. /3/

1-8 \3\ CYBERSECURITY.

All facility-related control systems (including systems separate from a utility monitoring and control system) must be planned, designed, acquired, executed, and maintained in accordance with UFC 4-010-06, and as required by individual Service Implementation Policy. /3/

1-9 GLOSSARY.

\3\ Appendix I contains acronyms, abbreviations, and terms. /3/

1-10 \3\ REFERENCES.

Appendix A contains a list of references used in this UFC. The publication date of the code or standard is not included in this document. Unless otherwise specified, the most recent edition of the referenced publication applies. References applicable to a specific topic are also listed and described in the appropriate sections of this UFC. /3/

CHAPTER 2 STANDBY POWER GENERATORS DESIGN CRITERIA

2-1 APPLICATIONS.

Refer to Appendix F for a list of facility types and typical applications within DoD. For the Army and Navy, the major command or program element determines if a generator system for standby power is required and its classification.

2-1.1 Design Guidance.

Provide designs for non-medical backup power applications in accordance with IEEE Std 446. Refer to UFC 4-510-01 for generator system requirements associated with Medical Military Facilities.

2-1.2 NFPA 110 Compliance.

For permanently installed generator systems, comply with the NFPA 110 requirements for emergency power supply systems (EPSS) with the following clarifications.

2-1.2.1 Classification.

Designate the EPSS as Class X, where “X” is the required operating time in hours.

Designate the EPSS as Type 10 for medical systems covered by UFC 4-510-01 and Type 60 for all other applications.

2-1.2.2 Remote Manual Stop.

Provide a remote manual stop station for the EPSS in one of the following locations:

• In a separate room of the same building that houses the generator system.

• In a building separate from the building served by the generator system.

• On the outside of the building that houses the generator system.

• On the outside of an enclosure that contains the generator system.

The requirement for a remote manual stop station may be deleted, such as when it has been determined that a location that restricts access to unqualified operators is not available. The designer of record must receive documentation from the activity that the fire chief or designated equivalent concurs with this determination.

2-1.2.3 Remote Control and Alarm.

Provide a remote control and alarm panel for the EPSS in a separate room of the same building that houses the generator system or in a building separate from the one that the generator system is serving. The requirement for a remote control and alarm panel may be deleted when it has been determined that a location is not available that restricts access to unqualified operators or if not desired by the activity. The designer of record must receive documentation from the activity for this determination.

Provide a remote common audible alarm to a 24-hour staffed location when the EPSS location is not staffed 24 hours per day. The requirement for a remote common audible alarm may be deleted when it has been determined that a suitable location is not available or if not desired by the activity. The designer of record must receive documentation from the activity for this determination.

2-1.3 NFPA 70 and NFPA 110 Compliance.

Comply with NFPA 70 and NFPA 110 as follows.

• Generator systems required to comply with NFPA 70 Article 700 must also comply with NFPA 110 Level 1 criteria.

• Generator systems required to comply with NFPA 70 Article 708 must also comply with NFPA 110 Level 2 criteria.

• Systems using permanently installed generators not designated as emergency systems or critical operations power system (COPS) must comply with NFPA 70 Article 701 \3\ (systems required by law) and NFPA 110 Level 2 (used when failure is less critical to human life and safety) /3/ criteria.

• Systems using portable generators must comply with NFPA 70 Article 702 (optional standby systems).

2-2 AUTHORIZED FUEL TYPES.

Select fuel oil (diesel or jet fuel) as the primary fuel source for applications where onsite storage is required. Natural gas may be used as the primary fuel source only for applications where onsite storage of fuel is not required.

• Diesel/natural gas dual fuel units are allowed.

• For the Air Force: Natural gas systems are not allowed.

• Bio-diesel and liquefied petroleum gas (LPG) fuel types are not allowed.

2-3 ONSITE FUEL STORAGE CAPACITY.

Provide a minimum of seven days of fuel storage either in a dedicated on-site main fuel tank or from a confirmed delivery source. If the fuel storage is from a confirmed delivery source, ensure the delivery source can provide reliable deliveries during long-duration power outages. Base this storage capacity on the fuel consumption required to support the mission load. When the seven-day requirement is accomplished by a delivery source, provide each generator set with a minimum local 24-hour capacity tank based on the full-load fuel consumption rate of the engine.

\3\ Fuel stored on site for 24-hour or longer capacity for diesel generators/engines should not be bio-diesel because a 1-hour run time for a test never uses all the fuel in the storage tank. /3/ The above requirements may be modified when it is validated (documented in writing and dated) that mission operations require a different operational duration (longer or shorter). For Army secure critical missions, the Army will reduce the risk by being capable of providing necessary energy and water for fourteen days. See Army Directive 2020-03.

2-4 ANALYSIS REQUIREMENTS.

2-4.1 Design Analysis.

Provide a design analysis which covers the general facility design requirements in accordance with UFC 1-200-01 and its referenced documents. Document in the design analysis how compliance with NFPA 37, NFPA 70, and NFPA 110 is achieved. In addition to the UFC 3-501-01 requirements for preliminary basis of design and follow-on submittals (short circuit analysis, protective device time-current coordination study, arc flash analysis, voltage drop analysis, motor starting/flicker analysis), provide the following general system-specific analysis information.

2-4.1.1 Facility – Features and Siting.

• Facility design features for maintenance, including lay-down space for major overhauls and access for repair by replacement, without removal of major components or building system equipment/features.

• Geographic and operating environment, including coastal locations/corrosive conditions, humidity, altitude, seismic zones, and ambient temperature extremes.

• Exhaust system design, including stack height, sampling port orientation, and location.

• Vibration (transmitted to structures).

• Ventilation.

2-4.1.2 Engine Generator Sizing.

• Generator sizing calculations. The Designer of Record must use commercially available generator sizing software provided by a generator manufacturer to determine the required rating. \3\ deleted /3/ Refer to Appendix D for additional information regarding generator sizing. Verify the commercially available sizing software addresses the generator sizing topics listed in Appendix D.

• Accommodate the effects or rating adjustments for nonlinear loads, transformer in-rush, motor starting, and UPS systems.

2-4.1.3 System Configuration.

• Classification of loads.

• Redundancy (reliability, availability, maintainability factors).

• Maintenance and testing.

2-4.1.4 System Operation and Control.

• Load shed plan.

• Communications plan.

• Electrical protection scheme.

• Modes of operation delineation and impacts analysis.

• Refueling capability to support generator operation during extended power outages at mission essential/critical facilities.

2-4.1.5 Focused Electrical System Analysis.

Perform harmonic analysis where switching power supplies contribute 25 percent or greater to the system loads, and/or electromagnetic filters are installed to mitigate the effects of high-energy EMP.

2-4.2 Environmental.

Evaluate environmental requirements (e.g., noise, air pollution, wildlife, storm water) developed during the initial project planning stages.

• Verify site is suitable for construction (e.g., are wetlands present, is the ground contaminated) without major environmental impacts.

• Field verify, through environmental and biological surveys, that impacts will be minimal and can be mitigated.

• All design and construction will provide electrical systems which must comply with Federal, state, and local environmental regulations. For overseas locations, follow the guidance specified in Host Nation-specific Final Governing Standards, or if none exist, the current DoD Overseas Environmental Baseline Guidance Document (OEBGD) and applicable Host Nation laws.

• \3\ For Air Force: Consult AFI 32-7001 and AFI 32-7091 for additional guidance. /3/

2-4.2.1 Environmental Studies and Permitting.

Plan for a permitting process that may take years, with duration depending upon the selected system and the locality (country, State, county and municipality) that is jurisdictionally responsible. Federal, state, and local requirements will vary with the local ambient air quality, size of the project and potential emissions. All new or modified stationary power generators (both engine- and turbine-based) are required to comply with applicable Environmental Protection Agency (EPA) New Source Performance Standards (NSPS). The specific characteristics of an emissions source determine the applicability of a particular NSPS. See 40 CFR Part 60 Subpart KKKK or 40 CFR Part 60 Subpart JJJJ. Studies and permitting requirements exist at all levels (Federal, state, and local) and may include:

• 316(a) – thermal discharge

• 316(b) – cooling water intake

• air permitting

• aquatic ecology

• avian and bat studies / protection

• cultural resources

• dredge and fill

• endangered species

• encroachment

• erosion and sediment control

• floodplain management

• lake management

• land and right-of-way grants

• Native American consultation

• natural resources

• National Environmental Policy Act

Environmental Assessments (EAs)

Environmental Impact Studies (EISs)

• noise/odor

• river crossing permits

• transmission line routing

• stormwater/water quality

• wetlands permitting, mitigation and design

2-4.2.2 Noise Mitigation.

Comply with Federal, state, and local codes, and for overseas locations, Host nation laws, for maximum noise levels permitted at property line or Table 2.1, whichever is less. Use A-weighting filter criteria (dBA) as adopted by the Occupational Safety and Health Administration (OSHA) as the official regulated sound level unit.

Table 2-1 Generator Noise Level Regulation

Noise Zone

Peak Daytime dBA

Peak Nighttime dBA

Continuous Daytime dBA Continuous

Nighttime dBA Residential 62 52 57 47

Light Industrial 67 57 62 52 Heavy Industrial 72 62 67 57

Hospital 45 40 35 30

2-4.3 Seismic Classification.

Comply with UFC 1-200-01, including all referenced criteria and standards.

2-4.4 Fuel Storage Design and Capacity.

Apply UFC 3-460-01 to petroleum fuel facilities designs.

2-4.5 Utility Requirements for Paralleling.

Where the generation equipment is connected to the utility’s system bus and is required to operate in parallel with the utility’s electric system, comply with specific utility provider guidelines on parallel generation connection accommodations.

\3\ For the Air Force: Equipment Authorization Inventory Data (EAID) or Real Property Installed Equipment (RPIE) generators, or any generator owned by another agency, will not operate in parallel with any utility provider unless authorized by AFCEC/CO in accordance with AFMAN 32-1062. /3/

2-4.6 Power Rating Category.

Determine the required power-rating category in accordance with Electrical Generating Systems Association (EGSA) 101P for DoD facilities and International Standards Organization (ISO 8528-1) for Host Nation facilities, as appropriate.

Each manufacturer has developed its own unique rating definitions that may or may not comply with these standards.

2-4.6.1 Continuous Power.

Continuous power is the maximum power, which the generating set is capable of delivering continuously and safely, while supplying a constant electrical load when operated for an unlimited number of hours per year under the agreed operating conditions with the maintenance intervals and procedures being carried out as prescribed by the manufacturer.

Note: The continuous power category is unlikely to be required for the standby power applications associated with this UFC.

2-4.6.2 Prime Power.

Prime power is the maximum power a generating set is capable of delivering continuously while supplying a variable electrical load when operated for an unlimited number of hours per year under the agreed operating conditions and crucially with maintenance intervals being carried out as per the manufacturers guidelines. Typically an overload of 10% is allowed for 1 hour in 12. Prime power is also defined by IEEE 446 as “The source of supply of electrical energy that is normally available and used continuously day and night, usually supplied by an electric utility company, but sometimes supplied by base-loaded user-owned generators.” EGSA Standard 101P defines a prime power generator as “a utility-type power plant that will deliver continuous power under normal varying load factors.” Wind turbines or solar generation cannot, by definition, be prime power.

Note: The prime power rating category is required for generator systems designated as COPS in accordance with NFPA 70 Article 708.

2-4.6.3 Limited Time Running Power.

Limited time running power is the maximum power available, under the agreed operating conditions, for which the generating set is capable of delivering for up to 500 hours of operation per year with the maintenance intervals and procedures being carried out as prescribed by the manufacturer.

2-4.6.4 Emergency Standby Power.

Emergency standby power is the maximum power available during a variable electrical power sequence, under the stated operating conditions, which a generating set is capable of delivering in the event of a utility power outage or under test conditions for up to 200 hours of operation per year with the maintenance intervals and procedures being carried out as prescribed by the manufacturer.

2-4.7 Performance Class Transient Limits.

Determine the required electrical performance class in accordance with ISO 8528-1, \3\ Part 1 and as described in paragraphs 2-4.7.1 through 2-4.7.4. /3/ Transient response limits are provided in Table 2-2 in accordance with ISO 8528-5:2013, Part 5.

2-4.7.1 Class G1.

Connected loads require only basic parameters of voltage such as general purpose lighting and other simple electrical loads.

2-4.7.2 Class G2.

In Class G2 applications, required voltage characteristics are very similar to those for the commercial public utility electrical power system with which it operates. When load changes occur, there may be temporary but acceptable deviations of voltage and frequency. Examples of this category include lighting systems, pumps, fans, and hoists.

2-4.7.3 Class G3.

In Class G3 applications, connected equipment makes severe demands on the stability and level of the frequency, voltage, and waveform characteristics of the electrical power supplied by the generating set. Examples of this category include telecommunications and thyristor-controlled loads. Note that both rectifier and thyristor-controlled loads may need special consideration with respect to their effect on generator-voltage waveform.

Class G3 loads require an evaluation by the designer of record to document the system voltage and frequency limitations, including transient response.

2-4.7.4 Class G4.

In Class G4 applications, demands made on the stability and level of the frequency, voltage and waveform characteristics of the electrical power supplied by the generating set are exceptionally severe. Examples include data-processing equipment or computer systems. Class G4 loads require an evaluation by the designer of record to document the system voltage and frequency limitations, including transient response.

Table 2-2 Performance Class Transient Limits

Parameter Performance Class

G1 G2 G3 *G4

Frequency Deviation (%) for 100 % Load Increase <-15 <-10 <-7 TBD Frequency Deviation (%) for 100 % Load Decrease <+18 <+12 <+10 TBD Frequency Recovery Time (sec) for 100 % Load Change <10 <5 <3 TBD

Voltage Deviation (%) for 100 % Load Increase <-25 <-20 <-15 TBD Voltage Deviation (%) for 100 % Load Decrease <+35 <+25 <+20 TBD Voltage Recovery Time (sec) for 100 % Load Change <10 <6 <4 TBD

Frequency Droop (%) <-8 <-5 <-3 TBD Steady-State Frequency Band (%) <2.5 <1.5 <0.5 TBD Steady-State Voltage Regulation (%) <5 <2.5 <1 TBD

\3\ *A site-specific analysis is required to determine voltage and frequency limits. See manufacturer’s recommendations. /3/

2-5 DESIGN CRITERIA.

Appendix B provides examples of various configurations.

2-5.1 Circuit Wiring for Legally Required and Optional Standby Systems.

For Legally Required (NFPA 70, Article 701) or Optional Standby Systems (NFPA 70, Article 702), keep the circuit wiring from the generator to the loads served entirely independent of all other wiring unless otherwise permitted in NFPA 70, Article 700.

2-5.2 Automatic Operation.

Use fixed (permanently installed) generators with automatic startup for facilities designated as emergency and COPS systems. Generators associated with facilities designated as standby systems may be either fixed or portable with automatic or manual operation. Equip generators configured for automatic operation with intelligent electronic controls to protect the generator sets and manage startup, operation, and shutdown.

2-5.3 Single Operation Generator Sets.

2-5.3.1 Configuration.

Configure single operation generator sets as separately derived systems.

Provide four-pole devices for a three-phase system to switch the supply to essential loads and to switch between multiple single operation generator sets.

\2\ For Air Force: Submit a design approval request to AFCEC/COSM at the 65 percent design milestone. Generators must be sized to achieve greater than 50 percent rated load using only facility loads. Whole building generators are approved only when the mission-essential load is greater than 70 percent of the total facility load. /2/

2-5.3.2 Automatic Transfer Switches.

Use automatic transfer switches (ATS) listed in accordance with UL 1008. Provide automatic transfer switches with integral maintenance bypass isolation for systems designated as emergency, COPS, or where validated (documented in writing and dated) by the user as being required.

2-5.3.2.1 Double-Throw Safety Switches.

A design using double-throw safety switches to accomplish maintenance bypass is not allowed under any circumstances.

\2\ For Air Force: Use of a double-throw design within line of site from the ATS to facilitate ATS replacement without mission impact is acceptable. /2/

2-5.3.2.2 Transition Transfer.

Provide an open transition transfer scheme unless facility operating procedures require paralleling with the utility. Closed transition transfer is rarely required for standby power applications. Closed transition will require coordination with the local utility and will require designing for the higher available short circuit current of the combined parallel power sources.

2-5.3.3 Metal Clad/Metal Enclosed Switchgear.

Provide free-standing metal clad or metal enclosed switchgear as required for generator voltage rating, load capacity, fault capacity (withstand/interrupting ratings), paralleling requirements, and operating scenarios.

CAUTION

To protect personnel, non-enclosed ATS must be contained in a dedicated isolated compartment when installed in switchgear or switchboards.

2-5.3.4 Automatic Transfer Switch Maintenance Access.

Provide switchboard or switchgear construction with draw out power or insulated case circuit breakers for the main power distribution equipment. Provide working clearance around each circuit breaker when in its withdrawn position in accordance with NFPA 70, Table 110.26 (A)(1).

2-5.3.5 Utility Service.

To allow for maintenance without incurring power outages when redundant utility services are provided, provide draw out circuit breakers to disconnect the utility service.

2-5.4 Requirements for Paralleling.

2-5.4.1 Parallel Operation with Public Utility.

Where the generation equipment is connected to the utility’s system bus and is required to operate in parallel with the utility’s electric system, comply with IEEE 1547 – Series, and specific utility provider guidelines on parallel generation connection agreements.

For the Air Force: EAID or RPIE generators or any generator owned by another agency will not operate in parallel with any utility provider unless authorized by AFCEC/CO in accordance with AFMAN 32-1062.

2-5.4.2 Parallel Operation with Other Distributed Energy Resources.

Where the generation equipment is connected to a local electrical distribution system bus and is required to operate in parallel with the other distributed energy generation resources (DERs) in islanded mode, comply with IEEE 1547–4.

For the Air Force: EAID or RPIE generators or any generator owned by another agency will not operate in parallel.

2-5.4.3 Main Power Distribution Equipment.

Provide switchboard or switchgear construction with draw out power or insulated case circuit breakers for the main power distribution equipment. Provide a minimum of 30 inches’ working clearance around each circuit breaker when in its withdrawn position.

2-5.4.4 Control Power.

Provide redundant AC control power for systems designated as emergency, COPS, or where validated by the user as being required. Provide a redundant AC control power system that is selectable via an ATS.

Provide redundant DC control power for systems designated as emergency, COPS, or where validated by the user as being required. Provide a redundant DC control power system through a best battery selector.

2-5.4.5 Control System.

2-5.4.5.1 Provide generator and electrical system protection in accordance with IEEE Std 446 and IEEE Std 242.

2-5.4.5.2 Provide redundant IEDs to run the logic for all programmed and operator-initiated automatic system sequences. Redundant master programmable logic controllers (PLCs) must control and monitor the main breakers, the tiebreakers, the feeder breakers (if load shedding is required), and the common system auxiliaries via paralleled input/output points.

2-5.4.5.3 Provide separate, dedicated generator controllers to run the logic for operation of each generator set. Automatic startup of the generator sets must be achieved via commands from the master controllers. Design the system so that manual startup of the generator sets is achieved via operator initiated commands independent of the master controllers. Generator controllers must control and monitor the generator breakers and associated generator set auxiliaries.

2-5.4.5.4 Provide close control commands for synchronizing that are direct outputs from separate controllers for each respective utility source and generator circuit breaker.

2-5.4.5.5 Provide system operator interface via minimum 15-inch thin film transfer (TFT) color touch panels. Provide a touch panel for each generator set, plus one additional local panel and an optional remote panel. Each display controller must provide real-time graphical control and monitoring for the system and all generators.

2-5.4.5.6 Communication should be via Ethernet and support IEC 61850 communications functions and protocols for supervisory control and data acquisition (SCADA) and relay devices.

2-5.4.5.7 Provide a breaker control switch for each main breaker, tie breaker, feeder breaker (if control is required for load shedding), and generator breaker to enable automatic control when the switch is in the “normal after close” position and disable automatic control when the switch is in the “normal after trip” position.

2-5.4.6 Generator Electrical Protection.

Install current transformers (CT) on the neutral side of the generator windings. Use these CTs as an input to a generator protective relay for overcurrent protection. For medium voltage delta generators, provide zigzag grounding transformers with a grounding resistor connected to the generator bus via a circuit breaker. Provide differential protection for the zigzag transformer. Do not provide ground fault protection;

the purpose of the zigzag transformer is to enable a reduced ground fault current.

Wye-wound generators require only a resistor or reactor from the wye point of the generator to ground. Install a CT in this circuit for ground fault protection.

CHAPTER 3 PRIME POWER GENERATORS /1/

3-1 PRIME POWER GENERATORS.

3-1.1 Purpose.

This chapter defines requirements for fossil fuel (reciprocating, gas/steam turbine) generators used for prime power applications.

3-1.2 Definitions.

Prime power generators are classified by manufacturing standards and operational requirements. For manufacturing standards and equipment specifications, EGSA 101P is used by manufacturers to classify their equipment. For operational requirements, ISO 8528, NFPA 70, and NFPA 110 are used to classify generators.

3-1.2.1 EGSA Classification.

EGSA 101P classifies generators by generator set rating, application class, criteria of use, and classification of operation. Prime power is a generator set rating defined by EGSA 101P as a generator set rating to include power that the generator set will deliver when used as a utility-type power plant under normal varying load factors to run continuously with a minimum momentary overload capability of 10 percent.

3-1.2.2 ISO 8528 Classification.

ISO 8528 classifies reciprocating generators by application criteria and performance class. There are four different application criteria modes for reciprocating engine generators including continuous and prime. The ISO 8528 application criteria mode for prime power is for variable loads with unlimited running hours where a generator set is used to supply power 24 hours a day, 365 days a year where there is no supply network or electrical service available or the service is down.

3-1.2.3 NFPA Classifications.

NFPA 70 Articles 701, 702, or 708 are used to determine the application classification of the load as being legally required or emergency, optional standby, or COPS. The Air Force defines optional standby as Other Permanently Installed and also has separate classifications for POL/Fuels and Portable.

NFPA 110 classifies generators by Class, Type, and Level. The Class is the minimum time hours for which the generator is designed to operate at its rated load without being refueled. The Type is the maximum time, in seconds, permitted for the generator to start and the load to transfer. The Level establishes whether loss of human life or serious injury will result if the generator fails to perform.

3-1.3 Renewable Power.

Due to intermittent generation, solar and wind systems are not considered prime power.

Geothermal and hydroelectric systems may be considered prime power, based upon their design. Similar generation and control systems exist for these systems; however, this UFC applies only to fuel-based prime power plants.

3-2 PRIME POWER GENERATOR CLASSIFICATION.

3-2.1 Rating Classification.

Determine generator rating classification as prime power per EGSA 101P for DoD facilities and ISO 8528 for host nation facilities, as appropriate. For combined heat and power plants, evaluate if generator is a continuous power classification with constant load and unlimited running hours. Unlike continuous generators that are designed for limited load fluctuations, prime generators can accommodate varying loads on an unlimited basis throughout the year. However, the average load factor cannot exceed 70 percent of the prime rating. Therefore, the primary calculations are to determine the load, the stability, and the amount of fluctuation.

3-2.2 Application Classes.

Determine generator application class per EGSA 101P for DoD facilities and ISO 8528 for host nation facilities as appropriate. ISO requirements are adopted by Europe and several other nations, and therefore are relevant only to those host nations which have adopted this standard.

3-2.3 Fuels Classification.

POL/fuels classification applies to Fuels Information Service Centers (Fuels Operation) and Type III, IV, and V hydrant fueling systems designed in accordance with Department of Defense Standard Designs AW 078-24-28 and AW 078-24-29 with a manual interlocked transfer switch. Size generators supporting hydrant fueling systems to 50 percent of pumping capacity for locations within the continental United States (CONUS) and 100 percent of pumping capacity for locations outside of the continental United States.

3-3 GENERATOR TYPE.

Generators must meet the requirements of ANSI C50.10, IEEE C50.13, and ANSI C50.14. \2\ For CONUS locations, /2/ use reciprocating engine generators for prime power generators of 100 kW to 3 MW capacity and gas turbine generators for capacities of 1 to 20 MW. Use life cycle cost analysis and mission factors to decide between gas turbine and reciprocating engines in the 1 to 3 MW size. For combined heat and power plants, steam turbines may be used where there is waste heat recovery using heat recovery steam generators between 1 to 20 MW. For generators over 20 MW capacity, obtain user agency approval.

3-4 PRIME POWER GENERATOR DESIGN.

3-4.1 Reliability, Availability and Maintainability (RAM).

3-4.1.1 Goals.

RAM goals will be provided by the user and must be propagated throughout the generation system and supporting subsystems (electrical, fuel, cooling). The designer will determine the system configuration necessary to meet the RAM requirements, and accomplish the design. Support design selections with RAM analyses and calculations.

IEEE 3006 series standards for reliability must be followed for Power Systems RAM analyses.

3-4.1.2 Resilience.

Depending upon mission requirements, a given level of high resilience will be required.

Ensure generator sets can adapt to changing conditions and withstand, respond to, and recover from, disruptions.

The largest disruption known is cascading generator failure based upon loading too close to online generator capacity. When there are large amounts of critical loads that cannot be adapted to hierarchical elimination by frequency load shedding, spinning reserve must be employed. This will require multiple generators running at a maximum of 50% loading, so that if one generator fails, the entire load may be picked up by the other generator without shutting down the entire power source. This is different from reliability, as the focus is the capability to recover quickly from problems.

3-4.2 Capacity Factors.

Capacity considerations are found in Appendix D.

3-4.3 General Requirements.

Locate equipment for accessibility, and for ease of operation, maintenance and repair.

Provide sufficient room between equipment items to facilitate ladders, working platforms, lifts and other equipment required for component removal and replacement.

3-4.4 Generator Sets.

Provide an alternator with a voltage capable of matching the distribution system on the facility. The alternator must have a base level with the prime engine.

Provide appropriate air circulation for generator set cooling.

3-4.4.1 Internal Combustion Engine.

Internal combustion reciprocating prime movers for prime power must use fuel oil (diesel, JP-5 or JP-8). Generators are revolving field, salient pole, air-cooled, open-type, and direct-connected, with amortisseur windings to dampen pulsating engine torque. The required number of poles is six or more to match low speeds typical of large fuel oil engines.

Prime mover for prime power can be diesel or spark-ignited natural gas engines.

Cooling must be coolant based with an air exchanger. Engine speed should be determined by factors such as load profile, emissions limits, maintenance intervals.

3-4.4.2 Gas Turbine.

Prime mover for prime power gas turbine service must use natural gas, landfill gas, or fuel oil (diesel, JP-5 or JP-8) with alternators that are revolving field, non-salient or salient pole, self-ventilated, open drip-proof type. If outdoors, alternators must be Totally Enclosed Fan Cooled (TEFC).

3-4.4.3 Steam Turbine.

Use triple pressure, single, or multiple casing, condensing type steam turbines with a heat recovery steam generator. Design for a 30-year life cycle. Steam turbine-driven generators must be service rated for 5-20 MVA, revolving field, non-salient, two-pole, totally enclosed, air-cooled with water cooling for air coolers, direct connected, and 3,600 rpm for 60 Hz frequency (sometimes connected through a gear reducer up to 10 MVA or more). Self-ventilation is provided for generators larger than 5 MVA by some manufacturers, but this is not recommended for steam power plant service.

Steam turbine driven generators rated 5 MVA and below are revolving field, non-salient or salient pole, self-ventilated, open drip-proof type. Base the generator turbine, gear, and generator configuration on economic evaluation. Configuration analysis is typically done by the manufacturer. Steam turbines are not used for standby generation.

3-4.5 Liquid Fuel Systems.

For self-contained prime power generators, provide with under-belly tank or bulk storage fuel system. For bulk storage fuel system, provide a separate day tank for each generator. Calculate fuel storage on the mission run time, volume required for delays in delivery of replacement fuel and excessive fuel consumption. For bulk storage systems, provide fuel management, fuel maintenance and leak detection systems. Fuel system must meet the requirements of UFC 3-460-01. Provide duplex filters system to allow continuous operations during filter change out.

3-4.6 Air Intake System.

Locate air filters and silencers where readily accessible for maintenance. Silencers must be capable of reducing the noise level of the intake so the sound air pressure conforms to Table 2-1 and Occupational Safety and Health Act (OSHA) requirements.

Perform analysis and document in accordance with UFC 3-450-01. The filtration system must protect the safety of life and prevent harmful foreign material, including water, from entering the system. Configure filtration system to the operational environment providing anti-icing and water separators as appropriate.

3-4.7 Lubrication System.

Provide either wet sump or dry sump lubricating systems. Provide lubrication system, filtration, and cooler per manufacturer recommendations.

3-4.8 Cooling System.

For packaged or modular (example, packaged in ISO containers or weather resistant containers) reciprocating engine prime power systems (example, packaged in ISO containers or weather resistant containers), use self-contained, liquid to air cooled heat exchanger system or air-cooled system.

For all other systems, use closed-cycle wet cooling system.

3-4.9 Exhaust/Air Emissions Control System.

Exhaust/air emissions from prime power generators must comply with federal, state, local and host nation air quality rules and regulations. Comply with approved operating permits. Adding a selective catalytic reduction (SCR) or other EPA-mandated emission control devices to a prime power generator may adversely affect its operation. Prior to adding SCR or other EPA-mandated emission control devices to a primer power generator, a thorough design review should be conducted and approved by the engine manufacturer prior to installation.

3-4.10 Starting System.

Mission requirements dictate reliability for starting systems. Select the starting system based upon mission requirements and life cycle cost analysis. Electric starters may be used for units up through 3 MW, if start times are met. Pneumatic starting may be used for units where a pneumatic system exists or the life cycle costs justify its use. For legally required or emergency stand-by generators, use electric starting systems.

3-4.11 Control System.

Provide generator and electrical system protection in accordance with IEEE Std 446 and IEEE Std 242.

3-4.11.1 Industrial Control Systems (ICS).

Provide an ICS for electrical power generation control and protection, either analog, programmable logic controllers, microprocessor, or distributed control system (DCS) as required by the sophistication required for operation of the generating units and associated systems.

3-4.11.2 SCADA.

Provide a SCADA system as required for operation of the generating units and associated subsystems and the needs for operator monitoring…