Original Part 3 specifications for Generator.pdf

INSECTARY HEADHOUSE USDA ARS WRRC

Parlier, CA PA-100-08

2.16 AUTOMATIC ENGINE-GENERATOR-SET SYSTEM OPERATION

Fully automatic operation shall be provided for the following operations:

engine-generator set starting and source transfer upon loss of preferred source; retransfer upon restoration of the preferred source; sequential starting; and stopping of each engine-generator set after cool down.

Devices shall automatically reset after termination of their function.

2.17 FACTORY INSPECTION AND TESTS

Factory inspection and tests shall be performed on each engine-generator set proposed to meet this specification section. Inspections shall be completed and necessary repairs made prior to testing. Inspectors shall look for leaks, looseness, defects in components, and proper assembly.

Factory tests shall be NEMA MG 1 routine tests and the manufacturers routine tests.

PART 3 EXECUTION

3.1 GENERAL INSTALLATION

Installation shall provide clear space for operation and maintenance in accordance with NFPA 70 and IEEE C2. Installation of pipe, duct, conduit, and ancillary equipment shall be configured to facilitate easy removal and replacement of major components and parts of the engine-generator set.

3.2 PIPING INSTALLATION

3.2.1 General

Piping shall be welded. Connections at valves shall be flanged.

Connections at equipment shall be flanged except that connections to the diesel engine may be threaded if the diesel-engine manufacturer's standard connection is threaded. Except as otherwise specified, flanged fittings shall be utilized to allow for complete dismantling and removal of each piping system from the facility without disconnecting or removing any portion of any other system's equipment or piping. Connections to all equipment shall be made with flexible connectors. Pipes extending through the roof shall be properly flashed. Piping shall be installed clear of windows, doors, and openings to permit thermal expansion and contraction without damage to joints or hangers, and with a 1/2 inch drain valve at each low point.

3.2.2 Supports

Hangers, inserts, and supports shall be of sufficient size to accommodate any insulation and shall conform to MSS SP-58 and MSS SP-69. Supports shall be spaced not more than 7 feet on center for pipes 2 inches in diameter or less, not more than 12 feet on center for pipes larger than 2 inches but no larger than 4 inches, and not more than 17 feet on center for pipes larger than 4 inches in diameter. Supports shall be provided at pipe bends or change of direction.

3.2.3 Cleaning

After fabrication and before assembly, piping interiors shall be manually wiped clean of all debris.

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3.3 ELECTRICAL INSTALLATION

Electrical installation shall comply with NFPA 70, IEEE C2, and Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. For vibration isolation, flexible fittings shall be provided for all conduit, cable trays, and raceways attached to engine-generator sets; metallic conductor cables installed on the engine generator set and from the engine generator set to equipment not mounted on the engine generator set shall be flexible stranded conductor;

and terminations of conductors on the engine generator set shall be crimp-type terminals or lugs. The Contractor shall submit proof of prototype tests as specified in the Submittals paragraph.

3.4 ONSITE INSPECTION AND TESTS

3.4.1 Test Conditions

3.4.1.1 Data

Measurements shall be made and recorded of parameters necessary to verify that each set meets specified parameters. If the results of any test step are not satisfactory, adjustments or replacements shall be made and the step repeated until satisfactory results are obtained. Unless otherwise indicated, data shall be taken during engine-generator set operation and recorded in 15 minute intervals and shall include: readings of engine-generator set meters and gauges for electrical and power parameters;

oil pressure; ambient temperature; and engine temperatures available from meters and gauges supplied as permanent equipment on the engine-generator set. In the following tests where measurements are to be recorded after stabilization of an engine-generator set parameter (voltage, frequency, current, temperature, etc.), stabilization is considered to have occurred when measurements are maintained within the specified bandwidths or tolerances, for a minimum of four consecutive readings. Electrical measurements shall be performed in accordance with IEEE Std 120.

Definitions and terms are in accordance with IEEE Std 100. Temperature limits in the rating of electrical equipment and for the evaluation of electrical insulation shall be in accordance with IEEE Std 1.

3.4.1.2 Instruments

Readings of panel gauges, meters, displays, and instruments, provided under this specification shall be verified during test runs by test instruments of precision and accuracy greater than the tested items. Test instrument accuracy shall be at least as follows: current, 1.5%; voltage, 1.5%; real power, 1.5%; reactive power, 1.5%; power factor, 3%; frequency, 0.5%. Test instruments shall be calibrated by a recognized standards laboratory within 30 days prior to testing.

3.4.1.3 Sequence

The sequence of testing shall be as specified in the approved testing plan unless variance in authorized by the Contracting Officer. Field testing shall be performed in the presence of the Contracting Officer. Tests may be scheduled and sequenced in order to optimize run-time periods; however the following general order of testing shall be followed: Construction Tests; Inspections; Safety run Tests; and Performance Tests and Final Inspection.

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3.4.2 Construction Tests

Individual component and equipment functional tests for fuel piping, coolant piping, and lubricating-oil piping, electrical circuit continuity, insulation resistance, circuit protective devices, and equipment not provided by the engine-generator set manufacturer shall be performed prior to connection to the engine-generator set.

3.4.2.1 Piping Test

a. Lube-oil and fuel-oil piping shall be flushed with the same type of fluid intended to flow through the piping, until the outflowing fluid has no obvious sediment or emulsion.

b. Fuel piping which is external to the engine-generator set shall be tested in accordance with NFPA 30. All remaining piping which is external to the engine generator set shall be pressure tested with air pressure at 150% of the maximum anticipated working pressure, but in no case less than 150 psig, for a period of 2 hours to prove the piping has no leaks. If piping is to be insulated, the test shall be performed before the insulation is applied.

3.4.2.2 Electrical Equipment Tests

a. Low-voltage cable insulation integrity tests shall be performed for cables connecting the generator breaker to the automatic transfer switch . Low-voltage cable, complete with splices, shall be tested for insulation resistance after the cables are installed, in their final configuration, ready for connection to the equipment, and prior to energization. The test voltage shall be 500 volts dc, applied for one minute between each conductor and ground and between all possible combinations conductors in the same trench, duct, or cable, with all other conductors in the same trench, duct, or conduit. The minimum value of insulation shall be:

1) R in megohms = (rated voltage in kV + 1) x 304,800/(length of cable in meters).

2) (R in megohms = (rated voltage in kV + 1) x 1000/(length of cable in feet)

3) Each cable failing this test shall be repaired or replaced.

The repaired cable shall be retested until failures have been eliminated.

b. Medium-voltage cable insulation integrity tests shall be performed for cables connecting the generator breaker to the generator switchgear .

After insulation and before the operating test or connection to an existing system, the medium-voltage cable system shall be given a high potential test. Direct-current voltage shall be applied on each phase conductor of the system by connecting conductors as one terminal and connecting grounds or metallic shieldings or sheaths of the cable as the other terminal for each test. Prior to making the test, the cables shall be isolated by opening applicable protective devices and disconnecting equipment. The test shall be conducted with all splices, connectors, and terminations in place. The method, voltage, length of time, and other characteristics of the test for initial installation shall be in accordance with NEMA WC 74 for the particular type of cable installed, except that 28kV and 35kV insulation test voltages shall be

DOCUMENT 26 32 14.00 10 Page 22 in accordance with either AEIC CS8 or AEIC CS8 as applicable, and shall not exceed the recommendations of IEEE Std 404 for cable joints and IEEE Std 48 for cable terminations unless the cable and accessory manufacturers indicate higher voltages are acceptable for testing.

Should any cable fail due to a weakness of conductor insulation or due to defects or injuries incidental to the installation or because of improper installation of cable, cable joints, terminations, or other connections, the Contractor shall make necessary repairs or replace cables as directed. Repaired or replaced cables shall be retested.

c. Ground-Resistance Tests. The resistance of each grounding electrode shall be measured using the fall-of-potential method defined in IEEE Std 81. Ground resistance measurements shall be made before the electrical distribution system is energized and shall be made in normally dry conditions not less than 48 hours after the last rainfall. Resistance measurements of separate grounding electrode systems shall be made before the systems are bonded together below grade. The combined resistance of separate systems may be used to meet the required resistance, but the specified number of electrodes must still be provided.

3.4.3 Inspections

The following inspections shall be performed jointly by the Contracting Officer and the Contractor, after complete installation of each engine-generator set and its associated equipment, and prior to startup of the engine-generator set. Checks applicable to the installation shall be performed. The results of those which are physical inspections (I) shall be documented by the Contractor and submitted in accordance with paragraph SUBMITTALS. The Contractor shall present manufacturer's data for the inspections designated (D) at the time of inspection. Inspections shall verify that equipment type, features, accessibility, installation and condition are in accordance with the contract specification.

Manufacturer's statements shall certify provision of features which cannot be verified visually.

1. Drive belts. (I)

2. Governor type and features. (I)

3. Engine timing mark. (I)

4. Starting motor. (I)

5. Starting aids. (I)

6. Coolant type and concentration. (D)

7. Radiator drains. (I)

8. Block coolant drains. (I)

9. Coolant fill level. (I)

10. Coolant line connections. (I)

11. Coolant hoses. (I)

12. Combustion air filter. (I)

13. Intake air silencer. (I)

14. Lube oil type. (D)

15. Lube oil drain. (I)

16. Lube-oil filter. (I)

17. Lube-oil-fill level. (I)

18. Lube-oil line connections. (I)

19. Lube-oil lines. (I)

20. Fuel type. (D)

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21. Fuel-level. (I)

22. Fuel-line connections. (I)

23. Fuel lines. (I)

24. Fuel filter. (I)

25. Access for maintenance. (I)

26. Voltage regulator. (I)

27. Battery-charger connections. (I)

28. Wiring & terminations. (I)

29. Instrumentation. (I)

30. Hazards to personnel. (I)

31. Base. (I)

32. Nameplates. (I)

33. Paint. (I)

34. Exhaust system. (I)

35. Access provided to controls. (I)

36. Enclosure. (I)

37. Engine & generator mounting bolts (proper application). (I)

3.4.4 Safety Run Tests

a. Perform and record engine manufacturer's recommended prestarting checks and inspections.

b. Start the engine, record the starting time, make and record engine manufacturer's after-starting checks and inspections during a reasonable warm-up period.

c. Activate the manual emergency stop switch and verify that the engine stops.

d. Remove the high and pre-high lubricating oil temperature sensing elements from the engine and temporarily install temperature gauge in their normal locations on the engine (required for safety, not for recorded data). Where necessary, provide temporary wiring harness to connect the sensing elements to their permanent electrical leads.

e. Start the engine, record the starting time, make and record engine manufacturer's after-starting checks and inspections and operate the engine generator-set at no load until the output voltage and frequency stabilize. Monitor the temporarily installed temperature gauges. If temperature reading exceeds the value for an alarm condition, activate the manual emergency stop switch.

f. Immerse the elements in a vessel containing controlled-temperature hot oil and record the temperature at which the pre-high alarm activates and the temperature at which the engine shuts down. Remove the temporary temperature gauges and reinstall the temperature sensors on the engine.

g. Remove the high and pre-high coolant temperature sensing elements from the engine and temporarily seal their normal location on the engine and temporarily install temperature gauges in their normal locations on the engine (required for safety, not for recorded data).

Where necessary provide temporary wiring harness to connect the sensing elements to their permanent electrical leads.

h. Start the engine, record the starting time, make and record engine manufacturer's after-starting checks and inspections and operate the engine generator-set at no load until the output voltage and frequency

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i. Immerse the elements in a vessel containing controlled-temperature hot oil and record the temperature at which the pre-high alarm activates and the temperature at which the engine shuts down. Remove the temporary temperature gauges and reinstall the temperature sensors on the engine.

j. Start the engine, record the starting time, make and record engine manufacturer's after-starting checks and inspections during a reasonable warm-up period.

k. Operate the engine generator-set for at least 30 minutes at 100 percent of service load.

l. Verify proper operation of the governor and voltage regulator.

m. Verify proper operation and setpoints of gauges and instruments.

n. Verify proper operation of ancillary equipment.

o. Manually adjust the governor to increase engine speed past the overspeed limit. Record the RPM at which the engine shuts down.

p. Start the engine, record the starting time, make and record engine manufacturer's after-starting checks and inspections and operate the engine generator-set for at least 15 minutes at 75 percent of rated load.

q. Manually fill the sub-base tank to a level above the overfill limit. Record the level at which the overfill alarm sounds. Verify shutdown of the fuel transfer pump. Drain the sub-base tank down below the overfill limit.

r. Shut down the engine. Remove the time-delay low lube oil pressure alarm bypass and try to start the engine. Record the results.

s. Attach a manifold to the engine oil system (at the oil sensor pressure port) that contains a shutoff valve in series with a connection for the engine's oil pressure sensor followed by an oil pressure gauge ending with a bleed valve. The engine's oil pressure sensor shall be moved from the engine to the manifold and its normal location on the engine temporarily sealed. The manifold shutoff valve shall be open and bleed valve closed.

t. Start the engine, record the starting time, make and record all engine manufacturer's after-starting checks and inspections and operate the engine generator-set for at least 15 minutes at 75 percent of service load.

u. Close the manifold shutoff valve. Slowly allow the pressure in the manifold to bleed off through the bleed valve while watching the pressure gauge. Record the pressure at which the engine shuts down.

Catch oil spillage from the bleed valve in a container. Add the oil from the container back to the engine, remove the manifold, and reinstall the engine's oil pressure sensor on the engine.

v. Start the engine, record the starting time, make and record all engine manufacturer's after-starting checks and inspections and operate

DOCUMENT 26 32 14.00 10 Page 25 the engine generator-set for at least 15 minutes at 100% of service load. Record the maximum sound level in each frequency band at a distance of 75 feet from the end of the exhaust and air intake piping directly along the path of intake and discharge horizontal piping; or at a radius of 75 feet from the engine at 45 degrees apart in all directions for vertical piping. The measurements should comply with the paragraph SOUND LIMITATIONS. If a sound limiting enclosure is provided, the enclosure, the muffler, and intake silencer shall be modified or replaced as required to meet the sound requirements contained within this specification.

w. Manually drain off fuel slowly from the sub-base tank to empty it to below the low fuel level limit and record the level at which the audible alarm sounds. Add fuel back to the sub-base tank to fill it above low level alarm limits.

3.4.5 Performance Tests

3.4.5.1 Continuous Engine Load Run Test

The engine-generator set and ancillary systems shall be tested at service load to: demonstrate reliability and durability; verify that heat of extended operation does not adversely affect or cause failure in any part of the system; and check all parts of the system. If the engine load run test is interrupted for any reason, the entire test shall be repeated. The engine load run test shall be accomplished principally during daylight hours.

After each change in load in the following test, measure the vibration at the end bearings (front and back of engine, outboard end of generator) in the horizontal, vertical, and axial directions. Verify that the vibration is within the allowable range. Measurements are to be recorded after stabilization of an engine-generator set parameter (voltage, frequency, current, temperature, etc.). Stabilization is considered to have occurred when measurements are maintained within the specified bandwidths or tolerances, for a minimum of four consecutive readings. Data taken at 15 minutes intervals shall include the following:

a. Electrical: Output amperes, voltage, real and reactive power, power factor, frequency.

b. Pressure: Lube-oil.

c. Temperature: Coolant, Lube-oil, Ambient.

(1) Perform and record engine manufacturer's recommended prestarting checks and inspections. Include as a minimum checking of coolant fluid, fuel, and lube-oil levels.

(2) Start the engine; make and record engine manufacturer's after-starting checks and inspections during a reasonable warm-up period.

(3) Operate the engine generator-set for at least 2 hours at 75 percent of service load.

(4) Increase load to 100%of service load and operate the engine generator-set for at least 2 hours.

(5) Remove load from the engine-generator set.

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3.4.5.2 Load Acceptance Test

Engine manufacturer's recommended prestarting checks and inspections shall be performed and recorded. The engine shall be started, and engine manufacturer's after-starting checks and inspections made and recorded during a reasonable warm-up period. For the following steps, the output line-line and line-neutral voltages and frequency shall be recorded after performing each step instruction (after stabilization of voltage and frequency). Stabilization is considered to have occurred when measurements are maintained within the specified bandwidths or tolerances, for a minimum of four consecutive readings.

a. Apply load in steps no larger than the Maximum Step Load Increase to load the engine-generator set to 100 of Service Load.

b. Verify that the engine-generator set responds to the load addition and that the output voltage returns to and stabilizes within the rated bandwidths.

3.4.6 Automatic Operation Tests for Stand-Alone Operation

The automatic loading system shall be tested to demonstrate automatic starting, of each engine-generator set. The loads for this test shall utilize the actual loads to be served, and the loading sequence shall be the indicated sequence. Perform this test for a minimum of two successive, successful tests. Data taken shall include the following:

a. Ambient temperature (at 15 minute intervals).

b. Generator output current (before and after load changes).

c. Generator output voltage (before and after load changes).

d. Generator output frequency (before and after load changes.)

1. Initiate loss of the primary power source and verify automatic sequence of operation.

2. Restore the primary power source and verify sequence of operation.

3. Verify resetting of controls to normal.

3.5 FINAL INSPECTION AND TESTING

a. Start the engine, record the starting time, make and record all engine manufacturer's after-starting checks and inspections during a reasonable warm-up period.

b. Increase the load in steps no greater than the maximum step load increase to 100% of service load, and operate the engine-generator set for at least 30 minutes. Measure the vibration at the end bearings (front and back of engine, outboard end of generator) in the horizontal, vertical, and axial directions. Verify that the vibration is within the same range as previous measurements and is within the required range.

c. Remove load and shut down the engine-generator set after the recommended cool down period. Perform the pre-test inspections and

DOCUMENT 26 32 14.00 10 Page 27 take necessary corrective actions.

d. Remove the lube oil filter and have the oil and filter examined by the engine manufacturer for excessive metal, abrasive foreign particles, etc. Any corrective action shall be verified for effectiveness by running the engine for 4 hours at service load, then re-examining the oil and filter.

e. Remove the fuel filter and examine the filter for trash, abrasive foreign particles, etc.

f. Visually inspect and check engine and generator mounting bolts for tightness and visible damage.

g. Replace air, oil, and fuel filters with new filters.

3.6 INSTRUCTIONS

Two sets of instructions shall be typed and framed under weatherproof laminated plastic, and posted side-by-side where directed before acceptance. First set of instructions shall include a one-line diagram, wiring and control diagrams and a complete layout of the system. Second set of instructions shall include the condensed operating instructions describing manufacturer's pre-start checklist and precautions; start procedures for test-mode, manual-start mode, and automatic-start mode (as applicable); running checks, procedures, and precautions; and shutdown procedures, checks, and precautions. Instructions shall include procedures for interrelated equipment (such as heat recovery systems, co-generation, load-shedding, and automatic transfer switches).

3.7 ACCEPTANCE

Final acceptance of the engine-generator set will not be given until the Contractor has successfully completed all tests and after all defects in installation material or operation have been corrected.

-- End of Section --

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