FA5205-15-R-0007-0004_Atch._2_Specifications_(Revised).pdf

REPR Main Base WWTP, B1190 QKKA071054 Misawa AB, Misawa, Japan

SECTION 26 32 14.00 10

DIESEL-GENERATOR SET, STATIONARY 15-300 KW, STANDBY APPLICATIONS

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI C39.1 (1981; R 1992) Requirements for Electrical Analog Indicating Instruments

ASME INTERNATIONAL (ASME)

ASME B16.11 (2011) Forged Fittings, Socket-Welding and Threaded

ASME B16.3 (2011) Malleable Iron Threaded Fittings, Classes 150 and 300

ASME B16.5 (2013) Pipe Flanges and Flanged Fittings:

NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME B31.1 (2014; INT 1-47) Power Piping

ASME BPVC SEC IX (2010) BPVC Section IX-Welding and Brazing Qualifications

ASTM INTERNATIONAL (ASTM)

ASTM A106/A106M (2014) Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service

ASTM A135/A135M (2009; R2014) Standard Specification for Electric-Resistance-Welded Steel Pipe

ASTM A181/A181M (2014) Standard Specification for Carbon Steel Forgings, for General-Purpose Piping

ASTM A234/A234M (2013; E 2014) Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service

ASTM A53/A53M (2012) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM D975 (2014a) Standard Specification for Diesel Fuel Oils

SECTION 26 32 14.00 10 Page 1

Attachment 2 to FA5205-15-R-0007-0004 Dated 21 Jul 15

ELECTRICAL GENERATING SYSTEMS ASSOCIATION (EGSA)

EGSA 101P (1995) Performance Standard for Engine Driven Generator Sets

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 1 (2000; R 2005) General Principles for Temperature Limits in the Rating of Electric Equipment and for the Evaluation of Electrical Insulation

IEEE 120 (1989; R 2007) Master Test Guide for Electrical Measurements in Power Circuits

IEEE 519 (2014) Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems

IEEE C2 (2012; Errata 2012; INT 1-4 2012; INT 5-7 2013; INT 8 2014) National Electrical Safety Code

IEEE Stds Dictionary (2009) IEEE Standards Dictionary: Glossary of Terms & Definitions

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-58 (1993; Reaffirmed 2010) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation

MSS SP-80 (2013) Bronze Gate, Globe, Angle and Check Valves

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 2 (2000; R 2005; Errata 2008) Standard for Controllers, Contactors, and Overload Relays Rated 600 V

NEMA ICS 6 (1993; R 2011) Enclosures

NEMA MG 1 (2011; Errata 2012) Motors and Generators

NEMA/ANSI C12.11 (2007) Instrument Transformers for Revenue Metering, 10 kV BIL through 350 kV BIL (0.6 kV NSV through 69 kV NSV)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 110 (2013) Standard for Emergency and Standby Power Systems

NFPA 30 (2015) Flammable and Combustible Liquids Code

SECTION 26 32 14.00 10 Page 2

NFPA 37 (2015) Standard for the Installation and Use of Stationary Combustion Engines and Gas Turbines

NFPA 70 (2014; AMD 1 2013; Errata 1 2013; AMD 2 2013; Errata 2 2013; AMD 3 2014; Errata 3-4 2014; AMD 4-6 2014) National Electrical Code

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE ARP892 (1965; R 1994) DC Starter-Generator, Engine

SAE J537 (2011) Storage Batteries

U.S. DEPARTMENT OF DEFENSE (DOD)

UFC 3-310-04 (2013) Seismic Design for Buildings

UNDERWRITERS LABORATORIES (UL)

UL 1236 (2006; Reprint Jul 2011) Standard for Battery Chargers for Charging Engine-Starter Batteries

UL 489 (2013; Reprint Mar 2014) Molded-Case Circuit Breakers, Molded-Case Switches, and Circuit-Breaker Enclosures

1.2 SYSTEM DESCRIPTION

a. Provide and install engine-generator set complete and totally functional, with all necessary ancillary equipment to include air filtration; starting system; generator controls, protection, and isolation; instrumentation; lubrication; fuel system; cooling system;

and engine exhaust system. Each engine generator set shall satisfy the requirements specified in the Engine Generator Parameter Schedule. Submit certification that the engine-generator set and cooling system function properly in the ambient temperatures specified.

b. Provide each engine-generator set consisting of one engine, one generator, and one exciter, mounted, assembled, and aligned on one base; and all other necessary ancillary equipment which may be mounted separately. Sets shall be assembled and attached to the base prior to shipping. Set components shall be environmentally suitable for the locations shown and shall be the manufacturer's standard product offered in catalogs for commercial or industrial use. Provide a generator strip heater for moisture control when the generator is not operating.

1.2.1 Engine-Generator Parameter Schedule

ENGINE GENERATOR PARAMETER SCHEDULE

Service Load 450 kVA

SECTION 26 32 14.00 10 Page 3

ENGINE GENERATOR PARAMETER SCHEDULE

Power Factor 0.89 lagging

Motor Starting kVA (maximum) 1154 kVA

Maximum Speed 1500 rpm

Engine-Generator Application stand-alone

Engine Cooling Type water/ethylene glycol

Heat Exchanger Type fin-tube

Governor Type Isochronous

Frequency Bandwidth percent steady state 0.25

Voltage Regulation (No load to full load) + 2 percent (max.)

Voltage Bandwidth (steady state) 1 percent

Frequency 50 Hz

Voltage 420 volts

Phases 3 Phase, Wye

Nonlinear Loads 307 kVA

Max Step Load Increase 100 30 percent of Service Load at 0.8 PF

Max Step Load Decrease (w/o shutdown) 100 30 percent of Service Load at 0.8 PF

Max Time to Start and be Ready to Assume Load

30 seconds

Max Summer Indoor Temp (Prior to Genset Operation)

38 degrees C

Min Winter Indoor Temp (Prior to Genset Operation)

10 degrees C

Min Winter Indoor Temp 10 degrees C

Max Summer Outdoor Temp (Ambient) 38 degrees C

Min Winter Outdoor Temp (Ambient) -6 degrees C

SECTION 26 32 14.00 10 Page 4 thojoh Line thojoh Line thojoh Typewritten Text thojoh Typewritten Text thojoh Typewritten Text thojoh Typewritten Text

ENGINE GENERATOR PARAMETER SCHEDULE

Installation Elevation 36 m above sea level

1.2.2 Output Capacity

Provide each generator set with power equal to the sum of service load plus the machine's efficiency loss and associated ancillary equipment loads. Rated output capacity shall also consider engine and/or generator oversizing required to meet requirements in paragraph Engine-Generator Parameter Schedule.

1.2.3 Power Rating

Standby ratings shall be in accordance with EGSA 101P.

1.2.4 Vibration Isolation

1.2.4.1 Vibration Limitations

The maximum engine-generator set vibration in the horizontal, vertical and axial directions shall be limited to 0.15 mm (peak-peak RMS), with an overall velocity limit of 24 mm/seconds RMS, for all speeds through 110 percent of rated speed. The engine-generator set shall be provided with vibration-isolation in accordance with the manufacturer's standard recommendation. Where the vibration-isolation system does not secure the base to the structure floor or unit foundation, provide seismic restraints in accordance with the seismic parameters specified.

1.2.4.2 Torsional Analysis

Submit torsional analysis including prototype testing or calculations which certify and demonstrate that no damaging or dangerous torsional vibrations will occur when the prime mover is connected to the generator, at synchronous speeds, plus/minus 10 percent.

1.2.4.3 Performance Data

Submit vibration isolation system performance data for the range of frequencies generated by the engine-generator set during operation from no load to full load and the maximum vibration transmitted to the floor.

Also submit a description of seismic qualification of the engine-generator mounting, base, and vibration isolation.

1.2.5 Reliability and Durability

Submit documentation which cites engines and generators in similar service to demonstrate compliance with the requirements of this specification.

Certification does not exclude annual technological improvements made by a manufacturer in the basic standard model set on which experience was obtained, provided parts interchangeability has not been substantially affected and the current standard model meets all the performance

SECTION 26 32 14.00 10 Page 5 requirements of this specification. For each different set, 2 like sets shall have performed satisfactorily in a stationary power application, independent and separate from the physical location of the manufacturer's and assembler's facilities, for a minimum of 2 consecutive years without any failure to start, including periodic exercise. The certification shall state that for the set proposed to meet this specification, there were no failures resulting in downtime for repairs in excess of 72 hours or any failure due to overheating during 2 consecutive years of service.

Like sets are of the same model, speed, bore, stroke, number and configuration of cylinders, and output power rating. Like generators are of the same model, speed, pitch, cooling, exciter, voltage regulator and output power rating. A list shall be provided with the name of the installations, completion dates, and name and telephone number of a point of contact.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Detailed Drawings; G Acceptance; G

SD-03 Product Data

Manufacturer's Catalog Instructions; G Experience Field Engineer Site Welding General Installation Site Visit

SD-05 Design Data

Sound Limitations; G Generator Power Factor Heat Exchanger Time-Delay on Alarms Cooling System Vibration Isolation

SD-06 Test Reports

Performance Tests Onsite Inspection and Tests; G

SD-07 Certificates

Vibration Isolation Prototype Tests Reliability and Durability Emissions

SECTION 26 32 14.00 10 Page 6

Sound limitations Current Balance Materials and Equipment Factory Inspection and Tests Inspections Cooling System

SD-10 Operation and Maintenance Data

Operation Manual; G Maintenance Manual; G Extra Materials

START-UP

1. Factory Representative of Manufacturer, who has complete knowledge of the proper installation and maintenance of the equipment, shall be on-site to instruct representatives of the CONTRACTOR and OWNER on proper operation and maintenance. Testing, training and start-up shall be furnished in accordance with Division 1, Section 01 75 00 - Starting And Adjusting.

2. CONTRACTOR shall assist Manufacturer with start-up of the equipment. CONTRACTOR shall verify all field connections with Manufacturer. CONTRACTOR shall make all changes required to conform to Manufacturer's installation requirements.

1.4 QUALITY ASSURANCE

1.4.1 Conformance to Codes and Standards

Where equipment is specified to conform to requirements of any code or standard such as UL, the design, fabrication and installation shall conform to the code.

1.4.2 Site Welding

Weld structural members in accordance with Section 05 50 13 MISCELLANEOUS METAL FABRICATIONS. For all other welding, qualify procedures and welders in accordance with ASME BPVC SEC IX .

a. Welding procedures qualified by others, and welders and welding operators qualified by a previously qualified employer may be accepted as permitted by ASME B31.1 .

b. Welder qualification tests shall be performed for each welder whose qualifications are not in compliance with the referenced standards.

Notify the Contracting Officer 24 hours in advance of qualification tests. The qualification tests shall be performed at the work site if practical.

c. The welder or welding operator shall apply the assigned personal symbol near each weld made as a permanent record

d. Submit a letter listing the welder qualifying procedures for each welder, complete with supporting data such as test procedures used, what was tested to, and a list of the names of all welders and their qualifications symbols.

SECTION 26 32 14.00 10 Page 7

1.4.3 Experience

Each component manufacturer shall have a minimum of 3 years experience in the manufacture, assembly and sale of components used with stationary diesel engine-generator sets for commercial and industrial use. The engine-generator set manufacture/assembler shall have a minimum of 3 years experience in the manufacture, assembly and sale of stationary diesel engine-generator sets for commercial and industrial use. Submit a statement showing and verifying these requirements.

1.4.4 Field Engineer

The engine-generator set manufacturer or assembler shall furnish a qualified field engineer to supervise the complete installation of the engine-generator set, assist in the performance of the onsite tests, and instruct personnel as to the operational and maintenance features of the equipment. The field engineer shall have attended the engine-generator manufacturer's training courses on installation and operation and maintenance for engine generator sets. Submit a letter listing the qualifications, schools, formal training, and experience of the field engineer.

1.4.5 Seismic Requirements

Seismic requirements shall be in accordance with UFC 3-310-04 and Sections

13 48 00 SEISMIC PROTECTION FOR MISCELLANEOUS EQUIPMENT, 13 48 00.00 10

SEISMIC PROTECTION FOR MECHANICAL EQUIPMENT and 26 05 48.00 10 SEISMIC

PROTECTION FOR ELECTRICAL EQUIPMENT.

1.4.6 Detailed Drawings

Submit detailed drawings showing the following:

a. Base-mounted equipment, complete with base and attachments including anchor bolt template and recommended clearances for maintenance and operation.

b. Starting system.

c. Fuel system.

d. Cooling system.

e. Exhaust system.

f. Electric wiring of relays, breakers, programmable controllers, and switches including single line and wiring diagrams.

g. Lubrication system, including piping, pumps, strainers, filters, controls and wiring.

h. Location, type, and description of vibration isolation devices.

i. The safety system, including wiring schematics.

j. One-line schematic and wiring diagrams of the generator, exciter, regulator, governor, and all instrumentation.

k. Panel layouts.

SECTION 26 32 14.00 10 Page 8

l. Mounting and support for each panel and major piece of electrical equipment.

m. Engine-generator set rigging points and lifting instructions.

1.5 DELIVERY, STORAGE AND HANDLING

Properly protect materials and equipment in accordance with the manufacturers recommended storage procedures, before, during, and after installation. Protect stored items from the weather and contamination.

During installation, piping and similar openings shall be capped to keep out dirt and other foreign matter.

1.6 MAINTENANCE SERVICE

Submit the operation and maintenance manuals and have them approved prior to commencing onsite tests.

1.6.1 Operation Manual

Provide three copies of the operation manual in 216 by 279 mm three-ring binders. Sections shall be separated by heavy plastic dividers with tabs which identify the material in the section. Drawings shall be folded blue lines, with the title block visible, and placed in 216 by 279 mm plastic pockets with reinforced holes. The manual shall include:

a. Step-by-step procedures for system startup, operation, and shutdown;

b. Drawings, diagrams, and single-line schematics to illustrate and define the electrical, mechanical, and hydraulic systems with their controls, alarms, and safety systems;

c. Procedures for interface and interaction with related systems to include automatic transfer switches.

1.6.2 Maintenance Manual

Provide three copies of the maintenance manual containing the information described below in 216 x 279 mm three-ring binders. Each section shall be separated by a heavy plastic divider with tabs. Drawings shall be folded, with the title block visible, and placed in plastic pockets with reinforced holes. The manual shall include:

a. Procedures for each routine maintenance item.

b. The manufacturer's recommended maintenance schedule.

c. A component list which includes the manufacturer's name, address, type or style, model or serial number, rating, and catalog number for the major components listed in paragraph GENERAL REQUIREMENTS.

d. A list of spare parts for each piece of equipment and a complete list of materials and supplies needed for operation.

1.6.3 Extra Materials

Provide two sets of special tools and two sets of filters required for maintenance. Special tools are those that only the manufacturer provides, SECTION 26 32 14.00 10 Page 9 for special purposes, or to reach otherwise inaccessible parts. One handset shall be provided for each electronic governor when required to indicate and/or change governor response settings. Supply two complete sets of filters in a suitable storage box in addition to filters replaced after testing.

PART 2 PRODUCTS

2.1 NAMEPLATES

Each major component of this specification shall have the manufacturer's name, type or style, model or serial number, and rating number on a plate secured to the equipment. As a minimum, nameplates shall be provided for: Engines; Relays; Generators; Day tanks; Transformers (CT & PT);

Regulators; Pumps and pump motors; Governors; Generator Breaker;

Economizers; Heat exchangers (other than base-mounted).

Where the following equipment is provided as a standard component by the diesel-engine generator set manufacturer, the nameplate information may be provided in the maintenance manual in lieu of nameplates.

Battery charger Heaters Exhaust mufflers Exciters Switchgear Silencers Battery

2.2 SAFETY DEVICES

Exposed moving parts, parts that produce high operating temperatures, parts which may be electrically energized, and parts that may be a hazard to operating personnel during normal operation shall be insulated, fully enclosed, guarded, or fitted with other types of safety devices. The safety devices shall be installed so that proper operation of the equipment is not impaired.

2.3 MATERIALS AND EQUIPMENT

Materials and equipment shall be as specified. Submit a letter certifying that where materials or equipment are specified to comply with requirements of UL, or other standards, written proof of such compliance has been obtained. The label or listing of the specified agency, or a written certificate from an approved, nationally recognized testing organization equipped to perform such services, stating that the items have been tested and conform to the requirements and testing methods of the specified agency are acceptable as proof.

2.3.1 Circuit Breakers, Low Voltage

UL 489 and UL 489 .

2.3.2 Filter Elements (Fuel-oil, Lubricating-oil, and Combustion-air)

Manufacturer's standard.

2.3.3 Instrument Transformers

NEMA/ANSI C12.11 .

SECTION 26 32 14.00 10 Page 10

2.3.4 Pipe (Fuel/Lube-oil, Compressed-Air, Coolant and Exhaust)

ASTM A53/A53M, ASTM A106/A106M or ASTM A135/A135M , steel pipe. Pipe smaller than 50 mm shall be Schedule 80. Pipe 50 mm and larger shall be Schedule 40.

2.3.5 Pipe Flanges and Fittings

2.3.5.1 Pipe Flanges and Flanged Fittings

ASTM A181/A181M , Class 60, or ASME B16.5 , Grade 1, Class 150.

2.3.5.2 Pipe Welding Fittings

ASTM A234/A234M , Grade WPB or WPC, Class 150, or ASME B16.11 , 1360.7 kg.

2.3.5.3 Threaded Fittings

ASME B16.3 , Class 150.

2.3.5.4 Valves

MSS SP-80 , Class 150.

2.3.5.5 Gaskets

Manufacturers Standard.

2.3.6 Pipe Hangers

MSS SP-58 .

2.3.7 Electrical Enclosures

2.3.7.1 General

NEMA ICS 6 .

2.3.8 Electric Motors

Electric motors shall conform to the requirements of NEMA MG 1. Motors shall have sealed ball bearings, a maximum speed of 1800 rpm and integral automatic or manual reset thermal overload protectors. Motors used indoors shall have drip proof frames. AC motors larger than 373 W (1/2 HP) shall be of the squirrel cage induction type for standard voltage of 420 volts, 50 Hz three phase power. AC motors 373 W (1/2 HP)or smaller, shall be for standard voltage 115 volts, 50 Hz, single phase power.

2.3.9 Motor Controllers

Motor controllers and starters shall conform to the requirements of NFPA 70 and NEMA ICS 2 .

2.4 ENGINE

Each engine shall operate on No. 2-D diesel conforming to ASTM D975, shall be designed for stationary applications and shall be complete with ancillaries. The engine shall be a standard production model described in the manufacturer's catalog data, which describes and depicts each

SECTION 26 32 14.00 10 Page 11 engine-generator set and all ancillary equipment in sufficient detail to demonstrate specification compliance. The engine shall be naturally aspirated, turbocharged. The engine shall be four-cycle and compression-ignition type. The engine shall be vertical inline type, with a solid cast block or individually cast cylinders. The engine shall have a minimum of two cylinders. Opposed-piston type engines shall have no less than four cylinders. Each block shall have a coolant drain port.

Each engine shall be equipped with an overspeed sensor.

2.5 FUEL SYSTEM

The fuel system for each engine generator set shall conform to the requirements of NFPA 30 and NFPA 37 and contain the following elements.

2.5.1 Pumps

2.5.1.1 Main Pump

Each engine shall be provided with an engine driven pump. The pump shall supply fuel at a minimum rate sufficient to provide the amount of fuel required to meet the performance indicated within the parameter schedule.

The fuel flow rate shall be based on meeting the load requirements and all necessary recirculation.

2.5.2 Filter

A minimum of one full flow fuel filter shall be provided for each engine.

The filter shall be readily accessible and capable of being changed without disconnecting the piping or disturbing other components. The filter shall have inlet and outlet connections plainly marked.

2.5.3 Fuel Supply System

The fuel supply from the existing main storage of fuel to the generator shall be as shown on the drawings.

2.6 LUBRICATION

Each engine shall have a separate lube-oil system conforming to NFPA 30 and NFPA 37 . Each system shall be pressurized by engine-driven oil pumps. Each system shall be furnished with a relief valve for oil pressure regulation (for closed systems) and a dip-stick for oil level indications. The crankcase shall be vented in accordance with the manufacturer's recommendation except that it shall not be vented to the engine exhaust system. Crankcase breathers, if provided on engines installed in buildings or enclosures, shall be piped to vent to the outside. The system shall be readily accessible for service such as draining, refilling, etc. Each system shall permit addition of oil and have oil-level indication with the set operating. The system shall utilize an oil cooler as recommended by the engine manufacturer.

2.6.1 Filter

One full-flow filter shall be provided for each pump. The filter shall be readily accessible and capable of being changed without disconnecting the piping or disturbing other components. The filter shall have inlet and outlet connections plainly marked.

SECTION 26 32 14.00 10 Page 12

2.6.2 Lube-Oil Sensors

Each engine shall be equipped with lube-oil pressure sensors. Pressure sensors shall be located downstream of the filters and provide signals for required indication and alarms.

2.7 COOLING SYSTEM

Each engine cooling system shall operate automatically while the engine is running. Each cooling system shall be sized for the maximum summer outdoor design temperature and site elevation. Water-cooled system coolant shall use a combination of water and ethylene-glycol sufficient for freeze protection at the minimum winter outdoor temperature specified. The maximum temperature rise of the coolant across the engine shall be no more than that recommended and submitted.

a. The maximum and minimum allowable inlet temperatures of the coolant fluid.

b. The maximum allowable temperature rise in the coolant fluid through the engine.

c. The minimum allowable inlet fuel temperature.

2.7.1 Coolant Pumps

Coolant pumps shall be the centrifugal type. Each engine shall have an engine-driven primary pump.

2.7.2 Heat Exchanger

Each heat exchanger shall be of a size and capacity to limit the maximum allowable temperature rise in the coolant across the engine to that recommended and submitted in accordance with paragraph SUBMITTALS for the maximum summer outdoor design temperature and site elevation. Each heat exchanger shall be corrosion resistant, suitable for service in ambient conditions of application. Submit manufacturers data to quantify heat rejected to the space with the engine generator set at rated capacity.

2.7.2.1 Fin-Tube-Type Heat Exchanger (Radiator)

Heat exchanger may be factory coated with corrosive resistant film providing that corrosion measures are taken to restore the heat rejection capability of the radiator to the initial design requirement via oversizing, or other compensating methods. Internal surfaces shall be compatible with liquid fluid coolant used. Materials and coolant are subject to approval by the Contracting Officer. Heat exchangers shall be pressure type incorporating a pressure valve, vacuum valve and a cap.

Caps shall be designed for pressure relief prior to removal. Each heat exchanger and the entire cooling system shall be capable of withstanding a minimum pressure of 48 kPa gauge. Each heat exchanger shall be protected with a strong grille or screen guard. Each heat exchanger shall have at least two tapped holes. One tapped hole in the heat exchanger shall be equipped with a drain cock, the rest shall be plugged.

2.7.3 Temperature Sensors

Each engine shall be equipped with coolant temperature sensors.

Temperature sensors shall provide signals for pre-high and high indication

SECTION 26 32 14.00 10 Page 13 and alarms.

2.8 SOUND LIMITATIONS

The noise generated by the diesel generator set operating at 100 percent load shall not exceed the following sound pressure levels in any of the indicated frequencies when measured in a free field at a radial distance of 7 meters at 45 degrees apart in all directions. Submit data to demonstrate compliance with these sound limitation requirements. Also submit certification from the manufacturer stating that the sound emissions meet the specification.

Frequency Band (Hz) Maximum Acceptable Pressure Level (Decibels)

31 N/A

63 78.7

125 86.7

250 90.7

500 94.7

1000 98.7

2000 98.7

4000 93.7

8000 87.7

2.9 EXHAUST SYSTEM

The system shall be separate and complete for each engine. Piping shall be supported so as to minimize vibration. Where a V-type engine is provided, a V-type connector with necessary flexible sections and hardware shall connect the engine exhaust outlets.

2.9.1 Flexible Sections and Expansion Joints

A flexible section at each engine and an expansion joint at each muffler shall be provided. Flexible sections and expansion joints shall have flanged connections. Flexible sections shall be made of convoluted seamless tube without joints or packing. Expansion joints shall be the bellows type. Expansion and flexible elements shall be stainless steel suitable for diesel-engine exhaust gas at the maximum exhaust temperature that is specified by the engine manufacturer. Expansion and flexible elements shall be capable of absorbing vibration from the engine and compensation for thermal expansion and contraction.

2.9.2 Exhaust Muffler

Existing exhaust muffler will be revised. New exhaust piping shall be

SECTION 26 32 14.00 10 Page 14 provided and existing piping will be modified.

2.9.3 Exhaust Piping

Existing exhaust piping shall be modified with new piping added as shown on the drawings to provide proper operation.

Horizontal sections of exhaust piping shall be sloped downward away from the engine to a condensate trap and drain valve. Changes in direction shall be long-radius. Exhaust piping, mufflers and silencers installed inside any building shall be insulated in accordance with paragraph THERMAL INSULATION and covered to protect personnel. Vertical exhaust piping shall be provided with a hinged, gravity operated, self-closing, rain cover.

2.10 EMISSIONS

The finished installation shall comply with local regulations and restrictions regarding the limits of emissions.

Submit a certification from the engine manufacturer stating that the engine exhaust emissions meet federal, state, and local regulations and restrictions specified. At a minimum, this certification shall include emission factors for criteria pollutants including nitrogen oxides, carbon monoxide, particulate matter, sulfur dioxide, non-methane hydrocarbon, and for hazardous air pollutants (HAPs).

2.11 STARTING SYSTEM

The starting system for engine generator sets used in non-emergency applications shall be as follows.

2.11.1 Controls

An engine control switch shall be provided with functions including:

run/start (manual), off/reset, and automatic mode. Start-stop logic shall be provided for adjustable cycle cranking and cool down operation. The logic shall be arranged for manual starting and fully automatic starting in accordance with paragraph AUTOMATIC ENGINE-GENERATOR SET SYSTEM OPERATION. Electrical starting systems shall be provided with an adjustable cranking limit device to limit cranking periods from 1 second up to the maximum duration.

2.11.2 Capacity

The starting system shall be of sufficient capacity, at the maximum outdoor summer temperature specified to crank the engine without damage or overheating. The system shall be capable of providing a minimum of three cranking periods with 15-second intervals between cranks. Each cranking period shall have a maximum duration of 15 seconds.

2.11.3 Functional Requirements

Starting system shall be manufacturers recommended dc system utilizing a negative circuit ground. Starting motors shall be in accordance with

SAE ARP892.

SECTION 26 32 14.00 10 Page 15

2.11.4 Battery

A starting battery system shall be provided and shall include the battery, battery rack, intercell connectors, and spacers. The battery shall be in accordance with SAE J537 . Critical system components (rack, protection, etc.) shall be sized to withstand the seismic acceleration forces specified. The battery shall be lead-acid type, with sufficient capacity, at the minimum indoor winter temperature specified to provide the specified cranking periods. Valve-regulated lead-acid batteries are not acceptable.

2.11.5 Battery Charger

A current-limiting battery charger, conforming to UL 1236 , shall be provided and shall automatically recharge the batteries. The charger shall be capable of an equalize charging rate for recharging fully depleted batteries within 24 hours and a float charge rate for maintaining the batteries in prime starting condition. An ammeter shall be provided to indicate charging rate. A timer shall be provided for the equalize charging rate setting. A battery is considered to be fully depleted when the output voltage falls to a value which will not operate the engine generator set and its components.

2.11.6 Starting Aids

The manufacturer shall provide one or more of the following methods to assist engine starting.

2.11.6.1 Glow Plugs

Glow plugs shall be designed to provide sufficient heat for combustion of fuel within the cylinders to guarantee starting at an ambient temperature of -32 degrees C.

2.11.6.2 Jacket-Coolant Heaters

A thermostatically controlled electric heater shall be mounted in the engine coolant jacketing to automatically maintain the coolant within plus or minus 3 degrees of the control temperature. The heater shall operate independently of engine operation so that starting times are minimized.

The control temperature shall be the temperature recommended by the engine manufacturer to meet the starting time specified.

2.12 GOVERNOR

Each engine shall be provided with a governor which maintains the frequency within a bandwidth of the rated frequency, over a steady-state load range of zero to 100 percent of rated output capacity. The governor shall be configured for safe manual adjustment of the speed/frequency during operation of the engine generator set, without special tools, from 90 to 110 percent of the rated speed/frequency, over a steady state load range of zero to 100 percent of rated capacity. Isochronous governors shall maintain the midpoint of the frequency bandwidth at the same value for steady-state loads over the range of zero to 100 percent of rated output capacity.

2.13 GENERATOR

Each generator shall be of the synchronous type, one or two bearing, SECTION 26 32 14.00 10 Page 16 conforming to NEMA MG 1, equipped with winding terminal housings in accordance with NEMA MG 1, equipped with an amortisseur winding, and directly connected to the engine. Insulation shall be Class H. Generator design shall protect against mechanical, electrical and thermal damage due to vibration, 25 percent overspeeds, or voltages and temperatures at a rated output capacity of 100 percent. Generator ancillary equipment shall meet the short circuit requirements of NEMA MG 1. Frames shall be the drip-proof type. Submit each generator KW rating and short circuit capacity (both symmetric and asymmetric).

2.13.1 Current Balance

At 100 percent rated load, and load impedance equal for each of the three phases, the permissible current difference between any two phases shall not exceed 2 percent of the largest current on either of the two phases.

Submit manufacturer's certification that the flywheel has been statically and dynamically balanced and is capable of being rotated at 125 percent of rated speed without vibration or damage.

2.13.2 Voltage Balance

At any balanced load between 75 and 100 percent of rated load, the difference in line-to-neutral voltage among the three phases shall not exceed 1 percent of the average line-to-neutral voltage. For a single-phase load condition, consisting of 25 percent load at unity power factor placed between any phase and neutral with no load on the other two phases, the maximum simultaneous difference in line-to-neutral voltage between the phases shall not exceed 3 percent of rated line to neutral voltage. The single-phase load requirement shall be valid utilizing normal exciter and regulator control. The interpretation of the 25 percent load for single phase load conditions means 25 percent of rated current at rated phase voltage and unity power factor.

2.13.3 Waveform

The deviation factor of the line-to-line voltage at zero load and at balanced full rated load at 0.8 power factor shall not exceed 10 percent.

The RMS of all harmonics shall be less than 5.0 percent and that of any one harmonic less than 3.0 percent at full rated load. Each engine-generator shall be designed and configured to meet the total harmonic distortion limits of IEEE 519 .

2.14 EXCITER

The generator exciter shall be of the brushless type. Semiconductor rectifiers shall have a minimum safety factor of 300 percent for peak inverse voltage and forward current ratings for all operating conditions, including 110 percent generator output at 4O degrees C ambient. The exciter and regulator in combination shall maintain generator-output voltage within the limits specified.

2.15 VOLTAGE REGULATOR

Each generator shall be provided with a solid-state voltage regulator, separate from the exciter. The regulator shall maintain the voltage within a bandwidth of the rated voltage, over a steady-state load range of zero to 100 percent of rated output capacity. Regulator shall be configured for safe manual adjustment of the engine generator voltage output without special tools, during operation from 90 to 110 percent of

SECTION 26 32 14.00 10 Page 17 the rated voltage over the steady state load range of zero to 100 percent of rated output capacity. Regulation drift shall not exceed plus or minus

0.5 percent for an ambient temperature change of 20 degrees C. The voltage regulator shall have a maximum droop of 2 percent of rated voltage over a load range from 0 to 100 percent of rated output capacity and automatically maintain the generator output voltage within the specified operational bandwidth.

2.16 GENERATOR PROTECTION

Short circuit and overload protection for the generator shall be provided.

The generator circuit breaker (IEEE Device 52) ratings shall be consistent with the generator rated voltage and frequency, with continuous, short circuit and interrupting current ratings to match the generator capacity.

The manufacturer shall determine the short circuit current interrupting rating of the breaker. The breaker shall be engine generator base mounted by the engine-generator set manufacturer. Molded case breakers shall be provided with shunt trip. Surge protection shall be provided for each phase of the generator, to be mounted at the generator terminals.

2.16.1 Devices

Switches, circuit breakers, switchgear, fuses, relays, and other protective devices shall be as specified in Section 26 28 01.00 10

COORDINATED POWER SYSTEM PROTECTION.

2.17 SAFETY SYSTEM

Devices, wiring, remote panels, local panels, etc., shall be provided and installed as a complete system to automatically activate the appropriate signals and initiate the appropriate actions. The safety system shall be provided with a self-test method to verify its operability. Alarm signals shall have manual acknowledgement and reset devices. The alarm signal systems shall reactivate for new signals after acknowledgment is given to any signal. The systems shall be configured so that loss of any monitoring device shall be dealt with as an alarm on that system element.

2.17.1 Audible Signal

The audible alarm signal shall sound at a frequency of 70 Hz at a volume of 75 dB at 3.1 m. The sound shall be continuously activated upon alarm and silenced upon acknowledgment. Signal devices shall be located as shown.

2.17.2 Visual Alarm Signal

The visual alarm signal shall be a panel light. The light shall be normally off, activated to be blinking upon alarm. The light shall change to continuously light upon acknowledgement. If automatic shutdown occurs, the display shall maintain activated status to indicate the cause of failure and shall not be reset until cause of alarm has been cleared and/or restored to normal condition. Shutdown alarms shall be red; all other alarms shall be amber.

2.17.3 Alarms and Action Logic

2.17.3.1 Shutdown

Simultaneous activation of the audible signal, activation of the visual

SECTION 26 32 14.00 10 Page 18 signal, stopping the engine, and opening the generator main circuit breakers shall be accomplished.

2.17.3.2 Problem

Activation of the visual signal shall be accomplished.

2.17.4 Local Alarm Panel

Provide a local alarm panel with the following shutdown and alarm functions in accordance with NFPA 110 level and including the listed Corps of Engineers requirements, mounted either on or adjacent to the engine generator set.

Device/ Condition/ Function

What/Where/ Sizes NFPA 99

N/A

NFPA 110

Level 1 N/A

NFPA 110

Level 2

Corps of Engineers Required

Shutdowns W/Alarms

High engine temperature

Automatic/ jacket water/ cylinder

SD/CP VA SD/CP VA SD/CP VA SD VA

Low lube-oil pressure

Automatic/ pressure/ level

SD/CP VA SD/CP VA SD/CP VA SD VA

Overspeed shutdown $ alarm

(110 percent ( + 2 percent) of rated speed

SD/CP VA SD/CP VA SD/CP VA SD VA

Overcrank failure to start

Automatic/ Failure to start

SD/CP VA SD/CP VA SD/CP VA

Air shutdown damper (200-600 kW)

When used SD/CP VA SD/CP VA

Red emergency stop switch

Manual switch SD/CP VA SD/CP VA SD VA

Failure to crank Corps of Engineers Required

Main Fuel Tank low fuel limit Device/ Condition/ indication (70 percent volume remaining)

Corps of Engineers Required

Alarms

SECTION 26 32 14.00 10 Page 19

Device/ Condition/ Function

What/Where/ Sizes NFPA 99

N/A

NFPA 110

Level 1 N/A

NFPA 110

Level 2

Corps of Engineers Required

Low lube-oil pressure

Pressure/ level CP VA CP VA CP VAO CP VA

Low fuel level Main tank, 3 hours remaining

VA/AA CP VA CP VAO

High fuel level Main Fuel Storage Tank 95 percent Volume

CP VA

Low coolant Jacket water CP/VA CP/VA CP/VA

Pre-high temperature

Jacket water/ cylinder

CP/VA CP/VA CP VAO CP/VA

Pre-low lube-oil pressure

CP/VA CP/VA

High battery voltage

CP/VA CP VAO

Low battery voltage CP/VA CP VAO

Battery charger AC failure

AC supply not available

CP/VA CP VAO

Control switch not in AUTO

CP/VA CP VAO

Low starting air pressure

CP/VA CP VAO

Low starting hydraulic pressure

CP/VA CP VAO

Symbol Key

SD Shut Down

CP On Control Panel

VA Visual Alarm

AA Audible Alarm

SECTION 26 32 14.00 10 Page 20

Device/ Condition/ Function

What/Where/ Sizes NFPA 99

N/A

NFPA 110

Level 1 N/A

NFPA 110

Level 2

Corps of Engineers Required

O Optional

2.17.5 Time-Delay on Alarms

For startup of the engine-generator set, time-delay devices shall be installed bypassing the low lubricating oil pressure alarm during cranking, and the coolant-fluid outlet temperature alarm. The lube-oil time-delay device shall return its alarm to normal status after the engine starts. The coolant time-delay device shall return its alarm to normal status 5 minutes after the engine starts.

Submit the magnitude of monitored values which define alarm or action setpoints, and the tolerance (plus and/or minus) at which the device activates the alarm or action.

2.17.6 Remote Alarm Panel

A remote alarm panel shall be provided in accordance with NFPA 110and as follows:

Device/ Condition/ Function

What/Where/Size NFPA 99

N/A

NFPA 110

Level 1 N/A

NFPA 110

Level 2

Remote annunciator panel

Battery powered Alarms

Loads on genset VA

Battery charger malfunction

VA

Low lube-oil Pressure/level VA/AA AA AAO

Low Temperature Jacket water VA/AA AA AAO

High Temperature Jacket water/cylinder VA/AA AA AAO

Low fuel level Main tank, 3 hr remaining

VA/AA AA AAO

Overcrank Failure to start VA/AA AA AAO

Overspeed VA/AA AA AAO

Pre-high temperature Jacket water/cylinder AA

Control switch not in

AA

SECTION 26 32 14.00 10 Page 21

Device/ Condition/ Function

What/Where/Size NFPA 99

N/A

NFPA 110

Level 1 N/A

NFPA 110

Level 2

AUTO

Common alarm contacts for local & remote common alarm

X X

Audible alarm silencing switch

X O

Air shutdown damper When used AA AAO

Common fault alarm AA

Symbology Key

X Required

SD Shut Down

CP On Control Panel

VA Visual Alarm

AA Audible Alarm

O Optional

2.18 ENGINE GENERATOR SET CONTROLS AND INSTRUMENTATION

Devices, wiring, remote panels, local panels, etc., shall be provided and installed as a complete system to automatically activate the appropriate signals and initiate the appropriate actions.

2.18.1 Controls

A local control panel shall be provided with controls in accordance with NFPA 110 level and as follows mounted either on or adjacent to the engine generator set.

Device/ Condition/ Function Corps Requirement

NFPA 110

Level 1 N/A

NFPA 110

Level 2

MFG Offering

Controls

Switch: run/start - off/set

- auto

CP CP/STD

Emergency stop switch & alarm CP CP/STD

SECTION 26 32 14.00 10 Page 22

Device/ Condition/ Function Corps Requirement

NFPA 110

Level 1 N/A

NFPA 110

Level 2

MFG Offering

Controls

Lamp test/indicator test CP CP VA CP VA CP/STD

Common alarm contacts/ fault relay

X X CP/O

Panel lighting CP CP/STD

Audible alarm & silencing/reset switch

CP

Voltage adjust for voltage regulator

CP CP/STD

Pyrometer display w/selector switch

CP

Remote emergency stop switch CP VA CP VA

Remote fuel shutoff switch

Remote lube-oil shutoff switch

2.18.2 Engine Generator Set Metering and Status Indication

A local panel shall be provided with devices in accordance with NFPA 110 level 2 mounted either on or adjacent to the engine generator set.

Device/ Condition/ Function Corps Requirement

NFPA 110

Level 1 N/A

NFPA 110

Level 2

MFG Offering

Genset Status & Metering

Genset supplying load CP VA CP VA CP VAO

System ready CP/STD

Engine oil pressure CP CP/STD

Engine coolant temperature CP CP/STD

Engine RPM (Tachometer) CP CP/STD

Engine run hours CP CP/STD

SECTION 26 32 14.00 10 Page 23

Device/ Condition/ Function Corps Requirement

NFPA 110

Level 1 N/A

NFPA 110

Level 2

MFG Offering

Pyrometer display w/selector switch

CP

AC volts (generator), 3-phase CP CP/STD

AC amps (generator), 3-phase CP CP/STD

Generator frequency CP CP/STD

Phase selector switches (amps & volts)

CP CP/STD

Watts/kW CP/VA-O

Voltage Regulator Adjustment CP

Symbology Key:

CP On Control Panel

VA Visual Alarm

AA Audible Alarm

O Optional

STD Manufacturers Standard Offering

2.19 PANELS

Each panel shall be of the type necessary to provide specified functions.

Panels shall be mounted on the engine generator set base by vibration/shock absorbing type mountings. Instruments shall be mounted flush or semiflush. Convenient access to the back of instruments shall be provided to facilitate maintenance. Instruments shall be calibrated using recognized industry calibration standards. Each panel shall be provided with a panel identification plate which clearly identifies the panel function as indicated. Each instrument and device on the panel shall be provided with a plate which clearly identifies the device and its function as indicated. Panels except the remote alarm panel can be combined into a single panel.

2.19.1 Enclosures

Enclosures shall be designed for the application and environment, conforming to NEMA ICS 6 , and provided with locking mechanisms which are keyed alike.

2.19.2 Analog

Analog electrical indicating instruments shall be in accordance with ANSI C39.1 with semiflush mounting. Switchgear, and control-room panel-mounted instruments shall have 250 degree scales with an accuracy of not less than 1 percent. Unit-mounted instruments shall be the manufacturer's standard with an accuracy of not less than 2 percent. The instrument's operating temperature range shall be minus 20 to plus 65

SECTION 26 32 14.00 10 Page 24 degrees C. Distorted generator output voltage waveform of a crest factor less than 5 shall not affect metering accuracy for phase voltages, hertz and amps.

2.19.3 Electronic

Electronic indicating instruments shall be true RMS indicating, 100 percent solid state, microprocessor controlled to provide all specified functions. Control, logic, and function devices shall be compatible as a system, sealed, dust and water tight, and shall utilize modular components with metal housings and digital instrumentation. An interface module shall be provided to decode serial link data from the electronic panel and translate alarm, fault and status conditions to set of relay contacts.

Instrument accuracy shall be not less than 2 percent for unit mounted devices and 1 percent for control room, panel mounted devices, throughout a temperature range of minus 20 to plus 65 degrees C. Data display shall utilize LED or back lit LCD. Additionally, the display shall provide indication of cycle programming and diagnostic codes for troubleshooting.

Numeral height shall be 13 mm.

2.19.4 Parameter Display

Indication or readouts of the lubricating-oil pressure, ac voltmeter, ac ammeter, frequency meter, and coolant temperature.

2.20 SURGE PROTECTION

Electrical and electronic components shall be protected from, or designed to withstand the effects of surges from switching and lightning.

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

Devices shall automatically reset after termination of their function.

2.21.1 Automatic Transfer Switch

Automatic transfer switches shall be in accordance with Section 26 36

00.00 10 AUTOMATIC TRANSFER SWITCH AND BY-PASS/ISOLATION SWITCH.

2.21.2 Monitoring and Transfer

Devices shall be provided to monitor voltage and frequency for the normal power source and each engine generator set, and control transfer from the normal source and retransfer upon restoration of the normal source.

2.22 MANUAL ENGINE-GENERATOR SET SYSTEM OPERATION

Complete facilities shall be provided for manual starting and testing of each set without load, loading and unloading of each set.

2.23 BASE

The base shall be constructed of steel. The base shall be designed to rigidly support the engine-generator set, ensure permanent alignment of all rotating parts, be arranged to provide easy access to allow changing

SECTION 26 32 14.00 10 Page 25 of lube-oil, and ensure that alignment will be maintained during shipping and normal operation. The base shall permit skidding in any direction during installation and shall be provided with suitable holes for foundation bolts. The base shall also withstand and mitigate the effects of synchronous vibration of the engine and generator, and shall be provided with suitable holes for anchor bolts and jacking screws for leveling.

2.24 THERMAL INSULATION

Thermal insulation shall be as specified in Section 23 07 00 THERMAL

INSULATION FOR MECHANICAL SYSTEMS.

2.25 PAINTING AND FINISHING

The engine-generator set shall be cleaned, primed and painted in accordance with the manufacturer's standard color and practice.

2.26 FACTORY INSPECTION AND TESTS

Perform factory inspection and tests 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.

Submit a certification that each engine generator set passed the factory tests and inspections and a list of the test and inspections.

PART 3 EXECUTION

3.1 EXAMINATION

After becoming familiar with all details of the work, perform a Site Visit to verify details of the work. Submit a site visit letter stating the date the site was visited and listing discrepancies found and advise the Contracting Officer in writing of any discrepancies before performing any work.

3.2 GENERAL INSTALLATION

Submit a complete copy of the manufacturer's installation procedures. A detailed description of the manufacturer's recommended break-in procedure.

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

3.3 PIPING INSTALLATION

3.3.1 General

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

Con…