Generator - GBSD_ICC_FE_Warren_SpecsVol2_RTA_24Feb23.pdf

GBSD Integrated Command Center CUI Ready to Advertise Submittal F.E. Warren Air Force Base, WY 24 February 2023

SECTION 26 32 15.00

ENGINE-GENERATOR SET STATIONARY 15-2500 KW, WITH AUXILIARIES

05/20

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 SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B16.1 (2020) Gray Iron Pipe Flanges and Flanged Fittings Classes 25, 125, and 250

ASME B16.3 (2016) Malleable Iron Threaded Fittings, Classes 150 and 300

ASME B16.5 (2020) Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME B16.9 (2018) Factory-Made Wrought Buttwelding Fittings

ASME B16.11 (2016) Forged Fittings, Socket-Welding and Threaded

ASME B16.21 (2016) Nonmetallic Flat Gaskets for Pipe Flanges

ASME B31.1 (2020) Power Piping

ASME B31.3 (2020) Process Piping

ASME BPVC SEC IX (2017; Errata 2018) BPVC Section IX-Welding, Brazing and Fusing Qualifications

ASME BPVC SEC VIII D1 (2019) BPVC Section VIII-Rules for Construction of Pressure Vessels Division 1

ASTM INTERNATIONAL (ASTM)

ASTM A53/A53M (2020) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A106/A106M (2019a) Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service

ASTM A126 (2004; R 2019) Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings

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CUI

ASTM A181/A181M (2014; R 2020) Standard Specification for Carbon Steel Forgings, for General-Purpose Piping

ASTM A193/A193M (2020) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A194/A194M (2020a) Standard Specification for Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

ASTM A234/A234M (2019) Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service

ASTM B395/B395M (2018) Standard Specification for U-Bend Seamless Copper and Copper Alloy Heat Exchanger and Condenser Tubes

ASTM D975 (2020) Standard Specification for Diesel Fuel Oils

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 2011) General Principles for Temperature Limits in the Rating of Electric Equipment and for the Evaluation of Electrical Insulation

IEEE 43 (2013) Recommended Practice for Testing Insulation Resistance of Rotating Machinery

IEEE 81 (2012) Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface Potentials of a Ground System

IEEE 100 (2000; Archived) The Authoritative Dictionary of IEEE Standards Terms

IEEE 115 (2019) Guide for Test Procedures for Synchronous Machines: Part I Acceptance and Performance Testing; Part II Test Procedures and Parameter Determination for Dynamic Analysis

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

IEEE 519 (2014) Recommended Practices and

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Requirements for Harmonic Control in Electrical Power Systems

IEEE C2 (2017; Errata 1-2 2017; INT 1 2017) National Electrical Safety Code

IEEE C50.12 (2005; R 2010) Standard for Salient Pole 50 HZ and 60 Hz Synchronous Generators and Generation/Motors for Hydraulic Turbine Applications Rated 5 MVA and above

IEEE C57.13 (2016) Requirements for Instrument Transformers

IEEE C57.13.1 (2006; R 2012) Guide for Field Testing of Relaying Current Transformers

INTERNATIONAL CODE COUNCIL (ICC)

ICC IBC (2021) International Building Code

INTERNATIONAL ELECTRICAL TESTING ASSOCIATION (NETA)

NETA ATS (2021) Standard for Acceptance Testing Specifications for Electrical Power Equipment and Systems

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 3046 (2002, 2006, 2009, 2001) Reciprocating Internal Combustion Engines - Performance--Part 1, 3, 4, 5, 6

ISO 8528 (1993; R 2018) Reciprocating Internal Combustion Engine Driven Alternating Current Generator Sets--Part 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 13

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-58 (2018) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation

MSS SP-70 (2011) Gray Iron Gate Valves, Flanged and Threaded Ends

MSS SP-71 (2018) Gray Iron Swing Check Valves, Flanged and Threaded Ends

MSS SP-80 (2019) Bronze Gate, Globe, Angle and Check Valves

MSS SP-85 (2011) Gray Iron Globe & Angle Valves Flanged and Threaded Ends

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NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 2 (2000; R 2020) Industrial Control and Systems Controllers, Contactors, and Overload Relays Rated 600 V

NEMA ICS 6 (1993; R 2016) Industrial Control and Systems: Enclosures

NEMA MG 1 (2018) Motors and Generators

NEMA PB 1 (2011) Panelboards

NEMA PB 2 (2011) Deadfront Distribution Switchboards

NEMA/ANSI C12.11 (2006; R 2019) 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 30 (2021; TIA 20-1; TIA 20-2) Flammable and Combustible Liquids Code

NFPA 37 (2021) Standard for the Installation and Use of Stationary Combustion Engines and Gas Turbines

NFPA 54 (2021) National Fuel Gas Code

NFPA 58 (2020; TIA 20-1; TIA 20-2; TIA 20-3)

Liquefied Petroleum Gas Code

NFPA 70 (2020; ERTA 20-1 2020; ERTA 20-2 2020; TIA

20-1; TIA 20-2; TIA 20-3; TIA 20-4)

National Electrical Code

NFPA 110 (2016) Standard for Emergency and Standby Power Systems

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

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

SAE J537 (2016) Storage Batteries

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-DTL-16884 (2017; Rev P) Fuel, Naval Distillate

MIL-STD-461 (2015; Rev G) Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

UFC 3-301-01 (2019) Structural Engineering

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

40 CFR 60 Standards of Performance for New

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Stationary Sources

UNDERWRITERS LABORATORIES (UL)

UL 142 (2006; Reprint Jan 2021) UL Standard for Safety Steel Aboveground Tanks for Flammable and Combustible Liquids

UL 467 (2013; Reprint Jun 2017) UL Standard for Safety Grounding and Bonding Equipment

UL 489 (2016; Rev 2019) UL Standard for Safety Molded-Case Circuit Breakers, Molded-Case Switches and Circuit-Breaker Enclosures

UL 1236 (2015; Reprint Feb 2021) UL Standard for Safety Battery Chargers for Charging Engine-Starter Batteries

UL 1437 (2006) Electrical Analog Instruments - Panel Board Types

1.2 RELATED MATERIALS

Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM, and Section 26 08 00 APPARATUS INSPECTION AND TESTING apply to this section, except as modified herein.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" or "S" classification. Submittals not having a "G" or "S" classification are for information only. When used, a code following the "G" classification 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

Engine-Generator Set and Auxiliary Equipment; G, AE

Auxiliary Systems; G, AE

Detailed Drawings; G, AE

Acceptance; G

SD-03 Product Data

Harmonic Requirements; G

Emissions; G

Filters; G special tools; G

Remote Alarm Annunciator; G, AE

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Engine-Generator Parameter Schedule

Heat Exchanger

Generator

Manufacturer's Catalog

Site Welding

Spare Parts

Onsite Training

Vibration-Isolation

Posted Data and Instructions; G

Instructions; G

Experience

Field Engineer

General Installation

Exciter

SD-05 Design Data

Performance Criteria

Sound Limitations; G

Integral Main Fuel Storage Tank

Power Factor

Heat Exchanger

Time-Delay on Alarms

Cooling System

Vibration Isolation

Battery Charger

Capacity Calculations for Engine-Generator Set; G, AE

Brake Mean Effective Pressure (BMEP) Calculations; G

Torsional Vibration Stress Analysis Computations; G

Capacity Calculations for Batteries; G, AE

Turbocharger Load Calculations; G

SD-06 Test Reports

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Performance Tests

Factory Inspection and Tests

Factory Tests

Onsite Inspection and Tests; G

Acceptance Checks and Tests; G

Functional Acceptance Tests; G

Maintenance Procedures; G

Operation and Maintenance Manuals; G

Inspections; G

Functional Acceptance Test Procedure; G

SD-07 Certificates

Cooling System

Vibration Isolation

Prototype Test

Reliability and Durability

Fuel System Certification; G

Start-Up Engineer; G

Instructor's Qualification Resume; G

Engine Emission Limits; G

Sound Limitations

Site Visit

Current Balance

Materials and Equipment

Factory Inspection and Tests

SD-09 Manufacturer's Field Reports

Engine Tests; G

Generator Tests; G

Assembled Engine-Generator Set Tests; G

SD-10 Operation and Maintenance Data

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Preliminary Assembled Operation and Maintenance Manuals; G

Submit in accordance with Section 01 78 23 OPERATION AND MAINTENANCE DATA and the paragraph ASSEMBLED OPERATION AND

MAINTENANCE MANUALS.

SD-11 Closeout Submittals

Posted Data and Instructions; G

Training Plan; G

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, NEMA, etc., the design, fabrication and installation must also conform to the code.

1.4.2 Site Welding

Weld structural members in accordance with Section 05 05 23.16 STRUCTURAL WELDING. 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. Submit a copy of qualifying procedures and a list of names and identification symbols of qualified welders and welding operators.

c. 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 identification symbols.

d. Perform welder qualification tests for each welder whose qualifications are not in compliance with the referenced standards.

Notify the Contracting Officer 24 hours in advance of qualification tests which must be performed at the work site, if practical.

e. The welder or welding operator must apply the personally assigned symbol near each weld made as a permanent record.

1.4.3 Vibration Limitation

Limit the maximum engine-generator set vibration in the horizontal, vertical, and axial directions to 6 mils (peak-peak RMS), with an overall velocity limit of 0.95 inches/second RMS, at rated speed for all loads through 110 percent of rated speed. The engine-generator set must 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.

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1.4.4 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.

1.4.5 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.

1.4.6 Seismic Requirements

Seismic requirements must be in accordance with UFC 3-301-01 and Section

13 48 73 SEISMIC CONTROL FOR MECHANICAL EQUIPMENT.

1.4.7 Experience

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

1.4.8 Field Engineer

The engine-generator set manufacturer or assembler must 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 must have attended the engine generator manufacturer's training courses on installation and operation and maintenance of engine generator sets. Submit a letter listing the qualifications, schools, formal training, and experience of the field engineer.

1.4.9 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

Jacobs D3420101 SECTION 26 32 15.00 Page 9 switches including single line and wiring diagrams.

g. Lubrication system, including piping, pumps, strainers, filters, heat exchangers for lube oil and turbocharger cooling, electric heater, controls and wiring.

h. Location, type, and description of vibration isolation devices for all applications.

i. The safety system, including wiring schematics.

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

k. Panel layouts.

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

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

1.4.10 Auxiliary Systems Engine-Generator Set and Auxiliary Equipment Drawing Requirements

Submit drawings pertaining to the engine-generator set and auxiliary equipment, including but not limited to the following:

a. Certified outline, general arrangement (setting plan), and anchor bolt details. Show total weight and center of gravity of assembled equipment on the steel sub-base.

b. Detailed elementary, schematic wiring, and interconnection diagrams of the engine starting system, jacket coolant heating system, engine protective devices, engine alarm devices, engine speed governor system, generator and excitation system, and other integral devices.

c. Detailed elementary, schematic wiring; and interconnection diagrams of the fuel system, starting battery system, engine-generator control panel, generator circuit breaker, and remote alarm annunciator.

d. Dimensional drawings or catalog cuts of exhaust silencers, radiator, fuel day tanks, fuel oil cooler, valves and pumps, intake filters, vibration isolators, and other auxiliary equipment not integral with the engine-generator set.

1.4.11 Auxiliary Systems Drawing Requirements

Submit drawings showing floor plan arrangement of exhaust, air intake, fuel oil cooler, and jacket coolant water systems including arrangement of piping and pipe sizes.

1.4.12 Vibration Isolation System Certification

Submit certification from the manufacturer that the vibration isolation system will reduce the vibration to the limits specified in the paragraph

VIBRATION ISOLATION.

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1.4.13 Fuel System Certification

When the fuel system requires a fuel oil cooler as described in the paragraph FUEL OIL COOLER, submit certification from the engine manufacturer that the fuel system design is satisfactory.

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, cap piping and similar openings to keep out dirt and other foreign matter.

Deliver equipment on pallets or blocking wrapped in heavy-duty plastic, sealed to protect parts and assemblies from moisture and dirt. Protect and prepare batteries for shipment as recommended by the battery manufacturer. Store auxiliary equipment at the site in covered enclosures, protected from atmospheric moisture, dirt, and ground water.

1.6 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, for special purposes, or to reach otherwise inaccessible parts. One handset must be provided for each electronic governor when required to indicate and/or change governor response settings. Furnish 4 liters one gallon of identical paint used on engine-generator set in manufacturer's sealed container with each engine-generator set.

Wrenches and tools specifically designed and required to work on the new equipment, which are not commercially available as standard mechanic's tools, must be furnished to the Contracting Officer.

Provide proposed operating instructions for the engine-generator set and auxiliary equipment laminated between matte-surface thermoplastic sheets and suitable for placement adjacent to corresponding equipment. After approval, install operating instructions where directed.

1.7 MAINTENANCE SERVICES

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

1.7.1 Operation Manual

Provide three copies of the . Sections must be separated by heavy plastic dividers with tabs which identify the material in the section. Fold drawings with the title block visible, and placed in 8-1/2 by 11 inch plastic pockets with reinforced holes. The manual must 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 and uninterruptible power supplies .

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1.7.2 Maintenance Manual

Provide three copies of the manufacturers standard maintenance manual .

Separate each section by a heavy plastic divider with tabs. Fold drawings with the title block visible, and placed in plastic pockets with reinforced holes. The manual must 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.

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

1.7.3 Assembled Operation and Maintenance Manuals

The contents of the assembled operation and maintenance manuals must include the manufacturer's O&M information required by the paragraph SD-10, OPERATION AND MAINTENANCE DATA and the manufacturer's O&M information specified in Section 26 36 23 AUTOMATIC TRANSFER SWITCHES AND

BY-PASS/ISOLATION SWITCH.

a. Manuals must be in separate books or volumes, assembled and bound securely in durable, hard covered, water resistant binder, and indexed by major assembly and components in sequential order.

b. A table of contents (index) must be made part of the assembled O&M.

The manual must be assembled in the order noted in table of contents.

c. The cover sheet or binder on each volume of the manuals must be identified and marked with the words, "Operation and Maintenance Manual."

1.8 SITE CONDITIONS

Protect the components of the engine-generator set, including cooling system components, pumps, fans, and similar auxiliaries when not operating and provide components capable of the specified outputs in the following environment:

a. Site Location: FE Warren AFB, Cheyenne, Wyoming

b. Site Elevation: 6,000 feet above mean sea level.

c. Ambient Temperatures:

(1) Maximum 92' degrees F dry bulb, 58 degrees F wet bulb.

(2) Minimum 14 degrees F dry bulb.

d. Seismic Zone: Zone C as defined by ICC IBC .

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PART 2 PRODUCTS

2.1 SYSTEM REQUIREMENTS

a. Provide and install each 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 must 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. Assemble sets having a capacity of 750 kW or smaller and attach to the base prior to shipping. Sets over 750 kW capacity may be shipped in sections. Provide set components that are environmentally suitable for the locations shown and that are 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. Identify any nonstandard products or components and the reason for their use.

2.1.1 Engine-Generator Parameter Schedule

Engine-Generator Set and Auxiliary Equipment Capacity Calculations for Engine-Generator Set

ENGINE-GENERATOR PARAMETER SCHEDULE

Identification Make/Model

Electrical Characteristics

Power Rating Emergency Standby Gross bhp rating / Net brake power rating as indicated on drawings kW at 0.8 power factor

Governor Type Type Make / Model Isochronous

Overload Capacity (Prime applications only)

110 percent of Service Load for 1 hour in 12 consecutive hours

Service Load Loads connected to generator as tabulated in panel schedules

Power Factor 0.8 lagging

Engine-Generator Applications stand-alone

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ENGINE-GENERATOR PARAMETER SCHEDULE

Voltage Regulation (No Load to Full Load)(Stand-alone applications) plus or minus 2 percent (maximum)

Voltage Bandwidth (steady state) plus or minus 1 percent

Frequency 60 Hz

Voltage 480/277 volts

Phases 3 Phase, Wye

Max Step Load Increase

75 percent of Service Load at 0.8 PF

Maximum Voltage Deviation with Step Load Increase

10 percent of rated voltage

Max Step Load Decrease (without shutdown)

100 percent of Service Load at 0.8 PF

Reactances Synchronous reactance, Xd Transient reactance, X'd Sub-transient reactance, X"d Negative sequence reactance, X2 Zero sequence reactance, Xo

Capacity Calculations

Calculations must verify that the engine-generator set power rating is adequate for loads indicated on drawings and schedule.

Capacity Calculations for Batteries

Calculation must verify that the engine starting battery capacity exceeds dc power requirements.

Mechanical Characteristics

Engine Description Strokes/cycle Number of cylinders Bore and Stroke, inches

Engine Speed 1800 rpm

Engine Cooling Type water/ethylene glycol

Intercooler Type Air-to-Air or Jacket Water

Induction Method Naturally Aspirated or Turbocharged

Turbocharger Make / Model

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ENGINE-GENERATOR PARAMETER SCHEDULE

Max Time to Start and be Ready to Assume Load

10 seconds

Max Summer Indoor Temp (Prior to Engine-generator Operation)

78 degrees F

Min Winter Indoor Temp (Prior to Engine-generator Operation)

40 degrees F

Max Allowable Heat Transferred To Engine Generator Space at Rated Output Capacity

33000 BTU/min

Max Summer Outdoor Temp (Ambient)

92 degrees F

Min Winter Outdoor Temp (Ambient)

-14 degrees F

Installation Elevation

6000 feet above sea level

Engine-Generator Set Emissions Data

Exhaust Temperature Approximately 910 degrees F at full load

Exhaust Flow Approximately 550 cfm

Combustion Air Approximately 65 scfm

Total Heat Rejected Approximately 33000 Btu/min, at full load to:

Jacket Coolant System Fuel Oil Cooling System

Emissions Particulate Matter with an average aerodynamic diameter of 10 microns Sulfur Dioxides Nitrogen Oxides (as NO2) Carbon Monoxide Volatile Organic Compounds

Visible Emissions Percent opacity at full load

Brake Mean Effective Pressure (BMEP) Calculations

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ENGINE-GENERATOR PARAMETER SCHEDULE

Calculation must verify that the engine meets the specified maximum BMEP, as follows:

BMEP psi = (120,000 X bkW) X (792,000 X bhp) (rpm X cu. in.)

Where:

bkW bhp = bkW' + bkW" bhp' + bhp" bkW" bhp" is the Brake kW horsepower required by engine driven fan for cooling radiator or motor driven fan for cooling radiator.

bkW' bhp' = kW/GEN.EFF. kW/(GEN.EFF. times 0.746) GEN.EFF. = Generator efficiency

cu. in. = Total engine piston displacement in cubic inches rpm = Engine revolutions per minute kW = Minimum power rating

Torsional Vibration Stress Analysis Computations

Torsional vibrational stresses in the crankshaft and generator shaft of assembled engine and driven generator must not exceed 5000 psi when engine is driving generator at rated speed while assembled unit is loaded to rated engine-generator set power. Computations must be based on a mathematical model of the assembled generator set provided or based on calculations using measured values from tests on a unit identical to the one provided. Calculations based on models of, or measured data from, the unassembled engine and generator will not be acceptable.

Calculations must include:

a. A description of the system relating information pertinent to analysis such as operating speed range and identification plate data.

b. A mass elastic assembly drawing, showing the arrangement of the units in the generator set and dimensions of shafting, including minimum diameters (or section moduli) of shafting in the system.

c. A labeled line diagram of the mass elastic system indicating values of masses, stiffness, equivalent lengths, and equivalent diameters including basic assumptions and definition of terms.

d. Sample computations showing procedures used to obtain resulting stress values.

e. Computations indicating assembled engine-generator speed of 1800 rpm with assembly loaded to rated generator power and the resulting computed critical torsional stress values in the assembled engine crankshaft and generator shaft.

Turbocharger Load Calculations

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ENGINE-GENERATOR PARAMETER SCHEDULE

NOTE: When the engine-generator set installation includes field installed exhaust system (i.e., the engine-generator set is installed internal to a building in lieu of in a self-contained outdoor enclosure), include the following paragraph.

When the proposed exhaust system layout is different from that shown on the contract drawings, submit calculations showing that the external loads from the exhaust system such as weight and thermal expansion do not exceed the engine manufacturer's maximum allowed forces and moments on the turbocharger.

2.1.2 Rated Output Capacity

Provide each engine-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 must also consider engine and/or generator oversizing required to meet requirements in paragraph Engine-Generator Parameter Schedule.

The engine must meet the specified maximum BMEP requirements at rated speed as calculated in accordance with the calculations in the engine-generator parameter schedule. The engine capacity must be based on the following:

a. Engine burning diesel fuel conforming to MIL-DTL-16884 or ASTM D975, Grade 2-D, or at an ambient temperature of 85 degrees F. For stationary engines operated in the United States, diesel fuel requirements are found in 40 CFR 60 Subpart IIII.

b. Engine cooled by a radiator fan mechanically driven by the engine or remote with a motor driven fan.

c. Engine cooled by coolant mixture of water and ethylene glycol, 50 percent by volume of each.

2.1.2.1 Engine Emission Limits

Engine must be certified by the manufacturer to meet applicable EPA emission standards found in 40 CFR 60 Subpart IIII. In addition, engine must meet any applicable state or local emission requirements (ex:

California SCAQMD).

2.1.2.2 Performance Class

The voltage and frequency behavior of the generator set must be in accordance with ISO 8528 operating limit values for performance Class G2.

2.1.3 Power Ratings

Power ratings must be in accordance with EGSA 101P.

2.1.4 Transient Response

The engine-generator set governor and voltage regulator must cause the

Jacobs D3420101 SECTION 26 32 15.00 Page 17 engine-generator set to respond to the maximum step load changes such that output voltage and frequency recover to and stabilize within the operational bandwidth within the transient recovery time. The engine-generator set must respond to maximum step load changes such that the maximum voltage and frequency deviations from bandwidth are not exceeded.

2.1.5 Reliability and Durability

Provide prime engine-generator sets that have both an engine and a generator capable of delivering the specified power on a prime basis with an anticipated mean time between overhauls of not less than 10,000 hours operating with a 70 percent load factor. Cite two like engines and two like generators that have performed satisfactorily in a stationary power plant, independent from the physical location of the manufacturer's and assembler's facilities. The engine and generators should have been in operation for a minimum of 8000 actual hours at a minimum load of 70 percent of the rated output capacity. During two consecutive years of service, the units should not have experienced any failure resulting in a downtime in excess of 72 hours. Provide engines that are the same model, speed, bore, stroke, number and configuration of cylinders and rated output capacity. Provide generators that are the same model, speed, pitch, cooling, exciter, voltage regulator and rated output capacity.

Submit a reliability and durability certification letter from the manufacturer and assembler to prove that existing facilities are and have been successfully utilizing the same components proposed to meet this specification, in similar service. Certification may be based on components, i.e. engines used with different models of generators and generators used with different engines, and does not exclude annual technological improvements made by a manufacturer in the basic standard-model component on which experience was obtained, provided parts interchangeability has not been substantially affected and the current standard model meets the performance requirements specified. Provide a list with the name of the installations, completion dates, and name and telephone number of a point of contact.

2.1.6 Vibration Isolation

Provide an engine-generator set with a vibration isolation system in accordance with the manufacturer's standard recommendation. 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 plus description of seismic qualification of the engine-generator mounting, base, and vibration isolation. Submit torsional analysis including prototype testing or and 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 10 percent. Design and qualify vibration isolation systems as an integral part of the base and mounting system in accordance with the seismic parameters specified. 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.

2.1.7 Harmonic Requirements

The generator must be capable of serving non-linear loads including a UPS, monitors, and other electronics as indicated in the panel schedules.

Jacobs D3420101 SECTION 26 32 15.00 Page 18

2.1.8 Starting Time Requirements

Upon receipt of a signal to start, each engine generator set will start, reach rated frequency and voltage and be ready to assume load within the time specified. For standby sets used in emergency power applications, each engine generator set will start, reach rated frequency and voltage, and power will be supplied to the load terminals of the automatic transfer switch within the starting time specified.

2.2 NAMEPLATES

Provide the manufacturer's name, type or style, model or serial number and rating on a plate secured to the equipment for each major component of this specification. Provide plates and tags sized so that inscription is readily legible to operating or maintenance personnel and securely mounted to or attached in proximity of their identified controls or equipment.

Lettering must be normal block lettering, a minimum of 0.25 inch high. As a minimum, provide nameplates for:

Engines Relays

Generators Transformers (CT & PT)

Regulators Day tanks

Pumps and pump motors Governors

Generator Breaker Air Starting System

Economizers Heat exchangers (other than base mounted)

Where the following equipment is not provided as a standard component by the engine generator set manufacturer, the nameplate information may be provided in the maintenance manual in lieu of nameplates.

Battery charger Heaters

Switchboards Exhaust mufflers

Switchgear Silencers

Battery Exciters

2.2.1 Materials

Construct ID plates and tags of 16 gage minimum thickness bronze or stainless steel sheet metal engraved or stamped with inscription.

Construct plates and tags not exposed to the weather or high operational temperature of the engine of laminated plastic, 0.125 inch thick, matte white finish with black center core, with lettering accurately aligned and engraved into the core.

2.2.2 Control Devices and Operation Indicators

Provide ID plates or tags for control devices and operation indicators, Jacobs D3420101 SECTION 26 32 15.00 Page 19 including valves, off-on switches, visual alarm annunciators, gages and thermometers, that are required for operation and maintenance of provided mechanical systems. Plates or tags must be minimum of 0.5 inch high and 2 inches long and must indicate component system and component function.

2.2.3 Equipment

Provide ID plates of a minimum size of high and 5 inches long on provided equipment indicating the following information:

a. Manufacturer's name, address, type and model number, serial number, and certificate of compliance with applicable EPA mission standards;

b. Contract number and accepted date;

c. Capacity or size;

d. System in which installed; and

e. System which it controls.

2.3 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 must be insulated, fully enclosed, guarded, or fitted with other types of safety devices. Install safety devices such that proper operation of the equipment is not impaired.

2.4 MATERIALS AND EQUIPMENT

Submit certification stating that where materials or equipment are specified to comply with requirements of UL, 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.

2.4.1 Circuit Breakers, Low Voltage

UL 489 .

2.4.2 Filter Elements

Provide the manufacturer's standard fuel-oil, lubricating-oil, and combustion-air filter elements.

2.4.3 Instrument Transformers

NEMA/ANSI C12.11 .

2.4.4 Revenue Metering

IEEE C57.13 .

2.4.5 Pipe (Fuel/Lube-Oil, Compressed Air, Coolant, and Exhaust)

ASTM A53/A53M, or ASTM A106/A106M steel pipe. Pipe smaller than 2 inches

Jacobs D3420101 SECTION 26 32 15.00 Page 20 must be Schedule 80. Pipe 2 inches and larger must be Schedule 40.

2.4.5.1 Flanges and Flanged Fittings

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

2.4.5.2 Pipe Welding Fittings

ASTM A234/A234M , Grade WPB or WPC, Class 150 or ASME B16.11 , 3000 lb.

2.4.5.3 Threaded Fittings

ASME B16.3 , Class 150.

2.4.5.4 Valves

MSS SP-80 , Class 150.

2.4.5.5 Gaskets

Manufacturer's standard.

2.4.6 Pipe Hangers

MSS SP-58 .

2.4.7 Electrical Enclosures

NEMA ICS 6 .

2.4.7.1 Switchboards

NEMA PB 2.

2.4.7.2 Panelboards

NEMA PB 1.

2.4.8 Electric Motors

Provide electric motors that conform to the requirements of NEMA MG 1.

Motors must have sealed ball bearings and a maximum speed of 1800 rpm.

Motors used indoors must have drip-proof frames; enclose those that are used outside. Alternating current motors larger than 1/2 Hp must be of the squirrel-cage induction type for operation on 208 volts or higher, 60 Hz, and three-phase power. Alternating current motors 1/2 Hp or smaller, must be suitable for operation on 120 volts, 60 Hz, and single-phase power. Direct current motors must be suitable for operation on 125 volts.

2.4.9 Motor Controllers

Provide motor controllers and starters that conform to the requirements of NFPA 70 and NEMA ICS 2 .

2.5 ENGINE

Each engine must operate on No. 2-D diesel fuel conforming to ASTM D975, must be designed for stationary applications and must be complete with ancillaries. The engine must be a standard production model shown in the

Jacobs D3420101 SECTION 26 32 15.00 Page 21 manufacturer's catalog describing and depicting each engine-generator set and all ancillary equipment in sufficient detail to demonstrate complete specification compliance. The engine must be naturally aspirated, supercharged, or turbocharged. The engine must be 2- or 4-stroke-cycle and compression-ignition type. The engine must be vertical in-line, V- or opposed-piston type, with a solid cast block or individually cast cylinders. The engine must have a minimum of two cylinders.

Opposed-piston type engines must have more than four cylinders. Each block must have a coolant drain port. Equip each engine with an over-speed sensor.

ISO 3046 . Diesel engines must be four-cycle naturally aspirated, or turbocharged, or turbocharged and intercooled; vertical in-line or vertical Vee type; designed for stationary service. Engines must be capable of immediate acceleration from rest to normal speed without intermediate idle/warm up period or pre-lubrication to provide essential electrical power. Two-cycle engines are not acceptable.

2.5.1 Sub-base Mounting

Mount each engine-generator set on a structural steel sub-base sized to support the engine, generator, and necessary accessories, auxiliaries and control equipment to produce a complete self-contained unit as standard with the manufacturer. Design the structural sub-base to properly support the equipment and maintain proper alignment of the engine-generator set in the specified seismic zone. In addition, provide sub-base with both lifting rings and jacking pads properly located to facilitate shipping and installation of the unit. Factory align engine and generator on the sub-base and securely bolt into place in accordance with the manufacturer's standard practice. Crankshaft must have rigid coupling for connection to the generator.

2.5.2 Assembly

Completely shop assemble each engine-generator set on its structural steel sub-base. Paint entire unit with manufacturer's standard paints and colors. After factory tests and before shipping, thoroughly clean and retouch painting as necessary to provide complete protection.

2.5.3 Turbocharger

If required by the manufacturer to meet the engine-generator set rating, provide turbine type driven by exhaust gas from engine cylinders, and direct connected to the blower supplying air to the engine intake manifold.

2.5.4 Intercooler

Provide manufacturer's standard intercooler for engine size specified.

2.5.5 Crankcase Protection

2.5.6 Miscellaneous Engine Accessories

Provide the following engine accessories where the manufacturer's standard design permits:

a. Piping on engine to inlet and outlet connections, including nonstandard companion flanges.

Jacobs D3420101 SECTION 26 32 15.00 Page 22

b. Structural steel sub-base and vibration isolators, foundation bolts, nuts, and pipe sleeves.

c. Level jack screws or shims, as required.

d. Rails, chocks, and shims for installation of sub-base on the foundation.

e. Removable guard, around fan. Support guard, on engine sub-base, to suit manufacturer's standard.

2.5.7 Intercooler

Provide manufacturer's standard intercooler for engine size specified.

2.6 FUEL SYSTEM

Provide fuel system conforming to the requirements of NFPA 30 and NFPA 37 and containing the following elements.

2.6.1 Pumps

Fuel transfer pumps may be mounted on the day tank. Pump must be horizontal, positive displacement. Direct-connect pump to motor through a flexible coupling. Equip each pump with a bypass relief valve, if not provided with an internal relief valve. Provide motor and controller in accordance with the paragraphs ELECTRIC MOTORS and MOTOR CONTROLLERS, respectively.

2.6.1.1 Main Pump

Provide engines with an engine driven pump. The pump must supply fuel at a minimum rate sufficient to provide the amount of fuel required to meet the performance indicated within the parameter schedule. Base the fuel flow rate on meeting the load requirements and all necessary recirculation.

2.6.1.2 Auxiliary Fuel Pump

Provide auxiliary fuel pumps to maintain the required engine fuel pressure, if either required by the installation or indicated on the drawings. The auxiliary pump must be driven by a dc electric motor powered by the starting/station batteries. Automatically actuate the auxiliary pump by a pressure-detecting device.

2.6.2 Fuel Filter

Provide a minimum of one full-flow fuel filter for each engine. The filter must be readily accessible and capable of being changed without disconnecting the piping or disturbing other components. Mark the inlet and outlet connections of the filter.

Provide intake filter assemblies for each engine of the oil bath or dry type, as standard with the manufacturer. Filters must be capable of removing a minimum of 92 percent of dirt and abrasive 3 microns and larger from intake air. Size filters to suit engine requirements at 100 percent of rated full load. Design unit for field access for maintenance purposes.

Jacobs D3420101 SECTION 26 32 15.00 Page 23

2.6.3 Relief/Bypass Valve

Provide a relief/bypass valve to regulate pressure in the fuel supply line, return excess fuel to a return line and prevent the build-up of excessive pressure in the fuel system.

2.6.4 Integral Main Fuel Storage Tank

Provide each engine with an integral main fuel tank. Each tank must be factory installed and provided as an integral part of the generator manufacturer's product. Provide each tank with connections for fuel supply line, fuel return line, local fuel fill port, gauge, vent line, and float switch assembly. Provide a fuel return line cooler as recommended by the manufacturer and assembler. The temperature of the fuel returning to the tank must be below the flash point of the fuel. Mount the tank within the enclosure for each engine-generator set provided with weatherproof enclosures. The fuel fill line must be accessible without opening the enclosure.

a. All Tanks: UL 142 . Provide integral in skid double wall (110 percent containment) fuel tanks with a minimum capacity of 24 hours of engine-generator set operation at full-rated load. Epoxy coat day tanks inside and prime and paint outside. Construct tanks of not less than 3/16 inch steel plate with welded joints and necessary stiffeners on exterior of tank. Provide a braced structural steel framework support. Weld tank top tight. Provide 4 1/2 inch square inspection port with a 2 inch NPT fill connection and spill box.

Provide proper normal and emergency venting for the primary tank and emergency venting only for the secondary tank / containment basin in accordance with UL 142 requirements.

b. Float Switches for Day Tanks: Provide tank-top mounted or external float cage, single-pole, single-throw type designed for use on fuel oil tanks. Arrange high level float switches to close on rise of liquid level, and low level float switches to close on fall of liquid level. Mount float cage units with isolating and drain valves.

Contacts must be suitable for the station battery voltage.

(1) Critical low level float switch which must activate at 5 percent of normal liquid level must shut engine off.

(2) Low-low level float switch which must activate alarm at 30 percent of normal liquid level.

(3) Low level float switch which must open the fuel oil solenoid valve and start the fuel transfer pump at 75 percent of normal liquid level.

(4) High level float switch which must close the fuel oil solenoid valve and stop the fuel transfer pump at 90 percent of normal liquid level.

(5) Critical high level float switch which must activate alarm at 95 percent of normal liquid level.

c. Leak Detector Switch for All Tanks: Actuates when fuel is detected in containment basin, stops fuel transfer pump, and closes the fuel oil solenoid valve.

Jacobs D3420101 SECTION 26 32 15.00 Page 24

d. Control Panel for All Tanks: Provide NEMA ICS 6 , Type 1, enclosed control panel for each day tank. Control panel must include the following accessories.

(1) Power available LED (green).

(2) Critical low fuel alarm contacts for shut down of engine.

(3) Low-low level fuel alarm LED.

(4) Low-low level fuel alarm contracts for remote annunciator.

(5) Critical high level fuel alarm LED.

(6) Leak detecting alarm LED.

(7) Alarm horn.

e. Tank Gages for All Tanks: Provide buoyant force type gages for fuel tanks with dial indicator not less than 4 inches in size and arranged for top mounting. Calibrate each reading dial or scale for its specific tank to read from empty to full, with intermediate points of 1/4, 1/2, and 3/4.

f. Integral Base Tanks Used as Primary Tank: Provide a 2 inch opening at the tank fill port, fitted an overfill prevention valve (OPV).

Additionally, the fill opening must be perpendicular to the tank in order to allow operation of the OPV. Integral base tank must be sized and configured such that the filling and venting nozzles are outside the generator cabinet for ease of accessibility, inspection, and maintenance. Level gage must be in the line of sight from the fill port.

g. Integral Base Tanks Located Inside Buildings. The tank vents must discharge outside the building in accordance with NFPA 30 and NFPA 37 .

The fill pipe must terminate outside the building. The fill pipe connection point must be housed in a sealed spill box. High level alarms or level gauges used as overfill protection mechanisms must annunciate at the fill connection point. Provide an overfill prevention valve (OPV) at the tank with a check valve mounted on the fill line in the spill box. The fill connection point must be labeled with tank contents and capacity.

2.6.4.1 Capacity

Each tank must have capacity to supply fuel to the engine for an uninterrupted 24-hour period at 100 percent rated load without being refilled.

2.6.4.2 Local Fuel Fill

Each local fuel fill port on the day tank must have a screw-on cap.

2.6.4.3 Fuel Level Controls

Provide tanks with a float-switch assembly to perform the following functions:

a. Activate the "Low Fuel Level" alarm at 70 percent of the rated tank

Jacobs D3420101 SECTION 26 32 15.00 Page 25 capacity.

b. Activate the "Overfill Fuel Level" alarm at 95 percent of the rated tank capacity.

2.6.4.4 Arrangement

Integral tanks may allow gravity flow into the engine. Gravity flow tanks and any tank that allows a fuel level above the fuel injectors must have an internal or external factory installed valve located as near as possible to the shell of the tank. The valve must close when the engine is not operating. Provide integral day tanks with any necessary pumps to supply fuel to the engine as recommended by the generator set manufacturer. The fuel supply line from the tank to the manufacturer's standard engine connection must be welded pipe.

2.6.5 Fuel Supply System

Provide the fuel supply from the main storage of fuel to the day tank as specified in Section 33 56 10 FACTORY-FABRICATED FUEL STORAGE TANKS.

2.6.6 Fuel Oil Cooler

Provide an air cooled fuel oil cooler if the temperature of the fuel returned to the tank from the engine will cause overheating of the tank fuel above the maximum fuel temperature allowed by the engine manufacturer when operating at maximum rated generator power output and low fuel level in the tank. The fuel oil cooler must be furnished by the engine manufacturer for the application and the installation must be complete including piping and power requirements.

2.7 LUBRICATION

Provide engine with a separate lube-oil system conforming to NFPA 30 and NFPA 37 . Pressurize each system by engine-driven pumps. Regulate system pressure as recommended by the engine manufacturer. Provide a pressure relief valve on the crankcase for closed systems. Vent the crankcase in accordance with the manufacturer's recommendation. Do not vent the crankcase to the engine exhaust system. Crankcase breathers, if provided on engines installed in buildings or enclosures, must be piped to vent to the outside. The system must be readily accessible for service such as draining, refilling, etc. Each system must permit addition of oil and have oil-level indication with the set operating. The system must utilize an oil cooler as recommended by the engine manufacturer.

2.7.1 Lube-Oil Filter

Provide one full-flow filter for each pump.