J.2.2 Generator Set Specifications 26 32 16.pdf

US Embassy, Baghdad, Iraq - BDSC June 23, 2024 Replacement 50Hz Generators

MEDIUM-VOLTAGE GENERATOR SETS

SBU – PROCUREMENT SENSITIVE

SECTION 26 3216 - 1

SBU - CONTRACTING AND ACQUISITIONS

Specification 263216 Revision Record Changes Made at Revision C

June 23, 2024

Change Description:

Specification clarifications/changes

1. Specified deviation performance factor for harmonic limits shall be identified within the contractor technical offer, including maximum factor if the 3% specified value is exceeded. Harmonic limits above 3% that may be incurred due to loading conditions shall be specified.

2. Contractor shall specify within the technical proposal dielectric test voltage limits, as applied to the equipment under test or if maximum test voltages cannot be applied per this specification and limited to 500V.\

3. Operations and maintenance manual submission shall include lubrication requirements and callouts, including lubricant type/make/model, etc. and quantity of applied lubricant for each application/use.

4. New alternator sub-transient direct axis reactance shall be per alternator manufacturer design specification as proposed.

5. Remote location or mounting of engine cooling radiator is removed from specification. Engine cooling and radiator shall be integral to system enclosure.

6. Pneumatic engine starting system is removed from specification. Standard manufacturer engine starting system shall be furnished.

7. Cartridge filters are acceptable for use. Contractor submittal shall include and specify filter type and details with O&M and parts manuals.

8. Synchronization rheostat can be substituted using the synchronization system provided with the generator controls. Synchronization controls shall include automatic and manual override capabilities.

Operator instructions shall be included with synchronization manuals including automatic operations, initial setup, user invoked changes and manual override functions/processing.

9. System operation including generator output, controls and electrical distribution and control shall be rated and capable to function at 50 Hz power frequency.

10. Generator switchgear medium voltage bus shall rated at full load ampere capacity in accordance with alternator full load output, as designed with switchgear system.

11. Generator output circuit breaker shall utilize a vacuum type interrupter. Short circuit interrupt rating shall be in accordance with alternator sub-transient reactance specification and manufacturer design.

SECTION 26 3216 - 2

Changes Made at Revision B

September 03, 2021

Replace/Revise Section 1.3, Definition L to read as follows:

Prime Power Rating - Each new generator system shall be rated and designed in accordance with ISO 8528 and per manufacturer ratings. Each generator system shall be rated as prime running power/prime power.

With unlimited hours of usage for varying load conditions. Average variable load factor shall be 70% of the prime power rating with 10% overload available but limited to 1 in 12 hours and not to exceed 25 hours per year. The 10% overload shall be in accordance with ISO 3046-1. To ensure maximum life expectancy and mean time to overhaul, the new generator systems shall be capable and permissible to provide an average power output over a 24 hour operational period not to exceed 70% of the prime power rating.

Revise Section 1.3, Definition N to read as follows:

Rated kW: Rated kW is Continuous Prime Power rating shown on genset name plate.

Revise Section 1.4 (A) (1)

Engine/generator set shall be continuous p r i m e power rated. Standby rated units are not acceptable

Revise Section 1.5 (A) (3) (a) to read as follows:

11,000 Volts, 3-phase, 3-wire, 50 Hz, 2,500 2,000 KVA/2,000 1,600 KW, 0.8 pf

SECTION 26 3216 - 3

Changes Made at Revision A

August 19, 2021

Change Section 2.1 (A) to read a follows. Change temperature rise from 105 degree Celsius to 80 degree Celsius

Generator: AC generator shall be synchronous, revolving field, brushless, single-bearing, air- cooled, self-ventilated alternator that is directly connected to engine crankshaft through flexible steel coupling.

Generator shall be capable of operation at 50 and 60 Hertz, shall have legibly identified power leads, and shall be connectable for the voltages shown in Article on “Performance Requirements. Generator shall conform to applicable requirements of ANSI C50.10, and NEMA MG-l. Generator windings shall be copper and wound with 2/3 pitch. Generator shall have Class H insulation system rated at 105 80 deg C temperature rise above 50 deg C ambient when operating at continuous rated load, and generator shall have amortisseur windings to minimize slot harmonics. Sub-transient direct axis reactance (X”D): 11% minimum; 12% maximum. Generator windings shall have protective overcoat for added protection in harsh conditions. Generator shall have drip-proof enclosure with ventilating openings covered by removable screens having mesh opening not larger than 13 mm. Bearing shall be double-sealed, sealed for life, permanently lubricated, anti-friction type. Generator shall have adequate capacity to produce rated power plus overloads (see Article on “Definitions”). Rotor assembly and fan assembly shall be balanced separately, and balanced in accordance with NEMA MG-l. When operating at rated speed and voltage, and at any load from no load to rated load, vibration amplitude (peak-to-peak) shall not exceed value as specified in NEMA MG-l for rated speed of generator. Measure vibration amplitude in all three axes (vertical, longitudinal, and transverse) at bearing housing or on generator frame adjacent to bearing housing.

SECTION 26 3216 - 4

SECTION 26 3216 – MEDIUM-VOLTAGE GENERATOR SETS

PART 1 - GENERAL

1.1 SUMMARY

A. This Section specifies medium-voltage generator sets (gensets) for use as continuous electric power sources. Genset consists of:

1. Liquid-cooled compression ignition diesel engine which is directly connected through flexible coupling to alternating current generator with rotating exciter.

2. Solid-state voltage regulator.

3. AC output circuit breaker.

4. Electronic governor.

5. Cooling system.

6. Day tank.

7. Air intake system.

8. Exhaust system.

9. Control panel.

10. Remote control capability.

11. Engine starting system.

12. Battery.

13. Battery cables, battery retainer, and engine driven battery charger.

14. Rigid box type channel steel or formed steel base.

15. Stand-alone fire-rated fuel day tank.

16. Remote, dual circuit genset radiator.

17. Auxiliary fuel connection.

18. Seismic Protection:

a. Spring isolator mounts with seismic restraints in other than seismic zone 0.

19. Maintenance spare parts maintenance and repair.

20. Other components necessary to provide complete self-contained genset.

B. Related Sections:

1. Division 23 Section "Vibration and Seismic Controls for HVAC Piping and Equipment" for muffler and exhaust piping supports.

2. Division 23 Section "HVAC Piping Insulation" for muffler and exhaust pipe insulation.

3. Division 23 Section "Building Fuel Oil Piping" for interior fuel piping and fuel storage tank.

4. Division 23 Section "Hydronic Piping" for coolant piping external to engine generator.

5. Division 23 Section “Metal Ducts" for combustion air and radiator fan discharge connections.

SECTION 26 3216 - 5

6. Division 26 Section "Vibration and Seismic Controls for Electrical Work."

7. Division 33 Section “Fuel Storage Tanks, Piping, and Dispensing Equipment.”

1.2 REFERENCES

A. The following publications form a part of this specification to the extent specified herein:

1. AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI).

a. ANSI C39.1, Requirements for Electrical Analog Indicating Instruments.

b. ANSI C50.13.89, Rotating Electrical Machinery - Cylindrical Synchronous

Generators."

c. ANSI/IEEE C57.13.1, Field Testing of Relaying Current Transformers.

d. ANSI Y32.2, Graphic Symbols for Electrical and Electronics Diagrams.

2. AMERICAN PETROLEUM INSTITUTE (API).

a. API-CF: American petroleum institute classifications.

3. AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM).

a. ASTM B117, Standard Practices for Operating Salt Spray (Fog) Apparatus.

b. ASTM D523, Standard Test Methods for Spectral Class.

c. ASTM D2247, Standard Test for Testing Water Resistance of Coatings in 100 percent Relative Humidity.

d. ASTM D2794, Standard Test Method for Resistance of Organic Coatings to the

Effects of Rapid Deformation (Impact).

e. ASTM D3359, Standard Test Methods for Measuring Adhesion by Tape Method.

f. ASTM E-84, Test Methods for Surface Burning Characteristic of building

Material.

4. BRITISH STANDARDS INSTITUTE (BSI)

a. BS EN 55014, Limits and Methods of Measurement of Radio Disturbance Characteristics of Electric Motor-Operator and Thermal Appliances for Household and Similar Purposes, Electric Tools and Similar Electric Apparatus (S).

5. INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO).

a. ISO 3046: Reciprocating internal combustion engines – Performance.

1) Part 1: Standard reference conditions, declarations of power, fuel and lubricating oil consumption's, and test method.

2) Part 3: Test.

3) Part 4: Speed governing.

SECTION 26 3216 - 6

4) Part 5: Torsional vibrations.

5) Part 6: Overspeed protection.

6) Part 7: Codes for engine power.

b. ISO 8528: Reciprocating internal combustion engine driven alternating current generating sets.

1) Part 1: Application, ratings and performance.

2) Part 2: Engines.

3) Part 3: Alternating current generators for generator sets.

4) Part 4: Control gear and switchgear.

5) Part 5: Generating sets.

6) Part 6: Test Methods.

7) Part 7: Technical declarations for specification and design.

8) Part 8: Requirements and tests for low- power generating sets.

9) Part 9: Measurement and evaluation of mechanical vibrations.

10) Part 10: Measurement of airborne noise by the enveloping surface method.

11) Part 12: Emergency power supply to safety devices.

c. ISO 9001: Quality systems, model for quality assurance in design, development, production, installation and servicing.

6. NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA).

a. MG1, Standard for Motors and Generators.

b. MG2, Safety Standard for Construction and Guide for Selection, Installation and

Use of Electric Motors and Generators.

c. NEMA's STD Publication No. 250, Enclosures for Electrical Equipment.

d. NEMA ICS 1, Industrial Controls and Systems.

7. NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

a. NFPA 30, Flammable and Combustible Liquids Code.

b. Electrical Code of Overseas Buildings Operations (NFPA 70, National Electrical

Code as amended by OBO).

c. NFPA 110, Standard for Emergency and Standby Power Systems.

8. SOCIETY OF AUTOMOTIVE ENGINEERS (SAE).

a. SAE Handbook of Standards.

b. SAE J614B: Bayonet dip stick marking.

9. UNDERWRITERS LABORATORIES INC (UL).

a. UL142, Steel Aboveground Tanks for Flammable and Combustible Liquids.

SECTION 26 3216 - 7

1.3 DEFINITIONS

A. Accuracy/error: Accuracy is ratio that defines limit of error expressed as percentage of full- scale value. Error is difference between indication and true value of quantity measured. It is quantity that, when algebraically subtracted from indication, gives true value. Positive error denotes that indication of meter is greater than true value.

B. Base load mode: Base load mode is defined as fixed load that genset is adjusted to carry when it is paralleled with commercial power.

C. Damage: Damage is defined as any failure (see definition below) or degradation in life. Blowing (opening) of replaceable fuse is not considered damage, provided it is performing its intended function.

D. Dangerous flexural vibration: Dangerous flexural vibration is defined as vibration that occurs at speed at which maximum stress in shaft from flexural vibration exceeds 630 kg/cm2 (9,000 psi).

E. Dangerous torsional critical speed: Dangerous torsional critical speed is defined as speed at which maximum vibrating stress in shaft from torsional vibration exceed 350 kg/cm2 (5,000 psi).

F. Dripproof enclosures/boxes: Dripproof enclosure/box is enclosure/box so constructed that falling drop of liquid or solid particles striking enclosure/box at angles from 0 to 15 degrees from vertical cannot enter enclosure/box, either directly or by striking and running along horizontal or inwardly inclined surface.

G. Failure: Failure is defined as inability of item to perform within specified limits.

H. Fuel day tank: Fuel day tank is defined as tank that is supplying fuel to engine, equipped with provisions (float valve, electric pump, solenoid, etc.) for receiving fuel from auxiliary source.

I. Maximum power: Maximum power is defined as largest load that genset can carry for two minutes and remain at rated voltage and frequency without damage.

J. Momentary overload: Momentary overload is defined as loads between rated and load required to trip safety devices.

K. Power exchange: Power exchange is difference between maximum and minimum power output delivered by one genset, for constant system load conditions, as determined from oscillographic measurements.

L. Continuous power rating: Continuous power is defined (ISO 8528-1) as maximum continuous load capability of genset. Continuous power is available up to full output (ISO 3046-7) for unlimited hours with no sustained overload capability.

M. Rated frequency: Rated frequency is specified in Article on “Performance Requirements.”

N. Rated kW: Rated kW is Continuous Power rating shown on genset name plate.

SECTION 26 3216 - 8

O. Rated load: Rated load is rated kW at rated power factor, rated frequency and rated voltage.

P. Rated power factor: Rated power factor (pf) is 0.8 lagging.

Q. Rated voltage: Rated voltage is genset name plate voltage.

R. Stable (engine) operating conditions: Stable (engine) operating conditions are conditions specified for short-term, steady-state performance.

S. Start: Genset is considered to have started when it is operating at rated voltage and rated frequency without further use of starting aids.

T. Stop: Genset is considered to have stopped when all rotating members are at zero rpm, except for turbo-charger, if used.

U. Temperature and Humidity Damage: Temperature and humidity damage is defined as conditions causing malfunction of any component or part, corrosion, breakage, deformation, or reduction of insulation resistance below 50,000 ohms.

1.4 PERFORMANCE REQUIREMENTS

A. General:

1. Engine/generator set shall be continuous power rated. Standby rated units are not acceptable

2. Classification: Gensets and all associated components (e.g., fuel pumps) shall operate at host country frequency and host country nominal voltage.

3. Voltage Connections: Gensets shall be connectable for the following output voltages:

a. 11,000 Volts, 3-phase, 3-wire, 50 Hz, 2,500 KVA/2,000 KW, 0.8 pf

4. Generator Performance:

a. Voltage waveform

1) Deviation factor: Deviation factor for line-to-line and line-to-neutral voltages for each connection shall not be more than three percent, nor shall any single harmonic exceed 3 percent when genset is operating at no load and rated load.

Voltage total harmonic distortion at full load shall not exceed 5 percent.

2) Telephone Influence Factor (TIF): TIF for line-to-line and line-to-neutral voltages for each connection shall not be more than 50 per NEMA MG 1- 22- 43 when genset is operating at no load or rated load.

SECTION 26 3216 - 9

b. Phase Balance (voltage): With genset under control of exciter and voltage regulator, and operating at rated voltage, frequency and no load, the maximum in line-to-neutral voltage shall not be more than one-half (0.5) percent of rated line- to-neutral voltage.

c. Dielectric Strength: Windings shall withstand the following 50 Hz voltages applied for one minute:

1) Generator Stator: Twice rated line-to-line voltage plus 1000 volts between phase windings, and twice rated line-to-neutral voltage plus 1000 volts between phase windings and ground.

2) Generator Field and Exciter Windings: 10 times ceiling voltage, but neither less than 1,500 nor more than 3,500 volts, applied between windings and ground.

3) Windings Energized by DC Control, Cranking and Battery Charging Systems:

500 volts, applied between windings and ground.

4) All Others: Twice rated voltage plus 1,000 volts, applied between winding and ground and between windings where applicable.

d. Voltage Regulation: Voltage regulation shall be less than or equal to one half of one percent of rated voltage.

e. Voltage Stability: At any constant load from no load to 110 percent of rated load, voltage shall remain within bandwidth of one percent of rated voltage.

f. Voltage Drift: With genset operating at constant load and voltage, change in ambient temperature of 15 deg C in eight hour period shall not cause voltage to change more than one percent of rated voltage. Genset shall be stabilized at both initial and final ambient condition

g. Voltage Transient Performance:

1) With genset operating at rated frequency and voltage, transient voltage response shall remain within transient voltage operating limit values listed in ISO 8258-5 Table 4, with maximum possible power increase applied in stages as given by ISO 8528-5 guide values for maximum possible sudden power increases..

2) With genset operating at rated frequency and voltage, voltage shall not decrease more than thirty percent when motor with starting kVA equal to three times rated kVA of genset is suddenly applied. Voltage shall return to 95 percent of rated voltage within 3 seconds, and recover to 100 percent within 5 seconds.

5. Voltage Operating Range: Voltage adjusting device shall be capable of adjusting voltage to plus-or-minus five percent of rated voltage with genset operating at any load up to 110 percent rated load.

6. Short Circuit: Generator and/or excitation system shall not be mechanically and/or electrically damaged when temperature is stabilized at rated load and then subjected to faults at genset load terminals that draw 300 percent rated current for 10 seconds.

7. Generator and Excitation System: Genset voltage performance shall conform to performance class G3 of ISO 8528.

SECTION 26 3216 - 10

8. Starting and Operating: Genset shall start (see Article on “Definitions”) within 10 seconds after receiving start signal under each and any combination of the following operating conditions. Immediately after starting, genset shall operate without failure (see Article on “Definitions”) at all loads, continuous and intermittent, up to and ncluding rated load as specified herein.

a. At all possible relative humidity, with ambient temperatures ranging from +50 deg

C to - 25 deg C, with engine coolant at higher than + 20 deg C

b. At altitude specified in paragraph on “Service Conditions.”

c. With base of set in planes from level to up to 15 degrees from level.

9. Stopping: Genset shall stop (see Article on “Definitions”) within 30 seconds after activation of any device intended to stop set.

10. Cool Down Period: Generators shall start and come on line automatically on loss of normal power. Before generators are shut down automatically on restoration of normal power, and after load has been transferred to normal power, generator shall run for at least 5 minutes to cool down.

11. Operating Speeds: Operating speed for 50 Hz gensets shall be 1500 revolutions per minute (rpm).

a. Overspeed: Sets shall be capable of operating at 115 percent of rated speed for 5 minutes without damage (see Article on “Definitions”). Rated speed of sets shall be that required for set to produce rated frequency.

b. Flexural vibration and critical speeds: Set shall be free from dangerous flexural vibrations (see Article on “Definitions”) and dangerous torsional critical speeds (see Article “on Definitions”) between minimum low idle speed and 115 percent of rated speed.

12. Sound Pressure Levels: Genset shall have sound attenuating accessories to reduce sound pressure level (SPL) at 7 meters (23 feet) from surface of genset and 1.2 meters (4 feet) above genset base to average "A" weighted sound pressure level as follows:

a. Style I (Unhoused gensets): 90 dBA

13. Radio Frequency Interferences: Radio interference emissions shall comply with BS

EN55014 when genset is operating at any load from no load to rated load.

14. Fuels and Lubricants: Engine shall start, operate and meet all performance requirements of this specification using commercial #2 diesel fuel and API CF multi-grade lubricating oil.

15. Smoke Limits: Set engine shall operate under all conditions specified herein at all set loads up to and including rated load, with smoke reading of not more than 2.0 when measured using Robert Bosch EFAW 65 sampling pump and analyzed on Robert Bosch EFAW 68 analyzing instrument. Above smoke limit is not required if engine is EPA certified at horsepower required to drive generator at rated output.

16. Life (Endurance) requirements: Genset shall have life expectancy of 10,000 hours at loads up to and including rated load under ambient conditions specified herein when maintained in accordance with manufacturer’s instructions.

SECTION 26 3216 - 11

17. Ease of Servicing, Operation, and Maintenance: Design and construction of gensets shall permit routine service and maintenance under field conditions. Parts that require adjustment or servicing shall be capable of being adjusted or serviced by personnel wearing heavy winter clothing or mittens. Genset shall be capable of being started and operated by one operator under all conditions. Starting or stopping set shall not require manipulation of more than one control or switch. Hardware that requires torquing shall be able to be installed and services so that nut, bolt, or screwhead is accessible for torque wrench application. In assemblies where both bolt and nut are used, nut shall be accessible for torque wrench application.

Genset maintenance and repair shall be accomplished with common standard tools.

Servicing, operation, and maintenance requirements shall be capable of being met with genset in its installed location.

B. Service Conditions:

1. Environmental Conditions: Engine generator system withstands the following environmental conditions without mechanical or electrical damage or degradation of performance capability. Additional climatic data provided per scope of work attachment, for informational purposes only.

a. Ambient temperature: 5 to 50 deg. C.

b. Relative Humidity: 0 to 95 percent.

c. Altitude: Sea level to 300 m (1,000 ft.) above installed site location.

2. Unusual Service Condition: Engine generator equipment and installation shall operate under the following conditions.

a. High dust content in the air due to blowing sand.

b. High air pollution content in the air due to proximity to International Airport

c. Engine assembly and complete fuel delivery, supply and injection system, pumps, injectors, valves and hoses and lines shall be compatible for use with high sulfur content #2 diesel fuel.

1.5 SUBMITTALS

A. Refer to scope of work contents and descriptions/requirements and include the following: Product data for system components. Include descriptive and technical literature, catalog cuts, and installation instructions. Provide dimensioned plans and elevations showing minimum clearances and installed features and devices. Include list of materials and UL listed data.

1. Installation manual. Include the following:

a. Genset noise levels at various distances from genset.

b. Allowable engine exhaust restriction if using exhaust extension.

c. Allowable genset cooling air discharge restriction if cooling air is ducted away from genset.

SECTION 26 3216 - 12

d. Elevation and distance limits for location of external fuel supply.

e. Instructions for installation of all equipment, non-integral components, and accessories.

f. Instructions for aligning genset before initial startup and after disassembly.

B. Shop drawings shall indicate fabrication details, dimensions, weights, loads, required clearances, method of field assembly, components, and location and size of each field connection.

1. Locate and identify each interface point (e.g., lube drain, exhaust outlet, fuel inlet), grounding terminal, and similar items.

2. Indicate proper genset location such as allowable ground slope, clearance required for door opening, and clearance required for engine exhaust.

3. Wiring Diagrams: Detail wiring for power and control connections and differentiate between factory-installed and field-installed wiring.

4. Vibration Isolation Base Details.

C. Factory design calculations.

D. Qualification data for firms and persons specified in Article on “Quality Assurance.”

E. Factory Test Reports: For units to be shipped for this Project, showing evidence of compliance with specified requirements.

1. Test report for prototype unit, including separate test reports for components and accessories that are equivalent, but not identical, to those tested on prototype unit.

F. Factory Test and Observation Reports: Indicate and interpret test results and inspection records relative to compliance with performance requirements.

G. Maintenance Data: For each genset, provide maintenance manual tailored for genset. Manuals shall have cover with clear identification tying manual to specific genset. All graphic symbols used on drawings shall conform to ANSI Y32.2.

1. Operators Manual: Operators manual shall accomplish and or contain the following information for minimally trained operators:

a. Assist genset operator in identifying and understanding function of each operator control.

b. Sufficient drawings and/or pictures to assist operator identify all major genset components.

c. Instructions for genset operator to determine if genset voltage, frequency and kW rating is proper for intended load.

d. Instructions for genset operator to connect genset ground terminal to earth electrode (driven ground rod).

e. Instructions for genset operator to safely connect load cables to genset output terminals. These instructions shall cover load neutral connection and phasing of the energized leads.

SECTION 26 3216 - 13

f. Step-by-step detailed instructions for genset operator to thoroughly inspect genset before attempting to start genset for first time.

g. Specific set of detailed instructions for starting, operating, and stopping genset.

h. Specific list of things to check each time genset is started.

i. Specific schedule of routine maintenance items such as lube oil changes, and filter changes.

j. Complete list of acceptable lube oil, fuel oil, engine coolant, battery acid, and similar items.

k. Explanation of what type of records operator needs to keep for each genset, and importance of accurate records.

l. Applicable cautions, warnings, and dangers for operation of genset.

m. Specific instructions for connecting electrical power to engine coolant heater, auxiliary fuel pump, external fuel tank level signal, and emergency stop and wall mounted battery charger, including location and identification of each interconnection point.

n. Detailed instruction for reconnection of genset power leads, and for any necessary changes to voltage regulator, governor, instrumentation, and main circuit breaker to obtain desired operating voltage and frequency.

o. Identify values (e.g., fuel level, oil pressure) at which warnings and shutdown devices will activate.

2. Parts Manual: Parts manual shall have sufficient drawings in top-down break down format to show each and every part in its relative position to other parts. Each part, except standard hardware, shall have unique part number, and this part number shall be referenced to part where it is shown on a drawing. In place of part numbers for standard hardware, size of hardware may be provided, such as "Machine Screw 4mm x 70 mm - 0.7mm pitch." This manual shall also identify source of supply for each part, including company name, address and phone number, and person to contact.

3. Service Manual: Service manual shall provide in narrative form theory of operation for each of major subsystems (e.g., generator and excitation system, governor) of genset. This manual shall contain all applicable wiring and schematic diagrams. Manual shall also contain trouble shooting procedures and detailed procedures for removing and/or replacing each component.

1.6 QUALITY ASSURANCE

A. Single-Source Responsibility: Obtain generator components from single source which assumes responsibility for compatibility of system components.

B. Testing Agency Qualifications: Testing agency as defined by OSHA in 29 CFR 1910.7 or member company of InterNational Electrical Testing Association.

C. Inspection:

SECTION 26 3216 - 14

1. Inspection system: Gensets, generators, and engines shall be manufactured in facility that has quality control program certified to be in compliance with ISO 9000-1, ISO 9000-2, ISO 9000-3, ISO 9000-4, ISO 9001, ISO 9002, ISO 9003, ISO 9004-1, ISO 9004-2, ISO 9004-3 and ISO 9004-4.

2. Responsibility for Inspection: Unless otherwise specified, Contractor is responsible for performance of all inspection/test requirements as specified herein. Except as otherwise specified herein or elsewhere in Contract, Contractor may perform this work at their own facilities or any other facilities suitable for performance of inspection/test requirements specified herein, unless disapproved by Project Director based upon input from OBO/PDCS/DE/EE. Contractor is responsible for ensuring that all components and materials used are manufactured, examined, and inspected/tested in accordance with industry standard practices.

a. Government reserves the right to perform or repeat any of inspections/tests set forth in this purchase description where such inspections/tests are deemed necessary to ensure supplies and services conform to prescribed requirements.

1.7 DELIVERY, STORAGE AND HANDLING

A. Packing for shipment:

1. Export shipping: Enclose each genset in wooden box on wooden shipping skid. All manuals and spare parts shall be enclosed in genset shipping box.

B. Connection Tag: As safety precaution, each genset shall have tag tied to output load terminals stating voltage and frequency of electrical output. Tag shall request installer to verify that this voltage and frequency match load requirements before removal of tag and connection of load cables.

C. Deliver engine generator set and system components to final location in protective wrappings, containers, and other protection that will exclude dirt and moisture and will prevent damage from construction operations. Remove protection only after equipment is safe from such hazards.

D. Handling: Equip genset skid base with towing and lifting provisions for lifting and/or towing of genset without damage using forklift, crane, or hoist.

1.8 MAINTENANCE PARTS

A. General parts: Provide one set of maintenance (spare) parts for each genset. An order of maintenance parts is defined as all items necessary to perform scheduled maintenance functions specified in Genset Manuals for one thousand operating hours plus replacement bulbs for indicators, replacement fuses for each fuse used on genset and any other like items manufacturer deems desirable. Package these maintenance parts in polyethylene bag, and pack inside the genset for which they are intended. Should there be insufficient room inside genset, SECTION 26 3216 - 15 enclose parts bag in protective package and attach to shipping skid. This group of parts shall include, but are not be limited, to the following:

1. Engine lubricating oil filters and filter gaskets, if separate from filter.

2. Fuel filters and filter gaskets, if separate from filter.

3. Water separator and elements, if separate from housing.

4. Engine intake air filters and filter gaskets, if separate from filter. Engine air intake prefilter/over wrap.

5. Engine accessory and drive belts, tensioner assembly.

6. Coolant hoses and clamps.

7. Intercooler hoses and clamps.

8. Two fuel injectors, connection lines and hardware.

9. Fuel pressure regulator and actuator.

10. Engine timing sensors, crank and cam position, coolant sensor.

11. A minimum of five light bulbs of each size light bulb used in the genset.

12. A minimum of five electrical fuses of each size fuse used in the genset.

13. One engine lubrication oil system drain plug.

14. Enclosure air filters and media/desiccants.

PART 2 - PRODUCTS

2.1 GENERATOR SET

A. Generator: AC generator shall be synchronous, revolving field, brushless, single-bearing, air-cooled, self-ventilated alternator that is directly connected to engine crankshaft through flexible steel coupling. Generator shall be capable of operation at 50 and 60 Hertz, shall have legibly identified power leads, and shall be connectable for the voltages shown in Article on “Performance Requirements. Generator shall conform to applicable requirements of ANSI C50.10, and NEMA MG-l. Generator windings shall be copper and wound with 2/3 pitch. Generator shall have Class H insulation system rated at 105 80 deg C temperature rise above 50 deg C ambient when operating at continuous rated load, and generator shall have amortisseur windings to minimize slot harmonics.

Sub-transient direct axis reactance (X”D): 11% minimum; 12% maximum. Generator windings shall have protective overcoat for added protection in harsh conditions. Generator shall have drip-proof enclosure with ventilating openings covered by removable screens having mesh opening not larger than 13 mm. Bearing shall be double-sealed, sealed for life, permanently lubricated, anti-friction type. Generator shall have adequate capacity to produce rated power plus overloads (see Article on “Definitions”). Rotor assembly and fan assembly shall be balanced separately, and balanced in accordance with NEMA MG-l. When operating at rated speed and voltage, and at any load from no load to rated load, vibration amplitude (peak-to-peak) shall not exceed value as specified in NEMA MG-l for rated speed of generator. Measure vibration amplitude in all three axes (vertical, longitudinal, and transverse) at bearing housing or on generator frame adjacent to bearing housing.

B. Materials and Components: Materials and components required but, not specifically specified shall be selected by Contractor, shall be subject to all requirements of this specification, and shall conform to accepted industry standards.

1. Hoses and Hose Fittings: Use hoses and hose fittings with piping systems where there is

SECTION 26 3216 - 16

relative motion between parts. Hoses and fittings shall be suitable for pressure involved.

2. Hardware: Hardware shall be as follows, with number of different sizes and types kept to minimum. All nuts, bolts and screws shall have standard metric or SAE threads.

a. Quick disconnect fasteners: Quick-disconnect fasteners shall be self-contained and corrosion resistant.

b. Pipe and Fittings: Pipe and pipe fittings shall conform to SAE standards.

c. Fasteners (except electrical): Each fastener (e.g., screw, stud, bolt, pin) shall be equipped with locking device to prevent loosening due to vibration. Locking shall be by locknuts, castellated nuts with cotter pins, lockwashers, lock wire, or lockplates.

No swedging, peening or stacking of parts subject to removal or adjustment is permitted. Fasteners and associated hardware (e.g., nuts, locking devices, washers) shall be made of corrosion-resistant material, or shall be provided with corrosion-resistant treatment. Unused length of threads on studs (or screws used as studs) shall not exceed half diameter of stud.

d. Sheet Metal Screws: Sheet metal screws are not permitted.

e. Blind Hardware: Locate nut such that it cannot be grasped by thumb and forefinger of one hand. Common tool shall be caged, or some equivalent means shall be used, to obviate need for handling of nut during removal and assembly.

f. Fasteners (electrical): Provide locking devices for each fastener used in making electrical connections. Each fastener, locking device, and other hardware shall be made of corrosion-resistant material or treated to be corrosion-resistant. Fasteners (bolts, screws, studs, or other fasteners) shall not generally carry current; they shall serve to hold current-carrying parts (lugs, terminals) in firm contact with each other.

Where flow of current through stud cannot be avoided, stud and associated hardware (nuts, locking devices, washers and other hardware) shall be made of high conductive corrosion-resistant material. Provide positive means (e.g., pins or square shanks) to prevent turning of studs in their mountings when nuts are tightened or loosened;

lockwashers that depend on friction or spring action are not permitted for this purpose.

Unused length of studs (or screws used as studs) shall not exceed half diameter of stud.

3. Instrument Transformers: Current and potential transformers used for instrumentation and relaying shall be in accordance with ANSI C57.13.1, and suitable for operation on 50 and 60 Hz. Transformers shall be 1.2 kV insulation class or higher. Instrument transformers shall be within limits specified for 0.6 accuracy class. Burden rating of all transformers shall be compatible with application requirements. Current transformers used for generator differential protection shall match (manufacturer and model number) the corresponding generator differential protection current transformers installed in the paralleling switch gear.

4. Shunts: Shunts for instrumentation purposes shall have industry standard outputs.

5. Terminal Lugs: Use terminal lugs for all conductors. Terminal lugs shall be insulated, ring tongue style, compression, or crimp type lugs. Install compression lugs with proper tools.

Terminal lugs shall be proper size for conductor and stud/bolt.

6. Connectors: Select plugs and connectors so that energized member, when connection is broken, is female part of connector. When more than one connector is used in same general location, different shell sizes or pin configuration shall be used to prevent cross connection.

7. Capacitors: Electrolytic capacitors, when used, shall be of tantalum type.

8. Toggle Switches: Toggle switches shall be of sealed toggle type with terminals marked.

Mount toggle switches so that "ON" position is "UP", "FORWARD", or "TO THE RIGHT".

SECTION 26 3216 - 17

9. Semiconductor Devices: Semiconductor devices shall be of hermetically-sealed silicon type.

Except for zener diodes, semiconductor devices shall have peak repetitive rating not less than three times peak repetitive voltage to which they will be subject in genset. They shall have current rating equal to or not less than 150 percent of maximum rectified current (DC) which they will carry when installed in genset, ignoring transients. Diodes or controlled rectifiers that supply DC power to alternator main field shall have peak inverse voltage rating of not less than ten times nominal alternator field voltage. Use of circuits that require semiconductor devices with matched or paired characteristics is prohibited.

10. Pushbuttons and Limit Switches: Limit switches shall be of sealed type. Pushbuttons shall be of sealed heavy-duty type. Pushbuttons and limit switches shall be appropriately sized for both voltage and current.

11. Relays: Relays shall be totally enclosed or hermetically sealed. Control relays shall be firmly secured to their mounting using clips, spring retainers or screws.

12. Resistor and Rheostats: Tapped resistors shall be used in preference to adjustable (slide wire) type. Where adjustable resistors are used and are of wire-wound type, wire shall be of sufficient size to preclude damage through tightening of adjust device or through corrosion at contact point. Rheostats and potentiometers shall be wire-wound type, preferably enclosed.

13. Hinges and Latches: Hinges shall be of stainless steel. Hinges or hinge pins shall be peened at ends, or other means provided to prevent workout of pins. Latches shall require manual, not spring, action for closing. Parts of latches having relative motion with each other shall be corrosion-resistant metal.

14. Drivebelts: Drivebelts shall be resistant to battery electrolyte, antifreeze and petroleum derivatives.

15. Printed Circuit Boards: Fabricate printed circuit boards using copper clad laminate. Boards shall be electrosolder-plated 25 microns minimum thickness with solder. After etching, boards shall be tin or solder immersed. Coat finished printed circuit boards with moisture-proof insulating compound.

16. Terminal Boards and Terminal Strips: Made from material other than thermosetting plastic.

17. Wire and Wire Marking: Wire shall be multi-stranded copper conductor, flame retardant, and moisture/heat/oil resistant in accordance with the Electrical Code of OBO, but not smaller than 1.5 sq. mm (16 AWG). All wire shall be numbered for easy identification. Marking shall be permanently applied to wire to withstand all specified operating conditions herein throughout life of genset. Marking shall be within 75 mm of each end. Contractor shall determine wire numbering scheme.

18. Starting and Control Devices: All starting and DC control devices shall be rated 24 volts (nominal).

2.2 ENGINE

A. Engine: Engine shall be heavy-duty standard commercial industrial diesel-fueled, liquid-cooled engine with sufficient power to drive generator and connected accessories, and to accept one- step application of rated load.

SECTION 26 3216 - 18

2.3 GOVERNOR

A. Governing: Engine speed shall be controlled by isochronous load sensing electronic governor.

Genset frequency performance shall conform to performance class G3 of ISO 8528.

1. Frequency Regulation: Frequency regulation shall be adjustable from 0 to three percent of rated frequency.

2. Frequency Stability: At any constant load from no load to 110 percent of rated load, frequency shall remain bandwidth of 1/2 percent of rated frequency.

3. Frequency Drift: With genset operating at constant load and voltage, change in ambient temperature of 15 deg C in eight-hour period shall not cause frequency to change more than one percent of rated frequency. Genset stabilization shall be accomplished at both initial and final ambient condition

4. Frequency Transient Performance: Following any sudden load change between no load and rated load, or sudden load change between rated load and no load, frequency shall not dip or rise more than ten percent of rated frequency. Frequency shall recover to rated frequency within 2 seconds.

5. Frequency Adjustment Range: Frequency adjustment device shall be capable of adjusting frequency to plus/minus 5 percent of rated frequency

2.4 ENGINE COOLING SYSTEM

A. Cooling System: Cooling system shall have capacity to limit maximum coolant temperature from engine to value recommended by engine manufacturer while genset is operating under any of environmental conditions specified herein for "Starting and Operating." Engine shall have block drain(s) as necessary to completely drain all coolant from block regardless of type of cooling system.

1. Coolant: Cooling system shall operate under all conditions specified in Article on

“Performance Requirements”, paragraph on "Starting and Operating" using 50/50 commercial antifreeze and water mixture which includes engine-compatible corrosion preventive additives and water mixture.

2. Remote Radiator: Remote radiator cooling system shall consist of liquid coolant to air, horizontally-mounted heat exchanger (radiator) with expansion tank and pressure cap, electric cooling fan(s), engine thermostat, engine driven coolant pump, internal engine coolant passages, and coolant hoses. Interconnect these components provide completely closed and pressurized system. Radiator coils/fins shall be copper/copper, copper/aluminum, or copper/cupro-nickel material and fin spacing shall be such that resulting air passages do not clog from dust and dirt. Radiator shall be capable of withstanding internal pressure of

0.35 kg/sq. cm greater than pressure setting of radiator cap. Radiator cap shall be captive, and when removed shall not interfere with radiator fan. There shall be radiator drain valve to permit complete draining of coolant. Radiator shall be epoxy coated to minimize salt-air deterioration. Use of this coating shall not reduce performance as specified in Article on “Performance Requirements,” paragraph on “Starting and Operating.”

3. Coolant Jacket Heater: Equip engine with thermostatically controlled electric immersion heater(s) in engine coolant. Heater system shall be capable of maintaining minimum

SECTION 26 3216 - 19

temperature of 32 deg C under all conditions specified in Article on “Performance Requirements,” paragraph on "Starting and Operating." If heater(s) are located external to engine water jacket and hoses are used for interconnection, provide isolation valves to permit repair and removal of heater and hoses without draining cooling system. Heater(s) shall be rated for 220V. Connect heater (s) through thermostat to terminals accessible for user connection to commercial power.

2.5 FUEL SUPPLY SYSTEM

A. General: Fuel system, including piping, valves, filters, and connections shall prevent air from entering the system, and shall prevent fuel flow from being restricted during operation under all conditions in this specification. Provide permanently-installed, manually-operated fuel pump capable of priming the engine fuel system after air has been allowed to enter fuel system.

1. Locate hot fuel return such that hot fuel cannot immediately be picked up by fuel pickup tube. Install inlet of fuel pickup not less than 13 mm from bottom of tank, and cut off inlet end of fuel pickup at angle or vee. Equip fuel suction pipe inside day tank with check valve to prevent loss of prime.

2. Connections: Provide fuel supply and fuel return fittings for connection to engine fuel system,

3. Monitoring and Controls: Day tank monitoring and controls shall be compatible with fuel pump controls and leak/load monitoring systems.

a. Install level control probe in top of tank to monitor fuel oil level and to communicate with pump controller in order to control supply pump operation.

b. Provide leak sensor located in annular space between primary and secondary tank, and interface with engine control and monitoring system to provide visual and audible signal when leak is detected.

c. Configure Low-Level, Critical-Low, High-Level, and Day Tank Leak alarms so they are transmitted to electronic control panel for facility fuel oil system.

B. Electric Auxiliary Fuel Return Pump: Provide auxiliary pump capable of returning excess fuel to remote fuel storage tank. Pump shall operate automatically when day tank fuel level exceeds high level alarm, and shall operate manually via switch. Size pump at twice flow rate of supply fuel rate to day tank.

C. Auxiliary Fuel Connection: Provide standard metric or SAE threaded fitting for connection of auxiliary fuel line between sub-base tank or stand-alone fuel day tank and external fuel source.

Locate fitting to permit auxiliary fuel line to be connected or disconnected without affecting operation of genset. Provide hand-operated manual fuel transfer pump that allows day tank to be filled in event of failure of primary electrical pump. Where necessary, provide 8-meters (25- foot) auxiliary fuel line; this fuel line shall have fitting on each end to mate with genset auxiliary fuel connection.

D. Fuel Filters/Water Separator: Fuel filtering system shall have sufficient filtration capacity to allow for continuous genset operation on fuel containing up to 15 milligrams of fine test dust per liter of fuel for a minimum of 300 hours. Permanently mark inlet and outlet connection for fuel filter, water separator, and fuel strainer (if used) assemblies. Water separator shall not be damaged by

SECTION 26 3216 - 20

freezing of any water that is accumulated therein.

E. Fuel Lines: Protect fuel lines projecting through metal apertures by grommets and secured to framing members. Use cushioned clips, braces, or brackets to securely fasten all piping between tank and engine. All high-pressure fuel lines shall be made of steel. Hose conforming to metric or SAE standards may be used for low-pressure fuel lines, except hose within 250 mm distance to engine exhaust system shall have metal shield.

F. Provide shutoff/isolation valve and threaded cap for future supply line connection and threaded fuel line and cap for future return line connection to external main supply tanks.

G. As available, refer to existing conditions and fuel oil system drawings for additional requirements.

2.6 ENGINE EXHAUST SYSTEM

A. Exhaust System: Engine exhaust system shall consist of hospital/critical-grade muffler(s), piping(s), and rain cap(s) to discharge exhaust gas to outside of genset. Rain cap shall be made of corrosion-resistant material as opposed to corrosion-resistant treated material. Provide section of flexible pipe between engine and muffler. Incorporate mechanical details and parts required to mount muffler. Muffler may be shipped unmounted, Contractor shall provide all brackets, flanges, gaskets, and hardware necessary to mount muffler on the genset. Design and construction of exhaust system shall be such that genset sound level requirements of this Section can be met.

Exhaust system shall facilitate easy removal of muffler(s) for external mounting. System shall be such that genset will operate at rated load with additional 25 kPa of water back pressure added to exhaust system when muffler is remotely mounted.

2.7 COMBUSTION-AIR INTAKE SYSTEM

A. Combustion Intake Air System: Air intake shall include heavy-duty dry-type air cleaner with disposable barrier-filter elements consisting of pleated paper. Equip air cleaner with air cleaner restriction indicator. Locate restriction indicator so that it can be readily observed.

2.8 STARTING SYSTEMS

A. Electric engine starting system shall be negative ground 24 volt (nominal). System shall consist of two (2) electric cranking motors, battery(s), battery charging system, battery retainer, battery cables and other components required to make complete system.

1. Cranking Motors: Provide means to prevent starting of motor and engagement of drive mechanism during running of genset, or when coming up to rated speed after cranking motor disengages.