26 32 13 REVISED.pdf

Building 1 Renovation Work Order #19-0037 Camp Lejeune, Jacksonville, NC

SECTION 26 32 13

SINGLE OPERATION GENERATOR SETS

01/07

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 in the text by the basic designation only.

ASME INTERNATIONAL (ASME)

ASME B16.1 (1998) Cast Iron Pipe Flanges and Flanged Fittings Classes 25, 125, and 250

ASME B16.5 (2017) Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard

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

ASTM INTERNATIONAL (ASTM)

ASTM A 53/A 53M (2002) Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A 181/A 181M (2001) Carbon Steel Forgings, for General-Purpose Piping

ASTM A193/A193M (2017) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A194/A194M (2018) Standard Specification for Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

ASTM A 234/A 234M (2002) Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service

ASTM D 975 (2002) Diesel Fuel Oils

INTERNATIONAL CODE COUNCIL (ICC)

ICC IBC (2018) International Building Code

SECTION 26 32 13 Page 1

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC 60034-2 (1972; Sup. A 1974, Amend. 1995 & 1996)Rotating Electrical Machines Part 2:

Methods for Determining Losses and Efficiency of Rotating Electrical Machinery from Tests (Excluding Machines for Traction Vehicles)

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE Std 115 (1995; R 2002) Test Procedures for Synchronous Machines Part 1 - Acceptance and Performance Testing Part II - Test Procedures and Parameter Determination for Dynamic Analysis

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

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 3046 (2002) Reciprocating Internal Combustion Engines - Performance

ISO 8528 (1993) Reciprocating Internal Combustion Engine Driven Alternating Current Generating Sets

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-58 (2009) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation

MSS SP-69 (2003; Notice 2012) Pipe Hangers and Supports - Selection and Application (ANSI Approved American National Standard)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA C50.10 (1990) Rotating Electrical Machinery - Synchronous Machines

NEMA C50.12 (1982; R 1989) Salient-Pole Synchronous Generators and Generator/Motors for Hydraulic Turbine Applications

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

NEMA MG 1 (2016; SUPP 2018) Motors and Generators

INTERNATIONAL ELECTRICAL TESTING ASSOCIATION (NETA)

NETA ATS (2017; Errata 2017) Standard for Acceptance Testing Specifications for Electrical Power Equipment and Systems

SECTION 26 32 13 Page 2

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 30 (2000) Flammable and Combustible Liquids Code

NFPA 37 (2002) Installation and Use of Stationary Combustion Engines and Gas Turbines

NFPA 70 (2017; ERTA 1-2 2017; TIA 17-1; TIA 17-2;

TIA 17-3; TIA 17-4; TIA 17-5; TIA 17-6;

TIA 17-7; TIA 17-8; TIA 17-9; TIA 17-10;

TIA 17-11; TIA 17-12; TIA 17-13; TIA

17-14; TIA 17-15; TIA 17-16; TIA 17-17 )

National Electrical Code

UNDERWRITERS LABORATORIES (UL)

UL 142 (2006; Reprint Jul 2013) 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) UL Standard for Safety Molded-Case Circuit Breakers, Molded-Case Switches and Circuit-Breaker Enclosures

UL 1236 (2015; Reprint Mar 2016) UL Standard for Safety Battery Chargers for Charging Engine-Starter Batteries

1.2 RELATED REQUIREMENTS

Section 26 00 00 , "Basic Electrical Materials and Methods," and Section 26 08 00 , "Apparatus Inspection and Testing" apply to this section except as modified herein.

1.3 SYSTEM DESCRIPTION

1.3.1 Engine-Generator Set Data

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

a. Make of engine.

b. Type or model of engine.

c. Gross bhp rating of engine shall be the total rated power output before deducting power requirements of electric motor-driven equipment or engine driven radiator fan.

d. Net brake power rating of engine shall include deductions for the total power requirements of electric motor-driven or engine-driven accessories as defined in ISO 3046 . Net ratings shall include a deduction in power output for cooling media system power requirements including radiator fans and any other power consuming devices required to provide cooling as specified.

SECTION 26 32 13 Page 3

e. Strokes per cycle.

f. Number of cylinders.

g. Bore and stroke, inches .

h. Engine speed, rpm.

i. Piston speed, fpm .

j. kW power rating of engine-generator set as defined in the paragraph entitled "Engine-Generator Set Ratings and Performance."

k. Induction method (naturally aspirated, turbocharged).

l. Intercooler type (air-to-air or jacket water).

m. Governor type, make, and model.

n. Make and model of turbochargers.

1.3.2 Engine-Generator Set Efficiencies

Submit data pertaining to the diesel engine-generator set including but not limited to the following: Loads shall be calculated on basis of rated engine-generator set power.

a. Fuel consumption at 0.80 power factor, gallons per hr .

1. 1/2 load

2. 3/4 load

3. Full load

b. Generator efficiency at 0.80 power factor (percent) in accordance with

IEC 60034-2 .

1. 1/2 load

2. 3/4 load

3. Full load

c. Radiator capacity at design conditions.

1. Coolant shall be antifreeze mixture as specified under paragraph entitled "Cooling System."

2. gpm of coolant

3. cfm of air through radiator

4. Btu per hr of heat exchange based on optimum coolant temperature to and from engine.

SECTION 26 32 13 Page 4

1.3.3 Diesel Engine Data

Submit data certified by the engine manufacturer including but not limited to the following: Loads shall be calculated on basis of rated engine-generator set power.

a. Approximate exhaust temperature degrees F at full load

1.3.4 Generator and Exciter Data

Submit data certified by the generator manufacturer including but not limited to the following:

a. Make and model number of generator

b. kW rating of generator

c. Generator reactances

1. Synchronous reactance, Xd

2. Transient reactance, X'd

3. Subtransient reactance, X"d

4. Negative sequence reactance, X2

5. Zero sequence reactance, Xo

1.3.5 Capacity Calculations for Engine-Generator Set

Calculations shall verify that the engine-generator set power rating is adequate for the load described in the paragraph entitled "Load Profile."

1.3.6 Calculations for Brake Mean Effective Pressure (BMEP)

Calculation shall verify that the diesel engine meets the specified maximum BMEP as follows:

a. kW: Minimum power rating of engine-generator set as defined in the paragraph entitled "Engine-Generator Set Ratings and Performance."

b. rpm: Engine revolutions per minute.

c. cu. in. : Total engine piston displacement in cubic inches .

d. GEN.EFF.: Generator efficiency.

e. x: Multiplication sign.

f. bhp' : Brake horsepower required from diesel engine by generator loaded to full power rating.

g. bhp' : kW/(GEN.EFF. x 0.746) .

h. bhp" : Brake horsepower required by diesel engine driven fan for cooling radiator or motor driven fan for cooling radiator.

i. bhp : bhp' + bhp" .

SECTION 26 32 13 Page 5

j. BMEP psi : (792,000 x bhp) /(rpm x cu. in. ).

1.3.7 Torsional Vibration Stress Analysis Computations

Torsional vibrational stresses in the crankshaft and generator shaft of assembled diesel engine and driven generator shall not exceed 5000 psi when engine is driving generator at rated speed while assembled unit is loaded to rated engine-generator set power. Computations shall 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 shall 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.

1.3.8 Capacity Calculations for Batteries

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

1.4 SUBMITTALS

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

submittals not having a "G" designation are for Contractor Quality Control approval. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.

The following shall be submitted in accordance with v

SD-02 Shop Drawings

Engine-Generator set and auxiliary equipment ; G

SD-03 Product Data

Engine-generator set data ; G

Engine-generator set efficiencies

Diesel engine data

SECTION 26 32 13 Page 6

Generator and exciter data

Diesel engine-generator set

Auxiliary systems and equipment

SD-05 Design Data

Capacity calculations for engine-generator set ; G

Calculations for brake mean effective pressure

Torsional vibration stress analysis computations

Capacity calculations for batteries

SD-06 Test Reports

Acceptance checks and tests

Functional acceptance tests

Functional acceptance test procedure

SD-07 Certificates

Vibration isolation system certification

Fuel system certification

Start-up engineer qualification resume

Instructor's qualification resume

SD-09 Manufacturer's Field Reports

Engine tests

Generator tests

Assembled engine-generator set tests

SD-10 Operation and Maintenance Data

Diesel engine-generator set , Data Package 4 ; G

Auxiliary systems and equipment , Data Package 4 ; G

Preliminary assembled operation and maintenance manuals ; G

Submit operation and maintenance manuals in accordance with Section 01 78 23 , "Operation and Maintenance Data" and the paragraph entitled "Assembled Operation and Maintenance Manuals."

SD-11 Closeout Submittals

Posted operating instructions ; G

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Training plan

1.5 QUALITY ASSURANCE

1.5.1 Drawing Requirements

1.5.1.1 Engine-Generator Set and Auxiliary Equipment

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 subbase.

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 diesel fuel system, starting battery system, engine-generator control panel, generator circuit breaker.

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

1.5.2 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 entitled "Vibration Isolation System."

1.5.3 Fuel System Certification

When the diesel fuel system requires a fuel oil cooler as described in the paragraph entitled "Fuel Oil Cooler," submit certification from the engine manufacturer that the fuel system design is satisfactory.

1.6 DELIVERY, STORAGE, AND HANDLING

Deliver equipment on pallets or blocking wrapped in heavy-duty plastic, sealed to protect parts and assemblies from moisture and dirt. Plug piping, conduit, exhaust, and air intake openings. 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.

1.7 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: Sub-tropical, coastal area

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b. Site Elevation: Mean sea level

c. Ambient Temperatures:

1. Maximum 104 degrees F dry bulb, 85 degrees F wet bulb.

2. Minimum 0 degrees F dry bulb.

d. Design Wind Velocity: 130 mph .

e. Atmospheric Conditions: Moist, dust-laden.

f. Seismic Zone: Zone 1 as defined by ICC IBC .

1.8 MAINTENANCE

1.8.1 Extra Materials

1.8.1.1 Paint

Furnish one gallon of identical paint used on engine-generator set in manufacturer's sealed container with each engine-generator set.

1.8.1.2 Filters

Furnish four spare replacement elements in their original containers for each filter with each unit.

1.8.2 Posted Operating Instructions

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.

PART 2 PRODUCTS

2.1 DIESEL ENGINE-GENERATOR SET

Provide diesel engine-generator sets consisting of a water cooled diesel engine direct connected to an ac generator with a brushless excitation system and accessories. Equipment and materials shall be the manufacturer's standard products offered in catalogs for commercial or industrial use.

2.1.1 Engine-Generator Set Ratings and Performance

ISO 8528 . Each engine-generator set shall have a power rating of not less than kW as determined by EOR at 0.8 power factor and supply[ 208Y/120][ 480Y/277] -volt, three-phase, 60-Hz ac output. Coordinate the engine-generator set to ensure an installed rating in the environment described in paragraph entitled "Site Conditions." The power of the engine-generator set is defined as the power output available at the generator terminals excluding the electrical power absorbed by the essential independent auxiliaries. Essential independent auxiliaries are items of equipment which are essential for the continued or repeated operation of the engine which uses power supplied from a source other than

SECTION 26 32 13 Page 9 the engine.

2.1.1.1 Diesel Engine Capacity

The diesel engine shall meet the specified maximum BMEP requirements at rated speed as calculated in accordance with the paragraph entitled "Calculations for BMEP." The engine capacity shall be based on the following:

a. Engine burning diesel fuel conforming to ASTM D 975 , Grade 2-D, at an ambient temperature of 85 degrees F .

b. Engine cooled by a radiator fan mechanically driven by the diesel 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.

Maximum BMEP, psi

Naturally Turbocharged Aspirated Turbocharged and Intercooled

Four-cycle engines [____] [____] [____]

Engine speed, rpm: 1800

2.1.1.2 Performance Class

The voltage and frequency behavior of the generator set shall be in accordance with ISO 8528 operating limit values for performance Class G3.

2.1.1.3 Load Profile

The diesel engine-generator set shall be of adequate capacity necessary for the load profile described on the plans. Load Factor: 85-percent load factor according to ISO 8528-1. Supplier shall provide Public Facing documents for performance to 85-percent load factor in regards to time before overhaul (TBO) and the respective maintenance schedule.

2.1.2 Diesel Engines and Accessories

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

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2.1.2.1 Subbase Mounting

Mount each engine-generator set on a structural steel subbase 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 subbase to properly support the equipment and maintain proper alignment of the engine-generator set in the specified seismic zone. In addition, provide subbase with both lifting rings and jacking pads properly located to facilitate shipping and installation of the unit. Factory align engine and generator on the subbase and securely bolt into place in accordance with the manufacturer's standard practice. Crankshaft shall have rigid coupling for connection to the generator.

2.1.2.2 Assembly

Completely shop assemble each engine-generator set on its structural steel subbase. 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.

2.1.2.3 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.

2.1.2.4 Intercooler

Provide manufacturer's standard intercooler for engine size specified.

2.1.2.5 Crankcase Protection

Provide manufacturer's standard method of preventing crankcase explosions and standard method of crankcase ventilation.

2.1.2.6 Engine Lubricating Oil System

Provide each engine with the manufacturer's standard full pressure lubricating oil system arranged to cool the pistons and to distribute oil to moving parts of the engine. Lubricating system must be run through the frame for external oil removal. Brass drain cock (shutoff valve) must be installed at the oil pan with iron NPT pipe threads and iron pipe plug at the external side of the frame. Provide oil type and oil filters as recommended by the engine manufacturer.

2.1.2.7 Engine Cooling System

Provide each engine with the manufacturer's standard jacket water pump.

Provide a thermostatic control valve in the jacket coolant system for each engine-generator set to maintain a constant jacket coolant temperature to the engine.

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2.1.2.8 Engine Fuel System

Provide each engine with the manufacturer's standard fuel system integral with the engine, complete with necessary piping, fittings, and valves for connecting items of equipment which are a part of the system. Provide engine manufacturer's standard hand priming pump. Provide manufacturer's standard filter for each engine, of the throwaway filter element type, consisting of shell filter elements, drains, and necessary connections and fittings.

2.1.2.9 Engine Intake Filter

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

Design unit for field access for maintenance purposes.

2.1.2.10 Engine Starting System

Starting shall be accomplished using an adequately sized dc starter system with a positive shift solenoid to engage the starter motor and to crank the engine continuously for 60 seconds without overheating.

2.1.2.11 Jacket Coolant Heating System

Provide a factory-installed, 208 volts ac, jacket coolant heating system to ensure rapid starting. Thermostatically control heater at the temperature recommended by engine manufacturer. Include necessary equipment, piping, controls, wiring, and accessories.

2.1.2.12 Engine Protective (Shutdown) Devices

Equip each engine with devices to shut down the engine by shutting off the fuel supply to the engine via a fuel shutoff solenoid. Auxiliary contacts shall be suitable for activating a remote alarm system. Shutdown shall open the associated generator circuit breaker. Provide the following shutdown devices:

a. Overspeed device which operates when engine speed exceeds normal synchronous speed by 18 percent or as recommended by manufacturer.

Device shall require manual reset.

b. Pressure switch which operates when lubricating oil pressure to engine drops below a preset value.

c. Temperature switch which operates when jacket coolant temperature exceeds a preset value.

d. Device which operates when the coolant level in the radiator drops below a preset level.

e. Other shutdown devices as recommended by the engine manufacturer.

SECTION 26 32 13 Page 12

2.1.2.13 Engine Alarm Devices

Equip each engine with alarm devices. Auxiliary contacts shall be suitable for activating a remote alarm system. Alarm devices shall have factory-fixed set points. Provide the following alarm contact devices:

a. Pressure switch which operates when lubricating oil pressure drops below a preset value. External signal conditioning between the controller and switch/sensor in not permitted.

b. Temperature switch which operates when jacket coolant temperature exceeds a preset value.

c. Temperature switch which operates when jacket coolant temperature is too low.

d. Other alarm devices as recommended by the engine manufacturer.

2.1.2.14 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.

b. Structural steel subbase 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 subbase on the foundation.

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

2.1.2.15 Engine Speed Governor System

Provide a forward acting type engine speed governor system. Steady-state frequency band and frequency regulation (droop) shall be in accordance with the operating limit values of the performance class specified in the paragraph entitled "Performance Class."

2.1.3 Generator and Excitation System

2.1.3.1 Generator

Provide salient-pole type, ac, brushless-excited, revolving field, air-cooled, self-ventilated, coupled type, synchronous generator conforming to NEMA MG 1, Part 16, NEMA C50.10 , and NEMA C50.12 . Generator shall be rated for standby duty at 100 percent of the power rating of the engine-generator set as specified in paragraph entitled "Engine-Generator Set Ratings and Performance." Temperature rise of each of the various parts of the generator shall not exceed 130 degrees C as measured by resistance, based on a maximum ambient temperature of 40 degrees C.

Winding insulation shall be Class H.

SECTION 26 32 13 Page 13

a. Stator: Stator windings shall be 2/3 pitch design, 10-12 lead reconnectable with VPI insulated coils.

b. Rotor: The rotor shall have connected amortisser windings.

c. Generator Strip Heater: Provide 120 volt ac heaters. Heater capacity shall be as recommended by the generator manufacturer to aid in keeping the generator insulation dry.

d. Grounding: Provide non-corrosive steel grounding pads located at two opposite mounting legs.

e. Filters: Provide manufacturer's standard generator cooling air filter assembly.

2.1.3.2 Excitation System

Provide a brushless excitation system consisting of an exciter and rotating rectifier assembly, and permanent magnet generator integral with the generator and a voltage regulator. Insulation class for parts integral with the generator shall be as specified in paragraph entitled "Generator." System shall provide a minimum short circuit of 300 percent rated engine-generator set current for at least 10 seconds. Steady state voltage regulation shall be in accordance with the operating limit values of the performance class specified in the paragraph entitled "Performance Class."

a. Exciter and Rotating Rectifier Assembly: Rectifiers shall be provided with surge voltage protection.

b. Permanent Magnet Generator: Provide a voltage spike suppression device for permanent magnet generator (PMG) excitation systems.

c. Voltage Regulator: Voltage regulator shall be external from the control system and solid state or digital, automatic, three-phase sensing, volts per hertz type regulator. External voltage reduction transformers must not be used in the voltage regulation system.

Regulator shall receive its input power from a PMG. Voltage variation for any 40 degree C change over the operating temperature range shall be less than plus or minus 1.0 percent. Operating temperature shall be minus 40 degree C to plus 70 degree C. Voltage adjust range shall be plus to minus 5.0 percent of nominal. Inherent regulator features shall include overexcitation shutdown.

2.2 ENGINE-GENERATOR SET AUXILIARY SYSTEMS AND EQUIPMENT

Provide auxiliary systems and equipment designed for continuous duty at 100 percent of the power rating of the engine-generator set as specified in the paragraph entitled "Engine-Generator Set Ratings and Performance."

2.2.1 Vibration Isolation System

Install the subbase on vibration isolators that are secured to a suitable concrete foundation. Provide isolators as recommended by the engine-generator set and isolator manufacturers and provide integral or external lateral support to limit lateral movement and overturning moments. The isolation system shall reduce the vibration transmitted to

SECTION 26 32 13 Page 14 the adjacent floor slab to a maximum of 0.0015 inch total amplitude throughout the frequency range down to 65 Hz. Isolators shall be rubber, Steel isolators not allowed.

2.2.2 Exhaust System

Provide exhaust systems for each engine.

2.2.2.1 Exhaust Silencers

A critical class silencer shall be provided for each engine which will reduce the exhaust sound spectrum by the following listed values at a 75 foot radius from the outlet, with generator set loaded to rated capacity and clear weather. Inlet and outlet connections shall be flanged.

Exhaust system shall be stainless steel. Muffler shall be mounted horizontally and shall discharge horizontally.

Octave Band Center Frequency (Hertz)

Minimum 63 125 250 500 1000 2000 4000 8000 Silencer Attenuation Decibels

Critical Class 15 32 37 36 30 36 37 37

2.2.2.2 Field Installed Exhaust Piping System

Field installed exhaust piping shall conform to the following:

a. Exhaust Piping: Provide flanges for connections to diesel engines, exhaust mufflers, and flexible connections. Provide stainless steel pipe conforming to ASTM A 53/A 53M for each engine complete with necessary stainless steel fittings, flanges, gaskets, bolts, and nuts. Exhaust piping shall be Schedule 40 pipe for 12 inches and smaller, standard weight for sizes 14 inches through 24 inches , and

0.25 inch wall thickness for sizes larger than 24 inches . Flanges shall be Class 150 slip-on stainless steel welding flanges in accordance with ASME B16.5 , with material in accordance with ASTM A 181/A 181M , Grade I. Fittings shall be buttwelding conforming to ASTM A 234/A 234M , with wall thickness same as adjoining piping.

Fittings shall be of same material and wall thickness as pipe.

Built-up miter welded fittings may be used. Miter angles of each individual section shall not exceed 22.5 degrees total and not more than 11.25 degrees relative to the axis of the pipe at any one cut.

Gaskets for exhaust piping shall be of high temperature asbestos-free material suitable for the service and shall be ASME B16.21 , composition ring, 0.0625 inch thick. Bolting material for exhaust flanges shall be stainless -steel bolt-studs conforming to ASTM A193/A193M , Grade B7 bolts and stainless -steel nuts conforming to ASTM A194/A194M , Grade 7. Bolts shall be of sufficient length to obtain full bearing on the nuts and shall project not more than two

SECTION 26 32 13 Page 15 full threads beyond the nut. Provide stainless steel counterbalance type rain caps at termination of each exhaust pipe.

b. Expansion (Flexible) Joints: Provide sections of multiple corrugated stainless steel expansion joints in the engine exhaust piping for each engine to absorb expansion strains and vibration transmitted to the piping. Flexible joints shall be suitable for operation at 200 degrees F above normal exhaust gas temperature at 100 percent load, 10,000 cycles, minimum. Joints shall be flanged and located between engine exhaust manifold and exhaust piping, shall be the same size as exhaust piping size, and shall be designed and constructed for diesel engine exhaust service.

c. Hangers and Supports: MSS SP-58 and MSS SP-69 . Hangers and supports shall be stainless steel.

2.2.3 Cooling System

Provide the specified cooling water system. Properly size equipment to handle the flow rate and pressure losses of the coolant mixture specified in the paragraph entitled "Diesel Engine Capacity," and at the site elevation specified in the paragraph entitled "Site Conditions."

2.2.3.1 Radiators

Provide for each engine-generator set, as standard with the manufacturer.

a. Design Conditions: Each radiator unit shall have ample capacity to remove not less than the total Btu per hour of heat rejected by its respective engine at 100 percent full-rated load to the jacket water, fuel oil, and lubricating oil system, and intercooler. Radiator capacity shall be rated at optimum temperature of coolant leaving the engine and intercooler as recommended by the engine manufacturer with an ambient dry bulb air temperature outside the enclosure of 110 degrees F maximum, and 0 degrees F minimum at the site elevation specified in the paragraph entitled "Site Conditions," and with the coolant mixture specified in the paragraph entitled "Diesel Engine Capacity." Pressure drop through the radiator shall not exceed 6 psi when circulating the maximum required coolant flow. Radiator air velocity shall be a maximum of 1500 feet per minute .

b. Engine Mounted Radiator Construction: Radiator fan shall direct airflow from the engine outward through the radiator. Fan shall be V-belt driven directly from the engine crankshaft. Radiator fan shall have sufficient capacity to meet design conditions against a static restriction of 1/2 inch of water . Fan static capacity shall be adjusted to suit the ductwork furnished. Cooling section shall have a tube and fin-type core consisting of copper or copper base alloy tubes with nonferrous fins. Select engine-driven fans for quiet vibration-free operation. Make provision for coolant expansion either by self-contained expansion tanks or separately mounted expansion tanks, as standard with the manufacturer. Provide suitable guards for

SECTION 26 32 13 Page 16 each fan and drive.

c. Coolant solution shall be a mixture of clean water and ethylene glycol, 50 percent by volume each. Provide an anti-freeze solution tester suitable for the mixture.

2.2.4 Diesel Fuel System

NFPA 30 and NFPA 37 and the requirements herein.

2.2.4.1 Diesel Fuel Piping System

Factory installed piping shall conform to the engine manufacturer's standard. Provide flange connections in accordance with ASME B16.1 Class 125 flanges.

2.2.4.2 Diesel Fuel Day Tank System

Provide diesel fuel day tank system. Include necessary equipment, piping, controls, wiring, and accessories.

a. Day Tanks: UL 142 . Provide integral in skid , sub base tank, double wall (110 percent containment) diesel fuel day tanks with a minimum capacity of 72 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 and provide an access opening with dustproof, removable 24 inch cover. Provide 4 1/2 inch square inspection port. Provide proper venting of both inner and outer containment. Provide fuel polishing ports with down tubes to help with agitation of the fuel. Tank shall be constructed with a taper so that external water does not pool on top of tank.

b. Float Switches: 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 shall be suitable for the station battery voltage.

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

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

3. Low level float switch which shall 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 shall 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 shall activate alarm at 95 percent of normal liquid level.

SECTION 26 32 13 Page 17

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

d. Generator Control Panel shall display the following alarms : Provide NEMA ICS 6 , Type 3R, enclosed control panel for each day tank. Control panel shall 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 contacts for remote annunciator.

5. Critical high level fuel alarm LED.

6. Leak detecting alarm LED.

7. Alarm horn.

e. Tank Gages: Provide buoyant force type gages for diesel fuel day 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.

2.2.4.3 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 shall be furnished by the engine manufacturer for the application and the installation shall be complete including piping and power requirements.

2.2.5 Starting Battery System

Provide a 24-volt dc starting battery installation for starting of each engine-generator set utilizing an electric cranking system.

2.2.5.1 Engine Starting Battery

Provide maintenance free, AGM diesel engine starting batteries. Batteries shall have sufficient capacity to provide 60 seconds of continuous cranking of the engine in an ambient temperature of 95 degrees F . Provide and install remote aluminum battery box with cover on concrete pad.

generator supplier is responsible for remotely mounting batteries and providing and installing all hardware, conduit and conductor for a complete operational system. coordinate final location with contracting officer.

SECTION 26 32 13 Page 18

2.2.5.2 Starting Battery Charger

UL 1236 . Provide 120 volt ac, enclosed, automatic equalizing, dual-rate, solid-state, constant voltage type battery charger with automatic ac line compensation capable of charging AGM batteries . Dc output shall be voltage regulated and current limited. Charger shall have two ranges, float and equalize, and shall provide continuous taper charging. The charger shall have a continuous output rating of not less than 10 amperes and shall be sized to recharge the engine starting batteries in a minimum of 8 hours while providing the control power needs of the engine-generator set. Enclosure shall be NEMA ICS 6 , Type 12. Automatic Temperature Compensation: Adjust float and equalize voltages for variations in ambient temperature from minus 40 deg F(minus 40 deg C) to 140 deg F(plus 60 deg C) to prevent overcharging at high temperatures and undercharging at low temperatures.

Temperature Probe: Equip battery charger with a temperature probe on the negative cable.

The following accessories shall be included:

a. Dc ammeter

b. Dc voltmeter

c. Equalize light

d. Ac on light

e. Low voltage light

f. High voltage light

g. Equalize test button/switch

h. Ac circuit breaker

i. Low dc voltage alarm relay

j. High dc voltage alarm relay

k. Current failure relay

l. Ac power failure relay

2.2.6 Engine-Generator Control Panel

Provide NEMA ICS 6 , Type 12, enclosed control panel mounted on the engine-generator set with vibration isolators. Provide the following control panel mounted devices and control features.

2.2.6.1 Control Panel Mounted Devices

a. Engine Control Switch (ECS): Provide a three position control switch with "MANUAL START" - "OFF/RESET" - "AUTO START" positions.

b. Emergency Stop Push Button (ESPB): Provide a red, mushroom head, twist-to-reset, maintained contact type push button.

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c. Generator Metering: Provide ac metering package that displays ac voltage, current, and frequency of one phase of the generator output simultaneously. Metering package shall include a voltmeter/ammeter phase selector switch to allow viewing of each phase.

d. Generator Voltage Adjust Potentiometer (VAP): Provide a potentiometer, locking screwdriver type, to adjust generator voltage.

e. Engine Instrumentation: Generator control shall meet utility grade ANSI level protection: 27, 32, 40Q, 47, 51, 59, 78, 81O, 81R, 81U.

Provide instrumentation package that displays the following engine information:

1. Engine oil pressure

2. Engine coolant temperature

3. Engine speed (rpm)

4. Engine running hours

f. Indicating Lamps: Provide LED type indicating lamps and a lamp test switch. Lamps shall indicate the following alarm and shutdown conditions:

1. Low engine lubricating oil pressure alarm

2. Low engine lubricating oil pressure shutdown

3. High engine coolant temperature alarm

4. High engine coolant temperature shutdown

5. Engine overcrank shutdown

6. Engine overspeed shutdown

7. Emergency stop shutdown

8. Starting battery system trouble alarm

9. Day tank low fuel shutdown

10. Low engine coolant temperature alarm

11. Low coolant level shutdown

g. Alarm Horn: Provide an alarm horn and a horn silence switch.

h. Panel Lamp: Provide a panel lamp and lamp "ON-OFF" switch.

i. Control Communication shall have, rs 232, RTU (rs485), Can-buss, and redundant TCP/IP connection.

2.2.6.2 Crank Cycle/Terminate Relay

Provide crank cycle/terminate relay with adjustable crank/rest periods of 1 to 60 seconds (initially set for 15 seconds) and adjustable total crank time of 30 seconds to 10 minutes (initially set for 75 seconds).

SECTION 26 32 13 Page 20

2.2.6.3 Engine Cooldown Relay

Provide cooldown relay with adjustable cool down time of 0 to 30 minutes (initially set at engine manufacturer's recommended time).

2.2.7 Generator Circuit Breaker

UL 489 , molded case, service equipment listed, adjustable thermal magnetic trip type circuit breaker. The circuit breaker continuous current rating shall be adequate for the power rating of the engine-generator set and the circuit breaker shall be rated to withstand the short circuit current provided by the generator set. Provide a second circuit breaker meeting above requirements and size that will be utilized for load testing the generator with portable load bank. Provide circuit breaker s in a NEMA ICS 6 , Type 1 enclosure mounted on the engine-generator set inside the enclosure . Load bank circuit breaker shall be provided with 4/0 AWG type PPE cable sufficient for breaker load (Governments test equipment is standardized with 4/0 conductor and CAM-LOKS) and female CAM-LOK devices with protective caps. Cable shall be of sufficient length to mount strain relief and entire CAM-LOK device outside breaker enclosure to allow connection of Male CAM-LOK.

2.2.8 Electrical Support Equipment

Furnish with respective pieces of equipment. Motors, controllers, contactors, and disconnects shall conform to Section 26 20 00 , "Interior Distribution System." Provide electrical connections under Section 26 20 00 , "Interior Distribution System." Provide controllers and contactors with maximum of 120-volt control circuits, and auxiliary contacts for use with controls furnished. When motors and equipment furnished are larger than size indicated, the cost of providing additional electrical service and related work shall be included under this section.

2.2.9 Weatherproof Enclosure

Provide for each engine-generator set and fabricate from marine grade almuminum in accordance with the manufacturer's standard design. Provide a complete, weatherproof enclosure for the engine, generator, and auxiliary systems and equipment. Support exhaust piping and silencer so that the turbocharger is not subjected to exhaust system weight or lateral forces generated in connecting piping that exceed the engine manufacturer's maximum allowed forces and moments. The housing shall have sufficient louvered openings to allow entrance of outside air for engine and generator cooling at full load. Design louvered openings to exclude driving rain and snow. Provide weather-resistant AC/DC-powered LED lighting with 30-fc(330-lx) average maintained. Factory-wired GFCI.

Arrange for external electrical connection. The enclosure shall have a distribution panelboard mounted and installed internal to the enclosure from factory with all AC powered loads prewired with 10kaic breakers.

Provide properly arranged and sized, hinged panels in the enclosure to allow convenient access to the engine, generator, and control equipment for maintenance and operational procedures. Provide hinged panels with spring type latches which shall hold the panels closed securely and will not allow them to vibrate. Brace the housing internally to prevent excessive vibration when the set is in operation.

2.3 SPECIAL WRENCHES AND TOOLS

Wrenches and tools specifically designed and required to work on the new

SECTION 26 32 13 Page 21 equipment, which are not commercially available as standard mechanic's tools, shall be furnished to the Contracting Officer.

2.4 IDENTIFICATION OF EQUIPMENT

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 shall be normal block lettering, a minimum of 0.25 inch high.

2.4.1 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 diesel engine of laminated plastic, 0.125 inch thick, matte white finish with black center core, with lettering accurately aligned and engraved into the core.

2.4.2 Control Devices and Operation Indicators

Provide ID plates or tags for control devices and operation indicators, 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 shall be minimum of 0.5 inch high and 2 inches long and shall indicate component system and component function.

2.4.3 Equipment

Provide ID plates of a minimum size of 3 inches high and 5 inches long on provided equipment indicating the following information:

a. Manufacturer's name, address, type and model number, and serial number;

b. Contract number and accepted date;

c. Capacity or size;

d. System in which installed; and

e. System which it controls.

2.5 ASSEMBLED OPERATION AND MAINTENANCE MANUALS

The contents of the assembled operation and maintenance manuals shall include the manufacturer's O&M information required by the paragraph entitled "SD-10, Operation and Maintenance Data" and the manufacturer's O&M information specified in Section 26 36 23.00 20 , "Automatic Transfer Switches."

a. Manuals shall 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) shall be made part of the assembled O&M.

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

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

SECTION 26 32 13 Page 22

Manual."

2.6 SOURCE QUALITY CONTROL

Perform and report on factory tests and inspections prior to shipment.

Provide certified copies of manufacturer's test data and results. Test procedures shall conform to ASME, IEEE, and ANSI standards, and to ISO requirements on testing, as appropriate and applicable. The manufacturer performing the tests shall provide equipment, labor, and consumables necessary for tests and measuring and indicating devices shall be certified to be within calibration. Tests shall indicate satisfactory operation and attainment of specified performance. If satisfactory, equipment tested will be given a tentative approval. Equipment shall not be shipped before approval of the factory test reports for the following tests.

2.6.1 Engine Tests

Perform customary commercial factory tests in accordance with ISO 3046 on each engine and associated engine protective device, including, but not limited to the following:

a. Perform dynamometer test at rated power. Record horsepower at rated speed and nominal characteristics such as lubricating oil pressure, jacket water temperature, and ambient temperature.

b. Test and record the values that the low oil pressure alarm and protective shutdown devices actuate prior to assembly on the engine.

c. Test and record values that the high jacket water temperature alarm and protective shutdown devices actuate prior to assembly on the engine.

2.6.2 Generator Tests

Tests shall be performed on the complete factory assembled generator prior to shipment. Conduct tests in accordance with IEEE Std 115 , NEMA C50.10 , and NEMA MG 1.

2.6.2.1 Routine Tests

Perform the following routine tests on the generators and their exciters:

a. Resistance of armature and field windings

b. Mechanical balance

c. Phases sequence

d. Open circuit saturation curve and phase (voltage) balance test

e. Insulation resistance of armature and field windings

f. High potential test

SECTION 26 32 13 Page 23

2.6.2.2 Design Tests

Submit the following design tests made on prototype machines that are physically and electrically identical to the generators specified.

a. Temperature rise test

b. Short circuit saturation curve and current balance test

2.6.3 Assembled Engine-Generator Set Tests

Submit the following tests made on prototype machines that are physically and electrically identical to the engine-generator set specified.

2.6.3.1 Initial Stabilization Readings

Operate the engine-generator set and allow the set to stabilize at rated kW at rated power factor, rated voltage, and rated frequency. During this period record instrument readings for output power (kW), terminal voltage, line current, power factor, frequency (rpm) generator (exciter) field voltage and current, lubricating oil pressure, jacket water temperature, and ambient temperature at minimum intervals of 15 minutes. Adjust the load, voltage, and frequency to maintain rated load at rated voltage and frequency. Adjustments to load, voltage, or frequency controls shall be recorded on the data sheet at the time of adjustment. Stabilization shall be considered to have occurred when four consecutive voltage and current recorded readings of the generator (or exciter) field either remain unchanged or have only minor variations about an equilibrium condition with no evident continued increase or decrease in value after the last adjustment to the load, voltage, or frequency has been made.

2.6.3.2 Regulator Range Test

Remove load and record instrument readings (after transients have subsided). Adjust voltage to the maximum attainable value or to a value just prior to actuation of the overvoltage protection device. Apply rated load and adjust voltage to the minimum attainable value or a value just prior to activation of the undervoltage protection device. The data sheets shall indicate the voltage regulation as a percent of rated voltage and the maximum and minimum voltages attainable. Voltage regulation shall be defined as follows:

Percent Regulation = ((No-Load Voltage) - (Rated-Load Voltage)) x 100 (Rated-Load Voltage)

2.6.3.3 Frequency Range Test

Adjust the engine-generator set frequency for the maximum attainable frequency at rated load. Record instrument readings. Adjust the engine-generator set frequency for the specified minimum attainable frequency at rated load. Record instrument readings. Reduce the load to zero and adjust the engine-generator set frequency for the maximum attainable frequency. Record instrument readings. Adjust the engine-generator set frequency for the minimum attainable frequency.

Record instrument readings. The data sheet shall show the maximum and minimum frequencies attained at rated load, and at no load.

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2.6.3.4 Transient Response Test

Drop the load to…