26 32 13.00 20 (24 Feb 2021).pdf

P-811 Port Operations Facilities 1561956

SECTION 26 32 13.00 20

SINGLE OPERATION GENERATOR SETS

04/07

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 within the text by the basic designation only.

ASME INTERNATIONAL (ASME)

ASME B16.1 (2015) Gray Iron Pipe Flanges and Flanged Fittings Classes 25, 125, and 250

ASTM INTERNATIONAL (ASTM)

ASTM D975 (2017a) Standard Specification for Diesel Fuel Oils

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 115 (2009) Guide for Test Procedures for Synchronous Machines: Part I 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

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

INTERNATIONAL CODE COUNCIL (ICC)

ICC UBC (1997; Erratas Vol 1, 2 & 3 01/2001; Vol 1 & 2 03/2001; Vol 2 10/2001) Uniform Building Code

INTERNATIONAL ELECTRICAL TESTING ASSOCIATION (NETA)

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

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC 60034-2A (1974; ED 1.0) Rotating Electrical Machines Part 2: Methods for Determining Losses and Efficiency of Rotating Electrical Machinery from Tests (Excluding Machines for Traction Vehicles)

SECTION 26 32 13.00 20 Page 1

Measurement of Losses by the Calorimetric Method

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 3046 (1986; Am. 1) Reciprocating Internal Combustion Engines - Performance

ISO 8528 (1993; R 2005) Reciprocating Internal Combustion Engine Driven Alternating Current Generator Sets

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

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

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

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

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 30 (2015; ERTA 1 2016) Flammable and Combustible Liquids Code

NFPA 37 (2018) Standard for the 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) National Electrical Code

UNDERWRITERS LABORATORIES (UL)

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

UL 142 (2006; Reprint Jul 2013) Steel Aboveground Tanks for Flammable and Combustible Liquids

UL 429 (2013) Electrically Operated Valves

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

1.2 RELATED REQUIREMENTS

Section 26 00 00.00 20 BASIC ELECTRICAL MATERIALS AND METHODS, and Section 26 08 00 APPARATUS INSPECTION AND TESTING apply to this section except as

SECTION 26 32 13.00 20 Page 2 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.

e. Strokes per cycle.

f. Number of cylinders.

g. Bore and stroke, mm.

h. Engine speed, rpm.

i. Piston speed, m/s.

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, liters per hr.

1. 1/2 load

2. 3/4 load

3. Full load

SECTION 26 32 13.00 20 Page 3

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

IEC 60034-2A .

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. L/s of coolant

3. L/s of air through radiator

4. kW of heat exchange based on optimum coolant temperature to and from engine.

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 C at full load

b. Weight of exhaust gas at full load kg per hr

c. Weight of intake air at full load kg per hr

d. Total heat rejected at full load kW

1. To jacket coolant system

2. To fuel oil cooling system

e. Emissions (Lbs/hr)(kg/hr) at full load

1. Total Suspended Particulate

2. Particulate matter with an average aerodynamic diameter of 10 microns (PM-10)

3. Sulfur dioxides

4. Nitrogen Oxides (as N02)

5. Carbon Monoxide

6. Volatile Organic Compounds

f. Visible Emissions (percent opacity) at full load

1.3.4 Generator and Exciter Data

Submit data certified by the generator manufacturer including but not

SECTION 26 32 13.00 20 Page 4 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 Torsional Vibration Stress Analysis Computations

Torsional vibrational stresses in the crankshaft and generator shaft of assembled diesel engine and driven generator shall not exceed 34,450 kPa 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.

1.3.6 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. Submittals with an "S" are for inclusion in the Sustainability

SECTION 26 32 13.00 20 Page 5 eNotebook, in conformance to Section 01 33 29 SUSTAINABILITY REPORTING.

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-02 Shop Drawings

Engine-Generator set and auxiliary equipment; G

SD-03 Product Data

Engine-generator set data; G

Engine-generator set efficiencies; G

Diesel engine data; G

Generator and exciter data; G

Diesel engine-generator set; G

Remote alarm annunciator; G

SD-05 Design Data

Torsional vibration stress analysis computations; G

Capacity calculations for batteries; G

SD-06 Test Reports

Acceptance checks and tests; G

Functional acceptance tests; G

Functional acceptance test procedure; G

SD-07 Certificates

Vibration isolation system certification; G

Fuel system certification; G

Start-up engineer qualification resume; G

Instructor's qualification resume; G

SD-09 Manufacturer's Field Reports

Engine tests; G

Generator tests; G

Assembled engine-generator set tests; G

SD-10 Operation and Maintenance Data

Diesel engine-generator set, Data Package 4; G

Auxiliary systems and equipment, Data Package 4; G

SECTION 26 32 13.00 20 Page 6

Preliminary assembled operation and maintenance manuals; G

Submit 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

Training plan; G

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, and remote alarm annunciator.

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

SECTION 26 32 13.00 20 Page 7 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: Rota, Spain

b. Site Elevation: 150 meters above mean sea level

c. Ambient Temperatures:

1. Maximum 33 degrees C dry bulb, 21 degrees C wet bulb.

2. Minimum 5 degrees C dry bulb.

d. Design Wind Velocity: 183 km/h.

e. Seismic Design Category: D as defined by ICC UBC.

1.8 MAINTENANCE

1.8.1 Extra Materials

1.8.1.1 Paint

Furnish 4 liters 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 as indicated at 0.8 power factor and supply 208Y/120 or 480Y/277-volt, three-phase, 60-Hz ac output. Coordinate the engine-generator set to

SECTION 26 32 13.00 20 Page 8 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 the engine.

2.1.1.1 Diesel Engine Capacity

TThe engine capacity shall be based on the following:

a. Engine burning diesel fuel conforming to ASTM D975, Grade 2-D, S15, and European Sulfur Free Diesel for Diesel Generators (less than 10 ppm) at an ambient temperature of 29 degrees C.

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.

2.1.1.2 Diesel Engine Emission Limits

Emissions from the operation of the engine-generator set shall comply with local regulations:

a. Regulation UE 2016/1628 of the European Parliament

b. Reglamento Delegado (UE) 2017/654 de la Comisión (19 December 2016)

2.1.1.3 Performance Class

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

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.

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.

SECTION 26 32 13.00 20 Page 9

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. 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.

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 simplex 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. 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

SECTION 26 32 13.00 20 Page 10 the engine continuously for 60 seconds without overheating.

2.1.2.11 Jacket Coolant Heating System

Provide a factory-installed, 120 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.

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.

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.

SECTION 26 32 13.00 20 Page 11

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 IEEE 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.

a. Stator: Stator windings shall be 2/3 pitch design.

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

c. Generator Space 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

SECTION 26 32 13.00 20 Page 12 device for permanent magnet generator (PMG) excitation systems.

c. Voltage Regulator: Voltage regulator shall be solid state or digital, automatic, three-phase sensing, volts per hertz type regulator.

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 the adjacent floor slab to a maximum of 0.038 mm total amplitude throughout the frequency range down to 65 Hz.

2.2.2 Exhaust System

Provide exhaust systems for each engine.

2.2.2.1 Exhaust Silencers

A residential class silencer shall be provided for each engine which will reduce the exhaust sound spectrum by the following listed values at a 23 m radius from the outlet, with generator set loaded to rated capacity and clear weather. Inlet and outlet connections shall be flanged.

Octave Band Center Frequency (Hertz)

Minimum Silencer Attenuation Decibels

63 125 250 500 1000 2000 4000 8000

Residental Class 10 25 32 30 25 25 24 23

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 kW of heat rejected by its respective

SECTION 26 32 13.00 20 Page 13 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 43 degrees C maximum, and 5 degrees C 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 41.34 kPa when circulating the maximum required coolant flow. Radiator air velocity shall be a maximum of 7.6 meters per second.

b. 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 Tank System

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

a. Integral Main Fuel Storage Tank: UL 142 . Provide integral in skid double wall (110 percent containment) diesel fuel day tanks with a minimum capacity of 24 hours of engine-generator set operation at full-rated load. Epoxy coat day tanks inside and prime and paint outside. Construct tanks of not less than 4.76 mm 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 600 mm cover.

Provide 114 mm square inspection port. Provide proper venting of both inner and outer containment.

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.

SECTION 26 32 13.00 20 Page 14

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.

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

d. Control Panel: Provide NEMA ICS 6 , Type 1, 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 100 mm in size and arranged for top mounting. Calibrate each reading dial or scale for its specific tank to read from empty to full, with intermediate points of 1/4, 1/2, and 3/4.

f. Integral Base Tanks Used as Primary Tank: Provide a 50 mm opening at the tank fill port, fitted an overfill prevention valve (OPV).

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

2.2.4.3 Fuel Transfer Pump

Fuel transfer pumps may be day tank or base mounted. Pump shall be horizontal, positive displacement. Direct-connect pump to motor through a flexible coupling. Equip each pump with a bypass relief valve, if not provided with an internal relief valve. Provide motor and controller in accordance with paragraph entitled "Electrical Support Equipment."

2.2.4.4 Fuel Oil Solenoid Valve

UL 429 . Provide electric solenoid type control valve for each day tank.

Solenoid shall be rated for starting battery voltage. Valve body shall have a minimum working pressure rating of 1033 kPa at 93 degrees C. Valve shall be capable of passing 0 to 0.63 L/s of fuel oil. Valves shall be two-way, direct acting, normally closed (open when energized, closed when de-energized), with brass body and resilient seat material. Solenoid

SECTION 26 32 13.00 20 Page 15 enclosures shall be NEMA ICS 6 , Type 1. Body connections shall be same size as connecting piping. Valve shall be in line before the fuel pump.

2.2.4.5 Strainer

Simplex strainers shall comply with manufacturer's recommendation.

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, sealed, lead-acid, SAE Type D diesel engine starting batteries. Batteries shall have sufficient capacity to provide 60 seconds of continuous cranking of the engine in an ambient temperature of 5 degrees C.

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. 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 1. 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 1, enclosed control panel mounted on the engine-generator set with vibration isolators. Provide the following

SECTION 26 32 13.00 20 Page 16 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.

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: 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.

SECTION 26 32 13.00 20 Page 17

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).

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 Remote Alarm Annunciator

Provide NEMA ICS 6 , Type 1, enclosed remote alarm annunciator powered by the engine starting battery system. The annunciator shall have a lamp test switch and LED type indicating lamps. The annunciator shall give visual and audible warnings for the following operating and alarm conditions:

a. Provide lamps for the following operating conditions:

1. Operating power source, normal or emergency

2. Starting battery system trouble

b. Provide lamps and an audible signal for the following alarm conditions:

1. Low engine lubricating oil pressure

2. Low engine coolant temperature

3. High engine coolant temperature

4. Low fuel

5. Engine overcrank shutdown

6. Engine overspeed shutdown

2.2.8 Generator Circuit Breaker

UL 489 , molded case, 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 circuit breaker in a NEMA ICS 6 , Type 1 enclosure mounted on the engine-generator set.

2.2.9 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.

SECTION 26 32 13.00 20 Page 18

2.2.10 Weatherproof Enclosure

Provide for each engine-generator set and fabricate from zinc coated or phosphatized and shop primed 16 gage minimum sheet steel 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 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 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 6.4 mm 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, 3.2 mm 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 13 mm high and 50 mm long and shall indicate component system and component function.

2.4.3 Equipment

Provide ID plates of a minimum size of 75 mm high and 130 mm 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;

SECTION 26 32 13.00 20 Page 19

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 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, IEC, 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 115 , NEMA C50.10 , SECTION 26 32 13.00 20 Page 20

IEC 60034-2A , 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

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

Perform the following tests on the assembled engine-generator set.

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:

SECTION 26 32 13.00 20 Page 21

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.

2.6.3.4 Transient Response Test

Drop the load to no load and re-apply rated load three times to ensure that the no load and rated load voltage and frequency values are repeatable and that the frequency and voltage regulation is within the limits specified. Record generator terminal voltage and frequency using a high speed strip chart recorder. The data sheet shall show the following results:

a. Frequency

1. Stability bandwidth or deviation in percent of rated frequency.

2. Recovery time.

3. Overshoot and undershoot.

b. Voltage

1. Stability bandwidth or deviation in percent of rated voltage.

2. Recovery time.

3. Overshoot and undershoot.

PART 3 EXECUTION

3.1 INSTALLATION

Installation shall conform to the applicable requirements of IEEE C2 NFPA 30 , NFPA 37 , and NFPA 70 .

3.2 GROUNDING

NFPA 70 and IEEE C2 , except that grounding systems shall have a resistance to solid earth ground not exceeding 5 ohms.

3.2.1 Grounding Electrodes

Provide driven ground rods as specified in Section 33 71 02 UNDERGROUND ELECTRICAL DISTRIBUTION. Connect ground conductors to the upper end of ground rods by exothermic weld or compression connector. Provide compression connectors at equipment end of ground conductors.

SECTION 26 32 13.00 20 Page 22

3.2.2 Engine-Generator Set Grounding

Provide separate copper grounding conductors and connect them to the ground system as indicated. When work in addition to that indicated or specified is required to obtain the specified ground resistance, the provision of the contract covering "Changes" shall apply.

3.2.3 Connections

Make joints in grounding conductors by exothermic weld or compression connector. Exothermic welds and compression connectors shall be installed as specified in Section 33 71 02 UNDERGROUND ELECTRICAL DISTRIBUTION paragraph regarding "Grounding."

3.2.4 Grounding and Bonding Equipment

UL 467 , except as indicated or specified otherwise.

3.3 START-UP ENGINEER

Provide the services of a qualified factory trained start-up engineer, regularly employed by the engine-generator set manufacturer. The start-up services shall include conducting preliminary operations and functional acceptance tests. The start-up engineer shall be present at the engine generator set installation site, full-time, while preliminary operations and functional acceptance tests are being conducted.

3.4 PREREQUISITES FOR FUNCTIONAL ACCEPTANCE TESTING

Completion of the following requirements is mandatory prior to scheduling functional acceptance tests for the engine-generator set and auxiliary equipment.

3.4.1 Performance of Acceptance Checks and Tests

The acceptance checks and tests shall be accomplished by the testing organization as described in Section 26 08 00 APPARATUS INSPECTION AND

TESTING.

3.4.1.1 Generator Sets

Complete as specified in the paragraph entitled "Acceptance Checks and Tests."

3.4.1.2 Automatic Transfer Switches

Complete acceptance checks and tests as specified in Section 26 36 23.00 20

AUTOMATIC TRANSFER SWITCHES.

3.4.2 Preliminary Operations

The start-up engineer shall conduct manufacturer recommended start-up procedures and tests to verify that the engine-generator set and auxiliary equipment are ready for functional acceptance tests. Give the Contracting Officer 15 days' advance notice that preliminary operations will be conducted. After preliminary operation has been successfully conducted, the start-up engineer will notify the Contracting Officer in writing stating the engine-generator set and auxiliary equipment are ready for functional acceptance tests.

SECTION 26 32 13.00 20 Page 23

3.4.3 Preliminary Assembled Operation and Maintenance Manuals

Preliminary assembled operation and maintenance manuals shall have been submitted to and approved by the Contracting Officer. Manuals shall be prepared as specified in the paragraph entitled "Assembled Operation and Maintenance Manuals."

3.4.4 Functional Acceptance Test Procedure

Test procedure shall be prepared by the start-up engineer specifically for the engine-generator set and auxiliary equipment. The test agenda shall cover the requirements specified in the paragraph entitled "Functional Acceptance Tests." The test procedure shall indicate in detail how tests are to be conducted. A statement of the tests that are to be performed without indicating how the tests are to be performed is not acceptable.

Indicate what work is planned on each workday and identify the calendar dates of the planned workdays. Specify what additional technical support personnel is needed such as factory representatives for major equipment.

Specify on which testing workday each technical support personnel is needed. Data recording forms to be used to document test results are to be submitted with the proposed test procedure. A list of test equipment and instruments shall also be included in the test procedure.

3.4.5 Test Equipment

Test equipment and instruments shall be on hand prior to scheduling field tests or, subject to Contracting Officer approval, evidence shall be provided to show that arrangements have been made to have the necessary equipment and instruments on site prior to field testing.

3.5 FIELD QUALITY CONTROL

Give Contracting Officer and NAVFAC Atlantic, Code CI44 30 days notice of dates and times scheduled for tests which require the presence of the Contracting Officer. The Contracting Officer will coordinate with the using activity and schedule a time that will eliminate or minimize interruptions and interference with the activity operations. The Contractor shall be responsible for costs associated with conducting tests outside of normal working hours and with incorporating special arrangements and procedures, including temporary power conditions. The Contractor shall provide labor, equipment, diesel fuel, test load, and consumables required for the specified tests. The test load shall be a cataloged product. Calibration of measuring devices and indicating devices shall be certified.