Attachment_J.1.1_Packaged_Generator_Set_Specification.docx

Attachment J.1.1 Packaged Generator Set Specification Attachment J.1.1 Packaged Generator Set Specification

Overseas Building Operations

CFSM/FAC/PS

DIESEL-GENERATOR SET

a. Provide equipment as specifically requested in a Delivery Order Proposal Request (DOPR) and as specified herein.

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

1.1.1 Output Capacity

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

1.1.2 Power Rating

Generators shall be prime-rated for the size required. Generator power requirements will be provided as part of an RFP and the sizing information provided will have taken into account performance adjustments for temperature and altitude based on the proposed location for which the engine generators will be used. For reference, the maximum temperature and elevation parameters along with adjustment factors will be provided for validation of proper sizing for the engine generator package.

1.1.3 Engine Generator Set Enclosure

The engine generator set enclosure shall be corrosion resistant for salt air environment, fully weather resistant, contain all set components, and provide ventilation to permit operation at rated load under secured conditions. Provide doors for access to all controls and equipment requiring periodic maintenance or adjustment. Provide removable panels for access to components requiring periodic replacement. The enclosure shall be capable of being removed without disassembly of the engine-generator set or removal of components other than exhaust system. The enclosure shall reduce the noise of the generator set to within the limits specified in the paragraph SOUND LIMITATIONS.

The maximum engine-generator set vibration in the horizontal, vertical and axial directions shall be limited to 6 mils (peak-peak RMS), with an overall velocity limit of 0.95 inches/seconds RMS, for all speeds through 110 percent of rated speed. The engine-generator set shall be provided with vibration-isolation in accordance with the manufacturer's standard recommendation and in accordance with paragraph 1.3.3 “Seismic Requirements”.

1.1.4.2 Torsional Analysis

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

1.1.4.3 Performance Data

Submit vibration isolation system performance data for the range of frequencies generated by the engine-generator set during operation from no load to full load and the maximum vibration transmitted to the floor. Also submit a description of seismic qualification of the engine-generator mounting, base, and vibration isolation based on requirements defined in paragraph 1.3.3 “Seismic Requirements”.

1.1.5 Reliability and Durability

Generator equipment shall be supplied with the expectation that this equipment will operate as a prime power source continuously and will transition from utility to generator power up to four times each day. Submit documentation that cites engines and generators in similar service with the sizes itemized in Section B of the RFP that demonstrates compliance with the requirements of this specification. Certification does not exclude annual technological improvements made by a manufacturer in the basic standard model set on which experience was obtained, provided parts interchangeability has not been substantially affected and the current standard model meets all the performance requirements of this specification. For each different set, two like sets shall have performed satisfactorily in a stationary power application, independent and separate from the physical location of the manufacturer's and assembler's facilities, for a minimum of two consecutive years without any failure to start, including periodic exercise. The certification shall state that for the set proposed to meet this specification, there were no failures resulting in downtime for repairs in excess of 72 hours or any failure due to overheating during two consecutive years of service. Like sets shall have the same model, speed, bore, stroke, number, and configuration of cylinders, and output power rating. Like generators shall have the same model, speed, pitch, cooling, exciter, voltage regulator, and output power rating.

1.2 SUBMITTALS

Provide electronic copies (PDF) of the submittals as detailed below:

Shop Drawings1 Detailed Drawings SD-03 Product Data1 Manufacturer's Catalog Instructions Experience General Installation SD-05 Design Data1 Sound Limitations Generator Integral Main Fuel Storage Tank Power Factor Heat Exchanger Time-Delay on Alarms Cooling System Vibration Isolation SD-06 Test Reports2 Performance Tests SD-07 Certificates2 Vibration Isolation Prototype Tests Reliability and Durability Emissions Sound limitations Current Balance Materials and Equipment Factory Inspection and Tests Inspections Cooling System SD-10 Operation and Maintenance Data2 Operation Manual Maintenance Manual Extra Materials 1 Required with initial RFP submission only based on defined generator sizes 2 Required with each task order issued under this contract

Equipment shall conform to the design, fabrication and performance codes and standards as specified herein.

1.3.2 Experience

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

1.3.3 Seismic Requirements

For all engine-generator packages units will be provided for placement in Seismic zone Category D based on ASCE Standard 7 where seismic acceleration factors SD1 > 0.2 and SDS > 0.5.

1.3.4 Detailed Drawings

Submit detailed drawings showing the following:

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

b. Starting system.

c. Fuel system.

d. Cooling system.

e. Exhaust system.

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

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

h. Location, type, and description of vibration isolation devices and as may be required by specific seismic requirements for the location identified.

i. The safety system, including wiring schematics.

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

k. Panel layouts.

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

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

1.4 DELIVERY, STORAGE AND HANDLING

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

1.5 MAINTENANCE SERVICE

Submit the operation and maintenance manuals.

1.5.1 Operation Manual

Provide an electronic (PDF) copy of the manufacturer’s standard operation manual. Sections shall be organized by bookmarks and include an index which links the material in each section. The manual shall include:

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

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

c. Procedures for interface and interaction with automatic transfer switches.

1.5.2 Maintenance Manual

Provide an electronic copy (PDF) of the manufacturer’s standard maintenance manual. Sections shall be organized by bookmarks and include an index which links the material each section. The manual shall include:

a. Procedures for each routine maintenance item, procedures for troubleshooting, and factory-service take-down overhaul and repair service manuals, with parts lists;

b. The manufacturer's recommended maintenance schedule;

c. A component list that includes the manufacturer's name, address, type or style, model or serial number, rating, and catalog number for all of the major components of the packaged generator; and

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

1.5.3 Spares

General parts: Provide one set of maintenance (spare) parts for each generator set ordered under this contract. An order of maintenance parts is defined as all items necessary to perform scheduled maintenance functions for 2000 operating hours plus replacement bulbs for indicators, replacement fuses for each fuse used on the generator set and any other like items that the manufacturer deems desirable. Package these maintenance parts in polyethylene bag, and pack inside the generator set for which they are intended. Should there be insufficient room inside generator set, enclose parts bag in protective package and attach to shipping skid. This group of parts shall include a complete list of all vendors recommended spares, including, but not limited to, the items listed below:

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

b. Fuel filters and associated gaskets, if separate from filter.

c. Engine intake air filters and associated gaskets, if separate from filter.

d. A minimum of five light bulbs of each size light bulb used in the generator set.

e. A minimum of five electrical fuses of each size fuse used in the generator set.

f. One engine lubrication oil system drain plug.

As part of the 2000-hour operation requirement, sufficient spare inventory will provide for filter and gasket replacements every 250 hours.

1.5.4 Warranty

The Offeror shall provide a one-year warranty on parts and labor which starts from the date the equipment is commissioned on-site. This requirement shall not modify or change the standard contract warranty agreement. Manufacturer shall also provide terms that will allow the local Post to extend the warranty period at any time.

Each major component of this specification shall have the manufacturer's name, type or style, model, serial number and rating number on a plate secured to the equipment. As a minimum, nameplates shall be provided for: Engines; Relays; Generators; Day tanks; Transformers (CT & PT); Regulators; Pumps and pump motors; Governors; Generator Breaker; Economizers; Heat exchangers (other than base-mounted).

Heat exchangers (other than base-mounted)

The following equipment provided as a standard component by the diesel-engine generator set manufacturer may provide detailed information in the maintenance manual in lieu of nameplates.

2.2 SAFETY DEVICES

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

2.3 MATERIALS AND EQUIPMENT

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

2.3.1 Circuit Breakers, Low Voltage

UL 489 and UL 489.

2.3.2 Filter Elements (Fuel-oil, Lubricating-oil, and Combustion-air) Manufacturer's standard.

2.3.3 Instrument Transformers

NEMA/ANSI C12.11.

2.3.4 Pipe (Fuel/Lube-oil, Compressed-Air, Coolant and Exhaust) Steel Pipe: ASTM A53/A53M, ASTM A106/A106M or ASTM A135/A135M. Pipe smaller than 2-inches shall be Schedule 80. Pipe 2-inches and larger shall be Schedule 40.

2.3.5 Pipe Flanges and Fittings

a. Pipe Flanges and Flanged Fittings: ASTM A181/A181M, Class 60, or ASME B16.5, Grade 1, Class 150.

b. Pipe Welding Fittings: ASTM A234/A234M, Grade WPB or WPC, Class 150, or ASME B16.11, 3000 lb.

c. Threaded Fittings: ASME B16.3, Class 150.

d. Valves: MSS SP-80, Class 150.

e. Gaskets: Manufacturers Standard.

2.3.6 Pipe Hangers

MSS SP-58 and MSS SP-69.

NEMA ICS 6.

2.4 ENGINE

Each engine shall operate on No. 2-D diesel conforming to ASTM D 975, shall be designed for stationary applications, and shall be complete with ancillaries. The engine shall be a standard production model described in the manufacturer's catalog data, which describes and depicts each engine-generator set and all ancillary equipment in sufficient detail to demonstrate specification compliance. The engine shall be naturally aspirated, scavenged, supercharged, or turbocharged. The engine shall be four-stroke-cycle and compression-ignition type. The engine shall be vertical inline, V, or opposed-piston type, with a solid cast block or individually cast cylinders. The engine shall have a minimum of four cylinders for generator output power of 50kVA or greater. Each block shall have a coolant drain port. Each engine shall be equipped with an over-speed sensor.

2.5 FUEL SYSTEM

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

Each engine shall be provided with an engine driven pump. The pump shall supply fuel at a minimum rate sufficient to provide the amount of fuel required to meet the performance indicated within the parameter schedule. The fuel flow rate shall be based on meeting the load requirements and all necessary recirculation.

2.5.1.2 Auxiliary Fuel Pump

The auxiliary pump shall be driven by a dc electric motor powered by the starting/station batteries. The auxiliary pump shall be automatically actuated by a pressure-detecting device.

2.5.2 Filter

A minimum of one full flow fuel filter shall be provided for each engine. The filter shall be readily accessible and capable of being changed without disconnecting the piping or disturbing other components. The filter shall have inlet and outlet connections plainly marked. A water separator with a glass bowl shall be furnished with each unit.

2.5.3 Relief/Bypass Valve

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

2.5.4 Integral Main Fuel Storage Tank

Each engine shall be provided with a double-wall integral main fuel tank. Each tank shall be factory installed and provided as an integral part of the diesel generator manufacturer's product. Each tank shall be provided with connections for fuel supply line, fuel return line, local fuel fill port, gauge, vent line, and float switch assembly. A fuel return line cooler shall be provided as recommended by the manufacturer and assembler. The temperature of the fuel returning to the tank shall be below the flash point of the fuel. Unless otherwise indicated in the RFP, each engine-generator set provided with weatherproof enclosures and shall have its tank mounted within the enclosure. The fuel fill line shall be accessible without opening the enclosure.

2.5.4.1 Capacity

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

2.5.4.2 Local Fuel Fill

Each local fuel fill port on the tank shall be provided with a screw-on cap.

2.5.4.3 Interstitial Leak Detection

Each tank shall have an interstitial leak detection probe. The probe shall be wired to an alarm in the control panel.

2.5.4.4 Fuel Level Controls

Each tank shall have a float-switch assembly to perform the following functions:

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

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

2.6 LUBRICATION

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

2.6.1 Filter

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

2.6.2 Lube-Oil Sensors

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

2.7 COOLING SYSTEM

Each engine cooling system shall operate automatically while the engine is running. Water-cooled system coolant shall use a combination of water and ethylene glycol sufficient for freeze protection at a temperature of 0 F or -18 C. The maximum temperature rise of the coolant across the engine shall be no more than that recommended and submitted. The cooling system shall be designed to accommodate the maximum power rating of the engine generator package and account for the maximum temperature and elevation parameters as defined in paragraph 1.1.2 “Power Rating”.

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

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

c. The minimum allowable inlet fuel temperature.

2.7.1 Coolant Pumps

Coolant pumps shall be the centrifugal type. Each engine shall have an engine-driven primary pump. Secondary pumps shall be electric motor driven and have automatic controllers.

2.7.2 Heat Exchanger

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

2.7.2.1 Fin-Tube-Type Heat Exchanger (Radiator)

Heat exchanger may be factory coated with corrosive resistant film providing that corrosion measures are taken to restore the heat rejection capability of the radiator to the initial design requirement via oversizing, or other compensating methods. Internal surfaces shall be compatible with liquid fluid coolant used. Materials and coolant are subject to approval by the Contracting Officer. Heat exchangers shall be pressure type incorporating a pressure valve, vacuum valve and a cap. Caps shall be designed for pressure relief prior to removal. Each heat exchanger and the entire cooling system shall be capable of withstanding a minimum pressure of 7 psi. Each heat exchanger shall be protected with a strong grille or screen guard. Each heat exchanger shall have at least two tapped holes. One tapped hole in the heat exchanger shall be equipped with a drain cock, the rest shall be plugged.

2.7.3 Temperature Sensors

Each engine shall be equipped with coolant temperature sensors. Temperature sensors shall provide signals for pre-high and high indication and alarms.

2.8 SOUND LIMITATIONS

The noise generated by the diesel generator set operating at 100 percent load shall not exceed average sound pressure levels that might normally be defined for a quiet residential zone when measured in a free field at a radial distance of 22.9 feet at 45 degrees apart in all directions. The average sound pressure levels for such areas will be no greater than 75 dbA. Submit data to demonstrate compliance with these sound limitation requirements. Also, submit certification from the manufacturer stating that the sound emissions meet the specification.

2.9 AIR INTAKE EQUIPMENT

Filters and silencers shall be provided in locations that are convenient for servicing. The silencer shall be of the high-frequency filter type, located in the air intake system as recommended by the engine manufacturer. Silencer shall be capable of reducing the noise level at the air intake to a point below the maximum acceptable levels specified in paragraph SOUND LIMITATIONS. A combined filter-silencer unit meeting requirements for the separate filter and silencer items may be provided. Expansion elements in air-intake lines shall be copper.

2.10 EXHAUST SYSTEM

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

2.10.1 Exhaust Muffler

A chamber type exhaust muffler shall be provided. The muffler shall be constructed of welded steel and designed for outside or inside and vertical or horizontal mounting as defined in the RFP. Eyebolts, lugs, flanges, or other items shall be provided as necessary for support in the location and position indicated. Pressure drop through the muffler shall not exceed the recommendations of the engine manufacturer. Outside mufflers shall be zinc coated or painted with high temperature 400 degrees F resisting paint. The muffler and exhaust piping together shall reduce the noise level to less than the maximum acceptable level listed for sound limitations in paragraph SOUND LIMITATIONS. The muffler shall have a drain valve, nipple, and cap at the low-point of the muffler.

2.10.2 Exhaust Piping

Horizontal sections of exhaust piping shall be sloped downward away from the engine to a condensate trap and drain valve. Changes in direction shall be long-radius

2.11 EMISSIONS

Submit a certification from the engine manufacturer stating that the engine exhaust emissions meet federal regulations and restrictions in accordance with Tier III or EU Stage III A emissions standards. At a minimum, this certification shall include emission factors for criteria pollutants including nitrogen oxides, carbon monoxide, particulate matter, sulfur dioxide, non-methane hydrocarbon, and for hazardous air pollutants (HAPs).

2.12 STARTING SYSTEM

The starting system for standby engine generator sets shall include the items in the following sections.

2.12.1 Controls

An engine control switch shall be provided with functions including: run/start (manual), off/reset, and automatic mode. Start-stop logic shall be provided for adjustable cycle cranking and cool down operation. Electrical starting systems shall be provided with an adjustable cranking limit device to limit cranking periods from 1 second up to the maximum duration.

2.12.2 Capacity

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

2.12.3 Functional Requirements

Starting system shall be manufacturers recommended dc system utilizing a negative circuit ground. Starting motors shall be in accordance with SAE ARP892.

2.12.4 Battery

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

2.12.5 Battery Charger

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

2.12.6 Starting Aids

The manufacturer shall provide the following methods to assist engine starting.

2.12.6.1 Jacket-Coolant Heaters

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

2.13 GOVERNOR

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

2.14 GENERATOR

Each generator shall be of the synchronous type, one or two bearing, conforming to NEMA MG 1, equipped with winding terminal housings in accordance with NEMA MG 1, equipped with an amortisseur winding, and directly connected to the engine. Insulation shall be Class F. Generator design shall protect against mechanical, electrical, and thermal damage due to vibration, 25 percent over-speeds, or voltages and temperatures at a rated output capacity of 100 percent. Generator ancillary equipment shall meet the short circuit requirements of NEMA MG 1. Frames shall be the drip-proof type. Submit each generator KW rating and short circuit capacity (both symmetric and asymmetric). Generators shall be compatible with the requirements for voltage regulation and adjustments as required in Section 2.16 “Voltage Regulation”. Provide anti-condensation heaters as a standard equipment option for all generators.

2.14.1 Current Balance

At 100 percent rated load, and load impedance equal for each of the three phases, the permissible current difference between any two phases shall not exceed 2 percent of the largest current on either of the two phases. Submit manufacturer's certification that the flywheel has been statically and dynamically balanced and is capable of being rotated at 125 percent of rated speed without vibration or damage.

2.14.2 Voltage Balance

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

2.14.3 Waveform

The deviation factor of the line-to-line voltage at zero load and at balanced full rated load at 0.8 power factor shall not exceed 10 percent. The RMS of all harmonics shall be less than 5.0 percent and that of any one harmonic less than 3.0 percent at full rated load. Each engine-generator shall be designed and configured to meet the total harmonic distortion limits of IEEE 519.

2.15 EXCITER

The generator exciter shall be of the brushless type. Semiconductor rectifiers shall have a minimum safety factor of 300 percent for peak inverse voltage and forward current ratings for all operating conditions, including 110 percent generator output at 104 degrees F ambient. The exciter and regulator in combination shall maintain generator-output voltage within the limits specified.

2.16 VOLTAGE REGULATOR

Each generator shall be provided with a solid-state voltage regulator, separate from the exciter. The regulator shall maintain the voltage within a bandwidth of the rated voltage, over a steady-state load range of zero to 100 percent of rated output capacity. Regulator shall be configured for safe manual adjustment of the engine generator voltage output without special tools, during operation from 90 to 110 percent (+/- 10%) of the rated voltage over the steady state load range of zero to 100 percent of rated output capacity. Regulation drift shall not exceed plus or minus 0.5 percent for an ambient temperature change of 36 degrees F. The voltage regulator shall have a maximum droop of 2 percent of rated voltage over a load range from 0 to 100 percent of rated output capacity and automatically maintain the generator output voltage within the specified operational bandwidth.

2.17 GENERATOR PROTECTION

Short circuit and overload protection for the generator shall be provided. The generator circuit breaker (IEEE Device 52) ratings shall be consistent with the generator rated voltage and frequency, with continuous, short circuit and interrupting current ratings to match the generator capacity. The manufacturer shall determine the short circuit current interrupting rating of the breaker. The breaker shall be engine generator base mounted by the engine-generator set manufacturer. Molded case breakers shall be provided with shunt trip. Surge protection shall be provided for each phase of the generator, to be mounted at the generator terminals.

2.18 SAFETY SYSTEM

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

2.18.1 Audible Signal

The audible alarm signal shall sound at a frequency of 70 Hz at a volume of 75 dB at 10 feet. The sound shall be continuously activated upon alarm and silenced upon acknowledgment.

2.18.2 Visual Alarm Signal

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

Simultaneous activation of the audible signal, activation of the visual signal, stopping the engine, and opening the generator main circuit breakers shall be accomplished.

2.18.3.2 Problem

Activation of the visual signal shall be accomplished.

2.18.4 Local Alarm Panel

Provide a local alarm panel with the following shutdown and alarm functions as indicated below, mounted on the engine generator set.

Pre-low lube-oil pressure

CP/VA

2.18.5 Time-Delay on Alarms

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

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

2.19 ENGINE GENERATOR SET CONTROLS AND INSTRUMENTATION

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

2.19.1 Controls

A local control panel shall be provided with controls as indicated mounted on the engine generator set.

Controls

Common alarm contacts/ fault relay

2.20 PANELS

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

2.20.1 Enclosures

Unless otherwise identified within the RFP, enclosures shall be provided and designed to comply with the sound specifications identified herein and conforming to NEMA ICS 6, and provided with locking mechanisms that are keyed alike. Electric heaters and controls will be provided within the enclosure to protect the equipment from being exposed to a condensed moisture environment.

2.20.2 Electronic

Electronic indicating instruments shall be true RMS indicating, 100 percent solid state, microprocessor controlled to provide all specified functions. Control, logic, and function devices shall be compatible as a system, sealed, dust and water tight, and shall utilize modular components with metal housings and digital instrumentation. An interface module shall be provided to decode serial link data from the electronic panel and translate alarm, fault and status conditions to set of relay contacts. Instrument accuracy shall be not less than 2 percent for unit mounted devices and 1 percent for control room, panel mounted devices, throughout a temperature range of minus 4 to plus 130 degrees F. Data display shall utilize LED or backlit LCD. Additionally, the display shall provide indication of cycle programming and diagnostic codes for troubleshooting. Numeral height shall be 1/2 inch.

2.20.3 Parameter Display

Displays shall provide indication or readouts of the lubricating-oil pressure, ac voltmeter, ac ammeter, frequency meter, and coolant temperature.

2.20.4 Exerciser

The exerciser shall be in accordance with AUTOMATIC TRANSFER SWITCH (ATS) Specification (Attachment J.1.2).

2.21 SURGE PROTECTION

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

2.22 AUTOMATIC ENGINE-GENERATOR-SET SYSTEM OPERATION

Fully automatic operation shall be provided for the following operations: engine-generator set starting and source transfer upon loss of normal source; retransfer upon restoration of the normal source; sequential starting; and stopping of each engine-generator set after cool down. Devices shall automatically reset after termination of their function.

2.22.1 Automatic Transfer Switch

Automatic transfer switches shall be in accordance with AUTOMATIC TRANSFER SWITCH (ATS) Attachment J.1.2.

2.22.2 Monitoring and Transfer

Devices shall be provided to monitor voltage and frequency for the normal power source and each engine generator set, and control transfer from the normal source and retransfer upon restoration of the normal source. Functions, actuation, and time delays shall be as described in Attachment J.1.2 Automatic Transfer Switch (ATS) Specification.

2.23 BASE

The base shall be constructed of steel. The base shall be designed to rigidly support the engine-generator set, ensure permanent alignment of all rotating parts, be arranged to provide easy access to allow changing of lube-oil, and ensure that alignment will be maintained during shipping and normal operation. The base shall permit skidding in any direction during installation and shall be provided with suitable holes for foundation bolts. The base shall also withstand and mitigate the effects of synchronous vibration of the engine and generator, and shall be provided with suitable holes for anchor bolts and jacking screws for leveling.

2.24 PAINTING AND FINISHING

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

2.25 Packaging and shipping

The manufacturer shall be responsible for aggregating the engine-generator set, required spare parts, and specified transfer switch into a single package for delivery to the designated location as specified by the Government. The bill of materials provided with the package will account for all of the individual components and associated quantities contained in the packaged container. Packaging methods and materials will comply with the requirements identified in the contract.

Perform factory inspection and tests on each engine-generator set proposed to meet this specification section. Inspections shall be completed and necessary repairs made prior to testing. Inspectors shall look for leaks, looseness, defects in components, and proper assembly.

Before shipment of the equipment, the engine-generator set shall be tested under rated load and power factor for performance and proper fronting of control and interfacing circuits. Tests shall include:

Attachment J.1.3 identifies locations around the world where the Department of State currently provides generator assets for its facilities.

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