Amendment_0006_Attachment_10.pdf

FY13 CERDEC FLIGHT ACTIVITY FACILITY

LAKEHURST NAES - JB MCGUIRE/DIX/LAKEHURST, NEW JERSEY JUNE 7, 2013

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.

ASTM INTERNATIONAL (ASTM)

ASTM A 463/A 463M (2009a) Standard Specification for Steel Sheet, Aluminum-Coated, by the Hot-Dip Process

CSA STANDARDS (CSA)

CSA C22.2 No. 100 (2004; R 2009) Motors and Generators

CSA C282 (2009) Emergency Electrical Power Supply for Buildings

EUROPEAN COMMITTEE FOR STANDARDIZATION (CEN/CENELEC)

EN 50081-2 (1994) Electromagnetic Compatibility.

Generic Emission Standard. Industrial Environment

EN 50082-2 (1995) Electromagnetic Compatibility.

Generic Immunity Standard. Industrial Environment

EN 55011 (2007) Industrial, scientific and medical (ISM) radio-frequency equipment - Electromagnetic disturbance characteristics - Limits and methods of measurement

EN 61000-6 (2007) Electromagnetic compatibility (EMC)

- Part 6-1: Generic standards - Immunity for residential, commercial and light-industrial environments

U.S. FEDERAL COMMUNICATIONS COMMISSION (FCC)

FCC Part 15 Radio Frequency Devices (47 CFR 15)

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C2 (2012) National Electrical Safety Code

INTERNATIONAL CODE COUNCIL (ICC)

ICC UBC (1997; Erratas Vol 1, 2 & 3 01/2001; Vol 1

SECTION 26 32 13.00 20 Page 1

& 2 03/2001; Vol 2 10/2001) Uniform Building Code

INTERNATIONAL ELECTRICAL TESTING ASSOCIATION (NETA)

NETA ATS (2009) Standard for Acceptance Testing Specifications for Electrical Power Equipment and Systems

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC 61000-4-5 (2005; Corr 2009) Electromagnetic Compatibility (EMC) - Part 4-5: Testing and Measurement Techniques; Surge Immunity Test; Ed 2.0

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

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

ISO 8178 (2006) Reciprocating Internal Combustion Engines

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

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG 1 (2011) Motors and Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 110 (2010; TIA 10-1) Standard for Emergency and Standby Power Systems

NFPA 30 (2012) Flammable and Combustible Liquids Code

NFPA 37 (2010; TIA 10-1) Standard for the Installation and Use of Stationary Combustion Engines and Gas Turbines

NFPA 70 (2011; Errata 2 2012) National Electrical Code

NFPA 99 (2005; TIA 05-1; TIA 05-2; TIA 05-3;

Errata 05-1) Standard for Health Care Facilities

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

40 CFR 60 Standards of Performance for New Stationary Sources

UNDERWRITERS LABORATORIES (UL)

UL 142 (2006; Reprint Jan 2008) Steel Aboveground

SECTION 26 32 13.00 20 Page 2

Tanks for Flammable and Combustible Liquids

UL 2200 (2009) Stationary Engine Generator Assemblies

UL 467 (2007) Grounding and Bonding Equipment

UL 508 (1999; Reprint Apr 2010) Industrial Control Equipment

1.2 RELATED REQUIREMENTS

Section 26 00 00.00 20 BASIC ELECTRICAL MATERIALS AND METHODS, and Section 26 08 10 COMMISSIONING OF ELECTRICAL SYSTEMS apply to this section except as modified herein.

1.3 STANDARDS

The generator set covered by these specifications shall be designed, tested, rated, assembled and installed in strict accordance with all applicable standards below:

CSA C22.2 No. 14

CSA C282

CSA C22.2 No. 100

EN 61000-6

EN 55011

FCC Part 15 Subpart B

ISO 8528

IEC 61000-4-5

UL 508

UL 2200

UL 142

Designed to allow for installed compliance to NFPA 70, NFPA 99 and

NFPA 110

1.4 SYSTEM DESCRIPTION

1.4.1 Engine-Generator Set Data

Submit data pertaining to each 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.

SECTION 26 32 13.00 20 Page 3

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.

1.4.2 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).

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.

1.4.3 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.

SECTION 26 32 13.00 20 Page 4

a. Approximate exhaust temperature degrees F at full load

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

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

d. Total heat rejected at full load Btu per hr

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

1.4.4 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

1.4.5 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."

1.4.6 Calculations for Brake Mean Effective Pressure (BMEP)

Calculation shall verify that the diesel engine meets the specified maximum

SECTION 26 32 13.00 20 Page 5

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. times 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' plus bhp".

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

1.4.7 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.

SECTION 26 32 13.00 20 Page 6

1.4.8 Capacity Calculations for Batteries

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

1.5 SUBMITTALS

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

submittals not having a "G" designation are for information only. 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 Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Engine-Generator set and auxiliary equipment; G, AE

SD-03 Product Data

Engine-generator set data; G, AE

Engine-generator set efficiencies; G, AE

Diesel engine data; G, AE

Generator and exciter data; G, AE

Diesel engine-generator set; G, AE

Auxiliary systems and equipment; G, AE

Remote alarm annunciator; G, AE

SD-05 Design Data

Capacity calculations for engine-generator set; G, AE

Calculations for brake mean effective pressure; G, AE

Torsional vibration stress analysis computations; G, AE

Capacity calculations for batteries; G, AE

SD-06 Test Reports

Acceptance checks and tests; G, RO

Functional acceptance tests; G, RO

Functional acceptance test procedure; G, RO

SD-07 Certificates

Vibration isolation system certification; G, RO

Fuel system certification; G, RO

Start-up engineer qualification resume; G, RO

SECTION 26 32 13.00 20 Page 7

Instructor's qualification resume; G, RO

SD-09 Manufacturer's Field Reports

Engine tests; G, RO

Generator tests; G, RO

Assembled engine-generator set tests; G, RO

SD-10 Operation and Maintenance Data

Diesel engine-generator set, Data Package 4; G, RO

Auxiliary systems and equipment, Data Package 4; G, RO

Preliminary assembled operation and maintenance manuals; G, RO

Submit in accordance with Section 01 78 23.00 18 OPERATION AND MAINTENANCE DATA and the paragraph entitled "Assembled Operation and Maintenance Manuals."

SD-11 Closeout Submittals

Posted operating instructions; G, RO

Training plan; G, RO

1.6 QUALITY ASSURANCE

1.6.1 Drawing Requirements

1.6.1.1 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.

1.6.2 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

SECTION 26 32 13.00 20 Page 8 entitled "Vibration Isolation System."

1.6.3 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.

1.7 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.

1.8 SITE CONDITIONS

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

a. Site Location: JB McGuire/Dix/Lakehurst, New Jersey

b. Site Elevation: 85 feet above mean sea level

c. Ambient Temperatures:

1. Maximum 97.2 degrees F dry bulb, 86.4 degrees F wet bulb.

2. Minimum 3.5 degrees F dry bulb.

d. Design Wind Velocity: 15 mph.

e. Prevailing Wind Direction: W.

f. Seismic Zone: Zone B as defined by ICC UBC.

1.9 MAINTENANCE

1.9.1 Extra Materials

1.9.1.1 Paint

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

1.9.1.2 Filters

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

1.9.2 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

SECTION 26 32 13.00 20 Page 9 approval, install operating instructions where directed.

PART 2 PRODUCTS

2.1 GENERAL REQUIREMENTS

2.1.1 Genset Requirements

1. Generator Set shall be Standby Duty rated at 150.0 ekW, 187.5 kVA, N/A RPM, 0.8 power factor, 480 V, 3-Phase, 60 hertz, including radiator fan and all parasitic loads.

2. Generator set shall be sized to operate at the specified load at a maximum ambient of 104 degrees F and altitude of 250.0 feet.

3. Standby Power Rating:

a. Power is available for the duration of an emergency outage

b. Average Power Output = 70% of standby power

c. Load = Varying

d. Typical Hours/Year = 200 Hours

e. Maximum Expected Usage = 500 hours/year

f. Typical Application = Standby

2.1.2 Materials and Parts

All materials and parts comprising the unit shall be new and unused.

2.1.3 Engine

The engine shall be diesel fueled, four (4) cycle, water-cooled, while operating with nominal speed not exceeding 1800 RPM. The engine will utilize in-cylinder combustion technology, as required, to meet applicable EPA non-road mobile regulations and/or the EPA NSPS rule for stationary reciprocating compression ignition engines. Additionally, the engine shall comply with the State Emission regulations at the time of installation/commissioning. Actual engine emissions values must be in compliance with applicable EPA emissions standards per ISO 8178 - D2 Emissions Cycle at specified ekW / bHP rating. Utilization of the "Transition Program for Equipment Manufacturers" (also known as "Flex Credits") to achieve EPA certification is not acceptable. The in-cylinder engine technology must not permit unfiltered exhaust gas to be introduced into the combustion cylinder. Emissions requirements / certifications of this package: EPA T3.

2.1.3.1 Engine Governing

The engine will be equipped with an isochronous electronic governor to maintain +/- 6 RPM steady state frequency variation from steady state no load to steady state full load.

2.2 GENERATOR

2.2.1 Generator Specifications

The synchronous three phase generator shall be a single bearing, self-ventilated, drip-proof design in accordance with NEMA MG 1 and directly connected to the engine flywheel housing with a flex coupling.

The generator shall meet performance class G2 of ISO 8528. The excitation

SECTION 26 32 13.00 20 Page 10 system shall enable the alternator to sustain 300% (250% for 50Hz) of rated current based on the 125C (Class H) or 105C (Class F) rise rating for ten seconds during a fault condition and shall improve the immunity of the voltage regulator to non-linear distorting loads. The excitation system shall be of brushless construction and be independent of main stator windings (either permanent magnet or auxiliary windings).

2.2.2 Voltage Regulator

2.2.2.1 Automatic Voltage Regulator

The automatic voltage regulator (AVR) shall maintain generator output voltage within +/- 0.5% for any constant load between no load and full load. The regulator shall be a totally solid state design, which includes electronic voltage buildup, volts per Hertz regulation, over-excitation protection, shall limit voltage overshoot on startup, and shall be environmentally sealed.

2.2.3 Motor Starting

a. Provide locked rotor motor starting capability of 420 skVA at 30% instantaneous voltage dip as defined per NEMA MG 1.

b. Sustained voltage dip data is not acceptable.

2.3 CIRCUIT BREAKER

2.3.1 Circuit Breaker Specifications

a. For Generator Set, provide a generator mounted 80% circuit breaker, molded case, Qty.(1) 300 amp trip, 3 pole, NEMA 1/IP22.

b. Breaker shall utilize a solid state trip unit. The breaker shall be UL/CSA Listed and connected to engine/generator safety shutdowns.

Breaker shall be housed in an extension terminal box which is isolated from vibrations induced by the generator set. Mechanical type lugs, sized for the circuit breaker feeders shown on drawing, shall be supplied on the load side of breaker.

2.4 CONTROLS - GENERATOR SET MOUNTED (EMCP 4.1)

Provide a fully solid-state, microprocessor based, generator set control.

The control panel shall be designed and built by the engine manufacturer.

The control shall provide all operating, monitoring, and control functions for the generator set. Provide a fully solid state, microprocessor based, Remote generator control and Annunciator panel mounted in Electrical room 108 (fully redundant to local control panel) with the following devices:

a. Run/start/off/reset switch

b. Emergency Stop Switch

c. Audible alarm and silencing reset switch

2.4.1 Environmental

The generator set control shall be tested and certified to the following environmental conditions.

a. -40°C to +70°C Operating Range

b. 100% condensing humidity, 30°C to 60°C

SECTION 26 32 13.00 20 Page 11

c. IP22 protection for rear of controller; IP55 when installed in control panel

d. 5% salt spray, 48 hours, +38°C, 36.8V system voltage

e. Sinusoidal vibration 4.3G's RMS, 24-1000Hz

f. Electromagnetic Capability (89/336/EEC, 91/368/EEC, 93/44/EEC, 93/68/EEC, BS EN 50081-2, EN 50082-2)

g. Shock: withstand 15G

2.4.2 Functional Requirements

The following functionality shall be integral to the control panel.

a. The control shall include a 33 x 132 pixel, 24mm x 95mm, positive image, transflective LCD display with text based alarm/event descriptions.

b. Audible horn for alarm and shutdown with horn silence switch

c. Standard ISO labeling

d. Multiple language capability

e. Remote start/stop control

f. Local run/off/auto control integral to system microprocessor

g. Cooldown timer

h. Lamp test

i. Emergency stop push button

2.4.3 Digital Monitoring Capability

The controls shall provide the following digital readouts for the engine and generator. All readings shall be indicated in either metric or English units.

a. Engine

1. Engine oil pressure

2. Engine coolant temperature

3. Engine RPM

4. Battery volts

b. Generator

1. Generator AC volts (Line to Line, Line to Neutral and Average)

2. Generator AC current (Per phase and Average)

3. Generator AC Frequency

2.4.4 Alarms and Shutdowns

The control shall monitor and provide alarm indication and subsequent shutdown for the following conditions. All alarms and shutdowns are accompanied by an engine hour stamp that is stored by the control panel for first and last occurrence.

a. Engine Alarm/Shutdown

1. Low oil pressure alarm/shutdown

2. High coolant temperature alarm/shutdown

3. Loss of coolant shutdown

4. Overspeed shutdown

5. Overcrank shutdown

6. Emergency stop shutdown

7. Low coolant temperature alarm

b. Generator Alarm/Shutdown

1. Generator phase sequence

SECTION 26 32 13.00 20 Page 12

2. Generator over voltage

3. Generator under voltage

4. Generator over frequency

5. Generator under frequency

2.4.5 Inputs and Outputs

2.4.5.1 Programmable Digital Inputs

The control shall include the ability to accept six (6) total with four (4) programmable digital input signals. The signals may be programmed for either high or low activation using programmable Normally Open or Normally Closed contacts.

2.4.5.2 Programmable Relay Outputs

The control shall include the ability to operate six (6) total with four

(4) form A (normally open) programmable relay output signals, integral to the controller. Relay shall be rated for a maximum of 2A @ 30 VDC.

2.4.6 Maintenance

All engine, voltage regulator, control panel and accessory units shall be accessible through a single electronic service tool. The following maintenance functionality shall be integral to the generator set control

a. Engine running hours display

b. 40 events are stored in control panel memory

2.5 COOLING SYSTEM

The generator set shall be equipped with a rail-mounted, engine-driven radiator with blower fan and all accessories. The cooling system shall be sized to operate at full load conditions and 110 F* ambient air entering the room or enclosure (If an enclosure is specified). The generator set supplier is responsible for providing a properly sized cooling system based on the enclosure static pressure restriction.

2.6 FUEL SYSTEM

2.6.1 Fuel System

The fuel system shall be integral with the engine. In addition to the standard fuel filters provided by the engine manufacturer, there shall also be installed a primary fuel filter/water separator in the fuel inlet line to the engine. All fuel piping shall be black iron or flexible fuel hose rated for this service. No galvanized piping will be permitted. Flexible fuel lines shall be minimally rated for 300 degrees F and 100 psi.

2.6.2 Fuel Sub-Base Tank

Provide a double wall sub-base tank constructed to meet all local codes and requirements. A fuel tank base of 48 hour capacity shall be provided as an integral part of the enclosure. It shall be contained in a rupture basin with 110% capacity. The tank shall meet UL 142 standards. A locking fill cap, a mechanical reading fuel level gauge, low fuel level alarm contact, and fuel tank rupture alarm contact shall be provided.

SECTION 26 32 13.00 20 Page 13

2.7 STARTING SYSTEM

2.7.1 Starting Motor

A DC electric starting system with positive engagement shall be furnished.

The motor voltage shall be as recommended by the engine manufacturer.

2.7.2 Jacket Water Heater

Jacket water heater shall be provided and shall be sized to insure that genset will start within the specified time period and ambient conditions.

2.7.3 Batteries

Batteries - A lead-acid storage battery set of the heavy-duty diesel starting type shall be provided. Battery voltage shall be compatible with the starting system.

2.7.4 Battery Charger

Battery Charger - A current limiting battery charger shall be furnished to automatically recharge batteries. The charger shall be dual charge rate with automatic switching to the boost rate when required. The battery charger shall be mounted on the genset package or inside the genset enclosure/room.

2.7.5 Generator Set Start Module

Supplied with an AC source from a UPS, the Generator Set Start Module will supply 1725 cold cranking amps @ 24 VDC to assist and backup the generator set starting batteries for improved system reliability. Generator Set Start Module shall have operating temperatures of (-20deg C to 50deg C).

Generator Set Start Module to be supplied from generator set equipment supplier. This will ensure system integration.

2.8 ENCLOSURE

2.8.1 Attenuated Enclosure

The complete diesel engine generator set, including generator control panel, engine starting batteries and fuel oil tank, shall be enclosed in a factory assembled, sound attenuated enclosure mounted on the fuel tank base.

a. A weather resistant, sound attenuated enclosure of steel with electrostatically applied powder coated baked polyester paint. The enclosure shall have a resulting sound level of 89 dba @ 7 meters with the genset running under full load. It shall consist of a roof, side walls, and end walls. Fasteners shall be either zinc plated or stainless steel.

b. Enclosure Sound Attenuation: Acoustical foam shall be provided between all supports and inside doors and sound baffles on air intake and air discharge.

2.9 LOAD BANK

2.9.1 Ratings

a. The total capacity of the load bank for the Generator shall be

SECTION 26 32 13.00 20 Page 14 rated 350150 KW at 480 Volts, 3-Phase, 3-Wire, 60 Hertz, 300180 Amps per Phase at unity Power Factor and 5 KW minimum load step resolution.

b. The load bank shall be designed for continuous duty cycle operation with no limitations. The load bank shall operate in an ambient temperature of -28°C to 49°C (-20°F to 120°F).

2.9.2 Material and Construction

a. The load bank shall be outdoor weatherproof construction, suitable for installation on a concrete pad or structural base. All exterior fasteners shall be stainless steel. The load bank shall include forklift channels in the base for lifting.

b. The load bank shall be constructed of heavy gauge aluminized steel per ASTM A 463/A 463M.

c. The main input load bus, load step relays, fuses and blower/control relays shall be located within the load bank enclosure. A thermostatically controlled heater shall be located within the control section to provide protection to the control devices from the effects of moisture and condensation.

d. Airflow throughout the load bank shall be horizontal. Intake openings shall be designed to prevent objects greater than 0.50 inch diameter from entering the unit.

e. The load bank exhaust hood shall be angled downward. The exhaust hood shall be constructed of non-corrosive aluminized steel or aluminum.

f. The load bank enclosure shall have a baked polyester powder coated finish with a film thickness of 2.8 +/- 0.4 Mils per coat.

g. Load elements shall be contained in an integral resistor case.

Resistors can be individually removed for inspection or service.

2.9.3 Resistive Load Elements

a. Load elements shall be helically wound chromium alloy rated to operate at approximately 1/2 of maximum continuous rating of wire.

Elements must be fully supported across the entire length within the air stream by segmented ceramic insulators on stainless steel rods.

Element supports shall be designed to prevent a short circuit to adjacent elements or to ground.

b. The change in resistance due to temperature shall be minimized by maintaining conservative watt densities.

c. The overall tolerance of the load bank shall be -0% to +5% KW at rated voltage. A -5%, +5% rating allows the load bank to deliver less than rated KW and shall not be used. The load bank must deliver full rated KW at rated voltage.

2.9.4 Cooling

a. The load bank shall be cooled by integral TEFC or TEAO motor(s) which is direct coupled to the cooling fan blade. The fan motor must be electrically protected against overload using a motor overload device and short circuit protected using three (3) current limiting

SECTION 26 32 13.00 20 Page 15 fuses with an interrupting rating of 200K A.I.C.

b. The fan blade is to be an airfoil design constructed from aluminum or non-corroding material.

c. An integral control power transformer shall be provided to supply 120V, 1 phase, 60 Hz to the load banks control and motor starter circuitry. Transformer primary and secondary control circuits shall be fuse protected.

2.9.5 Protective Devices

a. A differential pressure switch shall be provided to detect air loss. The switch shall be electrically interlocked with the load application controls to prevent load from being applied if cooling air is not present.

b. An over-temperature switch shall be provided to sense the load bank exhaust in the heater case assembly. The switch shall be electrically interlocked with the load application controls to remove load from being applied in the event of an over temperature condition.

c. To provide for major fault protection, branch fuses shall be provided on all three phases of switched load steps above 50KW. Branch fuses shall be current limiting type with an interrupting rating of 200K A.I.C.

d. The exterior of the load bank shall have appropriate warning/caution statements on access panels.

2.9.6 Control Panel

a. The control panel shall be a remote 19 inch rack mounted panel housed in a NEMA 1 type wall mount enclosure located in Electrical Room

108. The control panel shall contain the following manual controls:

1. Power ON/OFF switch.

2. Blower START/STOP pushbuttons.

3. Master load ON/OFF switch.

4. Load step switches for ON/OFF application of individual load steps.

b. Control panel visual indicators shall be as follows:

1. Power ON indication light.

2. Blower ON light.

3. Blower/Air FAILURE.

4. OVERTEMPERATURE light.

c. A standard remote load dump circuit shall be provided as part of the load bank control circuit. Provisions shall be provided to remove the load bank off-line from the operation of a remote normally closed set of auxiliary contacts from a transfer switch or other device. In the event of the remote contact opening, all load is removed.

2.9.7 Operation and Maintanance Manuals

a. Installation and operation manuals shall be provided with the equipment and shall include complete details for the installation, SECTION 26 32 13.00 20 Page 16 commissioning, operation, and maintenance of the load bank.

b. The manuals shall include the electrical schematic and interconnect drawings for the power and control wiring for the load bank and all control devices.

c. A complete parts list with part numbers, device identification, and rating shall be included in the manuals. The original manufacturers name and part number shall be included in the parts listing.

d. Two (2) sets of manuals shall be provided with the load bank.

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 70 02.00 10 ELECTRICAL DISTRIBUTION SYSTEM, UNDERGROUND. 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.

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 70 02.00 10 ELECTRICAL DISTRIBUTION SYSTEM, UNDERGROUND paragraph entitled "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.

SECTION 26 32 13.00 20 Page 17

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 10 COMMISSIONING OF ELECTRICAL

SYSTEMS.

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 00.00 10

AUTOMATIC TRANSFER SWITCH AND BY-PASS/ISOLATION SWITCH.

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.

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

SECTION 26 32 13.00 20 Page 18 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 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. Refer to Section 26 00 00.00 20 BASIC ELECTRICAL MATERIALS AND METHODS, for requirements for a cataloged product. Perform the following field tests.

3.5.1 Acceptance Checks and Tests

Perform in accordance with the manufacturer's recommendations, and include the following visual and mechanical inspections and electrical tests, performed in accordance with NETA ATS.

3.5.1.1 Circuit Breakers - Low Voltage Insulated Case/Molded Case

a. Visual and mechanical inspection

1. Compare nameplate data with specifications and approved shop drawings.

2. Inspect circuit breaker for correct mounting.

3. Operate circuit breaker to ensure smooth operation.

4. Inspect case for cracks or other defects.

5. Verify tightness of accessible bolted connections and cable connections by calibrated torque-wrench method. Thermographic survey is not required.

6. Inspect mechanism contacts and arc chutes in unsealed units.

b. Electrical Tests

1. Perform contact-resistance tests.

2. Perform insulation-resistance tests.

3. Adjust Breaker(s) for final settings in accordance with engine-generator set manufacturer's requirements.

3.5.1.2 Current Transformers

a. Visual and Mechanical Inspection

1. Compare equipment nameplate data with specifications and approved

SECTION 26 32 13.00 20 Page 19 shop drawings.

2. Inspect physical and mechanical condition.

3. Verify correct connection.

4. Verify that adequate clearances exist between primary and secondary circuit.

5. Verify tightness of accessible bolted electrical connections by calibrated torque-wrench method. Thermographic survey is not required.

6. Verify that all required grounding and shorting connections provide good contact.

b. Electrical Tests

1. Perform insulation-resistance tests.

2. Perform polarity tests.

3. Perform ratio-verification tests.

3.5.1.3 Metering and Instrumentation

a. Visual and Mechanical Inspection

1. Compare equipment nameplate data with specifications and approved shop drawings.

2. Inspect physical and mechanical condition.

3. Verify tightness of electrical connections.

b. Electrical Tests

1. Determine accuracy of meters at 25, 50, 75, and 100 percent of full scale.

2. Calibrate watthour meters according to manufacturer's published data.

3. Verify all instrument multipliers.

4. Electrically confirm that current transformer secondary circuits are intact.

3.5.1.4 Battery Systems

a. Visual and mechanical inspection

1. Compare equipment nameplate data with specifications and approved shop drawings.

2. Inspect physical and mechanical condition.

3. Verify tightness of accessible bolted electrical connections by calibrated torque-wrench method. Thermographic survey is not

SECTION 26 32 13.00 20 Page 20 required.

4. Measure electrolyte specific gravity and temperature and visually check fill level.

5. Verify adequacy of battery support racks, mounting, anchorage, and clearances.

b. Electrical tests

1. Set charger float and equalizing voltage levels.

2. Verify all charger functions and alarms.

3. Measure each cell voltage and total battery voltage with charger energized and in float mode of operation.

4. Perform a capacity load test.

3.5.1.5 Engine-Generator Set

a. Visual and mechanical inspection

1. Compare equipment nameplate data with specifications and approved shop drawings.

2. Inspect physical and mechanical condition.

3. Inspect for correct anchorage and grounding.

b. Electrical and mechanical tests

1. Perform an insulation-resistance test on generator winding with respect to ground. Calculate polarization index.

2. Perform phase rotation test to determine compatibility with load requirements.

3.5.1.6 Grounding System

a. Visual and mechanical inspection

1. Inspect ground system for compliance with contract plans and specifications.

b. Electrical tests

1. Perform ground-impedance measurements utilizing the fall-of-potential method. On systems consisting of interconnected ground rods, perform tests after interconnections are complete.

On systems consisting of a single ground rod perform tests before any wire is connected. Take measurements in normally dry weather, not less than 48 hours after rainfall. Use a portable ground testing megger in accordance with manufacturer's instructions to test each ground or group of grounds. The instrument shall be equipped with a meter reading directly in ohms or fractions thereof to indicate the ground value of the ground rod or grounding systems under test.

SECTION 26 32 13.00 20 Page 21

3.5.2 Functional Acceptance Tests

The tests shall be performed by the start-up engineer. Upon successful test completion, the start-up engineer shall provide the Contracting Officer with a written test report within 15 calendar days showing the tests performed and the results of each test. The report shall include the completed approved test data forms and certification from the start-up engineer that the test results fall within the manufacturer's recommended limits and meet the specified requirements performance. The report shall be dated and signed by the start-up engineer, and submitted for approval by the Contracting Officer. The Contracting Officer will witness final acceptance tests. Testing shall include but not be limited to:

a. Verify proper functioning of each engine protective shutdown device and pre-shutdown alarm device. Testing of the devices shall be accomplished by simulating device actuation and observing proper alarm and engine shutdown operation.

b. Verify proper functioning of the engine overspeed trip device.

Testing of the overspeed trip device shall be accomplished by raising the speed of the engine-generator set until an overspeed trip is experienced.

c. Verify proper functioning of the crank cycle/terminate relay. Testing of the relay shall be accomplished by engaging the starter motor with the engine being prevented from running. Observe the complete crank/rest cycle as described in the paragraph entitled "Crank Cycle/Terminate Relay."

d. Verify proper functioning of the following automatic and manual operations. Testing shall include but not be limited to:

1. Loss of Utility: Initiate a normal power failure with connected test load of rated kW at 1.0 power factor. Record time delay on start, cranking time until engine starts and runs, time to come up to operating speed, voltage and frequency overshoot, and time to achieve steady state conditions with all switches transferred to emergency position.

2. Return of Utility: Return normal power and record time delay on retransfer for each automatic transfer switch, and time delay on engine cooldown and shutdown.

3. Manual starting

4. Emergency stop

e. Operate the engine-generator set at rated current (amperes) until the jacket water temperature stabilizes. Stabilization will be considered to have occurred when three consecutive temperature readings remain unchanged. Continue to operate the generator set for an additional 2 hours. Record instrument readings for terminal voltage, line current, frequency (Hz), engine speed rpm, lubricating oil pressure, jacket water temperature, and ambient temperature at 5 minute intervals for first 15 minutes and at 15 minute intervals thereafter.

3.5.3 Emissions Tests

Provide on site testing by a certified testing organization of each

SECTION 26 32 13.00 20 Page 22 engine-generator set. Testing shall be in accordance with an EPA approved method, 40 CFR 60, (Appendix, Method 7, 7A, 7B, 7C, 7D or 7E). Emissions at rated full load shall be within the limits specified in the paragraph entitled "Diesel Engine Emissions Limits."

3.5.4 Load Bank Quality Control

a. The load bank shall be fully tested using a test specification written by the supplier. Tests shall include electrical functional testing, verifying conformance to assembly drawings and specifications. Each load step shall be cold resistance checked to verify proper calibration of resistive load steps and proper ohmic value.

b. The manufacturer shall maintain this data on file for inspection purposes by the purchaser. Tests using high potential equipment shall be performed to ensure isolation of the load circuits from the control circuits and to determine isolation of the load circuits from the load bank frame. Tests of all safety circuits shall be performed to verify conformance to the specification.

c. All electrical circuits shall have a high potential insulation resistance test performed at twice rated voltage plus 1000 VAC to assure insulation integrity.

d. All quality control test equipment shall be regularly maintained and calibrated to traceable national standards.

e. The Company's Quality System shall be ISO9001 Certified.

3.6 DEMONSTRATION

Upon completion of the work and at a time approved by the Contracting Officer, the Contractor shall provide instructions by a qualified instructor to the Government personnel in the proper operation and maintenance of the equipment. Government personnel shall receive training comparable to the equipment manufacturer's factory training. The duration of instruction shall be for not less than one 8 hour working day for instruction of operating personnel and not less than one 8 hour working day for instruction of maintenance personnel.

3.6.1 Instructor's Qualification Resume

Instructors shall be regular employees of the engine-generator set manufacturer. The instruction personnel provided to satisfy the requirements above shall be factory certified by the related equipment manufacturer to provide instruction services. Submit the name and qualification resume of instructor to the Contracting Officer for approval.

3.6.2 Training Plan

Submit training plan 30 calendar days prior to training sessions. Training plan shall include scheduling, content, outline, and training material (handouts). Content shall include but not limited to the following:

3.6.2.1 Operating Personnel Training

This instruction includes operating the engine-generator set, auxiliary equipment including automatic transfer switches in all modes, and the use

SECTION 26 32 13.00 20 Page 23 of all functions and features specified.

3.6.2.2 Maintenance Personnel Training

Shall include mechanical, hydraulic, electrical, and electronic instructions for the engine-generator set and auxiliary equipment including automatic transfer switches.

a. Mechanical Training: Shall include at least the following:

1. A review of mechanical diagrams and drawings.

2. Component location and functions.

3. Troubleshooting procedures and techniques.

4. Repair procedures.

5. Assembly/disassembly procedures.

6. Adjustments (how, when, and where).

7. Preventive maintenance procedures.

8. Review of flow diagram.

9. Valve locations and function.

10. Valve and hydraulic equipment adjustment and maintenance procedures.

11. Hydraulic system maintenance and servicing.

12. Lubrication points, type, and recommended procedures and frequency.

b. Electrical and Electronic Maintenance Training: Shall include at least the following:

1. A review of electrical and electronic systems including wiring diagrams and drawings.

2. Troubleshooting procedures for the machine and control systems.

3. Electrical and electronic equipment servicing and care.

4. Use of diagnostics to locate the causes of malfunction.

5. Procedures for adjustments (locating components, adjustments to be made, values to be measured, and equipment required for making adjustments).

6. Maintenance and troubleshooting procedures for microprocessor or

SECTION 26 32 13.00 20 Page 24 minicomputer where applicable.

7. Circuit board repair procedures where applicable (with schematics provided).

8. Use of diagnostic tapes.

9. Recommended maintenance servicing and repair for motors, switches, relays, solenoids, and other auxiliary equipment and devices.

-- End of Section --

SECTION 26 32 13.00 20 Page 25