26_32_15.00_10.pdf

Green Brook, Segment C-1

AMENDMENT # 4

SECTION 26 32 15.00 10

DIESEL-GENERATOR SET STATIONARY 100-2500 KW, WITH AUXILIARIES

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.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI C39.1 (1981; R 1992) Requirements for Electrical Analog Indicating Instruments

ASME INTERNATIONAL (ASME)

ASME B16.11 (2016) Forged Fittings, Socket-Welding and Threaded

ASME B16.3 (2011) Malleable Iron Threaded Fittings, Classes 150 and 300

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

ASME B31.1 (2016; Errata 2016) Power Piping

ASME BPVC SEC IX (2010) BPVC Section IX-Welding and Brazing Qualifications

ASME BPVC SEC VIII D1 (2015) BPVC Section VIII-Rules for Construction of Pressure Vessels Division 1

ASTM INTERNATIONAL (ASTM)

ASTM A106/A106M (2014) Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service

ASTM A181/A181M (2014) Standard Specification for Carbon Steel Forgings, for General-Purpose Piping

ASTM A234/A234M (2017) Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service

ASTM A53/A53M (2012) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM B395/B395M (2013) Standard Specification for U-Bend Seamless Copper and Copper Alloy Heat

SECTION 26 32 15.00 10 Page 1

Exchanger and Condenser Tubes

ASTM D975 (2017) Standard Specification for Diesel Fuel Oils

ELECTRICAL GENERATING SYSTEMS ASSOCIATION (EGSA)

EGSA 101P (1995) Performance Standard for Engine Driven Generator Sets

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 1 (2000; R 2011) General Principles for Temperature Limits in the Rating of Electric Equipment and for the Evaluation of Electrical Insulation

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 120 (1989; R 2007) Master Test Guide for Electrical Measurements in Power Circuits

IEEE 43 (2013) Recommended Practice for Testing Insulation Resistance of Rotating Machinery

IEEE 519 (2014) Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems

IEEE 81 (2012) Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface Potentials of a Ground System

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

IEEE C57.13 (2016) Requirements for Instrument Transformers

IEEE C57.13.1 (2006; R 2012) Guide for Field Testing of Relaying Current Transformers

IEEE Stds Dictionary (2009) IEEE Standards Dictionary: Glossary of Terms & Definitions

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-58 (1993; Reaffirmed 2010) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation

MSS SP-80 (2013) Bronze Gate, Globe, Angle and Check Valves

SECTION 26 32 15.00 10 Page 2

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 2 (2000; R 2005; Errata 2008) Industrial Control and Systems Controllers, Contactors, and Overload Relays Rated 600 V

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

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

NEMA PB 1 (2011) Panelboards

NEMA PB 2 (2011) Deadfront Distribution Switchboards

NEMA SG 6 (2000) Standard for Power Switching Equipment

NEMA/ANSI C12.11 (2007) Instrument Transformers for Revenue Metering, 10 kV BIL through 350 kV BIL (0.6 kV NSV through 69 kV NSV)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 110 (2016) Standard for Emergency and Standby Power Systems

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

NFPA 99 (2015; AMD 2016) Health Care Facilities Code

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE J537 (2016) Storage Batteries

UNDERWRITERS LABORATORIES (UL)

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

1.2 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

SECTION 26 32 15.00 10 Page 3 that will review the submittal for the Government. Submittals with an "S" are for inclusion in the Sustainability 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

Detailed Drawings; G, RO Acceptance; G, RO

SD-03 Product Data

Harmonic Requirements Engine-Generator Parameter Schedule Heat Exchanger Generator Manufacturer's Catalog Site Welding Spare Parts Onsite Training Vibration-Isolation Posted Data and Instructions; G, RO Instructions; G, RO Experience Field Engineer General Installation

SD-05 Design Data

Performance Criteria Sound Limitations; G, RO Day Tank Power Factor Time-Delay on Alarms Battery Charger

SD-06 Test Reports

Factory Inspection and Tests Factory Tests Onsite Inspection and Tests; G, RO

SD-07 Certificates

Cooling System Vibration Isolation Prototype Test Reliability and Durability Emissions Sound Limitations Site Visit Current Balance Materials and Equipment Inspections Cooling System

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals; G, RO

SECTION 26 32 15.00 10 Page 4

Maintenance Procedures; G, RO Special Tools Filters

1.3 QUALITY ASSURANCE

1.3.1 Conformance to Codes and Standards

Where equipment is specified to conform to requirements of any code or standard such as UL, NEMA, etc., the design, fabrication and installation shall also conform to the code.

1.3.2 Site Welding

Weld structural members in accordance with Section 05 05 23.16 STRUCTURAL WELDING. For all other welding, qualify procedures and welders in accordance with ASME BPVC SEC IX. Welding procedures qualified by others, and welders and welding operators qualified by a previously qualified employer may be accepted as permitted by ASME B31.1. Submit a copy of qualifying procedures and a list of names and identification symbols of qualified welders and welding operators. A letter listing the welder qualifying procedures for each welder, complete with supporting data such as test procedures used, what was tested to, and a list of the names of all welders and their identification symbols. Perform welder qualification tests for each welder whose qualifications are not in compliance with the referenced standards. Notify the Contracting Officer 24 hours in advance of qualification tests which shall be performed at the work site, if practical. The welder or welding operator shall apply the personally assigned symbol near each weld made as a permanent record.

1.3.3 Vibration Limitation

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/second RMS, for all speeds through 110 percent of rated speed.

1.3.4 Experience

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

1.3.5 Field Engineer

The engine-generator set manufacturer or assembler shall furnish a qualified field engineer to supervise the complete installation of the engine-generator set, assist in the performance of the onsite tests, and instruct personnel as to the operational and maintenance features of the equipment. Submit a letter listing the qualifications, schools, formal training, and experience of the field engineer. The field engineer shall

SECTION 26 32 15.00 10 Page 5 have attended the engine generator manufacturer's training courses on installation and operation and maintenance of engine generator sets.

1.3.6 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. Complete starting system.

c. Complete fuel system.

d. Complete cooling system.

e. Complete exhaust system.

f. Layout of relays, breakers, programmable controllers,switchgear, and switches including applicable single line and wiring diagrams with written description of sequence of operation and the instrumentation provided.

g. The complete 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 for all applications.

i. The safety system, together with a detailed description of how it is to work. Wiring schematics, safety devices with a listing of their normal ranges, alarm and shutdown values (to include operation parameters such as pressures, temperatures voltages, currents, and speeds) shall be included.

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

k. Layout of each panel.

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

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

1.4 DELIVERY, STORAGE, AND HANDLING

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

During installation, piping and similar openings shall be capped to keep out dirt and other foreign matter.

1.5 EXTRA MATERIALS

Submit a complete list of spare parts for each piece of equipment and a complete list of all material and supplies needed for continued operation.

SECTION 26 32 15.00 10 Page 6

Lists shall include supply source and current prices. Separate each list into two parts, those elements recommended by the manufacturer to be replaced after 3 years of service, and the remaining elements.

PART 2 PRODUCTS

2.1 SYSTEM REQUIREMENTA

a. Provide and install each engine-generator set complete and totally functional, with all necessary ancillary equipment to include: air filtration; starting system; generator controls, protection, and isolation; instrumentation; lubrication; fuel system; cooling system;

and engine exhaust system. Each engine-generator set shall satisfy the requirements specified in the Engine-Generator Parameter Schedule.

b. Each set shall consist of one engine, one generator, and one exciter mounted, assembled, and aligned on one base; and other necessary ancillary equipment which may be mounted separately. Sets having a capacity of 750 kW or smaller shall be assembled and attached to the base prior to shipping. Sets over 750 kW capacity may be shipped in sections. Each set component shall be environmentally suitable for the location shown and shall be the manufacturer's standard product offered in catalogs for commercial or industrial use. Any nonstandard products or components and the reason for their use shall be specifically identified.

2.1.1 Engine-Generator Parameter Schedule

Submit description of the generator features which mitigate the effects of the non-linear loads listed.

ENGINE-GENERATOR PARAMETER SCHEDULE

Power Rating Prime

Overload Capacity (Prime applications only)

110 percent of Service Load for 1 hour in 12 consecutive hours

Service Load As shown on drawings

As shown on drawings

Motor Starting kVA (Max.) 3800 kVA

Power Factor 0.8 lagging

Engine-Generator Applications stand-alone

Maximum Speed 1800 rpm

Heat Exchanger Type fin-tube (radiator)

Voltage Regulation (No Load to Full Load)(Stand alone

+ 2 percent (maximum)

SECTION 26 32 15.00 10 Page 7

ENGINE-GENERATOR PARAMETER SCHEDULE

Voltage Bandwidth (steady state) + 0.5 percent

Frequency 60 Hz

Voltage 480/277 volts

Phases 3 Phase, Wye

Minimum Generator Subtransient Reactance

15 percent

Max Step Load Increase 100 percent of Service Load at 0.8

PF

Maximum Voltage Deviation with Step Load Increase

20 percent of rated voltage

Maximum Frequency Deviation with Step Load Increase

0.5 percent of rated frequency

Max Time to Start and be Ready to Assume Load

10 seconds

Max Summer Indoor Temp (Prior to Genset Operation)

120 degrees F

Min Winter Indoor Temp (Prior to Genset Operation)

0 degrees F

Max Summer Outdoor Temp (Ambient) 100 degrees F

Min Winter Outdoor Temp (Ambient) 0 degrees F

Installation Elevation 15 above sea level

ENGINE-GENERATOR PARAMETER SCHEDULE - Governor

Governor Type Droop

Frequency Regulation (droop) (No Load to Full Load)

5 percent (maximum)

Frequency Bandwidth (steady state) + 0.4 percent

2.1.2 Rated Output Capacity

Each engine-generator-set shall provide 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 paragraph Engine-Generator Parameter Schedule.

2.1.3 Power Ratings

Power ratings shall be in accordance with EGSA 101P.

2.1.4 Transient Response

The engine-generator set governor and voltage regulator shall cause the engine-generator set to respond to the maximum step load changes such that output voltage and frequency recover to and stabilize within the

SECTION 26 32 15.00 10 Page 8 operational bandwidth within the transient recovery time. The engine-generator set shall respond to maximum step load changes such that the maximum voltage and frequency deviations from bandwidth are not exceeded.

2.1.5 Reliability and Durability

Each prime engine-generator set shall have both an engine and a generator capable of delivering the specified power on a prime basis with an anticipated mean time between overhauls of not less than 10,000 hours operating with a 70 percent load factor. Two like engines and two like generators shall be cited that have performed satisfactorily in a stationary power plant, independent from the physical location of the manufacturer's and assembler's facilities. The engine and generators should have been in operation for a minimum of 8000 actual hours at a minimum load of 70 percent of the rated output capacity. During two consecutive years of service, the units should not have experienced any failure resulting in a downtime in excess of 72 hours. Like engines shall be of the same model, speed, bore, stroke, number and configuration of cylinders and rated output capacity. Like generators shall be of the same model, speed, pitch, cooling, exciter, voltage regulator and rated output capacity.

Submit a reliability and durability certification letter from the manufacturer and assembler to prove that existing facilities are and have been successfully utilizing the same components proposed to meet this specification, in similar service. Certification may be based on components, i.e. engines used with different models of generators and generators used with different engines, and does not exclude annual technological improvements made by a manufacturer in the basic standard-model component on which experience was obtained, provided parts interchangeability has not been substantially affected and the current standard model meets the performance requirements specified. Provide a list with the name of the installations, completion dates, and name and telephone number of a point of contact.

2.1.6 Vibration Isolation

The engine-generator set shall be provided with a vibration-isolation system in accordance with the manufacturer's standard recommendation.

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 plus description of seismic qualification of the engine-generator mounting, base, and vibration isolation. Submit torsional analysis including prototype testing or and calculations which certify and demonstrate that no damaging or dangerous torsional vibrations will occur when the prime mover is connected to the generator, at synchronous speeds, + 10 percent.

Vibration-isolation systems shall be designed and qualified (as an integral part of the base and mounting system in accordance with the seismic parameters specified. Where the vibration-isolation system does not secure the base to the structure floor or unit foundation, seismic restraints shall be provided in accordance with the seismic parameters specified.

2.1.7 Fuel Consumption

Engine fuel consumption shall not exceed the following maximum limits based on the conditions listed below.

SECTION 26 32 15.00 10 Page 9

Size Range Net kW Percent of Rated Output Capacity

Fuel Usage lbs/kWH

100 - 299 75 and 100 0.600

50 0.643

300 - 999 75 and 100 0.575

50 0.600

1000 - 2500 75 and 100 0.536

50 0.573

Conditions:

a. Net kW of the Set corrected for engine auxiliaries that are electrically driven, where kW is electrical kilowatt hours.

b. 19,350 Btu/pound high-heat value for fuel used.

c. Sea level operation.

d. Intake-air temperature not over 90 degrees F.

e. Barometric pressure of intake air not less than 28-1/4 inches of mercury.

2.1.8 Fuel-Consumption Rebates

Fuel consumption rebates shall be assessed for failure of engine generator set to meet guaranteed rates. If the guaranteed fuel-consumption rate for 100 percent rated output capacity is verified in the tests but the rates for 75 or 50 percent rated output capacity are not verified, the appropriate 75 or 50 percent rate differences shall be used in assessing the rebates. If more than one fuel consumption guarantee is not met, rebates shall be computed for 100, 75, and 50 percent rated output capacity, and the highest computed figure shall be used in assessing the rebates.

Rebate = H x C x D x N where:

C Local fuel costs in dollars per pound

D A - G

A Measured fuel consumption in pounds per hour

G kW x R = Guaranteed fuel consumption in pounds per hour

N Number of generator sets provided

H Operating hours over a projected period of 15 years

Adjust fuel costs to the heat value BTU/lb for the fuel used in the test (requires fuel laboratory test) rationed to the 19,350 Btu/pound heat value

SECTION 26 32 15.00 10 Page 10 used as the basis of the guarantee.

2.1.9 Harmonic Requirements

Non-linear loads to be served by each engine-generator set are as indicated. The maximum linear load demand (kVA @ PF) when non-linear loads will also be in use is as indicated.

2.1.10 Starting Time Requirements

Upon receipt of a signal to start, each engine generator set will start, reach rated frequency and voltage and be ready to assume load within the time specified. For standby sets used in emergency power applications, each engine generator set will start, reach rated frequency and voltage, and power will be supplied to the load terminals of the automatic transfer switch within the starting time specified.

2.2 NAMEPLATES

Each major component of this specification shall have the manufacturer's name, type or style, model or serial number and rating on a plate secured to the equipment. As a minimum, nameplates shall be provided for:

Engines Relays

Generators Transformers (CT & PT)

Regulators Day tanks

Pumps and pump motors Governors

Generator Breaker Air Starting System

Economizers Heat exchangers (other than base mounted)

Where the following equipment is not provided as a standard component by the diesel engine generator set manufacturer, the nameplate information may be provided in the maintenance manual in lieu of nameplates.

Battery charger Heaters

Switchboards Exhaust mufflers

Switchgear Silencers

Battery Exciters

2.3 SAFETY DEVICES

Exposed moving parts, parts that produce high operating temperatures, parts which may be electrically energized, and parts that may be a hazard to operating personnel 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.

2.4 MATERIALS AND EQUIPMENT

Submit certification stating that where materials or equipment are

SECTION 26 32 15.00 10 Page 11 specified to comply with requirements of UL, 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.

2.4.1 Filter Elements

Fuel-oil, lubricating-oil, and combustion-air filter elements shall be manufacturer's standard.

2.4.2 Instrument Transformers

NEMA/ANSI C12.11.

2.4.3 Revenue Metering

IEEE C57.13.

2.4.4 Pipe (Fuel/Lube-Oil, Compressed Air, Coolant, and Exhaust)

ASTM A53/A53M, or ASTM A106/A106M steel pipe. Pipe smaller than 2 inches shall be Schedule 80. Pipe 2 inches and larger shall be Schedule 40.

2.4.4.1 Flanges and Flanged Fittings

ASTM A181/A181M, Class 60, or ASME B16.5, Grade 1, Class 150.

2.4.4.2 Pipe Welding Fittings

ASTM A234/A234M, Grade WPB or WPC, Class 150 or ASME B16.11, 3000 lb.

2.4.4.3 Threaded Fittings

ASME B16.3, Class 150.

2.4.4.4 Valves

MSS SP-80, Class 150.

2.4.4.5 Gaskets

Manufacturer's standard.

2.4.5 Pipe Hangers

MSS SP-58.

2.4.6 Electrical Enclosures

NEMA ICS 6.

2.4.6.1 Power Switchgear Assemblies

NEMA SG 6.

SECTION 26 32 15.00 10 Page 12

2.4.6.2 Switchboards

NEMA PB 2.

2.4.6.3 Panelboards

NEMA PB 1.

2.4.7 Electric Motors

Electric motors shall conform to the requirements of NEMA MG 1. Motors shall have sealed ball bearings and a maximum speed of 1800 rpm. Motors used indoors shall have drip-proof frames; those used outside shall be totally enclosed. Alternating current motors larger than 1/2 Hp shall be of the squirrel-cage induction type for operation on 208 volts or higher, 60 Hz, and three-phase power. Alternating current motors 1/2 Hp or smaller, shall be suitable for operation on 120 volts, 60 Hz, and single-phase power.

2.4.8 Motor Controllers

Motor controllers and starters shall conform to the requirements of NFPA 70 and NEMA ICS 2.

2.5 ENGINE

Each engine shall operate on No. 2-D diesel fuel conforming to ASTM D975, shall be designed for stationary applications and shall be complete with ancillaries. The engine shall be a standard production model shown in the manufacturer's catalog describing and depicting each engine-generator set and all ancillary equipment in sufficient detail to demonstrate complete specification compliance. The engine shall be naturally aspirated, supercharged, or turbocharged. The engine shall be 2- or 4-stroke-cycle and compression-ignition type. The engine shall be vertical in-line, V- or opposed-piston type, with a solid cast block or individually cast cylinders. The engine shall have a minimum of two cylinders.

Opposed-piston type engines shall have not less than four cylinders. Each block shall have a coolant drain port. Each engine shall be equipped with an overspeed sensor.

2.6 FUEL SYSTEM

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

2.6.1 Pumps

2.6.1.1 Main Pump

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.

2.6.1.2 Auxiliary Fuel Pump

Provide auxiliary fuel pumps to maintain the required engine fuel pressure, if either required by the installation or indicated on the drawings. The

SECTION 26 32 15.00 10 Page 13 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.

2.6.2 Fuel Filter

Provide a minimum of one full-flow fuel filter 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.

2.6.3 Relief/Bypass Valve

Provide a relief/bypass valve 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.

2.6.4 Integral Main Fuel Storage Tank

Provide each engine with an 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. Each engine-generator set provided with weatherproof enclosures shall have its tank mounted within the enclosure. The fuel fill line shall be accessible without opening the enclosure.

2.6.4.1 Local Fuel Fill

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

2.6.4.2 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.

2.6.4.3 Arrangement

Integral tanks may allow gravity flow into the engine. Gravity flow tanks and any tank that allows a fuel level above the fuel injectors shall be provided with an internal or external factory installed valve located as near as possible to the shell of the tank. The valve shall close when the engine is not operating. Integral day tanks shall be provided with any necessary pumps to supply fuel to the engine as recommended by the generator set manufacturer. The fuel supply line from the tank to the manufacturer's standard engine connection shall be welded pipe.

SECTION 26 32 15.00 10 Page 14

2.6.5 Day Tank

The project shall be provided with a separate self-supporting day tank in accordance with Section 33 11 13 FUEL STORAGE AND SUPPLY SYSTEM. The day tank shall be shared by the two generators as shown on the drawings. The Day Tank/Sub-Base Tank shall have a minimum capacity of 200 gallons, and the Day Tank shall be a SUB-BASE TYPE. A fuel return line cooler shall be provided as recommended by the manufacturer and assembler. The temperature of the fuel returning to the day tank shall be below the flash point of the fuel. A temperature sensing device shall be installed in the fuel supply line.

2.6.5.1 Fuel Level Controls

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

a. Start the supply of fuel into the day tank when the fuel level is at the "Low" level mark, 75 percent of the rated tank capacity.

b. Stop the supply of fuel into the day tank when the fuel level is at 90 percent of the rated tank capacity.

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

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

e. Activate the automatic fuel supply shut-off valve located on the fill line of the day tank and shut down the fuel pump which supplies fuel to the day tank at 95 percent of the rated tank capacity. The flow of fuel shall be stopped before any fuel can be forced into the fuel overflow line.

2.6.5.2 Arrangement

The fuel supply line from the day tank to the manufacturer's standard engine connection shall be welded pipe.

2.6.6 Fuel Supply System

The fuel supply from the main storage of fuel to the day tank shall be as specified in Section 33 56 10 FACTORY-FABRICATED FUEL STORAGE TANKS.

2.7 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 pumps. System pressure shall be regulated as recommended by the engine manufacturer. A pressure relief valve shall be provided on the crankcase for closed systems. 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, if provided on engines installed in buildings or enclosures, 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.

SECTION 26 32 15.00 10 Page 15

2.7.1 Lube-Oil Filter

Provide one full-flow filter 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.

2.7.2 Lube-Oil Sensors

Equip each engine with lube-oil pressure sensors located downstream of the filters and provide signals for required indication and alarms. Submit two complete sets of filters, required for maintenance, supplied in a suitable storage box. These filters shall be in addition to filters replaced after testing.

2.7.3 Precirculation Pump

Provide a motor-driven precirculation pump powered by the station battery, complete with motor starter, if recommended by the engine manufacturer.

2.8 COOLING SYSTEM

Provide each engine with its own cooling system to operate automatically while its engine is running. The cooling system coolant shall use a combination of water and ethylene-glycol sufficient for freeze protection at the minimum winter outdoor temperature specified. The maximum temperature rise of the coolant across each engine shall not exceed that recommended below. Submit a letter which certifies that the engine-generator set and cooling system function properly in the ambient temperature specified, stating the following values:

a. The maximum allowable inlet temperature of the coolant fluid.

b. The minimum allowable inlet temperature of the coolant fluid.

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

2.8.1 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.

2.8.2 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 for the maximum summer outdoor design temperature and site elevation. Submit manufacturer's data to quantify heat rejected to the space with the engine generator set at rated capacity. Each heat exchanger shall be corrosion resistant, suitable for service in ambient conditions of application.

2.8.2.1 Fin-Tube-Type Heat Exchanger (Radiator)

Heat exchanger may be factory coated with corrosive resistant film, provided that correction measures are taken to restore the heat rejection

SECTION 26 32 15.00 10 Page 16 capability of the radiator to the initial design requirement via over sizing, 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 and shall be protected with a strong grille or screen guard. Each heat exchanger shall have at least two tapped holes;

one tapped hole shall be equipped with a drain cock, the rest shall be plugged.

2.8.2.2 Shell and U-Tube Type Heat Exchanger

Heat exchanger shall be multiple pass shell and U-tube type. Exchanger shall operate with low temperature water in the shell and high temperature water in the tubes. Exchangers shall be constructed in accordance with ASME BPVC SEC VIII D1 and certified with ASME stamp secured to the unit.

U-tube bundles shall be completely removable for cleaning and tube replacement and shall be free to expand with the shell. Shells shall be constructed of seamless steel pipe or welded steel. Tubes shall be cupronickel or inhibited admiralty, constructed in accordance with ASTM B395/B395M, suitable for the temperatures and pressures specified.

Tubes shall not be less than 3/4 inch unless otherwise indicated. Shell side and tube side shall be designed for 150 psig working pressure and factory tested at 300 psig. High and low temperature water and pressure relief connections shall be located in accordance with the manufacturers standard practice. Water connections larger than 3 inches shall be ASME Class 150 flanged. Water pressure loss through clean tubes shall be as recommended by the engine manufacturer. Minimum water velocity through tubes shall be 1 fps and assure turbulent flow. One or more pressure relief valves shall be provided for each heat exchanger in accordance with ASME BPVC SEC VIII D1. The aggregate relieving capacity of the relief valves shall be not less than that required by the above code. Discharge from the valves shall be installed as indicated. The relief valves shall be installed on the heat exchanger shell. A drain connection with 3/4 inch hose bib shall be installed at the lowest point in the system near the heat exchanger. Additional drain connection with threaded cap or plug shall be installed wherever required for thorough draining of the system.

2.8.3 Expansion Tank

The cooling system shall include an air expansion tank which will accommodate the expanded water of the system generated within the normal operating temperature range, limiting the pressure increase at all components in the system to the maximum allowable pressure at those components. The tank shall be suitable for operating temperature of 250 degrees F and a working pressure of 125 psi. The tank shall be constructed of welded steel, tested and stamped in accordance with ASME BPVC SEC VIII D1 for the stated working pressure. A bladder type tank shall not used. The tank shall be supported by steel legs or bases for vertical or steel saddles for horizontal installation.

2.8.4 Thermostatic Control Valve

A modulating type, thermostatic control valve shall be provided in the coolant system to maintain the coolant temperature range submitted in paragraph SUBMITTALS.

SECTION 26 32 15.00 10 Page 17

2.8.5 Ductwork

Ductwork shall be as specified in Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEM except that a flexible connection shall be used to connect the duct to the diesel engine radiator. Material for the connection shall be wire-reinforced glass. The connection shall be rendered as airtight as possible.

2.8.6 Temperature Sensors

Each engine shall be equipped with coolant temperature sensors.

Temperature sensors shall provide signals for pre-high and high indication and alarms.

2.9 SOUND LIMITATIONS

Submit sound power level data for the packaged unit operating at 100 percent load in a free field environment. The data should demonstrate compliance with the sound limitation requirements of this specification.

Submit certification from the manufacturer stating that the sound emissions meet the specification. The noise generated by the diesel generator set operating at 100 percent load shall not exceed the following sound pressure levels in any of the indicated frequencies when measured in a free field at a radial distance of 22.9 feet 7 meters at 45 degrees apart in all directions.

Frequency Band (Hz) Maximum Acceptable Sound Level (Decibels)

31 87

63 77

125 70

250 64

500 64

1,000 61

2,000 60

4,000 60

8,000 62

2.10 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 so that the indicated pressure levels specified in paragraph SOUND LIMITATIONS will not be exceeded. 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 rubber.

SECTION 26 32 15.00 10 Page 18

2.11 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.

2.11.1 Flexible Sections and Expansion Joints

A flexible section shall be provided at each engine and an expansion joint at each muffler. Flexible sections and expansion joints shall have flanged connections. Flexible sections shall be made of convoluted seamless tube without joints or packing. Expansion joints shall be the bellows type.

Expansion and flexible elements shall be stainless steel suitable for diesel-engine exhaust gas at the maximum exhaust temperature that is specified by the engine manufacturer. Expansion and flexible elements shall be capable of absorbing vibration from the engine and compensation for thermal expansion and contraction.

2.11.2 Exhaust Muffler

A chamber type exhaust muffler shall be provided. The muffler shall be constructed of welded steel and designed for inside mounting. 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. 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.

2.11.3 Exhaust Piping

Horizontal sections of exhaust piping shall be sloped downward away from the engine to a drip leg for collection of condensate with drain valve and cap. Changes in direction shall be long radius. Exhaust piping, mufflers and silencers installed inside any building shall be insulated in accordance with paragraph THERMAL INSULATION and covered to protect personnel. Vertical exhaust piping shall be provided with a hinged, gravity-operated, self-closing, rain cover.

2.12 PYROMETER

A pyrometer, with calibrated leads shall be provided to show the temperature of the combined exhaust. For a supercharged engine, additional points, thermocouples and leads shall be provided to show the temperature in the turbocharger exhaust gas outlet and combustion air discharge passages. Graduated scale length shall be not less than 6 inches. The selector switch shall be double pole, with an "off" position, one set of points for each thermocouple, and suitable indicating dial. The pyrometer, thermocouples, leads and compensating devices shall be calibrated to show true exhaust temperature within plus or minus 1 percent above the highest temperature encountered at 110 percent load conditions.

2.13 EMISSIONS

The finished installation shall comply with Federal, state, and local regulations and restrictions regarding the limits of emissions. Submit certification from the engine manufacturer stating that the engine exhaust

SECTION 26 32 15.00 10 Page 19 emissions meet the federal, state, and local regulations and restrictions specified. 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 (HPAs).

2.14 STARTING SYSTEM

The starting system for engine generator sets used in non-emergency applications shall be as follows.

2.14.1 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 cooldown operation. The logic shall be arranged for manual starting and fully automatic starting in accordance with paragraph AUTOMATIC ENGINE-GENERATOR-SET SYSTEM 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.

2.14.2 Capacity

The starting system shall be of sufficient capacity, at the maximum indoor 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.

2.14.3 Electrical Starting

Manufacturers recommended dc system, utilizing a negative circuit ground.

2.14.3.1 Battery

A starting battery system shall be provided and shall include the battery, battery rack, intercell connectors, spacers, automatic battery charger with overcurrent protection, metering and relaying. The battery shall be in accordance with SAE J537. Critical system components (rack, protection, etc.) shall be sized to withstand the seismic acceleration forces specified. The battery shall be lead-acid , with sufficient capacity, at the minimum indoor and maximum indoor temperature specified, to provide the specified cranking periods. Valve-regulated lead-acid batteries are not acceptable.

2.14.3.2 Battery Charger

A current-limiting battery charger, conforming to UL 1236, shall be provided and shall automatically recharge the batteries. Submit battery charger sizing calculations. The charger shall be capable of an equalize-charging rate for recharging fully depleted batteries within 24 hours and a floating charge rate for maintaining the batteries at fully charged condition. An ammeter shall be provided to indicate charging rate. A voltmeter shall be provided to indicate charging voltage. A timer shall be provided for the equalize-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.

SECTION 26 32 15.00 10 Page 20

2.14.4 Starting Aids

The manufacturer shall provide one or more of other following methods to assist engine starting.

2.14.4.1 Glow Plugs

Glow plugs shall be designed to provide sufficient heat for combustion of fuel within the cylinders to guarantee starting at an ambient temperature of -25 degrees F.

2.14.4.2 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 F of the control temperature. The heater shall operate independently of engine operation so that starting times are minimized.

Power for the heaters shall be 208 volts ac.

2.14.4.2.1 Prime Rated Sets

The control temperature shall be the higher of the manufacturer's recommended temperature or the minimum coolant inlet temperature of the engine recommended in paragraph SUBMITTALS.

2.14.4.2.2 Standby Rated Sets

The control temperature shall be the temperature recommended by the engine manufacturer to meet the starting time specified at the minimum winter outdoor temperature.

2.14.4.3 Lubricating-Oil Heaters

A thermostatically controlled electric heater shall be mounted in the engine lubricating-oil system to automatically maintain the oil temperature within plus or minus 3 degrees F of the control temperature. The heater shall operate independently of engine operation so that starting times are minimized. Power for the heaters shall be 208 volts ac.

2.14.5 Exerciser

The exerciser shall be in accordance with Section 26 36 00.00 10 AUTOMATIC

TRANSFER SWITCH AND BY-PASS/ISOLATION SWITCH.

2.15 GOVERNOR

Each engine shall be provided with a governor which 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 0 to 100 percent or rated capacity. Submit two complete sets of special tools required for maintenance (except for electronic governor handset).

Special tools are those that only the manufacturer provides, for special purposes, or to reach otherwise inaccessible parts. The tools shall be supplied complete with a suitable tool box. One handset shall be provided for each electronic governor when required to indicate and/or change governor response settings. Isochronous governors shall maintain the

SECTION 26 32 15.00 10 Page 21 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.

2.16 GENERATOR

Each generator shall be of the synchronous type, one or two bearing, conforming to the performance criteria in 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. Submit calculations of the engine and generator output power capability, including efficiency and parasitic load data. Insulation shall be Class H .

a. Generator design shall protect against mechanical, electrical and thermal damage due to vibration, 25 percent overspeeds, or voltages and temperatures at a rated output capacity of 110 percent for prime applications and 100 percent for standby applications.

b. Generator ancillary equipment shall meet the short circuit requirements of NEMA MG 1. Frames shall be the drip-proof type.

c. Submit manufacturer's standard data for each generator (prototype data at the specified rating or above is acceptable), listing the following information:

(1) Direct-Axis subtransient reactance (per unit).

(2) The generator kW rating and short circuit current capacity (both symmetric and asymmetric).

2.16.1 Current Balance

At 100 percent rated output capacity, and load impedance equal for each of the 3 phases, the permissible current difference between any 2 phases shall not exceed 2 percent of the largest current on either of the 2 phases.

Submit certification stating 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.

2.16.2 Voltage Balance

At any balanced load between 75 and 100 percent of rated output capacity, the difference in line-to-neutral voltage among the 3 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 2 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.

2.16.3 Waveform

The deviation factor of the line-to-line voltage at zero load and at balanced rated output capacity 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 of the fundamental at rated output capacity. Each engine-generator shall be designed and configured to meet the total

SECTION 26 32 15.00 10 Page 22 harmonic distortion limits of IEEE 519.

2.17 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.

2.18 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 of the rated voltage over the steady state load range of 0 to 100 percent of rated output capacity. Regulation drift shall not exceed plus or minus 0.5 percent for an ambient temperature change of 68 degrees F. Reactive droop compensation or reactive differential compensation shall load share the reactive load proportionally between sets during parallel operation. 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.

2.19…