A22_W912EK25R0021_AMD_0002.pdf

W912EK25R0021

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print)

30-105-04EXCEPTION TO SF 30

APPROVED BY OIRM 11-84

STANDARD FORM 30 (Rev. 10-83) Prescribed by GSA

FAR (48 CFR) 53.243

Adding customer provided specif ications. Solicitation due date is hereby extended. Proposals are due 10 June 2025 at 2:00 p.m. CST. All other terms and conditions herein remain the same.

1. CONTRACT ID CODE PAGE OF PAGES

J 1 31

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

16C. DATE SIGNED

BY 03-Jun-2025

16B. UNITED STATES OF AMERICA15C. DATE SIGNED15B. CONTRACTOR/OFFEROR

(Signature of Contracting Officer)(Signature of person authorized to sign)

8. NAME AND ADDRESS OF CONTRACTOR (No., Street , County, State and Zip Code) X W912EK25R0021

X 9B. DATED (SEE ITEM 11)

22-May-2025

10B. DATED (SEE ITEM 13)

9A. AMENDMENT OF SOLICITATION NO.

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

X The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offer X is extended, is not extended.

Offer must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended by one of the following methods:

(a) By completing Items 8 and 15, and returning 1 copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN

REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required)

13. THIS ITEM APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE

CONTRACT ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(B).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

10A. MOD. OF CONTRACT/ORDER NO.

2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO.(If applicable)

6. ISSUED BY

3. EFFECTIVE DATE

03-Jun-2025

CODE

CONTRACTING DIVISION

US ARMY CORPS OF ENGINEERS 1500 ROCK ISLAND D

ROCK ISLAND IL 61201

W912EK 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

SECTION SF 30 - BLOCK 14 CONTINUATION PAGE

The following have been added by full text:

SPECIFICATIONS

SECTION 26 32 15

ENGINE-GENERATOR SET STATIONARY 15-2500 KW, WITH AUXILIARIES

05/20

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 SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B16.1 (2020) Gray Iron Pipe Flanges and Flanged

Fittings Classes 25, 125, and 250

ASME B16.3 (2021) Malleable Iron Threaded Fittings, Classes 150 and 300

ASME B16.5 (2020) Pipe Flanges and Flanged Fittings

NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME B16.9 (2018) Factory-Made Wrought Buttwelding

Fittings

ASME B16.11 (2022) Forged Fittings, Socket-Welding and Threaded

ASME B16.21 (2021) Nonmetallic Flat Gaskets for Pipe

Flanges

ASME B31.1 (2022) Power Piping

ASME B31.3 (2020) Process Piping

ASME BPVC SEC IX (2017; Errata 2018) BPVC Section

IX-Welding, Brazing and Fusing Qualifications

ASTM INTERNATIONAL (ASTM)

ASTM A53/A53M (2022) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM A106/A106M (2019a) Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service

ASTM A126 (2004; R 2019) Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings

ASTM A181/A181M (2014; R 2020) Standard Specification for Carbon Steel Forgings, for General-Purpose Piping

ASTM A193/A193M (2022a) Standard Specification for

Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A194/A194M (2022) Standard Specification for Carbon

Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

ASTM A234/A234M (2022) Standard Specification for Piping

Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service

ASTM D975 (2020) 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 81 (2012) Guide for Measuring Earth

Resistivity, Ground Impedance, and Earth Surface Potentials of a Ground System

IEEE 100 (2000; Archived) The Authoritative

Dictionary of IEEE Standards Terms

IEEE 115 (2019) 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 519 (2022) Standard for Harmonic Control in Electrical Power Systems

IEEE C50.12 (2005; R 2010) Standard for Salient Pole

50 HZ and 60 Hz Synchronous Generators and Generation/Motors for Hydraulic Turbine

Applications Rated 5 MVA and above

INTERNATIONAL ELECTRICAL TESTING ASSOCIATION (NETA)

NETA ATS (2021) Standard for Acceptance Testing Specifications for Electrical Power Equipment and Systems

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 8528 (1993; R 2018) Reciprocating Internal

Combustion Engine Driven Alternating Current Generator Sets--Part 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 13

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-58 (2018) Pipe Hangers and Supports -

Materials, Design and Manufacture, Selection, Application, and Installation

MSS SP-70 (2011) Gray Iron Gate Valves, Flanged and

Threaded Ends

MSS SP-71 (2018) Gray Iron Swing Check Valves, Flanged and Threaded Ends

MSS SP-80 (2019) Bronze Gate, Globe, Angle and Check

Valves

MSS SP-85 (2011) Gray Iron Globe & Angle Valves Flanged and Threaded Ends

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2020) Enclosures for Electrical Equipment

(1000 Volts Maximum)

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

NEMA MG 1 (2021) Motors and Generators

NEMA/ANSI C12.11 (2006; R 2019) 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 30 (2021; TIA 20-1; TIA 20-2; TIA 21-3)

Flammable and Combustible Liquids Code

NFPA 37 (2021) Standard for the Installation and Use of Stationary Combustion Engines and Gas Turbines

NFPA 54 (2021) National Fuel Gas Code

NFPA 58 (2020; TIA 20-1; TIA 20-2; TIA 20-3)

Liquefied Petroleum Gas Code

NFPA 70 (2023) National Electrical Code

NFPA 110

(2022) Standard for Emergency and Standby Power Systems

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE ARP892 (1965; R 1994) DC Starter-Generator, Engine

SAE J537 (2016) Storage Batteries

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 2021) UL Standard for

Safety Steel Aboveground Tanks for Flammable and Combustible Liquids

UL 467 (2022) UL Standard for Safety Grounding and Bonding Equipment

UL 489 (2016; Rev 2019) UL Standard for Safety Molded-Case Circuit Breakers, Molded-Case Switches and Circuit-Breaker Enclosures

UL 1236 (2015; Reprint Feb 2021) UL Standard for Safety Battery Chargers for Charging Engine-Starter Batteries

UL 1437 (2006) Electrical Analog Instruments

- Panel Board Types

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 that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Engine-Generator Set and Auxiliary Equipment; G EC-D Auxiliary Systems; G EC-D Detailed Drawings; G EC-D

SD-03 Product Data

Engine-Generator Set Efficiencies; G EC-D Emissions; G EC-D Filters; G Special Tools; G Remote Alarm Annunciator; G EC-D

Heat Exchanger Generator

Vibration-Isolation Instructions; G EC-D

General Installation SD-

05 Design Data Performance Criteria Sound Limitations; G EC-D Integral Main Fuel Storage Tank Power Factor

Heat Exchanger

Time-Delay on Alarms Cooling System Vibration Isolation Battery Charger

SD-06 Test Reports

Maintenance Procedures; G EC-D Operation and Maintenance Manuals; G SD-07 Certificates

Engine Emission Limits; G EC-D

SD-09 Manufacturer's Field Reports

Assembled Engine-Generator Set Tests; G EC-D SD-10 Operation and Maintenance Data

Preliminary Assembled Operation and Maintenance Manuals; G

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 must also conform to the code.

1.3.2 Vibration Limitation

Limit the maximum engine-generator set vibration in the horizontal, vertical, and axial directions to 6 mils (peak-peak RMS), with an overall velocity limit of 0.95 inches/second RMS, at rated speed for all loads through 110 percent of rated speed. The engine-generator set must be provided with vibration isolation in accordance with the manufacturer's standard recommendation. Where the vibration isolation system does not secure the base to the structure floor or unit foundation, provide seismic restraints in accordance with the seismic parameters specified.

1.3.3 Torsional Analysis

Submit torsional analysis including prototype testing or 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, plus/minus 10 percent.

1.3.4 Performance Data

Submit vibration isolation system performance data for the range of frequencies generated by the engine-generator set during operation from no load to full load and the maximum vibration transmitted to the floor.

Also submit a description of seismic qualification of the engine-generator mounting, base, and vibration isolation.

1.3.5 Experience

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

1.3.6 Field Engineer

The engine-generator set manufacturer or assembler must 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. The field engineer must have attended the engine generator manufacturer's training courses on installation and operation and maintenance of engine generator sets. Submit a letter listing the qualifications, schools, formal training, and experience of the field engineer.

1.3.7 Detailed Drawings

Submit detailed drawings showing the following:

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

b. Starting system.

c. Fuel system.

d. Cooling system.

e. Exhaust system.

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

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

h. Location, type, and description of vibration isolation devices for all applications.

i. The safety system, including wiring schematics.

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

k. Panel layouts.

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

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

1.3.8 Auxiliary Systems Engine-Generator Set and Auxiliary Equipment Drawing Requirements

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 sub-base.

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 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, fuel day tanks, fuel oil cooler, valves and pumps, intake filters, vibration isolators, and other auxiliary equipment not integral with the engine-generator set.

1.3.9 Auxiliary Systems Drawing Requirements

Submit drawings showing floor plan arrangement of exhaust, air intake, fuel oil cooler, and jacket coolant water systems including arrangement of piping and pipe sizes.

1.3.10 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 "Vibration Isolation."

1.3.11 Fuel System Certification

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

1.4 DELIVERY, STORAGE, AND HANDLING

Properly protect materials 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, cap piping and similar openings to keep out dirt and other foreign matter. Deliver equipment on pallets or blocking wrapped in heavy-duty plastic, sealed to protect parts and assemblies from moisture and dirt. 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.

1.5 EXTRA MATERIALS

Provide two sets of special tools and two sets of filters required for maintenance. Special tools are those that only the manufacturer provides, for special purposes, or to reach otherwise inaccessible parts.

One handset must be provided for each electronic governor when required to indicate and/or change governor response settings. Furnish 4 liters one gallon of identical paint used on engine-generator set in manufacturer's sealed container with each engine-generator set. Wrenches and tools specifically designed and required to work on the new equipment, which are not commercially available as standard mechanic's tools, must be furnished to the Contracting Officer. Provide proposed operating instructions for the engine-generator set and auxiliary equipment laminated between matte-surface thermoplastic sheets and suitable for placement adjacent to corresponding equipment. After approval, install operating instructions where directed.

1.6 MAINTENANCE SERVICES

Submit the operation and maintenance manuals and have them approved prior to commencing onsite tests.

1.6.1 Operation Manual

Provide three copies of the manufacturers standard operation manual in 8-1/2 by 11 inch three-ring binders. Sections must be separated by heavy plastic dividers with tabs which identify the material in the section.

Fold drawings with the title block visible, and placed in 8-1/2 by 11 inch plastic pockets with reinforced holes. The manual must include:

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

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

c. Procedures for interface and interaction with related systems to include automatic transfer switches.

1.6.2 Maintenance Manual

Provide three copies of the manufacturers standard maintenance manual in 8-1/2 x 11 inch three-ring binders. Separate each section by a heavy plastic divider with tabs. Fold drawings with the title block visible, and placed in plastic pockets with reinforced holes. The manual must include:

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

b. The manufacturer's recommended maintenance schedule.

c. A component list which includes the manufacturer's name, address, type or style, model or serial number, rating, and catalog number for the major components.

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

1.6.3 Assembled Operation and Maintenance Manuals

The contents of the assembled operation and maintenance manuals must include the manufacturer's O&M information required by the paragraph SD-10, OPERATION AND MAINTENANCE DATA and the manufacturer's O&M information specified in Section 26 36 23 AUTOMATIC TRANSFER SWITCHES.

a. Manuals must be in separate books or volumes, assembled and bound securely in durable, hard covered, water resistant binder, and indexed by major assembly and components in sequential order.

b. A table of contents (index) must be made part of the assembled O&M.

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

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

1.7 SITE CONDITIONS

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

a. Site Location: Starved Rock Lock in weatherproof enclosure

b. Site Elevation: 488 feet above mean sea level.

c. Environmental Conditions: Capacity and design of the air moving equipment and accessories must be suitable for 24-hour full load service and meet the following criteria.

1. Winter Design Temperature: Inside Air Temperature 55 degrees F.

2. Summer Design Temperature: Inside Air Temperature 104 degrees F.

3. Contaminants: Dust.

PART 2 PRODUCTS

2.1 SYSTEM REQUIREMENTS

a. Provide and install 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. Engine-generator set must satisfy the requirements specified in the Engine-Generator Parameter Schedule.

Submit certification that the engine-generator set and cooling system function properly in the ambient temperatures specified.

b. Provide engine-generator set consisting of one engine, one generator, and one exciter mounted, assembled, and aligned on one base; and all other necessary ancillary equipment which may be mounted separately.

Assemble sets having a capacity of 750 kW or smaller and attach to the base prior to shipping. Provide set components that are environmentally suitable for the locations shown and that are the manufacturer's standard product offered in catalogs for commercial or industrial use. Provide a generator strip heater for moisture control when the generator is not operating. Identify any nonstandard products or components and the reason for their use.

2.1.1 Rated Output Capacity

Provide engine-generator set with power equal to the sum of service load plus the machine's efficiency loss and associated ancillary equipment loads. Rated output capacity must also consider engine and/or generator oversizing required to meet requirements in paragraph Engine- Generator Parameter Schedule.

The engine capacity must be based on the following:

a. Engine burning diesel fuel conforming to ASTM D975, Grade 2-D, at an ambient temperature of 85 degrees F. For stationary engines operated in the United States, diesel fuel requirements are found in 40 CFR 60 Subpart IIII.

b. Max Transient Load Step: 463.3SkVA/146.9SkW, Final running load: 511.8 kVA/453.4kW.

c. Engine cooled by a radiator fan mechanically driven by the engine or remote with a motor driven fan.

d. Engine cooled by coolant mixture of water and ethylene glycol, 50 percent by volume of each.

2.1.1.1 Engine Emission Limits

Engine must be certified by the manufacturer to meet applicable EPA emission standards found in 40 CFR 60 Subpart IIII. In addition, engine must meet any applicable state or local emission requirements (ex: California SCAQMD).

2.1.1.2 Performance Class

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

2.1.2 Power Ratings

Power ratings must be in accordance with EGSA 101P.

2.1.3 Transient Response

The engine-generator set governor and voltage regulator must 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 operational bandwidth within the transient recovery time. The engine-generator set must respond to maximum step load changes such that the maximum voltage and frequency deviations from bandwidth are not exceeded.

2.1.4 Vibration Isolation

Provide an engine-generator set 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, plus 10 percent. Design and qualify vibration isolation systems 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, provide seismic restraints in accordance with the seismic parameters specified.

2.1.5 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 (10 seconds).

2.2 NAMEPLATES

Provide the manufacturer's name, type or style, model or serial number and rating on a plate secured to the equipment for each major component of this specification. Provide plates and tags sized so that inscription is readily legible to operating or maintenance personnel and securely mounted to or attached in proximity of their identified controls or equipment.

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

As a minimum, provide nameplates for:

Engines Generators Regulators

Pumps and pump motors Governors Generator Breaker Economizers

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

Battery charger Heaters

Exhaust mufflers Silencers

Battery Exciters

2.2.1 Materials

Construct ID plates and tags of 16 gage minimum thickness bronze or stainless steel sheet metal engraved or stamped with inscription.

Construct plates and tags not exposed to the weather or high operational temperature of the engine of laminated plastic, 0.125 inch thick, matte white finish with black center core, with lettering accurately aligned and engraved into the core.

2.2.2 Control Devices and Operation Indicators

Provide ID plates or tags for control devices and operation indicators, including valves, off-on switches, visual alarm annunciators, gages and thermometers, that are required for operation and maintenance of provided mechanical systems. Plates or tags must be minimum of 0.5 inch high and 2 inches long and must indicate component system and component function.

2.2.3 Equipment

Provide ID plates of a minimum size of 0.5 inches high and 5 inches long on provided equipment indicating the following information:

a. Manufacturer's name, address, type and model number, serial number, and certificate of compliance with applicable EPA mission standards;

b. Contract number and accepted date;

c. Capacity or size;

d. System in which installed; and

e. System which it controls.

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 must be insulated, fully enclosed, guarded, or fitted with other types of safety devices. Install safety devices such that proper operation of the equipment is not impaired.

2.4 MATERIALS AND EQUIPMENT

Submit certification stating that where materials or equipment are 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 Circuit Breakers, Low Voltage

UL 489, Electronic trip, Generator circuit breakers must be same manufacture as distribution equipment.

2.4.2 Filter Elements

Provide the manufacturer's standard fuel-oil, lubricating-oil, and combustion-air filter elements.

2.4.3 Instrument Transformers

NEMA/ANSI C12.11.

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 must be Schedule 80. Pipe 2 inches and larger must 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.

2.5 ENGINE

Engine must operate on No. 2-D diesel fuel conforming to ASTM D975, must be designed for stationary applications and must be complete with ancillaries. The engine must 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 must be naturally aspirated, supercharged, or turbocharged. The engine must be 4-stroke-cycle and compression-ignition type. The engine must be vertical in-line, V- or opposed-piston type, with a solid cast block or individually cast cylinders. The engine must have a minimum of two cylinders.

Opposed-piston type engines must have more than four cylinders.

Each block must have a coolant drain port. Equip each engine with an over-speed sensor.

2.5.1 Sub-base Mounting

Mount engine-generator set on a structural steel sub-base sized to support the engine, generator, and necessary accessories, auxiliaries and control equipment to produce a complete self-contained unit as standard with the manufacturer. Design the structural sub-base to properly support the equipment and maintain proper alignment of the engine-generator set in the specified seismic zone. In addition, provide sub-base with both lifting rings and jacking pads properly located to facilitate shipping and installation of the unit. Factory align engine and generator on the sub-base and securely bolt into place in accordance with the manufacturer's standard practice. Crankshaft must have rigid coupling for connection to the generator.

2.5.2 Assembly

Completely shop assemble each engine-generator set on its structural steel sub-base. Paint entire unit with manufacturer's standard paints and colors. After factory tests and before shipping, thoroughly clean and retouch painting as necessary to provide complete protection.

2.5.3 Turbocharger

If required by the manufacturer to meet the engine-generator set rating, provide turbine type driven by exhaust gas from engine cylinders, and direct connected to the blower supplying air to the engine intake manifold.

2.5.4 Intercooler

Provide manufacturer's standard intercooler for engine size specified.

2.5.5 Miscellaneous Engine Accessories

Provide the following engine accessories where the manufacturer's standard design permits:

a. Piping on engine to inlet and outlet connections, including nonstandard companion flanges.

b. Structural steel sub-base and vibration isolators, foundation bolts, nuts, and pipe sleeves.

c. Level jack screws or shims, as required.

d. Rails, chocks, and shims for installation of sub-base on the foundation.

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

2.5.6 Intercooler

Provide manufacturer's standard intercooler for engine size specified.

2.6 FUEL SYSTEM

Provide fuel system conforming to the requirements of NFPA 30 and NFPA 37 and containing the following elements.

2.6.1 Fuel Filter

Provide a minimum of one full-flow fuel filter for each engine. The filter must be readily accessible and capable of being changed without disconnecting the piping or disturbing other components. Mark the inlet and outlet connections of the filter. Provide intake filter assemblies for each engine of the oil bath or dry type, as standard with the manufacturer. Filters must be capable of removing a minimum of 92 percent of dirt and abrasive 3 microns and larger from intake air. Size filters to suit engine requirements at 100 percent of rated full load. Design unit for field access for maintenance purposes.

2.6.2 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.

2.6.3 Integral Main Fuel Storage Tank

Provide engine with an integral main fuel tank. Each tank must be factory installed and provided as an integral part of the generator manufacturer's product. Provide each tank with connections for fuel supply line, fuel return line, local fuel fill port, gauge, vent line, and float switch assembly. Provide a fuel return line cooler as recommended by the manufacturer and assembler. The temperature of the fuel returning to the tank must be below the flash point of the fuel. Mount the tank within the enclosure for each engine-generator set provided with weatherproof enclosures. The fuel fill line must be accessible without opening the enclosure.

a. All Tanks: Must be in accordance with UL 142. Provide integral in skid double wall (110 percent containment) fuel tanks with a minimum capacity of 1,200 gallons. Epoxy coat day tanks inside and prime and paint outside. Construct tanks of not less than 3/16 inch steel plate with welded joints and necessary stiffeners on exterior of tank.

Provide a braced structural steel framework support. Weld tank top tight. Provide 4-1/2 inch square inspection port with a 2 inch NPT fill connection and spill box. Provide proper normal and emergency venting for the primary tank and emergency venting only for the secondary tank / containment basin in accordance with UL 142 requirements.

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

c. Control Panel for All Tanks: Provide NEMA ICS 6, Type 1, enclosed control panel for each day tank. Control panel must include the following accessories.

(1) Power available LED (green).

(2) Critical low fuel alarm contacts for shut down of engine.

(3) Low-low level fuel alarm LED.

(4) Low-low level fuel alarm contracts for remote annunciator.

(5) Critical high level fuel alarm LED.

(6) Leak detecting alarm LED.

(7) Alarm horn.

d. Tank Gages for All Tanks: Provide buoyant force type gages for fuel tanks with dial indicator not less than 4 inches in size and arranged for top mounting. Calibrate each reading dial or scale for its specific tank to read from empty to full, with intermediate points of 1/4, 1/2, and 3/4.

e. Integral Base Tanks Used as Primary Tank: Provide a 2 inch opening at the tank fill port, fitted an overfill prevention valve (OPV).

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

f. Integral Base Tanks Located Inside Buildings. The tank vents must discharge outside the building in accordance with NFPA 30 and NFPA 37.

The fill pipe must terminate outside the building. The fill pipe connection point must be housed in a sealed spill box. High level alarms or level gauges used as overfill protection mechanisms must annunciate at the fill connection point. Provide an overfill prevention valve (OPV) at the tank with a check valve mounted on the fill line in the spill box. The fill connection point must be labeled with tank contents and capacity.

2.6.3.1 Capacity

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

2.6.3.2 Local Fuel Fill

Each local fuel fill port on the base tank must have a cap that can be padlocked.

2.6.3.3 Fuel Level Controls

Provide tanks with 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.

2.6.3.4 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 must have an internal or external factory installed valve located as near as possible to the shell of the tank. The valve must close when the engine is not operating. Provide integral day tanks 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 must be welded pipe.

2.6.4 Strainer

Provide simplex strainers.

2.6.5 Fuel Oil Cooler

Provide an air cooled fuel oil cooler if the temperature of the fuel returned to the tank from the engine will cause overheating of the tank fuel above the maximum fuel temperature allowed by the engine manufacturer when operating at maximum rated generator power output and low fuel level in the tank. The fuel oil cooler must be furnished by the engine manufacturer for the application and the installation must be complete including piping and power requirements.

2.7 LUBRICATION

Provide engine with a separate lube-oil system conforming to NFPA 30 and NFPA 37. Pressurize each system by engine-driven pumps. Regulate system pressure as recommended by the engine manufacturer. Provide a pressure relief valve on the crankcase for closed systems. Vent the crankcase in accordance with the manufacturer's recommendation. Do not vent the crankcase to the engine exhaust system. Crankcase breathers, if provided on engines installed in buildings or enclosures, must be piped to vent to the outside. The system must be readily accessible for service such as draining, refilling, etc. Each system must permit addition of oil and have oil-level indication with the set operating. The system must utilize an oil cooler as recommended by the engine manufacturer.

2.7.1 Lube-Oil Filter

Provide one full-flow filter for each pump. The filter must be readily accessible and capable of being changed without disconnecting the piping or disturbing other components. Mark inlet and outlet connections.

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. Provide these filters 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 engine with its own cooling system to operate automatically while its engine is running. The cooling system coolant must 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 must 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 through the engine.

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

d. The minimum allowable inlet fuel temperature.

2.8.1 Coolant Pumps

Provide centrifugal coolant pumps. Each engine must have an engine-driven primary pump. Provide secondary pumps that are electric motor driven and have automatic controllers.

2.8.2 Heat Exchanger

Provide heat exchanger with the 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. Provide heat exchangers that are 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 corrosion resistant film, provided that corrective measures are taken to restore the heat rejection capability of the radiator to the initial design requirement via over sizing, or other compensating methods. Provide internal surfaces that are compatible with liquid fluid coolant used. Materials and coolant are subject to approval by the Contracting Officer. Provide heat exchangers that are pressure type incorporating a pressure valve, vacuum valve and a cap. Design caps for pressure relief prior to removal. Provide heat exchanger and cooling system that is capable of withstanding a minimum pressure of 7 psi and protect with a strong grille or screen guard.

Provide heat exchanger with at least two tapped holes; equip one tapped hole with a drain cock, and plug the rest. Field installed jacket coolant water piping must conform to the following:

a. Piping: Provide seamless steel pipe, Schedule 40, conforming to

ASTM A53/A53M, Grade A.

b. Fittings and Flanges: Fittings, 1 1/2 inches or smaller, must be malleable iron conforming to ASME B16.3 for Class 300 threaded type.

Fittings, 2 inches and larger, must be steel butt welding conforming to ASME B16.9. Utilize either ASME B16.1 or Class A of ASTM A126 for Class 125 cast-iron flanged fittings. Flanges must be Class 150 slip-on forged steel welding flanges in accordance with ASME B16.5, with material in accordance with ASTM A181/A181M, Grade I. Provide flat face flanges for connecting to Class 125 standard cast-iron valves, fittings, and equipment connections.

c. Valves

(1) Gate Valves: For valves, 1 1/2 inches and smaller, provide double disk, rising stem, inside screw, union bonnet type, Class 125 bronze material conforming to MSS SP-80. For valves, 2 inches and larger, provide double-disk, parallel seat type, hydraulic-rated, Class 125, outside screw and yoke type with flanged ends and bronze trim conforming to MSS SP-70.

Provide stem packing of material compatible with the system coolant.

(2) Globe Valves: For valves, 1 1/2 inches and smaller, provide rising stem, inside screw, union bonnet type, Class 125 bronze valves conforming to MSS SP-80. For valves, 2 inches and larger, provide Class 125 cast iron, flanged ends, bronze trim globe valves conforming to MSS SP-85. Valves must have renewable composition or cast iron discs compatible with the system coolant.

(3) Check Valves: MSS SP-71 or MSS SP-80, swing check type.

d. Hangers and Supports: MSS SP-58.

e. Piping Sleeves: Provide where piping passes through masonry or concrete walls, floors, roofs, and partitions. Place sleeves during construction. Unless indicated otherwise, pipe sleeves must comply with following requirements: Sleeves in outside walls below and above grade, in floor, or in roof slabs, must be standard weight zinc coated steel pipe. Sleeves in partitions must be zinc coated sheet steel having a nominal weight of not less than 0.90 pound per square foot.

Space between piping insulation and the sleeve must be not less than

0.25 inch. Sleeves must be held securely in proper position and location during construction. Sleeves must be of sufficient length to pass through entire thickness of walls, partitions, or slabs.

Sleeves in floor slabs must extend 2 inches above the finished floor.

Space between the pipe and the sleeve must be firmly packed with insulation and caulked at both ends of the sleeve with plastic waterproof cement.

2.8.3 Thermostatic Control Valve

Provide a modulating type, thermostatic control valve in the coolant system to maintain the coolant temperature range submitted in paragraph

SUBMITTALS.

2.8.4 Temperature Sensors

Equip each engine with coolant temperature sensors. Provide temperature sensors with 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. Do 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 at 45 degrees apart in all directions when operating at 100 percent load.

Frequency Band (Hz)

Maximum Acceptable Sound Level (Decibels)

31 87

63 77

125 70

250 64

500 61

1,000 60

2,000 60

4,000 60

8,000 62

2.10 AIR INTAKE EQUIPMENT

Locate filters and silencers in locations that are convenient for servicing. Provide high-frequency filter type silencers and locate in the air intake system as recommended by the engine manufacturer. Provide silencer to reduce 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. Provide rubber expansion elements in air-intake lines.

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

2.11 EXHAUST SYSTEM

Provide a separate and complete system for each engine. Support piping to minimize vibration. Where a V-type engine is provided, use a V-type connector, with necessary flexible sections and hardware, to connect the engine exhaust outlets.

2.11.1 Flexible Sections and Expansion Joints

Provide a flexible section at each engine and an expansion joint at each muffler. Provide flexible sections and expansion joints that have flanged connections. Provide flexible sections made of convoluted seamless tube without joints or packing. Provide bellows type expansion joints.

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

2.11.2 Exhaust Muffler

Provide a chamber type exhaust muffler. Provide welded steel muffler designed for inside horizontal mounting. Provide eyebolts, lugs, flanges, or other items as necessary for support in the location and position indicated. Do not exceed the engine manufacturer's recommended pressure drop. Outside mufflers must be zinc coated or painted with high temperature 400 degrees F resisting paint. The muffler and exhaust piping together must reduce the noise level to less than the maximum acceptable level listed for sound limitations in paragraph SOUND LIMITATIONS.

Provide muffler with a drain valve, nipple, and cap at the low-point of the muffler.

2.11.3 Exhaust Piping

Slope horizontal sections of exhaust piping downward away from the engine to a drip leg for collection of condensate with drain valve and cap.

Changes in direction must be long radius. Insulate exhaust piping, mufflers and silencers installed inside any building in accordance with paragraph THERMAL INSULATION and covered to protect personnel. Provide vertical exhaust piping with a hinged, gravity-operated, self-closing, rain cover. Field installed exhaust piping must conform to the following:

a. Exhaust Piping: Provide flanges for connections to engines, exhaust mufflers, and flexible connections. Provide steel pipe conforming to ASTM A53/A53M for each engine complete with necessary fittings, flanges, gaskets, bolts, and nuts. Exhaust piping must be Schedule 40 pipe for 12 inches and smaller, standard weight for sizes 14 inches through 24 inches, and 0.25 inch wall thickness for sizes larger than 24 inches. Flanges must be Class 150 slip-on forged steel welding flanges in accordance with ASME B16.5, with material in accordance with ASTM A181/A181M, Grade I. Fittings must be butt welding conforming to ASTM A234/A234M, with wall thickness same as adjoining piping. Fittings must be of same material and wall thickness as pipe. Built-up miter welded fittings may be used. Miter angles of each individual section must not exceed 22.5 degrees total and not more than 11.25 degrees relative to the axis of the pipe at any one cut. Gaskets for exhaust piping must be of high temperature asbestos-free material suitable for the service and must be ASME B16.21, composition ring, 0.0625 inch thick. Bolting material for exhaust flanges must be alloy-steel bolt-studs conforming to ASTM A193/A193M, Grade B7 bolts and alloy-steel nuts conforming to ASTM A194/A194M, Grade 7. Bolts must be of sufficient length to obtain full bearing on the nuts and must project not more than two full threads beyond the nut. Provide stainless steel counterbalance type rain caps at termination of each exhaust pipe.

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

c. Hangers and Supports: MSS SP-58.

d. Piping Sleeves: Provide where piping passes through masonry or concrete walls, floors, roofs, and partitions. Sleeves must be placed during construction.