W912P523R0004_TSpecs_OLD Intake Crane Replacement_RTA AM0001_25JUL23.pdf

Intake and Spillway Crane Replacement Old Hickory Dam W912P523R0004 Amendment 0001 Hendersonville, TN

PROJECT TABLE OF CONTENTS

DI VI SI ON 01 - GENERAL REQUI REMENTS

01 00 00 GENERAL REQUIREMENTS

01 11 00 SUMMARY OF WORK

01 20 00 PRICE AND PAYMENT PROCEDURES

01 32 01.00 10 PROJECT SCHEDULE

01 33 00 SUBMITTAL PROCEDURES

01 35 26 GOVERNMENTAL SAFETY REQUIREMENTS

01 35 50 PROJECT SITE SECURITY AND AT/OPSEC PROCEDURES

01 42 00 SOURCES FOR REFERENCE PUBLICATIONS

01 45 00.00 10 QUALITY CONTROL

01 45 00.15 10 RESIDENT MANAGEMENT SYSTEM CONTRACTOR MODE (RMS CM)

01 57 19 TEMPORARY ENVIRONMENTAL CONTROLS

01 78 00 CLOSEOUT SUBMITTALS

01 78 23 OPERATION AND MAINTENANCE DATA

01 95 00 FORMS AND ATTACHMENTS

DI VI SI ON 02 - EXI STI NG CONDI TI ONS

02 41 00 DECONSTRUCTION

02 41 16.00 26 EXISTING CRANE DEMOLITION ACTIVITIES

02 82 00 ASBESTOS REMEDIATION

02 83 00 LEAD REMEDIATION

DI VI SI ON 03 - CONCRETE

03 60 00.01 26 CONCRETE DEMOLITION, REPAIR OF CONCRETE SURFACES, AND

MINOR EQUIPMENT FOUNDATIONS

DI VI SI ON 05 - METALS

05 05 23.17 26 STEEL WELDING AND FABRICATION

05 50 04.00 26 METALS: MATERIALS, PRODUCTS, AND MISCELLANEOUS ITEMS

DI VI SI ON 09 - FI NI SHES

09 97 02.10 26 PAINTING: STEEL STRUCTURES

DI VI SI ON 13 - SPECI AL CONSTRUCTI ON

13 48 00.00 26 SEISMIC RESTRAINT FOR MECHANICAL AND ELECTRICAL EQUIPMENT

DI VI SI ON 25 - I NTEGRATED AUTOMATI ON

25 05 11.00 26 CYBERSECURITY - CRANE CONTROL SYSTEMS WITH NO EXTERNAL

NETWORK CONNECTION

DI VI SI ON 26 - ELECTRI CAL

26 05 00.01 26 BASIC ELECTRICAL MATERIALS AND METHODS FOR CRANES

26 32 15.00 26 GENERATOR SET

DI VI SI ON 41 - MATERI AL PROCESSI NG AND HANDLI NG EQUI PMENT

41 22 13.71 26 NEW INTAKE GANTRY CRANE DATA, TESTING AND TRAINING

41 22 13.72 26 NEW INTAKE GANTRY CRANE MECHANICAL AND STRUCTURAL WORK

41 22 13.73 26 STRUCTURAL CRANE APPURTENANCES

PROJECT TABLE OF CONTENTS Page 1

41 22 13.74 26 NEW INTAKE GANTRY CRANE ELECTRICAL WORK

41 22 13.75 26 NEW LIFTING BEAM

-- End of Project Table of Contents --

PROJECT TABLE OF CONTENTS Page 2

SECTION TABLE OF CONTENTS

DIVISION 26 - ELECTRICAL

SECTION 26 32 15.00 26

GENERATOR SET

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 GENERAL REQUIREMENTS

1.3.1 Engine-Generator Set

1.3.2 Generator Set Parameter Schedule

1.3.3 Generator Set Enclosure

1.3.4 Sound Limitation Documentation

1.3.5 Personnel Safety Devices

1.3.6 Nameplates

1.4 QUALITY ASSURANCE

1.4.1 Conformance to Codes and Standards

1.4.2 Seismic Requirements

1.4.3 Concrete Repair

1.4.4 Experience

1.4.5 Field Engineer

1.4.6 Detailed Drawings

1.5 DELIVERY, STORAGE, AND HANDLING

1.6 MAINTENANCE SERVICES

1.6.1 Operation Manual

1.6.2 Maintenance Manual

1.6.3 Special Tools

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

2.1.1 General

2.1.2 Filter Elements

2.1.3 Pipe

2.1.4 Pipe Flanges and Fittings

2.1.5 Pipe Hangers

2.1.6 Pressure Gauges

2.1.7 Electric Motors

2.1.8 Electrical Enclosures

2.2 ENGINE

2.3 FUEL SYSTEM

2.4 LUBRICATION

2.5 COOLING SYSTEM

2.5.1 Coolant Pumps

2.5.2 Heat Exchanger (Radiator)

2.5.3 Temperature Sensors

2.6 AIR INTAKE EQUIPMENT

2.7 EXHAUST SYSTEM

2.7.1 General

2.7.2 Flexible Sections and Expansion Joints

SECTION 26 32 15.00 26 Page 1

2.7.3 Exhaust Muffler

2.7.4 Exhaust Piping

2.8 STARTING SYSTEM

2.8.1 Controls

2.8.2 Battery

2.8.3 Battery Charger

2.9 GOVERNOR

2.10 GENERATOR

2.10.1 Current Balance

2.10.2 Voltage Balance

2.10.3 Waveform and Harmonic Requirements

2.11 EXCITER

2.12 VOLTAGE REGULATOR

2.13 GENERATOR PROTECTION

2.13.1 Short Circuit and Overload Protection

2.13.2 Ground Fault Detection

2.14 PANELS

2.14.1 General

2.14.2 Analog

2.14.3 Electronic

2.15 GENERATOR SET CONTROLS AND INSTRUMENTATION

2.15.1 General

2.15.2 Local Control Panel

2.15.3 Remote (Operator Cab) Control Panel

2.16 SURGE PROTECTION

2.17 GENERATOR SET MOUNTING BASE

2.18 PAINTING AND FINISHING

2.19 SAFETY SYSTEM

2.19.1 AUDIBLE SIGNAL

2.20 LOAD BANK

2.20.1 Material And Construction

2.20.2 Resistive Load Elements

2.20.3 Cooling

2.20.4 Protective Devices

2.20.5 Control Panel

2.21 EMISSIONS

2.22 STARTING AIDS

2.22.1 Glow Plugs

2.22.2 Jacket-Coolant Heaters

2.22.3 Lubricating-Oil Heaters

2.23 FACTORY INSPECTION AND TESTS

PART 3 EXECUTION

3.1 FACTORY INSPECTION AND TESTS

3.1.1 General

3.1.2 Routine Tests

3.1.3 Additional Tests

3.2 EQUIPMENT INSTALLATION

3.3 PIPING INSTALLATION

3.4 ELECTRICAL INSTALLATION

3.5 OPERATION AND MAINTENANCE INSTRUCTIONS

3.6 ONSITE TRAINING

3.7 ONSITE INSPECTION AND TESTS

3.7.1 Test Conditions

3.7.1.1 Data

3.7.1.2 Contractor Supplied Items

3.7.2 Piping Tests

3.7.3 Electrical Equipment Tests

SECTION 26 32 15.00 26 Page 2

3.7.4 Inspections

3.7.5 Insulation Test

3.7.6 Safety Run Test

3.7.7 Frequency and Voltage Stability and Transient Response

3.7.8 Load Step Test

3.7.9 Performance and Commissioning Tests

3.8 POSTED DATA AND INSTRUCTIONS

3.9 ACCEPTANCE

-- End of Section Table of Contents --

SECTION 26 32 15.00 26 Page 3

THIS PAGE INTENTIONALLY LEFT BLANK

SECTION 26 32 15.00 26 Page 4

SECTION 26 32 15.00 26

GENERATOR SET

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

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

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

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 A135/A135M (2009; R2014) Standard Specification for Electric-Resistance-Welded Steel Pipe

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

ASTM A234/A234M (2022) Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service

ASTM A463/A463M (2010; R 2015) Standard Specification for Steel Sheet, Aluminum-Coated, by the Hot-Dip Process

ASTM D975 (2020) Standard Specification for Diesel Fuel Oils

SECTION 26 32 15.00 26 Page 5

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

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

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

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

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 C2 (2023) National Electrical Safety Code

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

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 2 (2000; R 2020) 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 (2021) Motors and Generators

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

Liquefied Petroleum Gas Code

NFPA 70 (2023) National Electrical Code

SECTION 26 32 15.00 26 Page 6

U.S. DEPARTMENT OF DEFENSE (DOD)

UFC 3-301-01 (2019, with Change 1, 2022) Structural Engineering

UNDERWRITERS LABORATORIES (UL)

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 2200 (1998) Stationary Engine Generator Assemblies

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. The following must be submitted in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Experience; G, HDC

Field Engineer; G, HDC

SD-02 Shop Drawings

Detailed Drawings; G HDC

SD-03 Product Data

Manufacturer's Catalog; G HDC

Maintenance Data; G, HDC

Special Tools; G, HDC

Installation Procedures; G, HDC

Spare Parts; G, HDC

SD-05 Design Data

Calculations; G HDC

Sound Limitation Data; G HDC

Fuel Tank; G HDC

Harmonic Requirements; G HDC

SECTION 26 32 15.00 26 Page 7

Power Factor; G, HDC

Battery Charger; G HDC

SD-06 Test Reports

Factory Inspection and Tests; G, HDC

Procedures For Onsite Tests; G, HDC

Onsite Inspection and Tests Report; G HDC

SD-07 Certificates

Emissions

Sound Limitation Certification

Materials And Equipment

Inspections

SD-11 Closeout Submittals

Posted Data and Instructions; G HDC

1.3 GENERAL REQUIREMENTS

1.3.1 Engine-Generator Set

a. The generator set will be a crane power source, used to power all hoists, trolleys, gantry drive, and all lights and incidental electrical equipment and devices forming a part of the crane power and control systems. Install the generator in the parking lot near the service bay, as directed by the COR. The generator must be clear of any objects that will contact the generator as well as maintain electrical clearances for safety and maintenance access. Submit calculations under these conditions and size the generator set accordingly. Include in the calculations the engine and generator output power capability, including efficiency and parasitic load data.

b. The generator set and its components must be standard units manufactured by reputable manufacturers; as defined as being a manufacturer regularly engaged in the design, manufacturing and testing of diesel engine generators. The complete generator set must be Listed to UL 2200 . The generator set is to consist 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. Set must be assembled and attached to the base prior to shipping. Set components must be environmentally suitable for outdoor application and be the manufacturer's standard product as evidenced by previously published catalog data. Provide anti-condensation heaters for moisture control, and other loads necessary to enable the generator to start in all conditions must be provided. These loads are to be supplied shore power via the overhead conductor system when the generator is not operating.

SECTION 26 32 15.00 26 Page 8

1.3.2 Generator Set Parameter Schedule

Power Rating...................... Emergency Standby Power Fuel Type......................... No. 2 Diesel

Power Factor...................... 0.8 lagging Application....................... Stand-alone Max Time to Start and be Ready to Assume Load.........................10 seconds Heat Exchanger Type............... Fin-tube (radiator) Starting System................... Battery Governor Type..................... Isochronous Frequency Bandwidth (steady state).................... +/- 0.25 % Voltage Regulation (no load to full load)............ +/- 1.0 % (maximum) Voltage Bandwidth (steady state).................... +/- 1.0 % Frequency......................... 60 Hz Voltage........................... 480 volts Phases............................ 3 phase, 4 wire Excitation Type................... PMG/Brushless Min Winter Outdoor Temperature (Ambient)......................... -10 degrees F Max Summer Outdoor Temperature (Ambient)......................... 115 degrees F Installation Elevation............ 450 ft above sea level Maximum Step Load Increase........ 100% of full load

Include in the Power Factor submittal, the generator capability curve showing generator kVA output capability (kW vs. kvar) for both leading and lagging power factors ranging from 0 to 1.0.

1.3.3 Generator Set Enclosure

Provide the generator set with a sound-attenuating and fully corrosion-and weather-resistant enclosure rated a minimum of NEMA 3R, with all louvering located on the side facing upstream. The enclosure must contain all generator set components. Provide doors for access to all controls and equipment requiring periodic maintenance or adjustment. Provide removable and gasketed panels for access to components requiring periodic replacement. The enclosure must be capable of being removed without disassembly of the generator set or removal of components other than exhaust system.

1.3.4 Sound Limitation Documentation

Submit Sound limitation data. Include data sound power level data for the packaged unit operating at 100 percent load in a free field environment.

Data must demonstrate compliance with sound limitation requirements.

Sound limitations for the enclosure must reduce the noise of the generator set to a sound pressure level of 75 dB when measured at a radius of 25 feet from the engine at 45 degrees apart in all directions, when operating at 100 percent rated load. Submit Sound Limitation Certification from the manufacturer stating that the sound emissions meet the specification as installed.

SECTION 26 32 15.00 26 Page 9

1.3.5 Personnel 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 during normal operation must be insulated, fully enclosed, guarded, or fitted with other types of safety devices. The safety devices must be installed so that proper operation of the equipment is not impaired.

1.3.6 Nameplates

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

engines, relays, generators, fuel tanks, transformers (CT & PT), regulators, pumps and pump motors, governors, generator breaker, economizers, heat exchangers, and load bank. Where the following equipment is provided as a standard component by the generator set manufacturer, the nameplate information may be provided in the maintenance manual in lieu of nameplates:

Battery charger Heaters Exhaust muffler Exciter Silencer Battery

1.4 QUALITY ASSURANCE

1.4.1 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.

1.4.2 Seismic Requirements

Seismic requirements must be in accordance with UFC 3-301-01 and Section

13 48 00.00 26 SEISMIC RESTRAINT FOR MECHANICAL AND ELECTRICAL EQUIPMENT.

1.4.3 Concrete Repair

Any concrete surfaces in the parking lot that are damaged during the installation of the diesel generator must be repaired in accordance with

03 60 00.01 26 CONCRETE DEMOLITION, REPAIR OF CONCRETE SURFACES, AND MINOR

EQUIPMENT FOUNDATIONS.

1.4.4 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.

1.4.5 Field Engineer

The engine-generator set manufacturer or assembler must furnish a qualified field engineer to supervise the complete installation of the

SECTION 26 32 15.00 26 Page 10 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.

1.4.6 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. 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, 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.

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

1.6 MAINTENANCE SERVICES

Furnish Operation and Maintenance (O&M) Manuals in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES and SECTION 01 78 23 OPERATION AND

MAINTENANCE DATA.

SECTION 26 32 15.00 26 Page 11

1.6.1 Operation Manual

The manufacturer's standard operation 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, time delay on alarms, and safety systems.

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

d. Procedures for load testing the generator with the load bank.

1.6.2 Maintenance Manual

Provide the manufacturers standard maintenance manual per Section 01 78 23 OPERATION AND MAINTENANCE DATA The manual shall 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 listed in paragraph GENERAL REQUIREMENTS.

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 Special Tools

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. Provide an ECU (Engine Control Unit) code reader for the engine, include all software licenses, programming cables and components required to operate the ECU code reader. Provide any O&M specific tools or devices used for the removal or installation of the Exciter. Supply two complete sets of filters in a suitable storage box in addition to filters replaced after testing.

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

2.1.1 General

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

SECTION 26 32 15.00 26 Page 12

2.1.2 Filter Elements

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

2.1.3 Pipe

Pipe for sleeves, fuel/lube-oil, compressed-air, coolant and exhaust must conform to ASTM A53/A53M, ASTM A106/A106M or ASTM A135/A135M , steel pipe.

Pipe smaller than 2 inches must be Schedule 80. Pipe 2 inches and larger must be Schedule 40.

2.1.4 Pipe Flanges and Fittings

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

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

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

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

e. Gaskets: Manufacturers Standard.

2.1.5 Pipe Hangers

Per MSS SP-58 .

2.1.6 Pressure Gauges

Pressure gauges must be the generator set manufacturer's standard.

2.1.7 Electric Motors

Electric motors specific to the generator set (such as those used for lubrication pumps, coolant pump, etc.) must conform to the requirements of NEMA MG 1. Motors must have sealed ball bearings, a maximum speed of 1800 rpm and integral automatic reset thermal overload protectors. Motors must be totally enclosed (TENV or TEFC). Motor controllers and starters specific to the generator set must conform to the requirements of NFPA 70 and NEMA ICS 2 .

2.1.8 Electrical Enclosures

Electrical enclosures mounted on the generator set must conform to applicable requirements of NEMA ICS 6 , having NEMA Type 4 enclosure rating. Electrical enclosures mounted elsewhere on the crane must conform to the applicable Paragraphs of SECTION 26 05 00.01 26 BASIC ELECTRICAL

MATERIALS AND METHODS FOR CRANES.

2.2 ENGINE

The engine must operate on No. 2 Diesel conforming to ASTM D975, be complete with all ancillaries, and be a standard production model described in the manufacturer's catalog. The engine must be turbocharged, four-stroke-cycle, and compression-ignition type. The engine must be

SECTION 26 32 15.00 26 Page 13 vertical inline, V-, or opposed-piston type, with a solid cast block or individually cast cylinders. The rotational speed can not exceed 1,800 rpm and the piston travel speed can not exceed 2,000 fpm. The engine must have a minimum of two cylinders. Opposed-piston type engines must have no less than four cylinders. The block must have a coolant drain port. The engine must be equipped with an overspeed sensor. The manufacturer's net rating of the engine for continuous duty under standard conditions must be equal to or exceed the power required to drive the generator at rated load and speed and capable of handling the highest block load imposed by the crane. The rating of the engine as specified above is to be based on or corrected to standard conditions of operation at 29.92 inches of mercury at an atmospheric temperature of 60 degrees F.Provide an engine block heater to allow quick start during the winter months. The heater must be an electric thermostatically controlled heater, specifically designed for the application.

2.3 FUEL SYSTEM

Supplemental heating is to be provided to ensure proper operation. The fuel system must conform to the requirements of NFPA 30 and NFPA 37 and contain the following elements:

a. Pump. Provide the engine with an engine-driven pump. The pump must supply fuel at a minimum rate sufficient to provide the amount of fuel required to meet the performance as sized by the contractor. The fuel flow rate is to be based on meeting the load requirements and all necessary recirculation.

b. Filters. Provide a minimum of one full-flow duplex fuel filter.

The filters must be readily accessible and capable of being changed without disconnecting the piping or disturbing other components and have inlet and outlet connections plainly marked.

c. Heater. An electric thermostatically controlled, in-line fuel heater must be provided between the fuel tank and the fuel filters and be an off-the-shelf unit, specifically designed for the application.

d. 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.

e. Fuel Tank. The fuel tank must be Listed to UL 142. Fuel tanks must be double wall and have fuel leak monitoring to alarm when leak is detected. Wire the fuel leak alarm to the HMI for display and annunciation. Provide fuel tanks 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.

Install fuel level indicators on the local control panel and remote control panel and show the level of the fuel and when the tank is full. A fuel level indicator is to be readily visible from the fuel port location. The fuel tank must have capacity to supply fuel to the engine for an uninterrupted 12 hour period at 100 percent rated load without being refilled. The location of the tank must be arranged so that the highest elevation of the fuel is below the injectors and the fuel fill port is no higher than 16 feet above the intake deck and located on the downstream side of the fuel tank.

SECTION 26 32 15.00 26 Page 14

f. Fill Nozzle. Fit the fill nozzle with a dust-tight cap and a removable, internal, basket-type screen of 50 mesh or finer and be protected against damage by a heavier wire basket or guard.

g. Drain Line. Tank drain lines must be accessible and equipped with shutoff valves.

2.4 LUBRICATION

The engine must have a lube-oil system conforming to NFPA 30 and NFPA 37 .

The system must be pressurized by an engine-driven oil pump. Furnish the system with a relief valve for oil pressure regulation (for closed systems) and a dip-stick for oil level indications. The crankcase is to be vented in accordance with the manufacturer's recommendation, except that it not be vented to the engine exhaust system. The system must be readily accessible for service such as draining, refilling, etc. Route the oil drain line to the side of generator allowing easy access for draining oil without obstruction during maintenance; the drain line must have a ball valve with plug at the end to allow the line to be positively closed. The 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. 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.

The engine must be equipped with lube-oil pressure sensors. Pressure sensors are to be located downstream of the filters and provide signals for required indication and alarms. Provide a motor-driven precirculation pump powered by the station battery, complete with motor starter, if recommended by the engine manufacturer.

2.5 COOLING SYSTEM

The engine cooling system must operate automatically while the engine is running. The cooling system must have a fill port located on the downstream side of generator allowing easy access for filling the system without obstruction during maintenance; the fill port must have gasket sealed cap. The cooling system must have a drain line routed to the downstream side of generator allowing easy access for draining the system without obstruction during maintenance; the drain line must have a ball valve at the end to allow the line to be closed. The cooling system is to be sized for the maximum summer outdoor design temperature and site elevation. Water-cooled system coolant must use a combination of water and propylene-glycol sufficient for freeze protection to a temperature of -25 degrees F. The maximum temperature rise of the coolant across the engine must be no more than that recommended by the manufacturer.

2.5.1 Coolant Pumps

Coolant pumps must be the centrifugal type, engine-driven or electric motor pump.

2.5.2 Heat Exchanger (Radiator)

The heat exchanger (radiator) must be of the fin-tube-type, and be of a size and capacity to limit the maximum allowable temperature rise in the coolant across the engine to that recommended by the manufacturer for the maximum summer outdoor design temperature and site elevation. The heat exchanger must be corrosion resistant, suitable for service in ambient conditions of application. Heat exchanger may be factory coated with

SECTION 26 32 15.00 26 Page 15 corrosive resistant film providing that correct measures are taken to restore the heat rejection capability of the radiator to the initial design requirement via oversizing, or other compensating methods.

Internal surfaces must be compatible with liquid fluid coolant used.

Materials and coolant are subject to approval by the Contracting Officer.

Heat exchangers must be pressure type incorporating a pressure valve, vacuum valve and a cap. Design Caps for pressure relief prior to removal. The heat exchanger and the entire cooling system must be capable of withstanding a minimum pressure of 7 psi. Protect the heat exchanger with a strong grille or screen guard. The heat exchanger is to have at least two tapped holes. Equip one tapped hole in the heat exchanger with a drain cock, the rest are to be plugged.

2.5.3 Temperature Sensors

The engine must be equipped with coolant temperature sensors. Temperature sensors are to provide signals for pre-high and high indication and alarms.

2.6 AIR INTAKE EQUIPMENT

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

2.7 EXHAUST SYSTEM

2.7.1 General

Exhaust system piping must be supported so as to minimize vibration.

Where a V-type engine is provided, a V-type connector with necessary flexible sections and hardware connect the engine exhaust outlets. The arrangement of the exhaust must be so that hot exhaust will not blow on structural members or other equipment or personnel that may be walking on the stairs.

2.7.2 Flexible Sections and Expansion Joints

Provide a flexible section at the engine and an expansion joint at the muffler. Flexible sections and expansion joints must have flanged connections. Make flexible sections of convoluted seamless tube without joints or packing. Expansion joints must be the bellows type. Expansion and flexible elements must 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 must be capable of absorbing vibration from the engine and compensation for thermal expansion and contraction.

2.7.3 Exhaust Muffler

Provide and Connect a chamber type exhaust muffler to the engine. The muffler must be constructed of welded steel and designed for outside vertical mounting. Provide eyebolts, lugs, flanges, or other items as necessary for support in the location and position indicated. Pressure drop through the muffler must not exceed the recommendations of the engine

SECTION 26 32 15.00 26 Page 16 manufacturer. 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 "Generator Set Enclosure." The muffler must have a drain valve, nipple, and cap at the low-point of the muffler.

2.7.4 Exhaust Piping

Slope horizontal sections of exhaust piping upward away from the engine to a condensate trap and drain valve. Changes in direction must be long-radius. Provide vertical exhaust piping with a hinged, gravity operated, self-closing, rain cover.

2.8 STARTING SYSTEM

2.8.1 Controls

Provide an engine control switch with functions including: manual start/run and off/reset. Provide start-stop logic for adjustable cycle cranking and cool down operation. The logic must be arranged for manual starting. Provide electrical starting systems with an adjustable cranking limit device to limit cranking periods from 1 second up to the maximum duration. The starting system must be of sufficient capacity at the maximum outdoor summer temperature specified to crank the engine without damage or overheating. The system must be capable of providing a minimum of three cranking periods with 15-second intervals between cranks. Each cranking period must have a maximum duration of 15 seconds. Starting system must be manufacturer's recommended dc system utilizing a negative circuit ground.

2.8.2 Battery

Provide a starting battery system including the battery, battery rack, intercell connectors, and spacers. Critical system components (rack, protection, etc.) must be sized to withstand vibration forces available during normal operation. The battery must have sufficient capacity at the minimum outdoor winter temperature specified to provide the specified cranking periods.

2.8.3 Battery Charger

Submit Battery charger sizing calculations for review. Provide a current-limiting battery charger, conforming to UL 1236 to automatically recharge the batteries. The charger must be capable of an equalize charging rate for recharging fully depleted batteries within 8 hours and a float charge rate for maintaining the batteries in prime starting condition. Provide an ammeter to indicate charging rate. Provide a voltmeter to indicate charging voltage. Provide a timer 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 generator set and its components. Provide a disconnecting means at the battery to isolate the battery from the system to prevent battery charge depletion during long term loss of charger power.

2.9 GOVERNOR

The engine must be provided with a governor which maintains the frequency within a bandwidth +/- 0.25 percent of the rated frequency over a

SECTION 26 32 15.00 26 Page 17 steady-state load range of zero to 100 percent of rated output capacity.

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

2.10 GENERATOR

The generator must be of the synchronous type, one or two bearing, conforming to NEMA MG 1, equipped with winding terminal housings in accordance with NEMA MG 1, equipped with an amortisseur winding, and directly connected to the engine. Insulation must be Class F or H.

Generator design must protect against mechanical, electrical and thermal damage due to vibration, 25 percent overspeed, or voltages and temperatures at a rated output capacity of 100 percent. Generator ancillary equipment must meet the short circuit requirements of NEMA MG 1.

Rating of generator is to be based on continuous operation at 0.80 power factor and be 480 V, 3-phase, 60 Hz. Generator must be Delta wound.

Frames must be the drip-proof type.

2.10.1 Current Balance

At 100 percent rated load, and load impedance equal for each of the three phases, the permissible current difference between any two phases can not exceed 2 percent of the largest current on either of the two phases.

2.10.2 Voltage Balance

At any balanced load between 75 and 100 percent of rated load, the difference in line-to-line voltage among the three phases from the average voltage can not exceed 1 percent of the average line-to-line voltage.

2.10.3 Waveform and Harmonic Requirements

Submit Harmonic Requirements for review. Harmonic Requirements must include a description of the generator features which mitigate the effects of the non-linear loads related to the variable frequency drives. The deviation factor of the line-to-line voltage at zero load and at balanced full rated load at 0.8 power factor can not exceed 10 percent. Harmonic distortion must be less than 3 percent for any single harmonic and less than 5 percent total at no load to full rated load.

2.11 EXCITER

The generator exciter must be of the permanent magnet generator (PMG)/brushless type. Semiconductor rectifiers must 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 system must be complete and operate in conjunction with the automatic voltage regulator system. The exciter must supply the necessary generator excitation under all operating conditions of the generator set. The exciter-regulator combination must maintain generator output voltage within the limits specified.

SECTION 26 32 15.00 26 Page 18

2.12 VOLTAGE REGULATOR

The generator must be provided with a solid-state voltage regulator, separate from the exciter. The regulator must 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 must be configured for safe manual adjustment of the generator set voltage output without special tools, during operation from 90 to 110 percent of the rated voltage over the steady state load range of zero to 100 percent of rated output capacity. Regulation drift must not exceed plus or minus 1 percent for an ambient temperature change of 68 degrees F.

2.13 GENERATOR PROTECTION

2.13.1 Short Circuit and Overload Protection

Provide short circuit and overload protection for the generator. The generator circuit breaker ratings must be consistent with the generator rated voltage and frequency, with continuous, short circuit and interrupting current ratings to match the generator capacity. The manufacturer must determine the short circuit current interrupting rating of the breaker. The breaker and its enclosure must be Listed to UL 489 .

The breaker must be generator set base mounted by the generator set manufacturer. Provide molded case breakers with shunt trip. Provide surge protection for each phase of the generator, to be mounted at the generator terminals.

2.13.2 Ground Fault Detection

Provide ground fault detection for all three phase of the generator. A detection of a ground fault on any of the three phases must activate a visual and audible alarm in the operator cab HMI system.

2.14 PANELS

2.14.1 General

Enclosure requirements given in SECTION 26 05 00.01 26 apply. Additional requirements follow. Each must be of the type necessary to provide specified functions. Mount panels on the generator set base by vibration/shock absorbing type mountings. Mount flush or semiflush all instruments . Provide convenient access to the back of instruments to facilitate maintenance. Calibrate all instruments using recognized industry calibration standards. Panels must be provided with an identification plate which clearly identifies the panel function as indicated. Each instrument and device on the panel must be provided with a plate which clearly identifies the device and its function as indicated.

2.14.2 Analog

Analog electrical indicating instruments must be in accordance with ANSI C39.1 with semiflush mounting. Unit-mounted instruments must be the manufacturer's standard with an accuracy within than 2 percent of actual indication. The instruments' operating temperature range must be -15 to +110 degrees F. Distorted generator output voltage waveform of a crest factor less than 5 can not affect metering accuracy for phase voltages, hertz and amps.

SECTION 26 32 15.00 26 Page 19

2.14.3 Electronic

Electronic indicating instruments must be true RMS indicating, 100 percent solid state, microprocessor controlled to provide all specified functions. Control, logic, and function devices must be compatible as a system, sealed, dust and water tight, and must utilize modular components with metal housings and digital instrumentation. Provide an interface module to decode serial link data from the electronic panel and translate alarm, fault and status conditions to set of relay contacts. Instrument accuracy can be not less than 2 percent of actual for unit mounted devices throughout a temperature range of -15 to +110 degrees F. Data display must utilize LED or back lit LCD. Additionally, the display must provide indication of cycle programming and diagnostic codes for troubleshooting.

Numeral height must be 1/2 inch, minimum.

2.15 GENERATOR SET CONTROLS AND INSTRUMENTATION

2.15.1 General

Provide devices, wiring, remote panels, local panels, etc., and installed as a complete system to automatically activate the appropriate signals and initiate the appropriate actions. Provide a local panel with devices, mounted on the generator set. Provide a remote panel with devices, mounted in the operator cab. Requirements given in Paragraph "PANELS" apply.

2.15.2 Local Control Panel

As a minimum, the following instruments and controls must be provided on the local panel:

a. Starting controls: manual start/run, remote start/run, and manual stop.

b. AC voltmeter.

c. AC ammeter.

d. Voltmeter-ammeter phase selector switch.

e. Frequency meter, Hz.

f. Automatic voltage regulator control.

g. Warning/fault status indication.

h. Audible alarm Capability.

i. Overspeed indication.

j. Run-time (hour) meter. Non-resettable.

k. Kilowatt meter (output as percent rated load).

l. Lubricating oil pressure.

m. Coolant temperature.

n. Emergency stop.

SECTION 26 32 15.00 26 Page 20

o. Battery Voltage.

p. Fuel Gauge.

2.15.3 Remote (Operator Cab) Control Panel

As a minimum, the following instruments and controls must be provided on the remote panel, located in the operator cab:

a. Starting controls: manual start/run and manual/remote stop.

b. AC voltmeter.

c. AC ammeter.

d. Frequency meter, Hz.

e. Warning/fault status indication.

f. Kilowatt meter (output as percent rated load).

g. Lubricating oil pressure.

h. Coolant temperature.

i. Emergency stop.

j. Battery Voltage.

k. Fuel Gauge.

l. Diesel Generator Breaker Position

m. Audible Alarm Capability

2.16 SURGE PROTECTION

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

2.17 GENERATOR SET MOUNTING BASE

Construct the mounting base of steel. The base must be designed to rigidly support the generator set, ensure permanent alignment of all rotating parts, be arranged to provide easy access to allow changing of lube-oil, and ensure that alignment will be maintained during shipping and normal operation. The base must permit skidding in any direction during installation and be designed to be mounted in the parking lot near the service bay. The base must also withstand and mitigate the effects of synchronous vibration of the engine and generator, and be provided with suitable holes for anchor bolts and jacking screws for leveling. Provide all additional structural materials and methods required for proper mounting of the generator set base.

2.18 PAINTING AND FINISHING

The generator set, fuel tank, and enclosure must be cleaned, primed and painted at the factory in accordance with the manufacturer's standard

SECTION 26 32 15.00 26 Page 21 color and practice.

2.19 SAFETY SYSTEM

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

2.19.1 AUDIBLE SIGNAL

An audible alarm signal must sound at a frequency of 60 Hz at a volume of 70 dB at 10 feet located on the remote operators control panel.

An audible alarm signal must sound at a frequency of 60 Hz at a volume of 85 dB at 10 feet located on the local control panel. The sound must be continuously activated upon alarm and silenced upon acknowledgment.

2.20 LOAD BANK

2.20.1 Material And Construction

a. The load must be outdoor weatherproof construction, suitable for portable operation. All exterior fasteners must be stainless steel.

The load bank must include forklift channels in the base for lifting.

Install the Load Banks as shown on contract drawings or as approved.

b. Construct the load bank of heavy gauge aluminized steel per

ASTM A463/A463M .

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

d. Airflow throughout the load bank must be horizontal. Design the intake openings to prevent objects greater than 0.50" diameter from entering the unit.

e. Angle the load bank exhaust hood downward. Construct the exhaust hood of non-corrosive aluminized steel or aluminum.

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

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

Ensure Resistors can be individually removed for inspection or service.

h. Size the Load Bank to handle 100% of the full resistive load rating of the generator as a minimum.

2.20.2 Resistive Load Elements

a. Load elements must be helically wound chromium alloy rated to

SECTION 26 32 15.00 26 Page 22 operate at approximately ½ of maximum continuous rating of wire.

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

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

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

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

2.20.3 Cooling

a. The load bank must be cooled by integral TEFC or TEAO motor(s) which is direct coupled to the cooling fan blade. The fan motor must be electrically protected against overload using a motor overload device and short circuit protected using three current limiting fuses with an interrupting rating of 200 kAIC.

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

c. Provide an integral control power transformer to supply 120V, 1 phase, 60 Hz to the load banks control and motor starter circuitry.

Fuse protect the Transformer primary and secondary control circuits.

2.20.4 Protective Devices

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

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

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

d. The exterior of the load bank must have manufacturer's recommended warning/caution statements on access panels.

2.20.5 Control Panel

a. The control panel must be a integral with the unit housed in a NEMA 4X type enclosure and contain the following manual controls:

(1) Power ON/OFF switch

(2) Blower START/STOP pushbuttons.

(3) Master load ON/OFF switch.

SECTION 26 32 15.00 26 Page 23

(4) Load step switches for ON/OFF application of individual load steps at 25 percent increments.

b. Control panel visual indicators must be as follows:

(1) Power ON indication light.

(2) Blower ON light.

(3) Blower/Air FAILURE light.

(4) Over Temperature light.

2.21 EMISSIONS

The finished installation must comply with Federal, state, and local regulations and restrictions regarding the limits of emissions.

2.22 STARTING AIDS

The manufacturer must provide glow plugs and either jacket coolant heaters or lubricating oil heaters as approved and as follows to assist engine starting.

2.22.1 Glow Plugs

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

2.22.2 Jacket-Coolant Heaters

Mount a thermostatically controlled electric heater in the engine coolant jacketing to automatically maintain the coolant within plus or minus 3 degrees F of the control temperature. The heater must operate independently of engine operation so that starting times are minimized.

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

2.22.3 Lubricating-Oil Heaters

Mount a thermostatically controlled electric…