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**************************************************************************USACE / NAVFAC / AFCESA / NASA UFGS-26 32 15.00 10 (October 2007)

----------------------------------Preparing Activity: USACE Superseding

UFGS-26 32 15.00 10 (April 2006)

UNIFIED FACILITIES GUIDE SPECIFICATIONS

References are in agreement with UMRL dated October 2011**************************************************************************

SECTION TABLE OF CONTENTS

DIVISION 26 - ELECTRICAL

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

10/07

PART 1 GENERAL

1.1 REFERENCES1.2 SYSTEM DESCRIPTION

1.2.1 Engine-Generator Parameter Schedule1.2.2 Rated Output Capacity1.2.3 Power Ratings1.2.4 Transient Response1.2.5 Reliability and Durability1.2.6 Parallel Operation1.2.7 Load Sharing1.2.8 Engine-Generator Set Enclosure1.2.9 Vibration Isolation1.2.10 Fuel Consumption1.2.11 Fuel-Consumption Rebates1.2.12 Harmonic Requirements1.2.13 Starting Time Requirements

1.3 SUBMITTALS1.4 QUALITY ASSURANCE

1.4.1 Conformance to Codes and Standards1.4.2 Site Welding1.4.3 Vibration Limitation1.4.4 Seismic Requirements1.4.5 Experience1.4.6 Field Engineer1.4.7 Detailed Drawings

1.5 DELIVERY, STORAGE, AND HANDLING1.6 EXTRA MATERIALS

PART 2 PRODUCTS

2.1 NAMEPLATES2.2 SAFETY DEVICES2.3 MATERIALS AND EQUIPMENT

2.3.1 Filter Elements2.3.2 Instrument Transformers

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2.3.3 Revenue Metering2.3.4 Pipe (Fuel/Lube-Oil, Compressed Air, Coolant, and Exhaust)2.3.5 Pipe Hangers2.3.6 Electrical Enclosures2.3.6.1 Power Switchgear Assemblies2.3.6.2 Switchboards2.3.6.3 Panelboards

2.3.7 Electric Motors2.3.8 Motor Controllers

2.4 ENGINE2.5 FUEL SYSTEM

2.5.1 Pumps2.5.1.1 Main Pump2.5.1.2 Auxiliary Fuel Pump

2.5.2 Fuel Filter2.5.3 Relief/Bypass Valve2.5.4 Integral Main Fuel Storage Tank2.5.4.1 Capacity2.5.4.2 Local Fuel Fill2.5.4.3 Fuel Level Controls2.5.4.4 Arrangement

2.5.5 Day Tank2.5.5.1 Capacity, Prime2.5.5.2 Capacity, Standby2.5.5.3 Drain Line2.5.5.4 Local Fuel Fill2.5.5.5 Fuel Level Controls2.5.5.6 Arrangement

2.5.6 Fuel Supply System2.6 LUBRICATION

2.6.1 Lube-Oil Filter2.6.2 Lube-Oil Sensors2.6.3 Precirculation Pump

2.7 COOLING SYSTEM2.7.1 Coolant Pumps2.7.2 Heat Exchanger2.7.2.1 Fin-Tube-Type Heat Exchanger (Radiator)2.7.2.2 Shell and U-Tube Type Heat Exchanger

2.7.3 Expansion Tank2.7.4 Thermostatic Control Valve2.7.5 Ductwork2.7.6 Temperature Sensors

2.8 SOUND LIMITATIONS2.9 AIR INTAKE EQUIPMENT2.10 EXHAUST SYSTEM

2.10.1 Flexible Sections and Expansion Joints2.10.2 Exhaust Muffler2.10.3 Exhaust Piping

2.11 PYROMETER2.12 EMISSIONS2.13 STARTING SYSTEM

2.13.1 Controls2.13.2 Capacity2.13.3 Electrical Starting2.13.3.1 Battery2.13.3.2 Battery Charger

2.13.4 Pneumatic2.13.4.1 Air Driven Motors2.13.4.2 Cylinder Injection

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2.13.5 Starting Aids2.13.5.1 Glow Plugs2.13.5.2 Jacket-Coolant Heaters2.13.5.3 Lubricating-Oil Heaters

2.13.6 Exerciser2.14 GOVERNOR2.15 GENERATOR

2.15.1 Current Balance2.15.2 Voltage Balance2.15.3 Waveform

2.16 EXCITER2.17 VOLTAGE REGULATOR2.18 GENERATOR ISOLATION AND PROTECTION

2.18.1 Switchboards2.18.2 Devices

2.19 SAFETY SYSTEM2.19.1 Audible Signal2.19.2 Visual Signal2.19.3 Alarms and Action Logic2.19.3.1 Shutdown2.19.3.2 Problem

2.19.4 Local Alarm Panel2.19.5 Time-Delay on Alarms2.19.6 Remote Alarm Panel

2.20 ENGINE GENERATOR SET CONTROLS AND INSTRUMENTATION2.20.1 Controls2.20.2 Engine Generator Set Metering and Status Indication

2.21 SYNCHRONIZING PANEL2.22 PANELS

2.22.1 Enclosures2.22.2 Analog2.22.3 Electronic2.22.4 Parameter Display

2.23 AUTOMATIC ENGINE-GENERATOR-SET SYSTEM OPERATION2.23.1 Automatic Transfer Switch2.23.2 Monitoring and Transfer2.23.3 Automatic Paralleling and Loading of Engine-Generator Sets

2.24 MANUAL ENGINE-GENERATOR-SET SYSTEM OPERATION2.25 STATION BATTERY SYSTEM

2.25.1 Battery2.25.2 Battery Capacity2.25.3 Battery Charger

2.26 BASE2.27 THERMAL INSULATION2.28 PAINTING AND FINISHING2.29 FACTORY INSPECTION AND TESTS

2.29.1 Factory Inspection2.29.2 Factory Tests

PART 3 EXECUTION

3.1 EXAMINATION3.2 GENERAL INSTALLATION3.3 PIPING INSTALLATION

3.3.1 Support3.3.1.1 Ceiling and Roof3.3.1.2 Wall

3.3.2 Flanged Joints3.3.3 Cleaning

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3.3.4 Pipe Sleeves3.4 ELECTRICAL INSTALLATION3.5 FIELD PAINTING3.6 ONSITE INSPECTION AND TESTS

3.6.1 Test Conditions3.6.1.1 Data3.6.1.2 Power Factor

3.6.1.3 Contractor Supplied Items3.6.1.4 Instruments3.6.1.5 Sequence

3.6.2 Construction Tests3.6.2.1 Piping Test3.6.2.2 Electrical Equipment Tests

3.6.3 Inspections3.6.4 Pre-operational Tests3.6.4.1 Protective Relays3.6.4.2 Insulation Test3.6.4.3 Engine-Generator Connection Coupling Test

3.6.5 Safety Run Test3.6.6 Performance Tests3.6.6.1 Continuous Engine Load Run Test

3.6.6.2 Voltage and Frequency Droop Test3.6.6.3 Voltage Regulator Range Test3.6.6.4 Governor Adjustment Range Test3.6.6.5 Frequency and Voltage Stability and Transient Response

3.6.7 Parallel Operation Test3.6.7.1 Combinations3.6.7.2 Multiple Combinations

3.6.8 Parallel Operation Test (Commercial Source)3.6.9 Automatic Operation Tests3.6.10 Automatic Operation Tests for Stand-Alone Operation3.6.11 Fuel Consumption Tests

3.7 ONSITE TRAINING3.8 FINAL TESTING AND INSPECTION3.9 POSTED DATA AND INSTRUCTIONS3.10 ACCEPTANCE

-- End of Section Table of Contents --

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**************************************************************************USACE / NAVFAC / AFCESA / NASA UFGS-26 32 15.00 10 (October 2007)

----------------------------------Preparing Activity: USACE Superseding

UFGS-26 32 15.00 10 (April 2006)

UNIFIED FACILITIES GUIDE SPECIFICATIONS

References are in agreement with UMRL dated October 2011**************************************************************************

SECTION 26 32 15.00 10

DIESEL-GENERATOR SET STATIONARY 100-2500 KW, WITH AUXILIARIES10/07

**************************************************************************NOTE: This guide specification covers therequirements for stationary diesel-driven generator

sets in the 100 to 2500 kilowatt capacity.

Adhere to UFC 1-300-02 Unified Facilities GuideSpecifications (UFGS) Format Standard when editingthis guide specification or preparing new projectspecification sections. Edit this guidespecification for project specific requirements byadding, deleting, or revising text. For bracketeditems, choose applicable items(s) or insertappropriate information.

Remove information and requirements not required inrespective project, whether or not brackets arepresent.

Comments, suggestions and recommended changes forthis guide specification are welcome and should besubmitted as a Criteria Change Request (CCR).

**************************************************************************

PART 1 GENERAL

**************************************************************************NOTE: This Specification is not for Procurement ofGas-fueled Engine-generator Sets.

Transient-load-response performance characteristicsof natural gas, digester gas, propane, and liquefiedpetroleum gas engines differ significantly fromthose of diesel engines because of the fueldifferences. Consult manufacturers for samplespecifications.

Select the features and fill in blanks with valuesappropriate for the design condition. Thisspecification does not apply to 400 Hz applications.

**************************************************************************

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1.1 REFERENCES

**************************************************************************NOTE: This paragraph is used to list thepublications cited in the text of the guidespecification. The publications are referred to in

the text by basic designation only and listed inthis paragraph by organization, designation, date,and title.

Use the Reference Wizard's Check Reference featurewhen you add a RID outside of the Section'sReference Article to automatically place thereference in the Reference Article. Also use theReference Wizard's Check Reference feature to updatethe issue dates.

References not used in the text will automaticallybe deleted from this section of the projectspecification when you choose to reconcile

references in the publish print process.**************************************************************************

The publications listed below form a part of this specification to theextent referenced. The publications are referred to within the text by thebasic designation only.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

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

ASME INTERNATIONAL (ASME)

ASME B16.11 (2009) Forged Fittings, Socket-Welding andThreaded

ASME B16.3 (2010) Malleable Iron Threaded Fittings,Classes 150 and 300

ASME B16.5 (2009) Pipe Flanges and Flanged Fittings:NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME B31.1 (2010) Power Piping

ASME BPVC SEC IX (2010) BPVC Section IX-Welding and BrazingQualifications

ASME BPVC SEC VIII D1 (2007; Addenda 2008; Addenda 2009) BPVCSection VIII-Rules for Construction ofPressure Vessels Division 1

ASSOCIATION OF EDISON ILLUMINATING COMPANIES (AEIC)

AEIC CS8 (2000) Extruded Dielectric Shielded PowerCables Rated 5 Through 46 kV

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ASTM INTERNATIONAL (ASTM)

ASTM A106/A106M (2010) Standard Specification for SeamlessCarbon Steel Pipe for High-TemperatureService

ASTM A181/A181M (2006) Standard Specification for Carbon

Steel Forgings, for General-Purpose Piping

ASTM A234/A234M (2011) Standard Specification for PipingFittings of Wrought Carbon Steel and AlloySteel for Moderate and High TemperatureService

ASTM A53/A53M (2010) Standard Specification for Pipe,Steel, Black and Hot-Dipped, Zinc-Coated,Welded and Seamless

ASTM B395/B395M (2008) Standard Specification for U-BendSeamless Copper and Copper Alloy HeatExchanger and Condenser Tubes

ASTM D 975 (2011) Standard Specification for DieselFuel Oils

ELECTRICAL GENERATING SYSTEMS ASSOCIATION (EGSA)

EGSA 101P (1995) Engine Driven Generator Sets

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 1 (2000; R 2005) General Principles forTemperature Limits in the Rating ofElectric Equipment and for the Evaluationof Electrical Insulation

IEEE 115 (2009) Guide for Test Procedures forSynchronous Machines: Part I Acceptanceand Performance Testing; Part II TestProcedures and Parameter Determination forDynamic Analysis

IEEE 120 (1989; R 2007) Master Test Guide forElectrical Measurements in Power Circuits

IEEE 404 (2006) Standard for Extruded and LaminatedDielectric Shielded Cable Joints Rated2500 V to 500,000 V

IEEE 43 (2000; R 2006) Recommended Practice forTesting Insulation Resistance of RotatingMachinery

IEEE 48 (2009) Standard for Test Procedures andRequirements for Alternating-Current CableTerminations Used on Shielded CablesHaving Laminated Insulation Rated 2.5 kVthrough 765 kV or Extruded InsulationRated 2.5 kV through 500 kV

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IEEE 484 (2002; R 2008) Recommended Practice forInstallation Design and Implementation ofVented Lead-Acid Batteries for StationaryApplications

IEEE 485 (2010) Recommended Practice for Sizing

Lead-Acid Batteries for StationaryApplications

IEEE 519 (1992; R 1993; Errata 2004) RecommendedPractices and Requirements for HarmonicControl in Electrical Power Systems

IEEE 81 (1983) Guide for Measuring EarthResistivity, Ground Impedance, and EarthSurface Potentials of a Ground System

IEEE C2 (2012) National Electrical Safety Code

IEEE C57.13 (2008) Standard Requirements for

Instrument Transformers

IEEE C57.13.1 (2006) Guide for Field Testing of RelayingCurrent Transformers

IEEE Stds Dictionary (2009) IEEE Standards Dictionary: Glossaryof Terms & Definitions

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGSINDUSTRY (MSS)

MSS SP-58 (2009) Pipe Hangers and Supports -Materials, Design and Manufacture,Selection, Application, and Installation

MSS SP-69 (2003) Pipe Hangers and Supports -Selection and Application (ANSI ApprovedAmerican National Standard)

MSS SP-80 (2008) Bronze Gate, Globe, Angle and CheckValves

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 2 (2000; R 2005; Errata 2008) Standard forControllers, Contactors, and OverloadRelays Rated 600 V

NEMA ICS 6 (1993; R 2006) Enclosures

NEMA MG 1 (2009) Motors and Generators

NEMA PB 1 (2006; Errata 2008) Panelboards

NEMA PB 2 (2006) Deadfront Distribution Switchboards

NEMA SG 6 (2000) Standard for Power SwitchingEquipment

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NEMA WC 74/ICEA S-93-639 (2006) 5-46 kV Shielded Power Cable forUse in the Transmission and Distributionof Electric Energy

NEMA/ANSI C12.11 (2007) Instrument Transformers for RevenueMetering, 10 kV BIL through 350 kV BIL

(0.6 kV NSV through 69 kV NSV)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

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

NFPA 30 (2012) Flammable and Combustible LiquidsCode

NFPA 37 (2010; TIA 10-1) Standard for theInstallation and Use of StationaryCombustion Engines and Gas Turbines

NFPA 70 (2011; TIA 11-1; Errata 2011) NationalElectrical Code

NFPA 99 (2005; TIA 05-1; TIA 05-2; TIA 05-3;Errata 05-1) Standard for Health CareFacilities

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE J537 (2011) Storage Batteries

U.S. DEPARTMENT OF DEFENSE (DOD)

UFC 3-310-04 (2007; Change 1) Seismic Design forBuildings

UNDERWRITERS LABORATORIES (UL)

UL 1236 (2006; Reprint Jul 2011) Standard forBattery Chargers for ChargingEngine-Starter Batteries

UL 891 (2005) Switchboards

1.2 SYSTEM DESCRIPTION

**************************************************************************NOTE: Engine Generator Parameter Schedule. Wheremultiple engine-generator sets of different sizes orapplications are to be provided, a ParameterSchedule should be shown on the contract drawings(one for each engine-generator set to beinstalled). If only one engine-generator set isprovided (or multiples of the same type, size,etc.), the schedule may be in the body of thespecification. Note that the specifications referto the Engine Generator Parameter Schedule and thedesigner must provide one each by that name.

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Some load applications require precise generatoroutput frequency, voltage, level waveformcharacteristics and control of transient response.Most loads do not require stricter control than mostoff-the-shelf engine generator sets can provide.The criticality of the output and response

characteristics can affect: selection of thegovernor type, whether it is to be isochronous ordroop, and its steady state bandwidth; selection ofthe voltage regulator parameters; transient recoverytime for frequency and voltage; maximum voltage andfrequency deviation for a transient event; andbecause of the maximum deviations and transientrecovery times, the sizing or oversizing of theengine and generator. The notes below are includedto assist the designer in making informed choiceswhen filling in the Engine Generator ParameterSchedule.

Power Ratings and Industry Terminology. The

following definitions are from the ElectricalGenerating Systems Association Standard 101P, EngineDriven Generating Sets. Stationarydiesel-engine-driven electric generator sets aredivided into the following four rating categories:EMERGENCY STANDBY, LIMITED RUNNING TIME, PRIMEPOWER, and INDUSTRIAL.

"EMERGENCY STANDBY RATING means the power that thegenerator set will deliver continuously under normalvarying load factors for the duration of a poweroutage." It must be understood that this definitionuses the term "normal varying load conditions".Most manufacturers use this terminology to indicatethat their units typically are not rated forcontinuous operation at the nameplate rating, butrather that the units provided are rated forcontinuous operation at 70 to 80 percent of theirnameplate rating, with periodic loading up to 100percent of the nameplate rating for short (cyclical)periods during a power outage. When specifying agenset be sure to specify what the peak load is andhow much is continuous.

"LIMITED RUNNING TIME RATING means the power thatthe generator set will deliver when used as autility type power source, typically in loadcurtailment type service, for a limited number ofhours, where there are non-varying load factorsand/or constant dedicated loads."

"PRIME POWER RATING means the power that thegenerator set will deliver when used as a utilitytype power plant under normal varying load factorsto run continuously. This rating requires a minimummomentary overload capability of 10 percent."

"INDUSTRIAL RATING means the power that the

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generator set will deliver 24 hours per day whenused as a utility type power plant where there arenon-varying load factors and/or constant dedicatedloads."

Overload Capacity. Overload capacity is only forPRIME rated units. Delete for standby applications.

Power Factor. Commercial genset power ratings areusually based on 0.8 power factor. Select 0.8unless the application requires one more stringent.

Loading. When specifying engine-generator sets thedesigner will analyze the load characteristics andprofiles of the load to be served to determine thepeak demand, maximum step load increase anddecrease, motor starting requirements represented asstarting kVA, continuous and non-continuous(cyclical/periodic), and the non-linear loads to beserved. This information should be included in theengine-generator set parameter schedule or on the

drawings for each different unit provided. For thisapplication, service load is the peak estimatedloading (continuous plus non-continuous) to beplaced on the engine generator set.

Peak demand calculation provides a figure from whichto determine the service load. For primeapplications the service load should include sparecapacity for future load growth and spinning reserve(reserve generation beyond that required to satisfyimmediate needs and/or system peak demands). Sparecapacity for prime applications should be based onthe facility master plan load projections.

Motor Starting Load. Motor starting requirementsare important to properly size engine generator setsbecause the starting current for motors can be asmuch as six times the running current, and can causegenerator output voltage and frequency to drop, eventhough the genset has been sized to carry therunning load. The designer must analyze the motorloads to determine if the starting characteristicsof a motor or a group of motors to be startedsimultaneously will cause objectionable gensetperformance. Provide a motor starting kVA value forthe largest motor or combination of motors to bestarted simultaneously. An increase in the sizerating of the genset may be necessary to compensatefor the inrush current. This assists the gensetsupplier in properly sizing the engine generator set.

Maximum Speed. The maximum allowable speed is 1800RPM. If there is not specific requirement or userrequirement for slower speed machines, select 1800RPM. Selection of the maximum 1800 RPM does notpreclude provision of slower speed machines, forexample, in the larger sizes (above 2000 kW), where1800 RPM machines may not be available.

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Heat Exchanger Type. Fin-tube heat exchangers(radiators) are the predominate method of cooling.Specify either a fin-tube or a shell-tube heatexchanger for each engine-generator set. Heatexchangers located remote from the engine-generatorset (i.e.,. not mounted on the engine-generator set

base) will be shown on the project plans, includingthe power source for associated fans and pumps.

Governor. The type of governor to be used on eachengine generator set should be identified asisochronous or droop on the engine-generator setparameter schedule. Isochronous governors holdfrequency at the setpoint frequency (withinbandwidth) for all steady state loads from 0 to 100percent load and are required for applications wheresevere demands are made on voltage and frequencyregulation. Droop governors allow frequency todroop to the specified percentage proportional tosteady state loads from 0 to 100 percent load and

are generally acceptable for general purpose andcommercial applications.

Engine-generator sets in stand alone service(isolated bus) may utilize either droop orisochronous governors. The designer should analyzethe application and loads to determine if the moreexpensive isochronous unit is actually required.Droop units provide added stability (less enginecycling) in single unit applications where constantspeeds are not critical and are less expensive thanisochronous governors.

Engine-generator sets in parallel (on an isolatedbus) may also utilize either droop or isochronousgovernors. Load swings are shared proportionallybased on the governor droop settings. The load willbe split equally among the units for all unitsequipped with isochronous governors with loadsharing controls, or if all units have droopgovernors that are set with the same droop. "Leadunits" are often designated in multiple unitapplications for tighter frequency control bysetting one governor at a much lower droop than theothers. A "lead unit" can be designated for gensetsequipped with isochronous governors if all unitshave governors with load sharing controls. In thiscase the "lead unit" will accept all load swings andthe other units will remain at a constant load.When all units have droop governors, the "leadunits" will accept most of the load swings and theother units will equally split a small portion ofthe load. If isochronous governors are specifiedfor two or more units to be paralleled on anisolated bus, the governors must be specified withload sharing controls. For applications involvingunits in parallel operation which are not operatorsupervised the designer should specify a

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load-sharing system which can proportionally loadtwo or more sets in parallel, each havingisochronous governors. Generators for use withexisting generators in parallel applications musthave similar characteristics. Droop paralleling isspecified for electrical and electro-hydraulicgovernors where interconnection of all controls is

not possible such as when paralleling to a largeelectrical utility grid network. When parallelingtwo or more droop units with a utility grid (or withother droop units), to achieve load sharing, theunit governors must be compatible, their speedsettings must be matched, and the droop must be setthe same on all units. Droop adjustment range of 0to 7 percent is typical for mechanical-hydraulicgovernors, and 0 to 10 percent is typical forelectro-hydraulic governors. Isochronous unitsshould not be paralleled with an infinite bus(utility grid system) without also specifyingsynchronizing and governor-load sharing controls.Delete speed droop adjustment for isochronous

governors in non-parallel applications.

Frequency Bandwidth. Governor frequency bandwidthdefines the allowable steady state variation infrequency as is typically quite small forcommercially available governors (typically lessthan + 0.4 percent with + 0.25 percent readilyavailable). The predominant type of device loadswhich are susceptible to steady state frequencydeviations less than + 0.4 percent are those whichemploy switching power supplies (computers andvariable frequency drives). The designer shouldselect the least restrictive value for bandwidth forthe application.

Voltage Regulators. Solid state regulators arereadily available which maintain the voltage level(regulation or voltage droop) to + 2 percent from noload to full load, while some manufacturers offerregulators which limit the droop to + 0.5 percent.Voltage regulator bandwidth is important relativeprimarily to transient response. EGSA Standard100R-1992 defines three performance classes forvoltage regulators: standard (2 percent bandwidth);high (1 percent bandwidth); and precision (0.5percent bandwidth). Select the least restrictivebandwidth necessary to satisfy the applicationrequirement.

Generator frequency and voltage should be shown onthe engine-generator set schedule. (For example:208Y/120 volts, 3-phase, 4-wire).

Subtransient Reactance. The subtransient reactanceof a generator is the impedance characteristic whichdetermines current during the first cycle after asystem short circuit condition is presented to thegenerator. Therefore, it is used to determine the

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necessary interrupting capacity of the gensetcircuit interrupting device. It also is utilized topredict generator response to non-linear loads.Typical values for generator subtransient reactanceare found in IEEE Std 141. Subtransient reactanceis specified in per unit of the generator ratedkVA. Also, see the following discussion on

non-linear loads.

Non-linear Loads: Non-linear loads are addressed inIEEE 519. They are loads that draw a non-sinusoidalcurrent waveform when supplied by a sinusoidalvoltage source. Typical non-linear loads includesolid state switching power supplies, computer powersupplies (including those found in desktop PC's,uninterruptible power supplies, variable frequencydrives, radar power supplies, and solid stateballasts in fluorescent light fixtures. They causedistortion of the source voltage and currentwaveforms that can have harmful effects on manytypes of electrical equipment and electronics,

including generators. Non-linear loads are similarto short circuits in that they provide momentary,sub-cycle-duration, short-circuiting of two phases.Switching power supplies consist ofSCR/thyristor-controlled rectifier bridges which actas three single-phase loads, each connected acrosstwo phases of the power system. When theSCR/thyristors are switched on and off a notch inthe voltage waveform will occur as a result of aninstantaneous phase-phase short-circuit during thecommutation of current. A low generatorsubtransient reactance minimizes the voltagewaveform distortion in the presence of such loads.For this reason when the non-linear loads comprise25 percent or more of the loads served, thegenerator subtransient reactance should be limitedto no more than 0.12.

Delete Subtransient Reactance from theEngine-Generator Parameter Schedule where the gensetmanufacturer is responsible for sizing the generatorbreaker and where the non-linear loads served areless than 25 percent.

Generators are particularly vulnerable to controlproblems and instability, excessive winding heating,neutral overheating, reduced efficiency, reducedtorque, shaft fatigue, accelerated aging, andinduced mechanical oscillations when non-linearloads are applied without careful consideration ofthe generator's capability to supply them. Measureswhich can be used to mitigate the effects ofnon-linear loads on generators include: procurementof low impedance generators with special windings tocompensate for the additional heating; installationof harmonic filter traps; avoidance of self-excitedgenerators; use of 2/3 pitch factor (rather than 5/6pitch) generator windings; and generator derating

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with oversized neutrals.

For large non-linear loads, filter traps which aretuned to the dominant harmonic frequencies of thenon-linear loads should be procured/provided withthe load component. This approach is normally lesscostly than procurement of specially designed or

derated generators.

For combinations of linear and non-linear loadswhere the percentage of non-linear loads is smallrelative to the capacity rating of the generator (25percent or less), standard generator configurationsare normally acceptable.

Provide a list of the non-linear loads in theparameter schedule, either on the drawings (anddenoted on the single-line diagram) or in tabularform in the specification section. The list shouldcontain a description of the load includingequipment type, whether the rectifier is 6-pulse or

12-pulse, kVA rating, and frequency. Provide alinear load value (kVA @ PF) which represents themaximum linear load demand when non-linear loadswill also be in use. The generator manufacturerwill be required to meet the total harmonicdistortion limits established in IEEE 519. Deletethe non-linear load paragraph when non-linear loadsare not served from the engine-generator set.

Maximum Step Load Increase. Maximum step loadincrease is used to account for the addition ofblock loads. These affect engine-generator setfrequency and voltage output and usually initiategovernor and regulator response. The change inengine-generator set output and the response of thegovernor and regulator defines the transient loadingresponse. The designer should provide the actualloads to be applied to the engine-generator setbecause specification of maximum step load increasesof 75 or 100 percent requires significant oversizingof engines and generators and/or addition of mass tofly-wheel, all of which add cost. Additionally,oversizing of engines causes maintenance problemsand increases operating costs. The followingpercentages may be used when the actual loadacquisition rate cannot be determined. A maximumstep load increase of 25 percent should be used forprime rated sets, 50 percent for optional standbyrated sets with step loading, and 100 percent forlegally required standby (emergency) service with nostep loading.

Transient Response Criteria (short time duration).Genset-set response and recovery times varyaccording to the size of the set, the block load,and the controls specified. Normal response toaddition of a block load will include dips in eitheroutput voltage or frequency or both and possible

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"overshoot" as the governor and voltage regulatorrespond to bring the voltage and frequency backwithin bandwidth. Normal response to loss of ablock load will include an upward spike in outputvoltage or frequency back within bandwidth. TheMaximum Voltage and Frequency Deviation apply toundervoltage/underfrequency ("dips") from the

addition of block loads and any undershoot resultingfrom the recovery of an upward spike, as well asovervoltage/overfrequency (upward spikes) from theloss of block loads and any overshoot resulting fromthe recovery of a dip.

Cost Impact. If stringent transient-responserequirements are specified, the manufacturer mayselect engine and generator models which havenominal rating much larger than the service load;may use an unnecessarily expensive governor; and mayuse a higher inertia flywheel. The designer shouldinvestigate what may actually be provided so thatthe cost estimate will be reasonably accurate and to

confirm the selected transient requirements are notunnecessarily stringent. A maximum size for theengine-generator set may be needed to avoid theproblems associated with a small load on a largecapacity set.

The designer must determine the cost benefits ofproviding an uninterruptible power system fortransient ride-through versus purchasing a generatorwith stringent transient response requirements. Indetermining the allowable voltage and frequencyvariation and recovery times, analyze the effects onequipment performance and recovery. Consult theNEMA utilization equipment standards to determinethe maximum allowable voltage dips/overshoots(excursions).

Maximum Voltage Deviation. Select the 5 percentMaximum Voltage Deviation option only ifcommunication equipment or other sensitiveelectronic equipment are a critical part of theload, and there is no UPS provided. Fluorescentlights can tolerate a maximum of 10 percent voltagevariation. NEMA induction motors and control relayscan tolerate a maximum of 10 percent variation, for30 cycles and one cycle respectively. Solenoids(brakes, valves, clutches) and ac & dc starter coilscan tolerate a maximum of minus 30 percentvariation, for 1/2 cycle, 2 cycles (dropout), and 5- 10 cycles (dropout) respectively. (The timeslisted in cycles are not given to define therecovery time back to bandwidth, but to assist thedesigner in defining the maximum allowable voltagedeviation.) The designer should realistically assesthe need for limiting the transient voltage dip toless than 30 percent.

Maximum Frequency Deviation. Computers can usually

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tolerate only + 0.5 Hz variation, so an UPS isnormally required where computer services should notbe interrupted, or where system recovery times arecritical. Inverters can tolerate + 2 Hz variation.NEMA induction motors and control relays cantolerate a maximum of 5 percent frequencyvariation. (The times listed in cycles are not

given to define the recovery time back to bandwidth,but to assist the designer in defining the maximumallowable frequency deviation.) The designer mustbe realistic in assessing the needs of the facilityto be served so that unnecessarily stringentrequirements are not specified.

Recovery Time Back to Bandwidth. The designershould determine the required recovery time for theloads served. The recovery time to bandwidth is notcritical to operation of most equipment if thevoltage and frequency do not deviate from thecritical limits, or if momentary interruption isacceptable to the loads being served. The primary

importance of this requirement is to ensure that theengine generator set recovers and stabilizes afterload changes. Most engine generator sets canrespond to 100 percent block loads and return tovoltage and frequency bandwidths within 15 - 20seconds, depending on the size of the machine (RPM,relative mass of the rotating elements, and ambientconditions).

Maximum Step Load Decrease (without shutdown). Anengine generator set should be capable of beingunloaded in a single step without tripping offline.In these situations the voltage and frequencytransients are of no concern because there is noload being served.

Nominal Step Load Decrease. Step load decrease isused to account for dropping of block loads. Thisaffects engine-generator set frequency and voltageoutput and usually initiates governor and regulatorresponse. The change in engine-generator set outputand the response of the governor and regulatordefines the transient loading response. Where theload served may be sensitive to voltage andfrequency variation due to significant loaddecrease, include the items below in the ParameterSchedule. The Nominal Step Load Decrease providesthe genset manufacturer with the informationnecessary to set the governor response for loaddecreases such than an overspeed (over-frequency)condition does not occur. The cost ofengine-generator sets increase by large percentagesfor smaller frequency and voltage deviations frombandwidth and improved recover times. Carefullyanalyze the user's need for restrictions onfrequency, voltage, and waveform characteristics.

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Nominal Step LoadDecrease

[25] [50] [75] percentof Service Load at

Transient Recovery Timewith Step Load Decrease(Voltage)

[_____] seconds

Transient Recovery Time

with Step Load Decrease(Frequency)

[_____] seconds

Maximum VoltageDeviation with Step Load

[5] [10] [30] [_____]percent of rated voltage

Maximum FrequencyDeviation with Step LoadDecrease

[2.5] [5] [_____]percent of ratedfrequency

Maximum Time To Start and Assume Load. Choose 10seconds for emergency-standby applications (criticalfor life safety). NFPA 70 requires that standby

engine-generator sets used in emergency applicationsstart and assume load in 10 seconds. Mostcommercially available engine generator sets arecapable of starting and assuming load within 10seconds, however, a default value of 20 second isnon-restrictive and provides a reasonable maximumvalue for non-critical applications.

Temperature Management. The designer is responsiblefor temperature control in the space occupied by theengine generator set. However, because the gensetsupplier normally provides the engine cooling system(and block heaters where required), the designermust provide ambient conditions under which theengine generator must operate, so that the suppliercan size the equipment. Typically, high temperatureprovides the most restrictive condition, thereforethe designer must design air-flow of adequatetemperature and sufficient quantity to maintain thetemperature of the generator and engine space withinacceptable limits. This requires the designer toconsult manufacturers literature and/orrepresentatives to determine the nominal heatrejection to the surroundings at rated gensetcapacity (from all heat sources) to determine therequired cooling or air flow through the enginegenerator set room or enclosure. In turn themanufacturer must submit the specific operating datain order for the contracting officer/designer toverify that the proposed equipment meets the designparameters.

**************************************************************************

a. Provide and install each engine-generator set complete and totallyfunctional, with all necessary ancillary equipment to include: airfiltration; starting system; generator controls, protection, andisolation; instrumentation; lubrication; fuel system; cooling system;and engine exhaust system. Each engine-generator set shall satisfy the

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requirements specified in the Engine-Generator Parameter Schedule.

b. Each set shall consist of one engine, one generator, and one excitermounted, assembled, and aligned on one base; and other necessaryancillary equipment which may be mounted separately. Sets having acapacity of 750 kW or smaller shall be assembled and attached to thebase prior to shipping. Sets over 750 kW capacity may be shipped in

sections. Each set component shall be environmentally suitable for thelocation shown and shall be the manufacturer's standard product offeredin catalogs for commercial or industrial use. Any nonstandard productsor components and the reason for their use shall be specificallyidentified.

1.2.1 Engine-Generator Parameter Schedule

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

ENGINE-GENERATOR PARAMETER SCHEDULE

Power Rating [Prime] [Limited RunningTime][Emergency Standby]

Overload Capacity (Primeapplications only)

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

Service Load [_____] kVA (maximum)

[_____] kVA (continuous

Motor Starting kVA (Max.) [_____] kVA

Power Factor [0.8] [_____] lagging

Engine-Generator Applications [stand-alone] [parallel withinfinite bus] [parallel with other

generators on an isolated bus][parallel with other generators onan infinite bus]

Maximum Speed [_____] [900] [1200] [1800] rpm

Heat Exchanger Type [fin-tube (radiator)] [shell-tube]

Voltage Regulation (No Load toFull Load)(Stand alone

+ 2 percent (maximum)

Voltage Bandwidth (steady state) + [0.5] [1] [2] percent

Frequency [50] [60] Hz

Voltage [_____] volts

Phases [3 Phase, Wye] [3 Phase, Delta]

Minimum Generator SubtransientReactance

[_____] percent

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ENGINE-GENERATOR PARAMETER SCHEDULE

Nonlinear Loads [_____] kVA

Max Step Load Increase [25] [50] [75] [100] percent ofService Load at [_____] PF

Transient Recovery Time with StepLoad Increase (Voltage)

[_____] seconds

Transient Recovery Time with StepLoad Increase (Frequency)

[_____] seconds

Maximum Voltage Deviation withStep Load Increase

[5] [10] [30] [_____] percent ofrated voltage

Maximum Frequency Deviation withStep Load Increase

[2.5] [5] [_____] percent of ratedfrequency

Max Step Load Decrease (withoutshutdown)

100 percent of Service Load at[_____] PF

Max Time to Start and be Ready toAssume Load

[10] [_____] seconds

Max Summer Indoor Temp (Prior to

Genset Operation)

[_____] degrees C F

Min Winter Indoor Temp (Prior toGenset Operation)

[_____] degrees C F

Max Allowable Heat Transferred ToEngine Generator Space at RatedOutput Capacity

[_____] MBTU/hr

Max Summer Outdoor Temp (Ambient) [_____] degrees C F

Min Winter Outdoor Temp (Ambient) [_____] degrees C F

Installation Elevation [_____] above sea level

[ENGINE-GENERATOR PARAMETER SCHEDULE - Governor

Governor Type Isochronous

Frequency Bandwidth (steady state) + [_____] [0.4] [0.25] percent

][

ENGINE-GENERATOR PARAMETER SCHEDULE - Governor

Governor Type Droop

Frequency Regulation (droop) (No [3] [_____] percent (maximum)

Frequency Bandwidth (steady state) + [_____] [0.4] [0.25] percent

]

1.2.2 Rated Output Capacity

**************************************************************************NOTE: The service load for each genset should beshown on the Engine-Generator Parameter Schedule.The designer must determine the service load. TheContractor, through the supplier'smanufacturer/assembler, determines the efficiencyand associated ancillary equipment loads. Thedesigner must examine spare capacity requirementsfor spinning reserve.

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**************************************************************************

Each engine-generator-set shall provide power equal to the sum of ServiceLoad plus the machine's efficiency loss and associated ancillary equipmentloads. Rated output capacity shall also consider engine and/or generatoroversizing required to meet requirements in paragraph Engine-GeneratorParameter Schedule.

1.2.3 Power Ratings

Power ratings shall be in accordance with EGSA 101P.

1.2.4 Transient Response

The engine-generator set governor and voltage regulator shall cause theengine-generator set to respond to the maximum step load changes such thatoutput voltage and frequency recover to and stabilize within theoperational bandwidth within the transient recovery time. Theengine-generator set shall respond to maximum step load changes such thatthe maximum voltage and frequency deviations from bandwidth are notexceeded.

1.2.5 Reliability and Durability

**************************************************************************NOTE: Mean time between overhauls describes theaverage number of operating hours that the enginewill operate satisfactorily without overhaul.Overhaul is a natural consequence of the engine inoperation due to worn out parts after the indicatedoperating hours.

**************************************************************************

[Each prime engine-generator set shall have both an engine and a generatorcapable of delivering the specified power on a prime basis with ananticipated mean time between overhauls of not less than 10,000 hoursoperating with a 70 percent load factor. Two like engines and two likegenerators shall be cited that have performed satisfactorily in astationary power plant, independent from the physical location of themanufacturer's and assembler's facilities. The engine and generatorsshould have been in operation for a minimum of 8000 actual hours at aminimum load of 70 percent of the rated output capacity. During twoconsecutive years of service, the units should not have experienced anyfailure resulting in a downtime in excess of 72 hours. Like engines shallbe of the same model, speed, bore, stroke, number and configuration ofcylinders and rated output capacity. Like generators shall be of the samemodel, speed, pitch, cooling, exciter, voltage regulator and rated outputcapacity.] [Each standby engine-generator set shall have both an engine anda generator capable of delivering the specified power on a standby basiswith an anticipated mean time between overhauls of no less than 5,000 hoursoperating with a load factor of 70 percent. Two like engines and two likegenerators shall be cited that have performed satisfactorily in astationary power plant, independent and separate from the physical locationof the manufacturer's and assembler's facilities, for standby without anyfailure to start, including all periodic exercise. Each like engine andgenerator shall have had no failures resulting in downtime for repairs inexcess of 72 hours during two consecutive years of service. Like enginesshall be of the same model, speed, bore, stroke, number and configurationof cylinders, and rated output capacity. Like generators shall be of the

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same model, speed, pitch, cooling, exciter, voltage regulator and ratedoutput capacity.]

Submit a reliability and durability certification letter from themanufacturer and assembler to prove that existing facilities are and havebeen successfully utilizing the same components proposed to meet thisspecification, in similar service. Certification may be based on

components, i.e. engines used with different models of generators andgenerators used with different engines, and does not exclude annualtechnological improvements made by a manufacturer in the basicstandard-model component on which experience was obtained, provided partsinterchangeability has not been substantially affected and the currentstandard model meets the performance requirements specified. Provide alist with the name of the installations, completion dates, and name andtelephone number of a point of contact.

1.2.6 Parallel Operation

**************************************************************************NOTE: Specification of an engine-generator setcapable of parallel operation with a utility

requires a 2/3 pitch generator winding and specialcoordination of protective devices with the utilitysystem protection scheme. Do not specify thisoption without also providing a design for theprotective device coordination which has beenapproved by the utility involved.

**************************************************************************

Each engine-generator set specified for parallel operation shall beconfigured for [automatic] [manual] parallel operation. Each set shall becapable of parallel operation with [a commercial power source on aninfinite bus] [one or more sets on an isolated bus] [a commercial powersource on an infinite bus and with one or more sets on an isolated bus].

1.2.7 Load Sharing

**************************************************************************NOTE: Coordinate with paragraph Engine Generatorparameter Schedule.

**************************************************************************

Each engine-generator set specified for parallel operation shall beconfigured to [manually load share with other sets.] [automatically loadshare with other sets by proportional loading. Proportional loading shallload each set to within 5 percent of its fair share. A set's fair share isits nameplate-rated capacity times the total load, divided by the sum ofall nameplate-rated capacities of on-line sets. Load sharing shallincorporate both the real and reactive components of the load.]

1.2.8 Engine-Generator Set Enclosure

**************************************************************************NOTE: If the engine-generator set is to beinstalled outdoors include requirements for theweatherproof enclosure in the engine-generator setschedule. Define corrosion resistance and/ormaterial required for the environment. Providestructural loading required for the geographic area

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(wind loads, snow loads, etc.). A generator setenclosure may also be needed to mitigate excessivenoise caused by the engine generator set mechanicalcomponents. Delete the reference to mechanicalnoise limitations if an enclosure is not needed tomitigate sound emissions. If a sound enclosure isnot provided, the designer must provide a design to

prevent excessive noise (meet OSHA requirements).Delete this paragraph if no engine-generator setenclosure is needed.

**************************************************************************

The engine-generator set enclosure shall be corrosion resistant and fullyweather resistant. The enclosure shall contain all set components andprovide ventilation to permit operation at Service Load under securedconditions. Doors shall be provided for access to controls and equipmentrequiring periodic maintenance or adjustment. Removable panels shall beprovided for access to components requiring periodic replacement. Theenclosure shall be capable of being removed without disassembly of theengine-generator set or removal of components other than the exhaustsystem. The enclosure shall reduce the noise of the generator set to

within the limits specified in the paragraph SOUND LIMITATIONS.

1.2.9 Vibration Isolation

**************************************************************************NOTE: See UFC 3-450-02, Power Plant Acoustics, andUFC 3-450-01, Noise and Vibration Control ForMechanical Equipment for vibration criteria.Vibration isolation systems should be applied wherevibration transmitted through the genset supportstructure produces (either directly or by resonantfrequencies of structural members) annoying ordamaging vibration in the surrounding environment.Select the manufacturer's standard or provide themaximum allowable vibration force where necessary tolimit the maximum vibration. Delete the vibrationisolation requirement for applications wherevibration does not affect the floor or foundation.

**************************************************************************

[A vibration-isolation system shall be installed between the floor and thebase. The vibration-isolation system shall limit the maximum vibrationtransmitted to the floor at all frequencies to a maximum of [_____] (peakforce).] [The engine-generator set shall be provided with avibration-isolation system in accordance with the manufacturer's standardrecommendation.] Submit vibration isolation system performance data forthe range of frequencies generated by the engine-generator set duringoperation from no load to full load and the maximum vibration transmittedto the floor plus description of seismic qualification of theengine-generator mounting, base, and vibration isolation. Submit torsionalanalysis including prototype testing or and calculations which certify anddemonstrate that no damaging or dangerous torsional vibrations will occurwhen the prime mover is connected to the generator, at synchronous speeds, +10 percent. Vibration-isolation systems shall be designed and qualified(as an integral part of the base and mounting system in accordance with theseismic parameters specified. Where the vibration-isolation system doesnot secure the base to the structure floor or unit foundation, seismicrestraints shall be provided in accordance with the seismic parameters

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specified.

1.2.10 Fuel Consumption

**************************************************************************NOTE: Delete this paragraph for standbyapplications. For prime applications the designer

should discuss this requirement with theinstallation to determine if it is required.

**************************************************************************

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

Size Range Net kW Percent of Rated OutputCapacity

Fuel Usage kg/kWHlbs/kWH

100 - 299 75 and 100 0.2720.600

50 0.2920.643

300 - 999 75 and 100 0.2610.575

50 0.2720.600

1000 - 2500 75 and 100 0.2430.536

50 0.2600.573

Conditions:

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

b. 45 MJ/kg (19,350 Btu/pound) 19,350 Btu/pound high-heat value for fuelused.

c. Sea level operation.

d. Intake-air temperature not over 32 degrees C 90 degrees F.

e. Barometric pressure of intake air not less than 95.7 kPa 28-1/4 inchesof mercury.

1.2.11 Fuel-Consumption Rebates

**************************************************************************NOTE: Delete this paragraph for standbyapplications. The designer will consult the usingAgency to determine the projected operating hours,including exercise periods.

**************************************************************************

Fuel consumption rebates shall be assessed for failure of engine generatorset to meet guaranteed rates. If the guaranteed fuel-consumption rate for100 percent rated output capacity is verified in the tests but the ratesfor 75 or 50 percent rated output capacity are not verified, theappropriate 75 or 50 percent rate differences shall be used in assessing

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the rebates. If more than one fuel consumption guarantee is not met,rebates shall be computed for 100, 75, and 50 percent rated outputcapacity, and the highest computed figure shall be used in assessing therebates.

Rebate = H x C x D x N where:

C Local fuel costs in dollars per kg pound

D A - G

A Measured fuel consumption in kgs per second pounds per hour

G kW x R = Guaranteed fuel consumption in kgs per second poundsper hour

N Number of generator sets provided

H Operating hours over a projected period of 15 years

Adjust fuel costs to the heat value kJ/kg BTU/lb for the fuel used in thetest (requires fuel laboratory test) rationed to the 45,000 kJ/kg 19,350Btu/pound heat value used as the basis of the guarantee.

1.2.12 Harmonic Requirements

**************************************************************************NOTE: Coordinate with paragraph ENGINE-GENERATORPARAMETER SCHEDULE.

**************************************************************************

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

1.2.13 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 thetime 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 transferswitch within the starting time specified.

1.3 SUBMITTALS

**************************************************************************NOTE: Review submittal description (SD) definitionsin Section 01 33 00 SUBMITTAL PROCEDURES and editthe following list to reflect only the submittalsrequired for the project. Submittals should be keptto the minimum required for adequate quality control.

A G following a submittal item indicates that thesubmittal requires Government approval. Somesubmittals are already marked with a G. Onlydelete an existing G if the submittal item is notcomplex and can be reviewed through the Contractors

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Quality Control system. Only add a G if thesubmittal is sufficiently important or complex incontext of the project.

For submittals requiring Government approval on Armyprojects, a code of up to three characters withinthe submittal tags may be used following the "G"

designation to indicate the approving authority.Codes for Army projects using the ResidentManagement System (RMS) are: "AE" forArchitect-Engineer; "DO" for District Office(Engineering Division or other organization in theDistrict Office); "AO" for Area Office; "RO" forResident Office; and "PO" for Project Office. Codesfollowing the "G" typically are not used for Navy,Air Force, and NASA projects.

Choose the first bracketed item for Navy, Air Forceand NASA projects, or choose the second bracketeditem for Army projects.

**************************************************************************

Government approval is required for submittals with a "G" designation;submittals not having a "G" designation are for [Contractor Quality Controlapproval.] [information only. When used, a designation following the "G"designation identifies the office that will review the submittal for theGovernment.] Submit the following in accordance with Section 01 33 00SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Detailed Drawings[; G][; G, [_____]]Acceptance[; G][; G, [_____]]

SD-03 Product Data

Harmonic RequirementsEngine-Generator Parameter ScheduleHeat ExchangerGeneratorManufacturer's CatalogSite WeldingSpare PartsOnsite TrainingVibration-IsolationPosted Data and Instructions[; G][; G, [_____]]Instructions[; G][; G, [_____]]ExperienceField EngineerGeneral Installation

SD-05 Design Data

Performance CriteriaSound Limitations[; G][; G, [_____]]Integral Main Fuel Storage TankDay TankPower FactorTime-Delay on Alarms

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Battery Charger

SD-06 Test Reports

Factory Inspection and TestsFactory TestsOnsite Inspection and Tests[; G][; G, [_____]]

SD-07 Certificates

Cooling SystemVibration IsolationPrototype TestReliability and DurabilityEmissionsSound LimitationsSite VisitCurrent BalanceMaterials and EquipmentInspectionsCooling System

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals[; G][; G, [_____]]Maintenance Procedures[; G][; G, [_____]]Special ToolsFilters

1.4 QUALITY ASSURANCE

1.4.1 Conformance to Codes and Standards

Where equipment is specified to conform to requirements of any code orstandard such as UL, NEMA, etc., the design, fabrication and installationshall also conform to the code.

1.4.2 Site Welding

Weld structural members in accordance with Section 05 05 23 WELDING,STRUCTURAL. For all other welding, qualify procedures and welders inaccordance withASME BPVC SEC IX. Welding procedures qualified by others,and welders and welding operators qualified by a previously qualifiedemployer may be accepted as permitted byASME B31.1. Submit a copy ofqualifying procedures and a list of names and identification symbols ofqualified welders and welding operators. A letter listing the welderqualifying procedures for each welder, complete with supporting data suchas test procedures used, what was tested to, and a list of the names of allwelders and their identification symbols. Perform welder qualificationtests for each welder whose qualifications are not in compliance with thereferenced standards. Notify the Contracting Officer 24 hours in advanceof qualification tests which shall be performed at the work site, ifpractical. The welder or welding operator shall apply the personallyassigned symbol near each weld made as a permanent record.

1.4.3 Vibration Limitation

The maximum engine-generator set vibration in the horizontal, vertical, andaxial directions shall be limited to 0.15 mm 6 mils (peak-peak RMS), with

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an overall velocity limit of 24 mm/second 0.95 inches/second RMS, for allspeeds through 110 percent of rated speed.

1.4.4 Seismic Requirements

**************************************************************************NOTE: Provide seismic requirements, if a Government

designer (either Corps office or A/E) is theEngineer of Record, and show on the drawings.Delete the bracketed phrase if seismic details arenot provided. Pertinent portions of UFC 3-310-04and Sections 13 48 00, 13 48 00.00 10, and26 05 48.00 10, properly edited, must be included inthe contract documents.

**************************************************************************

[Seismic requirements shall be in accordance with UFC 3-310-04 and Sections13 48 00 SEISMIC PROTECTION FOR MISCELLANEOUS EQUIPMENT, 13 48 00.00 10SEISMIC PROTECTION FOR MECHANICAL EQUIPMENT and 26 05 48.00 10 SEISMICPROTECTION FOR ELECTRICAL EQUIPMENT] [as shown on the drawings].

1.4.5 Experience

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

1.4.6 Field Engineer

The engine-generator set manufacturer or assembler shall furnish aqualified field engineer to supervise the complete installation of theengine-generator set, assist in the performance of the onsite tests, andinstruct personnel as to the operational and maintenance features of theequipment. Submit a letter listing the qualifications, schools, formaltraining, and experience of the field engineer. The field engineer shallhave attended the engine generator manufacturer's training courses oninstallation and operation and maintenance of engine generator sets.

1.4.7 Detailed Drawings

Submit detailed drawings showing the following:

a. Base-mounted equipment, complete with base and attachments, includinganchor bolt template and recommended clearances for maintenance andoperation.

b. Complete starting system.

c. Complete fuel system.

d. Complete cooling system.

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e. Complete exhaust system.

f. Layout of relays, breakers, programmable controllers,switchgear, andswitches including applicable single line and wiring diagrams withwritten description of sequence of operation and the instrumentationprovided.

g. The complete lubrication system, including piping, pumps, strainers,filters, [heat exchangers for lube oil and turbocharger cooling,][electric heater,] controls and wiring.

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

i. The safety system, together with a detailed description of how it is towork. Wiring schematics, safety devices with a listing of their normalranges, alarm and shutdown values (to include operation parameters suchas pressures, temperatures voltages, currents, and speeds) shall beincluded.

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

k. Layout of each panel.

l. Mounting and support for each panel and major piece of electricalequipment.

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

1.5 DELIVERY, STORAGE, AND HANDLING

Properly protect material and equipment, in accordance with themanufacturers recommended storage procedures,before, during, and afterinstallation. Protect stored items from the weather and contamination.During installation, piping and similar openings shall be capped to keepout dirt and other foreign matter.

1.6 EXTRA MATERIALS

Submit a complete list of spare parts for each piece of equipment and acomplete list of all material and supplies needed for continued operation.Lists shall include supply source and current prices. Separate each listinto two parts, those elements recommended by the manufacturer to bereplaced after 3 years of service, and the remaining elements.

PART 2 PRODUCTS

2.1 NAMEPLATES

**************************************************************************NOTE: Delete any equipment not applicable to theproject.

**************************************************************************

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

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Engines Relays

Generators Transformers (CT & PT)

Regulators Day tanks

Pumps and pump motors Governors

Generator Breaker Air Starting System

Economizers Heat exchangers (other than basemounted)

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

Battery charger Heaters

Switchboards Exhaust mufflers

Switchgear Silencers

Battery Exciters

2.2 SAFETY DEVICES

Exposed moving parts, parts that produce high operating temperatures, partswhich may be electrically energized, and parts that may be a hazard tooperating personnel shall be insulated, fully enclosed, guarded, or fittedwith other types of safety devices. The safety devices shall be installedso that proper operation of the equipment is not impaired.

2.3 MATERIALS AND EQUIPMENT

Submit certification stating that where materials or equipment arespecified to comply with requirements of UL, written proof of suchcompliance has been obtained. The label or listing of the specifiedagency, or a written certificate from an approved, nationally recognizedtesting organization equipped to perform such services, stating that theitems have been tested and conform to the requirements and testing methodsof the specified agency are acceptable as proof.

2.3.1 Filter Elements

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

2.3.2 Instrument Transformers

NEMA/ANSI C12.11.

2.3.3 Revenue Metering

IEEE C57.13.

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

ASTM A53/A53M, orASTM A106/A106M steel pipe. Pipe smaller than 50 mm 2inches shall be Schedule 80. Pipe 50 mm 2 inches and larger shall beSchedule 40.

a. Flanges and Flanged Fittings: ASTM A181/A181M, Class 60, orASME B16.5,

Grade 1, Class 150.

b. Pipe Welding Fittings: ASTM A234/A234M, Grade WPB or WPC, Class 150 orASME B16.11, 1360.7 kg 3000 lb.

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

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

e. Gaskets: Manufacturer's standard.

2.3.5 Pipe Hangers

MSS SP-58 and MSS SP-69.

2.3.6 Electrical Enclosures

NEMA ICS 6.

2.3.6.1 Power Switchgear Assemblies

NEMA SG 6.

2.3.6.2 Switchboards

NEMA PB 2.

2.3.6.3 Panelboards

NEMA PB 1.

2.3.7 Electric Motors

Electric motors shall conform to the requirements of NEMA MG 1. Motorsshall have sealed ball bearings and a maximum speed of 1800 rpm. Motorsused indoors shall have drip-proof frames; those used outside shall betotally enclosed. Alternating current motors larger than 373 W 1/2 Hpshall be of the squirrel-cage induction type for operation on 208 volts orhigher, [50] [60] Hz, and three-phase power. Alternating current motors373 W 1/2 Hp or smaller, shall be suitable for operation on 120 volts, [50][60] Hz, and single-phase power. Direct current motors shall be suitablefor operation on [125] [_____] volts.

2.3.8 Motor Controllers

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

2.4 ENGINE

**************************************************************************NOTE: Specify fuel type if different than No. 2

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diesel.

If units are required to operate on more than onefuel the designer must edit the components,performance requirements, and testing requirementsof this specification to define the requirements forthe fuels specified. If full performance is

required for the weakest or poorest burning fuels,then the units will be overrated for other fuels.

**************************************************************************

Each engine shall operate on No. 2-D diesel fuel conforming toASTM D 975,shall be designed for stationary applications and shall be complete withancillaries. The engine shall be a standard production model shown in themanufacturer's catalog describing and depicting each engine-generator setand all ancillary equipment in sufficient detail to demonstrate completespecification compliance. The engine shall be naturally aspirated,supercharged, or turbocharged. The engine shall be 2- or 4-stroke-cycleand compression-ignition type. The engine shall be vertical in-line, V- oropposed-piston type, with a solid cast block or individually castcylinders. The engine shall have a minimum of two cylinders.

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

2.5 FUEL SYSTEM

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

2.5.1 Pumps

2.5.1.1 Main Pump

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

2.5.1.2 Auxiliary Fuel Pump

**************************************************************************NOTE: The auxiliary fuel pump is required tosupport the main pump if the length of pipe from theday tank to the main pump is greater than the valuerecommended by the engine manufacturer. This valuemay be approximately 12 m (40 feet); however, enginemanufacturers should be consulted during design toverify the pumping requirements.

**************************************************************************

Provide auxiliary fuel pumps to maintain the required engine fuel pressure,if either required by the installation or indicated on the drawings. Theauxiliary pump shall be driven by a dc electric motor powered by thestarting/station batteries. The auxiliary pump shall be automaticallyactuated by a pressure-detecting device.

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2.5.2 Fuel Filter

Provide a minimum of one full-flow fuel filter for each engine. The filtershall be readily accessible and capable of being changed withoutdisconnecting the piping or disturbing other components. The filter shallhave inlet and outlet connections plainly marked.

2.5.3 Relief/Bypass Valve

Provide a relief/bypass valve to regulate pressure in the fuel supply line,return excess fuel to a return line and prevent the build-up of excessivepressure in the fuel system.

2.5.4 Integral Main Fuel Storage Tank

**************************************************************************NOTE: Delete this paragraph if an integral mainfuel storage tank is not desired.

An integral main fuel storage tank will be the onlyfuel source for the engine. These tanks may be

useful for applications that require a minimal fuelstorage capacity.

Due to the minimal storage capacity, integral mainfuel storage tanks are not practical for prime powerusage. They are also not practical for standby unitsthat require large fuel quantities. The designershould consider the availability and anticipatedfrequency of fuel truck deliveries when decidingwhether or not to use an integral main fuel storagetank. These tanks should also not be used inlocations where a truck fueling hose can not reachthe diesel generator set.

See NFPA 99 and NFPA 110 for guidance on fuel tanksizes.

See NFPA 37 restrictions on allowable tank sizes andenclosures. Integral tanks allow for 1 to 8 hoursof operation depending on diesel generator size andconfiguration. Consult generator set manufacturerfor the proper hours of operation for theapplication of integral tanks. Standby applicationsfor use with fire pumps will have tanks sized for 8hours duration. The tank can be sized by thedesigner or the Contractor. The size of the tankshould be based on a fuel flow rate that is equal tothe value of a typical engine manufacturer for theindicated engine generator size. A value of 200percent of the expected fuel consumption of theengine is not unusual for the flow rate of the mainfuel pump. Since the excess fuel will be returnedto the tank, the designer should consider the impactof heat buildup when sizing the tank. If a fuel oilcooler is not used, the day tank size may need to beincreased to properly dissipate the heat absorbed bythe fuel.

**************************************************************************

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Provide each engine with an integral main fuel tank. Each tank shall befactory installed and provided as an integral part of the diesel generatormanufacturer's product. Each tank shall be provided with connections forfuel supply line, fuel return line, local fuel fill port, gauge, vent line,and float switch assembly. A fuel return line cooler shall be provided asrecommended by the manufacturer and assembler. The temperature of the fuel

returning to the tank shall be below the flash point of the fuel. Eachengine-generator set provided with weatherproof enclosures shall have itstank mounted within the enclosure. The fuel fill line shall be accessiblewithout opening the enclosure.

2.5.4.1 Capacity

Each tank shall have capacity [as shown] [to supply fuel to the engine foran uninterrupted [4-hour][_____] period] at 100 percent rated load withoutbeing refilled.

2.5.4.2 Local Fuel Fill

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

cap.

2.5.4.3 Fuel Level Controls

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

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

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

2.5.4.4 Arrangement

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

2.5.5 Day Tank

**************************************************************************NOTE: Delete this paragraph if an integral mainfuel storage tank is used.

See NFPA 99 and NFPA 110 for guidance on fuel tanksizes.

See NFPA 37 restrictions on allowable day tank sizesand enclosures. Select either self-supporting orintegral day tank. Select the first option belowfor applications where fuel is returned to the daytank. Select the second option below for

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applications where fuel is returned to the maintank. Integral day tanks allow for 1 to 8 hours ofoperation. Consult generator set manufacturer forthe proper hours of operation for the application ofintegral day tanks. Standby applications for usewith fire pumps will have day tanks sized for 8hours duration. Select day tank capacity for either

prime or standby application. The day tank can besized by the designer or the Contractor. The sizeof the day tank should be based on a fuel flow ratethat is equal to the value of a typical enginemanufacturer for the indicated engine generatorsize. A value of 200 percent of the expected fuelconsumption of the engine is not unusual for theflow rate of the main fuel pump. The excess fuelmay be returned to the day tank or main fuel tank.The designer should also consider the impact of heatbuildup when sizing the day tank. If a fuel oilcooler is not used or if fuel is returned to the daytank, the day tank size may need to be increased toproperly dissipate the heat absorbed by the fuel.

**************************************************************************

Each engine shall be provided with [a separate self-supporting] [integral]day tank. Submit calculations for the capacity of each day tank, includingallowances for recirculated fuel, usable tank capacity, and duration offuel supply. Each day tank shall be provided with connections for fuelsupply line, [fuel return line, fuel overflow line, local fuel fill port,gauge, vent line, drain line, and float switch assembly for control. Afuel return line cooler shall be provided as recommended by themanufacturer and assembler. The temperature of the fuel returning to theday tank shall be below the flash point of the fuel. A temperature sensingdevice shall be installed in the fuel supply line], [fuel overflow line,local fuel fill port, gauge, vent line, drain line, and float switchassembly for control]. Each engine-generator set provided withweatherproof enclosures shall have its day tank mounted within theenclosure. The fuel fill line shall be accessible without opening theenclosure.

2.5.5.1 Capacity, Prime

Each day tank shall have capacity [as shown] [to supply fuel to the enginefor an uninterrupted [8-hour] [_____] period at 100 percent rated loadwithout being refilled, plus any fuel which may be returned to the mainfuel storage tank. The calculation of the capacity of each day tank shallincorporate the requirement to stop the supply of fuel into the day tank ata "High" level mark of 90 percent of the ultimate volume of the tank].

2.5.5.2 Capacity, Standby

Each day tank shall have capacity [as shown] [to supply fuel to the enginefor an uninterrupted [4-hour] [_____] period at 100 percent rated loadwithout being refilled, plus any fuel which may be returned to the mainfuel storage tank. The calculation of the capacity of each day tank shallincorporate the requirement to stop the supply of fuel into the day tank at90 percent of the ultimate volume of the tank].

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2.5.5.3 Drain Line

Each day tank drain line shall be accessible and equipped with a shutoffvalve. Self-supporting day tanks shall be arranged to allow drainage into a305 mm 12 inch tall bucket.

2.5.5.4 Local Fuel Fill

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

2.5.5.5 Fuel Level Controls

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

a. [When the main storage tank is located higher than the day tank, openthe solenoid valve located on the fuel supply line entering the daytank and start the supply of fuel into the day tank] [Start the supplyof fuel into the day tank] when the fuel level is at the "Low" levelmark, 75 percent of the rated tank capacity.

b. [When the main storage tank is located higher than the day tank, stopthe supply of fuel into the day tank and close the solenoid valvelocated on the fuel supply line entering the day tank] [Stop thesupply of fuel into the day tank] when the fuel level is at 90 percentof the rated tank capacity.

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

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

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

2.5.5.6 Arrangement

**************************************************************************NOTE: Select between integral and self supportingday tanks. Also, select between applications wherethe main fuel storage tank is located above the daytank and applications where the main fuel storagetank is located below the day tank. The location ofall tanks, piping, and valves should also beindicated on the drawings.

**************************************************************************

[Integral day tanks may allow gravity flow into the engine. Gravity flowtanks shall be provided with an internal or external valve located as nearas possible to the shell of the tank. The valve shall close when theengine is not operating. Integral day tanks shall be provided with anynecessary pumps to supply fuel to the engine as recommended by thegenerator set manufacturer. The overflow connection and the fuel supplyline for integral day tanks which do not rely upon gravity flow shall be

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arranged so that the highest possible fuel level is below the fuelinjectors.] [Self-supporting day tanks shall either be arranged so thatthe fuel level in the day tank remains above the suction port of the enginedriven fuel pump or be provided with a transfer pump to provide fuel to theengine driven pump. The overflow connection and fuel supply line shall bearranged so that the highest possible fuel level is below the fuelinjectors.] [When the main fuel storage tanks are located below the day

tank, a check valve shall be provided in the fuel supply line entering theday tank.] [When the main fuel storage tanks are located above the daytank, a solenoid valve shall be installed in the fuel supply line enteringthe day tank. The solenoid valve shall be in addition to the automaticfuel shut off valve.] The fuel supply line from the day tank to themanufacturer's standard engine connection shall be welded pipe.

2.5.6 Fuel Supply System

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

2.6 LUBRICATION

**************************************************************************NOTE: Delete the adjustable requirement forpressure regulation on sets smaller than 1000 kW.Sets larger than 500 kW will utilize apressure-relief valve on the crankcase. Showcrankcase vent piping for indoor installations.

**************************************************************************

Each engine shall have a separate lube-oil system conforming to NFPA 30 andNFPA 37. Each system shall be pressurized by engine-driven pumps. Systempressure shall be regulated as recommended by the engine manufacturer. Apressure relief valve shall be provided on the crankcase for closedsystems. The crankcase shall be vented in accordance with themanufacturer's recommendation except that it shall not be vented to theengine exhaust system. Crankcase breathers, if provided on enginesinstalled in buildings or enclosures, shall be piped to vent to theoutside. The system shall be readily accessible for service such asdraining, refilling, etc. Each system shall permit addition of oil andhave oil-level indication with the set operating. The system shall utilizean oil cooler as recommended by the engine manufacturer.

2.6.1 Lube-Oil Filter

Provide one full-flow filter for each pump. The filter shall be readilyaccessible and capable of being changed without disconnecting the piping ordisturbing other components. The filter shall have inlet and outletconnections plainly marked.

2.6.2 Lube-Oil Sensors

Equip each engine with lube-oil pressure sensors located downstream of thefilters and provide signals for required indication and alarms. Submit twocomplete sets of filters, required for maintenance, supplied in a suitablestorage box. These filters shall be in addition to filters replaced aftertesting.

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2.6.3 Precirculation Pump

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

2.7 COOLING SYSTEM

**************************************************************************NOTE: Coordinate with paragraph SYSTEM DESCRIPTION.

**************************************************************************

Provide each engine with its own cooling system to operate automaticallywhile its engine is running. The cooling system coolant shall use acombination of water and ethylene-glycol sufficient for freeze protectionat the minimum winter outdoor temperature specified. The maximumtemperature rise of the coolant across each engine shall not exceed thatrecommended below. Submit a letter which certifies that theengine-generator set and cooling system function properly in the ambienttemperature specified, stating the following values:

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

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

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

2.7.1 Coolant Pumps

**************************************************************************NOTE: Delete raw-water pump for closed-loop systems.

**************************************************************************

Coolant pumps shall be the centrifugal type. Each engine shall have anengine-driven primary pump. Secondary pumps shall be electric motor drivenand have automatic controllers. Raw-water circulating pump shall becontrolled by manual-off-automatic controllers and shall be [electricmotor] [engine] driven.

2.7.2 Heat Exchanger

Each heat exchanger shall be of a size and capacity to limit the maximumallowable temperature rise in the coolant across the engine to thatrecommended and submitted for the maximum summer outdoor design temperatureand site elevation. Submit manufacturer's data to quantify heat rejectedto the space with the engine generator set at rated capacity. Each heatexchanger shall be corrosion resistant, suitable for service in ambientconditions of application.

2.7.2.1 Fin-Tube-Type Heat Exchanger (Radiator)

**************************************************************************NOTE: Retain this paragraph and remove the next oneas required by the project.

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