Base Build-Out, ANA Regional Brigade, Herat, Afghanistan AFHERATA

SECTION 16263

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

PART 1 GENERAL

1.1 REFERENCES

Unless otherwise specified or indicated, electrical and electronics terms

used in these specifications and on the Drawings, shall be defined in DIN,
I.E.C., BS or EN standards.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI C12.11 (1987; R 1993) Instrument Transformers for

Revenue Metering, 10 kV BIL through 350 kV
BIL (0.6 kV NSV through 69 kV NSV)

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

Analog Indicating Instruments

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A 53/A 53M (2001) Pipe, Steel, Black and Hot-Dipped,

Zinc-Coated, Welded and Seamless

ASTM A 106 (2002) Seamless Carbon Steel Pipe for

High-Temperature Service

ASTM A 181/A 181M (2001) Carbon Steel Forgings, for

General-Purpose Piping

ASTM A 234/A 234M (2001a) Piping Fittings of Wrought Carbon

Steel and Alloy Steel for Moderate and
High Temperature Service

ASTM D 975 (1998b) Diesel Fuel Oils

ASME INTERNATIONAL (ASME)

ASME B16.3 (1998) Malleable Iron Threaded Fittings

ASME B16.5 (1996) Pipe Flanges and Flanged Fittings

ASME B16.11 (2001) Forged Fittings, Socket-Welding and

Threaded

ELECTRICAL GENERATING SYSTEMS ASSOCIATION (EGSA)

EGSA 101P (1995a) Engine Driven Generator Sets

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C57.13.1 (1981; R 1992) IEEE Guide for Field

Testing of Relaying Current Transformers

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IEEE Std 1 (1986; R 1992) General Principles for

Temperature Limits in the Rating of
Electric Equipment and for the Evaluation
of Electrical Insulation

IEEE Std 43 (1974; R 1991) Testing Insulation

Resistance of Rotating Machinery

IEEE Std 100 (1997) IEEE Standard Dictionary of

Electrical and Electronics Terms

IEEE Std 115 (1995) IEEE Guide: Test Procedures for

Synchronous Machines

IEEE Std 120 (1989) Electrical Measurements in Power

Circuits

IEEE Std 519 (1992) Harmonic Control in Electrical

Power systems

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-58 (1993) Pipe Hangers and Supports -

Materials, Design and Manufacture

MSS SP-69 (1996) Pipe Hangers and Supports -

Selection and Application

MSS SP-80 (1997) Bronze Gate, Globe, Angle and Check

Valves

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 6 (1993; R 2001) Industrial Control and

Systems, Enclosures

NEMA MG 1 (1998; Rev 1, 2000) Motors and Generators

NEMA PB 1 (1995) Panelboards

NEMA PB 2 (1995) Deadfront Distribution Switchboards

NEMA SG 5 (1995) Power Switchgear Assemblies

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 30 (2000) Flammable and Combustible Liquids

Code

NFPA 70 (2002) National Electrical Code

NFPA 99 (1999) Health Care Facilities

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE J537 (1996) Storage Batteries

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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 shall be
submitted in accordance with Section 01335 SUBMITTAL PROCEDURES:

SD-03 Product Data

Performance Criteria; G
Sound Limitations; G
Harmonic Requiremants; G
Engine-Generator Parameter Schedule; G
Power Factor; G
Heat Rejected To Engine-Generator Space; G
Cooling System; G
Time-Delay on Alarms; G
Generator; G

The generator kW rating and short circuit current capacity (both

symmetric and asymmetric).

Manufacturer's Catalog; G
Site Welding; G
Spare Parts; G
Onsite Training; G
Battery Charger; G
Vibration-Isolation; G
Posted Data and Instructions; G
Instructions; G

SD-06 Test Reports

Factory Inspection and Tests; G

Factory Tests; G

SD-07 Certificates

Vibration Isolation; G
Prototype Test; G
Reliability and Durability; G
Emissions; G
Sound Limitations; G
Flywheel Balance; G
Materials and Equipment; G
Cooling System; G

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals; G

Maintenance Procedures; G
Special Tools; G
Filters; G

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1.3 SYSTEM DESCRIPTION

Prime Power Generators: Generators shall be skid mounted industry size,

1500 RPM, diesel-engine Caterpillar DITA Prime Rated engine-generator sets.
Number of units shall be nine (Caterpillar 3512B diesel engine with
Caterpillar SR4B generator). Generating voltage shall be 3 phase, 380/220
volts, and 50 hertz, stepped up to 15kV, via transformers, for base wide
Primary Power Distribution through generator switchgear described below.
Each generator shall be provided with a day tank with a minimum fuel
capacity of 8 hours operating at 100% generated rated (kW) load. Maximum
generator size shall not exceed 1000kW (1275 kVA).

Generator Synchronizing Equipment: Generator synchronizing/paralleling

equipment shall be provided, in order for the generator(s) to synchronize
with an operating generator, prior to coming on-line. Minimum of one (1)
prime power generator shall be on line at all times. With an increase of
the demand load, all stand-by generator(s) shall start and the generator
that synchronizes first with the operating generator shall come on-line and
share load equally. The other generator(s) shall run through a complete
cool-down cycle and then stop. Similarly, with a decrease in the demand
load, the generator(s) shall drop-off line, one at a time, keeping a
minimum of one generator operating on-line. All generators shall go through
a cool-down cycle prior to coming to stop. All relaying shall be
automatically reset for automatic restart and stopping of generators as the
load demands increase or decrease. Load sharing by the stand-by
generator(s) shall be adjustable between 50% to 85% load on the operating
generator(s). Synchronizing/paralleling of generators shall be automatic
and manual.

Generator Paralleling/ Synchronizing Equipment Computer Software Operation:

The Contractor shall provide software for programming of the additional
generator paralleling/ synchronizing equipment.

1.3.1 Rated Output Capacity

Each engine-generator-set shall provide power equal to the sum of Service

Load plus the machine's efficiency loss and associated ancillary equipment
loads. Rated output capacity shall also consider engine and/or generator
oversizing required due to installation elevation.

1.3.2 Power Ratings

Power ratings shall be in accordance with EGSA 101P or equivalent DIN,

I.E.C., BS or EN standards.

1.3.3 Transient Response

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

1.3.5 Reliability and Durability

Each engine-generator set shall have both an engine and a generator capable
of delivering the specified power with an anticipated mean time between

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

1.4 GENERAL REQUIREMENTS

1.4.1 Engine-Generator Set

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

Included as part of the engine assembly, a manufacturers standard fuel oil

cooler is to be installed at the rear of the radiator. Cooler is to reduce
the fuel oil temperature returning back into the day tank system.

1.4.2 Nameplates

Each major component of this specification shall have the manufacturer's

name, type or style, model or serial number and rating on a plate secured
to the equipment. As a minimum, nameplates shall be provided for:

Engines Relays
Generators Transformers (CT & PT)
Regulators Day tanks
Pumps and pump motors Governors
Generator Breaker Air Starting System
Economizers Heat exchangers (other than base
mounted)

Where the following equipment is not provided as a standard component by

the diesel engine generator set manufacturer, the nameplate information may
be provided in the maintenance manual in lieu of nameplates.

Battery charger Heaters

Switchboards Exhaust mufflers
Switchgear Silencers
Battery Exciters

1.4.3 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 shall be insulated, fully enclosed, guarded, or fitted
with other types of safety devices. The safety devices shall be installed

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so that proper operation of the equipment is not impaired.

1.4.4 Verification of Dimensions

Before performing any work, the premises shall be visited and all details
of the work verified. The Contracting Officer shall be advised in writing
of any discrepancies.

1.4.5 Site Welding

Structural members shall be welded in accordance with DIN, I.E.C., BS or EN

standards. Welder qualification tests shall be performed for each welder
whose qualifications are not in compliance with the referenced standards.
The Contracting Officer shall be notified 24 hours in advance of
qualification tests. The qualification tests shall be performed at the
work site if practical. The welder or welding operator shall apply his
assigned symbol near each weld he makes as a permanent record.

1.4.6 Parallel Operation for use with Future Utility

Each engine-generator set specified for parallel operation shall be

configured for automatic and manual parallel operation. Each set shall be
capable of parallel operation with a future commercial power source on an
infinite bus and with one or more sets on an isolated bus.

Additional spaces in switchgear shall be provided to add paralleling

switchgear to operate as described herein.

Upon receiving a utility power failure signal or variance in power loads,

switchgear starts engine generator(s) and controls their synchronization
and individual circuit breaker closure to parallel the generators onto the
bus. Additional controls allow transfer of loads to the operating bus on a
priority basis.

Provisions shall be made upon return of the preferred source, utility

paralleling switchgear synchronizes and parallels the engine generators to
the preferred source, and transfers the loads without power interruption.
Generator test - transferring load from source to source without power
interruption - is also available. Use of the closed transition operation
minimizes load interruptions during test and transfer.

All equipment shall be UL and/or IEC listed.

The switchgear shall be provided with selector switches for open or closed
transition; automatic or manual paralleling of generator or utility
sources; automatic or manual retransfer to a normal source.

The switch gear shall be provided with active synchronization, PLC

controls, soft loading power factor, and interconnecting protective relay
design.

1.4.7 Vibration Limitation

The maximum engine-generator set vibration in the horizontal, vertical, and

axial directions shall be limited to 0.15 mm (peak-peak RMS), with an
overall velocity limit of 24 mm/second RMS, for all speeds through 110% of
rated speed.

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1.4.8 Vibration Isolation

Vibration-isolation systems shall be designed and qualified (as an integral

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

1.4.9 Seismic Requirements

Seismic requirements shall be in accordance with Section 16070 SEISMIC

PROTECTION FOR ELECTRICAL EQUIPMENT.

1.4.10 Fuel Consumption

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

Size Range % of Rated Fuel Usage

Net kW Output capacity kg/kWH (lbs/kWH)

100 - 299 75 and 100 0.272 (0.600)

50 0.292 (0.643)

300 - 999 75 and 100 0.261 (0.575)

50 0.272 (0.600)

1000 - 2500 75 and 100 0.243 (0.536)

50 0.260 (0.573)

Conditions:

a. Net kW of the Set corrected for engine auxiliaries that are

electrically driven, where kW is electrical kilowatt hours.

b. 45 megajoules per kilogram (19,350 Btu per pound) high-heat value

for fuel used.

c. Sea level operation.

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

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

1.4.11 Harmonic Requirements

Non-linear loads to be served by each engine-generator set are as

indicated.

1.4.12 Starting Time Requirements

Upon receipt of a signal to start, each engine generator set will start,
reach rated frequency and voltage and be ready to assume load within the
time specified.

1.4.13 Field Engineer

The engine-generator set manufacturer or assembler shall furnish a

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qualified field engineer to supervise the complete installation of the

engine-generator set(s), assist in the performance of the onsite tests, and
instruct personnel as to the operational and maintenance features of the
equipment. The field engineer shall have attended the engine generator
manufacturer's training courses on installation and operation and
maintenance of engine generator sets.

1.5 STORAGE AND INSTALLATION

The Contractor shall properly protect material and equipment, in accordance

with the manufacturers recommended storage procedures,before, during, and
after installation. Stored items shall be protected from the weather and
contamination. During installation, piping and similar openings shall be
capped to keep out dirt and other foreign matter.

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

2.1.1 Product

Prime Generator: Product shall be Caterpillar, Model 3512B-DITA. Diesel

Engine Generator.

Generator shall be rated for 380/220 voltage, 3 phase, 50 hertz.

2.1.2 Filter Elements

Fuel-oil, lubricating-oil, and combustion-air filter elements shall be

manufacturer's desert filter package.

2.1.3 Instrument Transformers

ANSI C12.11 or equivalent DIN, I.E.C., BS or EN standards.

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

ASTM A 53/A 53M, ASTM A 106 , or equivalent DIN, I.E.C., BS, or EN standard
steel pipe. Pipe smaller than 50 mm shall be Schedule 80. Pipe 50 mm
and larger shall be Schedule 40.

a. Flanges and Flanged Fittings: ASTM A 181/A 181M, Class 60, or

ASME B16.5, Grade 1, Class 150, or equivalent DIN, I.E.C., BS, or
EN standards.

b. Pipe Welding Fittings: ASTM A 234/A 234M, Grade WPB or WPC, Class
150, ASME B16.11, or equivalent DIN, I.E.C., BS, or EN standards,
1360.7 kg .

c. Threaded Fittings: ASME B16.3, Class 150, or equivalent DIN,

I.E.C., BS or EN standards.

d. Valves: MSS SP-80, Class 150, or equivalent DIN, I.E.C., BS or EN

standards.

e. Gaskets: Manufacturer's standard.

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2.1.5 Pipe Hangers

MSS SP-58 and MSS SP-69, or equivalent DIN, I.E.C., BS or EN standards.

2.1.6 Electrical Enclosures

NEMA ICS 6 or equivalent DIN, I.E.C., BS or EN standards.

2.1.6.1 Power Switchgear Assemblies

NEMA SG 5 or equivalent DIN, I.E.C., BS or EN standards.

2.1.6.2 Switchboards

NEMA PB 2 or equivalent DIN, I.E.C., BS or EN standards.

2.1.6.3 Panelboards

NEMA PB 1 or equivalent DIN, I.E.C., BS or EN standards.

2.2 ENGINE

Each engine shall operate on No. 2-D diesel fuel conforming to ASTM D 975
or equivalent DIN, I.E.C., BS or EN standards., shall be designed for
stationary applications and shall be complete with ancillaries. The engine
shall be a standard production model described in the manufacturer's catalog.
The engine shall be naturally aspirated, supercharged, or turbocharged.
The engine shall be 2- or 4-stroke-cycle and compression-ignition type.
The engine shall be vertical in-line, V- or opposed-piston type, with a
solid cast block or individually cast cylinders. The engine shall have a
minimum of two cylinders. Opposed-piston type engines shall have not less
than four cylinders. Each block shall have a coolant drain port. Each
engine shall be equipped with an overspeed sensor.

2.3 FUEL SYSTEM

The entire fuel system for each engine-generator set shall conform to the
requirements of NFPA 30 for the Power plant and equivalent DIN, BS, EN, or
I.E.C. standards for all buildings and contain the following elements.

2.3.1 Pumps

2.3.1.1 Main Pump

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

2.3.1.2 Auxiliary Fuel Pump

Auxiliary fuel pumps shall be provided to maintain the required engine fuel
pressure, if either required by the installation or indicated on the
drawings. The auxiliary pump shall be driven by a dc electric motor
powered by the starting/station batteries. The auxiliary pump shall be
automatically actuated by a pressure-detecting device.

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2.3.2 Fuel Filter

A minimum of one full-flow fuel filter shall be provided for each engine.
The filter shall be readily accessible and capable of being changed without
disconnecting the piping or disturbing other components. The filter shall
have inlet and outlet connections plainly marked.

2.3.3 Relief/Bypass Valve

A relief/bypass valve shall be provided to regulate pressure in the fuel

supply line, return excess fuel to a return line and prevent the build-up
of excessive pressure in the fuel system.

2.4 LUBRICATION

Each engine shall have a separate lube-oil system conforming to NFPA 30 for
the Power plant and equivalent DIN, BS, EN, or I.E.C. standards for all
buildings. Each system shall be pressurized by engine-driven pumps.
System pressure shall be regulated as recommended by the engine
manufacturer. A pressure relief valve shall be provided on the crankcase
for closed systems. The crankcase shall be vented in accordance with the
manufacturer's recommendation except that it shall not be vented to the
engine exhaust system. Crankcase breathers, if provided on engines
installed in buildings or enclosures, shall be piped to vent to the
outside. The system shall be readily accessible for service such as
draining, refilling, etc. Each system shall permit addition of oil and
have oil-level indication with the set operating. The system shall utilize
an oil cooler as recommended by the engine manufacturer.

2.4.1 Lube-Oil Filter

One full-flow filter shall be provided for each pump. The filter shall be
readily accessible and capable of being changed without disconnecting the
piping or disturbing other components. The filter shall have inlet and
outlet connections plainly marked.

2.4.2 Lube-Oil Sensors

Each engine shall be equipped with lube-oil pressure sensors. Pressure

sensors shall be located downstream of the filters and provide signals for
required indication and alarms.

2.4.3 Precirculation Pump

A motor-driven precirculation pump powered by the station battery, complete

with motor starter shall be provided if recommended by the engine
manufacturer.

2.5 COOLING SYSTEM

Each engine shall have its own cooling system. Each system shall operate
automatically while its engine is running. The cooling system coolant
shall use a combination of water and ethylene-glycol sufficient for freeze
protection at the minimum winter outdoor temperature specified. The
maximum temperature rise of the coolant across each engine shall not exceed
that recommended and submitted in paragraph SUBMITTALS.

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2.5.1 Coolant Pumps

Coolant pumps shall be the centrifugal type. Each engine shall have
engine-driven primary pumps.

2.5.2 Heat Exchanger

Each heat exchanger shall be of a size and capacity to limit the maximum
allowable temperature rise in the coolant across the engine to that
recommended and submitted in paragraph SUBMITTALS for the maximum summer
outdoor design temperature and site elevation. Each heat exchanger shall
be corrosion resistant, suitable for service in ambient conditions of
application.

2.5.2.1 Fin-Tube-Type Heat Exchanger (Radiator)

Heat exchanger may be factory coated with corrosive resistant film,

provided that correction measures are taken to restore the heat rejection
capability of the radiator to the initial design requirement via over
sizing, or other compensating methods. Internal surfaces shall be
compatible with liquid fluid coolant used. Materials and coolant are
subject to approval by the Contracting Officer. Heat exchangers shall be
pressure type incorporating a pressure valve, vacuum valve and a cap. Caps
shall be designed for pressure relief prior to removal. Each heat
exchanger and the entire cooling system shall be capable of withstanding a
minimum pressure of 48 kPa (7 psi) and shall be protected with a strong
grille or screen guard. Each heat exchanger shall have at least two tapped
holes; one tapped hole shall be equipped with a drain cock, the rest shall
be plugged.

The outside mean design ambient temperature at the project altitude is 95

degrees F/35 degrees C. At times it is possible for the outside air to
exceed the 35 degrees C. Temperatures in the range of 104 degrees F/40
degrees C. is probable. The indoor engine generator room temperature can
increase by up to 15 degrees C. due to heat produced by the engines as this
is a 24/7 system operation. Based on this, it is possible for the engine
radiators to experience 124-130 degrees F/51-55 degrees C. temperatures at
the rear face of the radiator. Design load calculations do not allow for
de-ration of the engine generator set due to temperatures in the range
indicated above and at the installed altitude. If the radiator normally
provided with the engine cannot provide proper cooling of the engine under
these conditions (55 degrees C), the manufacturer will provide a radiator
with capacity that will provide the system cooling necessary for the proper
operation of the engine without system de-ration. The openings through the
building exterior wall are sized generically for a standard radiator
provided with the specified engine. If the radiator actually used is
larger/smaller than the openings allowed for on the drawings, the openings
will be adjusted to properly accommodate the actual radiator being
provided. Shop drawings are to be submitted indicating any building
changes for approval by the project structural engineer.

2.5.3 Thermostatic Control Valve

A modulating type, thermostatic control valve shall be provided in the

coolant system to maintain the coolant temperature range submitted in
paragraph SUBMITTALS.

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2.5.4 Ductwork

Ductwork shall be as specified in Section 15895 AIR SUPPLY, DISTRIBUTION,

VENTILATION, AND EXHAUST SYSTEM except that a flexible connection shall be
used to connect the duct to the diesel engine radiator. Material for the
connection shall be wire-reinforced glass. The connection shall be
rendered as airtight as possible.

2.5.5 Temperature Sensors

Each engine shall be equipped with coolant temperature sensors.

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

2.6 AIR INTAKE EQUIPMENT

Filters and silencers shall be provided in locations that are convenient

for servicing. The silencer shall be of the high-frequency filter type,
located in the air intake system as recommended by the engine manufacturer.
Silencer shall be capable of reducing the noise level at the air intake so
that the indicated pressure levels specified in paragraph SOUND LIMITATIONS
will not be exceeded. A combined filter-silencer unit meeting requirements
for the separate filter and silencer items may be provided. Expansion
elements in air-intake lines shall be copper.

2.7 EXHAUST SYSTEM

The system shall be separate and complete for each engine. Piping shall be
supported to minimize vibration. Where a V-type engine is provided, a
V-type connector, with necessary flexible sections and hardware, shall
connect the engine exhaust outlets.

2.7.1 Flexible Sections and Expansion Joints

A flexible section shall be provided at each engine and an expansion joint

at each muffler. Flexible sections and expansion joints shall have flanged
connections. Flexible sections shall be made of convoluted seamless tube
without joints or packing. Expansion joints shall be the bellows type.
Expansion and flexible elements shall be stainless steel suitable for
diesel-engine exhaust gas at the maximum exhaust temperature that is
specified by the engine manufacturer. Expansion and flexible elements
shall be capable of absorbing vibration from the engine and compensation
for thermal expansion and contraction.

2.7.2 Exhaust Muffler

A chamber type exhaust muffler shall be provided. The muffler shall be

constructed of welded steel and designed for inside horizontal mounting.
Eyebolts, lugs, flanges, or other items shall be provided as necessary for
support in the location and position indicated. Pressure drop through the
muffler shall not exceed the recommendations of the engine manufacturer.
Outside mufflers shall be zinc coated or painted with high temperature 800
degrees C resisting paint. The muffler and exhaust piping together shall
reduce the noise level to less than the maximum acceptable level listed for
sound limitations in paragraph SOUND LIMITATIONS. The muffler shall have a
drain valve, nipple, and cap at the low-point of the muffler.

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2.7.3 Exhaust Piping

Horizontal sections of exhaust piping shall be sloped downward away from

the engine to a drip leg for collection of condensate with drain valve and
cap. Changes in direction shall be long radius. Exhaust piping, mufflers
and silencers installed inside any building shall be fully insulated with
100 mm (4 inches) calcium silicate insulation and covered with aluminum
protective jacket and covered to protect personnel. Vertical exhaust
piping shall be provided with a hinged, gravity-operated, self-closing,
rain cover.

2.8 STARTING SYSTEM

The starting system for engine generator sets used in non-emergency

applications shall be as follows.

2.8.1 Controls

An engine control switch shall be provided with functions including:

run/start(manual), off/reset, and, automatic mode. Start-stop logic shall
be provided for adjustable cycle cranking and cooldown operation. The
logic shall be arranged for fully automatic starting in accordance with
paragraph AUTOMATIC ENGINE-GENERATOR-SET SYSTEM OPERATION. Electrical
starting systems shall be provided with an adjustable cranking limit device
to limit cranking periods from 1 second up to the maximum duration.

2.8.2 Capacity

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

summer temperature specified to crank the engine without damage or
overheating. The system shall be capable of providing a minimum of three
cranking periods with 15 second intervals between cranks. Each cranking
period shall have a maximum duration of 15 seconds.

2.8.3 Electrical Starting

Manufacturers recommended dc system, utilizing a negative circuit ground.

2.8.3.1 Battery

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

Batteries:

Capacity: 1300 cold-cranking amps; 400 minute reserve capacity.

Quantity: Four.

Arrangement: One set of two batteries in parallel (for 24 vdc

output).

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Product: Caterpillar Model 7L7872

2.8.3.2 Battery Charging

Engine-mounted, 24 vdc, 45 amp alternator.

2.8.4 Starting Aids

The manufacturer shall provide one or more of other following methods to

assist engine starting.

2.8.4.1 Battery Heating Pads

Provide thermostatically controlled battery heating pads for each set of

engine batteries. Heating pads shall be connected to the 220 volts, 50 hz
AC system.

2.8.4.2 Jacket-Coolant Heaters

A thermostatically controlled electric heater shall be mounted in the

engine coolant jacketing to automatically maintain the coolant within plus
or minus 1.7 degrees C temperature. The heater shall operate
independently of engine operation so that starting times are minimized.
Power for the heaters shall be rated at 5000 watts at 220 volts ac, 50 Hz,
1 phase.

a. Prime Rated Sets

The control temperature shall be the higher of the manufacturer's

recommended temperature or the minimum coolant inlet temperature of the
engine recommended in paragraph SUBMITTALS.

2.9 GOVERNOR

Each engine shall be provided with a governor which maintains the frequency
within a bandwidth of the rated frequency, over a steady-state load range
of zero to 100% of rated output capacity. The governor shall be configured
for safe manual adjustment of the speed/frequency during operation of the
engine-generator set, without special tools, from 90 to 110% of the rated
speed/frequency, over a steady state load range of 0 to 100% or rated
capacity.

Product: Caterpillar ADEM Electronic Engine Control.

2.9.1 Governor Performance

Isochronous governors shall maintain the midpoint of the frequency

bandwidth at the same value for steady-state loads over the range of zero
to 100% of rated output capacity.

2.10 GENERATOR

Each generator shall be of the synchronous type, two bearing, close coupled
type, conforming to NEMA MG 1 or equivalent DIN, I.E.C., BS or EN standards,
equipped with winding terminal housings in accordance with NEMA MG 1 or
equivalent DIN, I.E.C., BS or EN standards, equipped with an amortisseur
winding, and directly connected to the engine. Insulation shall be Class H.
Generator design shall protect against mechanical, electrical and thermal
damage due to vibration, 25% overspeeds, or voltages and temperatures at a

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rated output capacity of 110% for prime applications and 100% for standby
applications. Generator ancillary equipment shall meet the short circuit
requirements of NEMA MG 1 or equivalent DIN, I.E.C., BS or EN standards.
Frames shall be the drip-proof type.

2.10.1 Current Balance

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

2.10.2 Voltage Balance

At any balanced load between 75 and 100% of rated output capacity, the
difference in line-to-neutral voltage among the 3 phases shall not exceed
1% of the average line-to-neutral voltage. For a single-phase load
condition, consisting of 25% load at unity power factor placed between any
phase and neutral with no load on the other 2 phases, the maximum
simultaneous difference in line-to-neutral voltage between the phases shall
not exceed 3% of rated line to neutral voltage. The single-phase load
requirement shall be valid utilizing normal exciter and regulator control.
The interpretation of the 25% load for single phase load conditions means
25% of rated current at rated phase voltage and unity power factor.

2.10.3 Waveform

The deviation factor of the line-to-line voltage at zero load and at

balanced rated output capacity shall not exceed 10%. The RMS of all
harmonics shall be less than 5.0% and that of any one harmonic less than
3.0% of the fundamental at rated output capacity. Each engine-generator
shall be designed and configured to meet the total harmonic distortion
limits of IEEE Std 519 or equivalent DIN, I.E.C., BS or EN standards.

2.11 EXCITER

The generator exciter shall be of the brushless type. Semiconductor

rectifiers shall have a minimum safety factor of 300% for peak inverse
voltage and forward current ratings for all operating conditions, including
110% generator output at 4O degrees C ambient. The exciter and regulator
in combination shall maintain generator-output voltage within the limits
specified.

2.12 VOLTAGE REGULATOR

Each generator shall be provided with a solid-state voltage regulator,

separate from the exciter. The regulator shall maintain the voltage within
a bandwidth of the rated voltage, over a steady-state load range of zero to
100% of rated output capacity. Regulator shall be configured for safe
manual adjustment of the engine-generator voltage output without special
tools, during operation, from 90 to 110% of the rated voltage over the
steady state load range of 0 to 100% of rated output capacity. Regulation
drift shall not exceed plus or minus 0.5% for an ambient temperature change
of 20 degrees C. Reactive droop compensation or reactive differential
compensation shall load share the reactive load proportionally between sets
during parallel operation.

Product: Caterpillar Digital Voltage Regulator.

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2.12.1 Steady State Performance (Regulation or Voltage Droop)

The voltage regulator shall have a maximum droop of 2% of rated voltage

over a load range from 0 to 100% of rated output capacity and automatically
maintain the generator output voltage within the specified operational
bandwidth.

2.13 GENERATOR ISOLATION AND PROTECTION (PRIME)

Devices necessary for electrical protection and isolation of each

engine-generator set and its ancillary equipment shall be provided. The
generator circuit breaker (IEEE Device 52) ratings shall be consistent with
the generator rated voltage and frequency, with continuous, short circuit
withstand, and interrupting current ratings to match the generator
capacity. The generator circuit breaker shall be operated as indicated. A
set of surge capacitors, to be mounted at the generator terminals shall be
provided. Monitoring and control devices shall be as specified in paragraph
GENERATOR PANEL.

2.14 SAFETY SYSTEM

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

2.14.1 Audible Signal

The audible alarm signal shall be continuously activated upon alarm and
silenced upon acknowledgment. Signal devices shall be located as shown.

2.14.2 Visual Signal

The visual alarm signal shall be a panel light. The light shall be
normally off, activated to be blinking upon alarm. The light shall change
to continuously lit upon acknowledgement. If automatic shutdown occurs,
the display shall maintain activated status to indicate the cause of
failure and shall not be reset until cause of alarm has been cleared and/or
restored to normal condition. Shutdown alarms shall be red; all other
alarms shall be amber.

2.14.3 Alarms and Action Logic

2.14.3.1 Shutdown

Simultaneous activation of the audible signal, activation of the visual

signal, stopping the engine, and opening the generator main circuit
breakers shall be accomplished.

2.14.3.2 Problem

Activation of the visual signal shall be accomplished.

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2.14.4 Local Alarm Panel

A local alarm panel shall be provided with the following shutdown and alarm
functions in accordance with NFPA 99 and including the listed Corps of
Engineer requirements mounted either on or adjacent to the engine generator
set.

2.14.5 Time-Delay on Alarms

For startup of the engine-generator set, time-delay devices shall be

installed bypassing the low lubricating oil pressure alarm during cranking,
and the coolant-fluid outlet temperature alarm. The lube-oil time-delay
device shall return its alarm to normal status after the engine starts.
The coolant time-delay device shall return its alarm to normal status 5
minutes after the engine starts.

2.14.6 Remote Alarm Panel

A remote alarm panel shall be provided as indicated.

2.15 ENGINE GENERATOR SET CONTROLS AND INSTRUMENTATION

Devices, wiring, remote panels, local panels, etc. shall be provided and
installed as a complete system to automatically activate the appropriate
signals and initiate the appropriate actions.

2.15.1 Controls

A local control panel shall be provided with controls as follows.

High coolant temperature, low oil pressure, and low water temperature
alarms.

High coolant temperature, low oil pressure, and engine overspeed and
overcrank shutdowns.

Engine instrumentation for coolant temperature, oil pressure, run hour,

DC voltage indicator and emergency shutdown.

Generator instrumentation for AC volts, amps, frequency, kW, kVA, kVAR,

kWhr, kWARhr, PF, and percent of rated load.

Product: Caterpillar Model EMCP II+ Generator Control Panel.

2.15.2 Engine Generator Set Metering and Status Indication

A local panel shall be provided.

2.16 GENERATOR SYNCHRONIZING/CONTROL SWITCHBOARD (PRIME)

2.17 PANELS

Each panel shall be of the type and kind necessary to provide specified
functions. Panels shall be mounted as shown. Instruments shall be mounted
flush or semiflush. Convenient access to the back of panels shall be
provided to facilitate maintenance. Instruments shall be calibrated using
recognized industry calibration standards. Each panel shall be provided
with a panel identification plate which clearly identifies the panel
function. Each instrument and device on the panel shall be provided with a
plate which clearly identifies the device and its function as indicated.

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Switch plates shall clearly identify the switch-position function.

2.17.1 Enclosures

Enclosures shall be designed for the application and environment.

2.17.2 Analog

Analog electrical indicating instruments shall be in accordance with ANSI

C39.1 or equivalent DIN, I.E.C., BS or EN standards with semiflush
mounting. Switchboard, switchgear, and control-room panel-mounted
instruments shall have 250 degree scales with an accuracy of not less than
99%. Unit-mounted instruments shall be the manufacturer's standard with an
accuracy of not less than 98%. The instrument's operating temperature
range shall be minus 20 to plus 65 degrees C. Distorted generator output
voltage waveform of a crest factor less than 5 shall not affect metering
accuracy for phase voltages, hertz and amps.

2.17.3 Electronic

Electronic indicating instruments shall be true RMS indicating instruments,

100% solid state, state-of-the-art, microprocessor controlled to provide
specified functions. Control, logic, and function devices shall be
compatible as a system, sealed, dust and water tight, and shall utilize
modular components with metal housings and digital instrumentation. An
interface module shall be provided to decode serial link data from the
electronic panel and translate alarm, fault and status conditions to set of
relay contacts. Instrument accuracy shall be not less than 98% for unit
mounted devices and 99% for control room, panel mounted devices, throughout
a temperature range of minus 20 to plus 65 degrees C. Data display shall
utilize LED or back lit LCD. Additionally, the display shall provide
indication of cycle programming and diagnostic codes for troubleshooting.
Numeral height shall be 13 mm .

2.17.4 Parameter Display

Indication or readouts of the tachometer, lubricating-oil pressure, ac

voltmeter, ac ammeter, frequency meter, and safety system parameters shall
be provided. A momentary switch shall be specified for other panels.

2.18 MANUAL ENGINE-GENERATOR-SET SYSTEM OPERATION

Complete facilities shall be provided for manual starting and testing of

each set without load, loading and unloading of each set, and
synchronization of each set with an energized bus.

2.19 BASE

The base shall be constructed of structural steel. The base shall be

designed to rigidly support the engine-generator set, ensure permanent
alignment of rotating parts, be arranged to provide easy access to allow
changing of lube-oil, and ensure that alignment is maintained during
shipping and normal operation. The base shall permit skidding in any
direction during installation and shall withstand and mitigate the affects
of synchronous vibration of the engine and generator. The base shall be
provided with suitable holes for anchor bolts and jacking screws for
leveling.

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2.20 THERMAL INSULATION

Thermal insulation shall be as specified in Section 15080 THERMAL

INSULATION FOR MECHANICAL SYSTEMS.

2.21 PAINTING AND FINISHING

The engine-generator set shall be cleaned, primed and painted in accordance

with the manufacturer's standard color and practice.

2.22 FACTORY INSPECTION AND TESTS

The factory tests shall be performed on each engine-generator set. The

component manufacturer's production line test is acceptable as noted. Each
engine-generator set shall be run not less than 1 hour at rated output
capacity prior to inspections. Inspections shall be completed and all
necessary repairs made, prior to testing. Engine generator controls and
protective devices that are provided by the generator set manufacturer as
part of the standard package shall be used for factory tests. When
controls and switchgear are not provided as part of the generator set
manufacturer's standard package, the actual controls and protective devices
provided for the project are not required to be used during the factory
test. The Contracting Officer may provide one or more representatives to
witness inspections and tests.

2.22.1 Factory Inspection

Inspections shall be performed prior to beginning and after completion of

testing of the assembled engine-generator set. Inspectors shall look for
leaks, looseness, defects in components, proper assembly, etc. and any item
found to be in need of correction shall be noted as a necessary repair.
The following checklist shall be used for the inspection:

INSPECTION ITEM GOOD BAD NOTES

1. Drive belts
2. Governor and adjustments
3. Engine timing mark
4. Starting motor
5. Starting aids
6. Coolant type and concentration
7. Radiator drains
8. Block coolant drains
9. Coolant fill level
10. All coolant line connections
11. All coolant hoses
12. Combustion air filter
13. Combustion air silencer
14. Lube oil type
15. Lube oil sump drain
16. Lube-oil filter
17. Lube-oil-level indicator
18. Lube-oil-fill level
19. All lube-oil line connections
20. All lube-oil lines
21. Fuel type and amount
22. All fuel-line connections
23. All fuel lines
24. Fuel filter

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25. Coupling and shaft alignment

26. Voltage regulators
27. Battery-charger connections
28. All wiring connections
29. Instrumentation
30. Hazards to personnel
31. Base
32. Nameplates
33. Paint
34. Exhaust-heat recovery unit
35. Switchboard
36. Switchgear

2.22.2 Factory Tests

On engine-generator set tests where the engine and generator are required
to be connected and operated together, the load power factor shall be the
power factor specified in the engine generator set parameter schedule. For
engine-generator set with dual-fuel operating capability the following
tests shall be performed using the primary fuel type. Electrical
measurements shall be performed in accordance with IEEE Std 120 or
equivalent DIN, I.E.C., BS or EN standards. Definitions of terms are in
accordance with IEEE Std 100 or equivalent DIN, I.E.C., BS or EN standards.
Temperature limits in the rating of electrical equipment and for the
evaluation of electrical insulation shall be in accordance with IEEE Std 1
or equivalent DIN, I.E.C., BS or EN standards. In the following tests
where measurements are to be recorded after stabilization of an
engine-generator set parameter (voltage, frequency, current, temperature,
etc.), stabilization is considered to have occurred when measurements are
maintained within the specified bandwidths or tolerances, for a minimum of
four consecutive readings. Tests specifically for the generator may be
performed utilizing any prime mover.

a. Insulation Resistance for Stator and Exciter Test, IEEE Std 115
and IEEE Std 43 or equivalent DIN, I.E.C., BS or EN standards, to
the performance criteria in NEMA MG 1, Part 22 or equivalent DIN,
I.E.C., BS or EN standards. Generator manufacturer's production
line test is acceptable.

b. High Potential Test, per IEEE Std 115 and NEMA MG 1 or equivalent
DIN, I.E.C., BS or EN standards, test voltage in accordance with
NEMA MG 1 or equivalent DIN, I.E.C., BS or EN standards.
Generator manufacturer's production line test is acceptable.

c. Winding Resistance Test, Stator and Exciter, per IEEE Std 115 or
equivalent DIN, I.E.C., BS or EN standards. Generator
manufacturer's production line test is acceptable.

d. Overspeed Vibration Test, per IEEE Std 115 or equivalent DIN,

I.E.C., BS or EN standards to the performance criteria in NEMA MG 1
or equivalent DIN, I.E.C., BS or EN standards. The test shall be
performed at 110% of rated speed for 5 minutes. The vibration
shall be measured at the end bearings (front and back of engine,
outboard end of generator) in the horizontal, vertical, and axial
directions. Vibration amplitude and speed shall be recorded at
one minute intervals.

e. Phase Balance Voltage Test, to the performance criteria specified

in paragraph GENERATOR. This test can be performed with any prime

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mover. Generator manufacturer's production line test results are

acceptable.

(1) Start and operate the generator at no load.

(2) Adjust a regulated phase voltage (line-to-neutral) to rated

voltage.

(3) Read and record the generator frequency, line-to-neutral

voltages, and the line-to-line voltages.

(4) Apply 75% rated load and record the generator frequency,
line-to-neutral voltages, and the line-to-line voltages.

(5) Apply rated load and record the generator frequency,

line-to-neutral voltages, and the line-to-line voltages.

(6) Calculate average line-neutral voltage and percent deviation

of individual line-neutral voltages from average for each load
condition.

f. Current Balance on Stator Winding Test, by measuring the current

on each phase of the winding with the generator operating at 100 %
of Rated Output Capacity, with the load impedance equal for each
of the three phases: to the performance criteria specified in
paragraph GENERATOR.

g. Voltage Waveform Deviation and Distortion Test per IEEE Std 115 or
equivalent DIN, I.E.C., BS or EN standards to the performance
criteria specified in paragraph GENERATOR. High-speed recording
instruments capable of recording voltage waveform deviation and
all distortion, including harmonic distortion shall be used.
Representation of results shall include appropriate scales to
provide a means to measure and interpret results.

h. Voltage and Frequency Droop Test. Verify that the output voltage
and frequency are within the specified parameters as follows:

(1.) With the generator operating at no load, adjust voltage and

frequency to rated voltage and frequency. Record the generator
output frequency and line-line and line-neutral voltages.

(2.) Increase load to Rated Output Capacity. Record the

generator output frequency and line-line and line-neutral voltages.

3. Calculate the percent droop for voltage and frequency with the
following equations:

(No-Load Volts) - (Rated Capacity volts)

Voltage droop % = -------------------------------------------- x 100
(Service-Load Volts)

(No-Load Hertz) - (Rated Capacity hertz)

Frequency droop % = ------------------------------------------ x 100
(Service-Load hertz)

4. Repeat steps 1 through 3 two additional times without making

any adjustments.

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i. Frequency and Voltage Stability and Transient Response. Verify

that the engine-generator set responds to addition and dropping of
blocks of load in accordance with the transient response
requirements. Document maximum voltage and frequency variation
from bandwidth and verify that voltage and frequency return to and
stabilize within the specified bandwidth, within the specified
response time period. Document results in tabular form and with
high resolution, high speed strip chart recorders or comparable
digital recorders, as approved by the Contracting Officer.
Tabular data shall include the following:

Ambient temperature (at 15 minute intervals).

Generator output current (before and after load changes).

Generator output voltage (before and after load changes).

Frequency (before and after load changes).

Generator output power (before and after load changes).

Graphic representations shall include the actual instrument trace

of voltage and frequency showing: charts marked at start of test;
observed steady-state band; mean of observed band; momentary
overshoot and undershoot (generator terminal voltage and
frequency) and recovery time for each load change together with
the voltage and frequency maximum and minimum trace excursions for
each steady state load condition prior to and immediately
following each load change. Generator terminal voltage and
frequency transient recovery time for each step load increase and
decrease.

(1.) Perform and record engine manufacturer's recommended

prestarting checks and inspections.

(2.) Start the engine, make and record engine manufacturer's

after-starting checks and inspections during a reasonable warm-up
period and no load. Verify stabilization of voltage and frequency
within specified bandwidths.

(3.) With the unit at no load, apply the Maximum Step Load
Increase.

(4.) Apply load in steps equal to the Maximum Step Load Increase
until the addition of one more step increase will exceed the
Service Load.

(5.) Decrease load to the unit such that addition of the Maximum
Step Load Increase will load the unit to 100% of Service Load.

(6.) Apply the Maximum Step Load Increase.

(7.) Decrease load to zero percent in steps equal to the Maximum

Step Load Decrease.

(8.) Repeat steps 3. through 7.

j. Test Voltage Unbalance with Unbalanced Load (Line-to-Neutral) to

the performance criteria specified in paragraph GENERATOR.

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Prototype test data is acceptable in lieu of the actual test.

This test may be performed using any prime mover.

(1.) Start and operate the generator set at rate voltage, no

load, rated frequency, and under control of the voltage regulator.
Read and record the generator frequency, line-to-neutral
voltages, and the line-to-line voltages.

(2.) Apply the specified load between terminals L1-L2, L2-L0, and
L3-L0 in turn. Record all instrument readings at each
line-neutral condition.

(3.) Express the greatest difference between any two of the

line-to-line voltages and any two of the line-to-neutral voltages
as a percent of rated voltage.

(4.) Compare the largest differences expressed in percent with

the maximum allowable difference specified.

PART 3 EXECUTION

3.1 GENERAL INSTALLATION

Installation shall provide clear space for operation and maintenancein

accordance with NFPA 70 for the Power plant and equivalent DIN, BS, EN, or
I.E.C. standards for all buildings. Installation of pipe, duct, conduit,
and ancillary equipment shall be configured to facilitate easy removal and
replacement of major components and parts of the engine-generator set.

3.2 PIPING INSTALLATION

Piping shall be welded. Connections at valves shall be flanged.

Connections at equipment shall be flanged except that connections to the
diesel engine may be threaded if the diesel-engine manufacturers standard
connection is threaded. Except where otherwise specified, welded flanged
fittings shall be utilized to allow for complete dismantling and removal of
each piping system from the facility without disconnecting or removing any
portion of any other system's equipment or piping. Connections to
equipment shall be made with vibration-isolation-type flexible connectors.
Piping and tubing shall be supported and aligned to prevent stressing of
flexible hoses and connectors. Pipes extending through the roof shall be
properly flashed. Piping shall be installed clear of windows, doors and
openings, to permit thermal expansion and contraction without damage to
joints or hangers, and shall be installed with a 15 mm (1/2 inch) drain
valve with cap at each low point.

3.2.1 Support

Hangers, inserts, and supports shall be of sufficient size to accommodate

any insulation and shall conform to MSS SP-58 and MSS SP-69, or equivalent
DIN, I.E.C., BS or EN standards. Supports shall be spaced not more than
2.1 m on center for pipes 50 mm (2 inches) in diameter or less, not more
than 3.6 m on center for pipes larger than 50 mm (2 inches) but smaller
than 100 mm (4 inches) in diameter, and not more than 5.2 m on center for
pipes larger than 100 mm in diameter. Supports shall be provided at pipe
bends or change of direction.

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3.2.1.1 Ceiling and Roof

Exhaust piping shall be supported with appropriately sized Type 41 single

pipe roll and threaded rods; all other piping shall be supported with
appropriately sized Type 1 clevis and threaded rods.

3.2.1.2 Wall

Wall supports for pipe shall be made by suspending the pipe from
appropriately sized Type 33 brackets with the appropriate ceiling and roof
pipe supports.

3.2.2 Flanged Joints

Flanges shall be Class 125 type, drilled, and of the proper size and
configuration to match the equipment and diesel engine connections.
Flanged joints shall be gasketed and made up square and tight.

3.2.3 Cleaning

After fabrication and before assembly, piping interiors shall be manually

wiped clean of debris.

3.2.4 Pipe Sleeves

Pipes passing through construction such as ceilings, floors, or walls shall

be fitted with sleeves. Each sleeve shall extend through and be securely
fastened in its respective structure and shall be cut flush with each
surface. The structure shall be built tightly to the sleeve. The inside
diameter of each sleeve shall be minimum 15 mm (1/2 inch), and where pipes
pass through combustible materials 25 mm (1 inch) larger than the outside
diameter of the passing pipe or pipe insulation/covering.

3.3 ELECTRICAL INSTALLATION

Electrical installation shall comply with NFPA 70 for the Power plant and
equivalent DIN, BS, EN, or I.E.C. standards for all buildings, and Section
16402 INTERIOR DISTRIBUTION SYSTEM.

3.3.1 Vibration Isolation

Flexible fittings shall be provided for conduit, cable trays, and raceways
attached to engine-generator sets. Metallic conductor cables installed on
the engine generator set and from the engine generator set to equipment not
mounted on the engine generator set shall be flexible stranded conductor.
Terminations of conductors on the engine generator set shall be crimp-type
terminals or lugs.

3.4 ONSITE INSPECTION AND TESTS

3.4.1 Test Conditions

3.4.1.1 Data

Measurements shall be made and recorded of all parameters necessary to

verify that each set meets specified parameters. If the results of any
test step are not satisfactory, adjustments, replacements, or repairs shall
be made and the step repeated until satisfactory results are obtained.
Unless otherwise indicated, data shall be recorded in 15 minute intervals

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during engine-generator set operation and shall include: readings of all

engine-generator set meters and gauges for electrical and power parameters;
oil pressure; ambient temperature; and engine temperatures available from
meters and gauges supplied as permanent equipment on the engine-generator
set.Electrical measurements shall be performed in accordance with IEEE Std
120 or equivalent DIN, I.E.C., BS or EN standards. Definitions of terms
are in accordance with IEEE Std 100 or equivalent DIN, I.E.C., BS or EN
standards. Temperature limits in the rating of electrical equipment and
for the evaluation of electrical insulations shall be in accordance with
IEEE Std 1 or equivalent DIN, I.E.C., BS or EN standards.

3.4.1.2 Contractor Supplied Items

The Contractor shall provide equipment and supplies required for

inspections and tests including fuel, test instruments, and loadbanks at
the specified power factors.

3.4.1.3 Instruments

Readings of panel gauges, meters, displays, and instruments provided as

permanent equipment shall be verified during test runs, using test
instruments of greater precision and accuracy. Test instrument accuracy
shall be within the following: current plus or minus 1.5%, voltage plus or
minus 1.5%, real power plus or minus 1.5%, reactive power plus or minus
1.5%, power factor plus or minus 3%, frequency plus or minus 0.5%. Test
instruments shall be calibrated by a recognized standards laboratory within
30 days prior to testing.

3.4.1.4 Sequence

The sequence of testing shall be as specified in the approved testing plan

unless variance is authorized by the Contracting Officer. Field testing
shall be performed in the presence of the Contracting Officer. Tests may
be scheduled and sequenced in order to optimize run-time periods; however,
the following general order of testing shall be followed: Construction
Tests; Inspections; Pre-operational Tests; Safety Run Tests; Performance
Tests; and Final Inspection.

3.4.2 Construction Tests

Individual component and equipment functional tests for fuel piping,

coolant piping, and lubricating-oil piping, electrical circuit continuity,
insulation resistance, circuit protective devices, and equipment not
provided by the engine-generator set manufacturer shall be performed prior
to connection to the engine-generator set.

3.4.2.1 Piping Test

a. Lube-oil and fuel-oil piping shall be flushed with the same type
of fluid intended to flow through the piping, until the outflowing
fluid has no obvious sediment or emulsion.

b. Fuel piping which is external to the engine-generator set shall be

tested in accordance with NFPA 30 for the Power plant and
equivalent DIN, BS, EN, or I.E.C. standards for all buildings.
All remaining piping which is external to the engine-generator set
shall be pressure tested with air pressure at 150% of the maximum
anticipated working pressure, but not less than 1.03 MPa, for a
period of 2 hours to prove the piping has no leaks. If piping is

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to be insulated, the test shall be performed before the insulation

is applied.

3.4.2.2 Electrical Equipment Tests

a. Low-voltage cable insulation integrity tests shall be performed

for cables connecting the generator breaker to the distribution bus.
Low-voltage cable, complete with splices, shall be tested for
insulation resistance after the cables are installed, in their
final configuration, ready for connection to the equipment, and
prior to energization. The test voltage shall be 500 volts dc,
applied for one minute between each conductor and ground and
between all possible combinations conductors in the same trench,
duct, or cable, with all other conductors in the same trench,
duct, or conduit. The minimum value of insulation shall be:

R in megohms = (rated voltage in kV + 1) x 304,800/(length of

cable in meters)

R in megohms = (rated voltage in kV + 1) x 1000/(length of cable

in feet)

Each cable failing this test shall be repaired or replaced. The

repair cable shall be retested until failures have been eliminated.

d. Circuit breakers and switchgear shall be examined and tested in

accordance with the manufacturer's published instructions for
functional testing.

3.4.3 Inspections

The following inspections shall be performed jointly by the Contracting

Officer and the Contractor, after complete installation of each
engine-generator set and its associated equipment, and prior to startup of
the engine-generator set. Checks applicable to the installation shall be
performed. The results of those which are physical inspections (I) shall
be documented by the Contractor and submitted in accordance with paragraph
SUBMITTALS. The Contractor shall present manufacturer's data for the
inspections designated (D) at the time of inspection. Inspections shall
verify that equipment type, features, accessibility, installation and
condition are in accordance with the contract specification.
Manufacturer's statements shall certify provision of features which cannot
be verified visually.

1. Drive belts. (I)

2. Governor type and features. (I)
3. Engine timing mark. (I)
4. Starting motor. (I)
5. Starting aids. (I)
6. Coolant type and concentration. (D)
7. Radiator drains. (I)
8. Block coolant drains. (I)
9. Coolant fill level. (I)
10. Coolant line connections. (I)
11. Coolant hoses. (I)
12. Combustion air filter. (I)
13. Intake air silencer. (I)
14. Lube oil type. (D)
15. Lube oil sump drain. (I)

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16. Lube-oil filter. (I)

17. Lube-oil level indicator. (I)
18. Lube-oil fill level. (I)
19. Lube-oil line connections. (I)
20. Lube-oil lines. (I)
21. Fuel type. (D)
22. Fuel-level. (I)
23. Fuel-line connections. (I)
24. Fuel lines. (I)
25. Fuel filter. (I)
26. Access for maintenance. (I)
27. Voltage regulator. (I)
28. Battery-charger connections. (I)
29. Wiring & terminations. (I)
30. Instrumentation. (I)
31. Hazards to personnel. (I)
32. Base. (I)
33. Nameplates. (I)
34. Paint. (I)
35. Exhaust-heat system. (I)
36. Exhaust muffler. (I)
37. Switchboard. (I)
38. Switchgear. (I)
39. Access provided to controls. (I)
40. Enclosure is weather resistant. (I)
41. Engine & generator mounting bolts (application). (I)

3.4.4 Pre-operational Tests

3.4.4.1 Protective Relays

Protective relays shall be visually and mechanically inspected, adjusted,

tested, and calibrated in accordance with the manufacturer's published
instructions. Tests shall include pick-up, timing, contact action,
restraint, and other aspects necessary to ensure proper calibration and
operation. Relay settings shall be implemented in accordance with the
installation coordination study. Relay contacts shall be manually or
electrically operated to verify that the proper breakers and alarms
initiate. Relaying current transformers shall be field tested in
accordance with IEEE C57.13.1 or equivalent DIN, I.E.C., BS or EN standards.

3.4.4.2 Engine-Generator Connection Coupling Test

When the generator provided is a two-bearing machine, the engine-generator

connection coupling shall be inspected and checked by dial indicator to
prove that no misalignment has occurred. The dial indicator shall measure
variation in radial positioning and axial clearance between the coupling
halves. Readings shall be taken at four points, spaced 90 degrees apart.
Solid couplings and pin-type flexible couplings shall be aligned within a
total indicator reading of 0.012 to 0.025 mm for both parallel and angular
misalignment. For gear-type or grid-type couplings, 0.05 mm will be
acceptable.

3.4.5 Safety Run Test

For the following tests, if any parts are changed, or adjustments made to
the generator set, its controls, or auxiliaries, the associated safety
tests shall be repeated.

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a. Perform and record engine manufacturer's recommended prestarting

checks and inspections.

b. Start the engine, record the starting time, make and record engine
manufacturer's after-starting checks and inspections during a
reasonable warm-up period.

c. Activate the manual emergency stop switch and verify that the
engine stops.

d. Remove the high and pre-high lubricating oil temperature sensing

elements from the engine and temporarily install a temperature
gauge in their normal locations on the engine (required for
safety, not for recorded data). Where necessary provide temporary
wiring harness to connect the sensing elements to their permanent
electrical leads.

e. Start the engine, record the starting time, make and record engine
manufacturer's after-starting checks and inspections during a
reasonable warm-up period. Operate the engine-generator set at no
load until the output voltage and frequency stabilize. Monitor
the temporarily installed temperature gauges. If either
temperature reading exceeds the value required for an alarm
condition, activate the manual emergency stop switch.

f. Remove the high and pre-high coolant temperature sensing elements

from the engine and temporarily install a temperature gauge in
their normal locations on the engine (required for safety, not for
recorded data). Where necessary provide temporary wiring harness
to connect the sensing elements to their permanent electrical
leads.

g. Start the engine, record the starting time, make and record engine
manufacturer's after-starting checks and inspections during a
reasonable warm-up period. Operate the engine generator-set at no
load until the output voltage and frequency stabilize.

h. Start the engine, record the starting time, make and record engine
manufacturer's after-starting checks and inspections during a
reasonable warm-up period.

i. Operate the engine generator-set for at least 2 hours at 75% of

Service Load.

j. Verify proper operation and setpoints of gauges and instruments.

k. Verify proper operation of ancillary equipment.

l. Manually adjust the governor to increase engine speed past the

overspeed limit. Record the RPM at which the engine shuts down.

m. Start the engine, record the starting time, make and record engine
manufacturer's after-starting checks and inspections and operate
the engine generator-set for at least 15 minutes at 75% of Service
Load.

n. Manually adjust the governor to increase engine speed to within 2%

of the overspeed trip speed previously determined and operate at
that point for 5 minutes. Manually adjust the governor to the

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rated frequency.

o. Shut down the engine. Remove the time-delay low lube oil pressure
alarm bypass and try to start the engine.

q. Start the engine, record the starting time, make and record engine
manufacturer's after-starting checks and inspections and operate
the engine generator-set for at least 15 minutes at 75% of Service
Load.

r. Close the manifold shutoff valve. Slowly allow the pressure in

the manifold to bleed off through the bleed valve while watching
the pressure gauge. Record the pressure at which the engine shuts
down. Catch oil spillage from the bleed valve in a container.
Add the oil from the container back to the engine, remove the
manifold, and reinstall the engine's oil pressure sensor on the
engine.

s. Start the engine, record the starting time, make and record engine
manufacturer's after-starting checks and inspections and operate
the engine generator-set for at least 15 minutes at 100% of
Service Load. If a sound limiting enclosure is provided, the
enclosure, the muffler, and intake silencer shall be modified or
replaced as required to meet the sound requirements contained
within this specification.

3.4.6 Performance Tests

In the following tests, where measurements are to be recorded after

stabilization of an engine-generator set parameter (voltage, frequency,
current, temperature, etc.), stabilization is considered to have occurred
when measurements are maintained within the specified bandwidths or
tolerances, for a minimum of four consecutive readings. For the following
tests, if any parts are changed, or adjustments made to the generator set,
its controls, or auxiliaries, the associated tests shall be repeated.

3.4.6.1 Continuous Engine Load Run Test

Test the engine-generator set and ancillary systems at service load to

demonstrate durability; verify that heat of extended operation does not
adversely affect or cause failure in any part of the system; and check all
parts of the system. After each change in load in the following test,
measure the vibration at the end bearings (front and back of engine,
outboard end of generator) in the horizontal, vertical, and axial
directions. Verify that the vibration is within the allowable range. Data
taken at 15 minute intervals shall include the following:

Electrical: Output amperes, voltage, real and reactive power, power

factor, frequency.

Pressure: Lube-oil.

Temperature: Coolant.
Lube-oil.
Exhaust.
Ambient.

a. Perform and record engine manufacturer's recommended prestarting

checks and inspections. Include as a minimum checking of coolant

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fluid, fuel, and lube-oil levels.

b. Start the engine, make and record engine manufacturer's

after-starting checks and inspections during a reasonable warmup
period.

c. Operate the engine generator-set for 2 hours at 75% of Service

Load.

d. Increase load to 100% of Service Load and operate the engine

generator-set for 4 hours.

e. For prime rated units, increase load to 110% of Service Load and
operate the engine generator-set for 2 hours.

f. Decrease load to 100% of Service Load and operate the engine

generator-set for 2 hours or until all temperatures have
stabilized.

g. Remove load from the engine-generator set.

3.4.6.2 Voltage and Frequency Droop Test

For the following steps, verify that the output voltage and frequency
return to and stabilize within the specified bandwidth values following
each load change. Record the generator output frequency and line-line and
line-neutral voltages following each load change.

a. With the generator operating at no load, adjust voltage and

frequency to rated voltage and frequency.

b. Increase load to 100% of Rated Output Capacity. Record the

generator output frequency and line-line and line-neutral voltages.

c. Calculate the percent droop for voltage and frequency with the
following equations.

Voltage droop % = No-load volts - rated output capacity volts

------------------------------------------- x 100
Rated output capacity volts

Frequency droop % = No load hertz - rated output capacity hertz

------------------------------------------- x 100
Rated output capacity volts

d. Repeat steps a. through c. two additional times without making any

adjustments.

3.4.6.3 Voltage Regulator Range Test

a. While operating at no load, verify that the voltage regulator

adjusts from 90% to 110% of rated voltage.

b. Increase load to 100% of Rated Output Capacity. Verify that the

voltage regulator adjusts from 90% to 110% of rated voltage.

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3.4.6.4 Governor Adjustment Range Test

a. While operating at no load, verify that the governor adjusts from

90% to 110% of rated frequency.

b. Increase load to 100% of Rated Output Capacity. Verify that the

governor adjusts from 90% to 110% of rated frequency.

3.4.6.5 Frequency and Voltage Stability and Transient Response

Verify that the engine-generator set responds to addition and dropping of

blocks of load in accordance with the transient response requirements.
Document maximum voltage and frequency variation from bandwidth and verify
that voltage and frequency return to and stabilize within the specified
bandwidth, within the specified response time period.

a. Perform and record engine manufacturer's recommended prestarting

checks and inspections.

b. Start the engine, make and record engine manufacturer's

after-starting checks and inspections during a reasonable warm-up
period and no load. Verify stabilization of voltage and frequency
within specified bandwidths.

c. With the unit at no load, apply the Maximum Step Load Increase.

d. Apply load in steps equal to the Maximum Step Load Increase until
the addition of one more step increase will exceed the Service
Load.

e. Decrease load to the unit such that addition of the Maximum Step
Load Increase will load the unit to 100% of Service Load.

f. Apply the Maximum Step Load Increase.

g. Decrease load to zero percent in steps equal to the Maximum Step

Load Decrease.

h. Repeat steps c. through g.

3.4.7 Parallel Operation Test

Test the capability of each engine-generator set to parallel and share load
with other generator sets, individually and in all combinations. This test
must be performed with the voltage regulator and governor adjustment
settings used for the Frequency and Voltage Stability and Transient
Response test. If settings are changed during the performance of this
test, a voltage and frequency stability and transient response test must be
performed for each engine generator set using the setting utilized in this
test. During operations record load-sharing characteristics of each set in
parallel operation. Data taken shall include the following:

(1.) Ambient temperature (at 15 minute intervals).

(2.) Generator output current (before and after load changes).

(3.) Generator output voltage (before and after load changes).

(4.) Power division and exchange between generator sets.

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(5.) Real power (watts) and reactive power (vars) on each set.

3.4.7.1 Combinations

Connect each set, while operating at no load, parallel with one other set
in the system, operating at service load, until all possible
two-unit-in-parallel combinations have been achieved. Verify stabilization
of voltage and frequency within specified bandwidths and proportional
sharing of real and reactive loads. Document stabilization of voltage and
frequency within specified bandwidth, the active power division, active
power exchange, reactive power division, and voltage and frequency
stability and transient response in the following steps for each
combination.

a. Divide the load proportionally between the sets and operate in

parallel for 15 minutes.

b. Increase the load, in steps equal to the Maximum Step Increase,

until each set is loaded to its service load.

c. Decrease the load, in steps equal to the Maximum Step Decrease,

until each set is loaded to approximately 25% of its service load.

d. Increase the load, in steps equal to the Maximum Step Increase,

until each set is loaded to approximately 50% of its service load
Verify stabilization of voltage and frequency within specified
bandwidths and proportional sharing of real and reactive load.

e. Reduce the sum of the loads on both sets to the output rating of
the smaller set.

f. Transfer a load equal to the output rating of the smaller of the 2

sets to and from each set. Verify stabilization of voltage and
frequency within specified bandwidths and proportional sharing of
real and reactive load.

g. Document the active power division, active power exchange,

reactive power division, and voltage and frequency stability and
transient response .

3.4.7.2 Multiple Combinations

Connect each set, while operating at no load, parallel with all multiple
combinations of all other set in the system, while operating at service
load, until all multiple combinations of parallel operations have been
achieved.

3.4.8 Automatic Operation Tests for Multiple Engine Generator Set Parallel
Operation In Standalone Mode

The automatic operating system shall be tested to demonstrate loading and

unloading, and paralleling of each engine-generator set. The loads for
this test shall utilize load banks at the indicated power factor, and the
loading sequence shall be the indicated sequence. During all operations
load-sharing characteristics shall be recorded. Perform this test for a
minimum of two successive, successful tests. Data taken shall include the
following:

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(1.) Ambient temperature (at 15 minute intervals).

(2.) Generator output current (before and after load changes).

(3.) Generator output voltage (before and after load changes).

(4.) Generator output frequency (before and after load changes).

(5.) Power division and exchange between generator sets.

(6.) Real and reactive power on each set.

a. Initiate loss of the preferred power source and verify the

specified sequence of operation.

b. Verify resetting of automatic starting and transfer logic.

3.4.9 Automatic Operation Tests for Stand-Alone Operation

The automatic loading system shall be tested to demonstrate loading and

unloading of each engine-generator set. The loads for this test shall
utilize the actual loads to be served, and the loading sequence shall be
the indicated sequence. Perform this test for a minimum of two successive,
successful tests. Data taken shall include the following:

(1.) Ambient temperature (at 15 minute intervals).

(2.) Generator output current (before and after load changes).

(3.) Generator output voltage (before and after load changes).

(4.) Generator output frequency (before and after load changes).

a. Initiate loss of the primary power source and verify automatic

sequence of operation.

b. Restore the primary power source and verify sequence of operation.

c. Verify resetting of controls to normal.

3.4.10 Fuel Consumption Tests

Fuel consumption tests to confirm the manufacturer's certified rates shall

be performed on engine generator set and the results tabulated and
averaged. Fuel consumption tests shall be conducted under the direct
supervision of the engine manufacturer's representative. Fuel consumption
readings shall be taken at 15 minute intervals, over a minimum period of 1
hour at 50% Service Load, 1 hour at 75% Service Load, and 4 hours at 100%
Service Load. Fuel consumption data may be taken during the 75% load test
and 100% load tests. Fuel consumption readings at site conditions shall be
correlated to the guarantee-baseline conditions. Test report shall
contain: readings of the output frequency, voltage, current, power factor,
and power; barometric pressure; ambient temperature; intake-air
temperature; fuel temperature; the site fuel consumption readings,
adjustment calculations, factors, and source references for correlation of
actual consumption rate of the guaranteed rate.

a. Start and operate the generator set and allow it to stabilize at

rated load, rated voltage and rated frequency. During this

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period, readings of all instruments including thermal

instrumentation shall be recorded at minimum intervals of 10
minutes. If necessary, adjustments to the load, voltage and
frequency may be made to maintain rated load at rated voltage and
rated frequency. However, adjustments to the voltage and
frequency shall be limited to those adjustments available to the
operator, specifically adjustments to the voltage or frequency
adjust devices. On generator sets utilizing a droop-type speed
control system as the prime speed control, the speed and droop
portions of the control may be adjusted. No other adjustments to
the voltage and frequency control systems shall be made unless
permitted by the procurement document. Adjustments to the load,
voltage or frequency controls shall be recorded on the data sheet.
Unless otherwise specified in the procurement document,
stabilization will be consideration to have occurred when four
consecutive voltage and current recorded readings of the generator
(or exciter) field either remain unchanged or have only minor
variations about an equilibrium condition with no evident
continued increase or decrease in value after the last adjustment
to the load, voltage or frequency has been made.

3.4.11 Final Testing and Inspection

a. Start the engine, record the starting time, make and record all
engine manufacturer's after-starting checks and inspections during
a reasonable warm-up period.

b. Increase the load in steps no greater than the Maximum Step Load
Increase to 100% of Service Load, and operate the engine-generator
set for at least 30 minutes. Measure the vibration at the end
bearings (front and back of engine, outboard end of generator) in
the horizontal, vertical, and axial directions. Verify that the
vibration is within the same range as previous measurements and is
within the required range.

c. Remove load and shut down the engine-generator set after the
recommended cool down period.

d. Remove the lube oil filter and have the oil and filter examined by
the engine manufacturer for excessive metal, abrasive foreign
particles, etc. Any corrective action shall be verified for
effectiveness by running the engine for 8 hours at Service Load,
then re-examining the oil and filter.

e. Remove the fuel filter and examine the filter for trash, abrasive
foreign particles, etc.

f. Visually inspect and check engine and generator mounting bolts for
tightness and visible damage.

g. Replace air, oil, and fuel filters with new filters.

3.5 POSTED DATA AND INSTRUCTIONS

Two sets of instructions/data shall be typed in A 4 format, laminated in

weatherproof plastic, and placed in three-ring vinyl binders. The binders
shall be placed as directed by the Contracting Officer. The instructions
shall be in place prior to acceptance of the engine generator set
installation. First set shall include a one-line diagram, wiring and

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control diagrams and a complete layout of the system. Second set shall
include the condensed operating instructions describing manufacturer's
pre-start checklist and precautions; startup procedures for test-mode,
manual-start mode, and automatic-start mode (as applicable); running
checks, procedures, and precautions; and shutdown procedures, checks, and
precautions. Instructions shall include procedures for interrelated
equipment (such as heat recovery systems, co-generation, load-shedding, and
automatic transfer switches).

3.6 ONSITE TRAINING

The Contractor shall conduct training course for operating staff as

designated by the Contracting Officer. The training period shall consist
of a total 8 hours of normal working time and shall start after the system
is functionally completed but prior to final acceptance. All operation and
maintenance manuals shall bee approved and made available for the training
course. All posted instructions shall be approved and posted prior to the
beginning date of the training course. The training course schedule shall
be coordinated with the Using Service's work schedule, and submitted for
approval 14 days prior to beginning date of proposed beginning date of
training. The course instructions shall cover pertinent points involved in
operating, starting, stopping, servicing the equipment, as well as major
elements of the operation and maintenance manuals. Additionally, the
course instructions shall demonstrate routine maintenance procedures as
described in the operation and maintenance manuals and installation of
spare parts. Two copies of a video tape of the manufacturers operating and
maintenance training course shall be submitted.

3.7 ACCEPTANCE

Final acceptance of the engine-generator set will not be given until the
contractor has successfully completed all tests and all defects in
installation material or operation have been corrected.

-- End of Section --

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