1.2 RELATED REQUIREMENTS

Section 1605, “Basic Electrical Materials and Methods”, applies to this section

with the additions and modifications specified herein.

1.3 DEFINITIONS

1.3.1 Intercooling

Intercooling as used in this specifications denotes the cooling of the charged

air leaving the turbocharger.

1.3.2 Rated-Net-Capacity

Rated-Net-Capacity of the engine-generator unit is defined as the gross

electrical power output of the generator minus total electrical power

requirements of the electric-motor-driven, engine accessories normally

constituting part of “engine assembly” as defined by DEMA requirements.

1.4 SUBMITTALS

Submit the following;

1.4.1 Manufacturer’s Catalog Data

a. Engine-generator unit

b. Engine-generator unit efficiencies

c. Diesel engine

d. Generator and exciter

1.4.1.1 Engine-Generator Unit Data

Submit the following data pertaining to the engine-generator unit and to the

proposed auxiliary equipment.

a. Make of engine.

b. Type or model of engine.

c. Gross bkW rating of engine. Gross rating shall be the total rated power output

before deducting power requirements of electric motor-driven equipment. Net

ratings shall be equal to gross ratings minus the total power requirements of

electric motor-driven accessories normally constituting part of “engine

assembly” as defined in DEMA SDGE and hereinafter referenced to as DEMA

requirements.

d. Net bow rating of engine. Net ratings shall include a deduction in power

output for the following parasitic loads.

1. Lubricating oil pump for lubricating oil circulation and piston cooling

service.

2. Fuel oil booster pump.

3. Cooling media system power requirements including pumps, radiator

fans and any other power consuming devices required to provide cooling

as specified.

Some of these devices may be electric motor-driven or engine-driven. Engine

net output rating shall be reduced by the kilowatt required to operate the engine-

driven devices and corrections shall be made to engine output, or generator

output for the electric motor-driven devices to determine the net rating of the

engine or engine generator set. Cooling media system power requirement may

not be possible to estimate for a manufacturer’s standard plant test. In this case

the net rating shall be exclusive of this item as defined by DEMA but shall be

further reduced by applying corrections for the cooling system specified to

obtain a net power output exclusive of parasitic loads.

e. Strokes per cycle.

f. Number of cylinders.

g. Bore and stroke, millimeters.

h. Engine speed, rpm.

i. Piston speed, m/s.

j. BMEP at full load.

k. kW rating of Generator.

l. kVA rating of Generator.

m. Gross kW rating of engine-generator unit.

n. Net kW rating of engine-generator unit.

o. Make of turbochargers.

1.4.1.2 Engine-Generator Unit Efficiencies

Submit the following. Fractional loads shall be calculated on basis of net ratings

unless otherwise called for.

a. Fuel consumption at 0.80 power factor (Joules per net kWh).

1. ½ load.

2 ¾ load.

3. Full load.

b. Fuel consumption at 1.00 power factor (Joules per net kWh).

1. ½ load.

2 ¾ load.

3. Full load.

c. Fuel consumption (Joules per Gross/kWh).

1. ½ load.

2 ¾ load.

3. Full load.

d. Generator efficiency at 0.80 power factor (percent).

1. ½ of full net-rated load.

2 ¾ of net-rated load.

3. Full net-rated load.

e. Radiator capacity at design conditions.

1. L/s of coolant.

2. Cubic meter per minute of air through radiator.

1.4.1.3 Diesel Engine Data

Submit the following data certified by the engine manufacturer. Provide the

following data for all units.

a. Indicated (developed) kW at specified engine speed.

b. Mechanical efficiency at full load (percent).

c. Maximum cylinder pressure (Pa(gauge)).

d. Approximate exhaust temperature degrees C.

1. 75 percent load.

2. Full load.

3. 110 percent load.

e. Weight of exhaust gas at full load (lb per hr).

f. Weight of intake air at full load (lb per hr).

g. Total heat rejected at full load (kW).

1. To jacket coolant systems.

2. To lubricating oil systems.

3. To intercooler system.

4. Total to cooling system.

h. Optimum jacket coolant temperature to engine degrees C at full load.

i. Optimum jacket coolant temperature from engine degrees C.

j. Maximum safe jacket coolant temperature from engine degrees C at full load.

k. Optimum lubricating oil temperature to engine degrees C at full load.

l. Optimum lubricating oil temperature from engine degrees C at full load.

m. Maximum safe lubricating oil temperature form engine degrees C.

n. Lubricating oil flow through lubricating oil heat exchanger at 110 percent-

rated full load.

o. Head loss through lubricating oil heat exchanger at flow listed above (Pa).

p. Coolant flow through lubricating oil heat exchanger at 110 percent-rated full

load.

q. Head loss through lubricating oil heat exchanger at flow listed above (Pa).

r. Coolant flow through jacket circuit heat exchanger at 110 percent –rated full

load.

s. Head loss through jacket circuit heat exchanger at flow listed above (Pa).

t. Jacket coolant flow through engine at full load.

u. Head Loss through engine at flow listed above (Pa).

v. Coolant flow through intercooler (L/s).

w. Lubricating oil consumption in liters per second at full load (estimated).

x. Recommended grade and type of lubricating oil.

1.4.1.4 Generator and Exciter Data

a. Make and model number of generator proposed.

b. Generator short circuit ratio.

1. Synchronous reactance, Xd.

2. Transient reactance, Xd.

3. Subtransient reactance, Xd.

c. Generator overspeed limit (percent).

d. Generator flywheel effect (kg-m²).

e. Test Voltage:

1. Generator stator.

2. Generator rotor.

3. Exciter.

f. Generator 60-Hz saturation curve.

g. Generator and exciter efficiency data in accordance with IEC 34.

h. Radio frequency interference data.

1.4.2 Drawings

a. Engine-generator unit and auxiliary equipment including day tank, muffler

and radiator exhaust dust.

b. Engine-generator unit electrical drawings.

1.4.2.1 Engine-Generator unit and Auxiliary Equipment

Submit the following.

a. Certified outline, general arrangement (setting plan), and anchor bolt

details. Drawing shall show the total weight and center of gravity of the

assembled equipment on the structural steel subbase.

b. General arrangement and detail piping of exhaust and air intake piping

systems.

c. General Arrangement, size and location of electrical interface points, and

detailed elementary, schematic wiring and interconnecting diagrams of

generator, exciter governor and other integral devices.

d. Generator guard or guard rail, if applicable.

e. Dimensional Drawings of exhaust and intake silencers, pumps fuel oil day

tank, and other auxiliary equipment.

f. General arrangement drawings showing location of auxiliary equipment in

relation to the engine-generator unit.

g. Heat balance diagram of the coolant system and lubricating oil system

showing cooling loads, flow quantities, and operating temperature levels.

h. Piping schematics for fuel oil, lubricating oil, jacket coolant, and cooling

water.

i. Detailed piping for piping 50mm and larger, showing arrangement of piping

and pipe siszes with flows in L/s or grams per second on each line.

1.4.2.2 Engine-Generator unit Electrical Drawings.

Submit electrical drawings including elementary, schematic, wiring and

interconnection diagrams. Utilize IEEE device numbers corresponding to the

function names and descriptions of IEEE C37.2 and this specification for the

following.

a. Engine and station control panels.

b. Dead-front distribution switchboard. Submit information and material in

accordance with ANSI/IEEE C37.20.1 or ANSI/IEEE C37.20.2

c. Generator protective devices.

d. Control switchboard.

e. Station battery system.

1.4.3 Design Data

a. Design Modifications

1.4.3.1 Design Modifications

Submit proposed cooling system design modifications.

1.4.4 Statements

a. Diesel engine generator successful operation

b. Field welding procedures

1.4.4.1 Diesel Engine Generator Successful Operation

Submit Certificates , as part of bid submittal, certifying that not less than two

engines of identical number of cylinders and cylinder size, identical rotative

speed , and identical or higher brake mean effective pressure (BMEP), and the

same basic configuration (In-line or Vee) as the engine to be provided, shall

have driven KWh of electricity for each kW of generator nameplate capability

within a 2-year period. Certificates shall include:

a. A list of at least three engine-generator unit installations meeting the

experience requirements.

b. Owner, location and date of initial operation of each such installation.

c. Number of kWh produced per kW of generator rated capacity of each

installation.

d. horsepower rating, kW rating, and rotative speed of each unit.

e. BMEP rating of each engine.

f. Design characteristics of each unit, such as bore and stroke, number of

cylinders, and configuration (in-line or Vee), generator rotor, stator, and exciter

system and insulation materials.

1.4.4.2 Field Welding Procedures (Piping)

Before performing field welding, submit to the engineer; three copies of field

welding procedure, specifications for metals included in the work, with proof of

qualification as outlined in ASME B31.1 .

1.4.5 Test Reports

a. Switchboard floor matting tests

Submit 20-kv ac proof test for switchboard floor matting.

1.4.6 Factory Test Reports

a. Engine tests

b. Generator tests

c. Switchboard tests

d. Radio frequency interference (RFI) tests

Submit within 15 calendar days after completion of tests. Provide in accordance

with the requirements set forth in paragraph entitled “Source Quality Control”.

1.4.7 Field Test Reports

a. Piping Tests

b. Preliminary operation tests

c. Phase relationship tests

d. Control panel and switchboard tests

e. Insulation resistance tests

f. Engine-generator unit acceptance tests

g. Auxiliary equipment test

Submit test and inspection reports for work required under the paragraph

entitled “Field Quality Control”.

1.4.8 Records

a. Posted operating instructions for diesel electric generator

Submit text for each piece of equipment.

1.4.9 Operation and Maintenance Manuals

a. Engine-generator units

b. Governor (IEEE Device 65), for low voltage

c. Excitation and voltage regulation systems

d. Low-voltage excitation and voltage regulation systems

e. Engine control panel

f. Generator switchboard

g. Generator protective devices

h. Control Switchboard

i. Control battery system

j. Motor Control centers

k. Switchgear floor matting

Submit operation and maintenance data. Submit storage and handling

procedures for switchboard floor matting. Include fuel adjustment procedures

and maximum tolerance of wear on bearings and other rubbing surfaces that

will require corrective measures.

1.5 Quality Assurance

1.5.1 Experience Requirements

a. Only stationary electric generation service is considered as equivalent

experience. Engines driving pumps or compressors or in marine propulsion or

railroad service are not acceptable.

b. Only experience on the same engine model is acceptable. Engine model is

considered to be given series or class of identical bore and stroke and of the

same type of engine, such as in-line or Vee. In-line and Vee engines with

identical bore and stroke are considered as two separate models of engines.

c. Only experience at the identical rotative speed as that which is specified is

acceptable.

d. Only experience at the identical or higher BMEP as that which is specified is

acceptable.

e. Only experience with diesel-fueled engines is acceptable.

1.5.2 Regulatory Requirements

a. Provide devices designed and installed to comply with the following

requirements:

1. Power Transmission Apparatus: Guard in accordance with

ANSI/ASME B15.1.

2. Electrical installations: Conform to NFPA 70 and PEC

3. Operator Protection: Guard in Accordance with 29 CFR 1910as

follows:

(a) Fan Blades: Part 1910.212(a)(5).

(b) Fixed Ladders: Part 1910.27.

(c) Platforms and Access Openings: Part 1910.23.

4. Mercury: Use of mercury in instruments, contacts and manometers is

not permitted.

5. Transformer Insulation: use of askarel or insulating liquids containing

polychlorinated byphenyls (PCBs) is not permitted.

b. File inspection certificates for compressed air storage system with the proper

authorities as may be required by law and furnished a copy to the Engineer.

1.6 DELIVERY, STORAGE AND HANDLING

Deliver equipment on pallets or blocking and with each entire unit or palletized

unit wrapped in heavy-duty plastic wrapping, sealed to protect parts and

assemblies from moisture and dirt. Plug and seal piping, conduit, exhaust and

air intake openings. Switchboard shall be packed in shipping sections which

can be handled and installed at the site. Protect and prepare batteries for

shipment as recommended by the battery manufacturer. Store equipment and

allied equipment at the site in covered enclosures, protected from atmospheric

moisture, dirt and ground water. Properly label each package on the exterior of

the wrapping as to identity of the enclosed equipment, contract number,

manufacturer, and purchaser. The manufacturer’s standard practice in product

protection and identification, meeting the above requirements will be

acceptable.

1.7 EXTRA MATERIAL

1.7.1 Paint

Furnish 4 liters of the identical paint used for the engine generator assembly in

the paint manufacturer’s sealed containers with the engine-generator unit.

1.7.2 Oil Filters

Furnish two separate replacement elements for the filter with the unit.

1.7.3 Power Circuit Breaker

In addition to circuit breakers shown furnish one additional spare circuit breaker.

1.7.4 Recording voltmeter and Totalizing Recording Watt Meter

Furnish a six month supply of ink and charts.

1.8 POSTED OPERATING INSTRUCTIONS

Provide posted operating instructions laminated between matte-surface

thermoplastic sheets and suitable for placement adjacent to corresponding

equipment.

PART 2 – PRODUCTS

2.1 MATERIALS

Provide materials and equipment of manufacturers regularly engaged in

production of such materials or equipment and the manufacturer’s latest

standard design that complies with specifications requirements. Provide

products of a single manufacturer where two units of the same class of

equipment are required however, component parts of the system need not be

products of the same manufacturer. The major component of equipment shall

have the manufacturer’s name, address and model and serial number on a

nameplate securely affixed in a conspicuous place; nameplate of the

distributing agent will not be acceptable. Nameplates shall not be painted.

2.2 ENGINE-GENERATOR UNITS

Provide engine-generator unit, correctly coordinated by the engine-generator

manufacturer to ensure an installed rating. The unit shall consist of a diesel

engine direct-connected to an ac generator having a brushless excitation

system and shall be provided with all necessary accessories, auxiliaries,

appurtenances, control equipment, and cooling systems, resulting in a

complete set and, except for external service connections, ready for operation.

The engine-generator set shall be mounted on a structural steel sub-base sized

to support the engine; generator-exciter, engine-generator control panel;

lubricating oil filters, fuel oil filters and pumps; jacket coolant heat exchangers

and pumps; and interconnecting piping and wiring for all systems. Provide

separate floor mounted on the engine-generator unit-mounted radiators and

auxiliaries shall be mounted on the engine-generator unit subbase. The engine-

generator unit shall include the electric starters, controls, and related wiring for

electric starting. The batteries, battery racks and charger assembly shall be

mounted on the unit sub-base. Provide structural subbase with vibration

isolators as recommended by the engine-generator unit and isolator

manufacturer to suit the specific equipment involved. Electrical and mechanical

field connections shall be made with flexible connectors. Where standard with

the manufacturer, the separately from the unit, and connections made to the

engine with corrosion resistant flexible connections. Engines and generators

shall be factory aligned on the subbase and securely bolted into place in

accordance with the manufacturer’s standard practice. The unit, after

assembly, shall be painted overall with the manufacturer’s standard paints and

colors. After tests and before shipping, thoroughly clean the unit and retouch

painting as necessary to provide complete protection to the unit. Units shall be

arranged for automatic unattended starting in addition to manual start-and-stop

by control panel pushbuttons. The engine-generator unit shall be capable of

automatically starting, coming up to synchronous speed, and providing full rated

power within 10 seconds after failure of normal power.

2.2.1 Equipment Rating and Capacity

The engine-generator unit shall have a net continuous rating capacity of not

less than 1020 kW at 0.8 power factor and supply 480-volt, three phase, four-

wire 60-Hz ac output. Gross kW rating of the engine-generator unit shall be not

more than the figure obtained by multiplying the delivered shaft-horsepower

rating of the engine by 0.746 and by the overall efficiency of the generator at

the corresponding load. The overall efficiency of the generator shall allow for

power required to operate the exciter, including power consumed in losses,

windage, and friction for the generator and rotating exciter. Furnish auxiliary

equipment designed for continuous duty at 110 percent of the rated-net-

capacity of the engine-generator unit. Size cooling system auxiliaries relative to

the engine coolant specified under cooling system.

2.2.1.1 Fuel Consumption

Fuel consumption at 0.80 power factor shall exceed the values listed below for

various loads. Fuel consumption shall be based upon the use of diesel fuel

substantially as specified and having a low heating value of 42383 kJ /kg.

kJ of Fuel/Net kWh

Load

½

¾

Full

Standby

11288

10814

10866

2.2.2 Critical Speeds

The complete engine-engine generator unit shall be free of critical speeds of

either a major or minor order that might endanger satisfactory operation of the

unit, or cause undue vibration in any part of plant equipment or structure.

Satisfactory operation will be considered endangered, if torsional vibration

stresses exceed 34.45 MPa within 10 percent above or below rated engine

speed.

2.3 Design and Construction

Rotating or reciprocating parts, or other parts that present a potential hazard to

operating personnel, shall be isolated or shielded to minimize danger. Design

characteristics shall limit operating temperatures at critical points of maximum

wear at full load operating conditions.

2.3.1 Fungus Control

For electrical components, fungus control is required as follows:

a. Electrical components such as switches, fuses, contacts, heater elements,

distributors, spark plugs, and magnetos shall not be treated. Other materials

and components which are inherently fungus resistant or are protected by

hermetic sealing need not be treated.

b. Circuit element, not covered above and which have a temperature rise of not

more than 23. 8 degrees C when operating at full load, shall be coated with a

fungus-resistant varnish. Circuit elements include, but are not limited to, cable,

wire, switchboard, terminal and junction blocks, junction boxes, capacitors and

coils.

c. Circuit elements, such as motor coils, generator and transformer windings,

and similar electrical components, which have a temperature rise exceeding

23.8 degrees C when operating at full load, shall not be coated with a fungitoxic

compound. Instead, such components shall be given two initial coats and one

seal coat varnish. Apply the coats by the vacuum-pressure immersion,

centrifugal, pulsating pressure, or built-up method so as to fill interistices in the

coils and prevent the entrapment of air or moisture. The sealer coat may also

be applied by brushing and spraying.

2.4 DIESEL ENGINES AND ACCESSORIES

Diesel engines shall be four-cycle turbo charged and intercooled; vertical In-

line or vertical Vee type; designed for continuous duty, stationary service.

Provide engine designed and constructed to eliminate undue heating, vibration,

and wear. Engines shall be capable of burning diesel fuel oil conforming to CID

A-A-52557, Grade JP-5. Provide engine capable of speeds and ratings not

higher than those for which they have been designed, which fulfill requirements

specified in paragraph entitled “Experience Requirements”. Provide engine only

at speeds and ratings not higher than those for which they have been deigned,

which fulfill requirements specified in the paragraph entitled “Experience

Requirements”. Limiting characteristics of the engines shall be as follows:

a. Maximum BMEP, kPa:

Four-Cycle Engines

Turbocharged and Intercooled – 1240

b. Maximum Engine Speed: 1800rpm

2.4.1 Construction

Engine shall be constructed to withstand sudden changes from no load to rated

load, and to preserve alignment of integral components under all conditions of

operation. The design shall incorporate pressure lubrication of pistons,

bearings and wrist pins, and the bearing journals shall be hardened or

chromium plated to provide a hard shock-resistant surface with ductile core.

Crankshafts shall be provided with replaceable liners. The piston rings shall be

constructed of a heat-resisting alloy steel or chromium plated cast-iron.

Camshafts may be gear or chain driven, and shall be clearly indicated on the

crankshaft gears. Valves shall have removable stem guides and seat inserts.

The flywheel shall be balanced, and shall be capable of being rotated 50

percent above the maximum rated engine rotative speed without danger of

breaking or exploding. Flywheel housing shall be provided with a drain hole at

the lowest point. Means for turning the crankshaft manually shall be provided,

and other barring means shall be provided as outlined under engine

accessories. Provide crankcase explosion relief doors sized to prevent engine

damage. Provide a rigid outboard bearing support, if required, and arrange for

mounting on engine-generator unit subbase.

2.4.2 Assembly

Completely shop assemble each engine and ship ready for coupling to the

flywheel or generator. Mount turbocharger and integral engine piping on the

engine.

2.4.3 Turbocharger

Provide turbine-type driven by exhaust gas from engine cylinders, and direct-

connected to the blower supplying air to the engine intake manifold. Mount

turbocharger, and piping integral with the engine, on the engine. Turbochargers

may be lubricated from the engine pressure lubricating system or as

recommended by the manufacturer. If recommended by the engine

manufacturer provide pre-startup and post-shutdown auxiliary lubricating oil

pumps. Provide necessary supports and connections.

2.4.4 Intercooler

Provide tubular heat exchanger type intercooler for cooling intake air from

turbochargers, including valves, controls, and integral piping needed for an

operable system. Mount intercooler, and piping integral with the engine, on the

engine. Size the capability of the coolant system specified herein to handle the

additional heat input from the intercooler. The cooling system shall handle the

jacket coolant, lubricating oil coolant, and intercooling air cooling loads.

2.4.5 Engine Lubricating Oil System

Provide engine with a full pressure lubricating oil system arranged to cool the

pistons and to distribute oil to moving parts of the engine. The lubrication oil

system integral with the engine shall be complete with necessary oil piping,

fittings, and valves for connecting items of equipment which are part of the

system. The oil type utilized shall be SAE J1349. Oil filters shall be provided as

recommended by the engine manufacturer. Lubricating oil piping shall be

pickled and entirely free of internal mill scale, rust, or other foreign materials

when installed. Include necessary stop, check, pressure relief, and pressure

control valves. Blank off connections for external piping with wood blind flanges

or plugs prior to shipment. Provide an engine-driven lubricating oil circulating

pump for each engine. Pump shall be positive displacement type and driven in

a positive manner from the engine crankshaft or camshaft. Pump shall have

ample capacity to circulate the amount of lubricating oil and cooling oil required

by the engine. Engine may have either a wet or dry crankcase arrangement.

Provide engines having dry crankcases with lubricating oil sump tanks of

sufficient capacity to suit the engine requirements and arranged to receive

necessary piping connections.

2.4.6 Engine Fuel System

Provide engine with a fuel system integral with the engine, complete with piping,

fittings, and valves for connecting items of equipment which are a part of the

system, and equipment, except external interconnecting piping, required to

provide a complete and workable fuel oil system. The overflow level of each

day tank shall be below the engine fuel injector level so as to preclude flooding

of the engine. Provide a mechanical fuel injection system on the engine.

Provide a modified common rail system or an individual pump system. Injection

pumps shall be an integral part of the engine and shall be driven in a suitable

manner from the camshaft. Provide suitable injection adjustments for timing and

for balance of cylinder pressures if standard with the manufacturer.

2.4.7 Engine Starting System

For engine starting, utilize a dc electric circuit, negative polarity grounded,

energized by a starting battery. Cranking motor shall be heavy-duty type with

adequate capacity to crank the motor repeatedly. Provide and coordinate

equipment, appurtenances, and controls necessary for a complete and

dependable cranking system.

2.4.8 Engine Speed Governor (IEEE Device 65), for Low Voltage

The engine speed governing system shall be suitable for controlling the speed

of the generator set to meet the performance requirements specified in ASME

PTC 26, Section II, when tested in accordance with ASME PTC 26.

Performance shall be accomplished without intermediate adjustment and shall

maintain the specified stability without hunting or cycling. Provide the governor

with a reversible synchronizing, electric motor or pneumatic speed changer,

connected to the speed adjusting mechanism by a slip coupling and arranged

for remote manual operation. Electric motors shall be direct current suitable for

the starting control battery voltage.

2.4.9 Engine Protective Devices

Provide the engine with protective devices as follows:

a. Engine Shutdown: Equip the engine with shutdown devices as listed herein.

These devices shall shut down the engine by shutting off the fuel supply to

the fuel injectors. Shutdown devices shall be positive and direct in action

and independent of the governor. Shutdown devices shall have factory-fixed

set-points and shall be equipped with either auxiliary electrical contacts and

cranking circuitry, relays or equivalent device for shutdown. Auxiliary

contacts shall be suitable for the starting control battery voltage. Shutdown

shall open the generator main circuit breaker. Provide the following

shutdown devices:

1. Over speed device which operates if engine speed exceeds normal

synchronous speed by 12 percent or as recommended by manufacturer.

Device shall require manual reset.

2. When turbocharger lubricating oil is separate from engine lubricating oil

system, provide pressure switch which operates when lubricating oil

pressure to turbocharger drops below a preset value.

3. Pressure switch which operates when lubricating oil pressure drops

below a preset value.

4. Temperature switch which operates when jacket coolant temperature

exceeds a preset value.

5. Other shutdown devices as recommended by the engine manufacturer.

b. Electrical Interlocks: Equip throttle valve or starting mechanism with two sets

of auxiliary contacts for interlocking with the generator main breaker control

circuit. With throttle valve open, one set of auxiliary contacts shall be open

and one set closed. Auxiliary contacts shall be suitable for the starting

battery voltage.

2.4.10 Engine Alarm Contact Devices

Equip the engine with alarm devices, relays, and auxiliary contacts, as required,

to actuate alarm system on the associated engine control panel. Auxiliary

contacts shall be suitable for the starting battery voltage. Alarm devices shall

have factory-fixed set points. Provide the following alarm contact devices:

a. Throttle valve limit switch contacts or equivalent device operating to

energize a portion of alarm system only when the engine is running and not

during cranking or shutdown.

b. Pressure switch in jacket coolant manifold piping at the engine to operate if

jacket coolant pressure drops below a preset value.

c. Pressure switch in engine lubricating oil system piping from engine to

operate when pressure drops below a preset value due to failure of engine-

driven lubricating oil pump. In addition to alarm contacts, provide set of

contacts to start the auxiliary oil pump.

d. If turbocharger lubricating oil is separate from engine lubricating oil system,

provide pressure switch in turbocharger lubricating oil system piping to

operate when pressure drops below a preset value.

e. Temperature switch in the jacket coolant discharge piping from the engine

to operate when temperature exceeds a preset value. Device shall have an

adjustable range between 37 and 100 degrees C.

f. Temperature switch in lubricating oil manifold leaving the engine to operate

when temperature exceeds a preset value, or as recommended by the

manufacturer.

g. Other alarm devices as recommended by the engine manufacturer.

2.4.11 Engine Accessories

Provide the following accessories for the engine where the manufacturer’s

standard design permits:

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

companion flanges.

b. Compression relief valve on the cylinder, when applicable.

c. Foundation bolts, nuts, and pipe sleeves for the engine-generator unit.

d. Level jack screws or shims, when applicable.

e. Chocks and shims for installation and leveling of engine-generator unit sub

base (when applicable).

f. Provide manually operated barring gear.

g. Indicating thermometers or temperature indicators per manufacturer’s

standard on coolant inlet and outlet headers and on turbocharger coolant

outlet. If turbocharger oil system is separate from engine oil system, provide

temperature gage on turbocharger lubricating oil outlet.

h. Drilled and tapped holes for attachment of manometer to measure

crankcase pressure or vacuum, if standard with the manufacturer.

i. Removable guard, housing, or rail around flywheel, generator, and exciter.

Support guard, housing, or rail entirely or the sub base and to suit

manufacturer’s standard.

2.4.12 Air Intake and Exhaust Systems

Provide air intake and exhaust systems for the engine. Include piping, fittings,

and expansion joints necessary to interconnect equipment with engines.

Arrangement of air intake and exhaust systems shall be similar to that indicated

and modified, as required, to suit the engine furnished, subject to the approval

of the Engineer. Turbocharger shall not subjected to piping weight or lateral

forces generated with paragraphs entitled “Flanged Connections,” and

“Motors”.

a. Air Intake Filters: Provide either of the oil bath or dry type, as standard with

the engine manufacturer, for the engine. Filter shall be capable of removing

a minimum of 92 percent of dirt and abrasive 3 microns and larger from

intake air. Size filter to suit engine requirements at 110 percent of rated full

load. Unit shall be designed for field access for maintenance purposes.

b. Air Intake Silencers: Provides for the engine to limit noise of intake air

system to a level below the audible mechanical noise level of the engine.

Silencers shall be as recommended by the manufacturer for the engine

furnished.

c. Exhaust Silencers: Provide exhaust silencers for the engine to reduce the

exhaust sound spectrum to, or below, the following listed levels, when

measured with a sound level meter conforming to ANSI S1.4 (ASA 47), 23

meters from the outlet, under full engine load and clear weather. Silencer

shall be complete with handhole openings and necessary brackets for

supporting purposes. Sizing of silencers shall be in accordance with

manufacturer’s recommendations.

Octave Band Maximum Sound Level Decibels

Center Frequency

Hz Industrial

63 and below 87

125 78

250 70

500 64

1000 58

2000 54

4000 52

8000 51

d. Expansion (Flexible) Joints: Provide sections of multiple corrugated

stainless steel expansion joints with liner in the engine exhaust piping

for the engine to absorb expansion strains and vibration transmitted to

the piping. Flexible joints shall be suitable for operation at 93 degrees C

above normal exhaust gas temperature at 100 percent load. Air intake

expansion joints shall be as specified for the exhaust piping or may be

metal reinforced rubber type suitable for the service. Air intake

expansion joints may be for plain end pipe.

e. Exhaust and Air Intake Piping: Provide piping for the engine complete

with necessary fittings, flanges, gaskets, bolts, and nuts. Pipe shall be

lap-welded, or seamless steel pipe conforming to ASTM A53. Exhaust

piping shall be Schedule 40 pipe for 300 mm and smaller sizes and for

larger sizes shall have wall thickness not less than 9.525mm and shall

slope away from the engine. Air intake piping shall have wall thickness

not less than 6.35mm. Flanges shall be 668 N slip-on forged steel

welding flanges conforming to ASME/ANSI B16.5, with material in

accordance with ASTM A 181M, Grade I. Fittings shall be butt welding

conforming to ASTM A 234M, with wall thickness same as adjoining

piping. Fittings shall be of same material and wall thickness as pipe.

Built-up miter welded fittings may be used. Miter angles of each

individual section shall not exceed 0.393 rad total and not more than

0.196 rad relative to the axis of the pipe at any one cut. Gaskets for

exhaust and air intake piping shall be of high temperature asbestos-free

material suitable for the service. Bolting material for air intake flanges

shall consist of square-head machine bolts with cold-pressed semi-

finished hexagon nuts of steel. Bolting material for exhaust flanges shall

be alloy-steel to ASTM A194M. Bolts shall be of sufficient length to

obtain full bearing on the nuts and shall project not more than two full

threads beyond the nut.

f. Exhaust pipe shall be insulated with preformed rock wool insulation, 50

mm thick, 150 kg/m3 density.

2.14.13 Crankcase Protection

Provide manufacturer’s standard method of preventing crankcase explosions.

System shall be complete with required appurtenances. System shall provide a

positive vacuum or pressure on the crankcase. If air is discharged from

crankcase by means of a pressure blower, provide an oil separator in the

system. Vapor discharge shall be carried to outdoors via piping.

2.5 LOW-VOLTAGE GENERATORS AND EXCITATION AND VOLTAGE

REGULATION SYSTEM

2.5.1 Low-Voltage Generator

Provide 0.80 power factor, synchronous, ac, brushless-excited revolving field,

air-cooled, self-ventilated unit conforming to NEMA MG 1 and rated as specified

in the paragraph entitled “Equipment Rating and Capability.” Enclosure frame

shall be drip proof. Match generator speed to that of the engine. Drive generator

directly from the engine crankshaft in a manner approved by both the engine

and generator manufacturers. Generator shall be capable of carrying at rated

voltage and 0.80 power-factor, a load equal to the net kW rating of the engine

without exceeding the temperature limits specified in NEMA MG 1 for

continuous duty. Winding insulation shall be Class B or F. An amortisseur

winding shall be provided and the generator and flywheel shall have sufficient

flywheel effect to meet the requirements of regulation and parallel operation

specified. Generator field voltage shall be the manufacturer’s standard voltage.

The generator neutral shall be solidly grounded. Ground the generator

enclosure at two opposite mounting legs.

2.5.2 Low-Voltage Excitation and Voltage Regulation Systems

Comply with IEEE 421.1.

2.5.2.1 Low-Voltage Exciter

The exciter shall be integral with the generator and shall be of the synchronous,

rotating armature, rotating rectifier type. The rotating rectifier assembly shall be

mounted in a manner to provide ready access for inspection and replacement

of the rectifier diodes. Semiconductor rectifiers shall have minimum factor of

safety of 300 percent for peak inverse voltage, and forward current ratings for

all operating conditions, including 110 percent generator output at 40 degrees

C ambient. Safety devices for the protection of the rectifiers against overload

currents and voltages shall be provided unless the design provides this

protection inherently. The acceptable ratio of exciter ceiling voltage to exciter

nominal voltage shall not be less than three to two. Exciter shall be equipped

with surge protection devices. Output of exciter alternator shall be three-phase

and shall be rectified by full-wave solid-state rotating rectifier mounted on the

generator shaft. Rotating rectifier shall consist of hermetically sealed diodes

connected between exciter and generator field without intervening brushes,

slip-rings, or commutators. Exciter field shall be stationary.

2.5.2.2 Voltage Regulator (IEEE Device 90)

Solid state and shall automatically control the generator field current through

action on the exciter. The reference voltage shall be three-phase averaged and

obtained from the generator output transformers, if required. The voltage

regulator shall enable manual adjustment of the set output voltage, while the

set is operating, by potentiometer adjustment at the generator control panel.

The voltage regulator shall enable parallel operation with like sets. Provide

automatic field flashing, using power from the starting battery and limiting the

flashing current to a safe value with controls for the circuit, to be installed in the

generator control panel.

a. Operation: Voltage regulator shall have characteristics and sensors which

provide the generator with the capability of operating alone in isochronous

load sharing mode and in conjunction with common solid-state control to

operate isochronously with proportional load sharing. A contact shall be

provided to short out the current transformer when a generator is not

connected to its output bus. Install instrument transformers and the voltage

regulator in the generator control panel along with a manual voltage setting

control system consisting of a manual voltage adjusting rheostat or variable

autotransformer and a manual-automatic-off switch.

b. Regulation: The voltage regulator/excitation systems shall be capable of

voltage regulation within plus or minus ½ percent from no-load to full-load,

and capable of maintaining a long-time voltage stability of within plus or

minus one percent. Up to a 5 percent variation in frequency and the effects

of field heating shall not affect the unit regulation performance. Provide full-

field-forcing series boost excitation system supplied as necessary and

furnish to the regulation power stage during all operating conditions

including generator overload and short circuit.

2.6 FUEL OIL SYSTEM

Conform to NFPA 30 and NFPA 37 and the requirements herein. Provide

motors and flange connections in accordance with paragraphs entitled “Motors”

and “Flange Connections.”

2.6.1 Tanks

Tanks may be standard design as recommended or used by the engine

manufacturer or shall be constructed as specified in paragraph entitled “Tank

Construction”.

2.6.1.1 Fuel Oil Day Tanks

Provide tanks with a minimum capacity of 8 hours of engine-generator unit

operation at full-rated load for the engine-generator unit. Provide tanks with a

level gage and makeup control valve. Include connections of the indicated size

for inlet, outlet, overflow, drain, vent, and level controller, and a high and low

level alarm switches.

2.6.1.2 Level Alarm Switches

Provide tank-top mounted or external float cage, single-pole, and single-throw

type designed for use on fuel oil tanks. Arrange high level alarm switches to

close on rise of liquid level, and low level alarm switches to close on fall of liquid

level. Mount float cage units with isolating and drain valves. Contacts shall be

suitable for the station battery voltage. Contact ratings shall be A150 in

accordance with NEMA ICS 2.

2.6.1.3 Tank Gages

Provide tank gages conforming to CID A-A-50568. Gages for fuel oil day tanks

shall be buoyant force type, with dial indicator not less than 100 mm in size and

arranged for side mounting. Each reading dial or scale shall be calibrated for

its specific tank to read from empty to full, with intermediate points of 1/4, 1/2,

and 3/4.

2.6.2 Duplex Fuel Oil Strainer

Provide the type having two straining chambers and arranged to divert the flow

from one chamber to the other without interruption at any point of the

changeover. Design shall allow for cleaning, by permitting removal of the

strainer basket not in use while the other strainer basket is in use. Construct

strainer baskets of corrosion-resistant metal. Strainer mesh, type, and size shall

be as recommended by the engine manufacturer. Construct body of cast iron

suitable for 861 kPa (gage) working pressure. Provide a remote differential

pressure gage between inlet and outlet of duplex-strainer to indicate the

pressure drop of strainer chamber on line.

2.6.3 Fuel Oil Meters

Provide positive displacement type. Maximum variation from absolute accuracy

measurement over entire range of meter shall be not greater than plus or minus

five-tenths of one percent. Provide meters with horizontal setback registers

calibrated to read in liters and tenths of liters. Construct meters with cast-irons

bodies, with working parts made of material to resist wear, friction, and

corrosion and can handle oil containing a small percentage of sulphur. The

meter shall have capacity to measure a maximum of 5L/s, with pressure drop

through meter not exceeding 40 kPa.

2.6.4 Fuel Oil Filters

Provide two filters of the throwaway filter element type, consisting of shell, filter

elements, drains and necessary connections and fittings. Equipment and

component parts shall be the standard product of the filter manufacturer to

ensure prompt and continuing service and delivery of repair or maintenance

parts and shall be standard with the engine manufacturer. Component parts of

the unit need not be the product of the same manufacturer. The filter shall be

capable of removing not less than 95 percent of all particles larger than 5

microns. Filter elements shall be factory-assembled type, with compression

type end seal gaskets at top and bottom and with suitable pullout device. Filter

material shall be cellulose, laminated fiber discs, or acid resistant textile

material. Elements shall be designed for an initial pressure drop not in excess

of 35 kPa at a flow rate of 0.0972 L/s per element. Construct filters with sides

having double walls. Install insulating material between the inner and outer

walls. Inner shell shall be pressed steel or welded steel construction enclosing,

supporting, and protecting all elements. Filters shall have flanged, removable

bolted top cover for access to all components without disconnecting any

connections or fittings. Provide compartments for clean and dirty oil. Provide

supports for base mounting. There shall be tie-bolts, or equivalent means, for

holding down the filter elements and cover, and recesses or other means for

receiving and locating the elements. Design and construction shall conform to

the ASME BPVC SEC VIII D1. Filter cover shall be steel and secured to the

shell by swing-type bolts with hex nuts. Use lifting devices with integral supports

for covers weighing over 14 kg. Arrange connections so that filter elements may

be removed without breaking outside connections. Mount pressure gages on

filter shell to indicate pressure before and after the filter elements. Provide a

tapped drain and exterior valve pipe connection. A duplex gage may be

provided. Gages shall conform to ANSI/ASME B40.1 and shall be pressure

detecting class, 108 mm size, and 0 to 689 kPa range. Provide a needle valve

and fittings for mounting each gage and differential pressure switch. Equip each

unit with instruction plates and diagrams, suitably located, describing special or

important procedures to be followed in operating and servicing the equipment.

Plates shall be copper or zinc base alloy, adequately secured to the unit.

Provide an adjustable pressure switch with contacts suitable for the starting

battery voltage to indicate high differential fuel-oil filter pressure.

2.7 LUBRICATING OIL SYSTEM

Provide tanks, motors, thermostatic control valves, and flange connections in

accordance respectively with paragraphs entitled “Tank Construction”, “Motor”,

“Thermostatic Control Valves,” and “Flange Connections.” Duplex strainers,

shall conform to the paragraph entitled “Duplex Fuel Oil Strainers,” except that

baskets shall be of 300-mesh corrosion-resistant metal.

2.7.1 Auxiliary Lubricating Oil Pumps

Provide one pump for the engine, the for “before-and-after” lubricating and

cooling service and capable of circulating not less than 10 percent of the full

flow rate of lubricating oil at the pressure required by the engine. Equip pump

with a bypass relief valve. Pump unit shall consist of a horizontal, positive-

displacement rotary pump driven by a three-phase electric motor either directly

or through a gear reduction unit. Pump shall conform to CID A-A-50561, except

as modified above.

2.7.2 Lubricating Oil Filtration

Provide the engine with a pressurized lubricating oil filtration system capable of

filtering the full rate of oil flow from the oil pumps at the maximum engine speed

in accordance with the standard practice of the engine manufacturer. Means

shall be provided to ensure delivery of lubricating oil to vital wearing surfaces

regardless of the condition of the filters without removing the engine from

service. Additionally, the filters shall provide means of automatically bypassing

the filter if it should become flow-restricting. When electric heaters are used,

provide thermostatically controlled type, suitable for three-phase, supply at the

same voltage as three-phase motors. Filter elements shall be of the throwaway

type. Where provided individual duplex strainers shall be in accordance with

the paragraph entitled “Duplex Fuel Oil Strainer.” A bypass lubricating system

shall be provided for each engine as follows:

a. Provide a bypass filter capable of passing not less than 10 percent of the

full flow engine circulating rate and removing not less than 95 percent of the

particles 5 microns and larger. Other requirement shall be same as for the

full rate of oil filters.

b. Provide bypass filter with a bypass filter pump to circulate the lubricating oil

as indicated. Pump capacity shall suit the capacity requirements of the

bypass filter, and pump head shall suit the requirements of the system.

Pump unit shall consist of a horizontal, positive displacement rotary pump

with built-in or external relief valve driven by a three-phase electric motor,

either directly or through a gear reduction unit, mounted on a common cast-

iron or steel base-plate.

2.7 COOLING SYSTEM

Provide the specified cooling water system. If the engine manufacturer

considers that a different arrangement is more suitable for the engine to be

installed, the Contractor may submit information to the Engineer on the

proposed cooling system arrangement. If proposed arrangement is approved

by the Engineer, the Contractor shall provide the proposed system at an agreed

upon reduction in contract price.

Equipment shall be properly sized to handle the flow rate and pressure losses of the

coolant specified at the specified site. Provide motors, tanks, flange connections,

and thermostatic control valves in accordance respectively with the paragraphs

entitled “ Motors” “ Tank Construction’’ “ Flange Connections,’’ and “ Thermostatic

Control Valves” .

2.7.1 Jacket Coolant Pumps

Provide a pump driven by the engine or by a three-phase electric motor of the

general purpose type with a horizontally split case and of the single-stage class.

Pump speed shall not exceed 1800 rpm. Pumps shall conform to CID A-A-50562.

Pump shall have ample capacity to circulate the required flow of coolant through the

system to remove the total heat rejected from the engine and, where required by the

design, from the lubricating oil and aftercoolers. Heat shall be rejected to the jacket

coolant to maintain optimum jacket coolant temperature leaving and entering engine

as recommended by the engine manufacturer. Pumps shall have characteristics

which will permit operation in parallel. Exact head rating based on flow required, as

determined by the engine manufacturer, shall be verified by the Contractor after the

selection of the engine-generator units.

2.7.2 Radiators

Provide one radiator unit for the engine-generator set. Provide engine

subbase mounted radiators of the forced draft type with horizontal or vertical air

discharge as standard with the engine manufacturer.

2.7.2.1 Design Conditions

The radiator unit shall have ample capacity to remove not less than the total

KW of heat rejected by its respective engine at 100 percent full-rated load to the

jacket coolant and lubricating oil system and that necessary for intercooler charge air

cooling. Radiator capacity shall be rated at optimum temperature of coolant leaving

the engine and intercooler as recommended by the engine manufacturer, with a dry

bulb air temperature of 43 degrees C. Pressure drop through the radiator shall not

exceed 41.34 KPa when recirculating the maximum required coolant flow. Radiator

air velocity shall be a maximum of 4.572 m/s.

2.7.2.2 Engine Subbase-Mounted Radiator Construction

The radiator fan shall direct the air flow from the engine outward through the

radiator. The fan may be driven directly from the engine crankshaft through V-belt

drive. The radiator shall have sufficient capacity to meet the design conditions

against a static restriction of 12.7 mm of water as may be imposed by louvers and

ductwork. Cooling section shall have a tube and fin type core which shall consist of

copper or copper base alloy tubes with nonferrous fins. Engine-driven fans shall be

the engine manufacturer’s standard units, selected for quiet vibration-free operation.

Provision shall be made for coolant expansion either by self-contained expansion

tanks or separately mounted expansion tanks, as standard with the manufacturer.

Provide suitable guards for the fan and drive.

2.8 Electric Starting System

A 24 – volt dc starting battery installation shall be provided for starting of the

engine-generator set utilizing an electric cranking system. The electric cranking

system shall be capable of rotating the engine at a speed sufficient for rapid starting

in an ambient temperature of 30 degrees C. the signal for starting shall come from

the engine-generator set control system.

2.8.1 Cranking

The electric cranking system shall be energized from the starting batteries’

negative polarity grounded, dc electrical circuit. The cranking motors shall be of the

heavy-duty type with adequate capacity to crank the engine continuously to start the

engine. The drive mechanism for engaging the starting motors with the engine

flywheel shall be designed to inherently engage and release without binding. When

the engine starts, a “stop cranking” switch shall be engine-speed actuated and cause

disengagement of the starting gearing and the shutdown of the starting motors. The

automatic cranking panel shall crank the engine as specified under paragraph

entitled “Engine Cranking Relay”.

2.8.2 Starting Battery Installation

The engine cranking battery shall be a nickel-cadmium pocket plate type

designed for diesel engine starting and of sufficient size and capacity in a fully

charged condition to start the engine-generator set six consecutive times. Provide

properly ventilated battery racks or enclosures, for the batteries and charger. Provide

necessary cabling.

2.8.3 Starting Battery Charger

Enclosed, automatic, dual-rate, solid-state, constant voltage type having ac

voltage compensation, dc voltage regulation, and current limiting. Charger shall

employ transistor-controlled magnetic amplifier circuits to provide continuous trickle

charging. Charger shall have two ranges, float and equalize, with 0-to-24 hour

equalizer time, dc cranking relay, silicon diode full-wave rectifiers, automatic surge

suppressors, dc ammeter, dc voltmeter, and fused inputs and outputs. Charger shall

have a continuous rated output of not less than 10 amperes. Charger shall conform

to UL 1236.

2.9 PIPING SPECIALTIES

2.9.1 Pressure Gages

Conform to ANSI/ASME B40.1, pressure detecting class, of 108 mm nominal

diameter, with silver or white dials and black markings. Provide each gage with a

properly rated shutoff valve of the needle type and suitable pressure snubber.

Provide duplex gages of the two Bourdon Tube style and simplex gages of the single

Bourdon tube style. Gages specified herein are in addition to those specified with the

specific items of equipment. Provide one pressure gage with ranges indicated for

each independent service, that is, one per engine, pump, cooler, header,

compressor, strainer, filter, or tank.

a. Duplex gages: Provide for the following services.

1. Before – and – after fuel oil duplex strainer.

2. Before – and – after lubricating oil filter.

3. Coolant to and from jacket coolant pumps

2.9.2 Alarm Contact Devices

Provide the following alarm contact devices to operate on the starting battery

voltage in conjunction with the control alarm system.

2.9.2.1 Pressure Switch Alarms

Provide single-pole, single-throw contact type pressure switches conforming

to MIL-S-62742 to alarm for pressure drops below a predetermined point.

a. Low fuel oil filter pressure switch: install as indicated, in the fuel oil piping

from the fuel oil system with an adjustable range.

b. Low starting air pressure switch: install as indicated, in engine compressed

air storage system with an adjustable range.

2.9.2.2 Level Alarm

Utilize the high level alarm switch provided in the fuel oil drip tank and provide

for auxiliary relay necessary to energize the control alarm system, if the fuel oil level

in the drip tank drops below a predetermined level.

2.9.3 Overflow Sight

Provide an overflow sight in the lubricating oil piping at sump tank as indicated

and position relative to the indicated sump tank oil level. Utilized an atmospheric vent

type equipped with a pyrex glass top for observation of liquid flow and designed to

eliminate syphoning. Construct body of cast-iron or bronze with a removable top with

50mm flanged inlet and outlet connections.

2.9.4 Pipeline Strainer

Install pipeline strainer conforming to FS WW-S-2739, with screwed

connections for sizes up to 40mm and flanged connections for 50mm and larger

sizes. Utilize Y pattern style rated not less than 862 kPa (gage). Provide one strainer

as specified below and elsewhere as follows:

a. Coolant return header.

b. Coolant suction header.

2.10 GENERAL CONTROL

Provide automatic control of engine-generator unit.

2.10.1 Automatic Control

Provide automatic starting and stopping at the switchboard.

2.10.2 Automatic Circuitry

Provide relays, switching, and other devices and wiring necessary for

automatic operation.

2.10.2.1 Automatic Starting

Provide undervoltage relays, IEEE Device 27, and auxiliary time-delay

relaying so that when the normal supply voltage in a phase drops below a

predetermined value, adjustable from 65-to-90 percent normal, for a predetermined

interval, adjustable 0-to-one minute, an automatic operation shall begin. The engine-

generator unit shall automatically start, accelerate to the governed speed, and build

up to the regulated voltage. When the engine-generator unit voltage reaches

approximately 90 percent normal, automatic transfer of the load from the normal

source to the engine-generator units shall occur.

2.10.2.2 Automatic Stopping

Provide overvoltage relays ( IEEE Device 59) and auxiliary time-delay relaying

so that when the normal supply voltage is restored to a predetermined value,

adjustable from 90-to-100 percent normal, for a predetermined time interval,

adjustable 0-to-2 minutes, the load shall be automatically transferred from the

engine-generator units to the normal supply, the generator circuit breaker shall open,

and the engine-generator units shall continue to run for a period of 5 minutes (

adjustable) and then automatically stop. Devices shall return to normal position,

ready to repeat the automatic operation above. Provide complete facilities for manual

control, including test operation of each engine-generator unit without load and

manual operation of load transfer devices. When engine-generator units are not

required to supply the connected load, the unneeded units shall also be shut down.

2.10.2.3 Engine Starting Switch

The switch shall be a four-position rotary, enclosed rear mounting type of the

maintained-position type. The switch positions shall be ‘’Automatic” ‘’OF”, “TEST”,

and “MANUAL” and shall be connected to provide the following operation:

a. In the “Automatic” position, the engine-generator unit shall start

automatically in response to loss of voltage, as described in the paragraph

entitled “Automatic Starting”.

b. In the “Off” position, the engine-generator unit starting circuits shall not

function.

c. In the “Test” position, the engine may be started and brought up to speed,

but the engine-generator unit cannot be put on line.

2.10.2.4 Engine Cranking Relay

Provide to operate as follows:

a. When actuated, device shall close contacts to actuate the engine starting

system.

b. Should the engine fail to start at once, cranking shall continue for 25

seconds (adjustable) after which a 10-second “off” period (adjustable) and

another 7-second “off” period, adjustable. Durations of cranking and

specified “off” periods may be modified in accordance with engine

manufacturer’s recommendations.

c. Repeat the specified cranking cycle for these three starting attempts.

d. If the engine still fails to start, the cranking device shall lock out further

starting attempts until it is manually reset. When the cranking relay lock

out, an alarm light shall be energized at the indicated location and remain

lighted until it is manually reset. The next engine in the sequential starting

selection shall then have its engine cranking relay actuated.

2.11 LOW-VOLTAGE ENGINE-GENERATOR UNIT PROTECTION AND SUPPORT

Provide an engine-generator control panel mounted on engine-generator unit

subbase, and a remote alarm panel.

2.11.1 Engine-Generator Control Panel

Provide on enclosed panel fabricated of not lighter than 14 gage sheet steel in

compliance with NEMA 250, Type 12. Construct cabinet with angle iron framework, if

required, for proper stiffness and support. Size the cabinet to accommodate the

equipment specified herein. Factory-mount panel on the engine unit subbase. Use

isolation mounting material between the subbase and the panel to isolate the panel

from engine vibrations. Provide panel-mounted, devices with suitable nameplates of

laminated black gloss-finished plastic with white engraved lettering. Provide

connecting piping, tubing, and wiring installed in circuit where not otherwise

enclosed.

2.11.1.1 Engine Control Panel

Provide devices of the type standard with the manufacturer utilizing minimum

50mm nominal diameter gages. Instruments subject to rapid pressure surges shall

be provided with dampening devices to give a steady reading. Provide the following

panel-mounted devices as a minimum:

a. Engine Controls: Engine controls shall be installed on the generator

control panel, except provide an emergency stop switch on the engine

control panel.

b. Engine instrumentation:

1. Fuel oil pressure gage.

2. Lube oil pressure gage.

3. Coolant temperature gage.

4. Elapsed time meter.

c. Engine Safety Circuit Devices: Provide the following devices to stop the

engine-generator set and to simultaneously open the engine-generator set

main circuit breaker. Stop switch may be connected to safety circuit if

recommended by the manufacturer. Source of energy for the engine safety

circuit devices shall be the starting battery, separate from the starting

circuit.

1. Overcranking.

2. Overspeed.

3. Excessive coolant temperature.

4. Dangerously low lubricating oil pressure.

2.11.1.2 Generator Control Panel

Install these controls in the generator switchboard. Generator controls and

instrumentation shall be provided as follows.

a. Generator Controls:

1. Generator circuit breaker, IEEE Device 52.

2. Voltage regulator and associated controls.

3. Governor remote control switch.

b. Generator Instrumentation and Metering

1. Voltmeter and Control switch.

2. Ammeter and Control switch.

3. Wattmeter.

4. Watthour meter.

5. Three current transformers.

c. Engine starting and stopping Controls and Protective Equipment

1. Engine starting switch.

2. Engine cranking relay.

3. Engine shutdown relay.

4. Automatic synchronizing and transfer circuitry.

2.11.2 Generator Switchboard

Provide a free-standing, metal-enclosed, general-purpose, indoor, low-voltage

switchboard. Switchboard shall be rated 600-volts, three-phase, and four-wire and

provided with continuous ground bus. Buses shall be copper. Interrupting and

continuous ampere ratings shall be as indicated.

2.11.2.1 Generator Units

Provide to switch and control the electrical output of the engine-generator set.

2.11.2.3 Feeder Units

Provide to switch and control each feeder

2.11.2.3 Auxiliary Units

Provide as follows.

2.11.3 Generator Control Panel Devices

Conform to the following requirements for each device:

2.11.3.1 Generator Circuit Breaker, IEEE Device 52

Provide a circuit breaker having a solid-state tripping device with adjustable

long-time and short-time tripping characteristics. Provide a stored-energy closing

mechanism for rapid and safe closing of the circuit breaker against fault currents

within the short-time rating of the circuit breaker independent of the operator’s

strength or effort in closing the handle. Size the circuit breaker for 100-percent full-

load capacity of the engine-generator set and provide lugs for the indicated electrical

connection.

a. Type: Provide a low-voltage power circuit breaker conforming to ANSI

C37.16 for all circuit breakers. Switchgear construction shall conform to

ANSI/IEEE C37.20.1 for metal-enclosed low voltage power circuit breaker

switchgear. Trip ratings shall conform to ANSI C37.17.

b. Operation: Generator and incoming feeder circuit breakers shall be

electrically-operated from the control battery. A switchboard type control

switch and red and green indicating lights shall be provided for power

circuit breaker.

c. Circuit breaker test set: Provide a test set suitable for performing routine

calibration and maintenance tests on the low-voltage power circuit

breakers furnished with the unit substation. Test set shall be suitable for

making operational tests, internal power supply tests, pickup current and

time delay tests, and trip signal output tests. Tests shall be suitable for use

on a 20-ampere, 240-volt, and 60-hz circuit.

2.11.3.2 Generator Voltage Adjustment

Install the manual voltage setting control system as specified under the

paragraph entitle “Voltage Regulator”.

2.11.3.3 General Remote Control

Provide a governor “raise-lower” control switch to manually operate the

electric motor or pneumatic speed changer specified under the paragraph entitled

“Engine Speed Governing System”.

2.11.3.4 Indicating Lights

Provide removable front, low drain, push-to-set, indicating lights equipped with

dropping resistors suitable for 240-volt ac service , as required and color caps as

specified.

2.11.3.5 Instruments

Provide semiflush-mounted, rectangular, switchboard instruments with rear

connecting terminals and conforming to ANSI C39.1. Construct with tault-band

suspension movement and 4.36 rad scale in a nominal 115mm square case. Design

and calibrate for vertical or horizontal mounting, as required. Elapsed time meters

shall totalize engine running time to 9999.9 hours total.

2.11.3.6 Instrument Transformers

Provide indoor, dry-type conforming to ANSI/IEEE C57.13. Coordinate

mechanical and thermal ratings with circuit breakers and other apparatus in the

switchboard in accordance with ANSI/IEEE C37.20.1.

2.11.3.7 Engine Shutdown Relay

Provide and actuate by the engine protective devices as specified in the

paragraph entitled “Engine Safety Circuit Devices”. Shutdown relay shall disable

engine starting circuits until manually reset. Provide reset pushbutton on

switchboard.

2.11.4 Generator Switchboard Unit Equipment Details

Provide nameplates for units, for front and rear identification and necessary

auxiliary relays, small wiring, nameplates, control and instrument buses, fuses,

terminal blocks, wire terminals, and accessories. Arrange cable compartments in the

switchboard for the indicated entrance of power and control cables. For free standing

section provide one set of phase, and ground buses, splices, and connections.

Buses shall be copper. Circuit breakers shall conform to the requirements specified

in paragraph entitled “Generator Circuit Breaker”.

2.11.4.1 Generator Units

Equip unit with the devices specified in paragraph entitled “Generator Control

Panel”.

2.11.4.2 Feeder Units

Equip units as follows.

a. Incoming Feeder Units:

1. 1 power circuit breaker, IEEE Device 52.

2. 1 ammeter and ammeter switch.

3. 3 current transformers.

4. 1 watthour meter demand type.

5. 1 surge arrester and capacitor assembly.

b. Outgoing Feeder Units:

1. 1 power circuit breaker, IEEE Device 52.

2. 1 ammeter and ammeter switch.

3. 3 current transformers.

2.12 WIRE AND CABLE

Provide wire and cable required for a complete electrical system as shown.

Low-voltage power cables shall conform to the applicable portions of Section 1639

“Interior Distribution System.”