July 22, 1994

Contract #TW0592

**SPECIAL SPECIFICATION**

**SECTION 16620**

**[PACKAGED ENGINE GENERATOR SYSTEMS]{.underline}**

**[PART 1 - GENERAL]{.underline} [Page]{.underline}**

1.01 Related Documents 3

1.02 Summary 3

1.03 Definitions 3

1.04 System Description 4

1.05 Submittals 4

1.06 Quality Assurance 5

1.07 Delivery, Storage and Handling 6

1.08 Extra Materials 6

**[PART 2 - PRODUCTS]{.underline}**

2.01 Manufacturers 8

2.02 System Service Conditions 9

2.03 Engine Generator System 9

2.04 System Performance 9

2.05 Engine Generator Set 10

2.06 Engine 11

2.07 Engine Cooling System 12

2.08 Fuel Supply System 13

2.09 Engine Exhaust System 14

2.10 Starting System 14

2.11 Control and Monitoring 15

2.12 Generator, Exciter, and Voltage Regulator 16

2.13 Load Bank 17

2.14 Outdoor Generator Set Enclosure 18

2.15 Finishes 18

2.16 Source Quality Control 19

**[PART 3 - EXECUTION]{.underline}**

3.01 Installation 21

3.02 Identification 21

3.03 Field Quality Control 21

3.04 Cleaning 23

3.05 Demonstration 23

3.06 Commissioning 23

**SPECIAL SPECIFICATION**

**SECTION 16620**

**[PACKAGED ENGINE GENERATOR SYSTEMS]{.underline}**

**[PART 1 - GENERAL]{.underline}**

**1.01 [RELATED DOCUMENTS]{.underline}**

> A. Drawings and general provisions of the Contract, including General
> and Supplementary Conditions and Division 1 Specification Sections,
> apply to this Section.

**1.02 [SUMMARY]{.underline}**

> A. This Section includes a packaged diesel engine generator system
> including engine generator set, cooling system, fuel system,
> combustion air intake and engine exhaust systems, starting system, and
> the following additional features:
>
> 1\. Weatherproof housing.
>
> 2\. Load bank.
>
> B. Related Sections: The following Sections contain requirements that
> relate to this Section:
>
> 1\. Division 16 Section \"Transfer Switches\" for transfer switches,
> including sensors and relays, to initiate automatic starting and
> stopping signals for engine generator set.

**1.03 [DEFINITIONS]{.underline}**

> A. Emergency or Standby Rating: Power output rating equal to the power
> the generator set delivers continuously under normally varying load
> factors for the duration of a power outage, with capability for a
> minimum overload of 10 percent of the rating for 2 continuous hours
> out of 24 continuous operating hours.
>
> B. Operational Bandwidth: The total variation from the lowest to the
> highest value of a parameter over the range of conditions indicated,
> expressed as a percentage of the nominal value of the parameter.
>
> C. Power Output Rating: Gross electrical power output of generator set
> minus total power requirements of electric motor-driven accessories
> normally constituting part of the engine assembly.
>
> D. Steady-State Voltage Modulation: The uniform cyclical variation of
> voltage within the operational bandwidth, expressed in Hz or cycles
> per second.

**1.04 [SYSTEM DESCRIPTION]{.underline}**

> A. System Includes: Standby-rated, automatically started diesel engine
> coupled to an a.c. generator unit. Engine and generator are
> factory-mounted and aligned on a structural steel skid. Subsystems and
> auxiliary components and equipment are as indicated.
>
> B. Functional Description: When the mode selector switch on the
> control and monitoring panel is in the \"automatic\" position, remote
> control contacts in one or more separate automatic transfer switches
> initiate the starting and stopping of the generator set. When the mode
> selector switch is placed in the \"on\" position, the generator set
> starts manually. The \"off\" position of the same switch initiates
> shutdown of the generator set. When the unit is running, specified
> system or equipment failures or derangements automatically shut the
> unit down and initiate alarms. Operation of a remote emergency stop
> switch also shuts down the unit. Automatic transfer switches are
> specified in another Section of these Specifications.

**1.05 [SUBMITTALS]{.underline}**

> A. General: Submit the following according to Conditions of Contract
> and Division 1 Specification Sections.
>
> B. Product data for products specified in this Section. Include data
> on features, components, ratings, and performance. Include dimensioned
> outline plan and elevation drawings of engine generator set and other
> system components.
>
> C. Maintenance data for system and components for inclusion in
> Operating and Maintenance Manual specified in Division 1. Include the
> following:
>
> D. Shop Drawings: Detail fabrication, piping, wiring, and installation
> of the field-installed portions of the system. Include general
> arrangement drawings showing locations of auxiliary components in
> relation to the engine generator set and duct, piping, and wiring
> connections between the generator set and the auxiliary equipment.
> Show connections, mounting, and support provisions and access and
> working space requirements.
>
> E. Wiring Diagrams for System: Show power and control connections and
> distinguish between factory-installed and field-installed wiring.
>
> F. Qualification Data for Manufacturer: Include capabilities and
> experience data required to demonstrate qualifications specified in
> Quality Assurance Article. Include list of completed projects with
> project names and addresses and names of Engineers and Owners, plus
> other information specified. Include separate data for each of the
> following items:
>
> 1\. Engine Generator System.
>
> 2\. Engine Generator Set.
>
> 3\. Remote Radiator.
>
> 4\. Load Banks.
>
> G. Independent Field-Testing Organization Certificates: Signed by
> Contractor, certifying that the organization complies with the
> requirements specified in Quality Assurance below.
>
> H. Certified Summary of Prototype Unit Test Report: Submit certified
> copies of actual prototype unit test report if subsequently requested.
>
> I. Certified Test Reports of Components and Accessories: Submit for
> devices that are equivalent, but not identical, to those tested on
> prototype unit.
>
> J. Exhaust Emissions Test Report.
>
> K. Certification of Torsional Vibration Compatibility: Conform to NFPA
> 110.
>
> L. Factory Test Reports: For units to be shipped for this Project
> showing evidence of compliance with specified requirements.
>
> M. Field Test Report: Record of tests specified in Part 3.

**1.06 [QUALITY ASSURANCE]{.underline}**

> A. Manufacturer Qualifications: Firms experienced in manufacturing
> equipment of the types and capacities indicated that have a record of
> successful in-service performance.
>
> 1\. Emergency Service: System manufacturer maintains a service center
> capable of providing training, parts, and emergency maintenance and
> repairs at the Project site with 4 hours maximum response time.
>
> B. Independent Field-Testing Organization Qualifications: To qualify
> for acceptance, an independent testing organization must demonstrate,
> based on evaluation of organization-submitted criteria conforming to
> ASTM E 699, that it has the experience and capability to conduct the
> indicated testing satisfactorily.
>
> C. Comply with NFPA 70, \"National Electrical Code.\"
>
> D. Comply with NFPA 110, \"Standard for Emergency and Standby Power
> Systems,\" for requirements for a Level 1 emergency power supply
> system.
>
> E. NRTL Listing: System components of types and ratings for which NRTL
> listing or labeling service is established and components are listed
> and labeled.
>
> 1\. The Terms \"Listed\" and \"Labeled\": As defined in the \"National
> Electrical Code,\" Article 100.
>
> 2\. Listing and Labeling Agency Qualifications: A \"Nationally
> Recognized Testing Laboratory\" (NRTL) as defined in OSHA Regulation
> 1910.7.
>
> F. Engine Exhaust Emissions: Comply with applicable Federal, State,
> and local government requirements.
>
> G. Single-Source Responsibility: Obtain engine generator system
> components from a single manufacturer with responsibility for entire
> system. Unit shall be a representative product built from components
> that have proven compatibility and reliability and are coordinated to
> operate as a unit as evidenced by records of prototype testing.

**1.07 [DELIVERY, STORAGE, AND HANDLING]{.underline}**

> A. Deliver engine generator set and system components to their final
> locations in protective wrappings, containers, and other protection
> that will exclude dirt and moisture and prevent damage from
> construction operations. Remove protection only after equipment is
> made safe from such hazards.

**1.08 [EXTRA MATERIALS]{.underline}**

> A. Furnish extra materials matching products installed, as described
> below, packaged with protective covering for storage, and identified
> with labels describing contents. Deliver extra materials to the Owner.
>
> 1\. Fuses: 1 for every 10 of each type and rating, but not less than 1
> of each.
>
> 2\. Pilot Lights: 2 for every 6 of each type used, but not less than 2
> of each.
>
> 3\. Filters: 1 set each of lubricating oil, fuel, and combustion air
> filters.

**[PART 2 - PRODUCTS]{.underline}**

**2.01 [MANUFACTURERS]{.underline}**

> A. Available Manufacturers: Subject to compliance with requirements,
> manufacturers offering products that may be incorporated in the Work
> include, but are not limited to, the following:
>
> B. Manufacturers: Subject to compliance with requirements, provide
> products by one of the following:
>
> 1\. Engine Generator Sets:
>
> a\. Caterpillar, Inc.
>
> b\. Cooper Industries, Ajax-Superior.
>
> c\. Detroit Diesel Corp.
>
> d\. Generac Corp.
>
> e\. Kohler Co.
>
> f\. Onan Corp, Electrical Products Div.
>
> 2\. Day Tanks Systems:
>
> a\. Euclid Equipment, Inc.
>
> b\. Katolight Corp.
>
> c\. Tiernay Turbines, Inc.
>
> 3\. Load Banks:
>
> a\. Avtron Mfg, Inc.
>
> b\. Fermont Div., Dynamics Corp. of America.
>
> c\. Libby Corp.
>
> 4\. Storage Batteries:
>
> a\. C&D Charter Power Systems.
>
> b\. Chloride Systems.
>
> c\. Exide Corp.
>
> 5\. Battery Chargers:
>
> a\. C&D Charter Power Systems.
>
> b\. Exide Corp.
>
> c\. Kohler Co.
>
> d\. LaMarche Mfg. Co.
>
> e\. Onan Corp.

**2.02 [SYSTEM SERVICE CONDITIONS]{.underline}**

> A. Environmental Conditions: Engine generator system withstands the
> following environmental conditions without mechanical or electrical
> damage or degradation of performance capability:
>
> 1\. Ambient Temperature: Minus 15 deg C to plus 40 deg C.
>
> 2\. Altitude: Sea level to 6000 feet (300 m).

**2.03 [ENGINE GENERATOR SYSTEM]{.underline}**

> A. General: System is a coordinated assembly of compatible components.
>
> B. Ratings: Voltage and power output ratings, at 60 Hz, of the system
> are as indicated.
>
> C. Output Connections: 3 phase, 4 wire.
>
> D. Safety Standard: Comply with ASME B15.1, \"Safety Standard for
> Mechanical Power Transmission Apparatus.\"
>
> E. Nameplates: Each major system component is equipped with a
> conspicuous nameplate of the component manufacturer. Nameplate
> identifies manufacturer of origin and address, and the model and
> serial number of the item.
>
> F. Resistance to Seismic Forces: Internal and external supports for
> components, supports, and fastenings for batteries, wiring, and piping
> are designed to withstand static or anticipated seismic forces, or
> both, in any direction. For each item, use a minimum force value equal
> to the weight of the item.
>
> G. Dimensions of the barrier walls indicated for system components are
> not exceeded.

**2.04 [SYSTEM PERFORMANCE]{.underline}**

> A. Steady-State Voltage Operational Bandwidth: 4 percent of rated
> output voltage from no load to full load.
>
> B. Steady-State Voltage Modulation: Less than 1 Hz.
>
> C. Transient Voltage Performance: Not more than 10 percent variation
> for 50 percent step-load increase or decrease. Voltage recovers to
> remain within the steady-state operating band within 2 seconds.
>
> D. Steady-State Frequency Operational Bandwidth: 0.5 percent of rated
> frequency from no load to full load.
>
> E. Steady-State Frequency Stability: When the system is operating at
> any constant load within the rated load, there are no random speed
> variations outside the steady-state operational band and no regular or
> cyclical hunting or surging of speed.
>
> F. Transient Frequency Performance: Less than 3 Hz variation for a 50
> percent step-load increase or decrease. Frequency recovers to remain
> within the steady-state operating band within 3 seconds.
>
> G. Output Waveform: At no load, the harmonic content measured
> line-to-line or line-to-neutral does not exceed 5 percent total and 3
> percent for single harmonics. The telephone influence factor
> determined according to NEMA MG1, \"Motors and Generators,\" does not
> exceed 50.
>
> H. Sustained Short-Circuit Current: For a 3-phase bolted short circuit
> at the system output terminals, the system will supply a minimum of
> 250 percent of rated full-load current for not less than 10 seconds
> and then clear the fault automatically, without damage to any
> generator system component.
>
> I. Temperature Rise of Generator: Within acceptable limits for
> insulation systems used according to NEMA MG1 when operating
> continuously at standby rating conditions, including 2 hours per 24
> hours at 110 percent of rated capacity.
>
> J. Nonlinear Load Performance: System performance is not degraded from
> that specified in this Article by continuous operation, with the load
> current having a minimum total harmonic content of 5 percent rms, and
> minimum single harmonic content of 3 percent rms.
>
> K. Starting Time: Maximum total time period for a cold start, with
> ambient temperature at the low end of the specified range, is 5
> seconds. Time period includes output voltage and frequency settlement
> within specified steady-state bands.

**2.05 [ENGINE GENERATOR SET]{.underline}**

> A. Power Output Rating: Nominal ratings as indicated, with capacity as
> required to operate as a unit as evidenced by records of prototype
> testing.
>
> B. Skid: Adequate strength and rigidity to maintain alignment of the
> mounted components without dependence on a concrete foundation. Skid
> is free from sharp edges and corners. Lifting attachments are arranged
> to facilitate lifting with slings without damaging any components.
>
> C. Rigging Diagram: Inscribed on a metal plate permanently attached to
> the skid. Diagram indicates location and lifting capacity of each
> lifting attachment and location of the center of gravity.

**2.06 [ENGINE]{.underline}**

> A. Comply with NFPA 37, \"Stationary Combustion Engines and Gas
> Turbines.\"
>
> B. Fuel: Diesel fuel oil grade DF-2.
>
> C. Maximum Speeds: Engine - 1800 rpm. Piston speed for 2-cycle
> engines - 1725 feet per minute. Piston speed for 4-cycle engines -
> 2250 feet per minute.
>
> D. Lubrication System: Pressurized by a positive displacement pump
> driven from the engine crankshaft. The following items are mounted on
> the engine or skid:
>
> 1\. Filter and Strainer: Rated to remove 90 percent of particles 5
> microns and smaller while passing full flow.
>
> 2\. Oil Cooler: Maintains lubricating oil at the manufacturer\'s
> recommended optimum temperature throughout 2 hours of operation of the
> generator set at 110 percent of system power output rating.
>
> 3\. Thermostatic Control Valve: Controls flow in the system to
> maintain optimum oil temperature. Unit is capable of full flow and is
> designed to be fail-safe.
>
> 4\. Crankcase Drain: Arranged for complete gravity drainage to an
> easily removable container with no disassembly and without the use of
> pumps or siphons or special tools or appliances.
>
> E. Engine Fuel System: Comply with NFPA 30, \"Flammable and
> Combustible Liquids.\" System includes:
>
> 1\. Integral Injection Pumps: Driven by the engine camshaft. Pumps are
> adjustable for timing and cylinder pressure balancing.
>
> 2\. Main Fuel Pump: Mounted on the engine. Pump ensures adequate
> primary fuel flow under starting and load conditions.
>
> 3\. Parallel Fuel Oil Filters: Ahead of the injection pumps.
> Changeover valves allow independent use of either filter.
>
> 4\. Relief/Bypass Valve: Automatically regulates pressure in the fuel
> line and returns excess fuel to the source.
>
> F. Jacket Coolant Heater: Electric immersion type, factory-installed
> in the jacket coolant system. Unit is rated and thermostatically
> controlled to maintain an engine temperature of 25 deg C at the low
> end of the ambient temperature range specified under \"Environmental
> Conditions\" above.
>
> G. Speed Governor: Mechanical type.

**2.07 [ENGINE COOLING SYSTEM]{.underline}**

> A. Description: Closed-loop, liquid-cooled, with radiator
> factory-mounted on engine generator set skid and integral
> engine-driven coolant pumping.
>
> B. Description: Closed-loop, liquid-cooled, with remote radiator and
> integral engine-driven coolant pumping.
>
> C. Radiator: Factory-piped and -rated for specified coolant.
>
> D. Remote Radiator System: Arranged for horizontal or vertical
> discharge as indicated. Unit is rated for specified coolant.
>
> 1\. Radiator Core Tubes: Nonferrous metal construction other than
> aluminum.
>
> 2\. Size of Radiator: Adequate to contain expansion of total system
> coolant from cold start to 110 percent load condition.
>
> 3\. Fan: Driven by multiple belts from engine shaft.
>
> 4\. Fan: Driven by totally enclosed electric motor with sealed
> bearings.
>
> E. Coolant: Water.
>
> F. Coolant: Solution of 50 percent ethylene glycol and 50 percent
> water.
>
> G. Expansion Tank: Constructed of welded steel plate and equipped with
> gage glass and petcock. Capacity is as indicated.
>
> H. Temperature Control: Self-contained thermostatic control valve
> modulates coolant flow automatically to maintain optimum constant
> coolant temperature as recommended by the engine manufacturer.
> Features include:
>
> 1\. Thermostatic Elements: Interchangeable and nonadjustable.
>
> 2\. Actuator Design: Normally-open valves to return to open position
> when actuator fails.
>
> I. Coolant Hose: Flexible assembly with nonporous rubber inside
> surface and aging, ultraviolet, and abrasion-resistant fabric outer
> covering.
>
> 1\. Rating: 50 psi (345 kPa) maximum working pressure with 180 deg F
> (82 deg C) coolant, and noncollapsible under vacuum.
>
> 2\. End Fittings: Flanges or steel pipe nipples with clamps to suit
> piping and equipment connections.
>
> J. Coolant piping external to engine generator set is as specified in
> Division 15 Section \"Hydronic Piping.\"

**2.08 [FUEL SUPPLY SYSTEM]{.underline}**

> A. System complies with NFPA 30, \"Flammable and Combustible Liquids
> Code,\" and NFPA 37, \"Standard for Stationary Combustion Engines and
> Gas Turbines.\"
>
> B. Day Tank: Factory-fabricated assembly of NRTL-listed fuel tank with
> integral, float-controlled transfer pump and the features described
> below.
>
> 1\. Tank Capacity: As indicated.
>
> 2\. Pump Capacity: Exceeds the maximum flow of fuel drawn by the
> engine-mounted fuel supply pump at 110 percent of rated capacity,
> including fuel returned from the engine.
>
> 3\. Unit, Including Alarm Contacts: Complies with UL 142, \"Steel
> Aboveground Tanks for Flammable and Combustible Liquids.\"
>
> 4\. Low-Level Alarm Sensor: Separate device operates alarm contacts at
> 75 percent of normal fuel level.
>
> 5\. High-Level Alarm Sensor: Separate device operates alarm and
> redundant fuel shut-off contacts at 106 percent of normal fuel level.
>
> 6\. Piping Connections: Include fuel suction and return lines to fuel
> storage tank, fuel supply, and return lines to engine, local fuel
> fill, vent line, overflow line, and tank drain line complete with
> shutoff valve.
>
> C. Redundant High-Level Fuel Shutoff: Actuated by the high-level alarm
> sensor in the day tank. It operates a separate motor disconnect device
> that disconnects the day tank pump motor. It also closes a solenoid
> valve in the fuel suction line from the fuel storage tank to the day
> tank. Both items remain in the shut-off state until manually reset.
> Shutoff action initiates an alarm signal to the control panel, but
> does not shut down the engine generator set.
>
> D. Fuel Piping: As specified in Division 15 Section \"Fuel Oil Piping
> Systems.\"
>
> E. Fuel Storage Tank: As specified in Division 15 Section \"Fuel Oil
> Piping Systems.\"

**2.09 [ENGINE EXHAUST SYSTEM]{.underline}**

> A. Muffler: Industrial-type, sized as recommended by the engine
> manufacturer. Measured sound level in the 20-75 Hz frequency band,
> according to the \"DEMA Test Code for the Measurement of Sound from
> Heavy-Duty Reciprocating Engines\" at a distance of 25 feet from the
> exhaust discharge, is 87 dB or less.
>
> B. Connections from Engine to Exhaust System: Flexible section of
> corrugated stainless steel pipe.
>
> C. Connection from Exhaust Pipe to Muffler: Stainless-steel expansion
> joint with liners.
>
> D. Insulation for Mufflers and Indoor Exhaust Piping: As specified in
> Division 15 Section \"Pipe Insulation.\"
>
> E. Supports for Muffler and Exhaust Piping: Vibration isolating-type
> specified in Division 15 Section \"Vibration Control.\"
>
> F. Thimbles for Exhaust Piping: Conform to NFPA 211, \"Chimneys,
> Fireplaces, Vents, and Solid-Fuel Burning Appliances.\"

**2.10 [STARTING SYSTEM]{.underline}**

> A. Description: 24 V electric with negative ground and including the
> following items:
>
> 1\. Components: Sized so they will not be damaged during a full
> engine-cranking cycle with the ambient temperature at the maximum
> specified in paragraph \"Environmental Conditions.\"
>
> 2\. Cranking Motor: Heavy-duty unit that automatically engages and
> releases from the engine flywheel without binding.
>
> 3\. Cranking Cycle: As required by NFPA 110 for system level
> specified.
>
> 4\. Battery complies with SAE J537, \"Storage Batteries,\" and has
> adequate capacity within the ambient temperature range specified in
> paragraph \"Environmental Conditions\" to provide the specified
> cranking cycle series at least twice without recharging.
>
> 5\. Battery Cable: Size as recommended by the generator set
> manufacturer for the cable length indicated. Include required
> interconnecting conductors and connection accessories.
>
> 6\. Battery Compartment: Factory-fabricated of metal with
> acid-resistant finish and thermal insulation. Thermostatically
> controlled heater is arranged to maintain battery above 10 deg C
> regardless of external ambient temperature within range specified
> under \"Environmental Conditions.\" Include accessories required to
> support and fasten batteries in place.
>
> 7\. Battery-Charging Alternator: Factory-mounted on engine with
> solid-state voltage-regulation and 35 ampere minimum continuous
> rating.
>
> 8\. Battery Charger: Current limiting, automatic equalizing and float
> charging-type designed for operation from a 120 V 60 Hz supply source.
> Unit complies with UL 508, \"Electrical Industrial Control
> Equipment,\" and includes the following features:
>
> a\. Operation: Equalizing charging rate of 10 amperes is initiated
> automatically after the battery has lost charge until an adjustable
> equalizing voltage is achieved at the battery terminals. The unit then
> automatically switches to a lower float-charging mode, and continues
> operating in that mode until the battery is discharged again.
>
> b\. Automatic Temperature Compensation: Adjusts the float and
> equalizes voltages for variations in the ambient temperature from
> minus 40 deg C to plus 60 deg C to prevent overcharging at high
> temperatures and undercharging at low temperatures.
>
> c\. Automatic Voltage Regulation: Maintains output voltage constant
> regardless of input voltage variations up to plus or minus 10 percent.
>
> d\. Ammeter and Voltmeter: Flush mounted in door. Meters indicate
> charging rates.
>
> e\. Safety Functions: Include sensing of abnormally low battery
> voltage arranged to close contacts providing \"low battery voltage\"
> indication on control and monitoring panel. Also include sensing of
> high battery voltage and loss of a.c. input or d.c. output of battery
> charger. Either of these conditions closes contacts that provide
> \"battery charger malfunction\" indication at system control and
> monitoring panel.
>
> f\. Enclosure and Mounting: NEMA Class 1 wall-mounted cabinet.

**2.11 [CONTROL AND MONITORING]{.underline}**

> A. Configuration: Operating and safety indications, protective
> devices, basic system controls, and engine gages are grouped on a
> common control and monitoring panel mounted on the generator set.
> Mounting method isolates the control panel from generator set
> vibration.
>
> 1\. Generator Circuit Breaker: Molded case type with adjustable ground
> fault tripping.
>
> 2\. Shunt Trip Device: For generator breaker, connected to trip
> breaker when generator set is shut down by protective devices.
>
> 3\. Current and Potential Transformers: Instrument accuracy class.
>
> B. Indicating and Protective Devices, and Controls: Include those
> required by NFPA 110 for a Level 1 system plus the following:
>
> C. Supporting Items: Include sensors, transducers, terminals, relays,
> and other devices, and wiring required to support specified items.
> Locate sensors and other supporting items on engine, generator, or
> elsewhere as indicated. Where not indicated, locate to suit
> manufacturer\'s standard.
>
> D. Common Remote Audible Alarms: Conform to NFPA 110 requirements for
> Level 1 systems. Include necessary contacts and terminals in control
> and monitoring panel. Locate audible device and silencing means where
> indicated.
>
> E. Remote Emergency Stop Switch: Flush wall-mounted except as
> otherwise indicated and prominently labeled. Pushbutton is protected
> from accidental operation.

**2.12 [GENERATOR, EXCITER, AND VOLTAGE REGULATOR]{.underline}**

> A. Comply with NEMA MG 1, \"Motors and Generators,\" and specified
> performance requirements.
>
> B. Drive: Generator shaft is directly connected to the engine shaft.
> Exciter is rotated integrally with generator rotor.
>
> C. Electrical Insulation: Class H or Class F.
>
> D. Station Winding Leads: Brought out to terminal box to permit future
> reconnection for other voltages if required.
>
> E. Construction prevents mechanical, electrical, and thermal damage
> due to vibration, overspeed up to 125 percent of rating, and heat
> during operation at 110 percent of rated capacity.
>
> F. Excitation uses no-slip or collector rings, or brushes, and is
> arranged to sustain generator output under short circuit conditions as
> specified.
>
> G. Enclosure: Dripproof.
>
> H. Instrument Transformers: Mounted within generator enclosure.
>
> I. Voltage Regulator: Solid-state-type, separate from exciter,
> providing performance as specified.
>
> 1\. Adjusting rheostat on control and monitoring panel provides plus
> or minus 5 percent adjustment of output voltage operating band.
>
> J. Strip Heater: Thermostatically controlled unit arranged to maintain
> stator windings above the dew point.

**2.13 [LOAD BANK]{.underline}**

> A. Description: Permanent, outdoor, weatherproof, remotely controlled,
> forced air-cooled, resistive/reactive unit capable of providing a
> balanced 3-phase, delta-connected load to the generator set at 100
> percent rated system capacity, at 80 percent power factor, lagging.
> Unit may be composed of separate resistive and reactive load banks
> controlled by a common control panel. Unit is capable of selective
> control of load in 25 percent steps with minimum step changes of
> approximately 5 percent and 10 percent available.
>
> B. Resistive Load Elements: Corrosion-resistant chromium alloy with
> ceramic and steel supports. Elements are double-insulated and designed
> for repetitive on-off cycling. Elements are mounted in removable
> aluminized steel heater cases.
>
> C. Reactive Load Elements: Epoxy-encapsulated reactor coils.
>
> D. Load Bank Heat Dissipation: Integral fan with totally enclosed
> motor provides uniform cooling air flow through load elements. Air
> flow and coil operating current are such that, at maximum load, with
> ambient temperature at the upper end of the specified range, load bank
> elements operate at not more than 50 percent of the maximum continuous
> temperature rating of the resistance wire.
>
> E. Load Element Switching: Remotely controlled contactors switch
> groups of load elements. Contactor coils are rated 120 V. Contactors
> are located in a separate NEMA 3R enclosure within the load bank
> enclosure, accessible from the exterior through hinged doors with
> tumbler locks.
>
> F. Contactor Enclosures: Heated by thermostatically controlled strip
> heaters to prevent condensation.
>
> G. Load Bank Enclosures: NEMA 3R, conforming with NEMA ICS 6,
> \"Enclosures for Industrial Control and Systems.\" Louvers at cooling
> air intake and discharge openings prevent entry of rain and snow.
> Openings for air flow are screened with 1/2-square galvanized steel
> mesh. Reactive load bank includes automatic shutters at air intake and
> discharge.
>
> H. Protective Devices: Power input circuits to load banks are fused,
> and fuses are selected to coordinate with generator circuit breaker.
> Fuse blocks are located in the contactor enclosure. Cooling air-flow
> and overtemperature sensors automatically shut down and lock out load
> bank until manually reset. Safety interlocks on access panels and
> doors disconnect load power, control, and heater circuits. Fan motor
> is separately protected by overload and short-circuit devices.
> Short-circuit devices are noninterchangeable fuses with 200,000
> amperes interrupting capacity.
>
> I. Control Sequence: Control panel may be operated manually or preset
> for adjustable single-step loading of the generator during automatic
> exercising. Connection of the load bank to the generator is by a
> remote-controlled switching device specified in another Section.

**2.14 [OUTDOOR GENERATOR SET ENCLOSURE]{.underline}**

> A. Description: Weatherproof steel housing. Multiple panels are
> lockable and provide adequate access to components requiring
> maintenance. Panels are removable by one person without tools.
>
> B. Fixed Louvers: At air inlet and discharge. Louvers prevent entry of
> rain and snow.
>
> C. Automatic Dampers: At air inlet and discharge. Dampers are closed
> to reduce engine and battery heat loss in cold weather when unit is
> not operating.
>
> D. Air Flow Through Housing: Adequate to maintain temperature rise of
> system components within required limits when unit operates at 110
> percent of rated load for 2 hours with ambient temperature at the top
> of the range specified under \"System Service Conditions.\"

**2.15 [FINISHES]{.underline}**

> A. Indoor Enclosures and Components: Manufacturer\'s standard enamel
> over corrosion-resistant pretreatment and primer.
>
> B. Outdoor Enclosures: Polyurethane enamel over corrosion-resistant
> pretreatment and manufacturer\'s compatible standard primer.

**2.16 [SOURCE QUALITY CONTROL]{.underline}**

> A. Factory Tests: Include prototype testing and Project-specific
> equipment tests (equipment manufactured specifically for this
> Project).
>
> B. Prototype Testing: Performed on a separate engine generator set
> using the same engine model, constructed of identical or equivalent
> components and equipped with identical or equivalent accessories.
>
> 1\. Tests: Conform to those required for Level 1 energy converters in
> paragraphs 3.2.1, 3.2.1.1, and 3.2.1.2 of NFPA 110.
>
> 2\. Components and Accessories: Items furnished with installed unit
> that are not identical to those on tested prototype have been
> acceptably tested to demonstrate compatibility and reliability.
>
> C. Project-Specific Equipment Tests: Test engine generator set and
> other system components and accessories prior to shipment. Test items
> individually and assembled and connected as a complete system at the
> factory in a manner equivalent to that required at the Project site.
> Record and report test data. Conform to SAE 8528, \"Engine Power Test
> Code-Spark Ignition and Diesel,\" and the following:
>
> 1\. Test Equipment: Use instruments calibrated within the previous 12
> months and with accuracy directly traceable to the National Institute
> of Standards and Technology (NIST).
>
> 2\. Hydrostatic Test: Perform on radiator, heat exchanger, and engine
> water jacket.
>
> 3\. Complete System Continuous Operation Test: Includes nonstop
> operation for a minimum of 8 hours, including at least 1 hour each at
> 1/2, 3/4, and full load, and 2 hours at 110 percent of full load. If
> unit stops during the 8-hour test, repeat the complete test. Record
> the following minimum data at the start and end of each load run, at
> 15-minute intervals between those times, and at 15-minute intervals
> during the balance of the test:
>
> a\. Fuel consumption.
>
> b\. Exhaust temperature.
>
> c\. Jacket water temperature.
>
> d\. Lubricating oil temperature and pressure.
>
> e\. Generator load current and voltage, each phase.
>
> f\. Generator system gross and net output kW.
>
> 4\. Complete System Performance Tests: Include the following to
> demonstrate conformance to specified performance requirements:
>
> a\. Single-step load pickup.
>
> b\. Transient and steady-state governing.
>
> c\. Transient and steady-state voltage performance.
>
> d\. Safety shutdown devices.
>
> 5\. Observation of Test: Provide 2-week advance notice of tests and
> opportunity for observation of test by Owner\'s representatives.
>
> 6\. Report test results within 10 days of completion of test.

**[PART 3 - EXECUTION]{.underline}**

**3.01 [INSTALLATION]{.underline}**

> A. Anchor generator set and other system components on concrete bases.
> Provide anchorage according to manufacturer\'s recommendations.
>
> B. Field Installation of Piping and Ductwork: As specified in Division
> 15 Sections \"Basic Mechanical Materials and Methods\" and \"Hydronic
> Piping.\"
>
> C. Maintain minimum working space around components according to
> manufacturer\'s shop drawings and NEC.
>
> D. Manufacturer\'s Field Services: Arrange and pay for the services of
> a factory-authorized service representative to supervise the
> installing, connecting, testing, and adjusting of the unit.

**3.02 [IDENTIFICATION]{.underline}**

> A. Identify system components according to Division 15 Section
> \"Mechanical Identification\" and Division 16 Section \"Electrical
> Identification.\"

**3.03 [FIELD QUALITY CONTROL]{.underline}**

> A. Supervised Adjusting and Pretesting: Under supervision of
> factory-authorized service representative, pretest all system
> functions, operations, and protective features. Provide all
> instruments and equipment required for tests. Adjust to ensure
> operation is according to Specifications. Load system using a variable
> resistive and reactive load bank simulating kW, and power factor of
> loads for which unit is rated.
>
> B. Tests: Provide the services of a qualified testing agency to
> perform the tests listed below according to manufacturer\'s
> recommendations upon completion of installation of system. Use
> instruments bearing records of calibration within the last 12 months,
> traceable to NIST standards, and adequate for making positive
> observation of test results. Include the following tests:
>
> 1\. Insulation Tests: Test generator windings using 500 V d.c. for
> units rated up to 250 volts and 1000 V d.c. for units rated between
> 250 and 600 volts. Verify minimum insulation resistance is 25 megaohms
> for units up to 250 volts, and 100 megaohms for units 251 to 600
> volts.
>
> 2\. Battery Tests: Measure charging voltage and voltages between
> available battery terminals for full-charging and float-charging
> conditions. Check electrolyte level and specific gravity under both
> conditions. Test for contact integrity of all connectors. Perform an
> integrity load test and a capacity load test for the battery. Verify
> acceptance of charge for each element of battery after discharge.
> Verify measurements are within manufacturer\'s specifications.
>
> 3\. Battery Charger Tests: Verify specified rates of charge for both
> equalizing and float-charging conditions.
>
> 4\. System Integrity Tests: Methodically verify proper installation,
> connection, and integrity of each element of engine generator system
> before and during system operation. Check for air, exhaust, and fluid
> leaks.
>
> 5\. Simulation of malfunctions to verify proper operation of local and
> remote protective, alarm, and monitoring devices.
>
> 6\. Load Test: Use variable load bank capable of simulating kVA, kW,
> and power factor of load for which unit is rated. Run unit at 25, 50,
> and 75 percent of rated capacity for 30 minutes each, and at 100
> percent for 3 hours. Make the 100-percent load run at 80 percent power
> factor. Record voltage, frequency, load current, battery-charging
> current, power output, oil pressure, and coolant temperature
> periodically during the test.
>
> 7\. Vibration Baseline Test: Measure amplitude for nominal frequency
> and for frequencies 5, 10, 15, and 20 percent above and below nominal
> at each main bearing cap. Vibration levels not exceeding those
> specified in NEMA MG1, \"Motors and Generators,\" are acceptable.
>
> 8\. Exhaust System Back-Pressure Test: Use a manometer with a scale
> exceeding 40 inches of water. Connect to the exhaust line close to the
> engine exhaust manifold. Verify that back pressure at full-rated load
> is within manufacturer\'s published allowable limits for the engine.
>
> 9\. Exhaust Emissions Test: Conform to applicable government test
> criteria.
>
> 10\. Voltage and Frequency Transient Stability Tests: Use recording
> oscilloscope to measure voltage and frequency transients for
> 50-percent and 100-percent step-load increases and decreases and
> verify that performance is as specified.
>
> 11\. Harmonic Content Tests: Measure harmonic content of input and
> output current under 25 percent and at 100 percent of rated linear
> load. Verify that harmonic content is within specified limits.
>
> C. Retest: Correct deficiencies identified by tests and observations
> and retest until specified requirements are met.

**3.04 [CLEANING]{.underline}**

> A. Upon completion of installation, inspect system components. Remove
> paint splatters and other spots, dirt, and debris. Touch up scratches
> and mars of finish to match original finish. Clean components
> internally using methods and materials recommended by manufacturer.

**3.05 [DEMONSTRATION]{.underline}**

> A. Training: Arrange and pay for the services of a factory-authorized
> service representative to demonstrate adjustment, operation, and
> maintenance of the system and to train Owner\'s personnel.
>
> B. Conduct a minimum of 8 hours of training as specified under
> Instructions to Owner\'s Employees in the Project Closeout Section of
> these Specifications.
>
> C. Schedule training with at least 7-day advance notice.

**3.06 [COMMISSIONING]{.underline}**

> A. Battery Equalization: Equalize charging of battery cells according
> to manufacturer\'s instructions. Record individual cell voltages.
>
> END OF SECTION