USACE / NAVFAC / AFCESA / NASA UFGS-41 65 10.00 10 (January 2008)
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Preparing Activity: USACE (CW) Superseding
UFGS-41 65 10.00 10 (October 2007)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2009
SECTION 41 65 10.00 10
DIESEL/NATURAL GAS FUELED ENGINE PUMP DRIVES
01/08
NOTE: This guide specification covers the requirement for diesel or natural
gas fueled engines used as prime movers for vertical pumps at civil works flood
control pumping stations.
Edit this guide specification for project specific requirements by adding, deleting,
or revising text. For bracketed items, choose applicable items(s) or insert
appropriate information.
Remove information and requirements not required in respective project, whether
or not brackets are present.
Comments and suggestions on this guide specification are welcome and should
be directed to the technical proponent of the specification. A listing of technical
proponents, including their organization designation and telephone number, is
on the Internet.
Recommended changes to a UFGS should be submitted as a Criteria Change Request
(CCR).
PART 1 GENERAL
NOTE: This guide is intended to be used in the preparation of project specifications
along with Section 22 10 00.00 10 VERTICAL PUMPS, AXIAL-FLOW AND MIXED-FLOW
IMPELLER-TYPE, and Section 33 45 00.00 10 SPEED REDUCERS FOR STORM WATER PUMPS.
The Designer should edit the title of this section to reflect appropriate project requirements.
The designer is responsible for making a prime mover selection from either an
electric motor, a diesel engine, or a natural gas engine. The guidance for
making proper selection is contained in EM 1110-2-3105, "Mechanical and Electrical
Design of Pumping Stations".
The specification is written for a construction contract. Under a construction
contract, these components can be purchased and installed by a Construction
Contractor. A single contract allows the Contractor to obtain the most optimum
combination and be responsible for the total performance of the unit, including
shaft alignment. This also makes it feasible for the Contractor to perform
a dynamic analysis of the pump, speed reducer, and prime mover system, as described
in Section 22 10 00.00 10, and makes the Contractor solely responsible for acquiring
the necessary data to perform such analysis.
1.1 REFERENCES
NOTE: This paragraph is used to list the publications cited in the text of
the guide specification. The publications are referred to in the text by basic
designation only and listed in this paragraph by organization, designation,
date, and title.
Use the Reference Wizard's Check Reference feature when you add a RID outside
of the Section's Reference Article to automatically place the reference in the
Reference Article. Also use the Reference Wizard's Check Reference feature
to update the issue dates.
References not used in the text will automatically be deleted from this section
of the project specification when you choose to reconcile references in the
publish print process.
The publications listed below form a part of this specification to the extent referenced. The publications are
referred to within the text by the basic designation only.
[AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)ANSI C39.1(1981; R 1992) Requirements for Electrical Analog Indicating Instruments][ASME INTERNATIONAL (ASME)ASME B16.11(2005) Forged Fittings, Socket-Welding and ThreadedASME B16.3(2006) Malleable Iron Threaded Fittings, Classes 150 and 300ASME B16.5(2003) Standard for Pipe Flanges and Flanged Fittings: NPS 1/2 Through NPS 24ASME B31.1(2007; Addenda 2008) Power PipingASME BPVC SEC IX(2007; Addenda 2008) Boiler and Pressure Vessel Code; Section IX, Welding and Brazing QualificationsASME BPVC SEC VIII D1(2007; Addenda 2008) Boiler and Pressure Vessel Code; Section VIII, Pressure Vessels Division 1 - Basic Coverage][ASTM INTERNATIONAL (ASTM)ASTM A 106/A 106M(2008) Standard Specification for Seamless Carbon Steel Pipe for High-Temperature ServiceASTM A 181/A 181M(2006) Standard Specification for Carbon Steel Forgings, for General-Purpose PipingASTM A 234/A 234M(2007) Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature ServiceASTM A 53/A 53M(2007) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and SeamlessASTM B 395/B 395M(2008) Standard Specification for U-Bend Seamless Copper and Copper Alloy Heat Exchanger and Condenser TubesASTM C 533(2007) Standard Specification for Calcium Silicate Block and Pipe Thermal InsulationASTM D 975(2008ae1) Standard Specification for Diesel Fuel Oils][INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)IEEE C2(2007; Errata 2007; INT 2008) National Electrical Safety Code][MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS)MSS SP-58(2002) Standard for Pipe Hangers and Supports - Materials, Design and ManufactureMSS SP-69(2003; R 2004) Standard for Pipe Hangers and Supports - Selection and ApplicationMSS SP-80(2008) Bronze Gate, Globe, Angle and Check Valves][NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)NEMA ICS 2(2000; Errata 2002; R 2005; Errata 2006) Standard for Industrial Control and Systems: Controllers, Contractors, and Overload Relays Rated Not More than 2000 Volts AC or 750 Volts DC: Part 8 - Disconnect Devices for Use in Industrial Control EquipmentNEMA ICS 6(1993; R 2006) Standard for Industrial Controls and Systems EnclosuresNEMA MG 1(2007; Errata 2008) Standard for Motors and Generators][NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)NFPA 30(2007; Errata 2008) Flammable and Combustible Liquids CodeNFPA 37(2006) Installation and Use of Stationary Combustion Engines and Gas TurbinesNFPA 70(2007; AMD 1 2008) National Electrical Code - 2008 Edition][SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)SAE ARP892(1965; R 1994) DC Starter-Generator, EngineSAE J1995(1990; R 1995) Engine Power Test Code - Spark Ignition and Compression Ignition - Gross Power RatingSAE J537(2000) Storage Batteries][UNDERWRITERS LABORATORIES (UL)UL 1236(2006) Standard for Safety Battery Chargers for Charging Engine-Starter Batteries]1.2 SYSTEM DESCRIPTION
1.2.1 General Requirements
Provide and install complete and totally functional, [the] [each] engine with all necessary ancillary equipment
including, but not limited to, air filtration, starting system, instrumentation, lubrication, fuel system, cooling
system, and engine exhaust system. [The] [Each] engine rating shall be in accordance with SAE J1995. The [diesel]
[natural gas fueled] engine pump drives shall be complete units with all components, accessories, and system
interconnections coordinated, so that the complete assembly shall have the capabilities required, for proper
operation with the pump specified under Section 22 10 00.00 10 VERTICAL PUMPS, AXIAL-FLOW AND MIXED-FLOW IMPELLER-TYPE
and the speed reducer specified in Section 33 45 00.00 10 SPEED REDUCERS FOR STORM WATER PUMPS.
1.2.2 Performance Requirements
NOTE: The designer should specify the service requirements for the pump drive:
Continuous, Standby, or Emergency. The designer should furnish pump manufacturer's
data including pump curves and plans unless this specification is used in conjunction
with pump specification Section 22 10 00.00 10 as a package. The selection
of the engine speed should follow the guidance given in EM 1110-2-3105. Rated
capacity should be based on the pump manufacturer's recommendation.
Service Requirements: [Continuous][Standby][Emergency]
Rated Capacity: [110 percent maximum kW (hp)
required from the pump curves at
specified speed plus power required
by the accessories]
Overload Capacity: [110 percent rated capacity for
2 hr in 24 consecutive hrs]
Maximum Speed: [_____][900][1,200][1,800] RPM
[Characteristics of the pump load for the engine drive are
described in the pump curves and pump plans included in [____].]
Site Ambient Conditions: The site characteristics are as
described in paragraph PROJECT/SITE CONDITIONS.
1.2.3 Arrangement
NOTES: The engine shaft can be connected to the gear box by either a flexible
coupling or universal joint assembly. In cases where the engine is large or
the operating floor space is limited, a flexible coupling would be more appropriate.
Manufacturer's recommendations should be solicited for arrangement alternatives.
The designer should determine the configuration of the day tank, main fuel storage
tank, and engine injection ports. If the main storage fuel tank is the lowest
point in the engine fuel system, then a pump will be required to deliver fuel
oil to the day tank.
Delete all requirements for a day tank if natural gas fueled engines are specified.
Each engine, as shown and specified, is to be used as the prime mover for the vertical pump.[ Connect the engine
shaft to the reducer input shaft with two universal joints and an intermediate shaft.][ Connect the engine shaft
to the reducer input shaft with a flexible coupling.] Coordinate among the manufacturers of the [diesel] [natural
gas fueled] engine, gear reducer, and the pump manufacturer to ensure the compatibility of these components including,
but not limited to, the proper fit of engine and reducer shafts, the interaction of major components, and control
of safety and alarm signals.[ Supply fuel for each engine by an individual day tank located near the engine
and in accordance with NFPA 37.] [Fuel oil will be [supplied by gravity] [pumped] to day tank from outside storage
tanks.] [Natural gas will be supplied to the fuel solenoid shutoff valve to be supplied on the engine.] Use
a cooling system to maintain engine and lubricating oil temperatures at the temperatures recommended by the manufacturer.
Furnish a starting system along with necessary accessories for engine start-up. Provide each engine with a completely
independent lubrication [and pre-lubrication] system with an engine-driven primary pump.
1.3 SUBMITTALS
NOTE: Review submittal description (SD) definitions in Section 01 33 00 SUBMITTAL
PROCEDURES and edit the following list to reflect only the submittals required
for the project. Submittals should be kept to the minimum required for adequate
quality control.
A “G” following a submittal item indicates that the submittal requires Government
approval. Some submittals are already marked with a “G”. Only delete an existing
“G” if the submittal item is not complex and can be reviewed through the Contractor’s
Quality Control system. Only add a “G” if the submittal is sufficiently important
or complex in context of the project.
For submittals requiring Government approval on Army projects, a code of up
to three characters within the submittal tags may be used following the "G"
designation to indicate the approving authority. Codes for Army projects using
the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO"
for District Office (Engineering Division or other organization in the District
Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project
Office. Codes following the "G" typically are not used for Navy, Air Force,
and NASA projects.
Choose the first bracketed item for Navy, Air Force and NASA projects, or choose
the second bracketed item for Army projects.
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation
are for [Contractor Quality Control approval.] [information only. When used, a designation following the "G"
designation identifies the office that will review the submittal for the Government.] The following shall be
submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Layout and Shop Drawings[; G][; G, [_____]]
Installation[; G][; G, [_____]]
Layout and shop drawings as specified.
As-Built Drawings[; G][; G, [_____]]
As-built drawings accurately depicting the as-built configuration of the supplied, installed,
and accepted [diesel] [natural gas fueled] engine pump drive.
SD-03 Product Data
[Diesel] [Natural Gas Fueled] Engine[; G][; G, [_____]]
Cooling System[; G][; G, [_____]]
NOTE: In subparagraph "e" below, select the first option for diesel engines
and the second option for natural gas fueled engines.
Equipment and performance data certifying that the engine and cooling system function properly
in the ambient temperature specified and provides the following design and performance data:
a. The maximum allowable inlet temperature of the [coolant fluid] [coolant air].
b. The minimum allowable inlet temperature of the [coolant fluid] [coolant air].
c. The maximum allowable temperature rise in the [coolant fluid through the engine] [cooling
air across the engine].
d. The magnitude of monitored values defining alarm or action set points, and the tolerance
(plus and/or minus) at which the protective device activates the alarm or action.
e. The minimum allowable [inlet fuel temperature] [fuel supply pressure].
f. The maximum impact/dynamic load that will be transferred from the engine to the structure.
Manufacturer's standard catalog data including a description and depiction of each engine
and all ancillary equipment in sufficient detail to demonstrate complete specification compliance.
If standard catalog data does not contain sufficient detail to verify compliance, then submit
supplementary support documentation to verify compliance. All data submitted shall be on the
engine manufacturer's letterhead and signed by a representative or official of the manufacturer
authorized to make technical representations of his company's products.
Dynamic Analysis of Engine, Pump, and Governor[; G][; G, [_____]]
NOTE: Delete requirement for dynamic analysis of engine, pump, and speed reducer
system, if this analysis will be performed by others.
Dynamic analysis with supporting calculations.
Project/Site Conditions
The record of the Contractor's survey of the existing installation site conditions and verification
of site work details.
Onsite Training[; G][; G, [_____]]
NOTE: Delete video taping requirement if not required for training needs (See
paragraph ON-SITE TRAINING).
A letter giving the proposed date for conducting the onsite training course[ and][,] the agenda
of instruction [, a description of the video taping service to be provided, and the kind and
quality of the tape].
Manufacturer's Published Instructions[; G][; G, [_____]]
Posted instructions, including wiring and control diagrams showing the key mechanical and
electrical control elements and a complete layout of the entire system. The instruction set
shall be weatherproof, laminated in plastic, framed, and posted at a location as directed.
Field Engineer[; G][; G, [_____]]
Certification that the field engineer is qualified to perform the specified functions.
[Diesel] [Natural Gas Fueled] Engine Pump Drive[; G][; G, [_____]]
Written documentation that the products being supplied are appropriate for this [diesel][natural
gas fueled] engine pump drive, including past performance of the drive on certain types of service,
i.e., marine generators, pump drives, locomotives, metal shredders, etc., with a minimum operation
of 2,000 hr per year of service with a minimum of 2 years of qualifying service. The certification
of the unit's speed, horsepower, and duty rating that forms the basis of the qualifying experience
is required for acceptance and shall be within 30 percent of [this drive's rating] [these drives'
ratings].
Welder Qualifications[; G][; G, [_____]]
A letter listing the welder-qualifying procedures for each welder, complete with all supporting
data such as test procedures used, what was tested to, and a list of the names of all welders
and their identification symbols.
Installation[; G][; G, [_____]]
A copy of the manufacturer's installation and alignment procedures, including a detailed description
of the manufacturer's recommended break-in procedure.
SD-06 Test Reports
Engine[; G][; G, [_____]]
A fully documented shop test report.
The field test report, documenting all data for lubrication oil temperature and flow, cooling
[water] [air] temperature and flow, and compliance with specified performance criteria tested
during the field tests.
SD-07 Certificates
Pressure Vessels[; G][; G, [_____]]
Certificates of compliance for pressure vessels including official, signed statements from
the fabricators of heat exchangers and expansion tanks associated with the engine cooling system
certifying compliance with ASME BPVC SEC VIII D1.
Regulatory Requirements[; G][; G, [_____]]
Certificates of compliance for equipment and installation including official, signed statements
from manufacturers and installation Contractors. The statements shall certify the item and
quantity supplied and either the date of shipment or installation.
SD-10 Operation and Maintenance Data
[Diesel] [Natural Gas Fueled] Engine[; G][; G, [_____]]
An Operation and Maintenance Manual detailing start-up and operating procedures, lubrication
instructions, installation and alignment procedures, routine maintenance requirements and procedures,
complete detailed procedures for disassembly and reassembly of the engine, parts list for all
parts detailed, assembly plans of the engine showing all parts, suppliers for all parts, settings
and adjustment for protective devices, and a list of all tools, handling devices, and spare
parts furnished.
1.4 WELDER QUALIFICATIONS
Welding shall be in accordance with qualifying procedures using performance qualified welders and welding operators.
Qualify procedures and welders in accordance with ASME BPVC SEC IX. Welding procedures qualified by others,
and welders and welding operators qualified by a previously qualified employer may be accepted as permitted by
ASME B31.1. Notify the Contracting Officer 24 hr in advance of tests, and the tests shall be performed at the
work site, if practical. The welder or welding operator shall apply the assigned symbol near each weld made
as a permanent personal record.[ Structural members shall be welded in accordance with Section 05 05 23 WELDING,
STRUCTURAL.][ Welding and nondestructive testing procedures shall be as specified in Section [[_____]][_____].]
1.5 REGULATORY REQUIREMENTS
1.5.1 General
Design, fabrication, and installation of the equipment shall conform to the [specified] [applicable national,
state, and local] codes. Submit documentation for conformance according to paragraph SUBMITTALS.
1.5.2 Layout and Shop Drawings
Submit layout and shop drawings including the following:
a. Base-mounted equipment, complete with base and all attachments including anchor bolt template
and recommended clearances for maintenance and operation.
b. Complete starting system.
c. Complete fuel system.
d. Complete cooling system.
e. Complete intake and exhaust systems.
f. Layout of relays, breakers, switches, and instrumentation provided and applicable single
line and wiring diagrams with a written description of the sequence of operation.
g. Lubrication system complete including piping, pump(s), strainers, filters, [heat exchangers
for lube oil and turbocharger cooling], [electric heater], controls, and wiring.
h. Location, type, and description of vibration isolation devices for all applications.
i. The safety system, together with a detailed description of its operation. Wiring schematics,
safety devices with a listing of their normal ranges, alarm and shutdown valves (to include
operation parameters such as pressures, temperatures, voltages, currents, and speeds) shall
be included.
j. Layout of the engine control panel and alarm panel.
k. Mounting and support for each panel and major piece of electrical equipment.
l. Engine lifting points and rigging instructions.
m. Alignment information for the engine, [gear box] and [pump] specifying sequences, tolerances,
and temperature change effects.
1.6 DELIVERY, STORAGE, AND HANDLING
Protect material and equipment from weather, humidity, temperature variation, dirt, dust, and other contaminants
during delivery and storage. Lifting, moving, and storage of the engine shall be in accordance with manufacturer's
requirements.
1.7 PROJECT/SITE CONDITIONS
NOTE: The designer should specify the ambient conditions where the engine drive
will be installed. Maximum and minimum air temperature is determined by location.
For indoor installation, use indoor design maximum and minimum temperatures.
For outdoor installations use the 99-percentile selection from ASHRAE Guide
application tables for the installation location.
Maximum Air Temperature [_____] degrees C F
Minimum Air Temperature [_____] degrees C F
Raw Water Temperature Max. [_____] degrees C F
Min. [_____] degrees C F
Installation Elevation [_____] m ft above sea level
1.8 MAINTENANCE
1.8.1 Extra Materials
NOTE: Spare parts to be furnished under this contract should be specified here.
The designer is responsible for determining and providing a list of spare parts
requirements. The following is a partial list:
Furnish the following minimum spare parts when applicable to the type of engine proposed.
UNITS DESCRIPTION
[_____] Complete engine cylinder head(s) and valve set,
etc. (if applicable)
[_____] Complete valve set(s) for one cylinder with springs,
cages, etc.
[_____] Cylinder liner(s) with all necessary water seal rings
[_____] Complete piston(s) with rings and connecting rod
assemblies
[_____] Wrist pins with retaining rings and wrist pine
bearing shells
[_____] Complete set(s) of piston rings for one engine
[_____] Complete set(s) of main bearing shell of each size
and type for the crankshaft of each engine rating
supplied
[_____] Crankpin bearing shell for each crankshaft of each engine
rating supplied
[_____] Complete fuel injector nozzle assembly and fuel injector pump
assembly
[_____] Air start motor (if applicable)
[_____] Air start check valve (if applicable)
[_____] Complete gaskets set for one engine
[_____] Refills, with storage box, for all lubricating oil
filters for each engine
[_____] Refills, with storage box, for all fuel oil filters
for each engine
[_____] Spare lubricating oil circulating pump assembly
[_____] Jacket water pump
[_____] Pre-lube oil pump and motor assembly (if applicable)
[_____] Pressure transducer(s)
1.8.2 Special Tools
Provide one complete set of special tools required for maintenance. Special tools are those that only the manufacturer
provides for special purposes or to reach otherwise inaccessible parts. The tools shall be supplied complete
with a suitable tool box.
PART 2 PRODUCTS
2.1 MATERIALS AND EQUIPMENT
2.1.1 Standard Products
Provide materials and equipment, comprising the engine drive system, which are the standard products of manufacturers
regularly engaged in the production of [diesel][natural gas fueled] engine pump drives and that essentially duplicate
products which have been used satisfactorily for at least two years prior to bid opening. An offer proposing
an experimental engine, one having a lesser or greater number of cylinders than the offerers' standard production
engines, or one without a demonstrated satisfactory service record as a full [diesel][natural gas fueled] engine
operating not less than 1,200 hr a year at not less than 75 percent rated load, will be rejected. All products
shall be new.
2.1.2 Nameplates
NOTE: Delete the requirement for day tanks if natural gas fueled engines are
specified.
Provide each major component with the manufacturer's name, address, type or style, model or serial number, and
catalog number on a plate secured to the equipment. As a minimum, nameplates shall be provided for the following
items:
a. Engines
b. Pumps and pump motors
c. Radiators
d. Heaters
e. Exhaust mufflers
f. Heat exchangers
[g. Day tanks]
2.1.3 Personnel Safety Devices
Insulate, fully enclose, guard, or fit with other types of safety devices all exposed moving parts, parts that
produce high operating temperatures, parts which may be electrically energized, and parts that may be a hazard
to operating personnel. Install the safety devices so that proper operation of the equipment is not impaired.
2.2 MATERIALS
2.2.1 Filter Elements
Provide fuel-oil, lubricating-oil, and combustion-air filter elements which are the manufacturer's standard type
and able to filter out particles down to a 25 to 40 micron size, unless otherwise noted.
2.2.2 Pipe (150 psi System and Under)
Pipe for sleeves, fuel/lube-oil, compressed air, coolant, exhaust, and miscellaneous uses shall comply with ASTM A 53/A 53M
, or ASTM A 106/A 106M steel pipe. Pipe smaller than 50 mm 2 inch shall be Schedule 80. Pipe 50 mm 2 inch and
larger shall be Schedule 40.
a. Flanges and flanged fittings: ASTM A 181/A 181M, Class 150, or ASME B16.5.
b. Pipe welding fittings: ASTM A 234/A 234M, Grade WPB or WPC, Class 150 or ASME B16.11, 1360.7 kg
3,000 lbs.
c. Threaded fittings: ASME B16.3, Class 150.
d. Valves: MSS SP-80, Class 150.
e. Gaskets: manufacturer's standard.
2.2.3 Temperature Gauges for Oil or Water Service
Manufacturer's standard flush-mounted, 100 mm 4 inch minimum diameter dial size with standard operating point
at 50 percent of the full gauge range. Gauge construction and materials shall be appropriate for the intended
service.
2.2.4 Pipe Hangers
MSS SP-58 and MSS SP-69
2.2.5 Pressure Gauges
Manufacturer's standard flush mounted, 100 mm 4 inch minimum dial diameter with standard operating point at 50
percent of the full gauge range. Gauge construction and materials shall be appropriate for the intended service.
2.3 [DIESEL] [NATURAL GAS FUELED] ENGINE
NOTES: Specify the fuel type if different than No. 2 diesel. The rating of
the equipment should be in accordance with SAE standards. If the facility is
located below 457 m (1,500 ft) in elevation above sea level and the intake air
temperature is under 38 degrees C (100 degrees F), then de-rating is not required.
Naturally aspirated engines are available to about 1,500 kW continuous. Turbocharged
engines are generally available from 50 to 350 kW continuous. Turbocharged-aftercooled
engines are generally available from 200 kW to over 4,000 kW continuous. Engine
suppliers should be contacted for recommendations regarding the appropriate
engine based on the application.
a. [The engine shall be a full diesel, 2 or 4 cycle, compression-ignition type, for stationary applications
and shall operate on No. 2-D diesel fuel conforming to ASTM D 975. The engine shall be naturally aspirated,
turbocharged, or turbocharged-aftercooled.]
b. [The engine shall be a natural gas fueled, 2 or 4 cycle, spark ignition type, for stationary applications
and shall operate on standard pipeline natural gas. The engine shall be naturally aspirated or turbocharged-aftercooled.]
c. The engine rating shall be as specified in paragraph PERFORMANCE REQUIREMENTS. The engine shall
be of the vertical in-line, vee, or opposed-piston type, with a solid cast block or individually cast
cylinders. Opposed-piston engines shall have no less than four cylinders. Engines shall be current
models of a type in regular production and shall be complete with all devices specified or normally furnished
with the engine.
2.3.1 Fuel Consumption
Engine fuel consumption shall not exceed the following maximum limits based on the conditions listed below:
NOTE: Use the following tables and subparagraphs for diesel engines.
SIZE RANGE PERCENT OF RATED FUEL USAGE
NET kW FULL LOAD kg/kWh
100 - 299 75 - 100 0.272
300 - 999 75 - 100 0.261
1,000 - 2,500 75 - 100 0.243
SIZE RANGE PERCENT OF RATED FUEL USAGE
NET kW FULL LOAD Lbs/bhp-hr
100 - 299 75 - 100 0.447
300 - 999 75 - 100 0.429
1,000 - 2,500 75 - 100 0.400
Conditions:
a. 45 MJ/kg 19,350 BTU/pound heat value for fuel.
b. Sea level operation.
c. Intake air temperature not over 32 degrees C 90 degrees F.
d. Intake air barometer pressure not less than 95.7 kPa 28.25 inch of mercury.
NOTE: Use the following tables and subparagraphs for natural gas fueled engines.
SIZE RANGE PERCENT OF RATED FUEL USAGE
NET kW FULL LOAD kJ/kWh
100 - 299 75 - 100 12,340
300 - 999 75 - 100 11,325
1,000 - 2,500 75 - 100 11,325
SIZE RANGE PERCENT OF RATED FUEL USAGE
NET kW FULL LOAD btu/bhp-hr
100 - 299 75 - 100 8,700
300 - 999 75 - 100 8,000
1,000 - 2,500 75 - 100 8,000
Conditions:
a. Based on 118 octane natural gas with a heat value of 33,500 kJ/m3 900 btu/ft3.
b. Sea level operation.
c. 25 degrees C 77 degrees F ambient air temperature at 30 percent relative humidity.
d. 100 kPa 29.53 inch of mercury barometer pressure.
2.3.2 Crankcase Pressure Relief Valve
NOTES: Engines larger than 20 kW (27 hp) shall utilize a pressure relief valve
on the crankcase to relieve primary crankcase explosions. The crankcase pressure
relief valve vents quickly and then reseats to prevent return of air and to
protect against secondary explosions. The plans should show the crankcase pressure
relief valve vent piping on indoor engine installations.
Use the first paragraph for diesel engines and the second paragraph for natural
gas fueled engines.
a. [A pressure relief valve shall be provided in the crankcase. The crankcase shall be vented in accordance
with the manufacturer's recommendations, except the engine exhaust shall not be used as the venting system.
Crankcase breathers, if provided on engines installed in either a building or enclosure, shall be piped
to vent to the outside. If the engine is located outside, the crankcase breather shall be fitted with
a goose-neck to prevent rain entry.]
b. [A pressure relief valve shall be provided in the crankcase. The crankcase shall be vented in accordance
with the manufacturer's recommendations. Crankcase breathers using the venturi effect of the exhaust
system will be allowed only when designed, installed, and provided directly from the engine manufacturer.
Otherwise, the crankcase shall be vented to the outside and fitted with a goose neck to prevent rain
entry.]
2.4 FUEL SYSTEM
The fuel system for each engine shall conform to requirements of NFPA 30 and NFPA 37. The fuel system shall
include the following items.
2.4.1 Fuel Pump
NOTE: Use the first paragraph for diesel engines and the second paragraph for
natural gas fueled engines.
a. [Each engine shall be provided with an engine-driven, positive displacement engine fuel pump. The
pump shall have the capacity to transfer fuel from the day tank at a rate in excess of maximum fuel consumption
stated in paragraph FUEL CONSUMPTION, as well as supplying adequate pressure for the fuel injectors.]
b. [Each engine shall be provided with a fuel solenoid shutoff wired to a shutdown system and a fuel
pressure regulator supplied by the engine manufacturer to control the fuel over air mixture to the engine.
The fuel supply pressure available at the site is [_____] kPainch H20. The engine fuel system design
shall be adequate to power to 110 percent load at the site fuel supply pressure as stated above.]
2.4.2 Filter
NOTE: Use the first paragraph for diesel engines and the second paragraph for
natural gas fueled engines.
a. [A minimum of one duplex filter with a trans-flow change-over valve shall be supplied for each engine.
The filter shall have inlet and outlet connections plainly marked. An indicating differential pressure
gauge shall be provided across the filter. The filter shall be located on the inlet side of the fuel
pump. The filter shall be capable of filtering out particles down to 25 micron size.]
b. [Each engine shall be provided with a fuel filter located upstream of the fuel solenoid shutoff to
filter 100 percent of the incoming gas. The filter shall have inlet and outlet connections plainly marked.
An indicating differential pressure gauge shall be provided across the filter. The filter shall be capable
of filtering out particles down to 5 micron size.]
2.4.3 [Strainer
NOTE: Use this paragraph with diesel engines only.
A full flow strainer of the replaceable cartridge type shall be provided between the engine and the fuel tank,
upstream of the duplex filter. An indicating differential pressure gauge shall be provided for upstream and
downstream of the strainer. The strainer cartridge shall be capable of filtering out particles down to 125 micron
size.]
2.4.4 [Fuel Gas Compressor
NOTE: Use this paragraph with natural gas fueled engines only.
Where the basic engine fuel system design requires fuel pressures above that available at the site, a fuel gas
compressor is required. This fuel gas compressor shall be selected and certified by the engine manufacturer
to comply with both these specifications and the requirements of the engine throughout its load range and up
to 110 percent load. The fuel gas compressor shall be packaged on the same skid as the engine with a fully plumbed
fuel system providing one point for fuel connection and junction boxes as required for electrical connections.]
2.4.5 Safety Bypass Valve
NOTE: Delete the last sentence if natural gas fueled engines are specified.
A safety bypass valve shall be provided next to the pump isolation valve to prevent the buildup of excessive
pressures if the discharge line or fuel pump filters become clogged. This bypass shall protect the fuel piping
from over-pressurizing and will relieve it at [_____] kPa psi.[ The bypass valve relief line shall return the
fuel to the engine day tank.]
2.4.6 [Day Tank
NOTE: See NFPA 37 and NFPA 30 for day tank restrictions on allowable day tank
sizes. The day tank should be located in close proximity to the engine to avoid
exceeding the total suction head capabilities of the engine-driven fuel pump
(paragraph FUEL PUMP). Nominal suction head capabilities of typical engine-driven
fuel pumps are in the range of 2.75 to 3.65 m (9 to 12 ft).
Delete this paragraph in its entirety if natural gas fueled engines are specified.
Each engine shall be provided with a day tank located next to the engine. Each day tank shall be fitted with
a fuel supply line, fuel return line, local fuel fill port, direct reading liquid level indicator, vent, fill
limit float switch assembly for automatic control of the fuel oil transfer pump (if provided), alarm level sensing
device, and a drain line. A fuel return line cooler shall be provided, if recommended by the engine manufacturer.
Each day tank shall have [a [_____] L gal capacity] [capacity sufficient to supply the engine without interruption
for 2 hr] [capacity sufficient to supply the engine for [_____] hr continuously at 100 percent rated load without
being refilled].]
2.4.6.1 Drain Line
Each day tank drain line shall be equipped with a shutoff valve and be arranged to allow drainage into 220 L
55 gal drums.
2.4.6.2 Local Fuel Fill
Each local fill port shall have a [screw-on cap][hinged, fill cap]. An air vent with brass screen shall be provided
so that the day tank does not develop a vacuum leading to the collapse of the day tank as the system empties.
2.4.6.3 Fuel Level Limit Devices
a. Each day tank shall be provided with a fill level float switch assembly device to:
(1) Initiate refueling of the day tank at the low level mark, (e.g., 30 percent volume remaining).
(2) Stop refueling of the day tank at the high level mark, (e.g., 90 percent volume).
b. Each day tank shall be provided with a separate level-sensing device to activate alarms at day tank
overfill and day tank empty. Day tank empty shall indicate at 20 percent volume remaining. Day tank
overfill shall indicate at 95 percent volume. See paragraph ALARM PANEL for further function requirements.
2.4.6.4 Redundant Fuel Shutoff
To stop fuel flow to the day tank, an automatic shutoff valve shall be provided on the fill line of the day tank
and an automatic safety device shall be provided to stop the pump supplying fuel to the day tank. The valve
and the safety device shall be activated at the overfill level as defined in paragraph SAFETY SYSTEM, and shall
respond before any fuel is forced out of the fuel overflow line.
2.4.6.5 Arrangement
The day tank shall be positioned and arranged so that fuel level in the day tank at the day tank empty level
is above the suction port of the engine-driven fuel pump. The day tank overflow connection shall be positioned
and arranged so that the highest possible fuel level in the day tank is below the fuel injectors. The fuel supply
line from the day tank to the engine connections shall be welded steel pipe. A water drain shall be provided
at the low point of the day tank.
2.4.7 Fuel Supply System
NOTE: Delete the second sentence and use Section 33 56 10 FACTORY-FABRICATED
FUEL STORAGE TANKSS to specify the fuel supply system if diesel engines are
specified. Delete the first sentence and use Section 33 51 15 NATURAL-GAS/LIQUID
PETROLEUM GAS DISTRIBUTION and Section 33 51 01.00 10 GAS PIPING SYSTEMS to
specify the fuel supply system if natural gas fueled engines are specified.
[The diesel fuel supply from the main diesel fuel storage to the day tank shall be as specified in Section
33 56 10 FACTORY-FABRICATED FUEL STORAGE TANKS.] [The natural gas fuel supply system shall be as specified in
Section 33 51 15 NATURAL-GAS/LIQUID PETROLEUM GAS DISTRIBUTION and Section 23 11 25 FACILITY GAS PIPING.]
2.4.8 Main Fuel Storage Tank
NOTE: The location of this tank is important for day tank draining and day
tank fuel supply. The appropriate type and location should be determined by
costs and operational requirements and should follow local, state, and Federal
Environmental Protection Agency regulations, Section 33 56 10 and NFPA-30.
Delete this paragraph if natural gas fueled engines are specified.
The main fuel storage tank is specified in [Section [33 56 10 FACTORY-FABRICATED FUEL STORAGE TANKS][[_____]]][_____].
2.5 LUBRICATION
NOTE: Delete the adjustable requirement for pressure regulation on the pressurized
lube oil system for engines smaller than 1,000 kW (1,350 hp).
Each engine shall have a separate lube-oil system conforming to NFPA 30 and NFPA 37. Each system shall be pressurized
by engine-driven pumps.[ The system pressure shall be adjustable and regulated as recommended by the engine
manufacturer.] A sump tank shall be furnished as required. The lube-oil pump shall draw oil from the oil pan
or sump tank through a mesh intake strainer and force it through a lubricating oil cooler and a single or duplex
full-flow strainer into the engine. The pump shall be protected by a relief valve to bypass the oil into sump.
A portion of the oil from the sump shall be bypassed through a lubricating oil filter and back into the engine
oil pan or sump. The lubricating oil temperature shall be regulated by means of an automatic temperature regulator
which will control the amount of bypass oil around the cooler. The system shall be readily accessible for service
such as draining or refilling. Each system shall permit the addition of oil and have oil-level indication with
the set operating.
2.5.1 Pump Filters
One full-flow, duplex, 80 micron filter shall be provided for each pump. The filter shall be readily accessible
and capable of being changed without disconnecting the piping or disturbing other components. The filter shall
have inlet and outlet connections plainly marked. An indicating differential pressure gauge shall be provided
across the filter.
2.5.2 Lube-Oil Sensors
Each engine shall be equipped with lube-oil temperature and pressure sensors. Temperature sensors shall provide
signals for pre-high and high lube-oil indication and alarms. Pressure sensors shall be located downstream of
the filters and provide signals for pre-low and low lube-oil indication and alarms.
2.5.3 Lubricating Oil Strainer
A full-flow, oil strainer shall be furnished in-line, ahead of the engine. The strainer shall be as recommended
by the engine manufacturer. A bottom drain plug shall allow easy removal of the sludge.
2.5.4 [Pre-Lubrication Oil Pump
NOTE: Normally, engine size greater than 350 kW (470 hp) and engines with a
period in excess of two weeks between operations require pre-lubrication. If
pre-lubrication is required, utilize this paragraph.
The pre-lubricating oil pump shall have a capacity and head rating as recommended by the engine manufacturer.
The pump shall incorporate a built-in relief valve and be directly connected to an electric motor with the motor-pump
assembly mounted on a common case iron or steel base. The pump shall be furnished complete and ready for operation
with all controls inclusive. The pre-lubrication pump shall completely fill the engine oil lines and establish
lubricating oil pressure prior to starting. The pump motor shall be in accordance with the requirements of paragraph
MOTORS.]
2.6 COOLING SYSTEM
NOTE: There are three basic types of engine cooling systems available. These
are systems using liquid-to-air heat exchangers (radiators) or cooling towers,
systems using liquid-to-liquid heat exchangers (systems using shell and tube,
plate and frame heat exchangers) and systems using submerged pipe systems.
No matter which system is specified, engine outlet water temperature should
be kept constant, and the differential between inlet water to outlet water of
the cooling system should be kept at about 8 degrees C (15 degrees F). The
radiator requires forced air through the heat exchanger causing higher noise
levels. For an indoor application, the radiator can be located outside with
a higher pressure pumping system to deliver the required flow to the radiator.
The radiator should be mounted less than 15 m (50 ft) above the engine to avoid
leakage at the engine water pump seal.
When the approach between coolant and air temperatures is under 15 degrees C
(27 degrees F), towers become more economical. A surrounding clean environment
is required with towers due to the openness of the design. The shell and tube
heat exchanger requires an expansion tank to remove air from the system. The
raw water supply system should be closely coordinated when applying a shell
and tube heat exchanger.
Cooling towers have limiting working ranges and can be applied successfully
only in certain climates.
The submerged pipe cooling system requires a large quantity of raw water and
an expansion tank. Factors for consideration when evaluating cooling systems
include engine size, space limitations, acceptable noise levels, raw water supply,
maintenance, operational requirements, and system operating costs. Engine suppliers
should be contacted for assistance in selecting the appropriate cooling system
for the application.
a. Each engine shall have its own cooling system. The system shall be of the closed type and operate
automatically while the engine is running.
b. The cooling system shall have an engine-driven water pump, [fin-tube radiator], [cooling tower],
[remotely mounted fin-tube radiator], [shell-tube heat exchanger, expansion tank], [plate and frame heat
exchanger, expansion tank], [submerged pipe, expansion tank], and an automatic temperature regulating
valve. The maximum temperature rise of the coolant across each engine shall not exceed the engine manufacturer's
recommendation as submitted in paragraph SUBMITTALS.
c. The engine cooling system shall be of the closed type arranged to prevent rust and minimize formation
of scale deposits within the engine. The system shall circulate jacket-coolant through the engine at
the temperature and flow rate recommended by the engine manufacturer. The coolant shall be an ethylene-glycol
water mixture with a concentration sufficient for freeze protection at the minimum outdoor temperature
specified. The maximum temperature rise of the coolant shall be no more than that recommended and submitted
in paragraph SUBMITTALS.
2.6.1 Coolant Pumps
NOTE: Delete raw-water pump option for closed-loop systems.
Engine-driven jacket water pumps shall be of the centrifugal type.[ Raw-water centrifugal circulating pumps
shall be [electric motor driven equipped with manual-off-automatic controllers] [engine driven].] Each engine
shall have an engine-driven primary pump. Secondary pumps shall be electric motor driven and have automatic
controllers. The pump shall be a bronze fitted, single stage type with removable seal rings and stuffing box
and properly sized for the intended purpose.
2.6.2 [Radiator
NOTE: Radiator location and mounting details should be shown on the plans.
An electric motor-driven fan is provided on remotely located radiators to circulate
air across the radiator. The fan should operate when the engine operates.
Each radiator shall be sized to limit the maximum allowable temperature rise on the coolant across the engine
to that recommended and submitted in paragraph SUBMITTALS, for the maximum outdoor design temperature and site
elevation. Radiator fabrication materials shall be corrosion resistant and suitable for service in the ambient
application conditions. The radiator may be factory coated with corrosive resistant film provided that corrective
measures are taken to restore the heat rejection capability of the radiator to the initial design requirement
via over-sizing or other compensating methods. Internal surfaces shall be compatible with liquid fluid coolant
used. Materials and coolant are subject to approval by the Contracting Officer. Radiators shall be the pressure
type incorporating a pressure valve, vacuum valve, and a radiator cap. Radiator caps shall provide for pressure
relief prior to removal. Each radiator and the entire cooling system shall be capable of withstanding a minimum
pressure of 48.4 kPa 7 psig. Each radiator shall be protected with a strong grille or screen guard. Radiators
shall have at least two tapped holes. One tapped hole in the radiator shall be equipped with a drain cock; the
rest shall be plugged.] [The remote located radiator shall be provided with an electric motor-driven fan. The
fan shall be wired to operate when the engine operates.]
2.6.2.1 [Shell and Tube Heat Exchanger
The heat exchanger shall be a multiple pass shell type with removable U-tube bundles to facilitate cleaning and
retubing. The heat exchanger shall be of sufficient capacity to cool the engine with [_____] degrees C F input
cooling water. The heat exchanger shall operate with low temperature water in the shell and high temperature
coolant in the tubes. Exchangers shall be constructed in accordance with requirements of ASME BPVC SEC VIII D1
and certified with an ASME stamp secured to the heat exchanger. Shells shall be constructed with seamless steel,
welded steel, or cast iron. Tubes shall be either cupronickel or inhibited admiralty, meeting requirements of
ASTM B 395/B 395M, suitable for the temperature and pressure specified. The shell side and tube side of the
heat exchanger shall be designed for 1.03 MPa 150 psig working pressure and factory tested at 2.06 MPa 300 psig
. High temperature, low temperature, and pressure relief connections shall be located in accordance with the
manufacturer's standard practice. Coolant pressure loss through clean tubes shall be as recommended by the engine
manufacturer. Minimum coolant velocity through the tubes shall be at least 300 mm/sec 12 inch/sec and sufficient
to assure turbulent flow. One or more pressure relief valves shall be provided for each heat exchanger in accordance
with ASME BPVC SEC VIII D1. A drain connection with a 19 mm 3/4 inch hose bib connection shall be installed
at the lowest point in the system near the heat exchanger.]
2.6.2.2 [Plate and Frame Heat Exchanger
The heat exchanger shall be a multiple pass type with removable plates to facilitate cleaning. The heat exchanger
shall be of sufficient capacity to cool the engine with [_____] degrees C F input cooling water. Heat exchangers
shall be constructed in accordance with ASME BPVC SEC VIII D1 and certified with an ASME stamp secured to the
heat exchanger. Materials selected for the plate and frames shall be appropriate for the service required.
High and low temperature and pressure relief connections shall be located in accordance with the manufacturer's
standard practice. Water pressure loss through clean plates shall be as recommended by the engine manufacturer.
One or more pressure relief valves shall be provided for each heat exchanger in accordance with ASME BPVC SEC VIII D1
. A drain connection with a 19 mm 3/4 inch hose bib connection shall be installed at the lowest point in the
system near the heat exchanger.]
2.6.2.3 [Cooling Tower
NOTE: The maximum outdoor design temperature, coolant temperature, and availability
of water are critical to the proper selection of the appropriate cooling tower.
Applicable ASHRAE guides should be consulted for application guidance.
Size the cooling tower to limit the maximum allowable temperature rise in the coolant across the engine to that
recommended by the engine manufacturer. The Contractor is responsible for the proper selection of system components
based on the site conditions and the [diesel] [natural gas fueled] engine pump drive[s] used. Internal and external
materials shall be appropriate for the heat used. Use cooling towers in conjunction with a liquid-to-liquid
heat exchanger to keep the engine cooling in a closed loop with conditioned coolant. Furnish the cooling tower
as a complete operating system with a liquid-to-liquid heat exchanger, a surge tank, an auxiliary water pump,
necessary filters in the water return lines, and interconnecting piping and isolation valves as required for
maintenance and operation.]
2.6.2.4 [Submerged Pipe
NOTE: Protection for the submerged pipe or coil should be considered. The
pipe or coil should be kept out of mud or silt and away from the bottom of the
cooling pond to ensure maximum efficiency.
The pipe or coil shall be of sufficient length to cool the engine at the specified raw water temperature. The
piping materials shall be as specified in paragraph PIPE. The pipe installation shall be as specified in paragraph
PIPING INSTALLATION. The pipe from the return bend shall always slope up to prevent air locks in the system.
A drain plug shall be furnished at the lowest point of the system. The system shall be connected so that the
jacket water flows from the engine to the cooling coils and then to the expansion tank before returning to the
jacket water pump inlet.]
2.6.3 Thermostatic Control Valve
A modulating type, thermostatic control valve shall be provided in the coolant system to maintain the engine
coolant temperature in the range submitted in paragraph SUBMITTALS.
2.6.4 Ductwork
The ductwork shall be as specified in [Section [23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEM]
[[_____]]] [_____] except that a flexible connection shall be used to connect the engine radiator. Material
for the connection shall be wire-reinforced fiber glass. The connection shall be airtight.
2.6.5 Temperature Sensors
NOTE: Use the first paragraph if diesel engines are specified and the second
paragraph if natural gas fueled engines are specified.
[Each engine shall be equipped with coolant temperature sensors. Temperature sensors shall provide signals for
pre-high and high coolant temperature indication and alarms.]
[Each engine shall be equipped with coolant temperature systems for both the jacket water system and the intercooler
system when the engine is turbocharged.]
2.6.6 Expansion Tank
NOTE: The size of the expansion tank shall be at least 15 percent of the coolant
volume in the total system to take care of expansion.
An expansion tank of not less than [_____] L gal shall be furnished for each engine. The tank shall be properly
fitted for vent, overflow, expansion, and make-up lines. The tank shall be suitable for an operating temperature
of 121 degrees C 250 degrees F and a working pressure of 860 kPa 125 psig. The tank shall be constructed of
welded steel, hot-dipped galvanized inside and outside after fabrication, tested, and stamped in accordance with
ASME BPVC SEC VIII D1 and registered with the National Board of Boiler and Pressure Vessel Inspectors. The tank
shall be mounted so that the bottom of the tank is above the top of the engine. The tank shall be supported
by steel legs or bases for vertical installations or steel saddles for horizontal installation.
2.7 SPECIAL LIMITATIONS
2.7.1 Sound Limitations
NOTE: The noise limits shall conform to applicable local and OSHA codes. The
designer is responsible for determining code noise limit requirements for specific
site applications. Specific information regarding applicable noise limits should
be inserted in this section. Site specific requirements and limitations are
key components in the criteria selection. Generally, the most cost effective
approach is to use hearing protection in conjunction with building and room
insulation to control noise.
[_____]
2.7.2 Vibration Isolation and Seismic Restraints
NOTE: Provide seismic requirements and show details on the drawings if the
Government designer (either Corps office or A/E) is the Engineer of Record.
Delete the bracketed phrase in the last sentence of this paragraph if seismic
details are not provided. Pertinent portions of UFC 3-310-04 and properly edited
Sections 13 48 00 and 22 05 48.00 20 must be included in the contract documents.
The maximum engine vibration in the horizontal, vertical, and axial directions shall be limited to 0.15 mm 6
mils peak-peak RMS, with an overall velocity limit of 24 mm/sec 0.95 inch/sec RMS.[ A vibration-isolation system
shall be installed between the floor and the base. The vibration-isolation system shall limit the maximum vibration
transmitted to the floor at all frequencies to a maximum of [_____] [_____] peak force.][ The engine shall be
provided with a vibration-isolation system in accordance with the manufacturer's standard practice.] Vibration-isolation
systems shall be designed and qualified (as an integral part of the base and mounting system) to the seismic
forces specified. Where the vibration-isolation system does not secure the base to the structure floor or unit
foundation, seismic restraints shall be provided in accordance with UFC 3-310-04 SEISMIC DESIGN FOR BUILDINGS
and Sections 13 48 00 SEISMIC PROTECTION FOR MISCELLANEOUS EQUIPMENT and 13 48 00.00 10 SEISMIC PROTECTION FOR
MECHANICAL EQUIPMENT [and as shown on the drawings].
2.8 AIR INTAKE EQUIPMENT
Filters and silencers shall be provided in locations that are convenient for servicing as shown on the project
plans. The silencer shall be of the high-frequency filter type, located in the air intake system as recommended
by the engine manufacturer. A combined filter silencer unit meeting requirements for the separate filter and
silencer items may be provided. Expansion elements in air-intake lines shall be [copper][rubber].
2.9 EXHAUST SYSTEM
The system shall be separate and complete for each engine. Exhaust piping shall be supported to minimize vibration.
Provisions shall be made for pipe thermal expansion. Where a V-type engine having more than one exhaust outlet
is provided, a V-type connector, with necessary flexible sections and hardware, shall connect the engine exhaust
outlets. The exhaust connectors shall incorporate engine-mating and silencer-mating flanges, eliminating the
need for adapters. The muffler and exhaust piping together shall be capable of reducing the noise level at the
exhaust discharge location to a point below the maximum sound levels specified in paragraph SOUND LIMITATIONS,
at a distance of [_____] m ft from the end of the exhaust piping directly along the path of discharge for horizontal
discharged exhaust; or at a radius of [_____] m ft from the muffler/discharge piping, at 45 deg apart in all
directions, for vertically discharged exhausts, with the engine operating at 100 percent of service load.
2.9.1 Flexible Sections and Expansion Joints
A flexible section shall be provided at each engine and an expansion joint at each muffler. Flexible sections
and expansion joints shall have flanged connections. Flexible sections shall be multiple-ply stainless steel
expansion bellows type with standard 38 and 76 mm 1.5 and 3 inch allowable axial expansion. Elements in the
flexible sections shall be capable of absorbing vibration from the engine and compensating for thermal expansion
and contraction.
2.9.2 Exhaust Muffler
NOTE: Muffler locations and mountings should be shown on the plans. The designer
should consider the use of first cost versus life-cycle cost analysis to determine
the appropriate metal to use. Stainless steel Series 321 and aluminized steel
should be considered in lieu of painted steel materials.
A chamber type exhaust muffler shall be provided. The muffler shall be fabricated of welded steel and designed
for [outside] [inside] [vertical] [horizontal] mounting. Eyebolts, lugs, flanges, or other items shall be provided
as necessary for support of the muffler in the location and position indicated on the plans. The pressure drop
through the muffler shall not exceed the recommendations of the engine manufacturer. Outside mufflers shall
be fabricated from [aluminized steel] [stainless steel]. The muffler shall have a drain valve, nipple, and cap
at the low-point of the muffler. The muffler shall be supplied complete with any necessary soot boxes or inspection
ports required for adequate operation and maintenance. The entire exhaust system shall be sized appropriately
so that the operation of the engine is not affected by the exhaust system.
2.9.3 Exhaust Piping
NOTE: Exhaust piping should be sized at a gas velocity of less than 25.4 m/p
sec (5,000 fpm). The exhaust piping location and routing should be shown on
the plans.
Horizontal sections of the exhaust piping shall be sloped downward away from the engine to a condensate trap
and drain valve. Changes in direction shall be made utilizing long radius fittings. Exhaust piping not covered
in this paragraph shall be run in accordance with paragraph PIPING INSTALLATION. Exhaust piping, mufflers, and
silencers shall be insulated with ASTM C 533 calcium silicate insulation, minimum of 75 mm 3 inch thickness or
an appropriate thickness to limit the surface temperature to values below 80 degrees C 175 degrees F. Insulation
shall be secured with not less than 9.525 mm 0.375 inch width Type 304 stainless steel bands spaced no farther
apart than 200 mm 8 inches on center. An aluminum jacket encasing the insulation shall be provided. The aluminum
jacket shall have a minimum thickness of 0.406 mm 0.016 inch with a factory-applied polyethylene and kraft paper
moisture barrier. The jacket shall be secured with not less than 13 mm1/2 inch wide stainless steel bands, spaced
no farther apart than 200 mm 8 inch on centers. Longitudinal and circumferential seams of the jacket shall be
lapped not less than 75 mm 3 inch. Jackets on horizontal lines shall be installed so that the longitudinal seams
are on the bottom side of the pipe. The seams of the jacket for the vertical lines shall be placed on the off-weather
side of the pipe. On vertical lines, the circumferential seams of the jacket shall overlap so that the lower
edge of each jacket overlaps the upper edge of the jacket below. Vertical exhaust piping shall be provided with
a hinged, gravity-operated, self-closing rain cover. When the exhaust pipe exits the building, the pipe should
be isolated from the [wall][roof] by means of thimbles in accordance with NFPA 37.
2.10 PYROMETER
NOTE: For engines smaller than 1,000 kW (1,340 hp) delete this paragraph.
Pyrometers with individual thermocouples are not normally available and should
not be specified for engines smaller than 1000 kW (1,340 hp).
[A pyrometer [multi-point selector with individual thermocouples] [and thermocouple] with calibrated leads shall
be provided to indicate the temperature [in each engine cylinder and the combined exhaust] [in the combined exhaust].
For a supercharged engine, additional points, thermocouples and leads shall be provided to show the temperature
in the turbocharger exhaust gas outlet and combustion air discharge passages. The selector switch shall be double
pole, with an off position, one set of points for each thermocouple, and a suitable indicating dial. The pyrometer,
thermocouple, leads, and compensating devices shall be calibrated to show true exhaust temperature within ñ1
percent above the highest temperature encountered at 110 percent load conditions.]
2.11 EMISSIONS
The finished installation shall comply with Federal and local regulations and restrictions regarding the limits
of emissions such as [CO, HC, and NOx] [carbon monoxide, hydrocarbon, and nitros].
2.12 STARTING SYSTEM
NOTE: The engine can be started by either pneumatic (compressed air) or an
electric starting system. The selection of the starting system should be based
on costs and availability of compressed air or electric power. The starting
system should be of adequate capacity to start the engine under the coldest
conditions encountered. Generally, in pumping plants with an existing station
air system or where a station air system will be installed, a pneumatic system
will have the lowest initial cost. The designer should ensure that the requirements
for the station air system include an air receiver of adequate size to accommodate
the cranking cycle of each engine in the station without recharge by the station
air compressor. Paragraph 2.11.1 ALTERNATE 1 should be deleted when a pneumatic
starting system is specified. ALTERNATE 2 of this paragraph should be deleted
when an electric start system is specified.
Torque available from air motors of pneumatic systems is capable of accelerating
the engine to twice the engine cranking speed in about half the time required
by electric starters. The starting system should be the manufacturer's standard
equipment.
The starting system, regardless of type, should have a start-stop switch providing
functions including testing, reset, manual run/start manual stop, an adjustable
cranking cycle and cool down mode of operation.
If an electric system is provided, an adjustable cranking limit device should
be specified to limit the engine cranking to a specified time limit.
Each diesel engine shall be provided with a starting system. The system shall be [pneumatic] [electric] and
of sufficient capacity to start the engine at the minimum temperature specified. The system shall have a start-stop
switch which provides functions including testing, reset, manual run/start, manual stop, and adjustable cranking
and cooling down operation. The starting system shall be the manufacturer's standard equipment.
2.12.1 Electrical Starting System
NOTE: Delete this paragraph and subparagraphs in their entirety if a pneumatic
starting system is specified.
An electrical starting system shall be provided to operate on a [24] [____]-V DC utilizing a negative circuit
ground. An adjustable cranking device should be included to limit the engine cranking to a specified time limit.
Starting motors shall be in accordance with SAE ARP892.
2.12.1.1 Battery
NOTE: Select a nickel-cadmium type battery only when the battery temperature
cannot be maintained above -6 degrees C (22 degrees F).
A starting battery system shall be provided and include the battery, battery rack, intercell connectors, spacers,
automatic battery charger with overcurrent protection, metering, and relaying. The battery shall be in accordance
with SAE J537. Critical system components (rack, protection, etc.) shall be designed to withstand the seismic
acceleration forces specified in subparagraph VIBRATION ISOLATION AND SEISMIC RESTRAINTS under paragraph SPECIAL
LIMITATIONS. The battery shall be a [lead-acid] [nickel-cadmium] type, with sufficient capacity, at the minimum
[outdoor] [indoor] temperature specified, to provide a minimum cranking cycle consisting of three cranking periods
of up to 8 sec per period with 8-sec intervals between crank periods.
2.12.1.2 Battery Charger
A current-limiting battery charger, conforming to UL 1236, shall be provided to automatically recharge the batteries.
The charger shall be capable of providing both automatic float charging and equalizing charging of the battery
installation. The charger shall be capable of recharging fully depleted batteries within [8] [_____] hr and
providing a floating charge rate for maintaining the batteries in a fully charged condition. An ammeter and
voltmeter shall be provided on the charger to indicate charging rate and voltage. The charger shall have alarm
functions providing indications of low battery voltage, high battery voltage, and battery charger malfunction.
2.12.2 Compressed Air Starting System
NOTES: Delete this paragraph and subparagraphs in their entirety if an electric
starting system is specified.
The complete compressed air system should be shown on the plans. Two receivers,
redundant piping, and two compressors may be required so that starting capability
is not lost when tank maintenance is required. Valve arrangement should permit
any receiver to be removed from service, drained, repaired, or replaced without
loss of starting air from the system. The check valves between the plant air
system and the air starting receivers should be considered to ensure that failure
of the plant air system does not deplete the backup supply. The designer should
analyze various starting scenarios and determine the necessity of providing
a gasoline or diesel engine-driven compressor for a black-plant (no electrical
sources available) start-up.
Each compressor should have sufficient capacity to refill the air starting system
air receiver in a maximum of 3 min. The receiver shall be sized to crank the
largest engine for 15 sec at an ambient temperature of 21 degrees C (60 degrees
F) without recharging.
Either the air-motor starting option or the cylinder injection starting option
should be used and the other paragraph deleted.
A compressed air starting system shall be provided. The starting system shall use station service air. The
system shall be furnished complete with oilers, regulators, and solenoid control valves. The starting system
shall be air motor type with a working pressure of 1.03 MPa 150 psig or cylinder injection type with a working
pressure of 2.07 MPa 300 psig. The compressed air system piping shall be as specified in Section 22 00 00 PLUMBING,
GENERAL PURPOSE.
2.12.2.1 Air Filter
An air filter shall be installed upstream of the air connection to each engine. The filter shall be capable
of removing particles 10 mm 3/8 inch and larger.
2.12.2.2 Air Driven Motors or Cylinder Injection
Either type of air starting system, air motors or direct injection, is acceptable. If an air motor starting
system is used, the cranking motors shall be complete with a solenoid valve, strainer, and lubricator. If cylinder
injection starting is used it shall be accomplished by admitting compressed air into two or more engine cylinders
through a timing valve, or through a distributor into a sufficient number of cylinders to ensure successful starting
regardless of piston positions.
2.12.3 Starting Aids
NOTE: Jacket coolant and/or lube-oil heaters are normally provided for most
applications to aid starting. Either injection or glow plugs may also be required
for combustion air temperatures significantly below 0 degrees C (32 degrees
F). Consult manufacturers for availability and need in the application size
range.
2.12.3.1 Jacket-Coolant Heaters
A thermostatically controlled electric heater shall be mounted in the engine coolant jacketing to automatically
maintain the coolant within ñ10 deg of the control temperature. The heater shall operate independently of engine
operation so that starting times are minimized, condensation is controlled, and the system ensures dependable,
cold weather starts. Power supply for the heaters will be [_____] volts AC.
2.12.3.2 [Glow Plugs
NOTE: Delete this paragraph if natural gas fueled spark ignited engines are
specified.
Glow plugs shall be designed to provide sufficient heat for fuel combustion within the cylinders to guarantee
starting at an ambient temperature of -23 degrees C -20 degrees F.]
2.12.3.3 [Lube Oil Heaters
A thermostatically controlled electric heater shall be mounted in the engine lube oil storage tank to automatically
maintain the lube oil within ñ10 deg of the control temperature. The heater shall operate independently of engine
operation so that starting times are minimized and the system ensures dependable cold weather starts. Heaters
shall be selected so that heater skin temperatures do not exceed 150 degrees C 300 degrees F and have maximum
heat densities of 0.02 W/mm square 13 W/inch square. Power supply for the heaters will be [_____] volts AC.]
2.13 SAFETY SYSTEM
Devices, wiring, remote annunciator panels, alarm panels, etc., shall be provided and installed as a complete
system to automatically activate the appropriate signals and initiate appropriate safety actions. The safety
system shall be provided with a self-test method to verify its operability. Alarm signals shall have manual
acknowledgment and reset devices. The alarm signal systems shall reactivate for new signals after acknowledgment
is given to any signal. The systems shall be dealt with as an alarm on that system element. The remote annunciator
panels and alarm panel shall be as specified in paragraph PANELS.
2.13.1 Audible Signal
NOTE: High dB levels are required for audible alarms located near an engine.
Audible signaling devices with sound levels in excess of 100 dB should be specified
for engine room application, and the alarm location should be shown on the plans.
The audible alarm signal shall sound at a frequency of [70] [_____] Hz at a volume of [75] [_____] dB at 3.1
m 10 ft. The sound shall be continuously activated upon alarm and silenced upon acknowledgment. Signal locations
shall be as shown on the plans.
2.13.2 Visual Signal
The visual signal shall be a panel light. The light shall normally be off but activated to blinking upon alarm.
The light shall change to continuously lit upon acknowledgment. If automatic shutdown occurs, the display shall
remain in an activated status to indicate the cause of failure and shall not be reset until the cause of alarm
has been cleared and/or restored to the normal condition. Shutdown alarms shall be amber.
2.13.3 Alarms and Action Logic
2.13.3.1 Shutdown
Shutdown signals shall simultaneously activate the audible signal, activate the visual signal, and stop the engine.
2.13.3.2 Problem
Problem signals shall activate the visual signal.
2.13.4 Alarm Panel
NOTE: Select the first subparagraph "b" and first subparagraph "j" below if
diesel engines are specified; select the second subparagraph "b" and second
subparagraph "j" if natural gas fueled engines are specified.
The panel shall be fabricated and located as specified in paragraph PANELS, and shall contain the following functions:
FUNCTION OR INDICATION/CONTROL ACTION (AUXILIARY ACTION)
a. Red emergency stop (push button or switch)/shutdown engine.
[b. Day tank overfill indication (95 percent volume)/problem (shutdown pump supplying fuel to day tank).]
[b. Panel-mounted detonation sensing system with alarm and shutdown lights. The detonation system will
sense individual cylinder detonation and individually adjust cylinder timing to avoid detonation. The
system must be programmable by standard PC with software and operating manual supplied at no additional
charge. The system installed must have the capability of up to 30 crankshaft degrees of total timing
variation for each cylinder. Beyond a programmed limit, the system will act to shut down the engine.]
c. Engine overspeed indication (overspeed indication point as recommended by the engine supplier)/shutdown
engine.
d. High lube-oil temperature indication (temperature as submitted)/shutdown engine.
e. Low lube-oil pressure indication (pressure as submitted)/shutdown engine.
f. High coolant fluid outlet temperature indication (temperature as submitted)/shutdown engine.
g. Pre-low lube-oil pressure indication (110 percent of low lube-oil pressure)/problem (none).
h. Pre-high coolant fluid temperature indication (5 degrees C 10 degrees F lower than high coolant-fluid
outlet temp. alarm)/problem (none).
i. Pre-high lube oil temperature indication (5 degrees C 10 degrees F) lower before problem (none).
[j. Day tank empty indication (20 percent volume remaining)/shutdown engine.]
[j. Crankcase pressure switch (adjustable) to detect crankcase pressure increase associated with scoring
of liner and possible short term catastrophic failure. Shutdown with setpoint as submitted. Setpoint
of the crankcase pressure switch is to be adjusted during start-up to provide close tolerance protection
without nuisance tripping.]
k. Failure to start within the specified time indication/problem (none).
[l. Compressed air low-pressure indication (80 percent of working pressure)/problem (none).]
[m. Engine battery voltage-low/problem (none).]
[n. Engine battery voltage-high/problem (none).]
[o. Engine battery charger malfunction/problem (none).]
2.13.5 Time-Delay on Alarms
For startup of the engine, time-delay devices shall be installed bypassing the low lubricating oil pressure alarm
during cranking [and the low coolant-fluid outlet temperature alarm]. The lube-oil time-delay device shall return
its alarm to normal status after the engine starts.[ The coolant time-delay device shall return its alarm to
normal status 5 minutes after the engine starts.]
2.13.6 [Remote Alarm Panel
NOTE: The remote alarm panel location should be shown on the plans. Delete
requirements for the remote alarm panel where it is not used. The remote panel
may be furnished loosely and unmounted, to be installed on the pump station
control console by others.
A remote alarm panel with 100 percent functional redundancy to the alarm panel shall be provided.[ The remote
panel shall be located and mounted as shown on the plans.] [The remote panel shall be suitably packed and shipped
as directed by the Contracting Officer for installation by others on the station control console.]]
2.14 GOVERNOR
Each engine shall be provided with a governor to control the rotational speed of the engine in response to changing
load requirements. The governor shall be configured for safe manual adjustment of the speed during operation
of the engine, without special tools.
2.14.1 Speed Regulating Governor
The engine governor shall maintain close speed regulation under all load conditions. The speed variation shall
not exceed 6 percent of normal speed when full load is suddenly applied or removed. The design of the governor
shall be such that the engine speed may be changed by governor adjustment during engine operation to any speed
between 80 and 100 percent of the normal speed (corresponding to normal operating pump speeds) within 2 percent.
The speed fluctuation at any load shall not exceed 2 percent. A raise/lower speed control shall be mounted on
the engine instrument board.[ The speed adjust control shall have provisions for allowing control of the speed
control circuits from a remote location.] The engine fuel rack servomotor shall be suitable for operation from
a 120-V AC source.
2.14.2 Emergency Overspeed Governor and Load Limit
NOTE: If the pump drive is out of service for extended periods with little
or no maintenance, then the shutdown mechanisms for overspeed should prevent
both fuel and air supplies from entering the cylinders. If the units are well
maintained and used frequently, either type termination should work satisfactorily.
An emergency governor with overspeed trip shall be provided on each engine to shutdown the unit should the speed
exceed a predetermined RPM. The overspeed trip shall also provide an alarm signal for remote indication. The
emergency governor shall be independent of the regulating governor. When the overspeed stop has been tripped,
the shutdown mechanisms shall be such that the engine fuel and [or] air supply is prevented in the shortest time
practicable from entering the engine cylinders. The trip mechanism may be part of the governor. The engine
shall have an overload fuel limit set at 110 percent of the full load specified in paragraph DIESEL ENGINE.
2.14.3 Governor Controls Location
The governor control shall be located at a point convenient to the location of the engine instrument board as
shown on the plans.
2.15 ENGINE INSTRUMENT BOARD
NOTES: All panels (including the engine instrument board), except the remote
panel, can be combined. Delete the pyrometer devices for engines smaller than
1,000 kW (1,340 hp). See paragraph PYROMETER.
Use the first subparagraph "f" and first subparagraph "g" if diesel engines
are specified; use the second subparagraph "f" and second subparagraph "g" if
natural gas fueled engines are specified.
The engine instrument board shall be as specified in paragraph PANELS, and shall contain the following items:
a. Coolant-fluid inlet temperature display
b. Lubricating-oil pressure indicator
c. Lubricating-oil inlet temperature display
d. Red emergency stop (push-button or switch)
e. Run-time meter
[f. Fuel meter display]
[f. Manifold vacuum display]
[g. Fuel-header-pressure display]
[g. Intake air temperature display]
h. Tachometer display
i. Engine start-stop switch
j. Start-attempt indicator light
k. Lubricating-oil prelubricating pump start-stop switch
l. Alarm panel
[m. Pyrometer display with selector switch]
NOTE: The following instrumentation may be included on the engine instrument
board.
[n. Ammeter for starting battery charger]
[o. Voltmeter for starting battery]
[p. Timer for setting the starting battery charger's equalize charging rate duration]
[q. Air starting system pressure]
2.16 PANELS
NOTE: All panels (including the engine instrument board), except the remote
panel, can be combined into a single panel paragraph. Provide a panel-mounting
location and detail for panels not mounted on the engine base. The designer
may elect other locations such as adjacent to the engine, etc. Provide panel
nameplate and instrument nameplate, unique identifiers, or user-preferred identifiers.
Provide sizes, materials, and attachment preferences.
Delete either the analog or electronic instruments paragraph option.
Each panel shall be of the type and kind necessary to provide specified functions. Panels shall be mounted [on
the engine base by vibration/shock absorbing type mountings][as shown on the plans]. Instruments shall be mounted
flush or semiflush. Convenient access to the back of panels shall be provided to facilitate maintenance. Instruments
shall be calibrated using recognized industry calibration standards. Each panel shall be provided with a panel
identification plate which clearly identifies the panel function as indicated. Each instrument and device on
the panel shall be provided with a plate which clearly identifies the device and its function as indicated.
All instruments and devices shall be vibration resistant.
2.16.1 Enclosures
Enclosures shall be designed for the application and environment, conforming to NEMA ICS 6. Locking mechanisms
[are optional] [shall be keyed alike].
2.16.2 [Analog] [Electronic]
NOTE: Select appropriate alternative paragraph.
a. [Analog electrical indicating instruments shall be in accordance with ANSI C39.1 with semiflush mounting.
Panel-mounted instruments shall [be the manufacturer's standard][have 100-deg scales] with an accuracy
of not less than 2 percent. The instrument's operating temperature range shall be -20 to +65 degrees
C -4 to +150 degrees F.]
b. [Electronic indicating instruments shall be 100 percent solid state, state-of-the-art, microprocessor
controlled to provide all specified functions. Control, logic, and function devices shall be compatible
as a system, sealed, dust and water tight, and shall utilize modular components with metal housings and
digital instrumentation. An interface module shall be provided to decode serial link data from the electronic
panel and translate alarm, fault, and status conditions to a set of relay contacts. Instrument accuracy
shall be not less than 2 percent for unit mounted devices, and 1 percent for control room, panel mounted
devices, throughout a temperature range of -20 to +65 degrees C -4 to +150 degrees F. Data display shall
utilize LED or back-lit LCD. Additionally, the display shall provide indication of cycle programming
and diagnostic codes for troubleshooting. Numeral height shall be [13 mm1/2 inch] [[_____] mminch].]
2.16.3 Parameter Display
Continuous indication of the tachometer, lubricating-oil pressure, and safety system parameters shall be provided.
A momentary switch shall be specified for other panels.
2.17 BASE
NOTES: The diesel-engine pump drive can be equipped so that it has its own
base, or it can be on an integral base with the pump and speed reducer. With
an integral base, coordination with the other equipment specifications and the
use of the statement, "suitable holes for anchor bolts", should be included
in the plans and specifications.
Coordinate with the subparagraph VIBRATION ISOLATION AND SEISMIC RESTRAINTS
under paragraph SPECIAL LIMITATIONS.
The base shall be constructed of structural steel. The base shall be designed to rigidly support the engine,
ensure permanent alignment of all rotating parts, be arranged to provide easy access to allow changing of lube-oil,
and ensure that alignment is maintained during shipping and normal operation. The base shall not permit skidding
in any direction during installation and shall withstand and mitigate the effects of synchronous vibration of
the engine and pump. The base shall be provided with [suitable holes for anchor bolts] [[_____] mm inch diameter
holes for anchor bolts]. The entire engine assembly shall be capable of withstanding the load imposed by earthquake
forces.
2.18 MOTORS
Electric motors shall conform to the requirements of NEMA MG 1. Motors shall have sealed ball bearings and a
maximum speed of 1,800 rpm. Motors shall have drip-proof frames; alternating current motors larger than 373
W 1/2 hp shall be of the squirrel-cage induction type for operation on [_____] V, [50] [60] Hz, three-phase AC
power. Alternating current motors 373 W (1/2 hp) or smaller, shall be suitable for operation on 120 V, [50]
[60] Hz, single-phase, AC power. Direct current motors shall be suitable for operation on [125] [_____] V DC.
Motor controllers and starters shall conform to the requirements of NFPA 70 and NEMA ICS 2.
2.19 PAINTING
The engine and the accessory equipment including, but not limited to, panels, valves, piping, intake, and exhaust
system components shall be cleaned, primed, and painted [in accordance with the manufacturer's standard color
and practice] [as specified in Section [09 90 00 PAINTS AND COATINGS] [09 97 02 PAINTING: HYDRAULIC STRUCTURES].]
2.20 FACTORY INSPECTION AND TESTS
Prior to shipment, each engine shall be inspected and tested at the factory in the presence of the Contracting
Officer or the authorized government representatives. The inspection shall cover all components including, but
not limited to, governors, instrumentation panels, engine starting system, intake and exhaust, lubrication system,
cooling system, and fuel system. Inspection shall be completed and all necessary repairs made prior to testing.
Unless otherwise directed by the Contracting Officer or the authorized government representative, the following
factory tests shall be performed:
a. Simulated emergency or overspeed trip test.
b. Sustained operation test of 4 hr at rated full load.
c. Sustained operation test of 2 hr at 70 percent of rated full load.
d. Fuel consumption tests of not less than 1 hr each at 70 and 100 percent rated full load, respectively,
using [the type of diesel fuel specified][natural gas].
e. The engine shall be operated at no load to demonstrate that the governor and its associated engine
manifold shutoff valve function properly.
f. Test data shall be taken at 30-min intervals and recorded on the manufacturer's [diesel] [natural
gas fueled] engine test data sheets. The test data sheets shall provide entries for all data required
for the evaluation of [diesel] [natural gas fueled] engine performance including noise and vibration.
The test data shall be submitted for approval as required in paragraph SUBMITTALS. No engine shall be
shipped until the test data has been approved by the Contracting Officer.
PART 3 EXECUTION
3.1 EXAMINATION
Before performing any work, visit the installation site and verify all details of the work. For new construction,
review plans and elevations for adequacy and notify the Contracting Officer in writing of any discrepancies.
3.2 INSTALLATION
NOTE: Provide an equipment layout on the plans which allow clear space for
operation and maintenance in accordance with NFPA 70 and IEEE C2. Include requirements
for staging and a laydown area for disassembly or removal and replacement of
major parts of the engine. Additionally, it is advisable to provide access
to remove the unit and/or major parts of equipment from the engine room and
the building through either doors/passageways or equipment hatches. For large
units, specify a bridge crane of an adequate capacity as recommended by the
engine manufacturer.
The installation of the equipment furnished under this section and related pumps and gear reducers under other
sections shall be coordinated and installed in accordance with the approved installation procedures specified
and submitted in accordance with the requirements of paragraph SUBMITTALS.
3.3 PIPING INSTALLATION
No section of pipe within a building shall exceed 6 m 20 ft in length between flanged fittings. Except where
otherwise specified, flanged fittings shall be utilized to allow for complete dismantling and removal of each
piping system from the facility without disconnecting or removing any portion of any other system's equipment
or piping. Connections to all equipment shall be made with flexible connectors and isolation valves. Bending
of pipe shall be done with pipe benders, and no malformation shall be visible on bent pipe. Pipes extending
through the roof shall be properly flashed. Piping shall be supported and permitted to expand and contract without
damage to joints or hangers. Drain valves of 15 mm 0.6 inch shall be installed at each low point in the piping.
3.3.1 Supports
Hangers, inserts, and supports shall be of sufficient size to accommodate any insulation and shall conform to
MSS SP-58 and MSS SP-69. Supports shall be spaced in accordance with ASME B31.1. Piping supports shall not
be attached to metal decking. Supports shall not be attached to the underside of concrete filled floors or concrete
roof decks unless approved by the Contracting Officer.
3.3.1.1 Ceiling and Roof
Exhaust piping shall be supported with appropriate sized Type-41 single pipe roll and threaded rods; all other
piping shall be supported with appropriately sized Type 1 clevis and threaded rods.
3.3.1.2 Wall
Wall supports for pipe shall be made by suspending the pipe from appropriately sized Type 33 brackets with the
appropriate ceiling and roof pipe supports.
3.3.2 Flanged Joints
Flanges shall be Class 125 type, drilled, and of the proper size and configuration to match the exhaust outlet
of the engine. Flanged joints shall be gasketed and made to be square and tight.
3.3.3 Cleaning
After fabrication and before assembly, all piping interiors shall manually be wiped clean of all debris.
3.3.4 Pipe Sleeves
Pipes passing through construction such as ceilings, floors, or walls shall be fitted with sleeves. Each sleeve
shall extend through and be securely fastened in its respective structure and shall be cut flush with each surface.
The structure shall be built tightly to the sleeve. The inside diameter of each sleeve shall be a minimum of
15 mm 0.6 inch larger than the outside diameter of the passing pipe or pipe covering, and where pipes pass through
combustible materials, 25 mm 1 inch larger than the outside diameter of the passing pipe or pipe covering.
3.4 ELECTRICAL INSTALLATION
Electrical installation shall comply with NFPA 70, IEEE C2, and Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.
Vibration isolation shall be provided for all conduit, cable trays, and raceways attached to the engine.
3.5 ONSITE INSPECTION AND TESTS
The tests outlined in the subsequent subparagraphs shall be performed after complete installation of each engine
and its associated equipment and in accordance with the approved Dynamic Analysis of Engine, Pump, and Governor
. Data taken during runs shall be recorded at 30-min intervals and shall include all available pressure and
temperature data which is monitored by the instrumentation furnished with the engine.
3.5.1 Contractor Supplied
Provide all equipment and supplies required for the inspections and tests including fuel and test instruments.
3.5.2 Instruments
Readings of panel gauges, meters, displays, instruments, etc. provided under the specification shall be verified
during all test runs by test instruments of greater precision and accuracy than the operational equipment. Instruments
used in the tests shall be calibrated by a recognized standards laboratory within 30 days prior to testing.
3.5.3 Sequence
The tests shall follow the sequence outlined in subsequent paragraphs. Measurements shall be made and recorded
of all parameters necessary to verify that each engine meets specified parameters. If the results of any of
the test sequences are not satisfactory, adjustments or replacements shall be made and the test sequence repeated
until satisfactory results are obtained.
3.5.3.1 Piping Test
a. Lube-oil and fuel-oil piping shall be flushed with the same type of fluid intended to flow through
the piping, until the out-flowing fluid is free of obvious sediment and emulsions.
b. The lube oil, fuel-oil and coolant piping [and piping and pressure vessels of the air starting system]
shall be hydrostatically pressure tested at 150 percent of the maximum anticipated working pressure,
but in no case less than 1.03 MPa 150 psig for a period of 2 hr to demonstrate the piping has no leaks.
If piping is to be insulated, the test shall be performed before the insulation is applied.
3.5.3.2 Initial Inspection
a. Engine mounting bolts shall be visually inspected and checked for proper application and torque.
b. Correct functioning of the high and pre-high lubricating oil temperature circuit shall be demonstrated
by removing the temperature-sensing elements from the engine and immersing the elements in a vessel containing
controlled-temperature hot oil and recording the temperature at which the elements activate.
c. Correct functioning of the high and pre-high coolant-fluid outlet temperature circuit shall be demonstrated
by removing the temperature-sensing elements of the circuit from the engine and immersing the elements
in a vessel containing controlled-temperature hot coolant-fluid and recording the temperature at which
the elements activate.
3.5.3.3 Electric Protective Device Tests
Protective devices shall be visually and mechanically inspected, adjusted, tested, and calibrated in accordance
with the manufacturer's published instructions. Device ratings, settings, and other operational data shall be
documented.
3.5.3.4 Safety Run Test
Should there be insufficient water available to operate the plant and to perform the engine tests, the Contracting
Officer may delay the test for up to 9 months. The safety run test consists of the following sequence of tests:
a. The engine shall be started, the starting time recorded, and all of the engine manufacturer's recommended
after-starting checks and inspections performed following a reasonable warm-up period.
b. The engine shall be operated for at least 2 hr at 75 percent rated speed.
c. Proper operation of all controls shall be verified.
d. Proper operation and set points of all gauges and instruments shall be verified. Setpoints shall
be recorded.
e. Proper operation of all ancillary equipment shall be verified.
f. The manual emergency stop switch shall be activated and the time to stop the engine recorded.
g. The engine shall be started, the starting time recorded, the engine manufacturer's after-starting
checks and inspections performed and recorded, and the engine operated for at least 15 min at 75 percent
of rated speed.
h. The governor shall be manually adjusted to increase engine speed past the overspeed limit. The engine
RPM at shutdown shall be recorded.
[i. The day tank shall be manually filled to a level above the overfill limit. The level at which the
overfill alarm activates shall be recorded. Shutdown of the fuel transfer pump shall be verified. The
day tank shall be drained below the overfill limit following the test.]
j. The time-delay low-lube oil pressure alarm bypass shall be temporarily removed from the engine safety
circuits and an attempt made to start the engine. The results shall be recorded.
k. A manifold shall be attached to the engine oil system containing a shutoff valve in series with a
connection for the engine's oil pressure sensor, followed by an oil pressure gauge, ending in a bleed
valve. The oil pressure sensor shall be moved from the engine to the manifold and its normal location
on the engine temporarily sealed. The manifold shutoff valve shall be placed in the open position and
the bleed valve closed.
l. The engine shall be started, the starting time recorded, the engine manufacturer's after-starting
checks and inspections performed and recorded and the engine operated for at least 15 min at 75 percent
of rated speed.
m. The manifold shutoff valve shall be closed. The pressure in the manifold shall be slowly bled off
through the bleed valve while observing the pressure gauge. The pressure at which the engine shuts down
shall be recorded. The oil spillage from the bleed valve shall be captured in a container. The oil
system shall be refilled, the manifold removed, and the engine's oil pressure sensor reinstalled on the
engine following the test.
n. The engine shall be started, the starting time recorded, the engine manufacturer's after-starting
checks and inspections performed and recorded and the engine operated for at least 15 min at 100 percent
of rated speed. The maximum sound level in each frequency band at a distance of 22.9 m 75 ft from the
end of the exhaust piping directly along the path of discharge for horizontally discharged exhausts shall
be recorded. The maximum sound level in each frequency band at a distance of [22.9 m 75 ft] [10.7 m
35 ft] from the silencer at 45 deg apart in all directions around the unit shall be recorded.
[o. The fuel from the day tank shall be slowly drained to lower the fuel level below the no fuel level
limit and the level at which the audible alarm sounds recorded. The fuel shall be added back to the
day tank, filling it above the low level alarm limit following the test.]
3.5.3.5 Final Inspection
a. The lube-oil filter shall be removed and the oil and filter examined by the engine manufacturer for
excessive metal, abrasive foreign particles, and other indications of engine distress. Any corrective
actions shall be verified for effectiveness by running the engine for 8 hr at full rated speed, then
re-examining the oil and filter.
b. The engine shall be inspected and all engine mounting bolts checked for tightness and visible damage.
3.6 MANUFACTURER'S FIELD SERVICE
3.6.1 Onsite Training
NOTE: Delete video taping if not required.
Conduct training courses for the plant operating staff as designated by the Contracting Officer. The training
period shall consist of a total of [_____] hr of normal working time and shall commence after the system is functionally
completed, but prior to final acceptance. The course instructions shall cover pertinent points involved in operating,
starting, stopping, and servicing the equipment, as well as all major elements addressed in the operations and
maintenance manuals. Additionally, the course shall include demonstrations and instruction in all routine maintenance
operations including oil change, oil filter change, air filter change, etc.[ Two copies of [_____] [BETA] [VHS]
format video tape of the entire training session shall be submitted.]
3.6.2 Field Engineer
The manufacturer or Contractor shall furnish a qualified engineer to supervise the complete installation of the
engine, assist in performance of the onsite tests, and instruct personnel regarding operational and maintenance
features of the equipment.
3.7 FIELD PAINTING
Field painting shall be as specified in Section [09 90 00 PAINTS AND COATINGS] [09 97 02 PAINTING: HYDRAULIC
STRUCTURES].
3.8 ACCEPTANCE
Final acceptance of the engine will not be made until the Contractor has successfully completed all tests, corrected
all defects in installation material, and/or installation procedures, and all deficiencies identified in on-site
testing or routine operation have been corrected. Submit As-Built Drawings as specified in the Submittals paragraph
before contract closing.