United Technologies Corporation

Pratt & Whitney Power Systems

80 Lamberton Road
Windsor, CT 06095
Revision 2
15 January 2002
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WARNING
This document is the property of United
Technologies Corporation (UTC). You may not
possess, use, copy, or disclose this document or
any other information in it, for any purpose
including
without
limitation
to
design,
manufacture, or repair parts, or to obtain FAA or
other government approval to do so, without
UTCs express written permission. Neither receipt
nor possession of this document alone, from any
source, constitutes such permission. Possession,
use, copying, or disclosure by anyone without
UTCs express written permission is not
authorized and may result in criminal and/or civil
liability.

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FT8 CONSTRUCTION MANUAL REVISION RECORD

Revision Number

Date of Issue

Issued By

Original Manual

September, 1999

Ken Nagy

Rev 1

September, 2000

Ken Nagy

Rev 2

January 15, 2002

Mike Cowan

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INTRODUCTION TO THE FT8 CONSTRUCTION MANUAL

1.0 Introduction
This manual has been prepared to assist and guide PWPS Site Supervisors and
Construction Engineers during the construction phases of FT8 Power Pac and Twin Pac
installations.
CAUTION
The information contained within this manual is not
intended to be specific to a particular site or configuration.
It is provided for reference purposes only and is generally
applicable to all FT8 Power Pac and Twin Pac installations.
Specific instructions for the field installation of equipment
at each specific site will be provided through the PWPS
drawing and documentation system described in Section 5 INSTALLING EQUIPMENT. Information on the proper
installation sequence is given in Section 8 SPECIFIC FT8
INSTALLATION SEQUENCE. When a conflict exists
between this manual and the applicable drawing, the
applicable drawing shall take precedence over this manual.
The material contained in this manual also includes typical
requirements for such activities as site preparation and
foundation work, as will be specified by the A&E
contractor for performance by the builder, general
contractor, and sub-contractors. It is provided for reference
purposes only.
2.0 Safety
Because of its importance, site safety information is a prominent part of this manual.
Section 1 SITE SAFETY outlines some of the regulations that currently apply to
construction, as issued by the Occupational Safety and Health Administration (OSHA), as
well as other guidelines for safe procedures to be followed.
3.0 Change Recommendations
Recommended changes to this manual or any other Pratt and Whitney Power Systems
manual may be submitted by anyone using a copy of the PWPS Manual Change
Recommendation form included at the end of this chapter. The completed form can be
submitted via email, standard ground mail or facsimile transmission. If submitting the
form via email, please transmit the completed form to: cowanm@pweh.com
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If submitting the completed form via standard mail, please address to:
Pratt and Whitney Power Systems
80 Lamberton Road
Windsor, CT 06095
Attn: Customer Technical Services
Publications Supervisor
If submitting the manual change recommendation via facsimile transmission please
forward to: (860) 565-8500. Address the facsimile cover sheet to the attention of the
Publications Supervisor, PWPS Customer Technical Services.
4.0 Change Symbols
The FT8 Construction manual is subject to amplification and revision as additional
information becomes available. Revised text is indicated by a black vertical line in either
margin of the page, adjacent to the affected text, like the one printed next to this
paragraph. The change symbol identifies the addition of either new information, a
changed procedure, the correction of an error, or a rephrasing of the previous material.
5.0 Warnings, Cautions and Notes
The following definitions apply to WARNINGS, CAUTIONS and NOTES found
throughout this manual.
WARNING
A procedure, practice or condition, etc. which may result in
injury or death if not carefully observed or followed.
CAUTION
A procedure, practice, or condition, etc. which may result in
damage to equipment if not carefully observed or followed.
NOTE
A procedure or condition, etc. which is essential to
emphasize or expand upon.

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6.0 Use of Tools and Instrumentation On PWPS Equipment

All subcontractor tools and/or instrumentation used for the installation and maintenance
of PWPS equipment shall be calibrated and/or certified in accordance with the specific
tool or instrument manufacturers recommended calibration cycle.
All subcontractor tools and/or instrumentation shall be used or operated in accordance
with the specific tool or instrument manufacturers recommended operating procedures

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PWPS MANUAL CHANGE RECOMMENDATION FORM

Date:
From:
To: Technical Publications Supervisor

Company:
PWPS Customer Technical Support
80 Lamberton Road
Windsor, CT 06095

Complete Name of Manual:

Revision Number and Date:
Chapter:
Page:
Paragraph:
Recommendation (Be Specific)

Justification (Be Specific):

Signature:

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FT8 CONSTRUCTION MANUAL TABLE OF CONTENTS

SECTION 1 - SITE SAFETY
Paragraph

Title

Page

1.1

Introduction

1-1

1.2

Purpose and Scope

1-1

1.3

General Requirements

1-1

1.4

Electrical Safety

1-3

1.5

Construction Safety

1-10

1.6

OSHA and the Site Supervisor

1-24

1.7

First Aid

1-35

1.8

Construction Rigging Equipment

1-35

1-1

Strength of Plank

1-36

1-2

Safe Loads On Timber Used as Beams

1-36

1-3

Safe Loads On Timber Columns, Posts Or Braces

1-37

1-4

Strength of Wire Rope

1-38

1-5

Strength of Wire Rope Connections

1-39

1-6

Wire Rope Clips

1-40

1-7

Bridling of Spreaders

1-41

1-8

Strength of Manila Rope Blocks

1-42

1-9

Strength of Standard Hooks

1-43

Tables

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1-10

Strength of Turnbuckles

1-43

1-11

Strength of Chains

1-44

1-12

Safe Hitches and Knots

1-44

1-13

Strength of Shackles

1-45

1-14

Crane or Swinging Boom Hand Signals

1-46

1-1

Accident Procedures

1-34

1-2

Tagging Log Format

1-47

Charts

SECTION 2 - SITE PREPARATION

Paragraph

Title

Page

2.1

Site Layout

2-1

2.2

Excavations

2-1

2.3

Fill and Backfill

2-2

2.4

Compaction and Tests

2-2

2.5

Piles

2-3

2.6

Foundation Forming

2-5

2.7

Embedded Hardware

2-5

SECTION 3 CONCRETE
Paragraph

Title

Page

3.1

Introduction

3-1

3.2

Composition of Concrete

3-1

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3.2.1

Cement

3-2

3.2.1.1

Types of Cement

3-2

3.2.2

Aggregates

3-4

3.2.3

Water

3-4

3.3

Job Site Hints for Concrete Construction

3-6

3.4

Curing Materials and Methods

3-11

3.5

Weather Conditions

3-12

3.6

Hot Weather Curing

3-13

3.7

Cold Weather Curing

3-13

SECTION 4 - RECEIVING EQUIPMENT

Paragraph

Title

Page

4.1

Introduction

4-1

4.2

Sources of Information

4-1

4.3

Equipment Schedule Chart

4-2

4.4

Equipment Arrivals

4-2

4.5

Damage and Short Equipment Delivery Procedures

4-2

4.6

Freight Collect

4.7

Handling Paperwork

4-3

4.8

Storage of Equipment

4-3

4.9

Material Issue

4-4

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Figure
4-1

Flow Diagram for Receiving FT8 Equipment at Site

4-5

SECTION 5 - INSTALLING EQUIPMENT

Paragraph

Title

Page

5.1

Introduction

5-1

5.2

PWPS Drawings and Numbering Systems

5-1

5.3

Vendor-designed Equipment

5-14

5.4

Instructions for Installing FT8 Systems

5-14

5.5

Installation of Electric Generator

5-15

5.6

Installation of Gas Turbine Base Assembly

5-20

5.7

Gas Turbine to Generator Alignment

5-20

5.8

Installation of Liquid Fuel System

5-23

5.9

Installation of Oil-Filled Transformers

5-29

5.10

Installation of Gas Compressors

5-31

5.11

Installation of Other FT8 Systems (Table 5-2)

5-32

5.12

Exploded Power Pac Drawing

5-40

5.13

Exploded Twin Pac Drawing

5-41

5-1

Drawing Tree Numbering System

5-4

5-2

Special Instructions for Installing FT8 Systems

5-34

Tables

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SECTION 6 - SUPPLEMENTAL ELECTRICAL

Paragraph

Title

Page

6.1

Scope

6-1

6.2

Inventory

6-1

6.3

Tools

6-1

6.4

Standard Practices

6-1

6.5

Prepping Before Final Placement

6-2

6.6

Wire Stripping & Wire Preparation

6-2

6.7

Grounding, General Requirements

6-2

6.8

Motor Wiring, AC & DC

6-3

6.9

Control House

6-4

6.10

High Voltage Cable & Equipment

6-5

6.11

Testing

6-5

Table
6-1

Battery Report

6-6

SECTION 7 - SUPPLEMENTAL MECHANICAL

Paragraph

Title

Page

7.1

Flushing and Leak Check

7-1

7.2

Blowdown and Leak Check

7-6

7-1

7-11

Tables

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Abbreviation Used in P&I Diagrams

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7-2

Valve Symbols

7-3

Symbols Used in P&I Diagrams

7-12

7-1

Initial Field Flushing Path for Liquid Fuel Systems

7-15

7-2

Final Field Flushing Path for Liquid Fuel Systems

7-16

7-3

Flushing Path for Gas Turbine Lube Oil System

7-17

7-4

Flushing Path for Injection Water System

7-18

7-5

Flushing Path for Water Wash

7-19

7-6

Flushing Path for Hydraulic System

7-20

7-7

Blowdown Path for Gaseous Fuel Supply System

7-21

7-8

Blowdown Path for Starter Air System

7-22

7-9

Blowdown Path for CO2 Fire Protection System

7-23

7-10

Blowdown Paths for Halon Fire Protection System

7-24

Figures

SECTION 8 - SPECIFIC FT8 INSTALLATION SEQUENCE

Paragraph

Title

Page

8.1

Introduction

8-1

8.2

Sequence (abbreviated)

8-1

8.3

Procedures

8-2

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SECTION 9 - FT8 CHECKOUT, STARTUP AND COMMISSIONING

Paragraph

Title

Page

9.1

Introduction

9-1

9.2

Checkout Tools and Equipment

9-1

9.3

Checkout

9-3

9.4

Startup

9-4

9.5

Commissioning

9-5

9.6

Sequence

9-5

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APPENDIX A - SELECTED SPECIFICATIONS

(For Reference Purposes Only)
Specification

Title

TPM-AR-1

Gas Turbine Injection Water Requirements (Rev. C)

TPM-AR-2

Potable Water Quality Specifications (Rev. A)

FR-1

GAS Turbine Liquid Distillate Fuel Requirements (Rev. C)

FR-2

Gas Turbine Natural Gas Fuel Requirements (Rev. D)

TPM124

Assembly Torque Limits (Rev. B)

TPM126

Identification Components and Assemblies (Rev. C)

TPM129

Coating System For Steel Surfaces (Rev. A)

TPM130

Grounding, General Requirements and Practices (Rev. 0)

TPM132

Wiring General Requirements and Practices (Rev. 0)

TPM139

Wiring, Field Termination, Standard Practice (Rev. 0)

APPENDIX B - EQUIPMENT WEIGHT AND DIMENSIONS

(For Reference Purposes Only)
Section

Title

Power Pac Weights and Dimensions

Twin Pac Weight and Dimensions

Optional Equipment Weight and Dimensions.

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1.0 SITE SAFETY

1.1 Introduction
It would be impossible to write a set of rules or guidelines for safe working practices that
would eliminate the necessity, as well as the responsibility, of a person to think. Safety
should, therefore, be the constant concern of each individual, requiring proper attitude,
knowledge of equipment, awareness of potential hazards, and the thoughtful application
of common sense and a few common sense rules.
1.2 Purpose and Scope
1. The purpose of this section is to bring to the attention of all construction site
personnel some of the rules that apply to construction.
2. The scope of this section is confined to safety requirements as related to the
construction, checkout, and initial operation of PWPS gas turbine electrical
generating installations.
1.3 General Requirements
1.3.1 Authority
The Occupational Safety and Health Administration (OSHA) of the U. S. Department of
Labor issue the regulations cited herein. They are contained in OSHA Regulations,
Standards 29 CFR (Code of Federal Regulations), primarily in PART 1926 - Safety and
Health Regulations for Construction, to promulgate the provisions of the WilliamsSteiger Occupational Safety and Health Act of 1970. Selected excerpts of these
regulations are provided in this chapter, as they apply to PWPSs construction procedures.
The complete requirements, as found in the OSHA Regulations, Standards 29 CFR,
shall be the controlling document.
Other rules given without citing an authority were developed through years of PWPS
experience in constructing previous models of gas turbine power plants.
1.3.2 Responsibility
OSHA Regulations, Standards 29 CFR, Part 1926, Subpart B, Section 1926.16 - Rules
for Construction, states that the overall responsibility for compliance with OSHA
requirements ultimately rests with the prime contractor.
With respect to the
subcontracted work, the prime contractor and any subcontractors have joint responsibility,
with the subcontractor assuming responsibility with respect to his portion of the work.

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The Prime Contractor and the PWPS Site Supervisor shall have the responsibility to
ensure that all work is performed in accordance with the safety and health regulations.
All visitors must check in with the Site Supervisor or his designate before entering the
site. The Site Supervisor should know who is on the site, and be able to caution visitors
about possible dangers.
1.3.3 Site Trailer
The Prime Contractor trailer and PWPS office trailer shall be placed as close to the
installation as practical. The trailer should be kept clean; shelves shall not be overloaded;
materials and drawings shall be stored or stacked neatly and all doorways and traffic areas
must be kept clear for safe movement and accessibility.
1.3.4 First Aid Kits
An OSHA-approved emergency first aid kit and emergency first aid instructions shall be
placed within the trailers so that they shall be easily accessible when required. The
contents of the first aid kit shall be checked at least weekly to ensure that the expended
items are replaced.
Refer to OSHA Regulations, Standards 29 CFR, Part 1926, Subpart D, Section 1926.50
Medical Services and First Aid.
1.3.5

Medical Attention

Provisions shall be made for prompt medical attention or prompt transportation of an

injured person to a doctor or hospital. The telephone numbers of the doctor, police,
hospital, and ambulance service shall be conspicuously posted.
Refer to OSHA Regulations, Standards 29 CFR, Part 1926, Subpart D, Section 1926.50
Medical Services and First Aid.
1.3.6

Hazard Communication

In recent years OSHA has placed increased emphasis on the reduction of chemical source
illness and injuries. OSHA has issued rules for a Hazard Communication Program to
increase employer and employee awareness of chemical hazards. This program ensures
that all employers receive the information they need to inform and train their employees
properly and to design and put in place employee protection programs. It also provides
necessary hazard information to employees, so they can participate in and support the
protective measures in place at their workplace.

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Paragraph 1.5.22 of this chapter outlines the requirements of the OSHA Hazard
Communication Standard, and provides the information on which steps must be taken to
comply with this Standard.
Refer to OSHA Regulations, Standards 29 CFR, Part 1910, Subpart Z, Section
1910.1200 Hazard Communication.
1.3.7

Safety Equipment

Nonmetal hard hats for site personnel and visitors shall be kept on hand and used in all
site construction areas. Ear protectors, safety glasses, welding goggles, face shields,
aprons, and rubber gloves shall be available as required under the regulations.
The trailer and areas where fire hazards exist shall be equipped with at least one fire
extinguisher of the type required for Class A, B, and C fires.
Refer to OSHA Regulations, Standards 29 CFR, Part 1910, Subpart I, Sections
1910.133 Eye and Face Protection, 1910.135 Head Protection and 1910.138 Hand
Protection
1.3.8 State Operated OSHA Programs
Under the provisions of Section 18 of the William-Steiger Act, several States operate
their own OSHA programs, as further explained in paragraph 1.6.1 of this chapter.
However, Section 18 (c) of the William-Steiger Act requires that individual state
standards and the enforcement of such standards must be at least as effective in providing
safe and healthful employment and places of employment as the Federal standards
promulgated by OSHA under the William-Steiger Act.
Therefore, the rules cited herein are to be considered the minimum standards. Further
state requirements that amend or supersede the Federal standards may be in force.
1.4

Electrical Safety

1.4.1 Theory of Electrical Shock

In the simplest form of electrical shock, the human body becomes the resistance, and with
a constant voltage supply, the amount of current flowing through the body is dependent
upon body resistance.
Because of a highly developed nervous system, humans are very sensitive to small
electric currents. Currents almost too small to measure can produce severe pain when
they flow into an open wound.

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Electrical current diffuses through the body from one contact area, usually on a hand, to
another area at a different voltage potential, such as a hand on another conductor or feet
on a wet floor with high voltage. Contact locations may exhibit burns due to the
resistance of the skin to the passage of electric current when the electrical energy is
converted into heat. If contact areas are large, such as that provided by water or good
grounding, no marks or burns may be evident.
Body organs must be in the path of the electric current if they are to experience harmful
effects. Once the skin is penetrated, the human body offers little resistance to current
flow. The path taken by the current flow determines an individuals ability to survive.
Paths through the heart or brain system may cause death from ventricular fibrillation
current passing through the heart and interrupting its proper rhythmic beat, or from
respiratory failure. Applying cardiopulmonary resuscitation (CPR) techniques may be the
only means to prevent death in such cases.
It is important to note that brief contact with a 1000 volt source with dry hands may be
less dangerous that contact with 120 volts when wet or grounded.
Investigations have demonstrated that muscular contractions increase with an increasing
current. A let-go current is defined as that which an individual can tolerate and still be
able to release his or her grip on the electrified object. If the current exceeds this value,
the victim is frozen onto the conductor.
Techniques used in the prevention of electrical shock accidents are usually limited to
isolation, insulation, and grounding.
Isolation refers to the placing of high voltage lines or equipment so as to be out of reach
of, or have adequate clearance to, workers and their equipment.
Insulation is a term which is largely self-explanatory. It is important to note however,
that the condition of the insulation determines its ability to protect against electrical
shock. Moreover, hard usage, age, and exposure can render a conductor unsafe, so that
the permanent covering or insulation on a wire or other electrical conductors should not
necessarily be considered as protection against electrical shock.
Grounding an electrical system or device is accomplished by connecting the non-current
carrying metal portion to earth ground with a conductor. Its purpose is to carry leakage
current to ground in the event of failure of the insulation. If ungrounded metal parts of a
device come into contact with the body and such leakage or fault current exists, the
body becomes the conductor to ground, resulting in possible shock, severe burning, or
death.
From an understanding of the factors involved in the use and application of electrical
energy, safe practices can be developed to prevent or minimize electrical shock accidents.
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1.4.2 General Guidelines for Safe Practices

In addition to being particularly cautious when working on or around electrical
equipment, the following general guidelines should be observed.
1. Only one hand should be used, whenever possible, when working on electrical
circuits or devices, and when it is necessary to touch electrical equipment, for
example to check for overheating, the back of the hand should be used. This
is to avoid freezing onto the conductor in the event of accidental shock.
2. Electrical equipment should never be handled when hands, feet, or body are
wet or perspiring, or when standing on a wet floor. All floors should be
regarded as conductive unless covered with suitable dry rubber matting.
3. Metal rings or watchbands should never be worn, and metallic rulers or
pencils should not be used when working on electrical equipment or circuits.
4. The use or storage of highly flammable or toxic liquids should be avoided in
the vicinity of electrical equipment. Care should be exercised when selecting
cleaning solvents. Benzene or carbon tetrachloride are toxic and should not be
used; a freon base material is suggested.
5. High voltage areas should be indicated with easily visible signs, stating the
approximate voltage.
6. When removing fuses, the breaker operating switch should be opened to
remove the load, and an insulated fuse puller, where applicable, should be
used. If the fuse is not protected by a switch, then supply end should be pulled
out first, and put in last when installed. Fuses should be replaced by the same
type and size.
7. Electrical contacts or conductors should be enclosed or insulated to preclude
accidental contact. Extreme care should be exercised when any part of the
body in inside a cubicle or panel to avoid accidental contact with the energized
wires, terminal strips or equipment.
8. All electrical equipment or devices should be treated as though they are
energized.
9. Circuits or equipment should never be energized until all persons are clear and
are aware it is going to be energized.
10. Work on electrical devices should be done with the power off whenever
possible, and lockout and tagging procedures observed to ensure that it stays
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off. Devices to be worked on should be checked with appropriate meters to

assure that the power is off. Work on live equipment or devices should be
conducted by those fully knowledgeable, and a second person should always
be present, preferably someone familiar with CPR and first aid procedures.
11. When working on electrical equipment, only tools having insulated handles
should be used. Plastic handle screw-holding screwdrivers, plastic case
flashlights, and drop lights with plastic shades and cages are recommended.
12. High voltage equipment or circuits containing capacitors are to be grounded,
the ground connection being maintained long enough to bleed off any residual
charge.
13. Circuits shall be subject to lockout and tagging procedures as given in
paragraph 1.5.14. The tag shall be attached to the operating switch and shall
be signed by the individual responsible for establishing the circuit condition.
No one under any circumstances shall be allowed to operate a tagged device
until such tag is removed by the responsible person or his designate.
It is important to note that, although the above procedures apply primarily to activities
related to electrical equipment, the term equipment is not necessarily limited to
electrical components. For example, a motor driven fuel pump is considered and integral
part of an electrical system. The electrical condition of that system must not be changed
without consideration of the related mechanical effect, and vice versa.
1.4.3

High Voltage (600 volts and Above)

In most cases high voltage equipment is more carefully guarded than low voltage
equipment due to the greater hazard. Some exceptions, such as the exposed high voltage
bus on switchyard equipment, require greater precautions. For example, safety barriers
may be required with exposed overhead bus leads. Also, construction activity near
switchyards, substations, or overhead power lines should not be allowed unless adequate
safety precautions have been taken.
Rubber gloves should be worn as a supplementary safety measure, never as a substitute
for safety devices or procedures. For an on-the-job test the cuffs on double-walled
electricians gloves should be rolled down toward the hand to trap and forced air into the
palms and fingers. They should not be used if they are wet or not in good condition.
Gloves should be worn, and personnel should be kept clear during the test.
1.4.4

Main Breaker (52G)

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hexaflouride (SF6) bottle for 13.8 kV (10.5 kV) and higher voltage applications. Rules as
given below must be observed for safe operation and maintenance of this equipment.
If air circuit breakers are to be used, such as in re-powering applications using FT8
engines to replace older engine models, personnel must observe additional safeguards for
air circuit breakers as also indicated below.
Vacuum and sulfur-hexaflouride bottle breakers are operated by high energy, high speed
mechanisms, interlocked to provide safe operating sequences. To ensure the safety of
personnel, the following rules must be observed:
1. Only qualified personnel trained in the installation, operation, and
maintenance of power circuit breakers should be allowed to work on these
breakers.
2. Do not work on an energized breaker.
3. Consult the manufacturers service instructions before any adjustment,
servicing, parts replacement, or other acts requiring physical contact with the
electrical working components or wiring of the breaker.
4. Do not work on a closed breaker.
5. Do not work on a breaker with closing springs charged.
6. Do not attempt to close the breaker by hand on a live circuit.
7. When working on equipment on the generator side of the electrical system, do
not use an open circuit breaker by itself as the sole means of isolating a high
voltage circuit. For complete isolation the circuit should be in the disconnect
position, or should be withdrawn completely.
8. For the safety of personnel performing maintenance operations on the breaker
or connected equipment, all components should be disconnected by means of
a visible break and securely grounded.
9. The circuit breaker must be either fully open or fully closed when making high
potential tests. Do not test with contact partially open.
10. During high voltage testing the operator must safeguard against X-radiation,
as explained below. Breakers must not be subject to direct current (DC) highpotential tests.

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11. The circuit breaker will display warning and caution labels. Whenever the
circuit breaker is handled or maintained, these warnings and cautions must be
followed.
When voltage is applied across the contacts of a vacuum breaker, there is the possibility
of generating X-rays. The radiation levels at normal operating voltage are negligible. At
the voltages specified for testing, it is recommended that the test operator observe
additional precautions of distance and shielding, as given in the vendors maintenance
manual.
WARNING
The breaker must not be subjected to the high voltage DC
tests since dangerous radiation may be produced.
When received and during installation, the breaker should be handled as instructed in the
vendors service manual. If it is not possible to put the breaker into service immediately,
it should be carefully protected against condensation and other forms of water. It should
be stored in a clean location, free from corrosive gases or fumes. Particular care should
be taken to protect the equipment from moisture and cement dust, as this combination has
a very corrosive effect on many parts.
In addition to the above general precautions that are also applicable to air circuit breakers,
handling main air circuit breakers requires additional care in moving because of their
size. Main breakers must never be lifted with a cable or strap in the form of a single
noose, nor should they be rolled down an incline without some means of preventing
tipping. Large breakers tend to be top heavy, and subject to rolling out of a single sling or
tipping over, endangering the equipment and personnel.
During inspection, especially if the arc chutes are lifted, personnel should stay clear of
moving parts. The arc chutes of an air circuit breaker can weigh up to approximately 400
pounds each.
Putting a wet air circuit breaker into operation could result in dangerous arcing, fire or
even explosive destruction. It is therefore very important that it be protected against
moisture and condensation during storage and handling
Before preliminary operation of the unit, the breaker should be tagged out in the test or
disconnect position and never racked in until ready to make power, except for possible
alignment checks of the primary disconnect.

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1.4.5 Motors
Before any work is performed on motors, such as coupling alignment, the operating
switch or breaker should be opened and tagged.
Motor winding should be protected against exposure to oil or water to guard against
shorting, grounding, and possible fire.
The location of the motor is important. For example, fuel forwarding equipment is not
mounted inside fuel tank dikes, as it would be a fire hazard in the event of a tank rupture.
Drive couplings should always be protected with a suitable guard.
1.4.6 Space Heaters
The generator space heaters, and exciter and switchgear cubicle strip heaters are normally
energized in the early phases of erection. The power supply is 480 VAC, with 240 VAC
across each heater. Construction personnel should be informed of the potential hazard,
since much activity is carried on in close proximity to the energized heaters, especially
those in the switchgear cubicles and the exciter housing.
During the replacement of generator shipping bearings (if used) with running bearings,
the power to the exciter heaters and any ground fault relay circuit should be de-energized.
Switchgear cubicles should be kept free from combustible material and tools to avoid a
fire or shock hazard.
Steps should be taken to keep debris from accumulating around or inside the generator,
especially during the period when the generator exhaust and lead compartment openings
are uncovered. The surface temperature of the generator space heaters or strip heaters is
high enough to ignite combustible material or burn the skin.
1.4.7

Direct Burial Cables

Equipment in the various enclosures and on the ancillary skids generally will be
connected to the control house via direct burial cables with terminal connections at both
ends. Connections at the load end will normally be at the driven equipment. Cables will
enter the control house through multi-cable transits in the floor under the two master
terminal board (MTB) cabinets. One is located on the control side of the control house
for the control wiring, and another one is located on the motor control center (MCC) side
for the power wiring. All connections will be made using terminal strips on the MTBs
for ease of assembly and checkout, except where connected directly to the motor starters
for some of the larger motors.

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Before removing any terminals, the applicable circuits must be de-energized and tagged
out. Also, it must be remembered that equipment must be inactive before tagging out.
For example, some equipment, such as the generator lube oil pumps, must remain
energized during coastdown.
1.4.8 Igniter Plugs
The gas turbine uses a 28 VDC ignition system, which produces a very high voltage
across an igniter plug gap. This results in a trigger spark. During functional checkout of
the ignition system, the igniter plugs should be removed from the engines, unless it can be
determined that no residual combustible mixtures could exist, such as before the fuel
lines have been connected. Personnel should be kept clear and all inflammables should
be removed from the area during testing. This is because the igniter plugs have a much
higher energy level than an automotive spark plug.
The igniter or exciter boxes must not be touched when the ignition is on or for a short
duration thereafter, because of the hazards of high voltages and high temperatures.
1.4.9

Current Transformers

No work should be performed on current transformers unless the primary is de-energized,

and steps taken to insure that it will stay de-energized. The main function of these
transformers is to step-down the primary (bus) current for measuring and protecting
instrumentation circuits. Current transformer output circuits should always be shorted out
with a jumper or shorting bar until the instrumentation is connected, and never opened
when the primary is energized, since extremely high voltage can develop across the open
circuited secondary coil. In this event, a dangerous arcing or explosive destruction of the
coil could occur.
1.4.10 Neutral Grounding Reactors
The primary function of a neutral grounding reactor is to limit ground fault currents or
currents resulting from unbalanced loads between transmission system phases. Unlike
fixed impedance grounding transformers, the grounding reactor impedance increases with
increasing current.
1.4.11 Grounding
An electrical system or piece of equipment is considered grounded when those metal
parts, which are not intended to carry current, are connected to earth ground. The purpose
of such a connection, of course, is to carry leakage or fault current harmlessly to ground
should uninsulated metal parts become energized. However, grounding portable
equipment does not completely prevent electrical accidents, but only reduces them.

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1.5

Construction Safety

1.5.1

Personnel Protective Equipment

Nonmetal hard hats shall be worn by employees working in areas where there is a danger
of head injury from impact, or from falling or flying objects, or from electrical shock and
burns. Refer to OSHA Regulations, Standards 29 CFR, Part 1926, Subpart E, Section
1926.100 Head Protection.
Ear protective devices shall be provided and used where the noise levels or duration of
exposures exceed those shown in Table D-2 contained in OSHA Regulations, Standards
29 CFR, Part 1926, Subpart D, Section 1926.52 Occupational Noise Exposure. In
addition, refer to OSHA Regulations, Standards 29 CFR, Part 1926, Subpart E, Section
1926.101 - Hearing Protection.
Eye and face protection equipment shall be provided where machines or operations
present potential eye or face injury. Refer to OSHA Regulations, Standards 29 CFR,
Part 1926, Subpart E, Section 1926.102 Eye and Face Protection.
1.5.2

Tools - Hand and Power

All hand and power tools and similar equipment, whether furnished by the employer or
the employee, shall be maintained in safe condition. Electric power operated tools shall
be of the approved double insulation type, or grounded in accordance with the
regulations. Refer to OSHA Regulations, Standards 29 CFR, Part 1926, Subpart I,
Section 301 Hand Tools and Section 302 Power Operated Hand Tools.
1.5.3 Fire Protection
The employer shall be responsible for the development of a fire protection program to be
followed throughout all phases of construction. He shall provide for the fire fighting
equipment, as specified in the regulations. As fire hazards occur, there shall be no delay
in providing the equipment necessary.
Fire fighting equipment shall be placed at potential hazard areas. It shall be readily
accessible from any point on the site. Fire fighting equipment must be periodically
inspected and maintained in an operating condition.
An asbestos blanket or fire retardant canvas shall be used when welding or burning
operations are conducted on or near the unit or related equipment to minimize the
possibility of damaging hardware, wiring or igniting flammable materials.
Availability of hydrants or other water supplies should be noted for possible use as
backup fire protection.
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Refer to OSHA Regulations, Standards 29 CFR, Part 1926, Subpart F, Section

1926.150 Fire Protection.
1.5.4

Fire Prevention

Particular attention should be paid to ignition hazards and the storage of combustible
materials in any active fire prevention program. Refer to OSHA Regulations, Standards
29 CFR, Part 1926, Subpart F, Section 1926.151 Fire Prevention.
1.5.4.1 Ignition Hazards
Electrical wiring and equipment for light, heat or power purposes shall be installed in
compliance with the requirements of the regulations. Internal combustion engine
powered equipment shall be located so that the exhausts are well away from combustible
materials. Smoking shall be prohibited at or in the vicinity of operations, which
constitute a fire hazard, and shall be conspicuously posted No Smoking or Open Flame.
1.5.4.1.1

Storage

Combustible materials in open yard storage shall be piled with due regard to the stability
of piles and in no case higher than twenty (20) feet. The entire storage site shall be kept
free from accumulation of unnecessary combustible materials. Weeds and grass should
be kept down and a regular procedure provided for the periodic cleanup of the entire area.
All indoor storage shall not obstruct or adversely affect means of exit.
1.5.5

Flammable and Combustible Liquids

Only approved containers and portable tanks shall be used for storage and handling of
flammable and combustible liquids. Approved metal safety cans shall be used for the
handling and use of the flammable liquids in quantities greater than one gallon, except
that this shall not apply to those flammable liquid materials which are extremely hard to
pour, which may be used and handled in original shipping containers. For quantities of
one gallon or less of flammable liquids, only the original container or approved metal
safety cans shall be used for storage, use and handling. Flammable liquids shall not be
stored in areas used for exits or stairways, or normally used for safe passage of people.
Refer to OSHA Regulations, Standards 29 CFR, Part 1926, Subpart F, Section
1926.152 Flammable and Combustible Liquids .

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1.5.6 Rigging Equipment for Material Handling

Rigging equipment for material handling shall be inspected prior to use on each shift, as
necessary, during its use to ensure that it is safe. Defective rigging equipment shall be
removed from service.
Rigging equipment shall not be loaded in excess of its recommended safe working load.
Welded alloy steel chain slings shall have permanently affixed, durable identification
stating size, grade, rated capacity, and sling manufacturer.
Hooks, rings, oblong links, pear shaped links, welded or mechanical coupling links or
other attachments, when used with alloy steel chains, shall have a rated capacity at least
equal to that of the chain.
Job or shop hooks and links or makeshift fasteners, formed from bolts, rods, etc., or other
such attachments shall not be used. Rated capacity (working load limit) for alloy steel
chain, wire rope, U-bolt wire rope clips, shackles, and natural or synthetic fiber rope
slings shall conform to the values shown in tables in the regulations.
When lifting enclosures, control houses, Air Pacs or similar equipment, spreader bars and
leveling beams should always be used to ensure a vertical load on lifting eyes.
Refer to OSHA Regulations, Standards 29 CFR, Part 1926, Subpart H, Section
1926.251 Rigging Equipment for Material Handling .
1.5.7 Cranes and Derricks
The employer shall comply with the manufacturers specifications and limitations
applicable to the operation of any and all cranes and derricks. Rated load capacities and
recommended operating speeds, special hazard warnings or instructions shall be
conspicuously posted on all equipment. Instructions and warnings shall be visible to the
operator while he is at his control station.
A thorough, annual inspection of the hoisting machinery shall be made by made by a
competent person, or by a government or private agency recognized by the U.S.
Department of Labor. The employer shall maintain a record of the dates and results of
inspections for each hoisting machine and piece of equipment.
Crane pads should be supported on firm, level ground. Back filled areas must be avoided
if possible, or firmly packed in layers if they must be used for crane pad support.
OSHA Regulations, Standards 29 CFR, Part 1926, Subpart N, Section 1926.550
Cranes and Derricks, should be referred to for further precautions and requirements
concerning safe use of cranes and derricks.
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OSHA Regulations, Standards 29 CFR, Part 1926, Subpart N, Section 1926.551

Helicopters, should be referred to for the special precautions and requirements for the use
of helicopters in hoisting construction loads.
1.5.8 Welding and Metal Cutting
Arc welding is a process for joining metals by heating with an electric arc. It is the most
commonly used type of welding found at PWPS construction sites since it is used to
fabricate nearly all types of carbon or alloy steels and common non-ferrous metals.
Oxygen-acetylene is the normal process used for metal cutting.
The voltage across the welding arc varies from 15 to 40 volts, depending on the type and
size of the electrode. To strike the arc however, a somewhat higher voltage is supplied
from the welding circuit. If an electrode holder should become overheated, it should
never be dipped in water to cool.
Because of the relatively low open circuit voltages on standard welding units, the
potential hazard tends to be overlooked, but if care is not exercised, the operator can
easily become grounded. This could be particularly dangerous if the electrode or holder
is allowed to contact bare or wet skin or wet clothing. Welding cables should be kept dry
and free of grease and oil and protected from falling sparks.
Electric arcs produce ultraviolet and infrared rays, which are harmful to the eyes and skin
upon continued exposure. Permanent eye injury can result from looking directly into a
powerful arc without eye protection.
Since welding and cutting create special fire hazards, fire protection equipment should be
readily available and protection equipment, such as fire resistant blankets, used. Also,
whenever welding or cutting is done in overhead locations, a watcher is recommended to
protect personnel and to guard against fires.
Welding on full fuel or lube oil tanks should be avoided. Welding on gas lines is
permitted only if the line is completely depressurized and thoroughly purged with a dry
inert gas, such as nitrogen. Fuel tanks or lines should also be drained and thoroughly
purged or filled with water prior to welding.
A common source of burns is the hot metal of recently cut or welded material. Personnel
should be alerted to this hazard either verbally or through the use of warning signs.
When welding or cutting operations are carried on or near any equipment, steps should be
taken to avoid damaging electrical insulation, accidental discharge of the fire protection
system, dropping of slag or used welding rods into inlet plenums, etc.

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When welding near an industrial gas turbine or on or near an electric generator, the
grounding lead must be no more than 18 inches from the weld. This is to prevent any
potential of arcing through the bearings of these machines.
Welding operations are covered under OSHA Regulations, Standards 29 CFR, Part
1926, Subpart J. The following sections of Subpart J pertain:
Section 1926.350 Gas Welding and Cutting
Section 1926.351 - Arc Welding and Cutting
Section 1926.352 Fire Prevent
Section 1926.353 - Ventilation and Protection in Welding, Cutting, and Heating
1.5.9 Batteries
The sulfuric acid electrolyte solution in battery cells can burn the skin and be very
dangerous if allowed to contact the eyes. Face shield, aprons, and rubber gloves shall be
provided for workmen handling acids and batteries. Facilities for quick drenching of the
eyes and body shall be provided within twenty-five (25) feet of battery handling areas.
Facilities shall be provided for flushing and neutralizing spilled electrolyte and for fire
protection. When batteries are being charged, the vent caps shall be kept in place to
avoid electrolyte spray.
1.5.10 Accident Prevention Signs and Tags
Warning signs shall be visible at all times when work is being performed and shall be
removed or covered promptly when the hazards no longer exist.
Danger signs shall be used only when an immediate hazard exists. Caution signs shall be
used only to warn against potential hazards or to caution against unsafe practices.
Color code requirements for danger, caution, exit, safety instructions, and traffic signs are
given in OSHA Regulations, Standards 29 CFR, Part 1926, Subpart G, Section
1926.200 Accident Prevention Signs and Tags.
1.5.11 Excavations
Prior to opening an excavation, effort shall be made to determine whether underground
installations, i.e., sewer, water, fuel, electric lines, etc., will be encountered and, if so,
where such underground installations are located. Utility companies shall be contacted
and advised of proposed work prior to the start of actual excavation. Refer to OSHA
Regulations, Standards 29 CFR, Part 1926, Subpart P, Section 1926.651 Specific
Excavation Requirements.

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Daily inspections of excavations and inspections after every rainstorm shall be made by a
competent person. If evidence of possible cave-ins or slides is apparent, all work in the
excavation shall cease until the necessary precautions have been taken to safeguard
employees. Refer to OSHA Regulations, Standards 29 CFR, Part 1926, Subpart P,
Section 1926.651 Specific Excavation Requirements.
In excavations where employees shall be required to enter, excavated material shall be
effectively stored and retained at least 2 feet or more from the edge of the excavation.
Further specific requirements for excavations are given in OSHA Regulations, Standards
29 CFR, Part 1926, Subpart P, Section 1926.651 Specific Excavation Requirements.
Banks more than 5 feet high shall be shored or sloped to the angle or repose where a
danger of slides or cave-ins exists as a result of excavation. Sides of trenches in unstable
or soft material 5 feet or more in depth shall be shored, sheeted, braced, sloped, or
otherwise supported by means of sufficient strength to protect the employees working
within them. Further specific requirements for trenching are given in Refer to OSHA
Regulations, Standards 29 CFR, Part 1926, Subpart P, Section 1926.652
Requirements for Protective Systems.
Barriers shall be placed around all excavation, or at least in exposed areas adjacent to
personnel and equipment traffic.
1.5.12 Ladders and Scaffolding
Refer to OSHA Regulations, Standards 29 CFR, Part 1926, Subpart L, Section
1926.450 Scope, Application and Definitions Applicable to This Subpart and Section
1926.454 Training Requirements.
The use of ladders with broken or missing rungs or steps, broken or split side rails, or
other faulty or defective construction is prohibited. When ladders with such defects are
discovered, they shall be withdrawn immediately from service. Inspection of metal
ladders shall include checking for corrosion of interiors of open end hollow rungs.
Ladders shall not be placed in passageways, doorways, driveways, or any location where
they may be displaced by activities being conducted in any other work, unless protected
by barriers or guards. The side rails shall extend not less than 36 inches above the
landing. When this is not practical, grab rails shall be installed.
Portable ladders in use shall be tied, blocked, or otherwise secured to prevent their being
displaced. Portable metal ladders shall not be used for electrical work or where they may
contact electrical conductors. Refer to OSHA Regulations, Standards 29 CFR, Part
1910, Subpart D, Section 1910.25 Portable Wood Ladders.

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Scaffolding shall be designed, erected, and used in accordance with requirements of

OSHA Regulations, Standards 29 CFR, Part 1926, Subpart L, Section 1926.450
Scope, Application and Definitions Applicable to This Subpart.
1.5.13 Housekeeping
During the course of construction, alterations, or repairs, forms and scrap lumber with
protruding nails and all other debris shall be kept cleared from work areas, passageways
and stairs.
Combustible scrap and debris shall be removed, at regular intervals, during the course of
construction. Safe means shall be provided to facilitate such removal.
Containers shall be provided for the collection and separation of waste, trash, oily and
used rags, and other refuse. Containers used for garbage and other oily, flammable, or
hazardous wastes shall be equipped with covers and disposed of at frequent intervals.
Disposal shall be in accordance with applicable environmental protection ordinances.
Refer to OSHA Regulations, Standards 29 CFR, Part 1926, Subpart C, Section 1926.25
Housekeeping.
1.5.14 Lockout and Tagging Circuits
Refer to OSHA Regulations, Standards 29 CFR, Part 1910, Subpart J, Section 1910.147
The Control of Hazardous Energy (Lockout/Tagout).
Controls that are to be deactivated during the course of work on energized or deenergized equipment or circuits shall be tagged. Equipment or circuits that are deenergized shall be rendered inoperative and shall have tags attached at all points where
such equipment or circuits can be energized. Tags shall be placed to identify plainly the
equipment or circuits being worked on.
The following lockout and tagging system is for the protection of personnel and
equipment and shall be initiated by the PWPS Site Supervisor when the customer does
not have a tagout system in force. Only the customers Site Manager of the PWPS Site
Supervisor or their specific designates have the responsibility for lockout, tagging, and
releasing all site equipment. A list of personnel who will be allowed to initiate the
lockout and tagging of equipment shall be filed and maintained. The list shall include
phone numbers for immediate contact.
Lockout is the mechanical means for rendering equipment inoperative. Normally, this
is accomplished by a lock on the handle in the OFF position of the circuit breaker(s) or
motor starter(s) powering the equipment to be worked on.

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The PWPS Site Supervisor shall maintain a tagging log that will list the equipment
tagged, when it was tagged, reason for tagging, when it was released, and by whom.
Also, space shall be provided for the signature of the person who releases the equipment
for return to service. Each release must be co-signed by the PWPS Site Supervisor or his
designate. A suggested Tagging Log Format is provided in Chart 1 2 at the end of this
chapter.
1.5.14.1 Responsibilities of the PWPS Site Supervisor
1. Determines whether or not site equipment can be taken out of service, and
when.
2. Reviews with the supervisors in charge of the work the safest method of
lockout of the equipment to be worked on.
3. Verifies the tagging at the correct lockout points.
4. Determines that no voltage, pressure, toxic fumes, or any unsafe condition
exists as a result of lockout of the equipment.
5. Issues indexed tag(s) as required, upon request, for tagging equipment.
6. Confirms with the supervisor in charge of the work that the equipment to be
worked on has been correctly locked out.
7. Obtains release from the supervisor in charge of the work that it is complete
and that the equipment can be returned to normal service.
8. Removes the lockout tags and verifies that all equipment is in normal status.
9. Informs any and all on-site personnel, directly or through PWPS
representatives, that tag out procedures are in effect, and that only the person
tagging the equipment can clear tag(s) to release equipment.
1.5.14.2 Responsibilities of the Work Supervisor
1. Determines area or work affected and requests lockout of the equipment
through the PWPS Site Supervisor.
2. Together with PWPS Site Supervisor determines the lockout points required
to allow safe working conditions on the equipment.
3. Upon completion of the tagging verifies that all points have been correctly
locked out and the equipment is safe to work on.
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4. Informs the PWPS Site Supervisor upon completion of his work that the
equipment is available for return to normal status.
1.5.14.3 General Rules for Tagging
1. The supervisor in charge of work on the equipment requiring tags must have
the equipment tagged in his name.
2. The person named on the tag or his one-time designate is the only person who
may initiate the removal of the tag.
3. No equipment tagged with a lockout tag or tags shall be operated by anyone
until all tags have been properly released and removed. In no case shall any
equipment be restored to service until all tags have been removed as
authorized.
4. Equipment shall be tagged as follows:
A. Remotely controlled equipment - Tags shall be attached to the control
switch handles and to the device itself.
B. Manually operated equipment - Tags shall be hung on the manually
operated handle.
C. Draw out type circuit breakers - Tags shall be hung on the levering-in
device when practical, or on the cubicle door for all other cases.
D. When equipment is locked out and tagged, the control circuits of that
equipment shall be locked out and tagged also. An example would be to
remove control circuit fuses for a gas generator lube oil cooling fan.
E. Entire mechanical systems or parts of systems controlling the flow of air,
water, or oil may be tagged as unit systems with lockout tags placed at the
isolating points. Any drains, vents, relief devices, or other devices, which
could, under certain conditions, allow energy in any form to accumulate,
must be tagged open with a lockout tag.
F. When installation or construction work has progressed to the point where
electrical equipment could be energized or mechanical equipment operated
from any other source, then the PWPS Site Supervisor or the customer or
their designates shall lock open and tag all switches, control apparatus,
valves, etc., that could endanger anyone working of the equipment.

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NOTE
All equipment under the customers jurisdiction shall
follow the lockout, tagging, and release procedures as
outlined above when no customer tag out procedure is in
effect. Where a customers procedure is available and in
force, it will be followed on a mutual responsibility basis
with PWPS, so as to provide maximum safety to all
personnel working on the site. The customer shall
coordinate all tagging of equipment under the customers
jurisdiction with the PWPS Site Supervisor.
1.5.15 Gas Turbine Safety Enclosure
WARNING
No person shall enter the gas turbine or exhaust enclosures
during startup or above idle speed. Equipment failure
during normal operation may expose personnel within the
enclosure to hazards that may result in serious injury or
death.
All personnel must be at least twenty (20) feet away from
the gas turbine enclosure during start cycles. The start
cycle is defined as from when the start horn activates and
until the gas turbine, including both sides of a Twin Pac if
both gas turbines are to be started, reach gas generator idle
and/or sync idle. Suitable high visibility tape or lines on
the ground shall be used to define the twenty (20) foot
boundary lines.
The Site Supervisor shall take all necessary steps to ensure that the following procedures
are adhered to:
1. Personnel shall not enter the gas turbine or exhaust enclosures during startup or
during operation above idle speed.
2. No person shall enter the gas turbine or exhaust enclosures with the gas turbine
running until he is fully instructed with regard to the following:
A. Ear and eye protection and nonmetal hats must always be worn in the
enclosure, or when standing near an open door.

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B. The vicinity of the power turbine output shaft is to be avoided, particularly if

the coupling guards are not securely in place, such as during coupling test or if
one coupling has been removed for the Twin Pac synchronous condenser
operation.
C. Depending on how long the unit has been running and at what power levels,
not only the gas turbine, the cold air buffer systems, and various lube oil lines,
but also certain areas of the enclosure walls themselves are hot enough to burn
exposed skin. Care should be exercised when moving about within the
enclosure.
D. Special care must be taken in handling the personnel doors because of the
positive pressure in the enclosure, caused by the secondary air fans.
NOTE
Doors will be forced outward when unlatched while the
secondary fans are operating.
Based on previous experience with positive pressure engine enclosures, the
door will be pushed out only about 1 inch before air escaping by the door
drops the force on the door to a negligible amount. This should pose no threat
to the person opening the door, but he should be prepared for door movement
and escaping air.
E. In the event of some occurrence requiring personnel to leave the enclosure,
such as activation of the fire protection system, leave the enclosure carefully do not jump and run.
F. Before entering the enclosure, attention should be given to such hazards as
open buttons, shoelaces, loose clothing, and exposed skin areas.
G. If one side of a Twin Pac is operating after the start cycle is completed, it is
acceptable to be in the opposite sides enclosure if the gas turbine is
windmilling or de-coupled.
H. It is acceptable to enter the gas turbine enclosure when the gas generator is
rotated on the starter only, start cycle not initiated, or during coast down, after
the gas turbine has been shutdown (fuel shutoff).
3. No person shall enter the turbine enclosure when the unit is running until he has
received permission to do so from the person in charge of operating the unit at the
time. In this event, a second person, to remain outside of the enclosure but within

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site of the person entering the enclosure, must be ready to lend assistance if
needed.
4. For personnel safety reasons, as well as to minimize the risk of equipment
damage, whenever possible, all adjustments, such as tightening leaking fittings,
jacking mounts, etc., shall be accomplished with the unit shut down.
5. Good judgment demands that as many other factors as possible be considered in
addition to those mentioned above before permitting anyone to enter the enclosure
with the equipment running. These factors range from the nature of the
equipment distress to such considerations as that the additional heat and noise in
the enclosures on hot summer days may exceed some individuals tolerance
levels.
6. The customers operating personnel should receive training and instruction in the
above.
1.5.16 Generator Enclosure Safety
The following items must be kept in mind when in the generator enclosure when the unit
is spinning, particularly under load:
1. When making adjustments to the lubrication oil system, be careful of hot metal
surfaces, and keep hands, tools, and clothing clear of the cooler fan and pump
couplings.
2. The exciter area should be avoided or precautions, such as eye and head
protection, used when the cover is removed for any reason, such as inspecting the
exciter fuses with a stroboscope. If a thermometer is used to take temperature
measurements at the exciter, care should be exercised to avoid rotating parts.
3. Care should be exercised when checking exciter fuses with a strobe light to avoid
dropping objects from pockets into rotating parts or getting hands or loose
clothing near them.
1.5.17 Pressurized Air, Gas, or Liquid System Safety
Before opening any valves or disconnecting piping in pressurized air, gas, or liquid
systems, and especially before removing pipe caps or plugs, ensure that they system has
been depressurized. A high velocity stream of air or flying particles could cause serious
eye injury. In addition, high pressure hoses or tubing, under pressure, can be extremely
hazardous due to the whipping action, which results when disconnected.

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Relief valves must be checked for proper setting and functionally checked prior to initial
operation.
Purging and leak checking of liquid and gas systems use high pressure air and liquids.
Particular caution should be exercised during these operations to avoid the above dangers.
During hydrostatic testing the system has not yet been proven to withstand either the
operating pressures or the over pressures used in testing.
1.5.18 Gaseous Fuel Compressor Safety
The danger of explosion is an additional and serious safety hazard associated with the
operation of gaseous fuel compressors. This hazard exists during pressure checking and
initial startup or gassing in as well as during normal operation. The following
precautions should be observed:
1. No smoking or open flame is allowed in the gas compressor area. Signs should be
displayed to this effect.
2. Prior to initial charging of the unit with natural gas, all air must be purged from
the system.
3. All vent and seal drain lines must be routed to a point well above ground level,
and have flame arresters installed.
4. Buildings used to house gaseous fuel compressors must be well ventilated and
have combustible gas detector units installed.
5. Relief valves should be set no higher than the maximum allowable working
pressure and functionally tested if possible. When compressors are housed in
buildings, relief valves and vent lines should be routed out of the building and
above roof level.
1.5.19 Air Compressor Safety
Before any work is performed on the Air Pac or related systems, the unit should be locked
out to protect against inadvertent starting, since the rotating compressor components
could cause injury. It is also well to remember the dangers associated with high pressure
systems, and that a high pressure stream of air, from a leak for example, can be
hazardous. Leak checking should always be done with caution.
1.5.20 Fuel System Safety
Field installed fuel piping, whether gas or liquid, must be properly pressure checked,
usually to one and one-half times the working pressure.
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Liquid fuel storage tanks must be surrounded by a dike capable of containing an amount
of fuel equal to the tank capacity. Forwarding equipment should be installed outside of
the dike area.
Liquid fuels, such as those used by gas turbines, are irritating to the skin and eyes; care
should be exercised during flushing, fueling, or filter changing operations.
1.5.21 Fire Protection Systems
The area must be cleared of all personnel prior to any functional test of a fire protection
system, and all site personnel must be informed that such a test is imminent. This
includes areas outside of the fire protection zone, such as on enclosure roofs, and
especially near fire damper doors. After the test is concluded, the fire zone shall be well
ventilated prior to entry.
1.5.21.1 Halon 1301
Halon 1301 fire protection systems use a colorless, odorless, non-conductive gas
(Bromotrifluoro-methane - CBrF3) with an exceptionally low toxicity. Exposure to this
agent in enclosed areas is, therefore, relatively safe. However, if a storage container
should discharge close to personnel, serious injury could result from the high pressure,
high velocity gas stream.
Environmental or operating conditions, which may short or ground the fire protection
systems logic components can result in malfunction or actual discharge of the system.
Therefore, when checking or servicing the components, the system should always be
disarmed.
All types of storage cylinders should have safety caps in place when handling or storing
to protect the cylinder valve. If the cylinder valve is damaged or broken off and safety
caps are not in place, the thrust from the escaping gas in capable of propelling the
cylinder and endangering personnel.
1.5.21.2 Carbon Dioxide
Carbon dioxide extinguishes a fire by diluting the amount of available oxygen. The
hazard to personnel is obvious, since the amount of available oxygen may be quickly
reduced to a level below that required to sustain life if the system is discharged.
When checking or servicing the system, or when work requiring extended periods of time
is done in fire protection zones, the system must be disarmed.
1.5.22 Hazard Communication
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Refer to OSHA Regulations, Standards 29 CFR, Part 1926, Subpart C, Section 1926.59
Hazard Communications.
1.5.22.1 Hazard Communication Standard
Refer to OSHA Regulations, Standards 29 CFR, Part 1910, Subpart Z, Section
1910.1200 Hazard Communication.
The OSHA Hazard Communication Standard was adopted August 24, 1987 to ensure that
the hazards of all chemicals produced or imported are evaluated, and that information
concerning their hazards is transmitted to employers and employees. The standard
requires employers to develop and maintain a written hazard communication program for
the workplace, and conform to other Hazard Communication requirements as listed in
paragraph 1.5.22.2.
An employer is defined by OSHA, in OSHA Regulations, Standards 29 CFR, Part
1926, Subpart D, Section 1926.59 Hazard Communication as a company engaged in a
business where chemicals are either used, distributed, or are produced for use or
distribution, including a contractor or subcontractor.
An employee is defined as a worker who may be exposed to hazardous chemicals
under normal operating conditions or in foreseeable emergencies. Workers such as office
workers or bank tellers who encounter hazardous chemicals only in non-routine, isolated
instances are not covered.
A list of toxic and hazardous air contaminants and the limits of employee exposure to
these substances are provided in OSHA Regulations, Standards 29 CFR, Part 1910,
Subpart Z, Section 1910.1000 Air Contaminants, Table Z1. The limits of exposure,
precautions, and requirements of communication of hazards to employees for asbestos,
tremolite, anthophyllite, and actinolite are given in OSHA Regulations, Standards 29
CFR, Part 1926, Subpart D for the construction industry.
The Standard requires that chemical manufacturers and importers must convey the hazard
information they learn from their evaluations to downstream employers by means of
labels on containers and Material Safety Data Sheets (MSDSs). The information to be
contained in these data sheets in described in OSHA Regulations, Standards 29 CFR,
Part 1926, Subpart D, Section 1926.59 Hazard Communication, paragraph (g). A copy
of these data sheets must be kept in a file on the construction site.

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1.5.22.2 How to Comply with the Standard

OSHA provides a guide, OSHA 3104, 1988, Hazard Communications - A Compliance
Kit, to assist employers who use hazardous chemicals to comply with the Hazard
Communication Standard. The kit contains background information and specific aids,
such as a sample Hazard Communication Program forms to list hazardous chemicals, and
sample letters to request a Material Safety Data Sheet (MSDS) or additional MSDS
information from the manufacturer.
As given in OSHA 3104, compliance with the Standard requires the employer to:
1. Develop a written hazard communication program.
2. List all of the hazardous chemicals used.
3. Establish a file for information on hazardous chemicals.
4. Obtain an MSDS for each hazardous chemical is use.
5. Develop a system to ensure that all incoming hazardous chemicals are labeled
with their identity and the appropriate hazard warnings.
6. Review each MSDS to be sure it is complete.
7. Make sure that MSDSs are available where necessary.
8. Develop a method to communicate hazards to employees and others.
9. Inform employees of protective measures for hazardous chemicals used.
10. Alert employees to other forms of warning that may be used.
The Hazard Communication Compliance Kit, OSHA 3104, also contains a list of the
Regional Coordinators for the Hazard Communication Standard, and a directory of
OSHAs Regional and Area Offices. These offices may be contacted for further
information on the Standard.
1.6 OSHA and the Site Supervisor
1.6.1 History of OSHA
In 1968 there were 240,000 disabling accidents, which included 2,800 deaths, in the
construction industry. This record was the greatest number in any single industry and
second only to mining on a per capita basis.

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Broad based lobbying led to the enactment of the Williams-Steiger Occupational Safety
and Health Act on December 29, 1970. This law applies to all industries affecting
commerce, including the construction industry. The law became effective on April 28,
1971.
Section 5 of the Act establishes that each employer:1
1. Shall furnish to each of his employees employment and a place of employment
that are free from recognized hazards that are causing or are likely to cause death
or serious physical harm to his employees.
2. Shall comply with occupational safety and health standards promulgated under
this act.
Each employee shall comply with occupational safety and health standards and all rules,
regulations, and orders issued pursuant to this Act that are applicable to his own actions
and conduct.
The regulations promulgated from this Act for the construction industry were first
published in April 17, 1971 Federal Register, Volume 36, Number 75, Part II. They were
originally called Part 1518, but were reissued for OSHA as Code of Federal Regulations,
Title 29, Part 1926 on December 30, 1971.
To interpret Section 5 of the Act, Part 1926 requires as a condition of each contract for
construction, alteration, and/or repair, including painting and redecorating, that no
contractor or subcontractor contracting for any part of the contract work shall require any
laborer or mechanic employed in the performance of the contract to work in surroundings
or under working conditions which are unsanitary, hazardous, or dangerous to his health
or safety, as determined under construction safety and health standards promulgated by
the regulations. Refer to OSHA Regulations, Standards 29 CFR, Part 1926, Subpart C,
Section 1926.20 General Safety and Health Provisions.
Section 18 (b) of the Act provides that any State which desires to assume responsibility
for the development and enforcement therein of occupational safety and health standards
relating to issues covered by corresponding standards promulgated (by the Act) shall
submit a plan for doing so to the Assistant Secretary. Section 18 (c) of the Act sets out
certain criteria that a plan which is submitted under section 18 (b) of the Act must meet.
Foremost among these criteria is the requirement that the plan must provide for the
development of State standards and the enforcement of such standards which are or will
be at least as effective in providing safe and healthful employment and places of
employment as the standards promulgated under the Act.
Laws of the 91st Congress - Second Session - Public Law 91-596, 84 Stat. 1590
Occupational Safety and Health Act of 1970
1

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The following States and territories currently operate their own OSHA programs under
Section 18 (b): Alaska, Arizona, California, Hawaii, Indiana, Iowa, Kentucky, Maryland,
Michigan, Minnesota, Nevada, New Mexico, North Carolina, Oregon, Puerto Rico, South
Carolina, Tennessee, Utah, Vermont, Virginia, the Virgin Islands, Washington, and
Wyoming. In addition, Connecticut and New York have OSHA approved plans that
cover public employees only. Therefore the rules cited herein are to be considered the
minimum standards. Further state requirements that amend or supersede the Federal
Standards may be in force.
Each volume of the Code of Federal Regulations is revised at least once each calendar
year and issued on a quarterly basis. OSHA Code of Federal Regulations, Title 29, Part
1926, covering the construction industry, is issued approximately July 1. The information
in this Construction Manual is based on the July 1, 1988 revision of Part 1926, which is
the latest revision that is currently available.
1.6.2 Inspections, Citations, and Proposed Penalties
The purpose of OSHA as Code of Federal Regulations, Title 29, Part 1903 is to prescribe
rules and set forth general policies for enforcement of the inspection, citation, and
proposed penalty provisions of the OSH Act of 1970.
Inspections take place at such times and in such places of employment as the Area
Director or the Compliance Safety and Health Officer (CSHO) may direct. At the
beginning of an inspection, the CSHO shall present their credentials, explain the nature
and the purpose of their inspection, and indicate generally the scope of the inspection and
the records that they wish to review. Refer to OSHA Regulations, Standards 29 CFR,
Part 1903, Section 1903.7 Conduct of Inspections.
Inspections are usually originated by:
1. Situations creating an imminent danger that can be expected to cause death or
serious physical harm.
2. Fatalities and accidents resulting in the hospitalization of five or more
employees.
3. Employee complaints of alleged violations of standards or of unsafe or
unhealthful working conditions.
4. Programmed inspections aimed at specific high hazard industries, occupations,
or health substances.

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When the OSHA inspector arrives on site, it is PWPSs policy that the OSHA inspector
be permitted entry. He has the right to talk to anyone on the site and he can require
testimony and evidence under oath.
When an inspection reveals a violation of the OSHA regulations which could reasonably
be expected to cause death or serious harm immediately, the CSHO shall inform the
affected employees and employer of the danger. The Area Director will review the
inspection report of the CSHO, and will issue either a citation or notice of de minimis
violation within six months if he believes that the employer has violated an OSHA
requirement. A de minimis violation is one which has no direct or immediate relationship
to safety or health.
If the citation is sent to the Site Supervisor, he must immediately post a copy in the
manner and location(s) as required in OSHA Regulations, Standards 29 CFR, Part
1903, Section 1903.16 Posting of Citations. The citation must be posted for a minimum
of three (3) working days and until the violation has been abated. He shall also send a
copy or facsimile of the citation immediately after its receipt to the Construction Office
Support Group at the PWPS Home Office.
The Area Director determines the amount of any proposed penalty, giving due
consideration to the appropriateness of the penalty with respect to the size of the business,
the gravity of the violation, the good faith of the employer, and the history of previous
violations. Penalties are not proposed for de minimis violations. The Area Director will
notify the employer of the proposed penalty, or that no penalty is being proposed.
NOTE
The Area Director will not notify the employer following
an inspection if the site is in compliance.
1.6.3 Records
The regulations require that certain records be accurately maintained and/or posted.
These records are:
1. OSHA No. 101, Supplementary Record of Occupational Injuries and
Illnesses
Occupational injuries and/or illnesses to be logged on this form within six
working days from the time the employer learns of the work-related injury or
illness.

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NOTE
A substitute for OSHA No. 101, such as insurance or
workers compensation forms, may be used it contains all
required information.
2. OSHA No. 200, Log and Summary of Occupational Injuries and Illnesses
Occupational injuries and/or illnesses to be logged on this form within six
working days from the time the employer learns of each recordable
occupational injury or illness. This log may be prepared and maintained at an
off-site location, but a copy updated within 45 calendar days must be present
at all times on site.
NOTE
A copy of the OSHA 200 log must be posted at the site
from February 1 to March 1 each year for the preceding
year, even though there were no injuries or illnesses during
the year.
Record keeping forms are not to be sent to OSHA or any other agency. They are TO BE
maintained for five years at the workplace and must be available for inspection by
representatives of OSHA, HHS (Health and Human Services), BLS (Bureau of Labor
Statistics), or the designated state agency.
It shall be the Site Managers responsibility to complete and file the Supplementary
Record of Occupational Injuries and Illnesses, OSHA Form 101, whenever an
occupational accident or injury occurs. A copy shall be maintained in a permanent file in
the Construction Office Support Group at the PWPS Home Office.
The Site Manager has the further responsibility to obtain and display the Safety and
Health Poster in the PWPS site trailer(s) and in the Contractors trailer(s). These posters
are obtainable from he Construction Office Support Group.
1.6.4 Accident Procedures
Should an accident occur on a job site for which you are responsible, follow the
procedures indicated in Chart 1-1 shown on page 1- 37. It is important of note that
OSHA Form 101 and a complete accident report must be filed with the Construction
Office Support Group within six days of the accident or occupational illness. Fatalities
and catastrophes injuring five or more employees must be reported to OSHA within fortyeight (48) hours of their occurrence.

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Fatalities resulting from heart attacks or like causes should be reported. The report can be
cancelled or withdrawn later if it is determined that the case was not occupational in
origin.
1.6.5 Procedures and What to Expect from an OSHA Inspection
Should an OSHA inspector, officially titled Compliance Safety Health Officer (CSHO),
come onto your job site with the intention of making an inspection, he is first required to
show his credentials. Once the CSHO has established his identity, he will ask for an
opening conference.
An authorized employee representative should be given the opportunity to attend the
opening conference and accompany the CSHO during the inspection. If the employees
are represented by a recognized bargaining representative, the union will ordinarily
designate the employee representative. If there is no authorized employee representative,
the CSHO will consult with a reasonable number of employees concerning safety and
health matters in the workplace. The Site Supervisor should also invite the
superintendent of each subcontractor.
At the opening conference the CSHO will:
1. Inform the employer that the purpose of his visit is to make an investigation to
ascertain whether the employer is in compliance with the requirements of the
Act.
2. Outline in general terms the scope of inspection, including records he may
desire to review, employee interviews, physical inspection of the worksite or
workplaces, and the closing conference with the employer or his designated
representative to discuss the inspection findings.
3. Give the employer copies of the laws, standards, regulations, and promotional
materials, as applicable.
4. Finish a copy of complaint(s) if appropriate.
5. Inform the employer how he may obtain additional copies of other applicable
materials.
6. At an appropriate time during the opening conference, the CSHO shall discuss
the all-round provisions under the Act. The employer should be asked to
designate his representative for walk around purposes. In addition, the CSHO
should determine if there is a certified or recognized union or unions in the
plant, or any other authorized employee representative and they should be
contacted. Where any authorized employee representative is designated at the
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beginning of the inspection, the CSHO should discuss with them the scope of
the walk around. To the extent possible, all issues relating to walk around
should be settled at the beginning of the inspection.
The Site Supervisor shall make a complete set of notes, including names and time, during
the CSHOs meetings and inspection, and send a report to the Construction Office
Support Group.
After this meeting is completed, the CSHO will conduct the walk around inspection. The
CSHO can deny the right of accompaniment to any person whose conduct interferes with
a full and orderly inspection.
During the inspection, the compliance officer usually takes photographs of specific
hazardous situations, as well as the overall site. If so, it is recommended that am
employer representative also take photographs to duplicate the compliance officers
photographs for record purposes.
During the inspection, the CSHO may note apparent violations of OSHA regulations. He
will indicate these apparent violations to the Site Supervisor and the other employee
representatives. Citations will not be issued during this visit. If the OSHA Area
Administrator decides that the violations warrant a citation, the citation will be mailed to
the employer. The CSHO is not allowed to discuss the possibility of a citation with the
Site Supervisor or others. However, he can inquire about estimates of corrective
measures, extenuating circumstances, and the period required for abatement.
After the walk around inspection is completed, the CSHO will conduct another meeting
with the employer representatives. The CSHO shall at that time disclose all conditions
and practices which constitute safety and health violations.
A complete report of the inspection should be written immediately and sent to the
Construction Office Support Group.
At no time during the inspection should the PWPS Site Supervisor argue with the
inspector over the interpretation of the OSHA regulations. If the site inspection reveals
violations for which a citation is issued, the citation should be mailed to the Site
Supervisor, unless the citation is issued to our contractor or his subcontractors only.

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1.6.6 Employers Rights and Responsibilities following an Inspection 2

The following general information defines the types of violations and explains the actions
that may be taken if an inspection results in a citation.
1.6.6.1 Type of Violations
The three types of OSHA violations are defined below:
1. Willful Violation
A willful violation is defined as a violation in which the employer knew that a
hazardous condition existed but made no reasonable effort to eliminate it.
2. Serious Violation
A serious violation exists when the workplace hazard could cause an accident or
illness that would most likely result in death or serious physical harm.
3. Repeated Violation
A repeated violation may be cited if the employer has been cited previously for a
substantially similar condition. For construction sites, repeated violations are
based on prior violations occurring anywhere the same OSHA Area Office
jurisdiction.
NOTE
In cases where a violation is determined to be extremely
serious, it can be cited as repeated if the employer has been
sited for the same serious violation anywhere in the nation
within the past three years.
1.6.6.2 Employer Options
An employer who has been cited may take either of the following courses of action:
1. Agree with the citation and Notification of Penalty. Correct the condition by the
date set in the citation and pay the penalty, if one is proposed;
or
Ref. OSHA 3000, 1989 (Revised) Employer Rights & Responsibilities Following an
OSHA Inspection
2

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2. If an employer does not agree, he has fifteen (15) working days from the date the
citation is received to contest in writing (1) the citation, (2) the proposed penalty,
and/or (3) the abatement date.
NOTE
If the employer does not contest within 15 working days,
the citation becomes a final order.
For violations not contested, the employer must:
1. Promptly notify the OSHA Area Director, by letter, that he has taken the
appropriate corrective action within the time set forth in the citation,
and
2. Pay the penalty within fifteen (15) working days of receipt of the penalty notice.
Before deciding whether to file a Notice of Intent to Contest, the employer may request an
informal conference with the OSHA Area Director to discuss the Citation and
Notification of Penalty. This is recommended if there is any difficulty in complying with
any part of the citation. However, the informal conference will not extend the 15 working
day Notice of Intent to Contest period, nor take the place of filing a written notice of
context.
The Notice of Intent to Contest must clearly state what is being contested. A proper
contest of any item suspends the legal obligation to abate and pay until the item contested
has been judicially resolved. If only the penalty is contested, the employer must still
correct all violation by the dates indicated on the citations.
1.6.7 The Site Supervisors, PWPSs Contractor(s), and OSHA
The General Conditions of the specifications to which the contractor is building the site
states, All material and services furnished (by the Contractor) shall be in compliance
with the provisions of the Occupational Safety and Health Act. It is the Site
Managers responsibility to ensure contractor compliance with OSHA regulations.
Following the below listed steps can help the Site Supervisor ensure compliance by
PWPS contractors:
1. Make certain that you, other PWPS personnel, and the contractors supervisory
personnel are knowledgeable in depth about the Act and its administration.

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2. Make regular site safety inspections with the contractors supervision.

immediate steps to correct any apparent violations.

Take

3. Make sure that MSDSs are filed and made available to contractors where
necessary.
4. Prior to commencement of work, determine with the contractors representative,
who is responsible for each of the mutual requirements of the regulations.
5. Ensure that cross training concerning hazardous materials occurs between
subcontractors, since employees of one subcontractor may be exposed to
hazardous materials used by another.
1.6.8 Summary
The Occupational Health and Safety Act require all employers to provide healthy and
safe employment and place of employment. OSHA provides for the promulgation of
regulations and for civil and criminal penalties for violation of these regulations.
The responsibility for compliance to all OSHA regulations rests on the prime contractor.
The Site Supervisor shall ensure that all contractors, their subcontractors and employees
comply with OSHA regulations.
Each of PWPSs construction personnel should become familiar with the regulations and
administration of OSHA.
Certain records must be maintained to comply with OSHA. The most important to the
Site Supervisor are the Supplementary Record of Occupational Injuries and Illnesses,
OSHA Form 101, and the Log and Summary of Occupational Injuries and Illnesses,
OSHA Form 200. The Site Supervisor shall have the OSHA Safety and Health poster
displayed in the PWPS office trailer, the Contractors trailers, and any other location
where all workers on the site are most likely to read them.
Accident procedures are outlined in Chart 1-1.
Should an OSHA inspection take place at one of our sites, the Site Supervisor shall:
1. Ensure that an employer representative from each contractor and each trade on site
is at the pre-inspection meeting, inspection, and post-inspection meeting.
2. Keep accurate and complete notes of all activities involved with the inspection.
3. Write an inspection report and submit it to the Construction Support Group at the
PWPS Home Office.
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4. If a violation receives a citation, the Site Supervisor shall post the citation in
accordance with OSHA requirements and will send a copy or facsimile of the
citation to the PWPS Home Office.

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1. Determine accident severity and take the appropriate action shown under that
heading.
MINOR

SERIOUS

GIVE FIRST AID

GIVE FIRST AID

SEND VICTIM TO
PHYSICIAN (IF
REQUIRED)

CALL AMBULANCE

REPLENISH FIRST AID

KIT

TRANSPORT VICTIM TO
HOSPITAL

FATALITY

REPLENISH FIRST AID

KIT
REPORT ACCIDENT VIA
TELEPHONE TO THE
PWPS HOME OFFICE

COMPLETE OSHA FORM

101. FILE AND SEND TO
THE PWPS HOME
OFFICE WITHIN 6 DAYS

IF 5 OR MORE
HOSPITALIZED, OR ONE
OR MORE DEATHS,
REPORT ACCIDENT TO
OSHA OFFICE CLOSEST
TO JOB SITE WITHIN 48
HOURS.

OSHA INSPECTION OF
JOB SITE.

WRITE A COMPLETE
ACCIDENT REPORT.
SEND TO THE PWPS
HOME OFFICE WITHIN 6
DAYS.

CHART 1-1 Accident Procedures

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1.7 First Aid

1. Only a qualified individual should administer first aid.
It is strongly
recommended that PWPS site personnel are trained in First Aid and CPR (CardioPulmonary Resuscitation) procedures. The Standard First Aid textbook, Stock
No. 329380, Rev. Sept 1989, is available from the Red Cross.
2. Posters on a variety of First Aid and health subjects are available from the
American Red Cross at no cost.
1.8 Construction Rigging Equipment Tables
The tables shown on the following pages give some very helpful information to be used
to assure safety in rigging equipment:
Table 1-1 Table 1-2 Table 1-3 Table 1-4 Table 1-5 Table 1-6 Table 1-7 Table 1-8 Table 1-9 Table 1-10 Table 1-11 Table 1-12 Table 1-13 Table 1-14 -

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Strength of Plank
Safe Loads on Timber used as Beams
Safe Loads on Timber Columns, Posts, or Braces
Strength of Wire Rope
Strength of Wire Rope Connections
Wire Rope Clips
Bridling of Spreaders
Strength of Manila Rope Blocks
Strength of Standard Hooks
Strength of Turnbuckles
Strength of Chains
Safe Hitches and Knots
Strength of Shackles
Crane or Swinging Boom Hand Signals

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Table 1-1 - Strength of Plank

Span in Feet
Size in
Inches

10

12

14

16

18

305
370
430

300
350

290

Self Load in Lbs.

1x6
1x8
1 x 10

54
72
90

33
43
55

2x8
2 x 10
2 x 12

400
500
600

260
325
390

190
235
285

180
220

165

3 x 10
3 x 12
3 x 14

1245
1495
1740

820
980
1145

600
720
840

465
555
650

370
445
520

The loads given are in pounds concentrated at the center of the span.
The above loads are for fir or spruce planks in first class condition. For yellow pine planks in first class
condition add 10% to the above allowable loads.
Safe loads given are based on planks surfaced under sizes shown.

Table 1-2 - Safe Loads on Timber Used as Beams

Span in Feet
Size in
Inches

Positio
n

10

12

14

16

18

20

24

260
400
930
1270
1760
2400
5730
7940
10500
4930
7260
10050
8790
12170
16090
14290

220
340
800
1090
1520
2070
4970
6890
9130
4270
6300
8730
7630
10570
14000
12410

690
950
1330
1810
4370
6070
8040
3740
5540
7690
6710
9310
12330
10930

610
830
1170
1600
3890
5410
7180
3320
4930
6860
5970
8300
11020
9750

940
1280
3160
4410
5870
2680
4000
5590
4840
6760
9000
7940

Safe Load in Lbs.

2x4
4x4
4x6
6x6
6x8
6x8
8x8
8 x 12
8 x 14
8 x 16
10 x 10
10 x 12
10 x 14
12 x 12
12 x 14
12 x 16
14 x 14

Hor.
Hor.
Hor.
Vert.
Vert.
Vert.
Vert.
Vert.
Vert.
Vert.
Vert.

200
990
1530
3440
4700
6430
6690
10250
12050
13820
10740
12960
15220
15690
18430
21170
21630

130
650
1010
2290
3120
4260
6660
10200
12000
13760
10690
12900
15150
15620
18340
21070
21520

90
480
750
1700
2320
3180
4330
10160
11940
13690
10640
12840
15080
15550
18260
20970
21420

380
590
1340
1830
2520
3440
8150
11260
13630
7020
10320
14280
12490
17240
20880
21320

310
480
1110
1510
2080
2840
6740
9320
12310
5800
8540
11810
10340
14300
18870
16780

The loads given are in pounds concentrated at the center of the span.
The above allowable loads are for fir or spruce in first class condition.
For yellow pine beams in first class condition add 10% to the above allowable loads.
Most yellow pine timber now available is short-leaf. Inspect carefully for cross-grain. If badly crossgrained, reduce above safe loads accordingly.
All loads given are based on surfaced timber.

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Table 1-3 - Safe Loads on Timber Columns, Posts, or Braces

Length of Column in Feet
Size in
Inches

10

12

14

16

18

20

25

30

35

40

45

50

60

13.5
28.5
48.3
72.9

9.4
23.4
42.1
65.5

18.2
35.9
58.3

13.1
29.7
51.1

23.4
43.7

17.2
36.5

21.9

Safe Load in Tons

B
4x4

...
4.7
4.0

13.4
27.3
45.9
69.4
97.7

11.0
24.0
41.9
64.5
91.8

A
6x6
8x8
10 x 10
12 x 12
14 x 14

12.2
25.6
43.9
67.0
94.8

9.8
22.4
39.8
61.9
89.0

8.6
20.8
37.7
59.4
86.0

7.5
19.2
35.7
57.0
83.1

6.3
17.5
33.6
54.5
80.2

The above loads are based on yellow pine or fir timber in first class condition.
Safe load on wood column is frequently limited by bearing cap or sill.
Loads below line A can only be permitted if the end grain of the post rests on steel beam or slab.
Loads between line A & B can only be permitted if the load is transferred in and out of post by bearing on
oak or similar pedestal or corbel, to distribute the load over a greater area of yellow pine cap or sill.
Permissible pressure across the grain of yellow pine is 400 lbs. Per square inch and for oak is 750 lbs. per
square inch.
Most yellow pine now available is short-leaf. Inspect carefully for cross-grain. If badly cross-grained,
reduced above safe loads accordingly.

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Table 1-4 - Strength of Wire Rope

6 x 25 Type W
Improved Plow Steel (Purple Strand or Equal)
Diameter
Rope
(Inches)

Minimum Size of
Sheave
(Inches)

Safe Working
Load Running
Cable
(Lbs.)

Safe Working
Load-Eye and Eye
Chokers
(Tons)

Approximate
Weight per Foot of
Cable
(Lbs.)

3/8
1/2
5/8
3/4
7/8

9
12
14
16
18

4200
7200
11100
15800
21500

1.3
2.2
3.3
4.8
6.5

0.23
0.40
0.63
0.90
1.23

1
1-1/8
1-1/4
1-3/8
1-1/2

20
24
28
32
36

28000
35300
43300
52300
61700

8.4
10.6
13.0
15.7
18.5

1.6
2.03
2.50
3.03
3.60

1-5/8
1-3/4
1-7/8
2

40
44
48
52

72000
82700
94700
107300

21.6
24.8
28.9
32.2

4.23
4.90
5.63
6.40

Braided Wire Rope

No. of Parts

Diameter each Part (in.)

Safe Working Load per Sling

(Tons)

3
3
5

3/8
1/2
1/2

3.7
6.4
10.7

The above tables are for First Grade wire rope.

For Second Grade Wire rope reduce the above values 25%.
First Grade wire rope is Al rope, as good as new.
Second Grade wire rope is rope that has been sued before, but which is in good condition, is not excessively
worn or flattened, and has few, or no, broken wires.

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Table 1-5 - Strength of Wire Rope Connections

Properly applied Socket .
Eye splice with thimble or spool
Eye splice in sling .
Cable Clamps properly installed
Long splice in running cable .

100% of cable
85%
80%
80%
85%

Safe Working Loads - Wire Rope Tackle

10,000 lbs. Lead Line Pull at Engine
Number of Parts in
Falls

Bronze Bushed Sheaves in Good

Condition Safe Load (lbs.)

Ball Bearing Sheaves in Good

Condition Safe Load (lbs.)

1
2
3
4

8300
16100
23450
30350

9120
18000
26550
34900

5
6
7
8

36850
42950
48650
54050

43000
50800
58400
65800

9
10
11
12

59100
63850
68350
72550

72950
79900
86600
93150

The above values are based on two snatches between the engines and the falls. For each additional snatch
block or sheave; add 6% to the lead line pull for bronze bushed sheaves; add 3% to the lead line pull for
ball-bearing sheaves.

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Table 1-6 Wire Rope Clips

How to Attach Wire Rope Clips
U-Bolt all clips on dead end of rope
Never stagger clips
Never put U-Bolt of clip on live end of rope
U- Bolt Clip

First Grip Clip

Diameter of Wire
Rope
(Inches)

Number of Clips
for Improved Plow
Steel

Minimum Spacing
D Between Clips
(Inches)

Number of Clips
for Improved Plow
Steel

Minimum Spacing
D Between Clips
(Inches)

3/8
1/2
5/8
3/4
7/8
1
1-1/8
1-1/4
1-3/8
1-1/2

3
4
4
5
5
6
6
7
7
8

3
3-1/2
4-1/4
5
5-3/4
6-1/2
7-1/4
8
8-3/4
9-1/2

3
3
3
4
4
5
5
6
6
6

3
3-1/2
4-1/4
5
5-3/4
6-1/2
7-1/4
8
8-3/4
9-1/2

The above are the minimum requirements to develop 85% of the full strength of the wire rope when using
U-Bolt Clips, and 90% of the full strength of the wire rope when using First Grip Clips.

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Table 1-7 - Bridling of Spreaders

When the legs are spread due to bridling, the capacity of the spreaders is reduced. The determine the
capacity of each leg of the spreader, follow the procedure shown below:
Wire Rope
Diameter

S
(Ins.)

1/2
5/8
3/4
7/8
1
3 Parts 3/8 Braided
3 Parts 1/2 Braided
5 Parts 1/2 Braided

22
33
48
65
84
37
64
107

Procedure:
1. Lay off length S as shown in sketch
2. Measure Distance R in inches.
3. R / 10 = Safe load in tons on one leg due to bridling
Example: Using 7/8 0 spreaders. Find allowable load.
1. Lay off S = 65 inches on one leg.
2. Distance R measures 64 inches.
3. Safe load on one leg = .46 / 10 = 4.6 tons
4. Total allowable safe load = 2 x 4.6 = 9.2 tons

Notes:
1.
2.

This procedure applies only when load is horizontal.

When a choker is used in bridling, the capacity of the choker must also be reduced.

S (inches) = Safe working load in tons x 10.

R (inches) = Reduced safe working load x 10.

Measure from here

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Table 1-8 - Strength of Manila Rope Blocks

Blocks with Hooks
Length Shell
(Inches)

Two Singles
(Pounds)

Two Doubles
(Pounds)

Two Triples
(Pounds)

3
4
5
6

600
750
1500
2250

825
1125
2250
3000

1050
1500
3000
3750

7
8
9
10

2550
3300
3900
4500

3675
4350
5100
5625

4800
5400
6300
6750

12
14
16

5400
6600
9000

7200
8550
11250

9000
10500
13500

Blocks With Shackles

Length Shell
(Inches)

Two Singles
(Pounds)

Two Doubles
(Pounds)

Two Triples
(Pounds)

3
4
5
6

750
1200
1650
2400

1350
2250
3300
4500

1950
3000
4200
6000

7
8
9
10

3000
3600
4050
6000

5700
7050
7500
10500

7200
10050
10500
13500

12
14
16

7500
9750
12000

13500
16500
21000

18000
22500
27000

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Table 1-9 - Strength of Standard Hooks

Standard Hook
Number

Inside Diam. Of Eye

(Inches) A

Throat Opening
(Inches) B

Safe Working Load

(Tons)

22
23
24
25

7/8
1
1-1/8

1
1-1/16
1-1/8
1-1/4

0.5
0.6
0.7
1.2

26
27
28
29
30

1-1/4
1-3/8
1-1/2
1-5/8
1-3/4

1-3/8
1-1/2
1-3/4
1-7/8
2-1/16

1.7
2.1
2.5
3.0
4.0

31
32
33
34
34a
35

2
2-3/8
2-3/4
3-1/8
3-1/4
3-1/2

2-1/4
2-1/2
3
3-3/8
3-5/8
4

4.7
5.5
6.8
8.0
10.0
11.0

36
38

4
4-1/2

4-1/2
5

20.0
30.0

The above values are for Vulcan and similarly designed standard hooks.
The capacity can be found by the diameter of the hole in the eye of the hook. If the throat opening of any
hook exceeds the dimensions given above for the corresponding diameter of the eye, the hook has been
overstrained and must not be used.

Table 1-10 - Strength of Turnbuckles

Size D
(Inches)

Safe Load Eye or Jaw

(Tons)

Minimum Size Wire Rope

Diameter in Inches

3/4
7/8

2.2
3.2

3/8
1/2

1
1-1/4

4.1
6.6

5/8
3/4

1-1/2
1-3/4

9.7
13.1

7/8
1

2
2-1/4

17.2
22.5

1-1/8
1-3/8

2-1/2
2-3/4

28.0
36.7

1-1/2
1-3/4

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Table 1-11 - Strength of Chains

Size of Chain
(Inches)

Weight per Foot

(Lbs.)

Safe Working Load

(Lbs.)

3/8
1/2
5/8
3/4
7/8

1.5
2.5
4.1
6.2
8.4

2300
4000
6300
9000
12300

1
1-1/8
1-1/4
1-3/8
1-1/2

10.5
13.6
16.0
19.3
23.0

16300
19600
24300
29300
35000

The above table is for Emergency use only.

Chains should only be used when it is impossible to secure wire rope slings or chokers.

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Table 1 Safe Hitches and Knots

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Table 1-13 - Strength of Shackles

Diameter of Pin-A
(Inches)

Diameter of Shank B
(Inches)

Maximum Width
between Eyes C
(Inches)

Safe Working Load

(Tons)

3/4
7/8
1
1-1/8
1-1/4

5/8
3/4
7/8
1
1-1/8

1-1/16
1-1/4
1-1/2
1-5/8
1-7/8

2.2
3.2
4.3
5.7
6.7

1-3/8
1-1/2
1-5/8
1-3/4
2

1-1/4
1-3/8
1-1/2
1-5/8
1-3/4

2
2-1/8
2-1/4
2-3/4
2-3/4

8.3
10.0
12.0
14.0
16.0

2-1/4
2-1/2
2-3/4
3
3-1/4

2
2-1/4
2-1/2
2-3/4
3

3-1/4
4
4-1/8
4-1/2
5

21.0
27.0
34.0
40.0
46.0

Size of shackle to be identified by diameter of pin.

All shackle pins must be straight.
If the width between eyes exceeds maximum given above, the safe load given must be materially reduced.

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Chart 1-2
Tagging Log Format
Equipment
No.

When Tagged
Date
Time

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Reason

Requested
By

Tagged
By

When Released
Date
Time

PAGE: 1-51

Released
By

PWPS Site Supervisor Release

2.0 SITE PREPARATION

For those installations where PWPS is responsible for all or part of the site preparation,
the following general information should be of assistance to the PWPS Site Supervisor
and Construction Engineers.
CAUTION
The information contained within this manual is not
intended to be specific to a particular site or configuration.
It is provided for reference purposes only and is generally
applicable to all FT8 Power Pac and Twin Pac installations.
Specific instructions for the field installation of equipment
at each specific site will be provided through the PWPS
drawing and documentation system described in Section 5 INSTALLING EQUIPMENT. Information on the proper
installation sequence is given in Section 8 SPECIFIC FT8
INSTALLATION SEQUENCE. When a conflict exists
between this manual and the applicable drawing, the
applicable drawing shall take precedence over this manual.
The material contained in this manual also includes typical
requirements for such activities as site preparation and
foundation work, as will be specified by the A&E
contractor for performance by the builder, general
contractor, and sub-contractors. It is provided for reference
purposes only.
2.1 Site Layout
Prior to commencing any earth, foundation, or pad work, the Contractor shall survey the
site and lay out all levels, centerlines, and datum lines per the drawings. PWPS shall
verify the site layout; however, acceptance of the layout shall not diminish the
contractors responsibility to maintain the correct layout. Periodic checks during the
construction period shall be made to determine the elevations, center, and datum lines are
being held, and that the customers formal bench marks or surveying targets are known
and documented.
2.2 Excavations
All excavations shall be performed to the elevations, densities, and dimensions required
for the work indicated on the specifications and drawings, or as directed by PWPS in
writing.

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All excavations shall be large enough to permit working space for subsequent operations
within them. Excavations shall be maintained in a dry condition, free of standing water
to permit progress of work. Grading in the vicinity of the work shall be controlled to
prevent water from running into the excavated area. If any water should accumulate
therein, the water shall be removed by pumping, draining, or other approved methods.
The Contractor shall be responsible for providing a dewatering system to lower the water
table where excavations are at an elevation below the water table. The excavations shall
be provided with barricades, signs, sheeting, and shoring per OSHA regulations for the
safety of personnel and the protection of the work.
All excavations shall be maintained free of frost and thoroughly cleaned immediately
before granular fill, concrete, piping, cable, backfill or other materials of construction are
placed therein.
A nominal amount of excavations for trenches will be necessary for the proper laying of
piping, insulated, and non-insulated cable, conduit or tubing. The bottom of the trenches
shall be cleaned of all stones and organic material, and accurately graded to provide
uniform bearing on washed sand compacted to 95 percent ASTM D1557.
Where required, the Contractor shall install and support the excavation shoring with
material and members dimensioned per OSHA shoring requirements. Shoring
requirements concerning excavations are given in section 1.5 (K). Refer to OSHA
Regulations, Standards 29 CFR, Part 1926, Subpart P- Excavations.
2.3 Fill and Backfill
All filling and backfilling necessary to complete the work shall be accomplished using
suitable excavated material or approved selected fill material.
Fill materials required for raising the subgrade for concrete foundation pads and slabs to
the elevations shown on the drawings and for backfilling around foundation walls shall be
selected and approved material placed and compacted as specified. Crushed stone,
granular fill, and backfill material shall not be placed until the subgrade or other below
grade work has been completed, inspected, and approved. However, when the subgrade
excavation is approved, the granular fill shall be placed immediately after the excavation
of the unsuitable material, debris, and organic matter.
The granular fill and backfill shall be deposited in layers not to exceed six inches, loose
measure, thoroughly compacting each layer as specified herein. Crushed stone layers for
the foundation and pads shall measure 18 inches, loose measure.
Granular fill and backfill shall not be placed on soil that is disturbed, muddy, contains
frost pockets, or is frozen. Fill placement and compaction operations shall be suspended

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during periods of rainfall. Compacted areas that have settled or have softened due to rain
or some other cause shall be restored and thoroughly recompacted.
Backfill around foundations and pads shall raise the grade to final rough grade. Backfill
shall be placed and compacted as specified herein. Redress and recompact any areas that
settle from traffic, precipitation, or storage loading.
After the piping, cables, conduit, and tubing are laid, inspected, tested, and approved, the
periphery of each shall be filled and compacted with approved, washed sand and gravel to
a minimum radius of six inches around the piping, etc., unless otherwise indicated on the
drawings or by the PWPS Site Supervisor in writing. Special care shall be taken in
backfilling around and over non-metal piping to prevent damage to the piping.
Backfilling around cables shall be completed per PWPS specifications.
2.4 Compaction and Tests
Each layer of fill or backfill material shall be thoroughly compacted throughout to the
requirements given below at optimum moisture content for the material using appropriate
methods and equipment for the conditions involved. The addition or removal of water, as
required, shall control moisture content.
All areas under new construction shall be compacted throughout to a density of at least 95
percent of the maximum value as determined by an ASTM D1557 designation (AASHOT-180) compaction test. Compaction densities specified on the drawing are minimum
limits to be achieved by maintaining soil moisture within +/- 2 percent of the optimum
moisture content determined by ASTM D1557 or D698. Compaction requirements for
the crushed stone are usually not specified, since it is anticipated that grading equipment
used to level the crushed rock will compact it sufficiently.
All other areas shall be compacted throughout to a density of at least 90 percent of the
maximum value, as determined by the same compaction test.
PWPS may arrange for an approved independent laboratory to obtain and examine test
specimens from the completed work to certify contract compliance in writing. Test
specimens shall be taken from the work at the locations and depths prescribed by PWPS.
The Contractor shall cooperate with the testing laboratory personnel.
NOTE
Arrange for this service early, before compaction must be
checked.

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If the fill does not meet the stated compaction requirements, the Contractor shall
recompact the fill and pay for all retesting until it is determined that the fill has been
constructed in accordance with this specification.
2.5 Piles
Normally, the piling area will be graded prior to driving the piles.
Logs of soil borings in the vicinity of the foundation are taken to indicate the general
nature and depth of soil formation.
In general, a technical specification covering all specific pile design requirements will be
written for each project. The following are typical driving and test requirements. Driving
requirements for different applications may vary.
2.5.1 Driving
All piles shall be driven from the ground surface existing after general nature and depth
of soil formation.
Piles shall be driven without interruption from the first hammer blow until final resistance
is developed in the bearing stratum, insofar as possible. In any event the last five feet of
pile length shall be driven without interruption.
The piles shall be driven as nearly as possible in the exact position shown on the plans.
Deviation of the location of the top of the pile from that shown on the plans shall not
exceed three inches.
Piles shall be driven with a maximum permissible deviation of two (2) inches in ten (10)
feet from the vertical.
A suitable cap shall be provided to prevent undue damage to the top of the pile and to
hold the pile centered under the hammer.
After each pile has been driven to the required depth and resistance, the top elevation of
the pile shall be recorded. Such levels shall be checked from time to time as adjacent
piles are driven to determine whether any heaving of piles has taken place. Where there
is a reason to believe, in the opinion of PWPS, that a pile has heaved, it shall be redriven
to specified final resistance.
Jetting is prohibited.
Piles shall not be driven within twenty (20) feet of concrete that is less than seven (7)
days old.
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2.5.2 Driving Records

An accurate record of driving each pile shall be furnished to PWPS. Typically, this
record shall include:
1. Date of driving.
2. Kind and size of hammer.
3. Location, length, tip, and cut-off elevation.
4. Continuous driving resistance in blows per foot for each foot of driving for all
piles, and the driving resistance in blows per inch for the last twelve (12) inches of
driving. For piles driven to refusal, record penetration for last five (5) blows.
5. Description of unusual circumstances or occurrences, including notes on stops,
redriving, and so on.
The Contractor and the Site Supervisor are to sign the driving records.
2.5.3 Test Pile
The first pile driven shall be driven to the resistance established by formula and testloaded to verify its capacity.
The test load shall be applied by means of loading a platform balanced on the pile.
Alternatively, the Site Supervisor may approve other means that will maintain full load
on the pile if settlement takes place.
The test pile is intended to be one of the load bearing piles and shall be located
accordingly. The Site Supervisor may direct which pile is to be driven first, and provide a
numbered plan for remaining piles.
Once the driving resistance of the test pile has been established, all of the other piles shall
be driven to the same resistance. In the event that any substantial change takes place in
the driving characteristics or driven lengths of the piles, the Site Supervisor may order
additional load tests.

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2.6 Foundation Forming

Forms for all cast-in-place concrete shall conform to ACI Standard 347-68, and shall be
constructed of material properly assembled and built to support the full load of wet
concrete and handling equipment.
Forms shall be removed in such a manner as to insure the complete safety of the structure.
Vertical forms may be removed after twenty-four (24) hours, provided the concrete is
sufficiently hard not to be injured thereby.
2.7 Embedded Hardware
Embedded hardware shall conform and be placed in the foundations per specifications
given by the A&E Contractor. The following are typical requirements for embedded
hardware.
2.7.1 Reinforcing Steel
The reinforcing steel for foundations for the gas turbine/generator, switchgear/control
house, start pac, fuel-forwarding skid, lube oil skid, and fuel filter should conform to
ASTM-A-615, unless otherwise specified.
The reinforcing steel shall be equally spaced as shown on the applicable drawings, except
that slight deviations will be allowed where the reinforcing steel interferes with the
anchor bolts. Minimum clearance of one and one-half (1-1/2) inches must be maintained
between parallel reinforcing bars.
All reinforcing steel shall be purchased, fabricated, and placed to conform to the latest
issue of ACI and CRSI standards. Prior to the purchase and fabrication of the reinforcing
steel, the Contractor shall submit shop drawings of the reinforcing steel for approval.
The steel shall be bent cold. All hooks not dimensioned on applicable drawings are
standard hooks as specified in the ACI building code. Spliced bars shall be lapped in
accordance with requirements of ACI Standard 318-71, unless otherwise specified.
Reinforcement shall be accurately placed and secured in position using annealed iron tie
wire of not less than No. 18 gauge or suitable clips at intersections, and shall be supported
by concrete or metal chairs, spacers, or metal hangers. All accessories, such as chairs,
ties, bolsters, spacers, etc., required for placing and holding the reinforcing steel in
position shall appear on the approved shop drawings.

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2.7.2 Anchor Bolts

NOTE
PWPS requires the use of Hilti concrete anchors.
Refer to Appendix C.
Unless otherwise specified, the contractor shall purchase, fabricate, provide, and place all
anchor bolts, sleeves, nuts, washers, and plates per applicable drawing and specifications.
All anchor bolt assemblies shall be firmly secured in wood or steel templates and fastened
to the reinforcing steel as required prior to and during the pouring of concrete, to insure
against displacement or misalignment. The anchor bolt placement and support methods
shall have prior approval and concurrence before the concrete is poured. Anchor bolt
sleeves shall be freeze protected from moisture after formwork removal.
All anchor bolts and anchor bolt assemblies shall be purchased and fabricated by the
Contractor. Materials shall comply with ASTM Standards as specified on the drawings.
Unless otherwise specified, the following materials will be used:
Plates: A 36
Pipes: A 53, Grade B
Bolts: A 307, A 193 Grade B7, A 325
Anchor bolt assemblies shall be placed within the tolerances shown in applicable
drawings.
All anchor bolt threads shall be chased with a mating nut, lubricated with a suitable
grease such as automobile chassis grease and wrapped with moisture proof paper or
fabric.
2.7.3 Datum and Centerline Plates
The datum and centerline plates shall be purchased by the Contractor and placed per
PWPS drawing. The above plates shall be placed after the concrete has been poured but
before the concrete begins to set. After the concrete has set and the formwork removed,
the datum and centerline points must be marked (with a center punch) exactly as
indicated on the above drawing (no tolerance allowed).
2.7.4 Jacking Plates
The Contractor shall provide and place jacking plates per applicable drawings.
The Contractor shall chip all grouting areas to remove laitance and roughen the surface
for good bonding of grout. Refer to paragraph 2.7.5 for further information on this
subject.
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The jacking plates shall be placed and grouted after the concrete formwork has been
removed. The grout to use is as specified in paragraph 2.7.6.
Grout consistency shall be stiff enough to support jacking plates as they are leveled.
When placing the grout for the jacking plates, the grout must not be allowed to enter the
anchor bolt sleeves or to restrict the movement of the anchor bolt within the sleeve.
Jackscrews should be coated with paste wax, putty, or wrapped with electrical tape. All
jackscrews must be removed before operation of equipment and after the grout cures.
2.7.5 Laitance
Laitance is the weaker mixture of cement, fine sand, and water that accumulates on the
surface of concrete. When an area of concrete is being prepared to receive grout, the
laitance is usually chipped away using a jackhammer to expose the aggregate beneath to
improve the bond between the epoxy grout and the concrete.
2.7.6 Grout
The Contractor shall provide and place a modified epoxy resin based grout mixture of
648CP Grout, produced by:
The Ceilcoate Co., Inc.
140 Sheldon Road
Berea, Ohio 44017.
Preparation of foundation, equipment, and grout mixture, and placing of grout shall be
per Ceilcotes installation instructions.
Shade the foundation from strong sunlight at least twenty-four (24) hours before and
forty-eight (48) hours after grouting; and, prevent any water or moisture from
accumulating on the foundation or in the anchor bolt sleeves. Proper curing of the grout
is important.

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3.0 CONCRETE
3.1 Introduction
It is the purpose of this section to provide a general understanding of the components
used in making concrete, as well as the approved methods of placement, finishing and
curing to give the required qualities in the finished product.
For further information on the specific materials and procedures used in making concrete,
refer to the 13th edition on the Portland Cement Associations Design and Control of
Concrete Mixtures. The Portland Cement Associations publication also references
appropriate American Concrete Institute reports for each of its topics.
The American Concrete Institute publishes the ACI Manual of Concrete Practice, a threepart series giving committee reports on concrete technology, as follows:
Part 1 Materials and Properties of Concrete
Construction and Practices and Inspection
Pavements and Slabs
Part 2 Notation
Structural Design
Structural Specifications
Structural Analysis
Part 3 Products and Processes
This manual should be used also as a reference for information on current practices in
concrete construction.
CAUTION
Prolonged contact with freshly mixed concrete will cause
skin irritation or chemical burns. Cement is alkaline and
therefore caustic. Cement is hygroscopic it absorbs
moisture from the skin.
3.2 Composition of Concrete
In general, the ready-mix supplier is responsible for the quality of all materials that go
into the concrete mix. Proportions of components and selection of materials are based on
the most economical used of available materials that will produce a concrete of required
workability, placeability, durability and strength. The A&E contractor responsible for
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this phase of the construction process will usually develop specifications for the materials
and their proportions.
Concrete is composed essentially of three materials: cement, water and aggregates.
Sometimes a fourth material, an admixture, is added for a variety of specific purposes,
such as entrainment of air, acceleration or retardation of setting and hardening, etc. A
brief discussion of each of these materials follows:
3.2.1

Cement

Normally, about 10 to 15 percent of the total volume of concrete consists of hydraulic

cement. This ingredient, with respect to volume, is the least of all ingredients.
Nevertheless, it is the most expensive and important. When combined with water, a paste
is formed. This paste is the cementing medium that binds the aggregate particles into a
solid mass. The two principal requirements of a hardened concrete - strength and
durability, depend on the quality of the paste. Paste covers the surface of all pieces of
aggregates, fills all void spaces between the aggregate particles, hardening into a solid,
unified mass concrete.
Special types of cement are available for use in concrete to help meet every job condition
and requirement. For general construction purposes, there is little need to be concerned
with the different types of cements. However, in addition to standard Portland cement for
general concrete construction purposes, special types of Portland cements are available
for special or specific uses where special properties are required. Normal Portland
cement, Type I, is furnished when the type of cement is not specified.
3.2.1.1 Types of Cement
Five different types of cements are normally available:
Type I

Standard Portland cement is used in general concrete construction,

when no special properties of other types are required. Ready mix
concrete usually is proportioned with Type I Cement, unless the
purchaser specifies another type.

Type II

Modified Portland cement is used in general concrete construction

that is exposed to moderate sulfate action, or where moderate heat
of hydration is required. It is used in large piers, heavy abutments,
heavy retaining walls, or other mass structures of considerable size,
where moderate heat of hydration will tend to minimize
temperature rise. Moderate sulfate resistance property gives
protection against sulfate attack where sulfate concentrations are
higher than normal, but not unusually severe.

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Type III

High early strength Portland cement is used when high strengths

are required at an earlier age. It is used where it is necessary to
remove forms as soon as possible, or to place the concrete in
service at an early date. In cold weather, it reduces the necessary
period of protection. Its most important characteristic is rapid rate
of strength development.

Type IV

Low heat Portland cement is used when a low heat of hydration is

required. It is used where the amount and rate of heat generation
must be kept to a minimum, and is especially adapted for use in
concrete for massive structures, such as dams, where temperature
rise resulting from hydration of the cement is a critical factor. It is
not generally suited for general concrete construction.

Type V

High sulfate resistant Portland cement is used in concrete exposed

to severe sulfate action.

Air-entrained Types I, II and III Portland cements are covered by ASTM specifications in
air-entrained types. The letter A following the type number identifies these types of
cement. In these cements, very small quantities of air-entrained agents are inter-ground
with the cement clinker during manufacturing. Air-entrained produces resistance to sever
frost action and the harmful effects of de-icing salts used for ice and snow removal. A
sufficient quantity of entrained air in concrete greatly improves durability properties with
respect to freezing, thawing or frost action. Types IA, IIA or IIIA cements are used for
the same type of construction and purposes as their counterpart Type I, II and III cements.
3.2.2 Aggregates
Aggregates normally represent 66 to 78 per cent of the volume of concrete. This bulk and
the relatively inexpensive unit cost are responsible for making concrete an economical,
competitive building material. For most concrete, the selection of aggregates is limited to
the types available locally. Aggregates also must meet specific specification
requirements, which is the responsibility of the ready mix dealer. Particle shape,
gradation and maximum size have a significant influence of both the proportions and
economy of the concrete, as well as ultimate quality. Aggregates must consist of clean,
hard, strong and durable particles, free of chemicals or coatings of clay of other fine
materials. Weak, friable particles are undesirable.
Two classifications of aggregates are utilized in the production of concrete. These are
designated fine aggregate and coarse aggregate, which are defined as follows:
1. Fine Aggregate - Consists of natural sand, manufactured sand, or a
combination thereof, graded in size from " (6.3 mm) maximum diameter
to near dust size.
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2. Course Aggregate - Consists of crushed stone, gravel; blast-furnace slag or

other approved similar materials, well graded with respect to size, in
conformance with specifications.
Concrete is scientifically designed to make the most economical use of a combination of
fine and coarse aggregates to produce the desired quality. The design is based on
laboratory physical tests of the aggregates.
Proper grading of aggregates is important. To insure dense stacking, or near solid
arrangement of particles in place, aggregate must be suitably graded from coarse to fine.
Favorable grading of aggregate serves two important functions:
1.

Contributing to the workability and uniformity of the concrete

2.

Reducing the quantity of cement paste required to produce quality

concrete.

For most construction, coarse aggregate is all below 2 inches (51 mm) in size. For
economy and quality, specify the largest size coarse aggregate practical to use for the
conditions of the job. The larger the maximum size of the coarse aggregate, the less
water and cement will be required to produce quality concrete. Maximum size will
depend on the size and shape of the concrete members and amount and distribution of
reinforcing steel, if any. This should not exceed 1/5 of the minimum dimension of the
member, nor of the clear spacing between reinforcement bars.
Shape of the aggregate particles also has significance. Very sharp, rough particles or flat
elongated pieces require more fine material (sand) to produce workable concrete than
aggregates rounded or cubical in shape.
The ready-mix dealer is qualified to advise on specifications, quality, ratio or fine to
coarse aggregate, and other matters relating to aggregates in concrete.
3.2.3 Water
Mixing water is perhaps the least costly of the ingredients in concrete, but nevertheless
one of the most important. The amount of water used largely determines the ultimate
strength of concrete. There is a definite relation between the amount of water used and
the quality of the resulting concrete; increasing amounts of water sacrifice quality.
Additional water dilutes the paste, reducing its cementing action. It is necessary to limit
mixing water to that which will just permit proper handling and placement.
Water in concrete serves a dual function. It first converts dry cement and aggregates into
a plastic, workable mass and secondly, reacts with cement chemically to hydrate and
harden the plastic mass into a solid strong unit.
The all-important relationship of water to cement is known as the water cement ratio.
This is expressed as a ratio of pounds of water to pounds of cement per unit of concrete.
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In general, the lower the ratio, the denser and stronger the paste. This ratio is established
either by the ready-mix producer or by the requirement of the consumer when specified.
Water used in concrete must be free of acids, alkalis and oils. Particularly avoid water
containing decayed vegetable matter or other organic materials. Generally, water that is
suitable for drinking purposes is usually satisfactory for concrete.
The importance of water content in providing compressive strength in concrete is shown
below in Figure 3-1.

(Non Air Entrained Concrete)

6000

6000

5000

5000

4000

4000

3200
3000
2500
2000

2000

1000
3

10

W A T E R C E M E N T R A T IO - G A L S . O F W A T E R P E R B A G O F C E M E N T

Figure 31 Effect of Water Content On Compressive Strength of Concrete

3.3 Job Site Hints for Concrete Construction
When ready mixed concrete is delivered to the site, is has been carefully proportioned and
thoroughly mixed to produce the strength ordered. However, there are many precautions
in the site preparation, placement, finishing and curing necessary in order that a
satisfactory quality finished product may be obtained. The neglect of any one of these
precautions may cause inferior concrete. Presented here are a number of basic rules of
thumb: DOs and DONTs that, if carefully observed, will result in quality concrete.

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3.3.1 Sub-grade Preparation

DO

DONT

Remove all vegetation, loose earth,

organic materials from the sub-grade.

Dont place concrete over loose or

frozen earth.

Remove all soggy or soft spots; replace

with dry earth, cinders, slag or gravel. A
well-compacted foundation of 4 inches
(100 mm) to 6 inches (150 mm) depth
will usually suffice.
Where an area is to be filled before
concrete is placed, tamp thoroughly.
Place fill in layers, about 6 inches (150
mm) and tamp between layers.
Wet down the sub-grade thoroughly to
prevent absorption of water from the
concrete. Rapid extraction of water from
the concrete will seriously impair its
strength.
Make provision
necessary.

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for

drainage

if

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3.3.2 Forms
DO

DONT

Build forms carefully. Forms should be

tight and of sufficient strength and rigidity
to insure the concrete adhering to desired
shape, lines and grades.

Dont forget to check forms before

placing, especially bracing.

Use clean forms to prevent discoloration

and marring of concrete surface.

When assembling forms, dont permit

form ties to come closer than 1 inch
(25 mm) to any finished surface.

Coat forms with a non-staining mineral oil

for easy removal. Coating should not be so
thick as to stain or otherwise impair the
concrete surface.
Thoroughly scrape and clean forms that
have been previously used, if necessary.
Place concrete as near as practical to its
final location. Provide additional delivery
points where pouring operations extend
over a large area. This is necessary to
avoid excessive handling, which results in
segregation.
Consider the use of inexpensive cardboard
cylindrical forms for columns and posts.
These eliminate the necessity of building
wood forms, and they can be cut and
quickly removed after curing. Columns
and posts are smoother, better looking, and
take up less room than square members of
the same strength. Cylindrical forms are
available in sized from 4 inches (100 mm)
to 48 inches (1200 mm) in diameter.
Use expansion joint material where a new
concrete slab abuts an existing walk,
driveway, building, curb, lighting standard,
fireplug or other rigid objects.

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3.3.3 Placing Concrete

DO

DONT

Place concrete in horizontal layers of uniform

thickness not more than 18 inches (450 mm)
deep.

Dont let concrete drop freely for a

distance of greater than 3 feet (900 mm)
or 4 feet (1200 mm). Longer free drops
cause segregation.

Achieve proper consolidation and avoid

honeycombing by spading and/or vibrating
thoroughly. Dont over-vibrate to the point of
segregation.
In winter use heated water and heated
aggregates in the mix. Cover finished concrete
with thick straw or provide heat externally
with salamander heaters or other heating
units to prevent freezing during the curing
process.
Place concrete as late as possible in the day
during extremely hot periods. This will help
prevent too-rapid drying of new concrete.
When placing concrete on a slope, start at the
bottom. This provides support for the mix all
the way up the slope. Starting at the top
causes the concrete to pull apart by
gravitational action, especially when a vibrator
is used for consolidation.
When using a vibrator for consolidation,
penetrate vertically and at regular distance
intervals, not at an angle and at haphazard
intervals. When vibrating in a wall form, let
the vibrator penetrate a few inches into the
previous lift to permit good integration
between layers.

Dont use flat chutes, even for short

distances. Chutes should be of rounded
cross section.
Dont under any circumstances add
water to the mix after the required
consistency has been reached. Extra
water reduces strength and durability,
increases bleeding, shrinkage and
finishing time. Dont allow mud from
boots to be left on the concrete surface.
It will be worked in during finishing
and usually will not be visible at the
time. After the concrete has cured, this
mud will crumble away or be washed
away by rain, often resulting in severe
surface damage.
When placing concrete in wall forms,
dont let the concrete hit against form
walls and ricochet against reinforcing
bars or opposite form walls. This
causes segregation and honeycombing
(rock pockets), resulting in poor
concrete. Use a hopper, if possible, to
funnel concrete directly to the center of
the form.

Place concrete against the face of the

previously placed concrete. To place in a
direction away from the already placed
material causes segregation of the aggregate.
Detail one man to pay special attention to form
faces, corners and around reinforcement.

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3.3.4 Finishing
DO
Plan to grade slabs for water runoff. Slope
should be a minimum of 1/8 inch in 10 feet
(3.2 mm in 3050 mm).
Permit wet spots to disappear before final
finish troweling.
Finish steel troweling twice first lightly
enough to remove surface defects; second
for final smoothing. Do second troweling
only after the concrete has hardened
sufficiently so that mortar adheres to the
edge of the trowel.

DONT
Dont overwork freshly placed
concrete. Excessive finishing brings
an excessive amount of water and
fines to the surface, resulting in a low
strength surface skin. Dont spread
dry cement on a finished surface to
absorb water. This reduces wear
resistance and durability of the surface
and induces crazing.

Provide contraction joints to control

cracking. On slabs such as sidewalks and
driveways, use a jointing tool at intervals
equal to the width of the slab, but not
greater than 20 feet (6,100 mm). On large
slabs, it may be desirable to run grooves in
both directions to reduce the slab thickness
at controlled joints, and including any
cracking from shrinkage stresses to occur
at these joints. These grooves should be
deep enough to be functional and not just
superficial.
On large concrete surfaces, it may be
desirable to cut joints one inch (25 mm) or
more into the concrete with a power saw
fitted with an abrasive blade. Cutting
should be done within 4 to 12 hours after
finishing, after the surface is firm enough
not to be damaged by the blade.

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3.3.5 Curing
DO
Cure by temperature and moisture control:
1. Keep concrete around 70F (21C) for
a minimum of 3 days after placement.
[The
hydration
process
ceases
altogether below 40F (4.5C)]
2. Keep concrete moist for at least 7 days
after pouring by (a) flooding the
surface to a depth of at least 1 inch (25
mm), or (b) covering with soaked
straw, burlap or waterproof paper, (c)
frequent sprinkling with water, or (d)
spraying the surface with a special
curing compound.
If possible, let concrete cure a full month
before putting it to full use. The first 3
days are very important in the life of
concrete. During this early period, when
the cement and water are combining
rapidly, the concrete is most susceptible to
permanent injury. At the age of 7 days, the
concrete has attained approximately 70
percent strength; at the end of 14 days,
approximately 85 percent; in 28 days,
almost full strength. Concrete actually
continues to gain strength for years.

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DONT
Dont permit concrete to lose water
rapidly. Cracking and loss of strength
occur when water evaporates too
rapidly. If concrete is kept moist for at
least 3 days after placement, it will
reach its peak strength with a
minimum of cracking.
Dont under any circumstances permit
freshly placed concrete to freeze. At
32F (0C) and below, expansion
changes within the mix will cause
permanent damage and drastic loss of
strength.
Dont let direct rays of the sun hit
freshly finished concrete. Direct heat
of the sun promotes too rapid drying.
Do shade the finished job and keep the
surface moist during the curing period.

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3.4 Curing Materials and Methods

Proper curing is one of the most important single factors in achieving proper strength
concrete. The water tightness, durability, strength and surface appearance of concrete
depend largely on whether or not the concrete has been properly cured. Structural
weaknesses, visible cracks, spalling and other surface imperfections may develop and
progress if insufficient attention is paid to curing the green concrete structure or slab.
Preliminary care in selection of materials, mixing, forming and in placement can be
nullified if concrete curing is neglected.
Proper curing accomplishes two very important functions:
1. It retains adequate moisture within the concrete, insuring sufficient water to
permit complete hydration of the cement.
2. It stabilizes temperature at the level required to insure the completion of this
chemical reaction. Proper initial curing conditions are achieved if the concrete is
maintained at a temperature about 70F (21C) and kept thoroughly moist for a
minimum of at least 3 days.
Recommended curing methods and materials include: (1) water-spraying, (2) burlap
tarpaulin, (3) membrane compounds, (4) water-proof paper, and (5) plastic sheeting.
1. Water spraying Water spraying forces a fine spray of water to cover the entire
concrete surface being cured. Usually a horizontal pipe with spray nozzles at set
intervals is laid down the center of a paved area. Care must be exercised to
prevent the weight of the pipe from marring the new concrete surface.
2. Burlap tarpaulin Burlap tarpaulin is an efficient secondary curing material for
slab construction. Spraying or ponding is employed until the concrete hardens.
Then a water saturated burlap tarpaulin is spread over the concrete surface. This
tarpaulin must be wet throughout the curing period. Burlap tarpaulins can be
treated with plastics, aluminum and other materials to improve handling qualities,
light reflectance, resistance to rot and fire resistance. Curing cost per operation is
reduced because burlap tarpaulins can be used repeatedly.
3. Membrane compounds Membrane compounds have become widely used curing
aids because of their ease of application. Membrane compounds can be applied
with hand or power sprays. The compounds can be ordered in clear, black, white
or gray.
A. Clear compounds Clear compounds are preferable for surfaces that must be
architecturally attractive, such as exposed walls, ceilings, and stairways. Dyes
that fade within a few days may be added to these compounds. These dyes
serve as visible aids to insure complete and uniform concrete coverage.
B. Black Compounds - Black compounds, which have an asphaltic base, are used
whenever color is of little importance. Black compounds provide an
especially effective moisture barrier because of the viscosity. The color assists
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in gauging the thickness of the application. Black compounds are both tough
and waterproof. When plans call for floor slabs to be covered with tile or
linoleum, a black curing compound provides an excellent base for those
materials. Black compounds should not be used in hot weather because black
pigments absorb heat.
C. White compounds White compounds are especially effective in hot weather
concreting. By reflecting a high percentage of heat rays, white compounds
help reduce the concrete temperature. If glare from white compounds is a
problem, a gray colored compound, which blends with the natural color of the
concrete can be used. Some of these compounds can inhibit the bonding of
paint to the concrete, so care should be exercised in the selection of a
compound.
4. Waterproof paper Waterproof paper is a widely used curing material, usually
available in widths of 18 inches (450 mm) to 96 inches (2,400 mm). This low
cost and efficient curing material is spread on the concrete surface with the edges
anchored with sand or planks. Waterproof paper provides an effective moisture
barrier, is easy to apply, offering some protection against damage from frost,
direct sun, traffic, mortar staining and debris. Cleanup is fast and easy. Often
waterproof paper can be reused, thereby offering still more economy. Some
waterproof curing papers are reinforced with a pattern of glass fibers to reduce
likelihood of tearing.
5. Plastic sheeting Plastic sheeting is a lightweight, flexible curing material.
Although higher in cost than most waterproof curing papers, plastic sheeting is
easy to fit over even the most complex shapes. Plastic sheeting is non-absorptive,
and therefore resists mildew and rotting. In addition, the weight of plastic
sheeting is constant, wet or dry. Plastic sheeting can be rolled up for reuse after
the curing process is completed. Plastic sheeting need not be idle between curing
applications it can be used for such jobs as protecting lumber and other job-site
materials from the weather.
Plastic sheeting is available in widths up to 32 feet. Because of the lightweight of
this material, little manpower is needed to handle the largest sizes. Durability
depends to a great extent upon the thickness of the material. Most plastic sheeting
used in the concrete industry is milky or white in appearance. This white pigment,
which has been added to an otherwise clear material, helps reflect heat rays, and
therefore helps keep concrete temperatures at the desired curing level. It can also
be welded, permitting airtight joints, thus aiding in preventing moisture
evaporation.

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NOTE
Wet earth, sand, straw, sawdust, cotton mats and similar
improvised materials commonly employed in the past have,
for the most part, fallen into disuse in the construction
industry. These materials are either inefficient or present
costly labor, material or cleanup problems. They may also
create a serious staining problem.
3.5 Weather Conditions
Applying a curing material to freshly placed concrete alone does not insure a properly
cured, finished product. Atmospheric conditions at the time of the pour and during the
curing period are very important in determining the final strength and surface perfection
of the concrete structure or slab. Problems must be anticipated, and provisions for
combating adverse conditions must be made in advance.
3.6 Hot Weather Curing
Hot weather can create excessive evaporation and excessive heat in freshly placed
concrete. If neglected during the curing period, these can cause permanent injury to
concrete.
Hot weather curing must be started as soon as possible after concrete is in place. If the
surface is hard enough to resist marring, the concrete is ready for protection against
evaporation loss and heat damage. If concrete is exposed to hot winds, windbreaks will
aid the curing process. Shading fresh concrete from direct rays of the sun will also help.
Water curing is very effective. Often, in very hot weather, it is advisable to cover the
concrete with standing water or to spray the concrete for 12 hours before employing other
curing mediums.
NOTE
Alternate wetting and drying must be avoided.
In hot weather, maximum strength and surface perfection will be attained if the curing
period is prolonged as long as possible at least 7 days. During the balance of the first
month, the green concrete should be subjected to limited use.
3.7 Cold Weather Curing
A basic rule for winter concreting is that the concrete must be prevented from freezing
during curing. It takes twice as long for concrete to set up and gain the strength needed
when the temperature is 50F (10C) as when it is 80F (27C). Strength gain of concrete
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is retarded significantly at temperature below 40F (4.5C). If no freezing occurs, curing

will continue when the temperature rises. If concrete freezes, severe damage is very
likely to occur.
While the strength of concrete subjected to a single freezing cycle at an early age may be
restored to normal by resumption of favorable curing conditions, such concrete may not
have the resistance to weathering, nor the watertightness as concrete that has not been
frozen. If several cycles of freezing and thawing occur at an early age, strength and other
desirable qualities are permanently reduced.
Concrete generates heat during hardening as a result of the chemical process by which
cement reacts with water. The heat generated is called the heat of hydration. It varies in
amount and rate, depending on the dimensions of the concrete, the ambient air
temperature, initial concrete temperature, water-cement ratio, cement composition and
fineness, amount of cement, and admixtures. Because of the heat of hydration, covering
concrete with a tarpaulin or other insulating material may be all that is necessary to keep
it from freezing. Thermometer readings of the concretes temperature will tell if the
covering is adequate.
High strength at an early age is desirable in winter construction to reduce the length of
time temporary protection is required. The use of Type III concrete, as outlined in
paragraph 3.2.1.1, is desirable for this reason.
Entrained air is particularly desirable in any concrete placed during freezing weather. Air
entrainment provides the capacity to absorb stresses due to ice formation within the
concrete. Further information on air entraining also is given in paragraph 3.2.1.1.
Small amounts of an accelerator, such as calcium chloride (at a maximum dosage of
2percent by weight of Portland cement) can be used to accelerate the setting and early-age
strength of concrete in cold weather. However, several restrictions on the use of
chlorides should be carefully noted if their use is contemplated.
Also, the use of so-called antifreeze compounds to lower the freezing point of concrete
must not be permitted. The quantity of these materials needed to lower the freezing point
of concrete appreciably is so great that strength and other properties are seriously affected
by their use.
Keeping concrete moist is essential in all curing procedures. If heating units are used, the
slab or structure should be sprayed with water and then covered with a waterproof
material. Heating with live steam is excellent practice in very cold climates, because
steam provides both heat and moisture.
Because fresh concrete surfaces absorb gases, avoid the use of non-vented heaters. If the
concrete absorbs carbon dioxide during the curing process, the surface can be
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permanently softened. This condition is known as surface carbonation and is directly

traceable to the use of non-vented heaters.

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4.0 RECEIVING EQUIPMENT

4.1 Introduction
For a given SWIFTPAC installation, the responsibilities of scheduling, procurement,
receiving and installation are divided among various PWPS departments, the customer
and the customers contractor and subcontractors, according to the contracts for site
construction. The variety of SWIFTPAC installation requirements that will occur will
require different scopes of equipment and different contractual arrangements. This
section provides a framework of responsibilities and procedures for monitoring and
controlling onsite materials from receipt through installation at a typical site, despite
varying installation requirements.
The customer has the overall responsibility for implementing procedures to receive, store
and issue equipment and materials supplied by PWPS. He has the responsibility to pass
on all shipment and delivery information to the appropriate contractor(s), and inform
them of changes when they occur. The Site Supervisor will also monitor equipment
schedules and progress of balance of plant systems as procured and installed under
contract with the general contractor.
4.2 Sources of Information
Before the equipment is delivered, the Site Supervisor will be provided information on
the types and quantities of equipment and when it is scheduled to arrive. This
information will be in the equipment ordered list from PWPS Purchasing.
Coordination of shipments to the site is the responsibility of the PWPS Project Manager
(PM). PWPS PM will issue project orders to PWPS Purchasing as applicable. PWPS
will be involved in assembling and shipping most of the skids used in the SWIFTPAC
system. When the vendor gives shipment/delivery information to the PM, this will be
sent as advance notice to the Site Supervisor. PWPS traffic will always be involved in
shipment by land, air and rail and, as needed, for other types of shipment. The Bill of
Material (BOM) for each SWIFTPAC project will indicate Purchasing contacts
concerning shipments.
Computer printouts will usually be generated by the general contractor and be available to
the Site Supervisor to schedule and track progress of the project. Such computer
programs as PRIMAVERA, MICROSOFT PROJECT, AUTOGRAPH and CPM (Critical
Path Method) will give a Construction Schedule Chart that will include the delivery
schedule.

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4.3 Equipment Schedule Chart

The Site Supervisor should maintain an equipment schedule chart on-site. This chart
identifies the equipment to be received, the purchase order, vendor, when it is expected at
the site, and comments on problems and other special information, as appropriate. This
chart could take the form of a status board, computer printout or other equivalent format.
The delivery dates must be updated as necessary and the information passed on to the
contractor responsible for handling that equipment.
4.4

Project Shipping and Site Inventory Procedures

4.4.1

Purpose

The purpose of this procedure is to provide standardized guidelines for the delivery of
project equipment and material. All project equipment and/or material will ship in
accordance with the guidelines contained within this procedure.
NOTE
No material will be transported to the job site without strict
adherence to the requirements established by this
procedure.
4.4.2

Areas of Responsibility

4.4.2.1 Purchasing Agent

The Purchasing Agent is responsible for direct shipment documentation in accordance
with Pratt & Whitney Power Systems (PWPS) Procedures.
4.4.2.2

Material Planner

The Material Planner is responsible for shipping authorization compliance and work
order closeout.
4.4.2.3

Transportation Coordinator

The Transportation Coordinator is responsible for the logistics in movement of cargo to

consolidation points and/or Project job sites, through receipt at job site.
4.4.2.4

Project Manager

The Project Manager is responsible for providing direction to PWPS personnel, the
Project Requirements in accordance with PWPS Contract.
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4.4.2.5

Customer and/or Customers Contractors

The customer and/or the customers contractor are responsible for equipment off-loading
from all incoming trucks.
4.4.2.2 Quality Assurance
Quality Assurance is responsible for the inspection of all equipment, coordination of
Quality Inspection subcontractors and final sign-off of direct ship paperwork.
4.4.2.7 Site Inventory Advisor
The Site Inventory Advisor is responsible for all site inventory receipts, completion of
required paperwork, assisting and witnessing the customers physical inventory of cargo,
and obtaining customer written acceptance of the cargo.
4.4.3

Shipping Processes

Two processes will be utilized for shipping cargo against projects:

1. Direct-Shipments for major ancillary equipment.
2. Shipping in-place at the point of manufacture in accordance with Procedure
PP 7.1.6.
NOTE
All direct shipments require Quality sign-off prior to
issuance of receiver.
Upon receipt in the ASK System, each shipment will be moved when the Material
Coordinator issues the Shipping Authorization (SA).
Shipments to PWPSs warehouse in East Hartford, CT, where material is inspected,
receiver issued by warehouse personnel and placed in inventory. The Material Planner
will be responsible for issuance of Shipping Authorization for the movement to the
project job sites.
The Transportation Coordinator will be responsible for the logistics of all equipment
moves to project job sites.
For direct shipments the suppliers will receive the following instruction from
Transportation/Logistics:
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1. Ship-to address
2. Shipping marks/labels (to be provided by Transportation/Logistics

NOTE
Each individual pallet or crate containing items shipped for
Project must be marked with this information.
A cargo manifest will be utilized in the event that one shipment is divided between two or
more trucks. The cargo manifest will describe exactly what is shipped on each truck.
Unit designators are required for each shipping authorization, for example Unit 1, Unit 2,
Unit 3, etc. These designators need to be communicated to the vendors/suppliers so that
they can properly mark their equipment, which will help to ensure that an accurate
inventory can be maintained at the site.
4.4.4

Shipment Tracking

A shipment tracking report will be available on PWPSs Website. This report will
contain all shipments that are currently moving to each site.
There will also be an inventory report, by warehouse location, on the internal PWPS Odrive server, which contains all equipment currently in storage.
Both of the shipment tracking report and the inventory report will be maintained and
updated daily by Transportation/Logistics.
4.4.5

Site Receiving Procedures

NOTE
The customer and the PWPS site representative must be
pre-alerted on the readiness to ship ten (10) days prior to
date of shipment to site

Upon shipment of material to a job site and/or from the PWPS warehouse, the
Transportation Coordinator will notify the customer and PWPS site representative via a
pre-alert e-mail and/or Fax to the below listed locations:
1. PWPS site trailer
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2. Customers contractors office

A shipping manifest will also be forwarded to each site representative through the
Transportation Coordinator
4.4.6

Shipment Pre-Alert

The shipment pre-alert will consist of the following information:

1. Ship from location
2. Site location
3. PWPS part or assembly number
4. Cargo description
5. Shipping dimensions / weights (including any special off-loading/storage
instructions)
6. ETA on site
7. Truck bill of lading (B/L) or air bill number
8. Transport via company name
9. PWPS shipping authorization number
10. Any special notes specific to the shipment
4.4.7

Receiving Project Cargo/Material

Upon receipt of the pre-alert notice, the PWPS Site Inventory Advisor will be ready to
receive the cargo. Once the cargo arrives at the site the PWPS Site Inventory Advisor
will complete the actions listed below. In the event material is damaged, the PWPS
representative(s) is to sign the B/L and state that material was received damaged. A copy
of the B/L will be transmitted back to the Transportation Coordinator, who will file claim
with the carrier and coordinate with the PWPS Purchasing Agent for inspection and/or
repair of the material.
Each Twin Pac/Power Pac will have its own folder listing a description of the item, part
number, top level assembly, shipping authorization, pre-alert notification and contain all
packing slips, bills of lading and bill of materials. The PWPS Site Inventory Advisor will:
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1. Cross-reference the number of pieces physically on the truck vs. the

number of pieces on the truck bill of lading (Straight Bill of Lading).
2. Check the overall condition of the cargo.
3. Match each shipping authorization with the appropriate top assembly
number.
4. Segregate each box, pallet, crate, or container by top assembly number.
5. PWPS Site Inventory Advisor will assist customer contractors in the
inventory of the equipment delivery.
6. The contractor shall be responsible for opening each box and crossreferencing the physical number of parts in the shipment to the number of
parts listed in the bill of material. The PWPS Site Inventory Advisors
role is what the title implies, one of an advisory nature only. His
responsibility should be strictly advisory and to keep the paperwork
moving.
7. It should be kept in mind that the individual accomplishing the inventory
should also be checking for proper bill of material item numbers and other
miscellaneous markings related to the identification of each individual
part, such as part numbers taped or written on each item.
8. The Site Inventory Advisor will be present during this time to answer
questions or to take action to resolve any problems which may arise during
the physical inventory process, such as part identification or BOM item
number verification.
9. The contractor will continue sorting each shipping authorization into each
top assembly numbers designated area.
10. The Site Inventory Advisor is responsible for completing the required onsite paperwork. This paperwork is as follows:
A. Shipping Authorization (SA) Shortage Log
B. Bill of Material Shortage (BOM) Log
C. BOM Audit
D. Daily Receiving Log
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E. Customer/Customer Representative signed receipts for the transfer

of material
4.4.7.1 Damaged and Short Equipment Delivery Procedures
Any shipment that has sustained obvious damage or is otherwise mishandled should be
unpacked and thoroughly inspected before it is signed for. Details of damage must be
reported immediately to the Traffic Department. If there is suspected damage, it should
be indicated on all copies of shipping documents. Also, if the number of pieces delivered
does not correspond to the shipping document information, this should be noted and
reported immediately to the PWPS Project Manager.
In case of damaged equipment, the package, its contents and packing material must be
held until the carriers representative makes an inspection. This inspection will be
arranged for by Traffic.
Where external damage is visible and/or internal damage is suspected, a preliminary
claim for $100 should be filed with the carrier. This allows additional time to search for
internal damage. If a claim is filed, a photograph should be taken to show signs of rough
handling, and the Traffic Manager should be notified.
Traffic will assign a claim number to shipments received under these conditions. This
claim number must then be given to the buyer in Purchasing, who will arrange to have the
damaged equipment repaired.
NOTE
It is not until the claim number is assigned and the carriers
representative has made his inspection that the equipment
can be used, moved to another receiving area, or the repair
work can be started.
Notification of concealed damage must be made to the delivery carrier as soon as it is
noted, preferably within forty-eight (48) hours after delivery.
Should it become necessary to deviate from these procedures, Traffic should be advised.
4.4.7.2 Freight Collect
Occasionally, a delivery will be made on a freight collect basis. If at all possible, the bill
should be sent to the Traffic Department for payment. If there is a problem, Traffic
should be alerted before paying the bill.
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4.4.7.3 Storage of Equipment

The Contractor shall provide secure and adequate storage for all material to protect
against loss or theft, mechanical damage, dirt, moisture, or excessive heat or cold. The
Project Manager will provide the Contractor with details of special storage requirements
in advance of delivery. Outdoor storage must have prior approval from the Site
Supervisor.
Whenever practical, material will be stored in the original shipping container and clearly
marked to show contents and quantities.
Material stored outdoors will be placed on pallets or blocks, with all openings sealed and
covered with tarpaulins, where required.
Under some circumstances, such as severe weather, poor site conditions, delayed
schedules, etc., it is wise to store the engine and other valuable equipment in a warehouse
local to the site. The added security and weather protection often outweigh the extra cost
involved. If equipment is stored, there should be coordination with the contractor(s)
involved as to when that equipment will be needed.
Electrical generators should be stored, sealed in the original shipping containers. As soon
as possible after receipt on site, the generator internal space heaters should be powered
using a temporary source of 3 phase, 380/480 volt power. Fire protection measures must
be implemented as required.
4.4.7.4 Material Issue
The Contractor shall strictly control release of material to construction personnel. A
written record shall be maintained, showing item(s), quantity and date released, and
signatures of recipients. As a general practice, high value and unique parts not used
during a work shift will be returned to shortage at the end of the shift.
The Site Supervisor has the right to audit Contractor storage areas and control documents
at any time. At the completion of construction, all unused PWPS furnished parts,
material and tools will be returned to the Site Supervisors control for disposition.
4.4.8

Documentation

PWPSs Inventory Advisor will email/fax the following documentation back to

Transportation Coordinator:
1. The Receiving Notes box on the Truck Bill of Lading (TBOL) should be
filled out with any pertinent information at the time of cargo delivery (i.e.:
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equipment shortages, damage, etc.). Damages are to be noted on the B/L

by the PWPS site representative and signed by the site representative.
Digital photos will be taken of the damage and distributed to home office
accordingly.
Diskette will reside on the job site with PWPS
representative.
2. The PWPS Inventory Advisor will complete the Receiving Inventory
Report. Upon the receipt of the Receiving Inventory Report back at
P&WPS, copies of the reports will be distributed to the following:
A. Project Manager
B. Project Engineer
C. Material Planner
D. Transportation Logistics Log Book
3. If any parts are missing from any Shipping Authorization, a copy of that
Shipping Authorization/Packing List must be faxed with any notes on the
missing parts to Transportation Coordinator/Material Planner. PWPS site
representative will work with customer/contractor when material is
inventoried against the packing slip and advise any discrepancies back to
the Quality Assurance representative and Planner.
4. PWPS site representative will be responsible for maintenance of a
spreadsheet with actionees and due dates for when all discrepancies are to
be completed.
NOTE
In the event that the list has too many pages to fax the first
page of the packing list will be faxed and a complete hard
copy of the list will be sent via overnight courier to the
Transportation Coordinator.

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CARGO MANIFEST
TBOL/AWB #:
Load Manifest:
Ship Via:
Shipping Authorization:
Description:
Ship From:

Ship To;

ETD:

ETA:

Notes/Status:

Cargo Dimensions:

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RECEIVING INVENTORY REPORT

TO:
DATE
FAX NUMBER: (860) 565-5780

FROM:
COPY:
NUMBER OF PAGES:

Attached please find the following documents:

Straight Bill of Lading Number:

P _________________

This document must be completed for each Straight Bill of Lading. When parts are
missing, please fax this document along with copies of the Bill of Lading and SA to
the phone number shown above. Mark the cover sheet Attn: Jeff Snelling
Attached are copies of the following Shipping Authorizations (SA) which have
missing parts:
SA Number

SA Number

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Remarks

Top Assembly

Part
Inventoried
Yes/No

Parts Missing
From SA
Yes/No

SA Accepted
and Signed By

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5.0 INSTALLING EQUIPMENT

5.1 Introduction
Site specific instructions for the field installation of a FT8 Power Pac and Twin Pac
systems are given through the drawings and documentation described in this section.
This section gives general information to assist and guide the Site Supervisor and/or
Construction Engineer during field installation of all FT8 systems. Paragraph 5.11
includes basic assembly drawings for the standard FT8 Power Pac and Twin Pac. These
drawings show the assembly of major system components.
5.2 PWPS Drawings and Numbering Systems
5.2.1 Drawings
Each major assembly drawing will contain the necessary information for its installation,
where possible. Installation information for a given project is located by referring to the
DRAWING TREE for that project. PWPS drawings are numbered based on the
following two numbering systems:
1.

There is a standardized drawing tree numbering system that will be used for
all site-specific drawings. The drawing number consists of a four (4)-digit
project number assigned to a given site followed by a dash and the
standardized drawing tree number. The standardized drawing tree number is
broken down into two parts. The first part is typically a three-digit number,
which is the top-level drawing number. The second part is the specific
drawing number, which is made up of five characters.
For example: 9612-138-M000D

ASSY, PWPS FIELD PIPING

9612-

is the four (4) digit PWPS project number

-138-

is the top level drawing number for Field Piping

-M000D

is the specific drawing number.

Note that the five (5) digit specific drawing number always starts and ends
with a letter. The number will start with one of the following three (3) letters:
E, M or S. These letters indicate which Engineering group is responsible for
generating the drawing. The letter E is for electrical, M is for mechanical and
S is for structural.

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The five- (5) digit specific drawing number will end with one of the following
letters: B, D, J, and L. The letter B denotes that this is the detached bill of
material for the drawing with the same number while the letter D indicates
that it is a drawing or blue print, for example drawing number 9612-123E400B is the detached bill of material for drawing 9612-123-E400D. The
letter J indicates that this is a job specification, typically vendor equipment,
while the letter L is for listings, such as Load Lists or Cable Lists etc. e.g.
9612-189-E007L.
The standardized drawing tree numbers of interest to construction personnel
for FT8 systems are given in Table 5-1. This list leaves out some of the lower
tiers of numbers in the complete drawing tree and also many drawings that
normally would not be required for construction. A complete drawing tree
will be available for each installation.
2.

Drawings that usually are the same from site to site are given an IPX prefix,
where X denotes the drawing size, A through E. These generic drawings will
be listed on the overall drawing tree for a given site and will be crossreferenced to the corresponding standardized drawing number described in
paragraph (1) above, for reference. When an IPX (generic) drawing number is
used for a project, the standardized/site specific drawing number for that
drawing will not exist.
For example:

IPE-22180

ASSY, OIL MIST ELIMINATOR

NOTE
Some of the IP drawing numbers will be followed by a GR1, or a
GR2, or GR. designator. This designator indicates that the
drawing has multiple bills of materials. GR1 indicates to use the
quantities listed under the number 1 bill of material on the IP
drawing; GR2 indicates to use the number 2 bill of material, etc.
5.2.2 Specifications
The bulk of the PWPS parts provided for a particular project will not be made up of
drawing numbers as noted above. They will be CT part numbers. The CT is the PWPS
Specification for common materials such as pipe, wire, nuts and bolts etc., as well as
more specialized equipment like pressure transducers, flow meters, protective relays, etc.
The CT part number starts with the two letters CT followed by six numbers. For example
the PWPS Specification for Mobil Jet 254 Gas Turbine Oil is CT116675.

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5.2.3 Bill of Materials

PWPS drawings are made with the bill of material on the body of the drawing or
detached, on a separate spreadsheet or printout. Some drawings are made without any bill
of material while no drawings are made with both detached bills and bills on the drawing.
When the bill of material is on the body of the drawing, it will normally be found on the
last page of multiple page drawings. When a detached bill of material is used there is no
special identification on the drawing to direct the user to look for the bill. If the drawing
has item numbers indicated in circular balloons without a bill of material on the body of
the drawing then there will be a detached bill of material for the drawing.
PWPS bill of materials are designates as EG or MG. These letters can be found at the top
center of the bill of material in parentheses. The letters EG stand for ENGINEERING bill
of material MG stands for MANUFACTURING bill of material.
CAUTION
The EG (Engineering) bill of material should never be used
for construction! The EG bill of material is an uncontrolled
document that can be modified by anyone at PWPS at any
time.
The MG (Manufacturing) bill of material is a controlled
document that once released requires an Engineering
Change Notice to make any modifications to quantities and
or part numbers. Construction and site personnel must use
only the MG bill of materials.
Note that some drawings are bill of material only and that not all items are shown on the
drawing. Several drawings exist as bill of material drawings only, such as the Startup
Spares, which would be a XXXX-172-S000B drawing number. In addition, some
drawings, like the General Arrangement drawing, XXXX-100-S000D or the top level
Field Electrical drawing, XXXX-123-E000D, will have expanded bill of materials that
may include significantly more material than what is depicted on the drawings. Typically
the note sections of these drawings will indicate how or where to use the material.
5.2.4 Other Part Numbers
PWPS will also use additional part numbering systems then those noted above. Special
purpose tooling will use a PWA or a TC prefix to their part numbers. For example a
borescope kit would use a PWA77460 part number while a gas turbine alignment cradle
assemble would use a TC350-116 part number. As well as using the PWPS part
numbers, the PWPS bill of materials will include military specification part numbers such

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as MS, AN, AS, ST, etc. In addition to these numbering systems, PWPS will use a
different numbering system for identification of gas turbine and power turbine parts.

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TABLE 5-1 DRAWING TREE NUMBERING SYSTEM * (Sheet 1 of 10)

XXXX-1
XXXX-100-S000D
XXXX-100-S000B
XXXX-111
XXXX-111-S000D-01
XXXX-111-S000D-02
XXXX-111-S000B-01
XXXX-111-S000B-02
XXXX-111-E000D
XXXX-111-E000B
XXXX-111-E000L
XXXX-111-M000D
XXXX-111-M000B

GENERAL ARRANGEMENT (SYSTEMS, PLANT)

ASSY, ARRANGEMENT, PLANT [where XXXX is the site
project number]
ASSY, ARR, PLANT, BILL OF MATERIAL
ASSY, GAS TURBINE AND BASE
ASSY, GAS TURBINE & BASE (LEFT)
ASSY, GAS TURBINE & BASE (RIGHT)
ASSY, GAS TURBINE & BASE, BILL OF MATERIAL
ASSY, GAS TURBINE & BASE, BILL OF MATERIAL
ASSY, GAS TURBINE TO BASE, ELECTRICAL
ASSY, GAS TURBINE TO BASE, ELECTRICAL, BILL OF
MATERIAL
LIST, WIRING, GAS TURBINE & BASE TO A JB
ASSY, GAS TURBINE & BASE, PIPING
ASSY, GAS TURBINE & BASE, PIPING, BILL OF
MATERIAL

XXXX-112
XXXX-112-S000D
XXXX-112-S000B

ASSY, ENCLOSURE FIELD

ASSY, ENCLOSURE FIELD
ASSY, ENCLOSURE FIELD, BILL OF MATERIAL

XXXX-113
XXXX-113-S000D
XXXX-113-S000B
XXXX-113-S100D
XXXX-113-M200D

ASSY, MECHANICAL FIELD

ASSY, MECHANICAL FIELD
ASSY, MECHANICAL FIELD, BILL OF MATERIAL
COLLECTOR BOX
ASSY, 6 STAGE SPENT AIR

XXXX-114
XXXX-114-S100D
XXXX-114-E100D
XXXX-114-S200D
XXXX-114-E200D
XXXX-114-S300D
XXXX-114-E300D

ASSY, STRUCTURES, OTHER

ENCLOSURE, MECHANICAL PACKAGE (L/O AND W/I)
ENCLOSURE, MECHANICAL PACKAGE, ELECTRICAL
ENCLOSURE, LUBE OIL SKID
ENCLOSURE, LUBE OIL SKID, ELECTRICAL
ENCLOSURE, WATER INJECTION SKID
ENCLOSURE, WATER INJECTION SKID, ELECTRICAL

This is a master drawing tree listing. A project will use some of these drawings, as required.

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TABLE 5-1 DRAWING TREE NUMBERING SYSTEM * (Sheet 2 of 10)

XXXX-115
XXXX-115-S000D
XXXX-115-S000B
XXXX-115-S100D
XXXX-115-S150D
XXXX-115-S200D
XXXX-115-S210D
XXXX-115-S300D
XXXX-115-S400D
XXXX-115-S500D
XXXX-115-S600D
XXXX-115-S700D
XXXX-115-S800D
XXXX-115-S850D
XXXX-115-S900D
XXXX-121
XXXX-121-E000D
XXXX-121-E000B
XXXX-121-E300D
XXXX-121-E301D
XXXX-121-E301B

ASSY, FOUNDATION
ASSY, FOUNDATION
ASSY, FOUNDATION, BILL OF MATERIAL
FOUNDATION INTERFACE, MAIN
FOUNDATION, INTERFACE, TRENCH
FOUNDATION, FUEL SYSTEM FILTER
FOUNDATION, FUEL SYSTEM FORWARDING
FOUNDATION, INTERFACE, MAIN BREAKER
FOUNDATION, INTERFACE, LUBE OIL SKID
FOUNDATION, INTERFACE, CONTROL ENCLOSURE
FOUNDATION, INTERFACE, DIESEL GENERATOR
FOUNDATION, INTERFACE, GAS SCRUBBER
FOUNDATION, INTERFACE, HYDRAULIC START
SYSTEM
FOUNDATION, INTERFACE, AIR START SYSTEM
FOUNDATION, INTERFACE, LIQUID FUEL SYSTEM

XXXX-121-E303D
XXXX-121-E303B
XXXX-121-E305J
XXXX-121-E306D
XXXX-121-E400D
XXXX-121-E401D
XXXX-121-E500D
XXXX-121-E500B

ASSY, CONTROL CENTER

ASSY, CONTROL CENTER ELECTRICAL
ASSY, CONTROL CENTER ELECTRICAL
ASSY, MOTOR CONTROL CENTER
ASSY, CABINET, MCC TERMINAL BOARD (CTB)
ASSY, CABINET, MCC TERMINAL BOARD (CTB), BILL
OF MATERIAL
ASSY, RACK I/O, MCC
ASSY, RACK I/O, MCC, BILL OF MATERIAL
SPEC, MOTOR CONTROL CENTER, AC & DC
MOTOR CONTROL CENTER, AC
ASSY, INSTR/OPERATOR CABINETS
ASSY, CABINET, UNIT CONTROL
ASSY, BATTERY, SYSTEM
ASSY, BATTERY, SYSTEM, BILL OF MATERIAL

XXXX-122
XXXX-122-E000D
XXXX-122-E100D

REMOTE CONTROL ASSEMBLY

ASSY, CABINET, REMOTE TERMINAL UNIT
ASSY, CABINET, REMOTE CONTROL

* This is a master drawing tree listing. A project will use some of these drawings as required.

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TABLE 5-1 DRAWING TREE NUMBERING SYSTEM * (Sheet 3 of 10)

XXXX-123
XXXX-123-E000D
XXXX-123-E000B
XXXX-123-E100D
XXXX-123-E100B

XXXX-123-E300D
XXXX-123-E300B
XXXX-123-E400D
XXXX-123-E400B
XXXX-123-E500D

ASSY, FIELD ELECTRICAL, INCL. GROUNDING

ASSY, PWPS FIELD ELECTRICAL
ASSY, PWPS FIELD ELECTRICAL, BILL OF MATERIAL
ASSY, INTERCONNECT CABLE, CONTROL
ASSY, INTERCONNECT CABLE, CONTROL, BILL OF
MATERIAL
LAYOUT, CABLE TRAY, PLANT
ASSY, INTERCONNECT CABLE, POWER
ASSY, INTERCONNECT CABLE, POWER, BILL OF
MATERIAL
ASSY, CABLE, GROUNDING
ASSY, CABLE, GROUNDING, BILL OF MATERIAL
ASSY, SITE LIGHTING SYSTEM
ASSY, SITE LIGHTING SYSTEM, BILL OF MATERIAL
LAYOUT, CABLE TRAY, CONTROL HOUSE

XXXX-13
XXXX-131

ANCILLARY SYSTEMS
SKID, STARTING

XXXX-132
XXXX-132-M00J

FIRE SYSTEM
SPEC, FIRE/GAS DETECTION & SUPPRESSION

XXXX-133
XXXX-133-M100J
XXXX-133-M200J
XXXX-133-M300J
XXXX-133-M400J

GAS FUEL
SPEC, SKID, GAS METERING
SPEC, SKID, GAS FILTERING
SPEC, SKID, GAS FUEL COMPRESSOR
SPEC, SKID, GAS PRESSURE REDUCING

XXXX-134
XXXX-134-M100D
XXXX-134-M100B

LIQUID FUEL SYSTEMS

ASSY, SKID, LIQUID FUEL METERING
ASSY, SKID, LIQUID FUEL METERING, BILL OF
MATERIAL
SPEC, SKID, LIQUID FUEL METERING
SPEC, SKID, LIQUID FUEL FILTERING
SPEC, SKID, LF FORWARDING

XXXX-123-E150D
XXXX-123-E200D
XXXX-123-E200B

XXXX-134-M100J
XXXX-134-M200J
XXXX-134-M300J

* This is a master drawing tree listing. A project will use some of these drawings as required.

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TABLE 5-1 DRAWING TREE NUMBERING SYSTEM * (Sheet 4 of 10)

XXXX-135
XXXX-135-M100J

WATER/STEAM INJECTION SYSTEMS

SPEC, SKID, WATER INJECTION

XXXX-136
XXXX-136-M100J

LUBE OIL SYSTEM

SPEC, SKID, LUBE OIL

XXXX-137

EQUIPMENT, MISCELLANEOUS

XXXX-138
XXXX-138-M000D
XXXX-138-M000B
XXXX-138-M400D
XXXX-138-M400B

FIELD PIPING
ASSY, PWPS FIELD PIPING
ASSY, PWPS FIELD PIPING, BILL OF MATERIAL
ASSY, FIELD, COLD AIR BUFFER
ASSY, FIELD, COLD AIR BUFFER, BILL OF MATERIAL

XXXX-14
XXXX-141
XXXX-141-S100J
XXXX-141-S200J
XXXX-141-S300J
XXXX-141-S400J
XXXX-141-S401J
XXXX-141-S402J

BALANCE OF PLANT
WASTE HEAT BOILER
SPEC, BOILER
SPEC, SYSTEM, BOILER FEED WATER
SPEC, SYSTEM, BYPASS
SPEC, CONDENSER
SPEC, CONDENSER INLET DUCT
SPEC, SKID, CONDENSATE PUMP

XXXX-142
XXXX-142-S100J
XXXX-142-S200J
XXXX-142-S300J

WATER TREATMENT
SPEC, SYSTEM ,WATER DEMINERALIZATION
SPEC, SYSTEM, WASTE WATER TREATMENT
SPEC, SKID, MAKEUP WATER

XXXX-143
XXXX-143-S100J
XXXX-143-S200J
XXXX-143-S300J
XXXX-143-S400J

EMISSIONS MONITORING
SPEC, SCR
SPEC, CO CONVERTER
SPEC, SYSTEM, CHEMICAL INJECTION
SPEC, SYSTEM, CONTINUOUS EMISSIONS
MONITORING
SPEC, MONITOR, OPACITY

XXXX-143-S500J

* This is a master drawing tree listing. A project will use some of these drawings as required.

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TABLE 5-1 DRAWING TREE NUMBERING SYSTEM * (Sheet 5 of 10)

XXXX-144
XXXX-144-S000D
XXXX-144-S000B

PLANT COOLING
ASSY, SYSTEM, PLANT COOLING
ASSY, SYSTEM, PLANT COOLING

XXXX-145
XXXX-145-S100J
XXXX-145-S200J
XXXX-145-S300J
XXXX-145-S400J
XXXX-145-S500J
XXXX-145-S600J

TANKS
SPEC, TANK, LIQUID FUEL OIL STORAGE
SPEC, TANK, RAW WATER STORAGE
SPEC, TANK, DEMINERALIZED WATER STORAGE
SPEC, TANK, CAUSTIC SODA STORAGE
SPEC, TANK, ACID STORAGE
SPEC, TANK CONDENSATE STORAGE

XXXX-146
XXXX-146-S100J

COMPRESSOR, MARINE
SPEC, COMPRESSOR/MARINE SYSTEM

XXXX-147
XXXX-147-S100J
XXXX-147-S200J

GEAR BOX, CLUTCH, ETC.

SPEC, CLUTCH
SPEC, SYSTEM, VACUUM

XXXX-151
XXXX-151-E100J
XXXX-151-E101J
XXXX-151-S102J
XXXX-151-E103J

ELECTRIC GENERATOR
SPEC, ELECTRIC GENERATOR
SPEC, DIESEL GENERATOR SET
SPEC, STEAM TURBINE GENERATOR
SPEC, AUTOMATIC VOLTAGE REGULATOR

XXXX-152
XXXX-152-E000D
XXXX-152-E100J
XXXX-152-E101J
XXXX-152-E102J
XXXX-152-E103J
XXXX-152-E105J
XXXX-152-E200J
XXXX-152-E300J
XXXX-152-E301J
XXXX-152-E302D
XXXX-152-E400J

ASSY, MEDIUM VOLTAGE

ASSY, SWITCHYARD
SPEC, COMBINED CONTROL HOUSE & SWITCHGEAR
SPEC, BUS DUCT
SPEC, BREAKER, GENERATOR CIRCUIT
SPEC, REACTOR, CURRENT LIMITING
SPEC, SWITCHGEAR & ENCLOSURE
SPEC, TRANSFORMERS, AUXILIARY
SPEC, LINE CUBICLE
SPEC, CUBICLE, NEUTRAL GROUNDING
ASSY, SURGE, PROTECTION
SPEC, TRANSFORMER, STEP UP

* This is a master drawing tree listing. A project will use some of these drawings, as required.

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TABLE 5-1 DRAWING TREE NUMBERING SYSTEM * (Sheet 6 of 10)

XXXX-153
XXXX-153-E200J

HIGH VOLTAGE
SPEC, ASSY, SYSTEM, STEP UP TRANSFORMER

XXXX-16

OPEN CATEGORY

XXXX-17
XXXX-171-S000B

STARTUP KIT, TOOLS AND MISC. PARTS

MISC, PARTS SHIPPED LOOSE

XXXX-172-S000B

START UP SPARES

XXXX-181
XXXX-181-M100D
XXXX-181-M200D
XXXX-181-M201D
XXXX-181-M202D
XXXX-181-M203D
XXXX-181-M204D
XXXX-181-M300D
XXXX-181-M301D
XXXX-181-M302D
XXXX-181-M303D
XXXX-181-M304D
XXXX-181-M305D
XXXX-181-M306D
XXXX-181-M307D
XXXX-181-M400D
XXXX-181-M401D
XXXX-181-M402D
XXXX-181-M403D
XXXX-181-M404D
XXXX-181-M405D
XXXX-181-M500D
XXXX-181-M501D
XXXX-181-M502D
XXXX-181-M505D
XXXX-181-M506D
XXXX-181-M507D

P & IDS
DIAGRAM, P&I, GAS TURBINE SYSTEMS
DIAGRAM, P&I, FUEL AND INJECTION SYSTEMS
DIAGRAM, P&I, LIQUID FUEL SYSTEM
DIAGRAM, P&I, GAS FUEL SYSTEM
DIAGRAM, P&I, WATER INJECTION SYSTEM
DIAGRAM, P&I, STEAM INJECTION SYSTEM
FUEL CONDITIONING SYSTEMS
DIAGRAM, P&I, GAS FUEL CONDITIONING SYSTEM
DIAGRAM, P&I, GAS METERING SYSTEM
DIAGRAM, P&I, GAS FILTERING SYSTEM
DIAGRAM, P&I, LIQUID FUEL CONDITIONING SYSTEM
DIAGRAM, P&I, LIQUID FUEL METERING SYSTEM
DIAGRAM, P&I, LIQUID FUEL FILTERING SYSTEM
DIAGRAM, P&I, LIQUID FUEL FORWARDING SYSTEM
AUXILIARY SYSTEMS
DIAGRAM, P&I, HYDRAULIC OIL SYSTEM
DIAGRAM, P&I, LUBRICATION SYSTEM
DIAGRAM, P&I, START SYSTEM
DIAGRAM, P&I, MUSCLE AIR SYSTEM
DIAGRAM, P&I, ENGINE HEAT SYSTEM
DIAGRAM, P&I, SUPPORT SYSTEMS
DIAGRAM, P&I, FIRE SYSTEM
DIAGRAM, P&I, ENGINE COOLING SYSTEM
DIAGRAM, P&I, ANTI-ICE SYSTEM
DIAGRAM, P&I, WATER WASH SYSTEM
DIAGRAM, P&I, VENT & DRAIN SYSTEM

* This is a master drawing tree listing. A project will use some of these drawings, as required.

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TABLE 5-1 DRAWING TREE NUMBERING SYSTEM * (Sheet 7 of 10)

XXXX-181-M600D
XXXX-181-M601D
XXXX-181-M602D
XXXX-181-M700D
XXXX-181-M700D-01

DIAGRAM, P&I, DRIVEN EQUIPMENT SYSTEMS

DIAGRAM, P&I, DRIVEN EQUIPMENT COOLING SYSTEM
DIAGRAM, P&I, DRIVEN EQUIPMENT FIRE SYSTEM
LEGEND
DIAGRAM, PIPING & INSTRUMENTATION LEGEND

XXXX-182

OPEN CATEGORY

XXXX-183
XXXX-183-S100D
XXXX-183-S101D
XXXX-183-S102D
XXXX-183-E102D
XXXX-183-S103D
XXXX-183-S104D
XXXX-183-M200D
XXXX-183-M300D
XXXX-183-M301D
XXXX-183-M400D
XXXX-183-M401D
XXXX-183-E500D
XXXX-183-E501D
XXXX-183-E506D
XXXX-183-E507D
XXXX-183-E508D
XXXX-183-E509D
XXXX-183-E510D
XXXX-183-E511D
XXXX-183-E512D
XXXX-183-E513D
XXXX-183-E514D
XXXX-183-E600D
XXXX-183-E601D

OUTLINE, DRAWINGS
ENCLOSURE/TURBINE OUTLINES
OUTLINE, ISLAND, GAS TURBINE
OUTLINE, GAS TURBINE & BASE
OUTLINE, A BOX
OUTLINE, ENCLOSURE, MECHANICAL PACKAGE
OUTLINE, COLLECTOR BOX, INTERFACE
PRIMARY SKID OUTLINES
MISC SKID OUTLINES
OUTLINE, LUBE OIL SKID
FUEL FILTERING/METERING SYSTEM OUTLINES
OUTLINE, LIQUID FUEL METERING
OUTLINE, CONTROL CENTER
OUTLINE, MCC
OUTLINE, CABINETS INSTRUMENT & CONTROL
OUTLINE, CABINET, REMOTE TERMINAL UNIT (RTU)
OUTLINE, CABINET, AUXILIARY EQUIPMENT
OUTLINE, CABINET, GAS TURBINE INSTRUMENT
OUTLINE, CABINET, OPERATOR CONTROL
OUTLINE, CABINET, GENERATOR INSTRUMENT
OUTLINE, CABINET, PROTECTIVE RELAY
OUTLINE, CABINET, MASTER TERMINAL BOARD (MTB)
OUTLINE, CABINET, REMOTE CONTROL
OUTLINE, ENCL. REMOTE I/O
OUTLINE, ENCL. EM35, DIGITAL DRIVER, GAS FUEL

XXXX-184
XXXX-184-S100D

FOUNDATION LOADING
LOADING, FOUNDATION, GAS TURBINE ISLAND

* This is a master drawing tree listing. A project will use some of these drawings as required.

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TABLE 5-1 DRAWING TREE NUMBERING SYSTEM * (Sheet 8 of 10)

XXXX-185
XXXX-185-E100D
XXXX-185-E200D
XXXX-185-E300D
XXXX-185-E400D
XXXX-185-E501D
XXXX-185-E600D
XXXX-185-E700D
XXXX-185-E800D

ONE-LINE/BLOCK/FLOW DIAGRAMS
DIAGRAM, ONE LINE
DIAGRAM, FLOW, WASTE HEAT RECOVERY SYSTEM
DIAGRAM, BLOCK, POWER ISLAND
DIAGRAM, BLOCK, CONTROL SYSTEM
DIAGRAM, INTERCONNECT, FIRE SYSTEM
DIAGRAM, ONE LINE, MCC
PLANT INTERCONNECT
DIAGRAM, CABLE, ENGINE & ENCLOSURE

XXXX-186
XXXX-186-C110D
XXXX-186-C140D
XXXX-186-C150D
XXXX-186-C160D
XXXX-186-C170D
XXXX-186-C180D
XXXX-186-C190D
XXXX-186-C210D
XXXX-186-C230D
XXXX-186-C240D
XXXX-186-C260D
XXXX-186-C280D
XXXX-186-C290D
XXXX-186-C360D
XXXX-186-C370D
XXXX-186-C380D
XXXX-186-C600D
XXXX-186-C601D

LOGIC DIAGRAMS
DIAGRAM, LOGIC, LUBE OIL
DIAGRAM, LOGIC, LIQUID FUEL SYSTEM
DIAGRAM, LOGIC, LIQUID FUEL CONDITIONING
DIAGRAM, LOGIC, PANEL INSTRUMENTATION & CONTR
DIAGRAM, LOGIC, WATER INJECTION
DIAGRAM, LOGIC, STEAM INJECTION
DIAGRAM, LOGIC, GAS TURBINE CONTROL INTERFACE
DIAGRAM, LOGIC, FIRE SYSTEM
DIAGRAM, LOGIC, GENERATOR LUBE OIL
DIAGRAM, LOGIC, GENERATOR INSTRUMENTATION
DIAGRAM, LOGIC, DIAGNOSTICS, UNIT CONTROL
DIAGRAM, LOGIC, ANCILLARY SYSTEMS
DIAGRAM, LOGIC, WATER WASH
DIAGRAM, LOGIC, BALANCE OF PLANT
DIAGRAM, LOGIC, START UP
DIAGRAM, LOGIC, SHUTDOWN
DIAGRAM, LOGIC, GAS TURBINE CONTROL (SIMPLIFIED)
DIAGRAM, LOGIC, GT CONTROL

XXXX-187
XXXX-187-E100D
XXXX-187-E101D
XXXX-187-E102D
XXXX-187-E103D
XXXX-187-E104D

SCHEMATICS
SCHEMATIC, CONTROLLERS
SCHEMATIC, UNIT CONTROL
SCHEMATIC, GAS TURBINE CONTROL
SCHEMATIC, PLANT CONTROL
SCHEMATIC, PHOENIX RELAY BLOCK

* This is a master drawing tree listing. A project will use some of these drawings as required.

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TABLE 5-1 DRAWING TREE NUMBERING SYSTEM * (Sheet 9 of 10)

XXXX-187-E200D
XXXX-187-E201D
XXXX-187-E202D
XXXX-187-E203D
XXXX-187-E204D
XXXX-187-E205D
XXXX-187-E206D
XXXX-187-E207D
XXXX-187-E300D
XXXX-187-E301D
XXXX-187-E302D
XXXX-187-E303D
XXXX-187-E304D
XXXX-187-E305D
XXXX-187-E306D
XXXX-187-E307D
XXXX-187-E308D
XXXX-187-E309D
XXXX-187-E309D
XXXX-187-E400D
XXXX-187-E401D
XXXX-187-E501D
XXXX-187-E600D

SCHEMATIC, MONITORING SYSTEM

SCHEMATIC, MONITORING SYSTEM
SCHEMATIC, INSTRUMENTATION AND CONTROL
SCHEMATIC, VIBRATION MONITORING
SCHEMATIC, COMBUSTIBLE GAS MONITORING
SCHEMATIC, FIRE PROTECTION MONITORING
SCHEMATIC, CONTINUOUS EMISSIONS MONITORING
SCHEMATIC, OPACITY MONITORING
SCHEMATIC, ELECTRICAL CONTROL
SCHEMATIC, GENERATOR EXCITATION & REGULATION
SCHEMATIC, MCC
SCHEMATIC, POWER DISTRIBUTION AND LIGHTING
SCHEMATIC, GENERATOR PROTECTIVE RELAYS
SCHEMATIC, SWITCHGEAR
SCHEMATIC, MAIN BREAKER AND TRANSFORMER
SCHEMATIC, THREE LINE
SCHEMATIC, SYMBOLOGY AND SPECIFICATIONS
SCHEMATIC, LIQUID FUEL METERING
SCHEMATIC, COLD BUFFER, VARIABLE FREQUENCY D
SCHEMATIC, CUSTOMER INTERFACE, A BOX
SCHEMATIC, CUSTOMER INTERFACE, RIO
SCHEMATIC, FIRE PROTECTION
SCHEMATIC, FIELD ELEC, CBA, RETROFIT

XXXX-188

OPEN CATEGORY

XXXX-189
XXXX-189-E000L
XXXX-189-C001L
XXXX-189-C002L
XXXX-189-C003L
XXXX-189-C004L
XXXX-189-C005L
XXXX-189-E006L
XXXX-189-E007L
XXXX-189-E008L
XXXX-189-E011L
XXXX-189-E102L

LISTS & SCHEDULES

LIST, WIRING, G. T. & BASE
LIST, EQUIPMENT
LIST, INSTRUMENT
LIST, I/O
LIST, ALARM/TRIP
LIST, COMMUNICATION
LIST, CABLE
LIST, CABLE, TERMINATIONS
LIST, LOAD
LIST, PROTECTIVE RELAY SETTINGS
LIST, WIRING, A BOX, INTERNAL

* This is a master drawing tree listing. A project will use some of these drawings as required.

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TABLE 5-1 DRAWING TREE NUMBERING SYSTEM * (Sheet 10 of 10)

XXXX-19
XXXX-19121
XXXX-1913
807421
807424
807423
807426

MANUALS
SPECIFIC OPERATING INSTRUCTIONS
FT8 SYSTEMS MAINTENANCE
GAS GENERATOR MAINTENANCE
POWER TURBINE MAINTENANCE
GG8 ILLUSTRATED PARTS CATALOG (IPC)
PT8 ILLUSTRATED PARTS CATALOG

* This is a master drawing tree listing. A project will use some of these drawings as required.

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5.3 Vendor-Designed Equipment

For vendor-designed equipment, the drawings and documentation that are typically
required of the vendor through the procurement contract are as follows:
1.

Approval Drawings (To be submitted 30 days after contract award).

A. Outline and general arrangement, showing dimensions, plan and elevation
views, all parts identified with part numbers or find numbers, lifting
means, cable entries, etc.
B. Interface drawings, giving complete details of all interfaces, including
mechanical, electrical, fluid, and all other interfaces as necessary to ensure
a satisfactory definition of the installation.
C. Installation drawings, giving any special drawings or specifications
necessary for installation, such as lube oil system flushing, alignment, etc.
Installation drawings are to cross-reference with installation instructions as
required.
D. Parts list
E. Wiring diagrams
F. Schematics

2.

Final Drawings (Certified drawings to be submitted not less than 30 days

before delivery of equipment).
A. Typically included are all drawings required for installation, interfaces,
schematics, wiring diagrams, pipework and construction details.

3.

Documentation (In addition, the manufacturer of vendor-designed equipment

will be required to furnish technical manuals)..
A. Review copies of the required technical manuals usually are to be
submitted 120 days after contract award. Final copies are to be submitted
30 days before delivery of equipment. Typically required are manuals
providing an equipment description and functional characteristics,
operating and maintenance manuals, and an installation manual that
includes all applicable illustrations and instructions pertinent to
installation, as well as, special tools, materials, unpacking, testing,
adjusting, calibration and checkout instructions.

Reference to the above drawing and documentation system should be adequate to provide
installation information for the Site Supervisor and/or Construction Engineers.

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5.4

Instructions for Installing FT8 Systems

The following sections provide general information to assist and guide the Site
Supervisor and/or Construction Engineers during installation of FT8 Power Pac, Twin
Pac and Swift Pac systems. The following sections cover sub-systems, such as the
electric generator and the gas turbine base assembly, for which additional information
might be helpful. Information is given in tabular form in Table 5-2 at the end of Section
5 for the remainder of the FT8 sub-systems.
5.4.1 Installation of Electric Generator
5.4.1.1 Prior to Placement
The following section outlines general procedures to prepare for placement and grouting
of the electric generator.
NOTE
Prior to setting the generator it is recommended that
accurate lateral and axial reference lines be established on
the foundation, preferably scribed on the metal plates under
the coupling(s) and at Engine Station 218.50 (reference
drawings XXXX-113-S000D, sheet 2 and XXXX-115S100D). This would allow precise axial and lateral
placement of the generator when initially set, possibly
eliminating the necessity for lateral and axial jacking of the
generator for precise location. This does not imply that
axial and lateral location need not be checked during and
after lateral and axial leveling.
Before any machinery is placed, the concrete areas that are grouted must be chipped back
and swept or air blown clean. A rough as-cast surface will not suffice.
Remove the protective water stops from the anchor bolt sleeves to inspect and remove
any water. The anchor bolt sleeves must be free of debris and water.
Wire brush the anchor bolts and threads if necessary. Lubricate with grease and spin on
the anchor bolts mating nuts to be certain the threads are clean. Then re-install the
protective water stops or back fill with clean, dry sand.
Verify the location of the generator guide pin and locating block embedments. If these
embedments are scheduled to be installed after the placement and grouting of the
electrical generator, insure that a large enough pocket is left in the foundation so that they
can properly installed after the installation of the generator.

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The electric generator will be shipped to site in a wooden create and bolted to two steel
shipping beams. Inside the create the generator will be wrapped in a protective vapor
barrier. The generator may be set over the foundation in the shipping create or removed
from the create and then sent on the foundation.
The removal of the wooden crate from around the electric generator requires some effort.
The crate will need to be cut around its entire perimeter near the bottom of the box. This
can be done by cutting through the protective sheeting and wood framing or by pulling off
the lower section of sheeting followed by cutting the wood framing. Once the wooded
crate is completely cut through at the perimeter then the top half of the box can be
removed with a crane. Use two safety lines when lifting the crate; and, use caution not to
damage any of the instrumentation or hardware on the generator. To remove the bottom
half of the crate, four of the generator access covers will need to be opened so that the
shipping beams can be unbolted from the generator frame. Once the shipping beams are
unbolted then the generator can be lifted by crane and the floor can be pulled out from
underneath the generator.
5.4.1.2 Installation
Electric generator installation procedures will vary depending upon the type,
manufacturer and model of generator to be installed. Specific instructions for a given site
will be given in the drawing system described above, and by the manufacturers
Installation Instruction Manual.
In general, these precautions must be observed:
1. Always use extreme care in handling of the equipment to prevent personal injury
and/or damage to the equipment.
2. Make certain that lifting devices (cranes, hoists, lift trucks, etc.) are of adequate
capacity.
3. Make certain that straps, chains, slings, etc. are of adequate capacity and in good
condition.
4. When lifting and handling the equipment, do not disturb or bend the piping on the
exterior of the frame.
5. If the rotor is shipped separate from the stator, check inside the stator for bolts,
rags, small tools, packing material, etc. Check the rotor surface to see that pieces
of steel are not clinging to it due to residual magnetism.
6. The generator is located as required in the mechanical field assembly drawing by
manipulating the jacking screws and grouted.

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Since much of the expertise in heavy equipment installation is gained through experience,
generator manufacturers normally recommend that the user should benefit from the
services of their representative during installation.
The contract with the generator manufacturer will normally include a requirement to have
a service representative assist during the test and checkout phase of installation and not
with installation.
Although a crane is desirable for moving the generator to its foundation, the generator
may be skidded or rolled into place with winches. If a crane is used, use spreader beams
to keep lifting cables vertical. If the generator is to be skidded or rolled, use two winches,
whether the ground is level or slopedone winch to pull, the other on the opposite side
to play out slack. This prevents the generator from having a surging movement that could
cause loss of control. Greased plates, rails and cribbing should always be arranged so that
tipping the generator more than 15 degrees from the vertical is unnecessary. Experienced
riggers can best determine the amount of plates, planks, rails, or rollers, the size of cranes,
etc..
Axial and lateral positioning should be established using the vendors instructions and
drawing for the specific generator being installed. Also, the design elevation of the
generator rotor axis above foundation elevation 0.000 must be maintained within limits so
that proper mating of gas turbine/generator enclosure components can be achieved,
because the gas turbine enclosure is located by placing it on a 1-inch gasket. This gasket,
compressed to one half inch (), precludes any elevation adjustment of the enclosure.
5.4.1.3 Running Bearing Installation
The following instructions are given for replacement of shipping bearings, if used, with
running bearings. Alternatively, the generator may be shipped with a sheet of Mylar
between the shaft journal and the running bearings, for protection during transit. In this
case, only step (1) below would be necessary to remove the Mylar.
NOTE
The instructions given herein are intended for an Electric
Machinery generator. For a generator from another
vendor, installation instructions may vary. Refer to the
vendors installation manual for the necessary tooling and
further instructions.
To remove the shipping bearing, if a shipping bearing is
used, removal of the upper end bell or sliding back of the
exciter housing may be required. The exciter end-bearing
cap can then be removed. A block and tackle will be

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helpful in removing the end bell and bearing caps and

lifting the rotor.
Cleaning and careful housekeeping is important during this and subsequent operations.
1. Unbolt and remove the upper half of the shipping bearing. Position the lifting
tools and lift the rotor slightly to allow rolling out of the bottom half of each
shipping bearing. If simply a sheet of Mylar is used with the running bearing, the
Mylar can be removed at this point.
2. Carefully inspect the exposed surfaces of the shaft journals and the interiors of the
bearing cavities for foreign material. Un-crate and wipe the running bearings
clean. Apply a film of oil per vendors specification to the shaft journals.
3. Roll in the bottom halves of the running bearings. On some installations, the
bearing thermocouple must be removed from the bottom half of the bearing before
rolling in. These bearings must be installed with proper orientation. They also
have rotation tags. The lower bearing half should be arranged for oil feed on the
down-going side of the journal, drain on the up-going side.
4. Check the thickness of the bearing seat axial spacers against the marked rotor on
its axial design location according to the vendors drawing.
5. Lower the rotor onto its bearings and confirm that the rotor has remained on
location. Ensure that the bearing is properly aligned with the journal and record
clearance; bearings are not self-aligning. This is achieved by having equal
clearances at each corner at bearing split, and also equal depth of a feeler gauge in
all four corners between journal and bearings.
5.4.1.4 Lateral and Axial Leveling
The design elevation of the generator horizontal center plane is determined from the
appropriate design drawings such as XXXX-113-M000D. Maintaining the design
dimension between the bottom of the generator sole plate and the top of the jacking plates
will achieve approximate design elevation of this plane; however, it is suggested that a
known elevation point be established on the generator foundation, referenced to a
benchmark.
Check the axial vertical plane of the rotor for coincidence with the vertical center plane of
the foundation. Jack the generator laterally, if required. Recheck the axial and lateral
levels.
When all conditions of this step are satisfied and all jacking bolts are bearing equally, the
anchor nuts may be tightened.

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5.4.1.5 Generator Lube Oil System

5.4.1.5.1 Prefabricated Systems
1. All piping on the generator and oil cooler is prefabricated, cleaned and flushed.
2. The piping between an external cooler assembly, if supplied, and generator is field
fabricated from pipe and fittings furnished by PWPS.
5.4.1.5.2 Piping Between Lube Oil System and Generator
1. Prior to connecting the lube oil system to the generator, inspect the lube oil supply
piping and clean if necessary. If major contamination is found in either the
prefabricated piping on the generator or oil cooler or in the field fabricated and
cleaned piping, it will be required to jumper all generator bearings and flush with
heated oil until clean. It is not expected that this will be the case unless
contamination is allowed into the pipes at the site. If major contamination is not
in evidence, proceed as follows:
A. Inspect the lube oil reservoir to insure that:
1)
2)
3)
4)

Suction screens are in place.

No foreign objects are present
Level switches are set per applicable procedures.
Tank is not dirty.

Correct these conditions, if necessary.

B. Connect all lube oil system piping and flush as follows:
1) Insert an 80-mesh strainer at the inlet to each bearing supply.
2) Fill the lube oil reservoir with running oil to the level adequate for
flushing.
3) Drain shop oil from the lube oil coolers.
4) Operate the AC lube oil pump and backup AC lube oil pump for two hours
with maximum allowable heating.
5) Then, operate the DC lube oil pump for ten minutes.
6) Inspect the 80 mesh strainers and if no contamination is found, remove the
strainers and make up the piping. If minor contamination is found, flush
an additional two hours with heat. If major contamination is found after
the initial two hours of flushing, an extended flush should be initiated to
prevent contamination of the bearings. If an extended flush is required,
the source of contamination will determine who is responsible for this
flush. Contamination from the cooler or generator may result in PWPSs

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vendor being responsible; contamination from field pipe or site sand or

dirt will result in the Contractors being responsible.
5.4.1.6 Electrical Testing
After the electrical generator has been grouted and has been in place with the generator
space heaters for a sufficient period of time, the stator winding will need to be tested for
dryness. This is accomplished by meggering the windings and performing a Polarity
Index, PI test. For the typical FT8 Power Pac and Twin Pac Generators a 5,000 volt DC
megger is required for ten minutes. The megger values will need to be recorded each
minute with a stopwatch. The ratio of reading at ten minutes to the reading taken at one
minute will generate the PI number. PI values of less than 1.0 indicate that the stator
windings are wet and supplemental dry techniques are required while values between 1.0
to 2.0 are questionable and supplemental drying is recommended. PI values above 2.0
indicates a dry stator winding.
After the successful completion of the stator-winding test, the installation of the generator
neutral cubicle can be completed. Also, the high voltage bus duct can be installed;
however, the taping of the first bus joint at the generator will have to be put off until after
startup of the gas turbine. This is required for proper testing of the protective relays
during open and short circuit testing of the generator. Shorting jumpers will be installed
at this location during checkout of the generator.
5.5 Installation of Gas Turbine Base Assembly
Prior to placement, it is presumed that the following procedures have been completed:
1. Center and datum lines for the gas turbine have been established and scribed on
steel foundation plates.
2. All laitance has to be chipped away where grout will be used under the base
assembly to improve the bond between the grout and the concrete. See Chapter 2,
paragraph 2.7.5 for more information on this subject.
3. Anchor bolts have been cleaned and brushed with lubricant.
4. All water is removed from the anchor bolt sleeves and sealed with a protective
water stop or back filled with clean, dry sand.
5. Embedded gas turbine jacking plates and blocks are installed at the proper
elevation and orientated correctly.
For a specific site, instructions and tolerances for the installation of the gas turbine and
base assembly, exhaust diffuser assembly, coupler spacer shaft, and alignment with the
electric generator will be found on the Mechanical and Structures Assembly drawings,
which are as follows:
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XXXX-111
XXXX-112
XXXX-113

ASSEMBLY, GAS TURBINE AND BASE

ASSEMBLY, ENCLOSURE
ASSEMBLY, MECHANICAL FIELD

The XXXX in these numbers will be the project number for the specific site.
Once the gas turbine assembly enclosure is installed, insure the maintenance trolley
assembly is installed prior to accomplishing any maintenance actions on the gas turbine
assembly. PWPS drawing IPE 21779, sheets 1 and 2 provide details of the maintenance
trolley assembly.
CAUTION
The guide tabs installed on the maintenance trolley
assembly are installed as safety devices. Do not use the
maintenance trolley without these tabs installed.
When not is use, secure the trolley to the end wall of the
enclosure using a cable to secure the maintenance trolley to
the wall.
5.6 Gas Turbine to Generator Alignment
The following section outlines the objectives and procedures involved in the alignment of
the gas turbine, coupling spacer shaft and generator packages.
NOTE
If the ambient temperature is less than 60F, provisions
should be made for gas turbine and generator enclosure
space heating during grouting and before engine alignment
begins.
Prior to the alignment procedures, it is presumed that the following procedures have been
completed as part of the gas turbine and generator installation:
1. Generator and exciter heaters have been energized for several days prior to the
start of engine-to-generator alignment. These heaters should remain energized
during the alignment and recording of final readings, or considerable
misalignment may occur.
2. Anchor bolt locations have been carefully checked before and after pouring of
foundations, and the jacking pads are on their design elevations. This is critical,
especially if this elevation is to be used for reference when establishing generator
elevation.
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3. Elevations of the top of all anchor bolts have been checked to insure sufficient
anchor bolt penetration through the bottom plates of the machinery.
5.6.1 Alignment Tools and Equipment
The following tools and equipment are required and are to be provided by the installing
contractor or owner:
Special Tools:

Tool No.

Tool Name

TC350-115
TC350-116

Cradle (1)
Rail (2 pieces)
or

PWA 77582
TC350-117

Cradle Support
Compressor (Lucas) (5)
or

TC350-118
TC350-165

Compressor (Kopflex) (3)

Parallel Bars

Additional Tools:

Tool Name
Magnetic Base (2)
Dial Indicator, 0 to 1inch (2)
ID Micrometer, 0-4
inch or equivalent
Center Head

Consumables:

Spec No.
PWA 521
PWA 586

Name
Engine Oil
Anti-seize Compound

5.6.2 Alignment Procedures

The specifications to be followed in installing and aligning the gas turbine assembly,
coupling spacer shaft, collector box and generator are given in the project drawing
XXXX-113-S000D Mechanical Field Assembly. The sequence of operations to be
followed in aligning the FT8 to the driven load is detailed in the PWPS FT8 Checkout
Manual in Section 19. The normal overall sequence will be as follows:
1. Prepare the foundations for the gas turbine and generator base assembly,
including lateral and axial reference lines scribed on embedded metal plates
and anchor bolts located accurately to drawing requirements.
NOTE
The gas turbine and generator enclosures may be erected
either before or after the placing and alignment of these
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main components, depending mostly on environmental

conditions and availability of parts. Wiring and piping
fieldwork to enclosures may progress during alignment.
2. Locate the generator in its final position and grout (see paragraph 5.4.1).
3. Assemble the diffuser assembly, and support it about ten (10) inches aft of its
final location inside the collector box.
4. Place gas turbine base assembly on anchor bolts at its approximate location
and elevation; and, attach and torque the diffuser assembly to the power
turbine.
NOTE
The gas turbine base must be free of all grease and oil prior
to grouting. During the placing of the gas turbine while it
is hanging on the crane is the ideal time to degrease its
base steel.
During the installation of the diffuser to the power turbine,
caution must be exercised while installing the gasket for the
inner cone. The gasket is a high temperature gasket that
will stretch due to its own weight if left on the inner cone
for more than a few minutes. A full 360-degree inspection
of this seal is required before final assembly to insure that it
is not pinched at the bottom.
5. Move in the coupling spacer shaft, using tool TC350-115 (Alignment Tool Roller)
mounted on TC350-116 (Rail) to support the forward end, and manually
supporting the back end until it is placed on a second tool TC350-115 for support.
6. After adjusting the Alignment Tool Roller supports to make the coupling spacer
shaft concentric with the turbine shaft, bolt the coupling spacer shaft forward
flange to the forward diaphragm assembly. Torque the bolts as called for on
drawing XXXX-113-S000D or as per TPM-124, if not noted on the -113 drawing.
NOTE
Do not use alignment points or shims on the gas turbine or
power turbine base to achieve the initial alignment.
7. Align the gas turbine base assembly relative to the generator while cold to
dimensional limits that will result in a hot running condition of a 0.050 inch
maximum parallel offset. Suggested procedures and dimensional limits to achieve
these requirements are given in drawing XXXX-113-S000D or equivalent generic
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drawing. A misalignment is intentionally created when cold, so that hot running

requirements will be met. Also, as the ambient temperature varies from 59F, the
axial air gap adjustment is made to compensate for coupling spacer shaft
temperature.
8. Install diaphragm assembly between coupling spacer shaft and generator adapter,
observing match marks at diaphragm rim.
NOTE
For Lucas coupling option, use tool number TC350-117 to
compress diaphragm at the generator end to assemble
diaphragm into the space between the coupling spacer shaft
and generator end adapter plate.
9. Grout between turbine base and foundation. After curing, remove jackscrews and
torque anchor bolts as noted on the -113 drawing.
10. Check alignment to confirm that drawing requirements are met after torquing
anchor bolts.
11. Complete the installation of diffuser and collector box insulation, as required in
mechanical assembly drawings.
12. Complete the collector box alignment per the FT8 checkout manual Section 19
and TPM Bulletin 97M03; and, install the collector box seals.
5.7 Installation of Liquid Fuel Systems
The fuel systems described on the following pages are primarily limited to those that are
external to the gas turbine enclosure. These are the fuel forwarding, filtering and
metering sections, which are optional equipment for the scope of supply in an FT8
system. Specifications given in these sections are typical. Actual specifications are as
provided in the drawing system and the contractors requirements for a particular site.
The fuel system components inside the enclosure are mounted on the fuel plate. Since the
fuel plate arrives at the site mounted on the engine base assembly, the only fuel plate field
installation required is connection of wiring and piping.
The type and quality of fuel and water used is an important factor in obtaining long life
and low maintenance gas turbine operation. The P&WA specification numbers for the
approved fuels are as follows:
Type

P&WA Spec. No.

1.

Distillate fuel

TPM FR-1

2.

Gaseous fuel

TPM FR-2

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3.

Injection Water

TPM AR-1

5.7.1 Description of External Liquid Fuel Systems

PWPS Specification FR-1, Gas Turbine Liquid Distillate Fuel Requirements contained in
Appendix A provides essential information to assist the customer with the design of their
fuel delivery system.
The purpose of the fuel oil system is to deliver clean, paraffin/moisture-free fuel oil at the
required pressure to the engine fuel pump. The fuel oil system typically consists of the
following components:
1. Tank loading skid (customer/vendor)
2. Storage tank (customer/vendor)
3. Fuel forwarding skid (optional)
4. Main fuel filter
5. Flow meter
6. Fire valve
7. Final filter
These components are described briefly in the following sections:
5.7.1.1 Tank Loading Skid
The primary objective of the tank-loading skid is to deliver fuel to the storage tank. The
skid normally consists of the following components:
1. Line Strainer A Y- type or a basket type strainer with a perforated metal screen
having 1/8 inch diameter holes is installed in the pump suction line to prevent
foreign particles from entering the pump and causing pump damage.
2. Gate Valves Flanged gate valves are installed in the pump suction, pump bypass
and the pump outlet. The valves permit the isolation of components to allow
servicing of the pump and operation of the pump bypass line.
3. Check Valve Check valves installed on skid discharge lines are to prevent back
flow from the storage tank when the pump is shut off.
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4. Pump and Motor Assembly The pump is driven by a 480V/380V, 3-phase,

60/50 Hz motor. The motor is waterproof and is overload protected.
5. Grounding The skid must be grounded to the site grounding grid.
6. Filter Installed between pump discharge and tanks (as an option to the Y-strainer
noted above).
5.7.1.2 Storage Tank
The following specifications establish a guide for construction of vendor supplied fuel oil
tanks.
Tank Type
Vertical above ground

Specifications
American Petroleum Institute Specifications Code 650
National Fire Protection Association Code 30

Horizontal above ground

Underwriters Laboratories U.L. 142 and N.F.P.A. Code 30

Underground

U.L. 58

The tank will be of butt welded construction, normally with adapters to receive the
equipment listed below, furnished and installed by the tank fabricator:
1. Outside ladders or stairs
2. Shell manhole
3. Automatic level gage with high low level contacts
4. Emergency vent and manway cover
5. A vent with bird screen
6. Non-freezing drain valve
7. Fill line connections
8. Discharge line connections
9. Floating suction assembly

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Whether horizontal or vertical, fuel tanks must have provisions for water draw-off.
Horizontal tanks should have a pitch of 1 to 3percent with a water draw line provided at
the lowest point of the tank. Vertical tank bottoms must have a sump near the outer
periphery of the tank. A bottom water draw-off line should pass through the shell and
terminate in the center of the sump below the lowest point of the tank bottom. Tank
bottom pump-out provision is required for underground tanks. Each storage tank must be
equipped with floating suction assembly.
At the lowest traverse, the suction bell shall be clear of the tank bottom in conformance
with the following:
Floating Suction Line
Diameter

Max. Flow Cap.

Clearance to Bottom

3 inch
4 inch
6 inch

0-150 gpm
150-350 gpm
above 350 gpm

7 inch
9inch
12 inch

The tank fill line must terminate within six (6) inches of the bottom of the tank to avoid
splash loading. The fill line termination must be located in a place as remote as possible
from the floating suction inlet.
5.7.1.2.1 Tank Exterior
All exterior surfaces are to be cleaned, primed and finish painted as required in tank
specifications.
5.7.1.2.2 Testing
After tank fabrication is completed, filling the tank with water shall test the welded
seams. Before inspecting the tank, the temperature of the water should be allowed to
equalize with the ambient temperature, so that sweating of the tank skin will not be
mistaken for leakage.
5.7.1.2.3 Grounding
The tank should be grounded to the site grounding grid.
5.7.1.3 Fuel Forwarding Skid
The purpose of the fuel forwarding skid is to deliver fuel oil from the fuel oil storage tank
to the engine fuel oil pump, passing through the fuel strainer, meter, fire valve and filter
at a pressure of 50 psi to the inlet of the engine fuel oil pump.
The skid consists of the following equipment:

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1. Strainer - Installed on the suction line of the pumps in order to prevent damage to
the pump impeller by foreign material.
2. Check Valve - Installed on each pump discharge line to prevent one pump from
motoring the other pump during the non-operating period of the inoperative pump.
3. Pressure Switch - Connected at the output of each AC pump in systems with two
AC pumps to indicate which pump is operating and if it is operating above the
minimum required pressure.
4. Orifice Plate - Installed in the line between pump discharge header and pump
suction header to bypass fuel during no flow conditions, thereby protecting the
pumps.
5. Main Pump and Motor Assembly - A 50 GPM, 50 psig, centrifugal pump, driven
by a 380/480 volt, 3-phase, 50-60 Hz motor on Power Pacs. Twin Pacs use a 100
GPM pump and motor.
6. Auxiliary Pump and Motor Assembly - A 5 GPM, 50 psig, centrifugal pump,
driven by a 125 VDC motor on Power Pacs and a 10 GPM pump on Twin Pacs.
7. Base Frame - A channel frame provides for complete component mounting and
support. Also, the skid should be grounded to the site grid system.
8. Pressure Gages - Installed with block and bleed valves to read pump input and
output pressures.
5.7.1.4 Main Fuel Filter
The main fuel filter is basically an unfired pressure vessel constructed of steel in
accordance with ASME code with its respective depth type filters. A depth type filter is
designed to filter out large particles at the O. D. of the element and small particles toward
the center, as well as remove moisture.
5.7.1.5 Flow Meter
If a liquid fuel flow meter is incorporated in the system, it should be installed according
to manufacturers recommendations. Also, the meter body should be checked to assure
that the direction of flow is correct.
5.7.1.6 Fire Valve
The fire valve, a trip release shutoff valve, is installed downstream of the final filter. The
valve is designed to close automatically when de-energized and is used to shut the unit
down in case of fire in the engine enclosure. It must be manually reset after closing to
restart the engine. Whenever possible, it is preferred that the valve be installed in a
horizontal pipeline with its top assembly upright. This is especially true whenever it is to
be located out-of-doors exposed to the weather.

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The trip valve must be mounted in the pipeline so that flow through it will be in the same
direction as that indicated by the arrow cast on the valve body. If the valve is located in a
long run of piping, supports must be provided to avoid placing the valve body in a bind.
To check valve operation, energize the circuit to the valve. Open the manual reset valve
to fully open, then break the current so that the valve closes. Repeat this operation
several times to provide a positive check on the valves performance and permit the seat
and disc to be wiped free of any foreign matter which may have accumulated in the line
during installation. Note that the valve must be functionally tested in conjunction with
the Fire Protection System.
5.7.1.7 Final Filter
A final filter is installed upstream of #1 and #2 shutoff valves, and is used to remove
particles between the main fuel filter and the fuel pump. In the installation of the filter,
the arrow on the body should be checked for direction of flow. Piping supports should be
installed within 12 of the inlet and outlet connections.
5.7.2 Installation
5.7.2.1 Skids
Prior to setting the individual skids on their foundation, the anchor bolt location should
be checked for proper alignment. The anchor bolt threads should be lubricated and
chased with a mating nut. The foundation surface should also be checked for levelness.
After the skid has been set, again check for levelness and, if necessary, add shims and
tighten down on the anchor bolts. After the anchor bolts have been tightened, the skid
should be grouted to its foundation. Even though the alignment between the skid pump
and motors is set at the factory prior to shipment, make a final check before operating.
5.7.2.2 Piping
All piping after the main filter must be schedule 40 seamless, stainless steel pipe, meeting
the required ASME specifications. Fuel forwarding piping is usually schedule 40 carbon
steel pipe. All pipe should be pickled, coated with non-additive SAE 20 mineral oil, and
the pipe ends capped before leaving the pipe manufacturers shop.
If pipe is to be stored outside for a considerable length of time at the construction site, it
should be supported on blocks every five (5) feet.
All welding on fuel oil pipe should meet the requirements of the American Welding
Society and the ASME Boiler and Pressure Vessel Code and Power Piping Code 31.1.
All fuel oil piping to be installed underground should have a protective covering, using
procedures as specified by the contractor.

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5.7.2.2.1 Hydrostatic Test and Flushing

When the liquid fuel piping is complete, the field installed piping should be
hydrostatically tested as specified in the specifications. After a successful pressure check
of the system, it must be thoroughly flushed with fuel oil to insure that no dirt or other
foreign materials have been introduced into the system. Typical requirements for
hydrostatic testing and flushing are given in Chapter 6.
5.8 Installation of Oil-Filled Transformers
5.8.1 Prior to Placement
Inspect the concrete pad. It should be clean, free of debris and checked for levelness.
Also, check proper location and elevation of any pipes, conduits or anchor bolts.
5.8.2 Installation
Although a crane is desirable for moving a transformer to its pad, the transformer may be
skidded or rolled into place with winches. Use the outline drawings for information on
moving and supporting the transformer. If using a crane, use spreader beams to keep
lifting cables vertical. If a transformer is to be skidded or rolled, use two winches,
whether the ground is level or sloped -- one winch to pull, the other on the opposite side
to play out slack. This prevents the transformer from having a surging movement that
could cause loss of control. Greased plates, rails, and cribbing should always be arranged
so that tipping the transformer more than fifteen (15) degrees from the vertical is
unnecessary. Experienced riggers can best determine the amount of plates, planks, rails,
or rollers, the size of cranes, etc..
After the transformer has been set on its pad, outline the installation sequence for the
installation people. Review the manufacturers instruction book and latest drawings for
installation details, and recheck availability of all necessary transformer components.
5.8.3 Practical Seventeen (17) Point Do Not List
1. Do not work on a transformer unless the tank, bushings, and oil handling
equipment are grounded.
2. Do not open a transformer manhole cover in rain or snow, or when the relative
humidity is above 65 percent, or if the temperature of the tank and internal parts is
less than 10C or higher than the dew point of the outside air.
3. Do not jack the transformer into position using drain valves, pipe connections, or
other transformer appendages. Use the jack pads for jacking.

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4. Do not use natural rubber hose, lamp cords, etc., with oil or oil handling
equipment.
5. Do not pull oil into a transformer unless it has been tested for dielectric strength.
Oil should test 30 KV or more. (Take a sample from the bottom of the oil
container)
6. Do not compress nitride gaskets more than 30 percent.
7. Do not test insulation with a megohmmeter or make electrical tests while the
transformer is under vacuum; it could cause insulation failure.
8. Do not enter a transformer until analysis of air in tank shows at least 19.5 percent
oxygen. Station a man near the manhole outside the tank when someone is inside
the transformer.
9. Do not stand on a transformer cover under vacuum.
10. Do not smoke on top of the transformer when the manhole covers are open, or in
the vicinity of oil handling equipment. When the transformer is open, no one
should be on the cover unless he has removed all loose items from his pockets,
cuffs, etc. All tools taken into the transformer must be accounted for before a
transformer is buttoned up.
11. Do not stand on any electrical insulation inside the transformer.
12. Do no make pressure or vacuum tests before checking the nameplate notes. Some
transformers require that pressure between the main tank and other compartments
be equalized.
13. Do not pull a vacuum on a transformer tank when it is raining, to avoid pulling
moisture into the unit. Likewise, do not let a vacuum pump run overnight
unattended.
14. Do not shut down the vacuum pump before closing the vacuum valve.
15. Do not attempt to take oil samples with a vacuum in the air space above the
transformer. (Air may enter into the oil and lodge in the core and coils).
16. Do not drill holes in the transformer tank braces before checking whether the
braces are air compartments.
17. Do not permit a three-phase transformer to soak without checking the output
voltages to insure that all three phases are applied to the transformer input. An
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open phase on the transformer input may result in ferroresonant overvoltages on

the transformer.
5.9 Installation of Gaseous Fuel Compressor
This section is intended to provide general descriptive information and points of
particular importance related to the installation of a typical gas compressor unit.
The installation instruction manual and drawings provided by the manufacturer and
applicable interface drawings for the particular installation should be given careful study.
The function of the gas compressor is to provide gaseous fuel to the gas turbine engine(s)
at desired capacity, pressure, and temperature where gas supply conditions are not
adequate. Capacity and pressure are controlled by outside-operated free air unloaders
and/or a bypass line. Temperature is controlled by a bypass cooler and/or after cooler.
5.9.1 Prior to Placement
The foundation slab should be allowed to set for at least five (5) days before setting the
compressor package. Check foundation, including anchor bolt locations and elevations,
piping or conduit size and locations. If the compressor is to be located in a building, it is
recommended that the foundation be isolated from the building to avoid transmission of
undesirable vibration. All vent and pressure relief lines should be routed to avoid
transmission of undesirable vibration. Also, all vent and pressure relief lines should be
removed and the foundation should be thoroughly cleaned. Further information on
laitance is given in Chapter 2.
Before setting the compressor, the anchor bolts should be chased, and the jack screws
properly extended for ease of leveling the unit and allowing space for grouting. A
spacing of one and one quarter (1-1/4) inch to two (2) inches is recommended for this. If
jack screws alone are not desired, the unit may be supported at intervals with leveling
wedges. A vendor service engineer should be present to supervise leveling and grouting.
NOTE
Before unloading the gas compressor from the truck, check
for damage, which may have occurred in transit.
5.9.2 Installation
1. Set on foundation with skid foundation holes over foundation bolts.

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2. Level unit with jack screws using dial indicators on coupling halves and bubble
level on flat of compressor crankcase surface. This operation will be done with a
vendors serviceman present.
3. Grout per instructions.
4. After grout has cured, back off on jack bolts.
5. Pull down on foundation bolts.
6. Recheck coupling alignment and, if correct, dowel motor as required per prints.
5.10 Installation of Other FT8 Sub-Systems (Refer to Table 5-2)
Table 5-2 presents PWPS drawing tree numbers and installation instructions for
additional FT8 sub-systems. The PWPS drawing tree system is described in paragraph
5.2.
5.10.1 FT8 Sub-Systems
Table 5-2 gives information on the following FT8 sub-systems:
1. Gas Turbine and Base

14. Fire Protection System

2. Enclosure Assembly

15. Gaseous Fuel Conditioning

3. Gas Turbine Enclosure

16. Liquid Fuel Conditioning

4. Exhaust Enclosure

17. Water Injection System

5. Driven Equipment Enclosure

18. Gaseous Fuel Skid

6. Secondary Air

19. Liquid Fuel Skid

7. Engine Heater

20. Hydraulic Oil System

8. Air Inlet System

21. Water Wash System

9. Exhaust System

22. Drain System

10. Mechanical Field Assembly

23. Generator

11. Ancillary Enclosures

24. Switchgear

12. Control House

25. Step-up Transformer

13. Starting System

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TABLE 5-2 SPECIAL INSTRUCTIONS FOR INSTALLING FT8 EQUIPMENT

(Sheet 1 of 7)
FT8 SUB-SYSTEM
ALL SKID-MOUNTED
ASSEMBLIES

DRAWING TREE
DRAWING NO.
XXXX-XXX

SPECIAL INSTRUCTIONS
Anchor bolts must be located within
tolerances (typically +/-1/8 inch) to avoid
poor assemblies.
Lubricate thread bolts and chase with a
mating nut.
Check conduit and piping stub-up
lengths, material, size, and locations
against the drawings.
Check incoming wiring against the
drawings.
When placing skid, avoid twisting the
frame, which can misalign motors and
driven loads.
Shim and grout per applicable drawing.
Make sure connecting pipes are clean.
Torque hold down bolts, making sure that
piping connections are stress-free.
Check location and method of attaching
ground cable.
Test system per specifications.
Paint assembly per specifications, if
applicable.
Lifting fixtures and spreader beams for
bottom lift skids.

GAS TURBINE AND

BASE

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XXXX-111-

See Section 5.6

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TABLE 5-2 SPECIAL INSTRUCTIONS FOR INSTALLING FT8 EQUIPMENT

(Sheet 2 of 7)
FT8 SUB-SYSTEM

DRAWING TREE
DRAWING NO.

SPECIAL INSTRUCTIONS

ENCLOSURE
ASSEMBLY

XXXX-112-

See Drawing XXXX-112 for weights

of enclosure assembly parts.

GAS TURBINE
ENCLOSURE

XXXX-112-

Foundation must be flat and level so

that enclosure mating surfaces can be
perpendicular and/or parallel at bolted
interfaces.

If enclosure items are removed for reassembly, they should be matchmarked.

EXHAUST
ENCLOSURE

XXXX-112-

See instructions for engine enclosure.

DRIVEN EQUIPMENT
ENCLOSURE

XXXX-112-

See instructions for engine enclosure.

SECONDARY AIR

XXXX-112-

Test operation of air /fire dampers per

checkout test procedure.

ENGINE HEATER

XXXX-112-

Torque hold down bolts.

Insure that check valve is installed in
correct direction. Do not install with
shipping bolts.

AIR INLET SYSTEM

XXXX-112-

Check cleanliness of air path before

operation to prevent foreign object
ingestion.
Open blow-in doors (if provided) and
check limit switch operation.

EXHAUST SYSTEM

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XXXX-112-

None

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TABLE 5-2 SPECIAL INSTRUCTIONS FOR INSTALLING FT8 EQUIPMENT

(Sheet 3 of 7)
FT8 SUB-SYSTEM
MECHANICAL FIELD
ASSEMBLY

DRAWING TREE
DRAWING NO.
XXXX-113-

SPECIAL INSTRUCTIONS
See Section 5.7 for alignment of
coupling between gas turbine and driven
load.
See drawing XXXX-113 for field
installation of bleed ducts, collector box,
and diffuser assembly. Align collector
box per requirement on drawing XXXX113.

ANCILLARY
ENCLOSURES

XXXX-114-

See instructions for gas turbine

enclosure (-112) and for the general
arrangement drawing (XXXX-S100D)

CONTROL HOUSE

XXXX-121-

Confirm foundation
locations.

and

anchor

bolt

Install air conditioner(s) per mechanical

field assembly drawing.
As when lifting most equipment, the control
house should be kept as close to the ground
as possible.
Used spreader beams to lift control house.
Entry doors to the control house and the
equipment cabinets should be kept closed
whenever possible to minimize entry of
dust, dirt, and water.
Lay a plywood or other temporary covering
to protect the floor. Take steps to minimize
tracking in dirt. Prior to and during
installation of the bus duct and switchgear
access panels, insure that these openings are
protected from weather.
Keep control house locked after working
hours.
Keep the control house clean at all
times.

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TABLE 5-2 SPECIAL INSTRUCTIONS FOR INSTALLING FT8 EQUIPMENT

(Sheet 4 of 7)
DRAWING TREE
FT8 SUB-SYSTEM
SPECIAL INSTRUCTIONS
DRAWING NO.
STARTING SYSTEM

XXXX-131-

When lifting, force should be

essentially vertical.
Check tank oil level before initial
startup.
Check operation of motors and
protection system per test instructions.
Hydrostatic test and blow down field
installed piping per instructions in
Chapter 7.

FIRE PROTECTION
SYSTEM
(See Sheet 5 for continued
information on the Fire
Protection System)

XXXX 132 -

Check operation of secondary air

dampers.
Hydrostatic test and blow down field
installed piping per instructions in
Chapter 7.
Paint pipe per specifications.
To ensure proper operation and
adequate sealing of outdoor devices,
make sure the contractor or vendor
installs the fire system devices as
required in the National Electric Code
(NEC) National Fire Protection
Association (NFPA) Standard 70,
Manufacturers Requirements and
Common Industry Practices for
Outdoor Locations.
Where possible, if an outdoor
electrical device has a choice of
having an electrical connection made
at the top or bottom of the device,
install it at the bottom.

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TABLE 5-2 SPECIAL INSTRUCTIONS FOR INSTALLING FT8 EQUIPMENT

(Sheet 5 of 7)
FT8 SUB-SYSTEM
FIRE PROTECTION
SYSTEM
(Continued from Sheet 4)

DRAWING TREE
DRAWING NO.

SPECIAL INSTRUCTIONS
Unused conduit openings must be
sealed with plugs. For the devices, a
shipping plug is installed when
shipped.
If one of the conduit
openings is not used, then the shipping
plug must be removed and a
permanent plug installed to insure no
moisture can enter the device.
For all outdoor connectors and fittings,
insure a proper rain-tight and/or rainproof seal is provided. In the past, fire
protection system installers have
found many of the fittings were
installed with the gasket on the fitting
not sealing against the body of the
device boxes.
For the manual pull stations, the
mounting box is supplied with spacers
attached at the screw locations and a
gasket is attached to the rear of the
pull station. See Figure 5 1. The
spacers must remain to insure a good
gasket seal with the pull station.
NOTE
Detailed spacers are not available from
the vendor. If spacers have already
been removed and/or lost, then the
only option is to install the manual
pull station without them.

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TABLE 5-2 SPECIAL INSTRUCTIONS FOR INSTALLING FT8 EQUIPMENT

(Sheet 6 of 7)
FT8 SUB-SYSTEM
GASEOUS FUEL
CONDITIONING

DRAWING TREE
DRAWING NO.
XXXX 133 -

SPECIAL INSTRUCTIONS
See instructions in Section 5.10 for
installation of gas compressor.
Check alignment between compressor
and motor before operating.
Hydrostatic test and blow down field
installed piping per instructions in
Chapter 7.
Check operation of compressor and
protection system per test instructions.

LIQUID FUEL
CONDITIONING

XXXX 134 -

See corresponding instructions for

gaseous fuel conditioning system,
substituting
pumps
for
compressor.
Hydrostatic test and flush field
installed piping per instructions in
Chapter 7.

WATER INJECTION
SYSTEM

XXXX 135 -

Check operation of motors and

protection system per test instructions.
Hydrostatic test and flush field
installed piping per instructions in
Section 6.

GASEOUS FUEL SKID

XXXX 133 -

Hydrostatic test and blow down field

installed piping per instructions in
Section 7.

LIQUID FUEL SKID

XXXX 134 -

See instructions for water injection

system.

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TABLE 5-2 SPECIAL INSTRUCTIONS FOR INSTALLING FT8 EQUIPMENT

(Sheet 7 of 7)
FT8 SUB-SYSTEM

DRAWING TREE
DRAWING NO.

SPECIAL INSTRUCTIONS

HYDRAULIC OIL
SYSTEM

XXXX 137 -

Pressure check hydraulic system per

instructions in Section 6.

WATER WASH
SYSTEM

XXXX 137 -

NOTE
Customer connection is under the
foundation, and must be made prior to
pouring the main foundation.
Hydrostatic test and flush field
installed piping per instructions in
Section 6.

DRAIN SYSTEM

XXXX 137 -

Drain system piping must be in

position before engine and exhaust
enclosure foundations are poured.

GENERATOR

XXXX - 151 -

See instructions in Section 5.5 for

installation of generator.

SWITCHGEAR

XXXX 152 -

See instructions in Section 1.4 (D) for

installation of 52G circuit breaker.

STEP-UP
TRANSFORMER

XXXX 153 -

See instructions in Section 5.9 for

installation of oil-filled transformer.

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Figure 5 1. Example of Water Proof Installation

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5.12 Exploded Power Pac Drawing

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5.12.1 Exploded Twin Pac Drawing

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6.0 SUPPLEMENTAL, ELECTRICAL

6.1 Scope
This section will provide general guidance in the electrical installation of a FT8 Power
Pac, Twin Pac, or a mechanical drive unit.
6.2 Inventory
All electrical material should be grouped by its Bill of Material (BOM).
NOTE
Some BOMs share the same PWPS part number, but each
has a different item number assigned to that CT part
number. It is important not to mix BOM parts. When an
electrician is assigned to a task, (i.e. install lamps in the
generator enclosure) the electrician will have a PWPS
drawing depicting the item numbers. To locate the parts
they would look for the group that matches the drawing
number minus the suffix D and replace it with a B.
6.3 Tools
1. Special screwdriver for Phoenix (SZS 0,6x3,5 P/N 12 05 05 3) type terminal
blocks.
2. Wire stripper.
3. Cable jacket cutter
4. Adjustable wrench
5. Insulated screw drivers
6. Heat gun
7. Soldering iron
8. Nut drivers
9. Cable tie installation tool
10. DVM
11. Megohmmeter
12. Brady wire marker
6.4 Standard Practices
Reference TPM Specification132 Wiring, General Requirements & Practices contained
in Appendix A in this manual.
1. It is important that contractor installation personnel become familiar with the
PWPS wiring practices and marking system.
2. Careful termination of wires is critical to future system reliability.
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3. Cable assemblies, junction boxes, and equipment shall be protected from the
weather and stored properly to prevent damage.
6.5 Prepping Before Final Placement
6.5.1 Engine Heat
Install control and power cables on engine heat unit junction box before placement on
roof of engine enclosure.
NOTE
The engine heat junction box that these cables plug to will
be located on the outside wall of the engine enclosure.
Power Pac Right Hand Side and Twin Pac, Unit A
Right Hand Side, Unit B Left Hand Side.
6.5.2 Cold Buffer Air
Check cold buffer skid for control box connected to motor. If supplied, remove and
notify PWPS site manager.
6.5.3 Generator Enclosure
To ease installation of conduit at the generator to cable tray, it will be acceptable to
eliminate conduits and replace with vertical pieces of tray.
NOTE
Use cable ties as required to secure cables.
6.5.4 Wire Markers
Wire labels must be installed on each terminated wire. A BRADY type marker system is
recommended. Wiring list will have the information for labels.
NOTE
Some labels include 1s and Is. Use care not to mix-up.
Proper identification of the wiring and cabling is a critical
task that must be accomplished by the installing electrician.

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6.6 Wire Stripping and Wire Preparation

Reference the National Electrical Code Article 300 and TPM Specification 132 Wiring,
General Requirements & Practices contained in Appendix A of this manual.
1. Poorly stripped wire can result in nicks, scrapes, or burnishes. Use proper
stripping tools to perform the work. No knives will be used on 10 AWG or
smaller. Knives will be permitted on large diameter wire only.
2. Use care when pulling wires and cables through cable trays and conduits so as not
damage the insulation.
3. Thermocouple cabling requires proper terminations to the A box and the FTM
terminal block in the control house. The type K T/C cable outer jacket is
YELLOW and has two inner conductors, one is RED which is the (-) also
magnetic and is called by the trade name Nickel-Aluminum (Ni) or ALUMEL.
The other conductor is YELLOW, which is the (+) and is called by its trade name
Nickel-Chromium (NiCr) or CHROMEL. NOTE: Only use with Type K terminal
blocks.
4. Power, control, and signal cables must be segregated to reduce A/C coupling and
noise.
5. For shielded wiring, the standard prep length for each cable pair shall be three (3)inch maximum unless otherwise specified.
6.7 Grounding, General Requirements
Refer to the National Electrical Code Article 250 and TPM Specification 130 Grounding, General Requirements contained in Appendix A of this manual.
1. Safety requires proper and adequate grounding. Improper grounding can be
dangerous to personnel and equipment resulting in shock or fire.
2. Shielding relies on good bonding to ground. Shields must be grounded only at
one end per the drawings to avoid ground current circulating loops.
3. Refer to the drawing entitled "Assembly Grounding Field Electrical" for
grounding locations.
NOTE
Remove painted surface under ground lugs to insure proper
electrical connection.
4. All wire trays shall have a bonding jumper installed at each tray connection point
to insure continuous grounding.
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5. All junction boxes, ancillary equipment, lube enclosure, engine enclosure, exhaust
enclosure, exhaust stack and generator enclosure require ground connections.
6. All ground grid connection shall be cad welded. Refer to TPM Specification 130
Grounding, General Requirements & Practices contained in Appendix A in this
manual.
6.8 Motor Wiring, AC and DC
Reference the National Electrical Code Article 430 and TPM Specification 132 Wiring,
General Requirements & Practices contained in Appendix A in this manual.
All 3 phase and DC motors shall use a split bolt type power connector. Size to be
determined at installation. Make electrical connection inside motor housing and tape
with approved rubber tape. It is essential that connections are tight and there are no
exposed conductive surfaces.
When connecting motors, it is required to establish the correct working voltage for proper
wiring.
6.8.1 Gas Generator DC Lube Motor
Make sure DC motor labels are well defined to insure proper
connection. Only 3 wires connect from the MCC to DC motor in the
GG Lube Oil enclosure. The supplied PWPS cable has numerals
printed on each conductor. NOTE: The motor is a 6 LEAD
COMPENSATED COMPOUND WOUND MOTOR and leads marked
J are not used (optional thermostat). Rotation is clockwise (CW) facing
the commutator end opposite of drive end (see fig 6.8.a). If the motor is
running backward reverse armature leads. DO NOT reverse all three
sets of leads. WARNING, Never start a DC motor without it being
connected to the pump and never run the motor with the pump dry.

CW

figure 6.8.a

NOTE
Generator lube oil motor turns CCW.
6.8.2 Generator Lube Oil DC Motor
Make sure DC motor labels are well defined to ensure proper connection. Only three (3)
wires connect from the motor control center (MCC) to the DC motor on the generator
lube oil skid. The supplied PWPS cable has numerals printed on each conductor.

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WARNING
Never start the DC motor without it being connected to the
pump and never run the motor with the pump dry.
NOTE
This motor is wired to a junction box on the rear side of
lube skid. Wire to terminal box per field wiring list. For
reference purposes, the compound wound motor uses a
different code system (BRITISH).
The only way to check rotation is to look for proper oil pressure.
WIRE
#1
F1

M3002 GENERATOR DC LUBE PUMP

F1(E1)

13

F2(E2)

GP

15
GP

SHUNT

(MCC)

A1

WIRE
#3

14

A2(B1)

S1(D1)

L2
(MCC)

S2(D2)

GP

(MCC)

WIRE
#2

A1(A2)

SERIES

NOTE: British nomenclature in parentheses.

6.9 Control House

Refer to TPM Specification 132 Wiring, General Requirements & Practices contained
in Appendix A of this manual.
Temporary 3-phase power wiring to the control house must
be phased correctly to the automatic transfer switch (Aux
power/Normal
and
Emergency
power/Back-up).
Connections to the switch will be wired from left to right
for phases A, B, C. Notify the on site PWPS field engineer
before turning on the power to control house and make sure
proper voltages and phases are correct.

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RED

WHITE

BLACK

PHASE

ATS
A

RED

WHITE

BLACK

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NOTE
Final power connections must keep the same phasing or
equipment could be damaged.
6.9.1 AUX Transformer
The AUX transformer located near switchgear must also be checked for proper phasing.
It also connects to above automatic transfer switch. The electrician must check the AUX
transformer tap settings to make sure they agree with required 3-phase voltage.
NOTE
AUX transformer feeds the automatic transfer switch Aux
power/Normal.
6.9.2 Battery Systems
Use caution not to short terminals to each other or to ground when installing battery cells.
CAUTION
The negative and positive of each battery must be isolated
from ground. For safety the electrician should use insulated
tools.
After installing batteries check each battery for proper electrolyte level. If the level is too
low, use only distilled water to fill the low cells. Record each battery cell voltage level
and specific gravity and temperature, before and after charging on Table 6-1 Battery
Report, and submit to PWPS site manager. Each battery should have a numeral assigned
to it.
Adjust battery chargers float, equalize, and current limit per PWPS Checkout Manual
and charger/battery manufacture instructions. Refer to Table 6-1.
6.9.3 Electro-Static Discharge (ESD)
Use wristband straps that are properly connected to earth before handling PC boards or
cards. The most common cause of electrostatic damage is the direct transfer of
electrostatic charge from the human body or a charged material to the electrostatic
discharge sensitive (ESDS) device. The Woodward Governor NetCon or MicroNet cards
are ESD sensitive. Never touch the pin of the connector unless ESD protected.
Motor overloads, breaker settings, electrical checks, and rotation to be performed by field
personnel. Refer to NEC Article 430.

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6.10 High Voltage Cable and Equipment

Refer to TPM Specification 132 Wiring, General Requirements & Practices contained
in Appendix A of this manual. In addition, please refer to the National Electrical Code,
Article 490.
When installing high voltage bus (above 600 volts) refer to Article 490, Table 490-24 for
proper clearances. The worker must take care not to compromise these clearances. An
example would be installing bolts that are too long, which could compromise the
clearance between energized parts and ground or other phases.
All connections must be properly torqued to allow for expansion and contraction of the
bus. All 90-degree splices should be wrapped with copper wire mesh to relieve electrical
stresses and then properly insulated with boots or tape.
Insure that all heaters that are used to prevent condensation are properly connected and
functional.
High voltage systems are monitored with current transformers (CTs) and potential
transformer (PTs). The technician must pay particular attention to the phase relationship
between PTs and CTs. Current transformers must never be left open circuited. Special
terminal blocks allow for shorting and grounding the secondary winding of the CTs.
High voltage cables come in many difference types such as paper lead cable, shielded
cable, and non-shield cable. The type that is typically used on FT8 sites is the shielded
type.
Only electricians with experience working with specific types of cables should install the
system.
The terminations at each end of the cable shall have a stress cones. Refer to the
manufacture's directions for proper stress cone installation. The drain wire (shield) is to
be grounded on each end of the cable
6.11 Testing
PWPS field personnel will advise, as needed, to the site contractor on system power ups
and electrical checks.

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TABLE 6-1 BATTERY REPORT

NAME:____________________ DATE:___________________PROJECT:_____________________
CELL
#

Sp.Gr.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39

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130 VDC BANK BATTERY P/N ______________

F CELL Sp.Gr. VOLTS F CELL Sp.Gr.

VOLTS

40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78

79
80
81
82
83
84
85
86
87
88
89
90
91
92

VOLTS

24 DCV BANK
BATTERY P/N _________
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

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7.0 SUPPLEMENTAL MECHANICAL

7.1 Flushing and Leak Check
After field installation all piping and carrying liquids shall be pressure tested, purged, and
flushed according to the applicable specifications. This section gives typical procedures
and general information for flushing and leak checking FT8 Power Pac and Twin Pac
liquid systems.
The lines and equipment leading to the equipment being tested must be cleaned by
procedures specified for those parts before starting the following procedures.
WARNING
To conform with standard safety practices, eye and ear
protection, as applicable, must be worn during these
operations.
7.1.1 Hydrostatic Test
All field installed piping shall be pressure tested to 1.5 times operating pressure or as
specified in the specifications. The gas generator, power turbine, and other system
components as directed by PWPS, must be isolated during this test.
Hydrostatic tests shall consist of pressurizing the piping with water to the specified test
pressure (typically 1.5 times the maximum design working pressure), holding the pressure
for a specified interval (typically 15 to 30 minutes) and then removing the source of the
pressure. The entire external surface of the piping system shall be completely dry.
Evidence of moisture shall require repairs and repetition of the test until satisfactory. The
contractor shall take precautions to protect system components by bringing the system to
full test pressure gradually.
7.1.2 Blowdown
Prior to putting any of the systems in service, all piping must be purged with inert gas or
air to clean any moisture or loose material from the line.
CAUTION
During the blowdown procedure, the exhaust gases must be
directed toward a safe area, and the hose or pipe positively
secured to prevent the end from whipping.

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7.1.3 Flushing
All field installed piping shall be flushed with the type of fluid used in the system to
assure that no dirt or other foreign materials have been introduced into the system. The
following guidelines describe methods to flush the system so that components not
requiring flushing are bypassed. Component identification (tag) numbers and field
connection numbers given are as referenced on their respective Piping and
Instrumentation Diagram (P&ID) drawings.
Flow diagrams, Figure 7-1 through 7-6, located at the end of this section, illustrate the
flushing paths recommended in the following procedures. These flow diagrams are
essentially overlays on the generic P&ID drawings for these sections. The P&ID drawing
numbers are referenced on the diagrams.
All P&ID symbols are diagrammed and defined in Table 7-1, located at the end of
Section 7.
7.1.3.1 Special Equipment Required for Flushing
1. Lube Oil Pump stainless steel body and impeller, 30-50 GPM flow, 50-75 psig
delivery pressure, 3-5 hp drive motor, 240/480 VAC
2. Lube Oil Heater 8-10 kW, 20 watts/square inch maximum, 195 to 210F range,
240/480 VAC
3. Lube Oil Pressure Gage 0-100 psig
4. Valves stainless steel, quantity and sizes as required
5. Screen 100 mesh, stainless steel
6. Flex hose 1, 1-1/2, and 2, as required
7. NPT to Swagelok and NPT to 37 degree AN fittings, as required
8. Lube Oil Filters 10 micron filters for F601 and F602, to remain in place
throughout flushing and initial startup
9. Liquid Fuel Filter 36 GPM, 5-50 psig
10. Other fittings, tees, caps, and plugs, as required

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7.1.4 Flushing the Liquid Fuel System

After a successful pressure check and blowdown of the system, it must be thoroughly
flushed with fuel oil. The initial field flushing purges the fuel forwarding system from
the tank to the lube skid fuel inlet. The final field flushing adds the piping up to the fire
valve in front of the engine enclosure.
CAUTION
Appropriate fire protection equipment must be readily
available during the flushing operation in view of the
obvious hazard of spilled fuel and combustible vapors.
7.1.4.1 Initial Field Flushing (Refer to Figure 7-1)
1. Remove the elements from the main fuel filter(s) (F) and reseal system.
2. If the system includes a flow meter, valve it off and open the bypass. Remove the
flow meter if there is no bypass line and replace with flex hose of an equivalent
size.
3. Attach a hose (equivalent to the size of the piping) at LF2. If practical, run this
hose back to the fuel storage tank, or, if not, into an empty tank truck, using an
extra strainer or filter before it enters the tank or tank truck. Plug and cap open
lines and fittings as necessary during these procedures.
4. Remove any orifices from the lines, such as those used in the forwarding skid.
5. The portion of the system from the storage tank, through the forwarding skid, and
through the main filter is now ready for flushing. The AC forwarding pump(s)
should remain energized during the flush, except for the intermittent energizing of
the DC forwarding pump (if DC power is available) during which time the AC
pump(s) should be shut down.
6. Take fuel samples frequently during the flush from some convenient point, such
as at the filter added in the return line. Placing the sample in a clean, clear glass
jar and holding it up to a strong light may determine fuel sample cleanliness.
Evidence of sediment or foreign particles at the bottom of the jar on any one of
the several samples would indicate that flushing should be continued.
g. When the fuel sample indicates that no contamination is present in the part of the
fuel system being flushed, remove the flushing hose added at LF2, reconnect the
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piping where the flushing hose was attached, and proceed with the final field
flushing.
7.1.4.2 Final Field flushing (Refer to Figure 7-2)
1. Connect the flushing hose at F3 before the fire valve FV1001, and route it
back through a filter to the storage tank or an empty tank truck. Cap the open
fitting to the fire valve at F3.
2. Install the main fuel filter elements removed in A.1 above.
3. Remove the filter element from the final filter F-1001.
4. Resume the flushing operation as described in steps A.5 through A.7, except
including the piping up to F3. Check the differential pressure gage reading on
the main filter periodically to determine the effectiveness of the initial flush.
5. When the samples indicate clean fuel, terminate the flush, install the final
filter elements, install the hose between the final filter and the engine, and
install the flow meter, if applicable. Install any orifices that have been
removed, and bleed air from the system by opening the appropriate valves,
such as those on top of the final filter and heating tank and the fuel pump
pressure sense line.
6. Remove the Y strainer between the forwarding skid and the storage tank.
Check for cleanliness, clean and replace, taking care not to introduce any
contaminates into the openings.
7.1.5 Flushing the Gas Turbine Lube Oil System (Refer to Figure 7-3)
The lube oil skid supplies filtered, cooled, de-aerated oil to both the gas generator and
power turbine. Lube oil system components are skid mounted and located outside of the
engine enclosure. Prior to shipment, this unit has been flushed and sealed per PWPS
specifications.
Flushing is to begin after installation of all the tubing and hose assemblies. (Inspection of
the system is required at this time.) Figure 7-3 shows the flushing paths used in the
following procedure.
The procedure for field flushing the FT8 lube oil system is detailed in TPM Specification
141.

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7.1.6 Flushing the Wash Water System

Figure 7-5 shows the flushing path used in the following procedure.
NOTE
This procedure is not to be performed through operation of
the water wash system using the station control, since water
wash is coordinated with the start system operation.
1. Disconnect the flex hose at the nozzle, locate don the outside of the inlet plenum
wall, and cap the nozzle fitting.
2. Attach a 1 inch hose to the flex hose and run to drain.
3. Open ball valve BAV-701 manually. This procedure assumes customer-supplied
water is available at nominal pressure.
4. Energize shutoff valve SOV-701 by applying 125 VDC at the Master Terminal
Board terminal for this valve.
5. Flush the injection water system until no traces of foreign material are found in
the effluent.
6. Check for leaks during flushing procedure.
7. Shut down the water wash system, disconnect the added hose, and reconnect the
flex hose at the nozzle for normal operating conditions.
7.1.7 GG Hydraulic System (Refer to Figure 7-6)
The hydraulic system draws its working fluid from the gas turbine lube oil system. Oil
for the hydraulic system is taken from after the filter screen following the engine-mounted
oil pump (GG MOP) and is returned to the lube oil tank after providing hydraulic
pressure to the actuators located on the engine base and water injection skid. The engine
base mounted equipment does not require field flushing. The supply and return tubing to
the water injection skid must be field cleaned and flushed.
The skid-mounted hydraulic system components are cleaned, flushed, and sealed by the
vendor at the factory. The three flex hoses use field interface locations H13, H20, and
H21 for a standard installation and are required to be smooth, clean, and free of blister,
dirt, oil, grease, and other foreign matter. The openings are capped securely with clean
plastic plugs designed for this purpose. Therefore, unless there is additional field
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installed piping for a particular installation; no additional cleaning and flushing should be
required for the hydraulic system. However, if no additional flushing is used, it is
particularly important to keep the interference of these three flex hoses clean during
handling and assembly.
7.1.8

Hydraulic Start System

The hydraulic start system consists of a factory-assembled skid with electric motor driven
pump(s), interconnection piping and tubing and an engine mounted hydraulic starter
motor.
CAUTION
The hydraulic system will be pressure tested to 1.5 times normal
pressure before initial operation. Because of this increased
pressure test requirement, the use of proper tooling is critical when
fabricating and installing the piping and tubing for the hydraulic
start system.
Use of the appropriate tooling will prevent
unnecessary leaks and damage to the equipment and eliminate the
added costs of having to replace equipment damaged through the
use of improper tooling.
When fabricating and installing hydraulic start system piping using
Swagelok fittings, the appropriate commercial Swagelok tools and
installation procedures shall be used to install all Swagelok fittings.
When fabricating and installing hydraulic start system piping using
Parker Instrumentation fittings, the Parker ICD Ferrule Presetting
Tool Kit and the tool kit assembly procedures shall be used to
install all Parker fittings.
The piping and tubing between the skid and the engine(s) is field fabricated and
assembled. The return and drain lines are fabricated from stainless steel tubing and must
be field flushed prior to operation. The high-pressure (5000 PSI) supply piping is double
strength stainless steel and is field welded. It must be cleaned and flushed prior to
operation.
7.1.8.1 Parker Instrumentation Fittings Remake Instructions. The instructions
contained in the next paragraph have been extracted from the Parker ICD Ferrule
Presetting Tool Kit Assembly Instructions, Bulletin 4290-B1, revised May 1997.
A disassembled joint can be remade simply by retightening the nut to the position of the
original make-up. For maximum number of remakes, mark the fitting and nut before
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disassembly. Before retightening, make sure the assembly has been inserted into the
fitting until the ferrule(s) seats in the fitting. Retighten the nut by hand. Rotate the nut
with a wrench to the original position as indicated by the previous marks lining up. (A
noticeable increase in mechanical resistance will be felt indicating the ferrule is being resprung into sealing position.) Then snug the nut 1/12 turn (1/2 hex flat) as shown from A
to B, past the original position.

7.2 BLOWDOWN AND LEAK CHECK

After field installation all piping carrying gases shall be pressure tested and purged
according to the applicable specifications. This section gives typical procedures and
general information for blowdown and leak checking Power Pac and Twin Pac liquid
systems.
The lines and equipment leading to the equipment being tested must be cleaned by
procedures specified for those parts before starting the following procedures.
WARNING
To conform with standard safety practices, eye and ear
protection, as applicable, must be worn during these
operations.
7.2.1 Hydrostatic Test
All field installed piping shall be pressure tested to 1.5 times operating pressure or as
specified in the specifications.
Hydrostatic tests shall consist of pressurizing the piping with water to the specified test
pressure, holding the pressure for a specified interval, typically 15 to 30 minutes, and then
removing the source of the pressure. The entire external surface of the piping system
shall be completely dry. Evidence of moisture shall require repairs and repetition of the
test until satisfactory. The contractor shall take precautions to protect system components
by bringing the system to full test pressure gradually.

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7.2.2 Blowdown
Prior to putting any of the systems in service, all piping must be purged with inert gas or
air to clean any moisture or loose material from the line.
Flow diagrams Figure 7-7 through 7-10 below illustrate the blowdown paths
recommended in the following procedures. These flow diagrams are essentially overlays
on the generic P&ID drawings for these sections. The P&ID drawing numbers are
referenced on the diagrams.
All P&ID symbols are diagrammed and defined in Table 7-1, located at the end of this
section.
CAUTION
During the blowdown procedure the exhaust gases must be
directed toward a safe area, and the hose or pipe positively
secured to prevent the end from whipping.
7.2.3 Gaseous Fuel Supply System (Refer to Figure 7-7)
7.2.3.1 Hydrostatic Test
1. Pressure test the lines before connecting the flange to the engine base fuel plate
input at G2, or disconnect this flange before performing the test to isolate the gas
generator. Cap the gas inlet flange at G2 to keep out the contamination, and seal
the terminations as necessary to conduct this test. Isolate other system
components as directed by PWPS personnel.
2. Hold the test pressure as required in the specification without depletion of
pressure.
3. Proceed with the blowdown procedure before reconnecting flange G2.
7.2.3.2 Blowdown
1. Blow the lines down to remove moisture and loose material following the
hydrostatic test. The blowdown path is show in Figure 7-7.
2. Control the air in short bursts until there is no evidence of foreign material in the
purge air.

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3. Reconnect the fuel inlet line at G2, taking care to avoid introducing contamination
into the openings.
7.2.4 Air Start Pac (Refer to Figure 7-8)
7.2.4.1 Hydrostatic Test
1. Pressure test the lines before connecting the 3 inch flex hose to the engine
starter at AS5, or disconnect this flex hose before performing the test. Plug the
starter inlet to keep out contamination, and seal terminations as necessary to
conduct this test. Isolate other system components as directed by PWPS
personnel.
2. Hold the test pressure as required in the specification without depletion of
pressure.
3. Proceed with the blowdown procedure before reconnecting the 3 inch flex hose
at AS5.
7.2.4.2 Blowdown
1. Blow the lines down to remove moisture and loose material following the
hydrostatic test, as shown in Figure 7-8.
2. Control the air in short bursts until there is no evidence of foreign material in the
purge air.
3. Reconnect the air start inlet line at AS5, taking care to avoid introducing
contamination into the openings.
7.2.5 CO2 Fire Protection System (Refer to Figure 7-9)
7.2.5.1 Hydrostatic Test
1. Pressure test the lines from the CO2 cylinder before connecting them to the
nozzles and secondary air dampers, or disconnect these terminations before
performing the test. Cap the lines from the cylinders to keep out contamination,
and seal terminations as necessary to conduct this test. Isolate other system
components as directed by PWPS personnel.
2. Hold the test pressure as required in the specification without depletion of
pressure.
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3. Proceed with the blowdown procedure before reconnecting the CO2 lines.
7.2.5.2 Blowdown
1. Blow the lines down to remove moisture and loose material following the
hydrostatic test, as shown in Figure 7-9. Each exit should be blown down
sequentially, starting with the closest exit (nozzle X-201) and progressing to the
most remote exit (secondary air damper pneumatic release R-202).
2. Control the air in short bursts until there is no evidence of foreign material in the
purge air.
3. Reconnect the CO2 lines, taking care to avoid introducing contamination into the
openings.
7.2.6 Halon Fire Protection System (Refer to Figure 7-10)
7.2.6.1 Hydrostatic Test
1. Pressure test the lines from the Halon cylinders as given above for the CO2
system, except two sets of lines must be tested, as shown in Figure 7-10.
7.2.6.2 Blowdown
1. Blow the lines down as given above for the CO2 system. For each of the two sets
of lines, each exit should be blown down sequentially, also, starting with the
closest exit and progressing to the most remote exit.
2. Reconnect the Halon lines, taking care to avoid introducing contamination into the
openings.
7.2.7 Cold Air Buffer System
7.2.7.1 Hydrostatic Test
1. Pressure test the three lines before connecting the flanges to the engine base input
at HX1, HX3 and HX4. Cap the flanges at HX9, HX10, HX11 and HX12 to keep
out the contamination, and seal the terminations as necessary to conduct this test.
Isolate other system components as directed by PWPS personnel.
2. Hold the test pressure as required in the specification without depletion of
pressure.
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3. Proceed with the blowdown procedure before connecting flanges HX1, HX3 and
HX4.
7.2.7.2 Blowdown
1. Blow the lines down to remove moisture and loose material following the
hydrostatic test.
2. Control the air in short bursts until there is no evidence of foreign material in the
purge air. Approximately 100 psi air or nitrogen will be required along with a
quick opening ball valve at the discharge end. The air supply line needs to be
firmly attached at on end and soft metal target needs to be placed at the discharge
end of the ball valve.
3. Continue the air blows in short, full-flow bursts until three consecutive shots
yields no visible marks on the target. The final three successful shots must be
witnessed and accepted by the PWPS site representative
4. Reconnect the ends of the three cold air buffer lines, taking care to avoid
introducing contamination into the openings.
5. Install the two nominal size orifice plates as shown on the XXXX-138-M400D
drawing.

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Table 7-1 ABBREVIATIONS USED IN P&I DIAGRAMS

AC
ACM
AS
BAV
BV
BFV
C
CV
DA
DV
EJ
F
FCV
FE
FO
FPT
FSV
FV
GV
GP
H
HS
HX
LAH
LAHH
LE
LG
LSH
LSHH
LSL
LSLL
LT
MOP
MOV
MPT
OME
P
PAL
PALL
PCV
PDI
PDAH
PDCV
PI
PRV
PSH
PSHH

AIR COOLER
ACCUMULATOR
AIR STARTER
BALL VALVE
BREATHER VALVE
BUTTERFLY VALVE
COMPRESSOR
CHECK VALVE
DEAERATOR
DUMP VALVE
EXPANSION JOINT
FILTER
FLOW CONTROL VALVE
FLOW ELEMENT
FLOW ORIFICE
FEMALE PIPE THREAD
FLUID STOP VALVE
FIRE VALVE
GATE VALVE
GEAR BOX PUMP
HEATER
HAND SWITCH
HEAT EXCHANGER
LEVEL ALARM HIGH
LEVEL ALARM HIGH HIGH
LEVEL ELEMENT
LEVEL GAGE
LEVEL SWITCH HIGH
LEVEL SWITCH HIGH HIGH
LEVEL SWITCH LOW
LEVEL SWITCH LOW-LOW
LEVEL TRANSDUCER
MAIN OIL PUMP
MAIN OPERATED VALVE
MALL PIPE THREAD
OIL MIST ELIMINATOR
PUMP
PRESSURE ALARM LOW
PRESSURE ALARM LOW-LOW
PRESSURE CONTROL VALVE
PRESSURE DIFFERENTIAL INDICATOR
PRESSURE DIFFERENTIAL ALARM HIGH
PRESSURE DIFFERENTIAL CONTROL VALVE
PRESSURE INDICATOR
PRESSURE REGULATING VALVE
PRESSURE SWITCH HIGH
PRESSURE SWITCH HIGH-HIGH

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PSL
PSLL
PSV
PT
RCV
RO
SAL
SAH
SI
SOP
SOV
SP
ST
SV
TAH
TAHH
TAL
TCV
TK
TE
TI
TRV
TS
VAH
VAHH
VI
VP
VT
XA
X
XS
ZA
ZS
ZT

PRESSURE SWITCH LOW

PRESSURE SWITCH LOW-LOW
PRESSURE SAFETY VALVE
PRESSURE TRANSMITTER
RECIRCULATING CONTROL VALVE
RESTRICTING ORIFICE
SPEED ALARM LOW
SPEED ALARM HIGH
SPEED INDICATOR
SCAVENGER OIL PUMP
SOLENOID VALVE
SEPARATOR
SPEED TRANSMITTER
SERVO VALVE
TEMPERATURE ALARM HIGH
TEMPERATURE ALARM HIGH HIGH
TEMPERATURE ALARM LOW
TEMPERATURE CONTROL VALVE
TANK
TEMPERATURE ELEMENT
TEMPERATURE INDICATOR
TRANSFER VALVE
TEMPERATURE SWITCH
VIBRATION ALARM HIGH
VIBRATION ALARM HIGH HIGH
VIBRATION INDICATOR
VACUUM PUMP
VIBRATION TRANSDUCER
UNCLASSIFIED ALARM
NOZZLE
UNCLASSIFIED SWITCH
POSITION ALARM
POSITION SWITCH
POSITION TRANSDUCER

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Table 7-2 VALVE SYMBOLS

PRESSURE SAFETY VALVE

GATE VALVE (NORMALLY OPEN)

GATE VALVE (NORMALLY CLOSED)

VACUUM BREAKER

3 WAY VALVE (ONE PORT CLOSED)

CHECK VALVE

BALL CHECK VALVE

BUTTERFLY VALVE

ELECTRO HYDRAULIC
METERING VALVE

REGULATING VALVE

SOLENOID VALVE (FAIL CLOSED)

BALL VALVE (OPEN)
NEEDLE VALVE (FAIL OPEN)
BALL VALVE (CLOSED)

NOTE
The NORMALLY OPEN (unshaded symbol) designation
means that the valve is open in normal system operation, and
does not indicate the de-energized condition of a solenoid valve.
The abbreviation FO and FC are added to the valve symbol
to indicate FAIL OPEN or FAIL CLOSED. As a rule, the
valve will fail to the de-energized state. Therefore, for instance,
a shaded solenoid valve symbol with FO will be normally
closed in system operation and energized to closethat is, the
solenoid will hold the valve closed in normal system operation.

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Table 7-3 SYMBOLS USED IN P&I DIAGRAMS (Sheet 1 of 2)

CONTRACTOR
SUPPLY

PWPS
SUPPLY

RESTRICTING
ORIFACE
BATTERY
LIMIT

HEATER

SHELL & TUBE TYPE

HEAT EXCHANGER

FILTER

DRIP LEG

NOZZLE

ELECTRIC HEAT TRACING

WITH INSLUATION

OIL MIST
ELIMINATOR

COMPONENT
(AS SPECIFIED)

SEPARATOR

SCREEN

FILTER Y-TYPE

FINNED TUBE TYPE

HEAT EXCHANGER

AIR STARTER

ACCUMULATOR
MOTOR

VALVE (MANUALLY OPERATED

WITH MANUAL RESET

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BREATHER
VALVE

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Table 7-3 SYMBOLS USED IN P&I DIAGRAMS (Sheet 2 of 2)

PROCESS LINE
PNEUMATIC LINE
ELECTRIC LINE
FLOW ELEMENT VENTURI TYPE

HYDRAULIC LINE

LOCAL MTD. INSTRUMENT

REMOTE MTD. INSTRUMENT

MISCELLANEOUS SYMBOLS
REDUCER
INSTRUMENT BLOCK AND BLEED VALVE

FLEXHOSE

EXPANSION JOINT

PLUG
PUMP SYMBOLS
TRAP
RESET

CENTRIFUGAL

POSITIVE
DISPLACEMENT

CONNECTION POINT

VACUUM
PUMP

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8.0

SPECIFIC FT8 INSTALLATION SEQUENCE

8.1 Introduction
The installation sequence for the FT8 Power Pac and the FT8 Twin Pac starts with
installing the power island, the main foundation equipment in parallel with the control
house and ancillary skids. The power island is then interconnected to the control house
and ancillary skids with the installation of the major field assemblies like the field
electrical, piping and mechanical assemblies.
The power island sequence starts with first placing, leveling and grouting the electric
generator. The electric generator enclosure is built around the electric generator followed
by the exhaust enclosure system. Then the gas turbine and its enclosure system are
installed followed by the installation of the inlet air silencers and inlet filter house. For
the FT8 Twin Pac, two of each of these assemblies are installed for a single electric
generator. The gas turbine(s) is then aligned to the grouted electric generator some time
after the installation of the gas turbine enclosure.
The control house, the start pac(s), the lube oil skid(s) and the other ancillary skid(s) are
placed on their respective foundations some time during the installation of the power
island equipment. Generally the control house is set in place after the installation of its
cable tray system. The first placement of the control house is only temporary. After the
installation of the electric generator and its enclosure, the high voltage bus duct is
erected from the electric generator to the control house. To make the final bus duct
connection, the control house is typically moved to line up with the bus duct.
8.2 Installation Sequence (Abbreviated)

Foundations
Completed
FT8 Equip
Received

Inventory
FT8 Equip.

Install
Exhaust Sys.

Install Elec.
Generator
Install Elec.
Gen. Enclosure

Install
Cable Tray

Set Gas
Turbine

Install GT
Enclosure

Install Field Assemblies:

Electrical, Piping, Mechanical, Etc.

Install Air Inlet

System

Align Gas
Turbine

*
Startup

Commissioning

Checkout

Set & Install

Control House
Set & Install
Lube Oil/Water Skid
Set & Install
Start Pac Skid
Set & Install Fuel
and/or Other Skids

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*
*
* Requires two of these items
for a FT8 Twin Pac

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8.3 Procedures
The following procedures apply to the abbreviated sequence shown above in section 8.2.
These procedures are in a simplified checklist format.
8.3.1 Foundations
1. Prior to installing any FT8 equipment, foundation installations must be completed
(by others), cured and ready for equipment placement.
2. Clean foundation surfaces for equipment placement.
3. Check size, depth and quality of gas turbine and electric generator chip back
areas.
4. Check the 4-inch square datum pad locations and elevations and scribe
centerlines.
5. Check anchor bolts location and elevation.
6. Check jacking pad location and elevation.
7. Remove all water from all anchor bolt sleeves.
8. Grease entire length of all anchor bolts.
9. Seal all anchor bolts sleeves and/or back fill sleeves with dry sand.
8.3.2 Receiving FT8 Equipment
1. Inspect all equipment for shipping damage.
2. Inventory equipment against all shipping documents.
3. Report any damages in writing to PWPS.
4. Mark, sign and fax a copy of the packing list (shipping authorization) to PWPS
project management.
5. Maintain copies on site of all shipping documents.
6. Properly locate and/or store equipment on site.
7. Weather protect all equipment as necessary.
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8. Energize electric generator(s) three phase space heaters when generator arrives
(prior to placement if there are any delays).
8.3.3 Inventorying FT8 Equipment
1. Inventory in detail all FT8 equipment, parts and tools received on site.
2. Cross check received equipment with released project bill of material noting all
shortages with respect to bill of material.
3. Mark each inventoried item with the appropriate drawing number and item
number (quantities and part number are to be previously provided by PWPS and
its vendors).
4. Recheck all material for shipping or storage damage.
5. Where possible store or kiddy equipment by assemblies and/or by field
assemblies.
8.3.4 Electric Generator
1. Complete Foundations checklist items paragraph 8.3.1 above.
2. Remove packaging and check for shipping and/or storage damage.
3. Assemble, clean and set electric generator sole plate assemblies on foundation
over anchor bolts with equal quantities of shims as per PWPS field drawings; bolt
to electric generator when placing generator.
4. Mark foundation with centerline from one end of unit to the other.
5. Place electric generator on foundation by skidding or crane. Connect temporary
power to generator heaters. Refer to Brush drawing. A03176257 Terminal box
#2. Refer to Section 3 of Brush manual for complete information.
6. Remove transportation bump meter(s) and return to PWPS.
7. Reconnect three phase power to space heaters.
8. Remove rotor-blocking fixture.
9. Align to centerlines, level and grout per PWPS field drawings. Verify that rotor is
on design pin gage dimension. If rotor is not on pin gage adjust the axial position
from 'A' datum station 218.5 by the required amount.
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10. There are two methods of placing generator: Sole plates mounted to the generator
plates, or, sole plates grouted to foundation prior to setting generator.
11. Tighten the generator anchor nuts on sole after grout has cured.
12. Install electric generator neutral cubicle onto the left side of the generator (with
your back to exciter end) (DO NOT MAKE HIGH VOLTAGE CONNECTION
UNTIL AFTER PI TESTING). See Brush drawing 9625696.
13. Install cable tray along generator wall on lube module side of generator prior to
placing module. Refer to PWPS drawing XXXX-123-E110D Sheet 2.
14. Install electric generator lube oil skid onto right side of generator (with your back
to exciter end). See Brush foundation drawing 3175823 for location on base. Do
not anchor at this time. Wait until piping is installed. Install required field
electrical assemblies.
15. When ready for the electric generator enclosure system, remove top mounted steel
plate and install generator exhaust damper assembly, two inlet grills, and install
transition duct provided with electric generator enclosure assembly.
16. Install electric generator enclosure system.
17. PI (polarity index) test electric generator stator windings. When successful make
neutral cubicle connections and start high voltage bus duct installation.
18. Start checkout, tank inspection, oil fill (Mobil DTE Lite, CT116676), flushing,
etc.
8.3.5 Electric Generator Enclosure System
1. Install per PWPS generator enclosure drawing (e.g. Power Pac: STND-112S300D-02, Twin Pac: STND-112-S300D-01).
2. Unpack and check for shipping and/or storage damage.
3. Before placing walls, mount sidewall inlet louvers (Power Pac); mount sidewall
silencer panels (Twin Pac).
4. Lift right side wall first and install gasket at bottom with contact cement (punch
holes in gasket).
5. Set right sidewall at dimension shown on drawing noted above.

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6. Install closure panel (open wall section at generator coupling end) with gaskets
and adhesive; install one for power pac and two for twin pac.
7. Install left wall section with gaskets.
8. Install enclosure end wall (Power Pac only).
9. Install roof panels with gaskets and adhesive.
10. Install the exhaust silencer (REMOVE ALL DRAIN PLUGS).
11. Install generator lube oil vent line to bottom of exhaust silencer.
12. Install field electrical assembly (e.g. XXXX-123-E110D).
13. Install fire system piping (if option purchased by customer).
8.3.6 Exhaust System
1. Assemble diffuser assembly. Degrease as necessary.
2. Un-crate, degrease and insulate collector box.
3. Place and block collector box in its proper position on foundation.
4. Lift and temporarily set diffuser assembly inside collector box.
5. Lift exhaust enclosure. Check that the enclosure is centered over the shaft center
line and install gaskets and set in place over collector box assembly (clearance left
and right is +/- 1inch (25 mm)).
6. Install high temperature gaskets and set exhaust transition duct on top of exhaust
enclosure.
7. Install next set of high temperature gaskets and set first exhaust duct on top of
transition duct; repeat above for remaining exhaust duct(s).
8. Install generator enclosure bulkhead/fire wall (one for Power Pac and two for
Twin Pac).
9. Repeat above procedures for second exhaust system (Twin Pac only).

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8.3.7 Installing Gas Turbine

1. Complete Foundations checklist items paragraph 8.3.1 above.
2. Remove gas turbine and base assembly from its shipping container and remove
top half of blue shipping bag.
3. Inspect gas turbine & base assembly for shipping and storage damage.
4. Remove power turbine rotor blocking fixture.
5. Install output shaft coupling to PT shaft and torque.
6. Install coupling hub to generator (if not already installed)
7. Remove grease from bottom of GT base (sole plates)
NOTE
The blue shipping bag and the power turbine rotor-blocking
fixture must be returned to PWPS.
8. Disconnect gas turbine right and left side flexible bleed ducts as necessary to
connect the contractors lifting slings to base assembly (longer slings are needed
in the front due to the high weight of the power turbine assembly).
9. Lift gas turbine and base assembly, degrease bottom/sole plates and set over
anchor bolts (on wood blocks or on jacking screws).
10. Rough align using gas turbine base jacking screws. A rearward slope of about
.010 inch per foot is wanted. Level front and rear transverse beams and set GT
height so that center of turbine and GG mounts are 62 1/8 inch (+/- 1/8 inch)
above top of concrete (same as vertical height of generator rotor).
11. Install rope exhaust seal (CT 114085) and bolt the diffuser assembly to power
turbine. Use masking tape to help hold seal in place by wrapping seal into slot
with tape. (DO NOT INSTALL THE BELLMOUTH OR COLLECTOR BOX
SEALS).
12. Move the diffuser/collector assembly forward and suspend collector box on
vertical thrust rods. Set distance between top bracket on enclosure wall and
mount on Collector box at 51.25-inch +/- .25-inch.
13. Bolt diffuser to GT noting the correct position for blowholes on diffuser rear
flange. Rotation of the diffuser may be necessary prior to attaching to GT. The
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correct diffuser location is to have a smaller bolt head located equal distance
between two larger tie rod bolts. This allows for correct position of N3 cable
channel and position of alignment tooling rear support bracket.
14. Install horizontal thrust rods and use special thrust washers.
15. Install shaft support tooling in diffuser tunnel and place shaft on rails and align to
the coupling piece installed in above step above.
16. Install shaft per Lucas print and PWPS drawing. Torque per instructions on
drawing.
17. Remove the front drive shaft support cradle. (now ready for alignment)
18. Repeat above procedures for second gas turbine (Twin Pac only).
8.3.8 Gas Turbine Enclosure System
1. Unpack and check for shipping and/or storage damage.
2. On the GT enclosure, remove rubber seals on inlet plenum opening so they do not
interfere with GT bell mouth when setting enclosure.
3. Set GT enclosure using gasket between enclosure and concrete. Align front of
enclosure so that centerline of enclosure is on centerline of GT base.
4. Install electrical junction box A and other external electrical hardware.
5. Install gas turbine enclosure trolley.
penetration for overhead lifting.

Install trolley using engine heater duct

NOTE
If trolley was installed by the manufacturer prior to delivery, insure
the alignment tabs are in place.
If trolley is to be installed at the site, mount the trolley on the
tracks within the enclosure and weld on the alignment tabs to
prevent the trolley from falling from the tracks. Refer to PWPS
drawings IPE 21778 and XXXX-112-S000D.
6. Install roof top engine heat unit.

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7. Attach gaskets to gas turbine enclosure and mount secondary air fire damper
assembly followed by secondary air inlet louver.
8. Install CO2 bottle and fire system.
9. Install external field electrical, mechanical, piping, cold air buffer systems, etc.
10. After gas turbine alignment & grouting, install nose cone and balance of field
electrical, mechanical, piping and cold air buffer systems.
11. Repeat above procedures for second GT enclosure (Twin Pac only).
8.3.9

Aligning Gas Turbine to Electric Generator

1. Tools required:
NOTE
All measuring equipment needs to be accurate to within .001-inch.
A. Two (2) precision levels --Two 6-inch levels or one 6-inch level and one 12 inch level.
B. One (1) bar - machined true over entire length to .001 inch. Dimensions - 24
inches long, 1/2 inch X 1.5 inch to 1 X 2 inch.
C. One (1) dial indicator - 1 inch travel.
D. Three (3) dial indicators 0.25-inch travel, with magnetic base.
E. One (1) set inside micrometers capable of measuring 1.5-inch to 3.0 inches or
Parallel bars and micrometer.
F. Specialized shaft support tooling:
TC350-115
TC350-116

Cradle
Rail

2 each
1 each

or
PWA 77582

Cradle Support

1 each

TC350-117

Compressor

5 each

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2.

Follow procedures outline on the Assembly, Mechanical Field Drawing (e.g.

XXXX-113-S000D, sheet 3) and Procedure 19 in the PWPS FT8 Checkout
Manual.

3. Install generator adapter flange, torque bolts, measure and record electrical
resistance down to Mega ohms.
4. Install output shaft with special PWPS alignment tooling (i.e. (2) TC350-115
cradles and (1) TC350-116 rail).
5. Torque all coupling bolts per TPM-124 specification.
6. Remove front cradle and install customers dial indicators.
7. Rotate shaft and zero output shaft to power turbine shaft. Zero shaft run out so
shaft centerline is in line with that of GT centerline. To do this place magnetic
base of indicator on shaft and locate stylus of dial indicator on coupling rear face
between two bolts on the OD mounting flange. Adjust rear PT shaft support to
have indicator read <. 001 FIR. Leave indicator installed and check occasionally
that is hasnt changed.
NOTE
Rotate the output shaft in only one direction; NEVER
ROTATE IN THE OPPOSITE DIRECTION WHILE
TAKING READINGS!
8. Verify that the GT two cross members are level. Check at the support legs
using machinist levels. Flat service located directly under PT is one and
the other is under GG just forward of gearbox. Maintain level orientation
while readings are being taken.
9. Install a second set of dial indicators at electric generator side of output
shaft.
10. Move gas turbine base assembly with jack screws as follows to satisfy
requirements on XXXX-113-S000D drawing:
A. Jack pads should have been grouted into place at top of concrete elevation. If
that has been done then screw-jack bolts through base until they protrude 1.5
inch. This should set GT vertical center line to that of generator but slightly
high. (It is easier to lower base than to raise on jackscrews.)

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B. Use the jack bolts at 4 locations (3 bolts at each location) to obtain the design
specifications for the ambient temperature. Keep all jack bolts snug when
making move.
C. For instance if required to go .050 aft loosen the bolts used to push forward.
Move the turbine aft with proper bolts and then snug the first bolts that were
loosened.
11. Determine generator rotor axial position. Normally a generator from the factory is
at design pin gage but this should be verified. If different than design position a
correction value equal to the amount of offset must be determined. Determine
ambient temperature. Correction values for temp and rotor offset must be applied
to the GT gap design value to give the required coupling gap. It is not necessary
to jack rotor into design pin gage position.
12. Mark Generator output coupling (install if not already installed) at 12, 3, 6, & 9
using carpenter level.
CAUTION
Never use a lead pencil anywhere on the GT.
13. Attach 24-inch parallel bar (true to .001 inch) on end of GT output shaft.
14. Take a set of readings and begin making the required moves at jack points to
obtain the corrected gap, design slope, and rotor centerline offset (peripheral).
NOTE
All clock positions are taken facing the PT toward the front
of the engine. It is easy to confuse the 3 and 9 readings so
assure that the reading orientation is correct before making
corrective moves.
15. Take face of bar reading to generator adapter piece at the 12,3,6,9 position at the
OD of generator coupling hub. Rotate PT to do this. Add width of parallel bar to
readings. Average of 3 and 9 readings should equal average of 12 and 6 readings.
The average of the four readings is the gap. The difference between 12 and 6 is
the slope.
NOTE
Constantly check that the shaft run out to the GT is less than
.001 inch
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16. Attach the base of a dial indicator to the attached parallel bar. Place the stylus of
indicator on the OD flange of generator adapter. Set indicator to zero at the 12
position. Rotate the GT shaft until stylus is at the 3 o'clock position. Record
reading. Rotate to 6 and record reading, Rotate to 9 and record. Rotate to 12 and
reading should return to zero. If indicator reading does not return to zero at the 12
position, repeat the above process. The sum of the 3 and 9 readings should equal
the 6 reading.
17. As you get closer to the alignment (maintaining level on GT cross members) you
can use the dial indicators at the front and rear cross members of the GT base to
verify effect at coupling. As you get closer make half the calculated move and
verify that the calculation was correct.
18. Repeat above procedures for second gas turbine (Twin Pac only).
8.3.9.1 A Typical Example
Design slope is .016
Design gap is 2.958 at 59 degrees F
Temperature is 80 degrees F. This means gap is reduced.
Rotor pin gage design is 125mm
Rotor is actually 2 mm away from design and is towards B (.078 inch)
This means gap is increased for A end and reduced for B end
Doing the A side of a TP, calculate required coupling gap
Design gap - (.0009 X 21) + Gen rotor offset
2.958 - .019 + .078 = 3.017 inch
8.3.9.2 Additional Information and Recommendations
1. Always rotate the PT shaft in the same direction
2. The PT thrust bearing has .050 inch of axial travel. Axial position should be
addressed after the GT is sloped in the proper direction (Back -PT is lower than
front - GG)
3. Do alignment when the temperature is fairly steady to get stable readings
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4. PWPS computerized alignment program can be used and the moves will be close
to what are required.
5. Pre-grout accuracy is essential to preclude the necessity of realignment and
shimming the GG and PT after grouting.
6. It is easy to reverse the 3 and 9 positions so it is best to find a convenient place
and note the 3 and 9 position prior to starting (Never use lead pencil)
7. After the final move check that shaft is still zeroed and that base cross members
are level
8. After final alignment install anchor nuts and snug to prevent movement when
grouting. This may move the GT base when tightening. Verify unit is still
aligned just before grouting.
8.3.9.2.1 Peripheral
1. The ratio between front jack bolts and effect at coupling is about 1 to 1.
2. The ratio between rear jack bolts and effect at coupling is about 2 to 1
8.3.9.2.2 Design Slope
1. 10 to 1 ratio for changing slope at front jack point
2. 5 to 1 at the rear mount
An example:
Slope is .014 and 0.16 is required. All other readings are within specification.
Raise front jack .020 and raise rear jack .010 Raise each in 50 percent
increments.
8.3.9.2.3 Temperature Correction
1. Design gap is at 59 degrees F.

Increase gap by .0009 for each degree below 59

Decrease Gap .0009 inch for each degree above 59 F

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8.3.9.2.4 Generator Pin Gage

1. Determined by Brush
2. Normally at design value when it arrives from factory with rotor locking clamp
3. Must be verified.
4. If not on design, the value the off set from design should be added or subtracted
from the design gap to get a corrected design gap. No movement of the generator
rotor should be required.
8.3.10 Collector Box Alignment
8.3.10.1 Vertical Exhaust
1. Measure and record both front and rear gaps between the diffuser and collector
box in the as found blanks of the sign-off section. They must fall within the
blueprint (specification) limits. If not, proceed.
2. Measure and record, in the as found blanks of the sign-off section, the axial
offset of collector box with reference to the diffuser flanges (front and rear). They
must fall within the blueprint (specification) limits. If not, proceed.
3. Loosen:
A. All the self-locking nuts on the four vertical support rods located at the
corners of the collector box.
B. The nuts securing the two thrust rods on either side of the collector box.
C. The hardware on the front side of the collector box securing the bottom of the
box to the triangular support plate. This will allow the collector box to be
moved into its proper position without restrictions.
4. Disconnect and/or remove anything attached to the collector box, which could
affect movement during alignment. This includes bleed valve exhaust duct flex
lines and 6th stage spent-air line(s) coming from the engine to either side of the
collector box, inside the engine enclosure. Also, disconnect the No. 8 & 9 oil
scavenge and pressure sense lines from the rear side of the collector box.

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5. Using hydraulic jacks, scissors jacks, chain falls, etc., move the collector box to
its proper position. A tape measure or go/no-go gages should be used to verify
position. If the go/no-go gages are used, two sizes will be required to
accommodate the front and rear of the collector box.
NOTE
After each move, check for inadvertent counter-moves that
may be caused by thermal distortion of the collector box or
blueprint tolerances. The collector box may not stay
positioned after adjustments.
A. Equalize the side-to-side (3:00 and 9:00) measurements on both front and rear
of the collector box.
B. Align the vertical position, both front and rear, so that the gap at 12:00 is
approximately 0.400 inch larger than the gap at 6:00.
C. Axially position the collector box so that the front side of the box (seal
mounting area) is no more that 0.125 to the rear of the diffuser front flange
(seal mounting area toward the engine).
1) In some cases, per the NOTE above, the best possible placement may be
to split the difference. Refer to the numbers recorded on the drawings in
the sign-off section for the as found position.
2) Record all final measurements in the as left blanks of the sign-off
section.
Include horizontal dimensions (3:00 and 9:00), vertical
dimensions (12:00 and 6:00) and axial dimensions (front and rear).
3) Tighten all the self-locking nuts on the four vertical support rods located at
the corners of the collector box, the nuts securing the two thrust rods on
either side of the collector box and the hardware (located on the front side
of the collector box) securing the bottom of the collector box to the
triangular support plate.
NOTE
The upper self-locking nuts should be snugged, not
tightened. This is to account for thermal expansion to
prevent the support rods from breaking.
D. Recheck all measurements for movement. Re-adjust as necessary.

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E. After all hardware has been secured, remove the hydraulic jacks, scissors
jacks, chain falls, etc.
F. Ensure that there is a minimum gap between the edge of the collector box
seals and the bottom of the mating groove per Table below.
NOTE
All seals must be checked.
FRONT SEALS
12:00
3:00
6:00
9:00

REAR SEALS
.55 - .75 inch
.40 - .60 inch
.25 - .45 inch
.40 - .60 inch

12:00
3:00
6:00
9:00

.60 - .80 inch

.40 - .60 inch
.20 - .40 inch
.40 - .60 inch

1) Proceed as follows:
a. Insert the seals, one at a time, in their proper locations and
bottom them out in the mounting groove.
b. With a suitable marker, trace edge of the mounting groove onto
the seal.
c. Move the seal out to its mounting position, secure with at least
two bolts, and trace the edge of the mounting groove again.
Remove the seal and note the distance between the lines.
d. If the distance is too small, remove the seal and grind off the
excess material. If the distance is too large, notify PWPS
engineering.
1) Install all front and rear collector box seals after
ensuring dimensional compliance. Installation must be
in the same location as removed.
2) Reconnect the bleed valve exhaust duct flex lines and
6th stage spent-air line(s) coming from the engine to
either side of the collector box, inside the engine
enclosure. Also, reconnect the No. 8 & 9 oil scavenge
and pressure sense lines at the rear side of the collector
box.

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8.3.10.2 Horizontal Exhaust

1. Measure and record both front and rear gaps between the diffuser and collector
box in the as found blanks of the sign-off section. They must fall within the
blueprint (specification) limits. If not, proceed.
2. Measure and record, in the as found blanks of the sign-off section, the axial
offset of collector box with reference to the diffuser flanges (front and rear). They
must fall within the blueprint (specification) limits. If not, proceed.
3. Loosen all the self-locking nuts on the four (4) vertical support rods located two
front and two rear on the collector box; loosen the nuts securing the four (4)
horizontal thrust rods two at the top and two at the bottom of the collector box
Loosen three (3) axial tie rods, two securing the mid-section and one at the top of
the collector box. This will allow the collector box to be moved into its proper
position without restrictions.
4. Disconnect and/or remove anything attached to the collector box that could affect
movement during alignment. This includes bleed valve exhaust duct flex lines
and 6th stage spent-air line(s) coming from the engine to either side of the
collector box, inside the engine enclosure. Also, disconnect the No. 8 & 9 oil
scavenge and pressure sense lines from the rear side of the collector box.
5. Using hydraulic jacks, scissors jacks, chain falls, etc., move the collector box to
its proper position. A tape measure or go/no-go gages should be used to verify
position. If the go/no-go gages are used, two sizes will be required to
accommodate the front and rear of the collector box.
NOTE
After each move, check for inadvertent counter-moves that
may be caused by thermal distortion of the collector box or
blueprint tolerances. The collector box may not stay
completely positioned after adjustments.
A. Equalize the side-to-side (3:00 and 9:00) measurements on both front and rear
of the collector box.
B. Align the vertical position, both front and rear, so that the gap at 12:00 is
approximately 0.400 inch larger than the gap at 6:00.
C. Axially position the collector box so that the front side of the box (seal
mounting area) is no more that 0.125-inch to the rear of the diffuser front
flange (seal mounting area toward the engine).
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1) In some cases, per the NOTE above, the best possible placement may be to
split the difference. Refer to the numbers recorded on the drawings in
the sign-off section for the as found position.
2) Record all final measurements in the as left blanks of the sign-off
section.
Include horizontal dimensions (3:00 and 9:00), vertical
dimensions (12:00 and 6:00) and axial dimensions (front and rear).
3) Tighten all the self-locking nuts on the four vertical support rods located at
the corners of the collector box. Also tighten the nuts securing the two
thrust rods on either side of the collector box and the hardware (located on
the front side of the collector box) securing the bottom of the collector box
to the triangle support plate.

COLLECTOR BOX ALIGNMENT ILLUSTRATIONS

ILLUSTRATIONS:
1. Rear Seal Gap
2. Vertical Exhaust Collector Box
3. Horizontal Exhaust Collector Box

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SEAL GAP

.12 + .12
AVERAGE ALL
AROUND

M + .40 + .10

X + .10

REAR SEAL GAP

NO SCALE

REAR SEAL GAP

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FOUR VERTICAL TIE-RODS

(2 FRONT, 2 REAR)

EXHAUST

TWO AXIAL TIE-RODS

(FRONT ONLY)

THIS END ATTACHED TO

ENGINE BASE

LOCATOR PLATE
HORIZINTAL RETRAINT

VERTICAL EXHAUST COLLECTOR BOX

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FOUR VERTICAL TIE-RODS

(2 FRONT 2 REAR)

ENCLOSURE WALL

EXHAUST

THREE AXIAL TIERODS (FRONT ONLY)

THIS END ATTACHED

TO ENGINE BASE

HORIZONTAL TIE-RODS
(2 FRONT 2 REAR)

LOCATOR PLATE
HORIZONTAL RESTRAINT

HORIZONTAL EXHAUST COLLECTOR BOX

8.3.11 Inlet and Inlet Air Filter System
1. Unpack and check for shipping and/or storage damage (check the sound baffles
closely where they attach to the wall sections).
2. Assemble entire filter house on the ground including rain hoods, platforms,
railings, pre and final filters, etc. (REMOVE ALL DRAIN PLUGS).
3. Reposition inlet plenum centered over welded nuts in gas turbine enclosure (the
plenum moves out of position during transportation).
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4. Fit gasket in place on gas turbine enclosure.

5. Lift, set and secure first inlet silencer on to gas turbine enclosure.
6. If additional silencers are required set gaskets on installed silencers then lift, set
and secure the next silencer.
7. Fit gasket in place on the last inlet silencer.
8. Before setting the filter house, fit gaskets and install the two piece secondary air
inlet assembly and louvers (before installing inlet silencer and filter) and mount
the two secondary air fans (note that some installation will require fan blade
change out for 50/60 Hz applications).
9. Lift, set and secure filter house on to inlet silencer.
10. Install ladder and complete field electrical assemblies.
11. Repeat above procedures for second inlet (Twin Pac only).
8.3.12 Cable Tray Systems
1. Install control house cable tray system per field electrical drawings.
2. Install trench cable tray system per field electrical drawings.
8.3.13 Control House
1. Unpack and check for shipping and/or storage damage (do not rack the main
breaker into position).
2. Set control house on foundation.
3. Remove transportation bump meter(s) and return to PWPS.
4. Install two external air conditioning units.
5. Install external electrical hardware (i.e. material removed for shipping).
6. Install rain leader and down spout.
7. Install 125 VDC and 24 VDC batteries.
8. Reinstall control monitor, CPU and printer.
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9. Connect control house grounds.

10. Connect temporary three phase power to MCC (open all breakers and switches).
11. Mount internal fire extinguishers and fill, then install the eyewash station
12. Install sub floor smoke detectors.
13. Lay down floor mats (after commissioning).
14. With PWPS checkout specialist back feed control house and start power up of
lights, air conditioning, etc. (check rotation of air conditioner motors).
15. Install remaining field electrical assemblies including termination and labeling of
wires.
16. Reposition control house then secure as required to connect high voltage bus duct.
17. Start FT8 checkout.
8.3.14 Combined GT Lube Oil/Water Injection Skid
1. Unpack and check for shipping and/or storage damage.
2. Lift, set and secure onto foundation.
3. Remove drain cap and connect to drain system.
4. Install external electrical and mechanical hardware (e.g. light, roof top oil mist
eliminator, fire protection junction box, etc.).
5. Cut, bend, thread and install electrical conduits per field drawings.
6. Install balance of field electrical assembly per PWPS drawings including
terminating and labeling wires, grounding, etc.
7. Install pipe and flex hoses per PWPS field piping drawing (XXXX-138-S000D)
for gas turbine lube oil, water injection (if optional equipment purchased), liquid
fuel (if purchased), etc.
8. Start checkout, tank inspection, oil fill (Mobil 254 only, CT 116675), flushing,
etc.
9. Repeat above procedures for second lube oil skid (Twin Pac Only).
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8.3.15 Hydraulic Start Pac Skid

1. Unpack and check for shipping and/or storage damage.
2. Lift and set (DO NOT secure) onto foundation.
3. Cut, bend, thread and install electrical conduits per field drawings.
4. Install hydraulic start pac piping and tubing per PWPS field drawings.
5. Install balance of field electrical assembly per PWPS drawings including
terminating and labeling wires, grounding, etc.
6. Locate skid into final position as required to make electrical and piping
connection and secure.
7. Remove motor shipping braces.
8. Start checkout, tank inspection, oil fill (Mobil DTE 25 hydraulic, CT 116677),
flushing, etc.(note: acid cleaning of all carbon steel supply and return piping is
required before first fill).
8.3.16 Fuel Skid and Optional FT8 Skidded Equipment
1. Install liquid fuel metering skid (liquid fuel sites only).
2. Install liquid fuel filter(s) (liquid fuel sites only).
3. Install liquid fuel forwarding skid(s) (optional for liquid fuel sites only).
4. Install gas scrubber (gas sites only).
5. Install remote control panel (optional).
6. Install diesel generator (optional for black start sites).
7. Install external high voltage switchgear (optional).
8. Install external station (control house) auxiliary transformer (optional).
8.3.17 Field Assemblies: Electrical, Mechanical, Piping, Etc.
1. Install field enclosure assembly per PWPS drawing XXXX-112-S000D.
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2. Install Field Mechanical Assembly per drawing XXXX-113-S000D.

3. Install Field Electrical Assemblies per drawing XXXX-123-E000D (use drawings
XXXX-123-E100D through -E800D for sub assemblies).
4. Install Field Piping Assembly per drawing XXXX-138-M000D.
5. Install Buffered Air Piping Assembly per drawing XXXX-112-S000D.
8.3.18 FT8 Checkout
1. Verify: purge, blowdown, cleaning, flushing and pressure testing of piping
systems.
2. Sample and test fuel(s) and water(s) (customers responsibility).
3. Inspect equipment and system (e.g. tanks, junction boxes, ground grid, filters,
etc.).
4. Verify: gas turbine alignment to electric generator.
5. Check motor rotations.
6. Calibrate all instruments and switches (e.g. pressure, temperature, and speed).
7. Calibrate protective relays (CUSTOMERS RESPONSIBILITY).
8. Complete functional tests.
9. Fire system checks and vendor verification.
10. Inlet filter, inlet plenum and engine inlet inspection.
8.3.19 FT8 Startup
1. Perform pre-operation equipment inspections and all required checkout.
2.

Confirm fuel(s) and water comply with the latest revision of PWPS Spec. (i.e.
FR-1, FR-2, AR-1 and AR-2).

3. Perform incomplete start sequences.

4. Perform initial lightoff sequence.
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5. Set and test power turbine overspeeds.

6. Start and complete electric generator open and short circuit testing.
7. Close breaker.
8. Complete balance of electric generator testing.
9. Run full load testing.
8.3.20 FT8 Commissioning
1. Complete performance testing and trimming of gas turbine.
2. Perform customer-commissioning run as required to demonstrate contract
requirements.
3. Perform emissions testing (customers responsibility or optional testing).

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9.0 FT8 CHECKOUT, STARTUP AND COMMISSIONING

9.1 Introduction
FT8 checkout starts when the field electrical systems including terminations are
complete, station service electrical power is available and the major mechanical systems
are substantially complete.
When all of the wiring is complete, the checkout team will measure and record the load
resistance of all wiring going to the control systems and going to the motor control
center. When the phase to phase resistances as well as the phase to ground resistances
are within allowable limits they will be connected to their respective control systems.
The control systems will be powered up and the software will be installed and checked.
Once all of the control systems are operating properly and all of the wiring resistance
checks are completed, instrumentation calibrations will start. Placing test equipment on
each device and observing the output on the control system monitor accomplish this.
Adjustments will be made in the control software offsets and gains by straight-line
interpolation to compensate for line losses and instrument error.
The checkout team will follow the procedures as noted in the FT8 Checkout Manual.
The checkout manual sign off sheets will record all data measured and will become a part
of the as built documentation for each unit. There will be signoff sections for all
activities completed such as purge/blowdown and leak checking of piping, MCC and
motor rotation checks, instrument calibration, inlet filter house inspection, lube oil system
flushing, fire system commissioning, etc.
Startup and commissioning of the FT8 plant will start only after the successful
completion of the calibration all of the instruments, checking all of the field wiring and
completion of all of the required mechanical checks, tests, inspections, flushing, etc.
9.2 Checkout Tools and Equipment
The following tools and equipment are required and are to be provided by the installing
contractor or owner:
Special Tools
Tool Type

Recommend Manufacturer or equivalent

1. Function Generator,
2. TC Meter
3. Infrared Thermometer
4. Multimeter
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Instek FG-8-1G
Fluke 51
Wahl DHS-26X, or
Raytek Raynger ST-4
Fluke 8060A
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Special Tools (Continued)

5. Digital Scope
6. AC Current Probe
7. Phase Rotation Meter
8. AC/DC Clamp-on Amp Meter
9. Multi Calibrator
10. Humidity Meter
11. TC Multi-Switch
12. Digital Pressure Gauge
13. Function Generator
14. Barometer (C0 and F0)
15. 5000v Meggar
16. Spectrum Analyzer
17. MV Supply
18. 0-300 PSI Digital Hand Pump
19. Wire Tracker System
20. Label Maker
21. Inlet Rake 6 Type K
22. Heat Gun
23. 0-5000 PSIG Hyd Hand Pump
24. 0-300 PSIG Hand Pump
25. 0-200 PSIG Gauge
26. 0-1500 PSIG Gauge
27. Conductivity Meter

Tektronix THS720P
Tektronix A621
Multi-Volt PSI-700
Amprobe ACDC-620T
Transcat Checkmate 1000
Vaisala HM-34
TEGAM 8012 Type K
Transcat 23300P
Dynalco F-16
Davis Inst. Model G-03316-80
AEMC 5100
HP3560A
TrigTek 401B
Druck DP1610
Triplett- Fox, and
Triplett-Hound2
I.D.ProPlus
CAL-D438
Master Appliance HG301J
Ametek T-620
Ametek T-740
Dial Gauge
Dial Gauge
Omega COH-80

Miscellaneous Tools: (Not Inclusive)

1.
2.
3.
4.
5.
6.
7.
8.

Hammer
Screwdrivers (flat, phillips, torx, and square heads)
Open/Box end 12pt wrenches, (5/16 to 1-3/4)
Adjustable wrenches, (4 to 24)
Socket Set, 12pt (5/16 to 1)
Pliers (various styles)
Lockwire Pliers
Flashlights
Special Equipment: (Not Inclusive)

1. 6 Outlet Power Strip

2. Miscellaneous cables (BNC, Power Cables)
3. Miscellaneous fittings, (Pipe, Swagelock)
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9.3 Checkout
Checkout is accomplished by following and completing the procedures listed in the FT8
Checkout Manual. A typical FT8 checkout manual will consist of 35 procedures or
sections. Procedures 1 through 25 will be for items needed to complete the checkout
phase.
The following is a list of these 22 procedures:
1. Air Conditioner
2. Battery Banks & Chargers
3. Purge/Blow down and Leak Check Piping
Clean and Inspect Reservoir or Tanks
Strainers and Filters
Gas Turbine Lube Oil System Flushing
Hydraulic Start system Flushing
Generator Lube System Flushing
Thrust Balance System Flushing
4. Fuel, Water, and Lube Oil Sampling
5. Systems Inspection
6. Inspection Gas Turbine and Auxiliary System Junction Boxes
7. Ground Grid Visual Inspection
8. Inlet Filter, Inlet Plenum, and Engine Inlet Inspection
9. MCC & Motor Rotation
10. NL and NH Rotation
11. Vibration Monitor
12. Manual Transfer Switch
13. Gas Turbine Engine Heat System
14. Initial Software Loading
15. Engine & Unit Control
A. Discrete Inputs--Pressure Switches
B. Discrete Inputs--Temperature Switches
C. Other Contact Closures
D. T5.0 Thermocouples Cr Al type K
E. RTDs 100 Ohm Analog Inputs
F. NL, NH, NP Speed Transducers
G. Pressure Transducers
H. Clutch, Igniters and SOVs
I. I/O Check, MCC
J. Liquid, Gas and Water Mod Valve Calibration
K. IGV & VSV Static Calibration
L. Generator RTD Calibration
16. Fire Protection System
17. Hydraulic Start System
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18.
19.
20.
21.
22.
23.
24.

Chip Detectors
Airpax Tach-Pak 3
Alignment Verification
Starter Speed Hydraulic
Lube Oil Systems Functional Test
Cold Air Buffer System
Thrust Balance

Once the above procedures are completed, the gas turbine can be safely rotated on its
starter and fuel should be made available for the startup phase of checkout.
9.4 Startup
After successful completion of the required checkout procedures fuel can be introduced
to the gas turbine and the startup activities can be completed.
Startup of the FT8 always begins with a series of incomplete start sequences. The
incomplete sequences are start attempts that are designed to result in failure to light off
while double checking the start and shut down logic of the control and safety systems.
Fuel will be introduced into the engine, however the igniters will be disabled.
The following is a list of the startup procedures found in a typical FT8 Checkout Manual:
25.
26.
27.
28.
29.
30.

Incomplete Sequence Starts

Initial Light Off
Overspeed Test
Short Circuit Test
Phasing Checks
Breaker Closure and Under Excitation Tests

It is important to note that no one should consider an operating FT8 power station to be
safe until the gas turbine overspeeds have been set and demonstrated to be operating
properly.
9.5 Commissioning
The actual commissioning of an FT8 power plant will be defined by the requirements set
forth in the contract documents. The following five procedures are set-aside in the
typical FT8 checkout to record the commissioning phase of checkout:
31.
32.
33.
34.

Full Load Data Run

Water Injection System
Drop Load Test (Optional)
Water Wash System

REV-2
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35. Performance Testing

9.6 Sequence
The attached chart shows a checkout sequence that may be followed for Twin Pac
installation. The power pack sequence is similar but of shorter duration. This sequence
is an expansion of line item 55 on the Twin Pac installation sequence included in Section
8.

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CONSTRUCTION MANUAL
APPENDIX A - SELECTED SPECIFICATIONS
(For Reference Purposes Only)
Appendix A contains copies of TPM/PWPS Specifications and Service Bulletins, which are
being provided for informational purposes only. The referenced specification and/or service
bulletin may not contain the latest technical information available from PWPS. Please contact
PWPS for copies of the latest revisions of these documents when installing, operating or
maintaining any FT8 equipment.
The following TPM/PWPS specifications are provided in this section:
TPM-AR-1
TPM-AR-2
FR-1
FR-2
TPM124
TPM126
TPM129
TPM130
TPM132
TPM139

REV-2

GAS TURBINE INJECTION WATER REQUIREMENTS

POTABLE WATER QUALITY SPECIFICATIONS
GAS TURBINE LIQUID DISTILLATE FUEL REQUIREMENTS
GAS TURBINE NATURAL GAS FUEL REQUIREMENTS
ASSEMBLY TORQUE LIMITS
IDENTIFICATION OF COMPONENTS AND ASSEMBLIES
COATING SYSTEM FOR STEEL SURFACES
GROUNDING, GENERAL REQUIREMENTS & PRACTICES
WIRING GENERAL REQUIREMENTS & PRACTICES
WIRING, FIELD TERMINATION, STANDARD PRACTICE

APPENDIX: A-1

15 January 2002

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GENERAL
The amount of oxides of nitrogen (NOx) produced by a gas turbine engine can be significantly reduced by injecting water
or steam during operation. However, the quality of water available may be such that continuous usage could have adverse
effects on long term engine maintenance. It is recommended that the customer follow a good water management program.
Basically, this would consist of analyzing the water (or steam) available and providing monitoring and/or treatment equipment as required.
GUIDELINES FOR EFFECTIVE WATER MANAGEMENT
The customers initial step in water management is to determine the quality of water or steam that is available for utilization
in gas turbines. He should then institute treatment, if required, to bring the water up to an acceptable quality level. This may
involve floc treatment, filtering, demineralizing, chemical treatment or vaporizing. Generalizations as to treatment systems
are usually avoided because of the variations in water quality from one area to another. Samples of the water (ASTM D510)
or steam (ASTM D1066) should be analyzed before a water management system is finalized.
The contaminants generally found in water depend on the source of the water. The dirtier the water, the more it should be
cleaned before usage in gas turbine engines. There are three major levels of water purity:
1.

Natural water comes from rivers, streams, lakes or wells. This water tends to be high in particulate matter and
chemical content. It is highly unlikely that natural water could be used in gas turbine engines on a continuous
basis without treatment. The ordinary levels of minerals and metals found in even good well water are sufficient
to cause deposit buildup and corrosion in the gas turbine hot section.

2.

Treated water includes facility prepared or municipal potable water, softened or demineralized boiler makeup
water and processed natural water. The quality level of treated water will depend on the amount and type of
treatment used. Analyses should be performed to determine whether the water is acceptable for continuous gas
turbine usage without further treatment.

3.

Condensate quality is achieved by properly vaporizing either natural or treated water. This vapor may then be
condensed, depending on whether steam or water injection is to be used. Water of this quality can be obtained
by using a gas turbine waste heat boiler or by extracting steam or condenser water from a steam power plant. In
either case, care must be exercised so that impurity carryover is held to acceptable levels. Condensate quality
water will ordinarily be acceptable for continuous gas turbine usage.

When the nature and quantity of the water impurities have been determined, a system design can be established. Undissolved
solids are normally removed with filters or separators. Ion exchange resins may be used for removal of many of the dissolved
solids. However, in some cases, it may be necessary to include chemical treatment of the water. The trade-offs between removal of impurities and chemical treatment to minimize adverse effects would have to be made for each installation. Chemicals may also be used to control other properties such as pH and to inhibit the formation of boiler scale. Individual assessment can be made by PWPS to judge the suitability of various chemical additives.

Handling and storage should also be considered as part of any water management system. Storage tanks, pumps,
vaporizors and plumbing should be such that they do not add significantly to water contamination.
This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that
it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any purpose
without the express written consent of Pratt & Whitney Power Systems, Inc.; and that no right is granted to disclose
or so use any information contained in said document. These restrictions do not limit the right to use information
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GAS TURBINE INJECTION WATER REQUIREMENTS

In order to protect the customers equipment, a program which periodically measures the water supplied to the gas
turbine is recommended. This is an important step in ensuring low maintenance operation of gas turbines. If undesirable water is detected, immediate corrective action should be taken. This may involve changing the basic source of water supplied to the facility or performing maintenance on the water handling system.
In order to prevent undesirable water from reaching the gas turbine, a periodic maintenance program is recommended. This
will ensure water quality as it passes through the handling, storage and filtration equipment. Items such as periodic filter
element replacement and draining sediment from filters and storage tank sumps are also recommended. Additional detailed
guidance can be obtained through the appropriate PWPS representative. See Table 1 below for water property requirements
which must be met at the inlet interface with PWPSs water injection skid.
TABLE 1. WATER PROPERTY REQUIREMENTS
I.

Continuous Usage
The requirements below are for either 1) liquid treated water or 2)condensate of the steam delivered to the gas turbine
for continuous usage:
Limit

Test Method
(See Note 1 & 2)

1.00

ASTM D1888

Grab

Sodium (ppm)

0.10

ASTM D2791

In-Line

Silica (ppm)

0.02

ASTM D859

Grab

2. Particle Size (microns)

10 max.

ASTM F312

Grab

3. Conductivity (micromho/cm)

1.5 max

ASTM D5391

Grab

Property
1. Total Solids

1.0 max.

Test Location
(See Note 3)

In-Line

II. Intermittent Usage

Intermittent injection of water for power augmentation does not require the same quality level as continuous injection.
Water should be of such purity that its level of total dissolved and undissolved solids is not greater than 10 parts per
million.
III. Water Wash
Engine gas path water washing may be done with clean, clear drinking quality water. Since this procedure involves
motoring the engine with the starter only, deposits of solids are negligible. Ignition is not accomplished until the engine has been drained and purged.

This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that
it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any purpose
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NOTES TO REQUIREMENTS
Note 1:
The latest issue of the ASTM test methods should be used insofar as practicable. If applicable, equivalent test methods may
be used in lieu of ASTM test methods.
Note 2:
Alternate test methods to be agreed upon by customer and PWPS.
Note 3:
Grab samples should be at least 4 liters for lab analysis.

This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that
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without the express written consent of Pratt & Whitney Power Systems, Inc.; and that no right is granted to disclose
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REV SHEETS
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& DATE

& DATE

Added to last sentence before Table 1: which must be met RMS

at the inlet interface with PWPSs water injection skid.
2/3/93
Table 1, I: 1) Added treated to sentence.
2) Changed pH range from 7.0-8.5 to 6.0 -8.5
3) Added requirement 4, conductivity

1, 2, 3

All
2,3

1) Revised test methods to the latest ASTM specifications

2) Deleted PH requirement
3) In Table 1, Conductivity was .27.

P. Lavendier
12/19/96
EC#8757

Updated Logo to new PWPS Logo.

Updated all TPM references to PWPS references.
1. Add "ASTM F312" to test method for particle size.
2. Change Note 2 to add "Alternate".

EC#9925
L. DiSalvo
J. Kennedy
7/23/01

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POTABLE WATER QUALITY SPECIFICATION

PHYSICAL
Color
Ph
Temperature
Total Dissolved Solids *
Threshold Odor Number
Turbidity

MAXIMUM PERMITTED LEVELS

15 Units
6.4 - 8.5
75F (25C)
500 mg/l
2
5 units

INORGANIC
Arsenic
Barium
Cadmium
Chlorides
Chromium
Copper
Cyanide
Fluoride
Iron
Lead
Magnesium
Maganese
Mercury
Nitrite Nitrogen
Nitrite plus Nitrite Nitrogen
Selenium
Silver
Sodium
Sulfate
Zinc

MILLIGRAMS/LITER
0.05
1
0.01
250
0.05
1.0
0.2
2.0
0.3
0.05
125
0.05
0.002
1.0 (as N)
10.0 (as N)
0.01
0.05
20
250
5.0

*Samples should be at least 2 liters for lab analysis.

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POTABLE WATER QUALITY SPECIFICATION

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EC#9909
"Milligrams.Liter" to Milligrams/Liter. Deleted extra blank J. Kennedy
pages attached to spec.
7/25/01
Added note "*Sample should be at least 2 liters for lab
analysis".

This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that
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GAS TURBINE LIQUID DISTILLATE FUEL REQUIREMENTS

GENERAL
This document provides the requirements and general guidelines for light and medium hydrocarbon liquid
distillate fuels which can be burned satisfactorily in PWPS/P&W aeroderivative industrial gas turbines.
Industrial gas turbines are capable of burning a variety of liquid fuels providing they have appropriate fuel
delivery, injection and combustion systems for each class of fuel. Distillate liquid fuels are complex
hydrocarbon mixtures processed from a wide variety of basic crude oil stocks, and have a broad range of
property values. In some cases, such as gasoline, the hydrocarbon fraction may undergo further processing and
acquire additives or, as with naphtha, may be offered for use in the as-distilled form.
This document recognizes three general categories of distillate fuels as defined by ANSI/ASME B 133.7M
which may be employed in properly configured PWPS/P&W gas turbines. Category a is No. 0-GT fuels such
as light naphtha, gasoline, and JP-4/ Jet B fuels which are highly volatile and require special handling and fuel
system design. Categories b and c are No. 1-GT and No. 2-GT such as light to medium kerosene and diesel
fuels which can be burned in the standard gas turbine, providing all fuel properties specified in the following
Table 1 are met. Fuel treatment or conditioning, including heating, may be necessary to satisfy these
requirements. Residual, ash bearing fuels, and blends of distillate and residual fuels are not suitable for
aeroderivative gas turbines.
Industrial fuels may be obtained from a large number of producers with a broad range of properties.
Contamination in transport and deterioration in storage are common problems. Poor and contaminated fuels
greatly affect the performance and durability of gas turbines. Therefore, it is imperative for the gas turbine user
to install a proper fuel system design and institute an effective fuel quality management program to insure and
maintain clean, high quality fuels.

GUIDELINES FOR EFFECTIVE FUEL QUALITY MANAGEMENT

The fuel management system should be designed and in place prior to the site start-up. The following
considerations should be addressed:
1) The fuel type is generally chosen on the basis of cost and availability, however, the effects of fuel on
gas turbine operation and life cycle economics should be considered. Normally, high viscosity fuels
such as heavy diesel are less expensive initially, but usually impact engine life and increase overall life
cycle costs. Some fuels can be made usable through treatment and/or conditioning, and the cost of
these processes should be factored into the overall economics. Possible treatment processes are water
wash, heating, filtration, and centrifuge or cyclone separation.
2) The transport path between the fuel producing location and the customer's unloading/ storage area
should be analyzed for possible contamination potential. Dedicated transport containers are highly

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recommended.
3) The fuel storage equipment should be properly designed and sized and should be free of any
contaminating or corrosive materials. Fuel storage time versus tank capacity should be balanced.
Sufficient time should be allowed for incoming fuel to settle. The fuel for the gas turbine should not
be removed from the bottom of the tanks, so as to avoid picking up heavy bottom ends. Tanks should
be regularly drained from the bottom to remove the sediment.
4) The on-site conditioning and treatment systems should clean the impurities from the fuel and maintain
high quality as it forwards the fuel to the gas turbine. The design should consider the quantity,
placement and filtration efficiency of the filters.
5) The requirement for fuel preheating, if necessary, should be considered. Preheating is required for
viscosity enhancement of heavy fuels and wax removal from high cloud point (waxy) fuels.
6) Safety requirements should be considered in the initial design phase, particularly if the fuel is one of
the highly volatile Category a type fuels.
7) Contaminants brought in with the incoming gas turbine airflow should be considered. Proper air
filtration is required. It is the normal practice to subtract the incoming air contaminants from the
allowable fuel contaminant limit through a formula given in Note 7 of Table 1.
The operators of PWPS/P&W equipment must comply with all aspects of this specification, and ensure
compliance by regularly taking and analyzing liquid fuel samples. Contaminants not normally present in the
fuel at the production site may be introduced as a result of contact with sea water, other fuels, or insufficiently
cleaned equipment during the transportation, handling and storage phases. If the fuel arriving at the user
location falls out of compliance with the specification, and can not be made compliant by treatment, then the
fuel supplier should be contacted immediately for a corrective action. Even a short period of operation with
fuel of excess contaminants (salts, trace metals, particulates, wax. etc.) could seriously impact the gas turbine
life and performance.
To further insure high quality fuel and continuous compliance, a regular maintenance program must be adopted
for all on-site fuel handling, storage, conditioning and treatment systems. Regular replacement of filter
elements, periodic draining of water, removal of sediments from the tanks, lines and sumps, and replacement
of treatment fluids, etc., should be planned for and implemented.
PWPS/P&W requests review of the customer's final overall fuel management system design. PWPS bulletin
no. 97M01 entitled Distillate Fuel System Recommendations is available for further details on implementing
a quality fuel system. Additional guidance can be obtained by contacting your PWPS/P&W Marketing
representative.

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RECOMMENDED DISTILLATE FUELS
The following liquid distillate fuels can be used in the gas turbine, if the fuel property requirements listed in
Table 1 are met for the fuel delivered to the inlet of gas turbine.

Category a (No. 0-GT):

Naphtha Fuels, Unleaded gasoline types, wide-cut fuels of the JP-4

(MIL-T-5624), and Jet B (ASTM D 1655) types - SEE NOTE 3

Category b (No. 1-GT):

Kerosene or other distillates of the JP-5 (MIL-T-5624); Jet A and A-1

(ASTM D1655); No. 1-D diesel fuel (ASTM D975); No. 1 fuel oil (ASTM
D 396); and No. 1 GT gas turbine fuel oil (ASTM D2880) types.

Category c (No. 2-GT):

Distillates of the No. 2 diesel fuel (ASTM D975) No. 2 fuel oil (ASTM
D 396), No. 2 GT gas turbine, and marine diesel (MIL-F-16884) types.

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TABLE 1: GAS TURBINE LIQUID FUEL PROPERTY REQUIREMENTS
Property
Viscosity - cSt:
Max. (for category a, b, and c)
Min. at 100 degrees F (37.8C) (for category a)
Min. at 100 degrees F (37.8C)
(for category b&c)
Free Water - % by volume
Sediment - mg/gallon (mg/l)
Particle Size - microns (micrometer)

Limit

NOTE(S)

Test Method
(Note 1)

6.0 max. for starting,

12.0 max. for operation
0.5 min.
1.0 min

ASTM D445

ASTM D445
ASTM D445

0.025 max.
10.0 max.(2.7)
20 max

ASTM D1744
ASTM D2276
ASTM D2002

Hydrogen - % by weight

12.4 min

ASTM D1018

Metal Contaminants - ppm by wt.

Vanadium (V)
Sodium (Na) + Potassium (K)
Calcium (Ca)
Lead (Pb)
Copper (Cu)

0.2 max.
0.2 max.
2.0 max.
0.1 max.
0.02 max.

6&7
6&7
6&7
6&7
6&7

Copper corrosion

No.1 max.

ASTM D130

To be reported
12.5 max.

ASTM D93
ASTM D323

Fuel Category a (only)

Flash Point, degrees F (C)
Reid Vapor Pressure, psi
or
Vapor Pressure by Mini- method, psi
Fuel Category b and c (only)
Flash Point, degrees F (C)
Cloud Point, degrees F (C)
Carbon Residue (on 10% bottoms), %
Sulfur, % by mass
Ash, % by mass

12.5 max.
10

1.3

11, 12

Net Heating Value, Btu/lb (kcal/kg)

To be reported

Specific Gravity

To be reported

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ASTM D5191

100 deg F (37.7C) or local

regulatory limit
25 deg F (14C) below GT inlet fuel temp.
0.25 max.

0.005 max.

IP288, ASTM
D3605

ASTM D93
ASTM D2500
ASTM D524
ASTM D4294
ASTM 482

ASTM D1298

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NOTES TO REQUIREMENTS (TABLE 1)

NOTE 1
The most recent revision of the ASTM test method should be used insofar as practicable. An equivalent test
method may be used in lieu of ASTM test method, if approved by PWPS/P&W.
NOTE 2
Maximum fuel viscosity at gas turbine fuel pump inlet shall be 6.0 cSt for starting and 12.0 cSt during
operation. Fuel may be heated, to a maximum of 160 deg F (71C), to meet this requirement.
NOTE 3
In order to operate FT8 with Category a fuels, such as naphtha, specially designed PWPS/P&W fuel system
components are required.
NOTE 4
The fuel delivered to the inlet of the gas turbine is to have a sediment level less than 10 mg./gallon of fuel.
However, for practical extended fuel filter life, the fuel should have lower sediment levels
NOTE 5
Minimum hydrogen percentage by weight is 12.4; however, for optimum combustion, higher hydrogen
percentage is recommended.
NOTE 6
To achieve the level of sensitivity required for the detection of some of these metals, the furnace atomic
absorption method may be necessary. Since some trace metals can have harmful effects on gas turbine
operation, it is necessary to impose limitations. Higher levels of Table 1 metallic levels, even for short period,
will increase the gas turbine maintenance costs.
NOTE 7
Limits of metal contaminants in Table 1 assume no contaminants in the inlet air or injected water. For operation
with contaminants in the inlet air or injected water, the maximum allowable limit of any particular contaminant
in the fuel must be reduced according to the following formula:
Af = Lf - [Cair X (air/fuel weight ratio)] - [Cwater X (water/fuel weight ratio)]
where,

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Af
Lf
Cair
Cwater

= Maximum allowable contaminant in the fuel, ppm by wt.

= Contaminant Limit as called out in Table 1, for example 0.2 for (Na+K)
= Contaminant in inlet air, ppm by wt.
= Contaminant in injection and/or evaporative cooling water, ppm by wt.

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NOTE 8
Copper corrosion test conditions are 2 hours at 212 deg F (100 deg C).
NOTE 9
No flash point limitation is specified; however, local regulatory limits and safety regulations must be met.
NOTE 10
The cloud point shall be at least 25 degrees F below the anticipated gas turbine fuel inlet temperature. To meet
this requirement, additional fuel heating, to a maximum of 160 degrees F (71C), may be needed.
NOTE 11
Sulfur content limits Below 1.3% WT. are imposed when:
a) The local regulatory limits of sulfur oxides exhaust emissions are exceeded; then the fuel sulfur content
must be reduced until the local regulatory limits are satisfied. For instance, the USA EPA limits fuel
Sulphur content to 0.8% for S02 emissions control, but local codes vary widely.
b) If exhaust heat recovery equipment is employed; then the equipment manufacturer's limit may apply.
NOTE 12
High sulfer fuels will impact hot section repair interval dependent on the amount of alkalai metals present. The
combination of high sulfur and high alkalais must be avoided.

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DATE: 7/23/01

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REV:

GAS TURBINE LIQUID DISTILLATE FUEL REQUIREMENTS

REV SHEETS
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1-4

All

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SHEETS
ADDED

DESCRIPTION

REV BY

APPVD

& DATE

& DATE

1) Added 1.7 cs lower limit of viscosity

2) Changed NA + K limit to 0.2 ppm
3) Added sulfur limit to 1.3% max.
4) Changed format to FrameMaker
5) Revised verbiage to put more stringent requirements for
fuel management
6) Updated test procedures to current standard

P. Lavendier
8/18/95
EC#8352

Completely re-written and updated to allow the use of

Naptha Fuels, lower min viscosities. Max allowable fuel
viscosities were changed to be based on actual operating
temperatures, rather than a fixed temperature.

EC#9025
T. Fox/D. Dalal
2/11/98

Updated Logo to new PWPS Logo.

Updated all TPM references to PWPS references.

EC#9925
L. DiSalvo
7/23/01

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PWPS
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GAS TURBINE NATURAL GAS FUEL REQUIREMENTS

GENERAL
This document provides the requirements and application guidelines for natural gas fuels which can be fired
satisfactorily in PWPS/P&W gas turbines without fuel system modification.
The term gas fuel can refer to a range of fuels which are normally in the gas state in gas turbine operational use.
These range from low BTU content types such as coke oven gas to high BTU types such as propane. Because
of the wide variation of gas fuels in ignition and combustion properties, as well as volume throughput
requirements, their combustor and fuel delivery systems may differ widely. The fuel specification must be
matched to the gas generator design.
The most common gas fuels used are those of the natural gas family. For satisfactory use in gas turbines, these
fuels must meet minimum specifications so as to avoid combustion and fuel system problems, as well as hot
section corrosive damage.
In addition to reviewing the composition and contaminants of the gas fuels being considered for use, the
customer is urged to institute good fuel management, handling and treatment systems. A fuel that might not
meet the requirements at the engine fuel inlet location may be treated prior to that location.
Present gas turbine combustion systems are comprised of conventional types which may or may not employ
water injection to reduce oxides of nitrogen (NOx) emission, or Dry Low NOx (DLN) types which control NOx
emissions without water. The latter are more sensitive to certain fuel properties than conventional systems and
therefore have more stringent limits on some properties, as noted in the following specification.

GUIDELINES FOR EFFECTIVE FUEL MANAGEMENT

The first step in designing an effective fuel management system is to identify the composition and contaminants
in the gaseous fuels being considered for use in PWPS/P&W aeroderivative gas turbines. The gas analysis
performed to analyze the gas composition and contaminants should include, as a minimum, all properties listed
in Table 1. Clean, dry fuel is required for safe and durable operation of a gas turbine.
The minimum and maximum limits of gas fuel supply temperature are listed in Table 1. The gas supply to the
site should be evaluated to prevent any liquid from accumulating in the off site piping and then flooding the
site fuel systems with large volume of liquids.
In reviewing the gas composition, the presence of corrosion-producing substances such as alkali metals
(sodium, potassium, etc.), sulfur compounds, etc. should be noted so that proper precautions can be taken to
minimize gas turbine and/or fuel system corrosion. When exhaust recovery equipment is utilized, there will be
further requirements for fuel sulfur limit to minimize corrosion of the cold end surfaces.

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REV:

GAS TURBINE NATURAL GAS FUEL REQUIREMENTS

The contaminants in natural gas are normally introduced as a result of production and transportation processes.
These contaminants may include tar, resins, water, salt water, rust (iron oxide), sand, lubricating oil, crude oil,
gas hydrates, ice, construction debris, etc. Widely distributed gaseous fuels such as natural gas are usually
cleaned prior to distribution. Water with its associated pipeline corrosion and condensate are probably the
largest contaminants occurring in the gas distribution systems.
The design of an adequate fuel handling/treatment system is based on the actual gas composition and the
contaminants present in the gas fuel delivered to the site. The following considerations should be addressed in
the design of an effective gas fuel management system:

Pressure reducing station

Type of filtration systems such as inertial separators (scrubbers), gas separator, coalescing filter, or
filter separator to remove liquid and/or solid contaminants
Fuel handling system materials that are compatible with the gaseous fuel properties
Fuel heating to raise the temperature of the gas sufficiently above the hydrocarbon and moisture dew
points
Safety precautions for handling the fuel

To protect the power plant equipment, a fuel testing program to periodically measure contaminant removal
from the fuel and perform maintenance on the fuel filtration system is recommended. This is an important step
in ensuring that the proper quality fuel is provided to the gas turbine.
PWPS/P&W fuel requirements of Table 1 are the allowable limits of fuel properties. The operators of the
PWPS/P&W equipment must comply with all aspects of this specification, and confirm compliance through
analysis of gas fuel samples taken regularly. Additional detailed guidance can be obtained through a PWPS/
P&W representative.

OTHER GASEOUS FUELS

The standard model gas turbine is optimized to operate on gaseous fuels within this specification. The gas
turbine has the basic capability of operating on a range of fuels outside of this specification, but may
require modifications to fit the specific application. Such modifications could include fuel system
component re-sizing, additional safety equipment, fuel pre-heating or gasification equipment, and engine
controls adjustment. To judge the suitability of other gaseous fuels for a given application, please contact
the PWPS/P&W Marketing Department.

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REV:

GAS TURBINE NATURAL GAS FUEL REQUIREMENTS

TABLE 1: GAS TURBINE GASEOUS FUEL REQUIREMENTS

COMBUSTOR TYPE
NOTE(S)

Test Method
(Note 1)

800-1200
(30 - 45)

ASTM D3588

1040-1350
(39 - 50)

1040-1350
(39 - 50)

2, 3

ASTM D3588

Hydrogen Gas (H2) Content,

% Vol. Max

Note 4

1.0

ASTM D1945

Carbon Monoxide (CO) Content,% Vol

Note 6

Note 6

ASTM D1946

Total Particulate, PPM WT. MAX.

30

30

5, 7, 10

ASTM D2009

Max Particle Size, Microns (Micrometre)

10

10

ASTM D2009

Max Gas Supply Temp, F (C)

300
(149)

300
(149)

Min. Gas Supply Temp, F (C)

32
(0)

32
(0)

Min Gas Fuel Superheat

Above Hydrocarbon Dew Pt, F (C)

+28
(+16)

+50
(+28)
Note 13

Min Gas Fuel Superheat

Above Moisture Dew Pt, F (C)

+28
(+16)

+50
(+28)

Total Sulfur Content,% Wt Max

Note 8

Note 8

5, 10, 8

ASTM D1072
or
ASTM D3246

0.2

0.2

5, 10

ASTM D3605

Note 10

Note 10

5, 11

ASTM D1142

Not Applicable

2.2

12

Property

Conventional

DLN

Lower Heating Value (LHV)

BTU/SCF (MJ/m3)

800-1200
(30 - 45)

Wobbe Index, BTU/SCF

(MJ/m3)

Total Metals, PPM Wt, Max

Sodium + Potassium
Water Content
Flammability Ratio (UFL/LFL), MIN

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REV:

GAS TURBINE NATURAL GAS FUEL REQUIREMENTS

NOTES TO REQUIREMENTS (TABLE 1)

NOTE 1
The most recent revision of the ASTM test method should be used insofar as practicable. Equivalent test
method may be used in lieu of ASTM test method if approved by PWPS/P&W.
NOTE 2
At standard conditions of 60 F (15.6 C) 1 atm (101.3 KPa).
NOTE 3
Wobbe Index = LHV/SQRT(S.G. *(Tgf+460)/520) OR Wobbe Index = LHV/SQRT(S.G. *(Tgc+273)/288.6)
(corr. to 60 F)
(corr. to 15.6 C)
Where:
Tgf = inlet gas temperature, F
S.G = specific gravity relative to air
LHV in BTU / SCF

Where:
Tgc = inlet gas temperature, C
S.G = specific gravity relative to air
LHV in MJ/m3 (note 2)

NOTE 4
Hydrogen content up to 4% vol. may be used. Higher amounts of hydrogen content can be used but should
be approved by PWPS/P&W and must satisfy all applicable safety codes for the fuel system.
NOTE 5
At the inlet to the gas turbine fuel plate or at gas turbine enclosure interface, if the enclosure is provided
by PWPS.
NOTE 6
Fuel CO content will increase CO output, thus CO fuel content may require control to meet guarantee
exhaust emissions levels.
NOTE 7
Particulates are composed of any solids in the gas fuel stream, including sand, rust, clay, coke, tar, iron
sulfide, etc.
NOTE 8
Total sulfur includes hydrogen sulfide (H2S), mercaptans, carbon disulfide(CS2), carbonyl sulfide(COS),
thiopene, sulfur oxides, etc.

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REV:

GAS TURBINE NATURAL GAS FUEL REQUIREMENTS

NOTE 9
Limits on fuel sulfur are imposed when:
a) The local regulatory limits of sulfur oxides exhaust emissions are exceeded, then the fuel sulfur content
must be reduced until the local regulatory limits are satisfied.
b) When exhaust heat recovery equipment is employed, the equipment manufacturer's limits will apply.
NOTE 10
The allowable gas fuel contaminants shall be debited by the amounts of that contaminants entering with
the inlet airflow (type A&B combustor) and water injection flow (type A combustor):
Allowable fuel limit = Overall limit - (Air/Fuel x Inlet Air Level) -(Water/Fuel x Water Level)
NOTE 11
Gas Hydrates are not allowed, therefore water content should be below the concentration which would
allow gas hydrates to form at the operating temperature and pressure. Fuel heating is allowed to bring gas
fuel temperature above the moisture saturation (dew) point.
NOTE 12
Flammability limits at 1 atm (101.3 KPa) and 77 Deg. F (25 Deg. C).
NOTE 13
FOR DRY LOW NOx (DLN) COMBUSTORS ONLY:
Hydrocarbon dew points are to be evaluated from ambient pressure up to the maximum gas turbine
inlet pressure
Dew points will be based on extended analysis to C14 level according to method of GPA 2286-95.
Gas samples shall be taken per method of GPA 2166-86.
Concentrations should be determined to an accuracy of 10 PPM or less.
The maximum expected dew point line during the operating period, must be used to establish the
minimum required fuel temperature at the gas turbine inlet

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GAS TURBINE NATURAL GAS FUEL REQUIREMENTS

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3&4

Specification completely re-written incorporating

Gas Turbine Gaseous Fuel Requirements for
Dry Low Nox. Title was Gas Turbine Gaseous Fuel
Requirements. Proprietary box was removed.

EC#8975
D. J. Dalal
10/28/97

All

In table sht 3 deleted absolute in max. particle size

Changed MJ/nm3 to MJ/m3

EC#9012
D.J. Dalal/T. Fox
12/22/97

3
5

In table sht 3, added note 13 in column B

Added note 13 requirements for H/C dew point.

EC#9077
T. Fox
8/20/98

All

Updated Logo to new PWPS Logo.

EC#9925
Updated all TPM references to PWPS references.
L. DiSalvo
In Table1:
J. Kennedy
1. Change test method for CO from ASTM D2099 to ASTM 7/23/01
D1946.
2. Added ASTM D3246 as an alternate test method for
total sulfer content.

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ASSEMBLY TORQUE LIMITS

1.0

PURPOSE
This specification establishes acceptable torque values for various sizes and types of threaded members
assembled under specified conditions.

2.0

APPLICATION
Torque limits in this specification apply to threaded assemblies when this specification is referenced on
the drawing or in a document referenced on the drawing. Torque limits specifically shown on the drawing
or in a document referenced on the drawing shall take precedence over the torques listed in this specification.
2.1

Torquing procedure
It is preferred that the nut be turned rather than the bolt wherever possible. If the bolt is to be turned,
observe the following to assure proper tension can be achieved and that there will be no scoring of
bolt, hole or bearing surface.

3.0

(a)

The bolt (including close tolerance shank bolts) must pass freely through aligned holes.

(b)

Where the flange material is soft (e.g., Al, Mg) an Engineering specified washer must be
present under the bolt head.

(c)

The bolt head bearing surface shall be lubricated.

LUBRICANTS AND LUBRICATION

Unless otherwise specified, torque values given in this spec apply when lubrication is applied to at least
one of each pair of surfaces that will experience rubbing contact during the torquing process. Oil lubrication shall be used unless an anti-galling compound is called for in this specification or on the fastener drawing. The application of both oil and anti-galling compound on the same pair of surfaces shall not be used
unless specifically authorized.
3.1

Torque for lubricated parts, except studs:

3.1.1

Oil lubricated parts

Torque limits given in this specification for oil lubricated parts apply specifically to the use
of engine oil or equivalent on the parts.

3.1.2

Anti-gallant lubricated parts

Torque limits given in this specification shall be used unless other values are specified on
the pertinent drawings.
This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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3.2

4.0

Torque for studs:

3.2.1

Oil lubricated studs

The torque values in Tables XIV and XV assume the use of engine oil, SAE 250 petroleum
oil, or equivalent on the drive threads.

3.2.2

Studs in self-locking helical coil inserts:

Studs may be installed with or without being lubricated per para. 3.1.1 and 3.1.2, whichever
is preferable for assembly convenience; however, the minimum and maximum torque limits in Table XVI shall be maintained.

FREE-SPINNING FASTENERS
For free-spinning nuts, bolts, and screws (including free-spinning self-locking nuts; see para. 5.2) use the
torque values listed in Table I.
4.1

General
Torque values for nuts, bolts, and screws have been established to provide sufficient preload without over-stressing the parts and are based on materials having minimum ultimate tensile strengths
of 125,000 PSI, equivalent to a hardness of 26HRC for steel parts.

4.2

Thin nuts, slotted nuts

The torque values in Table I shall apply to nuts where the height of the nut is greater than 75% of
the major diameter of the thread. For thin nuts, where the height of the nut is 40% to 75% of the
size of the major diameter, reduce the torque values 50%. For slotted nuts, the height shall be taken
as the distance from the washer face to the bottom of the slots. Values do not apply to hollow bolts
and screws.

4.3

Safety wire and cotterpin requirements

After a castle nut, screw, or bolt has been tightened to the proper torque, it should not be loosened
to permit the insertion of safety wire or a cotterpin. If the slot in the nut or the safety wire hole in
the bolt or screw is not properly aligned at the minimum torque limit, the nut, screw, or bolt should
be further tightened to the next aligning position, but the maximum torque limit must not be exceeded. If alignment cannot be accomplished without exceeding the maximum limit, back off the
nut, screw, or bolt half a turn, then retighten. It may be necessary to select a new fastener.

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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5.0

SELF-LOCKING NUTS
For self-locking bolts or screws, bolts or screws used in self-locking inserts, or prevailing torque type selflocking nuts (see para. 5.1), except if used on a stud, use the torque values listed in Table II. For prevailing
torque self-locking nuts used on studs and free-spinning self-locking nuts (see para. 5.2) use values listed
in Table I.
5.1

Prevailing torque type locknut definition

The nut spins freely on the bolt until bolt enters the locking portion of the nut at which time the
bolt interferes with the deformed section of the nut causing a tight frictional hold on the bolt thread
blanks.

5.2

Free spinning locknut definition

The nut spins freely on the bolt until it contacts the mating surface, then additional torque causes
activation of the locking feature.

6.0

STEEL PIPE PLUGS IN ALUMINUM AND MAGNESIUM CASES

The torque values for steel pipe plugs only when installed in aluminum and magnesium cases shown in
Table III have been established to provide for tightening plugs sufficiently to prevent leakage without
overstressing cases. If a pipe plug is found to leak after it has been tightened to these limits it should not
be tightened further, but should be removed, reinstalled and retightened to the indicated limits. When plugs
are tightened in a hot engine, the torque should be reduced 20% to allow for the difference in expansion
between steel plugs and aluminum or magnesium cases. See paragraph 17 for normal NPT pipe thread installation.

7.0

HEX-HEAD STRAIGHT THREADED FITTINGS & PLUGS

The torques in Table IV are based on strength of thread in cast aluminum or magnesium; they may also be
used in stronger materials. Note that separate torque specifications are provided for Aircraft type fittings
(MS, AN, AS and ST types) and Industrial type fittings (SAE J514) respectively.

8.0

FLEXIBLE FITTINGS AND SEALASTIC-TYPE FITTINGS (See Figure 1 for illustration)

When assembling flexible fittings, the packing and fitting threads must be lubricated with light film of engine oil or petrolatum. The packing must be bottomed and the tube aligned before applying the torque listed in Table V. It is expected that these flexible tube connections will experience slight loss of torque over
a period of time due to the seating of the rubber in the mating parts. To minimize the condition, parts
should be torqued to the listed value, then loosened, and torqued again to the listed value.
This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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9.0

CONE SEAT CONNECTORS (See Figure 3 for illustration)

The torque value for the nut on 37 cone seat connectors shall be in accordance with para. 9.1 or 9.2. No
attempt should be made to correct any leakage of the joint by overtorquing. The fitting should be disassembled and checked for nicks, burrs, dirt, etc. If necessary, use new parts. These torque values are applicable for Aircraft type fitting applications as well as Industrial type fitting applications.
9.1

37 Cone seat connectors without gaskets

Use torque values in Table VI.

9.2

37 Cone seat connectors with nickel gaskets (E.G., AS3074 and AS3075)
Use torque values in Table VII.

10.0

CONCENTRIC TUBE CONNECTORS (See Figure 2 for illustration)

For this type of connection use the following sequence:

11.0

a.

Tighten inner nut at each end of tube assembly hand tight.

b.

Tighten inner nut at each end of tube assembly to torque given in Table VIII while holding inner
nut at opposite end with wrench.

c.

Without loosening repeat step b.

d.

If inner nut maintains torque, proceed with step e. If inner nut does not maintain torque, repeat step
c. If inner nut does not maintain torque after repeating step c four times, replace tube assembly.

e.

Tighten outer nut at each end of tube assembly to torque given in Table VIII.

JAM NUTS FOR BULKHEAD OR POSITIONING FITTINGS

(See Figures 3 and 4 for typical illustrations)
The torques listed in Table IX are to be used for jam nuts (locknuts) of the type used on fittings for tube
and hose connections. On elbow fittings, the jam nut shall be torqued after the connecting tube or hose has
been installed and properly aligned per installation drawing instructions. Note that separate torque specifications are provided for Aircraft type fittings (MS, AN, AS and ST types) and Industrial type fittings
(SAE J514) respectively.

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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12.0

INSTALLATION OF CRUSH TYPE METAL-FILLED GASKETS

Install crush type gaskets with the unbroken surface against the flange of the plug or part being tightened
against the seal. Turn the mating part until sealing surfaces are in contact, then tighten through the angle
of turn shown in Table X for the appropriate thread pitch.

13.0

INSTALLING AND/OR ATTACHING THE VARIOUS COMPONENTS OF JET ENGINE

IGNITION SYSTEMS, THERMOCOUPLE SYSTEMS, AND ELECTRONIC CONTROL SYSTEMS

13.1

Plug-in type threaded connectors (see Figure 5)

After engaging the key(s) to the slot(s), if applicable, plug-in type threaded connectors shall be secured by hand tightening the coupling ring (knurled or hex) until the plug is fully engaged in the
receptacle. Additional tightening shall be in accordance with torque limits specified on the Assembly Drawing or in the Table of Limits. Application of thread lubricant or anti-galling compound is
not permitted.

13.2

Igniter plug (see Figure 6)

Igniter plugs should be installed in engines with a torque of 300 to 360 lb-in.

13.3

Cigarette type electrical connectors

All "Cigarette" type electrical connections (located at the end of intermediate voltage leads and
high tension leads) should be torqued until the connection is bottomed on its shoulder. This normally takes approximately 140 to 160 lb-in of torque.

13.4

Exhaust temperature probe

Tighten terminal attaching nuts (except Klincher nuts, see 13.6) and thermocouple harness-to-lead
attaching screws in accordance with Table XI.

13.5

Exhaust gas temperature junction box

Tighten harness terminal and bus bar attaching nuts (except Klincher nuts, see 13.6) in accordance
with Table XII.

13.6

Klincher locknuts (see Figure 3)

Torque these free spinning locknuts in accordance with Table XIII.
This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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14.0

STUDS
The torque limits given in para. 14.1 and 14.2 for driving studs are based on stud materials having a minimum ultimate tensile strength of 125,000 psi, equivalent to a minimum hardness of 26 HRC. For studs
having a minimum hardness of 34 HRC, the maximum torque values may be increased by 25%.
14.1

Studs installed directly into bosses

14.1.1 Standard interference fit studs
For driving studs where the nominal thread sizes on both ends are the same, use the torque
limits in Table XIV.
14.1.2 Stepped interference fit studs
For driving studs where the nominal thread size of the nut end is smaller than the nominal
thread size of the drive end, use torque limits in Table XV.
14.1.3 Stud selection
If the torque required to drive a stud directly into a boss to the correct projection length
specified on the drawing does not come up to the minimum or exceeds the maximum given
in Tables XIV and XV another stud should be selected. Where available, .003 undersize or
.003 oversize studs may be used.
14.1.4 Burnishing studs
The use of burnishing studs (to size the internal thread of the boss) is permitted if required.
These studs may be plain or made with two opposed flat surfaces at or below the minor diameter of the thread.

14.2

Studs installed into self-locking helical coil inserts

For driving studs into self-locking helical coil inserts, use the torque limits in Table XVI. These
limits apply to studs where the nominal thread size on both ends are the same (i.e., standard studs)
as well as to studs where the nominal thread size of the nut end is smaller than the nominal thread
size of the driven end (i.e., stepped studs).

14.3

Studs driven from coarse pitch thread

For studs designed to be driven from an extended coarse pitch thread (or from wrenching flats adjacent to the coarse pitch thread) the plain stud torque values in Tables XIV or XV as applicable
shall be used.

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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SPECIFICATION

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TPM124
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7
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DATE: 6/14/90

S. Leavitt

DATE: 11/17/92

REVISED BY: J. Martin

RELEASED

SHEET

REFERENCE:

ASSEMBLY TORQUE LIMITS

14.4

Studs installed into non-locking helical coil inserts

For driving interference fit studs into non-locking helical coil inserts use the torque limits in Table
XIV.

15.0

REUSE OF SELF-LOCKING FASTENERS

Prevailing torque type locknuts or helical coil inserts, and self-locking bolts or screws shall be capable of
meeting the torque limits given below. Where required, torque should be verified at reassembly with the
locking feature fully engaged and the fastener unseated so that only the frictional hold on the screw thread
is measured.
15.1

Minimum breakaway torque

The torque required to overcome static friction shall not be less than the value given in Table XVII.

15.2

Maximum locking torque

The torque required to overcome kinetic friction shall not be greater than the value given in Table
XVII.

16.0

PIPE FLANGE BOLTING (Nuts, Bolts, Stud Bolts)

Assembly torque specifications for high strength flange bolting used in conjunction with flat or spiral
wound gaskets are provided in Table XVIII. Note that the values are given in ft-lbs and are applicable for
fasteners lubricated with anti-seize compound.

17.0

TAPERED PIPE THREADS

Because of the large number of variables involved, pipe threads are not normally installed to a predetermined torque value. Sealing is dependent on a progressive interference fit at assembly.
17.1

Standard Equipment
Approximately one and one half turns beyond normal hand engagement is considered sufficient to
effect a seal. Table XIX can be used as an approximate guide. In the case of elbows, if excessive
force is required for proper alignment, then the elbow should be replaced by another part with different thread orientation.

17.2

Thread Sealing Compounds

Pipe dope, teflon tape, etc. should only be used as specified for a particular application. Improper
This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

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TPM124
ISSUED BY:

OF

8
22

DATE: 6/14/90

S. Leavitt

DATE: 11/17/92

REVISED BY: J. Martin

RELEASED

SHEET

REFERENCE:

ASSEMBLY TORQUE LIMITS

use of these devices can result in fluid contamination or the release of fragments into the flow
stream. Tape or paste compounds should be installed/applied so as to avoid the first two threads of
the male members.
18.0

METRIC TORQUE VALUES

The nomo-graph, Figure 7, can be used to convert torque from English units (ft-lb) to metric units (Nm).
To use the graph:
1)

Find the torque in ft-lb along the bottom of the graph.

2)

Move upward to the corresponding point on the line.

3)

Find the Nm value that corresponds to that point.

4)

Multiply the Nm value by the factor that appears to the left of the row from which the original ftlb torque came.

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

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9
22

DATE: 6/14/90

S. Leavitt

DATE: 11/17/92

REVISED BY: J. Martin

RELEASED

SHEET

REV B

TPM124

REFERENCE:

ASSEMBLY TORQUE LIMITS

TABLE I
Assembly Torques for Free-spinning fasteners (Nuts, bolts, or screws) & for self-locking nuts on studs (See para. 4 & 5)
Assembly Torque, lb-in.
Thread
Oil lubricated
Anti-gallant coated
size
Max.
Min.*
Max.
Min.*
Type I
Type II
Type I
Type II
.112-40
6
4.5
5
4.5
3.5
4
.138-32
11.5
8.5
10
8.5
6.5
7.5
.164-32
22
16
20
16.5
12.5
15
.164-36
24
18
22
18
13.5
16

.190-24
.190-32
.250-20
.250-28

30
36
70
85

23**
24**
50**
65**

27**
32**
65**
75**

21.5
26
50
60

16
19.5
37**
45**

19.5
23**
45**
54**

.3125-18
.3125-24
.375-16
.375-24

150
170
270
300

110**
125**
200**
225**

135**
150**
250**
275**

105
120
185
215

80**
90**
140**
160**

95
110**
170**
190**

.4375-14
.4375-20
.500-13
.500-20

425
475
650
750

325
350
500
550

375
425
600
675

300
340
450
515

225
255
340
390

270
310
400
460

.5625-12
.5625-18
.625-11
.625-18

950
1050
1300
1500

700
800
1000
1150

850
950
1200
1350

675
750
900
1025

500
550
675
775

600
675
800
925

.750-10
.750-16
.875-9
.875-14

2300
2600
3700
4200

1700
2000
2800
3200

2100
2400
3400
3800

1600
1800
2600
2900

1200
1350
1950
2200

1450
1600
2350
2600

1.000-8
1.000-12
1.125-7
1.125-8

5600
6400
7900
8400

4700
4800
5900
6300

5100
5800
7200
7600

3900
4300
5400
5700

2900
3200
4100
4300

3500
3850
4900
5100

1.250-7
1.250-8
1.375-6
1.375-8

11200
11700
14700
15900

8400
8800
11000
11900

10100
10600
13300
14400

7700
7900
10100
10600

5800
5900
7600
8000

6900
7100
9100
9500

1.500-6
1.500-8
1.750-5
1.750-8

19600
21100
30900
34500

14700
15800
23200
25900

17700
19000
27900
31100

13300
14000
21100
22700

10000
10500
15800
17000

12000
12600
19000
20400

2.000-4.5
2.000-8

46600
52600

35000
39500

42000
47400

31700
34400

23800
25800

28500
31000

* Use Type I minimum values only where alignment of locking holes for cotterpins or safety wire is required at assembly.
Use Type II minimum values where alignment of locking holes is not required at assembly.
**

For screws having screwdriver slots only (no external wrenching provisions) 22 lb in. minimum is permissible.

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SPECIFICATION

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DATE: 6/14/90

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DATE: 11/17/92

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REFERENCE:

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TABLE II
Assembly Torques for self-locking fasteners (nuts, bolts, or screws), and for free running bolts and screws used in selflocking helical coil inserts (See para. 5 & 15).

Thread
size

Assembly Torque, lb-in.

Oil
Anti-gallant
lubricated
coated

Thread
size

Assembly Torque, lb-in

Oil
Anti-gallant
lubricated
coated

.112-40
.138-32
.164-32
.164-36

6-7
12-14
23-26
25-28

5-6
9-11
18-20
20-22

.750-10
.750-16
.875-9
.875-14

2200-2450
2500-2750
3600-4000
4000-4450

1600-1750
1750-1950
2500-2850
2800-3100

.190-24
.190-32
.250-20
.250-28

32-35
36-40
74*-82
85*-95

24-27
27-30
55*-62
62*-72

1.000-8
1.000-12
1.125-7
1.125-8

5400-6000
6000-6700
7600-8200
8000-8700

3800-4200
4000-4500
4300-5700
5500-6000

.3125-18
.3125-24
.375-16
.375-24

160*-175
180*-200
270*-300
290*-325

115*-130
125*-140
200*-220
225*-250

1.250-7
1.250-8
1.375-6
1.375-8

10500-11600
11000-12100
13800-15100
14900-16300

7300-8100
7500-8300
9600-10500
10000-11000

.4375-14
.4375-20
.500-13
.500-20

420-465
450-500
630-700
720-800

315-350
340-380
450-500
515-575

1.500-6
1.500-8
1.750-5
1.750-8

18200-20100
19500-21600
28500-31500
31700-35100

12500-13800
13100-14500
19600-21700
21000-23300

.5624-12
.5625-18
.625-11
.625-18

950-1050
1050-1150
1250-1400
1450-1600

675-750
750-825
900-1000
1030-1150

2.000-4.5
2.000-8

42800-47400
48200-53400

29300-32500
31800-35200

For screws having screwdriver slots only (no external wrench provisions), the minimum permissible torque is 22 lbin, plus the torque necessary to turn the screw thru the nut or self-locking helical coil insert.

TABLE III
Assembly Torques for pipe plugs, ANPT or NPT, oil lubricated* (See para. 6)

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Thread Size

Torque, lb-in

Thread Size

Torque, lb-in

.062
.125
.250
.375

30-40
30-40
70-85
95-110

.500
.750
1.000
1.250

140-160
210-230
285-315
355-385

Where sealing compounds are used, oil lubrication shall be omitted.

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TPM
SPECIFICATION

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11
22

DATE: 6/14/90

S. Leavitt

DATE: 11/17/92

REVISED BY: J. Martin

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TPM124

REFERENCE:

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TABLE IV
Assembly Torques for Hex-head, straight thread fittings & plugs (see para. 7)

Thread Size

Assembly Torque, lb-in

Aircraft Type Fittings
Industrial Type Fittings
Oil lube
Anti-gallant coated
Oil Lube
Anti-gallant coated

.250-28
.3125-24
.375-24

15-20
35-40
40-50

10-13
23-26
26-33

--40-45
80-90

--25-30
50-60

.4375-20
.500-20
.5625-18

65-75
90-100
110-120

42-49
58-65
70-80

100-115
120-135
150-170

65-75
80-90
95-110

.625-18
.750-16
.8125-16

150-170
200-225
225-250

95-110
130-145
145-160

--270-300
---

--175-195
---

.875-14
1.000-12
1.0625-12

250-275
275-300
375-425

160-175
175-190
240-270

505-555
--625-675

330-360
--405-440

1.1875-12
1.250-12
1.3125-12

450-550
500-600
525-625

285-350
315-380
330-395

835-915
--920-1000

545-595
--600-650

1.500-12
1.625-12
1.750-12

600-700
650-750
650-750

375-440
400-470
400-470

--1275-1425
---

--830-925
---

1.875-12
2.250-12
2.500-12

650-750
650-750
650-750

400-470
400-470
400-470

1425-1575
--1850-2050

925-1025
--1200-1330

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

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TPM124

12
22

DATE: 11/17/92

REVISED BY: J. Martin

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OF

DATE: 6/14/90

S. Leavitt

ISSUED BY:

SHEET

REFERENCE:

ASSEMBLY TORQUE LIMITS

TABLE V
Assembly Torques for PWA flexible fittings, oil lubricated (See para. 8)

Assembly Torque, lb-in.

Thread
size

Thread
size

For 75 durometer "A"

packing, e.g. AMS
7260

For 77 durometer "C"

(100 durometer "A")
packing, e.g. PWA 401

.125
.1875
.250

.4375-24
.500-20
.625-18

25-30
25-30
25-30

55-60
55-60
55-60

.3125
.375
.4375

.6875-16
.750-16
.8125-16

30-35
30-35
45-50

65-70
65-70
90-100

.500
.5625
.625

.875-14
1.000-12
1.0625-12

55-60
60-65
65-70

110-120
120-130
130-140

.750
.875
1.000

1.1875-12
1.375-12
1.500-12

70-80
75-85
100-110

140-160
150-170
200-220

1.125
1.250
1.500

1.625-12
1.750-12
2.125-12

100-110
100-110
100-110

200-220
200-220
200-220

Figure 1
This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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REV B

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TPM
SPECIFICATION

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DATE: 6/14/90

S. Leavitt

DATE: 11/17/92

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RELEASED

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REFERENCE:

ASSEMBLY TORQUE LIMITS

TABLE VI
Assembly Torques for 37 cone seat connectors without gaskets (See para. 9)
Assembly Torque, lb-in
Hose
size

Tubing
OD

Thread
size

Aluminum Fittings

Steel

All lubricants

Oil lubricated

Anti-gallant coated

-3
-4
-5

.1875
.250
.3125

.375-24
.4375-20
.500-20

30-50
40-65
60-80

70-80
90-100
135-150

50-60
65-75
100-110

-6
--8
--10

.375
.4375
.500
.5625
.625

.5625-18
.625-18
.750-16
.8125-16
.875-14

75-125
100-175
150-250
175-300
200-350

270-300
320-350
450-500
550-600
650-700

200-225
225-250
340-375
400-450
475-525

----

-.6875
--

.875-16
1.000-12
1.000-14

200-350
275-450
275-450

650-700
800-900
800-900

475-525
600-675
600-675

-12
---

.750
.875
--

1.0625-12
1.1875-12
1.250-12

300-500
400-600
400-650

900-1000
1100-1200
1150-1300

675-750
825-900
900-1000

-16
--20

1.000
1.125
1.250

1.3125-12
1.500-12
1.625-12

500-700
600-900
600-900

1300-1400
1500-1600
1700-1800

950-1050
1050-1200
1150-1300

-24

1.500

1.875-12

600-900

2100-2200

1500-1600

*If the nut or either of the mating sealing surfaces is aluminum, the required torque limits for aluminum fittings apply.

Figure 3
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TPM
SPECIFICATION

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14
22

DATE: 6/14/90

S. Leavitt

DATE: 11/17/92

REVISED BY: J. Martin

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REV B

TPM124

REFERENCE:

ASSEMBLY TORQUE LIMITS

TABLE VII
Assembly Torques for 37 cone seat connectors with nickel or copper gaskets (See para. 9)
Assembly Torque, lb-in
Hose
size

Tubing
OD

Thread
size

Steel Fittings

Oil lubricated

Anti-gallant coated

-3
-4
-5

.1875
.250
.3125

.375-24
.4375-20
.500-20

50-60
90-100
135-150

40-45
65-75
100-110

-6
--8

.375
.4375
.500

.5625-18
.625-18
.750-16

200-220
250-270
350-400

150-165
185-200
270-300

--10
--

.5625
.625
.6875

.8125-16
.875-14
1.000-12

400-450
500-550
600-700

300-350
360-400
480-530

-12
--16

.750
.875
1.000

1.0625-12
1.1875
1.3125-12

700-800
800-900
1000-1100

540-600
600-675
750-825

--20
-24

1.125
1.250
1.500

1.500-12
1.625-12
1.875-12

1300-1400
1400-1500
1600-1700

900-1000
1000-1100
1200-1300

Figure 2
This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

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OF

15
22

DATE: 6/14/90

S. Leavitt

DATE: 11/17/92

REVISED BY: J. Martin

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TPM124

REFERENCE:

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TABLE VIII
Assembly Torques for concentric tube connectors, anti-gallant lubricated (see para. 10)

Inner Nut

Outer Nut

Thd size

Torque, lb-in

Thd size

Torque. lb in

.750-16
.8125-16
.9375-12
1.750-12

340-375
400-450
525-600
1325-1450

1.1875-12
1.1875-12
1.375-8
2.375-8

290-340
290-340
370-420
1055-1130

TABLE IX
Assembly Torques for jam nuts for bulkhead or positioning fittings, oil lubricated (see para. 11)
Thread
size
.250-28
.3125-24
.375-24
.4375-20
.500-20
.5625-18
.625-18
.750-16
.8125-16
.875-14
1.000-12
1.0625-12
1.1875-12
1.250-12
1.3125-12
1.500-12
1.625-12
1.875-12
2.250-12
2.500-12

Assembly Torque, lb-in

Aircraft Type Fittings
Industrial Type Fittings
14-16
22-24
28-32
38-42
58-62
70-80
95-105
145-155
165-185
190-210
260-290
285-315
350-390
380-420
475-525
570-630
570-630
570-630
570-630
570-630

--30-35
60-70
90-100
120-135
150-170
--270-295
--345-375
--455-505
835-910
--920-1000
--1275-1425
1425-1575
--1850-2050

Figure 4
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SPECIFICATION

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16
22

DATE: 6/14/90

S. Leavitt

ISSUED BY:

DATE: 11/17/92

REVISED BY: J. Martin

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REV B

TPM124

REFERENCE:

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TABLE X
Angle of turn for fittings with metal-asbestos gaskets (See para. 12)
Angle of turn, tolerance 5
Thread pitch on part
to be tightened

Aluminum asbestos

Copper asbestos
Nickel asbestos
Steel asbestos

8 threads per inch

9 threads per inch
10 threads per inch
11 threads per inch
12 threads per inch
13 threads per inch
14 threads per inch
16 threads per inch
18 threads per inch
20 threads per inch
24 threads per inch
28 threads per inch

135
135
135
180
180
180
180
270
270
270
360
360

67
67
67
90
90
90
90
135
135
135
180
180

These values provide for a compression of approximately 40% for aluminum-asbestos

and 20% for copper-asbestos, nickel asbestos, and steel-asbestos gaskets.

TABLE XI

TABLE XII

Assembly Torques for temperature probe nuts and

screws, oil lubricated (See para. 13.4)
Thread size
.138-32
.164-32
.190-32
.216-32
.250-32

Assembly Torques for harness terminal and

bus bar nuts, oil lubricated (See para. 13.5)

Torque, lb-in

Thread size

Torque, lb-in

8-10
8-12
10-15
30-35
35-40

.164-32
.190-32

20-25
25-30

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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REV B

TPM124

TPM
SPECIFICATION

ISSUED BY:

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17
22

DATE: 6/14/90

S. Leavitt

DATE: 11/17/92

REVISED BY: J. Martin

RELEASED

SHEET

REFERENCE:

ASSEMBLY TORQUE LIMITS

TABLE XIII
Assembly Torques for free spinning Klincher
locknuts, oil lubricated (See para. 13.6)
Thread size

Torque, lb-in

.164-32
.190-32

15-20
24-40

TABLE XIV
Installation Torques for standard interference fit studs (See para. 14)
Torque limits, lb-in (See para. 3.2)
Thread
(Stud end)

Maximum
Minimum
Necked-down*

Plain**

.164-32
.190-24

10
15

30
40

30
45

.250-20
.3125-18
.375-16

40
85
160

95
210
375

105
230
425

.4375-14
.500-13
.5625-12

200
250
425

600
950
1400

675
1050
1500

.625-11
.750-10

625
1100

1900
3500

2100
3800

These limits apply where the unthreaded diameter of the stud is less than the
minimum minor diameter of the coarse pitch thread (stud end).

**

These limits apply where the unthreaded diameter of the stud is equal to or greater
than the minimum minor diameter of the coarse pitch thread (stud end).

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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REV B

TPM124

TPM
SPECIFICATION

ISSUED BY:

OF

18
22

DATE: 6/14/90

S. Leavitt

DATE: 11/17/92

REVISED BY: J. Martin

RELEASED

SHEET

REFERENCE:

ASSEMBLY TORQUE LIMITS

TABLE XV
Installation Torques for stepped interference fit studs (See para. 14)
Torque limits, lb-in (See para. 3.2)
Thread
(Nut end)

Maximum
Minimum
Necked-down*

Plain*

.164-36
.190-32

10
15

30
45

30
50

.250-28
.3125-24
.375-24

40
85
160

115
240
450

125
260
500

.4375-20
.500-20
.5625-18

200
250
425

700
1150
1600

800
1300
1800

.625-18
.750-20

625
1100

2400
4200

2600
4600

These limits apply where the unthreaded diameter of the stud is less than the
minimum minor diameter of the fine pitch thread (nut end).

**

These limits apply where the unthreaded diameter of the stud is equal to or greater
than the minimum minor diameter of the fine pitch thread (nut end).

TABLE XVI
Installation Torques for standard and stepped studs installed in self-locking
helical coil inserts (See para.14)
Torque Limits, lb-in.**
Thread size
(Nut end)

Minimum

Maximum

.190-32*
.250-28
.3125-24

23
52
105

45*
90
180

.375-24
.4375-20
.500-20

140
175
260

240
300
450

.5625-18
.625-18

350
525

640
900

*
**

Homepage

When drive end is .190-24 reduce maximum value to 40.

with or without lubrication

Previous Document

TPM
SPECIFICATION

ISSUED BY:

OF

19
22

DATE: 6/14/90

S. Leavitt

DATE: 11/17/92

REVISED BY: J. Martin

RELEASED

SHEET

REV B

TPM124

REFERENCE:

ASSEMBLY TORQUE LIMITS

TABLE XVII
Assembly Torques for reuse of fasteners* (See para. 15)

Thread
size

Torque, lb-in.
Min
Max
breakaway
locking

Thread
size

Torque, lb-in
Min
Max
breakaway
locking

.112-40
.112-48
.138-32
.138-40

0.5
0.5
1.0
1.0

3
3
6
6

.500-14
.500-20
.5625-12
.5625-18

24.0
18.0
30.0
24.0

150
150
200
200

.164-32
.164-36
.190-24
.190-32

1.5
1.5
2.0
2.0

9
9
13
13

.625-11
.625-18
.750-10
.750-16

40.0
32.0
60.0
50.0

300
300
400
400

.250-20
.250-28
.3125-18
.3125-24

4.5
3.5
7.5
6.5

30
30
60
60

.875-9
.875-14
1.000-8
1.000-14

82.0
70.0
110.0
92.0

600
600
800
800

.375-16
.375-24
.4375-14
.4375-20

12.0
9.5
16.5
14.0

80
80
100
100

Lubricated per para. 3.0.

Igniter plug (See para 13.2)

Figure 6
Plug-in Type Threaded Connector
(See para 13.11)
Figure 5

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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REV B

TPM124

TPM

ISSUED BY:

SPECIFICATION

OF

20
22

DATE: 6/14/90

S. Leavitt

DATE: 11/17/92

REVISED BY: J. Martin

RELEASED

SHEET

REFERENCE:

ASSEMBLY TORQUE LIMITS

TABLE XVI
Assembly Torques for bolting used in conjunction with flat or spiral wound gaskets and commercial type pipe flanges
(See para 16) *+
Thread Size

Assembly Torque, lb-ft **

1/2-13
5/8-11
3/4-10
7/8-9
1-8
1 1/8-8
1 1/4-8

35-40
70-80
120-135
195-220
290-330
420-480
595-675

Notes:
* Applicable only for high strength bolting materials:
Bolts- ASTM A193, Grade B7 or Grade B8M
Nuts- ASTM A194, Grade 2H or Grade 8M

**

Threads and bearing surfaces lubricated with anti seize compound.

For spiral wound gasket applications, the flange faces should bottom out on gasket inner/outer rings prior to reaching the final assembly torque (A feeler gauge can be used for purposes of checking this).

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

ISSUED BY:

OF

21
22

DATE: 6/14/90

S. Leavitt

DATE: 11/17/92

REVISED BY: J. Martin

RELEASED

SHEET

REV B

TPM124

REFERENCE:

ASSEMBLY TORQUE LIMITS

TABLE XI
Length of engagement of taper pipe threads.

Normal
hand
engagement
L

Pitch
P

.062-27
.125-27
.250-18

.1600
.1615
.2278

.375-18
.500-14
.750-14

X basic
(Nominal)
tight
engagement
L + 1.5 p

X minimum
(X basic-2p)

X maximum
(X basic + 2p)

X maximum + p

.03704
.03704
.05556

.2156
.2171
.3111

.1415
.1430
.2000

.2897
.2912
.4222

.3267
.3282
.4778

.2400
.3200
.3390

.05556
.07143
.07143

.3233
.4271
.4461

.2122
.2843
.3033

.4344
.5700
.5890

.4900
.6414
.6604

1.000-11.5
1.250-11.5
1.500-11.5

.4000
.4200
.4200

.08696
.08696
.08696

.5304
.5504
.5504

.3565
.3765
.3765

.7043
.7243
.7243

.7913
.8113
.8113

2.000-11.5
2.500-8
3.000-8

.4360
.6820
.7660

.08696
.12500
.12500

.5664
.8695
.9535

.3925
.6195
.7035

.7403
1.1195
1.2035

.8273
1.2445
1.3285

Thread

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

REV B

TPM124
ISSUED BY:

OF

22
22

DATE: 6/14/90

S. Leavitt

DATE: 11/17/92

REVISED BY: J. Martin

RELEASED

SHEET

REFERENCE:

ASSEMBLY TORQUE LIMITS

CONVERSION OF FOOT-POUNDS TO NEWTON-METERS
(See Para 18.0

Figure 7

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TPM
SPECIFICATION
RELEASED

REV

TPM124
ISSUED BY:

S. Leavitt

SHEET
OF

1A
1

DATE: 6/14/90

REVISED BY: J. Martin

DATE: 11/17/92

REFERENCE:

ASSEMBLY TORQUE LIMITS

REV SHEETS
LET AFFECTED

SHEETS
ADDED

DESCRIPTION

REV BY

APPVD

& DATE

& DATE

--

Revised to include pipe, thread and metric torque data.

1
3

---

--

--

Para 3.0 was "...compound is called for on the fastener..."

J. Martin
Para 7.0: removed from heading (MS9193, MS9015,
11/12/92
or similar) Added "Note that ...respectively."
EC#6591
Para 9.0: Added "These torque...applications;"
Para 11.0: Added "Note that...respectively."
Para 16.0: was BOLTS & STUD BOLTS
For bolts used in pipe flanges in conjunction with flat or spiral
spiral wound gaskets, use the values given in Table XV111.
These values are equivalent to those given in Table 1 for
Type I oil lubricated fasteners, but are given in lb-ft. As in Table
I, the values listed are for lubricated fasteners.
Para 17.2: "installed/applied" was "installed"
"Torque" heading references changed to "Assembly Torques"
Various value typo errors corrected
Table IV:
Heading was Hex head straight fittings & plugs (see Para 7)
Added "Aircraft Type Fittings" sub-heading
Oil lube torque valve 525-625 was 375-425
Anti-gallant coated torque valve 330-395 was 240-270
Added Industrial Type Fittings section
Added Hose Sizes:
"-8", Tubing OD-" .500", Thread Size- ".750-16" and corresponding torque values.
"---", Tubing OD-".5625", Thread Size-".8125-16" and corresp. torque values.
Table VIII: sub-headings "Torque, lb-in" were "Torque"
Table IX:
Added "Aircraft Type Fittings" sub-heading
Added Industrial Type Fittings section
Table XVI:
Sub-heading "Torque Limits, lb-in**" was "Torque, lb-in**"
"with or without lubrication" was "see Para 4.2.3"

8
-All Tables -11

--

13

--

15

--

18

--

S. Leavitt
10/22/90
EC#3462

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION
RELEASED

REV

TPM124
ISSUED BY:

S. Leavitt

SHEET
OF

2A
2

DATE: 6/14/90

REVISED BY: J. Martin

DATE: 11/17/92

REFERENCE:

ASSEMBLY TORQUE LIMITS

REV SHEETS
LET AFFECTED

20

SHEETS
DESCRIPTION

ADDED

--

REV BY

APPVD

& DATE

& DATE

Table XVIII Completely Revised - was:

Thread Size

Torque lb-ft

1/4-20
5/16-18
3/8-16
7/16-14
1/2-13
9/16-12
5/8-11
3/4-10
7/8-9
1-8
1 1/8-8
1 1/4-8
1 3/8-8
1 1/2-8
1 5/8-8
1 3/4-8
1 7/8-8
2-8
2 1/4-8
2 1/2-8
2 3/4-8
3

6
12
18
30
45
68
90
150
240
368
533
750
1020
1200
1650
2250
3000
3300
4770
6600
8880
11580

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

REV C

TPM126
ISSUED BY:

OF

1
3

DATE: 1/21/91

S. Leavitt

DATE: 3/20/92

REVISED BY: B. Jelen

RELEASED

SHEET

REFERENCE:

IDENTIFICATION - COMPONENTS AND ASSEMBLIES

1.0

SCOPE
This specification establishes the requirements for field connection identification, component identification, ancillary assembly (skid) identification and federally mandated warning tags.

2.0

3.0

FIELD CONNECTIONS AND COMPONENTS

2.1

Identification tags are intended to provide a readily visible means to correlate the assembly P&I diagram with the actual physical components.

2.2

One and one-half inch diameter stainless steel (Ref. CT115508-1200) or blue anodized aluminum
tags (Ref. CT112872-2400) shall be utilized as specified on the skid assembly drawing or purchase
order.

2.3

As shown on the applicable assembly drawing, identification shall be legibly marked on each tag in
letters 1/4 inch high to a minimum depth of .010.

2.4

Tags shall be secured to each field connection and component in a visible location so as to not interfere with the physical installation and operation of the skid. Tags shall be attached by annealed stainless steel wire of .025 to .035 diameter (Ref. CT112940 or as otherwise specified).

2.5

If tags are attached prior to final skid painting, they shall be suitably protected from the painting process.

ASSEMBLY (SKID)
3.1

Each major system assembly or skid delivered by TPM shall carry a nameplate.
3.1.1

3.2

In addition to the specific information required in paragraphs 3.3 thru 3.6, name plates shall
carry the corporate logo, engine logo, etc., as required by company policy (Ref. IPD21140).

"TYPE OF SKID" shall be as indicated on the specific assembly and test specification.

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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REV C

TPM126

TPM
SPECIFICATION

ISSUED BY:

OF

2
3

DATE: 1/21/91

S. Leavitt

DATE: 3/20/92

REVISED BY: B. Jelen

RELEASED

SHEET

REFERENCE:

IDENTIFICATION - COMPONENTS AND ASSEMBLIES

3.3

"Serial NUMBER" shall be determined as follows:

XXXXYYZZ
Sequential Number 01 to 99
Type Code

01
02
03
04

Project Number
05
06
07
08
09
10
11
12
13
14
16
17
18

Starting Skid
Fire Skid
Gas Fuel Conditioning Skid(s)
Liquid Fuel Conditioning Skid(s)
(Fuel forwarding, fuel filtering)
Hydraulic Skid
Lubrication Skid(s)
Water Wash Skid
Water Injection Skid
Steam Injection Skid
Liquid Fuel Skid (Fuel Plate for FT8)
Gas Fuel Skid
Engine Drying
Muscle Air Skid
Drain Skid
Turbine Cooling Air Skid
Water Purge Skid
Ignition Gas Skid

3.4

"Assembly Number" shall be the assembly number or part number each skid is built to.
i.e. - IPE20685GR1

3.5

"For USE WITH" shall be:

FT8, V84.2, or V64.3, etc.

3.6

"MFG DATE" shall be DD-MMM-YY

i.e.: 10-OCT-90

3.7

Required information shall be legibly marked on the plates in 1/8 inch high letters to a minimum
depth of .010.

3.8

Nameplates shall be permanently attached to the skids by CT112921-0500 drive screws or as otherwise specified on the applicable assembly drawing.

3.9

If plates are attached prior to final skid painting, they shall be suitably protected from the painting
process.
This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

REV C

TPM126
ISSUED BY:

OF

3
3

DATE: 1/21/91

S. Leavitt

DATE: 3/20/92

REVISED BY: B. Jelen

RELEASED

SHEET

REFERENCE:

IDENTIFICATION - COMPONENTS AND ASSEMBLIES

3.10 Each major system assembly or skid assembly manufactured by a vendor shall carry a nameplate
stating (as a minimum): Company name, TPM Part No, and Manufacturing Date. Nameplate and fasteners shall be corrosion resistant and legibly marked in 1/8 inch high letters to a minimum depth of
.010 inch. The nameplate shall not be painted.
4.0

HAZARD LABELS
4.1

Hazard warning tags or labels shall be provided as determined by the responsible engineer or corporate legal staff and as indicated on the assembly drawings. Such tags shall be in accordance with the
governing regulating specification.

4.2

Particular attention should be given to locations which include elevated temperatures (over 140F),
electrical conductors and potentially explosive environments. (Ref. CT114063 for high temperature
warning).

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION
RELEASED

REV

TPM126
ISSUED BY:

SHEET

OF

S. Leavitt

1A
1

DATE: 1/21/91

REVISED BY: B. Jelen

DATE: 3/20/92

REFERENCE:

IDENTIFICATION - COMPONENTS AND ASSEMBLIES

REV SHEETS
LET AFFECTED

SHEETS
ADDED

DESCRIPTION

REV BY

APPVD

& DATE

& DATE

1, 2

--

Para 2.4.3.1 - Revised marking procedure to eliminate

hammer stamp requirement.
Para 2.4., 3.1 - Removed specific part no. to allow spec. to
serve for all engine models.

SLL
4/3/91

--

Para 3.1 expanded requirements for use of nameplates

SLL
1/13/92
EC#5274

--

B. Jelen
3/3/92
EC#5484

--

1.0 Scope was "This specification establishes the

requirements for component identification, ancillary
assembly (skid) identification and federally
mandated warning tags."
2.0 Was "Component Identification Tags"
Par 2.2 was "One and one-half inch diameter blue
anodized aluminum tags (CT112872-2400) shall be
utilized as specified on the individual skid assembly
drawing."
Para 3.0 Was "Assembly Nameplates"
Para 3.10 added to address vendor nameplates.

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

ISSUED BY:

OF

1
3

DATE: 5/11/91

B. Staib

REVISED BY: E. Kisilis

RELEASED

SHEET

REV A

TPM129

DATE:

12/14/92

REFERENCE:

COATING SYSTEM FOR STEEL SURFACES

1.0

2.0

SCOPE
1.1

This specification establishes the minimum requirements for preparation and painting of steel surfaces
of equipment for Turbo Power and Marine Systems, Inc. (TPM).

1.2

Where alternate requirements are presented, the document which references this specification will
identify those sections which are applicable.

1.3

Where this document and referenced documents are in conflict, this document shall have precedence.

SURFACE PREPARATION
2.1

All steel shall be thoroughly cleaned. Loose rust, rust scale, mill scale, and other foreign material
including dust, dirt, oil, grease, chemical contamination, or any previously applied paint shall be
removed so as to produce a clean surface satisfactory for the application of paint.

2.2

Welded joints and areas in the vicinity of welded joints shall have splatter, slag, and flux deposits
removed. Break all sharp edges.

2.3

Cleaned steel shall be prime painted within eight hours after cleaning.

2.4

All galvanized steel shall be chemically etched prior to painting, using "Galvaprep" by Amchem
Products, or equal.

2.5

Surface preparation shall be in accordance with one of the following Steel Structures Painting Council
(4400 Fifth Avenue, Pittsburgh, Pennsylvania) specifications.
2.5.1

Solvent Cleaning, SSPC-SP1-82.

2.5.2

Power Tool Cleaning, SSPC-SP3-82.

2.5.3

Commercial Blast Cleaning, SSPC-SP6-85.

2.6

Note that power tool or blast cleaning must be preceded by solvent cleaning to remove heavy deposits
of oil or grease.

2.7

On galvanized steel the specification of Section 2.5.2 or 2.5.3 may be relaxed to 2.5.1.

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

ISSUED BY:

OF

2
3

DATE: 5/11/91

B. Staib

REVISED BY: E. Kisilis

RELEASED

SHEET

REV A

TPM129

DATE:

12/14/92

REFERENCE:

COATING SYSTEM FOR STEEL SURFACES

3.0

COATINGS
All paint shall be applied in accordance with Steel Structures Painting Council SSPC-PA1-82, and with paint
manufacturers instructions with particular attention given to limits on humidity, surface temperature, and
time between coatings. Paint shall be applied thoroughly and evenly and shall be worked well into pores,
joints, and other openings. Workmanship shall be of the highest quality with no running paint or other
unsightly blemishes. The TPM inspector may check the dry film thickness measurements in accordance with
Steel Structures Painting Council SSPC-PA2-82. Measurements will be made at random at the judgement
of the TPM inspector. The specified film thicknesses are stated in mils where one mil = 0.001 inch = 25
microns. Maximum dry film thickness shall not exceed twice the stated minimum thickness. Surface
coatings shall be per one of the following, as specified in the referring document.
3.1

Protective Oil
3.1.1

3.2

4.0

Machine finished surfaces which are not to be painted shall be protected against corrosion by
coating with E. F. Houghton "Rust Veto" #76-HF. Coating shall not be harmful to adjoining
painted areas. Application shall be preceded by solvent cleaning.

Inorganic Zinc Silicate

3.2.1

Prepare surface per Section 2.5.3 minimum.

3.2.2

Apply one coat Ameron Dimetcote #21-5 Inorganic Zinc Silicate, 3 mils minimum dry film
thickness. Color to be light gray.

INTERMEDIATE AND TOP COATS

Intermediate and top coats, where specified, shall be applied in accordance with Section 3.0. Tinting, if
specified, to be in accordance with paint manufacturers instructions.
4.1

Acrylic
4.1.1

Use only over surfaces previously coated per Section 3.2 (or 2.5.1 if galvanized).

4.1.2

Clean and touch up damaged areas per Section 3.2.

4.1.3

Apply one coat of Ameron Amerguard #220 Acrylic, 2 mils minimum dry film thickness for a
total of 5 mils minimum dry film thickness including primer. Color to be Pearl Gray (GR-3).
An intermediate mist coat is required, using Ameron #856 wetting agent additive and thinned
with clean water.

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

ISSUED BY:

OF

3
3

DATE: 5/11/91

B. Staib

REVISED BY: E. Kisilis

RELEASED

SHEET

REV A

TPM129

DATE:

12/14/92

REFERENCE:

COATING SYSTEM FOR STEEL SURFACES

4.2

4.3

4.4

4.5

5.0

Epoxy, High Build

4.2.1

Use only over surfaces previously coated per Section 3.2.

4.2.2

Clean and touch up damaged areas per Section 3.2.

4.2.3

Apply one coat of Ameron Amerlock #400 High Build Epoxy, 3 mils dry film thickness for a
total of 6 mils minimum dry film thickness including primer. Color to be Pearl Gray (GR-3).
An intermediate mist coat is required.

Polyurethane
4.3.1

Use only over surfaces previously coated per Section 4.2.

4.3.2

Clean and touch up damaged areas per Section 3.2 and 4.2.

4.3.3

Apply one coat of Ameron Amercoat #450 HS Polyurethane, 2 mils dry film thickness for a
total of 8 mils minimum dry film thickness including primer. Color will be specified in
referring document.

Inorganic Topcoat
4.4.1

Use only over surfaces previously coated per Section 3.2.

4.4.2

Clean and touch up damaged areas per Section 3.2.

4.4.3

Apply one coat of Ameron Amercoat #741 Inorganic Topcoat, 3 mils dry film thickness for a
total of 6 mils minimum dry film thickness including primer. Color to be Pearl Gray (GR-3).

Epoxy, Self-Prime
4.5.1

Prepare surfaces per Section 2.5.1 if existing coating is tightly adhering and in good condition,
or 2.5.2 if not. See referring document for masking requirements, if any.

4.5.2

Apply one coat of Ameron Amerlock #400 Epoxy, 5 mils minimum dry film thickness. Color
to be Pearl Gray (GR-3).

COATING MANUFACTURERS
E.F. Houghton, Valley Forge, Pennsylvania
Ameron Protective Coatings, Brea, California
Amchem Products, Ambler, Pennsylvania

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INDEX

1.0
2.0
3.0
4.0
5.0
6.0

7.0

8.0
9.0

10.0
11.0

12.0
13.0

Scope and Purpose

Reference Documents
Grounding of Gas Turbine Generator Output
Backup Generators, Uninterruptable Power Supplies, and Inverters
Separately Derived Systems
Grounding of Cabinets And Equipment For Control and Instrumentation
6.1 General
6.2 Cabinet Main Ground Bus
6.3 Instrument/Shield Common Bus
6.4 Connection of Shields to the Instrument/Shield Common Bus
6.5 Grounding of Equipment Housings in Control and Instrument Cabinets
6.6 Grounding of Cabinet Sides, Panels, and Doors
6.7 Grounding of Instrument Transformers
Grounding of Field Installed or Remote Located Sensing and Control Devices
7.1 Equipment Grounding
7.2 Supplemental Skid Grounding
Grounding of Intrinsically Safe Barriers
Grounding of Motor Control Center (MCC) Equipment
9.1 Power or Control Transformers
9.2 Connection of Electrical Equipment Enclosures to MCC Ground Bus
Grounding of Motors 100 Horsepower and Over
Alternate Procedure for Equipment Grounding of Existing Installations
11.1 Bonding Jumper
11.2 Discontinuity of Raceway
11.3 Inspection
Grounding Electrode System
Inspection and Measurement of Resistance to Ground (After Installation)
13.1 Skid Mounted Enclosures
13.2 Intrinsically Safe Barriers

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1.0 Scope and Purpose
This specification establishes minimum grounding requirements for gas turbine electrical systems
manufactured and/or installed for United Technologies, Turbo Power and Marine Systems, Inc.,
hereafter referred to as TPM. This specification does not apply to the main station ground grid which is
the customers scope of supply. However, grounding should be in accordance with Reference 2.4.
Conductive materials enclosing conductors or electrical equipment are grounded to limit the voltage to
ground on the enclosures and to facilitate over-current device operation in case of ground faults (NEC;
Reference 2.1, Article 250-1). Equipment enclosures that must be grounded include motor frames,
raceways, and junction boxes. The National Electrical Code (NEC; Reference 2.1) is to be used for
grounding criteria except where superseded by this specification. When there is a difference between this
specification and project specific specifications or schematics, the project specific document will
override the more general requirements of this specification.
The purpose of this specification is to address TPM grounding requirements that either are not covered
by the NEC such as shield grounding or TPM grounding requirements that surpass or supplement NEC
minimum grounding standards such as cabinet and skid grounding requirements.
2.0 Reference Documents
2.1

National Electrical Code (NEC) 1993 Edition

2.2

Schematics, Outlines, and Cable Lists

2.3

TPM Specification TPM132; Wiring - General Requirements and Practices

2.4

IEEE 80 IEEE Guide for Safety in AC Substation Grounding

2.5

IEEE 665; IEEE Guide for Generating Station Grounding

2.6

IEEE 142; IEEE Recommended Practice for Grounding of Industrial and Commercial Power
Systems

2.7

IEEE 837; IEEE Standard for Qualifying Permanent Connections Used in Substation Grounding

2.8

ANSI/ISA - RP12.6; Installation of Intrinsically Safe Instrument Systems in Class I Hazardous

Areas.

3.0 Grounding of Gas Turbine Generator Output

The generator ground is as shown on Figure 1. The generator neutral is normally grounded through a
high impedance grounding transformer and resistor as shown in Figure 1. However, it may sometimes
be grounded through a current limiting reactor or grounding resistor. The generator grounding electrode
conductor is sized according to Reference 2.5 and is as given on the Cable List, Reference 2.2. It is
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installed by the constructor from the neutral cubicle to the customer ground grid. Recommended
minimum grid resistance and grid construction is per Reference 2.4. Either high compression lugs
designed to meet Reference 2.7 (such as the Thomas & Betts high compression grounding connectors,
"GG" or "GR" series) or an exothermic welding connection (such as the Erico "Cadweld" exothermic
system) is to be used for connection of the grounding conductor at both ends. The ground grid connection
shall be permanently accessible for later maintenance inspections. Per Section 3.0, the generator frame
shall be separately grounded as shown in Figure 1. The generator neutral cubicle is also supplied with a
separate grounding electrode conductor as shown in Figure 1. All grounding conductors are sized as per
the Cable List, Reference 2.2.

FIGURE
GENERATOR GROUND

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4.0

Backup Generators, Uninterruptable Power Supplies, and Inverters

The typical backup generator and TPM Motor Control Center (MCC) do not require a neutral. An
equipment grounding conductor is run to the generator frame or grounding bus bar as well as the MCC
ground lug as shown on Figure 2A. They are sized per Article 250-94 of the NEC. When a neutral is
required, the generator neutral shall be solidly connected to the premises neutral busbar at the point of
transfer as shown in Figure 2A. The same grounding requirements apply to Uninterruptable Power
Supply Systems (UPS) or DC to AC inverters that TPM installs as these also have their neutrals solidly
connected to the premises neutral busbar at the point of transfer. Reference Figure 2B for UPS or inverter
grounding and neutral connections. When an emergency power generator is installed, a separate
electrode grounding conductor to the generator is not required.

FIGURE 2A
EMERGENCY GENERATOR GROUNDING
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FIGURE 2B
Ups Solid State Neutral Intertie To Premises System Neutral Busbar
5.0

Separately Derived Systems

The NEC recognizes certain systems as independent sources of power. The NEC addresses these in
Article 250-5 and calls them "separately derived systems". The NEC requires these systems to be
grounded. The most typical case to be encountered with TPM installations is a step down transformer.
Also, D.C. power supplies that do not have ground detection instrumentation are separately derived
systems. These systems shall be grounded as defined by Article 250-26 of the NEC.

6.0

Grounding of Cabinets And Equipment for Control and Instrumentation

6.1

General
6.1.1

All Analog Signals Are Shielded.

All shields are grounded to eliminate EMI/RFI interference. All shields are grounded at
one point only to eliminate multiple ground paths and consequent ground current loops.
TPM terminates each individual shield ground point within the control cabinets. Unless
special termination and grounding requirements are dictated by the equipment vendor or
by the schematics, attach a #16AWG green insulated drain wire to the shield at the point
of termination of the shielded wire to the equipment monitor or control enddevice. The
unshielded portion of the conductor shall be kept as short as possible. This insulated
shield drain wire is then run to the Instrument/Shield Common Bus. The Instrument/
Shield Common Bus is isolated from the panel with insulated standoffs. It is then
grounded to the main cabinet grounding bus via a #6 grounding conductor. The
grounding configuration is as shown in Figure 3. Figure 3 is to be used for panel
fabrication and for control panel grounding to the customer grounding grid. If shield
terminations are different from the detail as shown on Figure 3, they will be called out on
the control schematics.
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that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
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6.1.2

Instrument/Shield Common Bus

This ground bus is provided strictly for shield and instrument grounding to isolate the
shields from 50 or 60 Hertz ground currents.

6.1.3

Dedicated Cabinet Grounding Electrode Conductor

The control panel receives power from various voltage sources. Each power source is
provided with its own grounding conductor as required by the NEC. This grounding
conductor is attached to the grounding lug provided with the equipment that receives the
power. In addition to this, the general constructor is to make provisions for a separate #4/0
AWG grounding conductor to the customers ground grid as shown in Figure 3.

FIGURE 3
CONTROL CABINET GROUNDING

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6.2

Cabinet Main Ground Bus

6.2.1

The cabinet main ground bus shall be secured at the bottom of the cabinet, as shown in
Figure 4 of this specification. It shall be located towards the rear of the cabinet so that it
will not be in the way of regular maintenance activities but it shall be forward of the
wireways mounted on the rear panel.

6.2.2

Two methods of securing the cabinet main ground bus are given in Figures 4A & 4B.
Figure 4A mounts the ground bus on angle brackets mounted on bottom side rails. Figure
4B mounts the ground bus directly on the bottom side rails. Choice can be made between
the two, based on available space and accessibility to the ground bus. The ground bus may
be spliced using 1" x 1/4" copper bus, if necessary.

6.2.3

When more than one cabinet is mechanically attached to form a lineup of cabinets as an
assembly, the ground bus shall traverse all cabinets, and be equipped on each end for
connection to the grounding electrode system. The conductor between the ground bus and
the grounding electrode is installed by the constructor and shall be sized and attached as
shown in Figure 4A & 4B.

FIGURE 4A - VERTICAL GROUND BUS

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FIGURE 4B - HORIZONTAL GROUND BUS

6.3

Instrument/Shield Common Bus

Each cabinet bay that contains equipment utilizing analog signals shall have a signal common bus
for connecting together shields of signal level cables within the cabinet to form a single point
ground. The ground bus hardware and connection procedures to be used are shown in Figure 5.
More than one instrument/shield signal common bus may be used if required to avoid lengthy
wire runs within the cabinet. The instrument/shield common bus(es) shall be connected at a single
point on the cabinet main ground bus using a #6 AWG conductor as shown in Figure 3.

FIGURE 5
INSTRUMENT/SHIELD COMMON BUS

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6.4

Connection of Shields to the Instrument/Shield Common Bus

Instruments and shields on wiring between signal source and monitoring/ control equipment shall
be prepared as specified in TPM132. Shields shall be connected to the instrument/shield common
bus only where shown in the schematic diagrams.

6.5

Grounding of Equipment Housings in Control and Instrument Cabinets

Control and instrument housings are grounded through their attachment to the control panel.
Equipment housings to be grounded include but are not limited to: Vibration Monitoring
Equipment, meters, switches, monitors, synchronizers, and Fire Control Panels. Where ground
terminals are provided in their design, these terminals shall be connected to the control cabinet
ground bus, using a #12 AWG green insulated wire. Four spare drilled and tapped holes with
screws and washers shall be provided in the ground bus in each cabinet for these ground
connections. Additional drilled and tapped holes will be made in the ground bus as necessary.

6.6

Grounding of Cabinet Sides, Panels, and Doors

Cabinet side and rear mounting panels shall be grounded to the main ground bus using a #6 AWG
bonding conductor as shown in Figure 4. Where there is door mounted electrical equipment, the
doors shall have bonding straps as shown on Figure 6.

FIGURE 6
CABINET DOOR GROUNDING STRAP

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6.7

Grounding of Instrument Transformers

The secondary circuits of all potential and current transformers shall be grounded according to
Article 250-121 of the NEC. Cases or frames shall be grounded according to Article 250-122 of
the NEC.

7.0

Grounding of Field Installed or Remote Located Sensing and Control Devices

All of Article 250 of the NEC is applicable to this section. However, the following specifies TPM
requirements where the NEC allows several options in grounding techniques.
7.1

Equipment Grounding
The NEC (Article 250-92) requires that one of the following three methods be used for
grounding ac equipment enclosures:
1. By the raceway, cable tray, cable armor, or cable sheath (The term "raceway" is defined to
include rigid metal conduit, plus a variety of other "enclosed channels".)
2.

By a wire within a raceway or cable.

3. By a separate equipment grounding conductor.

The grounding conductor must run in close proximity to the power conductors to minimize the
inductive reactance and ac resistance. (NEC Article 250-57). Housings of sensing and control
devices, such as vibration accelerometer sensors and bleed valves, are grounded through their
mounting attachment (Reference NEC Article 250-58). Control circuits that are dc, are not
required to have a grounding conductor brought back to the source of power. Grounding only by
a conductor between the equipment enclosure and a grounded skid is not sufficient. (NEC 25091(c) and 250-51) The exception (NEC 250-57) is grounding of dc circuits, where the equipment
grounding conductor may run separately from the circuit conductors, because inductance is not
a factor.
The equipment grounding conductor is not required to be larger than the circuit conductors
supplying the equipment (NEC Article 250-95, Exception No. 2). When a single raceway
(between a junction box and the MCC) serves multiple loads, a single grounding conductor may
be used to ground all of the equipment enclosures supplied by that junction box. (NEC 250-95).
The single grounding conductor shall be sized for the largest grounding conductor requirement
in the group of multiple conductors. When motors or other electrical equipment are supplied
from junction boxes on a skid, a green grounding conductor shall be brought from the grounding
provisions on the electrical equipment through the conduit and terminated internally at a ground
terminal in the junction box. The junction box ground terminal shall be grounded through the
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interconnecting cable to the next higher assembly back to the service ground at the power source
(MCC).
7.2

Supplemental Skid Grounding

TP&M supplies several preassembled system skids. As supplementary grounding, a #4/0 AWG
bare or green color insulated grounding conductor is to be run from the customers ground grid
to the grounding lug provided on each skid.

8.0

Grounding of Intrinsically Safe Barriers

Grounding requirements vary between manufacturing and model numbers of various intrinsically safe
barriers. See Reference 2.2, the project specific schematics for the appropriate grounding requirements.
When a ground is required, a dedicated grounding conductor shall be run from the intrinsically safe
barrier ground lines to the main cabinet ground bus as shown in Figure 7. The grounding conductor shall
be a minimum size of #12 AWG per Section A.4.2 of Reference 2.8. Projects that are built according to
the Canadian Electrical Code shall have redundant grounding conductors.

FIGURE 7
INTRINSICALLY SAFE BARRIER GROUND

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9.0 Grounding of Motor Control Center (MCC) Equipment
The MCC and all its associated downstream motor branch circuits are effectively grounded by
means of the grounding conductor supplied with the incoming power feeder. This incoming
grounding conductor is connected to the MCC grounding busbar. The grounding conductor is of
a type and size as specified in Article 250-95 of the National Electrical Code. The MCC
grounding busbar shall run the entire length of the MCC cabinet assembly. The frame of each
MCC cabinet shall be effectively bonded to the grounding busbar.
9.1

Power or Control Transformers

Step down power transformers or control transformers over 1000 Volt- Amperes shall be
furnished with a separate grounding electrode conductor as required by NEC Article 250-26 and
sized according to 250-94. This dedicated conductor shall be connected to the main ground grid
system; it is not permitted to use the grounding conductor supplied with the main incoming MCC
feeder as the transformer grounding conductor.

9.2

Connection of Electrical Equipment Enclosures to MCC Ground Bus

All enclosures of electrical equipment powered by the MCC shall be grounded by a grounding
conductor continuous from the enclosure back to the MCC ground bus as specified in Article 25095 of the National Electrical Code. The grounding conductor shall be a separate dedicated
conductor and shall not consist solely of the branch circuit raceway. Irrespective of whether the
raceway is used for grounding, all motor branch circuit raceways entering the MCC shall be
effectively bonded to the MCC ground bus

10.0

Grounding of Motors 100 Horsepower and Over

In addition to grounding methods required by the National Electrical Code, motors with ratings
of 100 hp and over shall be grounded to the skid on which it is installed by a mounting strap.
Mounting straps may be selected from the following table:
----- Strap Length ----Horsepower

12"

18"

100

BD12

BD18

125-200

BE12

BE18

Note: The Part Numbers on the above table are available from Burndy Corp.
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Alternatively, the mounting strap may be a bare, stranded copper grounding wire, as normally
used for grounding of skids and raceways, using a bulldog-type terminal for cable 2/0 to 4/0, bolt
hole 3/8 (Thomas Bett Part No. 31011), and rust resistant, 3/8-16, shakeproof lockwashers and
hex-head, unc bolts.
The mounting strap may be attached to the motor frame by cleaning the mounting surfaces
(scraping off paint) on the mounting foot, and securing the strap with the mounting bolt.
Alternatively, a drilled, tapped hole is sometimes provided on large frame motors for the purpose
of grounding, or such a hole could be drilled and tapped for this purpose.
The preferable method of attaching the grounding strap to the skid is to braze a copper pad on the
skid near the motor foot, and drill and tap. If an existing pad is used, the mounting surface must
be clear of paint before attaching the grounding strap. A drilled and tapped hole in the skid is also
acceptable, providing the penetration will not result in oil leakage. Apply clear lacquer or paint
over the bonded surfaces after installation to prevent corrosion.1
11.0

Alternate Procedure for Equipment Grounding of Existing Installations

When equipment is being installed in an existing facility and the raceway system is used as the only
means of grounding, the following procedures for grounding and bonding are to be employed.
11.1

Bonding Jumper
Install a bonding jumper from the equipment enclosure (e.g., motor frame or motor terminal box)
to the conduit supplying the power, using an approved bonding jumper and conduit ground
clamp. The conduit must be continuous from the equipment to the power source. If a flexible
conduit is used for vibration damping, the bonding jumper shall be installed according to Article
250-91(b) and Article 350-5 of the NEC.

11.2

Discontinuity of Raceway
If the conduit is interrupted in any way (e. g., by a trench or cableway) additional provisions must
be made to continue the ground back to the service ground. Bonding jumpers shall connect the
conduit to the cableway, or a separate bare or green (or green with yellow stripes) insulated
conductor shall be clamped to the conduit and terminated at the service ground at the power
source cabinet (MCC). The separate conductor shall be routed in close proximity (parallel) to the
power cable or conductors.

1. The motor branch circuit is routed from the MCC via various wiring methods (i.e. direct burial, trenches, cable tray) and the
continuity of the raceway system can not be assured
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purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
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DATE: 8/2/93

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REFERENCE:

GROUNDING, GENERAL REQUIREMENTS AND PRACTICES

11.3

Inspection
Inspection and resistance measurements to ground shall be made after installation in accordance
with Section 12.0

12.0

Grounding Electrode System

The grounding electrode system (also referred to as the ground grid) is the responsibility of the client.
Reference 2.4 is the recommended guideline for good grounding design. This meets and exceeds any
NEC requirements.

13.0

Inspection and Measurement of Resistance to Ground (After Installation)

13.1

Skid Mounted Enclosures

A thorough visual inspection shall be made after installation to confirm that equipment enclosure
grounding methods comply with this specification. Resistance to grid ground shall be measured
using a meter that is accurate in the 10 to 100 milliohm range. A Fluke Model 29 multimeter is
adequate for this purpose. Resistances between the equipment housing(s) and the skids
grounding conductor shall be less than 100 milliohms. Sharpened probes may be necessary to
pierce the paint on these surfaces. A "short circuit resistance" reading should be taken with the
probes touching each other, and this value should be subtracted from the total resistance reading
to get the actual ground resistance value. In making these measurements for a motor, the
measurement shall be made from the metal of the motor housing to the skids grounding
conductor, and also from the end-caps of the motor to the skids grounding conductor.

13.2

Intrinsically Safe Barriers

The resistance between the intrinsically safe barrier ground point and the signal ground reference
point (the instrument/shield common bus) shall be measured to be less than one ohm per Section
5.2 of Reference 2.8.

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
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DATE:

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TPM130

REFERENCE:

GROUNDING, GENERAL REQUIREMENTS AND PRACTICES

REV SHEETS
LET AFFECTED

SHEETS
ADDED

DESCRIPTION

REV BY

APPVD

& DATE

& DATE

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
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TPM132

REFERENCE:

WIRING - GENERAL REQUIREMENTS & PRACTICES

INDEX
1.0

Scope

2.0

Reference Documents

3.0

Quality Assurance

4.0

Requirements - Control Panel Wiring

4.1
Ampacity and Wire Sizes
4.2
Terminations And Wire Routing
4.3
Lugs
4.4
Conductors
4.4.1
Instrumentation and Control Conductors
4.4.2
Multiconductor Cables
4.4.3
Shielded Cables
4.4.4
Coaxial Cable
4.4.5
Thermocouple Cable

5.0

Requirements - Field Cabling

5.1
Ampacity and Wire Sizes
5.2
Cable Trays
5.3
Terminations and Transition Points
5.4
Testing
5.5
Cable Types
5.5.1
Control and Power Distribution Wiring
5.5.2
Thermocouple Extension Cables
5.5.3
Signal Extension Cables

6.0

TPM Wire Marking, Numbers and Identification System

6.1
Wire Numbers
6.2
Wire Labels

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
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WIRING - GENERAL REQUIREMENTS & PRACTICES

1.0

Scope
This specification establishes the minimum requirements for the wiring and interconnecting cables for
control systems, electrical equipment, cabinets, panels, devices, switches, relays, etc. manufactured for
United Technologies, Turbo Power and Marine Systems, Inc. (Hereafter referred to as TPM). This
specification is applicable to both internal control cabinet wiring and field installed wiring. Project specific
criteria as detailed or project specific drawings override this specification.

2.0

Reference Documents
2.1 NFPA 70; National Electrical Code (NEC)
2.2 Project Schematics and Wiring Diagrams
2.3

IEEE 422; IEEE Guide for the Design and Installation of Cable Systems in Power Generating
Stations

2.4

TPM130; Grounding, General Requirements and Practices

2.5

TPM131; Specification for Control Cabinets

2.6 NFPA 79; Electrical Standard for Industrial Machinery

3.0

Quality Control
3.1

The vendor shall have a Quality Control System which complies with TPM-QA-200A.

3.2

The vendor shall furnish a complete written inspection and test procedure for review and approval
by TPM prior to commencement of manufacturing. TPM will select designated witness points and
notify the vendor by Purchase Order supplement and/or written communication by Engineering.

3.3

Unless otherwise specified, the vendor is responsible for the planning, performance and cost of all
inspections and tests.

3.4

TPM reserves the right to witness all inspections and tests including source inspections, in-process
tests and final acceptance tests. The vendor shall notify TPM prior to the inspection and test date(s).

3.5

The vendor shall submit to TPM, via written communication, any and all exceptions taken to the
requirements specified by either this specification or TPM Purchase Order.

3.6

Acceptance after inspection does not relieve the vendor from the responsibility of complying with
the performance requirements specified herein.
This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
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WIRING - GENERAL REQUIREMENTS & PRACTICES

4.0

Requirements - Control Panel Wiring

4.1

Ampacity and Wire Sizes

4.1.1

Ampacity
The following table defines the maximum ampacity allowed for the different sizes of
conductor: (1)
Conductor Size AWG
20
18
16
14
12
10
8

Ampacity
5
7
10
15
20
30
40

(1) Derived from Reference 2.6

4.2

4.1.2

Minimum Wire Size

Control Circuits - The main feed for a group of individual branch I/O associated with the
Woodward Controller shall be #14AWG. 15 Amp fuse protection is provided for each feed.
Individual I/O branch wiring associated with respective individual I/O addresses of the
Woodward Controller shall have #16AWG. The Woodward Controller provides electronic
short circuit protection for each individual address. Reference Figures 2A and 2B for typical
I/O wiring.

4.1.3

Control wiring not associated with the Woodward Governor is protected by fusing,
matching the ampacity table as given in section 4.1.1. a minimum of #16AWG is to be used.

4.1.4

Current transformer circuits having 5 Amps secondary current shall all be #12AWG.

4.1.5

Fire Protective Circuits - The minimum wire size for Fire Protective Circuits is #14 AWG.

Terminations and Wire Routing

The panel vendor shall wire all internal panel wiring in groups to provide isolation/separation for
the following:
1. Power (120 Vac, 125 Vdc, 24 Vdc)
This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
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WIRING - GENERAL REQUIREMENTS & PRACTICES

2. Control (digital, make and break contacts)
3. Signal (shielded inputs, analog)
The terminal blocks shall be arranged to provide this separation. Separation between power (120
Vac, 125 Vdc and 24 Vdc) is also required on terminal blocks. Signal and power wires shall not be
run parallel to each other. Where they have to cross, they shall do so at right angles.
Not more than two (2) conductors will be connected to a position on a terminal block or device,
except a special lug may be added to specified positions for suppressors. All interpanel wiring shall
be run in wiring troughs, grouped together in a neat manner. Trough wiring shall not be looped back
on itself. Provide grommets, plastic edging and/or tube sleeving wherever wire insulation passes
through a hole or over an edge.Wrapping tape around a wire or bundle is not allowed. In-line wire
splices are not allowed, except for connection to pigtail wires of standard lighting fixtures. Provide
adequate service loops to allow removal and servicing of all equipment. All conductor and cable
bend radius shall be in accordance with cable manufacturers recommendations.
Terminal blocks - compression type unless otherwise specified. Screw type shall be used for
connections to potential transformers, current transformers and current transformer circuits. At least
20% spare terminals shall be provided on each terminal block assembly. Phoenix type (.24")
terminal blocks or approved equivalent shall be used. Use of three tier blocks must be approved by
TPM. If three-tier blocks are approved for shielded cables, lower terminal must be used for shield,
signal return or (-) dc next, and signal or (+) dc on top.
4.3

Lugs
Either ring or fork tongue lugs can be used to terminate suppressor
4.3.1

Ring Tongue Lugs

Ring tongue lugs shall be used on current transformer wiring in the control system, i.e., from
terminal blocks to devices. Ring tongue lugs shall be used on all wires terminating at
potential transformers, current transformers, selector switches, and protective relays and all
other devices where fork tongue lugs could hamper proper mechanical or electrical
operation of the device and where screw or nut and stud terminations are provided.

4.3.2

Fork Tongue Lugs

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
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Fork tongue lugs shall be of the locking spring type, if used. Fork tongue lugs may be
used throughout except where ring type are specified above. Fork tongue lugs must be
approved by TPM for locations as determined necessary by equipment vendor.
4.3.3

Tools
Only ratchet type crimping tools shall be used when installing pins, lugs, splices and coaxial connectors.
All crimping tools shall be checked according to manufacturers recommended procedure at
least once a month.
Tool manufacturer shall be the same as lug manufacturer, unless tool and lug compatibility
is controlled by recognized industry standards.

4.4

Conductors
4.4.1

Instrumentation and Control Conductors

These are single conductors for instrumentation and control circuits.
Single conductors shall be of the following colors and insulation types:
Application

Color

NEC Type

120 Vac (All)

SIS

125 Vdc (All)

Gray for power conductors,

protective relaying circuits
and generator control wiring
White for Neutral
Orange

THHN / MTW or MTW

24 Vdc (All)

Blue

THHN / MTW or MTW

Ground (GND)

Green

THHN / MTW or MTW

Stranding
This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
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REFERENCE:

WIRING - GENERAL REQUIREMENTS & PRACTICES

Size (AWG)

4.4.2

No. Strands/Gauge

Alpha No. (or Equal)

16

19/29

7134

14

19/27

7135

12

19/25

7136

Multiconductor Cables
Multiconductor cables and miscellaneous cables are to be as specified on assembly
drawings and associated bill of material.

4.4.3

Shielded Cables
Multi-conductor cables and miscellaneous cables are to be as specified on assembly
drawings and associated bill of material. Shielded cable shall be braided or foil with drain
wire type. Multi-conductors shall be twisted. Shielded wire shall be Alpha type
5610B1601E (or equal). Wire size #16 AWG unless otherwise specified. Rated 300V, -20C
to +105C.
Shield terminations - Braided tinned copper. See attached (Figure 1).
1. Remove outside jacket back three (3) inches from the end.
2. Unwrap and prepare per standard practice.
3. To prepared shield, add ground pigtail per Fig. 1A.
4. Put one inch shrink tubing over exposed shield or HYRING and pigtail per Fig. 1A.
5. Lug wire ends for attachment to grounding studs and bus.
Shields shall be continuous from signal source to monitoring and control equipment. When
it is necessary to pass through a terminal block a separate terminal shall be utilized for the
shield. Shielded leads shall be grounded to the monitoring or control device at the monitor
or control device end only. The unsaddled portion of the conductor shall be kept as short as
practical. If the monitor or control device is not provided with a terminal for shield
termination, a short pigtail splice (See Fig 1A) green #16 AWG, shall be added to facilitate
grounding the shield to the instrument shield common bus. Locate a point as close as
practical to the conductors being shielded to ground (or bond) the pigtail splice. Alternate
This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
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REFERENCE:

WIRING - GENERAL REQUIREMENTS & PRACTICES

acceptable practice for adding pigtail to shields - Burndy type HYRINGS (or equal) may be
used. Shrink tubing 1" long to be applied over HYRING assembly as noted above.
4.4.4

Coaxial Cable
Coaxial cables are used for PLC intercommunication drops. Cables shall be 75 ohm RG-6
quad shield (foil-braid, foil-braid) type. Temperature Rating -40 to +80C. Polyethylene or
polypropylene core with PVC or polyethylene outer jacket. Copper covered steel conductor.
Connectors shall be single piece type F-56QS (for foil-braid, foil braid type cable)
manufactured by Augat, LRC series. Cable to be dressed using proper stripping tool.
Connectors to be installed using proper crimping tool. See Figure 1B for recommended and
acceptable lead dressing.

4.4.5

Thermocouple Cable
Thermocouple extension wire shall be solid, duplex, (thermocouple pair) #16AWG, of an
ANSI Type matching the thermocouple Type (Type K is the usual choice). The wire shall
meet ANSI MC96.1 specifications for thermocouple type wire and color coding. Polyvinyl
insulation 0 to 105 C insulation. Omega part number EXPP-x-16 or equivalent.

5.0

Requirements - Field Cabling

5.1

Ampacity
Cables as detailed in this specification are the TPM recommended cables to be used for the
interconnection wiring between the control cabinets and the field located skid assemblies, junction
boxes, etc. Cables are as specified in the project specific Cable List, xxxx-189-E006L. In this
document, wire size is selected from the 60 C Insulation Column of Table 310-16 of the NEC. No
corrections have been made for derating due to direct burial, covered, or unventilated cable trays
located within cable troughs, or for cables located within the high ambient temperature environment
of the gas turbine enclosure. Minimum wire sizes for control circuits and fire protective circuits are
as noted in Section 4.1.

5.2

Cable Trays
When cabling is run in a cable tray installation where the power and signal cables form a multi-tier
assembly as detailed in Figure 3, separation of cable types shall be observed with regard to the
following sections of the NEC:
318

Cable Trays

430

Motors, Motor Circuits, and Controllers

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
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REFERENCE:

WIRING - GENERAL REQUIREMENTS & PRACTICES

504

Intrinsically Safe Systems

725

Remote-Control, Signalling, and Power-Limited Circuits

760

Fire Protective Signalling Systems

As shown in Figure 3, the Remote-Control, Signalling and Power-Limited Circuits, as well as the
intrinsically safe and fire signalling circuitry is installed in a cable tray separate from the power
wiring. A minimum vertical separation of 18 inches between the top of the bottom tray and the
bottom of the top tray is required. When this separation can not be maintained (such as installation
in a wiring trough), then a tray cover is to be installed over the lower tray as shown in Figure 3. This
is as recommended in Reference 2.3 to eliminate EMI / RFI. The fire protective signal wiring and
the intrinsically safe wiring is to be physically separated from the rest of the wiring by either
raceways or tray barriers. Intrinsically Safe Wiring signs are to be applied to the intrinsically safe
wiring per Section 504 of the NEC. Medium voltage cable is to be installed in cable tray or raceway
separate from low voltage signal and power wiring. In the signal circuit cable tray, analog signals
are to be physically and electrically isolated from the discrete control signals by means of a cable
tray barrier as shown in Figure 3.
5.3

Terminations and Transition Points

Lug terminations are similar to Section 4.3. Motor terminations are direct to the motor with flexible
conduit used for vibration damping. Conduits are to be sealed when terminated at a cable tray to
prevent moisture entry. Fire barriers are to be installed when crossing designated fire walls. Seals
are required per Section 500 of the NEC when crossing hazardous area boundaries.

5.4

Testing
The vendor shall ring out all wiring Ring out means to use an audible or visual electrical device to
check continuity from one point to all other points in a circuit. Low voltage devices shall be used,
i.e., ohmmeter, check out buzzer. Power shall be applied to panels, cabinets, devices, etc., only
under the supervision of TPM Test Engineer/Inspector. A two week notice shall be given to TPM
for inspection and checkout of equipment at the vendor's facility. All repairs to faulty wiring or
damaged equipment shall be at the vendor's expense, unless it can be proven the equipment was
damaged prior to assembly. Incoming inspection of all equipment is advised.

5.5

Cable Types

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
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16

REFERENCE:

WIRING - GENERAL REQUIREMENTS & PRACTICES

Cables must be suitable for wiring method and service environment in which they are used. This
includes use in conduits, ducts, trays or racks for both free air and direct burial applications.
Specific requirements of individual cables including outer jacket diameter or service intended shall
be as listed in the Cable List.
5.5.1

Control and Power Distribution Wiring

Cables shall be rated for 600 V minimum with conductors sized for applicable loads. Conductors
shall be color coded and identified in accordance with NEMA and ICEA table K-2.

CONDUCTOR COLOR CODE

Per NEMA and ICEA
Table K-2/Method 1
Cond
No.

Base

Hash Marks
or Stripes

Cond
No.

Base

Hash Marks
or Stripes

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

Black
Red
Blue
Orange
Yellow
Brown
Red
Blue
Orange
Yellow
Brown
Black
Blue
Orange
Yellow
Brown
Black
Red

Black
Black
Black
Black
Black
Red
Red
Red
Red
Red
Blue
Blue

19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

Orange
Yellow
Brown
Black
Red
Blue
Yellow
Brown
Black
Red
Blue
Orange
Brown
Black
Red
Blue
Orange
Yellow

Blue
Blue
Blue
Orange
Orange
Orange
Orange
Orange
Yellow
Yellow
Yellow
Yellow
Yellow
Brown
Brown
Brown
Brown
Brown

Color Code repeats after 36 conductors

5.5.2

Thermocouple Extension Cables

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that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
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The cable shall meet ANSI MC96.1 specifications for thermocouple type wire and color
coding. Unless otherwise specified T/C extension cables shall be rated for 300 V minimum,
and insulated for continuous use at 105C. Conductors are to be solid, minimum wire size
16 AWG. Each pair of conductors to be equipped with a shield consisting of aluminum
mylar type and #22 AWG (minimum) drain wire. Shield grounding shall be in accordance
with Section 4.4.4. Conductors shall be color coded per ANSI MC96.1. These cables shall
comply with applicable requirements of NEC article 725.
5.5.3

Signal Extension Cables

Shielded pairs or triads in multi conductor cables shall be provided with complete isolation
between shields of any other shielded pair or triads in the same cable. Shields may be foil
with drain wire or web type shield. Care must be taken to properly insulate drain wires and
pigtails as specified in Reference 4.4.3. These cables shall be rated for continuous use at
90C.

6.0

TPM Wire Marking, Numbers and Identification System

6.1

Wire Numbers:
6.1.1

The wire number consists of 6 alpha numeric characters with a dash (-) separating the first
three characters from the last three. The separation allows easy location of the wire number
on the schematic and for service purposes.

6.1.2

The first character is a letter that is chosen to define the schematic group (system), followed
by two numbers representing the schematic sheet number. The next two numbers represent
the line number (LN) on the schematic sheet and the last number is the position of the wire
in the line.

6.1.3

Wire numbers will be consecutive from top left to lower right on the schematic diagram. All
conductors or cables of the same potential will carry the same wire number, resulting in all
conductors on the same device terminal having the same wire number. Conductors passing
thru a terminal block will have the same wire number on both sides (i.e., entering and
leaving the terminal block).

6.1.4

Type Wire Number

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that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
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U10-120
POSITION ON LINE
LINE ON SHEET
SHEET NO.
UNIT SCHEMATIC
(Earlier Designs are S for Station Control)

L2

L1
Line #
10

100

100

CR1
101

102
CR3

100

11
12

LS1

4/117
102 10 101 103
A
PLC

102

CR2
120

4/118
120 11
A

111 121

Actual Wire No. on Conductor

will have six characters
e.g. S10-120
Terminal Block

6.1.5

Schematic Group (System) Letter

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that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
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OF

12
16

DATE: 7/27/93

R. Darveau

DATE:

REVISED BY:

RELEASED

SHEET

REV

TPM132

REFERENCE:

WIRING - GENERAL REQUIREMENTS & PRACTICES

U - Unit Control (Earlier designs are S for Station Control)
G - Generator Three Line
M - Monitoring System
P - Power Distribution and Motor Controls
A - Combustible Gas System
F - Fire Protection System
R - Protective Relaying
V - Vibration Monitoring
X - Generator Excitation and Regulation
W - Switchgear Schematic
B - Main Breaker & Transformer
Z - Instrumentation and Control
E - Emissions Monitoring
6.2

Wire Labels
All wire labels shall be of the heat shrinkable type, sized for the conductor or cable. The label shall
be installed so that the wire number is visible for service purposes. Label markings shall be
permanent, not easily rubbed off during normal usage. The marking shall be typed, hot stamped or
neatly hand printed. The hand printing is preferred for repair or emergency usage and is not
acceptable on original supplied equipment from vendor.

SOLDER TYPE GROUNDING CONNECTION

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

ISSUED BY:

OF

13
16

DATE: 7/27/93

R. Darveau

DATE:

REVISED BY:

RELEASED

SHEET

REV

TPM132

REFERENCE:

WIRING - GENERAL REQUIREMENTS & PRACTICES

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

ISSUED BY:

OF

14
16

DATE: 7/27/93

R. Darveau

DATE:

REVISED BY:

RELEASED

SHEET

REV

TPM132

REFERENCE:

WIRING - GENERAL REQUIREMENTS & PRACTICES

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

ISSUED BY:

OF

15
16

DATE: 7/27/93

R. Darveau

DATE:

REVISED BY:

RELEASED

SHEET

REV

TPM132

REFERENCE:

WIRING - GENERAL REQUIREMENTS & PRACTICES

FIGURE 3
This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

ISSUED BY:

OF

16
16

DATE: 7/27/93

R. Darveau

DATE:

REVISED BY:

RELEASED

SHEET

REV

TPM132

REFERENCE:

WIRING - GENERAL REQUIREMENTS & PRACTICES

TYPICAL CABLE TRAY INSTALLATION

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

ISSUED BY:

SHEET

REV

TPM132

OF

R. Darveau

DATE: 7/27/93
DATE:

REVISED BY:

RELEASED

1A
1

REFERENCE:

WIRING - GENERAL REQUIREMENTS & PRACTICES

REV SHEETS
LET AFFECTED

SHEETS
ADDED

DESCRIPTION

REV BY

APPVD

& DATE

& DATE

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

ISSUED BY:

OF

1
7

DATE: 1/23/95

C. Spencer

DATE:

REVISED BY:

RELEASED

SHEET

REV

TPM139

REFERENCE:

WIRING, FIELD TERMINATION, STANDARD PRACTICE

1.0

SCOPE
1.1

2.0

This specification establishes the minimum requirements for the interconnecting cable
termination for TPM installed equipment. This specification is applicable to all field installed
low voltage (less than 600V) wiring. In such a case where project specific documents are in
conflict with this specification, the information depicted in the project specific documents shall
take precedence.

PREPARATION OF CABLES
2.1

GENERAL
2.1.1

Prior to making any terminations, all cables must be inspected for continuity, shield
isolation, and proper installation of trays. (See paragraph 4.2 and Figure 1).
2.1.1.1

All power cables must be megger checked line to line and line to ground
before termination. Use 500V megger for this check.

2.1.2

All cables shall be dressed as neatly as possible. Wire ties shall be used in the junction
boxes, cabinets and wire trays as required. Provide slack in cables for bend radius and
at terminations for at least two (2) future repairs. Tight bend radius and crossing of
cables must be avoided. Workmanship must be approved by the site manager.

2.1.3

Cable segregation shall be maintained between signal, control and power cables. No
signal cable shall occupy the same tray with power cables or control cables without a
metal grounded barrier isolating (shielding) them. See Figure 1.

2.1.4

When and if signal cables cross power or control cables they must cross at right
angles. If it is impractical to separate control and power cables, they may occupy the
same wireway but the control cables should be grouped away from the power cables.

2.1.5

Cable shields are terminated at one end only, usually at Control Enclosure end. The
shield is brought through terminal blocks and is isolated from ground.
NOTE: On some cables, an overall shield may be supplied that is not required in the
design. In this case, no direction is given in the terminal list regarding the
termination of the shield. This shield must be grounded at the Control Enclosure end
only. The shield is to be brought to power ground (copper ground bar) through an
unused terminal in the Motor Control Center (MCC) or Instrument Cabinets, using a
#14 AWG green conductor. The unused terminal selected must be approved by the site
manager and shall be clearly marked on the site drawing set. The other end of the
This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

ISSUED BY:

OF

2
7

DATE: 1/23/95

C. Spencer

DATE:

REVISED BY:

RELEASED

SHEET

REV

TPM139

REFERENCE:

WIRING, FIELD TERMINATION, STANDARD PRACTICE

shield is to be cut back and protected from contact with ground using a two (2) inch
long shrink sleeve (See Figures 2 and 3).
2.2

POWER AND CONTROL CABLES

2.2.1

2.3

The outer jacket shall be removed to a minimum length required for proper installation
purposes. In no case shall unjacketed cable be exposed in trenches or uncovered
wireways. Cable jacket may be removed to facilitate installation in conduit, covered
wireways, junction boxes or cabinets.

SIGNAL INSTRUMENTATION CABLES (See Figure 2 & 3 for typical illustration of

shielded cable)
2.3.1

Removal of the outer jacket shall comply with 2.2.1 above.

2.3.2

If an outer (overall) shield is provided on the cable, the outer shield shall be terminated
with a green ground conductor (not smaller than the largest conductor in the cable) and
brought to the closest equipment ground stud or grounding bar at the Control
Enclosure end only (See Figure 2). The other end shall remain under the outer jacket
or shall be protected under shrink tubing (See Figure 3). The overall shield shall be
terminated at one point only. Care must be taken to insure shield does not come in
contact with ground except through the green ground conductor.

2.3.3

The shielded conductors (TSP, Twisted Shielded Pair or TST, Twisted Shielded
Triplex) shall be terminated per the Cable Termination List applicable to the project.
The TSP/TST shield must not contact ground or any other shield, and is to remain
isolated except as noted on the termination list. The jacket may be removed from the
TSP/TST as necessary to facilitate termination. The shield must be brought as close as
practical to the terminating point (3" maximum). The drain wire is to be brought to the
applicable terminal as noted on the termination list. A sleeve shall be installed over the
exposed drain wire to prevent it from coming in contact with any other shield or
conductor.

2.3.4

The TSP/TST cables are supplied with a foil shield and outer mylar wrap. Care must
be taken when removing the overall jacket to insure that the foil and mylar wrap does
not come lose destroying the shielding capability. A two (2) inch long shrink sleeve or
equivalent method shall be used to insure the integrity of the foil shield with its outer
mylar wrap at the terminating point. Electrical tape can be used until the shrink tubing
is installed. Shrink tubing can be installed over the electrical tape if desired (See
Figure 2).
This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

ISSUED BY:

OF

3
7

DATE: 1/23/95

C. Spencer

DATE:

REVISED BY:

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REV

TPM139

REFERENCE:

WIRING, FIELD TERMINATION, STANDARD PRACTICE

2.4

THERMOCOUPLE CABLES
2.4.1

2.5

Thermocouple cables must be terminated properly. That is, conductor jacket must
match the color on both sides of the terminal block. Thermocouples are type K
cromel (+) yellow and alumel (-) red. The cromel must be connected to cromel and
alumel must be connected to alumel at the terminal blocks.

FIBER OPTIC CABLES

2.5.1

3.0

Fiber optic cables can be checked by exposing one end to a bright light source and
observing the light emitted at the other end. The light should not be diminished in any
way. Broken fibers will diminish the optical capability. Inspect mating connectors on
equipment to insure good quality connections and optical capability.

CABLE AND WIRE MARKING

3.1

All conductors are to be permanently identified with the Wire Number as specified on the
applicable termination list. A heat shrinkable sleeve containing wire number shall be used. The
wire number shall by typed, hot stamped or neatly hand printed on the sleeve. The sleeve is to
be attached to the conductor so that the number can be viewed without disturbing the
installation.

3.2

The wire number is made up of six (6) characters, (3) and (3) separated by a dash. The first (1)
character identifies the system schematic i.e. U Unit Control schematic (see Symbology
Drawing for complete list). The next two (2&3) characters identify the applicable sheet of the
schematic. The next two (4&5) characters identify the line number on the applicable sheet. The
last character (6) identifies the location on the line of the applicable schematic sheet.

3.3

A permanent cable ID shall be placed at both ends of all cables (See Figures 2&3). A heat
shrinkable sleeve shall be used. The cable ID is called out on the Cable List and the
Termination List (External Wiring List).
3.3.1

Cables are identified with an ID consisting of alpha numeric characters.

I=instrumentation, C=control, P=power. The cables to the MCC buckets also have an
M prefix identifier. Other characters in the cable ID identify to and from, the last
digit(s) identifies the cable number. (Example; AMAC1, A=Unit A, M=Main
Terminal Board, A=junction box A, C=control cable, 1=cable #1).

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

ISSUED BY:

OF

4
7

DATE: 1/23/95

C. Spencer

DATE:

REVISED BY:

RELEASED

SHEET

REV

TPM139

REFERENCE:

WIRING, FIELD TERMINATION, STANDARD PRACTICE

4.0

TESTING
4.1

After all wiring is completed for a system, a point to point wiring check shall be made to
confirm all wiring is complete and continuity is established between point to point. The system
schematic diagram shall be used to confirm this wiring. Recognizing that the termination list
is developed from the schematic diagram, the schematic diagram must be used as the governing
document.
4.1.1

A volt-ohmmeter or a low voltage buzzer/light can be used for this check. A

discontinuity check shall also be made regarding the surrounding conductors, that is,
check to be sure that continuity is not made between adjacent conductors and
associated shields.

4.2

After the installation is completed, the work shall be inspected for good workmanship by a
person skilled in this type of installation and a written report of the completion shall be given to
the site manager.

4.3

Motor power circuits are to be Megger checked before any motor is energized. Use a 500V
megger for this purpose. Be sure circuit breakers are open at the motor source. Check between
each conductor and ground. Record all readings and supply site manager with report prior to
activating any circuits.

4.4

NOTE: Care must be taken when using any test equipment on circuits that have been terminated
to avoid any possible damage to equipment.

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

ISSUED BY:

OF

5
7

DATE: 1/23/95

C. Spencer

DATE:

REVISED BY:

RELEASED

SHEET

REV

TPM139

REFERENCE:

WIRING, FIELD TERMINATION, STANDARD PRACTICE

FIGURE 1
SUGGESTED CABLE TRAY INSTALLATION

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

ISSUED BY:

OF

6
7

DATE: 1/23/95

C. Spencer

DATE:

REVISED BY:

RELEASED

SHEET

REV

TPM139

REFERENCE:

WIRING, FIELD TERMINATION, STANDARD PRACTICE

FIGURE 2
TYPICAL DRESSING OF SHIELDED CABLES
(TERMINATED SHIELDS)

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

ISSUED BY:

OF

7
7

DATE: 1/23/95

C. Spencer

DATE:

REVISED BY:

RELEASED

SHEET

REV

TPM139

REFERENCE:

WIRING, FIELD TERMINATION, STANDARD PRACTICE

FIGURE 3
TYPICAL DRESSING OF SHIELDED CABLES
(UN-TERMINATED SHIELDS)

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
to disclose or so use any information contained in said document. These restrictions do not limit the right to use information obtained from another source.

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TPM
SPECIFICATION

ISSUED BY:

C. Spencer

OF

1A
1

DATE: 1/23/95
DATE:

REVISED BY:

RELEASED

SHEET

REV

TPM139

REFERENCE:

WIRING, FIELD TERMINATION, STANDARD PRACTICE

REV SHEETS
LET AFFECTED

SHEETS
ADDED

DESCRIPTION

REV BY

APPVD

& DATE

& DATE

This document is the property of Turbo Power and Marine Systems, Inc. and is delivered on the express condition
that it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any
purpose without the express written consent of Turbo Power and Marine Systems, Inc.; and that no right is granted
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APPENDIX B - EQUIPMENT WEIGHTS AND DIMENSIONS

(For Reference Purposes Only)
Appendix B is divided into the following three sections:
Section 1- Power Pac Weights and Dimensions
Section 2- Twin Pac Weight and Dimensions
Section 3- Optional Equipment Weight and Dimensions.
NOTE
These are representative lists of equipment. The actual
equipment, as delivered, may be different in size, weight
and quantity due to contractual requirements, equipment
availability, changes in packaging and/or shipping
techniques, etc.

REV-2
15 January 2002
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APPENDIX: B-1

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REV-2
15 January 2002

APPENDIX: B-2

REV-2
15 January 2002

APPENDIX: B-3

REV-2
15 January 2002

APPENDIX: B-4

REV-2
15 January 2002

APPENDIX: B-5

REV-2
15 January 2002

APPENDIX: B-6

REV-2
15 January 2002

APPENDIX: B-7

REV-2
15 January 2002

APPENDIX: B-8

APPENDIX C - HILTI CONCRETE ANCHORS

REV-2
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Pratt & Whitney

A United Technologies Company

PWPS
SPECIFICATION

Pratt & Whitney Power Systems, Inc.

RELEASED

SHEET

REV A

CT118001

1
3

DATE:

12/17/04

REVISE BY : M. Etre

DATE:

1/13/05

REFERENCE :

REV:

ISSUED BY :

P. Maiorana

OF

STUD, CONCRETE, HILTI, HIT HY 150 INJECTION ADHESIVE ANCHOR

DESCRIPTION:

Threaded Anchor for Concrete

Extended Threads

MATERIAL:

ASTM A193 Grade B7

PWPS P/N

HILTI P/N

SIZE
DIA. x LENGTH

CT118001-03041Z

00068657

3/8" X 5 1/8"

CT118001-04052Z

00068658

1/2" X 6 1/2"

CT118001-04072H

Special Order - Hot Dipped

Galvanized & 9" Length

1/2" x 9"

CT118001-05061Z

00068659

5/8" X 7 5/8"

CT118001-05084H

Special Order - Hot Dipped

Galvanized &10 1/2" Length

5/8" x 10 1/2"

CT118001-06077Z

00068660

3/4" X 9 5/8"

CT118001-06104H

Special Order - Hot Dipped

Galvanized & 13" Length

3/4" x 13"

CT118001-07080H

00068661

7/8" X 10"

CT118001-07128H

00045259

7/8" X 16"

CT118001-08096H

Special Order
Hot Dipped Galvanized

1" x 12"

CT118001-08096Z

00068662

1" X 12"

CT118001-08144H

Special Order - Hot Dipped

Galvanized & 18" Length

1" x 18"

CT118001-10128Z

00068663

1 1/4" X 16"

CT118001-10168H

Special Order - Hot Dipped

Galvanized & 21" Length

1 1/4" x 21"

This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that
it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any purpose
without the express written consent of Pratt & Whitney Power Systems, Inc.; and that no right is granted to disclose
or so use any information contained in said document. These restrictions do not limit the right to use information
obtained from another source.

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PWPS

Pratt & Whitney

A United Technologies Company

SPECIFICATION

Pratt & Whitney Power Systems, Inc.

RELEASED

SHEET

REV A

CT118001

2
3

DATE:

12/17/04

REVISE BY : M. Etre

DATE:

1/13/05

REFERENCE :

REV:

ISSUED BY :

P. Maiorana

OF

STUD, CONCRETE, HILTI, HIT HY 150 INJECTION ADHESIVE ANCHOR

Notes:
1.
The first two digits of the PWPS dash number represent the anchor diameter in eights of an inch. The second
three digits represent the anchor length in eights of an inch.
H = Hot Dipped Galvanized
Z = Zinc plated.
2.

Material shall be ASTM A193-B7

3.

Nuts and washers shall be furnished to meet the requirements of the above material specification.

DISPENSERS:

PWPS P/N

DESCRIPTION

HILTI P/N

CT118001-10

HIT MD 2000 Manual Dispenser for HY150 or HY20 Refill Pack

(Refill Pack Holder Included)

00229154

CT118001-11

HIT P5000 HY (Pneumatic)

00256889

MIXERS AND FILLER TUBES:

PWPS P/N

DESCRIPTION

HILTI P/N

QUANTITY/PKG

CT118001-20

Mixer, HIT M

00089912

CT118001-21

Mixer, HIT M (case)

00068156

100

CT118001-22

Mixer, HIT HY

00256082

This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that
it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any purpose
without the express written consent of Pratt & Whitney Power Systems, Inc.; and that no right is granted to disclose
or so use any information contained in said document. These restrictions do not limit the right to use information
obtained from another source.

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PWPS

Pratt & Whitney

A United Technologies Company

SPECIFICATION

Pratt & Whitney Power Systems, Inc.

RELEASED

SHEET

REV A

CT118001

3
3

DATE:

12/17/04

REVISE BY : M. Etre

DATE:

1/13/05

REFERENCE :

REV:

ISSUED BY :

P. Maiorana

OF

STUD, CONCRETE, HILTI, HIT HY 150 INJECTION ADHESIVE ANCHOR

ADHESIVE CARTRIDGES*:

PWPS P/N

DESCRIPTION

HILTI P/N

CONTENTS

INCL IN PKG.

USABLE VOL.

CT118001-30

HY150/330/1

00246650

1 Mixer HIT M

16.5 In3
(270 ml)

CT118001-31

HY 150 Large
(32. oz)

00256480

1 Mixer HIT HY

61.0 In3
(1000 ml)

* MSDS sheets shall be supplied with all shipments.

Reference: Adhesive Volume Requirements
Example: Determine approximate fastenings for 5/8" rod embedded 10" deep.

Rod Diameter
(in.)

Drill Bit
Diameter
(in.)

Adhesive Volume Required per

inch of embedment (in3)

1/4

5/16

0.055

3/8

7/16

0.095

1/2

9/16

0.133

5/8

11/16

0.184

3/4

13/16

0.232

7/8

24mm

0.272

1 1/16

0.366

1 1/4

1 1/2

0.918

10 x 0.184 = 1.84 in3 of adhesive per anchor.

HIT HY 150 small cartridge:
16.5 divided by 1.84 = 9 fastenings

MANUFACTURER:
Hilti
This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that
it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any purpose
without the express written consent of Pratt & Whitney Power Systems, Inc.; and that no right is granted to disclose
or so use any information contained in said document. These restrictions do not limit the right to use information
obtained from another source.

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Pratt & Whitney

A United Technologies Company

PWPS
SPECIFICATION

Pratt & Whitney Power Systems, Inc.

RELEASED

ISSUED BY :
REVISE BY :

P. Maiorana
M. Etre

1A
1

SHEET

REV A

CT118001

OF

DATE:

12/17/04

DATE:

1/13/05

REV:

REFERENCE :

STUD, CONCRETE, HILTI, HIT HY 150 INJECTION ADHESIVE ANCHOR

REV SHEETS
LET AFFECTED

SHEETS
ADDED

DESCRIPTION

Added the following to main anchor chart:

CT118001-04072H, 05084H, 06104H, 08096H, 08144H,
& 10168H.
Added additional chart for Adhesive Volume Reqmts.

REV BY

APPVD

& DATE

& DATE

EC#11262
M. Etre
1/13/05

This document is the property of Pratt & Whitney Power Systems, Inc. and is delivered on the express condition that
it and the information contained in it are not to be used, disclosed, or reproduced in whole or in part, for any purpose
without the express written consent of Pratt & Whitney Power Systems, Inc.; and that no right is granted to disclose
or so use any information contained in said document. These restrictions do not limit the right to use information
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Anchoring Systems

4.2.2

HIT HY 150/HIT-ICE Injection Adhesive Anchor

4.2.2.4 Installation Instructions

HAS, Rebar and Insert Installation Instructions

1. Drill anchor hole with a carbide

bit. Contact Hilti for use of
Diamond Core bits.

2. Clean hole with wire brush.Proper

hole cleaning is essential.

3. Insert air nozzle to bottom of

hole and blow out hole using a
pump, or compressed air.

4. HY 150 only: Put refill pack into

holder. Remove cap covering
threaded projection.

7. Inject adhesive into hole starting at

the bottom until 1/2 to 2/3 full. Use
mixer filler tube extensions when
needed to reach the hole bottom.

8. Unlock dispenser.

2
1

5. Screw on static mixer.

6. Put holder/cartridge into appropriate

dispenser and DISCARD FIRST TWO
TRIGGER PULLS OF ADHESIVE
FROM EACH REFILL PACK/CARTRIDGE.

ROD

INSERT

REBAR

9. Insert rod, threaded insert or

rebar. Twist during installation.

10

10

10

10. Fastener may be adjusted during

specified gel time.

11

11

11
11. Do not disturb anchor between
specified gel time and cure time.

12

12

12
TTmax
inst

12. Apply specified torque as required to

secure items to be fastened. Do not
exceed maximum torque specified.

TTmax
inst

HIT-TZ and HIT-RTZ Installation Instructions

HIT HY 150/
HIT-ICE

HIT HY 150/
HIT-ICE

Drill hole using a

rotohammer or Hilti
diamond coring
machine.

96

Push the HIT-TZ in the hole to verify sufficient hole

depth (only threads visible). For floor applications
pushing the rod compacts the drill dust.

Inject adhesive starting

from the bottom of
the hole.

HIT HY 150/
HIT-ICE

HIT HY 150/
HIT-ICE

Fill the hole 1/2-2/3rds full. If the hole is full of

water, it is suggested to start injecting from the
bottom of the hole and fill entirely with adhesive.

Do not adjust the HIT-TZ

rod between the gel and
cure times. Apply a load
only after the appropriate
cure time has elapsed.

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HIT HY 150/HIT-ICE Adhesive Anchor

4.2.4
Adhesive Anchoring Systems
HIT-ICE Dispenser

HIT-ICE Mixer

HIT-ICE Cartridge

4.2.4

HIT HY 150/HIT-ICE

4.2.4.1 Product Description

4.2.4.2 Material Specifications
Mixing Nozzle

HY 150 Refill Pack

HIT Refill Pack Holder

4.2.4.3 Technical Data

or

4.2.4.4

Installation Instructions

4.2.4.5

Ordering Information

Listings/Approvals
4.2.4.1 Product Description
Hilti HIT HY 150 is a hybrid adhesive consisting of a
methacrylate resin, hardener, cement and water. It is
formulated for fast curing and installation in a wide range
of solid base material temperatures from 104F (40C)
down to 23F (5C). For colder environmental
installations, HIT-ICE adhesive is a winter formulation of
HIT HY 150 for base material temperatures down to
10F (23C). HIT-ICE consists of a methacrylate resin
and hardener.
The systems consist of adhesive refill packs, a mixing
nozzle, a HIT dispenser and either a threaded rod, rebar,
HIS internally threaded insert or eyebolts. HY 150/HIT-ICE
is specifically designed for fastening into solid base
materials such as concrete, grout, stone or grout filled
block.
The Hilti HIT-TZ is an innovative threaded rod installed
with HIT HY 150/HIT-ICE hybrid adhesive. Please refer to
section 4.2.3 for details on HIT-TZ. With the combination
of HIT HY 150/HIT-ICE and the innovative design of the
HIT-TZ rod, anchoring into uncleaned holes, wet holes
(including standing water) and/or Hilti matched tolerance
diamond-cored holes does not adversely affect tensile
capacity. Use HIT-ICE in base material temperatures
40 F (5 C).
Product Features of HIT HY 150/HIT-ICE
Seismic qualified per ICC-ES AC58
Small edge distance and anchor spacing allowance
Mixing tube provides proper mixing and accurate
dispensing of mixed resin
Contains no styrene; virtually odorless
Cures quickly over a large range of base
material temperatures
Excellent weathering resistance; high temperature
resistance
High load capacities

Guide Specifications
Master Format Section:03250 (Concrete accessories)
Related Sections:
03200 (Concrete Reinforcing
Reinforcing Accessories)
05050 (Metal Fabrication)
05120 (Structural Steel;
Masonry Accessories)
Injectable adhesive shall be used for installation of all
reinforcing steel dowels or threaded anchor rods and
inserts into new or existing concrete. Adhesive shall be
furnished in containers which keep component A and
component B separate. Containers shall be designed to
accept static mixing nozzle which thoroughly blends
component A and component B and allows injection
directly into drilled hole. Only injection tools and static
mixing nozzles as recommended by manufacturer shall
be used. Manufacturers instructions shall be followed.
Injection adhesive shall be formulated to include resin
and hardener to provide optimal curing speed as well as
high strength and stiffness. Typical curing time at 68F
shall be 50 minutes for HIT HY 150 and 1 hour for
HIT-ICE. Injection adhesive shall be HIT HY 150 or
HIT-ICE, as furnished by Hilti.
Anchor Rods: Shall be furnished with chamfered ends
so that either end will accept a nut and washer.
Alternatively, anchor rods shall be furnished with a 45
degree chisel point on one end to allow for easy insertion
into the adhesive-filled hole. Anchor rods shall be
manufactured to meet the following requirements: 1. ISO
898 Class 5.8 2. ASTM A 193, Grade B7 (high strength
carbon steel anchor); 3. AISI 304 or AISI 316 stainless
steel, meeting the requirements of ASTM F 593
(condition CW).

ICC-ES (International Code Council)

ER-5193 (HIT HY 150 only)
COLA (City of Los Angeles)
Research Report #25257
(HIT HY 150 only)
NSF/ANSI Standard 61
certification for use of HIT HY 150 in
potable water
Metro-Dade County
approval 01-1119.03 (HIT HY 150
only)

Fastener Components
HAS Threaded Rod

HIT-TZ and HIT-RTZ Rods

(Refer to section 4.2.3)

HIS Internally Threaded Inserts

Rebar (supplied by contractor)

Special order length HAS Rods may vary from standard

product.
Nuts and Washers shall be furnished to meet the
requirements of the above anchor rod specifications.

HIT-ICE has equivalent load performance

to HIT HY 150

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95

4.2.4

HIT HY 150/HIT-ICE Adhesive Anchor

Adhesive Anchoring Systems

4.2.4.2 Material Specifications

Material Properties for Cured Adhesive

HY 150

HIT-ICE

Compressive Strength ASTM C 579 (HY 150) DIN 53454 (HIT-ICE)

71.8 MPa

10,420 psi

72 MPa

10,440 psi

Tensile Strength ASTM C 307 (HY 150) DIN/EN 527-1 (HIT-ICE)

15.9 MPa

2310 psi

12 MPa

1740 psi

Flexural Strength ASTM C 580

29.3 MPa

4250 psi

Modulus of Elasticity ASTM C 307

7032 MPa

1.02 x 106 psi

0.12%

0.12%

2.4%

2.4%

2x1011 OHM/cm

5.1x1011 OHM/in.

2x1011OHM/in.

5.1x1011OHM/in.

Water Absorption ASTM D 570 (HY 150) DIN 53495 (HIT-ICE)

Electrical Resistance DIN/VDE 0303T3 (HY 150) DIN/VDE 0303T3 (HIT-ICE)

Standard HAS-E rod material meets the requirements of ISO 898 Class 5.8

Mechanical Properties
fy
min. fu
ksi (MPa)
ksi (MPa)
58 (400)
72.5 (500)

High Strength or Super HAS rod material meets the requirements of ASTM A 193, Grade B7

105 (724)

125 (862)

Stainless HAS rod material meets the requirements of ASTM F 593 (AISI 304/316) Condition CW 3/8" to 5/8"

65 (448)

100 (689)

Stainless HAS rod material meets the requirements of ASTM F 593 (AISI 304/316) Condition CW 3/4" to 1-1/4"

45 (310)

85 (586)

Material

HIS Insert 9SMNPB28K Carbon Steel conforming to DIN 1651

54.4 (375)

66.7 (460)

HIS-R Insert X5CrNiMo17122 K700 Stainless Steel conforming to DIN 17440

50.8 (350)

101.5 (700)

HAS Super & HAS-E Standard Nut material meets the requirements of ASTM A 563, Grade DH
HAS Stainless Steel Nut material meets the requirements of ASTM F 594
HAS Standard and Stainless Steel Washers meet dimensional requirements of ANSI B18.22.1 Type A Plain
HAS Stainless Steel Washers meet the requirements of AISI 304 or AISI 316 conforming to ASTM A 240
HAS Super & HAS-E Standard Washers meet the requirements of ASTM F 436
All HAS Super Rods (except 7/8") & HAS-E Standard, HIS inserts, nuts & washers are zinc plated to ASTM B 633 SC 1
7/8" HAS Super rods hot-dip galvanized in accordance with ASTM A 153
Note: Special Order threaded rods may vary from standard materials.

4.2.4.3 Technical Data

HY 150/HIT-ICE Installation Specification Table for HAS Rods
HAS Rod Size in.
(mm)

3/8
(9.5)

1/2
(12.7)

5/8
(15.9)

3/4
(19.1)

7/8
(22.2)

1
(25.4)

1-1/4
(31.8)

in.

7/16

9/16

11/16

13/16

15/16

1-1/16

1-1/2

in.
(mm)

3-1/2
(90)

4-1/4
(110)

5
(125)

6-5/8
(170)

7-1/2
(190)

8-1/4
(210)

12
(305)

hef hnom

ft lb
(Nm)

18
(24)

30
(41)

75
(102)

150
(203)

175
(237)

235
(319)

400
(540)

Threaded hef < hnom

Rods

ft lb
(Nm)

15
(20)

20
(27)

50
(68)

105
(142)

125
(169)

165
(224)

280
(375)

hef = hnom

minimum
base material
thickness4

in.
(mm)

5-1/2
(140)

6-1/4
(160)

7
(180)

8-1/2
(220)

9-1/2
(240)

10-1/2
(270)

15
(380)

hef hnom

in.
(mm)

Details
dbit

bit diameter1, 2

hef = hnom
std. depth of embed.3
Tmax
max.
tighening
torque

All
Hilti

1.0 hef+ 1.0 hef+ 1.0 hef+ 1.0 hef+ 1.0 hef+ 1.0 hef+ 1.0 hef+
2
2
2
2
2
2-1/4
3
(51)
(51)
(51)
(51)
(51)
(57)
(76)

Approximate number of fastenings at standard embedment

HY 150/HIT-ICE Small Refill Pack
HY 150 Jumbo Cartridge

50/45

31/28

18/16

10/9

8/7

6/5

2/2

236

145

85

45

38

29

dbit

Tmax
t

hef

h

1 Use matched tolerance carbide tipped

bits.
2 For Hilti matched tolerance carbide
tipped drill bits, see section 8.4.1
3 Data available for varying embedments;
see Load Tables.
4 Minimum base material thickness given
to avoid backside blowout during drilling
process. Ability of base material to
withstand loads applied (e.g. bending of
concrete slab) should be determined by
design engineer.

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HIT HY 150/HIT-ICE Adhesive Anchor

4.2.4
Adhesive Anchoring Systems

4.2.4.3 Technical Data

HY 150/HIT-ICE Installation Specification Table for HIS Inserts
HIS Insert
Details

in.
(mm)

3/8
(9.5)

1/2
(12.7)

5/8
(15.9)

3/4
(19.1)

in.

11/16

7/8

1-1/8

1-1/4

dbit

bit diameter1

hnom

std. depth
of embed.

in.
(mm)

4-1/4
(110)

5
(125)

6-5/8
(170)

8-1/4
(210)

th

useable thread
length

in.
(mm)

1
(25)

1-3/16
(30)

1-1/2
(40)

2
(50)

Tmax

Max. tightening
torque

ft lb
(Nm)

18
(24)

35
(47)

80
(108)

160
(217)

min. base material

thickness

in.
(mm)

6-3/8
(162)

7-1/2
(191)

10
(254)

12-3/8
(314)

Recommended Hilti
Rotary Hammer Drill

TE 5, 15, TE 18-M,
18-M, 25 25, 55, 76

dbit

Tmax
hhef

nom

TE-55, 76

1 For Hilti matched tolerance carbide tipped drill bits, see section 8.4.1.

HY 150/HIT-ICE Installation Specification Table for Rebar in Concrete

Rebar Size:

No. 3

No. 4

No. 5

No. 6

No. 7

No. 8

No. 9

No. 10

No. 11

1/2

5/8

3/4

7/8

1-1/8

1-3/8

1-1/2

1-9/16

Details
bit diameter1, 2

dbit:

in.

1 Rebar diameters may vary. Use smallest drill bit which will accommodate rebar.
2 Use Hilti matched tolerance carbide tipped drill bits, see section 8.4.1.

HY 150/HIT-ICE Installation Specification Table for

Metric Rebar in Concrete (Canada Only)
Rebar Number :
dbit : bit diameter1, 2

10M

15M

20M

25M

30M

35M

14 mm

3/4"

24mm

1-1/8"

37mm

1-9/16"

1 Rebar diameters may vary. Use smallest drill bit which will accommodate rebar.
2 For Hilti matched tolerance carbide tipped drill bits, see section 8.4.1.

Combined Shear and Tension Loading

5/3

( NN )
d

rec

5/3

( VV )
d

1.0 (Ref. Section 4.1.2.7)

rec

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97

4.2.4

HIT HY 150/HIT-ICE Adhesive Anchor

Adhesive Anchoring Systems

HIT HY 150/HIT-ICE Allowable and Ultimate Bond/Concrete Capacity for HAS Rods in Normal Weight Concrete1,2,3
HIT HY-150/HIT-ICE Allowable Bond/Concrete Capacity
Tensile
Shear
Anchor Embedment
Diameter
Depth
in (mm)

3/8
(9.5)

1/2
(12.7)

5/8
(15.9)

3/4
(19.1)

7/8
(22.2)

1
(25.4)

1-1/4
(31.8)

HIT HY-150/HIT-ICE Ultimate Bond/Concrete Capacity

Tensile
Shear

in (mm)

fc = 2000 psi
(13.8 MPa)
lb (kN)

fc = 4000 psi
(27.6 MPa)
lb (kN)

fc = 2000 psi
(13.8 MPa)
lb (kN)

fc = 4000 psi
(27.6 MPa)
lb (kN)

fc = 2000 psi
(13.8 MPa)
lb (kN)

fc = 4000 psi
(27.6 MPa)
lb (kN)

fc = 2000 psi
(13.8 MPa)
lb (kN)

fc = 4000 psi
(27.6 MPa)
lb (kN)

1-3/4
(44)
3-1/2
(89)
5-1/4
(133)
2-1/8
(54)
4-1/4
(108)
6-3/8
(162)
2-1/2
(64)
5
(127)
7-1/2
(191)
3-3/8
(86)
6-5/8
(168)
10
(254)
3-3/4
(95)
7-1/2
(191)
11-1/4
(286)
4-1/8
(105)
8-1/4
(210)
12-3/8
(314)
6
(152)
12
(305)
15
(381)

720
(3.2)
1895
(8.4)
2635
(11.7)
1220
(5.4)
2725
(12.1)
4300
(19.1)
1620
(7.2)
4395
(19.6)
6025
(26.8)
2365
(10.5)
4655
(20.7)
9515
(42.3)
3080
(13.7)
7845
(34.9)
13330
(59.3)
3445
(15.3)
8330
(37.1)
15540
(69.1)
4645
(20.7)
15490
(68.9)
19210
(85.5)

1265
(5.6)
2705
(12.0)
2800
(12.5)
1575
(7.0)
3935
(17.5)
5295
(23.6)
1985
(8.8)
5250
(23.4)
8225
(36.6)
3925
(17.5)
8885
(39.5)
12140
(54.0)
4800
(21.4)
11020
(49.0)
16645
(74.0)
4865
(21.6)
11635
(51.8)
19525
(86.85)
7000
(31.1)
20770
(92.4)
26815
(119.3)

1390
(6.2)
3435
(15.3)
6485
(30.4)
1980
(8.8)
5210
(23.2)
10380
(46.2)
2460
(10.9)
7345
(32.7)
14630
(65.1)
5430
(24.2)
12515
(55.7)
25200
(112.1)
6700
(29.8)
16185
(72.0)
32245
(143.4)
8260
(36.7)
19810
(88.1)
39465
(175.5)
14760
(65.7)
40045
(178.1)
58520
(260.3)

1965
(8.7)
4860
(21.6)
9680
(43.1)
2800
(12.5)
7370
(32.8)
14680
(65.3)
3480
(15.5)
10385
(46.2)
20690
(92.0)
7680
(34.2)
17700
(78.7)
35640
(158.5)
9475
(42.1)
22890
(101.8)
45600
(202.8)
11680
(52.0)
28015
(124.6)
55810
(248.3)
20870
(92.8)
56635
(251.9)
82760
(368.1)

2710
(12.1)
7120
(31.7)
9880
(44.0)
4580
(20.4)
10220
(44.5)
16140
(71.8)
6090
(27.1)
16480
(73.3)
22595
(100.5)
8870
(39.5)
17460
(77.7)
35695
(158.8)
11555
(51.4)
29430
(130.9)
49990
(222.4)
12920
(57.5)
31250
(139.0)
58280
(259.3)
17430
(77.5)
58085
(258.4)
72040
(320.5)

4750
(21.1)
10160
(45.2)
10510
(46.8)
5910
(26.3)
14760
(65.7)
19860
(88.3)
7460
(33.2)
19690
(87.6)
30850
(137.2)
14720
(65.5)
33330
(148.3)
45530
(202.5)
18000
(80.1)
41000
(182.3)
62425
(277.7)
18250
(81.2)
43640
(194.1)
73220
(325.7)
26265
(116.8)
77900
(346.5)
100560
(447.3)

4175
(18.6)
10305
(45.8)
20535
(91.3)
5940
(26.4)
15630
(69.5)
31140
(138.5)
7380
(32.8)
22030
(98.0)
43890
(195.2)
16295
(72.5)
37545
(167.0)
75600
(336.3)
20105
(89.4)
48550
(216.0)
96730
(430.3)
24790
(110.3)
59425
(264.3)
118395
(526.6)
44280
(197.0)
120140
(534.4)
175560
(780.9)

5900
(26.2)
14575
(64.8)
29040
(129.2)
8400
(37.4)
22105
(98.3)
44040
(195.9)
10440
(46.4)
31155
(138.6)
62070
(276.1)
23040
(102.5)
53095
(236.2)
106915
(475.6)
28430
(126.5)
68665
(305.4)
136800
(608.5)
35050
(155.9)
84040
(373.8)
167435
(744.8)
62610
(278.5)
169900
(755.8)
248285
(1104.4)

1 Influence factors for spacing and/or edge distance are

applied to concrete/bond values above, and then
compared to the steel value. The lesser of the values
is to be used for the design.

2 For hef hnom average ultimate concrete shear capacity based on Concrete Capacity Design (CCD) method.
For hef < hnom average ultimate concrete shear values
based on testing.

3 All values based on holes drilled with carbide bit (see

section 8.4.1) and cleaned with wire brush.

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HIT HY 150/HIT-ICE Adhesive Anchor

4.2.4
Adhesive Anchoring Systems

Allowable Steel Strength for HAS Rods1

HAS-E Standard
ISO 898 Class 5.8

HAS Super
ASTM A 193 B7

HAS SS
AISI 304/316 SS

Rod
Diameter
in. (mm)

Tensile
lb (kN)

Shear
lb (kN)

Tensile
lb (kN)

Shear
lb (kN)

Tensile
lb (kN)

Shear
lb (kN)

3/8
(9.5)

2640
(11.7)

1360
(6.0)

4555
(20.3)

2345
(10.4)

3645
(16.2)

1875
(8.3)

1/2
(12.7)

4700
(20.9)

2420
(10.8)

8100
(36.0)

4170
(18.5)

6480
(28.8)

3335
(14.8)

5/8
(15.9)

7340
(32.7)

3780
(16.8)

12655
(56.3)

6520
(29.0)

10125
(45.0)

5215
(23.2)

3/4
(19.1)

10570
(47.0)

5445
(24.2)

18225
(81.1)

9390
(41.8)

12390
(55.1)

6385
(28.4)

7/8
(22.2)

14385
(64.0)

7410
(33.0)

24805
(110.3)

12780
(56.9)

16865
(75.0)

8690
(38.6)

1
(25.4)

18790
(83.6)

9680
(43.0)

32400
(144.1)

16690
(74.2)

22030
(98.0)

11350
(50.5)

1-1/4
(31.8)

29360
(130.6)

15125
(67.3)

50620
(225.2)

26080
(116.0)

34425
(153.1)

17735
(78.9)

1 Steel strength as defined in AISC Manual of Steel Construction (ASD):

Tensile = 0.33 x Fu x Nominal Area
Shear = 0.17 x Fu x Nominal Area

Ultimate Steel Strength for HAS Rods1

HAS-E Standard
ISO 898 Class 5.8
Yield
Tensile
Shear
lb (kN)
lb (kN)
lb (kN)

HAS Super
ASTM A 193 B7
Yield
Tensile
lb (kN)
lb (kN)

Shear
lb (kN)

HAS SS
AISI 304/316 SS
Yield
Tensile
Shear
lb (kN)
lb (kN)
lb (kN)

3/8
(9.5)

4495
(20.0)

6005
(26.7)

3605
(16.0)

8135
(36.2)

10350
(43.4)

6210
(27.6)

5035
(22.4)

8280
(36.8)

4970
(22.1)

1/2
(12.7)

8230
(36.6)

10675
(47.5)

6405
(28.5)

14900
(66.3)

18405
(79.0)

11040
(49.1)

9225
(41.0)

14720
(65.5)

8835
(39.3)

5/8
(15.9)

13110
(58.3)

16680
(74.2)

10010
(44.2)

23730
(105.6)

28760
(125.7)

17260
(76.8)

14690
(65.3)

23010
(102.4)

13805
(61.4)

3/4
(19.1)

19400
(86.3)

24020
(106.9)

14415
(64.1)

35120
(156.2)

41420
(185.7)

24850
(110.5)

15050
(66.9)

28165
(125.3)

16800
(75.2)

7/8
(22.2)

26780
(119.1)

32695
(145.4)

19620
(87.3)

48480
(215.7)

56370
(256.9)

33825
(150.5)

20775
(92.4)

38335
(170.5)

23000
(102.3)

1
(25.4)

35130
(156.3)

42705
(190.0)

25625
(114.0)

63600
(282.9)

73630
(337.0)

44180
(196.5)

27255
(121.2)

50070
(222.7)

30040
(133.6)

1-1/4
(31.8)

56210
(250.0)

66730
(296.8)

40035
(178.1)

101755
(452.6)

115050
(511.8)

69030
(307.1)

43610
(194.0)

78235
(348.0)

46940
(208.8)

Rod
Diameter
in. (mm)

1 Steel strength as defined in AISC Manual of Steel Construction (LRFD):

Yield = Fy x Tensile Stress Area
Tensile = 0.75 x Fu x Nominal Area
Shear = 0.45 x Fu x Nominal Area

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4.2.4

HIT HY 150/HIT-ICE Adhesive Anchor

Adhesive Anchoring Systems

HIT HY 150/HIT-ICE Allowable Bond/Concrete Capacity and Steel Strength

for HIS Carbon Steel and HIS-R Stainless Steel Internally Threaded Inserts

Anchor
Diameter
in. (mm)

Embedment
Depth
in. (mm)

3/8
(9.5)
1/2
(12.7)
5/8
(15.9)
3/4
(19.1)

4-1/4
(108)
5
(127)
6-5/8
(168)
8-1/4
(210)

HIT HY 150/HIT-ICE Allowable

Bond/Concrete Capacity
Tensile
Shear
fc 2000 psi
fc 2000 psi
(13.8 MPa)
(13.8 MPa)
lb (kN)
lb (kN)

2750
(12.2)
4195
(18.7)
6700
(29.8)
7855
(34.9)

1605
(7.1)
3040
(13.5)
4575
(20.4)
6305
(28.0)

Allowable Bolt Strength1,2

ASTM A 325
Carbon Steel
Tensile1
Shear1
lb (kN)
lb (kN)

ASTM F 593
Stainless Steel
Tensile1
Shear1
lb (kN)
lb (kN)

4370
(19.4)
7775
(34.6)
12150
(54.0)
17495
(77.8)

3645
(16.2)
6480
(28.8)
10125
(45.0)
12395
(55.1)

2250
(10.0)
4005
(17.8)
6260
(27.8)
9010
(40.1)

1875
(8.3)
3335
(14.8)
5215
(23.2)
6385
(28.4)

HIT HY 150/HIT-ICE Ultimate Bond/Concrete Capacity and Steel Strength

for HIS Carbon Steel and HIS-R Stainless Steel Internally Threaded Inserts

Anchor
Diameter
in. (mm)

Embedment
Depth
in. (mm)

3/8
(9.5)
1/2
(12.7)
5/8
(15.9)
3/4
(19.1)

4-1/4
(108)
5
(127)
6-5/8
(168)
8-1/4
(210)

HIT HY 150/HIT-ICE Ultimate

Bond/Concrete Capacity2
Tensile
Shear
fc 2000 psi
fc 2000 psi
(13.8 MPa)
(13.8 MPa)
lb (kN)
lb (kN)

11000
(48.9)
16790
(74.7)
26795
(119.2)
31430
(139.8)

6425
(28.6)
12170
(54.1)
18310
(81.5)
25215
(112.2)

Ultimate Bolt Strength1,2

ASTM A 325
Carbon Steel
Tensile1
Shear1
lb (kN)
lb (kN)

ASTM F 593
Stainless Steel
Tensile1
Shear1
lb (kN)
lb (kN)

9935
(44.2)
17665
(78.6)
27610
(122.8)
39760
(176.9)

8280
(36.8)
14720
(65.5)
23010
(102.4)
28165
(125.3)

5960
(26.5)
10600
(47.2)
16565
(73.7)
23855
(106.1)

4970
(22.1)
8835
(39.3)
13805
(61.4)
16900
(75.1)

1 Steel values in accordance with AISC

ASTM A 325 bolts: Fy = 92 ksi , Fu = 120 ksi
ASTM F 593 (AISI 304/316): Fy = 65 ksi, Fu = 100 ksi for 3/8" thru 5/8"
Fy = 45 ksi, Fu = 85 ksi for 3/4"
Allowable Load Values
Tension = 0.33 x Fu x Anom
Shear = 0.17 x Fu x Anom

Ultimate Load Values

Tension = 0.75 x Fu x Anom
Shear = 0.45 x Fu x Anom

2 Use lower value of either bond/concrete capacity or steel strength.

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HIT HY 150/HIT-ICE Adhesive Anchor

4.2.4
Adhesive Anchoring Systems

HIT HY 150/HIT-ICE Allowable and Ultimate Bond/Concrete Capacity for HAS Rods
Installed in Lightweight Concrete 3000 psi (207 MPa)
Anchor
Diameter
in. (mm)
3/8
(9.5)

1/2
(12.7)
5/8
(15.9)
3/4
(19.1)

Embedment
Depth
in. (mm)
1-3/4
(44)
3-1/2
(89)
2-1/8
(54)
4-1/4
(108)
2-1/2
(63)
3-3/8
(86)

Allowable Bond/Concrete Capacity1

lb (kN)
Tensile
Shear
745
1285
(3.3)
(5.7)
1220
1580
(5.4)
(7.0)
975
2130
(4.3)
(9.5)
1210
2910
(5.4)
(12.9)
1200
2480
(5.3)
(11.0)
1760
4000
(7.8)
(17.8)

1 Influence factors for spacing and/or edge distance are applied to allowable
concrete/bond values above, and then compared to the allowable steel value (See
page 99). The lesser of these values is to be used for design.

Ultimate Bond/Concrete Capacity

lb (kN)
Tensile
Shear
2980
5150
(13.3)
(22.9)
4920
6320
(21.9)
(28.1)
3900
8520
(17.3)
(37.9)
4840
11640
(21.5)
(51.8)
4800
9920
(21.4)
(44.1)
7040
15985
(31.3)
(71.1)

2 All values based on holes drilled with matched tolerance carbide tipped bit (see section 8.4.1) and cleaned with a wire brush.

HIT HY 150/HIT-ICE Allowable Bond/Concrete Capacity for Sill Plate Applications

Allowable Loads for Attachment of Sill Plates to f'c = 2000 PSI Normal Weight Concrete
with HIT HY 150/HIT-ICE1
Anchor
Diameter
in. (mm)

Embedment
Depth
in. (mm)

1/2 (12.7)

4-1/4 (108.0)

5/8 (15.9)

5 (127.0)

Edge
Distance
in. (mm)
1-3/4 (44.5)
2-3/4 (69.9)
1-3/4 (44.5)
2-3/4 (69.9)

Shear lb (kN)
Tension
lb (kN)
1280 (5.3)
1800 (8.1)
1700 (7.6)
2725 (12.1)

Load II to Edge
1445 (6.4)
2100 (9.5)
1445 (6.4)
2455 (10.9)

Load
to Edge
400 (1.8)
845 (3.8)
400 (1.8)
960 (4.3)

Allowable Loads for Attachment of Sill Plates to top of grout filled block wall with HIT HY 150/HIT-ICE1
Anchor
Diameter
in. (mm)

Embedment
Depth
in. (mm)

1/2 (12.7)

4-1/4 (108.0)

5/8 (15.9)

5 (127.0)

Edge
Distance
in. (mm)
1-3/4 (44.5)
2-3/4 (69.9)
1-3/4 (44.5)
2-3/4 (69.9)

Shear lb (kN)
Tension
lb (kN)
1395 (6.2)
1795 (8.0)
1840 (8.2)
1965 (8.7)

Load II to Edge
1425 (6.3)
2085 (9.3)
1800 (8.0)
3070 (13.7)

Load
to Edge
560 (2.5)
1110 (4.9)
680 (3.0)
1110 (4.9)

1 Loads are based on concrete or masonry failure. Steel strength must be checked separately. Values based on safety factor of 4.0

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4.2.4

HIT HY 150/HIT-ICE Adhesive Anchor

Adhesive Anchoring Systems

HIT HY 150/HIT-ICE Allowable Loads for Threaded Rods in Grout-Filled Concrete Masonry Units
(ASTM C 90 Block)1, 2, 3, 4
Anchor Diameter
in.
(mm)

Embedment Depth
in. (mm)

3/8

( 9.5 )

3-1/2 ( 88.9 )

1/2

(12.7)

4-1/4 ( 108 )

5/8

(15.9)

3/4

(19.1)

( 127 )

6-5/8 (168.3)

4
_>12
4
_>12
4
_>12
4
_>12

Shear lb (kN)5

Tension5
lb
(kN)

Distance from Edge

in.
(mm)
(101.6)
(304.8)
(101.6)
(304.8)
(101.6)
(304.8)
(101.6)
(304.8)

HAS-E

HAS Super

HAS SS

1550

( 6.9 )

1360

( 6.0)

2345

(10.4)

1875

( 8.3)

1785

( 7.9 )

2020
2420

( 9.0)
(10.8)

2020
4170

( 9.0)
(18.5)

2020
3335

( 9.0)
(14.8)

2265

(10.1)

3740

(16.6)

2220
3780
2020
5445

( 9.0)
(16.8)
( 9.0)
(24.2)

2020
5625
2020
5625

( 9.0)
(25.0)
( 9.0)
(25.0)

2020
5215
2020
5625

( 9.0)
(23.2)
( 9.0)
(25.0)

HIT HY 150/HIT-ICE Ultimate Loads for Threaded Rods in Grout-Filled Concrete Masonry Units
(ASTM C 90 Block)1, 2, 3, 4
Anchor Diameter
in.
(mm)

Embedment Depth
in. (mm)

Tension lb (kN)5

Distance from Edge

in.
(mm)

HAS-E

HAS Super

HAS SS (304SS)

Shear lb (kN)5
HAS-E

HAS Super

HAS SS

3/8

(9.5)

3-1/2

(88.9)

4
_>12

(101.6)
(304.8)

6005 (26.7) 6200 (27.6) 6200 (27.6) 3605 (16.0) 6210

(27.6) 4970

(22.1)
(35.9)

4-1/4

(108)

(101.6)
(304.8)

(35.9) 8075

(12.7)

4
_>12

8075

1/2

7140 (31.8) 7140 (31.8) 7140 (31.8) 6405 (28.5)

5/8

(15.9)

3/4

(19.1)

(127)

6-5/8 (168.3)

4
_>12

(101.6)
(304.8)

9060 (40.3) 9060 (40.3) 9060 (40.3)

4
_>12

(101.6)
(304.8)

14970 (66.6) 14970 (66.6) 14970 (66.6)

conforming to ASTM C 90 with 2000 psi grout conforming to ASTM C 476.

2 Embedment depth is measured from the outside face of the concrete masonry unit.

(35.9) 8075

(39.3)
(35.9)

10010 (44.2) 17260 (76.8) 13805 (61.4)

8075 (44.2) 8075

1 Values are for lightweight, medium weight or normal weight concrete masonry units

3 Values are for anchors located in the grouted cell, head joint, bed joint, T joint,
cross web or any combination of the above.

11040 (49.1) 8835

8075 (35.9) 8075

(35.9) 8075

(35.9)

14415 (64.1) 22500 (100.1) 16800 (75.2)

4 Values for edge distances between 4 inches and 12 inches can be calculated by
linear interpolation.
5 Loads are based on the lesser of bond strength, steel strength or base material
strength.

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HIT HY 150/HIT-ICE Adhesive Anchor

4.2.4
Adhesive Anchoring Systems

Anchor Spacing and Edge Distance Guidelines for Grout-Filled Block

Influence of Anchor Spacing and Edge Distance
Anchor
Size

in.
(mm)

3/8
(9.5)

1/2
(12.7)

5/8
(15.8)

3/4
(19.1)

hnom

in.
(mm)

31/2
(90)

41/4
(110)

5
(125)

65/8
(170)

hnom = standard embedment depth

s
V
c

Edge Distance for Shear and Tension:

Grout Filled, Normal Weight and Lightweight Block
ccr

= 12 in. (305 mm) minimum from free edge

cmin = 4 in. (102 mm) minimum from free edge

Anchor Spacing for Shear and Tension:
Grout Filled, Normal Weight and Lightweight Block
scr

= smin = One (1) anchor per cell, or 8 in. (203mm) minimum

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4.2.4

HIT HY 150/HIT-ICE Adhesive Anchor

Adhesive Anchoring Systems

HIT HY 150/HIT-ICE Ultimate Bond Strength and Steel Strength for Rebar in Concrete
Concrete Compressive Strength
fc = 2000 psi (13.8 MPa)

Nominal
Rebar
Size

Embed.
Depth
in. (mm)

#3

1-1/2
(38)
3-1/2
(89)
7
(178)

2500
(11.1)
6300
(28.0)
12600
(56.0)

#4

2
(51)
4
(102)
8
(203)

4200
(18.7)
9000
(40.0)
18000
(80.1)

#5

2-1/2
(64)
5
(127)
10
(254)

5600
(24.9)
13500
(60.1)
27000
(120.1)

#6

3-1/2
(90)
7
(178)
14
(356)

10200
(45.4)
22100
(98.3)
44200
(196.6)

#7

3-3/4
(95)
7-1/2
(190)
15
(380)

10700
(47.6)
27100
(120.6)
54200
(241.1)

#8

4
(102)
8
(204)
16
(408)

14100
(62.7)
32500
(144.6)
65000
(289.1)

#9

5
(127)
10
(254)
18
(457)

16700
(74.3)
47400
(210.9)
85300
(379.4)

#10

6
(152)
12
(304)
20
(508)

23300
(103.6)
59600
(265.1)
99300
(441.7)

#11

7
(178)
14
(356)
20
(508)

32000
(142.3)
75800
(337.2)
108400
(482.2)

Ultimate
Bond
Strength
lb (kN)

Embed. to
Embed. to
Develop Yield Develop Tensile
Strength1
Strength1
in. (mm)
in. (mm)

3-3/4
(95.3)

5-1/2
(139.7)

7
(177.8)

8-1/2
(215.9)

10
(254.0)

11-3/4
(298.5)

12-3/4
(323.9)

15-1/2
(393.7)

17-1/4
(438.2)

Grade 60 Rebar

fc = 4000 psi (27.6 MPa)

Ultimate
Bond
Strength
lb (kN)

Embed. to
Embed. to
Yield
Develop Yield Develop Tensile Strength
Strength1
Strength1
lb (kN)
in. (mm)
in. (mm)

Tensile
Strength
lb (kN)

5-1/2
(139.7)

3800
(16.9)
8200
(36.5)
16500
(73.4)

2-3/4
(69.9)

4-1/4
(108.0)

6600
(29.4)

9900
(44.0)

8
(203.2)

6000
(26.7)
11800
(52.5)
23600
(105.0)

4-1/4
(108.0)

6-1/4
(158.8)

12000
(53.4)

18000
(80.1)

10-1/4
(260.4)

6900
(30.7)
17700
(78.7)
35300
(157.0)

5-1/4
(133.4)

8
(203.2)

18600
(82.7)

27900
(124.1)

12-3/4
(323.9)

12800
(56.9)
28900
(128.6)
57700
(256.7)

6-1/2
(165.1)

9-3/4
(247.7)

26400
(117.4)

39600
(176.2)

15
(381)

15800
(70.3)
35300
(157.0)
70700
(314.5)

7-3/4
(196.9)

11-1/2
(292.1)

36000
(160.1)

54000
(240.2)

17-1/2
(444.5)

18100
(80.5)
42400
(188.6)
84800
(377.2)

9
(228.6)

13-1/2
(342.9)

47450
(211.1)

71100
(316.3)

19
(482.6)

21800
(97.0)
61800
(274.9)
111300
(495.1)

10
(254.0)

15-3/4
(400.1)

60000
(266.9)

90000
(400.4)

23
(584.2)

32400
(144.1)
77700
(345.6)
129600
(576.5)

12
(304.8)

17-3/4
(450.9)

76200
(339.0)

114300
(508.5)

26
(660.4)

41300
(183.7)
99000
(440.4)
141400
(629.0)

13-1/2
(342.9)

20
(508.0)

93600
(416.4)

140400
(624.6)

1 Based on comparison of average ultimate adhesive bond test values versus minimum yield and ultimate tensile strength of rebar; for more information, contact Hilti.

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HIT HY 150/HIT-ICE Adhesive Anchor

4.2.4
Adhesive Anchoring Systems

HIT HY 150/HIT-ICE Bond Strength and Steel Strength for Metric Rebar in Concrete (Canada Only)1, 4, 5
Strength Properties of Metric Rebar 2, 3
f y = 400 MPa

HY 150/HIT-ICE Tensile Bond Strength 2, 3, 4

fc = 14 MPa
fc = 28 MPa
Rebar
Size

Embedment
Depth
(mm)

Ultimate
Bond
(kN)

Allowable
Bond
(kN)

Ultimate
Bond
(kN)

Allowable
Bond
(kN)

Yield
Strength
(kN)

Tensile
Strength
(kN)

10M
(#3)

40
90
180

11.1
28.0
56.0

2.8
7.0
14.0

16.9
36.5
73.4

4.2
9.1
18.3

40

60

15M
(#5)

65
130
250

24.9
60.1
120

6.2
15.0
30.0

30.7
78.7
157

7.7
19.7
39.2

80

120

20M
(#6)

90
180
355

45.4
98.3
197

11.3
24.6
49.2

56.9
129
257

14.2
32.2
64.2

120

180

25M
(#8)

100
200
405

62.7
145
289

15.7
36.2
72.2

80.5
189
377

20.1
47.2
94.2

200

300

30M
(#9)

125
250
455

74.3
211
379

18.6
52.8
94.8

97.0
275
495

24.2
68.8
124

280

420

35M
(#11)

180
355
510

142
337
482

35.5
84.2
120

184
440
629

46.0
110
157

400

600

1 For anchoring to grout-filled block or bond beams, please refer to page 102 of this
HIT HY 150/HIT-ICE Injection Adhesive System section.

4 Test data developed for hammer-drilled holes. For diamond cored holes, contact
Hilti Engineering.

2 Use lesser value of bond strength or rebars steel strength for tensile capacity.

5 For anchoring spacing and edge distance guidelines, please refer to page 106 of
this HIT HY 150/HIT-ICE Injection Adhesive Anchor section.

3 Actual tensile bond test data developed for imperial-sized rebar. Yield and ultimate
rebar strengths are for metric sizes.

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105

4.2.4

HIT HY 150/HIT-ICE Adhesive Anchor

Adhesive Anchoring Systems

Anchor Spacing and Edge Distance Guidelines in Concrete for HIT HY 150/HIT-ICE

Edge Distance Adjustment Factors

Anchor Spacing Adjustment Factors

c = Actual Edge Distance

s = Actual spacing

cmin = 0.5 hef

smin = 0.5 hef

s
V

ccr = 1.5 hef Tension

= 2.0 hef for Shear

scr = 1.5 hef

hef = Actual embedment

hef = Actual Embedment

scr

1.5

ccr

2.0

Shear (
to Edge)
Note: Tables apply for listed embedment
depths. Reduction factors for
other embedment depths must be
calculated using equations below.

1.5

1.0

Shear (II to Edge)

s
hef

smin

0.5

1.0

c
hef

Spacing Tension/Shear
smin = 0.5 hef, scr = 1.5 hef
fA = 0.3(s/hef) + 0.55
for scr>s>smin

ccr

Shear & Tension

0.5

0
.2

.4

.6

.8

1.0

Anchor Spacing Adjustment Factor

(fA)

Edge Distance Tension

Tension

cmin

cmin = 0.5 hef, ccr = 1.5 hef

fRN = 0.40(c/hef) + 0.40

for ccr>c>cmin

.6
.2
.4
.8
1.0
Edge Distance Adjustment Factor
(fRV, fRN)

Edge Distance Shear

( toward edge)
cmin = 0.5 hef, ccr = 2.0 hef
fRV
= 0.54(c/hef) 0.09
for ccr>c>cmin
Edge Distance Shear
(II to or away from edge)
cmin = 0.5 hef, ccr = 2.0 hef

Load Adjustment Factors for 3/8" Diameter Anchor

Anchor
Diameter
Adjustment
Factor
Embedment
Depth, in.

Spacing (s)/Edge Distance (c), in.

fRVII = 0.36(c/hef) + 0.28

for ccr>c>cmin

7/8
1-1/4
1-3/4
2
2-5/8
3
3-1/2
4
4-1/2
5-1/4
6-1/2
7
7-7/8
9
10-1/2

3/8" diameter
Spacing
Tension/Shear,
fA

Edge Distance
Tension,
fRN

Edge Distance Shear

(
toward edge),
fRV

Edge Distance Shear

(II to or away from edge),

1-3/4 3-1/2 5-1/4 1-3/4 3-1/2 5-1/4 1-3/4 3-1/2 5-1/4 1-3/4

0.70
0.76
0.85 0.70
0.89 0.72
1.00 0.78 0.70
0.81 0.72
0.85 0.75
0.89 0.78
0.94 0.81
1.00 0.85
0.92
0.95
1.00

0.60
0.69
0.80 0.60
0.86 0.63
1.00 0.70 0.60
0.74 0.63
0.80 0.67
0.86 0.70
0.91 0.74
1.00 0.80
0.90
0.93
1.00

0.18
0.30
0.45
0.53
0.72
0.84
1.00

0.46
0.54
0.18
0.64
0.22
0.69
0.32 0.18 0.82
0.37 0.22 0.90
0.45 0.27 1.00
0.53 0.32
0.60 0.37
0.72 0.45
0.91 0.58
1.00 0.63
0.72
0.84
1.00

fRVII
3-1/2 5-1/4

0.46
0.49
0.55
0.59
0.64
0.69
0.74
0.82
0.95
1.00

0.46
0.49
0.52
0.55
0.59
0.64
0.73
0.76
0.82
0.90
1.00

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106

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HIT HY 150/HIT-ICE Adhesive Anchor

4.2.4
Adhesive Anchoring Systems
Note: Tables apply for listed embedment
depths. Reduction factors for
other embedment depths must be
calculated using equations below.

Load Adjustment Factors for 1/2" Diameter Anchor

Anchor
Diameter
Adjustment
Factor

Spacing (s)/Edge Distance (c), in.

Embedment
Depth, in.

1-1/16
1-1/2
2
2-1/8
2-3/4
3
3-3/16
4
4-1/4
5
6
6-3/8
7
7-1/2
8-1/2
9
9-9/16
10
11
12-3/4

1/2" diameter
Spacing
Tension/Shear,
fA

Edge Distance
Tension,
fRN

Edge Distance Shear

(
toward edge),
fRV

Edge Distance Shear

fRVII

2-1/8 4-1/4 6-3/8 2-1/8 4-1/4 6-3/8 2-1/8 4-1/4 6-3/8 2-1/8

0.70
0.76
0.83
0.85
0.94
0.97
1.00

0.70
0.74
0.76
0.78
0.83
0.85
0.90
0.97
1.00

0.60
0.68
0.78
0.80
0.92
0.96
0.70 1.00
0.74
0.75
0.79
0.83
0.85
0.88
0.90
0.95
0.97
1.00

0.18
0.29
0.42
0.60
0.45
0.66
0.61
0.68
0.67
0.70 0.60 0.72
0.78 0.65 0.93
0.80 0.67 1.00
0.87 0.71
0.96 0.78
1.00 0.80
0.84
0.87
0.93
0.96
1.00

Spacing Tension/Shear

(II to or away from edge),

0.46
0.53
0.62
0.18
0.64
0.26
0.75
0.29
0.79
0.32 0.18 0.82
0.42 0.25 0.96
0.45 0.27 1.00
0.55 0.33
0.67 0.42
0.72 0.45
0.80 0.50
0.86 0.55
1.00 0.63
0.67
0.72
0.76
0.84
1.00

smin = 0.5 hef, scr = 1.5 hef

4-1/4 6-3/8

fA = 0.3 (s/hef) + 0.55

for scr>s>smin
0.46
0.51
0.53
0.55
0.62
0.64
0.70
0.79
0.82
0.87
0.92
1.00

Edge Distance Tension

cmin = 0.5 hef, ccr = 1.5 hef
fRN = 0.40 (c/hef) + 0.40
for ccr>c>cmin

0.46
0.51
0.52
0.56
0.62
0.64
0.68
0.70
0.76
0.79
0.82
0.84
0.90
1.00

Edge Distance Shear

( toward edge)
cmin = 0.5 hef, ccr = 2.0 hef
fRV
= 0.54 (c/hef) 0.09
for ccr>c>cmin
Edge Distance Shear
(II to or away from edge)
cmin = 0.5 hef, ccr = 2.0 hef
fRVII = 0.36 (c/hef) + 0.28
for ccr>c>cmin

Load Adjustment Factors for 5/8" and 3/4" Diameter Anchors

Anchor
Diameter
Adjustment
Factor

5/8" diameter
Spacing

Edge Distance

Edge Distance Shear

Edge Distance Shear

Spacing

Edge Distance

Edge Distance Shear

Edge Distance Shear

Tension/Shear,

Tension,

(
toward edge),

(II to or away from edge),

Tension/Shear,

Tension,

(
toward edge),

(II to or away from edge),

fA

Spacing (s)/Edge Distance (c), in.

Embedment
Depth, in.

1-1/4
1-11/16
2
2-1/2
3
3-5/16
3-3/4
4
4-1/2
5
5-1/16
5-1/2
6
6-3/4
7-1/2
8
8-1/2
9
9-15/16
10
11-1/4
12
13-1/4
14
15
16
18
20

2-1/2

0.70
0.75
0.79
0.85
0.91
0.95
1.00

3/4" diameter

0.70
0.73
0.75
0.78
0.79
0.82
0.85
0.85
0.88
0.91
0.96
1.00

fRN
7-1/2 2-1/2

0.60
0.67
0.72
0.80
0.88
0.93
0.70 1.00
0.71
0.73
0.75
0.75
0.77
0.79
0.82
0.85
0.87
0.89
0.91
0.95
0.95
1.00

0.60
0.64
0.67
0.70
0.72
0.76
0.80
0.81
0.84
0.88
0.94
1.00

fRV

7-1/2 2-1/2

0.60
0.61
0.64
0.67
0.67
0.69
0.72
0.76
0.80
0.83
0.85
0.88
0.93
0.93
1.00

0.18
0.27
0.34
0.45
0.56
0.63
0.72
0.77
0.88
1.00

0.18
0.23
0.27
0.32
0.34
0.40
0.45
0.46
0.50
0.56
0.64
0.72
0.77
0.83
0.88
0.98
1.00

fRVII
7-1/2 2-1/2

0.18
0.20
0.23
0.27
0.27
0.31
0.34
0.40
0.45
0.49
0.52
0.56
0.63
0.63
0.72
0.77
0.86
0.92
1.00

0.46
0.52
0.57
0.64
0.71
0.76
0.82
0.86
0.93
1.00

0.46
0.50
0.52
0.55
0.57
0.60
0.64
0.64
0.68
0.71
0.77
0.82
0.86
0.89
0.93
1.00

fA
7-1/2 3-3/8 6-5/8

0.46
0.47
0.50
0.52
0.52
0.54
0.57
0.60
0.64
0.66
0.69
0.71
0.76
0.76
0.82
0.86
0.92
0.95
1.00

0.70
0.73
0.77
0.82
0.84
0.88
0.91
0.95
0.99
1.00

fRN
10

3-3/8 6-5/8

0.60
0.64
0.70
0.76
0.70
0.79
0.72
0.84
0.73
0.87
0.75
0.93
0.78 0.70 0.99
0.78 0.70 1.00
0.80 0.72
0.82 0.73
0.86 0.75
0.89 0.78
0.91 0.79
0.93 0.81
0.96 0.82
1.00 0.85
0.85
0.89
0.91
0.95
0.97
1.00

0.60
0.63
0.64
0.67
0.70
0.71
0.73
0.76
0.81
0.85
0.88
0.91
0.94
1.00

fRV

10

0.60
0.60
0.62
0.64
0.67
0.70
0.72
0.74
0.76
0.80
0.80
0.85
0.88
0.93
0.96
1.00

3-3/8 6-5/8

0.18
0.23
0.31
0.39
0.44
0.51
0.55
0.63
0.71
0.72
0.79
0.87
1.00

0.18
0.22
0.24
0.28
0.32
0.32
0.36
0.40
0.46
0.52
0.56
0.60
0.64
0.72
0.73
0.83
0.89
1.00

fRVII
10

0.18
0.18
0.21
0.23
0.27
0.32
0.34
0.37
0.40
0.45
0.45
0.52
0.56
0.63
0.67
0.72
0.77
0.88
1.00

3-3/8 6-5/8

0.46
0.49
0.55
0.60
0.63
0.68
0.71
0.76
0.81
0.82
0.87
0.92
1.00

0.46
0.48
0.50
0.52
0.55
0.56
0.58
0.61
0.65
0.69
0.71
0.74
0.77
0.82
0.82
0.89
0.93
1.00

10

0.46
0.46
0.48
0.50
0.52
0.55
0.57
0.59
0.60
0.64
0.64
0.69
0.71
0.76
0.78
0.82
0.93
1.00

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107

4.2.4

HIT HY 150/HIT-ICE Adhesive Anchor

Adhesive Anchoring Systems

Note: Tables apply for listed embedment
depths. Reduction factors for
other embedment depths must be
calculated using equations below.

Load Adjustment Factors for 7/8" Diameter Anchor

Anchor
Diameter
Adjustment
Factor

Spacing (s)/Edge Distance (c), in.

Embedment
Depth, in.

1-7/8
2-1/2
3
3-3/4
4
4-1/2
5
5-5/8
6
6-1/2
7
7-1/2
8
8-1/2
9
9-15/16
10
11-1/4
12
14
15
16-7/8
18
20
22-1/2

7/8" diameter
Spacing
Tension/Shear,
fA

Edge Distance
Tension,
fRN

Edge Distance Shear

(
toward edge),
fRV

Edge Distance Shear

(II to or away from edge),

fRVII

3-3/4 7-1/2 11-1/4 3-3/4 7-1/2 11-1/4 3-3/4 7-1/2 11-1/4 3-3/4

0.70
0.75
0.79
0.85
0.87
0.91
0.95
1.00

0.70
0.71
0.73
0.75
0.78
0.79
0.81
0.83
0.85
0.87
0.89
0.91
0.95
0.95
1.00

0.60
0.67
0.72
0.80
0.83
0.88
0.93
0.70 1.00
0.71
0.72
0.74
0.75
0.76
0.78
0.79
0.82
0.82
0.85
0.87
0.92
0.95
1.00

0.60
0.61
0.64
0.67
0.70
0.72
0.75
0.77
0.80
0.83
0.85
0.88
0.93
0.93
1.00

0.60
0.61
0.63
0.65
0.67
0.68
0.70
0.72
0.75
0.76
0.80
0.83
0.90
0.93
1.00

0.18
0.27
0.34
0.45
0.49
0.56
0.63
0.72
0.77
0.85
0.92
1.00

0.18
0.20
0.23
0.27
0.32
0.34
0.38
0.41
0.45
0.49
0.52
0.56
0.63
0.63
0.72
0.77
0.92
1.00

0.18
0.20
0.22
0.25
0.27
0.29
0.32
0.34
0.39
0.39
0.45
0.49
0.58
0.63
0.72
0.77
0.87
1.00

0.46
0.52
0.57
0.64
0.66
0.71
0.76
0.82
0.86
0.90
0.95
1.00

Spacing Tension/Shear

7-1/2 11-1/4

smin = 0.5 hef, scr = 1.5 hef

fA = 0.3 (s/hef) + 0.55
for scr>s>smin
0.46
0.47
0.50
0.52
0.55
0.57
0.59
0.62
0.64
0.66
0.69
0.71
0.76
0.76
0.82
0.86
0.95
1.00

Edge Distance Tension

cmin = 0.5 hef, ccr = 1.5 hef
fRN = 0.40 (c/hef) + 0.40
for ccr>c>cmin

0.46
0.47
0.49
0.50
0.52
0.54
0.55
0.57
0.60
0.60
0.64
0.66
0.73
0.76
0.82
0.86
0.92
1.00

Edge Distance Shear

( toward edge)
cmin = 0.5 hef, ccr = 2.0 hef
fRV
= 0.54 (c/hef) 0.09
for ccr>c>cmin
Edge Distance Shear
(II to or away from edge)
cmin = 0.5 hef, ccr = 2.0 hef
fRVII = 0.36 (c/hef) + 0.28
for ccr>c>cmin

Load Adjustment Factors for 1" and 1 1/4" Diameter Anchors

Anchor
Diameter
Adjustment
Factor

Spacing (s)/Edge Distance (c), in.

Embedment
Depth, in.

108

2-1/16
3
3-1/2
4-1/8
5
5-1/2
6
6-3/16
7-1/2
8-1/4
9
9-1/2
10
10-1/2
12
12-3/8
14
16-1/2
18
18-9/16
20
22-1/2
24
24-3/4
26
28
30

1" diameter

1 1/4" diameter

Spacing

Edge Distance

Edge Distance Shear

Edge Distance Shear

Spacing

Edge Distance

Edge Distance Shear

Edge Distance Shear

Tension/Shear,

Tension,

( toward edge),

(II to or away from edge),

Tension/Shear,

Tension,

( toward edge),

(II to or away from edge),

fA

fRN

fRV

4-1/8 8-1/4 12-3/8 4-1/8 8-1/4 12-3/8 4-1/8 8-1/4 12-3/8 4-1/8

0.70
0.77
0.80
0.85
0.91
0.95
0.99
1.00

0.70
0.73
0.75
0.77
0.78
0.82
0.85
0.88
0.90
0.91
0.93
0.99
1.00

0.60
0.69
0.74
0.80
0.88
0.93
0.98
0.70 1.00
0.73
0.75
0.77
0.78
0.79
0.80
0.84
0.85
0.89
0.95
0.99
1.00

0.18
0.30
0.37
0.60
0.45
0.64
0.56
0.67
0.63
0.69
0.70
0.70 0.60 0.72
0.76 0.64 0.89
0.80 0.67 1.00
0.84 0.69
0.86 0.71
0.88 0.72
0.91 0.74
0.98 0.79
1.00 0.80
0.85
0.93
0.98
1.00

0.46
0.54
0.59
0.18
0.64
0.24
0.72
0.27
0.76
0.30
0.80
0.32 0.18 0.82
0.40 0.24 0.93
0.45 0.27 1.00
0.50 0.30
0.53 0.32
0.56 0.35
0.60 0.37
0.70 0.43
0.72 0.45
0.83 0.52
1.00 0.63
0.70
0.72
0.78
0.89
0.96
1.00

fRVII

fA

8-1/4 12-3/8

0.46
0.50
0.52
0.54
0.55
0.61
0.64
0.67
0.69
0.72
0.74
0.80
0.82
0.89
1.00

0.46
0.50
0.52
0.54
0.56
0.57
0.59
0.63
0.64
0.69
0.76
0.80
0.82
0.86
0.93
0.98
1.00

0.70
0.73
0.76
0.80
0.83
0.85
0.86
0.93
0.96
1.00

12

fRN
15

0.60
0.63
0.68
0.73
0.77
0.70
0.80
0.70
0.81
0.74 0.70 0.90
0.76 0.72 0.95
0.78 0.73 1.00
0.79 0.74
0.80 0.75
0.81 0.76
0.85 0.79
0.86 0.80
0.90 0.83
0.96 0.88
1.00 0.91
0.92
0.95
1.00

12

0.60
0.61
0.65
0.68
0.70
0.72
0.73
0.75
0.80
0.81
0.87
0.95
1.00

fRV
15

0.60
0.62
0.64
0.65
0.67
0.68
0.72
0.73
0.77
0.84
0.88
0.90
0.93
1.00

0.18
0.23
0.28
0.36
0.41
0.45
0.47
0.59
0.65
0.72
0.77
0.81
0.86
1.00

12

0.18
0.19
0.25
0.28
0.32
0.34
0.36
0.38
0.45
0.47
0.54
0.65
0.72
0.75
0.81
0.92
1.00

fRVII
15

0.18
0.21
0.23
0.25
0.27
0.29
0.34
0.36
0.41
0.50
0.56
0.58
0.63
0.72
0.77
0.80
0.85
0.92
1.00

0.46
0.49
0.53
0.58
0.61
0.64
0.65
0.73
0.78
0.82
0.85
0.88
0.91
1.00

12

0.46
0.47
0.51
0.53
0.55
0.57
0.58
0.60
0.64
0.65
0.70
0.78
0.82
0.84
0.88
0.96
1.00

Hilti, Inc. (US) 1-800-879-8000 I Product Technical Guide 2004 I Hilti (Canada) Corporation 1-800-363-4458

15

0.46
0.48
0.50
0.51
0.52
0.53
0.57
0.58
0.62
0.68
0.71
0.73
0.76
0.82
0.86
0.87
0.90
0.95
1.00

HIT HY 150/HIT-ICE Adhesive Anchor

4.2.4
Adhesive Anchoring Systems

Resistance of HIT HY 150 to Chemicals1

Chemical

Behavior

Sulphuric acid

conc.
30%
10%
conc.
10%
conc.
10%
conc.
10%
conc.
10%
conc.
10%
conc.
10%
10%
40%
20%
5%
conc.
5%
10%
10%
10%
2%
10%
10%

Hydrochloric acid
Nitric acid
Phosphoric acid
Acetic acid
Formic acid
Lactic acid
Citric acid
Sodium Hydroxide
(Caustic soda)
Ammonia
Soda solution
Common salt solution
Chlorinated lime solution
Sodium hypochlorite
Hydrogen peroxide
Carbolic acid solution
Ethanol
Sea water
Glycol
Acetone
Carbon tetrachloride
Toluene
Petrol/Gasoline
Machine oil
Diesel oil
Key: non-resistant
1

+
+

+
+
+

+
+

+
+
+
+
+
+

+
+

limited resistance

+ resistant

HIT-ICE information unavailable as of this printing.

23F

70F

Note: In actual use, the majority of the resin is encased in the base
material, leaving very little surface area exposed. In some cases, this would
allow the HY 150 to be used where it would be exposed to the
Partially Resistant chemical compounds.

Open Gel Time Table (Approximate)1

Base Material Temperature
F

HIT HY 150 2

HIT-ICE

10
0
23
32
41
68
86
104

23
18
5
0
5
20
30
40

25 min
18 min
13 min
5 min
4 min
2 min

1.5 hrs
1.5 hrs
40 min
26 min
11 min
4 min
1.5 min

Final Cure Time Table (Approximate)1

Base Material Temperature
F

HIT HY 150 2

HIT-ICE

10
0
23
32
41
68
86
104

23
18
5
0
5
20
30
40

6 hrs
3 hrs
90 min
50 min
40 min
30 min

24 hrs
24 hrs
6 hrs
4 hrs
2 hrs
1 hrs
30 min

1 Product temperatures must be maintained above 41F (5C), with the

exception of HIT-ICE which must be above 0F (18C).
2 Use of HIT HY 150 and HIT-TZ rods must be installed in base material
temperatures 40 F (5 C).
Influence of High Energy Radiation on HIT HY 1501

HIT HY 150

100F

140F

64% at 212F

HIT-ICE
64% at 155F

120
110
100
90
80
70
60
50
40
30
20
10
0

100% at 100F

Allowable Bond Strength

(% of load at 70F)

Influence of Temperature on Bond Strength

Samples of the HY 150 resin were immersed in the various chemical

compounds for up to one year. At the end of the test period, the samples were
analyzed. Any samples showing no visible damage and having less than a
25% reduction in bending (flexural) strength were classified as Resistant.
Samples that had slight damage, such as small cracks, chips, etc. or reduction
in bending strength of 25% or more, were classified as Partially Resistant.
Samples that were heavily damaged or destroyed were classified as Not
Resistant.

180F

Radiation
Exposure2, 3

Detrimental
Effect

< 10 Mrad

Insignificant

10 100 Mrad
> 100 Mrad

Note: Test procedure involves the concrete being held at the elevated temperature for
24 hours them removing it from the controlled environment and testing to failure.

Full Use

Moderate

Restricted Use
Frec. = 0.5 Fperm.

Medium to strong

220F

Base Material Temperature (F)

Recommendation
for Use

No recommendation
for use

1 HIT-ICE information is unavailable.

2 Mrad = Megarad
3 Dosage over a life span.

Long-term creep test at 176F for HIT HY 150 is also available; contact Hilti
Technical Services.

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4.2.4

HIT HY 150/HIT-ICE Adhesive Anchor

Adhesive Anchoring Systems

4.2.4.4 Installation Instructions

HAS, Rebar and Insert Installation Instructions

1. Drill anchor hole with a carbide bit. Contact Hilti for use
of Diamond Core bits.

2. Clean hole with wire brush.

Proper hole cleaning is
essential.

3. Insert air nozzle to bottom of

hole and blow out hole using
a pump, or compressed air.

4. HY 150 only: Put refill pack

into holder. Remove cap covering threaded projection.

7. Inject adhesive into hole

starting at the bottom until
1/2 to 2/3 full. Use mixer
filler tube extensions when
needed to reach the hole
bottom.

8. Unlock dispenser.

2
1

5. Screw on static mixer.

6. Put holder/cartridge into

appropriate dispenser and
discard first two trigger
pulls of adhesive from each
refill pack or cartridge.

Rod

9. Insert rod. Twist during installation.

10

11

10. Fastener may be adjusted during specified gel time.

11. Do not disturb anchor between

specified gel time and cure
time.

10

11

Insert

2
Tmax
Tmax

12. Apply specified torque as

required to secure items to be
fastened. Do not exceed maximum torque specified.

2
Tmax
T

max

9. Insert threaded insert.

Twist during installation.

10. Fastener may be adjusted during specified gel time.

11. Do not disturb anchor between

specified gel time and cure
time.

12. Apply specified torque as

required to secure items to be
fastened. Do not exceed maximum torque specified.

10

11

12

10. Fastener may be adjusted during specified gel time.

11. Do not disturb anchor between

specified gel time and cure
time.

Rebar

9. Insert rebar. Twist during installation.

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12. Apply specified torque as

required to secure items to be
fastened. Do not exceed maximum torque specified.

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HIT HY 150/HIT-ICE Adhesive Anchor

4.2.4
Adhesive Anchoring Systems

HIT HY 150/HIT-ICE Volume Charts

Threaded Rod & HIT-TZ Rod
Installation
Rod
Drill Bit1 Adhesive Volume
Diameter Diameter Required per Inch
(in.)
(in.)
of embedment (in 3)
1/4
3/8
1/2
5/8
3/4
7/8
1
1-1/4

5/16
7/16
9/16
11/16
13/16
24mm
1-1/16
1-1/2

0.055
0.095
0.133
0.184
0.232
0.272
0.366
0.918

Metric Rebar Installation

(Canada Only)

Rebar Installation
Rod
Diameter
(in.)
#3 or 3/8
#4 or 1/2
#5 or 5/8
#6 or 3/4
#7 or 7/8
#8 or 1
#9 or 1-1/8
#10 or 1-1/4
#11 or 1-3/8

Drill Bit1 Adhesive Volume

Diameter Required per Inch
(in.)
of embedment (in3)
1/2
5/8
3/4
7/8
1
1-1/8
1-3/8
1-1/2
1-9/16

Bar
Drill Bit1
Diameter Diameter

0.110
0.146
0.176
0.218
0.252
0.299
0.601
0.659
0.547

Example: Determine approximate fastenings for

5/8" rod embedded 10" deep.

Note: Usable volume of:

10 x 0.184 = 1.84 in3 of adhesive per anchor

HIT HY 150 refill pack is 16.5 in3 (270ml).

HIT HY 150 small cartridge:

16.5 1.84 9 fastenings

HIT-ICE is 15 in3 (243 ml)

10M
15M
20M
25M
30M
35M

14 mm
3/4"
24 mm
1-1/8"
37 mm
1-9/16"

Adhesive Volume
Required per Inch
of embedment (in3)
0.101
0.176
0.268
0.309
0.644
0.480

HIT HY 150 jumbo cartridges is 81.8 in3 (1340 ml).

HIT HY 150 jumbo cartridge:

81.8 1.84 45 fastenings
HIT-ICE cartridge:
15.0 1.84 8 fastenings

1 Rebar diameter may vary. Use smallest drill bit which will accommodate rebar. For Hilti matched tolerance carbide tipped drill bits, see section 8.4.1.

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111

4.2.4

HIT HY 150/HIT-ICE Adhesive Anchor

Adhesive Anchoring Systems

4.2.4.5 Ordering Information

HIT Adhesives
Item No.

Description

Contents

00371292
00371957
00305713

HIT-ICE (10 oz) 297 ml

HY 150 (11.1 oz) 400 ml
HY 150 Jumbo (47.3 oz) 1400 ml

1 Cartridge, 1 Mixer
1 Refill Pack, 1 Mixer w/ filler tube
4 Cartridges, 4 Mixers

HIT Dispensers

BD2000
Battery
Dispenser

Battery Powered Dispenser

Item No.

Description

00335288

BD2000 Battery Dispenser Kit Complete

MD1000
Dispenser

Manual Dispensers
Item No.

Description

00371291
00229154
00229170

MD1000 Dispenser for HIT-ICE Cartridges

MD2000 Dispenser + 1 refill holder for HIT HY refill packs
Refill Holder Replacement for MD2000, BD 2000 or P-3000HY dispensers

P-3000HY
Pneumatic
Dispenser

HIT-ICE Cartridge

HY 150 Refill Pack

HY 150 Jumbo Cartridge

MD2000
Dispenser

P-8000HY
Pneumatic
Dispenser

Pneumatic Dispensers
Item No.

Description

00255032
00373959
00373960

HIT P-3000HY Pneumatic Dispenser, + 1 refill holder for HIT HY refill packs
HIT P-8000 Pneumatic Dispenser (for Jumbo cartridges)
Jumbo pack holder replacement fo HIT P-8000 Dispenser

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HIT HY 150/HIT-ICE Adhesive Anchor

4.2.4
Adhesive Anchoring Systems

4.2.4.5 Ordering Information

HIT Filler Tube

HIT-HY Mixer (Large)

HIT-ICE Mixer

HIT-M Mixer (Small)

Mixers & Filler Tubes

Item No.

Description

00068156
00337111
00371290
00063799
00063994
00063995

HIT-M, Mixer for HY 150

HIT-RE-M Static Mixer, Large HY 150
HIT-M2 for HIT-ICE
Filler Tube 3/8" x 8"
Filler Tube 1/2" x 11-1/2"
Filler Tube 1/2" x 17-1/2"

Wire Brush

Qty/Pkg

1
1
1
1
1
1

Notes

For use with small HIT HY 150 refill packs

For use with Jumbo cartridges
For use with HIT-ICE cartridges
Attach filler tube to small mixer to fill deeper holes
Attach filler tube to large mixer to fill deeper holes
Attach filler tube to large mixer to fill deeper holes

Air Nozzle

Hole Cleaning Accessories

Item No.

Description

00063964
00255781
00255782
00059893
00255783
00255784
00003206

Air Nozzle (Length 24")

Wire Brush 3/8" (for 7/16" to 1/2" holes)
Wire Brush 1/2" (for 9/16" to 5/8" holes)
Wire Brush 5/8" (for 11/16" to 3/4" holes)
Wire Brush 3/4" (for 13/16" to 15/16" holes)
Wire Brush 1" (for 1" to 1-1/8" holes)
Flat Wire Brush (for > 1-1/8" holes)

Qty/Pkg

1
1
1
1
1
1
1

Wire brushes are required for all applications using HY 150/HIT-ICE Adhesive, except HIT-TZ rod fastenings.

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4.2.4

HIT HY 150/HIT-ICE Adhesive Anchor

Adhesive Anchoring Systems

HAS-E Threaded Rods

HAS-E ISO
898 Class 5.8
Item No.
333184
333185
333183
333186
333187
333188
333189
333190
333191
333192
333193
333194
333197
333195
333196

HAS-E
Description
38-3
38-438
38-518
38-8
38-12
12-318
12-412
12-612
12-8
12-10
12-12
58-8
58-9
58-12
58-17

HAS-E
Description
34-10
34-11
34-12
34-14
34-17
34-19
34-21
34-25
78-10
78-13
1-12
1-14
1-16
1-20
114-16
114-22

Qty/Pkg
10
10
20
10
10
10
10
20
10
10
10
20
10
10
10

HAS-E ISO
898 Class 5.8
Item No.
333201
333198
333202
333203
333204
333205
333206
333207
333208
333209
333210
333211
333212
333213
333214
333215

Qty/Pkg
10
10
10
10
10
10
10
10
10
10
4
2
2
2
4
2

HAS Super, HAS Stainless Steel Rods, HIS and HIS-R Stainless Steel Inserts3
Description

HAS Super 3
Item No.

3/8" x 5-1/8"
1/2" x 6-1/2"

00068657
00068658

5/8" x 7-5/8"

HAS 304 SS2,3

Item No.

Qty/Box

HIS
Description

HIS Insert
Item No.

HIS-R 316 SS Insert

Item No.

Qty/Box

00068675
00068676

10
10

3/8" x 4-1/4"
1/2" x 5"

00258020
00258021

00258029
00258030

10
5

00333783

00333782

10

5/8" x 6-5/8"

00258022

00258031

3/4" x 9-5/8"

00068660

00068678

3/4" x 8-1/4"

00258023

00258032

7/8" x 10"1

000686611

968020064

1" x 12"

00068662

968020074

11/4" x 16"

00333779

1 Hot Dipped Galvanized (3/8" rod only). Coating thickness 2 mils (50.8m)
2 316 Stainless Steel HAS Rods are also available.
3 More HAS rod lengths are available, refer to Hilti Full Line Catalog or contact a Customer Service Representative.
4. Available by the individual piece.

HIT-TZ and HIT-RTZ Rods

HIT-TZ & HIT-RTZ Description
3/8" x 2-7/8" / 1"
1/2" x 3-1/2" / 1-1/2"
5/8" x 4" / 2-1/4"
3/4" x 5-1/4" / 2-1/4"

Item No. HIT-TZ

00337484
00337485
00337486
00337484

Item No. HIT-RTZ

00337498
00337499
00337500
00337501

Qty/Box
40
24
16
8

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PART TWO...

Types of Anchors for

Anchoring to Concrete
Everything you wanted to know about types of anchors
for use in concrete (well almost everything)
by Richard E. Wollmershauser, P.E., FACI

Designers and installers of anchors

for fastening attachments and structural
components to concrete face a seemingly unlimited variety of anchoring products. How is one supposed to know
which is the right anchor for a given
application? This article gives a brief
overview of the types of anchors available, how they develop the capacity to
resist loads, and some general comments
about appropriateness of these anchors
for different applications.
Anchors can be separated into two
major categories, those that are placed
before the concrete is cast, known as
cast-in-place anchors, and those that are
installed into hardened concrete, known
as post-installed or drilled-in anchors.
Each of these two categories is composed
of a variety of different anchors, all of
which transfer loads from the attachment to the concrete in a variety of ways
depending on their individual designs.

LOADS AND LOAD-TRANSFER

MECHANISMS
Before reviewing the various types of
anchors, it is appropriate to present the
types of loads that anchors must resist
and mechanisms for load-transfer from
anchor to concrete.
The primar y types of loads to be
resisted in normal construction are static
and dynamic. Load factors are spelled

Friction

out in the applicable building codes. Static loads can be tension, shear, or combinations of both. Dynamic loads can be
seismic, fatigue, wind, and shock. The
many types of anchors available have
characteristics that make them suitable
for or unsuitable for use under these various types of loads. Two state-of-the-art
documents, references 1 and 2, give
much more detailed information. Especially good are approval agency evaluation reports such as ICBO ES, BOCA,
and SBCCI or product listings for specific use as issued by listing agencies (e.g.
UL and FM). Manufacturers literature
may specify the applications for which
anchors are qualified and if test reports
are available to document capacities.
The primar y load-transfer mechanisms under tension loading are (in no
particular order of importance): keying
or bearing, friction, and bonding as well
as combinations. For shear loading, it is
keying or direct bearing.
Keying is the direct transfer of load
from the anchor into the concrete by
bearing forces in the same direction of
loading of the anchor. Friction is the
transfer of load through friction between
expansion sleeves of the anchor and the
wall of the drilled hole in the concrete.
Bonding takes place when resins or
grouts are used around the anchor, usually with post-installed anchors. Local

Keying

crushing occurs when the expansion

forces at the sleeve are great enough to
locally crush the concrete. In this case,
the load-transfer mechanism becomes a
combination of friction and localized
keying. With many bonding systems, keying is also part of the load-transfer as the
resin or grout fills the local pores in the
wall of the hole. See Figure 1 for illustrations of the basic mechanisms.

CAST-IN-PLACE SYSTEMS
Traditionally, design engineers specify
cast-in-place anchors if they know beforehand where anchors are to be installed.
Table 1 provides a brief overview of the
major types of cast-in-place anchors available, all of which use keying as a load
transfer means, in tension, shear, or
both.
Table 1. Cast-in-place Anchors
Standard fasteners

Proprietary shapes

Through bolts
Special shapes

Headed bolts
J and L bolts
Stud-welded plates
Threaded inserts
Proprietary anchors
and shapes
Usually sleeved
Shear lugs
Channel bars

Bonding

FIGURE 1. Load-Transfer Mechanisms

Homepage

Previous Document

Traditionally, design
engineers specify
cast-in-place anchors if
they know beforehand
where anchors are to
be installed.

1.5

Headed Bolt

L-Bolt

J-Bolt

Stud-welded Plate

FIGURE 2. Cast-in-place Anchors

Many of these types of anchors have

special uses. Shear lugs and stud-welded
plates provide large shear resistance,
while channel bars give specific attachment capability. J and L bolts are typically used for anchoring sill plates to
foundations, but have a tendency to
straighten and pull out under high tension loading. Headed bolts under
ASTM A 490 and F 1554 specifications
are veritable workhorses for structural
engineers.
But what if the cast-in-place anchor is
mislocated, or if the location of the
anchor is not known before construction, or additional anchorages need to
be made after the concrete is cast? The
post-installed anchor industry has developed a wide variety of products for these
situations.

POST-INSTALLED ANCHORS
With the development and improvements of rotary hammer drills and carbide-tipped bits, the user has the
capability to install many different kinds
of post-installed anchors in hardened
concrete virtually anywhere that is accessible to the drills.
Post-installed anchors can be divided
into two major types, depending on the
method of transferring load into the
concrete. They are mechanical systems
and bonded or adhesive systems.
Anchors can also be cross-classified
according to their load carrying capability; heavy-duty, medium-duty and lightduty. Table 2 provides an overview of the
major types of post-installed anchors currently available as well as a generalized
load categorization.

Homepage

Table 2. Post-Installed Anchors

MECHANICAL SYSTEMS
Undercut Anchors
Torque-controlled expansion anchors
Heavy duty sleeve anchor
Wedge anchors
Coil anchors
Screw anchors
Sleeve anchors
Light duty metal anchors
Plastic anchors
Displacement-controlled expansion anchors
Drop-in
Self-drilling
BONDED OR ADHESIVE SYSTEMS
Using threaded rods or reinforcing bars
Capsule systems
Cartridge systems
Bulk-injection systems
Cemetitious or epoxy grouted systems

HEAVYDUTY

MEDIUMDUTY

LIGHTDUTY

x
x

x
x

x
x
x
x

x
x

Indicates normal category

x Indicates possible but not primary category

MECHANICAL
ANCHORING SYSTEMS
While mechanical anchors have been
available for several decades, there have
been significant advances in the types
and capabilities of these systems. They
cover the range from heavy duty to light
duty capacities. The major concern is to
select the appropriate anchors that will
resist the expected loads for the given
application. Is the anchor expected to
experience seismic or fatigue loads, or
merely static loads? While some anchors
will withstand all of these types of loads,
others may fail abruptly under dynamic
loading at a load level less than the static
capacity.

UNDERCUT ANCHORS

These anchors have been on the market for about 20 years. They are excellent for use under both static and
dynamic loads. They obtain their holding capacity through keying, that is,
direct bearing on the concrete, and,
under proper installation, can withstand
very high loads without slipping out of
the drilled hole. They are the preferred
anchors for use where cracks in tension
zones of the concrete can be expected to
occur.

Previous Document

 EXPANSION ANCHORS

Expansion anchors have been available for at least 30 years. There are two
basic types that are distinguished by their
operating principles. The first, torquecontrolled expansion anchors, are
installed by inserting the anchor into the
drilled hole, and applying the prescribed
setting torque to the head or nut. A cone
at the bottom of the anchor is pulled up
into an expansion sleeve that expands
into the concrete with local crushing,
and providing both friction and localized keying as load-transfer mechanisms.
Most have a beneficial follow-up expansion characteristic that under tension
loading, the more the anchor bolt displaces upward out of the hole, the
greater the expansion forces.
There are several types available that
vary significantly in their ability to resist
static and dynamic loads. The heavy-duty
sleeve anchor (not to be confused with
the light duty sleeve anchor composed of
a sheet metal sleeve around a cone) can
resist dynamic loads as well as function
well in expected cracks in concrete.
Wedge anchors are the most common
type of torque-controlled expansion
anchor. Many have been tested for resisting seismic loads and have received
ICBO ES Evaluation Report listings for
such service.
Sleeve anchors are generally considered light duty, and rely more on friction
and less on local crushing and keying of
the concrete. They can be used in hollow masonry.
The second major type of expansion
anchor is the displacement-controlled
expansion anchor. Two primary examples are the drop-in and the self-driller.
Drop-in anchors are installed in the
predrilled hole by use of a setting tool
that drives a plug into the expansion
portion of the anchor. The lower section
of the anchor is expanded into the concrete, which experiences local crushing.
The second type has cutting teeth on the
lower end and drills its own hole. The
anchor is driven onto an expansion plug
that expands the lower portion of the
anchor into the concrete. These anchors
derive their holding capacity from friction and keying. The drawback is that
they do not have any follow-up expansion. Once set, they do not expand further under loading. If the plug is not

Homepage

Sleeve Anchor

Torque-controlled
Expansion Anchor

Heavy-duty
Sleeve Anchor

Undercut
Anchor

FIGURE 3. Mechanical Anchors

Drop-in Anchor

Self-drilling Anchor

Stud Anchor

FIGURE 4. Displacement-controlled Expansion Anchors

sufficiently set, the anchor may experience reduced capacity.

OTHER TYPES OF
MECHANICAL ANCHORS

Screw anchors of smaller diameters

and used for light duty applications have
been available for many years. They are
installed into holes drilled with matchedtolerance bits. Recently, manufacturers
have been introducing larger diameter
screw anchors in the heavy-duty range,
either installed into holes drilled with
matched-tolerance bits or using bits
meeting the requirements of ANSI
B212.15. They distribute the load into
the concrete through load transfer from
the threads to the concrete (keying).
Coil anchors have also been introduced into the market in the heavy-duty

load range. A coil anchor is composed of

a coil near the end of a specially
designed lag bolt. As the bolt is torqued,
the screw advances through the coil,
which expands into the concrete. High
load capacities can be developed.
LIGHT DUTY ANCHORS

There are many light duty anchors

available, made of metals and plastics.
They function in a variety of base materials, concrete, masonry, wood, drywall,
etc. Manufacturers publish test data to
document their capacities in these base
materials.

BONDED ANCHOR SYSTEMS

Bonded resin or adhesive anchors
were generally introduced into the construction market about twenty years ago.

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Bonded systems use a combination of

adhesive bond and micro keying into the
pores of the concrete. Early systems used
polyester resin, epoxies, and later, vinyl
ester resins. In recent years, a larger variety of resins have been developed that
have individual advantages, such as use
in high temperatures, low temperatures,
damp and wet holes, etc. For two component epoxy systems, the ratio of hardener to resin is critical. Prepackaged
cartridge systems assure that the proper
mixing is obtained. While a variety of
installation methods are used, most are
two component resin systems that
anchor threaded rod into predrilled
holes. Most will resist dynamic loads,
both seismic and fatigue, but documentation in the form of test reports should
be obtained. Bonded or adhesive
anchoring systems are not well suited for
cracked tensile zones of concrete since
about 1/2 the bonding is lost, unless one
uses special anchoring systems developed for use in cracked concrete. One
should also use the recommended drill
bit size, since many of the adhesives are
sensitive to the size of the gap between
the anchor rod and the concrete.
CAPSULE SYSTEMS

The original capsules were made of

glass, with an internal glass capsule that
contained the hardener. Recent versions
use plastic foil instead of the glass cap-

sules. The capsule is inserted into the

hole. The threaded rod or reinforcing
bar is then rotary-hammered into the
glass capsule, breaking the glass and mixing the resin and hardener. Capsule
anchors provide very good bonding as
the rotar y mixing action wipes and
cleans the surface of the hole, allowing
the adhesive to bond well.
CARTRIDGE SYSTEMS

Introduced also about 20 years ago,

cartridge systems are the most popular
delivery method since they are also the
most versatile. The resin and hardener
are packaged in separate but connected
side-by-side plastic or foil tubes. A mixing
nozzle is placed on the end of the tubes
and the resin and hardener dispensed by
a hand operated or a pneumatic dispenser. Also used for heavy-duty applications, hole cleaning is very critical since
dust on the concrete hole surface limits
the bond and micro keying.
BULK INJECTION SYSTEMS

For high volume applications such as

highway contracts or large building
where repetitive installation of anchors is
required, bulk mechanical and hydraulic
dispensing systems are available. Attention to the proper mixing ratio for epoxy
resins is critical since bulk equipment
can go off ratio.
GROUTED SYSTEMS

Predating resin systems are cemetitious grouts. There are a variety of proprietary systems available. Non-shrink or
slightly expansive grouts are preferred to
prevent shrinkage and lack of bonding
to the existing concrete.

Adhesive Capsule
Anchor

IN SUMMARY
A wide variety of anchoring systems
are available. The correct selection
depends on several factors, including
types of loads to be resisted, magnitude
of the load, type of base material (concrete or masonr y), and environment
conditions (damp, wet, dry), among others. The manufacturers literature provides a good starting place, but also look
for evaluation reports and product listings, since they may be required under
many building codes.

REFERENCES
1. State-of-the-Art Report on Anchorage to
Concrete ACI 355.1R-91, American
Concrete Institute, Detroit, 1991.
2. Fastenings to Concrete and Masonr y
Str uctures; State of the Ar t Repor t,
Comit Euro-Intrnational du Bton,
Thomas Telford Services Ltd., London, 1994.
3. ANSI B212.15-1994, American National
Standard for Cutting ToolsCarbideTipped Masonry Drills and Blanks for
Carbide-Tipped Masonry Drills, American National Standards Institute, New
York, N. Y., 10 pp.
Richard Wollmershauser is Director Technical Ser vices for Hilti, Inc. of Tulsa,
Oklahoma. He has been active in the concrete anchor industry for the past 20 years.
He is a registered PE in Ohio and
Oklahoma and a Fellow of the American
Concrete Institute. He currently serves as
Vice-President of CAMA, The Concrete
Anchor Manufactures Association, Chairman of ASTM Subcommittee E06.13,
Performance of Connections in Building
Construction, and just completed 7 years as
Chairman of the American Concrete
Institute Committee 355, Anchorage to
Concrete. He was editor of the ACI State-ofthe-Report on Anchorage to Concrete (ACI
355R1-93). He also serves on the Federation International du Beton Task Group
SAG 4 Fastening to Concrete and Masonry.
He served on three committees of the recent
NEHRP 2000 Seismic Provisions Update
program where he was concerned with the
introduction of anchoring design methods.

Adhesive Cartridge
System

FIGURE 5. Adhesive Bonded Anchor Systems

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