SHELL FALLS WAYSIDE 263213 – 1

BIGHORN NF PACKAGED ENGINE GENERATORS

SECTION 263213

PACKAGED ENGINE GENERATORS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary

Conditions and Division 01 Specifications, apply to this Section.

1.2 SUMMARY

A. Provide, install, and acceptance test a complete and operable prime electric generating system, including all devices and equipment specified herein, as shown on the drawings, or required for the service. Equipment shall be new, factory tested, and delivered ready for installation.

B. This Section includes packaged engine-generator sets for prime power supply with the following features:

1. Gas engine.

2. Unit-mounted cooling system.

3. Remote-mounting control and monitoring.

4. Battery charger

5. Muffler

6. Exhaust piping external to set

7. Outdoor enclosure

8. Remote stop switch

9. Starting battery

1.3 DEFINITIONS

A. Prime Rating: Power output rating equal to the power the generator set delivers continuously under normally varying load factors.

B. Operational Bandwidth: The total variation from the lowest to highest value of a parameter over the range of conditions indicated, expressed as a percentage of the nominal value of the parameter.

C. LP: Liquid petroleum.

D. Steady-State Voltage Modulation: The uniform cyclical variation of voltage within the operational bandwidth, expressed in Hertz or cycles per second.

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1.4 SUBMITTALS

A. Product Data: For each type of packaged engine generator indicated. Include the following:

1. Manufacturer’s product literature including all features, rated capacities, operating characteristics, furnished specialties and accessories, components, and performance data, sufficient to verify compliance to specification requirements.

2. Manufacturer's certification of prototype testing.

3. Manufacturer's published warranty documents.

4. Shop drawings showing plan and elevation views with certified overall dimensions, weight, and dimensioned mounting bolt locations.

5. Interconnection wiring diagrams showing all external connections required; with field wiring terminals marked in a consistent point-to-point manner.

6. Manufacturer's installation instructions, including required clearances.

7. Thermal damage curve for generator.

8. Time-current characteristic curves for generator protective device.

B. Shop Drawings: Detail equipment assemblies and indicate dimensions, weights, loads, required clearances, method of field assembly, components, and location and size of each field connection.

1. Dimensioned outline plan and elevation drawings of engine-generator set and other components specified.

2. Design Calculations: Signed and sealed by a qualified professional engineer.

Calculate requirements for selecting vibration isolators and for designing vibration isolation bases.

3. Vibration Isolation Base Details: Signed and sealed by a qualified professional engineer. Detail fabrication, including anchorages and attachments to structure and to supported equipment. Include base weights.

4. Wiring Diagrams: Power, signal, and control wiring.

C. Source quality-control test reports.

1. Certified Test Reports: For components and accessories that are equivalent, but not identical, to those tested on prototype unit.

2. Report of factory test on units to be shipped for this Project, showing evidence of compliance with specified requirements.

3. Report of sound generation.

4. Report of exhaust emissions showing compliance with applicable regulations.

D. Field test report of tests specified in Part 3.

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E. Operation and Maintenance Data: For packaged engine generators to include in emergency, operation, and maintenance manuals. In addition to items specified in

Division 01 Section "Operation and Maintenance Data," include the following:

1. The manuals shall include outline, interconnection, wiring, and control drawings accurately describing the equipment provided. Provide ladder logic for all programmable logic controllers in the system.

2. List of tools and replacement items recommended to be stored at the Project for ready access. Include part and drawing numbers, current unit prices, and source of supply.

3. Detail operating instructions for both normal and abnormal conditions.

4. Include all features and operating sequences, both automatic and manual. List all factory settings of relays and provide relay-setting and calibration instructions, including software, where applicable.

F. Commissioning Plan

1. A commissioning plan shall be developed and documented according to NFPA

70B-2013, Recommended Practice for Electrical Equipment Maintenance.

2. Provide a commissioning plan to perform baseline test results to verify the proper operation and sequence of operation of electrical equipment:

a. component and system tests

b. a set of baseline test results shall be documented

c. a functional performance test program shall be established, documented, and executed upon complete installation

d. acceptance testing

e. integrated system testing

f. operational tune-up

g. start-up testing

1.5 QUALITY ASSURANCE

A. Source Limitations: Obtain packaged engine generator and auxiliary components specified in this Section through one source from a single manufacturer.

B. Electrical Components, Devices, and Accessories: Listed and labeled as defined in

NFPA 70, Article 100.

C. Comply with NFPA 70.

D. Engine Exhaust Emissions: Comply with applicable state and local government requirements.

E. Manufacturer Qualifications: Maintain a service center capable of emergency maintenance and repairs at the Project with eight hours' maximum response time of

Project site. Service center shall be capable of providing training, parts, and emergency maintenance repairs.

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F. Electrical Components, Devices, and Accessories: Listed and labeled as defined in

NFPA 70, Article 100, by a testing agency, and marked for intended use.

G. Comply with ASME B15.1.

H. Comply with NFPA 37.

I. Comply with UL 2200.

J. Engine Exhaust Emissions: Comply with applicable state and local government requirements.

K. Noise Emission: Comply with Wyoming requirements for maximum noise level at adjacent property boundaries.

1.6 DELIVERY, STORAGE, AND HANDLING

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

1.7 PROJECT CONDITIONS

A. Environmental Conditions: Engine-generator system shall withstand the following environmental conditions without mechanical or electrical damage or degradation of performance capability:

1. Ambient Temperature: Minus 15 to plus 40°C.

2. Relative Humidity: 0 to 95%.

3. Altitude: Sea level to 6500 feet.

1.8 COORDINATION

A. Coordinate size and location of concrete bases for package engine generators. Cast anchor-bolt inserts into bases. Concrete, reinforcement, and formwork requirements are specified in Division 03.

1.9 EXTRA MATERIALS

A. Furnish extra materials described below that match products installed and that are packaged with protective covering for storage and identified with labels describing contents.

1. Filters: One set each of lubricating oil, fuel, and combustion-air filters.

2. Generator: Once spare generator.

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PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Basis-of-Design Product: Kohler 14RESA(L). Subject to compliance with requirements, provide the product indicated or a comparable product by one of the following:

1. Caterpillar; Engine Div.

2. Cummins Power Generation; Industrial Business Group

3. Generac Power Systems, Inc

4. Kohler Co.; Generator Division

5. MTU Onsite Energy Corporation

2.2 ENGINE-GENERATOR SET

A. Factory-assembled and -tested, engine-generator set.

B. Mounting Frame: Maintain alignment of mounted components without depending on concrete foundation; and have lifting attachments.

C. Rigging Diagram: Inscribed on metal plate permanently attached to mounting frame to indicate location and lifting capacity of each lifting attachment and generator-set center of gravity.

D. Capacities and Characteristics:

1. Power Output Ratings: Nominal ratings as indicated.

2. Output Connections: 1-phase, 3-wire.

3. Nameplates: For each major system component to identify manufacturer's name and address, and model and serial number of component.

E. Generator-Set Performance:

1. Steady-State Voltage Operational Bandwidth: 3% of rated output voltage from no load to full load.

2. Transient Voltage Performance: Not more than 20% variation for 50% step-load increase or decrease. Voltage shall recover and remain within the steady-state operating band within 3 seconds.

3. Steady-State Frequency Operational Bandwidth: 0.5% of rated frequency from no load to full load.

4. Steady-State Frequency Stability: When system is operating at any constant load within the rated load, there shall be no random speed variations outside the steady-state operational band and no hunting or surging of speed.

5. Transient Frequency Performance: Less than 5% variation for 50% step-load increase or decrease. Frequency shall recover and remain within the steady-state operating band within 5 seconds.

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6. Output Waveform: At no load, harmonic content measured line to line or line to neutral shall not exceed 5% total and 3% for single harmonics. Telephone influence factor, determined according to NEMA MG 1, shall not exceed 50%.

7. Sustained Short-Circuit Current: For a 3-phase, bolted short circuit at system output terminals, system shall supply a minimum of 250% of rated full-load current for not less than 10 seconds and then clear the fault automatically, without damage to generator system components.

2.3 ENGINE

A. Fuel: LP-gas

B. Rated Engine Speed: 1800 rpm.

C. Maximum Piston Speed for Four-Cycle Engines: 2250 fpm.

D. Lubrication System: The following items are mounted on engine or skid:

1. Filter and Strainer: Rated to remove 90% of particles 5 micrometers and smaller while passing full flow.

2. Thermostatic Control Valve: Control flow in system to maintain optimum oil temperature. Unit shall be capable of full flow and is designed to be fail-safe.

3. Crankcase Drain: Arranged for complete gravity drainage to an easily removable container with no disassembly and without use of pumps, siphons, special tools, or appliances.

E. Engine Fuel System:

1. LP-Gas (Vapor-Withdrawal) System:

a. Carburetor.

b. Secondary Gas Regulators.

c. Fuel-Shutoff Solenoid Valves.

d. Flexible Fuel Connectors.

F. Governor: Adjustable isochronous, with speed sensing.

G. Cooling System: Closed loop, liquid cooled, with radiator factory mounted on engine-generator-set mounting frame and integral engine-driven coolant pump.

1. Coolant: Solution of 50% ethylene-glycol-based antifreeze and 50% water, with anticorrosion additives as recommended by engine manufacturer.

2. Size of Radiator: Adequate to contain expansion of total system coolant from cold start to 110% load condition.

3. Temperature Control: Self-contained, thermostatic-control valve modulates coolant flow automatically to maintain optimum constant coolant temperature as recommended by the engine manufacturer.

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4. Coolant Hose: Flexible assembly with inside surface of nonporous rubber and outer covering of aging-, ultraviolet-, and abrasion-resistant fabric.

a. Rating: 50-psig maximum working pressure with coolant at 180°F, and noncollapsible under vacuum.

b. End Fittings: Flanges or steel pipe nipples with clamps to suit piping and equipment connections.

H. Muffler/Silencer: Critical type, sized as recommended by engine manufacturer and selected with exhaust piping system to not exceed engine manufacturer's engine backpressure requirements.

1. Minimum sound attenuation of 25 dB at 500 Hz.

2. Sound level measured at a distance of 10 feet from exhaust discharge after installation is complete shall be 67 dBA or less.

I. Air-Intake Filter: Heavy-duty, engine-mounted air cleaner with replaceable dry-filter element and "blocked filter" indicator.

J. Starting System: 12V electric, with negative ground.

1. Components: Sized so they will not be damaged during a full engine-cranking cycle with ambient temperature at maximum specified in Part 1 "Project

Conditions" Article.

2. Cranking Motor: Heavy-duty unit that automatically engages and releases from engine flywheel without binding.

3. Cranking Cycle: 60 seconds.

4. Battery: Adequate capacity within ambient temperature range specified in Part 1

"Project Conditions" Article to provide specified cranking cycle at least three times without recharging.

5. Battery Cable: Size as recommended by engine manufacturer for cable length indicated. Include required interconnecting conductors and connection accessories.

6. Battery Charger: Current-limiting, automatic-equalizing and float-charging type.

Unit shall comply with UL 1236 and include the following features:

a. Operation: Equalizing-charging rate of 10 A shall be initiated automatically after battery has lost charge until an adjustable equalizing voltage is achieved at battery terminals. Unit shall then be automatically switched to a lower float-charging mode and shall continue to operate in that mode until battery is discharged again.

b. Automatic Temperature Compensation: Adjust float and equalize voltages for variations in ambient temperature from minus 40°C to plus

60°C to prevent overcharging at high temperatures and undercharging at low temperatures.

c. Automatic Voltage Regulation: Maintain constant output voltage regardless of input voltage variations up to plus or minus 10%.

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d. Ammeter and Voltmeter: Flush mounted in door. Meters shall indicate charging rates.

2.4 CONTROL AND MONITORING

A. Automatic Starting System Sequence of Operation: When mode-selector switch on the control and monitoring panel is in the automatic position, remote-control contacts in one or more separate automatic transfer switches initiate starting and stopping of generator set. When mode-selector switch is switched to the on position, generator set starts. The off position of same switch initiates generator-set shutdown. When generator set is running, specified system or equipment failures or derangements automatically shut down generator set and initiate alarms. Operation of a remote emergency-stop switch also shuts down generator set.

B. Configuration: Operating and safety indications, protective devices, basic system controls, and engine gages shall be grouped in a common control and monitoring panel mounted on the generator set. Mounting method shall isolate the control panel from generator-set vibration.

C. Indicating and Protective Devices and Controls:

1. AC voltmeter.

2. AC ammeter.

3. AC frequency meter.

4. DC voltmeter (alternator battery charging).

5. Engine-coolant temperature gage.

6. Engine lubricating-oil pressure gage.

7. Running-time meter.

8. Ammeter-voltmeter, phase-selector switch(es).

9. Generator-voltage adjusting rheostat.

10. Start-stop switch.

11. Overspeed shutdown device.

12. Coolant high-temperature shutdown device.

13. Coolant low-level shutdown device.

14. Oil low-pressure shutdown device.

D. Supporting Items: Include sensors, transducers, terminals, relays, and other devices and include wiring required to support specified items. Locate sensors and other supporting items on engine or generator, unless otherwise indicated.

E. Remote Emergency-Stop Switch: Flush, wall mounted, unless otherwise indicated, and labeled. Pushbutton shall be protected from accidental operation via protective cover.

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2.5 GENERATOR OVERCURRENT AND FAULT PROTECTION

A. Generator Circuit Breaker: Molded-case, thermal-magnetic type; 100% rated; complying with NEMA AB 1 and UL 489.

1. Tripping Characteristic: Designed specifically for generator protection.

2. Trip Rating: Matched to generator rating.

3. Shunt Trip: Connected to trip breaker when generator set is shut down by other protective devices.

4. Mounting: Adjacent to or integrated with control and monitoring panel.

2.6 GENERATOR, EXCITER, AND VOLTAGE REGULATOR

A. Comply with NEMA MG 1.

B. Drive: Generator shaft shall be directly connected to engine shaft. Exciter shall be rotated integrally with generator rotor.

C. Electrical Insulation: Class H or Class F.

D. Stator-Winding Leads: Brought out to terminal box to permit future reconnection for other voltages if required.

E. Construction shall prevent mechanical, electrical, and thermal damage due to vibration, overspeed up to 125% of rating, and heat during operation at 110% of rated capacity.

F. Enclosure: Dripproof.

G. Voltage Regulator:

1. Solid-state type, separate from exciter, providing performance as specified.

2. Adjusting rheostat on control and monitoring panel shall provide plus or minus

5% adjustment of output-voltage operating band.

H. Subtransient Reactance: minimum 23%.

2.7 OUTDOOR GENERATOR-SET ENCLOSURE

A. Description: Vandal-resistant, weatherproof housing, wind resistant up to 100 mph.

Multiple panels shall be lockable and provide adequate access to components requiring maintenance. Panels shall be removable by one person without tools. Instruments and control shall be mounted within enclosure.

B. Engine Cooling Airflow through Enclosure: Maintain temperature rise of system components within required limits when unit operates at 110% of rated load for 2 hours with ambient temperature at top of range specified in system service conditions.

1. Louvers: Fixed-engine, cooling air inlet and discharge. Storm-proof and drainable louvers prevent entry of rain and snow.

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2. Automatic Dampers: At engine cooling-air inlet and discharge. Dampers shall be closed to reduce enclosure heat loss in cold weather when unit is not operating.

2.8 FINISHES

A. Indoor and Outdoor Enclosures and Components: Manufacturer's standard finish over corrosion-resistant pretreatment and compatible primer.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine areas, equipment bases, and conditions, with Installer present, for compliance with requirements for installation and other conditions affecting packaged engine-generator performance.

B. Examine roughing-in of piping systems and electrical connections. Verify actual locations of connections before packaged engine-generator installation.

C. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 INSTALLATION

A. Equipment shall be installed in accordance with final submittals and contract documents.

B. Installation shall comply with applicable state and local codes.

C. Install equipment in accordance with manufacturer's instructions and instructions included in the listing or labeling of UL listed products. Comply with packaged engine-generator manufacturers' written installation and alignment instructions and with NFPA.

D. Installation of equipment shall include furnishing and installing all interconnecting wiring between all major equipment provided for the on-site power system. The contractor shall also perform interconnecting wiring between equipment sections (when required), under the supervision of the equipment supplier.

E. Equipment shall be installed on concrete housekeeping pads. Equipment shall be permanently fastened to the pad in accordance with manufacturer’s instructions and seismic requirements of the site.

F. Equipment shall be initially started and operated by representatives of the manufacturer.

G. All equipment shall be physically inspected for damage. Scratches and other installation damage shall be repaired prior to final system testing. Equipment shall be thoroughly cleaned to remove all dirt and construction debris prior to final testing of the system.

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H. Install packaged engine generator to provide access, without removing connections or accessories, for periodic maintenance.

I. Electrical Wiring: Install electrical devices furnished by equipment manufacturers but not specified to be factory mounted.

3.3 CONNECTIONS

A. Connect fuel, cooling-system, and exhaust-system piping adjacent to packaged engine generator to allow service and maintenance.

B. Connect fuel piping to engines with a gate valve and union and flexible connector.

1. LP-gas piping, valves, and specialties for gas piping are specified in Division 23

Section "Facility Liquefied-Petroleum Gas Piping."

C. Ground equipment according to Division 26 Section "Grounding and Bonding for

Electrical Systems."

D. Connect wiring according to Division 26 Section "Low-Voltage Electrical Power

Conductors and Cables."

3.4 IDENTIFICATION

A. Identify system components according to Division 26 Section "Common Work Results for Electrical."

3.5 FACTORY TESTS

A. Equipment supplied shall be fully tested at the factory for function and performance.

3.6 FIELD QUALITY CONTROL

A. Perform tests and inspections and prepare test reports.

1. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect components, assemblies, and equipment installations, including connections, and to assist in testing.

B. Tests and Inspections:

1. Perform tests recommended by manufacturer and each electrical test and visual and mechanical inspection (except those indicated to be optional) for "AC

Generators and for Emergency Systems" specified in NETA Acceptance Testing

Specification. Certify compliance with test parameters.

2. NFPA Acceptance Tests: Perform tests required by NFPA that are additional to those specified here including, but not limited to, single-step full-load pickup test.

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3. Battery Tests: Equalize charging of battery cells according to manufacturer's written instructions. Record individual cell voltages.

a. Measure charging voltage and voltages between available battery terminals for full-charging and float-charging conditions. Check electrolyte level and specific gravity under both conditions.

b. Test for contact integrity of all connectors. Perform an integrity load test and a capacity load test for the battery.

c. Verify acceptance of charge for each element of the battery after discharge.

d. Verify that measurements are within manufacturer's specifications.

4. Battery-Charger Tests: Verify specified rates of charge for both equalizing and float-charging conditions.

5. System Integrity Tests: Methodically verify proper installation, connection, and integrity of each element of engine-generator system before and during system operation. Check for air, exhaust, and fluid leaks.

6. Voltage and Frequency Transient Stability Tests: Use recording oscilloscope to measure voltage and frequency transients for 50 and 100% step-load increases and decreases, and verify that performance is as specified.

7. Harmonic-Content Tests: Measure harmonic content of output voltage under

25% and at 100% of rated linear load. Verify that harmonic content is within specified limits.

8. Noise Level Tests: Measure A-weighted level of noise emanating from generator-set installation, including engine exhaust and cooling-air intake and discharge, at four locations on the property line, and compare measured levels with required values.

C. Coordinate tests with tests for transfer switches and run them concurrently.

D. Test instruments shall have been calibrated within the last 12 months, traceable to standards of NIST, and adequate for making positive observation of test results. Make calibration records available for examination on request.

E. Leak Test: After installation, charge system and test for leaks. Repair leaks and retest until no leaks exist.

F. Operational Test: After electrical circuitry has been energized, start units to confirm proper motor rotation and unit operation.

G. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment.

H. Remove and replace malfunctioning units and retest as specified above.

I. Retest: Correct deficiencies identified by tests and observations and retest until specified requirements are met.

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J. Report results of tests and inspections in writing. Record adjustable relay settings and measured insulation resistances, time delays, and other values and observations. Attach a label or tag to each tested component indicating satisfactory completion of tests.

3.7 COMMISSIONING PLAN

A. Perform the approved commissioning plan; establish baseline test results to verify the proper operation and sequence of operation of electrical equipment.

3.8 TRAINING

A. The equipment supplier shall provide training for the facility operating personnel covering operation and maintenance of the equipment provided. The training program shall be not less than 4 hours in duration. Training date shall be coordinated with the

Contracting Officer.

B. Engage a factory-authorized service representative to train Government’s maintenance personnel to adjust, operate, and maintain packaged engine generators.

END OF SECTION 263213