263213.pdf

GENERATOR SYSTEM 26 32 13- 1

SECTION 23 32 13 – GENERATOR SYSTEM

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. The electrical contractor shall procure and install a packaged standby generator system, consisting of a generator set and generator controls, and all required accessories as specified.

The equipment supplier shall be the authorized distributor for each component of the products specified herein. The work shall include furnishing of all equipment, testing, and training to provide a complete and workable power system, including generator set, generator set controls, and testing as specified herein. It is the intent of these specifications to have a single source responsibility for the generator set, generator set controls, and generator accessories.

B. Any and all exceptions to the published specifications shall be subject to the approval of the engineer.

C. The power system shall be furnished by a single manufacturer who shall be responsible for the design, coordination, and testing of the complete system. The entire system shall be provided and installed in accordance with the specifications herein.

D. The equipment shall be produced by a manufacturer who has produced this type of equipment for a period of at least 10 years and who maintains a service organization available twenty-four hours a day throughout the year.

E. The manufacturer or representative shall be on-site to assist in final check-out and commissioning of all generator system equipment.

F. Seismic Performance: Generator shall withstand the effects of earthquake motions determined according to SEI/ASCE 7.

G. The term "withstand" means "the unit will remain in place without separation of any parts from the device when subjected to the seismic forces specified.

1.2 GENERAL REQUIREMENTS

A. The equipment supplier shall provide a standby generator system that has been tested during design verification, production and at the final job site and meets the requirements of NFPA 110 for a Class X, Type 10, Level 1 system, NFPA 99 for a Type 1 system, NFPA 37, NFPA 1221 and UL 2200.

B. All furnished equipment shall be of recent commercial design and will be complete with all of the necessary accessories for complete installation as described in this specification. The equipment supplied and installed shall meet the requirements of the National Electrical Code, along with all applicable local codes and regulations.

C. Equipment shall be new and of recent production of a national firm that manufactures generator sets, controls and accessories, and assembles the generator sets as a complete and coordinated

Amendment 0005 to RFP 19-102-SOL-00026

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system. There shall be one source responsibility for warranty, parts, and service through a local representative with factory-trained servicemen. The service personnel shall be located within the State of Montana.

D. The generator shall be installed in a drop over, weather proof walk-in enclosure. The secure enclosure shall be capable of resisting the entrance of precipitation at the maximum wind velocities referenced in NFPA 5000

E. Diesel Fuel Source.

1.3 ACCEPTABLE MANUFACTURERS

A. Onan

B. Kohler

C. Caterpillar

D. Generac (TWE)

1.4 SHOP DRAWING SUBMITTALS

A. Shop drawing submittals shall include:

1. Prototype test certification and specification sheets showing all standard and optional accessories to be supplied.

2. Detailed installation diagrams including all terminal locations.

3. Dimension drawings, including weights of all components.

4. Dimension drawings and installation requirements of drop over enclosure

5. Interconnection diagrams identifying by terminal number, each required interconnection between the generator set, controllers, switchgear (if equipped), remote annunciator panel, and all other accessories.

B. See specification 260000 for additional shop drawing requirements.

1.5 WARRANTY, MAINTENANCE AND DOCUMENTATION

A. All provided equipment and materials shall be guaranteed against defective material and workmanship in accordance with the manufacturer’s published warranty for one year from date of project substantial completion.

B. The equipment manufacturer and its distributor shall maintain a 24-hour parts and service organization within the State of Montana. This organization shall be regularly engaged in a maintenance contract program to perform preventive maintenance and service on equipment specified. A service agreement shall be available and shall include system operation under simulated operating conditions, adjustment to the generator and controls as required, and certification in the owner's maintenance log of repairs made and proper functioning of all systems.

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C. At the time orders are placed for any item of equipment requiring service or operating maintenance, the supplier shall request the manufacturer furnish three (3) copies of OPERATION AND MAINTENANCE INSTRUCTIONS for each piece of equipment. These shall be original manuals, not photocopies. All manuals shall be organized into binders and presented to the Owner upon start of the warranty period. These binders shall be submitted to the Architect/Engineer and approved by him before authorization of final payment.

PART 2 - GENERATOR SET:

2.1 TESTING

A. To assure that the equipment has been designed and built to the highest reliability and quality standards, the manufacturer and/or local representative shall be responsible for three separate tests: design prototype tests, final production tests, and site tests.

1. Design Prototype Tests: Components of the emergency system such as the engine/generator set and accessories shall not be subjected to prototype tests since the tests are potentially damaging. Rather, similar design prototypes and preproduction models, which will not be sold, shall have been used for the following tests.

a. Maximum power (kW).

b. Maximum motor starting (kVA) at 35% instantaneous voltage dip.

c. Alternator temperature rise by embedded thermocouple and/or by resistance method per NEMA MG1-22.40 and 16.40.

d. Governor speed regulation under steady-state and transient conditions.

e. Voltage regulation and generator transient response.

f. Fuel consumption at 1/4, 1/2, 3/4, and full load.

g. Harmonic analysis, voltage waveform deviation, and telephone influence factor.

h. Three-phase short circuit tests.

i. Alternator cooling air flow.

j. Torsional analysis to verify that the generator set is free of harmful torsional stresses.

k. Endurance testing.

2. Final Production Tests: Each generator set shall be tested under varying loads with guards and exhaust system in place. Tests shall include:

a. Single-step load pickup.

b. Transient and steady-state governing.

c. Safety shutdown device testing.

d. Voltage regulation.

e. Rated Power @ 0.8 PF

f. Maximum Power.

3. Upon request, arrangements to either witness this test will be made, or a certified test record will be sent prior to shipment.

4. Site Tests:

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a. An installation check, start-up, and building load test shall be performed by the manufacturer's local representative. The engineer, regular operators, and the maintenance staff shall be notified of the time and date of the site test. The tests shall include:

b. Fuel, lubricating oil, and antifreeze shall be checked for conformity to the manufacturer's recommendations, under the environmental conditions present and expected.

c. Accessories that normally function while the set is “standing by” shall be checked prior to cranking the engine. These shall include: battery charger, and remote annunciator.

d. Start-up under test mode to check for exhaust leaks, path of exhaust gases outside the building, cooling air flow, movement during starting and stopping, vibration during running, normal and emergency line-to-line voltage and frequency, and phase rotation.

e. Automatic start-up by means of simulated power outage to test remote- automatic starting, transfer of the load, paralleling, operation of sequenced loading and automatic shutdown. Prior to this test, all transfer switch timers shall be adjusted for proper system coordination. Engine coolant temperature, oil pressure, and battery charge level along with generator voltage, amperes, and frequency shall be monitored throughout the test. An external load bank shall be connected to the system if sufficient building load is unavailable to load the generator to the nameplate kW rating.

2.2 EQUIPMENT

A. The generator set shall provide 150 kW, 188 kVA while operating at 120/208 volts 3-phase, 0.8 power factor. Generator set shall be capable of this rating while operating in an ambient condition of 77°F (59.2°C) and 1991 feet above sea level.

B. The generator set shall be capable of starting motor loads of 199 kVA inrush, with a maximum voltage dip of 20%.

C. Provide the generator with a walk-in weatherproof, drop over insulated enclosure. The enclosure set shall occupy a space no larger than 18' long by 12' wide. No equipment larger than this shall be bid without requesting prior approval and specifically identifying the larger dimensions.

D. Vibration isolators shall be provided between the engine-generator and concrete base.

2.3 ENGINE

A. Generator engine shall deliver approximately 350 hp at a governed speed of 2300 rpm. The engine shall be equipped with the following:

1. An isochronous governor capable of +.25% steady-state frequency regulation.

2. Positive engagement solenoid shift-starting motor.

3. Automatic battery charging alternator with solid-state voltage regulation.

4. Positive displacement, full pressure lubrication oil pump, cartridge oil filters, dipstick, and oil drain.

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5. Dry-type replaceable air cleaner elements for standard-duty applications.

6. The engine shall be liquid-cooled by a unit-mounted radiator, blower fan, water pump, and thermostats.

7. Radiator duct adaptor flange.

8. Oil Heater

2.4 GENERATOR

A. The alternator shall be salient-pole, brushless, 12-lead re-connectable, self-ventilated of drip-proof construction with amortisseur rotor windings and skewed stator for smooth voltage waveform. The insulation shall meet the NEMA standard (MG1-22.40 and 16.40) for Class H and be insulated with epoxy varnish to be fungus resistant per MIL 1-24092. Temperature rise of the rotor and stator shall be limited to NEMA Class F ratings. The excitation system shall be of brushless construction controlled by a solid- state voltage regulator capable of maintaining voltage within +/- 2% at any constant load from 0% to 100% of rating. The regulator must be isolated to prevent tracking when connected to SCR loads, and provide individual adjustments for voltage range, stability and volts-per-hertz operations; and be protected from the environment by conformal coating.

B. Upon 1-step application of any load up to 100% of the rated load at 0.8 power factor, the voltage dip shall not exceed 20% and the generator shall recover to rated voltage and frequency.

C. The generator shall be capable of sustaining at least 250% of rated current for at least 10 seconds under a 3-phase symmetrical short circuit without the addition of separate current support devices.

D. The generator, having a single maintenance-free bearing, shall be directly connected to the flywheel housing with a semi-flexible coupling between the rotor and the flywheel.

E. Diesel fuel type.

2.5 Accessories

A. Battery rack, and battery cables, capable of holding the manufacturer's recommended batteries, shall be supplied.

B. Block heater & coolant heater, factory installed. Each unit shall be rated 2000 watt, single phase at 208V.

C. 12-volt batteries capable of delivering the manufacturer's recommended minimum cold-cranking Amps required at 0oF, per SAE Standard J-537, shall be supplied.

D. Automatic float and equalize battery charger with +/- 1% constant voltage regulation from no load to full load over +/-10% AC input line variation, current limited during engine cranking and short circuit conditions, temperature compensated for ambient temperatures from -40oC to +60oC, 5% accurate voltmeter and ammeter, fused, reverse polarity and transient protected.

E. The generator-mounted radiator shall include a mounting flange.

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F. 24” high double-wall UL142 fuel base tank for minimum 24-hour run time at 100% load.

G. IBC Seismic Certified/Seismic Rated Vibration Isolators

H. The engine exhaust silencer shall be constructed of carbon steel and shall be coated to be temperature and rust resistance. The silencer shall be rated for critical application and shall reduce total engine exhaust noise by 25-35 dB(A). A flanged flex connector, non-combustible ceiling thimble, and appropriate rain cap shall be provided. The silencer shall be configured with a bottom inlet and top outlet to extend exhaust piping vertically up through the ceiling of the generator room.

I. Remote annunciator panel shall be provided along with all interconnecting cabling, enabling the generator status to be viewed remotely. The remote annunciator panels shall be capable of connecting to the system controller (SC). The panels shall be capable of flush-mounting into a standard 2x4 framed wall. Surface-mounted annunciators are not acceptable. The annunciator shall be located in Reception #106 adjacent to FAA. Provide ¾” conduit to annunciator and all cabling required. The annunciator shall indicate alarm conditions through visual and audible indicators as follows, per NFPA 99 4.4.1.1.18:

1. Generator Set Supplying Power to the Load

2. Battery Charger Malfunctioning

3. Low Lube Oil Pressure

4. Low Water Temperature

5. Excessive Water Temperature

6. Low Fuel

7. Overcrank (failed to start)

8. Overspeed

2.6 INTEGRATED CONTROL SYSTEM

A. The generator set shall include a generator controller that digitally controls the engine and alternator for governor speed, voltage regulation, engine functions, auto-synchronization, load sharing and protection.

1. The controller shall annunciate in audible form the following minimal conditions:

a. Over current

b. Over/under voltage

c. Sync check

d. Reverse Power

e. Over-Speed

2. The controller shall display, as a minimum:

a. Volts and amps

b. kW, kVAR, and power factor

c. Engine speed and alternator frequency

d. Oil pressure and temperature

e. Coolant temperature

f. Battery voltage

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g. Fuel level

h. Run hours

3. The controller shall include a touch screen interface to navigate screens and access system parameters.

2.7 AUTOMATIC TRANSFER SWITCHES (quantity of 2)

A. Open transition automatic transfer switches shall be provided with number of poles, amperage, and voltage as shown on the plans.

B. The switches shall be UL 1008 listed.

C. The switches shall be equal to Generac GTS series.

D. Provide a set of dry contacts for a connection to the mechanical control panel for operational sequence during normal power failure.

2.8 DROP OVER WEATHERPROOF ENCLOSURE

A. Vandal-resistant, weatherproof insulated enclosure with 14 gauge galvaneal panel construction with eight stage powder coat finish.

B. Install generator and enclosure on 6” reinforced concrete slab, exact dimensions determined by specific generator enclosure supplied. Location to be prepared with gravel sub-base as required by project structural engineer.

C. Insulated enclosure with minimum 2” 4LB CU/FT Rockwool Insulation. Provide 22 GA galvanized perforated interior liner.

D. Walk-In Style with minimum 24” clearance on each side of engine and 42” clearance behind generator. Provide minimum 36” working clearance in front of panelboard location and generator main circuit breaker.

E. One 36” wide walk-in door with stainless steel spring loaded door hold back and panic push bar door release hardware. Provide drip edge around all openings.

F. Custom color finish on exterior of enclosure. Owner to provide RAL color.

G. Enclosure base frame 6” tall, designed to remove entire enclosure for major service.

H. Pitched roof construction with safety lanyard tie off spaced across entire roof.

I. Exhaust opening rain shield and hardware for enclosure mounting. Provide drip edge around opening.

J. Aluminum intake and radiator air discharge louvers. Provide 120 volt motorized dampers on all louvers, spring open/motor closed.

K. Critical grade exhaust silencer to be internally mounted in enclosure.

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L. Extend oil and coolant drains to exterior of enclosure. Provide valves mounted on enclosure.

M. 120/208 volt, 3-phase 100A load center panel with main circuit breaker and required branch circuit breakers. All electrical components provided on generator and enclosure including, but not limited to, block heater, battery charger, light fixtures, receptacles, heater, etc. to be circuited to panel by electrical contractor on-site for a complete installation. Panel to be connected to Panel MDP in building with 40A, 3-phase circuit with 4 #8 AWG conductors in 1” conduit to panel. Provide a 40A/3P circuit breaker in Panel MDP.

N. Four LED vapor tight light fixtures to provide minimum 50 footcandles average maintained with light switch at door entrance.

O. Two LED emergency battery lights connected to 120 volt supply.

P. Two GFCI type duplex receptacles connected to 120 volt supply.

Q. 5 KW electric space heater connected to 208 volt, 1-phase supply.

R. Electrical Contractor to coordinate with generator enclosure supplier for field installation of electrical panel and all devices that are not factory mounted.

2.9 TESTS AND CERTIFICATION

A. The complete generator system shall be factory tested to ensure proper operation of the individual components and correct overall sequence of operation and to ensure that all equipment is in compliance with the specification requirements. Tests and certifications shall meet the requirements of NFPA 110 section 7.13.

2.10 TRAINING

A. The equipment manufacturer or representative shall supply on-site training at the owner's facility. The training shall continue until the owner is fully satisfied that he understands the operation of his system and shall be conducted by a full time employee of the manufacturer.

The training shall cover installation, operation, maintenance, and troubleshooting of the equipment.

END OF SECTION 26 32 13