26 32 13 - Packaged Engine Generator Systems.pdf

26 32 13 – PACKAGED ENGINE GENERATOR SYSTEMS

Herbert, Rowland & Grubic, Inc. 26 32 13-1 005153.0436

SECTION 26 32 13 - PACKAGED ENGINE GENERATOR SYSTEMS

PART 1 - GENERAL

1.1 SUMMARY

A. Packaged Tier 3 EPA compliant engine generator set with above ground fuel storage tank.

B. Exhaust silencer and fittings.

C. Battery and charger.

1.2 RELATED SECTIONS

A. Division 26.

B. Division 40.

1.3 REFERENCES

NEMA AB1 Molded Case Circuit Breakers

NEMA MG1 Motors and Generators

NEMA 250 Enclosures for Electrical Equipment (1000 Volts Max)

NFPA 30 Flammable and Combustible Liquids Code

NFPA 70 National Electrical Code

NFPA 99 Health Care Facilities

NFPA 101 Life Safety Code

NFPA 110 Emergency and Standby Power Systems

1.4 SUBMITTALS

A. Provide in accordance with Sections 01 33 00 - Submittals and 01 78 23 - Operation And

Maintenance Data and as supplemented herein.

B. Indicate electrical characteristics and connection requirements. Show plan and elevation views with overall and interconnection point dimensions, fuel consumption rate curves at various loads, ventilation and combustion air requirements, and electrical diagrams including schematic and interconnection diagrams. Indicate weights of all major components.

C. Provide Product data showing dimensions, weights, ratings, interconnection points, and internal wiring diagrams for engine, generator, control panel, battery, battery rack, battery charger, exhaust silencer, vibration isolators, lighting fixtures, receptacles, power distribution equipment, and all other ancillary devices.

D. Submit detailed information on all generator controls and accessories specified and shown on the Contract Drawings.

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E. Submit sizing report from manufacturer’s sizing software for all connected loads as shown on the Contract Drawings.

F. Submit scaled layout drawings for weather protective enclosures, acoustical sound limiting enclosures. Drawings shall identify National Electric Code work space clearance for electrical equipment, panel and equipment layouts, lighting fixtures, switches, receptacles, louvers, battery and charger locations and other details.

G. Test Reports - Indicate results of performance testing.

H. Manufacturer’s Installation Instructions - Indicate application conditions and limitations of use stipulated by Product testing agency. Include instructions for storage, handling, protection, examination, preparation, installation, and starting of Product.

I. Manufacturer’s Performance Affidavit - Certify that Products meet or exceed specified requirements.

J. Submit all Manufacturers’ Field Reports.

K. Manufacturer’s Field Reports - Indicate procedures and findings.

L. Power System Study – Furnish manufacturer’s catalog information, equipment ratings, and circuit breaker/fuse curves to the Contractor for use in the Power System Study as specified in Section 26 05 73 - Power System Study and Testing.

M. The Contractor shall submit the Preliminary Power System Study Report as specified in Section 26 05 73 - Power System Study and Testing prior to, or concurrent with the generator equipment submittals. The report information will be used by the Engineer to review the equipment submittals for overall approval of the shop drawings. Submittals will not be reviewed prior to receiving the preliminary report and will be returned to the Contractor.

N. Manufacturer shall provide additional design information to Owner, as required, to assist in obtaining an Air Quality Discharge Permit for the generator unit.

1.5 QUALITY ASSURANCE

A. Perform Work in accordance with NFPA 110.

B. Maintain one copy of document on site.

1.6 QUALIFICATIONS

A. Manufacturer - Company specializing in manufacturing the Products specified in this Section with minimum 10 years’ documented experience, and with service facilities within 100 miles of project site. Manufacturer must provide generator sizing software, specific to manufacturer, available for engineer’s use.

B. Supplier - Authorized distributor of specified manufacturer with minimum 10 years’ documented experience.

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1.7 REGULATORY REQUIREMENTS

A. Conform to requirements of NFPA 70, NFPA 110, and NFPA 101.

B. Furnish Products listed and classified by Underwriters Laboratories or testing firm acceptable to authority having jurisdiction as suitable for purpose specified and indicated.

C. Generator set shall be an EPA Compliant Product, certified and labeled to comply with the EPA’s Tier 3 Exhaust Emission Standards for Non-Road Equipment. Additionally, the engine shall comply with the State Emission regulations at the time of installation/commissioning. Actual engine emissions values must be in compliance with applicable EPA emissions standards per ISO 8178 – D2 Emissions Cycle at specified ekW / bHP rating. Utilization of the “Transition Program for Equipment Manufacturers” (also known as “Flex Credits”) to achieve EPA certification shall not be acceptable. The in-cylinder engine technology shall not permit unfiltered exhaust gas to be introduced into the combustion cylinder. Emissions requirements / certifications of this package: EPA Tier 3.

1.8 PRE-INSTALLATION CONFERENCE

A. Convene one week prior to commencing work of this Section.

1.9 DELIVERY, STORAGE, AND HANDLING

A. Deliver, store, protect and handle products to site.

B. Accept unit on site on skids. Inspect for damage.

C. Protect equipment from dirt and moisture by securely wrapping in heavy plastic.

1.10 WARRANTY

A. Provide 5 year Parts & Labor comprehensive warranty with no deductible. Parts, labor and travel expenses shall be included. Warranty shall be registered to the Owner.

1.11 EXTRA MATERIALS

A. Provide two of each fuel, coolant filters (if provided), oil and air filter element for each generator set.

1.12 FACTORY TESTING

A. Provide a factory certified load test report on the specific genset to be provided for this project. The factory test shall be conducted for two hours @ 0.8 PF. The manufacturer shall submit test report to Engineer for review and approval prior to shipment from the factory.

Herbert, Rowland & Grubic, Inc. 26 32 13-4 005153.0436

1.13 UL2200 – STANDARD FOR STATIONARY ENGINE GENERATOR ASSEMBLIES

A. The generator set shall be listed to UL2200 or submit to an independent third party certification process to verify compliance as installed.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Kohler.

B. Cummins.

C. MTU Onsite Energy.

D. Or Equal.

2.2 PACKAGE ENGINE GENERATOR SYSTEM

A. Description - NFPA 110, engine generator system to provide source of power for Level 1 applications, and conforming to NFPA 99.

B. Size – 80 Kw.

2.3 ENGINE

A. Type - Water-cooled inline or V-type, compression ignition Diesel internal combustion engine.

B. Rating - Sufficient to operate under 10 percent overload for one hour in an ambient of 90 degrees F at elevation of 500 feet.

C. Fuel System – Liquid Propane.

D. Engine speed – 1800 rpm.

E. Governor - Electronic governor, standard product of the generator manufacturer.

F. Safety Devices - Engine shutdown on high water temperature, low oil pressure, overspeed, low coolant level, engine overcrank, and fuel leak. Limits as selected by manufacturer.

G. Engine Starting - DC starting system with positive engagement, number and voltage of starter motors in accordance with manufacturer's instructions. Include remote starting control circuit, with MANUAL-OFF-REMOTE selector switch on engine-generator control panel.

H. Engine Jacket Heater – Tank type, thermal circulation-type water heater with integral thermostatic control, sized to maintain engine jacket water at 90 degrees F

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(32 degrees C), and suitable for voltage ratings as shown on the Contract Drawings.

Contractor shall coordinate branch circuit breaker rating as required to feed the heater.

I. Radiator - Radiator using glycol coolant, with blower type fan, sized to maintain safe engine temperature in ambient temperature of 122 degrees F (50 degrees C). Radiator air flow restriction 0.5 inches of water (1.25 Pa) maximum. Radiator shall be remote mounted. Provide all piping and pumps required for the location of the radiator shown on the Contract Drawings. The contractor shall be responsible for installing the radiator at a height so as to ensure the expansion tanks are located outside, on the radiator unit.

J. Engine Accessories - Fuel filter, lube oil filter, intake air filter, lube oil cooler, fuel transfer pump, fuel priming pump, water pump. Include fuel pressure gauge, water temperature gauge, and lube oil pressure gauge on engine/generator control panel.

Include spin on coolant filters, if available.

K. Mounting - Provide unit with suitable spring-type vibration isolators and mount on structural steel base.

L. Provide extended lube oil and coolant drains with ball valves. Coolant drains shall be brass pipe.

2.4 ALTERNATOR

A. Generator - NEMA MG1, three phase, 4 pole, reconnectable brushless synchronous generator with brushless PMG exciter.

B. Generator Minimum Rating – The Engineer has initially sized each of the generators as noted on the Contract Drawings (90 percent sustained voltage) at 0.9 PF, 208/120 volts, 3-Phase, 60 Hz at 1800 rpm using commercially available manufacturer’s software. The supplier/manufacturer shall verify this sizing as being either proper for the installation or provide a unit that will meet the requirements of this specification. The size shall not be less than that shown. The supplier/manufacturer shall submit the sizing calculations with the shop drawing submittal. No additional costs will be allowed for the supplier/manufacturer’s compliance with these Contract Documents.

C. Insulation Class – H.

D. Temperature Rise – 125 degrees C.

E. Enclosure - NEMA MG1, open drip-proof.

F. Voltage Regulation - Include generator-mounted volts per hertz exciter-regulator to match engine and generator characteristics, with voltage regulation +1 percent from no load to full load. Include manual controls to adjust voltage drop, voltage level (+5 percent) and voltage gain.

G. Provide 120 VAC alternator strip heater.

Herbert, Rowland & Grubic, Inc. 26 32 13-6 005153.0436

2.5 ACCESSORIES

A. Exhaust Silencer - Critical type silencer, with muffler companion flanges, tailpipe, stainless steel rain cap, flexible stainless steel exhaust fitting, sized in accordance with engine manufacturer’s instructions and condensate drain with plug type drain valve in accordance with manufacturer’s recommendations. The drain shall be piped with copper tubing to the closest sump or waste drain. Provide stainless steel wall or ceiling thimbles as required for each specific application. All exhaust piping to be provided with insulation and stainless steel metal jacket. Provide all waterproofing necessary at penetrations and patch existing openings.

B. Housing, louvers, exhaust system, etc. shall be designed as sound-proofed systems with maximum sound level not exceeding 91 DBA at 23 feet. Compliance with the sound restriction shall be included with the submissions, including all necessary backup data to satisfy local authorities.

C. Batteries - Heavy duty, diesel starting type lead-acid storage batteries, 170 ampere-hours minimum 700 cold cranking amps capacity. Match battery voltage to starting system. Include necessary cables and clamps.

1. Provide battery pad heater.

D. Battery - Marine style HDPE, battery boxes.

E. Battery Charger - Current limiting type designed to float at 2.17 volts per cell and equalize at 2.33 volts per cell. Include overload protection, full wave rectifier, DC voltmeter and ammeter, and 120 volts AC fused input. LaMarche Model A46 or equal.

F. Provide wall-mounted enclosure to meet NEMA 250, Type 1 requirements.

G. (1) Line Circuit Breaker - NEMA AB1, 100% rated circuit breakers on generator output with integral thermal magnetic & LSI sized to the output of the generator set. Circuit breaker shall include a battery operated, 24 VDC shunt trip.

H. Engine-Generator Control Panel - NEMA 250, Type 1 generator mounted control panel enclosure with engine and generator controls and indicators. Include provision for padlock and the following equipment and features:

1. Frequency Meter - 45-65 Hz. range, 3.5 inch (89 mm) dial.

2. AC Output Voltmeter - 3.5 inch (89 mm) dial, 2 percent accuracy, with phase selector switch.

3. AC Output Ammeter - 3.5 inch (89 mm) dial, 2 percent accuracy, with phase selector switch.

4. Output voltage adjustment.

5. Push-to-test indicator lamps, one each for low oil pressure, high water temperature, overspeed, and overcrank.

6. Engine start/stop selector switch.

7. Engine running time meter.

8. Oil pressure gauge.

9. Water temperature gauge.

Herbert, Rowland & Grubic, Inc. 26 32 13-7 005153.0436

10. Auxiliary Relay - 3 SPDT, operates when engine runs, with contact terminals prewired to terminal strip. These contacts shall be reserved for PLC monitoring.

Provide additional contacts as required for automatic operation.

11. Additional visual indicators and alarms as required by NFPA 110 - Level 2 use.

12. Remote Alarm Contacts - Pre-wire SPDT contacts to terminal strip for remote alarm functions required by NFPA 110.

13. Generator manufacturer shall coordinate mounting location of the generator control panel. Mounting height shall not exceed 60” above finished floor.

I. Remote Annunciator – NEMA 1 enclosure to be mounted in electrical building:

1. 120VAC power source.

2. LED indicating lights for status, warning, and/or shutdown.

3. RS-485 Modbus.

4. Operating temperature range: -4F to +158F.

J. Vibration Isolators - Mount generator on adjustable spring isolators complete with side movement snubbers. At least four such isolators shall be utilized and be sized to load the spring within their proper working range for the unit supplied.

K. Provide a ground fault indication on generator set in accordance with the National Electric Code (latest edition).

2.6 ELEVATED WORK PLATFORM

A. Generator control panel shall be readily accessible from the exterior of the generator. If required to maintain standard operating access height to generator unit (including circuit breaker and generator controls), generator manufacturer shall provide an elevated work platform around the perimeter of the generator. Platform shall be constructed of aluminum and shall include non-skid access steps, and aluminum handrail/guardrail. Platform shall be a minimum of 42” wide or larger to permit 90 degree opening of enclosure doors. Contractor shall coordinate, with Generator Manufacturer; platform’s supports and anchors, as well as all related fabrication requirements. Access steps and aluminum handrail/guardrail shall be in accordance with Architectural and Structural drawings and specifications.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install in accordance with manufacturer’s instructions.

B. Height - Per Section 26 27 16 - Control Panels and Enclosures.

3.2 FIELD QUALITY CONTROL

A. Perform field inspection and testing.

B. Record in 20-minute intervals during four hour test:

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1. Kilowatts.

2. Amperes.

3. Voltage.

4. Coolant temperature.

5. Room temperature.

6. Frequency.

7. Oil pressure.

3.3 MANUFACTURER’S SERVICES

A. Prepare and start systems.

B. The Contractor will arrange for the supplier of the engine generator to furnish the services of qualified service technician(s) to perform the following:

Service Minimum Time At Plant Site

Observe the installation and test and calibrate the system.(1)

1/2 day (four hours)

Instruct Owner’s operators in the operation, maintenance, and repair of the entire system.

Two 1/2-day (four-hour) sessions(2)

1. If manufacturer’s representative determines that the installation is not acceptable or corrections to any part of the installation are required, the Contractor shall, at his expense, make all necessary modifications or corrections and reschedule the testing and calibration test. Cost of the rescheduled session is also at the Contractor’s expense. A written report of findings shall be delivered in duplicate to the Engineer.

2. The first session shall be scheduled two weeks in advance of the actual date of instruction. The actual day shall be scheduled with the Engineer and Owner. The second session will be as requested by the Owner at some time during the warranty period. The times of these training sessions shall be determined by the Owner.

C. The Owner’s initial instruction session for operation, maintenance, and repair of the entire system shall be recorded by the Contractor at his expense. Video shall be DVD and left with the Owner. If the recording is not of good quality, as determined by the Owner, the Contractor shall have the service technicians redo the instructional session with an additional recording made for the Owner’s use. This second instructional session and recording are also at the Contractor’s expense.

D. All times are actual on-site times. All costs, including overtime, travel, and subsistence are the responsibility of the Contractor.

3.4 ADJUSTING

A. Adjust work as necessary.

B. Adjust generator output voltage and engine speed.

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3.5 CLEANING

A. Clean work as necessary.

B. Clean engine and generator surfaces. Replace oil and fuel filters after load test.

3.6 DEMONSTRATION

A. Provide systems demonstration.

B. Describe loads connected to emergency system and restrictions for future load additions.

C. Simulate power outage by interrupting normal source, and demonstrate that system operates to provide emergency power.

END OF SECTION