478_08B_Portable Generator Specs.docx

Portable Generator

PART 1 - GENERAL

References:

The equipment covered by these specifications shall be designed, tested, rated, assembled and installed in strict accordance with all applicable standards of ANSI, NEC, ISO, U.L., IEEE, U.S. EPA Tier IV Emissions, and NEMA.

Work Included:

The work includes supplying a complete trailer mounted integrated emergency generator system. The system consists of a diesel generator set with related component accessories.

A complete system load test shall be performed after all equipment is installed.

The equipment supplied shall meet the requirements of the NEC and all applicable local codes and regulations. All equipment shall be of new and current production by a Manufacturer who has 25 years of experience building this type of equipment. Manufacturer shall be ISO9001 certified.

Generator shall be furnished with a variable 208-480 120V, 3P load center. Load center shall include a main breaker and all branch breakers required. All ancillary devices (lights, block heaters, battery charger, louvers, etc.) shall be factory wired back to the load center. All conduit in enclosures shall be RGS.

Manufacturers:

There shall be one source responsibility for warranty, parts and service through a local representative with factory trained service personnel.

Manufacturers: Subject to compliance with requirements, provide products by one of the following: (Listed in Alphabetical Order) Generator Set:

Caterpillar Kohler Onan-Cummins Submittals:

Engine-generator submittals shall include the following information Factory published specification sheet indicating standard and optional accessories, ratings, etc.

Manufacturer’s catalog cut sheets of all auxiliary components such as Transfer Switches, battery charger, control panel, enclosure, main circuit breaker, etc.

Weights of all equipment.

Interconnect wiring diagram of complete emergency system, including generator, switchgear, battery charger, jacket water heater, remote alarm indications.

Engine mechanical data including heat rejection, exhaust gas flows, combustion air and ventilation air flows, noise data, fuel consumption, etc.

Generator electrical data including temperature and insulation data, cooling requirements, excitation ratings, voltage regulation, voltage regulator, efficiencies, waveform distortion and telephone influence factor.

Generator resistances, reactances, and time constants.

Generator motor starting capability.

Control panel schematics.

Oil sampling analysis, laboratory location, and information.

Manufacturer’s and dealer’s written warranty.

Warranty:

The manufacturer’s standard warranty shall in no event be for a period of less than two (2) years from date completion and shall include repair parts, labor, reasonable travel expense necessary for repairs at the job site, and expendables (lubricating oil, filters, antifreeze, and other service items made unusable by the defect) used during the course of repair. Warranty service calls shall not include a deductible cost. Submittals received without written warranties as specified will be rejected in their entirety.

Parts And Service Qualifications:

The engine-generator supplier shall have service facilities within 75 miles of the project site and maintain 24-hour parts and service capability. The distributor shall stock parts as needed to support the generator set package for this specific project.

The dealer shall maintain qualified, factory trained service personnel that can be reached within 10 minutes of an emergency call and can respond on site within 4 hours of notification, 24 hours per day.

- PRODUCTS

General Requirements:

The generator set shall be Standby and have a 70 kW/87 kVA rating. The ratings shall be at 1800 RPM, 0.8 power factor, 480Y/277 VAC, 3 phase, 4 wire, 60 hertz, including radiator fan and all parasitic loads.

All materials and parts comprising the unit shall be new and unused.

Diesel Engine:

The engine shall be as manufactured by one of the approved manufacturers listed above. The engine shall be water-cooled inline or vee-type, four cycle compression ignition diesel. The engine shall be equipped with fuel, lube oil, and intake air filters, lube oil cooler, fuel transfer pump, fuel priming pump, service meter, gear-driven water pump.

The engine shall include a Closed Crankcase Ventilation (CCV) system. If the engine does not have integral CCV, an external system, by Racor or equal, shall be added. System shall filter crankcase fumes, returning the filtered air to the engine intake and the captured oil back to the oil pan.

The complete engine block shall be machined from one casting. Designs incorporating multiple blocks bolted together are not acceptable.

The engine shall utilize a gear-type, positive displacement, full pressure lubricating oil pump and water-cooled lube oil cooler. Pistons shall be spray-cooled. Provide oil filters, oil pressure gauge, dipstick and oil drain.

Fuel filter and serviceable fuel system components shall be located to prevent fuel from spilling onto generator set batteries.

The engine shall be equipped with an isochronous electronic governor +/- 0.25% steady state frequency variation. The governor shall be equipped with speed adjustment.

Generation:

The synchronous generator shall be a single bearing, self-ventilated, drip-proof design in accordance with NEMA MG 1 and directly connected to the engine flywheel housing with a flex coupling.

The insulation material shall meet NEMA standards for Class H insulation and be vacuum impregnated with epoxy varnish to be fungus resistant. Temperature rise of the rotor and stator shall not exceed NEMA class F (130° C rise by resistance over 40° C ambient). The excitation system shall be of brushless construction.

The brushless exciter shall be independent of main stator windings (either permanent magnet or auxiliary windings) and shall consist of a three-phase armature and a three-phase full wave bridge rectifier mounted on the rotor shaft. Surge suppressors shall be included to protect the diodes from voltage spikes. Generator shall have the ability to sustain short circuit current of 300% of rated current to allow protective devices to operate.

The automatic voltage regulator (AVR) shall maintain generator output voltage within +/- 0.5% for any constant load between no load and full load. The regulator shall be a totally solid state design which includes electronic voltage buildup, volts per Hertz regulation, three phase sensing, over-excitation protection, loss of sensing protection, temperature compensation, shall limit voltage overshoot on startup, and shall be environmentally sealed.

Distribution Panel:

Provide Two (2) 20 Amp GFCI, 120 V duplex receptacles, - Three (3) 50 Amp 240 V Twist Lock connectors.

Controls:

Generator Mounted Control Panel:

Provide a generator mounted control panel for complete control and monitoring of the engine and generator set functions. Panel shall include automatic start/stop operation, adjustable cycle cranking, digital LCD AC metering (0.5% true rms accuracy) with phase selector switch, digital engine monitoring, shutdown sensors and alarms with horn and reset, adjustable cooldown timer and emergency stop push-button. Panel shall incorporate self-diagnostics capabilities and fault logging. Critical components shall be environmentally sealed to protect against failure from moisture and dirt. Components shall be housed in a NEMA 1/IP22 enclosure with hinged lid.

Provide the following digital readouts on the Generator Mounted Control Panel:

Engine oil pressure Coolant temperature Diesel Exhaust Fluid (DEF) level Engine RPM System DC Volts Engine running hours Generator AC volts Generator AC amps Generator frequency Control Panel Annunciation - Provide the following indications for protection and diagnostics according to NFPA 110 level 1:

Low oil pressure High water temperature Low coolant level Overspeed Overcrank Emergency stop depressed Approaching high coolant temperature Approaching low oil pressure Low coolant temperature Low voltage in battery Control switch not in auto. position Low fuel main tank Battery charger ac failure High battery voltage Generator supplying load Spare Cooling System:

The generator set shall be equipped with a rail-mounted, engine-driven radiator with blower fan and all accessories. The cooling system shall be sized to operate at full load conditions and 122° F ambient air entering the room or enclosure (If an enclosure is specified) without derating the unit and 60/40 anti-freeze mixture. The generator set supplier is responsible for providing a properly sized cooling system based on the enclosure static pressure restriction.

Fuel System:

Filter/Separator - In addition to the standard fuel filters provided by the engine manufacturer, there shall also be installed a primary fuel filter/water separator in the fuel inlet line to the engine.

All fuel piping shall be black iron or flexible fuel hose rated for this service. No galvanized piping will be permitted.

Flexible fuel lines shall be rated for 300 degrees F and 100 PSI.

Exhaust System:

A critical type silencer, companion flanges, and flexible stainless steel exhaust fitting properly sized shall be furnished and installed according to the manufacturer’s recommendation.

The silencer shall be located inside the generator set enclosure. The silencer shall be mounted so that its weight is not supported by the engine.

Exhaust pipe size shall be sufficient to ensure that exhaust back pressure does not exceed the maximum limitations specified by the engine manufacturer.

Starting System:

A DC electric starting system with positive engagement shall be furnished. The motor voltage shall be as recommended by the engine manufacturer.

Jacket Water Heater: A unit mounted thermal circulation type water heater. The heater watt rating shall be sized by the manufacturer to maintain jacket water temperature at 90 degrees F in an ambient temperature down to -20 Deg F. Heaters <= 6000W shall be 208 – 240V single phase, 60 Hz. Heaters greater than 6000W shall be 208 – 240V, three phase, 60 Hz.

Batteries: A lead-acid storage battery set of the heavy duty diesel starting type shall be provided. Battery voltage shall be compatible with the starting system. The battery set shall be rated no less than 140 ampere hours and 1300 CCA. Necessary cables and clamps shall be provided.

A battery tray shall be provided for the batteries and shall conform to NEC 480-7(b). It shall treated to be resistant to deterioration by battery electrolyte. Further, construction shall be such that any spillage or boil-over battery electrolyte shall be contained within the tray to prevent a direct path to ground.

Battery Charger: A current limiting battery charger shall be furnish to automatically recharge batteries. Charger shall float at 2.17 volts per cell and equalize at 2.33 volts per cell. It shall include overload protection, silicon diode full wave rectifiers, voltage surge suppressor, DC ammeter, DC voltmeter, and fused AC input. Ac input voltage shall be 120 volts, single phase. Charger shall have LED annunciation for low DC volts, rectifier failure, loss of AC power, high DC volts. Amperage output shall be no less than ten (10) amperes. Charger shall be wall mounting type in NEMA 1 enclosure, installed in the generator set enclosure.

Generator Set Enclosure – Sound Attenuated and Weather Protective:

The complete diesel engine generator set, including generator control panel, engine starting batteries and fuel oil tank, shall be enclosed in a factory assembled, weather protective enclosure mounted on the fuel tank base.

The enclosure shall be constructed of corrosion resistant steel with electrostatically applied powder coated baked polyester paint. It shall consist of a roof, side walls, and end walls. Fasteners shall be either zinc plated or stainless steel.

The enclosure shall reduce the ambient noise level at full load to a maximum of 78 dB at 23 feet.

Number of doors on enclosure shall be as required so that all normal maintenance operations, such as lube oil change, filter change, belt adjustment and replacements, hose replacements, access to the control panels, etc., may be accomplished without disassembly of any enclosure components. Access doors shall be fabricated of the same material as the enclosure walls and shall be reinforced for rigidity.

Provide six LED wall packs on exterior of enclosure to illuminate the access platform. Wall packs shall be controlled by an H-O-A switch located on interior of enclosure. In ‘A” position, lights shall be controlled by a photocell mounted to exterior of enclosure.

Handles shall be key lockable, all doors keyed alike, and hinges shall be zinc die cast or stainless steel. Fasteners shall be zinc plated or stainless steel. Doors shall be of a lift off design allowing one person to remove door if necessary.

Air handling will be sized and designed by the manufacturer for 0.5” static pressure drop through enclosure.

Air intake openings shall include fixed louvers with motorized dampers (120VAC power to close, fail open) and shall be screened to prevent the entrance of rodents.

Radiator air exhaust shall include fixed louvers with gravity type dampers, and sound attenuated exhaust plenum with vertical discharge.

Lube oil and coolant drains shall be extended to the exterior of the enclosure and terminated with drain valves. Radiator access shall be through a hinged, lockable cover on enclosure. Cooling fan and charging alternator shall be fully guarded to prevent injury.

Lifting points shall be provided on base frame suitable for lifting combined weight of base tank, generator set and enclosure.

A dual wall fuel tank base of 24 hour capacity at 100% load shall be provided as an integral part of the enclosure. It shall be contained in a rupture basin with 110% capacity. The tank shall be pressure tested for leaks prior to shipment and have all necessary venting per UL142 standards. A locking fill cap, a mechanical reading fuel level gauge, low fuel level alarm contact, and fuel tank rupture alarm contact shall be provided.

The genset vendor shall supply a service access platform. The platform shall be of aluminum construction, shall be a minimum of 48” wide, shall provide room for full enclosure door opening, and shall include stairs and handrails per OSHA requirements. Platforms will be required on all sides / ends of the enclosure with door openings. Platform height shall be such that the control panel, breaker handle(s), and oil level dipstick shall all be within 6’ from the top of the platform after installation. Installing contractor shall coordinate any additional concrete requirements to support the platform with generator supplier.

Trailer:

General: The trailer shall have tandem axles constructed to GAWR requirements, tires shall have the appropriate Ply Rating associated with the GAWR of the trailer.

The trailer shall have all lighting and reflectors as required by the Georgia Department of Public Safety.

The trailer shall be equipped with a Pintel type hitch, unless otherwise approved by the OWNER.

Start Up and Testing:

Coordinate all start-up and testing activities with the Engineer and Owner.

After installation is complete and normal power is available, the manufacturer’s local dealer shall perform the following:

Verify that the equipment is installed properly.

Check all auxiliary devices for proper operation, including battery charger, jacket water heater(s), generator space heater, remote annunciator, etc.

Test all alarms and safety shutdown devices for proper operation and annunciation.

Check all fluid levels.

Start engine and check for exhaust, oil, fuel leaks, vibrations, etc.

Verify proper voltage and phase rotation at the transfer switch before connecting to the load.

Connect the generator to building load and verify that the generator will start and run all designated loads in the plant.

Verify and test all connections to the existing automatic transfer switch.

Perform a 4 hour resistive load bank test at full nameplate load using a load bank and cables supplied by the local generator dealer. Observe and record the following data at 15 minute intervals:

Service meter hours Volts AC - All phases Amps AC - All phases Frequency Power factor or Vars Jacket water temperature Oil Pressure Fuel pressure Ambient temperature Operation and Maintenance Manuals Provide three (3) sets of operation and maintenance manuals covering the generator, switchgear, and auxiliary components. Include parts manuals, final as-built wiring interconnect diagrams and recommended preventative maintenance schedules.

Demonstration:

Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain packaged engine generators. Refer to Division 1 Section “Demonstration and Training.”

Train Owner’s maintenance personnel on procedures and schedules for starting and stopping, troubleshooting, servicing, and maintaining equipment.

Review data in maintenance manuals. Refer to Division 1 Section “Operation and Maintenance Data”.

Schedule training with Owner, with at least seven days’ advance notice.

Minimum Instruction Period: Four hours.

END OF SECTION

478-08B