26 32 13 - ENGINE GENERATOR(S) AND ACCESSORIES.pdf

PROPERTY OF UNITED STATES GOVERNMENT -

FOR OFFICIAL USE ONLY

LBJ FEDERAL BUILDING

CONSOLIDATION DoED

ENGINE GENERATOR(S) AND

ACCESSORIES

263213 - 1 04/23/2021

SECTION 263213

ENGINE GENERATOR(S) AND ACCESSORIES

PART 1 - GENERAL

1.1 DESCRIPTION

A. Provide standby engine generator(s) and accessories in accordance with the Contract Documents.

1.2 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.

1.3 WORK INCLUDED

A. Engine/Generator(s).

B. Exhaust Silencer(s).

C. Batteries.

D. Battery Charger(s).

E. Remote Fan Radiator(s).

F. Indoor door Stairs, Catwalk and Platform.

G. Resistive Type Unit Mounted Load Bank.

H. Vibration Isolation and Seismic Restraints.

I. Remote Mounted Double Lined Fuel Day Tank.

J. Remote Annunciators.

K. Warranty.

L. Testing (Field and Factory).

M. Tier 4 Compliant Emission Controls.

N. Camlock.

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1.4 SUBMITTALS

A. Shop Drawings

1. A complete ½" = 1'-0" scaled elevation and plan drawings showing the exact generator system layout including all components and accessories being provided or required for operation as specified herein.

2. All seismically restraint concrete housekeeping pads must be sized and illustrated.

This must be signed and sealed by a professional engineer in the State of project.

3. Indicate any shipping splits and weights.

4. For outdoor installation, indicate required access clearances and all external stairs, platforms and landings.

B. Product Data

1. Engine manufacturer's catalog cut sheets, performance data, detailed drawings, power output curves, and fuel consumption curves which relate to the design criteria specified.

2. Generator manufacturer's catalog cut sheets, detailed drawings and performance data.

3. Complete list of materials and catalog cuts of all components being provided.

4. Complete detailed wiring diagram of the system, including power and controls.

5. Starting battery sizing calculations showing compliance with specifications at ambient conditions.

6. After the engine generator system is accepted, submit a completed permit application for the local Air Quality Management District, ready for submission by the Owner.

7. Name and location of certified testing agency.

8. Weights of all equipment.

9. Engine mechanical data at varying loads up to full load, including heat rejection, exhaust gas flows, combustion air and ventilation air flows, noise data, fuel consumption, etc.

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

11. Generator resistances, reactances, and time constraints.

12. Generator current decrement curve.

13. Generator motor starting capability.

14. Generator thermal damage curve.

15. Jacket water heater connection diagram.

16. Control panel schematics.

17. Manufacturer’s dealer warranty.

18. Emissions data, complying with all applicable regulations.

19. All warranty data.

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20. Sound data for mechanical and engine exhaust in octave band frequencies between 31.5 Hz to 8,000 Hz and sound data for manufacturer engine exhaust silencer options, complying with all applicable regulations.

21. Vibration Isolation Base Detail must be signed and sealed by a professional engineer in the state of the project. This includes detail fabrication, anchorage and attachments to the structure and to supported equipment.

22. Exterior enclosure color samples.

C. Test Reports

1. Certified factory test report.

2. Certified field test reports.

3. Report of sound generation.

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

5. Field quality control test reports.

D. Permits

1. Provide all necessary documents required to obtain State and Local approvals for installing a generator and a petroleum bulk storage tank which includes, but is not limited to:

a. As-built drawings, signed and sealed by a Professional Engineer in the State of the project, passing tightness testing for the new fuel oil storage tank with a list of materials used in the installation.

b. Site plan on 8-1/2x11 paper which includes property lines, buildings, adjacent streets with names, tanks identified by ID number, storm drains, and non-stationary tank storage areas. Plans must be signed and sealed by the vendor’s professional engineer licensed in the State of the project.

1.5 QUALITY ASSURANCE

A. Except as modified by governing codes and the Contract Documents, comply with the latest applicable provisions and the latest recommendations of the following:

1. Alternator:

a. NEMA MG-1-22

b. ASTM D396

2. Battery Charger:

a. U.L. 1236

3. Engine Generator:

a. Local Air Quality Management District.

b. U.L. 2200, as a complete assembly.

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4. Control and Status Panels:

a. NFPA 110

5. Testing:

a. NETA

B. Equipment suppliers shall have local representation and shall have been actively engaged in the assembly, installation and service of this equipment for emergency power purposes for a period of not less than 10 years in the Job Site area. The engine-generator supplier shall have service facilities within 50 miles of the project site.

C. The equipment supplier must be the manufacturer’s local authorized distributor.

Generators provided by a 3rd Party dealer with limited authority to perform any type of warranty service of all components incorporated into the generator set will not be acceptable.

D. Equipment suppliers shall have full parts backup and a 24 hour per day service availability for this equipment.

E. The emergency generator shall be adaptable to the emerging technologies that may be required with new regulations. At a minimum, the generator shall comply with EPA off-road diesel engine Tier standards for standby applications.

1.6 LOCATION CRITERIA

A. Altitude: 1000 feet above sea level.

B. Seismic: IBC Ss (Short Period Spectral Response Acceleration).

C. Wind Loading: IBC Force: 150 mph.

PART 2 - PRODUCTS

2.1 CRITERIA

A. The engine generator system and accessories described herein shall be fully capable of operation as specified in the following environmental conditions:

1. Maximum outdoor ambient temperature: 120°F

2. Minimum outdoor ambient temperature: -30°F

3. Altitude: 1000 feet above sea level

B. The generators shall share real and reactive load proportionally within plus or minus 5% with all other generator sets in the system.

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C. Frequency regulation shall be isochronous from steady state no load to steady state rated load. Random frequency variation with any steady load from no load to full load shall not exceed plus or minus 0.25%.

D. The diesel engine-generator sets shall be capable of single step load pick up of 100% nameplate kW and power factor, less applicable derating factors, with the engine-generator set at operating temperature.

2.2 ENGINE

A. The engine shall be diesel fueled with number 2 diesel oil, 1800 rpm, compression ignition type, four stroke-cycle, water cooled, solid injection, V configuration.

B. The engine shall be EPA Tier Certified and in compliance with the State Emission regulations at the time of installation/commissioning. Actual engine emissions values must be in compliance with EPA Tier 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 Tier certification is not acceptable. Unit shall be Tier rated as required for an Emergency standby system given the generator set HP rating as defined by EPA and/or local regulations.

C. Fuel consumption of the engine generator shall be substantiated by means of manufacturer's published curves.

D. The engine shall be equipped with an electronic governor to maintain engine speed within limits specified herein. Governor shall be adjustable from isochronous to five (5) percent droop. Provision shall be made to run the engine at idle speed for test and startup purposes.

E. Engine safety devices, including high water temperature switch, overspeed sensing switch, low oil pressure switch, and low water temperature switch, shall be mounted on the engine and connected to the engine/generator control panel instruments and alarms as specified herein.

F. Engine wiring shall be high quality, heat resistant, insulated, stranded copper conductor.

Wiring shall be protected with suitable woven loom protection and shall be isolated from high temperature engine parts. Wiring for alternating current power circuits shall be protected by rigid or flexible metallic conduit.

G. Engine shall be equipped with integral radiator mounted fuel oil coolers. It shall be mounted on the radiator in the cooling air stream before it enters the radiator core. It shall be capable of reducing the return fuel temperature to a level acceptable to the manufacturer’s requirement, given the project ambient requirements.

H. The complete engine block shall be machined from one (1) casting. Designs incorporating multiple blocks bolted together are not acceptable.

I. 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, ENGINE GENERATOR(S) AND

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263213 - 6 04/23/2021 oil pressure gauge, dipstick, and oil drain.

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

K. The engine governor shall be Electronic Load Sharing and Speed Control type. Speed droop shall be externally adjustable from 0 (isochronous) to 10% from no load to full rated load. Steady state frequency regulation shall be +/-0.25 percent. It shall be capable of sharing load with 5% when paralleled with similarly equipped engines. Speed shall be sensed by a magnetic pickup off the engine flywheel ring gear. A provision for remote speed adjustment shall be included. The governor shall incorporate provisions for limiting fuel during startup and include capability for actuator compensation adjustment. Protection from voltage spikes and reverse polarity shall be included. In the event of a DC power loss, the forward acting actuator will move to the minimum fuel position.

2.3 ELECTRIC STARTING SYSTEM

A. Dual starting motor with solenoid and either Bendix or overrunning clutch drive shall be furnished on the engine. The starting motor shall be of the required voltage and ampere rating.

B. Provide a system of nickel cadmium (sealed lead acid) batteries sized such that the set may complete four (4) sixty-second complete cranking cycles at firing speed and specified room temperature. Provide a matching metal frame rack and cables of sufficient ampacities. Floor mounted batteries will not be acceptable.

C. Provide a wall mounted 120 volt AC battery charger to recharge the batteries to full capacity within 8 hours. Battery charger shall have both a high rate and low rate charging system. The battery charger shall be current limiting and shall not require cranking cutout contacts for charger protection when cranking. Accessories shall include: D.C. ammeter, fused input, D.C. voltmeter, high/low DC output voltage relay and input voltage failure relay. Battery charger output shall be rated ten (10) amperes minimum at required voltage.

D. The entire electric starting system shall be rated for 24 VDC operation.

2.4 ENGINE HEATING SYSTEM

A. Jacket water heaters, rated for operation on 208 VAC, single phase power shall be provided and shall be sized to ensure that the generator set will start within the specified time period and ambient conditions. Heaters shall include thermostats, oil pressure disconnecting device and required connection boxes.

B. Provide isolation valves that allow for change out of the heater without draining the entire cooling system.

C. The capacity of the jacket heaters shall be sized by the engine manufacturer to maintain criteria listed above.

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2.5 ENGINE COOLING SYSTEM

A. The engine shall be liquid cooled by means of an remote mounted vertical core radiator.

The radiator shall be adequately sized to cool the engine on a continuous basis at the maximum ambient temperature (122°F) and altitude specified. Ambient temperature stated shall be for actual ambient capability, and the manufacturer shall allow for a minimum of seven (7) degree rise across the engine as measured at the fan. Suitable expansion space, either by means of surge tanks or radiator top tank shall be provided.

The cooling system shall allow proper deaeration for the engine. An engine driven propeller type fan shall be provided with 1 inch water (H20) column static pressure external to the radiator and radiator assembly to allow for proper air-flow. Engine coolant shall be a mixture of fifty (50) percent ethylene glycol-based antifreeze and fifty (50) percent water. A duct adaptor flange shall be included for flex connection provided by another trade.

B. The engine shall be liquid cooled by means of a remote fan radiator. The radiator shall be adequately sized to cool the engine on a continuous basis at the maximum ambient temperature and altitude specified. Radiator shall be suitable for outdoor application and include fan, fan guard, core guard, steel supporting legs, cooling coils, steel frame, filler neck and pressure cap. Fan motor shall be single speed, totally enclosed fan cooled (TEFC) for 3 phase, 60 Hertz, 480 volt (208 volt) operation. Radiators without integral surge space must be supplied with a 20 gallon minimum expansion tank, (tank shall be sized at 15% of the system capacity), complete with mounting angles, sight glass, fittings and filler neck with pressure cap. Engine coolant shall be a mixture of fifty (50) percent ethylene glycol based antifreeze and fifty (50) percent water. Coolant solution shall be provided by the installing contractor.

C. The engine cooling system shall include one (1) or more spin-on type engine water filters which will treat the coolant and prevent corrosion and scale deposits inside the cooling system.

D. Provide all heat exchanger, pumps, fans, etc. required to remote mount unit on roof above generator room.

2.6 AIR INTAKE AND EXHAUST SYSTEM

A. An air cleaner/silencer shall be furnished as recommended by the engine manufacturer.

Air cleaners shall be dry heavy-duty type with built-in restriction gauge to monitor.

B. Engine exhaust outlets shall be coupled to the exhaust silencer(s) by means of an adequately sized section of stainless steel corrugated flexible tubing. Flexible tubing connector(s) shall be flanged at both ends for mating to the engine and exhaust system.

C. A critical grade exhaust silencer(s) shall be provided. Sound levels shall be rated no more than 80 dBA average sound level when measured five (5) feet from the exhaust outlet and 60 dBA at 5 feet. Exhaust silencer(s) shall be sized to limit exhaust back pressure to acceptable values. The exhaust silencer(s) shall be suitable for horizontal mounting and shall be equipped with flanged bottom inlet and flanged end outlet. The exhaust silencer(s) shall be double wall construction and shall have a high temperature

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263213 - 8 04/23/2021 anti-corrosion coating applied uniformly on the outside surface.

D. Silencer configuration shall be pancake type, unless otherwise noted.

E. Provide a stainless steel bellows flexible connections between the engine outlet and the muffler inlet. Flex shall allow for proper thermal expansion and vibration during engine operation. Flanges shall match the engine outlet and muffler inlet. Provide all nut bolt and gasket kits for each flange on the engine, muffler inlet and outlet.

F. The generator shall meet most stringent of the applicable EPA Tier off-road diesel engine standards without the use of pipe exhaust treatments.

2.7 FUEL SYSTEM

A. Provide a 330-gallon, "ready supply", double-lined (200% rupture basin) package fuel day tank for remote mounting to provide an immediate fuel supply to the engine fuel pump upon engine start-up. Fuel shall be supplied to the tank by means of a 120 volt electric fuel transfer pump mounted on the day tank. Also, provide a hand pump. Equip tank with an automatic float to control the day tank level with a low-level contact (nearly empty) for remote alarm indication. Fill connection shall be via two (2) flexible metal hoses. A drain cock and valve shall be provided. Rupture basin shall contain a leak detection system for remote monitoring to an alarm panel.

B. Provide a 330-gallon, “ready supply”, package base mounted double-lined (200% rupture basin) fuel day tank to provide an immediate fuel supply to the engine fuel pump upon engine start-up. Tank shall comply with all Code requirements. Fuel shall be supplied to the tank by means of 120 volt electric fuel transfer pump mounted on the day tank. Also, provide a hand pump for priming. Equip tank with an automatic float to control the day tank level with a low-level contact (set at 25% capacity) for remote alarm indication and a high-level contact set at 95% of the tank capacity for remote alarm indications. Provide independent fuel pumps control floats/contacts set at pump on 35% capacity and pump off at 90% capacity. Supply and return connects shall be brought to the outside of each generator enclosure for contractor connection. A drain cock and valve shall be provided in the tank and rupture basin. Rupture basin shall contain a leak detection system for remote indication to the alarm panel.

C. The fuel tank shall be rated for 25 psi construction to comply with GAS requirements and Local Washington DC Code. The fuel tank shall be rated to comply with UL 142.

D. Fuel lines between injection pumps and valves shall be of heavy seamless tubing and to eliminate irregularity of fuel injections, shall be of the same length for all cylinders.

E. Provide fusible link type safety shutoff valves to fail close.

F. The fuel system shall be equipped with a fuel filter having replaceable elements which may be easily removed from their housing for replacing without breaking any fuel line connections or disturbing the fuel pumps or any other parts of the engine. All fuel filters shall be conveniently located in one accessible housing, ahead of the injection pumps, so that the fuel will have been thoroughly filtered before it reaches the pumps. No screens or filters requiring cleaning or replacement shall be used in the injection pump or injection

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263213 - 9 04/23/2021 assemblies. Filters shall be duplex type and have a value arrangement so filters can be changed during operation. Filter flow rate shall allow for engine operation while one (1) filter is being serviced and not in operation.

G. Provide crankcase fumes reclamation system. System shall collect engine crankcase emissions, filter out airbourne lube oil, and reintroduce the emissions back into the engine combustion air system.

2.8 ALTERNATOR

A. Generator shall be rated 480Y/277 volt, three phase, four wire, 60 hertz, 0.8 power factor of a kilowatt capacity as indicated on the Contract Documents.

B. The alternator shall be a four (4) pole, synchronous brushless type. The alternator shall be dual bearing type coupled directly to the engine flywheel by means of a flexible disc coupling.

C. The alternator voltage regulator shall be solid state type, three phase true RMS sensing and shall incorporate an under-frequency protective circuit to limit generator excitation at lower than normal operating speeds. The voltage regulator shall be equipped with a voltage adjusting rheostat capable of plus or minus five (5) percent rated voltage adjustment. The voltage regulator shall maintain the voltage within the limits specified.

D. The alternator insulation system shall be NEMA Class H and shall be a combination of epoxy coating and varnish. The alternator shall be sized and properly derated according to NEMA MG1-22 to yield a maximum temperature rise required by UL 220 Certification using resistance method above an ambient temperature of 40°C at rated altitude.

E. Excitation shall be provided by a direct connected brushless permanent magnetic rotating exciter. The armature shall be of the three-phase design and connected to a full wave three phase rotating bridge. Diodes used shall be of the silicon type mounted on proper heat sinks with surge protector to prevent voltage spikes during parallel operation.

F. Exciter field power shall be provided by a separate permanent magnet generator directly connected to the brushless exciter. The PMG shall provide sufficient power to the excitations system to produce 300% short circuit from the main operator armature during a three-phase fault with sufficient duration for protective devices to operate.

G. The sub transient reactions shall be 12% or less.

2.9 MAIN LINE CIRCUIT BREAKER

A. Main line circuit breaker which shall operate both manually as an isolation switch and automatically during overload and short circuit conditions. The trip unit for each pole shall have elements providing inverse time delay features during overload conditions and instantaneous magnetic tripping for short circuit protection. Circuit breaker shall be suitable for 100% load. The circuit breaker shall be provided with an auxiliary contact to provide a trouble indication should the breaker be in the “OFF” or tripped position.

B. Provide a 3 pole 100% rated molded case circuit breaker for the radiator mounted load

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C. The circuit breaker(s) shall be mounted in a NEMA 1 generator mounted cabinet. The cabinet shall be formed frame design to support the weight of the installed devices.

Cabinet shall be welded construction, no bolt together structures will be allowed. Box material shall be minimum 12 gauge construction. Cabinet will be provided with a bolt-on front access door. Cabinet shall be finish painted to match the generator. Circuit breaker shall be equipped with load side, full rated bus to accommodate 2-hole, long barrel copper compression lugs. Bus hole centers shall be NEMA standard 1.75” hole centers. A neutral disconnect link shall be provided for the neutral connection. Bus shall accept fully rated feeders for neutral and ground connections. Neutral and ground connections shall be isolated from the box frame. Circuit breaker shall be equipped with a minimum 1a/1b auxiliary contacts and 24 VDC-shunt trip. An external zero sequence ground fault protection system will be installed for the circuit breaker for trip activation upon ground fault sensing. A light shall be provided for local annunciation. The mainline circuit breaker shall be cabled from the line side to the generator. The circuit breaker shall be provided with an identification labeling.

D. Provide a fused disconnect switch, painted red, for the fire alarm system tap. Coordinate location of switch prior to any work.

E. Provide an additional shunt trip breaker that can be used for interconnection to an external load bank. This breaker shall be kirk keyed to a remote disconnect switch that will be located near the entrance door in the buildings parking garage.

2.10 CONTROL PANEL

A. A generator mounted control panel shall be provided with lockable hinged front door for complete control and monitoring of the respective generator set functions. Panel shall be environmentally sealed in a NEMA 1 enclosure.

B. The following shall be included in the control panel:

1. Automatic start/stop operation.

2. Adjustable cycle cranking.

3. Digital engine monitoring.

4. Shutdown sensors and alarms with horns and reset.

5. Adjustable cool down timer.

6. Emergency stop button.

7. Self-diagnostic capabilities and fault logging.

8. AC digital ammeter, .5% true RMS accuracy, with phase selector.

9. AC digital voltmeter.

10. Frequency digital meter.

11. Elapse time digital meter.

12. Engine water temperature digital readout.

13. Engine oil temperature digital readout.

14. Engine oil pressure digital readout.

15. Voltage adjusting rheostat.

16. All items specified under remote status panels.

17. Provide a fixed nameplate consisting of red bakelite with white, 1-inch lettering, identifying the generator controlled.

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18. Engine speed digital readout.

2.11 Serial interface to BMS (BACnet MSTP or Modbus RTU).AUTOMATIC ELECTRIC-SET

PROTECTION

A. Protection System: Provide power for sensors, trips, indicator lights, and alarm by engine cranking batteries. Provide fault sensors to cause emergency engine shutdown when any of the following faults occur:

1. High water temperature sensors set to trip at 205°F ±3°F, 96°C ±2°C.

2. Approach to high water temperature sensors set to pre-alarm at 190°F.

3. Low water temperature sensors set to trip at 80°F.

4. Overspeed sensors set to trip at 2050 revolutions per minute.

5. Low lube oil pressure sensors set to trip at the engine manufacturer's recommendation for lowest permissible oil pressure.

6. Overcrank sensors set to trip after four (4) 15-second attempts to start.

7. Low water level shut down.

2.12 REMOTE STATUS PANELS

A. Provide three (3) panels per generator set. One (1) in the engineering office or Security , another in the Fire Command Center, and the remaining shall be furnished as part of the generator control panel. Provide alarm indicators per NFPA No. 110 Level 1 and as specified herein. When actuated, these alarms shall sound audible alarms and indicate, by means of individual lights at the annunciator panels, which particular malfunction is initiating the alarm. Provide 3/16-inch high (minimum) labeling to identify the alarm.

B. Provide a horn at each panel with silencing (override) switch to silence alarm. Override switch shall have flashing pilot lamp labeled "Override" to indicate that alarm is silenced.

Provide power for alarm system from generator battery system. Alarm annunciators shall indicate the following malfunctions:

Item Lens Cap Color

1. High water temperature** Red

2. Low water temperature* Red

3. Approach to high water temperature* Yellow

4. Approach to low oil pressure* Yellow

5. Overspeed* Red

6. Cranking failure (after 60 seconds)* Red

7. Generator in operation* Green

8. High and low battery charge** Red

9. Battery charger input failure** Red

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Item Lens Cap Color

10. Automatic transfer switch position lights for each automatic transfer switch. Two (2) lamps for each switch.*

Red & Green

11. Pilot light denoting engine selector switch in "OFF" position*

Red

12. Start/stop switch (Fire Command Center Only) --

13. Test switch (Fire Command Center only) --

14. Main circuit breaker tripped open* Red

15. Running pilot lights for each fuel oil pump (Fire Command Center only)

Red

16. Hand/off/automatic switch for each fuel oil pump* --

17. Low and high fuel oil (day tank)* Red

18. Low fuel oil (main tank)* Red

19. Load bank cooling failure* Red

20. Remote shutdown activation (via break glass station at the generator)

Red

21. Spare --

* Provide one (1) set of normally closed = normal dry contacts for BMS interface.

**Provide one (1) set of normally closed = normally dry contacts summary alarm for BMS interface

1. Provide a serial interface (BACnet MSTP or Modbus RTU) for integration with the Building Management System (BMS). The BMS shall be able to monitor all alarms and status through this interface. Refer to Section 230923 for more information.

2. Connection to Data Link: A separate terminal block, factory wired to Form C contacts, for each alarm and status indication is reserved for connections for data-link transmission of indications to remote data terminals. Data system connections to terminals for “Electrical Power Monitoring and Control.”

3. Provide serial port (RS 232, RS 422, or RS 485) to communicate with the power monitoring system.

4. Provide the capability to shunt trip the load bank circuit breaker if while the generator is being tested, the facility loses normal utility power and the generator is called to power building load.

2.13 GENERATOR SET PERFORMANCE

A. The completed generator set shall meet or exceed the following performance criteria:

1. Voltage regulation shall be ±1 percent rated voltage.

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2. Steady state voltage stability ±0.5 percent rated voltage.

3. Balanced telephone interference factor (TIF) shall not exceed 50.

4. Frequency regulation from no load to full load shall be adjustable from isochronous to 5 percent.

5. Steady state frequency stability shall be ±0.5 percent.

6. Maximum recovery time to return to frequency stability, bandwidth shall not exceed

6-8 seconds.

7. Generator set shall be capable of start-up and accepting rated load within 10 seconds.

2.14 SYNCHRONIZER

A. The generator set shall be provided with a synchronizer and an electronic governor to operate the generator in phase with the utility whenever the utility is on line.

2.15 OUTDOOR SOUND ATTENUATED WEATHERPROOF ENCLOSURE

A. The emergency generator set,

2.16 VIBRATION ISOLATION AND SEISMIC RESTRAINTS

A. Installation shall be in accordance with the reviewed vibration isolation and seismic restraint submittal.

B. Fuel oil and coolant line shall be flexible braided bronze hoses.

C. Provide isolators with a minimum 1 inch of deflection under operating loads.

Restrained Open Springs:

1. Provide built-in adjustable spring restraints for equipment with operating weight greater than weight upon installation to prevent equipment from deflecting (or rising) when the additional weight is applied (or removed in the future).

2. Provide isolators with restraint studs and adjustable nuts.

3. Provide 1/2 inch minimum clearance around the restraint studs.

4. Use bridge-bearing quality neoprene for elastomeric friction pads at chillers and cooling towers.

5. Acceptable products:

a. SLR by Mason Industries

b. FLS by Kinetics Noise Control

c. M by VMC Group

2.17 Raceway connections to the generator shall be in liquid tight flexible metal conduits. Only steel or malleable iron material will be acceptable. Fittings must incorporate a threaded grounding cone, a steel or plastic compression ring, and a gland for tightening

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2.18 GENERATOR OVERCURRENT AND FAULT PROTECTION

A. Generator Circuit Breaker: Insulated-case or power breaker, electronic-trip type; 100 percent rated; complying with UL 489.

1. Tripping Characteristics: Adjustable long-time and short-time delay and instantaneous.

2. Trip Settings: Selected to coordinate with generator thermal damage curve.

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.

B. Generator Protector: Microprocessor-based unit shall continuously monitor current level in each phase of generator output, integrate generator heating effect over time, and predict when thermal damage of alternator will occur. When signaled by generator protector or other generator-set protective devices, a shunt-trip device in the generator disconnect switch shall open the switch to disconnect the generator from load circuits.

Protector shall perform the following functions:

1. Initiates a generator overload alarm when generator has operated at an overload equivalent to 110 percent of full-rated load for 60 seconds. Indication for this alarm is integrated with other generator-set malfunction alarms.

2. Under single or three-phase fault conditions, regulates generator to 300 percent of rated full-load current for up to 10 seconds.

3. As overcurrent heating effect on the generator approaches the thermal damage point of the unit, protector switches the excitation system off, opens the generator disconnect device, and shuts down the generator set.

4. Senses clearing of a fault by other overcurrent devices and controls recovery of rated voltage to avoid overshoot.

C. Ground-Fault Indication: Comply with NFPA 70, "Emergency System" signals for ground-fault. Integrate ground-fault alarm indication with other generator-set alarm indications.

2.19 LOAD BANK

A. Provide an engine radiator mounted airflow cooled permanent resistive load bank.

Load bank shall be for local manual operation.

B. The load bank shall be installed within the air discharge of the engine unit mounted radiator and cooled by the radiator airflow. Load bank shall be solidly attached to radiator and provided with a flexible coupling to attach to the discharge plenum.

C. Load bank shall be rated 500 kW at 480 volts. A separate load bank feeder breaker and feeder shall be provided in the generator terminal compartment or at paralleling switchgear.

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D. The load bank shall be completely self-contained, including resistive load elements, load control devices, load element branch circuit fuse protectors, main load bus and terminals, control terminals, system protection devices and enclosure.

E. Enclosure shall be NEMA Type 1 3R, galvanized steel construction. Control components shall be sub-panel mounted and isolated from load elements and cooling airflow. Airflow through the load elements shall be horizontal. Provide mounting adaptors suitable for the installation method.

F. Load elements shall be totally enclosed, sealed and weatherproofed with an electrically grounded outlet sheath such that the element cannot be electrically short-circuited by external foreign objects and personnel are protected against accidental electrical shock. Elements shall be individually replaceable.

G. Provide branch circuit fuses for each 50 kW load branch circuit. Fuses shall be

200,000 RMS symmetrical amperes, current limiting type.

H. Load step control shall utilize one (1) magnetic contactor per each fused branch circuit. Load bank power wiring shall be 150°C insulated.

I. Main terminals shall be copper bus sized at 1,000A per square inch.

J. Control panel shall be serviced internally from the main load bus. Control and protective circuits shall operate at 120 volts using a central power transformer.

K. The load bank shall include a protection system to protect against overheating.

The system shall disconnect the load elements from the power source and activate an alarm upon sensing a loss of cooling airflow or an exhaust air temperature greater than 300°F.

L. Control Panel

1. NEMA 1 3R enclosure.

2. Control power on-off pushbuttons.

3. "NORMAL OPERATION" indicating lamp.

4. Master load control switch.

5. Load step control switches.

6. "COOLING FAILURE" alarm indication lamps with alarm contact.

7. Load bank disconnect circuit to disconnect load bank on engine start signal.

8. Load bank disconnect circuit bypass to allow the load bank to supplement the actual building load.

9. Provide a 2-year warranty from the date of acceptance.

10. Provide directional air flow hoods on top of the load bank as shown on the

Contract Documents.

11. In the event that a utility company power outage occurs while testing, the load bank shall shed from the bus automatically.

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12. Load bank shall have Auto Load feature to add load when actual connected load falls below 30% and shall disconnect when actual load increases to

50%.

2.20 Provide remote emergency shut-off buttons (breakglass stations) for the generator. Locate in the field and provide all required wiring and conduit.

2.21 ACCEPTABLE MANUFACTURERS

A. The documents are based upon engine generator physical sizing criteria of one (1) particular manufacturer. The Contractor shall be responsible for modifications necessary in the use of a proposed manufacturer. These modifications are to include all mechanical and electrical work, architectural work and structural work.

B. The following manufacturers are acceptable:

1. Prime Mover and Generator:

a. Caterpillar

b. Cummins

c. Generac

2. Exhaust Silencer:

a. Harco

b. GT Exhaust

c. Silex

3. Day Tank:

a. Simplex

b. Pryco

c. Tramont

4. Vibration Isolators:

a. Mason Industries, Inc.

b. Kinetic Noise Control

c. Amber Booth Company

d. Ace Mountings

5. Governor:

a. Woodward

b. Basler

c. Approved Equal.

6. Batteries:

a. Nife

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b. Exide

c. C&D

d. Interstate Battery Charger:

e. Lamarche

f. Sens

g. Charles

7. Voltage Regulations:

a. Basler

b. Approved Equal.

8. Circuit Breakers:

a. General Electric/ABB

b. Siemens

c. Square D

d. Eaton

9. Load Bank

a. Avtron

b. Simplex

c. Loadtec

10. Enclosures

a. Acoustical Sheetmetal Inc. (ASI)

b. International Supply Co.

c. Robinson Enclosure Co.

d. Professional Power Products

PART 3 - EXECUTION

3.1 GENERAL

A. Install the emergency generator system as shown on the Contract Documents, as indicated in the manufacturer's instructions and as required for a neat workmanlike and fully operational system. Insure that the manufacturer's recommended clearances are maintained.

B. Provide an empty raceway system capable of supporting the elevator supply wiring. The raceway system shall meet the requirements of the elevator supplier. As a minimum, provide one (1) two-inch empty conduit with pull cord from each elevator shaft to the Fire Command Center.

C. Provide a minimum of two (2) remote emergency shut off buttons for the generator.

Locate in the field and provide all control wiring and conduit. Provide equipment

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263213 - 19 04/23/2021 grounding connections for the generator. Tighten connections to comply with tightening torque levels specified in UL Std 486A.

D. Provide all control and monitoring wiring and conduit between the generator and all remote status panels.

3.2 VIBRATION ISOLATION

A. Isolate the generator set at the base by means of combination spring type isolators and neoprene pads. Provide isolators of not less than 98% efficiency of a sufficient quantity such that each is loaded to not more than 75% of its rated value. Provide a minimum static deflection of 3”.

B. All fuel oil and coolant lines shall be isolated by means of flexible light tight braided metallic hoses. Provide automatic fusible link valve on the fuel supply connections to the engine. The fusible link shall fail close.

C. All raceway connections to the generator set shall be in flexible metal conduit.

D. Entire run of engine exhaust piping shall be supported on spring hangers or mounts such as Mason 30N or Mason Type SLF respectively or approved equal. Isolators shall be sized for 1” minimum static deflection.

3.3 SEQUENCE OF OPERATION

A. Engine start contacts shall signal generator to start when the voltage of the normal source drops below 80% on any phase, after a time delay of one (1) second to allow for momentary dips. The voltage sensing relay shall be field adjustable while energized.

B. The automatic transfer switch shall transfer to emergency when 90% of rated voltage and frequency of the emergency source have been reached.

C. After restoration of normal power of all phases to 90% of rated voltage, an adjustable time delay period shall delay retransfer to allow stabilization of normal power. If the emergency power source should fail during this time delay period, the automatic transfer switch shall bypass the timing relay and transfer to the normal source.

D. After retransfer to normal, the engine generator shall be allowed to operate at no load for five (5) minutes.

E. A test on the automatic transfer switch shall simulate normal power failure.

F. When the generator begins to start (and is cranking) the following shall occur:

1. Fuel oil solenoids shall “OPEN”.

2. Air intake motorized dampers shall “OPEN”.

3. Air exhaust motorized dampers shall “OPEN”.

4. The fuel oil transfer pumps shall be “ON”.

5. When the generator is “OFF”, the following shall occur:

6. Fuel oil solenoid valves shall “CLOSE”.

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7. Air intake motorized dampers shall “CLOSE”.

8. Air exhaust motorized dampers shall “CLOSE”.

9. The fuel oil transfer pumps shall be “OFF”.

3.4 FUEL OIL

A. Upon acceptance of field testing and prior to final payment, the main fuel oil tank and the day tank shall be topped off by the installing contractor.

3.5 TESTING

A. Factory Testing

1. Prior to shipment of the engine-generator set from the factory, a certified load test shall be performed in the presence of the Owner/Engineer. The results shall be submitted to the Architect/Engineer for review before shipment of the unit. The tests shall verify the proper operation of all alarms and shut down circuits.

2. Provide costs for up to five (5) Owner/Engineer representatives to witness the testing. This includes all travel and lodging costs.

3. The tests shall also demonstrate compliance with the generator performance criteria as specified herein.

4. Testing shall be performed as follows:

a. Verify operation of all shut down and alarm points specified.

b. Perform transient response testing to verify performance as specified. Load steps shall be performed as follows:

1) 0% - 25% - 0%

2) 0% - 50% - 0%

3) 0% - 75% - 0%

4) 0% - 100% - 0%

5) 0% - 25% -75% - 25% - 0%

6) 0% - 50% -100% - 50% - 0%

c. All load steps shall be recorded on a chart recorder or light beam oscilloscope.

d. In a period of four (4) hours with a loading 25, 50, 75 and 100 percent of rated load. Step loading procedure shall be utilized (i.e., 25 percent first hour, 50 percent second hour, etc.).

e. Maintain 100% load for 1 hour.

f. Factory testing shall be accomplished using resistive and reactive load banks to match kW and kVA requirements set forth in the Contract Documents.

g. The factory testing shall include the “Generator Set Performance” criteria, listed in Section 2 above.Field Testing

5. After completion of the installation, the Contractor shall perform a certified load test, in accordance with NFPA 110, of the engine generator and related automatic transfer switches. The generator shall be required to start-up and accept full load within 10 seconds. The unit shall continue to operate for not less than four (4)

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263213 - 21 04/23/2021 hours at 100 percent rated load. The test shall also include demonstrating that all alarms, signals, shut down devices, elevator recall, etc., are functioning properly.

The Contractor shall be responsible for securing all temporary load-banks, temporary cables, etc., required for the tests.

6. The full load test shall utilize all required load banks sufficient to provide a load equal to 100 percent of the generator nameplate rating. Electrical Contractor shall secure all such load banks, cabling, hoisting, and terminations needed to perform the full load test.

7. This Contractor shall supply all fuel for the testing. Upon acceptance by the Owner, the day tank and main fuel oil tank shall be filled to capacity after each testing.

B. Certified Test Reports

1. Field testing shall be performed by the manufacturer’s certified factory field service technicians.

2. Test procedures shall be in accordance with NFPA 110.

3. Verify that the installation is in accordance with the manufacturer's instructions.

4. Verify that the equipment has been fully tested and is operational.

5. Perform reactive testing and compile detailed test reports for each piece of equipment and system tested.

6. Perform pull-the-plug test to demonstrate proper operation of the entire emergency electrical system.

C. Miscellaneous – Provide the following:

1. Location of a factory authorized service center. Number of full-time factory trained personnel at each service center and the experience of personnel.

2. The response time for service calls. There should be a maximum response time of two hours on-site.

3. Recommended preventive maintenance procedures and recommended intervals with one included within the first year. Also contract prices for the 2nd and 3rd years.

4. Recommended spare parts to minimize downtime for repairs with pricing.

3.6 CLASSROOM INSTRUCTION

A. The generator set supplier shall provide a minimum of four (4) hours of classroom instruction on maintenance and operation of the emergency power system. Classes shall be held at the supplier’s facility, shall be administered by a full-time instructor and shall be open to up to three (3) representatives of the Owner's maintenance staff.

B. Training shall be videotaped and turned over to the Owner.

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3.7 Provide all necessary wiring and conduit to each remote alarm panel.

3.8 Bond generator weatherproof enclosure to the lightning protection system.

3.9 HOUSEKEEPING PADS

A. Provide a six-inch high concrete housekeeping pad beneath the generator.

B. Provide a concrete curb around the fuel oil day tank to contain the full capacity of fuel plus 50% in the event of a day tank leak.

C. Provide a concrete curb under each door of the generator room to prevent migration of spilled liquids out of the room.

D. Provide a leak detection system for fuel containment and connect to the Building Management System for monitoring. Provide a 120 volt power supply from nearest emergency panel location.

3.10 WARRANTY

A. The manufacturer’s standard warranty shall in no event be for a period of less than five

(5) years from date of initial start-up of the system 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. Include a temporary generator set at no cost to the Owner should a warrantable repair take an extended period of time. Submittals received without written warranties as specified will be rejected in their entirety.

3.11 FIELD REPRESENTATION

A. Provide services of manufacturer’s field representative (factory trained) for a period of five (5) working days to supervise start-up, testing and two (2) training sessions for operating personnel.

B. The generator set distributor shall be responsible for coordination between all related generator control wiring, regulator and governor equipment, testing and start-up and all associated systems that affect the coordination of the switchgear with the generator sets.

All submittal packages relating to the two systems shall be supplied as a one (1) source package for review by the engineer. The one (1) source of responsibility criteria would rest upon the generator supplier to ensure a smooth transition in every step of the installation process, as well as being available for coordination meetings with his associated sub-vendor.

C. Owner reserves the right along with his authorized representatives to visit the factory during the course of fabrication of equipment to observe progress, quality control, schedule of completion, etc. All costs shall be paid by this Contractor.

3.12 SPARE PARTS

A. Deliver one (1) set of filter elements (air, fuel and oil) and one (1) belt for every belt drive

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B. Deliver one (1) complete set of fuses and one (1) injector.

C. Deliver two (2) for every six (6) of each indicator lamp type used, but no fewer than two (2).

D. Deliver two (2) quarts of touch paint – each color on generator and accessories.

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3.13 TECHNICAL LITERATURE – CLOSE-OUT SUBMITTALS

A. Provide the Owner with three (3) copies of technical literature on all system components consisting of a manual of sequential operations, recommended preventive maintenance, parts list with recommended spares, and all pertinent control manuals and wiring diagrams.

B. Provide a list of tools and replacement items recommended to be stored at the project for ready access.

3.14 LOAD BANK FIELD TESTING

A. Prior to energizing the load bank, the insulation resistance on the bus shall be measured from phase-to-phase and phase-to-ground.

B. After installation is completed, all switches shall be functionally tested.

C. All protective functions shall be tested, and all remote functions simulated to determine if the units have been wired properly.

D. All testing of the completed installations shall be performed in the presence of and as directed by the Engineer. The Contractor shall notify the Engineer when the equipment is installed and ready for testing.

E. Testing shall be performed in the following manner.

1. All control and power cable connections shall pass inspection for workmanship, tightness, and continuity.

2. All load banks shall be tested for equipment grounds. Maximum acceptable resistance shall be 1 ohm.

3. The unit shall be given a phase-to-phase and phase-to-ground megger test and all feeder load terminals grounded.

4. Megger tests shall be applied between each phase and ground with phases not under test also grounded.

5. All alarm devices shall be adjusted and set.

6. All control circuits shall be given operational tests form the supply source for which they were designated. This shall include normal operation three (3) times from each control point, and activation of alarm devices.

3.15 All test results shall be in accordance with the manufacturer’s recommendations for

MAINTENANCE SERVICE

A. Initial Maintenance Service: Beginning at Substantial Completion, provide 12 months’ full maintenance by trained employees of manufacturer’s designated service organization.

Include quarterly exercising to check for proper starting, load transfer, and running under load. Include routine preventive maintenance as recommended by manufacturer and adjusting as required for proper operation. Provide parts and supplies same as those used in the manufacture and installation of original equipment.

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B. The generator set manufacturer and its distributor shall maintain a 24-hour parts and service organization.