16.2__OBN_Specification_Generator.docx

SPECIFICATION

O’BANION SUBSTATION DIESEL GENERATOR SET

5712 O’BANION ROAD, YUBA CITY, CA 95993

EQUIPMENT TECHNICAL SPECIFICATION

SECTION 1: GENERAL

Description Western Area Power Administration (WAPA) has developed this specification for the procurement and testing of an industrial grade Diesel Generator Set, 170KW, 3 phase, 240/120V 60 Hz with delta wired stator to provide standby power at WAPA’s O’Banion Series Compensation Substation. The Diesel Generator Set (generator) with fuel tank shall be factory-assembled and wired (except for the field connections). The Diesel Generator set shall include associated equipment as identified in this specification. The generator will be installed on a concrete pad by WAPA to be later integrated into new station service equipment furnished and installed as a part of the O’Banion Station Service Upgrade.

Safety Standards The diesel generator set will be installed in Sutter County, California. The equipment shall conform to Federal, State, and local requirements including but not limited to the following standards:

· American Petroleum Institute (API)

· Institute of Electrical and Electronics Engineers (IEEE)

· International Building Codes (IBC)

· International Organization for Standardization (ISO)

· National Board of Fire Underwriters (NBFU)

· National Electric Code (NEC)

· National Electrical Manufacturers Association (NEMA)

· National Fire Protection Association (NFPA)

· Occupational Safety and Health Administration (OSHA)

· Underwriters Laboratories (UL)

Quality Assurance The manufacturer of the equipment shall be specialized in the design, manufacture and assembly of diesel generator sets. The equipment shall conform to the standards prepared by:

· American Society for Non-destructive Testing (ASNT)

· American Society for Testing and Materials (ASTM)

· International Organization for Standardization (ISO)

· National Electrical Manufacturers Association (NEMA)

Emissions Compliance The diesel generator set shall have EPA Emissions Certification of Final Tier 4 or higher. It shall comply with all applicable federal, state, county, and other local emission regulations and requirements.

Factory Tests Factory Test Results shall be provided as follows: Functional testing of the diesel generator set during the Factory Acceptance Testing (FAT) is required. The manufacturer shall furnish fuel, load banks, test instruments, and all other equipment necessary to perform these tests. Tests shall demonstrate automatic operation start time, load tests, regulation, motor starting capability, and functionality of all system safety features.

Test results to be provided include:

· A chart recording shall be made of the unit to verify frequency and voltage stability, transient response, and output power.

· Transient response and steady state governing

· Single step load pickup per NFPA 76A-822

· Harmonic analysis and voltage waveform deviation per MIL-STD-705B, Method 601.4

· Alternator temperature rise per NEMA MG1-22.40

· 3 phase short circuit test for mechanical and electrical strength

· Cold Start Test and record time required for the diesel generator set to develop specified voltage, frequency, and kW load from a standstill condition with engine at ambient temperature.

Load tests shall be two (2) hours duration while the diesel generator set is delivering 100% of the specified kW, and four (4) hours duration while the diesel generator set is delivering 80% of the specified kW. During these tests, the following data shall be recorded at 15-minute intervals:

· Ambient temperature

· Coolant temperature

· Engine RPM

· Voltage

· Current

· Frequency

· Real and reactive power

· Power factor

· Fuel consumption

· Fuel pressure

· Oil pressure

· Oil temperature

· dB sound level

Site Test Provide option for on-site Field Technical Support: Manufacturer shall perform site testing to ensure that each system is fully functional and that each item of equipment is complete, free from damage, adjusted and ready for operation as designed. Manufacturer shall also demonstrate functionality of all automatic operation and system safety features. The supplier of the diesel generator set shall provide a load bank of sufficient capacity to complement the available site load for testing. The site test shall be performed by a qualified manufacturer representative and shall include running the diesel generator set under load.

Storage and Handling The diesel generator set shall be properly restrained and supported to withstand shipping and handling stresses. The diesel generator set shall be designed to withstand the mechanical stresses which occur during operation of the system.

Certifications

1.1.1 Seismic qualification is required. Data requirements shall be provided in accordance with the latest IEEE 693. The data and requirements shall be prepared in a report format which shall be included in the informational drawings and data package as described in paragraph 2.15, table 1.

1.1.2 Certification from the engine manufacturer stating that the engine exhaust emissions meet at minimum the Tier 4 EPA Emissions Standard as well as federal, state, and local regulations and restrictions. The certification shall include emission factors for criteria pollutants including nitrogen oxides, non-methane hydrocarbon, and hazardous air pollutants (HPAs).

1.1.3 Seven (7) days prior to shipment of the diesel generator set, the manufacturer shall submit certified factory test data.

Personnel Security Requirements

1.1.4 No Contractor, Contractor employee or sub-Contractor employee shall be allowed to perform any work under this contract without prior approval being obtained from WAPA. This includes management personnel visiting site.

1.1.5 Prior to being granted access to sensitive information such as technical system or architectural drawings, Contractor employees may be required to execute a Confidentiality and Nondisclosure Agreement with WAPA. Failure to execute this agreement shall be grounds for requesting removal from performance on this contract.

1.1.6 All information related to this contract is property of the Government and as such, must be safeguarded. This information may only be disclosed to Contractor personnel directly involved in the program management, administration, servicing or installation and shall not be released to anyone without the express written consent of WAPA or the originator of the information.

Submittals Document submittals shall include, but not be limited to:

1.1.7 Performance criteria per general WAPA specification requirements.

1.1.8 A written description of the system operation with all exceptions and/or deviations clearly identified.

1.1.9 Completely identified and marked catalog cut sheets of all associated equipment and devices, with all non-applicable items crossed out, and applicable equipment or devices clearly identified.

1.1.10 A written description of the maximum generator kVA and kW.

1.1.11 Plan and elevation view drawings with a dimensional description of the standby electric power system and associated equipment, locating the system equipment and accessories within the allotted space.

1.1.12 Internal wiring drawings of the diesel generator set.

1.1.13 Field connection drawings to indicate terminal connections to the diesel generator set and point of interconnection.

1.1.14 Wiring diagrams indicating field terminal connections for specified alarm points and other external connections.

1.1.15 A detailed maintenance schedule plan.

1.1.16 Complete spare parts list for all equipment.

1.1.17 Complete bill of material for all equipment.

1.1.18 Complete warranty information of all equipment.

1.1.19 Test plans and test results as specified in section 1.5 titled Factory Test.

1.1.20 Instruction Manuals and drawings as specified in section 2.19.

1.1.21 Foundation requirements (physical dimensions and loading)

SECTION 2: TECHNICAL REQUIREMENTS

Diesel Generator Set Requirements The diesel generator set shall be fully assembled at the factory so that only external connections need to be made at the construction site.

1.1.1 Diesel Generator set shall be factory-painted with manufacturer's rust inhibiting primer and standard finishes.

1.1.2 All electrical, mechanical, hydraulic connections between components of the system shall conform to best industry design practices.

1.1.3 Couplings, shafts, and other moving parts shall be enclosed and guarded. Guards shall be metal, ruggedly constructed, rigidly fastened, and readily removable for convenient servicing of the equipment without disassembling any pipes and fittings.

1.1.4 Diesel generator set shall have the following features:

· Factory-mounted on a common, rigid, welded, structural steel base.

· Diesel generator set shall be the sub-base type (with the generator mounted directly on top of the fuel tank).

· Diesel generator set and sub-base tank footprint should not exceed the size of the concrete pad upon which it will be mounted. Manufacturer to provide required dimensions of concrete pad.

· The isolators shall be constrained with restraints capable of withstanding static forces in any direction equal to twice the weight of the supported equipment.

1.1.5 The diesel generator set shall be capable of operating satisfactorily as specified for no fewer than 10,000 hours between major overhauls.

Table 1: Diesel Generator Set Requirements Engine System

Electrical System Rating

Fuel Storage Tank Requirements

Service Condition Requirements

Governor

1.1.6 Isochronous, electronic type.

1.1.7 Steady-state speed band at 60 Hz.

Generator

1.1.8 The generator shall be of synchronous, amortisseur windings, self-venting, rotating-field type connected directly to the engine, designed for sustained short-circuit currents in conformance with NEMA Standards and designed for sustained operation at 100% of the RPM specified for the diesel generator set without damage.

1.1.9 Nameplates attached to the diesel generator set shall show the manufacturer's name, equipment identification, serial number, voltage ratings, field current ratings, kVA output rating, power factor rating, time rating, temperature rise ratings, RPM ratings, full load current rating, number of phases and frequency, and date of manufacture.

1.1.10 Telephone influence factor shall conform to NEMA MG 1.

Generator Isolation and Protection A generator circuit breaker shall be provided. The circuit breaker shall be insulated-case, electronic-trip type; 100 percent rated; complying with UL 489. Tripping characteristics shall include adjustable long-time delay, short-time delay, and instantaneous over current trips. The breaker shall include shunt trip capability to be opened when the diesel generator set is shut down by other protective devices.

The generator circuit breaker shall include lockout/tagout provisions.

The breaker enclosure shall also contain terminations for neutral and equipment grounding conductors as necessary.

Engine

1.1.11 The engine shall be coupled directly to a generator and able to start the diesel generator set at negative 20 degrees Celsius (-20C).

1.1.12 The Engine shall have a minimum of four cylinders.

Engine Starting System

1.1.13 An engine switch shall be provided with functions including run/start (manual), off/reset and automatic mode. Start-stop logic shall be provided for adjustable cycle and cooldown operation. The starting system shall comply with NEC 700.10 to include remote engine start with circuit monitoring and alarm.

1.1.14 The engine starting system shall start the engine at any position of the flywheel. Electric cranking motor rating shall be designed for cranking the cold engine at the voltage provided by the battery system, and at the required RPM during consecutive starting attempts without damage.

1.1.15 The battery (s) shall have a minimum and maximum electrolyte level indicators and a flip-top flame arrestor vent cap and shall have connector covers for protection against external short circuits.

1.1.16 The battery charger shall be current limiting conforming to UL 1236 and shall be provided and shall automatically recharge the battery (s). The charger shall be capable of an equalize-charging rate for recharging fully depleted batteries within 24 hours and a floating charge rate for maintaining the battery (s) at fully charged condition.

1.1.17 Indication of battery charging rate and battery charging voltage shall be provided.

Remote Manual Stop The remote manual stop shall be provided per NFPA 101, and shall be a red mushroom-head push-button switch. It shall be connected to the main generator control panel to provide emergency shutdown of the generator and shall have permanent label reading “EMERGENCY STOP”.

Wiring

· Insulated, rated at 600 V

· All installed wires shall be in vertical and horizontal runs, neatly harnessed.

· All terminal contacts shall be screw terminals type and torque tightened per manufacturer’s recommendation.

Enclosure

1.1.18 The diesel generator set shall be housed in an NEMA 3R outdoor weather resistant enclosure and shall be sound-attenuated to meet the OSHA standards, and maximum permissible dBA level noted in Table 1. Sound ratings shall be based on full load condition of diesel generator set in a single unit operation condition. For the maximum sound limits under full load, please refer to table 1 found in section 2.1.5.

1.1.19 The enclosure shall meet the following requirements:

· The entire diesel generator set shall have all exposed metal surfaces primed with a rust inhibiting primer and multiple finish coats of the manufacturer's standard machinery enamel finish.

· Enclosure shall have hinges and gasketed access doors and access panels to allow complete unit operation and maintenance without removal of the enclosure.

· All doors shall be lockable.

· Unit shall have adequate protection to prevent entrance by small animals.

· Batteries shall fit inside enclosure and alongside the diesel generator set. Batteries under the generator are not acceptable.

· The muffler shall be mounted and thermally-insulated inside the enclosure.

Vibration Isolation Per Section 1.8.1 if seismic analysis shows the equipment not operating as designed, then vibration isolators shall be provided. Isolators shall be sized to properly support the generator.

Labeling The equipment, wiring terminals, and wires shall be clearly and permanently labeled. The appropriate wiring diagrams shall be laminated or mounted under plexiglass within the frame on the inside of the cubicles and panels.

Lubrication Oil System The system shall include a thermostatically-controlled electric heater to automatically maintain the oil temperature within +/- 1.7 °C (3 °F) of the control temperature recommended by the engine manufacturer to minimize starting time.

Fuel System

1.1.20 The diesel fuel system shall comply with NFPA 30 and NFPA 37, and have the following features:

· Injection pump(s) and nozzles.

· Plungers shall be carefully lapped for precision fit and shall not require any packing.

· Filters or screens that require periodic cleaning or replacement shall not be permitted in the injection system assemblies.

· Return surplus fuel from the injectors to the storage tank by gravity or a pump.

1.1.21 The filter system shall be secondary filters (engine-mounted) and shall be located such that the fuel will be thoroughly filtered before it reaches the injection system assemblies. The filters shall be cleanable or replaceable type and shall entrap and remove water from fuel as recommended by the engine manufacturer. Filters shall be readily accessible and capable of being changed without disconnecting piping or disturbing other components.

1.1.22 The storage tank shall be provided with a welded steel double-wall fuel containment tank. The tank shall be fully integrated sub base fuel tank under the generator and shall have capacity to supply fuel to the engine without refueling for a minimum of 72 hour period at 60% of 170KW or 400 gallons, whichever is smaller.

1.1.23 The connection of the pipe and tank shall be designed for maximum protection from fire hazards and leaks.

1.1.24 If required, a float switch on the storage tank shall control a fuel pump to actuate a low fuel alarm at 30%, activate a no fuel alarm at 5% and shutoff the fuel pump to prevent cavitation.

Cooling System

1.1.25 The cooling system shall be closed looped liquid-cooled with cooling capacity not less than the cooling requirements of the diesel generator set and its lubricating oil while operating continuously at 100% of its specified rating at the ambient temperatures listed in section 2.1.5 table 1.

1.1.26 Cooling system circulating pumps shall be the centrifugal type driven by engine. Incorporate pressure relief devices where required to prevent excessive pressure increase after the engine stops.

Lubricating Oil Heater The system shall consist of a thermostatically-controlled electric heater to automatically maintain the oil temperature within plus or minus 1.7 °C (3 °F) of the control temperature.

Jacket Coolant Heater The system shall consist of a thermostatically-controlled electric heater mounted in the engine coolant jacketing to automatically maintain the coolant temperature as recommended by the engine manufacturer.

Controls

1.1.27 General Controls

· Control equipment shall be in accordance with UL 508, NEMA ICS-4, ICS-6, and ANSI C37.90.1.

· Panels shall be in accordance with UL 50.

· Cubicles shall be in accordance with UL 891

1.1.28 Diesel Generator Set Control

Starting and Stopping Controls

· A three-position, maintained-contact type selector switch with positions marked "AUTOMATIC," "OFF," and "MANUAL."

· A momentary contact push-button switch with positions marked "MANUAL START" and "MANUAL STOP."

· Selector switch in AUTOMATIC position shall cause the engine to start automatically when a single pole contact in a remote device closes. When the generator's output voltage increases to not less than 90% of its rated voltage, and its frequency increases to not less than 58 Hz, the remote devices shall transfer the load to the generator. An adjustable time delay relay, in the 0 to 15 minute range, shall cause the generator to continue operating without any load after completion of the period of operation with load. Upon completion of the additional 0 to 15 minute (adjustable) period, the generator shall stop.

· Selector switch in OFF position shall prevent the engine from starting either automatically or manually. Selector switch in MANUAL position shall also cause the engine to start when the manual start push-button is depressed momentarily.

· With selector switch is in MANUAL position, depressing the MANUAL STOP push-button momentarily shall stop the engine after a cool-down period.

· A maintained-contact, red mushroom-head push-button switch marked "EMERGENCY STOP" will cause the engine to stop without a cool-down period, independent of the position of the selector switch.

Engine Cranking Controls

· The cranking cycles shall be controlled by a timer that will be independent of the battery voltage fluctuations.

· The controls shall crank the engine through one complete cranking cycle.

· Cranking shall terminate when the engine starts so that the starting system will not be damaged. Termination of the cranking shall be controlled by self-contained, speed-sensitive switch. The switch shall prevent re-cranking of the engine until after the engine stops.

Automatic Voltage Regulator

· The Automatic voltage regulator shall correct voltage fluctuations rapidly and restore the output voltage within 2 percent of the predetermined level from no load to full load. It shall also include voltage level rheostat located inside the control cubicle and provide a 3-phase automatic voltage regulator immune to waveform distortion.

Supervisory Controls Coolant Temperature

· HIGH COOLANT TEMPERATURE ALARM: The system shall alarm when the coolant temperature rises to the alarm setpoint.

· HIGH COOLANT TEMPERATURE SHUTDOWN: The system shall alarm and shutdown when the temperature rises to the high coolant temperature trip setpoint, which shall be low enough to prevent any damage to the engine and high enough to avoid unnecessary engine shutdowns.

· LOW COOLANT TEMPERATURE SHUTDOWN: The system shall alarm and shutdown when the coolant temperature drops to below the low coolant temperature trip setpoint.

Lubricating Oil Pressure

· LOW OIL PRESSURE ALARM: The system will alarm when the pressure falls to the Alarm setpoint.

· LOW OIL PRESSURE SHUTDOWN: The system will alarm and shutdown when the pressure falls to the low oil pressure trip setpoint, which shall be high enough to prevent damage to the engine and low enough to avoid unnecessary engine shutdowns.

· The pressure settings near the associated signal light shall be stored and displayed until reset, so that the running oil pressure can be compared to the target (setpoint) value.

Overspeed

· OVERSPEED SHUTDOWN: The system will alarm and shutdown when the engine RPM exceeds the maximum RPM recommended by the manufacturer of the engine.

Overcrank Shutdown

· OVERCRANK SHUTDOWN: The engine shall alarm and automatically stop when the overcrank limit has exceeded the maximum recommended value set by the manufacturer.

Low Fuel – Storage Tank

· LOW FUEL – STORAGE TANK ALARM: The system will alarm when the fuel oil level in the storage tank decreases to less than 30% of the total tank capacity.

No Fuel – Storage Tank

· NO FUEL – STORAGE TANK SHUTDOWN: The system will alarm and shutdown when the fuel level in the storage tank decreases to 5% of the total tank capacity. The tank fuel pump (if required) shall shutoff.

Generator Breaker Indication

· Visual targets and position contacts shall indicate when the generator circuit breaker is in the OPEN, CLOSE or TRIPPED position.

Monitoring The following local diagnostic information, as a minimum, shall be provided at the generator control unit:

· Engine oil pressure

· Engine temperature

· Engine speed

· Fuel level

· Battery voltage level

· Engine coolant input temperature

· Engine coolant output temperature

· Generator kW output

· Generator line voltage output

· Generator frequency

· Running time Inputs and Outputs The status of all critical generator alarms points shall be visible locally and be available as outputs for external monitoring. Expected digital outputs are as follows:

· Generator Over Voltage – Alarm

· Generator Over Voltage – Trip

· Generator Under Voltage Alarm

· Generator Under Voltage Trip

· Generator Over Frequency - Alarm

· Generator Over Frequency - Trip

· Generator Under Frequency Alarm

· Generator Under Frequency Trip

· High Coolant Temperature – Alarm

· High Coolant Temperature – Shutdown

· Low Coolant Temperature Shutdown

· High Oil Pressure – Alarm

· High Oil Pressure – Shutdown

· Low Oil Pressure – Alarm

· Low Oil Pressure –Shutdown

· Low Coolant Level –Alarm

· Generator Breaker status

· Overspeed – shutdown

· Low Fuel – Storage Tank Alarm

· No Fuel – Storage Tank Shutdown

· High Battery Voltage Alarm

· Low Battery Voltage Alarm

· System Ready Status

· Sensor Fail Shutdown

· Generator Power Detection

· Line Power Detection Contact Outputs: The system shall have a minimum of two (2) configurable Form C dry contact relay outputs rated at 125 VDC available for use by WAPA.

Expected Inputs:

· Remote start

· Remote shutdown

Spare Parts Manufacturer shall provide a list of recommended spare parts.

Manufacturer shall provide spare parts according to the list of recommended spare parts.

Manufacturer shall provide a list of distributers that carry the recommended spare parts and other parts required for repair of the diesel generator set.

Instruction Manuals and Drawings A complete set of hardcopy Instruction Manuals and Drawings, consisting of operating and maintenance manuals, parts book, dimensional drawings, separate unit wiring diagrams, schematic diagrams, and interconnecting wiring diagrams shall be provided. A second set of Instruction Manuals and Drawings shall be provided in electronic format on a CD.

Operator Training The manufacturer’s representative shall provide a minimum of 4 hours of onsite operating, programming, and maintenance training to WAPA maintenance personnel. The detailed Maintenance Schedule Plan and Approved Operating and Maintenance Manuals shall be available to WAPA personnel one week prior to the training session.

Technical assistance Provide contact information for a local representative for repair of the diesel generator set.

Provide contact information for technical support of the diesel generator set.

NOTES:

If there are any deviations to the specification the manufacturer shall clearly specify what portion(s) of this specification the manufacturer will deviate and provide a reason for the deviation(s).

16 | Page