Addendum_#1_-_266120-ELEC_GENSET_.pdf

CLAY CO FIRE STATION 24 26 6102-1 ENGINE GENERATOR SET

DH Comm. No. 22003

SECTION 266120 ENGINE GENERATOR SET

REVISED PER ADDENDUM #1

PART 1 – GENERAL

1.1 CONTRACT

A. General Requirements, included in Division 1, are hereby made a part of this section as if fully repeated herein.

B. Specifications and drawings shall be considered as supplementary to each other, requiring materials and labor indicated, specified, or implied by either specifications or drawings.

Contradictions shall be presented to the Architect for resolution.

C. Interpretation of specifications or drawings, where deemed necessary, shall be made only by the Architect.

1.2 SUBMITTALS

A. Submittals shall include specification sheets showing all standard and optional accessories to be supplied, schematic wiring diagrams, dimension drawings, and interconnection diagrams identifying by terminal number each required interconnection between the generator set, the transfer switch, and other remote devices if included elsewhere in these specifications.

1.3 CATALOG, OPERATION AND MAINTENANCE DATA

A. Provide four (4) complete sets of a compilation of catalog data for engine generator set and included accessories and components. In addition to the catalog data, installation, operating and maintenance data and bill of materials shall be included.

B. It is the intent of this catalog, operation and maintenance data to provide the Owner with complete instructions on the proper operation and use, lubrication and periodic maintenance, together with the source of replacement parts and service.

1.4 TESTING

A. To assure that the equipment has been designed and built to the highest reliability and quality standards, the manufacturer shall be responsible for design prototype tests as described herein:

Components of the emergency system, such as the engine/generator set, transfer switch, and accessories shall not be subjected to prototype tests since the tests are potentially damaging.

Rather, similar design prototypes which will not be sold, shall be used for these tests. Prototype test programs shall include the requirements of NFPA-110 and the following:

1. Maximum power (kw).

2. Maximum starting (kva) at 35% instantaneous voltage dip.

3. Alternator temperature rise by embedded thermocouple and by resistance method per

NEMA MG1-22.40 and 16.40.

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

5. Voltage regulation and generator transient response.

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

CLAY CO FIRE STATION 24 26 6102-2 ENGINE GENERATOR SET

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

8. Three-phase line-to-line short circuit test.

9. Alternator cooling air flow.

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

11. Endurance testing.

1.5 WARRANTY

A. The emergency generator system shall be warranted by the manufacturer for one year or 1,500 hours, whichever occurs first, from the date of the site start-up.

PART 2 – PRODUCTS

2.1 MATERIALS

A. The generator set rated for continuous standby power 120/208 volts, 3 phase, 4 wire, .8 power factor, 275KW, 343KVA, 954 amperes at 100 feet altitude, 104 degrees Fahrenheit, as Manufactured by Caterpillar or submit alternate Generator 10 days prior to bid for review.

Vibration isolators shall be provided between the engine-generator and heavy duty steel base or between the base and the floor. Final Production Tests: Generator set shall be tested under varying loads with guards and exhaust system in place. Tests shall include:

1. Single-step load pickup.

2. Transient and steady-state governing.

3. Safety shutdown device testing.

4. Voltage regulation.

5. Rated Power.

6. Maximum Power.

2.2 ENGINE

A. The engine shall be equipped with the following:

1. Engine driven or electric fuel transfer pump, fuel filters and electric fuel shut-off valve.

2. Woodward 1724 isochronous governor or equivalent capable of 0.25% Steady State frequency regulation.

3. 24 volt positive engagement solenoid shift-starting motor.

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

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

6. Dry-type replaceable air cleaner elements.

7. The naturally aspirated or turbocharged engine shall be fueled with No. 2 diesel, have 6 cylinders and be liquid cooled. A unit-mounted high capacity radiator, blower fan, water pump, thermostat, and radiator duct flange shall properly cool the engine at 120 degrees F ambient at the generator nameplate rating with 50% glycol.

2.3 GENERATOR

A. The generator shall be listed in accordance with UL 2200.

CLAY CO FIRE STATION 24 26 6102-3 ENGINE GENERATOR SET

B. Generator shall be salient-pole, self-ventilated of drip-proof construction with amortisseur rotor windings and skewed for smooth voltage waveform. The insulation material shall meet the NEMA standard (MGI-22.40 and 16.40) for Class H and be vacuum impregnated with epoxy varnish to be fungus resistant per MIL I-24092. Temperature rise of the rotor and stator shall be limited to NEMA class F. The excitation system shall be of brushless construction controlled by a solid-state digital voltage regulator with three phase true rms sensing and adjustable Volts-per-Hertz operation capable of maintaining voltage within + or - 0.5% at any constant load from 0 to 100% of rating. The regulator must be sealed from the environment and isolated from the load.

C. The generator shall be capable of sustaining at least 300% of rated current for at least 10 seconds under a 3 phase symmetrical short by permanent magnet exciter.

D. Output circuit breakers shall be provided as indicated on drawings, and shall be line current sensing type with inverse time versus current response shall be furnished and shall not automatically reset preventing restoration of voltage if maintenance is being performed. This breaker shall protect the generator from damage due to its own high current capability and shall not trip within the 10 seconds specified above to allow selective tripping of down-stream fuses or circuit breakers under a fault condition.

E. The generator, having a single maintenance free bearing, shall be directly connected to the flywheel housing with a semiflexible coupling between the rotor and the flywheel.

F. The generator shall be sized to provide 275KW at 208VAC and NEMA temperature rise not to exceed 130 degrees C at rated nameplate conditions.

G. Provide with a generator winding heater.

2.4 CONTROLLER

A. Set-mounted controller shall be vibration isolated on the generator enclosure. The microprocessor control board shall be moisture proof and capable of operation from -40c to 85c.

Relays will only be acceptable in high current circuits.

B. The controller shall include:

1. Fused DC circuits.

2. Complete two-wire start/stop control which shall operate on closure of a remote contact.

3. Speed sensing and a second independent starter motor disengagement systems shall protect against the starter engaging with a moving flywheel. Battery charging alternator voltage will not be acceptable for this purpose.

4. The starting system shall be designed for restarting in the event of a false engine start, by permitting the engine to completely stop and then reengage the starter.

5. Cranking cycler with 15-second ON and OFF cranking periods.

6. Overcrank protection designed to open the cranking circuit after 75 seconds if the engine fails to start.

7. Circuitry to shut down the engine when signal for high coolant temperature, low oil pressure, overcrank or overspeed are received.

CLAY CO FIRE STATION 24 26 6102-4 ENGINE GENERATOR SET

8. Engine cool down timer factory set at five minutes to permit unloaded running of the standby set after transfer of the load to normal.

9. Four-position (Automatic, Manual, Cooldown/Stop, Off/Reset) selector switch. In the automatic position, the engine shall start when contacts in the remote control circuit close and stop five minutes after those contacts open. In the manual position the engine will start immediately. In the cooldown/stop position the engine will stop after the predetermined cooldown period. In the off/reset position, the engine shall not start even though the remote start contacts close. This position shall also provide for immediate shutdown in case of an emergency. Reset of any fault lamp shall also be accomplished by putting the switch to the off position.

10. Indicating lights to signal:

a. (Not-in-auto (flashing red))

b. (Overcrank (red))

c. (Emergency stop (red))

d. (High engine temperature/low coolant level (red))

e. (Overspeed (red))

11. Test button for indicating lights.

12. Alarm horn with silencer switch per NFPA-110.

13. Terminals shall be provided for each signal in 10 above for connection to remote monitoring devices.

14. Emergency Stop mushroom type pushbutton, local emergency off at main electrical disconnect (ATS)

2.5 INSTRUMENT PANEL

A. A set mounted instrument panel shall include:

1. Voltmeter, true RMS digital,± .5% accuracy.

2. Ammeter, true RMS digital, ± .5% accuracy.

3. Voltmeter-ammeter phase selector switch.

4. Direct reading pointer-type frequency meter, digital,± .5% accuracy, 45 to 65 Hz scale.

5. Panel illuminating lights.

6. Battery charging voltmeter.

7. Coolant temperature gauge.

8. Oil pressure gauge.

9. Running time meter.

10. Voltage adjust rheostat (± 5% range).

11. Speed adjust rheostat.

2.6 ACCESSORIES

A. The following accessories shall be provided:

1. Provide a racor duplex filter/water separator at the engine.

2. Battery rack, battery cables, 24 vdc batteries, (2) 4D heavy duty lead acid type, 190 amp-hour capacity.

3. Gasproof, seamless, stainless steel, flexible exhaust connector(s) ending in pipe thread or

SAE flange.

4. Flexible fuel line(s) rated 300 degrees F and 100 PSI ending in pipe thread.

CLAY CO FIRE STATION 24 26 6102-5 ENGINE GENERATOR SET

5. Provide a critical grade silencer. Silencer shall be mounted inside the enclosure with adequate supports. All internal exhaust components shall be insulated. Provide a stainless steel flex connector, elbow, rain cap and all hardware.

6. Block heater of proper wattage and voltage, thermostatically controlled to maintain engine coolant at proper temperature to meet the start-up requirement of NFPA-110 regulations.

7. Automatic float and equalize battery charger with +- 1% constant voltage regulation from no load to full load over +- 10% AC input line variation, current limited during engine cranking and short circuit conditions, temperature compensated for ambients from -40 degrees C to +60 degrees C, 5% accurate voltmeter and ammeter, fused, reverse polarity and transient protected. Optional alarm circuit board to meet the requirements of NFPA- 110 for low battery voltage, high battery voltage, and battery charger malfunction.

8. Break-glass type remote emergency stop station which meets the requirements of NFPA- 110.

9. Fuel shut-off solenoid valve, 1" N.C. 24 VDC on engine fuel inlet line. Provide a strainer in front of the solenoid valve.

2.7 GENERATOR ENCLOSURE

A. Provide a weatherproof enclosure to house a diesel engine/generator set, designed, for concrete or sub-base tank mounting. Enclosure shall be constructed of formed interlocking aluminum panels with screw type mechanical fasteners to prevent water intrusion. The enclosure shall be sized to adequately house the genset and all accessories. Walls shall be constructed of marine grade pre-painted 0.080 minimum thickness formed aluminum panels.

Roof shall be constructed of marine grade mill finish 0.125 minimum thickness formed aluminum panels using an interlocking standing seam design capable of supporting 75 pounds per square foot. All external attaching hardware shall be stainless steel screw type mechanical fasteners.

Enclosure roof and base shall be framed with 3/16" aluminum channel. The enclosure shall be designed for a minimum wind load rating of 120 mph. Enclosure color shall be white.

B. Entrance doors shall be provided and shall be strategically located to provide easy access and serviceability. One door shall be located directly in front of the generator mounted circuit breaker and control panel. Each door shall consist of a formed minimum 1/8" aluminum frame with internal skin stressed door panel reinforcement. Door handles shall be two-point pad lockable type. Provide 1/8" drip rails above each door. All door hardware shall be aluminum or stainless steel.

C. Provide fixed aluminum intake louvers with bird screens and a vertical gravity open aluminum discharge chute sized as required for radiator air discharge. Gravity discharge louver shall be counterbalanced to permit easy opening. Engineered louvers shall be adequately sized to insure that the generator cooling system operates so as not to exceed 0.50 inches of water gauge static pressure drop with minimal water intrusion. Air intake shall be 1250 feet per minute or less to prevent water intrusion. Calculations shall be required.

D. Oil and water drain lines shall be extended to the exterior of the enclosure, labeled and plugged.

The fumes disposal tube shall be terminated into the exterior or radiator exhaust plenum.

E. Provide all the necessary hardware to externally/internally mount the specified exhaust silencer and maintain the weatherproof integrity of the system. This includes, but not limited to such items as muffler brackets and supports, rain shield and collar, and a 6-inch diameter radiator

CLAY CO FIRE STATION 24 26 6102-6 ENGINE GENERATOR SET

access cap. The exhaust system shall be completely assembled by the generator set supplier prior to start-up.

F. Note deleted.

PART 3 – DELIVERY, INSTILLATION AND TESTING

3.1 DELIVERY

A. The engine generator set and all accessories shall delivered to the project site as directed.

Coordinate delivery schedule with project contractor.

3.2 INSTALLATION

A. The installation shall be coordinated and inspected by the manufacturer's local representative prior to start-up and testing.

B. Provide steel reinforced concrete pad in accordance with manufacturer's requirements for generator mounting and support.

C. All fuel piping shall be provided in accordance with division 15. All piping shall be APT double wall self contained - no galvanized pipe shall be permitted.

D. Provide all control wiring from generator to ATS and remote annunciator as required.

3.3 TESTING

A. Site Tests: Site testing shall be performed after the engine generator system is installed and inspected. Site tests shall be performed under full load conditions using load bank provided by manufacturer's local representative. The installation check, start-up, and load test shall be performed by the manufacturer's local representative. The regular operators, and the maintenance staff shall be notified of the time and date of the site test. The tests shall include:

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

2. Accessories that normally function while the set is standing by shall be checked prior to cranking the engine. This shall include: engine heaters, battery charger, remote annunciator, etc.

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

4. Automatic start-up by means of simulated power outage to test remote-automatic starting, transfer of the load, and automatic shutdown. Prior to this test, all transfer switch timers shall be adjusted for proper systems coordination. Engine temperature, oil pressure and battery charge level along with generator voltage, amperes, and frequency shall be monitored throughout the test.

CLAY CO FIRE STATION 24 26 6102-7 ENGINE GENERATOR SET

END OF SECTION 266120