Feedlot_Well_Generator_Total.pdf

BID SCHEDULE

ITEM NO. DESCRIPTION AMOUNT

BASIC BID For furnishing labor, supervision, materials, ITEM #1 tools, equipment, transportation, etc., necessary to install a generator/engine set, panelboard, automatic transfer switch, variable frequency drive, and all other associated electrical work for a feedlot water supply well at the UNITED

STATES DEPARTMENT OF AGRICULTURE,

Agricultural Research Service, Roman L.

Hruska U.S. Meat Animal Research Center, Clay Center, Nebraska, in accordance with the attached specifications and drawings.

ALL FOR THE LUMP SUM OF………………$___________

OPTION #1 For furnishing labor, supervision, materials, tools, equipment, transportation, etc., necessary to install an inverter duty 15 hp motor for a feedlot water supply well at the UNITED

STATES DEPARTMENT OF AGRICULTURE,

Agricultural Research Service, Roman L.

Hruska U.S. Meat Animal Research Center, Clay Center, Nebraska, in accordance with the attached specifications and drawings.

ALL FOR THE LUMP SUM OF………………$___________

TABLE OF CONTENTS

DIVISION 1- GENERAL REQUIREMENTS

0101 - SUMMARY OF WORK

0130 - SHOP DRAWINGS

0160 - USE OF GOVERNMENT FACILITIES (UTILITIES, ETC.)

0180 - CLEANUP

DIVISION 16 – ELECTRICAL

1604 - AUTOMATIC TRANSFER SWITCHES

1605 – ELECTRICAL SYSTEMS

2632 - GENERATORS AND ENGINES

DIVISION I

SECTION 0101

SUMMARY OF WORK

The work consists of providing all labor, material, and equipment and performing all work to install an emergency generator system for the west water supply well at the feedlot so that the well is fully operable upon a loss of utility electrical service. The transfer from utility power to generator power shall be done automatically and shall return to utility power automatically upon restoration of utility power. Generator shall also automatically test at a set interval (typically once per month). This work shall include, but shall not be limited to the following:

1. Installation of 1 pad mounted emergency outdoor generator/engine set located just east of the well house.

2. Installation of an automatic transfer switch, controllers, panel board with breakers, and all other material for a completely operable, automatic emergency electrical power system.

3. Installation of a variable frequency drive (VFD) and a new inverter duty well motor (as required for compatibility with VFD) with piping pressure sensor for controlling VFD.

4. Connection to existing electrical utility service.

5. All trenching and back fill for conductors and conduit from generator and any other trenching and backfill needed to complete the project.

6. 6" thick reinforced concrete pad with footing for generator as approved by manufacturer.

6" pipe bollards shall be installed at each of 4 corners of pad. Owner will grade the site for the pad.

7. All wiring, conduit, wire protection devices, etc. for a completely operable, and safe system.

8. All wiring in conduit between generators, panel board, controllers, automatic transfer switches, variable frequency drive, well motor, utility power, etc.

9. Communication conductors from generator to automatic transfer switch.

Note: This well is one of two water supply wells at the USMARC feedlot. Both wells are needed to be on at the same time during the hottest months of the year.

10. Commissioning: Complete commissioning shall be performed by factory trained and experienced start-up personnel.

0101-1

11. Training: Training of location personnel as necessary for complete maintenance and operation of system.

12. If there is anything indicated for the project in the design documents that isn't compatible with contractor's supplier's equipment, the contractor shall still be responsible for providing all necessary equipment and material for the generators and generator systems to function as intended.

13. Contractor shall return after one year after completion of project to fully test operation of generator and associated equipment.

SECTION 0130

SHOP DRAWINGS

1. Submit shop drawings to the Contracting Officer’s Representative (COR) for approval prior to installation. Information in the form of drawings, product literature, manufacturer’s specification, equipment lists, etc. shall be submitted on the following:

Specification

Description Drawings Literature Schedule

a. Engines/Generators x x x

b. Automatic Transfer Switch x x x

d. Panel Board x x

e. Controllers x

f. Items under Division 16 x

The Contracting Officer may request submittals in addition to those listed when deemed necessary to adequately describe the work covered in the respective sections.

2. Each submittal shall be complete and in sufficient detail for ready determination of compliance with the contract requirements.

3. Submittal shall be submitted in four (4) copies to the COR using the transmittal form. The form shall be properly completed by filling out all the heading block spaces and identifying each item submitted. Special care should be exercised to insure proper listing of the specification paragraph and/or sheet number of the contract drawings pertinent to the data submitted for each item. A separate transmittal form shall be attached to each copy of the data being submitted.

4. Brand Name: Identification of items in the contract documents is intended to be descriptive, not restrictive, and is to indicate the quality and characteristics of products that will be satisfactory.

0101-2, 0130-1

SECTION 0160

USE OF GOVERNMENT FACILITIES (UTILITIES, ETC.)

1. Water, Gas, Electricity:

a. As mutually agreed upon between the Contractor and the COR, the Contractor may use nearby utilities required for his performance under this contract.

b. Contractor shall bear the cost of temporary connections (if necessary) and restoration upon conclusion of use.

c. The Government shall bear the cost of reasonable utility consumption. Government will not pay the cost of utilities if usage is abused.

d. The Contractor shall submit for approval written notification not less than 4 working days in advance of requirement to shut down any utilities or other services to or within existing building or facilities used by others.

2. Telephone:

a. Contractor shall arrange and pay for any telephone service they choose to provide for themselves.

3. Toilet:

a. Contractor shall provide their own toilet facility.

4. Access to Buildings:

a. Contractor’s access to buildings shall be limited to those areas where work is being performed.

5. Material Receiving:

a. Contractor shall be on-site to receive materials. Contractor shall arrange for own storage of materials unless other arrangements have been agreed to by owner.

SECTION 0180

CLEANUP

0160-1, 0180-1

1. Cleanup:

a. The Contractor shall keep the premises clean during construction and shall remove all rejected material, rubbish, etc., after completion of work and prior to final inspection.

b. Materials removed by the Contractor shall become the property of the contractor and shall be removed from the site unless otherwise agreed to by the owner.

c. Government dumpsters shall not be used by the contractor.

0180-2

* End of Section

SECTION 1604

AUTOMATIC TRANSFER SWITCH

1. General:

a. Furnish all labor, materials, tools, equipment, and services for automatic transfer switches, as indicated and in accordance with contract documents for complete and automatic operation.

2. System Description:

a. Provide automatic transfer switches with number of poles, amperage, voltage, withstand, and close-on ratings as described and/or shown.

b. Provide interface control wiring in conduit to other equipment as required for complete and operational systems.

c. Transfer switches and controllers shall be products of same manufacturer. Transfer switches shall consist of double throw power transfer and microprocessor controller to provide automatic operation.

3. Quality Assurance:

a. UL 1008 Standard for Transfer Switch Equipment

b. IEC 947-6-1 Low-voltage switchgear and control gear

c. IEEE Standard 446 Recommended Practice for Emergency and Standby Power

d. NEMA Standard ICS10-1993

e. UL 508 Industrial Control Equipment

f. Certified to ISO 9001 International Quality Standard

4. Submittals:

a. Switches:

1. Outline drawings of assembly

2. One line diagrams and wiring diagrams for assembly and components

3. Interconnection wiring diagrams

b. Product Data:

1. Technical data on each size and type of transfer switch

2. Factory test reports

3. Letter certifying compliance with all requirements of specifications.

1604-1

c. Closeout Information:

1.Operation and maintenance data

2. Owner instruction report

3. Field test reports

5. Products:

a. Automatic transfer switch shall be as manufactured by CAT, or equal and shall be compatible with generator/engine set.

b. Service:

1. Service center's personnel must be factory trained and on call 24 hours per day, 365 days per year.

2. Manufacturer shall keep records of each switch , by serial number, for min. of 20 yrs.

c. Characteristics:

1. Electrically operated, mechanically held.

2. Switches shall be positively locked and unaffected by momentary outages

3. All transfer switch sizes shall use only one type of main operator for ease of maintenance

4. Parts which are not intended for continuous duty, repetitive switching or transfer between two active power sources are not acceptable.

5. All transfer switches serving line to neutral load(s) shall be 4 pole switches unless otherwise noted. Transfer switches serving strictly line to line load(s) shall be 3 pole switches unless otherwise noted.

6. Make all contacts and coils readily accessible for replacement from front of panel without major disassembly.

7. Provide red and green indicating lights with fuses, identification nameplates, and test switch on front to simulate normal power failure at switch.

8. Provide cable terminal lugs to accommodate conductors indicated on one line diagram.

9. Provide engine starting contacts and all other auxiliary contacts and accessory devices for functions to be performed.

10. Time delays:

a. Provide time delay on engine start, field adjustable from 0 to 6 sec, by sec, and set at 2 sec, to avoid unnecessary starting caused by short time outages.

b. Provide time delay on transfer to emergency, field adjustable from 0-60 minutes.

c. Provide two independently adjustable time delay modes on retransfer to normal, field adjustable from 0 to 60 minutes to avoid erratic operation caused by short time reestablishment of normal source. Set time delay at 5 minutes.

d. Provide engine shut down time delay for engine generator cool down, adjustable from 0 to 60 minutes. Set at 5 minutes.

1604-2

e. Provide time delay activated output signal to drive external relay(s) for selective load disconnect control.

f. All time delays shall be adjustable in 1 second increments unless otherwise indicated.

g. All time delays shall be adjustable by using LCD display and keypad or with remote device connected to serial communications port. Time delay value displayed on LCD or remote device shall be remaining time until next event occurs.

h. Provide three position momentary-type test/automatic/reset switch.

i. Provide SPDT contact, rated 5 amps at 30 VDC, for low-voltage engine start signal.

j. Provide minimum of two sets of auxiliary contacts, rated 10 amps, 250 VAC consisting of one contact, closed when transfer switch is connected to normal source and one contact closed, when automatic transfer switch is connected to emergency source.

k. Provide LED indicating lights (16 mm industrial grade, type 12) shall be provided;

one to indicate when automatic transfer switch is connected to normal source

(green) and one to indicate when automatic transfer switch is connected to emergency source (red).

l. Provide LED indicating lights energized by controller to provide true source availability of normal and emergency sources, as determined by voltage sensing trip and reset settings for each source.

d. Microprocessor Controller:

1. Sensing and logic shall be provided by single built-in microprocessor in each switch for maximum reliability, minimum maintenance, and ability to communicate serially through optional serial communication module.

2. Single controller shall provide selectable nominal voltages for maximum application flexibility and minimal spare part requirements.

3. Controller shall be connected to transfer switch by interconnecting wiring harness with keyed disconnect plug to enable controller to be disconnected from transfer switch for routine maintenance.

4. All customer connections shall be wired to common terminal block to simplify field-wiring connections.

5. Provide LCD display three to four lines, up to 20 character and keypad as part of controller for viewing all available data and setting desired operational parameters.

6. Operation:

a. Engine starting contacts shall be normally open contacts that close to start engine(s).

1604-3

b. Controller operational parameter shall be available for viewing and limited control through serial communications input port. The following parameters shall be adjustable on controller:

1. Nominal line voltage and frequency.

2. Single or three phase sensing.

3. Operating parameter protection.

4. Transfer operating mode configuration.

c. All instructions and controller settings shall be easily accessible, readable and accomplished without use of codes, calculations or instruction manuals.

d. Continuously monitor voltage and frequency on both normal and emergency sources and provide adjustable dropout and pickup setting ranges (nominal) as follows:

1. Under-voltage dropout: 70 to 98 percent of nominal voltage. (3 phase)

2. Under-voltage pickup: 85 to 100 percent of nominal voltage. (3 phase)

3. Over-voltage dropout: 102 to 115 percent of nominal voltage. (3 phase)

4. Over-voltage pickup: 2 percent below over-voltage dropout. (3 phase)

5. Under-frequency dropout: 85 to 98 percent of nominal frequency.

6. Under-frequency pickup: 90 to 100 percent of nominal frequency.

7. Over-frequency dropout: 102 to 110 percent of nominal frequency.

8. Over-frequency pickup: 2 percent below over-frequency dropout.

9. Voltage unbalance dropout: 5 to 20 percent of nominal voltage.

10. Voltage unbalance pickup: 1 percent below voltage unbalance dropout.

e. Repetitive accuracy of all settings shall be within plus or minus 0.5 percent over an operating temperature range of minus 20 degC to plus 60 degC.

f. Voltage and frequency settings shall be field adjustable in 1 percent increments either locally with display and keypad or remotely via serial communications port access.

g. Controller shall be capable (when activated by keypad or through serial port) of sensing phase rotation of both normal and emergency sources. Source shall be considered unacceptable if phase rotation is not preferred rotation selected (ABC or CBA).

h. Source status screens shall be provided for both normal and emergency to provide digital readout of voltage on all 3 phases, frequency, and phase rotation.

i. Following features shall be built into controller and shall also be capable of being activated through keypad programming or serial port when required by user:

1. Provide ability to select “commit/no commit to transfer” to determine whether load should be transferred to the emergency generator if normal source restores before generator(s) are ready to accept load.

1604-4

2. Provide in-phase monitor in controller to control transfer so that motor load inrush currents do not exceed normal starting currents and shall not require external control of power sources. In-phase monitor shall be specifically designed for and be product of automatic transfer switch manufacturer.

3. Controller shall be capable of accepting normally open contact that will allow transfer switch to function in non-automatic mode using an external control device.

4. Provide internal engine exerciser that shall allow user to program up to seven different exercise routines.

a. For each routine, user shall be able to:

1) Enable or disable routine.

2) Enable or disable transfer of load during routine.

3) Set start time:

a) Time of day.

b) Day of week.

c) Week of month (1st, 2nd, 3rd, 4th, alternate or every)

4) Set duration of run.

b. At end of specified duration switch shall transfer load back to normal and run generator(s) for specified cool down period.

c. 10-year life battery that supplies power to real time clock in event of power loss will maintain all time and date information.

j. System Status:

1. Controller LCD display shall include “System Status” screen which shall be readily accessible from any point in menu by depressing “ESC” key maximum of two times. This screen shall display clear description of active operating sequence and switch position. For example:

Normal Failed

Load on Normal

TD Normal to Emerg

2min 15s

2. Controllers that require multiple screens to determine system status or display

“coded” system status messages, which must be explained by references in operator’s manual, are not permissible.

k. Self diagnostics:

1. Controller shall contain diagnostic screen for purpose of detecting system errors.

Screen shall provide information on status input signals to controller which may be preventing load transfer commands from being completed.

l. Communications interface:

1604-5

1. Controller shall be capable of interfacing, through optional serial communication module, with network of transfer switches, locally (up to 4000 ft.) or remotely through modem serial communications.

2. Standard software specific for transfer switch applications shall be available by transfer switch manufacturer.

3. Software shall allow for monitoring, control and setup of parameters.

m. Data Logging:

1. Controller shall have ability to log data and to maintain last 99 events, even in event of total power loss. Following events shall be time and date stamped and maintained in non-volatile memory:

a. Event Logging:

1) Date, time and reason for transfer normal to emergency.

2) Date, time and reason for transfer emergency to normal.

3) Date, time and reason for engine start.

4) Date and time engine stopped.

5) Date and time emergency source available.

6) Date and time emergency source not available.

b. Statistical Data:

1) Total number of transfers.

2) Total number of transfers due to source failure.

3) Total number of days controller is energized.

4) Total number of hours both normal and emergency sources are available.

n. Communications Module:

1. Full duplex RS485 interface shall be installed in controller to enable serial communications.

2. Serial communications shall be capable of direct connect or multi-drop configured network.

3. Module shall allow for seamless integration of existing or new communication transfer devices.

7. Installation:

a. Locate automatic transfer switches at locations shown on drawings. Switches and controllers shall be installed in Type 3R enclosures.

b. Adjust relays per manufacturer's recommendations unless otherwise noted.

c. Provide and terminate all interface control wiring in conduit from automatic transfer switches to other equipment or systems as required including but not limited to:

1604-6

1. Generator control panel (engine start circuiting): Provide separate engine start circuit from each transfer switch to generator control panel.

2. Annunciator/control panels if provided.

3. Time delay signal prior to and after transfer from one source to another where indicated.

4. Building Control System

5. Label both ends of all conductors noting points of opposite termination.

8. Testing:

a. Each automatic transfer switch shall be factory tested to ensure proper operation of individual components, correct overall sequence of operation and to ensure that operating transfer time, voltage, frequency and time delay settings are in compliance with specification requirements. Document and submit report.

b. Each automatic transfer switch shall be field tested by authorized factory representative to confirm proper operation of individual components, correct overall sequence of operation and to verify that operating transfer time, voltage, frequency and time delay settings are in compliance with specification requirements. Document and submit report.

1604-7

*End of Section

DIVISION 16

SECTION 1605

ELECTRICAL SYSTEMS

1. Scope:

The work covered by this section of the specifications consists of furnishing all labor, equipment, supplies, materials, and in performing all operations necessary for installing the generator/engine and controller, panel board, automatic transfer switch and controller, conductors, conduit, disconnect, variable frequency drive, and all other electrical components as required for a complete automatic emergency generator system for the west feedlot water supply well as shown on the drawings. All electrical components shall be in NEMA 1 rated enclosures.

2. General:

a. Rules:

The installation shall be in strict accordance with the requirements of the latest rules of the National Electrical Code and the National Fire Protection Association and as indicated on the drawings.

b. Coordination:

The drawings indicate the extent and general location and arrangement of equipment, conduit, and wiring. The contractor shall study building plans and details so that the outlets and equipment shall be properly located and readily accessible. Equipment and outlets shall be located to avoid interference with mechanical or structural features.

c. Materials and Schedules:

As soon as practical and before starting installation of any material and equipment, the contractor shall submit to the Contracting Officer’s Representative (COR) for approval, a complete list in triplicate of materials and equipment proposed for installation. This list shall include manufacturer’s names and materials equipment identification such as styles, types, catalog numbers, etc., to permit ready and complete identification. The label or listing of the Underwriters’

Laboratories, Inc. will be acceptable as evidence that the materials or equipment conform to the applicable standards of that Agency.

3. Materials and Equipment:

1605-1

a. Raceway

1. All wiring shall be installed in raceways.

2. Raceways exposed to weather, and any other area subject to damage shall be zinc-coated, rigid steel conduit.

3. Raceways for underground conductors shall be schedule 80 pvc.

4. Rigid steel conduit and steel electrical metallic tubing shall be hot dipped galvanized as manufactured by Allied Tube and Conduit Corporation, or approved equal. IMC conduit shall be as manufactured by Allied Tube and

Conduit Corporation, or approved equal.

5. No raceway smaller than 3/4” shall be used unless otherwise noted. Flexible conduit may be used where conditions warrant its use.

6. Existing conduit may be reused as approved by owner.

b. Boxes:

1. Boxes and outlets shall be hot dipped galvanized Raco or equal and shall be water tight.

2. Conduit fittings shall be as manufactured by T & B or Raco. Bushings on all conduits 1” and larger shall be the O.Z. Type “B” insulated type, with body, threads and conduit stop of malleable iron or steel, and with phenolic insulation molded on an irregular surface at the top so that it becomes an integral part of the bushing. Grounding bushings shall be the O.Z. Type

“BL”.

3. Provide minimum NEC required size pull boxes unless larger box is noted.

c. Conductors:

1. Conductors shall be copper or aluminum for above ground wiring:

a. Conductor insulation shall be THHN.

b. No wire shall be smaller than #12 unless otherwise noted, except that wiring for signal and pilot control circuits may be #14. All wire shall be such that a maximum of 2% voltage drop is maintained.

c. Insulated ground wires shall be run with circuit conductors for all circuits.

1605-2

d. All conductors shall be color coded in their entirety for wire sizes where color coding is commercially available. Phase wires of different multi-wire circuits in same raceway shall be of different color to provide identification.

e. Conductors in sizes which are not commercially available in color coding shall be taped with corresponding colors at all termination points and in all pullboxes, wireways, gutters, etc. All conductors found not to conform to these requirements will be directed to be removed and replaced as specified at no additional cost for the Owner.

f. Conductors shall be continuous from outlet to outlet and no splices shall be made except within outlet or junction boxes. Junction boxes may be utilized where required. All outlet, junction and pull boxes used with rigid conduit shall be water tight.

g. Splices and taps for smaller than #6 wire shall be made with 3M Ideal, or

Buchanan twist-on insulated connectors. Connectors of the porcelain cup type, with or without metal inserts, shall not be used. Splices in wire #6 and larger, shall be made with approved solderless lugs. If any other type of connector is proposed for use in any size conductor, it shall be specifically submitted for approval prior to use.

2. Conductors shall be aluminum from panel boards to automatic transfer switches.

3. Conductors used on poles for connection to automatic transfer switches shall be of the type currently being used off of the pole transformers.

d. Disconnects: Any disconnects needed shall be heavy duty non-fusible disconnect.

e. Panel Board: Panel board shall be 120/240 V, 3 phase, 125 amp, min. 32 space. Enclosure shall be NEMA 1. It shall have a main circuit breaker and all other breakers for existing and new equipment. It shall be as manufactured by

Schneider Electric, or equal.

f. Variable Frequency Drive: The variable frequency drive for the well motor is to be ABB, part# ACS550 series, or equal. It is to be in a NEMA

1 enclosure and rated for a 15 hp, 3 phase, 240 V continuous duty motor.

4. Excavating, Trenching, & Back-filling:

a. Excavating and Trenching:

1605-3

Trenches for all underground conduit shall be excavated to the required depths.

The bottom of trenches shall be tamped hard and graded to secure the required fall. Conduit shall rest on solid ground for its entire length.

b. Back-filling:

Materials for back-filling shall consist of the excavation, or borrow of sand, gravel, or other materials approved by the Project Inspector, and shall be free of trash, lumber, or other debris. Backfill shall be placed in horizontal layers, not exceeding 9 inches in thickness, and density that will prevent excessive settlement or shrinkage. Backfill shall be brought to a suitable elevation above grade to provide for anticipated settlement and shrinkage.

5. Installation and Workmanship:

a. The installation of all electrical work shall be in accordance with the drawings, these specifications, and shall be accomplished by electricians with a minimum of a “journeyman’s” license. See drawings for location of disconnects, combination starters with disconnects and other electrical components.

b. Conductors shall be continuous from outlet to outlet and no splices shall be made except within outlet or junction boxes. Conductor identification shall be color coded.

c. All conduit shall be interconnected for continuous electrical connection to ground. All raceways, etc., shall be grounded in accordance with Article 250 of the National Electrical Code. All exposed non-current carrying metallic parts of electrical equipment and raceway systems shall be grounded.

d. All motors and receptacles shall be grounded with a green ground wire extending from the motor or wiring device to the ground lug within the breaker panels.

e. Upon completion of the installation, make tests for operation with and to the satisfaction of the Owner.

1605-4

* End of Section .

SECTION 2632

GENERATORS AND ENGINES

1. General:

a. This section includes packaged engine-generator sets for standby power supply with the following features:

1. Diesel engine with below generator/engine tank

2. Unit mounted cooling system.

3. Unit mounted control and monitoring

4. Outdoor enclosure

b. See "Automatic Transfer Switches" specification for transfer switches including sensors and relays to initiate automatic starting and stopping signals for engine generator sets.

2. Submittals:

a. Product data for each type of packaged engine generator and accessory indicated.

1. Include rated capacities, operating characteristics, electrical characteristics, and furnished specialties and accessories.

2. Include thermal damage curve for generator.

3. Include time current characteristic curves for generator protective device.

4. Include fuel consumption in cubic feet per hour at .8 power factor at .5, .75, and 1.0 times generator capacity.

5. Include generator efficiency at .8 power factor at .5, .75, and 1.0 times generator capacity.

6. Include air flow requirements for cooling and combustion air in cfm at .8 power factor, with air supply temperature of 95, 80, 70, and 50 degree F. Provide drawings showing requirements and limitations for location of air intake and exhausts.

7. Include generator characteristics, including, but not limited to kw rating, efficiency, reactances, and short circuit current capability.

b. Shop Drawings: Detail equipment assemblies and indicate dimensions, weights, loads, required clearances, method of field assembly, components, and location and size of each field connection.

1. Include plans and elevations for engine generator set and other components specified.

2. Include details of equipment assemblies. Indicate dimensions, weights, loads, required clearances, method of field assembly, components, and location and size of each field connection.

2632-1

3. Identify fluid drain ports and clearance requirements for proper fluid drain.

4. Design calculations for selecting vibration isolators and seismic restraints and for designing vibration isolation bases.

5. Vibration isolation base details: Detail fabrication including anchorages and attachments to structure and to supported equipment. Include base weights.

6. Include diagrams for power, signal, and control wiring. Complete schematic, wiring, and interconnection diagrams showing terminal markings for EPS equipment and functional relationship between all electrical components.

7. Include schedule for interior mounted appliance panel.

3. Informational Submittals:

a. Source quality control test reports.

1. Certified summary of prototype unit test report.

2. Certified test reports: For components and accessories that are equivalent, but not identical to those tested on prototype unit.

3. Report of exhaust emissions showing compliance with applicable regulations.

4. Report of sound generation.

5. Certified torsional vibration compatibility: Comply with NFPA 110.

b. Field quality control test reports.

c. Warranty: Special warranty specified in this section.

4. Closeout Submittals:

a. Operation and maintenance data.

1. List of tools and replacement items recommended to be stored at project for ready access. Include part and drawing numbers, current unit prices, and source of supply.

2. Operating instructions laminated and mounted adjacent to generator location.

3. Training plan.

5. Quality Assurance:

a. Installer qualifications: Manufacturer's authorized representative who is trained and approved for installation of units required for the project.

b. Manufacturer qualifications: A qualified manufacturer. Maintain, within 50 miles of project site, a service center capable of providing training, parts, and emergency maintenance repairs with 90% parts availability in stock.

2632-2

c. Electrical components, devices, and accessories: Listed and labeled as defined in

NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.

d. Comply with ASME B15.1, NFPA 37, NFPA 70.

e. Comply with NFPA 110 requirements for Level 2 emergency power supply system.

f. Comply with UL 2200.

g. Engine exhaust emissions: Comply with applicable federal, state, and local government requirements.

h. Noise emission: comply with applicable state and local government requirements for maximum noise level at adjacent property boundaries due to sound emitted by generator set including engine, engine exhaust, engine cooling air intake and discharge, and other components of installation.

6. Project Conditions:

a. Environmental conditions: Engine generator system shall withstand the following environmental conditions without mechanical or electrical damage or degradation of performance capability:

1. Ambient Temperature: Minus 15 to plus 40 deg C.

2. Altitude: Sea level to 1000 feet.

7. Warranty

a. Special warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace components of packaged engine generators and associated auxiliary components that fail in materials or workmanship within specified warranty period.

1. Warranty Period: Two (2) years from date of substantial completion. Also include rental generator when unit is down during warranty work.

2. Extended Warranty/Service Agreement: Provide a 5 and 10 year extended warranty and service agreement options to the owner for their consideration.

8. Products - Manufacturers

a. Manufacturers" Subject to compliance with requirements, generator /engine set shall be as manufactured by CAT, or equal.

b. Generator shall be compatible with the automatic transfer switch being provided as part of this project.

2632-3

9. Engine-Generator Set

a. Factory assembled and tested, engine-generator set.

b. Mounting Frame: Maintain alignment of mounted components without depending on concrete foundation and having lifting attachments.

c. Capacities and Characteristics:

1. Power output rating: Generator set shall be rated for 40 kv, minimum, or as needed to provide power for pump, heater lights, outlets, solenoid valve.

2. Output connections: Three phase, four wire.

3. Nameplates: For each major system component to identify manufacturer's name and address, and model and serial number of component.

d. Generator Set Performance:

1. Steady state voltage operational bandwidth: 3 percent of rated output voltage from no load to full load.

2. Transient voltage performance: Not more than 10 percent variation for 50 percent step load increase or decrease. Voltage shall recover and remain within the steady state operating band within three seconds.

3. Steady state frequency operational bandwidth: .5 percent of rated frequency from no load to full load.

4. Steady state frequency stability: When system is operating at any constant load within the rated load, there shall be no random speed variations outside the steady state operational band and no hunting or surging of speed.

5. Transient frequency performance: Less than 5 percent variation for 50 percent step load increase or decrease. Frequency shall recover and remain within the steady state operating band within five seconds.

6. Output wave form: At no load, harmonic content measured line to line or line to neutral shall not exceed 5 percent total and 3 percent for single harmonics.

Telephone influence factor, determined according to NEMA MG 1, shall not exceed 50 percent.

7. Sustained short circuit current: For a 3 phase, bolted short circuit at system output terminals, system shall supply a minimum of 250 percent of rated full load current for not less than 10 seconds and then clear the fault automatically, without damage to generator system components.

2632-4

10. Engine:

a. Fuel: Fuel oil, Grade DF-2

b. Rated Engine Speed: 1800 rpm

c. Maximum piston speed for four cycle engines: 2250 fpm

d. Lubrication system: The following items are mounted on engine or skid:

1. Filter and strainer: Rated to remove 90 percent of particles 5 micrometers and smaller while passing full flow.

2. Thermostatic control valve: Control flow in system to maintain optimum oil temperature. Unit shall be capable of full flow and is designed to be fail safe.

3. Crankcase drain: Arranged for complete gravity drainage to aneasily removable container with no disassembly and without use of pumps, siphons, special tools, or appliances.

e. Engine Fuel System:

1. Main fuel pump: Mounted on engine. Pump ensures adequate primary fuel flow under starting and load conditions.

2. Relief bypass valve: Automatically regulates pressure in fuel line and returns excess fuel to source.

f. Coolant jacket heater: Electric immersion type, factory installed in coolant jacket system.

g. Governor: Adjustable isochronous, with speed sensing.

h. Cooling system: Closed loop, liquid cooled, with radiator factory mounted on engine generator set mounting frame and integral engine driven coolant pump.

1. Coolant: Solution of 50 percent ethylene-glycol-based antifreeze and 50 percent water, with anticorrosion additives as recommended by engine manufacturer.

2. Temperature Control: Self-contained, thermostatic-control valve modulates coolant flow automatically to maintain optimum constant coolant temperature as recommended by engine manufacturer.

i. Muffler/Silencer: Critical type, sized as recommended by engine manufacturer and selected with exhaust piping system to not exceed engine manufacturer's engine backpressure requirements.

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1. Minimum sound attenuation of 25 dB at 500 Hz.

2. Sound level measured at a distance of 10 feet (3 m) from exhaust discharge after installation is complete shall be 85 dBA or less.

j. Air-Intake Filter: Heavy-duty, engine-mounted air cleaner with replaceable dry-filter element and "blocked filter" indicator.

k. Starting System: 24-V electric, with negative ground.

1. Components: Sized so they will not be damaged during a full engine-cranking cycle with ambient temperature at maximum specified in Part 1 "Project

Conditions" Article.

2. Cranking Motor: Heavy-duty unit that automatically engages and releases from engine flywheel without binding.

3. Cranking Cycle: As required by NFPA 110 for system level specified.

4. Battery: Adequate capacity within ambient temperature range specified in

Part 1 "Project Conditions" Article to provide specified cranking cycle at least twice without recharging.

5. Battery-Charging Alternator: Factory mounted on engine with solid-state voltage regulation and 35-A minimum continuous rating.

a. Battery Charger: Current-limiting, automatic-equalizing and float-charging type. Unit shall comply with UL 1236.

11. FUEL OIL STORAGE

a. Comply with NFPA 30.

b. Base-Mounted Fuel Oil Tank: Factory installed and piped, complying with UL 142 fuel oil tank. Features include the following:

1. Tank level indicator.

2. Capacity: Fuel for 24 hours' continuous operation at 80 percent rated power output.

3. Vandal-resistant fill cap.

4. Containment Provisions: Comply with requirements of authorities having jurisdiction.

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12. CONTROL AND MONITORING

a. Automatic Starting System Sequence of Operation: When mode-selector switch on the control and monitoring panel is in the automatic position, remote-control contacts in one or more separate automatic transfer switches initiate starting and stopping of generator set. When mode-selector switch is switched to the on position, generator set starts. The off position of same switch initiates generator-set shutdown. When generator set is running, specified system or equipment failures or derangements automatically shut down generator set and initiate alarms.

b. Manual Starting System Sequence of Operation: Switching on-off switch on the generator control panel to the on position starts generator set. The off position of same switch initiates generator-set shutdown. When generator set is running, specified system or equipment failures or derangements automatically shut down generator set and initiate alarms.

c. Configuration: Operating and safety indications, protective devices, basic system controls, and engine gages shall be grouped in a common control and monitoring panel mounted on the generator set. Mounting method shall isolate the control panel from generator-set vibration.

d. Indicating and Protective Devices and Controls: As required by NFPA 110 for Level 2 system, and the following:

1. AC voltmeter.

2. AC ammeter.

3. AC frequency meter.

4. DC voltmeter (alternator battery charging).

5. Engine-coolant temperature gage.

6. Engine lubricating-oil pressure gage.

7. Running-time meter.

8. Ammeter-voltmeter, phase-selector switch(es).

9. Generator-voltage adjusting rheostat.

10. Fuel tank derangement alarm.

11. Fuel tank high-level shutdown of fuel supply alarm.

12. Generator overload.

e. Supporting Items: Include sensors, transducers, terminals, relays, and other devices and include wiring required to support specified items. Locate sensors and other supporting items on engine or generator, unless otherwise indicated.

f. Common Remote Audible Alarm: Comply with NFPA 110 requirements for Level 2 systems. Include necessary contacts and terminals in control and monitoring panel.

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1. Overcrank shutdown.

2. Coolant low-temperature alarm.

3. Control switch not in auto position.

4. Battery-charger malfunction alarm.

5. Battery low-voltage alarm.

g. Remote Alarm Annunciator: An LED labeled with proper alarm conditions shall identify each alarm event and a common audible signal shall sound for each alarm condition.

Silencing switch in face of panel shall silence signal without altering visual indication.

Connect so that after an alarm is silenced, clearing of initiating condition will reactivate alarm until silencing switch is reset. Cabinet and faceplate are surface- or flush-mounting type to suit mounting conditions indicated.

13. GENERATOR OVERCURRENT AND FAULT PROTECTION

a. Generator Circuit Breaker: Molded-case, thermal-magnetic type; 100 percent

1. Tripping Characteristic: Designed specifically for generator protection.

2. Trip Rating: Matched to generator rating.

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

c. System shall be connected as a separately derived system.

14. GENERATOR, EXCITER, AND VOLTAGE REGULATOR

a. Comply with NEMA MG 1.

b. Drive: Generator shaft shall be directly connected to engine shaft. Exciter shall be rotated integrally with generator rotor.

c. Electrical Insulation: Class H.

d. Stator-Winding Leads: Brought out to terminal box to permit future reconnection for other voltages if required.

e. Construction shall prevent mechanical, electrical, and thermal damage due to vibration, overspeed up to 125 percent of rating, and heat during operation at 110 percent of rated capacity.

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f. Enclosure: Drip proof.

g. Instrument Transformers: Mounted within generator enclosure.

h. Voltage Regulator: Solid-state type, separate from exciter, providing performance as specified.

1. Adjusting rheostat on control and monitoring panel shall provide plus or minus

2. percent adjustment of output-voltage operating band.

i. Strip Heater: Thermostatically controlled unit arranged to maintain stator windings above dew point.

j Windings: Two-thirds pitch stator winding and fully linked amortisseur winding.

k. Subtransient Reactance: 12 percent, maximum.

15. OUTDOOR GENERATOR-SET ENCLOSURE

a. Engine Cooling Airflow through Enclosure: Maintain temperature rise of system components within required limits when unit operates at 110 percent of rated load for 2 hours with ambient temperature at top of range specified in system service conditions.

1. Louvers: Fixed-engine, cooling-air inlet and discharge. Storm-proof and drainable louvers prevent entry of rain and snow.

2. Convenience Outlets: Factory wired, GFCI. Arrange for external electrical connection.

16. VIBRATION ISOLATION DEVICES

a. Elastomeric Isolator Pads: Oil- and water-resistant elastomer or natural rubber, arranged in single or multiple layers, molded with a nonslip pattern and galvanized-steel baseplates of sufficient stiffness for uniform loading over pad area, and factory cut to sizes that match requirements of supported equipment.

1. Material: Standard neoprene separated by steel shims.

2. Durometer Rating: 50.

3. Number of Layers: Three.

17. FINISHES

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a. Outdoor Enclosures and Components: Manufacturer's standard finish over corrosion-resistant pretreatment and compatible primer.

18. SOURCE QUALITY CONTROL

a. Prototype Testing: Factory test engine-generator set using same engine model, constructed of identical or equivalent components and equipped with identical or equivalent accessories.

1. Tests: Comply with NFPA 110, Level 21 Energy Converters and with

IEEE 115.

2. Report factory test results within 10 days of completion of test.

19. INSTALLATION

a. Comply with packaged engine-generator manufacturers' written installation and alignment instructions and with NFPA 110.

b. Install packaged engine generator to provide access, without removing connections or accessories, for periodic maintenance.

c. Install packaged engine generator with elastomeric isolator pads having a minimum deflection of 1 inch (25 mm) on concrete base. Secure sets to anchor bolts installed in concrete bases. Concrete base shall be 6" thick with size as recommended by generator manufacturer. Base shall have 8" diameter footings, 4' deep at each corner. Base shall be reinforced with #3 rebar on 12" centers both ways. Rebar shall also extend to bottom of footings. Concrete is required to reach 3,000 psi. Six (6") in. sch 40 pipe bollards

(concrete filled) shall be installed at each of the 4 corners of the pad, a minimum of 4' deep with 4' above ground. Bollards shall be painted with a minimum of 2 coats of best quality yellow paint.

d. Packaged generator shall include schedule 40, black steel piping with welded joints and connected to engine muffler. Install thimble at wall of housing. Piping shall be same diameter as muffler outlet.

e. Packaged generator shall include condensate drain piping to muffler drain outlet full size of drain connection with a shutoff valve, stainless-steel flexible connector, and

Schedule 40, black steel pipe with welded joints. Flexible connectors and piping materials and installation requirements shall be as per manufacturers specifications.

f. Electrical Wiring: Install electrical devices furnished by equipment manufacturers but not specified to be factory mounted.

g. Ground equipment according to the latest version of the NEC.

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h. Connect wiring according to Section 1605 and the latest version of the NEC.

i. Identify electrical systems components.

20. FIELD QUALITY CONTROL

a. Perform tests and inspections and prepare test reports.

1. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect components, assemblies, and equipment installations, including connections, and to assist in testing.

b. Tests and Inspections:

1. Perform tests recommended by manufacturer and each electrical test and visual and mechanical inspection for "AC Generators and for Emergency Systems" specified in NETA Acceptance Testing Specification. Certify compliance with test parameters.

2. NFPA 110 Acceptance Tests: Perform tests required by NFPA 110 that are additional to those specified here including, but not limited to, single-step full-load pickup test.

3. Battery Tests: Equalize charging of battery cells according to manufacturer's written instructions. Record individual cell voltages.

a. Measure charging voltage and voltages between available battery terminals for full-charging and float-charging conditions. Check electrolyte level and specific gravity under both conditions.

b. Test for contact integrity of all connectors. Perform an integrity load test and a capacity load test for the battery.

c. Verify acceptance of charge for each element of the battery after discharge.

d. Verify that measurements are within manufacturer's specifications.

4. Battery-Charger Tests: Verify specified rates of charge for both equalizing and float-charging conditions.

5. System Integrity Tests: Methodically verify proper installation, connection, and integrity of each element of engine-generator system before and during system operation. Check for air, exhaust, and fluid leaks.

6. Exhaust Emissions Test: Comply with applicable government test criteria.

7. Voltage and Frequency Transient Stability Tests: Use recording oscilloscope to measure voltage and frequency transients for 50 and 100 percent step-load increases and decreases, and verify that performance is as specified.

8. Harmonic-Content Tests: Measure harmonic content of output voltage under

25 percent and at 100 percent of rated linear load. Verify that harmonic content is within specified limits.

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9. Provide a 3-hour, 100 percent resistant load test.

10. Provide all tests required by all authorities having jurisdiction.

11. Noise Level Tests: Measure A-weighted level of noise emanating from generator-set installation, including engine exhaust and cooling-air intake and discharge, at four locations 25 feet from the generator enclosure, and compare measured levels with required values.

c. Coordinate tests with tests for transfer switches and run them concurrently.

d. Leak Test: After installation, charge system and test for leaks. Repair leaks and retest until no leaks exist.

e. Operational Test: After electrical circuitry has been energized, start units to confirm proper motor rotation and unit operation.

f. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment.

g. Remove and replace malfunctioning units and retest as specified above.

h. Retest: Correct deficiencies identified by tests and observations and retest until specified requirements are met.

i. Report results of tests and inspections in writing. Record adjustable relay settings and measured insulation resistances, time delays, and other values and observations.

Attach a label or tag to each tested component indicating satisfactory completion of tests.

21. DEMONSTRATION

a. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain packaged engine generators.

b. Provide owner 3 sets of O & M Manuals.

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* End of Section