Attachment A.pdf

South Carolina Department of Transportation

PROJECT MANUAL

HORRY MAINTENANCE GENERATOR REPLACEMENT

4145 HIGHWAY 701 NORTH

CONWAY, SOUTH CAROLINA 29526

CAPITAL IMPROVEMENTS OFFICE

955 PARK STREET, ROOM 121

COLUMBIA, SOUTH CAROLINA 29201

March 22, 2019

Contact: Ernest Williams, Project Manager Phone: (803) 737-1298 Cell: (803) 413-2615 Fax: (803) 737-1542 Email: williamse@scdot.org mailto:williamse@scdot.org

TABLE OF CONTENTS

Site Photos – CS1, CS2, & CS3 3 Pages

Section 260500 – Common Work Results for Electrical 8 Pages

Section 262826 – Automatic Transfer Switches 7 Pages

Section 263213 – Packaged Engine Generators 9 Pages

SCDOT Horry Maintenance Generator Replacement

Horry Maintenance Facility Maintenance Shop Generator/ATS Replacement 4145 Highway 701 North - Conway, South Carolina

03/15/18

CS - 1

LOCATION –

MAINTENANCE SHOP BUILDING

Maintenance Shop Generator/ATS Replacement 4145 Highway 701 North - Conway, South Carolina

CS - 2

SCOPE OF WORK –

Remove existing 60kw generator and existing 225-amp automatic transfer switch from existing Maintenance Shop and provide 60kw generator and 225-amp automatic transfer switch per attached specifications. Fuel source shall be diesel; provide 36-hour double wall skid mounted tank with spill protection. System voltage is 120/240v, 3 phase, high leg. Remove existing conductors and provide #4/0 conductors between generator and ATS in existing conduit. The existing ATS is fed with normal power from adjacent 800-amp panel (panel on left in the photo below) with 225-amp, 3 pole circuit breaker. The ATS feeds an adjacent 250-amp panel to the right in the photo. Expand housekeeping concrete pad for generator so conduit stub ups are under unit.

APPROXIMATE LOCATION OF “ATS”

EQUIPMENT LOCATION – EXISTING GENERATOR

Maintenance Shop Generator/ATS Replacement 4145 Highway 701 North - Conway, South Carolina

CS - 3

Existing Generator in Exterior Equipment Yard

Existing Automatic Transfer Switch in Electrical Room

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COMMON WORK RESULTS FOR ELECTRICAL 260500 - 1

SECTION 260500 - COMMON WORK RESULTS FOR ELECTRICAL

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. Provide all labor, materials, equipment and supervision to construct complete and operable electrical systems as indicated on the drawings and specified herein.

B. All materials and equipment used shall be new, undamaged and free from any defects.

1.2 ELECTRICAL DRAWINGS

A. Electrical contract drawings are diagrammatic and indicate the general arrangement of electrical equipment. Do not scale electrical plans.

B. Coordinate installation of electrical equipment with the mechanical equipment and access thereto.

C. Discrepancies shown on different drawings, between drawings and specifications or between documents and field conditions shall be installed to provide the better quality or greater quantity of work; or, comply with the more stringent requirement; either or both in accordance with the A/E’s interpretation.

1.3

A.

EXISTING SERVICES AND FACILITIES

Damage to Existing Services: Existing services and facilities damaged by the Contractor through negligence or through use of faulty materials or workmanship shall be promptly repaired, replaced, or otherwise restored to previous conditions by the Contractor without additional cost to the Owner.

B. Interruption of Services: Interruptions of services necessary for connection to or modification of existing systems or facilities shall occur only at prearranged times approved by the Owner.

Interruptions shall only occur after the provision of all temporary work and the availability of adequate labor and materials will assure that the duration of the interruption will not exceed the time agreed upon.

C. Removed Materials: Existing materials made unnecessary by the new installation shall be stored on site. They shall remain the property of the Owner and shall be stored at a location and in a manner as directed by the Owner. If classified by the Owner's authorized representative as unsuitable for further use, the material shall become the property of the Contractor and shall be removed from the site at no additional cost to the owner.

PART 2 - PRODUCTS

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COMMON WORK RESULTS FOR ELECTRICAL 260500 - 2

2.1 FIRESTOPPING:

A. A firestop system shall be used to seal penetrations of electrical conduits and cables through fire-rated partitions per NEC 300.21, and NEC 800.26. The firestop system shall be qualified by formal performance testing in accordance with ASTM E-814, or UL 1479.

B. The firestop system shall consist of a fire-rated caulk type substance and a high temperature fiber insulation. It shall be permanently flexible, waterproof, non-toxic, smoke and gas tight and have a high adhesion to all solids so damming is not required. Only metal conduit shall be used in conjunction with this system to penetrate fire rated partitions. Install in strict compliance with manufacturer's recommendations. 3M or approved equal.

C. Comply with TIA/EIA-569-A, Annex A, "Firestopping."

D. Comply with BICSI TDMM, "Firestopping Systems" Article.

PART 3 - EXECUTION

3.1 PRODUCT INSTALLATION, GENERAL

A. Except where more stringent requirements are indicated, comply with the product manufacturer's installation instructions and recommendations, including handling, anchorage, assembly, connections, cleaning and testing, charging, lubrication, startup, test operation and shut-down of operating equipment. Consult with manufacturer's technical experts, for specific instructions on unique product conditions and unforeseen problems.

B. Protection and Identification: Deliver products to project properly identified with names, model numbers, types, grades, compliance labels and similar information needed for distinct identifications; adequately packaged or protected to prevent deterioration during shipment, storage and handling. Store in a dry, well ventilated, indoor space, except where prepared and protected by the manufacturer specifically for exterior storage.

C. Clean all equipment, inside and out, upon completion of the work. Scratched or marred surfaces shall be touched-up with touch-up paint furnished by the equipment manufacturer.

D. Replace all equipment and materials that become damaged.

3.2 ELECTRICAL WORK:

A. Electrical work shall be accomplished with all affected circuits or equipment de-energized.

When an electrical outage cannot be accomplished in this manner for the required work, the following requirements are mandatory:

1. Electricians must use full protective equipment (i.e., certified and tested insulating

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COMMON WORK RESULTS FOR ELECTRICAL 260500 - 3

material to cover exposed energized electrical components, certified and tested insulated tools, etc.) while working on energized systems in accordance with NFPA 70E.

2. Electricians must wear personal protective equipment while working on energized systems in accordance with NFPA 70E.

3. Before initiating any work, a job specific work plan must be developed by the contractor with a peer review conducted and documented by the Contractor. The work plan must include procedures to be used on and near the live electrical equipment, barriers to be installed, safety equipment to be used and exit pathways.

4. Work on energized circuits or equipment cannot begin until prior written approval is obtained from the Owner/ Architect.

LOW-VOLTAGE ELECTRICAL POWER CONDUCTORS AND CABLES

1.1 SUMMARY

A. This section includes the requirements for the following:

1. Wire and cable for 600 volts and less.

2. Wiring connectors and connections.

2.1 WIRING REQUIREMENTS

A. Exposed Dry Interior Locations: Use only THHN, THHW, or XHHW in raceway.

B. Metal Clad (MC) cable shall not be used unless prior approval has been granted by the architect and engineer.

2.2 BUILDING WIRE

A. Conductor: Copper.

B. Insulation Voltage Rating: 600 volts.

3.1 INSTALLATION

A. Use insulated spring wire connectors with plastic caps for copper conductor splices and

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COMMON WORK RESULTS FOR ELECTRICAL 260500 - 4

taps, 10 AWG and smaller.

B. Motor connections shall be made with compression connectors forming a bolted in-line or stub-type connection.

C. All splices made underground or in the pipe basement shall be rated suitable for water immersion.

GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS

A. Grounding and bonding components.

B. Provide all components necessary to complete the grounding system(s).

2.1 CONDUCTORS

A. Bonding Jumper Braid: Copper braided tape, sized for application.

B. Electrical Grounding conductors: Unless otherwise indicated, provide bare or green insulated stranded copper electrical grounding conductors sized according to NEC or as shown or specified. Provide green insulated for conductors sized No. 10 AWG and smaller.

3.3 SECONDARY EQUIPMENT AND CIRCUITS

A. Branch Circuits: Install equipment grounding conductors with all feeders and power branch circuits, sized in accordance with Article 250 of NFPA 70.

B. Metallic Conduit: Metallic conduits which terminate without mechanical connection to an electrical equipment housing by means of locknut and bushings or adapters, shall be provided with grounding bushings. Connect bushings with a bare grounding conductor to the equipment ground bus.

HANGERS AND SUPPORTS FOR ELECTRICAL SYSTEMS

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COMMON WORK RESULTS FOR ELECTRICAL 260500 - 5

PART 1 - GENERAL (NOT USED)

PART 2 - PRODUCTS.

2.1 MATERIALS

A. Hangers, Supports, Anchors, and Fasteners - General: Corrosion-resistant materials of size and type adequate to carry the loads of equipment and conduit, including weight of wire in conduit.

B. Supports: Fabricated of structural steel or formed steel members; galvanized, or PVC

C. Anchors and Fasteners:

1. Do not use powder-actuated anchors.

2. Concrete Structural Elements: Use precast inserts, expansion anchors, or preset inserts.

3. Steel Structural Elements: Use beam clamps, steel spring clips, steel ramset fasteners, or welded fasteners.

4. Concrete Surfaces: Use self-drilling anchors or expansion anchors.

5. Hollow Masonry, Plaster, and Gypsum Board Partitions: Use toggle bolts or hollow wall fasteners.

6. Solid Masonry Walls: Use expansion anchors or preset inserts.

7. Sheet Metal: Use sheet metal screws.

8. Wood Elements: Use wood screws.

A. Rigidly weld support members or use hexagon-head bolts to present neat appearance with adequate strength and rigidity. Use spring lock washers under all nuts.

B. In wet and damp locations use steel channel supports to stand cabinets, disconnects and panelboards 1 inch (25 mm) off wall.

C. Use sheet metal channel to bridge studs above and below cabinets and panelboards recessed in hollow partitions.

RACEWAY AND BOXES FOR ELECTRICAL SYSTEMS

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COMMON WORK RESULTS FOR ELECTRICAL 260500 - 6

2.1 CONDUIT REQUIREMENTS

A. Conduit Size: Comply with NFPA 70.

1. Minimum Size: 3/4 inch

B. Wet and Damp Locations:

1. Interior: RMC, IMC, or LTFMC

2.2 METAL CONDUIT

A. Rigid Steel Galvanized Conduit (RMC): ANSI C80.1.

B. Intermediate Metal Conduit (IMC): ANSI C80.6.

C. Fittings and Conduit Bodies: NEMA FB 1; material to match conduit.

1. Standard threaded couplings, locknuts, bushings, and elbows: Only steel or malleable iron materials are acceptable. Integral retractable type IMC couplings are also acceptable.

2. Die-cast or pressure-cast zinc-alloy fittings or fittings made of "pot metal" are prohibited.

3. Bushings: Metallic insulating type, consisting of an insulating insert molded or locked into the metallic body of the fitting. Bushings made entirely of metal or nonmetallic material are not permitted.

4. Sealing fittings: Threaded cast iron type. Use continuous drain type sealing fittings to prevent passage of water vapor. In concealed work, install fittings in flush steel boxes with blank cover plates having the same finishes as that of other electrical plates in the room.

2.3 LIQUIDTIGHT FLEXIBLE METAL CONDUIT

A. LIQUIDTIGHT FLEXIBLE METAL CONDUIT (LTFMC) Description: Interlocked steel construction with PVC jacket. Liquid-tight flexible metal conduit: Shall Conform to UL 360.

B. Fittings: UL 514B and ANSI/ NEMA FB1.

1. Only steel or malleable iron materials are acceptable.

2. Die-cast or pressure-cast zinc-alloy fittings or fittings made of "pot metal" are prohibited.

3. Fittings must incorporate a threaded grounding cone, a steel or plastic compression ring, and a gland for tightening. Connectors shall have insulated throats.

4. Coating for Fittings for PVC-Coated Conduit: Minimum thickness, 0.040 inch, with overlapping sleeves protecting threaded joints.

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3.1 CONDUIT INSTALLATION

A. Waterproofing: At floor, exterior wall, and roof conduit penetrations, completely seal clearances around the conduit and make watertight.

B. For power conduits install no more than equivalent of three 90 degree bends between boxes.

Use conduit bodies to make sharp changes in direction, as around beams. Use hydraulic one shot bender to fabricate bends in metal conduit larger than 2 inch (50 mm) size.

C. Provide suitable fittings to accommodate expansion and deflection where conduit crosses seismic, control, and expansion joints.

IDENTIFICATION FOR ELECTRICAL SYSTEMS

2.1 NAMEPLATES AND LABELS

A. Nameplates: Engraved three-layer laminated plastic, black letters on white background unless noted otherwise.

B. Locations:

1. Each electrical distribution and control equipment enclosure.

C. Letter Size:

1. Use 1/4 inch (6 mm) letters for identifying grouped equipment and loads.

D. Labels: Embossed adhesive tape, with 3/16 inch (5 mm) white letters on black background.

Use only for identification of individual wall switches, receptacles, and control device stations. Labels shall identify the panel and circuit number (Ex: PANEL: CIRCUIT).

3.1 PREPARATION

A. Degrease and clean surfaces to receive nameplates and labels.

3.2 INSTALLATION

A. Install nameplates and labels parallel to equipment lines.

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B. Secure nameplates to equipment front using corrosion resistant screws.

C. Provide the following insulation coloring of conductors -

1. Phase A – Black.

2. Phase B – Red.

3. Phase C – Blue.

4. Neutral – White.

5. Ground – Green.

D. Provide name plates on all disconnect switches.

E. Provide updated, typed panel directories where new circuits originate.

END OF SECTION 260500

Maintenance Shop Generator/ATS Replacement 4145 Highway 701 North - Conway, South Carolina

AUTOMATIC TRANSFER SWITCHES 262826 - 1

SECTION 262826 – AUTOMATIC TRANSFER SWITCHES

A. This Section includes transfer switches rated 240 V and less, including the following:

1. Automatic transfer switches

1.2 SUBMITTALS

A. Product Data: Include ratings and dimensioned plans, sections, and elevations showing minimum clearances, conductor entry provisions, gutter space, installed features and devices, and material lists for each switch specified.

B. Wiring Diagrams: Detail wiring for transfer switches and differentiate between manufacturer-installed and field-installed wiring. Show both power and control wiring.

C. Single-Line Diagram: Show connections between transfer switch, power sources, and load.

D. Product Certificates: Signed by manufacturer certifying that products furnished comply with requirements and that switches have been tested for load ratings and short-circuit closing and withstand ratings applicable to units for project.

E. Qualification Data: For firms and persons specified in "Quality Assurance" Article.

F. Field Test Reports: Indicate and interpret test and inspection results for compliance with performance requirements.

G. Maintenance Data: For each type of product to include in maintenance manuals. Include all features and operating sequences, both automatic and manual. List all factory settings of relays and provide relay-setting and calibration instructions, including software, where applicable.

1.3 QUALITY ASSURANCE

A. Manufacturer Qualifications: Maintain a service center capable of providing emergency maintenance and repairs at project site with an eight-hour maximum response time.

B. Testing Agency Qualifications: Testing agency as defined by OSHA in 29 CFR 1910.7 or a member company of the InterNational Electrical Testing Association and that is acceptable to authorities having jurisdiction.

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1. Testing Agency's Field Supervisor: Person currently certified by the InterNational Electrical Testing Association or the National Institute for Certification in Engineering Technologies (Level 3 or higher), to supervise on-site testing specified in Part 3.

C. Source Limitations: Obtain automatic transfer switches, and remote annunciator and control panels through one source from a single generator manufacturer.

D. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, for emergency service under UL 1008, by a testing agency acceptable to authorities having jurisdiction.

E. Comply with NEMA ICS 1.

F. Comply with NFPA 70.

G. Comply with NFPA 110.

H. Comply with UL 1008, unless requirements of these Specifications are stricter.

2.1 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, provide products by the following:

1. Automatic Transfer Switches:

a. ASCO Power Technologies, LP

b. Caterpillar Inc.

c. Cummins Inc.

d. Kohler Power Systems Co.

e. Russell Electric Inc.

f. Zenith Inc.

2.2 GENERAL TRANSFER-SWITCH PRODUCT REQUIREMENTS

A. Indicated Current Ratings: Apply as defined in UL 1008 for continuous loading and total system transfer, including tungsten filament lamp loads not exceeding 30 percent of switch ampere rating, unless otherwise indicated. The automatic transfer switch for this project shall be 225 amps, 120/240v, 3 phase, 4 wire.

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B. Tested Fault-Current Closing and Withstand Ratings: Adequate for duty imposed by protective devices at installation locations in project under the fault conditions indicated, based on testing according to UL 1008.

1. Transfer Switch shall include Internal Fault-Current Protection on the utility side of the switch per UL. Rating of switch shall 65,000 A.I.C., minimum.

C. Annunciation, Control, and Programming Interface Components: Devices at transfer switches for communicating with remote programming devices and annunciator and control panels shall have communications capability matched with remote device.

D. Solid-State Controls: Repetitive accuracy of all settings shall be plus or minus 2 percent or better over an operating temperature range of minus 20 to plus 70 deg C.

E. Resistance to Damage by Voltage Transients: Components shall meet or exceed voltage-surge withstand capability requirements when tested according to IEEE C62.41. Components meet or exceed voltage-impulse withstand test of NEMA ICS 1.

F. Neutral Terminal: Solid and fully rated, unless otherwise indicated.

G. Enclosure: General-purpose NEMA 250, Type 1, complying with NEMA ICS 6; UL 508, unless otherwise indicated.

H. Factory Wiring: Train and bundle factory wiring and label consistent with Shop Drawings, either by color code or by numbered or lettered wire and cable tape markers at terminations.

1. Designated Terminals: Pressure type suitable for types and sizes of field wiring indicated.

2. Power-Terminal Arrangement and Field-Wiring Space: Suitable for top, side, or bottom entrance of feeder conductors as indicated.

3. Control Wiring: Equipped with lugs suitable for connection to terminal strips.

I. Electrical Operation: Accomplish by a nonfused, momentarily energized solenoid or electric-motor-operated mechanism, mechanically and electrically interlocked in both directions.

J. Switch Characteristics: Designed for continuous-duty repetitive transfer of full-rated current between active power sources.

1. Switch Action: Double throw; mechanically held in both directions.

2. Contacts: Silver composition or silver alloy for load-current switching. Conventional automatic transfer-switch units rated 225 A and greater have separate arcing contacts.

2.3 AUTOMATIC TRANSFER SWITCHES

A. Comply with Level 1 equipment according to NFPA 110.

B. Switching Arrangement: Double-throw type.

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C. Manual Switch Operation: Under load, with door closed and with either or both sources energized. Transfer time is the same as for electrical operation. Control circuit automatically disconnects from electrical operator during manual operation.

D. Manual Switch Operation: Unloaded. Control circuit automatically disconnects from electrical operator during manual operation.

E. Signal-before-Transfer Contacts: A set of normally open/normally closed dry contacts shall operate in advance of retransfer to normal source. Interval shall be adjustable from 1 to 30 seconds.

F. Digital Communications Interface: Matched to capability of existing remote annunciator and control panels.

G. Programmed Neutral Switch Position: Switch operator shall have a programmed neutral position arranged to provide a midpoint between the two working switch positions, with an intentional, time-controlled pause at midpoint during transfer. Pause shall be adjustable from

0.5 to 30 seconds minimum and factory set for 0.5 seconds, unless otherwise indicated. Time delay shall occur for both transfer directions. Pause shall be disabled, unless both sources are live.

2.4 AUTOMATIC TRANSFER-SWITCH FEATURES

A. Undervoltage Sensing for Each Phase of Normal Source: Senses low phase-to-ground voltage on each phase. Pickup voltage shall be adjustable from 85 to 100 percent of nominal, and dropout voltage shall be adjustable from 75 to 98 percent of pickup value. Switch shall be factory set for pickup at 90 percent and dropout at 85 percent.

B. Switch shall have a time delay feature that will override normal-source voltage sensing which shall delay transfer and engine start signals. Time delay feature shall be adjustable from zero to six seconds, and factory set to one second.

C. Voltage/Frequency Lockout Relay: Relay shall prevent premature transfer to generator set.

Pickup voltage shall be adjustable from 85 to 100 percent of nominal, and shall be factory set for pickup at 90 percent. Pickup frequency shall be adjustable from 90 to 100 percent of nominal, and shall be factory set for pickup at 95 percent.

D. Time Delay Feature for Retransfer to Normal Source: Feature shall be adjustable from 0 to 30 minutes, and shall be factory set to 10 minutes. Feature shall provide automatic defeat of delay on loss of voltage or sustained undervoltage of emergency source, provided normal supply has been restored.

E. Test Switch: Simulates normal-source failure.

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F. Switch-Position Pilot Lights: Indicate source to which load is connected.

G. Source-Available Indicating Lights: Supervise normal- and emergency-source sensing circuits and provide indicating lights and labels as follows:

1. Normal Power Supervision: Green light with nameplate engraved "Normal Source

Available."

2. Emergency Power Supervision: Red light with nameplate engraved "Emergency Source

Available."

H. Unassigned Auxiliary Contacts: Include two normally-open single-pole, double-throw contacts for each switch position rated 10 Amps at 240-Volts AC.

I. Transfer Override Switch: Switch shall override automatic retransfer control so automatic transfer switch will remain connected to emergency power source regardless of condition of normal source. Include a pilot light to indicate override status.

J. Engine Starting Contacts: Include one isolated, normally-closed starting contact and one isolated, normally-open starting contact. Contacts shall be rated 10 Amps at 32-Volts DC, minimum.

K. Engine Shutdown Contacts: Include contacts for time delay shutdown feature that is adjustable from zero to five minutes. Factory set time delay to five minutes. Contacts shall initiate shutdown at remote engine-generator controls after retransfer of load to normal source.

2.5 CONTROL SYSTEMS

A. Functional Description: Include the following functions for transfer switches:

1. Indication of sources available, as defined by actual pickup and dropout settings of transfer-switch controls.

2. Indication of switch position.

3. Indication of failure of digital communications link.

4. Key-switch or user-code access to control functions of panel.

5. Control of switch-test initiation.

B. Malfunction of annunciator and control panels shall not affect functions of automatic transfer switch. Automatic transfer-switch sensing, controlling, or operating function shall not depend on remote panel for proper operation.

C. Remote Annunciation and Control Panel: Provide raceway, wiring, and controls as required to interface the existing remaote annunciator panel to the new transfer switch.

2.6 FINISHES

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A. Enclosure: Manufacturer's standard enamel over corrosion-resistant pretreatment and primer.

2.7 SOURCE QUALITY CONTROL

A. Factory Test Components, Assembled Switches, and Associated Equipment: Ensure proper operation. Check transfer time and voltage, frequency, and time-delay settings for compliance with specified requirements. Perform dielectric strength test complying with NEMA ICS 1.

A. Free-Standing Switch: Level and properly support unit.

B. Annunciator and Control Panel Mounting: flush mounted in location chosen by Owner.

3.2 WIRING TO REMOTE COMPONENTS

A. Match type and number of cables and conductors of packaged engine generator with control and communications requirements of transfer switches as recommended by manufacturer.

Increase raceway sizes at no additional cost to Owner if necessary to accommodate required wiring.

3.3 CONNECTIONS

A. Ground equipment as indicated and as required by NFPA 70.

3.4 FIELD QUALITY CONTROL

A. Testing: Perform the following field quality-control testing under the supervision of the manufacturer's factory-authorized service representative in addition to tests recommended by the manufacturer:

1. Before energizing equipment, after transfer-switch products have been installed:

a. Measure insulation resistance phase-to phase and phase-to-ground with insulation-resistance tester. Include external annunciation and control circuits. Use test voltages and procedure recommended by manufacturer. Meet manufacturer's specified minimum resistance.

b. Check for electrical continuity of circuits and for short circuits.

c. Inspect for physical damage; proper installation and connection; and integrity of barriers, covers, and safety features.

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d. Verify that manual transfer warnings are properly placed.

e. Perform manual transfer operation.

2. After energizing circuits, demonstrate interlocking sequence and operational function for each switch at least three times.

a. Simulate power failures of normal source to automatic transfer switch and of emergency source with normal source available.

b. Simulate loss of phase-to-ground voltage for each phase of normal source.

c. Verify time-delay settings.

d. Verify pickup and dropout voltages by data readout or inspection of control settings.

e. Adjust and record relay and circuit breaker trip settings

f. Verify proper sequence and correct timing of automatic engine starting, transfer time delay, retransfer time delay on restoration of normal power, and engine cool-down and shutdown sequence.

B. Report results of tests and inspections in writing. Record adjustable relay settings and measured insulation and contact resistances and time delays. Attach a label or tag to each tested component indicating satisfactory completion of tests.

3.5 CLEANING

A. After completing equipment installation, inspect unit components. Remove paint splatters and other spots, dirt, and debris. Repair damaged finish to match original finish.

B. Clean equipment internally, on completion of installation, according to manufacturer's written instructions.

3.6 DEMONSTRATION

A. Engage a factory-authorized service representative to train Owner's personnel to adjust, operate, and maintain transfer switch and related equipment as specified below:

1. Coordinate this training with that for generator equipment.

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

3. Review data in maintenance manuals.

4. Schedule training with Owner, through Architect, with at least seven days' advance notice.

5. Provide a minimum of eight hours of instruction, concurrent with training associated with packaged engine generator.

END OF SECTION 262826

Maintenance Shop Generator/ATS Replacement 4145 Highway 701 North - Conway, South Carolina

ENGINE GENERATORS 263213 - 1

SECTION 263213 - ENGINE GENERATORS

A. This Section includes packaged engine-generator sets for emergency and standby power supply with the following features:

1. Diesel engine.

2. Unit-mounted cooling system.

3. Performance requirements for sensitive loads.

4. Outdoor enclosure.

1.2 CODES AND STANDARDS

A. The generator set covered by these specifications shall be designed, tested, rated, assembled and installed in strict accordance with all applicable standards below:

1. CSA C22.2 No14

2. CSA 282

3. CSA 100

4. EN61000-6

5. EN55011

6. FCC Part 15 Subpart B

7. ISO8528

8. IEC61000

9. UL508

10. UL2200

11. UL142

1.3

B.

Designed to allow for installed compliance to NFPA 70, NFPA99 and NFPA 110

WORK INCLUDED

Installation: The work includes supplying and installing a complete integrated generator system. The system consists of a diesel generator set with related component accessories.

Expand concrete housekeeping pad so that conduit stub ups are under unit.

B. Fuel System: The contractor shall provide a full tank of diesel fuel for the completion of all testing.

C. System Test: A complete system load test shall be performed after all equipment is installed.

Guidelines in the Start-up Section.

D. Requirements, Codes and Regulations: The equipment supplied and installed shall meet the requirements of the NEC and all applicable local codes and regulations. All equipment shall

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ENGINE GENERATORS 263213 - 2

be of new and current production by a MANUFACTURER who has 25 years of experience building this type of equipment. Manufacturer shall be ISO9001 certified.

1.4 SUBMITTALS

A. Engine-generator submittals shall include the following information:

1. Factory published specification sheet.

2. Manufacturer's catalog cut sheets of all auxiliary components such as battery charger, control panel, enclosure, etc.

3. Dimensional elevation and layout drawings of the generator set, and related accessories.

4. Weights of all equipment.

5. Concrete pad recommendation, layout and stub-up locations of electrical and fuel systems.

6. Interconnect wiring diagram of complete emergency system, including generator, switchgear, day tank, remote pumps, battery charger, control panel, and remote alarm indications.

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

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

9. Generator resistances, reactance and time constants.

10. Generator locked rotor motor starting curves.

11. Manufacturer's documentation showing maximum expected transient voltage and frequency dips, and recovery time during operation of the generator set at the specified site conditions with the specified loads.

12. Manufacturer's and dealer's written warranty.

1.5

B.

CLOSEOUT SUBMITTALS

Division 01 Specifications - Execution and Closeout Requirements: Closeout procedures.

Provide two (2) sets of operation and maintenance manuals covering the generator, switchgear, and auxiliary components. Include final as-built wiring interconnect diagrams and recommended preventative maintenance schedules.

1.6 SYSTEM RESPONSIBILITY

A. Generator Set Distributor: The completed engine generator set shall be supplied by the Manufacturer's authorized distributor only.

B. Warranty: There shall be one source responsibility for warranty; parts and service through a local representative with factory trained service personnel. Extended Warranty Coverage shall be provided for a period of 5 years and shall include no deductible. Extended Warranty Coverage provides for 100 percent of usual and customary parts and labor costs for failures due to defects in materials and workmanship to the “as shipped consist” from the factory, Maintenance Shop Generator/ATS Replacement 4145 Highway 701 North - Conway, South Carolina

ENGINE GENERATORS 263213 - 3

excluding filters, fluids, vee belts, hoses, power take-offs, paint, batteries and clutches. Provide for a rental power unit due to unscheduled failures causing unexpected downtime to the customer in excess of 48 hours from the time of diagnoses. All repairs will be performed by factory trained dealer service personnel and allows for repairer travel and mileage for all repairs up to 8 hours and 320 miles per incident.

1.7 PARTS AND SERVICE QUALIFICATIONS

A. Service Facility: The engine-generator supplier shall maintain 24-hour parts and service capability within 100 miles of the project site. The distributor shall stock parts as needed to support the generator set package for this specific project. The supplier must carry sufficient inventory to cover no less than 80% parts service within 24hrs and 95% within 48 hours.

B. Service Personnel: The dealer shall maintain qualified factory trained service personnel.

C. Product Support: The authorized dealer shall provide a preventive maintenance agreement using qualified factory trained service personnel, for a period of 1-year minimum. The dealer shall provide genuine manufacturer parts and filters, shall provide all recommended fluids, dealer labor, travel labor and travel mileage to complete the suggested preventive maintenance as defined in the manufacturer’s Operation and Maintenance Manual. Provide parts and supplies same as those used in the manufacture and installation of original equipment.

2.1 MANUFACTURERS

A. The power system has been designed to the specified manufacturer's electrical and physical characteristics. The equipment sizing, spacing, amounts, electrical wiring, ventilation equipment, fuel, and exhaust components have all been sized and designed around CATERPILLAR supplied equipment. Subject to compliance with requirements, provide CATERPILLAR systems or comparable product by one of the following:

1. Onan/Cummins

2. Kohler

3. Generac

4. MTU

5. Generac.

2.2 GENERAL REQUIREMENTS

A. Genset Requirements: The generator set shall be Standby Duty rated at 60 kW, 75 kVA, 1800 RPM, 0.8 power factor, 240 V, 3-Phase, 60 hertz, including radiator fan and all parasitic loads.

Generator set shall be sized to operate at the specified load at a maximum ambient of 100F (37.8C) and altitude of 500.0 feet (152.4 m).

1. Standby Power Rating: 60kW

2. Power is available for the duration of an emergency outage

3. Average Power Output = 70% of standby power

Maintenance Shop Generator/ATS Replacement 4145 Highway 701 North - Conway, South Carolina

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4. Load = Varying

5. Typical Hours/Year = 200 Hours

6. Maximum Expected Usage = 500 hours/year

7. Typical Application = Standby

B. Material and Parts: All materials and parts comprising the unit shall be new and unused.

C. Engine: The engine shall be diesel fueled, four (4) cycle, water-cooled, while operating with nominal speed not exceeding 1800 RPM. The engine will utilize in-cylinder combustion technology, as required, to meet applicable EPA non-road mobile regulations and/or the EPA NSPS rule for stationary reciprocating compression ignition engines. Additionally, the engine shall comply with the State Emission regulations at the time of installation/commissioning.

Actual engine emissions values must be in compliance with applicable EPA emissions standards per ISO 8178 – D2 Emissions Cycle at specified ekW / bHP rating. Utilization of the “Transition Program for Equipment Manufacturers” (also known as “Flex Credits”) to achieve EPA certification is not acceptable. The in-cylinder engine technology must not permit unfiltered exhaust gas to be introduced into the combustion cylinder. Emissions requirements / certifications of this package: EPA T3

D. Engine Governing: The engine governor shall be a electronic Engine Control Module (ECM) with 24-volt DC Electric Actuator. The ECM shall be enclosed in an environmentally sealed, die-cast aluminum housing which isolates and protects electronic components from moisture and dirt contamination. Speed droop shall be adjustable from 0 (isochronous) to 10%, from no load to full rated load. Steady state frequency regulation shall be +/- 6 RPM. Speed shall be sensed by a magnetic pickup off the engine flywheel ring gear. A provision for remote speed adjustment shall be included. The ECM shall adjust fuel delivery according to exhaust smoke, altitude and cold mode limits. In the event of a DC power loss, the forward acting actuator will move to the minimum fuel position.

2.3 GENERATOR

A. Product Description: NEMA MG1, three phase, reconnectable brushless synchronous generator with brushless exciter.

B. Rating: As indicated on plans.

C. Insulation Class: F.

D. Temperature Rise: 130 degrees C Standby.

E. Enclosure: NEMA MG1, open drip proof.

F. Voltage Regulation: Furnish generator mounted volts per hertz exciter-regulator to match engine and generator characteristics, with voltage regulation plus or minus 1 percent from no load to full load. Furnish manual controls to adjust voltage droop, voltage level (plus or minus 5 percent) and voltage gain.

Maintenance Shop Generator/ATS Replacement 4145 Highway 701 North - Conway, South Carolina

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G. Motor Starting: Provide locked rotor motor starting capability of 75kVA at 30% instantaneous voltage dip as defined per NEMA MG 1. Sustained voltage dip data is not acceptable.

2.4 ACCESSORIES

A. Skid-Mounted Fuel Tank: Double-wall Steel tank, with fill and vent. Sized to support generator at full load for 36-hours.

B. Exhaust Silencer: Residential type silencer, with muffler companion flanges and flexible stainless-steel exhaust fitting, sized in accordance with engine manufacturer's instructions.

C. Batteries: Heavy duty, diesel starting type lead-acid storage batteries. Match battery voltage to starting system. Furnish cables and clamps.

D. Battery Tray: Treated for electrolyte resistance, constructed to contain spillage.

E. Battery Charger: Current limiting type designed to float at 2.17 volts for each cell and equalize at 2.33 volts for each cell. Furnish overload protection, full wave rectifier, DC voltmeter and ammeter, and 120 volts AC fused input. Furnish wall mounted enclosure to meet NEMA 250, Type 1 requirements.

F. Line Circuit Breaker: NEMA AB 1, molded case circuit breakers on generator output with integral thermal and instantaneous magnetic trip in each pole. Furnish battery voltage operated shunt trip, connected to open circuit breaker on engine failure. Unit mount in enclosure to meet NEMA 250, Type 1 requirements.

G. Engine-Generator Control Panel: NEMA 250, Type 1 generator-mounted control panel enclosure with engine and generator controls and indicators. Furnish provision for padlock and the following equipment and features:

1. Frequency Meter: 45-65 Hz. range, 3.5 inch (89 mm) dial.

2. AC Output Voltmeter: 3.5 inch (89 mm) dial, 2 percent accuracy, with phase selector switch.

3. AC Output Ammeter: 3.5 inch (89 mm) dial, 2 percent accuracy, with phase selector switch.

4. Output voltage adjustment.

5. Push-to-test indicator lamps, one each for low oil pressure, high water temperature, overspeed, and over crank.

6. Engine start/stop selector switch.

7. Engine running time meter.

8. Oil pressure gage.

9. Water temperature gage.

10. Auxiliary Relay: 3PDT, operates when engine runs, with contact terminals prewired to terminal strip.

11. Additional visual indicators and alarms in accordance with by NFPA 110.

12. Remote Alarm Contacts: Factory wire SPDT contacts to terminal strip for remote alarm functions in accordance with NFPA 110.

Maintenance Shop Generator/ATS Replacement 4145 Highway 701 North - Conway, South Carolina

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H. Remote Annunciator Panel: Flush mounted panel with painted finish. Furnish audible and visible indicators and alarms in accordance with NFPA 110.

2.5 COOLING SYSTEM

A. The generator set shall be equipped with a rail-mounted, engine-driven radiator with blower fan and all accessories. The cooling system shall be sized to operate at full load conditions and 110 F* ambient air entering the room or enclosure (If an enclosure is specified). The generator set supplier is responsible for providing a properly sized cooling system based on the enclosure static pressure restriction.

2.6 FUEL SYSTEM

A. The fuel system shall be integral with the engine. In addition to the standard fuel filters provided by the engine manufacturer, there shall also be installed a primary fuel filter/water separator in the fuel inlet line to the engine. All fuel piping shall be black iron or flexible fuel hose rated for this service. No galvanized piping will be permitted. Flexible fuel lines shall be minimally rated for 300 degrees F and 100 psi.

B. Fuel Sub Base Tank: Provide a double wall sub-base tank constructed to meet all local codes and requirements. A fuel tank base of 36-hour capacity shall be provided as an integral part of the enclosure. It shall be contained in a rupture basin with 110% capacity. The tank shall meet UL142 standards. A locking fill cap, a mechanical reading fuel level gauge, low fuel level alarm contact, and fuel tank rupture alarm contact shall be provided.

1. Provide 5 Gallon Fuel Fill spill containment (without exception)

2. Configure height of tank fuel so generator does not require a maintenance platform.

Bottom of generator housing shall be no greater than 24 inches above pad.

2.7 EXHAUST SYSTEM

A. Silencer: A super critical grade pancake silencer, companion flanges, and flexible stainless steel exhaust fitting properly sized shall be furnished and installed inside enclosure (no exception). The silencer shall be mounted so that its weight is not supported by the engine nor will exhaust system growth due to thermal expansion be imposed on the engine.

2.8 STARTING SYSTEM

A. Starting Motor: A DC electric starting system with positive engagement shall be furnished.

The motor voltage shall be as recommended by the engine manufacturer.

B. Jacket Water Heater: Jacket water heater shall be provided and shall be sized to insure that genset will start within the specified time period and ambient conditions.

Maintenance Shop Generator/ATS Replacement 4145 Highway 701 North - Conway, South Carolina

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C. Batteries: Batteries - A lead-acid storage battery set of the heavy-duty diesel starting type shall be provided. Battery voltage shall be compatible with the starting system

D. Battery Charger: A current limiting, 10amp battery charger shall be furnished to automatically recharge batteries. The charger shall be dual charge rate with automatic switching to the boost rate when required. The battery charger shall be mounted on the genset package or inside the genset enclosure/room.

E. Manufacturer Seismic Qualification Certification: Submit certification that engine-generator set, enclosure and sub base tank, batteries, battery racks, accessories, and components will withstand seismic forces. Include the following with quotation:

1. Basis for Certification: Indicate whether withstand certification is based on actual test of assembled components or on calculation.

a. The term "withstand" means "the unit will remain in place without separation of any parts from the device when subjected to the seismic forces specified and the unit will be fully operational after the seismic event."

b. Dimensioned Outline Drawings of Equipment Unit: Identify center of gravity and locate and describe mounting and anchorage provisions.

c. Detailed description of equipment anchorage devices on which the certification is based and their installation requirements.

2.9 OUTDOOR GENERATOR-SET ENCLOSURE

A. Description: Weather Aluminum housing. Multiple panels shall be lockable and provide adequate access to components requiring maintenance. Instruments, control, and battery system shall be mounted within enclosure.

B. Construction:

1. Hinged Doors: With padlocking provisions. Restraint/Hold back hardware to prevent door to keep door open at 180 degrees during maintenance. Rain lips over all doors.

2. Exhaust System:

a. Muffler Location: Within enclosure.

3. Hardware: All hardware and hinges shall be stainless steel.

4. Mounting Base: Suitable for mounting on existing housekeeping pad. Enlarge existing concrete pad as required for new generator installation.

5. A weather protective enclosure shall be provided which allows the generator set to operate at full rated load with a static pressure drop equal to or less than 0.5 inches of water.

Maintenance Shop Generator/ATS Replacement 4145 Highway 701 North - Conway, South Carolina

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C. Engine Cooling Airflow through Enclosure: Housing shall provide ample airflow for engine generator operation at rated load in an ambient temperature of 40 deg C.

D. Sound Performance: Reduce the sound level of the engine generator while operating at full rated load to a maximum of 78 dBA measured at any location 7 m from the engine generator in a free field environment.

E. Site Provisions:

1. Lifting: Complete assembly of engine generator, enclosure shall be designed to be lifted into place as a single unit, using spreader bars.

2. Housekeeping Pad: Expand existing concrete pad to accommodate fuel tank and generator. Coordinate existing conduit stub up locations with position of tank and generator.

3.1 PROJECT-SPECIFIC FACTORY EQUIPMENT TESTS

A. Before shipment, factory test engine-generator set and other system components and accessories manufactured specifically for this Project. Perform tests at rated load and power factor. Include the following tests:

1. Test components and accessories furnished with installed unit that are not identical to those on tested prototype to demonstrate compatibility and reliability.

2. Full load run.

3. Maximum power.

4. Voltage regulation.

5. Transient and steady-state governing.

6. Single-step load pickup.

7. Safety shutdown.

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

3.2

INSTALLATION

Install equipment in accordance with manufacturer's recommendations, the project drawings and specifications, and all applicable codes.

B. Ground and bond generator and other electrical system components in accordance with Section 26 05 26.

3.3 START-UP AND TESTING

A. Coordinate all start-up and testing activities with the Engineer and Owner. After installation is complete and normal power is available, the manufacturer's local dealer shall perform the following:

Maintenance Shop Generator/ATS Replacement 4145 Highway 701 North - Conway, South Carolina

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1. Perform a 4 hour load bank test at a 0.8 PF at full nameplate rating. Load bank, cables and other equipment required for this test to be supplied by the genset supplier.

3.4 TRAINING

A. On-Site Training: Factory representative shall provide a minimum of 1 day of owner training in the complete operation and maintenance of the automatic transfer switch system and generator system. Training session for the automatic transfer switch system and generator system shall be scheduled on a separate day from the startup & testing day and shall be scheduled at least two weeks in advance with the Owner and before building acceptance.

END OF SECTION 263213