Byron Generator Replacement Scope of Work~1.docx

ILLINOIS EMERGENCY MANAGEMENT AGENCY

BYRON GEMS DIESEL GENERATOR REPLACEMENT

SCOPE OF WORK

1.0 Anomaly Description:

1.1 The Illinois Emergency Management Agency (IEMA) Gaseous Effluent Monitoring System (GEMS) is installed inside the protected area of the Byron Power Station. To avoid potential environmental hazards with the underground storage of diesel fuel, IEMA has decided to replace all Underground Storage Tanks (UST) with Aboveground Storage Tanks (AST). IEMA has determined that the best course of action to do this is to replace the existing generator with a unit equipped with a built-in AST.

There are two models of generators that are acceptable for this application. Only bids for these two models will be considered.

Kohler Generator, 50REOZK, Diesel Fueled, UL2200 Listed, Rated Stationary/Emergency (Standby), Outdoor, 52kW /65kVA at 0.8 pf, 120/208V, 3ph-4w, 60Hz @ 1800 RPM, Max. Output: 180 amps. Standard Sub-base fuel tank, UL 142, 403 Gallon.

Cummins-Onan C50D6, 50kW, 60Hz, Standby, Diesel Genset, UL2200 Listed, Voltage - 120 / 208, 3 Phase, Fuel Tank - Regional, Dual Wall, Sub Base, 72 Hour Minimum 403 gallon, Annunciator-panel mount with enclosure (RS485)

Work location: 4450 N German Church Rd, Byron, IL 61010

2.0 Work Description:

2.1 Prior to beginning work, contractor will work with Office of the State Fire Marshall to obtain a permit for the Bulk Aboveground Storage Tank associated with the new generator.

2.2 All workers will need to access the protected area, bringing in all tools, equipment and personnel to perform the work. The work shall include the following:

2.3 Perform safety instruction briefing, including use of masks, safety glasses, gloves, hard hats, and lock out tag out procedures. Safety briefing for replacement of generator should include the following:

2.3.1 Proper electrical work safety.

2.3.1.1 Remove metallic conductive personal items (i.e. watches, jewelry, badges…etc.) prior to working near energized equipment.

2.3.1.2 Install temporary protective barriers where applicable when working near energized circuits.

2.3.1.3 De-energize equipment when feasible

2.3.1.4 Test before Touch: Always ASSUME a circuit is energized until proven de-energized with an approved voltage test device.

2.3.2 Safety is everyone’s responsibility and all personnel have the ability and responsibility to stop work if conditions are unsafe.

2.3.3 Work should not begin until unsafe conditions have been made safe.

2.4 Prepare to extend length of existing concrete pad 24 inches to accommodate new generator subbase tank length and ensure a minimum 5 inch margin between perimeter of subbase tank and perimeter of concrete pad.

2.4.1 Remove existing gravel base and dirt to a depth of 6 inches below bottom of existing concrete pad.

2.4.2 Bore a minimum of four 1/2" x 12 inch holes into end of existing concrete pad for rebar to join the pads together.

2.4.3 Frame a 24 inch long by 54 inch wide by 16 inch deep extension onto the end of the existing concrete pad (this extension will make the overall length of the pad 125.5 inches. The length of the subbase tank is 114 inches. This extension will support the subbase tank and give at least a 5 inch margin at each end of the concrete pad.)

2.4.4 Place a 6 inch thick base of #6 aggregate or equivalent into the framed area. Tamp aggregate.

2.4.5 Insert #4 rebar into previously drilled holes to provide a secure tie in of fresh concrete to existing concrete. Secure rebar to concrete in bored holes. Support rebar above tamped aggregate with rebar chairs as needed.

2.4.6 Set up rebar to fortify concrete pad. Place #4 rebar on 12" centers, each way, top and bottom.

2.4.7 Mix bagged high early strength concrete onsite (approximately 11.8 cubic feet) and pour into form. Strike edge with rounding tool. Broom finish surface. Minimum cure time of 48 hours will be allowed for this pour.

2.5 Decommission and removal of existing 50kW Kohler diesel generator:

2.5.1 Disconnect negative lead from engine starting battery.

2.5.2 Secure all AC power supplied to generator (e.g. battery charger and/or engine block heater). Confirm with handheld meter.

2.5.3 Secure all AC power supplied to existing transfer pump. Confirm with handheld meter.

2.5.4 Disconnect all control wiring between generator and the automatic transfer switch (ATS) inside the ATS.

2.5.5 Disconnect all phase, neutral and ground conductors between generator and the ATS inside the ATS.

2.5.6 Place drip pans and sorbent material around connection points of handheld pump and drain fuel from generator day tank to UST.

2.5.7 Place sorbent material around UST diesel supply and return lines.

2.5.8 Position container under UST diesel supply and return lines to capture any residual diesel fuel in lines when couplings are broken free. Break couplings of both UST diesel supply and return lines. Capture any residual diesel fuel in lines.

2.5.9 Cut off and cap UST diesel supply and return lines near ground. Plug off diesel supply and return ports on generator.

2.5.10 Drain UST of fuel, pumping it into 55-gallon drums and remove from location, performed by IEMA.

2.5.11 Clean up any diesel spill. Dispose of sorbent material.

2.5.12 Disconnect all wiring (phase, neutral, ground, control) inside of generator.

2.5.13 Disconnect all conduit connections to existing generator housing and pull all wiring clear of generator.

2.5.14 Remove nuts holding generator to concrete pad.

2.5.15 Remove old generator from concrete pad and stage it out of the way for eventual loading onto trailer.

2.6 Prepare site for installation of new generator:

2.6.1 Cut threaded studs used to secure generator to concrete pad (4 places) flush to concrete.

2.6.2 Cut existing conduits to a height or install new conduit that will accommodate installation into new generator.

2.7 Install new generator:

2.7.1 Unload new generator; temporarily stage away from immediate job site.

2.7.2 Lift off old generator from pad and load onto trailer.

2.7.3 Recover new generator from temporary staging area and place onto extended concrete pad. Center subbase tank on extended concrete pad (minimum 5 inch margin between edge of subbase tank and all 4 sides of concrete pad).

2.7.4 Bore (minimum) 1/2 inch x 4 inch hole in concrete through mounting holes of subbase tank. Secure subbase tank to concrete pad with (minimum) 1/2 inch stainless steel concrete stud anchors – 4 locations.

2.7.5 Strip off concrete form.

2.7.6 Install conduit as needed on new generator.

2.7.7 Determine phase rotation of the new generator and ensure that it will be wired to match phase rotation of the site’s building power.

2.7.8 Run phase, neutral, ground, and control wires through appropriate conduits and land on appropriate connecting points and bus bars inside generator for correct operation of system. Note: phase wires must be installed to match building power phase rotation.

2.7.9 Reconnect all control wiring between generator and the automatic transfer switch (ATS) inside the ATS.

2.7.10 Reconnect all phase, neutral and ground conductors between generator and the ATS inside the ATS.

2.7.11 Install new annunciator as necessary.

2.7.12 Rewire generator annunciator inside of GEMS building.

2.8 Commission new generator:

2.8.1 Ensure generator main line circuit breaker is in the OFF position.

2.8.2 Confirm oil level in crankcase.

2.8.3 Confirm coolant level in radiator.

2.8.4 Install starting battery. Coat battery posts and battery cable terminals with dielectric grease to inhibit corrosion.

2.8.5 Ensure proper phase rotation between generator and ATS connection points.

2.8.6 Simulate a loss of utility power. Confirm engine cranks, starts and runs. Confirm transfer switch operates correctly. Run load on generator power a minimum of 15 minutes ensuring all components function properly.

2.8.7 Restore utility power. Confirm ATS returns to utility as power source and generator shuts down following cool down period.

2.8.8 Verify generator exercise schedule is still set for Monday at 7am.

2.8.9 Receive signoff from OSFM for the newly installed AST.

2.8.10 Subbase tank (403 gallon capacity) to be filled. Recommended fuel is #2, off-road, winter blend, double shot anti-gel, non-bio..

3.0 Tools/Equipment Required:

3.1 IEMA Provided

3.1.1 N/A

3.2 Contractor Provided

3.2.1 All necessary equipment will be itemized and provided by the contractor upon commencement of the project.

3.3 Constellation Provided

3.3.1 Additional safety equipment and training (as required).

3.3.2 Lifting equipment as available

4.0 Supplies and/or Services Required

4.1 Option 1: Kohler Generator 50REOZK, Diesel Fueled, UL2200 Listed, Rated Stationary/Emergency (Standby), Outdoor, 52kW /65kVA at 0.8 pf, 120/208V, 3ph-4w, 60Hz @ 1800 RPM, Max. Output: 180 amps. INCLUDES,

4.1.1 Kohler Alternator # 4P8X

4.1.2 Unit Mounted Radiator

4.1.3 Steel Sound Shield Enclosure w /Installed Internal Critical Silencer & raincap

4.1.4 Controller APM402, 12V

4.1.5 Block Heater, 120V, 1000W, 1Ph

4.1.6 Starting Battery 12V, provided at start-up

4.1.7 Battery Charger Float/Equalize 12V-6 amps, mounted on generator

4.1.8 Isochronous Governor

4.1.9 Common Failure Relay

4.1.10 Run Relay

4.1.11 Generator Output Circuit Breaker, 200 amp, 3-pole, TMT, UL

4.1.12 Standard Sub-base fuel tank, UL 142, 403 Gallon.

4.1.13 Building Annunciator

4.2 Option 2: Cummins Onan - C50D6, Diesel Genset, 60Hz, 50kW

4.2.1 U.S. EPA, Stationary Emergency Application

4.2.2 C50D6, 50kW, 60Hz, Standby, Diesel Genset

4.2.3 Duty Rating - Standby Power (ESP)

4.2.4 Listing - UL 2200

4.2.5 NFPA 110 Type 10 Level 1 Capable

4.2.6 Emission Certification, EPA, Tier 3, NSPS CI Stationary Emergency

4.2.7 Voltage - 120 / 208, 3 Phase, Wye

4.2.8 Alternator - 60Hz, 12L, 208 / 120V, 120C, 40C Ambient

4.2.9 Exciter / Regulator - Permanent Magnet Generator, 3 Phase Sensor

4.2.10 Aluminum Sound Attenuated Level 1 Enclosure, with Exhaust System

4.2.11 Enclosure Color - Green, Aluminum

4.2.12 Enclosure - Wind Load 180 MPH, ASCE7-10

4.2.13 Skidbase - Housing Ready

4.2.14 Fuel Tank - Regional, Dual Wall, Sub Base, 72 Hour Minimum

4.2.15 Low Fuel Level Switch, 40%

4.2.16 Mechanical Fuel Gauge

4.2.17 Switch - Fuel Tank, Rupture Basin

4.2.18 Control Mounting - Right Facing

4.2.19 PowerCommand1.1 Controller

4.2.20 Gauge - Oil Pressure

4.2.21 Stop Switch - Emergency

4.2.22 Control Display Language - English

4.2.23 Load Connection - Single

4.2.24 Circuit Breaker, Location A, 175A, 3P, 600 Volts AC, 80%, UL

4.2.25 Right CB - None

4.2.26 Engine Governor - Electronic, Isochronous

4.2.27 Engine Starter - 12 Volt DC Motor

4.2.28 Engine Air Cleaner - Normal Duty

4.2.29 Battery Charging Alternator

4.2.30 Battery Charger - 6 Amp, Regulated

4.2.31 Engine Cooling - Radiator, High Ambient Air Temperature, Ship Fitted

4.2.32 Shutdown - Low Coolant Level

4.2.33 Extension - Coolant Drain

4.2.34 Engine Coolant - 50% Antifreeze, 50% Water Mixture

4.2.35 Coolant Heater

4.2.36 Extension - Oil Drain

4.2.37 Engine Oil

4.2.38 Genset Warranty - 2 Years Base

4.2.39 Literature - English

4.2.40 Packing - Skid, Poly Bag

4.2.41 Larger Battery Rack

4.2.42 Annunciator-panel mount with enclosure (RS485)

5.0 Sequence of Events

5.1 Vendor shall coordinate dates to be on-site with IEMA representatives so that they may serve as security escorts as required by station security policy.

6.0 Additional Site Work Notes

6.1 Only hand tools allowed for excavation unless vacuum excavation techniques are used.

6.2 Any disturbed asphalt, gravel, or soil shall be returned to original condition and grade. Most sites have gravel surface around tank area. (See photos below.)

7.0 Access to Nuclear Station

7.1 Contractor shall comply with all requirements of nuclear stations to obtain access for equipment and personnel. A valid driver’s license, State ID Card, or passport are required by all personnel for entry into the plant. These specific forms of identification are the only permissible forms of ID to be used.

7.2 Delays should be expected when taking tools, machinery, and construction materials through daily security inspections.

7.3 Weapons and other contraband are strictly prohibited. Persons under the influence of drugs or alcohol are not permitted on site.

7.4 In order to work on site, all persons must submit Social Security Number and statement of U.S. citizenship to IEMA seven days prior to arrival. Vehicles entering the site must submit make, model, and license plate number seven days prior to arrival.

7.5 Workers must wear hard hats, safety glasses, safety shoes, and gloves at all times while working.

8.0 Site Photos

8.1 Attached photos show generator on side of IEMA building.

Example of new generator at Braidwood image4.jpeg image5.jpeg image6.jpeg image7.emf

DG Day Tank

Existing Diesel

Generator Cabinet

ABOVE GROUND

STORAGE TANK

Diesel Generator Cabinet

Pad

Extension

Existing

Pad

Existing Diesel

Pad is about 8" thick plus 8" below ground

Division Of Nuclear Safety 1035 Outer Park Drive Springfield, IL 62704

Illinois Emergency Management Agency

AutoCAD SHX Text

IEMA GEMS BUILDING

DAY TANK LINES

NORTH

EXISTING GENERATOR PAD

GEN PAD EXTENSION

UST

Conduits

UST VENT

FENCE

GATE

S

N

O

I

S

I

V

E

R

CCR #

DATE

NUMBER

TECHNICAL DOCUMENT

SHEETS

NO.

APPROVED BY

CHECKED BY

DRAWN BY

DESIGN BY

OF

SHEET

GR-BY-01 REV. B

DIESEL GENERATOR WITH AST REPLACEMENT

GASEOUS EFFLUENT MONITORING SYSTEM

BYRON, ILLINOIS

T. Hendrickson

7-25-2022

A

T. Hendrickson

B

Sheets and Views

Generator and Building layout Byron-Layout2 image1.jpeg image2.jpeg image3.jpeg