ESBD_481086_1767893037399_Specifications.pdf

[A/E or TDCJ FACILITIES ENGINEERING] [INCLUDE v.# in FILE NAME INFO FOR SECTION NAME] [name]Unit Section[USE SPEC # FROM FILE NAME INFO FOR SECTION NUMBER] – Page 1 of 11 [proj. name] MWR# [number]

SECTION 26 32 13.13 – DIESEL POWERED ENGINE GENERATOR SET v.20250609 [Standard TDCJ Specification]

PART 1 - GENERAL

1.1 SUMMARY

A. Requirements for a complete packaged engine/generator set (electric generating plant) configured to interface/operate as a stand-by power system with a transfer switch and a generator docking station (refer to Section 26 25 50). Engine, generator and all elements of the system as well as all generator auxiliaries shall be included; including all necessary instruments, controls, and other devices or appurtenances for proper operation of the unit.

PART 2 - PRODUCTS

2.1 GENERAL REQUIREMENTS

A. Brand or manufacturer’s references are descriptive only, and indicate type and quality to be provided. All references to brand or manufacturer names shall be interpreted to include the language “or A/E approved equal”. Any brand or manufacturer meeting specifications will be considered, irrespective of the language “or A/E approved equal” appearing in conjunction with the brand or manufacturer name.

B. Equipment, products, material, and/or services provided under this Section shall comply with:

1. UL2200 (Stationary Engine/Generator Assemblies of 600 volts or less).

2. ASME B15.1 (Safeguarding of Mechanical Power Transmission

Apparatus).

3. NFPA 110 (Standard for Emergency and Standby Power Systems) for a Class 24, Type 60, Level 2 genset.

4. IEEE Standard 446 (IEEE Recommended Practice for Emergency and

Standby Power Systems for Commercial and Industrial Applications).

5. NEMA ICS 1 (General Standards for Industrial Control).

6. EPA Tier 3 or latest requirements for stationary, non-road engine emissions in a rural area, and shall comply with all applicable state and local government requirements.

7. UL 1008 (Standard for Safety for Transfer Switches).

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8. Applicable state and local government requirements for maximum noise level due to sound emitted by generator set including engine, engine exhaust, engine cooling-air intake and discharge, and other components of installation.

9. NFPA 30 (Flammable and Combustible Liquids Code).

10. UL 142 (Above Ground Flammable Liquids Tank).

11. NEMA MG 1 (Motors & Generators).

12. Electrical Components, Devices, and Accessories: Shall all be listed an labeled as defined in NFPA 70, Article 100 and marked for intended use.

C. Additional Source/Manufacturer Requirements:

1. Manufacturer of the specified equipment shall be ISO 9001 (or later) certified verifying quality assurance in design/development, production, installation, and servicing of specified equipment.

2.2 PRODUCT REQUIREMENTS

A. Engine-Generator Set:

1. Fully factory-assembled and tested by a single manufacturer, pre-wired, pre-piped and aligned on a single skid-type base with integral vibration isolators.

2. Mounting Frame: Maintain alignment of mounted components without depending on a concrete foundation and provide lifting attachments;

engine-generator set to be provided with integral vibration isolators mounted between the engine mount and skid. Additional spring-type isolators, coordinated with those provided between the engine mount and skid, are permitted as required. Structural design shall be adequate to permit unit to be mounted to, and supported by, 4-4 inch structural l-beams, furnished and installed by the owner, beneath and across width of genset sub-tank/enclosure at installation, if required.

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

4. Additional Generator-Set Performance and Requirements:

a. Duty: Stand-by

b. Output connections:

1) For 1-ph/3-wire or 3-ph/4-wire systems: provide with neutral terminals.

2) For 3-ph/3-wire systems: provide without neutral terminals.

c. Steady-State Voltage Operational Bandwidth: maximum 1% of rated output voltage from no load to full load.

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d. Transient Voltage Performance: Not more than 10% variation for 50% step-load increase or decrease at 35% power factor. Voltage shall recover and remain within the steady-state operating band within three seconds.

e. Steady-State Frequency Operational Bandwidth: 0.5% of rated frequency from no load to full load.

f. 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.

g. Transient Frequency Performance Less than 5% variation for 50% step-load increase or decrease. Frequency shall recover and remain within the steady-state operating band within five seconds.

h. Output Waveform: Bolted short circuit at system output terminals, system shall supply a minimum of 300% of rated full-load current for not less than 10 seconds and then clear the fault automatically, without damage to generator system components.

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

1) Ambient Temperature: 0 °F to 105 °F.

2) Relative Humidity: 20% to 100%.

3) Altitude: Sea level to 5000 feet.

j. WiFi enabled.

k. Cellular access port that provides access to:

1) Diagnostics and trouble shooting.

2) Statistics including but not limited to:

a) Load

b) Voltage

c) Amperage

d) Alarms – including but not limited to –

i. High temperature

ii. Low oil

l. Where a laptop is required for diagnostics and/or reset, provide laptop with required capabilities and required software. Include instruction on operation in required training.

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B. Engine:

1. Type: Stationary, liquid-cooled, full diesel, compression ignition engine, either naturally aspirated or turbocharged, suitable for No. 2 diesel fuel with 12 or 24 volt electrical system.

2. Rating: Brake horsepower not less than 10% greater than required by the full load rating of the generator, including losses, and with all accessories attached.

3. Fuel: Diesel fuel oil, Grade DF-2.

4. Rated Engine Speed: 1800 rpm max.

5. Maximum Piston Speed for Four-Cycle Engines: 2250 fpm (11.4 m/s).

6. Lubrication System: The following items are mounted on engine or skid:

a. Filter and Strainer: Rated to remove 90% of particles 5 micrometers and smaller while passing full flow; provide for spring-load bypass.

b. Positive displacement crankshaft-driven mechanical lube oil pump.

c. Thermostatic Control Valve: Control flow in system to maintain optimum oil temperature. Unit shall be cap able of full flow and designed to be fail-safe.

d. Crankcase Drain: Arranged for complete gravity drainage to an easily removable container with no disassembly and without use of pumps, siphons, special tools, or appliances.

7. Engine Fuel System:

a. Main Fuel Pump: Engine-driven, self-priming injection pump to provide adequate primary fuel flow under starting and load conditions.

b. Relief-Bypass Valve: Automatically regulates pressure in fuel line and returns excess fuel to source.

c. Filters: Full flow, fuel water separator(s) and replaceable element, primary and secondary fuel filters for a minimum of 95% particulate removal at 2 microns.

8. Governor: Adjustable isochronous, with speed sensing.

9. Cooling System: Unit mounted, closed loop, liquid-cooled, with radiator factory mounted on engine-generator-set mounting frame and integral engine-driven coolant pump.

a. Coolant: Fill system with a solution of 50% ethylene-glycol-based antifreeze and 50% with anticorrosion additives as recommended by engine manufacturer.

b. Temperature Control: Self-contained, thermostatic-control valve modulates coolant flow automatically to maintain optimum

[name]Unit Section[USE SPEC # FROM FILE NAME INFO FOR SECTION NUMBER] – Page 5 of 11 constant coolant temperature as recommended by engine manufacturer.

c. Cooling System Jacket (engine block) Heater: Heater shall be rated 208 Volts, 60 Hz, single-phase, and shall be thermostatically controlled, corrosion-resistant, with leads brought out to a screw terminal block, suitable identified and factory wired to the 2-pole breaker in the on-board low-voltage distribution panel (LVDP) specified in this Section.

10. 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.

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

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

c. Exhaust to be vertically discharged and fitted with rain cap.

11. Air-Intake Filter: Standard-duty, engine-mounted air cleaner with replaceable dry-filter element and “blocked filter” indicator.

12. Starting System: Electric, battery-driven, with negative ground.

a. Components: Sized so they will not be damaged during a full engine-cranking cycle at rated maximum ambient temperature with two (2) factory installed batteries.

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

c. Battery: Fully-charged, rechargeable type with adequate capacity within average ambient temperature range at project location to provide cranking cycle of 30 seconds with 15 second rest periods, at least twice without recharging with rotation alternator/charger controls for 12VDC or 24 CDC charging/float equalizer.

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

e. Battery-Charging: Separately AC powered, solid-state circuitry, current-limiting, solid state floats, automatic-equalizing with trickle-charge, and suitable for operation at 120 volts, single phase, 60 Hz with a maximum charging time of 24 hours. Charger to be mounted on unit with anti-vibration devices.

13. Engine Block Heater: Factory installed, powered from LVDP.

C. Fuel Oil Storage:

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1. Base-Mounted Fuel Oil Tank: Factory installed and piped, double-walled, fuel oil tank installed with engine/generator on skid. Features including the following:

a. Tank level indicator with mechanical gauge.

b. Capacity: Fuel for 24 hours (minimum) continuous operations at

100% rated power output.

c. Lockable fill cap & fuel fill design that complies with all EPA, state, and local codes.

d. Normal vent with mushroom cap.

e. Fuel supply and return fuel openings.

f. Basin drain.

g. Primary fuel tank leakage alarm.

D. Control and Monitoring:

1. Configuration: Unit mounted, electronic control and monitoring of operation and safety indications, protective devices, basic system controls, and engine gages shall be grouped in a common control and monitoring panel, weather-proof, mounted on the generator set.

Mounting method shall isolate control panel from generator-set vibration.

2. Indicating and Protective Devices and Controls:

a. AC voltmeter, 0-300 volts.

b. AC ammeter.

c. AC frequency meter.

d. DC voltmeter (alternator battery charging).

e. Engine-coolant temperature gage.

f. Engine shut down & indication on:

1) Low oil pressure.

2) Low coolant level.

3) High coolant temperature.

4) Over-cranking.

5) Generator overload

6) Unit over-speed.

g. Engine lubricating-oil pressure gage.

h. Running-time meter.

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

j. Generator-voltage adjusting rheostat.

k. Selectable non-automatic or automatic (ATS-initiated) starting.

3. Generator Over-Current & Fault Protection: Generator shall be protected by a manufacturer specific, factory installed, 100% generator output rated, 100% duty cycle, molded case circuit breaker.

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4. Supporting Items: Include sensors, transducers, terminals, relays, and other devices and include wiring required to support specific items.

Locate sensors and other supporting items on engine or generator, unless otherwise indicated.

5. Audible Alarm: Include local indication as well as necessary contacts and terminals in control and monitoring panel to remotely alarm;

a. Over-crank shutdown.

b. Coolant low-temperature alarm.

c. Control switch not in auto position.

d. Battery-charger malfunction alarm.

e. Battery low-voltage alarm.

E. Generator, Exciter, and Voltage Regulator:

1. Drive: Generator alternator shaft shall be directly connected to engine shaft. Alternator shall be a synchronous, copper wound, brushless type with revolving field powered by an integrally rotating excited, and shall have a built-in static rectifier and statically regulated excitation system.

Alternator shall have a ball bearing rater 40,000 hours minimum.

2. Coupling: Semi-flexible with metal safety guard.

3. Electrical Insulation: Class H or Class F. Alternator shall be rated for

130 °C rise full load operation.

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

5. Construction shall prevent mechanical, electrical, and thermal damage due to vibration, over-speed up to 125% of rating and head during operation oat 110% of rated capacity.

6. Instrument Transformers: Mounted within generator enclosure.

7. {3-ph systems only} Voltage Regulator: Solid-state type, separate from excited, providing transient voltage & short-circuit support performance as specified. Regulator shall have three-phase sensing and shall provide a maximum no load voltage drop of 0.5%. Regulator ‘gain’ shall be field adjustable. Adjusting rheostat on control and monitor panel shall provide plus or minus 5% adjustment of output-voltage operating band.

8. Space Heaters: Provide thermostatically-controlled, low surface temperature space heaters to prevent condensation within alternator and genset housing. Heater size shall have adequate wattage to control enclosure internal humidity for enclosure volume and system service project conditions and shall be wired to the on-board low-voltage distribution panel (LVDP).

F. Generator-Set Enclosure

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1. Description: Engine generator set shall be furnished with vandal-resistant, weatherproof steel housing, wind resistant up to 90 mph.

a. Multiple hinged or removable panels shall provide adequate access to components requiring maintenance.

b. Instruments and controls shall be mounted within enclosure.

c. Optional sound enclosure is not required.

d. Rodent Guards.

e. Protected by a paint system consisting of manufacturer’s standard finish over corrosion-resistant pretreatment and compatible primer.

2. Safety: Unit shall have steel safety guards around tall rotating parts within overall waterproof steel housing.

3. Engine Cooling Airflow through Enclosure: Maintain temperature rise of system components within required limits when unit operates at 110% of rated load for 2 hours with ambient temperature at top of range specified in system service project conditions. Louvers shall be storm-proof and drainable, preventing entry of rain and snow.

4. Interior Lights with Switch: Factory wired, vapor-proof type LED fixtures within housing; arranged to illuminate controls and accessible interior.

Fixture(s) shall be wired to the on-board LVDP.

a. AC lighting system and connection point for operation when remote source is available.

b. DC lighting system for operation when remote source and generator are both unavailable.

5. Convenience Outlets: Factory wired, 120V, GFCI convenience outlets shall be provided within each service/maintenance access chamber at the genset end. Outlets shall be wired to the on-board LVDP.

6. On Board Low-Voltage Distribution Panel (LVDP): Factory installed MDP on the interior of the genset enclosure.

a. For 3-ph system: 120/208v, 1-ph, 100A

b. For 1-ph system: 120/240v, 1-ph, 100A

7. For 480v service applications, a factory installed onboard step down transformer shall be mounted on the interior of the genset enclosure to supply the LVDP.

2.3 REQUIRED FIELD SERVICES

A. Inspect components, assemblies, and equipment installation including connections, prior to initial start-up.

B. Correct any deficiencies or non-conformances with equipment specifications.

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C. Brief TDCJ personnel of initial start-up and functional testing procedures, prior to initial start-up.

D. Perform initial start-up and functional testing per manufacturer’s recommendations and/or requirements.

E. Train TDCJ’s maintenance personnel to adjust, operate, and maintain packaged engine/generator.

1. Conduct training for at least 8 hours at project site. Estimated attendance will be 5-10 persons.

2. Include in training all aspects of operations and maintenance to degree required for Owner’s personnel to proceed with normal operations in a safe and efficient manner.

2.4 PRODUCT, EQUIPMENT AND/OR FIELD SERVICES WARRANTY

REQUIREMENTS

A. Warranty Period: Two (2) years.

2.5 PRODUCT, EQUIPMENT AND/OR FIELD SERVICES SUBMITTALS

A. A cover letter/sheet stating manufacturer’s model/catalog number with a listing of any supplier options included along with a statement specifically confirming compliance with all requirements of this specification, and/or listing any specific exceptions or clarification.

B. Manufacturer’s descriptive literature detailing the overall genset system as well as each system major component product (i.e. engine, alternator, battery charger, control panel(s), etc.) including model numbers and manufacturer of each such system major component.

C. Complete, supplemental listing showing inclusion of each accessory and control function specified herein or identifying any omitted shall be provided.

D. Certified drawings illustrating sizes, weights (dry and wet), loads, required clearances, method of field assembly, components, and all equipment outline dimensions with sufficient accuracy for design as well as location and size of each field connection.

E. Schematic and wiring diagrams of the generator and transfer switch system, indicating connections that are to be made in the field, location and size of each field connection, and showing wattage and voltage of all components.

F. Supporting documentation that genset complies with all listed standards and codes identified in this Section.

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G. Factory test report on actual or identical type-tested unit showing specified genset performance under rated load certified by equipment manufacturer(s).

1. Requirements include testing with identical accessories.

PART 3 - EXECUTION

3.1 INSTALLER QUALIFICATIONS

A. For other than TDCJ personnel: Three (3) years documented experience installing equipment of same rating or greater.

3.2 PREPARATION

A. No additional requirements.

3.3 EXECUTION

A. Comply with packaged engine-generator manufacturer’s written instructions and recommendations for Grounding equipment.

3.4 QUALITY CONTROL

A. Field Acceptance Testing.

1. Confirm operational requirements.

B. TDCJ QA shall report any non-conformance or discrepancy with installation requirements.

3.5 COMMISSIONING

A. No additional requirements.

3.6 EXECUTION SUBMITTALS

A. Documentation supporting Installer Qualifications.

3.7 THRU 3.8

A. No additional requirements.

END OF SECTION

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l. Where a laptop is required for diagnostics and/or reset, provide laptop with required capabilities and required software. Include instruction on operation in required training.

13. Engine Block Heater: Factory installed, powered from LVDP.

7. For 480v service applications, a factory installed onboard step down transformer shall be mounted on the interior of the genset enclosure to supply the LVDP.

B. TDCJ QA shall report any non-conformance or discrepancy with installation requirements.