Mobile Generator Set.pdf

BID# 032025-04

MOBILE GENERATOR SET

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. It is the intent of this specification to secure TWO(2) engine-driven generator sets that have been prototype tested, factory built, production-tested, and site-tested together with all accessories necessary for a complete installation as specified herein.

B. Any and all exceptions to the published specifications shall be subject to the approval of the engineer.

C. The power system shall be furnished by a single manufacturer who shall be responsible for the design, coordination, and testing of the complete system. The entire system shall be installed as shown on the plans, drawings, and specifications herein.

D. The equipment shall be produced by a manufacturer who has produced this type of equipment for a period of at least 10 years and who maintains a service organization available twenty-four hours a day throughout the year.

E. The equipment shall be produced by a manufacturer who is ISO 9001 certified for the design, development, production and service of its complete product line.

Drawings and general provisions of Contract, including General and Supplemental Conditions and Division-1 Specification sections, apply to work of this section and all following Division 26, Electrical Specifications.

1.2 GENERAL REQUIREMENTS

A. It is the intent of this specification to secure a generator set system that has been tested during design verification, in production, and at the final job site. The generator set will be a commercial design and will be complete with all of the necessary accessories for complete installation as shown on the plans, drawings, and specifications herein. The equipment supplied shall meet the requirements of

Newport Utilities Emergency Portable Genset Procurement

03/2025 Issued for [Permitting] [Bidding] [Construction] the National Electrical Code and applicable local codes and regulations.

B. All equipment shall be new and of current production by a national firm that manufactures the generator sets and controls, transfer switches, and switchgear, and assembles the generator sets as a complete and coordinated system. There will be one-source responsibility for warranty, parts, and service through a local representative with factory-trained servicemen.

1.3 SUBMITTAL

A. The submittal shall include prototype test certification and specification sheets showing all standard and optional accessories to be supplied; schematic wiring diagrams, dimension drawings, and interconnection diagrams identifying by terminal number each required interconnection between the generator set, the transfer switch, and the remote annunciator panel if it is included elsewhere in these specifications.

1.4 CODES AND STANDARDS

A. The generator set shall conform to the requirements of the following codes and standards:

1. CSA C22.2, No. 14-M91 Industrial Control Equipment.

2. 61000-6

3. BS 4999, BS5000, and BS5514

4. IEC 60034

5. NFPA 70, National Electrical Code, Equipment shall be suitable for use in systems in compliance to Article 700, 701, and 702.

1.5 TESTING

A. To ensure that the equipment has been designed and built to the highest reliability and quality standards, the manufacturer and/or local representative shall be responsible for three separate tests: design prototype tests, final production tests, and site tests.

B. Design Prototype Tests. Components of the emergency system, such as the engine/generator set, transfer switch, and accessories, shall not be subjected to

Newport Utilities prototype tests because the tests are potentially damaging. Rather, similar design prototypes and preproduction models shall be subject to the following tests:

1. Maximum power (Kw).

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

3. Alternator temperature rise by embedded thermocouple and/or by resistance method per NEMA MG1-32.6.

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

5. Voltage regulation and generator transient response.

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

7. Three-phase short circuit tests.

8. Alternator cooling air flow.

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

10. Endurance testing.

C. Final Production Tests. Each generator set shall be tested under varying loads with guards and exhaust system in place. Tests shall include:

1. Single-step load pickup

2. Transient and steady-state governing

3. Safety shutdown device testing

4. Voltage regulation

5. Rated Power @ 0.8 PF

6. Maximum power

D. Site Tests. The manufacturer's distribution representative shall perform an installation check, startup, and building load test. The engineer, regular operators, and the maintenance staff shall be notified of the time and date of the site test. The tests shall include:

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

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2. Accessories that normally function while the set is standing by shall be checked prior to cranking the engine. These shall include: block heaters, battery chargers, alternator strip heaters, remote annunciators, etc.

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

1.6 WARRANTY AND MAINTENANCE

A. The generator set shall include a minimum of one year warranty to guarantee against defective material and workmanship in accordance with the manufacturer's published warranty from date of startup. Optional warranties shall be available upon request.

B. The generator set manufacturer and its distributor shall maintain a 24-hour parts and service organization. This organization shall regularly engage in maintenance contract programs to perform preventive maintenance and service on equipment similar to that specified. A service agreement shall be available and shall include system operation under simulated operating conditions; adjustment to the generator set, transfer switch, and switchgear controls as required, and certification in the owner's maintenance log of repairs made and function tests performed on all systems.

1.7 EQUIPMENT id107_Equipment

A. The basis of design for the generator set shall be Caterpillar XQ330 tandem Axel trailer mounted, provide a minimum of 288kW/360.0 KVA when operating at 120/208 three phase 60 Hz, at .8 power factor, 277/480 volts, 60 Hz, three phase at .8 power factor and 230kW/230 KVA at 120/240 Single phase at 1.0 power factor using unit mounted voltage selector switch. Equivalent generators of equal products from other manufacturers are acceptable.

B. Vibration isolators shall be provided between the engine-alternator and heavy-duty steel base.

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1.8 ENGINE id108_Engine

A. The 9.3 Liter displacement engine at a governed speed of 1800 rpm. The engine shall be equipped with the following:

1. Electronic isochronous governor capable of 0.25% steady-state frequency regulation.

2. 24-volt positive-engagement solenoid shift-starting motor.

3. 45-ampere automatic battery charging alternator with solid-state voltage regulation.

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

5. Dry-type replaceable air cleaner elements for normal applications.

6. Engine-driven or electric fuel-transfer pump including fuel filter and electric solenoid fuel shutoff valve capable of lifting fuel.

B. The turbocharged and after cooled/intercooled engine shall be fueled by diesel.

C. The engine shall have a minimum of 6 cylinders and be liquid-cooled by Unit Mounted Radiator 122°F/50°C.

D. The engine shall be EPA Tier 4 certified from the factory.

1.9 ALTERNATOR id109_Alternator

A. The alternator shall be salient-pole, brushless, 2/3-pitch, 12 lead, self-ventilated with drip-proof construction and amortisseur rotor windings and skewed for smooth voltage waveform. The ratings shall meet the NEMA standard (MG1-32.40) temperature rise limits. The insulation shall be class H per UL1446 and the varnish shall be a fungus resistant epoxy. Temperature rise of the rotor and stator shall be limited to Standby 130°C. The excitation system shall be of brushless construction controlled by a solid- state voltage regulator capable of maintaining voltage within ±2.0% at any constant load from 0% to 100% of rating.

The AVR shall be capable of proper operation under severe nonlinear loads and provide individual adjustments for voltage range, stability and volts-per-hertz

Newport Utilities operations. The AVR shall be protected from the environment by conformal coating. The waveform harmonic distortion shall not exceed 5% total RMS measured line-to-line at full rated load. The TIF factor shall not exceed 50.

B. The alternator shall have a single maintenance-free bearing, designed for 40000 hour B10 life. The alternator shall be directly connected to the flywheel housing with a semi-flexible coupling between the rotor and the flywheel.

C. The generator shall be inherently capable of sustaining at least 250% of rated current for at least 10 seconds under a 3-phase symmetrical short circuit without the addition of separate current-support devices.

1.10 CONTROLLER id110_Controller

A. Based on the Caterpillar EMCP-4.4 Design.

1. The generator set controller must meet NFPA 110 Level 1 requirements (1996 version) and shall include an integral alarm horn as required by

NFPA.

2. The controller shall meet NFPA 99 and NEC requirements

3. The controller shall be UL 508 listed.

B. Applicability

1. The controller shall be standard on a 200REOZJD.

2. The controller shall support 12- or 24-volt starting systems.

3. The controller's environmental specification shall be: -40°C to 70°C operating temperature range and 5-95% humidity, non-condensing.

4. The controller shall mount on the generator or remotely within 40 feet with viewable access.

C. Hardware Requirements

1. Control Panel shall include:

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• The control shall have a run-off/reset-auto three-position selector switch.

• A controller-mounted, latch-type emergency stop pushbutton.

• Five indicating lights: System Ready - green Not in Auto - yellow

Programming Mode - yellow System Warning - yellow System

Shudown - red.

• Display with two lines of 20-alphanumeric characters, viewable in all light conditions.

• Sixteen position snap action sealed keypad for menu selection and data entry.

• For ease of use, an operating guide shall be printed on the controller faceplate.

• An audible alarm with alarm silence capability.

• Panel lights shall be supplied as standard.

D. Control Functional Requirements

1. Field-programmable time delay for engine start. Adjustment range 0-5 minutes in 1 second increments.

2. Field-programmable time delay engine cool down. Adjustment range 0- 10 minutes in 1 second increments.

3. Capability to start and run at user-adjustable idle speed during warm up for a selectable time period (0-10 minutes), until engine reaches preprogrammed temperature, or as supported by ECM-equipped engine.

4. The idle function including engine cool down at idle speed.

5. Real-time clock and calendar for time stamping of events.

6. Output with adjustable timer for an ether injection starting system. Adjustment range, 0-10 seconds.

7. Output for shedding of loads if the generator set reaches a user programmable percentage of its kW rating. Load shed must also be

Newport Utilities enabled if the generator set output frequency falls below 59 Hz (60 Hz system) or 49 Hz (50 Hz system).

8. Programmable cyclic cranking that allows up to six crank cycles and up to 35 seconds of crank time per crank cycle.

9. The capability to reduce controller current battery draw, for applications where no continuous battery charging is available. The controller vacuum fluorescent display should turn off automatically after the controller is inactive for 5 minutes.

10. Control logic with alternator protection for overload and short circuit matched to each individual alternator and duty cycle.

11. Control logic with RMS digital voltage regulation. A separate voltage regulator is not acceptable. The digital voltage regulator must be applicable to single- or three-phase systems.

12 The capability to exercise the generator set by programming a running time into the controller. This feature must also be programmable through the PC software.

13. Control function shall include output voltage adjustment.

14. Battle switch function selection to override normal fault shutdowns, except emergency stop and over speed shutdown.

15. The control shall detect the following conditions and display on control panel:

• Customer programmed digital auxiliary input ON (any of the 21 inputs available)

• Customer programmed analog auxiliary input out of bounds (any of 7 inputs for ECM equipped engines and 5 inputs for non ECM engines)

• Emergency stop

• High coolant temperature

• High oil temperature

• Controller internal fault

• Locked rotor - fail to rotate

• Low coolant level

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• Low oil pressure

• Master switch error

• NFPA common alarm

• Overcrank

• Overspeed with user-adjustable level, range 65-70 Hz on 60 Hz systems and 55-70 Hz on 50 Hz systems

• Overvoltage with user adjustable level, range 105% to 135%

• Overfrequency with user adjustable level, range 102% to 140%

• Underfrequency with user adjustable level, range 80% to 90%

• Undervoltage with user adjustable level, range 70% to 95%

• Coolant temperature signal loss

• Oil pressure gauge signal loss

Conditions resulting in generator warning (generator will continue to operate):

• Battery charger failure

• Customer programmed digital auxiliary input on (any of the 21 inputs available)

• Customer programmed analog auxiliary input on (any of the 7 inputs available on ECM engines and 5 inputs for non ECM engines)

• Power system supplying load

• Ground fault detected - detection by others

• High battery voltage - Level must be user adjustable.

• Range 29-33 volts for 24-volt systems.

• High coolant temperature

• Load shed

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• Loss of AC sensing

• Underfrequency

• Low battery voltage - level must be user adjustable, range 20-25 volts for 24-volt systems.

• Low coolant temperature

• Low fuel level or pressure

• Low oil pressure

• NFPA common alarms

• Overcurrent

• Speed sensor fault

• Weak battery

• Alternator protection activated

E. Control Monitoring Requirements

1. All monitored functions must be viewable on the control panel display.

2. The following generator set functions shall be monitored:

• All output voltages - single phase, three phase, line to line, and line to neutral, 0.25% accuracy

• All single phase and three phase currents, 0.25% accuracy

• Output frequency, 0.25% accuracy

• Power factor by phase with leading/lagging indication

• Total instantaneous kilowatt loading and kilowatts per phase, 0.5% accuracy

• kVARS total and per phase, 0.5% accuracy

• Kva total and per phase, 0.5% accuracy

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• kW hours

• A display of percent generator set duty level (actual kW loading divided by the kW rating)

3. Engine parameters listed below shall be monitored: (*available with ECM equipped engines)

• Coolant temperature both in English and metric units

• Oil pressure in English and metric units

• Battery voltage

• RPM

• Lube oil temperature*

• Lube oil level*

• Crankcase pressure*

• Coolant level*

• Coolant pressure*

• Fuel pressure*

• Fuel temperature*

• Fuel rate*

• Fuel used during the last run*

• Ambient temperature*

4. Operational records shall be stored in the control beginning at system startup.

• Run time hours

• Run time loaded hours

• Run time unloaded hours

• Number of starts

• Factory test date

• Last run data including date, duration, and whether loaded or

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• Run time kilowatt hours

5. The following operational records shall be a resettable for maintenance purposes:

• Run time hours

• Run time loaded hours

• Run time unloaded hours

• Run time kilowatt hours

• Days of operation

• Number of starts

• Start date after reset

6. The controller shall store the last one hundred generator set system events with date and time of the event.

7. For maintenance and service purposes, the controller shall store and display on demand the following information:

• Manufacturer's model and serial number

• Battery voltage

• Generator set kilowatt rating

• Rated current

• System voltage

• System frequency

• Number of phases

F. Inputs and Outputs

1. Inputs

• There shall be 21 dry contact inputs that can be user-configured to shut down the generator set or provide a warning.

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• There shall be 7 user-programmable analog inputs for ECM-equipped engines (5 for non-ECM engines) for monitoring and control.

• Each analog input can accept 0-5 volt analog signals

• Resolution shall be 1:10,000

• Each input shall include range settings for 2 warnings and 2 shutdowns.

• All values shall be on the control panel display.

• Shall be user-assigned

• Additional standard inputs required:

• Input for an external ground fault detector. Digital display must show "ground fault" upon detection of a ground fault.

• Reset of system faults.

• Remote two-wire start.

• Remote emergency stop

• Idle mode enable.

2. Outputs

• All NFPA 110 Level 1 outputs must be available.

• Thirty outputs shall be available for interfacing with other equipment:

• All outputs shall be user-configurable from a list of 25 functions and faults

• These outputs shall drive optional dry contacts.

• A programmable user-defined common fault output with over 40 selections shall be available.

G. Communications

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1. If the generator set engine is equipped with an ECM (engine control module), the controller shall communicate with the ECM for control, monitoring, diagnosis, and meet SAE J1939 standards.

2. Industry standard Modbus communication shall be available.

3. A Modbus master shall able to monitor and alter parameters, and start or stop a generator.

4. The controller shall have the capability to communicate to a personal computer (IBM or compatible) running Windows 10.

5. Communications shall be available for serial, CAN, and Ethernet bus networks.

6. A variety of connections shall be available based on requirements:

• A single control connection to a PC.

• Multiple controls on an intranet network connected to a PC.

• A single control connection to a PC via phone line.

• Multiple controls to a PC via phone line.

7. Generator and transfer switch controls shall be equipped with communications modules capable of connecting to the same communication network.

8. The capability to connect up to 128 controls (any combination of generator sets and transfer switches) on a single network shall be supported.

9. Cabling shall not be limited to the controller location.

10. Network shall be self-powered.

1.11 ACCESSORIES

A. Battery Charger. A 10-ampere automatic float to equalize battery charger with the following features:

• 12 or 24 VDC output

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• Voltage regulation of 1% from no to full load over 10% AC input line voltage variations

• Ammeter and voltmeter with 5% full-scale accuracy

• LED lamp for power indication

• Current limited during engine cranking, short circuit, and reverse polarity conditions

• Temperature compensated for ambient temperatures for -40°C to 60°C

• UL Listed

B. Block Heater. The block heater shall be thermostatically controlled and sized to maintain manufacturers recommended engine coolant temperature to meet the start-up requirements of NFPA 99 and NFPA 110, Level 1.

C. Circuit Breaker. factory mounted, 100% rated line circuit breaker of 1000 amperes, molded-case type, generator-mounted with load side lugs with 24Volt shut trip on breaker.

D. Critical Silencer. The engine exhaust silencer shall be temperature and rust resistant, and rated for critical applications. The silencer will reduce total engine exhaust noise by 25-35 db(A).

E. Dry Contact Kits. The 10 Dry Contact Kit shall provide normally open and normally closed, gold-plated contacts in a form C configuration to activate warning devices and other customer-provided accessories allowing remote monitoring of the generator set. Typically, lamps, audible alarms, or other devices signal faults or status conditions.

F. Flex Exhaust Tube. The exhaust piping shall be gas proof, seamless, stainless steel, flexible exhaust bellows with threaded NPT connection.

G. Flexible Fuel Lines. The two fuel lines shall have fittings for the engine inlet/return and threaded pipe fittings for connection to the trailer sub base fuel tank.

H. Standard Air Cleaner. The air cleaner shall provide engine air filtration which meets the engine manufacturer's specifications under typical operating conditions.

1.12 SOUND ENCLOSURE: SOUND LEVEL MAXIMUM DB (a) 73.3

A. All enclosures are to be constructed from high strength, low alloy steel, aluminum

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B. The enclosure shall be finish coated with powder baked paint for superior finish, durability and appearance. Enclosures will be finished in the manufacturer's standard color.

C. The enclosures must allow the generator set to operate at full load in an ambient of 40°C - 45°C with no additional de rating of the electrical output.

D. Enclosures must be equipped with sufficient side and end doors to allow access for operation, inspection, and service of the unit and all options. Minimum requirements are two doors per side. When the generator set controller faces the rear of the generator set, an additional rear facing door is required. Access to the controller and main line circuit breaker must meet the requirements of the National Electric Code.

E. Doors must be hinged with stainless steel hinges and hardware and be removable.

F. Doors must be equipped with lockable latches. Locks must be keyed alike.

G. The enclosure roof must be pitched to prevent accumulation of water.

H. A duct between the radiator and air outlet must be provided to prevent re-circulation of hot air.

I. The complete exhaust system shall be internal to the enclosure or optional with external mounted silencer.

J. All acoustical insulation must be fixed to the mounting surface with pressure sensitive adhesive or mechanically fastened. In addition, all acoustical insulation mounted on a horizontal plane must be mechanically fastened. The acoustical insulation must be flame retardant.

K. The enclosures must include an exhaust scoop to direct the cooling air in a vertical direction. Sound attenuation shall be 73.3 DB (A) or less measured at 7 meters in an open area.

1.13 TRAILER SPECIFICATION

Generator to be Mounted and Ready to Operate when delivered to Job Site, with Load test performed and test results supplied on each of the three voltages supplied.

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Quantity Description

(1) 12,000# 2 Axle Trailer with 1359 Gallon Fuel Cell

Standard Features

Quantity Part # 2 9510 6,700# Torflex Axle 1 9000 Electric Brakes 1 9200 Electric Break Away Kit 1 9110 Tongue Mounted Utility Box 2 9320 Safety Chains 1 9310 7000# Tongue Jack

2 9315 77000# Rear Stabilizer Jacks

1 3650 Supply/Return Dip Tube Package (1/2" NPT)

1 1000 Low Fuel Level Alarm (2” NPT) (Set at 50% Tank Capacity) 1 1003 Rochester Fuel Level Gauge (2” NPT) (Swing Arm) 1 9400 DOT Fill Cap (2” NPT)

1 9205 DOT Light Package

1 9500 2 5/16” Adjustable Coupler 1 9505 3” Pintel Eye Coupler or 2"Ball Receiver as directed by owner 1 9605 7-Pin Trailer Plug 1 3195 Extra Piping Connection w/ Plug (2" NPT, located in containment basin for basin testing) 1 3190 Extra Piping Connection w/Plug (3/8" NPT) Containment

Drain 1 Black Paint Color Black

Options Included

1 4305 Fuel in Basin Alarm (1/2" NPT, side mounted)

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1 9120 Spare Tire 6700# Axle

1.14 VOLTAGE SELECTOR SWITCH SPECIFICATION

A. Voltage Selector/Reconnection Switch

1. Voltage selector/reconnection switch shall be a three position cam operated type with two (2) isolated outputs for use with two breakers. Switch shall be provided with pad lockable handle, four (4) auxiliary contacts closed in each position and escutcheon plate. The switch shall feature four-hole mounting.

2. Voltage selector/reconnection switch shall be suitable for off load switching.

3. The voltage selector/ reconnection switch shall be suitable for “off” load switching and reconnection of the following output voltages and capacities:

1) 120/240VAC, single phase, zig-zag/ dogleg, connected, 505 amperes minimum

2) 120/208VAC, three phase, high wye connected, 916 amperes minimum

3) 277/480VAC, three phase, high wye connected, 397 amperes minimum

4. Terminals shall be accessible from the side to facilitate wiring and shall be protected against accidental finger contact

5. The escutcheon plate shall be a plexi-glass plate with brushed aluminum backing and black inscription for each switch position.

Include five sets (5 cables each set) #4/0, 50’ cables shipped loose with twist cam lock on one end and bare cable on the other end.

END OF SECTION

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