S02 Installation Narrative 20250613 Building 98 Power Upgrade.pdf

Construction Design Narrative

Provide Backup Power For

McClellan VAMC Building 98

McClellan VA Medical Center

Submitted to:

U.S. DEPARTMENT OF VETERAN AFFAIRS

Chief of Engineering and Facility Management Services

VA Northern California Healthcare Systems

10535 Hospital Way, Mather, CA 95655

Submitted by:

Alares LLC

248 Copeland Street

Quincy, MA 02169

June 2023

JUNE 2023 ii

TABLE OF CONTENTS

1 EXECUTIVE SUMMARY

2 ELECTRICAL DESIGN APPROACH

2.1 APPLICABLE CODES/REFERENCES

2.2 CONTRACTOR INVESTIGATION REQUIREMENTS

2.2.1 SELECTIVE COORDINATION AND STUDY

2.2.2 SHORT-CIRCUIT RATINGS AND STUDY

2.2.3 ARC-FLASH HAZARD WARNINGS AND STUDY

2.2.4 SHORT-CIRCUIT RATINGS AND COORDINATION OF OVERCURRENT

PROTECTION

2.3 DESIGN RECOMMENDATION

2.3.1 METERING

2.3.2 AUTOMATIC TRANSFER SWITCH

2.3.3 LOAD STEPPING

2.3.4 EQUIPMENT POWER REQUIREMENTS

2.3.5 CONTROLS

3 MECHANICAL DESIGN APPROACH

3.1 APPLICABLE CODES/REFERENCES

3.2 DESIGN RECOMMENDATION

3.2.1 DIESEL FUEL OIL STORAGE TANK

3.2.2 DIESEL FUEL OIL TRANSFER PUMPS

3.2.3 DIESEL FUEL OIL RETURN PUMPS

3.2.4 STEEL PIPE AND FITTINGS

3.2.5 SENSORS

3.2.6 CONTROLS

4 STRUCTURAL DESIGN APPROACH

4.1 DESIGN RECOMMENDATION

APPENDICES

Appendix A – Electrical Calculations

Appendix B – Equipment Cutsheets

JUNE 2023 1

1 EXECUTIVE SUMMARY

The McClellan VAMC Building 98 Community-Based Outpatient Clinic (CBOC) does not have generator backup. The existing electrical service is composed of a 1600A 480Y/277V Switchboard and downstream distribution. The VA Electrical Design Manual has specific requirements for the classification and segregation of life safety, critical, and equipment loads; to help load step a generator. In the case of Building 98, such an effort would be very expensive, as all the building loads are combined into the existing 1600A 480Y/277V Switchboard.

The VA has decided to reuse an existing generator to backup Building 98. This generator is currently located at the Mather VAMC and will be relocated to the McClellan site. Additional fuel storage and associated mechanical systems will be added to meet VA requirements. New concrete equipment pads will be constructed to house the reused generator and all new mechanical and electrical equipment.

2 ELECTRICAL DESIGN APPROACH

Because of the high cost associated with fully classifying and segregating the life safety, critical, and equipment loads; a single 725kW 480Y/277V generator will be used to back up the entire

1600A electrical service.

This Standby Generator Backup of Building 98 is highly desirable to meet the Generator Backup requirements of the VA Electrical Design Manual for Outpatient Clinics. By selecting to back up the entire Building 98 CBOC with the reused generator, the VA Electrical Design Manual compliance will be reached with the lowest available cost.

With the decision to use a single generator for Building 98 backup, the VA has granted a variance with the following discrepancies from VA Electrical Design Requirements:

a. One Essential Electrical System will be used instead of the required minimum three separate Essential Electrical System branches. The Standby Electrical system may not meet the performance requirements of NFPA 110.

b. The required 1600A Automatic Transfer Switch is greater than the VA Maximum allowable Standard of 800A.

c. The inrush currents of the existing electrical system must be mitigated with an additional contactor to allow for load stepping so as not to overwhelm the 725kW, 480Y/277V generator.

The contractor must service and commission the generator according to the manufacturers recommendations and ensure that the generator is fully functional prior to transporting it to the new site.

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The contractor must submit a transportation plan to the VA for review before generator transportation.

The contractor must perform a Ground-Penetrating Radar Survey before the start of construction to locate existing underground utilities. Shop drawings for the routing around these existing underground utilities must be submitted for review. This may result in a change order.

There are some electrical code issues, such as NFPA 70 Article 705.12, where the existing 400A solar renewable energy system feeding the existing 1600A Cutler-Hammer 480Y/277V switchboard exceeds the 20 percent rating of the switchboard. This project will not correct this issue.

2.1 APPLICABLE CODES/REFERENCES

2019 Edition of VA Electrical Design Manual

2023 Edition of VA Physical Security and Resiliency Design Manual

2020 Edition of VA Seismic Design Requirements

2023 Edition of NFPA 70

2022 Edition of NFPA 110

2.2 CONTRACTOR INVESTIGATION REQUIREMENTS

According to the VA Electrical Design Manual and VA Master Specification Section 26 05 73, the new standby generator backup system will require that the contractor conduct the following investigations.

2.2.1 SELECTIVE COORDINATION AND STUDY

Contractor shall perform a selective coordination study for localization of an overcurrent condition to restrict outages to the circuit or equipment affected. This is accomplished by the selection and installation of overcurrent protective devices and their ratings or settings for the full range of available over currents, from overload to the maximum available fault current; and for the full range of overcurrent protective device opening times associated with those over currents. Final new Paralleling Switchboard Distribution shall be coordinated with all existing to remain upstream and downstream electrical distribution.

2.2.2 SHORT-CIRCUIT RATINGS AND STUDY

Contractor shall perform a short-circuit study to determine the prospective symmetrical fault currents at the nominal voltage, to which an apparatus or system is able to be connected without sustaining damage exceeding defined acceptance criteria; with all existing to remain upstream and downstream electrical distribution.

JUNE 2023 3

2.2.3 ARC-FLASH HAZARD WARNINGS AND STUDY

Contractor shall perform an arc-flash study to determine electrical equipment; such as switchboards, switchgear, panelboards, industrial control panels, meter socket enclosures, and motor control centers; that is in other-than-dwelling units; and is likely to require examination, adjustment, servicing, or maintenance while energized. This identified electrical equipment shall be field or factory marked to warn qualified persons of potential electric arc flash hazards. The marking shall meet the requirements in NFPA 70 Article 110.21(B) and shall be located to be clearly visible to qualified persons before examination, adjustment, servicing, or maintenance of the equipment.

2.2.4 SHORT-CIRCUIT RATINGS AND COORDINATION OF OVERCURRENT

PROTECTION

The contractor must ensure compliance with the short-circuit ratings and coordination of overcurrent protection requirements of the VA Electrical Design Manual and of applicable NFPA codes such as NFPA 70 and NFPA 110.

2.3 DESIGN RECOMMENDATION

2.3.1 METERING

To meet Sacramento Municipal Utility District (SMUD) metering requirements, the redesigned electrical service entrance 1600A, 480Y/277V a Siemens NEMA 3R switchboard must be configured with hot sequence metering.

2.3.2 AUTOMATIC TRANSFER SWITCH

A new weatherproof NEMA 3R 1600A, 3-Phase, 4-Pole Automatic Transfer Switch is required to transfer the entire 1600A 480Y/277V to the existing 725kW 480Y/277V generator.

2.3.3 LOAD STEPPING

Multiple 480Y/277V large electrical contactors must be used to load step the transformer (x12

FLA inrush currents) and motors (x6 FLA inrush currents) so as not to overwhelm the generator with inrush load currents. The contactors and motor starters will be sequenced so that they do not operate at the same time. This sequencing is accomplished using timers and auxiliary contacts when starting up the various building loads.

2.3.4 EQUIPMENT POWER REQUIREMENTS

Building switchboard electrical power must be provided to the generator trailer for both the generator trailer such as lighting, receptacles and heating along with generator support for battery chargers, heaters, monitoring and controls.

A new 125A, 120/208V Electrical Panel (98-G1) will provide power to local generator loads such as battery charges and upgraded fuel oils system pumps.

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2.3.5 CONTROLS

A controller will be installed in the buildings main electrical room. This controller will provide communication between the new generator and equipment and the existing building automation system (BAS) and will monitor and control the generator and automatic transfer switch, as well as the various supporting electrical and mechanical systems.

3 MECHANICAL DESIGN APPROACH

3.1 APPLICABLE CODES/REFERENCES

2023 Edition of VA HVAC Design Manual

2023 Edition of VA Physical Security and Resiliency Design Manual

2020 Edition of VA Seismic Design Requirements

3.2 DESIGN RECOMMENDATION

The reused generator has a 1,000-gallon day tank. With a burn rate of 60 gal per hour at full load;

this allows the generator to run for 16 hours. In order to meet the VA required 96 hour run time, a diesel fuel oil storage tank must be added.

The addition of this tank necessitates the addition of some accessories, including transfer pumps, return pumps, and a fuel polisher.

3.2.1 DIESEL FUEL OIL STORAGE TANK

According to a decision by the VA, the diesel fuel oil storage tank will be sized at 5,000 gallons to provide approximately 80 additional hours of operation for the generator. The tank will be 169 inches long and 103 inches in diameter with double wall insulated construction, according to UL-

2085 standards. The basis of design is Modern Welding Company, Fireguard 5,000 gal or approved equal.

An access platform must be provided by the contractor for access and inspection of the tank. Shop drawings for the access platform must be submitted for review.

A fuel polisher will be included to remove water and other contaminants from the diesel fuel. The basis of design is Preferred Utilities Model: PF-503 or approved equal.

3.2.2 DIESEL FUEL OIL TRANSFER PUMPS

Fuel transfer pumps transfer fuel from the main storage tank to the day tank. The transfer pumps for the emergency generator will be located on the new pad, between the storage tank and the generator trailer. The pumps will be installed inside a factory provided NEMA 3R pump set enclosures for outdoor application and security.

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The fuel oil pump set will be provided with a touch screen and will communicate with the building automation system.

The basis of design is Preferred Utilities Model: ATPSF-104-208-1450-D-L with the following requirements.

- 163 gph

- 50 psi rating

- 1725 rpm

- 1/3 hp

- 208 V

- 3 phase power

The duplex pumps will have an automatic starter with lead/lag.

3.2.3 DIESEL FUEL OIL RETURN PUMPS

The return pump is used to recirculate oil from the fuel oil tank to prevent stagnation. The return pump will be located inside the reused generator trailer, see drawings for more info.

The basis of design is Simplex Return Pump Model: 502 with the following requirements.

- 480 gph

- 50 psi rating

- 1725 rpm

- 1/3 hp

- 120 V

- 1 phase

3.2.4 STEEL PIPE AND FITTINGS

Steel, seamless or electric resistance welded (ERW), ASTM A53/A53M Grade B or ASTM

A106/A106M Grade B, Schedule 40 pipes are required. Aboveground piping shall be painted per

VA Spec Section 09 91 00 PAINTING. Fuel oil piping will comply with VA specification section

23 10 00 FACILITY FUEL SYSTEMS.

Heat tracing must be provided on the gravity over-flow return piping and will be controlled and monitored via the BAS.

3.2.5 SENSORS

Leak detection sensors will be provided both for the transfer pump assembly and the diesel fuel day tank and will communicate with the BAS. Leak detection is not required for the new storage tank as the tank is located outside.

Level switches will be provided for the reused day tank. The level switches will communicate with the BAS.

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3.2.6 CONTROLS

All sensors and fuel oil level controls will be integrated into the existing BAS using the new controller installed in the building’s main electrical room. The BAS will have full monitoring and control of the entire fuel oil system.

4 STRUCTURAL DESIGN APPROACH

4.1 DESIGN RECOMMENDATION

Two new equipment pads are required to support reused and new equipment for mechanical and electrical.

The new mechanical equipment pad will support the reused generator trailer, new transfer pump set, new fuel polishing skid and new storage tank. The total weight of all equipment at full load is approximately 100,000 lbs. A 56 ft by 14 ft equipment pad will be provided. The pad will be 16 in thick with 6 in above the finish grade; rebar will be included throughout. Compact crushed stone will be laid to support the pad. Removable bollards will be included along the perimeter of the pad to protect all equipment.

The new electrical equipment pad will support the new weatherproof automatic transfer switch and switchboard. The total weight of all equipment is approximately 10,000 lbs. A 15 ft by 7 ft 6 in equipment pad with openings for underground conduits will be provided. The pad will be 12 in thick with 4 in above the finish grade; rebar will be included throughout. Compact crushed stone will be laid to support the pad. A cmu wall will be provided along one side of the pad as shown on the drawings. A chain-link fence will be provided along the other two open sides.

Design Development Narrative

JUNE 2023

APPENDIX A

ELECTRICAL CALCULATIONS

Calculations for Electrical Equipment Short-Circuit Ratings that Impact Life Safety

- These calculations are worst-case and the actual fault conditions are expected to be substantially less

- Existing utility transformer is 1,000kVA

- Worst case transformer Impedance is 2.5%

- Typical impedance of a transformer this size is 5%

Transformer Full Load Amps = 1,000 kVA / [(3-Phases) * 277V per Phase] = 1,203A

Worst Case Available Short-Circuit Current = 1,203A / 2.5% Transformer Impedance = 48,135A

- Standard Short-Circuit Withstand specified for new Metering Switchboard and ATS is

65,000A or 65 kAIC which can handle the 48,135A fault current calculated above.

When the contractor verifies the transformer impedance is 5% then the available fault current will drop to half of what we calculated and a 35 kAIC rating (less steel needed) can be used for the new electrical equipment.

APPENDIX B

EQUIPMENT CUTSHEETS

Modern Welding Company, Inc.

Toll Free: (800) 922-1932

Phone: (270) 685-4400 modweldco.com

Fire-Rated Aboveground Tanks

FIREGUARD® double-wall, fire-protected aboveground storage tanks feature an inner and outer steel tank with lightweight thermal insulation that exceeds the UL 2-hour fire test.

Features

• Insulating material is 75% lighter than concrete, reducing shipping, installation and relocation costs

• Insulates product from ambient temperature variations, reducing emissions to the environment

• Compatible with a wide range of fuels and chemicals, including biodiesel and ethanol

• Support designs available for all seismic requirements

• Meets 4-hour furnace test requirements

• Interstitial space can be monitored for leak detection

• Capacities range up to 70,000 gallons

• Low-cost compartments and customization

• Built to nationally-recognized STI standards with a strict third-party quality control inspection program

• Ballistic and vehicle impact resistant

• Hose stream tested

Why Fireguard®?

Steel Primary Tank Built to UL Standards

Steel Secondary Tank Built to UL Standards

Lightweight Thermal Insulation

• Unique feature that helped Fireguard® exceed the UL 2-hour fire test

• Sufficiently porous to facilitate quick emergency venting and/or leak detection

• UL-2085 Listed

• Inner and outer steel tanks are built to UL-142 standards

• Optional UL-752 Level 9 advanced ballistics construction available on certain configurations

• National Fire Protection Association

(NFPA) 30 & 30A

• International Fire Code (IFC)

• California Air Resources Board (CARB) Standing Loss Control testing requirements for air emissions

• Steel Tank Institute (STI) Standard F941 for Protected Aboveground Storage Tanks

• ULC-S655 Underwriters Laboratories of Canada Standard

• Alternative construction to tank diking requirements

The Standard in Fire-Rated AST’s

186 2,119 250 68

2,513

300 50

GALLONS APPROX.

WEIGHT (lbs.)LENGTHDIAMETER

FIREGUARD® SPECIFICATIONS — CYLINDRICAL DESIGN

72 2,821 2,413500 70

560 78 2,606 1,000 5,338 1,000 70

78 5,005 1,500 70 6,537 2,000 70 150

8,309 9,6442,500 70 186

3,000 4,000 4,000

70 222 10,979 78 233 13,523

14,072

17,149

90 175 5,000 79 290 18,998 5,000 103 169

3476,000 79 21,961 6,000 103 199 19,206 8,000 103 259 23,319 10,000 103 331 28,256 12,000 103 391 32,370 15,000 127 313

35,821 44,506

64,575

20,000 127 25,000 127 517 55,891 30,000 127 619

110,000 40,000 144 635 93,000 50,000 144 792

All dimensions are outer. Please note that all dimensions and weights are approximate. Individual tanks may vary from these values.

Is Your Aboveground Tank Everything It’s Cracked Up To Be?

Concrete Encased

• Secondary containment is tightness-tested at the manufacturing site using standard, economical testing procedures.

• Fireguard®’s steel outer wall provides low-cost maintenance and protects the insulation material from weathering.

• An average 12,000 gallon Fireguard® weighs under 35,000 pounds - well within the legal load limit for trucking.

• The secondary containment on certain designs may require elaborate and expensive procedures to be tested on-site.

• Exposed concrete outer wall is susceptible to cracking, spalling and weathering - problems that are expensive to correct and are usually not covered by warranty.

• An average 12,000 gallon concrete-encased tank weighs upwards of 100,000 pounds. Imagine the advantages gained in handling a 12,000 gallon Fireguard® tank that weighs a third of that.

Revised: 08/2019 Modern Welding Company, Inc.

Subsidiaries Nationwide

Toll Free: (800) 922-1932 | Phone: (270) 685-4400 modweldco.com

Peter Rectangle modern

FIREGUARD

U.S. Patents No. 5695089, 5809650

L I G H T W E I G H T D O U B L E W A L L S T E E L T A N K I N S T I T U T E

Steel modern

S T E E L T A N K I N S T I T U T E L I G H T W E I G H T D O U B L E W A L L

U.S. Patents No. 5695089, 5809650

FIREGUARD

Steel

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TANK NOM. CAPACITY: 5,000 GALLONS

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MODERN WELDING COMPANY, INC.

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"FIREGUARD" FIRE-PROTECTED AST HORIZONTAL

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THIS DRAWING IS FOR ILLUSTRATION PURPOSES ONLY AND IS NO TO BE RELIED UPON FOR

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ANY OTHER PURPOSE. NO WARRANTY OF MERCHANTABILITY, OF FITNESS FOR A PARTICULAR

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PURPOSE OR OF ANY OTHER KIND, EXPRESSED OF IMPLIED, IS HEREBY MADE.

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AutoCAD SHX Text DESIGN: FABRICATED PER UL-2085 SPECIFICATIONS MEETS 2001 CBC REQUIREMENTS MEETS 1997 ICBO UBC REQUIREMENTS BULLET RESISTANT UNDER 1997 IFIC UFC STANDARD 79-7 IMPACT RESISTANT UNDER 1997 IFIC UFC STANDARD 79-7 CARB EXECUTIVE ORDER G-79-162-A INSPECTION: MODERN WELDING COMPANY MATERIAL: MILD CARBON STEEL (UNLESS NOTED) INTERNAL SURFACE PREP: CLEAN OF DEBRIS, UNPAINTED EXTERNAL SURFACE PREP: SSPC-SP6 (COM. BLAST) COATING: WHITE EPOXY INTERSTITIALSPACE: LIGHTWEIGHT PROPRIETARY CONCRETE PRODUCT

AutoCAD SHX Text OPERATING PRESSURE: ATMOSPHERIC PRESSURE TEST: 3-5 PSI NOTE: AT NO TIME SHALL THE PRESSURE IN THE SECONDARY TANK EXCEED THE PRESSURE IN THE PRIMARY TANK.

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PS

203.743.6741 • 203.798.7313 www.preferred-mfg.com

Fuel Management Systems

Catalog 25

Fuel M anagem ent S ystem s

The Automatic Fuel Oil Filtration Set, Model PF, is the most complete, efficient and reliable engine protection system you can install. These self-contained, fully automatic systems remove water, suspended rust, dirt and other contaminants in order to maintain the quality and purity of stored diesel fuel.

Standard Equipment

• Preferred FSC-based control with color touch screen

• Pump “Hand-Off-Auto” switch

• Control power “On-Off” switch

• Leak detector switch

• Pump and motor assembly

• Simplex strainer

• Filter / Water separation cartridge

• Primary/secondary filter DP switch/gauge

Water enters fuel systems through vents, leaks, and sometimes with the delivered fuel. Microorganisms can grow in fuel, especially in the presence of moisture. The resulting sludge left in the system can cause tank, fuel line, strainer, pump and engine injectors to clog. Water induced corrosion (rusting) can reduce tank life expectancy and reliability of the emergency diesel generator or boiler.

The Model PF automatic fuel oil filtration set combines microprocessor-based control and monitoring with a “three stage” fuel oil de-watering and cleaning process:

1. Fuel Straining: Large contaminates are removed

2. Filtration: Fuel filtration to 5 micron

3. Water Removal: Removes water through special filter design.

Note: diesel engine manufacturers recommend 10 micron filtration of fuel oil. Filter elements smaller than 5 microns are prone to clogging and are not recommended.

For more information, consult the maintenance manual for your engines.

Key Benefits

• Standard flows from 180 to 1200 GPH

• Cleans and de-waters fuel with:

- Nearly 100% water removal

- 99% particulate removal (to 5 micron)

• Automatic cycling based on the time of day and the day of the week ensures continuous fuel maintenance.

• Alarm and safety shutdown for filter water level “High”, filter “Saturated”, system base “Leak” detected

• Microprocessor-based

• Factory mounted and wired control cabinet

• NEMA 4 cabinet (standard)

• Available for biodiesel applications

Model PF Automatic Fuel Oil Filtration Set

AUTOMATIC FUEL OIL FILTRATION SET

Recommended by NFPA 110 Standard for Emergency and Standby Power Systems

Automatic Fuel Oil Filtration Set Application Example

The separated contaminants and water are monitored by an integral filter water level detector. Depending on the size of the system, this waste water is piped to an optional Waste Water Holding and Removal System or connected directly to the customer's waste tank (by others). A differential pressure switch/ indicator is installed around the filter units to provide a visual indication of filter element condition.

An alarm notifies plant personnel when the filter elements require replacement.

Systems are available in standard sizes ranging from 180 to 1200 gallons per hour, to custom units for processing 50 gallons per minute or more.

Integral Preferred FSC-based controller can communicate via NodeNet to other FSC controllers in the fuel system.

Fuel Management Systems

Catalog 25

Fu el

M an ag em en t S ys te m s

For best results, use in conjunction with the waste water removal and storage option (WR-1) and Preferred fuel additives system (CA-1) option. See page 9 for photo.

Specifications Power: 120 VAC (external) Fluid: No. 2 Fuel Oil (diesel fuel) is standard.

Consult factory for other fuel types.

Pump: Positive displacement type with cast iron housings:

Model PF-501, 502 & 503 are spur gear;

Model PF-504 & 505 are internal gear

Motors: Base mounted, Totally Enclosed Fan Cooled (TEFC) construction

Strainer: Simplex 1” , or 1½” (according to inlet line size) complete with 100 mesh perforated basket

Automatic Controls: - Adjustable run-time period

- Indications/Alarms:

Control power on Pump run Filter saturated Filter water level high System basin leak detected

Tank Turnover Time In Hours (Rounded to Nearest Hour)

Storage Tank Size (Gallons) 1,000 2,000 4,000 8,000 16,000 20,000

PF-501 6 11 22 44 89 111

PF-502 2 4 8 17 33 42

PF-503 2 3 7 13 27 33

PF-504 1 2 4 9 18 22

PF-505 1 2 3 7 13 16

Notes:

1. Shaded hours are not recommended.

2. Due to the mixing of filtered fuel with unfiltered fuel, a minimum of three tank turnovers are recommended to ensure fuel quality.

AUTOMATIC FUEL OIL FILTRATION SET

Specifications

Ordering Information Select catalog number from the table below.

Catalog Number

G.P.H.

Oil #2 P.S.I.

Motor Dimension Connection Size

Shipment

R.P.M. H.P. W H D Inlet - Outlet

PF-501 180 15 1725 ¼ 48" 48" 12" ¾" - 1½" 2-3 Weeks

PF-502 480 15 3450 ⅓ 48" 48" 12" ¾" - 1½" 2-3 Weeks

PF-503 600 30 1725 ½ 48" 48" 12" ¾" - 1½" 2-3 Weeks

PF-504 900 30 1725 ¾ 48" 48" 12" 1½" - 1½" 2-3 Weeks

PF-505 1200 25 1725 ¾ 48" 48" 12" 1½" - 1½" 2-3 Weeks

Note: All pumps are 115 V, 60 Hz , single phase.

Optional Accessories

1. Waste water holding and removal system:

A gear pump automatically pumps water from the secondary filter housing to the holding tank based on an integral filter water detector signal. Automatic isolating valves prevent water leakage into the fuel or fuel into the water holding tank when the system is idle. The holding tank is equipped with a high level switch to alarm and shutdown the fuel maintenance system until the tank is emptied.

A hand pump is provided for periodic removal of waste water from the holding tank. Requires mounting skid. Specify P/N-WR-01.

2. Chemical additive holding tank and injection system:

Chemical treatment helps to prevent fuel degradation and improve cetane rating. Higher cetane rating improves cold starting, reduces white smoke, and maximizes engine efficiency. A gear metering pump injects additives into the oil while the oil is circulating in order to ensure complete mixing. The additive feed pump operating cycle runs biannually, or it can be activated when new fuel is delivered. A welded steel chemical additive holding tank is provided. Separate skid if ordered in conjunction with standard PF series. Specify P/N-CA-01.

W

H

D

Fuel Management Systems

Catalog 25

Fuel M anagem ent S ystem s

AUTOMATIC FUEL OIL FILTRATION SET

Suggested Specifications

8. Control Hardware The control strategy shall be microprocessor-based. RELAY LOGIC SHALL NOT BE ACCEPTABLE. The control strategy shall be factory configured and stored on a EEPROM, and shall be safeguarded against re-configuration by unauthorized/ unqualified personnel. Control hardware shall include combination magnetic motor starter with overload protection and circuit breaker. The control system shall provide common alarm dry contacts to be interfaced with the Building Maintenance System as required.

9. Automatic Operation In order to ensure automatic fuel maintenance the filtration system shall have an adjustable automatic start and run time. The operator shall be able to set the system to run at a certain time every day or week.

10. Safety Interlocks Provide safety interlocks to shutdown pump when a “leak” is detected.

11. Operator Interface All operator interface shall be cabinet front door mounted. As a minimum, the following indications, alarms, control switches and pushbuttons shall be provided:

1. Alarm silence, manual reset, lamp/ alarm test pushbuttons

2. Pump “hand-off-auto” control switch

3. “Pump on”, indicator

4. “Filter saturated”, “Filter water level high” and “system basin leak detected” alarms

12. Quality Assurance Inspection, Labeling and Testing The control cabinet shall be manufactured in accordance with UL 508A. Simply supplying UL recognized individual components is not sufficient. The assembled control cabinet as a whole must be inspected for proper wiring methods, fusing, etc., and must be labeled as conforming to UL 508A (CSA C22.2 #14 for use in Canada). Inspection and labeling shall be supervised by UL or other OSHA approved Nationally Recognized Test Lab (NRTL).

The system must be manufactured by a nationally recognized trade union (I.B.E.W. or similar trade union). Lack of an NRTL certified UL 508A wiring methods inspection and label or lack of a trade union label will be grounds for rejection.

1. Enclosure, Piping And Mounting Provide a fuel oil filtration system as recommended by NFPA 110 Standard for Emergency and Standby Power Systems. The filtration system shall be factory assembled with components piped and mounted inside a continuously welded steel enclosure. The enclosure shall be constructed of 14 gauge steel as minimum, continuously welded and constructed to NEMA 4 standards and have an integral 2" steel containment basin with plugged drain options. The basin shall be sized to contain (capture) potential leaks from all factory installed piping and components. Doors shall be fully gasketed with a turned edge, piano hinges, and a three point lockable latching mechanism. The enclosure interior shall be primed and finished in a white gloss, chemical resistant enamel.

The enclosure exterior shall be primed and finished in a durable, chemical resistant, textured gray enamel, suitable for industrial environments. Pipe shall be schedule 40 ASTM A-53 Grade “A” with ANSI B16.3 Class 150 malleable iron threaded fittings. The fuel oil filtration system shall be Preferred Utilities Mfg. Corp. Danbury, CT Model PF-____ rated at ___GPH of No. 2 fuel oil.

2. Containment Basin Leak Detection Switch Provide, mount and wire a float-operated containment basin leak detection switch to shut off the pumps and energize an audible and visual alarm should a leak be detected. The level sensor shall be a plasma welded stainless steel construction. Electrical connections shall be contained in a weatherproof junction box.

3. Strainer Oil strainer shall have cast iron body, threaded connection, size shall be suitable for the required flow and suitable for working pressures to 150 PSIG. Clamped cover and handle shall permit easy removal of the basket. Basket shall be constructed of 100 mesh stainless steel.

4. Pump and Motor Assembly A base mounted, TEFC motor, and positive displacement pump with cast iron housing shall be provided. Pumps that have aluminum, brass, or bronze housing or rotors or centrifugal pumps are not acceptable. The pump shall be an industrial type intended for continuous heavy-duty service.

5. Filtration One filter element shall provide both particulate and water removal.

Filtration provided to 5 micron.

6. Element Replacement No special tools are required to change the filter.

7. Filter Monitoring Both filter stages shall have a differential pressure switch piped across them to indicate when the filters need to be changed. The switch shall provide indication on the main filtration control cabinet to alert operators and sound a horn. The differential pressure switch shall provide clear indication of strainer basket status with the use of a colored scale plate with GREEN denoting clean, and RED denoting dirty strainer. This switch shall have one piece aluminum body and shall be suitable for pressure to 200 PSIG.

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AUTOMATIC FUEL OIL TRANSFER PUMP SET

Overview

The Automatic Fuel Oil Transfer Pump Set (ATPSF) is a state-of-the-art duplex pump sequencing and monitoring system. This system includes automatic lag pump back-up features that improve fuel system availability and safety.

The ATPSF pump set has been upgraded to include the Preferred Flexible System Controller (FSC) to reduce field wiring and commissioning time.

• Loop or Day Tank Fuel Oil Transfer System

- No. 2 or No. 4 fuel oil

- Flows from 20 to 2200 GPH

- Industrial type cast iron internal gear pumps

• Microprocessor-Based Monitoring And Control

- 4” or 10” color touchscreen

- Elapsed time recorders

- Main storage tank gauge and discriminating leak monitoring by addition of optional Fuel Sentry tank gauge

• Automatic Lead/ Lag

- Lead pump manual selection or automatic alternation on call for operation or run time hours

- Automatic lag pump back-up based on lead pump thermal overload, failure to produce flow, fuel demand exceeds capacity of the lead pump

- Automatic pump prime and suction line integrity check. Fuel transfer system suction piping, pump prime and pump operation are automatically verified each week (adjustable). Fuel system trouble can be identified and repaired before the unit is needed.

• Alarm and Event Summaries

- Alarm and event summary with time and date stamp

The Automatic Fuel Oil Transfer Pump Set is a factory packaged, pre-engineered, pre-wired and pre-plumbed system that includes pumps, industrial motors and accessories. These systems are shipped to the job site, requiring only external fluid and electrical connections, ensuring undivided responsibility of delivering fuel at the selected flow.

Standard Equipment

• Microprocessor-based control with color touchscreen display and alarm/event and operator action log in a NEMA 4 enclosure.

• Included FSC controller communicates by redundant digital link to other FSC controllers on day tanks, filtration sets, and fill boxes to reduce field wiring.

• Control circuit transformer (if required)

• Alarm bell with alarm silence/reset pushbutton

• Two “Hand-Off-Auto” switches

• “Pump On” indicators

• Two magnetic motor starters with overload protection

• Two motor circuit breakers

• Two pump and motor assemblies

• Two relief valves, two check valves and four ball valves

• Two Simplex inlet strainers

• Pump discharge pressure gauges

• Pump set flow proving switch (shipped loose)

Automatic Pump Set Application Example

Duplex Pump Set with Inlet Oil Stainer and Pump Control Cabinet

AUTOMATIC FUEL OIL TRANSFER PUMP SET

Overview

Day Tank Fuel Oil Transfer System The lead fuel pump is energized when day tank oil level falls below 50%. The lead pump continues to operate until the day tank level is greater than 80%. Upon the next call for fuel, the lead pump automatically alternates. The control system automatically energizes the back-up pump upon detecting a low level condition, (40% full condition). Both pumps then continue to operate until the level of oil reaches the high level point, 90% full condition. Upon detection of loss of flow or pressure or lead pump thermal overload the control system automatically energizes the backup pump and de-energizes the lead pump.

Loop Fuel Oil Transfer System The lead fuel pump is energized upon a call for oil and run continuously until the demand is removed. Upon the next call for fuel, the lead pump automatically alternates. The lead pump shall automatically rotate every 1 to 168 hours or shall be manually selected by the operator. Upon detection of loss of flow or pressure, or lead pump thermal overload the control system shall automatically energize the backup pump and de-energize the lead pump.

Automatic Pump Prime And Suction Line Integrity Check Fuel transfer system suction piping, pump prime and pump operation are automatically verified each week (adjustable). The lead pump is automatically energized. Once the lead pump has been proven, the lag pump is energized and run through the same test. These tests are recorded in the controller memory with a time-date stamp for later verification. If either lead or lag pump fails any of these tests, the control system generates an audible and visual alarm and logs the “failed pump” condition.

To permit pump set testing, fuel oil piping system design must allow the pump set discharge to return to the main storage tank. The above diagrams show suitable Boiler Loop and Day Tank system arrangements. Additionally, system designs may include return flow pumps or solenoid valves. Consult factory for additional information.

Modbus Communication Interface Off-site monitoring and control is available via RS-485 Modbus, Ethernet TCP/IP, or BacNet IP digital communication.

Alarms / Event Summary Up to 200 alarms, system events and operator actions are listed in “first in-first out” order with time & date stamp. Alarms include “pump thermal overload,” “pump loss of flow,” and “pump set failure” with “day tank leak,” “day tank high level” and “day tank low level” alarms added for day tank systems. The following events are recorded with time & date stamp: “pump started,” “pump control switch in ‘off’ position,” “pump set prime test OK” and “pump selected as lead.”

Building Automation System Building Automation System (BAS) interface includes isolated relay contact outputs for “pump 1 fail,” “pump 2 fail,” “strainer high differential,” “pump set leak,” “day tank high,” “day tank low” and “day tank leak” (all when applicable). Digital monitoring available via Ethernet TCP/IP or BacNet interface.

Duplex Strainer (Option “-D”) A Preferred Model 72 duplex fuel oil strainer is provided on the suction side of the pump set instead of the two simplex strainers.

Strainer baskets are 40 mesh stainless steel.

Duplex Strainer Differential Pressure Switch (Option “-DP”) A differential pressure switch/ indicator with isolation cocks is provided to energize an audible and visual alarm should an excessively dirty strainer condition be detected (Option “-DP” can only be used with option “-D”).

Pump Set Leak Detector Switch (Option “-L”) A float-operated “containment basin leak” detection switch is provided to shut off the pumps and energize an audible and visual alarm should a pump set leak be detected.

Main Storage Tank Monitoring (Optional) Fuel Sentry Model TG-EL-D4A tank gauges may be integrated into the Model ATPSF Transfer Pump Set.

FUEL OIL SUPPLY TO BOILERS,

GENERATORS, AND / OR DAY TANKS

BACK

PRESSURE

REGULATING

VALVE

FUEL OIL

SUPPLY

FROM TANK

FUEL OIL

RETURN

TO TANK

RELIEF VALVES

RETURN

TO TANK

FUEL OIL

RETURN

TO TANK

DAY TANK

DAY TANK

S

S

FUEL OIL

SUPPLY

FROM TANK

RELIEF VALVES

RETURN

TO TANK

Boiler Loop Fuel Oil Transfer System Day Tank Fuel Oil Transfer System

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Catalog Size

G.P.H. Oil #2 / #4 P.S.I.

Motor Dimension Connection Size

WeightR.P.M. H.P. Voltage Phase L. W. H. Inlet Outlet Relief Valve 101 23 / 24 100 1725 ⅓ 115, 208 or 230 1 30 ½" 22 ½" 69 7/8" 1" ½" ½" 450 lbs.

24 / 25 50 1725 ⅓ 115, 208 or 230 1 30 ½" 22 ½" 69 7/8" 1" ½" ½" 450 lbs.

102 51 / 54 100 1725 ⅓ 115, 208 or 230 1 30 ½" 22 ½" 69 7/8" 1" ½" ½" 450 lbs.

54 / 46 50 1725 ⅓ 115, 208 or 230 1 30 ½" 22 ½" 69 7/8" 1" ½" ½" 450 lbs.

103 89 / 96 100 1725 ⅓ 115, 208 or 230 1 30 ½" 22 ½" 69 7/8" 1" ½" ½" 450 lbs.

97 / 100 50 1725 ⅓ 115, 208 or 230 1 30 ½" 22 ½" 69 7/8" 1" ½" ½" 450 lbs.

104 150 / 161 100 1725 ½ 208, 230 or 460 3 30 ½" 22 ½" 69 7/8" 1" ½" ½" 450 lbs.

163 / 169 50 1725 ½ 208, 230 or 460 3 30 ½" 22 ½" 69 7/8" 1" ½" ½" 450 lbs.

105 328 / 344 50 1725 ¾ 208, 230 or 460 3 30 ½" 22 ½" 69 7/8" 1" ½" ½" 450 lbs.

106 305 / 337 100 1760 1 208, 230 or 460 3 30 ½" 22 ½" 69 7/8" 1" ½" ½" 450 lbs.

201 375 / 423 50 1140 ½ 208, 230 or 460 3 65 ½" 30 ½" 76 5/8" 1" 1" ½" 700 lbs.

202 340 / 408 100 1140 ¾ 208, 230 or 460 3 65 ½" 30 ½" 76 5/8" 1" 1" ½" 700 lbs.

203 757 / 875 50 1140 ¾ 208, 230 or 460 3 65 ½" 30 ½" 81 5/8" 1 ½" 1 ½" ¾" 700 lbs.

204 714 / 881 100 1165 1 ½ 208, 230 or 460 3 65 ½" 30 ½" 81 5/8" 1 ½" 1 ½" ¾" 700 lbs.

205 1095 / 1287 50 1165 1 ½ 208, 230 or 460 3 65 ½" 30 ½" 81 5/8" 1 ½" 1 ½" 1 ¼" 700 lbs.

206 1005 / 1277 100 1170 2 208, 230 or 460 3 65 ½" 30 ½" 81 5/8" 1 ½" 1 ½" 1" 700 lbs.

Pump set ratings are nominal at pressures shown with a maximum 10" Hg vacuum at pump inlet

Motor Power: 120, 208, or 230 VAC single phase or 208, 230, or 460 VAC 3 phase

Control Circuit Power: 120 VAC single phase step down transformer included when selected motor voltage is other than 120 VAC

Fluid: No. 2 or No. 4 Fuel oil is standard. Consult factory for other fuel types.

Pump: Bi-rotational, positive displacement type with cast iron housings and self-adjusting mechanical seals

Motors: Base mounted, TEFC construction Strainer: Simplex, ½", 1", 1½", or 2" (according to inlet line size) complete with 40 mesh basket

AUTOMATIC FUEL OIL TRANSFER PUMP SET

Specifications

Ordering Information

1. Specify the pump set catalog number as follows:

ATPSF - [101] - [120] - [50]

Size (see table) Voltage* 120 Pressure 50

* Pump Set sizes 101 through 103 are single phase only, sizes 104 through 206 are three phase only.

2. Supply a complete list of inputs and outputs intended to be hard-wired directly into the ATPSF controller including flow switches, leak detectors, and motor starters.

Optional Features Catalog Number Duplex strainer in lieu of two simplex strainers add “-D” suffix

Duplex strainer differential pressure switch add “-DP” suffix

Pump set leak detection switch add “-L” suffix

3. Supply a complete list of additional FSC controlled devices in the system (day tanks, filtration systems, offloading skids)

4. Provide a complete list of TG-EL-D4A tank gauges to be connected to the ATPSF system.

AUTOMATIC FUEL OIL TRANSFER PUMP SET

Application

ATPSF Pump Set Application The ATPSF pump set is typically at the heart of a complete fuel oil storage and handling system. The FSC controller that makes up the brain of the ATPSF pump set has enough inputs and outputs to control a typical boiler loop system, or a typical generator system up to three day tanks. In this single-node configuration, all the day tank and main tank instruments hard-wire back to the FSC controller in the pump set enclosure.

Larger fuel oil handling systems, or systems where the tanks and generators are spread out geographically, will benefit from a multi-node FSC-based control system. In this configuration, each of the major components of a fuel oil handling system (pump set, day tank, filtration system, etc.) will include it’s own FSC controller. Locally mounted-devices will hard-wire to the nearest FSC controller, and each of the FSC controllers will interconnect via a redundant digital communication system carried over a pair of three conductor shielded cables. This configuration can accommodate up to eighteen generator tanks, and greatly reduce the amount of field wiring and trouble-shooting.

Reduced Field Wiring As shown in the diagram below, using multiple, distributed FSC processors shortens the conduit and wire runs for the entire system. The NodeNetA and NodeNet B each consist of a single three conductor shielded cable.

ATPSF pump set in a multi-node configuration.

Reduced Programming Cost By breaking a large fuel oil system into many small parts, Preferred is able to re-use programs from our library to reduce programming hours and shorten lead times. In the example below, the FSC controllers for each trio of day tanks, and the FSC controller in the filtration system, would be loaded with pre-coded configurations. Only the pump set controller would require a custom program.

Lower Controller Hardware Costs Each FSC controller is a relatively small microprocessor, purchased in large quantities. Several FSC microprocessors cost much less than a programmable logic controller with equivalent I/O.

Easy to Interface Each FSC controller can have it’s own 4” color touchscreen local display. Through the NodeNet, each color touchscreen can access data from every FSC controller on the network and communicate that data via Ethernet or BacNet IP protocol to a Building Automation System (BAS). Pre-coded configurations mean Modbus address registers are pre-assigned.

Increased System Hardening The redundant NodeNet system linking all the FSC controllers runs two channels simultaneously. Loss of communication in one channel sounds an alarm, but communication continues on the other channel. The three conductor shielded cables for each NodeNet channel can be run in separate conduits for increased security.

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AUTOMATIC FUEL OIL TRANSFER PUMP SET

Application

Enhances System Reliability In a typical centralized PLC system, the entire system is down if the PLC goes down. With distributed control using a multi-node Preferred FSC system, loss of one FSC controller takes down just the components hard-wired to that controller.

Since all FSC controllers are identical, a spare FSC controller.

can be installed in a couple minutes using the quick disconnect terminals, and it’s program reloaded from an SD chip for minimum downtime. Meanwhile, the rest of the FSC controllers

This real world example illustrates the reduced wiring requirements of the multi-node Preferred FSC controller system. Instead of running multiple hard-wires between floors in a typical hospital, the FSC controllers can communicate via a pair of two conductor shielded cables run in one or two 1/2” conduits.

Boiler Room Node 2

Gen Room Bldg A Node 1

NetA

NetB

NetA

NetB

Transfer Pump Set Node 0

NetA

NetBMain Tank Filtration Node 4

NetANetB

Building Automation

SystemModbus RS-458 Ethernet IP Bacnet IP

Gen Room Bldg B Node 3 and hardware attached to them continues to run. Even in a critical day tank application, an operator will likely be able to replace a controller before the generator runs out of fuel in the day tank.

AUTOMATIC FUEL OIL TRANSFER PUMP SET

Suggested Specifications

1. Application Supply a self-contained, automatic fuel oil transfer and monitoring system to ensure a reliable supply of fuel oil to the emergency generators or boilers included in this project. The system shall include automatic pump set lead/ lag, storage tank and day tank level monitoring, leak monitoring, LCD operator display, manual back-up stations, time and date stamped alarm and event summary, and the system shall include the capability to simultaneously communicate to a Data Acquisition System (DAS), Building Automation System (BAS) or Building Management System (BMS) via Modbus protocol, and dial out to an alphanumeric pager system via field installable plug-in option modules in the future. The control system shall be microprocessor-based and can be expanded by adding additional FSC modules. The Automatic Fuel Oil Transfer Pump Set and monitoring system shall be Preferred Utilities Mfg. Corp. Danbury, CT Model ATPSF-____ rated at ___GPH of (No. 2), (No. 4), (Diesel) oil against a discharge pressure of ___PSIG.

2. Pump Set and Control Cabinet The pump set and control cabinet shall be completely pre-wired and tested to ensure job site reliability. The pump set and control cabinet shall be the product of one manufacturer for single source responsibility. Provide a factory assembled NEMA 4 steel enclosure with all operator interface control switches, indicators and displays physically separated from any field terminations.

3. Controller Hardware Each microprocessor controller shall include the following inputs and outputs:

(24) 120 VAC digital inputs

(5) 2 A relay outputs

(5) 1/2 HP (10 A) relay outputs

(8) loop-powered 4-20 mA analog inputs

(3) 4-20 mA analog outputs Each controller shall include two RS-485 NodeNet communication ports for communicating to the other controllers in the distributed control system. In addition, each controller shall include two RS-485 communication ports for connection to a color touchscreen or other external device.

4. Operating Displays The fuel system controller shall be equipped with a 4” color touchscreen Operating Interface Terminal (OIT) for pump set status, storage tank level indication, alarm listing, and trouble shooting functions. Provide dedicated pushbuttons for alarm silence and for the home page display and a “hand-off-automatic” control switch for each fuel pump. In “hand” position the pump shall be capable of manual operation in the event of a controller failure. The control system shall monitor the position of each “hand-off-automatic” control switch. Should a switch be put into the “off” position, the controller shall log the event with a time/ date stamp and store within the controller memory. Provide an Elapsed Time Recorder (ETR) to measure running time for each pump. Provide a fuel oil overview display (home page) capable of simultaneous viewing of pump set status, day tank status and main storage tank status. The fuel oil overview display shall include the following information:

a) Lead pump selection – auto/manual

b) Pump status – off/ run/ standby

c) Day tank status – normal/ high/ low/ leak

d) Main tank status – normal/ high/ low/ leak

e) Three most recent alarms

The touchscreen shall communicate to the controller via RS-485 Modbus protocol. The touchscreen shall be pre-programmed at the factory with graphic pages for operation, setup, trouble-shooting, and alarm indication. Each touchscreen shall be capable of displaying information from any of the controllers in the distributed control system.

The touchscreens can communicate to an external controller, building automation system, or energy management system via RS-485 Modbus, Ethernet TCP/IP, or BacNet IP protocol.

5. Reliability The controllers shall communicate using two NodeNet Communication Ports (A and B) that continuously communicate between all controllers wired in series (up to 10 controllers maximum). All of the information from all of the controllers will travel through all of the units. Upon start up NodeNet A will be the lead communication port with NodeNet B being the back up. In the event of a loss of communication NodeNet B will become the lead communication port. If one controller in the network fails, a common alarm will be activated and the other controllers will continue to function.

6. Alarm and event Logs The control system shall…