SECTION 16620 STATIONARY STANDBY POWER GENERATOR AND LOADBANK

This spec was part of the Des Plaines, IL River WRF project that bid Feb 26, 2015.


SECTION 16620 STATIONARY STANDBY POWER GENERATOR AND LOADBANK



PART 1 GENERAL

1.1 RELATED REQUIREMENTS

A. Applicable provisions of Division 0 and Division 1 shall govern work in this Section.

1.2 DESCRIPTION

A. Where indicated on the plans, provide a diesel powered, standby, electrical power generator.  Installation shall include generator fuel tank, custom enclosure, load bank, piping, and all accessories pre-wired.

1.3 QUALITY ASSURANCE

A. Equipment and installation shall conform to the requirements of the following agencies:
1. U.S. Environmental Protection Agency (EPA):  Shall meet EPA emissions standards.  Design Criteria of Mechanical, Electrical, and Fluid System and Component Reliability.
2. National Fire Protection Association (NFPA)
3. NFPA-70 - National Electrical Code (NEC), and Illinois amendments thereto.
4. NFPA - 76A Essential Electrical Systems for Health Care Facilities.
5. NFPA-101 Life Safety Code.
6. Underwriter's Laboratories (UL).  Electrical Construction Material List.
7. U.L. Listed to Standard #2200.
8. Local Codes and Ordinances
9. American National Standards Institute ANSI Y32.2.
10. Institute of Electronic and Electrical Engineers (IEEE).
11. National Electrical Manufacturers Association (NEMA).
12. State of Illinois Fire Marshall Requirements.

B. The following production tests shall be completed on the engine/generator assembly.
1. Mechanical operation test.
2. Ground tests.
3. Control wiring tests.
4. Operation test.

C. Engine/generator set shall be product of a manufacturer who shall warranty the complete engine/generator package including all accessories as described.

1.4 SUBMITTALS

A. Shop drawing submittal shall include the following documents as a minimum.

B. Manufacturer's cut sheets of all system equipment.  Information included on cut sheets shall be sufficient to determine compliance with these specifications.
1. Dimensional drawings of all system equipment.  As a minimum, drawings shall show all critical dimensions and shall show all field connection points. Drawings shall be project-specific. Accessories not being offered for this project shall not be shown on the drawings furnished.

C. Single line diagram in accordance with ANSI Y32.2 indicating connections and controls.

D. A complete MODBUS map of all available generator controller output information along with the necessary information to obtain the generator monitoring data.

E. Submit test reports including:
1. Certified test reports of prototype, production, and field tests.
2. Submit to the owner, manufacturer's instructions for start-up, performing cleaning, operating, and maintaining standby power systems.

F. Submit operation and maintenance manuals under provisions of Section 01730.

G. Submit certificates of proper installation and operator training (by manufacturer’s representative) under provisions of Section 01445.


PART 2 PRODUCTS

2.1 ACCEPTABLE MANUFACTURERS

A. Kohler Co. (for factory-assembled generator set, the generator enclosure, and sub-base fuel tank), or approved equal.

B. AVTRON (for load bank), or approved equal.

2.2 ENGINE/GENERATOR RATINGS

A. Rate standby engine/generator set at not less than 1500 kw, standby duty at 0.8 pf, 480V, 3 ph, 4 wire, 60 Hz. Base rating on operation when equipped with operating accessories at 1000 ft elevation.

B. Regulator system filtered to be compatible with and capable of regulating generator output to permit starting of and running of the loads as shown on the drawings, simultaneously with a maximum of 20% voltage dip at locked rotor current with return to steady state in less than 2 sec.  Steady state is defined as operation with terminal voltage remaining constant within ??½ of 1% of rated voltage.

C. Air emission: Generator set shall meet EPA and Illinois EPA emissions standards.

D. Diesel generator, with weather-proof, sound-attenuated enclosure shall not emit noise in excess of 79 dB(A) free-field, running at full load, measured at 7 meters distance. Provide LEVEL 2 enclosure, min.

E. Protection against freeze. Generator assembly, with enclosure, shall include engine block and space heaters to prevent freeze-up when the ambient/outdoor temperature is -15 degrees F, with a 20 mph wind. Generator assembly shall include a low temperature switch for exclusive use by the Owner’s SCADA system.

F. Integral enclosure ventilation. The enclosed generator assembly shall include a complete ventilation system suitable for operation when ambient temperature is 100 degrees F. System shall include inlet and outlet dampers.

2.3 ENGINE CONSTRUCTION AND RATINGS

A. Engine speed of 1,800 rpm.

B. Water cooled with unit mounted radiator.

C. Inline four stroke cycle compression ignition diesel.

D. Heavy duty industrial type.

E. No. 2D diesel fuel.

F. 24 v dc positive engagement, automatic starting motor(s).

2.4 ACCESSORY EQUIPMENT TO BE INCLUDED:

A. Digital governor to maintain frequency regulation not to exceed 1% from no load to full rated load @ 60Hz.

B. Lubrication break-in oil.

C. Electric fuel solenoid shut-off valve with standard fuel filter on engine.

D. Oil drain extension through side of skid base.

E. Heavy duty air cleaner.

F. Lube oil filter with replaceable elements.

G. Overspeed cut-out.

H. Low oil pressure cut-out.

I. High coolant temperature cut-out.

J. Complete pre-piped exhaust system with enclosed critical silencer.

K. Engine coolant heater(s).

L. Integral double-wall sub-base fuel tank sized for 30 hour (min) operation at 75% of rated load. Fuel tank shall include stainless-steel fuel lines (rubber fuel lines not acceptable).

M. Welded steel skid type base securely mounted with anchored mounting bolts and with integral spring vibration isolators. The proper quantity and size of spring isolators shall be provided to assure that the isolators are not totally compressed during operation.

N. Weatherproof, sound-attenuating aluminum enclosure with hinged, gasketed, and padlockable access panels. The weatherproof enclosure shall be designed and configured to prevent the entry of rodents.

O. Elevated aluminum access and working platform along perimeter with stairs and railings along both sides of the generator (to allow generator servicing) shall meet all applicable OSHA accessibility and safety standards.

P. Enclosure heaters with thermostat.

Q. Interior lights with switches

R. Two interior GFI duplex receptacles (convenience outlets).

S. Motorized, galvanized enclosure inlet dampers.

T. Gravity aluminum outlet discharge dampers.

U. 120/208V three-phase power distribution system. The generator assembly shall include a 480V-120/208V step-down dry-type transformer and 120/208V distribution panelboard complete with branch circuit breakers. This system shall be furnished pre-wired to all generator system accessories including, but not limited to: inlet dampers battery chargers, block heaters, space heaters, interior lighting fixtures, convenience outlets, load-bank fans, and misc. sensors/instruments.

V. Load Bank: Diesel generator shall include a separate (pad-mounted) 750 kW, 480V, 3- phase, 3-wire forced-air cooled load bank. Unit shall be UL listed and shall conform to NEMA, NEC, and ANSI standards. Unit’s enclosure shall be heavy gauge aluminized steel per ASTM A463. The overall assembly shall be NEMA 3R rated (minimum). The assembly shall offer 25%, 50%, 75%, and 100% load steps. Wiring shall be UL 508A listed. Load bank shall include TEFC or TEAO motors, pre-wired; and a NEMA 4 control panel that is unit-mounted and pre-wired. Power wiring for the control panel shall be provided from the generators 120/208V distribution panel. All power and control wiring between the generator and load bank shall be furnished by the Contractor. Provide AVTRON model K875A resistive load bank.

2.5 ENGINE COOLING EQUIPMENT

A. Unit Mounted Radiator

B. Pusher type fan.

C. Duct flange.

D. Sized for 50% ethylene-glycol solution at 40?C. ambient and 1,000 ft elevation.

E. Ethylene-glycol antifreeze with rust inhibitor to -40?C.

2.6 GENERATOR CONSTRUCTION

A. 3-ph, 60 Hz.

B. Single bearing.

C. 12 lead reconnectable.

D. Drip-proof construction.

E. Radio suppression.

F. Class H Insulated.

G. Permanent Magnet Generator (PMG); brushless, direct-connected type exciter with shaft mounted diodes to eliminate field flashing.

H. Digital 3-phase sensing voltage regulator to provide 1% voltage regulation from no load to full load.

I. Application of one-step load of 50% of rated load shall not result in voltage dip of more than 5% with recovery to within ??½ of 1% in less than 2 sec.

J. Regulator shall be filtered to eliminate the effect of SCR loads on the regulator.

K. Grounding provisions - the generator assembly shall include grounding provisions: Generator shall be furnished with grounding pads on each side (2 per side) for connection to the access platform (see 38-SE-1), and a larger ground pad for connection to a grounding electrode conductor going to a trio of ground rods (see 20-E-1).

2.7 ENGINE/GENERATOR CONTROLLER

A. NEMA Type 1 enclosure, vibration isolated in generator enclosure.

B. Plug-in design circuitry for quick replacement.

C. Fused DC circuits.

D. Complete 2-wire start/stop control to operate on activation of remote contact from automatic transfer switch.

E. Design starting system for restarting in event of false engine start by permitting engine to completely stop and then re-engage starter.

F. Overcranking protection designed to open cranking circuit after 60-sec (adjustable) if engine fails to start.

G. Circuitry to shut down engine when signals for high coolant temperature, low oil pressure, overcrank or overspeed are received, with reset button.

H. 5 minute time delay on engine shutdown after retransfer to normal to allow unloaded running cool down.

I. Three position automatic/off/test selector switch.

J. Emergency stop switch.

K. Indicating lights to signal
1. Selector switch OFF - Red (flashing).
2. Overcrank - red.
3. High coolant temperature - red.
4. Overspeed - red.
5. Low oil pressure - red.

L. Test button for indicating lights.

M. Voltmeter

N. Ammeter

O. Voltmeter-ammeter phase selector switch.

P. Frequency meter.

Q. Panel illumination lights with on/off switch.

R. Battery charging ammeter (s): one on each battery charger.

S. Oil pressure gauge.

T. Coolant temperature gauge.

U. Running time meter.

V. Plug-in voltage regulator with voltage adjusting rheostat.

W. Unpowered normally open auxiliary interlock contacts wired to terminal block.

X. Generator failure signal to remote location.

Y. Generator run signal to remote location.

Z. Controller shall provide all output signals shown on P&ID.

AA. Electronic adjustable trip, resettable type, 3 pole, 600V, in NEMA 1 enclosure, unit mounted.  Circuit breaker shall be 2,500 amperes, 100%-rated UL or CSA listed for use as service equipment. Circuit breaker shall include (1) dry Form-C contact.

BB. Common failure relay, dry, Form C (to provide summary of any alarm conditions). CC. RUN relay; dry, Form-C.
2.8 STARTING BATTERIES

A. Quantity and voltage as required by MFR.

B. Ampere-hour rating as required by factory

C. Internally-mounted.

2.9 AUTOMATIC BATTERY CHARGER(S)

A. Automatic battery charger (s) shall have a phase controlled rectifier to provide continuous taper charging.

B. Maintain constant voltage output with ac line fluctuations of ??10%.

C. Two ranges, float at 2.17 v dc and equalize at 2.33 v dc.

D. Automatic ac line compensation.

E. Automatic overload protection current limiting.

F. SCR design.

G. Automatic surge suppressors.

H. DC ammeter and voltmeter.

I. Fused AC input and DC output.

J. 10 amp DC output minimum, sufficient to recharge the batteries within 8 hours.

K. Internally-mounted.

2.10 EXHAUST EQUIPMENT

A. Provide enclosed Critical-Grade exhaust silencer.

B. Provide with drain plug at bottom of muffler opposite of exhaust outlet.

C. Exhaust Piping. Stainless steel shall include condensate drip pocket and drain valve.

D. Stainless-steel through-roof exhaust thimble and rein cap.

2.11 TANK MONITORING EQUIPMENT

A. Tank shall include one 4-20mA level sensing device for remote monitoring.

B. Tank shall also include three sets of Form-C contacts: One set to indicate 50% low fuel level, one set to indicate 25% critical low fuel level, and a third set to indicate a high over-fill level.

C. Equipment shall monitor the interstitial space of the double wall storage tank. Equipment will detect the presence of liquid (water or diesel fuel and the presence of hydrocarbons from diesel fuel. Tank shall provide dry Form-C contacts and an audible alarm when liquid is detected in the rupture basin.

D. Refer to P&ID for all tank output signals.


PART 3 EXECUTION

3.1 INSPECTION

A. Verify that mounting area is level and free of irregularities.

B. Start work only after unsatisfactory conditions are corrected.

3.2 INSTALLATION

A. Engine - Generator
1. Install engine/generator in accordance with manufacturer's written instructions and NEC.
2. Lubrication and break-in oil to be supplied and installed by supplier's or manufacturer's technician at time of start-up.
3. Anti-freeze with rust inhibitor (set to -40?C.) to be supplied and installed by supplier's or manufacturer's technician at time of startup.

B. Required grounding as a separately-derived source: Provide a neutral-to-ground link, in accordance with NFPA and NEMA, so that the generator frame/chassis is common with the alternator’s neutral and the grounding electrode conductor (see also 20-E-1).

C. For diesel-powered generators for installation in Illinois, notify the Fire Marshall two weeks in advance of the initial fuel tank fill.  Contact (312) 814-2693 to request application form.  Form is also available on their website: www.state.il.us/osfm/FirePrevention/Applications.htm

3.3 FIELD TESTS PRIOR TO START UP

A. Megger check of phase-to-phase and phase-to-ground insulation levels.  Do not megger check solid state equipment.

B. Ground continuity.

C. Short circuit.

D. Perform additional tests according to engine/generator manufacturer's instruction.

E. Submit generator startup testing procedures.

3.4 CLEANING/TOUCH-UP

A. Touch up scratches or marred surfaces to match original finish.

3.5 SUPPLIER'S OR MANUFACTURER'S SERVICES

A. Retain services of engine/generator set manufacturer's factory trained technician employed by engine/generator set manufacturer or his authorized distributor to perform following services:
1. Installation Services.
2. Visit project site to review installation requirements with Contractors involved. Visit shall be made prior to permanently installing equipment and/or making mechanical or electrical connections.
3. Visit site and meet with all concerned Contractor s to ensure installation is properly coordinated.  Electrical Contractor to coordinate meeting to ensure presence of all parties concerned.
4. Testing Services.
5. In addition to normal factory tests, provide a 3-phase portable load bank at project site. Load bank test shall occur after equipment has been permanently installed and shall be performed in the presence of Engineer:
6. Connect engine/generator set to the load bank and conduct a 2-hr test
7. During two-hour test, vary load on generator from 10% to 100% to determine that voltage, frequency, capacity, fuel, combustion air, cooling, and ventilation systems are adequate.  Step load during test as follows.
a. 10% load for 15 min.
b. 25% load for 15 min.
c. 50% load for 15 min.
d. 75% load for 15 min.
e. 100% load for 1 hr.
8. Apply each increment of load in one step.
9. During the test the following performance criteria shall be met.
10. Maximum voltage dip of 20%.

11. Recovery of less than 2 sec to maintain voltage and frequency as specified.
12. Submit release signed by supplier and Contractor to Owner and Engineer with deficiencies noted, if any, along with proposed solutions.
13. Include a minimum of three simulated power failures in the presence of transfer switch manufacturer's start-up representative.
14. Test remotely connected engine/generator status indication signals.
15. Test transfer switch.
16. Instructional Services. Provide a comprehensive demonstration to Owner or maintenance personnel and Engineer of system maintenance and operation after load bank test and after engine/generator set is electrically connected to automatic transfer switch.

3.6 PRODUCT DELIVERY, STORAGE, AND HANDLING

A. Lift engine/generator using eyes, yokes and skids provided by manufacturer.

B. Protect from work of other trades.



END OF SECTION