EMERGENCY GENERATOR SET

Transcription

1 PART 8.1: EMERGENCY GENERATOR SET PART 1 - GENERAL I SCOPE A. This specification covers the design, furnishing, installation and start up of a factory built, production tested, operable, liquid cooled electric generating set complete with a diesel sub base fuel tank, main control panel, circuit breaker, and all components and devices required for stand by services. B. The generators shall be furnished in weatherproof enclosures and shall be suitable for installation outdoors in Central Florida. C. The generator systems shall be furnished complete with all accessories and a diesel fuel tank mounted integrally within and beneath the weatherproof enclosure. The Manufacturer shall furnish and install all interconnection piping for the diesel fuel supply and return lines, so that the system shall be self reliant and completely operable. D. All foundations and anchor bolts will be provided by the Contractor in accordance with the manufacturer's specifications, loading and anchor bolt plan. II SUBMITTALS A. The contractor shall submit to the City for approval, shop drawings, as furnished by the engine generator set supplier, information showing manufacturer's model number, dimensions and weights for unit and major auxiliary equipment. Outline drawings and/or schematic drawings shall be submitted for approval for the following: 1. Generator set specifications sheet showing KW rating with and without radiator. 2. Engine generator set dimensions with entrance points for electrical and fuel connections. 3. Foundation plan showing spring isolator spacing and connections to steel subbase. 4. Flexible exhaust and silencer. 5. Battery charger, battery and rack. 6. Electrical schematics and interconnecting wiring diagrams showing extent of factory prewiring and details of control panels. 7. Schematic fuel diagram and details of fuel tank. 8. Horsepower curve of engine as published by engine manufacturer. 9. Equipment catalog cut sheets, outline dimensions of all equipment 10. Cross sectional drawings of all equipment with parts identification and materials specifications 11. Shop drawings including layout and dimensions for the generator enclosure and entrance steps and platform. 12. Generator exhaust insulation system. 13. Recommended spare parts with current pricing 14. Operation and maintenance manuals. 1

2 III WARRANTY A. Equipment furnished under this section shall be guaranteed against defective parts or workmanship under terms of the manufacturer and dealers standard warranty. In no event shall it be for a period of not less than two years from date of acceptance, with three years thereafter of Extended Service Coverage. Warranty to include full parts and labor during the first two-year period without cost to initial user. PART 2 - PRODUCTS I MANUFACTURER A. Engine generator set shall be as manufactured by Caterpillar, Kohler, or Generac. II MATERIAL AND WORKMANSHIP A. All materials, equipment and parts comprising the unit specified herein shall be of the latest commercial type and design. They shall be new and unused. The engine and all major items of auxiliary equipment shall be manufactured in the U.S.A. by manufacturers currently engaged in the production of such equipment. B. The units shall be factory assembled, tested by the engine manufacturer and shipped to the job site by an authorized dealer having parts and a service facility within a 50-mile radius of the job site. In addition, and in order not to penalize the Owner for unnecessary or prolonged period of time for service or repairs to the emergency system, the bidding generator set supplier shall carry engine replacement parts in his stock at all times. It is the intent of this specification that the generator and engine for the unit be furnished by a single manufacturer and that the generator be manufactured under the name of the manufacturers listed in this specification as acceptable. C. The equipment and material shall comply with the latest issue of the applicable standards and codes listed below. 1. Institute of Electrical and Electronics Engineers (IEEE) 2. National Electrical Safety Code (NESC) 3. National Electrical Manufacturers Association (NEMA) 4. National Electrical Code (NEC) 2

3 III GENERATOR EQUIPMENT A. The units shall have the following ratings: Standby Rated KW, KVA (Note generator shall be sized to operate all lift station pumps and controls with no more than a 20% voltage dip when the pumps are started sequentially) Power Factor: 0.8 Frequency: 60 Hz Phase: 3 Voltage: 277/480 V Maximum Speed: 1800 RPM Model: Caterpillar Kohler Generac Ambient Temperature: 110 F B. Diesel Engine: The diesel engine shall be water cooled inline or vee type two- or fourstroke cycle compression ignition. The engine is to have a maximum horsepower output as stated herein at 1800 RPM. This rating must be substantiated by manufacturers standard published curves. Special ratings or engines requiring special fuels will not be acceptable. The engine shall be equipped with the following minimum accessories: 1. Fuel, lube oil and air filters. 2. Lube oil cooler, water cooled. 3. Fuel priming, fuel, lube oil and water pumps. 4. Governor, isochronous, electronic. 5. Flexible fuel lines. 6. Flexible exhaust connector, stainless steel. 7. Instruments. a. Engine Oil Pressure b. Engine Oil Temperature c. Engine Coolant Temperature 8. Alarm lights and annunciator panel a. Overcrank light & alarm b. Overspeed light & alarm c. Low water temperature light & alarm d. Low oil pressure light & alarm e. High water temperature light & alarm f. Low engine coolant level light & alarm g. Alarm silence light & switch 9. Vernier throttle control 10. Structural steel subbase. Formed heavy gauge sheet steel to support unit as a base will not be acceptable. 11. Safety shutdown devices for high water temperature, low oil pressure, overcrank, electronic solid-state overspeed switch and low coolant level. 12. Jacket water heater: Resistive type, 240VAC, 1 ph to maintain 120 F jacket water temperature. C. Cooling System: An engine mounted radiator complete with a belt driven blower type fan, shall be furnished to maintain a safe operation in a 125 F ambient temperature. Air 3

4 flow restriction from the radiator shall not exceed 0.5" H 2 0. Furnish and fill the engine and radiator with a 25% by volume of anti-freeze solution. D. Exhaust System: Furnish a critical type silencer complete with companion flanges, bolts and gaskets. Arrangement shall be a side inlet and end outlet and the unit shall be mounted inside the enclosure. A stainless steel flexible exhaust connector complete with threaded connection at one end and a double companion flange on the other shall be installed between engine and silencer. Exhaust piping and the silencer located inside the enclosure shall be insulated with manufacturer s standard insulation. E. Generator: The generator shall be rated as noted with a temperature rise not to exceed NEMA standards. It shall be a three phase, 60 Hertz, single bearing rotating field, synchronous type. Voltage level adjustment shall be a minimum of 5%. Generator shall accept 100% of nameplate KW rating in one step, in compliance with NFPA 110, Para Other characteristics to be as follows: 1. Voltage regulation ½% from no load to full load 2. Volts per Hertz regulation 3. TIF less than Voltage level stability under steady state conditions of 1%. 5. Three phase sensing 6. Less than 4% wave form deviation 7. Coils braced for 150% over-speed 8. Tropicalization treatment-fungus resistant with epoxy treatment F. The generator shall have a generator starting and control panel in a metal NEMA 12 enclosure. This panel shall contain a main line molded case three pole circuit breaker with internal, dc shunt trip sized to generator output, mounted and cabled direct from the generator output. G. The breaker trip unit for each pole shall have elements providing inverse trip delay during overload and instantaneous magnetic tripping for short circuit protection. The circuit breaker shall meet standards established by Underwriters Laboratories, NEMA and NEC. H. Generator Control Panel and Engine Motor System: A generator panel shall be mounted on the unit with vibration isolators at its mounting. Panel shall contain, but not be limited to, the following equipment: 1. Voltmeter, LCD Readout, 0.5% accuracy. 2. Ammeter/Voltmeter phase selector switch. 3. Ammeter, LCD readout, 2% accuracy. 4. Frequency meter, 3½ gauge, 2% accuracy. 5. Tachometer - digital 6. Battery voltage meter - digital 7. Running time meter - digital 8. Alarm annunciator feature for indication of coolant temperature high and low temperature, low oil pressure, low fuel, fuel leak, not in auto, and battery low alarms. 9. Engine Oil Pressure - digital 10. Engine Oil Temperature - digital 11. Engine Coolant Temperature - digital 12. Panel illumination light and switch. 13. Voltage level rheostat. 4

5 14. Sets of dry contacts to indicate separate safety shutdown (generator trouble), low fuel, and generator running wired to terminal strip for remote alarm and indication. 15. Ready light in automatic position of selector switch. 16. Automatic start-stop controls to be signaled from a set of normally open set of contacts in the automatic transfer switch. Set shall automatically shutdown in the event of low oil pressure, high water temperature, over-speed, overcrank and low coolant level. An adjustable 1 to 60 second single crank control with lockout shall crank the electric start motor. 17. Fault light indicators for low oil pressure, high water temperature, over-speed, overcrank and low coolant level. Lights to have push-to-test light test without sounding any local or remote alarm. 18. Four position selector switch, "auto", "manual", "off/reset", and "stop". 19. Hinged front protective cover over instruments and switches with provision for padlock. 20. Instrument transformers. I. Batteries and Charger: A 24 volt lead acid battery set of the heavy duty diesel starting type shall be furnished and connected to the engine. A battery rack, necessary cables and clamp shall be included to comply with NFPA code. Battery charger shall be current limiting, automatic two rate, float at 2.17 volts per cell and equalize at 2.33 volts per cell. It shall have an ammeter and voltmeter, mounted in the generator weatherproof enclosure. Battery charger shall be as recommended by generator manufacturer. J. Vibration Isolators: The unit shall be mounted on a set of spring type vibration isolators as recommended by the generator set manufacturer. Isolators shall be welded to the base tank structural steel supports and shall have leveling screws to keep unit on a level plane. IV ENCLOSURE / FUEL TANK A. Enclosure: The enclosure shall be weatherproof and sound attenuated formed, sheet steel construction. The construction shall be of 14 gauge galvannealed steel for all component parts. The enclosure shall be reinforced with tube steel supports and a galvanized structural angle base. Maximum full load noise level at 25 feet shall be 78 dba. B. Doors: All doors on the enclosure shall be strategically located in areas as to allow ease of maintenance and allow good access to and visibility of instruments, controls, and etc. The doors shall be fitted with piano-type hinges and flush-mounted, adjustable, keylock latches. All hinges and latches shall be stainless steel. Provide gas struts to hold doors open. C. Pipe lube oil and cooling water drains to exterior of the enclosure. D. Air Flow: The enclosure shall be constructed to meet or exceed the generator set manufacturer s requirements for air flow. The intake air shall enter the enclosure through a fixed intake louver. The exhaust air shall be discharged through a gravity shutter. The intake openings shall be screened to prevent the entrance of birds. E. Roof: The roof of the enclosure shall be constructed and reinforced as to support the weight of the largest commercially available exhaust silencer recommended by the 5

6 generator set manufacturer, and the weight of 2 maintenance workers. manufacturer of the enclosure shall provide silencer mounting brackets. The F. Finish: Upon final assembly, the enclosure shall polyester powder coated. G. Sub-base double wall tank shall be two pieces; the inner tank, and the double wall base. The inner tank shall be made of 10 ga. steel, with 10 ga. baffles spaced every 20 inches for added support and rigidity. The tank shall be completely welded, and pressure tested at 5-7 pig for a minimum of 60 minutes. H. The double wall base shall be made of structural steel main rails and 12 ga. top and bottom. There shall also be channels below the double wall bottom to separate it from the concrete mounting pad. The double wall base shall support all the weight of a generator as well as providing a rupture basin. The weight and vibration carrying part of the base shall not be mechanically connected to the inner tank. The inner tank and the double wall top are welded together around the tank fittings only, to provide a completely sealed rupture basin. I. The tank shall come with the following fittings; fill, engine supply, engine return, inner tank drain, rupture basin drain, separated by a baffle, to provide a completely sealed rupture basin. Fuel tank shall be designed to provide a minimum of 48 hours of run time under 75% of generator s rated load. J. Sub-base fuel tank shall comply with NFPA Standards 30 and 37 and UL Standard 142. PART 3 - EXECUTION I TESTS A. The intent of this specification is to provide equipment of proven reliability and compatibility. Two separate tests shall be performed; factory production tests and field tests. 1. Factory Production Tests: Before shipment of the equipment, all components shall be tested under rated load and power factor for performance and proper functioning of control and interface. These tests shall be performed to the name plate power factor rating with a reactive load bank. 2. Field Test After Installation. The complete installation shall be initially started and checked for operational compliance by a factory representative. 3. Upon completion of initial start-up and system check out, the supplier of the Emergency Generator set shall perform a field test to demonstrate load carrying capability, stability, voltage, and frequency. 4. The equipment shall be tested to show it is free of defects and will start automatically and shall be subjected to full load test by using portable load banks provided by generator set supplier. Load bank shall be capable of definite and precise incremental loading and shall not be dependent on generator control instrumentation to read amperage and voltage of each phase. Test instrumentation shall serve as a check of generator set meters. Salt water brine tanks are not acceptable. Under no circumstances shall job site load be utilized for this test. Load bank testing shall be done in the presence of the Owner's Representative after unit is permanently installed in accordance with the drawings and specifications. Testing shall be for a minimum of four hours under full load. 6

7 5. Prior to acceptance, any defects which became evident during this test shall be corrected at no additional expense to the Owner. II START-UP AND INSTRUCTIONS A. On completion of the installation the initial start up shall be performed by a factory trained service representative of the engine supplier. At the time of start-up, operating instructions and maintenance procedures shall be thoroughly explained to Owner's operating personnel. Six (6) copies of operating and maintenance instruction books shall be provided and submitted to the City. B. Service representative shall demonstrate and test the ability of the engine controls to automatically shut-off the engine for hot water temperature, low oil pressure, over-speed, over-crank and low coolant level. The service representative shall be provided for a minimum of one 8-hour day for start-up and training purposes. III MISCELLANEOUS A. The Contractor shall provide all piping, valves, fittings, conduits, wiring, pumps, switches, panels, controls, enclosure, integral fuel tank and incidentals required for a complete operable system. B. It is preferred that an electrical engineer provide signed and sealed calculations for the generator sizing. As an alternate, the engineer may use the following sizes: Pump Size (hp) Generator Rating Fuel Tank Size Voltage/Phase kw (Standby) (gals.) <3 hp V/ 1 or hp V/3 5.1 to 10 hp V/ to15 hp V/ to 25 hp V/ to 30 hp V/ to 50 hp V/3 7

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