SPECIAL SPECIFICATION 8334 Packaged Engine Generator

Transcription

1 2004 Specifications CSJ SPECIAL SPECIFICATION 8334 Packaged Engine Generator 1. Description. Furnish and install packaged engine-generator of the types and ratings shown on the plans. Where indicated on the Plans, ensure the equipment is suitable for installation in an outdoor environment. Include all accessories and appurtenances as indicated, or as required for proper equipment operation in intended environment. Definitions A. Packaged Engine-Generator: An electrical generator and its prime mover, typically a piston engine (fueled by liquid propane, natural gas or diesel oil) or turbine (fueled by liquid propane or natural gas), designed to operate together as a single piece of equipment and mounted on a common base structure to maintain alignment between prime mover and generator. 2. Materials. Each packaged engine-generator will be factory assembled from water-cooled, four cycle, diesel oil fueled internal combustion engine with compression ignition and threephase, four-pole, six-lead brushless synchronous generator with brushless exciter. Assembly shall conform to requirements of National Electrical Manufacturers Association (NEMA) standards 250 and MG 1, National Fire Protection Association (NFPA) standards 30, 70 and 110. The generator set package will be factory assembled and prototype tested. Evidence of prototype testing will be supplied upon request. As a minimum, the generator set supplier will manufacturer the diesel engine used in the package. Ensure that each packaged engine-generator is suitable for the installed environment. Engines will have critical-grade silencers as required by parameters of the installed environment. A. Packaged engine-generators indicated or designated for outdoor use will have weathertight enclosures. B. Packaged engine-generators indicated or designated for outdoor use in sound-sensitive environments will have weather-tight, sound-attenuating enclosures. The sound attenuation requirements will be defined by environment parameters. C. Ensure that all terminal lugs and circuit breaker terminals, size 1/0 AWG and larger are rated for aluminum conductors. Ensure conductors are properly terminated per National Electrical Code and manufacturer s requirements 3. Construction. Packaged engine-generators will have electrical ratings and configurations as indicated on the plans

2 A. Engine: Liquid-cooled, four-stroke turbo-charged and aftercooled internal combustion engine with compression ignition and pressurized lubrication system with engine-driven lube oil pumps and dual oil filters. Converted automobile engine will not be acceptable. 1) Rating: Sufficient to operate continuously as standby power source at rated load capacity at specified elevation and ambient temperature limits with all accessories attached and functioning properly. 2) Fuel system: Suitable for use with No. 2 diesel fuel. Accessories include: a. Dual Fuel filters, located in accessible position on engine block, ahead of injection pumps. Injection pump or injection valve will not include screens or filters requiring cleaning or replacement. b. Fuel transfer pump. c. Fuel priming pump. 3) Air intake: Provide separate intake, with filter, for each cylinder bank 4) Engine speed: Not more than 1800 crankshaft revolutions per minute. 5) Starting system: 24 volt DC starting system with positive engagement; starting motor quantity and voltage in accordance with manufacturer s requirements. Provide remote starting circuit, with MANUAL OFF AUTO selector switch on engine-generator control panel. Provide combination remote start/stop and status indication stations where indicated on the Plans. 6) Jacket heater: Thermal circulation-type water heater with integral, manually adjustable thermostatic control, sized to maintain engine jacket water at 90 ºF. Heater elements will be compatible with accessory supply voltage. 7) Engine cooling system: Air-cooled radiator, mounted vertically on engine skid, with engine-driven, blower-type fan and coolant pump sized to maintain safe engine temperatures in ambient air temperature of 110 ºF, using 50/50 mixture of water and ethylene glycol. 8) Engine governor: Isochronous type to maintain engine speed within 0.5 percent, steady state, no load to full load. Equip governor with means for manual operation and adjustment. Maintain frequency regulation within 0.25 percent for any steady-state condition. 9) Protective devices: Provide shutdown devices for the following conditions: a. Engine-overspeed. b. Low oil pressure. c. High water temperature. 10) Mounting: Mount on structural base assembly, using suitable spring-type vibration isolators. B. Generator: 1) The alternator will be a 4-pole revolving field type, wired for 277/480 VAC, three phase, four wire, 60 Hz rated for a minimum of 2000 kw for standby duty up, 105C temperature rise in a 44C ambient, with an instantaneous motor starting capability of 2,907 SKVA at 20% voltage dip per NEMA MG-1. Sustained voltage dip data is not acceptable. Unit will have a brushless, Permanent Magnet exciter. The stator will be form wound and direct connected to the engine to insure permanent alignment

3 2) The generator insulation will meet Class H requirements. All leads must be extended into an AC connection panel. The alternator will be protected by internal thermal overload protection and an automatic reset field circuit breaker. 3) One step load acceptance will be 100% of engine-generator set nameplate rating and meet the requirements of NFPA 110 paragraph The generator set will be capable of sustaining 300% of rated current for 10 seconds. 4) The digital voltage regulator will be microprocessor based with fully programmable operating and protection characteristics. The regulator will maintain generator output voltage within +/- 0.25% for any constant load between no load and full load. The regulator will be capable of sensing true RMS in three phases of alternator output voltage, or operating in single phase sensing mode. The voltage regulator will include a VAR/Pf control feature as standard. The regulator will provide an adjustable dual slope regulation characteristic in order to optimize voltage and frequency response for site conditions. 5) The voltage regulator will communicate with the Generator Control Panel via a J1939 communication network with generator voltage adjustments made via the controller keypad. Additionally, the controller will allow system parameter setup and monitoring, and provide fault alarm and shutdown information through the controller. A PC-based user interface will be available to allow viewing and modifying operating parameters in a windows compatible environment. 6) Provide a unit mounted circuit breaker and terminal box, 3200 amp, 3 pole, 100% rated, with LSIG trip functions (ground fault alarm indication only), auxiliary contacts and 24 VDC shunt trip. Bus bar connections for phases and neutral connection with Nema 2-hole pattern will be provided for compression lug terminations (contractor furnished lugs). C. Controls: 1) Provide a fully solid-state, microprocessor based, generator set control panel. The control panel will be designed and built by the engine manufacturer. The control will provide all operating, monitoring, and control functions for the generator set. The control panel will provide real time digital communications to all engine and regulator controls via SAE J ) The generator set control will be tested and certified to the following environmental conditions: a. 40 C to +70 C Operating Range b. 95% humidity non-condensing, 30 C to 60 C c. IP22 protection d. 5% salt spray, 48 hours, +38 C, 36.8V system voltage e. Sinusoidal vibration 4.3G's RMS, Hz f. Electromagnetic Capability (89/336/EEC, 91/368/EEC, 93/44/EEC, 93/68/EEC, BS EN , ) g. Shock: withstand 15G 3) The following functionality will be integral to the control panel. a. The control will include a minimum 64 x 240 pixel, 28mm x 100mm, white backlight graphical display with text based alarm/event descriptions

4 b. The control will include a minimum of 3-line data display c. Audible horn for alarm and shutdown with horn silence switch d. Standard ISO labeling e. Multiple language capability f. Remote start/stop control g. Local run/off/auto control integral to system microprocessor h. Cool-down timer i. Speed adjust j. Lamp test k. Push button emergency stop button l. Voltage adjust m. Voltage regulator V/Hz slope - adjustable n. Password protected system programming 4) The controls will provide the following digital readouts for the engine and generator. All readings will be indicated in either metric or English units a. Engine 1. Engine oil pressure 2. Engine oil temperature 3. Engine coolant temperature 4. Engine RPM 5. Battery volts 6. Engine hours 7. Engine crank attempt counter 8. Engine successful start counter 9. Service maintenance interval 10. Real time clock b. Generator 1. Generator AC volts (Line to Line, Line to Neutral and Average) 2. Generator AC current (Avg and Per Phase) 3. Generator AC Frequency 4. Generator kw (Total and Per Phase) 5. Generator kva (Total and Per Phase) 6. Generator kvar (Total and Per Phase) 7. Power Factor (Avg and Per Phase) 8. Total kw-hr 9. Total kvar-hr 10. % kw 11. % kva 12. % kvar c. Voltage Regulation 1. Excitation voltage 2. Excitation current

5 5) The control will monitor and provide alarm indication and subsequent shutdown for the following conditions. All alarms and shutdowns are accompanied by a time, date, and engine hour stamp that are stored by the control panel for first and last occurrence: a. Engine Alarm/Shutdown 1. Low oil pressure alarm/shutdown 2. High coolant temperature alarm/shutdown 3. Loss of coolant shutdown 4. Overspeed shutdown 5. Overcrank shutdown 6. Emergency stop depressed shutdown 7. Low coolant temperature alarm 8. Low battery voltage alarm 9. High battery voltage alarm 10. Control switch not in auto position alarm 11. Battery charger failure alarm b. Generator Alarm/Shutdown 1. Generator over voltage 2. Generator under voltage 3. Generator over frequency 4. Generator under frequency 5. Generator reverse power 6. Generator overcurrent c. Voltage Regulator Alarm/Shutdown 1. Loss of excitation alarm/shutdown 2. Instantaneous over excitation alarm/shutdown 3. Time over excitation alarm/shutdown 4. Rotating diode failure 5. Loss of sensing 6. Loss of PMG 6) The Controller will include the ability to accept eighteen (18) programmable digital input signals. The signals may be programmed for either high or low activation using programmable Normally Open or Normally Closed contacts. 7) The control will include the ability to operate fourteen (14) programmable relay output signals, integral to the controller. The output relays will be rated for 30VDC and consist of six (6) Form A (Normally Open) contacts and two (10) Form C (Normally Open & Normally Closed) contacts. 8) The control will include the ability to operate two (2) discrete outputs, integral to the controller, which are capable of sinking up to 300mA

6 9) All engine, voltage regulator, control panel and accessory units will be accessible through a single electronic service tool. The following maintenance functionality will be integral to the generator set controls: a. Engine running hours display b. Service maintenance interval (running hours or calendar days) c. Engine crank attempt counter d. Engine successful starts counter e. 20 events are stored in control panel memory f. Programmable cycle timer that starts and runs the generator for a predetermined time. The timer will use 14 user-programmable sequences that are repeated in a 7-day cycle. Each sequence will have the following programmable set points: 1. Day of week 2. Time of day to start 3. Duration of cycle 10) The control will include Modbus RTU communications as standard via RS-485 half duplex with configurable baud rates from 2.4k to 57.6k. 11) The controls will include a fiber optic communications port to allow connection to the facility management system. 12) Provide a local, control panel mounted, annunciator to meet the requirements of NFPA 110, Level 1. a. Annunciators will be networked directly to the generator set control b. Local Annunciator will include a lamp test pushbutton, alarm horn and alarm acknowledge pushbutton c. Provide the following individual light indications for protection and diagnostics 1. Over-crank 2. Low coolant temperature 3. High coolant temperature warning 4. High coolant temperature shutdown 5. Low oil pressure warning 6. Low oil pressure shutdown 7. Over-speed 8. Low coolant level 9. EPS supplying load 10. Control switch not in auto 11. High battery voltage 12. Low battery voltage 13. Battery charger AC failure 14. Emergency stop 15. Spare 16. Spare D. Fuel System: 1) The complete generator package and sound attenuated enclosure will be mounted on a structural steel base that incorporates an integral protected double wall fuel

7 storage tank. The base will be designed with adequate provisions to lift and transport the complete package to the jobsite. 2) The generator sub-base tank will be listed and labeled as UL2085 special purpose, protected secondary containment generator base tank. The fuel tank will be sized for 24 hours operation of the standby generator at 100% load. 3) The primary tank will be fabricated from minimum 3/16 steel and designed, tested and labeled per UL requirements. Lift lugs will be approved by UL with a 4 to 1 safety factor. The primary fuel tank and secondary tank will be tested as outlined by UL ) The tank will be clearly labeled with the label indicating the type of product, the volume capacity and the manufacturer. 5) Updraft and emergency venting systems will be provided by tank manufacturer. All vents will extend a minimum of 12 feet above grade. 6) The tank is intended for stationary installation and in accordance with NFPA 37, NFPA 110 and Uniform Fire Code. The tank will comply with the local City of Dallas requirements for fuel storage. 7) Prior to fill, the genset manufacturer will perform a field pressure test of the fuel tank as required and witnessed by the Dallas Fire Prevention Department. 8) The following accessories will be installed in the tank: E. Enclosure: a. Leak sensor switch installed in interstitial space and wired to generator I/O module. b. Low level switch set to alarm at 30% of tank capacity and wired to generator I/O module. c. High level switch set to alarm at 90% of tank capacity and wired to generator I/O module. d. External spill containment fill, 7.5 gallon capacity, affixed to the top of the tank. Provide a handle pull drain to allow spilled fuel to return to the tank. e. Mechanical fill limiter with tight fill adapter and high level alarm indication set to stop the flow of fuel at 95% of tank capacity. f. Mechanical level gauge. g. Engine supply pick-up tube and return connections with suction drop tube. h. Electrical stub-up, rectangular type, located directly beneath the generator power terminations. 1) Provide a sound attenuated walk-in type weatherproof enclosure with a resulting sound level not to exceed 85 3 feet when measured 5 feet above grade and operating at full load. Enclosure will be constructed of formed galvanized sheet metal panels. The enclosure will be sized to adequately house the generator set, load bank and all accessories. Enclosure will be designed for a minimum wind load rating of 100 mph. 2) Walls and roof will be constructed of minimum 14 gauge galvanized sheet metal. The roof will be adequately braced to support the exhaust silencers and other roof mounted components. Provide acoustic insulation and a perforated galvanized liner in the walls and roof as needed to achieve the sound level specified

8 Enclosure will be equipped with 4 point lifting means to remove the enclosure from the base. 3) Provide a structural base with full steel floor engineered to support the generator, enclosure and all related accessories. All conduits will enter through an electrical stub-up located directly under the generator terminal box. Provide four point lifting lugs suitable for lifting the entire package. 4) Provide two entrance doors on each side for access to the generator and one door for access to the load bank connections and control panel. Doors will be strategically located to provide easy access and serviceability. One door will be located directly in front of the generator terminal box. Door latches will be refrigerator type. Door hinges and hardware will be stainless steel. Provide steel stairs, with landing, at all entry doors with sills more than 12 inches above grade. 5) Intake air will enter the enclosure through an acoustic baffle section or hood located in the rear wall of the enclosure and will include bird screen. Air intake will be 1250 feet per minute of less to minimize water intrusion. The radiator discharge air will pass through an acoustic baffle section and vertical discharge plenum section, which incorporates a gravity damper and bird screen. Intake louvers will be fixed open galvanized construction. The air handling system will be engineered and constructed so as not to exceed a total of 0.50 inches of water gauge static pressure drop with minimal water intrusion. 6) Provide a complete pre-fabricated exhaust system for external mounting of the silencer, including stainless steel flex connector, silencer, elbow, rain cap, rain shield and silencer mounting brackets. 7) Provide a 100 amp load panel board, 208Y120 VAC or 120/240 VAC, 1 phase with breakers for all auxiliary devices, including battery charger, jacket water heater, generator space heater, lighting and receptacles. Mount the load center on a back plate inside the enclosure with proper code clearance per NEC and wire out all devices in EMT conduit with compression fittings or seal-tight fittings. Provide a minimum four 48-inch fluorescent lights with two 3-way light switches and two duplex GFI receptacles. 8) Provide four (4) 24 VDC lights powered from the engine cranking batteries with spring wound 1 hour timer. 9) Enclosure will be as manufactured by Industrial Noise Control, ACS Manufacturing or approved equal. F. Accessories: 1) Exhaust silencer: Provide silencing grade required to meet the overall sound attenuation level specified above. 2) Starting batteries: Heavy-duty diesel starting type storage batteries, 200 amp-hour minimum capacity. Match battery voltage to starting system; include all necessary cables, clamps and mounting rack. Mark and group batteries to provide rated engine starting power at four-hour discharge rate. 3) Battery charger: Current-limiting type, 20 amp minimum, with both float and equalize charge rates, matched to battery characteristics. Include input and output overload protection, full-wave rectifier, DC ammeter and voltmeter; input voltage will be compatible with accessory supply voltage. Charger will have capacity to recharge battery within six hours

9 4. Submittals. Submittal shall consist of manufacturer s standard product data and projectspecific shop drawings. A. Product data shall include dimensions, weights, ratings, interconnection points and internal wiring diagrams for engine, generator, control panel, battery, battery rack, battery charger, exhaust silencer, vibration isolators, day tank and remote annunciator. Submit computer analysis for generator loading, motor starting, critical speed and vibratory stress. B. Shop drawings shall include generator plan and elevation views with overall and interconnection point dimensions, fuel consumption rate curves at various loads, ventilation and combustion air requirements, and electrical diagrams including schematic and interconnection diagrams. Show actual room layout and verify combustion air requirements and cooling water requirements. Provide a minimum of eight (8) copies of submittal for review by Engineer. Each submittal shall include a unique identifying number, assigned by Contractor, to be used for tracking purposes. Identifying number for materials being re-submitted to Engineer for second, and subsequent, reviews shall add a unique alphabetic suffix to original identification number. 5. Measurement. This Item will be measured by each engine-generator indicated in Plans, complete-in-place, connected, energized, tested and made fully operational. 6. Payment. The work performed and materials furnished in accordance with this Item and measured as provided under, "Measurement" will be paid for at the unit price bid for the Items shown on the Plans, upon satisfactory completion of all work associated with each packaged engine-generator. This price will be full compensation for all equipment described or required under this item; and for all furnishing all labor, equipment, tools, materials and incidentals necessary to complete the work