PART 1 GENERAL 1.01 SCOPE OF WORK A. The Contractor shall provide, install, and acceptance test a complete and operable emergency standby electric generating system, including all devices and equipment specified herein, as shown on the drawings, or required for the service. Materials and equipment shall be new, and delivered to the job site factory tested and ready for installation. B. The Contractor shall also provide as part of this package the required gas connection system (i.e., National Grid). 1.02 RELATED WORK A. Division 16, Electrical. B. Section 16410, Transfer Switches 1.03 SUBMITTALS A. Shop Drawings submitted shall be in accordance with Section 01660. B. The Contractor shall submit six (6) copies each of the following as part of the Shop Drawing submittal package: 1. Specification and data sheets showing ratings and derating schedules, operating performance, weights, fuel consumption rates, ventilation and combination air requirements, exhaust flow data, cooling system data, and engine and generator data. 2. Manufacturer s certification of generator set prototype testing. 3. Manufacturer s warranty documents. 4. Itemized list of all exceptions taken to this specification. 5. Shop drawings showing plan and elevation views with certified overall and interconnection point dimensions. 6. Electrical interconnection wiring diagrams showing all external connections required; with terminal and destination markings for all equipment, controls, and devices included in the system. Terminals for field wiring the system controls between equipment, shall be marked in a consistent manner point-topoint by the manufacturer. TALL OAKS STP 16231-1
7. Manufacturer s installation instructions 8. Manufacturer s and distributor s name, address, and telephone number. 1.04 REFERENCE STANDARDS A. Equipment and equipment installation shall meet all applicable state and local codes. B. NFPA 70, National Electric Code C. NFPA 110, Emergency and Standby Power Systems D. NFPA 99, Health Care Facilities E. NFPA 37, Installation of Stationary Engines F. Underwriter s Laboratories Standard 2200 Generator Sets. G. Underwriter s Laboratories Standard 1008 Transfer Switch Equipment. 1.05 QUALITY ASSURANCE A. Emergency generator manufacturer shall have a minimum of 5 years of experience manufacturing generator sets with equal or larger capacities. 1.06 GENERAL INFORMATION FOR APPROVAL A. Manufacturer: The emergency standby electrical generating system equipment shall be the standard production of a single manufacturer. It shall be factory built, tested and shipped by this single manufacturer. Approved Manufactures: Cummins or equal. B. Warranty: The complete electrical power system (generator set, controls and associated switches, switchgear and accessories), as provided by the single source manufacturer shall be warranted by the manufacturer against defects in materials and workmanship for a period of five years or 1500 hours, whichever occurs first from the date of the system start up. Coverage shall include parts, labor, travel expenses, and labor to remove/reinstall the equipment per the manufacturer s standard published limited warranty. There shall be no deductibles applied to the warranty. C. Technical Support: The manufacturer shall provide factory trained service and parts support available through a factory authorized distributor. TALL OAKS STP 16231-2
D. Single Supplier: The supplier shall be the manufacturer s authorized distributor, who shall provide initial start-up services, conduct field acceptance testing, and warranty service. The supplier shall have 24-hour service availability and factory trained service technicians authorized to do warranty service on all equipment supplied. E. Substitute Manufacturer: Equipment, documentation and services described in this specification and indicated on the plans are as provided by Cummins Corporation, Minneapolis, Minnesota. Proposals for any substitute equipment shall provide complete submittal data, as specified herein, to the Engineer and Architect for approval/disapproval not less than 10 days prior to the scheduled bid date. F. Approval of Substitute Equipment: If approved, the Contractor shall be responsible for the charges of any necessary revisions to the plans and specifications, drawings, and project documentation; and charges related to equipment spacing, mounts, electrical wiring, ventilation equipment, fuel, exhaust components, etc. PART 2 - PRODUCTS 2.01 NATURAL GAS ENGINE GENERATOR SET A. General 1. Generator set nominal ratings: 85 kw Standby rating Cummins 85GGHG 2. The standby power rating shall be for supplying emergency power for the duration of a normal power interruption. 3. System voltage of: 120/208 WYE volts AC, three-phase, four-wire, 60 hertz. 4. Generator set capacity shall be a minimum of rated kw at an elevation of 500 feet (152 meters) above sea level, and ambient temperature between 10 and 100 F. 5. The system shall include the following: a. 1-engine generator set, (with accessories). Transfer switch equipment, starting batteries, battery charger (10 amp rating, mount in transfer switch), other control devices, accessories, tests, documents, and services as needed to meet specifications. b. Related mechanical work shall be completed as specified in Division 15. TALL OAKS STP 16231-3
c. Exhaust muffler(s) critical grade, flanges, and flexible exhaust pipe section, as specified herein; sized as required for the engine and installation. 6. The generator set shall have the ability to operate on either natural gas or propane without the need to change fuel regulator or other major equipment items. B. Performance 1. The generator set manufacturer shall verify the natural gas engine as capable of driving the generator with all accessories in place and operating at the generator set kw rating after derating for the range of temperatures expected in service and the altitude of the installation. 2. The manufacturer shall provide documentation demonstrating satisfactory prototype test results for the model specified and production test results for equipment supplied for this project. Generator sets that have not been factory tested at 0.8 PF will not be acceptable. 3. Voltage regulation shall be 0.5 percent of rated voltage for any constant load between no load and rated load. 4. Frequency regulation shall be isochronous from steady state no load to steady state rated load. 5. Total harmonic distortion; the sum of AC voltage waveform harmonics, from no load to full linear load, shall not exceed 5% of rated voltage (L- N, L-L, L-L-L) and no single harmonic shall exceed 3% of rated voltage. 6. Telephone influence factor; TIF shall be less than 50 per NEMA MG1-22.43. 7. The natural gas engine-generator set shall be capable of single step load pick up of 100% nameplate kw and power factor, less applicable derating factors, with the engine-generator set at operating temperature. 8. Motor starting capability shall be a minimum of 87 kva for each generator set. After an initial instantaneous voltage dip not to exceed 15 percent, the generator set shall be capable of sustaining a minimum of 90% of rated no load voltage with the specified kva load at near zero power factor applied to the generator set. C. AC Generator 1. AC generator, exciter and voltage regulator shall be designed and manufactured by the engine-generator set manufacturer as a complete generator system. TALL OAKS STP 16231-4
2. The AC generator shall be synchronous, four pole, revolving field, dripproof construction, single prelubricated sealed bearing, air cooled by a direct drive centrifugal blower fan, and directly connected to the engine laminations of insulated electrical grade steel, two thirds pitch windings. The rotor shall have amortisseur (damper) windings. The rotor shall be dynamically balanced. The exciter shall be brushless, three phase, with full wave silicon diodes mounted on the rotating shaft and a surge suppressor connected in parallel with the field winding. 3. All insulation system components shall meet NEMA MG1 standard temperature limits for Class H insulation system. Actual temperature rise measured by resistance method at full load shall not exceed 80 degrees. 4. The generator shall be capable of delivering rated output (kva) at rated frequency and power factor, at any voltage not more than 5 percent above or below rated voltage. 5. The main generator and exciter insulation systems must be suitably impregnated for operation in severe environments for resistance to sand, salt, and sea spray. 6. A permanent magnet generator (PMG) shall provide excitation power to the automatic voltage regulator for immunity from voltage distortion caused by non-linear SCR controlled loads on the generator. The PMG shall sustain main field excitation power for optimum motor starting and to sustain short circuit current at approximately 300% of rated current for approximately 10 seconds. 7. The automatic voltage regulator shall be temperature compensated, solid state design. The voltage regulator shall be equipped with three phase RMS sensing. 8. The regulator shall control buildup of AC generator voltage to provide a linear rise and limit overshoot. Overvoltage protection shall sense the AC generator output voltage and in the event of regulator failure or loss of reference, shut down regulator output on a sustained overvoltage of one (1) second duration. Overexcitation protection shall sense regulator output and shut down regulator output if overloads exceed ten (10) seconds duration. Both overvoltage and overexcitation protection shutdowns shall be latched, requiring the AC generator to be stopped for reset. 9. The regulator shall include an under frequency rolloff torque-matching characteristic, which shall reduce output voltage in proportion to frequency below a threshold of 58-59 HZ. The torque matching characteristic shall include differential rate of frequency change compensation to use maximum available engine torque and provide optimal transient load response. Regulators which use a fixed volts per hertz characteristic are not acceptable. TALL OAKS STP 16231-5
D. Engine-Generator Set Control 1. The control shall have a 3 position selector switch with automatic remote start capability. A panel mounted switch shall stop the engine in the STOP position, start and run the engine in the RUN position, and allow the engine to start and run by closing a remote contact, and stop by opening the remote contact when in the AUTOMATIC position. 2. The control shall include a cycle cranking function. The cranking cycle, non-adjustable, shall consist of an automatic crank period of approximately 15 seconds duration followed by a rest period of approximately 15 seconds duration. Cranking shall cease upon engine starting and running. Two separate means of cranking termination shall be provided, one completely redundant to the other with no common components. Failure to start after three cranking attempts (75 seconds) shall shut down and lockout the engine, and visually indicate an overcrank shutdown on the panel. 3. The control shall shut down and lock out the engine failing to start after the specified time (overcrank), overspeed, low lubricating oil pressure, high engine temperature, or operation of a remote manual stop station, or coolant low level. 4. The control shall provide an engine monitor. A panel mounted switch shall reset the engine monitor and test all the lamps. Lamp indications on the control panel shall include: a. Overcrank shutdown red b. Overspeed shutdown red c. Low oil pressure shutdown red d. High engine temperature shutdown red e. High engine temperature prealarm yellow f. Low engine oil pressure prealarm yellow g. Low coolant temperature yellow h. Low fuel yellow i. Run green j. Not in automatic start flashing red k. Low coolant level shutdown red l. Auxiliary (2 each) red (overfill alarm and leak alarm). 5. The engine-generator set starting battery(ies) shall power the monitor. The control shall include surge suppression for the protection of solid state components. Operation of shut down circuits shall be independent of indication and prealarm circuits. Individual relay signals shall be provided for each indication for external circuit connections (not to TALL OAKS STP 16231-6
exceed 1/2 amp draw) to a remote annunciator. A common alarm contact for external connection to an audible alarm shall be provided. E. Engine 6. The NEMA 12 enclosed control panel shall be mounted on the generator set with vibration isolators. A front control panel illumination lamp with On/Off switch shall be provided. Control panel mounted indicating meters and devices shall include: a. Engine oil pressure gauge, coolant temperature gauge, DC voltmeter, and running time meter (hours). b. Voltage adjusting rheostat, locking screwdriver type, to adjust voltage 5% from rated value. c. Analog AC voltmeter, dual range, 90 degree scale, 2% accuracy. d. Analog AC ammeter, dual range, 90 degree scale, 2% accuracy e. Analog frequency/rpm meter, 45-65 Hz. 1350-1950 RPM, 90 degree scale 0.6 Hz accuracy f. Analog power factor meter, 90 degree scale, 2% accuracy g. Analog wattmeter, 90 degree scale, 2% accuracy. h. Seven position phase selector switch with Off position to allow meter display of current and voltage in each generator phase. When supplied with reconnectable generators, the meter panel shall be reconnectable for the voltage specified. 1. The engine shall be combination natural gas/lp vapor fueled, radiator and fan cooled. Minimum displacement shall be 412.5 cu in. with 10 cylinders. 176 bhp gross engine power output. The horsepower rating of the engine at it's minimum tolerance level shall be sufficient to drive the alternator and all connected accessories. Engine accessories and features shall include: a. Complete engine fuel system, including all pressure regulators, strainers, and control valves. The fuel system shall be plumbed to the generator set skid for ease of site connections to the generator set. For dual fuel systems, changeover from primary to secondary fuel shall be automatic. b. An electronic governor system shall provide automatic isochronous frequency regulation. c. Skid-mounted radiator and cooling system rated for full load operation in 104 degrees F (40 degrees C) ambient as measured at the generator air TALL OAKS STP 16231-7
inlet, based on 0.5 in H 2 O external static head. Radiator shall be sized based on a core temperature which is 20F higher than the rated operation temperature, or prototype tested to verify cooling performance of the engine/radiator/fan operation in a controlled environment. Radiator shall be provided with a duct adapter flange. The equipment manufacturer shall fill the cooling system with a 50/50-ethylene glycol/water mixture. Rotating parts shall be guarded against accidental contact. d. Electric starter(s) capable of three complete cranking cycles without overheating. e. Positive displacement, mechanical, full pressure, lubrication oil pump. f. Full flow lubrication oil filters with replaceable spin-on canister elements and dipstick oil level indicator. g. Replaceable dry element air cleaner with restriction indicator. h. Flexible fuel lines. i. Engine mounted battery charging alternator, 40-ampere minimum, and solid-state voltage regulator. j. Coolant heater i. Engine mounted, thermostatically controlled, coolant heater(s) for each engine. Heater voltage shall be as shown on the project drawings. The coolant heater shall be UL499 listed and labeled. ii. iii. iv. The coolant heater shall be installed on the engine with silicone hose connections. Steel tubing shall be used for connections into the engine coolant system wherever the length of pipe run exceeds 12 inches. The coolant heater installation shall be specifically designed to provide proper venting of the system. The coolant heaters shall be installed using quick disconnect couplers to isolate the heater for replacement of the heater element. The quick disconnect/automatic sealing couplers shall allow the heater element to be replaced without draining the engine cooling system or significant coolant loss. The coolant heater shall be provided with a 24VDC thermostat, installed at the engine thermostat housing. An AC power connection box shall be provided for a single AC power connection to the coolant heater system. The coolant heater(s) shall be sized as recommended by the engine manufacturer to warm the engine to a minimum of 100F (40C) in a 40F ambient, in compliance with NFPA110 requirements, or the temperature required for starting and load pickup requirements of this specification. TALL OAKS STP 16231-8
k. Provide vibration isolators, spring/pad type, quantity as recommended by the generator set manufacturer. Isolators shall include seismic restraints if required by site location. l. Starting and Control Batteries shall be calcium/lead antimony type, 24 volt DC, sized as recommended by the engine manufacturer, complete with battery cables and connectors. m. Provide exhaust silencer(s) for each engine of size and type as recommended by the generator set manufacturer and approved by the engine manufacturer. The mufflers shall be critical grade. Exhaust system shall be installed according to the engine manufacturer s recommendations and applicable codes and standards. F. Engine Accessory Equipment G. Base The engine-generator shall include the accessories as follows: 1. An electric starter(s) capable of three complete cranking cycles without overheating, before overcrank shutdown (75 seconds). 2. Positive displacement, mechanical, full pressure, lubrication oil pump. Full flow lubrication oil filters with replaceable spin on canister elements and dipstick oil level indicator. 3. An engine driven, mechanical, positive displacement fuel pump. Fuel filter with replaceable spin on canister element. Replaceable dry element air cleaner with restriction indicator. Flexible supply and return fuel line. 4. Engine mounted battery charging alternator, 45 ampere minimum and solid state voltage regulator. 1. The engine-generator set shall be mounted on a heavy duty steel base to maintain a proper alignment between components. The engine-generator set shall incorporate a battery tray with holdown clamps within the base rails. Provisions for stub up of electrical and fuel connections shall be within the footprint of the generator set base rails. H. Generator Set Auxiliary Equipment 1. Generator main circuit breaker, set-mounted and wired, UL listed, molded case thermal-magnetic type, rated at 400 amps 3-pole, 208 volts. Field circuit breakers shall be furnished but not acceptable for generator overcurrent protection. Main breaker shall be mounted in a NEMA 12 enclosure with bending space per UL requirements. Include a neutral block. TALL OAKS STP 16231-9
2. Engine mounted, thermostatically controlled, water jacket heater(2) for each engine. The heater(s) shall be sized as recommended by the equipment supplier. Heater voltage shall be 120 volt, single phase. 3. Vibration isolators, spring isolators type, quantity as recommended by the generator set manufacturer. 4. Starting and Control Batteries: Starting batteries, lead acid type 24-volt DC, sized as recommended by the generator set manufacturer, shall be supplied for each generator set with battery cables and connectors. 5. Battery Charger: A 10 amp voltage regulated battery charger shall be provided for each engine-generator set. Input AC voltage and DC output voltage shall be as required. Chargers shall be equipped with float, taper, and equalize charge settings. Operational monitors shall provide visual output along with individual form C contacts rated at 4 amps, 120 VAC, 30 VDC for remote indication of: a. Loss of AC power red light b. Low battery voltage red light c. High battery voltage red light d. Power ON green light (no relay contact) 6. Critical Grade Silencer I. Outdoor Weather-Protective Sound Attenuating Housing 1. The generator set shall be provided with a factory-installed soundattenuated housing which allows the generator set to operate at full rated load in ambient conditions previously specified. 2. The Enclosure shall reduce the sound level of the generator set while operating at full rated load to a maximum of 66.6 dba at any location 7 meters from the generator set in a free field environment. 3. Housing configuration and material used may be of any suitable design which meets the application needs, except that acoustical materials used shall be oil and water resistant. No foam materials shall be sued unless they can be demonstrated to have the same durability and life as fiberglass. 4. The enclosure shall include hinged doors for access to both sides of the engine and alternator, and the control equipment. Key-locking and pad lockable door latches shall be provided for all doors. Door hinges shall be stainless steel. Provide a window in the control panel door for viewing of the panel with the door closed. 5. The enclosure shall be provided with an exhaust silencer, which is mounted inside of the enclosure, and allows the generator set package to TALL OAKS STP 16231-10
meet specified sound level requirements. Silencer and exhaust shall include a raincap and rainshield. 6. All sheetmetal shall be primed for corrosion protection and finish painted with the manufacturers standard color using a two-step electrocoating paint process, or equal meeting the requirements specified below. All surfaces of all metal parts shall be primed and painted. The painting process shall result in a coating which meets the following requirements: a. Primer thickness, 0.5-2.0 mils. b. Top coat thickness, 0.8-1.2 mils. c. Gloss, per ASTM D523-89, 80% plus or minus 5%. Gloss retention after one year shall exceed 50%. d. Crosshatch adhesion per ASTM D3359-93, 4B-5B. e. Impact resistance per ASTM D2794-93, 120-160 inch-pounds. f. Salt Spray per ASTM B117-90, 1000+ hours. g. Humidity per ASTM D2247-92, 1000+ hours. h. Water Soak per ASTM D2247-92, 1000+ hours. 7. Painted of hoses, clamps, wiring harnesses, and other non-metallic service parts shall not be acceptable. Fasteners used shall be corrosion resistant, and designed to minimize marring of the painted surface when removed for normal installation or service work. PART 3 - EXECUTION 3.01 INSTALLATION A. Installation shall comply with applicable state and local codes as required by the authority having jurisdiction. Install equipment in accordance with manufacturer s instructions and instructions included in the listing or labeling of UL listed products. B. Provide branch circuits and motor starters, where required, from the emergency panel for the generator set auxiliaries. C. Provide and install emergency system conductors in a raceway system completely separate from other wiring. Control interconnection wiring shall be properly sized and run in a raceway separate from power cables. 3.02 TESTING A. To provide proven reliability of the system, three series of tests shall be performed: Prototype model tests, production model tests, and field tests. The manufacturer shall provide documentation demonstrating satisfactory prototype and production test results. Generator sets that have not been prototype tested and factory tested at 0.8 PF will not be acceptable. TALL OAKS STP 16231-11
B. Generator Set Factory Prototype Tests and Evaluation. These tests and evaluations must have been performed on a prototype generator set representative of the model specified. A summary of the generator set testing results shall be submitted for review. The manufacturer s standard series of component development tests on the generator system, engine, and other major components shall also be performed and available for review but shall not be acceptable as a substitute for prototype testing on the complete representative generator set prototype. C. Torsiograph Analysis and Test. The manufacturer of the generator set shall verify that the engine-generator set, as configured, is free from harmful torsional stresses. The analysis shall include correlation of empirical data from tests on a representative prototype. The empirical data must include spectrum analysis of the torsional transducer output within the operating speed range of the enginegenerator set. Calculations based on engine and generator separately are not acceptable. D. Temperature Rise Test. Complete thermal evaluation of a prototype generator rotor and stator must include actual measurement of internal generator and exciter temperatures by embedded detector method, and measurement of average temperature rise by method, and measurement of average temperature rise by resistance method. No position measured any place in the windings may exceed the temperature rise limits of NEMA for the particular type of insulation system used. Resistance method temperature rise data shall be confirmed by a full load test on the generator set prototype to include conducted and radiated heat from the engine. E. Short Circuit Test. A test on a prototype generator set shall have demonstrated that the generator set is designed to withstand the mechanical forces associated with a short circuit condition. With the generator set operating at rated load and speed, the generator terminals must be short circuited on all three phases for a duration of 20 seconds. At the conclusion of this test, the generator set must be capable of full load operation. F. Endurance Run Test. A minimum of five hundred (500) continuous hours of endurance testing with a representative generator set prototype operating as defined by the manufacturer s standby rating shall have been performed. Endurance testing shall be used to verify structural soundness and durability. G. Maximum Power Test. With the prototype generator set at normal operating temperature and with all power consuming auxiliaries in place, the maximum power available at rated speed shall be determined with the governor set at its fuel stop. The generator set shall maintain this power for a minimum of two minutes. H. Linear Vibration Test. A test for in-line motion of components occurring along a repeatable path shall meet the manufacturer s acceptance criteria. I. Cooling System Test. A cooling system test shall demonstrate the ability of the generator set cooling system to maintain normal operating temperature while TALL OAKS STP 16231-12
operating at full rated load and power factor at the highest ambient temperature of the system rating. Cooling air requirements, radiator, airflow and maximum allowable restriction at radiator discharge shall be verified by this test. J. Maximum Motor Starting kva. Motor starting kva shall be determined by test, based on a sustained RMS recovery voltage of at least 90% of no load voltage with the specified load kva at near zero power factor applied to the generator set. K. Transient Response, Steady-State Speed Control, and Voltage Regulation. Prototype generator set tests shall demonstrate consistent performance as follows: stable voltage and frequency at all loads from no load to full rated load, consistent frequency bandwidth with steady-state load, maximum voltage and frequency dip on load acceptance and rejection, and restoration to steady state after sudden load changes. Transient response is a complete generator set (engine, generator, exciter, and regulator) performance criteria and cannot be established based on generator data alone. L. Transfer Equipment Prototype Tests: Prototype samples, representative of the production transfer switches supplied, shall have been tested as defined in UL 1008, including but not limited to: 1. Overload tests for the capability to make and break six (6) times the transfer switch rated current at low power factor without any electrical or mechanical malfunction. 2. Temperature rise test at 100% of rated current without exceeding temperature rise limits. Transfer switches incorporating integral overcurrent devices in the main power circuit and tested at 80% of rating shall not be permitted. 3. Endurance tests for a minimum of 3,000 mechanical operation cycles. 4. A dielectric voltage withstand test of 1000 volts plus twice rated for one minute. 5. Withstand and closing tests with specific overcurrent devices. All withstand and closing tests shall be performed with the overcurrent protective devices located external to the transfer switch. Tests conducted with overcurrent protective devices internal to the switch, in such a manner that the transfer switch interrupts the current rather than withstanding the current, are not acceptable under this definition of withstand. 6. The entire transfer switch shall be performance treated per the requirements of IEEE 587-1980, for voltage surge withstand capability. TALL OAKS STP 16231-13
3.03 FACTORY TESTS A. Generator set factory production tests on the equipment to be shipped, shall be performed at rated load and 0.8 PF. These tests shall include run at full load, maximum power, voltage regulation, transient and steady-state governing, single step load pickup, and safety shutdowns. Provide a factory certified test record of the production testing. B. Transfer equipment production model tests. Each production model transfer switch supplied shall be factory tested before shipment. Factory tests shall include a complete functional test of the transfer switch control, including calibration of the voltage sensor potentiometers. 3.04 ON SITE ACCEPTANCE TEST A. The complete installation shall be tested for compliance with the specification following completion of all site work. Testing shall be conducted by representatives of the manufacturer, with required fuel supplied by contractor. The engineer shall be notified in advance and shall have the option to witness the tests, installation acceptance tests to be conducted on-site shall include a cold start test, a two hour full load test, and a one step rated load pickup test in accordance with NFPA 110. Provide a resistive load bank and make temporary connections for full load test, if necessary. END OF SECTION TALL OAKS STP 16231-14