Transcript
SECTION 263213 - PACKAGED STADNBY ENGINE GENERATOR SYSTEM PART 1 1.01
GENERAL SECTION INCLUDES
A.
Packaged standby engine generator system.
B.
Emergency panelboard.
C.
Automatic transfer switch (ATS).
D.
Gas piping, fittings & valves.
E.
Controls and monitoring.
F.
Wiring/conduits.
1.02
REFERENCES
A.
ANSI/NEMA 250 - Enclosures for Electrical Equipment (1000 Volts Maximum).
B.
ANSI/NEMA MG 1 - Motors and Generators.
C.
2011 ANSI/NFPA 70 - National Electrical Code.
D.
ANSI/NFPA 99 - Health Care Facilities.
E.
ANSI/NEMA AB 1 - Molded Case Circuit Breakers.
1.03
SYSTEM DESCRIPTION
A.
Furnish & install a gas-fired, liquid-cooled 70 KW packaged standby engine generator system at 120/208V, 3 Phase, UL 2200 listed, equal to “Generac”, MODEL QT070, meeting the EPA emissions regulations, with two-line LCD controller, closed coolant recovery system, smart battery charger, sound attenuated enclosure, and field install a 200 Amps, 42 circuits emergency panelboard (with molded circuit breakers) and automatic transfer switch, controls, gas piping & valves, mechanical & electrical interconnections, for a complete operational system, tested, demonstrated to and approved in writing by the local authorities having jurisdiction and Owner’s Representative. This Contractor shall be responsible to coordinate the upgrade of the present gas service with Eversouce.
B.
Engine generator system to provide source of emergency standby power.
C.
Operation: In accordance with ANSI/NFPA 99.
1.04
SUBMITTALS
A.
Qualification Data: Manufacturer, Installer and Testing Agency.
B.
Seismic Qualification Certificates: For engine-generator set, accessories, and components.
C.
Submit product data showing dimensions, weights, rating, interconnection points, and internal wiring diagrams for engine, generator, control panel, battery, battery rack, battery charger, exhaust silencer, vibration isolators, remote annunciator, etc.
D.
Submit manufacturer's installation instructions.
E.
Operation and Maintenance Data.
F.
Source quality-control reports including but not limited to the following: certified summary of prototype-unit test report, certified test reports, certified summary of performance tests, report of factory test on unit to be shipped for this project, report of exhaust emissions showing compliance with applicable regulations and certified torsional vibration compatibility as per NFPA 110.
1.05 A.
1.06
PROJECT RECORD DOCUMENTS Submit record documents at project completion including (3) sets of “AsBuilt” drawings indicating accurately location of packaged engine standby generator, emergency panelboard, automatic transfer switch, gas piping & valves, mechanical and electrical connections. etc. QUALITY ASSURANCE
A.
Manufacturer Qualifications: Manufacturer accepted as an ISO9001 manufacturer.
B.
Installer Qualifications: Manufacturer’s authorized representative who is trained and approved by manufacturer.
C.
Supplier: Authorize distributor of engine generator manufacturer with service facilities within 50 miles of project site.
D.
Third-Party Testing Agency Qualifications: Member company of NETA or NRTL, with Testing Agency’s Field Supervisor certified by NETA to supervise onsite testing.
1.07
A.
1.08 A.
1.09 A.
WARRANTY
Manufacturer’s Warranty: Manufacturer agrees to repair or replace components of packaged standby generator system and associated components that fail in materials or workmanship within a 5-year period from the date of Substantial Completion. MAINTENANCE SERVICE Furnish service and maintenance of packaged standby engine generator system for one years from Date of Substantial Completion. EXTRA MATERIALS Furnish extra materials to Owner’s Representative at project’s completion that match products installed and that are packaged with protective covering for storage and identified with labels describing components, such as: fuses two for every 10 of each type), indicator lamps (two for
every six of each type), filters (one set each of lubricating oil, fuel and combustion air filters)and special tools (tools unique to the product for standard maintenance).
PART 2
2.1 A.
2.2
PRODUCTS
MANUFACTURERS Approved manufactures are Generac, Kohler and Onan.
PACKAGED STANDBY ENGINE GENERATOR SYSTEM
A.
Type: Gas-fired, liquid-cooled, electric ignition internal combustion engine, capable of operating with natural gas at 10 percent overload for one hour at this elevation and ambient limits.
B.
Generator: ANSI/NEMA MG 1; three phase, re-connectible brushless synchronous generator with brushless exciter.
C.
Rating: as indicated.
D.
Insulation: ANSI/NEMA MG 1, Class F.
E.
Temperature Rise: 105 degrees C continuous and 130 degrees C standby.
F.
Enclosure: ANSI/NEMA MG 1; open drip proof.
2.3
EMERGENCY PANELBOARD
A.
Panel board with copper bus of rated for 200A @ 120/208V, 3 Phase, as indicated. This panel board shall include all existing heating loads, such as boilers, air handlers, circulating pumps from the existing Boiler Panel, and shall include up to (6)selected existing lighting circuits (including two exterior lighting circuits), and up to (4) existing convenience receptacles circuits. The final selection of all emergency circuits shall be approved by the Owner’s Representative.
B.
Minimum integrated short circuit rating: 10,000 RMS symmetrical.
C.
Molded Case Circuit Breakers: NEMA AB 1, bolt-on type thermal magnetic trip circuit breakers, with common trip handle for all poles. Provide circuit breakers UL listed as Type SWD for lighting circuits. Provide UL Class A ground fault interrupter circuit breakers where required. Do not use tandem circuit breakers.
D.
Enclosure:
E.
Cabinet Front: Surface cabinet front with concealed trim clamps, concealed hinge, and flush lock all keyed alike. Finish in manufacturer's standard gray enamel.
NEMA PB 1, Type 1. Locate in basement.
2.4 A.
2.5
AUTOMATIC TRANSFER SWITCH (ATS) Furnish and install a 200 Amps, 3 Phase ATS, equal to “Generac” model RTS, furnished with bypass/isolation mechanism and closed transition microprocessor controller. All timing and sensing functions shall originate in the generator controller with utility voltage drop-out at less 60%, 10 seconds factory set timer to generator start, 5 seconds engine warm-up delay, 60% for 5 seconds standby voltage sensor, utility pickup at more than 80%, 15 seconds re-transfer time delay, 60 seconds engine cool down timer, and 12 minutes every 7 days exerciser.
GAS PIPING, FITTINGS & VALVES
A.
Furnish & install natural gas piping system to the packaged standby engine generator system, including piping, fittings, valves, etc., complying with NFPA 37 and 54, for a complete operational system. Gas piping shall be sized to provide adequate natural gas to the engine while allowing for no greater than 1 inch water column pressure drop from no load to full load. Natural gas piping will supply pressure to the generator set inlet per manufacturer’s recommendations, nominally 11 to 14 inches of water column. If a gas pressure regulator is provided shall be sized for 125 percent of full-load generator set capacity. Gas train shall comply with NFPA 37.
B.
Steel Pipe: ASTM A53 or A120, Schedule 40 black. 1. Fittings: ASTM A234, forged steel welding type, with AWWA C105 polyethylene jacket or double layer, half-lapped 10 mil polyethylene tape.
C.
2.6
2. Joints: ANSI B31.1, welded. Plug valves up to and including 2 Inches: Bronze body, bronze tapered plug, non-lubricated, teflon packing, threaded ends. Over 2 Inches: Cast iron body and plug, non-lubricated, teflon packing, flanged ends.
CONTROLS AND MONITORING
A.
Automatic Starting System Sequence of Operation: When mode-selector switch on the control and monitoring panel is in the automatic position, remote-control contacts in one or more separate automatic transfer switches initiate starting and stopping of generator set. When modeselector switch is switched to the manual position, generator set starts. The off position of same switch initiates generator-set shutdown. When generator set is running, specified system or equipment failures or derangements automatically shut down generator set and initiate alarms.
B.
Manual Starting System Sequence of Operation: Switching on-off switch on the generator control panel to the manual position starts generator set. The off position of same switch initiates generator-set shutdown. When generator set is running, specified system or equipment failures or derangements automatically shut down generator set and initiate alarms.
C.
Provide minimum run time control set for 15 minutes with override only by operation of a remote emergency-stop switch.
D.
Comply with UL 508A.
E.
Configuration: Operating and safety indications, protective devices, basic system controls, and engine gages shall be grouped in a common control and monitoring panel mounted on the generator set. Mounting method shall isolate the control panel from generator-set vibration. Panel shall be powered from the engine-generator set battery.
F.
Engine and generator control wiring shall be multi-stranded annealed copper conductors encased by cross-linked polyethylene insulation resistant to heat, abrasion, oil, water, diesel fuel, and antifreeze. Wiring shall be suitable for continuous use at 250 deg F with insulation not brittle at minus 60 deg F. Cables shall be enclosed in nylon flexible conduit, which is slotted to allow easy access and moisture to escape.
G.
Engines that are equipped with an electronic engine control module (ECM) shall monitor and control engine functionality and seamlessly integrate with the generator set controller through digital communications. ECM monitored parameters shall be integrated into the genset controllers NFPA 110 alarm and warning requirements.
H.
For engines without ECM functionality or for any additional generator set controller monitoring, sensors are to be conditioned to a 4 to 20 ma signal level to enhance noise immunity and all sensor connections shall be sealed to prevent corrosion.
I.
Construction: All circuitry within the control panel shall be individually environmentally sealed to prevent corrosion. Encapsulated circuit boards with surface mounted components and sealed, automotivestyle connectors for sensors and circuit board connectors. Enclosed circuit boards and terminal strips that are susceptible to corrosion are not acceptable.
J.
Custom ladder logic functionality inside the generator controller shall be supported to provide application support flexibility. The ladder logic function shall have access to all the controller inputs and customer assignable outputs.
K.
Indicating Devices: As required by NFPA 110 for Level 2 system. All ECM fault codes shall be displayed at the generator set controller in standard language; fault code numbers are not acceptable. Utilizing a digital display, including the following: (a) Retain first four subparagraphs below for Level 1 systems because they are required by NFPA 110. Consider retaining them for Level 2 systems also. (b) AC voltage: True three-phase sensing. (c) AC current. (d) Frequency. (e) EPS supplying load indicator. (f) DC voltage (alternator battery charging). (g) Engine-coolant temperature. (h) Engine lubricating-oil pressure. (i) Running-time meter. (j) Current and Potential Transformers: Instrument accuracy class.
L.
Protective Devices and Controls in Local Control Panel: Shutdown devices and common visual alarm indication as required by NFPA 110 for Level 2 system, including the following: (a) See the Evaluations for typical local and remote alarm indications and shutdowns. (b) Start-stop switch. (c) Overcrank shutdown device. (d) Overspeed shutdown device. (e) Coolant high-temperature shutdown device. (f) Coolant low-level shutdown device. (g) Low lube oil pressure shutdown device. (h) Overcrank alarm. (i) Overspeed alarm. (j) Coolant high-temperature alarm. (k) Coolant low-temperature alarm. (l) Coolant low-level alarm. (m) Low lube oil pressure alarm. (n) Lamp test. (o) Contacts for local and remote common alarm. (p) Retain first three subparagraphs below for Level 1 systems because they are required by NFPA 110. Consider retaining them for Level 2 systems also. (q) Coolant high-temperature prealarm. (r) Generator-voltage; digitally adjustable via controller, password protected. (s) Main fuel tank low-level alarm. (t) Low fuel level alarm shall be initiated when the level falls below that required for operation for the duration required in "Fuel Tank Capacity" Paragraph in "Diesel Fuel-Oil System" Article. (u) Retain first two subparagraphs below for automatic start systems. Delete for manual start systems. (v) Run-Off-Manual selector switch. (w) Control switch not in automatic position alarm. (x) Retain first four subparagraphs below for Level 1 battery start engines. Consider retaining them for Level 2 systems also. (y) Low cranking voltage alarm. (z) Battery-charger malfunction alarm. (aa) Battery low-voltage alarm. (bb) Battery high-voltage alarm. (cc) Retain subparagraph below for units with "generator-protector" feature. (dd) Generator overcurrent protective device not closed alarm.
M.
Supporting Items: Include sensors, transducers, terminals, relays, and other devices and include wiring required to support specified items. Locate sensors and other supporting items on engine or generator, unless otherwise indicated. Sensors are to be conditioned to a 4 to 20 mA signal level to enhance noise immunity and all sensor connections shall be sealed to prevent corrosions.
N.
Connection to Datalink: Provide connections for datalink transmission of indications to remote data terminals via ModBus RS232.
O.
Remote Alarm Annunciator: Comply with NFPA 99. An LED labeled with proper alarm conditions shall identify each alarm event, and a common audible signal shall sound for each alarm condition. Silencing switch in face of panel shall silence signal without altering visual indication. Connect so
that after an alarm is silenced, clearing of initiating condition will reactivate alarm until silencing switch is reset. Cabinet and faceplate are surface- or flush-mounting type to suit mounting conditions indicated. (a) Overcrank alarm. (b) Coolant low-temperature alarm. (c) High engine temperature prealarm. (d) High engine temperature alarm. (e) Low lube oil pressure alarm. (f) Overspeed alarm. (g) Low fuel main tank alarm. (h) Low coolant level alarm. (i) Low cranking voltage alarm. (j) Contacts for local and remote common alarm. (k) Audible-alarm silencing switch. (l) Control switch not in automatic position alarm. (m) Devices in first three subparagraphs below are optional. (n) Fuel tank derangement alarm. (o) Fuel tank high-level shutdown of fuel supply alarm. (p) Lamp test. (q) Retain first subparagraph below for Level 1 battery start engines. Consider retaining it for Level 2 systems also. (r) Low cranking voltage alarm. (s) Protective device alarm in subparagraph below may not be standard or available for all generator sets. Verify availability with manufacturers. (t) Generator overcurrent protective device not closed. P.
The control system shall provide pre-wired customer use I/O: 4 relay outputs (user definable functions), 4 contact inputs, 2 analog inputs, communications support via RS232, RS485, or an optional modem. Additional I/O must be an available option. Customer I/O shall be software configurable providing full access to all alarm, event, data logging, and shutdown functionality.
Q.
Supporting Items: Include sensors, transducers, terminals, relays, and other devices and include wiring required to support specified items. Locate sensors and other supporting items on engine or generator, unless otherwise indicated.
R.
Maintenance: (a) All engine, voltage regulator, control panel, and accessory units shall be accessible through a single electronic service tool. The following maintenance functionality shall be integral to the generator set controls: (b) Engine running hours. (c) Service maintenance interval (running hours, calendar days). (d) Engine crank attempt counter. (e) Engine successful starts counter. (f) 20 events are stored in control panel memory. (g) Control panel shall time and date stamp all alarms and warnings. A snap shot of key parameters shall be saved in the control panel for use in troubleshooting alarms. (h) A predictive maintenance algorithm will determine the optimal time for maintenance service based on the generator loading and operation.
S.
Programmable Cycle Timer: To start and run the generator for a predetermined time. The timer shall use 14 user-programmable sequences that are repeated in a 7-day cycle. Each sequence shall have the following programmable set points: (a) Day of the week. (b) Time of the day start. (c) Duration of cycle. (d) Option to exercise at reduced speed for quiet test mode.
T.
Monitoring Software: Provide monitoring software capable of communicating to no less than 15 generator sets. Software shall be connectable via RS232 connection directly on the generator control panel. Software functionality to include: (a) Display generator set operating parameters including necessary pressures and temperatures, electrical output, fuel level. (b) Ability to program custom I/O alarms as well as modify standard alarm settings for applications (password protected). (c) Data logging and trending of up to 15 parameters, user selectable, for testing, troubleshooting, and record keeping. (d) High speed data logging and trending of up to 0.2 millisecond providing sine wave visibility for testing and identification of harmonic distortion levels.
U.
Overcurrent protective devices for the entire EPSS shall be coordinated to optimize selective tripping when a short circuit occurs. Coordination of protective devices shall consider both utility and EPSS as the voltage source. (a) Overcurrent protective devices for the EPSS shall be accessible only to authorized personnel and each located in a separate box per NEC700 separation of circuits.
V.
Generator Disconnect Switch: Molded-case type, 100 percent rated. (a) Trip Rating: Matched to generator output rating. (b) Shunt Trip: Connected to trip switch when signaled by generator protector or by other protective devices.
W.
Generator Protector: Microprocessor-based unit shall continuously monitor current level in each phase of generator output, integrate generator heating effect over time, and predict when thermal damage of alternator will occur. When signaled by generator protector or other generator-set protective devices, a shunt-trip device in the generator disconnect switch shall open the switch to disconnect the generator from load circuits. Protector performs the following functions: (a) Coordinate load shed actions in subparagraphs below with Drawings. Indicate which loads will be shed on generator overload and sequence of action if more than one. (b) Initiates a generator overload alarm when generator has operated at an overload equivalent to 110 percent of full-rated load for 60 seconds. Indication for this alarm is integrated with other generator-set malfunction alarms. Contacts shall be available for load shed functions. (c) Under single or three-phase fault conditions, regulates generator to 300 percent of rated full-load current for up to 10 seconds. (d) As overcurrent heating effect on the generator approaches the thermal damage point of the unit, protector switches the excitation
system off, opens the generator disconnect device, and shuts down the generator set. (e) Senses clearing of a fault by other overcurrent devices and controls recovery of rated voltage to avoid overshoot. X.
2.7 A.
PART 3
2.8 A. B.
C. D.
2.9 A.
B.
C.
2.10 A. B.
2.11 A.
B.
Comply with NEMA MG 1 and UL2200, sized for 248 deg F temperature rise above ambient at rated load.
WIRING/CONDUITS Description: Single copper conductor wire, rated for 300 volts with ANSI/NFPA 70, Type THW or THWN insulation. Run all wiring in EMT conduits in dry interior areas, in galvanized steel with liquid tight fittings in mechanical/electrical rooms, wet areas and where exposed outside. EXECUTION
PREPARATION Delete "Interruption of Existing Electrical Service" Paragraph below if no interruption of existing electrical service is required. Interruption of Existing Electrical Service: Do not interrupt electrical service to facilities occupied by Owner or others unless permitted under the following conditions and then only after arranging to provide temporary electrical service according to requirements indicated: Notify Construction Manager no fewer than two working days in advance of proposed interruption of electrical service. Do not proceed with interruption of electrical service without Construction Manager's written permission.
EXAMINATION Examine areas, equipment bases, and conditions, with Installer present, for compliance with requirements for installation and other conditions affecting packaged engine-generator performance. Examine roughing-in for piping systems and electrical connections. Verify actual locations of connections before packaged engine-generator installation. Proceed with installation only after unsatisfactory conditions have been corrected. NSTALLATION Comply with packaged engine-generator manufacturers' written installation and alignment instructions and with NFPA 110. Verify with Project participants which concrete section in the "Equipment Mounting" Paragraph below will be used for concrete pads and bases. Equipment Mounting: Install packaged engine generator on 8 inch thick cast-in-place concrete equipment base at location indicated by the Owner’s Representative. Coordinate size and location of concrete base for packaged engine generator. Cast anchor-bolt inserts into base. Retain first subparagraph below to require equipment to be installed on cast-in-place concrete equipment bases.
C. D.
E.
2.12 A. B. C. D. E. F. G. H.
2.13
Install packaged engine-generator to provide access, without removing connections or accessories, for periodic maintenance. NFPA 110 requires indoor Level 1 engine generators to be installed in a dedicated room with 1 or 2 hour fire rating. Indoor installations also require the storage of fuel within the building and large air flows for cooling and combustion. Consult NFPA 110 and the authority having jurisdiction for requirements. Minimum deflection should be verified with structural or seismic engineer. Electrical Wiring: Install electrical devices furnished by equipment manufacturers but not specified to be factory mounted. CONNECTIONS Piping installation requirements are specified in thi8s section. Connect fuel, cooling-system, and exhaust-system piping adjacent to packaged engine-generator to allow service and maintenance. Connect natural gas piping to engines with a gate valve and union and AGA approved flexible connector. Natural-gas piping, valves, and specialties for gas distribution are specified in this section. Install manual plug shutoff valve in a remote location to isolate natural-gas supply to the generator enclosure. Ground all equipment according to 2011 National Electrical Code (NEC). Connect wiring according to 2011 NEC. Provide a minimum of one 90 degree bend in flexible conduit routed to the generator set from a stationary element. IDENTIFICATION
A. Identify system components according to ANSI standards. B.
2.14
Install a sign indicating the generator neutral is bonded to the main service neutral at the main service location. FIELD QUALITY CONTROL
A.
Retain one of first three paragraphs below, which identify who shall perform tests and inspections. If retaining second option in "Testing Agency" Paragraph or if retaining "Manufacturer's Field Service" or "Perform tests and inspections" paragraphs, retain "Field qualitycontrol reports" Paragraph in "Informational Submittals" Article.
B.
Testing Agency: At the owner's request, the contractor shall engage a qualified, third-party, testing agency to witness tests and inspections.
C.
Retain "Manufacturer's Field Service" Paragraph below to require a factory-authorized service representative to perform inspections, tests, and adjustments.
D.
Manufacturer's Field Service: Engage a factory-authorized service representative to inspect, test, and adjust components, assemblies, and equipment installations, including all connections.
E.
Retain "Tests and Inspections" Paragraph below to describe tests and inspections to be performed by any of the entities in three paragraphs above.
F.
Tests and Inspections: NETA and other testing requirements indicated in subparagraphs below may be in excess of those required for Project. Review NETA and other tests listed and revise subparagraphs below to retain only those tests deemed necessary Perform tests recommended by manufacturer and each visual and mechanical inspection and electrical and mechanical test listed in the first two subparagraphs as specified in NETA Acceptance Testing Specification. Certify compliance with test parameters. a) Visual and Mechanical Inspection 1. Compare equipment nameplate data with drawings and specifications. 2. Inspect physical and mechanical condition. 3. Inspect anchorage, alignment, and grounding. 4. Verify the unit is clean. b) Electrical and Mechanical Tests 1. Test protective relay devices per manufacturer recommendations. 2. Verify phase rotation, phasing, and synchronized operation as required by the application. 3. Functionally test engine shutdown for low oil pressure, over temperature, over speed, and other protection features as applicable. 4. Conduct performance test in accordance with NFPA 110. 5. Verify correct functioning of the governor and regulator. c) NFPA 110 Acceptance Tests: Perform tests required by NFPA 110 that are additional to those specified here including, but not limited to, single-step full-load pickup test. 1. Battery Tests: Equalize charging of battery cells according to manufacturer's written instructions. Record individual cell voltages. Measure charging voltage and voltages between available battery terminals for full-charging and float-charging conditions. Check electrolyte level and specific gravity under both conditions. 2. Test for contact integrity of all connectors. Perform an integrity load test and a capacity load test for the battery. 3. Verify acceptance of charge for each element of the battery after discharge. Verify that measurements are within manufacturer's specifications.Battery-Charger Tests: Verify specified rates of charge for both equalizing and float-charging conditions.
G.
Coordinate tests with tests for transfer switches and run them concurrently.
H.
Operational Test: After electrical circuitry has been energized, start units to confirm proper motor rotation and unit operation for generator and associated equipment.
I.
Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment.
J.
Remove and replace malfunctioning units and retest, re-inspect as specified above.
K.
Retest: Correct deficiencies identified by tests and observations and retest until specified requirements are met.
J.
Report results of tests and inspections in writing. Record adjustable relay settings and measured insulation resistances, time delays, and other values and observations. Attach a label or tag to each tested component indicating satisfactory completion of tests.
2.15
MAINTENANCE SERVICE
A.
Retain this article for critical installations and consider including a provision for submitting a continuing maintenance agreement proposal. Revise starting date if required. Obtain a copy of maintenance agreement before retaining or editing below. Maintenance contracts may not be allowed for publicly funded projects.
B.
Initial Maintenance Service: Beginning at Substantial Completion, provide 60 months' full maintenance by EGSA Certified employees of manufacturer's designated service organization. Include quarterly exercising to check for proper starting, load transfer, and running under load. Include routine preventive maintenance as recommended by manufacturer and adjusting as required for proper operation. Provide parts and supplies same as those used in the manufacture and installation of original equipment.
2.16 A.
TRAINING The equipment supplier shall provide training for the facility operating personnel covering operation and maintenance of the equipment provided. The training program shall be not less than 4 hours in duration and the class size shall be limited to 5 persons. Training date shall be coordinated with the facility owner.
END OF SECTION
