CITY OF KYLE, TEXAS
Attachment 6
Section 16231 Packaged Engine Generators
Diesel Generator for the Public Works Department
"K16-17-5"
CITY OF KYLE – GENERATOR INSTALLATION 16231 - 1 AUGUST 2017 AT PUBLIC WORKS DEPARTMENT PACKAGED ENGINE GENERATORS
SECTION 16231 PACKAGED ENGINE GENERATORS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Provide a standby power system to supply electrical power in event of failure of normal supply, consisting of a liquid cooled engine, AC alternator and system controls with all necessary accessories for a complete operating system, including but not limited to the items as specified.
B. The standby power system shall consist of a single engine/alternator system. The system will only be acceptable if all components necessary to automatically control the generator is provided as a complete system.
C. Provide (an) automatic transfer switch if described elsewhere in this specification so the system comes on-line fully automatically, and on restoration of utility power manually retransfers load to normal power, automatically shuts down the standby power system after cool down and returns to readiness for another operating cycle.
D. Provide all labor, materials, and equipment, necessary to result in a fully installed, workable standby power system as defined on the drawings and within this specification.
E. Provide startup and on-site testing by a manufacturer's authorized dealer or agent. The technicians that provide startup must be certified by the generator manufacturer to provide all required support and warranty service to the generator on site.
F. Provide on-site training by a manufacturer's authorized dealer or agent.
G. Any and all exceptions to this specification are subject to the engineer’s approval.
1.02 CODES AND STANDARDS
A. The standby power system, its installation, and on-site testing shall conform to all relevant local codes.
B. The equipment provided shall be listed for use in standby power systems as defined below: 1. UL 2200 - Stationary Engine Generator Assemblies (Low Voltage) 2. UL 1008 - Transfer Switch Equipment 3. UL 891 - Dead-Front Switchboards (Low Voltage) 4. UL 142 - Steel Aboveground Tanks for Flammable and Combustible Liquids
C. The standby power system, its installation, and on-site testing shall conform to the following national codes and standards as applicable. 1. NFPA 70 / National Electrical Code, specifically: a. NFPA 20 -- Standards for the Installation of Stationary Pumps for Fire Protection b. NFPA 110 Level 1 -- Emergency and Standby Power Systems
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c. IEEE 446 -- Recommended Practices for Emergency and Standby Power Systems for Industrial and Commercial Applications
1.03 MANUFACTURER QUALIFICATIONS
A. This system shall be supplied by Caterpillar, Generac or an approved manufacturer who has been regularly engaged in the production of engine-alternator sets, automatic transfer switches, and associated controls for a minimum of 10 years, thereby identifying one source of supply and responsibility.
B. It is the intent of this specification to have a single source responsible for the standby power system. A preference will be shown to generator set manufacturers that warranty and service all equipment herein specified.
C. The manufacturer shall have printed literature and brochures describing the standard series specified, custom, one-of-a-kind systems will not be considered unless specifically identified.
PART 2 ENGINE-GENERATOR SET
2.01 RATINGS
A. The generator set shall operate at 120/208 Volts, three phase, 4 wire, Wye connected, 60 Hertz.
B. The generator set shall be rated at a minimum of 300kW (running), at 0.8 power factor (lagging). Refer to Section 2.3, Alternator, for specific alternator starting kVA requirements (SkVA).
C. The generator set system rating shall be based upon site conditions of 500 feet (152 meters) altitude and 104 F (40 C) ambient.
D. The generator set shall accept a single step of 100% of rated load and recover to rated speed and voltage as required in Section 7.13.7 of NFPA 110, 2002 Edition.
2.02 ENGINE
A. The engine shall be capable of operating on a high quality, off-road, #2 grade diesel fuel.
B. The diesel engine shall be equipped with an applicable mechanical direct coupled injection system, or electronic fuel injection system that is integral to the engine, and designed to optimize operation at rated engine speed and output. 1. Mechanical injection systems shall have an electronic actuator that is directly linked to the injector rack. The actuator shall be designed so that it is a fail/close type design, in that if power is lost, the rack automatically closes. 2. Electronic injection systems shall have integral governing via proportional injection based on parameters of engine speed, and or measured load as specified by the engine manufacturer.
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C. Flexible fuel line compatible with the diesel fuel specified shall be supplied and installed between each generator and the internal/external fuel piping.
D. The engine’s full load fuel consumption rate shall be specified in the bid documents. For multiple engine systems, total full-load fuel consumption rate shall be specified for the system.
E. The generator set shall operate at an RPM consistent with desired engine durability. Engine RPM to be specified in bid documents.
F. The generator set shall operate at a BMEP (brake mean effective pressure) consistent with favorable engine durability. Engine BMEP to be specified in bid documents.
G. The engine shall be of a 4 cycle design.
H. The engine shall be liquid cooled.
I. For each engine, the cooling system shall be a unit mounted radiator, fan, water pump, and closed coolant recovery system.
J. Coolant drain connections shall be easily accessible and incorporate an isolation valve and pipe plug for convenient engine servicing.
K. The cooling system shall be sized to maintain acceptable engine temperatures at the specified rated power level and the specified site ambient and elevation conditions. Maximum engine coolant temperature to be specified in the bid documents.
L. Coolant used in the system shall meet or exceed generator manufacturer’s specifications and shall be specified in the bid documents.
M. The engine shall have (a) unit mounted, thermostatically controlled jacket water heater to aid in quick starting and longer engine life. The heater shall operate at 120/240 volts, and the wattage shall be as recommended by the generator manufacturer. The heater shall be wired into an appropriate branch circuit from normal utility power source. The number, wattage, and type of block heater shall be listed in the bid documents. 1. The jacket water heater shall be of sufficient capacity to assure conformance to NFPA 110 Level 1 in that the heater shall provide adequate heat to maintain a jacket water temperature of 90F (32.2C) at an ambient temperature of 32F (0C). 2. For an emergency power system housed outdoors or in an outside enclosure, the enclosure shall be heated to not less than 40F (4.4C). 3. Provisions shall be made to maintain the enclosure temperature at 32F (0C).
N. Intake air filter with a replaceable dry element must be mounted on the engine.
O. A positive displacement lube oil pump shall supply engine lubrication. The engine shall have a replaceable oil filter with internal bypass and replaceable element. Engine oil drain connection shall be easily accessible and incorporate an isolation valve and pipe plug for convenient engine servicing.
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P. Recommended engine oil type and use of oil coolers, if applicable, are to be specified in bid documents. A preference will be shown for engines not requiring oil coolers external to the engine.
Q. A crankcase oil heater shall be provided to maintain a minimum oil temperature at 70 F (21.1 C), while in an ambient of 32 F (0 C). The heater’s surface temperature shall be designed such that no oil carbonization/coking occurs. A preference will be shown to circulating oil heaters. Include heater specifics in the bid documents.
R. Fan and belt guards that comply with UL2200 must be installed for personnel safety.
S. The engine shall have a battery charging DC alternator with an electronic voltage regulator. Charging alternator amperage shall be provided in the bid documents, and shall be sufficient to support engine charging system and parasitic loads.
T. The engine shall have lead acid cranking batteries that are capable of providing 3 to 10 cranking cycles of approximately 8 to 15 seconds per cycle in accordance with Section 5.6.4 of NFPA 110, 2002 Edition, in a minimum ambient of 50 F (10 C).
U. The genset shall have a unit mounted, dual rate, 10 amp battery charger to maintain the charge in the engine cranking batteries when the engine is not running. Due to line voltage drop concerns, a battery charger mounted remotely from the generator is not preferred. The charger shall be wired into a dedicated branch circuit from normal utility power.
V. The engine shall use a solenoid actuated, electric starter with engine speed for disengagement adjustable via genset control system.
W. The generator set shall include a sub-base fuel storage tank. The tank capacitiy shall be sufficient to provide 24 hours of generator operation at full rated load. The sub-base tank shall be structurally adequate to fully support the generator set and shall be UL142 Listed. The tank shall be of double-wall construction with a switched sensor to detect the presence of fuel in the secondary containment, indicating a primary fuel tank leak. Venting provisions shall be provided in accordance with UL142.
X. Engine speed shall be controlled by an isochronous governor to maintain alternator frequency within 0.5% from no load to full load. Steady state regulation is to be 0.25%. To minimize possible interaction of load induced harmonics with the speed governor system, the governor shall be powered from the DC cranking batteries and measure engine speed from a dedicated magnetic pickup mounted on the engine flywheel housing.
Y. Sensing elements are to be located on the engine as necessary for the control system to comply with the requirements of NFPA 110. A preference will be shown to wiring utilizing a molded rubber boot to cover the electrical connection on each sensor to prevent corrosion. A preference will also be shown to units with dual wire sensing elements for improved grounding. Specify on bid documents.
Z. Engine wiring shall incorporate wire number labeling on each end of the wire run for easy identification. A preference will be shown to manufacturers who demonstrate a wire number system that is keyed to generator functions. Specify on bid documents. CITY OF KYLE – GENERATOR INSTALLATION 16231 - 5 AUGUST 2017 AT PUBLIC WORKS DEPARTMENT PACKAGED ENGINE GENERATORS
AA. The manufacturer shall supply its recommended stainless steel, flexible connector to couple the engine exhaust manifold to the exhaust system. Specify on bid documents. All components of the exhaust system, including the muffler and attaching components, shall be stainless steel in construction. Include specific muffler construction in the submittal documents.
BB. Submittal drawings will show silencer that are mounted within the weather protective enclosure for reduced exhaust noise and clean, smooth exterior design. Exhaust silencer shall be provided of the size as recommended by the manufacturer. A rain cap shall terminate the exhaust pipe. All components must be properly sized to assure operation without excessive backpressure when installed.
2.03 ALTERNATOR
A. The alternator shall be a 4-pole revolving field type, wired for 120/208 Volts AC, three phase, 60 Hertz.
B. The alternator shall be constructed with materials that meet NEMA MG-1 requirements for a Class "H" insulation system. Preference will be given to alternators that use Class "H" materials but operate within Class "F" temperature rises for greater thermal tolerance to load imbalances and harmonic conditions.
C. The alternator shall be able to provide a minimum of starting 280kVA with a maximum 20% instantaneous voltage dip. Sustained kVA values will not be acceptable.
D. Alternator main rotor shall be varnished and secured with coil supports for good mechanical strength. The rotor shall be able to withstand an overspeed of at least 125% of rated RPM. The rotor shall include appropriate insulating materials for good electrical life. Three-phase rotor shall include amortisseur windings. A preference will be shown for rotors that by design and construction operate at less than rated temperatures. Rotor operating temperature at rated load to be provided in the bid documents.
E. Alternator main stator shall be two-thirds pitch and skewed one slot. The stator shall be varnished using standard industry practices. The stator shall be directly connected or close-coupled to the engine flywheel housing or gear reduction unit, resulting in consistent engine / alternator alignment. The main stator shall incorporate anti- condensation heater.
F. The voltage regulator shall maintain 0.25% steady state regulation, and include under voltage protection (Volts per Hertz). The regulator shall have an external means to adjust voltage.
G. Powering the voltage regulator from the main stator power leads is acceptable. However, a preference will be shown for designs which use a permanent magnet generator (PMG) or auxiliary stator winding to power the regulator.
H. The alternator excitation system shall incorporate a permanent magnet generator (PMG) as the power source for the voltage regulator. This system shall be capable of providing 300% steady state, three phase fault current for ten seconds to enable circuit breaker coordination. CITY OF KYLE – GENERATOR INSTALLATION 16231 - 6 AUGUST 2017 AT PUBLIC WORKS DEPARTMENT PACKAGED ENGINE GENERATORS
I. The alternator shall incorporate a field circuit breaker or an over-excitation circuit in the voltage regulator to help protect the main rotor from over-excitation.
J. A NEMA 1 junction box that is an integral part of the generator set must be provided to allow the installer a convenient location in which to make electrical power output connections. A fully rated, isolated neutral must be included. The junction box layout shall support wiring the main line circuit breaker, if included, without any connection box modifications.
K. For each alternator in the system, a main line circuit breaker carrying the UL mark shall be factory installed. The breaker shall be rated as shown on the drawings and regardless of the size shown, the generator shall include a UL2200 listing. The breaker shall be mounted in the generators junction box or in a freestanding enclosure provided by the manufacturer. For generator-mounted breakers, the line side connections are to be made at the factory. Output lugs or bus bars shall be provided for load side connections. A system utilizing manual reset field circuit breakers and current transformers is unacceptable.
L. The electrical system shall be equipped with surge protective devices on switch board and panels.
2.04 CONTROLS
A. All engine / alternator controls and instrumentation shall be designed, built, wired, tested and shock mounted in a NEMA 4 enclosure to the engine-generator set by the manufacturer. It shall contain a fused DC circuit to protect the controls and provide a secure means of powering down the controls.
B. The control panel shall comply with all the requirements of NFPA 110, Level 1.
C. The control panel shall allow remote digital communication directly or through a modem. Software from the manufacture shall be available for this purpose.
D. A preference will be shown for control panels that have user definable analog and digital inputs. Details shall be provided in bid documents.
E. An emergency stop push button shall be installed either at a remote location or at generator enclosure with easy access.
PART 3 ADDITIONAL REQUIREMENTS
3.01 GENERATOR WEATHER ENCLOSURE
A. The engine-generator set shall be supplied with a factory assembled enclosure constructed to withstand 90 mph windload. Where practical, the enclosure shall be factory assembled on the generator set to simplify shipping and site installation. The roof shall aid in the runoff of water and include a drip edge. The generator, operating under 100% loading, will not exceed 74dB(a) measured at 23 feet (7 meters) from the generator enclosure. The manufacturer shall include data sheets showing the measured sound level for the equipment, and shall include any calculations required to
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determine the sound level at the distance shown above. All generator components, including the exhaust system and muffler, shall be installed within the enclosure of the generator. Only the exhaust rain cap may be visible from outside the enclosure.
B. The enclosure shall be protected against outdoor exposure in accordance with Section 65 of UL2200.
C. The enclosure is to have large, hinged, removable doors to allow access to the engine, alternator and control panel. Hinges and all exposed fasteners shall be corrosion resistant. Each door shall have lockable hardware with identical keys.
PART 4 ADDITIONAL PROJECT REQUIREMENTS
4.01 APPLIED STANDARDS
A. The generator set must be manufactured to the applicable specifications on file with Underwriters Laboratories and the UL 2200 mark must be affixed.
4.02 FACTORY TESTING
A. An electric generating system, consisting of a prime mover, generator, governor, coupling and all controls, must have been tested, as a complete unit, on a representative engineering prototype model of the equipment to be sold. Prototype test reports shall be made available to the engineer upon request.
B. Before shipment of the equipment, the engine-generator set shall be tested under rated load for performance and proper functioning of control and interfacing circuits. Tests shall include: 1. Verifying all safety shutdowns are functioning properly 2. Verify single step load pick-up per NFPA 110. 3. Verify transient and voltage dip responses and steady state voltage and speed (frequency) checks.
4.03 OWNER’S MANUAL
A. Three (3) sets of owner’s manuals specific to the product supplied must accompany delivery of the equipment. General operating instruction, preventive maintenance, wiring diagrams, schematics and parts exploded views specific to this model must be included.
4.04 INSTALLATION
A. Contractor shall install the complete electrical generating system including all fuel connections in accordance with the manufacturer’s recommendations as reviewed by the Engineer.
4.05 SERVICE
A. Supplier of the electric plant and associated items shall have permanent service facilities in this trade area. These facilities shall comprise a permanent force of factory trained service personnel on 24-hour call, experienced in servicing this type of equipment, CITY OF KYLE – GENERATOR INSTALLATION 16231 - 8 AUGUST 2017 AT PUBLIC WORKS DEPARTMENT PACKAGED ENGINE GENERATORS
providing warranty and routine maintenance service to afford the owner maximum protection. Service contracts shall also be available.
B. At the discretion of the customer, the system may also include a 1 year maintenance contract, that can be included with the initial cost of the system. If selected, the supplier shall provide a copy of the maintenance schedule, including all monitored, tested and recorded items that will take place during the maintenance period. The contact shall include two visits, once every 6 months, to take place. The second maintenance interval shall include the standard above mentioned inspection, along with the manufacturer’s specified fluid and product changes. Provide the maintenance program with submittal documents for approval.
4.06 ON-SITE TRAINING
A. On-site training of the generator set shall be provided as required for the customer by a manufacturer's authorized dealer or agent. Training shall include but not limited to general maintenance, general system operation, and general troubleshooting of the generator system. On-site training shall be of four-hour duration or as mutually agreed upon.
4.07 WARRANTY
A. The standby electric generating system components, complete engine-generator and instrumentation panel shall be warranted by the manufacturer against defective materials and factory workmanship for a period of two (2) years. Such defective parts shall be repaired or replaced at the manufacturer's option, free of charge for parts, labor and travel. The warranty period shall commence when the standby power system is first placed into service. Multiple warranties for individual components (engine, alternator, controls, etc.) will not be acceptable. Satisfactory warranty documents must be provided. Also, in the judgment of the specifying authority, the manufacturer supplying the warranty for the complete system must have the necessary financial strength and technical expertise with all components supplied to provide adequate warranty support.
4.08 STARTUP AND CHECKOUT
A. The supplier of the electric generating plant and associated items covered herein shall provide factory trained technicians to checkout the completed installation and to perform an initial startup inspection to include: 1. Ensuring the engine starts (both hot and cold) within the specified time. 2. Verification of engine parameters within specification. 3. Verify no load frequency and voltage, adjusting if required. 4. Test all automatic shutdowns of the engine-generator. 5. Perform a load test of the electric plant, ensuring frequency and voltage are within specification by using building load.
4.09 SUBMITTALS
A. Provide three complete sets of Engineering Submittal for approval, prior to production release, showing all components, in addition to the engine and generator. Submittals shall include compliance with these specifications.
END OF SECTION CITY OF KYLE – GENERATOR INSTALLATION 16231 - 9 AUGUST 2017 AT PUBLIC WORKS DEPARTMENT PACKAGED ENGINE GENERATORS