maintenance facility october 24, 2012 oklahoma department of … · 2018. 8. 10. · maintenance...

Maintenance Facility October 24, 2012 Oklahoma Department of Transportation McAlester, Oklahoma

ENGINE GENERATORS 26 32 13 - 1

SECTION 26 32 13

ENGINE GENERATORS

PART 1: GENERAL

1.01 RELATED DOCUMENTS

A. The general provisions of the contract, including General and Supplementary Conditions and General Requirements (if any), apply to the work specified in this section.

1.02 DESCRIPTION OF WORK

A. 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. Equipment shall be new, factory tested, and delivered ready for installation. 1. Generator-set ratings:

a. 150 KW, 188 KVA at 0.8 PF, Standby rating (Base Bid). b. 200KW, 250 KVA at .8 PF, Standby rating (Alternate #A).

2. System voltage: 240/120 Volts AC, Single phase, Three-wire, 60 hertz. 3. Fuel: Diesel 4. Alternator: 105 degree C 5. System: Emergency NFPA 110, Class 48, Type 10, Level 2

B. Provide automatic transfer switch for each generator set.

C. Provide interconnecting raceways and conductors.

D. Isolated concrete mounting pad shall be constructed under Division 2 - Site work and Division 3 - Concrete.

1.03 QUALITY ASSURANCE

A. Manufacturers: 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.

B. NEC Compliance: Comply with National Electrical Code (NFPA 70).

C. NFPA Compliance: Comply with all applicable NFPA Codes



1.04 SUBMITTALS

A. Specification and data sheets.

B. Manufacturer's certification of prototype testing.

C. Manufacturer's published warranty documents.

D. Shop drawings showing plan and elevation views with certified overall and interconnection point dimensions.

E. Interconnection wiring diagrams showing all external connections required; with field wiring terminals marked in a consistent point-to-point manner.

F. Manufacturer's installation instructions..

G. Submit shop drawings showing all pertinent physical characteristics.

H. Submit test reports.

1.05 SINGLE SUPPLIER

A. 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 warrantable products.

1.06 WARRANTY

A. A no deductible warranty shall be provided for all products against defects in materials and workmanship for a two year or 1500 hour period from the start-up date.

PART 2: PRODUCTS

2.01 ACCEPTABLE MANUFACTURERS

A. Provide engine generator sets manufactures by one of the following: 1. Cummins/Onan 2. Kohler 3. Caterpillar 4. MTU On-Site Power 5. Generac

2.02 DIESEL ENGINE-GENERATOR SET

A. Provide diesel engine-generator set with 4-cycle, 1800 rpm, diesel engine generator set with low reactance brushless generator, torque-matched excitation system,



asynchronous automatic voltage regulator, set-mounted control panel, and high ambient cooling system (50 degrees C).

B. Prototype Tests and Evaluation: Prototype tests shall have been done on a complete and functional unit, component level type tests will not substitute for this requirement.

C. Performance: 1. Voltage regulation shall be +/- 2 percent for any constant load between no load

and rated load. 2. Frequency regulation shall be isochronous from steady state no load to steady

state rated load. The diesel 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.

3. Motor starting KVA capability at 30% voltage dip: a. 150 KW Gen-Set – 420 KVA (Base Bid) b. 200 KW Gen-Set – 593 KVA (Alternate #A)

4. Maximum transient voltage dip shall not exceed 20 percent below rated on application of the single largest surge load step.

D. AC Generator: 1. The AC generator shall be; synchronous, four pole, revolving field, dripproof

construction, single pre-lubricated bearing, air cooled by a direct drive centrifugal blower fan, and directly connected to the engine with a drive disc(s).

2. The generator output voltage shall be broad range re-connectable, 12 leads, and the generator shall be capable of delivering rated output (KVA) at rated frequency and power factor, at any voltage within the broad range.

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 105 degrees Centigrade.

4. The generator shall be capable of full single phase output. 5. The automatic voltage regulator shall be temperature compensated, solid-state

design. The voltage regulator shall be equipped with single-phase, average sensing.

6. The voltage regulator shall be of an asynchronous pulse width modulated design that is immune to distortion from nonlinear loads. The regulator shall include a torque-matching characteristic to allow the engine to use its fullest power producing capacity at speeds lower than rated, to optimize motor starting capability and provide the fastest possible recovery from transient speed dips. Regulators which use a fixed volts per hertz characteristic are not acceptable.

E. Engine-Generator Set Control: 1. The control shall have automatic remote start capability from a panel-mounted

3-position (Stop, Run, Remote) switch. 2. Provide cycle cranking of 15 SEC (ON)/15 SEC (OFF) for three attempts (75

SEC). If engine fails to start lockout the engine and indicate over-crank on alarm status panel.

3. The control shall shut down and lock out upon: failing to start (over-crank), over-speed, low lubricating oil pressure, high engine temperature, or operation of a



remote manual stop station. A panel mounted switch shall reset the engine monitor and test all the lamps. Lamp indications on the control panel shall include: a. Over-crank shutdown - red b. Over-speed 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. Auxiliary (2 each)- red. (Customer identified)

4. The 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 Wattmeter, 90 degree scale, 2% accuracy g. Seven position phase selector switch with OFF position to allow meter

display of current and voltage in each generator phase. When supplied with re-connectable generators, the meter panel shall be re-connectable for the voltage specified.

F. Engine: 1. The engine shall be 1800 rpm, diesel, 4 cycle, radiator and fan cooled. Two

cycle engines are not acceptable. a. 150 KW Gen-Set – 10 Cylinder, 6.8 L minimum b. 200 KW Gen-Set – 6 Cylinder, 12.88 L minimum

2. Engine speed electronic governor to provide isochronous frequency control. Governor shall be capable of parallel operation with the addition of load sharing controls.

3. The cooling system shall be rated for full rated load operation in 122 degrees F (50 degrees C) ambient condition with the ambient temperature as measured at the generator air inlet. Radiators shall be provided with a duct adapter flange. The cooling system shall be filled with 50/50 ethylene glycol/water mixture by the equipment supplier.

4. Rotating parts shall be guarded against accidental contact.



G. Engine Accessory Equipment: 1. An electric starter(s) capable of three complete cranking attempts without

overheating. 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 lines.

4. Engine mounted battery charging alternator, 65 ampere, and solid-state voltage regulator.

H. Base: The engine-generator set shall be mounted on a heavy duty steel base to maintain alignment between components. The base shall incorporate a battery tray with battery hold-down clamps within the base rails. Provisions for stub up of electrical conduits shall be within the footprint of the generator set base rails. Vibration isolators, standard quantity and type of the manufacturer, shall be integral between the set and base.

I. Generator Set Auxiliary Equipment and Accessories: 1. Generator main circuit breaker, set-mounted and wired, UL listed, molded case

thermal-magnetic type. Ratings as shown on the drawings. 2. Engine mounted, thermostatically controlled, water jacket heater(s) for each

engine. The heater(s) shall be sized as recommended by the equipment supplier. Heater voltage shall be 240V.

3. Sub-Base Fuel Storage Tank: Provide a double wall sub-base fuel storage tank with capacity to provide a minimum full load running time of 8 hours. The tank shall be made of corrosion resistant steel. Provide an automatic leak detection system in the space between the walls.

4. Outdoor weather-protective housing, factory-assembled to generator set base and radiator cowling. Housing shall provide ample airflow for generator set operation. The housing shall have hinged side-access doors and rear control door. All doors shall be lockable. All sheetmetal shall be primed for corrosion protection and finish painted with the manufacturers standard color.

5. Starting and Control Batteries: Starting batteries, lead acid type, 12 volt DC, sized as recommended by the generator set manufacturer, shall be supplied for each generator set with battery cables and connectors.

6. 10 A Battery Charger. 7. Remote Annunciator: Provide and install a remote alarm annunciator located as

shown on the drawings. The remote annunciator shall provide all the indications and audible alarms called for by NFPA Standard 110 as provided on the engine-generator set control panel; and in addition shall provide indications for high battery voltage, low battery voltage, normal battery voltage, battery charger malfunction. Alarm silence and lamp test switches shall be provided.

8. Generator emergency kill switch: Provide mushroom head emergency kill switch with engraved 5”x7” placard to read “Generator Emergency Kill Switch”.



2.03 TRANSFER SWITCH EQUIPMENT

A. Complete factory assembled transfer equipment with electronic control designed for surge voltage isolation, voltage sensors on all phases of both sources, linear operator, permanently attached manual handles, positive mechanical and electrical interlocking, and mechanically held contacts. Equipment rated 1000 amps and less shall include quick-make, quick-break contact mechanisms for manual transfer under load.

B. Transfer Switch: Shall be configured as follows: 1. ATS-1 (Base Bid)

a. Poles - 3 b. Amperes - 600 c. Volts - 240 d. Type - Automatic e. Withstand and Closing Rating

1) MCCB - 42 KA @ 240 V f. Enclosure - NEMA 1 g. Accessories

1) Exerciser Clock 2. ATS-2 (Alternate #A)

a. Poles - 3 b. Amperes - 150 c. Volts - 240 d. Type - Automatic e. Withstand and Closing Rating

1) MCCB - 30 KA @ 240 V f. Enclosure - NEMA 12/3R g. Accessories

1) Exerciser Clock

C. All transfer switches and accessories shall be UL listed and labeled, tested per UL Standard 1008, and CSA Approved. 1. Ratings: Main contacts shall be rated for 600 Volts AC minimum on transfer

switches 40 - 1000 amps; and 480 Volts AC minimum on transfer switches 1200 - 3000 amps.

2. Transfer switches shall be rated to carry 100 percent of rated current continuously in the enclosure. Circuit breaker type transfer switches do not meet this specification.

3. Transfer switches shall be continuously rated in ambient temperatures of -40 to +50 degrees C , relative humidity up to 95% (non-condensing), and altitudes up to 10,000 feet.

4. Transfer switch equipment shall have a withstand and closing rating (WCR) in RMS symmetrical amperes greater than the available fault currents shown on the drawings.



D. Construction: Transfer switches shall be double-throw, electrically and mechanically interlocked, and mechanically held in both positions. 1. Transfer switches rated through 1000 amperes shall be equipped with

permanently attached manual operating handles and quick-break, quick-make over-center contact mechanisms suitable for safe manual operation under load. Transfer switches over 1000 amperes shall be equipped with manual operators for service use only under de-energized conditions.

2. Main switch contacts shall be high-pressure silver alloy. Contact assemblies shall have arc chutes for positive arc extinguishment. Arc chutes shall have insulating covers to prevent inter-phase flashover.

3. Provide two sets Form C auxiliary contacts on both sides, operated by transfer switch position, rated 10 amp 250 VAC.

4. Transfer switches shall be supplied with a switched neutral pole (4-poles). The neutral pole shall be of the same construction and have the same ratings as the phase poles. All poles shall be switched simultaneously using a common crossbar. Equipment using add-on accessory overlapping contacts are not acceptable.

5. Enclosures shall be UL listed. The enclosure shall provide NEC wire bend space. The cabinet door shall be key-locking. Controls on cabinet door shall be key-operated. Provide switch position indicator lamps and power available lamps for both sources (four total) on the outside cabinet door.

E. Automatic Controls: Control shall be solid-state and designed for a high level of immunity to power line surges and transients, demonstrated by test to IEEE Standard 587-1980. The control shall have optically isolated logic inputs, high isolation transformers for AC inputs, and relays on all outputs. 1. Solid-state undervoltage sensors shall simultaneously monitor all phases of both

sources. Pick-up and drop-out settings shall be adjustable. Voltage sensors shall allow for adjustment to sense partial loss of voltage on any phase. Voltage sensors shall have field calibration of actual supply voltage to nominal system voltage.

2. Automatic controls shall signal the engine-generator set to start upon signal from normal source sensors. Solid-state time delay start, adjustable from 0 to 15 seconds (factory set at 2 seconds) shall avoid nuisance start-ups. Battery voltage starting contacts shall be gold, dry type contacts factory wired to a field wiring terminal block.

3. The switch shall transfer when the emergency source reaches the set point voltage and frequency. Provide a solid-state time delay on transfer, adjustable from 0 to 120 seconds.

4. The switch shall retransfer the load to the normal source after a time delay retransfer, adjustable from 0 to 30 minutes. Retransfer time delay shall be immediately bypassed if the emergency power source fails.

5. Controls shall signal the engine-generator set to stop after a time delay, adjustable from 0 to 10 minutes, beginning on return to the normal source.

6. Power for transfer operation shall be from the source to which the load is being transferred.



7. The control shall include latching diagnostic indicators to pinpoint the last successful step in the sequence of control functions, and to indicate the present status of the control functions in real time, as follows: a. Source 1 OK b. Start Gen Set c. Source 2 OK d. Transfer Timing e. Transfer Complete f. Retransfer Timing g. Retransfer Complete h. Timing for Stop

8. The control shall include provisions for remote transfer inhibit and area protection.

F. Front Panel Devices: Provide devices mounted on cabinet front consisting of: 1. A key-operated selector switch to provide the following positions and functions:

a. Test - Simulates normal power loss to control for testing of generator set. Controls shall provide for a test with or without load transfer.

b. Normal - Normal operating position. c. Retransfer - Momentary position to override retransfer time delay and

cause immediate return to normal source, if available.

G. Accessory Items: Transfer switches designated in the schedule herein, shall be equipped with accessories as follows: 1. Provide solid state exerciser clock to set the day, time, and duration of

generator set exercise/test period. Provide a with/without load selector switch for the exercise period.

2. Provide a float charge battery charger rated 10 amps. DC output voltage shall be as required for the starting batteries. An ammeter shall display charging current. The battery charger shall have fused AC input and fused DC output. Include fault indications and Form C contact for AC Fail, High Battery Voltage, and Low Battery Voltage.

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.

3.02 FACTORY TESTS

A. Generator set factory tests on the equipment to be shipped shall be performed at rated load and 0.8 PF. Generator sets that have not been factory tested at 0.8 PF will not be acceptable. Tests shall include; 45 minute run at full load, maximum power, voltage regulation, transient and steady-state governing, single step load



pickup, and safety shutdowns. Provide a factory certified record of the production testing.

B. Transfer equipment factory tests: Each transfer switch supplied shall be factory tested before shipment. Factory tests shall include a complete functional test of the transfer switch controls, including calibration of the voltage sensors.

3.03 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 Architect 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.

END OF SECTION

maintenance facility october 24, 2012 oklahoma department of … · 2018. 8. 10. · maintenance...

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