HomeMy WebLinkAbout16900.pdfBICKFORD OF CARMEL, IN 12/12/2012
ENGINE GENERATORS 263213 - 1
SECTION 16900 - ENGINE GENERATORS
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division 01 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes packaged engine-generator sets for emergency power supply with the
following features:
1. Diesel engine.
2. Unit-mounted cooling system.
3. Unit-mounted control and monitoring.
B. Related Sections include the following:
1. Division 16 Section "Transfer Switches" for transfer switches including sensors and
relays to initiate automatic-starting and -stopping signals for engine-generator sets.
1.3 DEFINITIONS
A. Operational Bandwidth: The total variation from the lowest to highest value of a parameter
over the range of conditions indicated, expressed as a percentage of the nominal value of the
parameter.
B. LP: Liquid petroleum.
1.4 SUBMITTALS
1. Product Data: For each type of packaged engine generator indicated. Include rated
capacities, operating characteristics, and furnished specialties and accessories
B. Shop Drawings: Detail equipment assemblies and indicate dimensions, weights, loads, required
clearances, method of field assembly, components, and location and size of each field
connection.
1. Dimensioned outline plan and elevation drawings of engine-generator set and other
components specified.
2. Wiring Diagrams: Power, signal, and control wiring.
C. Field quality-control test reports.
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D. Operation and Maintenance Data: For packaged engine generators to include in emergency,
operation, and maintenance manuals. In addition to items specified in Division 01 Section
"Operation and Maintenance Data," include the following:
1. List of tools and replacement items recommended to be stored at Project for ready access.
Include part and drawing numbers, current unit prices, and source of supply.
E. Warranty: Special warranty specified in this Section.
1.5 QUALITY ASSURANCE
A. Installer Qualifications: Manufacturer's authorized representative who is trained and approved
for installation of units required for this Project.
1. Maintenance Proximity: Not more than four hours' normal travel time from Installer's
place of business to Project site.
B. Manufacturer Qualifications: A qualified manufacturer. Maintain, within 200 miles (321 km)
of Project site, a service center capable of providing training, parts, and emergency maintenance
repairs.
C. Source Limitations: Obtain packaged generator sets and auxiliary components through one
source from a single manufacturer.
D. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70,
Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for
intended use.
E. Comply with ASME B15.1.
F. Comply with NFPA 37.
G. Comply with NFPA 70.
H. Comply with NFPA 110 requirements for Level 1 emergency power supply system.
I. Comply with UL 2200.
J. Engine Exhaust Emissions: Comply with applicable state and local government requirements.
K. Noise Emission: Comply with applicable state and local government for maximum noise level
at adjacent property boundaries due to sound emitted by generator set including engine, engine
exhaust, engine cooling-air intake and discharge, and other components of installation.
1.6 PROJECT CONDITIONS
A. Environmental Conditions: Engine-generator system shall withstand environmental conditions
without mechanical or electrical damage or degradation of performance capability
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1.7 COORDINATION
A. Coordinate size and location of concrete bases for package engine generators. Cast anchor-bolt
inserts into bases. Concrete, reinforcement, and formwork requirements are specified in
Division 03.
B. Provide weatherproof enclosure.
1.8 WARRANTY
A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or
replace components of packaged engine generators and associated auxiliary components that
fail in materials or workmanship within specified warranty period.
1. Warranty Period: 2 years from date of Substantial Completion.
1.9 EXTRA MATERIALS
A. Furnish extra materials described below that match products installed and that are packaged
with protective covering for storage and identified with labels describing contents.
1. Fuses: One for every 10 of each type and rating, but no fewer than one of each.
2. Indicator Lamps: Two for every six of each type used, but no fewer than two of each.
3. Filters: One set each of lubricating oil, fuel, and combustion-air filters.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. Manufacturers: Subject to compliance with requirements, provide products by one of the
following:
1. Caterpillar; Engine Div.
2. Generac Power Systems, Inc.
3. Kohler Co.; Generator Division.
4. Onan/Cummins Power Generation; Industrial Business Group.
2.2 ENGINE-GENERATOR SET
A. Factory-assembled and -tested, engine-generator set.
B. Mounting Frame: Maintain alignment of mounted components without depending on concrete
foundation; and have lifting attachments.
C. Capacities and Characteristics:
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1. Power Output Ratings: Nominal ratings as indicated.
2. Output Connections: Three-phase,four wire.
3. Nameplates: For each major system component to identify manufacturer's name and
address, and model and serial number of component.
D. Generator-Set Performance:
1. Steady-State Voltage Operational Bandwidth: 3 percent of rated output voltage from no
load to full load.
2. Transient Voltage Performance: Not more than 20 percent variation for 50 percent step-
load increase or decrease. Voltage shall recover and remain within the steady-state
operating band within three seconds.
3. Steady-State Frequency Operational Bandwidth: 0.5 percent of rated frequency from no
load to full load.
4. Steady-State Frequency Stability: When system is operating at any constant load within
the rated load, there shall be no random speed variations outside the steady-state
operational band and no hunting or surging of speed.
5. Transient Frequency Performance: Less than 5 percent variation for 50 percent step-load
increase or decrease. Frequency shall recover and remain within the steady-state
operating band within five seconds.
6. Output Waveform: At no load, harmonic content measured line to line or line to neutral
shall not exceed 5 percent total and 3 percent for single harmonics. Telephone influence
factor, determined according to NEMA MG 1, shall not exceed 50 percent.
7. Sustained Short-Circuit Current: For a 3-phase, bolted short circuit at system output
terminals, system shall supply a minimum of 250 percent of rated full-load current for not
less than 10 seconds and then clear the fault automatically, without damage to generator
system components.
8. Start Time: Comply with NFPA 110, Type 10, system requirements.
2.3 ENGINE
1. Fuel: Fuel oil, Grade DF-2
B. Rated Engine Speed: 1800 rpm.
C. Maximum Piston Speed for Four-Cycle Engines: 2250 fpm (11.4 m/s).
D. Lubrication System: The following items are mounted on engine or skid:
1. Filter and Strainer: Rated to remove 90 percent of particles 5 micrometers and smaller
while passing full flow.
2. Thermostatic Control Valve: Control flow in system to maintain optimum oil
temperature. Unit shall be capable of full flow and is designed to be fail-safe.
3. Crankcase Drain: Arranged for complete gravity drainage to an easily removable
container with no disassembly and without use of pumps, siphons, special tools, or
appliances.
E. Engine Fuel System:
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1. Main Fuel Pump: Mounted on engine. Pump ensures adequate primary fuel flow under
starting and load conditions.
2. Relief-Bypass Valve: Automatically regulates pressure in fuel line and returns excess
fuel to source.
F. Governor: Adjustable isochronous, with speed sensing.
G. Cooling System: Closed loop, liquid cooled, with radiator factory mounted on engine-
generator-set mounting frame and integral engine-driven coolant pump.
1. Coolant: Solution of 50 percent ethylene-glycol-based antifreeze and 50 percent water,
with anticorrosion additives as recommended by engine manufacturer.
2. Size of Radiator: Adequate to contain expansion of total system coolant from cold start
to 110 percent load condition.
3. Temperature Control: Self-contained, thermostatic-control valve modulates coolant flow
automatically to maintain optimum constant coolant temperature as recommended by
engine manufacturer.
4. Coolant Hose: Flexible assembly with inside surface of nonporous rubber and outer
covering of aging-, ultraviolet-, and abrasion-resistant fabric.
a. Rating: 50-psig (345-kPa) maximum working pressure with coolant at 180 deg F
(82 deg C), and noncollapsible under vacuum.
b. End Fittings: Flanges or steel pipe nipples with clamps to suit piping and
equipment connections.
H. Muffler/Silencer: Critical type, sized as recommended by engine manufacturer and selected
with exhaust piping system to not exceed engine manufacturer's engine backpressure
requirements.
1. Minimum sound attenuation of 25 dB at 500 Hz.
2. Sound level measured at a distance of 10 feet (3 m) from exhaust discharge after
installation is complete shall be 85 dBA or less.
I. Air-Intake Filter: Heavy-duty, engine-mounted air cleaner with replaceable dry-filter element
and "blocked filter" indicator.
J. Starting System: 12V electric, with negative ground.
1. Components: Sized so they will not be damaged during a full engine-cranking cycle with
ambient temperature at maximum specified in Part 1 "Project Conditions" Article.
2. Cranking Motor: Heavy-duty unit that automatically engages and releases from engine
flywheel without binding.
3. Cranking Cycle: As required by NFPA 110 for system level specified.
4. Battery: Adequate capacity within ambient temperature range specified in Part 1 "Project
Conditions" Article to provide specified cranking cycle at least twice without recharging.
5. Battery Cable: Size as recommended by engine manufacturer for cable length indicated.
Include required interconnecting conductors and connection accessories.
6. Battery Compartment: Factory fabricated of metal with acid-resistant finish and thermal
insulation. Thermostatically controlled heater shall be arranged to maintain battery above
10 deg C regardless of external ambient temperature within range specified in Part 1
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"Project Conditions" Article. Include accessories required to support and fasten batteries
in place.
7. Battery-Charging Alternator: Factory mounted on engine with solid-state voltage
regulation and 35-A minimum continuous rating.
8. Battery Charger: Current-limiting, automatic-equalizing and float-charging type. Unit
shall comply with UL 1236 and include the following features:
a. Operation: Equalizing-charging rate of 10 A shall be initiated automatically after
battery has lost charge until an adjustable equalizing voltage is achieved at battery
terminals. Unit shall then be automatically switched to a lower float-charging
mode and shall continue to operate in that mode until battery is discharged again.
b. Automatic Temperature Compensation: Adjust float and equalize voltages for
variations in ambient temperature from minus 40 deg C to plus 60 deg C to prevent
overcharging at high temperatures and undercharging at low temperatures.
c. Automatic Voltage Regulation: Maintain constant output voltage regardless of
input voltage variations up to plus or minus 10 percent.
d. Ammeter and Voltmeter: Flush mounted in door. Meters shall indicate charging
rates.
e. Safety Functions: Sense abnormally low battery voltage and close contacts
providing low battery voltage indication on control and monitoring panel. Sense
high battery voltage and loss of ac input or dc output of battery charger. Either
condition shall close contacts that provide a battery-charger malfunction indication
at system control and monitoring panel.
f. Enclosure and Mounting: NEMA 250, Type 1, wall-mounted cabinet.
2.4 FUEL OIL STORAGE
A. Comply with NFPA 30.
B. Base-Mounted (In-Skid) Fuel Oil Tank: Factory installed and piped, complying with UL 142
fuel oil tank. Tank shall function as both the day tank and the main fuel storage tank. Features
include the following:
1. Tank level indicator.
2. Capacity: Fuel for eight hours' continuous operation at 100 percent rated power output.
3. Vandal-resistant fill cap.
4. Containment Provisions: Comply with requirements of authorities having jurisdiction.
2.5 CONTROL 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 mode-
selector switch is switched to the on 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.
Operation of a remote emergency-stop switch also shuts down generator set.
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B. 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.
1. Wall-Mounting Cabinet Construction: Rigid, self-supporting steel unit complying with
NEMA ICS 6. Power bus shall be copper. Bus, bus supports, control wiring, and
temperature rise shall comply with UL 891.
2. Current and Potential Transformers: Instrument accuracy class.
C. Indicating and Protective Devices and Controls: As required by NFPA 110 for Level 1 System.
2.6 GENERATOR OVERCURRENT
A. Generator Circuit Breaker: Molded-case, thermal-magnetic type; 100 percent rated; complying
with NEMA AB 1 and UL 489.
1. Tripping Characteristic: Designed specifically for generator protection.
2. Trip Rating: Matched to generator rating.
3. Mounting: Adjacent to or integrated with control and monitoring panel.
2.7 GENERATOR, EXCITER, AND VOLTAGE REGULATOR
A. Comply with NEMA MG 1.
B. Drive: Generator shaft shall be directly connected to engine shaft. Exciter shall be rotated
integrally with generator rotor.
C. Electrical Insulation: Class H or Class F.
D. Stator-Winding Leads: Brought out to terminal box to permit future reconnection for other
voltages if required.
E. Construction shall prevent mechanical, electrical, and thermal damage due to vibration,
overspeed up to 125 percent of rating, and heat during operation at 110 percent of rated
capacity.
F. Enclosure: Dripproof.
G. Voltage Regulator: Solid-state type, separate from exciter, providing performance as specified.
1. Adjusting rheostat on control and monitoring panel shall provide plus or minus 5 percent
adjustment of output-voltage operating band.
2.8 MOTORS
A. General requirements for motors are specified in Division 23 Section "Common Motor
Requirements for HVAC Equipment."
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1. Motor Sizes: Minimum size as indicated. If not indicated, large enough so driven load
will not require motor to operate in service factor range above 1.0.
2. Controllers, Electrical Devices, and Wiring: Electrical devices and connections are
specified in Division 26 Sections.
2.9 OUTDOOR GENERATOR-SET ENCLOSURE
A. Description: Vandal-resistant, weatherproof steel housing, wind resistant up to 100 mph (160
km/h). Multiple panels shall be lockable and provide adequate access to components requiring
maintenance. Panels shall be removable by one person without tools. Instruments and control
shall be mounted within enclosure.
B. Description: Prefabricated or pre-engineered walk-in enclosure with the following features:
1. Construction: Galvanized-steel, metal-clad, integral structural-steel-framed building
erected on concrete foundation.
2. Structural Design and Anchorage: Comply with ASCE 7 for wind loads.
3. Space Heater: Thermostatically controlled and sized to prevent condensation.
4. Louvers: Equipped with bird screen and filter arranged to permit air circulation when
engine is not running while excluding exterior dust, birds, and rodents.
5. Hinged Doors: With padlocking provisions.
6. Ventilation: Louvers equipped with bird screen and filter arranged to permit air
circulation while excluding exterior dust, birds, and rodents.
7. Thermal Insulation: Manufacturer’s standard materials and thickness selected in
coordination with space heater to maintain winter interior temperature within operating
limits required by engine-generator-set components.
8. Muffler Location: External to enclosure.
C. Engine Cooling Airflow through Enclosure: Maintain temperature rise of system components
within required limits when unit operates at 110 percent of rated load for 2 hours with ambient
temperature at top of range specified in system service conditions.
1. Louvers: Fixed-engine, cooling-air inlet and discharge. Storm-proof and drainable
louvers prevent entry of rain and snow.
2. Automatic Dampers: At engine cooling-air inlet and discharge. Dampers shall be closed
to reduce enclosure heat loss in cold weather when unit is not operating.
2.10 VIBRATION ISOLATION DEVICES
A. Elastomeric Isolator Pads: Oil- and water-resistant elastomer or natural rubber, arranged in
single or multiple layers, molded with a nonslip pattern and galvanized-steel baseplates of
sufficient stiffness for uniform loading over pad area, and factory cut to sizes that match
requirements of supported equipment.
2.11 REMOTE ANNUNCIATOR AND CONTROL
A. 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
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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.
B. Mount remote annunciator in main office or mechanical room at direction of owner.
C. Remote Manual Start: Provide the ability to manually start generator from a clearly labeled
mushroom switch or a button on the annunciator panel.
D. Remote Emergency-Stop Switch: Flush; wall mounted unless otherwise indicated; and labeled.
Push button shall be protected from accidental operation.
2.12 FINISHES
A. Indoor Enclosures and Components: Manufacturer's standard finish over corrosion-resistant
pretreatment and compatible primer.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Examine areas, equipment bases, and conditions, with Installer present, for compliance with
requirements for installation and other conditions affecting packaged engine-generator
performance.
B. Examine roughing-in of piping systems and electrical connections. Verify actual locations of
connections before packaged engine-generator installation.
C. Proceed with installation only after unsatisfactory conditions have been corrected.
3.2 INSTALLATION
A. Comply with packaged engine-generator manufacturers' written installation and alignment
instructions and with NFPA 110.
B. Install packaged engine generator to provide access, without removing connections or
accessories, for periodic maintenance.
C. Install Schedule 40, black steel piping with welded joints and connect to engine muffler. Install
thimble at wall. Piping shall be same diameter as muffler outlet. Flexible connectors and steel
piping materials and installation requirements are specified in Division 23 Section "Hydronic
Piping."
1. Install condensate drain piping to muffler drain outlet full size of drain connection with a
shutoff valve, stainless-steel flexible connector, and Schedule 40, black steel pipe with
welded joints. Flexible connectors and piping materials and installation requirements are
specified in Division 23 Section "Hydronic Piping."
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D. Electrical Wiring: Install electrical devices furnished by equipment manufacturers but not
specified to be factory mounted.
3.3 CONNECTIONS
A. Piping installation requirements are specified in Division 23 Sections. Drawings indicate
general arrangement of piping and specialties.
B. Connect fuel, cooling-system, and exhaust-system piping adjacent to packaged engine generator
to allow service and maintenance.
C. Connect engine exhaust pipe to engine with flexible connector.
D. Ground equipment according to Division 26 Section "Grounding and Bonding for Electrical
Systems."
E. Connect wiring according to Division 26 Section "Low-Voltage Electrical Power Conductors
and Cables."
3.4 IDENTIFICATION
A. Identify system components according to Division 23 Section "Identification for HVAC Piping
and Equipment" and Division 26 Section "Identification for Electrical Systems."
3.5 FIELD QUALITY CONTROL
A. Perform tests and inspections and prepare test reports.
1. Manufacturer's Field Service: Engage a factory-authorized service representative to
inspect components, assemblies, and equipment installations, including connections, and
to assist in testing.
B. Tests and Inspections:
1. Perform tests recommended by manufacturer and each electrical test and visual and
mechanical inspection (except those indicated to be optional) for "AC Generators and for
Emergency Systems" specified in NETA Acceptance Testing Specification. Certify
compliance with test parameters.
2. 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.
3. Battery Tests: Equalize charging of battery cells according to manufacturer's written
instructions. Record individual cell voltages.
a. 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.
b. Test for contact integrity of all connectors. Perform an integrity load test and a
capacity load test for the battery.
c. Verify acceptance of charge for each element of the battery after discharge.
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d. Verify that measurements are within manufacturer's specifications.
4. Battery-Charger Tests: Verify specified rates of charge for both equalizing and float-
charging conditions.
5. System Integrity Tests: Methodically verify proper installation, connection, and integrity
of each element of engine-generator system before and during system operation. Check
for air, exhaust, and fluid leaks.
6. Exhaust Emissions Test: Comply with applicable government test criteria.
7. Voltage and Frequency Transient Stability Tests: Use recording oscilloscope to measure
voltage and frequency transients for 50 and 100 percent step-load increases and
decreases, and verify that performance is as specified.
C. Coordinate tests with tests for transfer switches and run them concurrently.
D. Test instruments shall have been calibrated within the last 12 months, traceable to standards of
NIST, and adequate for making positive observation of test results. Make calibration records
available for examination on request.
E. Leak Test: After installation, charge system and test for leaks. Repair leaks and retest until no
leaks exist.
F. Operational Test: After electrical circuitry has been energized, start units to confirm proper
motor rotation and unit operation.
G. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and
equipment.
H. Remove and replace malfunctioning units and retest as specified above.
I. 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.
3.6 DEMONSTRATION
A. Engage a factory-authorized service representative to train Owner's maintenance personnel to
adjust, operate, and maintain packaged engine generators. Refer to Division 01 Section
"Demonstration and Training."
3.7 FUEL
A. Provide fuel for testing and fill tank after testing is complete.
END OF SECTION 16900