Section 1600 Generator



SECTION 26 32 00

PACKAGED GENERATORS ASSEMBILIES

- GENERAL

2. SUMMARY

A. Section includes: EPA NSPA and California Certified Tier Compliant, UL2200, engine generator set, sound attenuated enclosure each generators will meet each unit 79 dba @ 23 feet, exhaust silencer factory installed, fuel tank, battery and charger, remote annunciator panel, meets Tier 2 Certified.

2. SYSTEM DESCRIPTION

A. Description: Engine generator assembly and accessories to provide source of power for Level 1 applications in accordance with NFPA 110.

B. Paralleled System Capacity: Total System 2000 KW, consisting of two Generac Gemini Modules with two 500 KW units each factory installed inside each module to meet the total of 2000 KW on site load.

C. Must be capable of meeting NFPA 110 – within 10 Seconds starting the capacity of 1000KW, each generator will have a total capacity of 500 kW, 625 kVA, 4 x 500 KW Diesel Units, at an elevation of 100 feet above sea level, standby rating using specified engine and cooling scheme, paralleling switchgear is not required.

3. SUBMITTALS

A. Shop Drawings: Required.

B. Product Data: Required.

C. Test Reports: Required.

D. Manufacturer's Field Reports: Required.

4. CLOSEOUT SUBMITTALS

A. 4 sets Operation and Maintenance Data: Required in binders, per O&M Spec.

5. WARRANTY

5 year comprehensive warranty

– PRODUCTS

2. ENGINE GENERATORS

A. Manufacturers:

1. Generac Power Systems, Inc. (Contact: Energy Systems - Bob Formicola 209-470-3056 bobf@)

B. Product Description: Water-cooled in-line or V-type, four-stroke cycle, compression ignition Diesel internal combustion engine.

6. ENGINE

A. Fuel System: No. 2 fuel oil.

B. Safety Devices: Engine shutdown on high water temperature, low oil pressure, overspeed, and engine overcrank. Limits as selected by manufacturer.

C. Engine Starting: DC starting system with positive engagement, number and voltage of starter motors in accordance with manufacturer's instructions. Furnish remote starting control circuit, with MANUAL-OFF-REMOTE selector switch on engine-generator control panel.

D. Engine Jacket Heater: 2 per engine, thermal circulation type water heater with integral thermostatic control.

E. Radiator: Radiator using glycol coolant, with blower type fan, sized to maintain safe engine temperature in ambient temperature of 122 degrees F Radiator air flow restriction 0.5 inches of water maximum.

F. Engine Accessories: Fuel filter and water separator, Fuel shut-off solenoid valve, Fuel filter, lube oil filter, intake air filter, lube oil cooler, fuel transfer pump, fuel priming pump, gear-driven water pump. Furnish fuel pressure gage, water temperature gage, and lube oil pressure gage on engine/generator control panel.

G. Mounting: Furnish unit with suitable spring-type vibration isolators and mount on structural steel base.

7. GENERATOR

A. Product Description: NEMA MG1, three phase, four pole, re-connectable brushless synchronous generator with brushless exciter.

B. Each Generator will be rated: 2 x 500 KW - 1000kW, 1,250 kVA, at 0.8 power factor, 480Y/277 volts, 60 Hz at 1800 rpm, for a total of 2000 KW, single 2000KW’s and Single 1000KW are not permitted, each 1000 KW must consist of 2 x 500 KW within a single housing with the 2000 gallon base tank.

C. Insulation Class: H.

D. Temperature Rise: 130 degrees C Standby, each 500 KW Alternator.

E. Enclosure: NEMA MG1, open drip proof.

F. Voltage Regulation: Digital Paralleling Type, Switchgear mounted volts per hertz exciter-regulator to match engine and generator characteristics, with voltage regulation plus or minus 1 percent from no load to full load. Furnish manual controls to adjust voltage droop, voltage level (plus or minus 5 percent) and voltage gain.

8. GOVERNOR – DIGITAL, LOAD SHARE TYPE FOR PARALLELING

A. Product Description: Governor for mounting in Switchgear, to maintain engine speed within 0.5 percent, steady state, and 5 percent, no load to full load, with recovery to steady state within 2 seconds following sudden load changes.

9. BASE FUEL (Day Tanks) TANKS EACH - UL 2085

A. Product Description: UL 2085

B. 2000 gallon each unit dual walled with alarms and connections for remote monitoring of low level and leak detection.

C. Furnish, fuel gage, check-valve, high fuel level alarm contact, and indicating light, fuel probe.

D. Conform to UL 2085 fire Rating and ballistic rating, and NFPA 30.

10. ACCESSORIES

A. Exhaust Silencer: “Will” be installed inside of the Enclosure. Critical Grade Type Silencer, with companion flanges and flexible stainless steel exhaust fitting.

B. Initial Fill Oil and antifreeze

C. Air cleaner and oil filter with internal bypass

D. Battery Tray: will be located outside of each generator a battery frame and plastic battery boxes w/tops to prevent the elements will be provided – and to be treated for electrolyte resistance, constructed to contain spillage.

E. Batteries: Heavy duty, diesel starting type lead-acid storage batteries, 170 ampere-hours minimum capacity. Furnish cables and clamps.

F. Battery Charger: 10 amp current limiting type designed to float at 2.17 volts for each cell and equalize at 2.33 volts for each cell. Furnish overload protection, full wave rectifier, DC voltmeter and ammeter, and 120 volts AC fused input. Furnish enclosure to meet NEMA 250, Type 1 requirements.

G. A paralleling contactor (Motorized or Electrically Operated Breakers “will not” be allowed) manufactured by Generac shall be integrated into each generator (Built on each generator) panel to allow for automatic electrical closure onto a dead bus or in parallel with other generators once required conditions are satisfied. The contactor shall be an electrically operated (line power closed, DC power trip) mechanically held device with main contacts composed of silver alloy to resist welding and minimize voltage dip on closure.

H. The contactor shall be capable of 65,000 amp maximum RMS symmetrical fault current.

I. It shall have mechanical lugs for connecting cable (350 MCM to 700 MCM) installed.

J. Line Circuit Breaker: 800 amp NEMA AB 1, 100% Rated, Electronic Trip, molded case circuit breaker on generator output with integral thermal and instantaneous magnetic trip in each pole. Furnish battery voltage operated shunt trip, connected to open circuit breaker on engine failure. Unit mounted in an enclosure to meet NEMA 250, Type 1 requirements.

11. CONTROLS

A. Each generator panel shall contain the paralleling and protection functions to allow the unit to assume a dead generator system bus or parallel to it. Included will be the governor control, voltage regulator, auto-synchronizer, load sharing, sync check, reverse power and an independent over-speed sensor. 2-way digital communications with the system controller will direct these functions to assure, auto-synchronization, and proportional load sharing between gensets. It will feature factory-programmed functions to customer specified tolerances as follows: Frequency differential within +/- 0.1 Hz to +/- .25 Hz (adjustable).Phase difference settable to within +/- 2 to +/- 20 degrees for 50/60 Hz.

B. Load Control Management: this will allow all generators to come up and parallel to the system, then with the support of the BMS Systems, the Generator Controls will be told to turn on and or off generators as required, if the load is smaller than the total output of 1 x 1000 KW the Primary System Controller will begin to shut down the not required not needed capacity, then as the requirement for increased capacity returns, the generators will be returned to the system – each generator will parallel back to the buss to allow for the increased capacity to operate the system fully.

C. Generator Control Panel:

1. Digital Control Platform configured for Paralleling System

2. Engine run relay

3. 32 bit microprocessor structured with: Real time clock, 47 inputs, 32 outputs, 2- RS232 ports, 2- RS485, ports, RJ45 modem port, CANBus port 0.25% digital voltage regulator with:

a. 3 phase RMS sensing, Soft start voltage ramping – adjustable, Loss of sensing protection – adjustable

b. Negative power limit – adjustable

c. Hi/lo voltage limit adjustable

d. V/F slope and gain – adjustable

e. Fault protection

f. Encapsulated and sealed

4. 0.25% digital frequency regulation with:

a. Soft start ramping - adjustable,

b. Gain – adjustable

c. Overshoot limit – adjustable

5. Electronic governor – isochronous, Steady state regulation +/-0.25%

6. On board PLC for customer configuration with:

a. (24) Digital inputs

b. (43) Analog inputs

c. (24) digital open collector outputs - 30vdc

d. (16) Timers

e. (16) Counters

7. Programmable touch screen engine control and monitoring module with:

a. Auto/Manual/off key switch

b. Alarm LED

c. Not in Auto LED

d. Audible alarm

e. Emergency stop switch

f. 30 page readout including:

a. Oil pressure and optional oil temperature

b. Coolant temperature and level

c. Fuel level (where applicable)

d. Engine speed

e. DC battery voltage

f. Run time hours

g. Generator voltages

h. Amps

i. Frequency

j. Power

k. Power factor Alarm Status:

a) Low or high AC voltage

b) Low or high battery voltage

c) Low or High frequency

d) Pre-low or low oil pressure

e) Pre-high or high oil temperature (optional)

f) Low water level and temperature

g) Pre-high or high engine temperature

h) Low fuel levels

8. Overcrank, Over and under speed, Unit not in "Automatic Mode"

12. PRIMARY SYSTEM PARALLELING CONTROLLER

A. Manufacturers:

B. Primary Main System Controller (PMSC)

Mfg. Generac Power System

C. Main Controller

1. To Control the (Number of units and KW sizes = 8 x 500 KW) System, NEMA 3R (Single Skidded 2 x 500KW Diesel Units)

2. Generac, MASTER PARALLELING CONTROLLER

3. Digital Control Platform configured for System Controller (PM-SC)

a. 32 bit microprocessor structured with:

b. Real time clock

c. 47 inputs, 32 outputs

d. 2- RS232 ports

e. 2- RS485 ports

f. RJ45 modem port

g. CANBus port

4. Programmable touch screen system control monitoring module with:

a. Utility status via ATS 2-wire start

b. Individual generator status via digital communications with PM-PC

5. On board ILC for customer configuration with:

a. (24) Digital inputs

b. (43) Analog inputs

c. (24) digital open collector outputs - 30vdc

d. (16) Timers,

e. (16) Counters

6. Protective Paralleling Relay Package

a. 25 Synch check

b. Current and potential transformer ratio.

c. Loss of excitation

d. over/under frequency

e. 27/59 three phase with enable feature

f. 27/59 under/over voltage

g. 15 Automatic Synchronizer

h. 32 reverse power

i. Auto and manual synchronizing with voltage matching

7. Generator bus status via digital communications

a. ATS operation via programmable permissive signal

b. Proportional load sharing via digital communications with PM-PC

8. Programmable ATS load shed initiation

a. Alarm and event logging

b. System communications

c. Internal modem

9. System Controller Housed in NEMA 3R Enclosure

a. 120VAC GFCI duplex receptacle

A. Remote Annunciator Panel: 1 each per generator - with painted finish. Furnish audible and visible indicators and alarms in accordance with NFPA 110.

10. 21 Light Remote Annunciator

11. Generator remote start capabilities

12. 24 Volt DC input

13. Integrated 8 function relay panel for remote monitoring

a. activation of up to 8 generator set parameters

14. Communication via RS485 data link

15. Solid-state LED lamps - Annunciation of:

a. Generator Run

b. Pre-Low Oil Pressure

c. Battery Charger AC Fail

d. Pre-High Water Temp

e. Low Battery Voltage

f. Pre-Low Water Temp

g. High Battery Voltage

h. Pre-Low Fuel

i. RPM Sensor Loss

j. Low Oil Pressure

k. Overcrank

l. High Water Temp / Low Water Level

m. Overspeed

n. Emergency Stop

o. Generator Power

p. Not in Auto

q. System Ready

r. Line Power

s. Communication OK

t. Spare

A. Remote Emergency Stop-Surface shipped separately

B. Weather-Sound Attenuated Protective Enclosure Factory Supplied – Skin Tight/Non-Walk in type: Required dba Level 79 dba @ 23 feet each unit running alone – sound data sheet must include exhaust noise and enclosure sound level. Sound Enclosure Systems excluding exhaust noise will not be acceptable. Exhaust Air Discharge must be Vertical Discharge. Reinforced steel housing allowing access to control panel and service points, with lockable doors and panels. Furnish fixed louvers, and silencer installed inside enclosure.

C. Load Center 60 amp - with input and output breakers to power Coolant Heater, Battery Charger and 120V AC Interior Lights, include 12V DC Interior Light, Oil and radiator drain extensions.

D. Enclosure to house (2 x 500 KW) Standard Generac Package with a Single Point of paralleling and Load Connections, to be completely installed within the enclosure housing.

E. Batteries will be installed outside the Enclosure in an approved Battery Box and resting on an approved battery rack, to prevent acid and corrosion.

13. LOAD BANK 1000 KW OF TOTAL RATING

A. Stand Alone

B. MODEL: OSL4v-1000.1-480V33-0600-10

C. RATING: 1000 KW @ 480 V, 3∅, 3W, 60 Hz, 1.0 P.F.

D. RESOLUTION: 10 KW nominal load step adjustment from 0-100% of unit rating.

E. TOLERANCE: 0 -+5% overall tolerance, +/- 2% phase-to-phase balance DUTY

CYCLE: Continuous

F. APPLICATION: The unit has the capability of loading power sources at varying power ratings.

G. CONFIGURATION: The Load Bank consists of two (2) separate items: 1) An outdoor weatherproof load enclosure containing the load resistors, power control devices, and cooling fan. 2) A Wall mounted Operator Interface Panel

H. ENCLOSURE: Load: Outdoor Weatherproof Vertical Exhaust, Nema 3R, with bolt down provisions for permanent mounting; captive fork lifting provisions and lifting eyes for handling during installation. The enclosure is fabricated of galvanized steel that is primed and painted as described below. The top exhaust is protect with articulated cover doors automatically operated.

I. Control: (1)Nema 12 Wall Mounted Enclosure

J. PHYSICAL: Load Enclosure: 96"H x 48.5"W x 66"D, 2000 LBS

K. Control Enclosure: 14"H x 12"W x 8"D, 30 LBS

L. PAINT: Environmentally friendly waterborne enamel

M. Preparation: SSPC Surface Preparation Standards # SP1

N. Primer: Acrylic direct-to metal (DTM) primer (high solids); MIL-P-28577B

and TT-P-1975

O. Finish: Premium High Performance UV Resistant Acrylic Enamel

P. Color: ASA 61 Lt. Gray

a. AMBIENT: Temperature.: -20 F./-30 C. to +120 F./+50 C.

Q. Humidity: up to 100 %

R. Altitude: 4000 Ft / 1200 M

S. LOAD RESISTOR: The Loadtec RESISTAR is designed specifically for high density applications. The resistor is continuously supported to eliminate possible shorting contact with surrounding resistors. Load resistors are mounted in trays that are independently mounted so each is removable without affecting any other tray. The RESISTAR has an industry exclusive 3 year limited warranty.

T. COOLING: Forced air cooled by a TEFC motor with a direct drive airfoil propeller.

U. CONTROL POWER: Internal

V. Cooling Motor: 10HP, 460V, 3∅, 60Hz., internally derived from the connected test power source.

W. Control: 24 VAC, 1∅, 60 Hz., derived from the fan power 3∅ source via a control power transformer.

X. CONTROL POWER: External

Y. Processor: 24 VDC from engine starting battery.

Z. CONTROL: Processor Control / Metering System

AA. Features: ⇑ The control system provides integrated control and metering for the load bank

Serial interface to Control Panel(s) using conventional Category 5 data cable connection.Up to (4)Control Panels can be connected on a single unit with a simple “daisy chain” wiring.

a. Remote Control Panel(s) install with up to 1,000ft of control cabling without external control power required for the control panel. Control Module installed in the load enclosure and the OIP installed in the control panel areboth upgradeable with firmware flash capability. Additional serial RS232, RS422 and RS485 ports are available for optional Modbus and optional Windows DLL external control interfaces.Ethernet port for optional TCP/IP interface functions.

AB. Operation:The control system is accessed at the Operator Interface Panel (OIP) installed in the Control Panel

AC. The control system provides the following programmable functions:

a. Manual Load Step Control

b. Automatic Loading Operation

c. Regenerative Absorption Operation

d. Base Load Control for enhanced transfer and block load response.

AD. Exercise Monitoring and Alarm Circuitry

a. Automatic Load Sequencing (External Exercise Clock)

b. Transfer Switch position monitoring for operational logic coordination

AE. Metering: The control system provides metering values on the Operator Interface Panel.

a. All values are true RMS

b. The metering values available for selected display:

c. Voltage each Ø-Ø, +/-1.0%

d. Voltage Average, +/-1.0%

e. Current each Ø, +/-1.0%

f. Current Average +/-1.0%

g. Frequency: 45-65 Hz, +/-0.2%

h. Kilowatts Average, +/-1.0%

AF. Aux. Contacts: (4) Addressable “C” Form Auxiliary contact signals are provided. Standard Signals:.

a. Generator Start – for Automatic Exercise Operation

b. Exercise Failure – for Automatic Exercise Operation

c. Normal Operation

d. Common Failure

AG. Operator Interface: Wall mounted Panel.

a. The features of the system is accessed by the Operator Interface Panel.

b. Serial interface to Control Panel(s) using conventional Category 5 data cable connection.

c. Up to (4)Control Panels can be connected on a single unit with a simple “daisy chain” wiring.

d. The panel consists of the following components:

e. LCD Graphics Display Screen

f. Control Keypad

g. Audible Input Signal

h. LED General Operational Indicators

i. Lamp & Graphical Display Test

j. The LCD Display provides:

k. Soft Key Legend

l. Metering display

m. Operational Mode

n. Operational status and alarm condition details

AH. PROTECTIVE SYSTEM

AI. Cooling: A temperature & air flow sensors monitors cooling and disconnects the unit on failure.

AJ. Voltage: Voltage monitoring circuits monitor for connected sources and alarms and disconnects on faults.

AK. Cooling Motors: Thermal overload relays with thermal magnetic circuit breaker for protection and disconnect.

AL. FUSES: Fuse protection is provided for each individual load section and control circuit.

AM. POWER CONTROL: The load is controlled by contactors that are applied for continuous and cycling operation.

AN. MANUALS: (2) As built drawing manuals are provided at time of shipment.

AO. WARRANTY: Tier 1 Standard Limited Warranty

14. SOURCE QUALITY CONTROL Generators only

A. Factory Inspection: 4 hours each inspection:

1. Unity Power Factor .08 Testing – 4 hours each unit

a. Provide Testing Data at Closeout

- EXECUTION

2. FIELD QUALITY CONTROL

B. Onsite start-up and testing according to the manufactures recommendations.

1. Manufacturer's Field Services: Required.

2. Load Bank Testing Total System 4 hours on-site supply and test units at full rated load utilizing the resistive load bank on site, and a provided portable 1000 KW worth of Load Bank Load.

3. Building Load Test Required, with BMS System.

C. Demonstration and Training: Furnish 4-6 hours of instruction for maintenance persons, to be conducted at project site with manufacturer's representative.

END OF SECTION

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