Chrysler LLCConstruction Standards

12/17/04

SECTION 16231 - PACKAGED ENGINE GENERATORS

PART 1 - GENERAL

1.1SUMMARY

  1. This Section includes purchase and delivery of packaged engine generator sets with the following features and accessories:
  2. Engine and generator.
  3. Exhaust piping with muffler.
  4. Starting battery and charging system.
  5. Unit enclosure.
  6. Related Sections include the following:
  7. Division16 Section "Transfer Switches."

1.2DEFINITIONS

  1. 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.
  2. Steady-State Voltage Modulation: The uniform cyclical variation of voltage within the operational bandwidth, expressed in Hertz or cycles per second.

1.3SERVICE CONDITIONS

  1. Environmental Conditions: Engine-generator system shall operate in the following environmental conditions without mechanical or electrical damage or degradation of performance capability:
  2. Ambient Temperature: 5 to 40 degC.
  3. Relative Humidity: 0 to 95 percent.
  4. Altitude: Sea level to 1000 feet.
  5. Seismic Design: Zone 1.

1.4SUBMITTALS

  1. Product Data: Include the following:
  2. Data on features, components, accessories ratings, and performance.
  3. Time-current characteristic curves for protective devices.
  4. Thermal damage curve for alternator.
  5. ServiceCenter Information:
  6. Provide contact information for a service center capable of providing training, parts, preventative maintenance and emergency repairs, located not more than four hours' normal travel time to the site.
  7. Field Assembly and Installation Drawings: Detail equipment assemblies and components, indicating dimensions, weights, loads, required clearances, and location and size of each field connection.
  8. Dimensioned plans elevations and tabulated weights of engine-generator set and components.
  9. Detail structural requirements for coordination of anchorages and attachments with concrete base.
  10. Detail requirements for field assembly and connections.
  11. Detail piping requirements and connections of fuel and exhaust systems.
  12. Detail conductor requirements and connections of power, signal, and control wiring.
  13. Test Reports: Include the following:
  14. Factory tests on units showing evidence of compliance with specified performance requirements.
  15. Record of factory measurements of sound levels.
  16. Field quality-control test reports.
  17. Operation and Maintenance Data: Operation and maintenance manuals.
  18. Warranty: Certificate of warranty.

1.5QUALITY ASSURANCE

  1. Installer Assistance: Provide the services of a manufacturer's representative, trained in and approved for installation of units, to assist the installer.
  2. Testing Agency Qualifications: Independent agency, with the experience and capability to conduct the testing indicated. Member company of the InterNational Electrical Testing Association or is a nationally recognized testing laboratory (NRTL) as defined by OSHA in 29CFR1910.7. Acceptable to authorities having jurisdiction.
  3. Testing Agency's Field Supervisor: Certified by the InterNational Electrical Testing Association or the National Institute for Certification in Engineering Technologies to supervise on-site testing.
  4. Source Limitations: Obtain generator sets and components through one source by a single manufacturer.
  5. Listing and Labeling: Provide products specified in this Section that are listed and labeled.
  6. The Terms "Listed and Labeled": As defined in the National Electrical Code, Article 100.
  7. Listing and Labeling Agency Qualifications: A "Nationally Recognized Testing Laboratory" (NRTL) as defined in OSHA Regulation 1910.7.
  8. Comply with NFPA37.
  9. Comply with NFPA70 for components and installation.
  10. Comply with NFPA110.
  11. Comply with ASMEB15.1.

1.6REGULATORY AGENCY COMPLIANCE

  1. Air Quality: Comply with applicable state and local government requirements.
  2. Noise Emission: Comply with applicable state and local government requirements 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.

1.7WARRANTY

  1. Manufacturer's standard form in which manufacturer agrees to repair or replace components of engine generators and associated auxiliary components that fail in materials or workmanship within specified warranty period.
  2. Warranty Period: Five years from date of Substantial Completion.

1.8MAINTENANCE SERVICE

  1. Initial Service: Beginning at Substantial Completion, provide a 12-month period of recommended maintenance, performed by skilled employees of manufacturer's designated service organization.
  2. Include recommended exercising to verify proper starting, load transfer, and running under load.
  3. Include routine maintenance and adjustments recommended by manufacturer to ensure proper operation.
  4. Provide equipment, parts and supplies approved by manufacturer.

PART 2 - PRODUCTS

2.1MANUFACTURERS

  1. Manufacturers: Subject to compliance with requirements, provide products by one of the following:
  2. Kohler Co; Generator Division.
  3. Cummins-Power Generation.
  4. Caterpillar, Inc.
  5. Owner approved substitute.

2.2ENGINE-GENERATOR SET

  1. Packaged engine-generator set shall be a coordinated and integrated assembly of compatible components.
  2. Nameplates: Provide a nameplate to identify model and serial number on each major system component.
  3. Rigging Diagram: Inscribed on metal plate permanently attached to mounting frame to indicate location and lifting capacity of each lifting attachment and generator-set center of gravity.
  4. Mounting Frame Design: Adequate strength and rigidity to maintain alignment of mounted components without depending on concrete foundation. Mounting frame shall be free from sharp edges and corners and shall have lifting attachments arranged for lifting with slings without damaging components.

2.3SYSTEM PERFORMANCE

  1. Power Output: Nominal ratings of 80kW/100kVA in standby duty.
  2. Voltage Output: 480Y/277 volt, 3-phase, 4-wire, 60 Hertz.
  3. Steady-State Voltage Performance: Within 4 percent of rated output voltage from no load to full load.
  4. Steady-State Voltage Modulation Frequency: Less than 1 Hz.
  5. Transient Voltage Performance: Not more than 20 percent variation for 50 percent step-load increase or decrease, to recover and remain within the steady-state operating band within three seconds.
  6. Steady-State Frequency Performance: No random speed variations outside the steady-state operational band, and no hunting or surging of speed, when system is operating at any constant load within ratings. Maintain frequency within 0.5 percent of rated from no load to full load.
  7. Transient Frequency Performance: Less than 5 percent variation with a 50 percent step-load increase or decrease, to recover and remain within the steady state operating band within five seconds.
  8. Output Waveform: No-load harmonic content shall not exceed 5 percent total and 3 percent for any single harmonic. The telephone influence factor, determined according to NEMAMG1, shall not exceed 50 percent.
  9. Sustained Short-Circuit Current: Minimum 250 percent of rated full-load current for not less than 10 seconds.
  10. Start Time: 10-second maximum start-up time.

2.4ENGINE

  1. Type: Internal combustion, reciprocating pistons in multiple cylinders, crankshaft output.
  2. Fuel: Natural gas.
  3. Fuel Distribution System: Comply with NFPA54 and NFPA58.
  4. Torque and Horsepower: Provide an engine with sufficient torque and horsepower to drive the charging alternator, airflow cooling fan and coolant pump, and also to maintain the voltage, frequency and power output of the alternator within the steady state and transient limits specified.
  5. Crankshaft Rotational Speed: 1,800 rpm.

2.5ENGINE LUBRICATION SYSTEM

  1. Lubricant: Oil, as recommended by the manufacturer, closed loop, with integral engine-driven pump.
  2. Filter and Strainer: Removes 90 percent of particles 5 micrometers and smaller while passing full flow.
  3. Drainage: System requiring no disassembly or use of pumps, siphons, special tools, or appliances.
  4. Temperature Control: Full flow, fail-safe, thermostatic-control valve automatically maintains temperature.

2.6ENGINE COOLING SYSTEM

  1. Liquid coolant, closed loop, with integral engine-driven fan and coolant pump.
  2. Cooling Fan: Engine-driven fan to provide airflow to maintain the coolant temperature rise through the radiator, and the temperature rise of system components located in the enclosure, within specified and required limits.
  3. Provide fan capacity to operate the unit at 110 percent of rated power output for 2 hours, in the maximum specified ambient temperature, without overheating.
  4. Provide fan capacity to induce the required airflow through the radiator and associated louvers and dampers in the enclosure.
  5. Provide multiple belts if a belt-drive system is used.
  6. Radiator: Factory mounted on engine-generator-set mounting frame, rated for specified coolant.
  7. Core Tubes: Nonferrous-metal construction other than aluminum.
  8. Overflow Tank: Sized to contain expansion of total system coolant from cold start to 110 percent load.
  9. Coolant: 50/50 mixture of ethylene-glycol-based antifreeze and water, with additives as recommended.
  10. Temperature Control: Full flow, fail-safe, thermostatic-control valve automatically maintains temperature.
  11. Heater: Factory installed electric-immersion type. Comply with NFPA110 requirements for Level1 equipment.

2.7ENGINE EXHAUST SYSTEM

  1. Muffler: Critical-type, sized to attenuate sound level to 75dBA or less, measured 10 feet from discharge.
  2. Muffler Condensate Drain: Schedule40, black steel pipe muffler drain outlet, through a petcock, to a drain connection at the enclosure.
  3. Muffler Location: Within the enclosure.
  4. Exhaust Connection
  5. Provide flexible, corrugated stainless steel pipe connecting the engine exhaust manifold to the muffler, and connecting the muffler to a flanged connection point outside of the enclosure.
  6. Provide a flanged connection point compatible with ASTMA53/A53M, Schedule40, welded, black steel pipe outside of enclosure.

2.8COMBUSTION AIR INTAKE CLEANER

  1. Standard-duty, engine-mounted air cleaner with replaceable dry filter element and "blocked filter" indicating.

2.9ENGINE STARTING SYSTEM

  1. Description: 24 volts DC, negative ground. Include the following items:
  2. Components: Sized to withstand three full engine-cranking cycles at maximum ambient temperature.
  3. Minimum Cranking Cycle: 60 seconds.
  4. Battery or Batteries: Capacity to provide three cranking cycles without recharging.
  5. Battery Cables: Furnish cables recommended by manufacturer, including battery interconnection cables.

2.10STARTING BATTERY CHARGING SYSTEM

  1. Battery Charging Alternator: Factory mounted on engine with solid-state voltage regulation.
  2. Provide multiple belts if a belt-drive system is used.
  3. External Battery Charger: Current-limiting, automatic-equalizing and float-charging type. Unit shall comply with UL1236 and include the following features:
  4. Operation: Automatically initiate a 10A charge rate after battery discharge. Automatically switch to a float-charging voltage when battery terminals reach the equalized voltage setting.
  5. Automatic Temperature Compensation: Adjust float and equalize voltages for variations in ambient temperature from minus 40degC to plus 60degC to provide proper charging.
  6. Automatic Regulation: Maintain required output for input voltages plus or minus 10 percent.
  7. Ammeter and Voltmeter: Provide flush mounted in door to indicate charging rates.
  8. Low Battery Voltage Alarm: Sense abnormally low battery voltage and close contacts providing low battery voltage indication on control and monitoring panel.
  9. High Battery Voltage Alarm: Sense abnormally high battery voltage and close contacts providing high battery voltage indication on control and monitoring panel.
  10. Loss of Input/Output Alarm: Sense loss of ac input or dc output of battery charger and close contacts providing a battery-charger malfunction indication on control and monitoring panel.
  11. Enclosure: NEMA250, Type1 cabinet.

2.11LOCAL CONTROL AND MONITORING

  1. Local Control and Monitoring Panel: Group operating and safety indications, protective devices, basic system controls, and engine gages in a common control and monitoring panel mounted on the generator set. Provide a mounting method to reduce isolate the panel from expected vibration. Provide indicating and protective devices and controls required by NFPA110 for a Level1 system. Include sensors, transducers, terminals, relays, other devices and their respective wiring connections to the local panel.
  2. Control Selector.
  3. Automatic: Permits remote contacts in automatic transfer switch to initiate start and stop.
  4. Stop: Selector switch stops unit, and blocks remote starting.
  5. Run: Selector switch initiates start, and unit runs continuously.
  6. Emergency Stop: Stops the generator set and blocks starting by any action.
  7. AC voltmeter and phase selector switch.
  8. AC ammeter and phase selector switch.
  9. AC frequency meter.
  10. DC voltmeter to indicate battery and alternator voltage.
  11. Coolant temperature gage with indications for acceptable and unacceptable ranges of operation.
  12. Lubricating oil pressure gage with indications for acceptable and unacceptable ranges of operation.
  13. Elapsed time meter to log running hours.
  14. Output voltage adjustment.
  15. Overload indication.
  16. Safety Shutdown: Indicates that failures or derangements have shut down the generator set.

2.12REMOTE ALARM PANEL

  1. Remote Audible Alarm Panel: Comply with NFPA110 requirements for Level1 systems.
  2. Engine high-temperature shutdown.
  3. Engine high-temperature warning.
  4. Lubricating-oil low-pressure shutdown.
  5. Lube-oil low-pressure warning.
  6. Engine overspeed shutdown.
  7. Overcrank shutdown.
  8. Emergency-stop shutdown.
  9. Coolant level low.
  10. Coolant temperature low.
  11. Battery voltage low.
  12. Airflow blocked.
  13. Controls not in Automatic.
  14. Battery charger malfunction.

2.13ALTERNATOR

  1. Comply with NEMAMG1 and specified performance requirements.
  2. Electrical Insulation: ClassH or ClassF.
  3. Subtransient Reactance: 12 percent, maximum.
  4. Alternator Drive Connection: Directly connect alternator shaft to engine shaft.
  5. Provide alternator capable of withstanding damage from momentary operation at 125 percent of rated speed, and two hours of operation at 110 percent of rated output.
  6. Windings: Two-thirds pitch stator winding and fully linked amortisseur winding.
  7. Stator Winding Leads: Connect stator leads in a terminal box to conductors terminating on the circuit breaker.

2.14EXCITER AND VOLTAGE REGULATOR

  1. Exciter Drive: Directly connect exciter shaft to alternator shaft.
  2. Exciter Output: Brushless exciter, to sustain generator output under overload and short circuit conditions.
  3. Voltage Regulator: Solid-state type, to provide specified performance.
  4. Provide for adjustment on remote control and monitoring panel of plus or minus 5 percent adjustment.
  5. Enclosure: Ventilated, drip proof construction.

2.15ALTERNATOR OVERCURRENT AND FAULT PROTECTION

  1. Circuit Breaker: Molded-case, thermal-magnetic type; comply with NEMAAB1 and UL489.
  2. Ratings and Characteristics: Shall not trip unless load exceeds alternator ratings.
  3. Auxiliary Trip: Provide controls to trip the breaker when other protective devices shut down the unit.
  4. Enclosure: NEMA250, Type1 cabinet if breaker is not integrated into control and monitoring panel.

2.16GENERATOR-SET ENCLOSURE

  1. Description: Vandal-resistant, steel housing for indoor installation.
  2. Construction: Galvanized steel structural frame and panel enclosure.
  3. Access: Hinged doors with padlocking provisions, removable by one person without tools.
  4. Enclosure Ventilation: Provide enclosure ventilation louvers equipped with screen and filter, sized to provide necessary air circulation when engine is not running.
  5. Cooling Airflow: Provide louvers and dampers coordinated with engine cooling fan requirements.
  6. Louvers: Fixed-blade for cooling-air inlet and discharge, screened to prevent entry of foreign objects.
  7. Automatic Dampers: At engine cooling-air inlet and discharge louvers, closed when unit is not operating.
  8. Sound Level: Maximum of 70 dBA.

2.17FINISHES

  1. Indoor Enclosure and Components: Manufacturer's standard light gray enamel over corrosion-resistant pretreatment and compatible standard primer.

2.18SOURCE QUALITY CONTROL

  1. Prototype Testing: Factory test engine-generator set using same engine model, constructed of identical or equivalent components and equipped with identical or equivalent accessories.
  2. Tests: Comply with NFPA110, Level1 energy converters in Paragraphs3.2.1, 3.2.1.1, and 3.2.1.2.
  3. Alternator Tests: Comply with IEEE115.
  4. Equivalent Components and Accessories: Submit evidence that items furnished with the unit, but that are not identical to those on the prototype, are reliable and compatible with the application.
  5. Project-Specific Equipment Tests: Before shipment, factory test engine-generator set and other system components and accessories manufactured specifically for this Project. Perform tests at rated load and power factor. Include the following tests:
  6. Full load run.
  7. Maximum power.
  8. Voltage regulation.
  9. Transient and steady state governing.
  10. Single-step load pickup.
  11. Safety shutdown.
  12. Observation: Provide 14-day advance notice of tests and permit Owner's representative to observe tests.
  13. Report factory test results within 10 days of completion of test.

PART 3 - EXECUTION

3.1STARTUP

  1. Provide the services of a factory-authorized service representative for startup service.
  2. Inspect field-assembled components, equipment installation and piping and electrical connections.
  3. Report any observed defects in writing.
  4. Proceed only after correcting defects to the satisfaction of the service representative.
  5. Perform checks using manufacturer's written instructions.

3.2DEMONSTRATION

  1. Demonstrate that the completed system functions as specified
  2. Demonstrate automatic start and stop by remote signal from transfer switch.
  3. Demonstrate manual start and stop at local control panel selector.
  4. Demonstrate blocking of remote start operation with Stop selected.
  5. Demonstrate that remote monitoring panel indications are as specified.

END OF SECTION

PACKAGED ENGINE GENERATORS16231 - 1 of 9