Southeastern Pennsylvania Transportation … Facility CHP RFP 14...Southeastern Pennsylvania ....

Southeastern Pennsylvania Transportation Authority

Technical Specifications

COMBINED HEATING & POWER PLANT

FOR SEPTA MIDVALE SITE

SEPTA RFP NO.: 14-297-JFK

50 % Design Package

Client Name: SEPTA Project Name: SEPTA Midvale CHP Plant Revision: 0 Date: 10/6/2014

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TABLE OF CONTENTS

SECTION TITLE PAGE 15400 RECIPROCATING ENGINE GENERATOR 3 15402 SELECTIVE CATALYTIC REDUCTION SYSTEM 39 16346 MEDIUM VOLTAGE GENERATOR METAL CLAD 62 SWITCHGEAR


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15400 RECIPROCATING ENGINE GENERATOR PART I - GENERAL

1.1 DESCRIPTION

A. The Supplier shall design, fabricate, assemble, factory test, deliver and provide startup and commissioning and training for two (2) Engine Generator systems. The Engine Generator systems shall be complete with all components and design features as specified herein for installation at SEPTA Midvale, also referred to herein as “Owner”, Combined Heat and Power Plant (CHP), located in Philadelphia, Pennsylvania.

B. The Engine Generator shall be capable of operating from 50% gross power output to 100% gross power output in a load following or base load operations. The Engine Generator system shall be the Supplier's standard and shall be designed in accordance with the latest applicable codes and standards.

C. It is the intention of this specification that the Supplier shall be solely and entirely responsible for the design, procurement of materials and components, fabrication and assembly, inspection and testing, preparation for shipment, delivery and guarantee of the performance of the equipment, as well as the commercial liability of the entire system: Engine Generator and Switchgear and all auxiliary components as specified and as required, including subsequent startup, operation and maintenance support, as required by the Owner. The individual equipment packages of the Engine Generator system shall be integrated by the Supplier to form a completely functional system such that the Engineer need only to design the interconnecting utilities, piping, wiring and appurtenances to form a complete, functional, and reliable system.

D. The Engine Generator package, with minimum ISO base load continuous rating of between 4,000 kW and 4,400 kW at the generator bus bar, shall consist of a spark ignited, internal combustion engine and a lean burn, turbo charged, fuel system suitable for low pressure (less than 10 psig) natural gas. The Engine Generator system shall be installed indoors.

E. The Engine Generator shall operate at a speed of 900, 1200 or 1800 rpm. The Supplier's proposed design shall be fully defined and shall be accompanied by drawings and data to describe in sufficient detail the construction and general arrangement to allow for an acceptable evaluation. Completed Data Sheets with the proposal are required before the proposal can be accepted. The Supplier shall, as a minimum, furnish drawings, data and descriptive information for the Engine Generator system in detail, as specified herein.

1.2 WORK INCLUDED

A. The scope of work shall cover the supply of two (2) Engine Generator packages, consisting of, but not limited to, the following major items:


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1. Engine with turbocharger, ignition and combustion system.

2. Load gear, flywheel and couplings.

3. Preassembled fuel gas train - low pressure natural gas.

4. Pre chamber fuel gas booster if required.

5. Start up system.

6. Cooling system for jacket water, intercooler and lube oil systems, including: remote, outdoor ground mounted, horizontal radiator (vertical airflow), self-contained jacket water temperature control valve, expansion tank, required pipe work on engine, vents, drains, filling device, safety valve(s) as required, jacket water heater and circulation pump with check valve.

7. Complete engine lubrication oil system with automated makeup and flow control system.

8. Engine mounted intercooler, lube oil and jacket water cooler heat exchangers designed for heat recovery complete with all interconnecting pipe work.

9. Generator and accessory gear.

10. Engine governing and control system with capability for facility plant control system interface via data highway and remote diagnostics via high speed internet.

11. Automatic ignition control system.

12. Thermal insulation for all hot parts, as required.

13. Engine air intake and ducting for combustion air consisting of filters and support, where applicable.

14. Engine exhaust silencer, flue gas expansion joints, including the Engine outlet fitting.

15. Flexible connections for all interconnecting utilities piping at engine.

16. Operational and startup spare parts.

17. Special tools.

B. The Engine Generator package shall consist of a 0.8 power factor, 13200 volts, three phase 60-hertz electric generator, complete with all its auxiliaries herein. The auxiliaries shall include, but shall not be limited to the following:

1. Brush-less excitation system with PMG


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2. Automatic voltage regulator

3. Electronic isochronous/load sharing governor

4. On-skid Engine and Generator Control Module (ECM), metering, alarm, and protection panel, including customer communications module and (2) spare programmable relays

5. One (1) CCCT

6. One set of batteries and charger (24 volts)

7. All on-skid wiring, conduits and junction/terminal boxes for external connections

C. Common structural steel base for the Engine Generator and all accessories.

D. Complete instrumentation including all local instruments, gauge boards, sensors, switches, transmitters, final control elements, junction boxes, along with local control panels, power supplies, etc.

E. Vibration isolators, shim plates, adjustment bolts, sylomer strips etc., required for installation of the set on the foundation.

F. Supply and application of priming, rust inhibiting, and final painting at the shop.

G. Shop testing.

H. Construction support and commissioning, startup and testing.

I. Initial fill of lubricants and glycol mixture.

J. In the event the exhaust temperature exceeds 975 °F (including all exhaust temperature tolerances) thus causing ammonia slip above state and local limits at any load point, an additional oxidizing catalyst or a pre-cooler shall be provided to cool the exhaust prior to the SCR catalyst and to limit the ammonia slip to the level acceptable by EPA. The SCR catalyst shall be able to handle the elevated flue gas temperatures during the engine low load operations.

K. Exhaust silencer.

L. Waste heat recovery plate and frame heat exchanger designed to recover heat from high temperature cooling loop.

M. Low temperature and high temperature circuit pumps, two (2) per service with braids.

N. Technical support to assist the Engineer in obtaining all necessary licenses and permits.


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1.1 WORK BY OTHERS

A. Foundation.

B. Installation, including anchor and hold down bolting to the foundation in accordance with Supplier anchor location details.

C. Engine flue gas breeching and stack, including all transition pieces, connection to SCR equipment, expansion joints and components not supplied by the Vendor.

D. Field wiring from pre-assembled skid terminal connection or field-mounted components.

E. Field installation of loose shipped trim and ancillaries.

F. Power supply wiring to Radiator fan motors.

G. Interconnecting piping between remote radiator-cooler and engine; plate and frame heat exchanger to engine and utilities.

H. Field testing and preparations for startup as specified herein.

I. Performance and acceptance testing as specified herein.

J. Utilities, as required and specified by the Supplier, including instrument air, electricity, etc.

K. Paralleling switchgear for connecting the generator to the 13.2 kV utility source.

1.2 UTILITIES AVAILABLE

A. Electricity: 480 Volt, 3 phase, 60 hertz

120 Volt, 1 phase, 60 hertz

B. Municipal Water Supply: 30-50 psig at 65 °F

C. Natural Gas Pressure: Will be regulated to suit engine (15 psig available)

1.3 CODES, STANDARDS AND REGULATIONS

A. All materials, design, fabrication, assembly and test procedures shall be in accordance with the requirements of all applicable codes, standards or regulations having jurisdiction over the work.


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B. The organizations having jurisdiction include, but are not limited to, the following:

• ANSI/IEEE 112 Test Procedures for Polyphase Induction Motors and Generators. • ANSI/IEEE 115 Test Procedures for Synchronous Machines. • ANSI/IEEE C.2 National Electric Safety Code. • ASME American Society of Mechanical Engineers • EPA Federal, State and Local Environmental Protection Agencies • IBC International Building Code • ANSI/ISA S18.1 Annunciator Sequence and Specification. • NEC National Electrical Code. • NEMA ICS-2 Enclosures for Industrial Control and Systems. • NEMA MGI Motors and Generators. • NEMA MG2 Safety Standard for Construction and Guide for Selection,

Installation and Use of Electric Motors and Generators. • NESC National Electrical Safety Code. • NFAC National Fire Alarm Code. • NFPA 37 Installation and Use of Stationary Combustion Engines and Gas

Turbines. • OSHA Regulations of the Occupations Safety and Health

Administration. • UL Underwriter's Laboratories Inc.

• The state, county or municipal laws and regulations governing the location where the

equipment is to be installed.

C. Reference to any code, standard or regulation shall mean the latest published edition, including addenda, supplements and revisions thereto, which are in effect when the purchase order is awarded.

D. In the event of conflict between codes, standards or regulations, the conflict shall be referred to the Engineer for resolution.

1.4 INSPECTION

A. The Engineer reserves the right to inspect the unit during fabrication at the Manufacturer’s plant. Dates and times shall be mutually agreeable to the Manufacturer and the Engineer.

B. Inspection by the Engineer, or lack of, shall in no way relieve the Manufacturer of its responsibility to meet the requirements of the Codes and this specification.


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1.5 QUALITY ASSURANCE

A. The Supplier of the Engine Generator set shall be responsible for satisfactory total operation of the system and its certification. This Supplier shall have had experience with three or more installations of systems of comparable size and complexity in regards to coordinating, engineering, testing and supervising. Each of these installations shall have been in successful operation for three or more years. Prior to review of submittals, the Engineer reserves the right to:

1. Have the Supplier submit a list of locations of similar installations.

2. Inspect any of these installations and operations of Engine Generator package, and question the user concerning the installations without the presence of the Supplier.

B. Factory authorized representative shall be capable of providing emergency maintenance and repairs at the project site within four (4) hours maximum of notification.

C. A single Supplier shall be responsible for the furnishing of the Engine Generator, Switchgear and SCR with auxiliary components as specified and as required.

D. Noise level developed by the generator set shall be as herein specified.

E. Supplier shall submit certification that Engine Generator, accessories, and components will withstand seismic forces defined in the 2009 IBC “International Building Code".

1.6 SHOP TESTING

A. The Engine shall be factory tested under varying loads with guards in place. The Engineer reserves the right to witness all, or any portion of the following tests at the factory. The Supplier shall notify the Engineer fifteen (15) days prior to date of testing. Supplier shall furnish load banks, testing instruments and all other equipment as necessary to perform these tests.

B. These tests shall include the following:

1. Rated continuous output (BHP / kW) of engine and generator at design / site conditions.

2. Speed regulation and stability of generator output voltage and frequency (at 100% load), overspeed capability and trip speed (120%). Provide voltage and frequency strip-chart recordings confirming transient and steady-state governor and voltage-regulator performance.


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3. Test multi-step load pickup capability (manufacturer to specify the maximum load step) at unity P.F. to verify that generator, regulator and governor performance meet all applicable specifications, and to verify recovery time.

4. Voltage, current, frequency and power output ratings shall be verified by a one-hour full-load test.

5. Vibration and noise level (including exhaust noise) of the Engine Generator package at full load.

6. Test the proper operation of all controller logic circuitry, pre-alarm warnings and safety shutdown functions and devices.

C. The Supplier shall make all necessary adjustments or modifications required if shop and/or field testing identifies performance or design deficiencies.

D. Certified copies of all shop tests and examinations performed by the Supplier shall be provided to the Engineer for record purposes. All test reports shall be countersigned by the inspecting authority where required by code.

1.7 FIELD TESTING AND PREPARATION FOR START-UP

A. System shall be tested thoroughly for both control panel integrity and satisfactory equipment operation. Each test shall be conducted in a safe and professional manner avoiding interference with normal building operations. Documentation of tests shall be forwarded to the Engineer or Owner's Representative in the form of a test report. Testing shall be performed in the presence of the Engineer. The Owner's Representative may waive the right to be present for the testing, but this shall not relieve the Supplier from his testing obligations. Six (6) copies of report shall be supplied and shall include the following:

1. Project name; system description.

2. Date of test.

3. Name of Supplier - equipment manufacturers.

4. Technician performing test.

5. Engine tests performed, and results.

6. Generator tests performed, and results.

7. Charger tests performed, and results.


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B. An installation check, start-up, and facility load tests shall be performed by the Engine Generator set manufacturer or its qualified representative. The following site tests shall be performed as a minimum:

1. Fuel, lubricating oil, and antifreeze shall be checked for conformity to the manufacturer's recommendations under the environmental conditions specified.

2. Accessories that are normally functioning while the set is standing by shall be checked prior to starting the engine. These include but not limited to block heaters, battery charger, remote annunciators/interfaces, fuel transfer system, etc.

3. Engine tests shall include the following procedures:

a. Check engine monitors and meters, and note readings after 15 minutes of operation.

b. Restart engine to ensure no stall-out condition when hot. c. Check alarms and shutdowns to ensure proper functioning. d. Check for exhaust leaks, path of exhaust gases, and cooling air flow.

4. Generator tests shall include the following procedures:

a. With no load, start the Engine Generator package and check voltage and frequency for each phase.

b. With available load, check voltage, frequency and current for each phase after unit has stabilized. Ensure balanced load in tests. Run Engine Generators from cold start for a period of one-half hour noting instrument and gauge readings at 3, 8, 15 and 30 minutes.

c. Testing shall also include a minimum four (4) hour, 100% capacity, load test.

d. Record the following in 20 minute intervals, during the four hour test:

1) Kilowatts

2) Current

3) Voltage

4) Coolant Temperature

5) Room Temperature

6) Frequency

7) Oil Pressure


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e. Test alarm and shutdown circuits by simulating conditions. Correct any defects, which become evident during testing.

5. Charger tests shall include the following general procedures:

a. Check trickle-rate charge. b. Check hi-rate charge. c. Check equalizing timer.

6. System testing shall be performed to simulate the operating requirements described in this specification.

C. Field Service:

1. Final tie-in and initial system start-up for the system shall be made by or under direct supervision of manufacturer’s representative.

2. Tests required by this specification for the subject system shall be performed at start-up by Engine Generator manufacturer's representative.

3. The Supplier shall include in his cost of services, a field Engineer to check the installation, following completion by the Contractor, and to supervise start-up of equipment. If for any reason attributable to difficulty with the equipment, the manufacturer's representative is required for a longer period of time to accomplish successful start-up, the Supplier shall bear the costs for such additional time.

4. After successful start-up, the manufacturer's representative shall also be available for a period of eight (8) hours to instruct and train the Operating personnel in the proper operation and maintenance of equipment. Supplier shall coordinate specific date for instructions and training with requirements of the Owner. Cost of this training shall be included in quotation.

D. Demonstration: Certification that tie-in have been done correctly; that tests have been completed; and that system is operating properly in accordance with both this specification and the manufacturer's instructions, shall be furnished to the Engineer or the Owner's Representative on Supplier's letterhead.

1. System acceptance will be contingent upon receipt of such certification.

2. If tests were required, and were performed as part of start-up, test results shall be attached to certification.

3. Include as a minimum: Project name, system description, date of test, Supplier and manufacturer's names, technician performing tests, procedures and set-up description where applicable; and test results.


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1.8 SUBSTITUTIONS

Unless approved in advance by the Engineer, there shall be no substitutions for equipment, materials or components specified or previously approved.

1.9 SUBMITTALS REQUIRED WITH EACH PROPOSAL

A. Failure to submit any of the following information may be cause for rejection of proposal. B. Total net pricing (FOB site), estimated freight costs broken out and proposal validity date. C. Complete Engine Generator fabrication and delivery project schedule, including, but not

limited to approval drawing submittal delivery after order; finalization of detail engineering, release for manufacturing, equipment delivery to jobsite after approval of drawings. All deliveries to be quoted as the best achievable.

D. Guaranteed performance as specified herein. E. Completed Data Sheets per attachment.

F. Statement of compliance with Bid specification. Technical clarifications and exceptions to the specification.

G. A certificate by the Supplier that the engine-generator set, accessories, and components will withstand the seismic forces and seismic load, as required by the IBC, and that the system will be fully operational after the seismic event at the project site.

H. Scope of supply, including materials of construction, component listing identifying the manufacturer of specialty valves and components and all work by Others.

I. Proposed general arrangement drawings (plan and elevation views), P&ID, shipping and operating weights of major components, and space requirements for erection and maintenance.

J. Preliminary utility requirements, including, cooling water demand, electrical loads, flow rates for compressed air, etc.

K. The Supplier shall provide a complete and detailed description and design features of the systems including construction, controls (identifying all local and remote control devices), and safety precautions. The Supplier shall provide a summary of design features and their associated competitive advantage(s).

L. The Supplier shall identify specific design ideas that will minimize field installation work and overall project cost that is not specified herein.


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M. The Supplier shall provide detailed information regarding his ability to service the systems both during startup and subsequent operation. The information shall, as a minimum, include the following: is service organization part of corporate group or done through agents, are service personnel specialized in particular type of equipment.

N. The Supplier shall provide a complete list of components that will be shipped loose for field installation.

1.10 SUBMITTALS REQUIRED AFTER PURCHASE ORDER

A. All non-proprietary design drawings, calculations, manuals, data sheets, etc., as a minimum, shall be submitted in accordance with this specification for review, approval, and final certification as required. The Supplier shall submit an initial drawing schedule, identifying drawing titles and numbers within two (2) weeks of issuance of the purchase order. All submittals shall be submitted to Concord Engineering Group’s Project Manager as follows:

1. For Approval – Seven (7) legible prints of sizes larger than 11” x 17” to be provided including CD(s) containing general arrangement drawings, as required for plant layout of equipment, in AutoCAD Version 2000 or higher or convertible to AutoCAD.

2. After Final Approval – Two (2) certified sets of sizes larger than 11” x 17” to be provided including CD(s) containing general arrangement drawings, as required for plant layout of equipment, in AutoCAD Version 2000 or higher or convertible to AutoCAD.

3. Operating and Maintenance Manuals – Eight (8) sets

4. All Supplier drawings shall have the project name (“Midvale Combined Heat and Power Plant”), Engineer's name (“Concord Engineering Group”), and the Owner’s purchase order number indicated near the drawing title.

5. Drawings shall be submitted for approval prior to fabrication of the equipment or development of software. Unless otherwise identified in writing in the purchase order, fabrication shall not commence until these drawings are returned "Proceed" or "Proceed as Noted."

B. Prior to fabrication, submit for approval the following data for the Engine Generator set, auxiliary equipment, transfer device and control and supervisory equipment:

1. Data Sheets; Engine Generator, including auxiliary equipment motors, pumps, heaters, exchangers, etc.

2. P&ID’s


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3. Equipment Layouts; Engine Generator and auxiliary equipment, silencer assembly, radiator-cooler, expansion tank, circulating pumps, etc.

4. Wiring diagrams and schematics

5. Batteries, racks and charger

6. Torsional vibration certificate

7. Control and Supervisory Equipment (with available signals for remote control and monitoring)

8. List of equipment and items shipped loose for field installation by Contractor

9. Internal ECM and external communications protocol description and register data mapping

10. Performance calculations:

a. Voltage regulating equipment

b. Frequency regulating equipment

c. Voltage and frequency dips and recovery times due to specified motor loading

d. Antifreeze derating

e. Ambient derating

f. Remote radiator

g. Cooling system

h. Vibration isolators

C. Manuals:

1. Submit, simultaneously with approval drawings, companion copies of Maintenance and Operating manuals of the Engine Generator set and auxiliaries including technical data sheets, wiring diagrams, and information, such as telephone number, fax number, and web sites, for ordering replacement parts.

2. Two weeks prior to the final inspection, submit four (4) copies of the updated Maintenance and Operating Manual to the Engineer:


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a. Include complete "As installed" diagrams, which indicate all items of equipment and their interconnecting wiring.

b. Include complete diagrams of the internal wiring for each of the items of equipment, including "As installed" revisions of the diagrams.

c. The wiring diagrams shall identify the terminals to facilitate installation, maintenance, operation and testing.

d. Complete lists of spare parts and special tools recommended for two (2) years of normal operation of the complete system.

e. Recommended set up for protecting devices.

D. Certifications:

1. Prior to fabrication of the Engine Generator packages, submit the following for approval, to the Engineer:

a. A certification in writing that a Engine Generator of the same model and configuration, with the same bore, stroke, number of cylinders, and equal or higher BMEP and RPM ratings as the proposed Engine has been operating satisfactorily on natural gas, with connected loads of not less than 75 percent of the specified KW/KVA rating, for not less than 2,000 hours without any failure of a crankshaft, camshaft, piston, valve, injector or governor system.

b. A certification in writing that devices and circuits will be incorporated to protect the voltage regulator and other components of the auxiliary electrical power system during operation of the engine-generator set at speeds other than the rated RPM while performing maintenance. Include thorough descriptions with submittal of any precautions, which will be necessary to protect the voltage regulator and other components of the system during operation of the engine-generator set at speeds other than the rated RPM.

c. A certification in writing that the Engine Generator will operate reliably using natural gas.

2. Prior to installation of the Engine Generator system at the job site, submit four (4) copies of the following to the Engineer:

a. Certified test data, alternator temperature rise test and strip chart recordings, and photographs showing test setup and equipment.


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3. Two (2) weeks prior to the final inspection, submit four (4) copies of the following, to the Engineer:

a. Certified test report by the manufacturer of the Engine Generator system, stating that the auxiliary electrical power system conforms to the requirements of the drawings and specifications.

b. Certified report of field tests from the manufacturer that the engine-generator set and major auxiliaries have been properly installed, adjusted and tested.

E. Drawing Requirements (not all inclusive):

1. Equipment layouts shall include arrangement drawings in plan and elevation, with all components identified. Product and service tie-ins shall be identified by size, type and dimensions for locating tie-ins. Access clearances for service of equipment and removal of components shall also be shown. Mechanical interfaces to other systems or utilities shall be clearly identified and dimensioned, including size and type of connection. Detailed location and characteristics of all terminal points, electric connection requirements, etc. shall be provided.

2. Engine Piping and Instrumentation Diagrams (P&IDs):

a. Engine Generator sections and auxiliary equipment.

b. Interconnecting, terminal, and trim piping including flow directions, Supplier's line designation and line sizes.

c. All Supplier furnished valves, flanges, silencers, trim, instruments, controls, vents, and drains with trim list identification.

d. Exhaust gas test and instrument connections, instruments, flow control devices, dampers, and silencers.

e. Indication of any required temporary connections or special provisions for Engine and lines cleaning.

f. Engine settings, design temperatures and pressures, and safety valve set pressures.

g. Motor HP, GPM, and TDH (ft) for Supplier furnished pumps.

3. Elevations and sections shall be provided as necessary to show full details of tie-ins, service access and control components.

4. Outline drawings with locations of electrical boxes, conduits and grounding pads.


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5. Electrical drawings, schematics and electrical interconnecting diagrams.

6. Electrical data for all power consumers and Mechanical utility requirements.

7. Weights and overall dimensions and detailed floor loadings shall be shown. Provide unit-mounting details.

1.11 SOUND AND VIBRATION

A. The Supplier shall make every effort to design and manufacture the equipment in a manner such that sound generation is held to a minimum.

B. The Supplier shall state the sound level in their proposal for the equipment, as measured in accordance with ANSI Standards S1.2, "Method for the Physical Measurement of Sound" and S 1.4, "Specification for General Purpose Sound Level Meter.”

1.12 SAFETY

A. All mechanical equipment shall be fully guarded and interlocked with machine operations; i.e., exposed gears, chains, belts, sprockets and hazardous moving parts to meet current OSHA standards in effect at the time of delivery. Guard doors shall include electrical interlocks to stop or prevent machine operations if the guard door is opened. In order to comply with OSHA requirements for lockout/tag out, padlockable devices shall be provided to isolate and safely release electrical, pneumatic and other potential sources of energy release.

B. The Supplier shall warrant that all equipment complies with the appropriate standards for machine guarding and design set out in United States Code of Federal Regulations (CFR) Title 29, Chapter XVII, Part 1910, Subpart O.

1.13 COMMISSIONING AND STARTUP

B. A. The Supplier shall provide the necessary field startup services to fully commission the equipment to achieve performance guarantees. This service shall include, but not be limited to, verification of proper installation, performance of all tests and procedures as stated in the startup and installation manuals, verification of the proper operation of the control panels to perform as designed, performance of all necessary adjustments and calibrations of all unit sensors and meters and necessary technical assistance to assure that the Supplier’s equipment meets the performance guarantees. The Supplier shall make all reasonable attempts to insure that the same service technician is utilized for startup, training and commissioning for each of the Supplier’s equipment packages for the duration of the project.


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1.14 TRAINING

C. A. The Supplier shall provide on-site training for operating and maintenance personnel. This service shall include operating instructions and training for Owner's personnel. Instructions shall include, but not be limited to, training materials, hands-on and classroom instruction and complete review of all manuals. Classroom training shall be performed in a maximum of 8-hour daily sessions. The hands-on instructions shall include start-up, operation (normal and expected transients), shutdown and maintenance of all systems.

1.15 SPARE PARTS

D. A. With his proposal, the Supplier shall identify all spare parts, including source, cost and identification of the manufacturer and associated model number, critical to initial startup that are recommended for the Engineer/Owner to have on-hand to minimize unplanned construction delays or equipment downtime, as well as a standard priced spare parts list for replacement of components as needed. The Supplier shall recommend spare parts expected for replacement during two (2) years of operation.

1.16 SPECIAL TOOLS

E. A. The Supplier shall furnish one (1) set of special tools required for the Engine Generator system proposed. Permanent hoisting equipment is not provided for maintenance of the Engine Generator set. Maintenance should be priced assuming portable lifting devices provide by Supplier.

1.17 WARRANTY

A. The Manufacturer shall warrant that all materials and equipment furnished under this contract will be new and of good quality, free from defects in design, workmanship, and materials.

B. Each item of equipment, or part thereof, proving to be defective within the specified period of the warranty shall be replaced, free of defect, without cost to the Owner.

C. The warranty period shall be the Manufacturer's standard warranty period, but not less than a minimum of twelve (12) months after startup, or 18 months after delivery of the Engine Generator system at the site (whichever comes first).

1.18 PERFORMANCE GUARANTEES

A. The Supplier shall provide performance guarantee of the Engine Generator system including each package, for total power output, total fuel input, emissions and total heat recovery.


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1.19 PRODUCT DELIVERY AND HANDLING

A. The Engine Generator Supplier shall be responsible for the shipment of the unit to the job site. Supplier shall be responsible for packaging and all precautions necessary for shipments to arrive at destinations in the condition shipped when handled by commercial carriers.

B. Installing Contractor shall be responsible for the receiving and unloading of the equipment at the job site. This responsibility includes proper protection for storage at the job site.

C. Supplier shall confirm shipping clearances and shall provide the status of shipments in transit upon request.

D. Supplier shall, 4 weeks prior to shipping, provide a complete list of material to be shipped. Included in this submittal shall be a list of loose ship material including the weight and sizing of such packages

PART II - PRODUCTS

2.1 ACCEPTABLE MANUFACTURERS

A. Caterpillar

B. Cummins

C. GE Jenbacher

D. Waukesha

E. MWM

2.2 PERFORMANCE

A. Engine exhaust emissions at full load shall meet the criteria listed in Attachment # 2 prior to any emission control device.

B. In the event, that the emissions from the system do not meet the required level, then an emission test will be performed on the engine exhaust prior to any emission control device, using the testing ports installed on the discharge of the engine. If it is determined that the engine emissions exceed the guaranteed levels, then the manufacturer shall take whatever actions are required to comply with the guarantees.


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C. The Engine Generator set shall conform to the technical criteria listed in Attachment # 1

2.3 GENERAL DESIGN

A. The design of the entire Engine Generator System shall be the responsibility of the Supplier. Details of the Engine Generator system design shall be made available to Engineer for overall coordination and completion of the building utilities.

B. The pressure containing components, with an operating pressure of 15 psig and above, shall be designed, fabricated, examined, inspected, and tested in accordance with Section I, Division 1 - Pressure Vessels, Section II - Material Specifications, and Section IX - Welding and Brazing Qualifications of the ASME Boiler and Pressure Vessel Code.

C. ANSI 300 lb. and 150 lb. rated system connections shall be flanged, except for connection sizes 2" and smaller shall be either threaded or socket weld union-end, as required by applicable codes.

D. The Engine Generator exhaust will be connected to a Static Mixer, SCR, and Silencer. The Static Mixer, SCR Catalyst system are not included in the scope of this specification, but the Static Mixer and SCR Catalyst system are included in the scope of the overall supply package by Supplier.

E. All equipment, piping and associated components, etc., provided by the Supplier shall be so designed to ensure that a maximum equipment casing, piping and ductwork surface temperature will not exceed 140°F, considering that all units will be installed indoor and a still surrounding air temperature of 104°F, or that a surface temperature differential does not exceed 40°F from ambient under any load conditions.

F. Materials

1. The Supplier shall indicate on his approval prints, what ASME specification grade number he will be furnishing for materials specified. Material shall be Supplier’s standard for the application or as specified herein.

2. Nozzle, nozzle reinforcement plates and fittings shall be constructed of the same materials as the components, which they are attached.

3. No asbestos or asbestos bearing materials are permitted.


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2.4 DETAIL DESIGN

A. System Function

1. The automatic operation of the Engine Generator will be controlled by the Engine Generator Control Module (ECM), furnished by the Engine Generator Supplier. The ECM shall be pre-wired to the Engine at the factory and mounted on the Engine frame. Provide adequate vibration isolation between each engine and ECM, if it not practical, Engine ECM shall be shipped loose for field installation by Contractor.

2. The ECM shall provide for power distribution to engine auxiliaries, power supply from the starter and battery charger, terminal strip(s) for engine-generator wiring terminations, and all necessary points of interface to engine controls in the generator control panel. The ECM shall include all necessary relays, contacts, fuses, and engine contact switches to control valves and auxiliaries.

3. The Engine Generator shall be provided with CAN-BUS or Ethernet cables as required

for interface between the ECM and any freestanding Engine Generator control panel. Installation shall be by Others.

4. Operation and monitoring of the Engine Generator and the switchgear equipment will be by a Programmable Automation Controller based Plant Control System (PAC), Allen Bradley Control Logix provided by switchgear Supplier. The PAC shall control the operation of the Engine Generator by interfacing with the ECM.

5. The ECM shall be able to transmit real-time data to/from the PAC located in the system

switchgear. In addition, the PAC in the switchgear shall also be able to communicate with the plant control system. These bidirectional communications links between the engines, switchgear and plant control system shall allow remote operation and monitoring of the engine. Communications between the two packages shall be over a dedicated serial interface, utilizing an open protocol such as Modbus/TCP, OPC or a mutually compatible protocol on which engine, switchgear and plant control system suppliers will coordinate. The use of modems is not acceptable. If needed, protocol conversion hardware may be used. The Supplier shall provide all hardware needed to implement the interface and will coordinate with the switchgear supplier to assure communications interface compatibility. Maximum data transmission cycle time between the ECM to the plant control system processor shall be 5 seconds.

6. In general, the PAC shall have a capability of operating the Engine in following modes:

a. Automatically control operation of the Engine Generator unit.

b. After starting, the unit will attain rated speed and voltage. The Engine Generator speed shall be controlled by the engine governor, while Generator output voltage


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regulation shall be a function of the automatic voltage regulator. Manual adjustment of the Generator speed and voltage shall be provided.

c. Starting and stopping sequence can be initiated manually or automatically from the PAC.

d. The Engine Generator shall immediately shut down in the event of overspeed, low oil pressure, high cooling water temperature and over-crank. Cause of shut down shall be indicated by annunciator screen. The system logic shall prevent the restart until fault is cleared. There are shall be a provision for a manual shut down in the event of emergency.

B. Engine

1. The Engine shall be stationary, liquid-cooled, natural gas fueled with gross electric power output capability between 4,000 kW and 4,400 kW. The Engine shall be capable of driving the generator of this rating on a continuous basis at all site ambient conditions.

2. The engine shall include the following:

a. Engine speed isochronous / load sharing electronic governing system to control generator frequency within plus or minus 0.25% of rated frequency under steady state load conditions. Speed shall be sensed by a magnetic pickup off the engine flywheel ring gear. A provision for remote speed adjustment shall be included. The governor shall have provisions for multiple gain settings to allow optimizing the governor adjustments and engine performance for the various modes of operation anticipated in this application.

b. Engine-mounted thermostatically controlled water jacket heater to aid in quick starting. Heater shall be a three phase, rated for a 480 V, and shall be disconnected whenever engine starts. The heater shall be thermostatically controlled to maintain engine coolant at not less than 55 °F (to be confirmed by Supplier) at specified ambient temperature (refer to Attachment # 1).

3. As a minimum, the engine shall be provided with alarms and safety shutdowns as follows:

a. Low oil pressure alarm

b. High coolant temperature alarm

c. Low coolant temperature alarm

d. Low coolant level alarm


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e. Low natural gas pressure alarm

f. Low oil pressure shutdown

g. High coolant temperature shutdown

h. Over-crank shutdown

i. Over-speed shutdown

j. Emergency stop shutdown

4. The following accessories shall be provided with each Engine Generator and mounted on or adjacent to the Engine Generator mounting base or assembly:

a. Replaceable type air intake filters

b. Replaceable type oil filters

c. Flexible connectors: fuel gas, coolant, vents, combustion air, lube oil and exhaust gas

d. Jacket water heater

e. Jacket water and intercooler thermostats

f. Water pumps

g. Coolant control valves

h. Coolant and oil manual isolation and drain valves

i. Crankcase ventilation valves

j. Engine hour meter, fuel pressure gauge, coolant temperature gauge and lubricating oil pressure gauge

k. The engine shall be provided with a lube oil make-up system. This shall include a float valve in lube oil feed line, lube oil tank with inspection sight glass and stand.

C. Mounting Base and Assembly

1. Engine Generator unit shall be skid-mounted on structural steel, self-supporting frame constructed of wide flange beam or channel iron suitable for lifting or jacking.


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2. The Engine Generator set shall be isolated from the foundation by isolators sized and located to adequately support the unit without deflection or misalignment.

3. Steel spring isolators or isolation pads shall be installed between the generator set base and the mounting surface.

4. The generator shall be connected to engine through a flexible coupling, be self-ventilated and have self-lubricated self-aligning bearing.

D. Engine Cooling Equipment Auxiliaries

1. The Engine Jacket Water, Intercooler and Lubrication Oil systems shall be provided with a remote outdoor ground mounted cooling radiator system. The remote mounted radiator shall have a horizontal core and vertical air discharge. The radiator shall be suitable for year-round, outdoor operation between 0° F and 110 °F and must be of a type and capacity recommended by the radiator manufacturer based on the engine manufacturer’s requirements.

2. The radiator shall be manufactured by Amercool, I.E.A, Rocore or approved equal. The Supplier shall provide with his proposal engineering data sheets detailing radiator performance as well as radiator prints depicting all physical dimensions in detail.

3. The radiator shall be of heavy-duty construction with a self-supporting base with mounting holes and lifting lugs to facilitate handling during installation.

4. The radiator shall be supplied with a weather screen for core protection.

5. The radiator coil shall be designed and tested in accordance with ASME code.

6. The radiator shall be one or two (2) bay, multi-circuit design furnished with blow through fans and electric motors. The radiator shall be equipped with a minimum of two fans. The radiator shall be equipped with OSHA approved heavy-duty fan, belt, and core guards.

7. The maximum permissible sound pressure generated by the fan shall not exceed 85 dBA at a distance of three feet in any direction from the radiator.

8. Each radiator fan shall be driven by a heavy duty, TEFC, three phase, 460 Volt, 60 Hertz electric motor with a 1.15 service factor.

9. The radiator shall have sufficient capacity to maintain safe engine operation at 110% of the maximum rated generator output, with a maximum ambient air temperature at the fan of 110° F at an elevation of 50 feet above sea level. The coolant shall be comprised of 50% water and 50% glycol solution.


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10. The radiator shall be equipped with a two probe, two stage thermostatically actuated fan control, with one thermostatic probe per engine cooling circuit (Jacket Water, Lube Oil and intercooler).

11. The radiator shall be supplied with a standalone control panel for each radiator. All required control devices needed for start/stop and sequencing of the radiator fans based on coolant temperature shall be provided with this panel. Thermocouple or RTD type temperature sensors shall be provided for process input to the controls and these sensors shall be supplied with thermowells. Each panel shall be provided with Hand-Off-Auto control switch with indicating lights for operation modes and fan statuses. The controller shall be provided with the following external control inputs:

a. System Enable Input (active with HOA switch in Auto position)

b. System Trouble Alarm Output (dry contact)

c. Motor Trip Alarm Output (dry contact).

12. Flexible stainless braided hoses, as recommended by the engine manufacturer, shall be provided at the engine and at the radiator. All water braided hose welds shall meet ASME Section IX Code.

13. The high temperature cooling water circuit shall include a waste heat plate and frame heat exchanger. The heat exchanger shall be designed to transfer the full high temperature engine cooling circuit heating load to site distribution hot water.

14. Engine cooling circuit system shall be supplied with circulation pumps, two (2) 100% capacity pumps per service. Pump head shall be large enough to meet the needs to the system specified by the engineer. Cooling systems shall be supplied with safety valves and ASME Section V111 Division 1 diaphragm expansion tanks adequately sized to support the glycol system thermal expansion/contraction and automatic air release valves.

15. The cooling system shall be furnished with provision for glycol fill and makeup.

E. Exhaust System

1. If engine exhaust discharge temperature is >750 °F at any engine load, exhaust components shall be fabricated from stainless steel. If Supplier has specific operating experience with other materials, which meet the design temperature, Supplier shall state such in his proposal.

2. The Engine Generator exhaust will be equipped with a Static Mixer, Selective Catalytic Reduction (SCR) system, and any other equipment as required. Supplier shall ensure the


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total back pressure from all in-line components does not exceed the back pressure specified by the engine manufacturer.

3. A residential grade horizontal exhaust silencer shall be provided with the engine. The silencer shall be coated with a temperature and rust resistant compound.

4. The silencer shall be designed so that together with the Static Mixer and SCR, it limits the engine exhaust system overall exhaust noise to less than 85 dB(A) at 3 feet, based on OSHA requirements.

5. The silencer shall have integral condensate bottom drain connection and shall be suitable for the rain-water run though the internal core, when the Engine is “Off” for maintenance. The silencer shall be fabricated from stainless steel, unless the manufacturer has specific operating experience with other materials, which meet the design temperature.

6. Nuts and bolts utilized in the exhaust system shall be high strength, conforming to the following: ASTM A193, Gr B7 Bolts or Studs and ASTM A194, Gr 4 Nuts.

7. The supplier shall furnish an exhaust system relief valve to protect equipment in the event of an engine backfire.

F. Fuel System

1. The Engine shall be suitable for operation on natural gas fuel pressure of less than 5 psig supplied at the inlet of the engine gas train. Any pressure reducing valves needed to reduce the fuel gas pressure from 5 psig to the level required by the engine shall be supplied with the engine.

2. The engine shall be supplied with a fuel gas train shipped loose, fully assembled and ready for installation. The fuel gas train shall be designed to meet NFPA 37 requirements.

3. The fuel system within the Engine Generator boundary of supply shall be as fully pre-piped and pre-wired at the factory.

G. Starting System

1. All engines shall be equipped with electric start, and to be provided with batteries and charger as follows:

a. Battery Set:


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1) Heavy duty starting type SAE rated electrical storage battery set, 24 volts DC, number of cells compatible with starting system. Battery shall have sufficient capacity to provide for minimum cold-cranking amps as required at an ambient temperature of 10° F. The battery set shall be supplied with approved standing battery rack and all necessary cables and accessories. Battery system shall be guaranteed for three years on a prorated replacement basis.

b. Battery Charger:

1) Unfiltered double rate solid-state voltage regulator type, designed for reliable recharging and maintaining starting batteries in fully charged condition. The battery charger shall be at least of 20 amp capacity and shall incorporate solid state current limiting circuit to prevent damaging overloads during battery charging and engine starting.

2) Charging characteristics optimized to provide recharge and minimum cell voltage drop, assuring fast recharge with full protection of battery. Charger to automatically shut down if battery becomes disconnected.

3) The charger shall be automatic float and equalize battery charger type + 1% constant voltage regulation from no load to + 10% AC in-out line variation, and having current limited during engine cranking and short circuit condition, temperature compensated for ambient from –40°C to 60°C. DC output voltage regulation shall be fully automatic and controlled in relation to battery voltage and load condition. AC in-out, tapped type suitable for 120 volts.

4) Construction: Compact, well ventilated welded steel enclosure, furnished with large scale 5% accuracy voltmeter and ammeter and alarm circuit board to meet the requirements of NFPA 110 for low battery charge, high battery voltage and battery charge malfunction.

H. Ducts and Expansion Joints

1. Expansion Joints

a. Expansion joints at the Engine shall be provided to absorb longitudinal expansion or contraction and shear movements due to temperature differential or misalignment and thus relieve stress out of major equipment. Expansion joints shall be of 2-ply stainless steel heat resistant, suitable for the working environment, and shall be of bellows design to maintain leak tightness. Sliding or sleeve type expansion joints are not acceptable.

b. Welds on expansion joints shall be dye penetrant tested, after forming and welding.


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2. Duct and Breeching

a. All exhaust flue gas discharge ductwork shall be provided by Others.

I. Vents and Drains

1. The Engine Generator system shall be provided with all necessary vent and drain systems required for safe operation and maintenance.

2. All drain and vent lines, which are commonly closed, or required for maintenance, shall be complete with isolation valves.

J. Generator

1. The generator shall be sized for the base load operation. Generator shall be two-bearing, self-aligning, synchronous type, 2/3 winding pitch factor, revolving field, with amortisseur windings, with direct drive centrifugal blower for proper cooling and minimum noise. Generator shall be connected to engine flywheel housing and driven through a flexible coupling to insure permanent alignment. Insulation shall meet NEMA standards for Class H and additionally shall meet source quality control testing requirements herein. The maximum temperature rise shall not exceed 105 °C at 40 °C ambient. Generator design shall prevent potentially damaging shaft currents.

2. Voltage regulator shall be solid-state design and shall function by controlling the exciter magnetic field between stator and rotor to provide no load to full load regulation at rated voltage within plus or minus 0.25% during steady-state conditions. The excitation system shall be of brushless construction, controlled by a solid-state voltage regulator and shall employ a permanent magnet generator (PMG) to supply power to the voltage regulator.

3. The voltage regulator shall be of a design that is insensitive to severe load induced wave shape distortion from thyrister circuits such as those used in battery charging, UPS and motor speed control equipment. A rheostat shall provide a minimum of plus or minus 10% voltage adjustment from rated value.

4. The generator set shall be equipped with all devices necessary for parallel operation with duplicate sets, including reactive droop compensation current transformer, remote speed and voltage adjust potentiometers, and isochronous load sharing modules.

5. Upon application of planned load steps at 0.8 power factor, the voltage dip shall not exceed 25% and shall recover to +1% of rated voltage.

6. Minimum efficiency shall be no less than 95% at full load.


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7. The Generator shall be designed for continuous operation. Reactive droop compensation transformer shall be installed. The generator Supplier shall furnish and install one (1) PT and CT for operation and control of the engine-generator control system.

8. Provide adequately sized side entry terminal boxes on the generator for control wiring and for main power leads. The leads will be routed overhead and brought to the generator set for side or top entry through the junction box wall by means of flexible conduit fixed securely to the junction box with a retainer type fitting. Isolate high voltage from low voltage wiring in separate terminal boxes.

9. Three (3) generator control CT’s and one (1) generator control PT shall be used to provide all generator control functions and monitor of all generator power and current functions and will be furnished and installed by the switchgear Supplier within the switchgear.

10. The generator shall be equipped with anti-condensation heaters.

11. Exciter shall be three-phase, full-wave, rectified, with heavy-duty silicon diodes mounted on the common rotor shaft and sized for maximum motor starting loads. Systems using three-wire solid-state control elements (such as transistors) rotating on the rotor shall not be acceptable.

12. The generator shall be capable of sustaining a minimum of 300% of rated current for at least 10 seconds under a three-phase symmetrical short circuit, by inherent design.

2.5 INSTRUMENTATION AND CONTROLS

A. The Engine Generator system shall be designed to operate as base load or load following. The system shall be capable of starting manually from the master control panel. Upon initiation from the master control panel, the engines shall start, increase speed, and at a specific point, synchronize with the bus. The system is intended to operate in parallel or isolated from the Utility, supplying power to Septa. Shutdown shall be manually initiated from the master control panel or remotely. Remote signals shall be available as hardwired and over a serial communications link. An unload pushbutton (available locally and remotely) shall be provided to allow for a soft unloading of the generator prior to shutdown. The system shall reduce load and import more power from the utility and then the breaker shall open and disconnect the generator from parallel operation. Supervisory control of the engine shall be available from the plant control system and shall include the ability to start/stop control, load adjustment and monitoring of the Engine Generator using both soft and hardwired signals.

B. The Engine Generator package shall be supplied with its own local microprocessor-based Engine Generator Control Module (ECM). The ECM shall monitor and control the operation


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and associated sensors, actuators, relays and switches. It shall also signal alarms for non-standard performance or failures. The ECM shall permit the Engine-Generator package to run in local and remote modes. Each control Module is to be housed in a NEMA 12 enclosure, mounted on or adjacent to Engine Generator and isolated from engine set vibration.

C. As a minimum, the ECM shall be provided with the following

1) Fully automatic engine start-stop controls in generator control panel. Engine cranking controls and time delay relay shall provide for over crank and lockout after sixty seconds; a sensing device shall automatically disconnect starting circuit when engine has started. If engine has not started at completion of starting program, over cranking signal shall alarm. Engine starting controls shall be locked out and no further starting attempt shall take place until over cranking device has been manually reset.

2) A 3-position selector switch shall be incorporated into panel and automatic control circuits having the following functions:

a. In the “OFF /RESET” position, the engine shall be locked out. Whenever the selector switch is placed in the “OFF /RESET” position while the engine is operating, it shall immediately shut down and its circuit breaker shall trip.

b. In “MANUAL” position, the engine shall be capable of starting manually and paralleled with the utility via the “automatic synchronizer” and loaded to a pre-set level. After the generator is unloaded, the generator circuit breaker shall trip but the engine shall continue to operate for cooling down, until the expiration of time delay setting of the idle relay.

c. In the “TEST” position, the engine shall start and run as if a start signal were received, except it shall not be connected to the bus, unless the breaker control switch is placed in the close position.

3) Provide adjustable time delay for 0-10 minutes unloaded running time to delay shut down of Engine Generator set after generator is signaled to stop.

4) To reset an engine-generator after a safety shutdown, the selector switch shall be switched to the “OFF/RESET” position. This will result in resetting the control system if the cause of the shutdown has been corrected.

5) After the control system has been reset, the engine shall be returned to an operational status by switching the selector switch to the “MANUAL” position.

6) Instrument and Switches including the elapsed time meter

7) Shutdown Circuits with Indicators


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a. Low oil pressure

b. High water temperature

c. Emergency Stop Button

8) Alarm Status Circuits with Indicators

a. Unit not in auto

b. Engine running

c. Low oil pressure prealarm

d. High water temperature prealarm

e. Low water temperature prealarm

f. Engine cooldown cycle

g. Battery charge failure

9) Control Devices and Circuits

a. Engine Control switch (off-auto-on)

b. Light test button

c. Alarm reset button

d. Alarm silence switch with ring back circuit

e. Engine cranking panel with cyclic cranking and engine cool down.

f. Generator temperature monitor

2.6 ELECTRICAL

A. Motors shall be selected in accordance with the driven equipment requirement, as indicated in the individual equipment specifications. The continuous nameplate rating shall be 15% greater than the maximum brake horsepower required by the driven equipment. Service factor ratings shall not be used to meet this requirement.

B. The Supplier shall be completely responsible for the selection and application of the motor drives, so that the driven equipment shall perform satisfactorily under the specified conditions.


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The design and construction of all motors shall be fully coordinated with the mounting arrangement, alignment, connection, end play, direction of rotation, vibration and other applicable requirements of the driven equipment.

C. Motor performance shall be coordinated with the required performance of the driven equipment. All motors shall have ratings suitable for the torque and WK2 characteristics of the driven equipment. The Design letter shall be in accordance with NEMA Standard MG1-1.12, and shall be furnished with the Motor Data Sheets.

D. All AC motors ½ to 250 hp shall be high-efficiency, constant-speed, squirrel-cage induction, TEFC, severe-duty (mill and chemical) type, rated 460 V, 3-phase, 60 Hz, with Class F insulation, and a 1.15 service factor. The motors shall have a corrosion-resistant nameplate, re-greasable fittings, oversized conduit box and a corrosion-resistant paint system. Temperature rise above 40°C ambient throughout the motor shall not exceed NEMA specified values. Motors shall be designed, manufactured and tested per ANSI/NEMA Standards. The full-load efficiency index letter and power factor shall be stamped on the nameplate.

E. Fractional-horsepower motors smaller than ½ hp shall be rated 115 V, single-phase, 60 Hz. Motors shall be totally enclosed, fan cooled, with Class “B” insulation or better and suitable for indoor/outdoor use.

F. Motor terminal box shall be provided with grounding terminals.

G. Motors shall be manufactured by General Electric, U.S. Motors, Reliance make or approved equal.

H. All motors shall be designed to provide a continuous horsepower output, equal to the rated horsepower multiplied by the 1.15 service factor, without exceeding the total limiting temperature rise for the insulation system and enclosure specified.

I. All motors shall have a safe stall time equal to or greater than the maximum accelerating time under the minimum starting voltage conditions.

J. Starting current at full-voltage shall not exceed 650 % of the motor full-load current for all ac motors. DC motors shall be rated for use with starters that limit the starting current to a maximum of 400 % of motor rated full-load current.

2.7 CLEANING, PACKAGING AND TAGGING

A. All equipment, components and subassemblies shall be thoroughly cleaned of all water, sand, grease, oil and other foreign materials prior to shipment.


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B. All flanged openings shall be covered with 3/8” thick plywood flange protectors; threaded openings shall be protected with plastic end caps or plugs.

C. All caps, plugs and flange covers shall be sealed with tape to provide a dust-tight closure.

D. The equipment shall be suitably skidded, crated, boxed, sealed or otherwise protected from damage during shipment.

E. Each separate shipping crate, box or skid shall be clearly and indelibly labeled with equipment tag numbers. Letters shall be a minimum of 1” high.

F. Each piece of equipment shall be identified with an equipment number and shall have a 304 stainless steel nameplate permanently attached to it.

G. The nameplate shall contain the following information:

1. Equipment number.

2. Purchase order number and date fabricated.

3. Manufacturer’s name and address.

4. Manufacturer’s serial number and model number.

5. Equipment Data: Maximum working pressure and temperature, operating volume, etc.

H. All information shall be embossed on the nameplate or otherwise permanently affixed.

I. Motor nameplates shall be the responsibility of the Supplier and shall contain the motor manufacturer’s standard information.

J. The cleaning and packaging requirements of this section are minimum standards to be followed. The Supplier shall submit in writing, his standard procedures for cleaning and packaging for Engineer’s review. In addition, he shall submit written recommendations for field storage, both indoor and outdoor.

2.8 PAINTING

A. All components with carbon steel and iron surfaces shall be primed and finished painted in accordance with manufacturer’s standard. Color shall be Supplier’s standard.

B. In the absence of specific manufacturer’s standards, prime and finished painting shall be as follows: one coat of zinc primer, followed by one finish coat of enamel. High temperature


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aluminum paint shall be used for uninsulated hot components. Prior to painting, all surfaces shall be sandblasted to SSPC-SP6 or SP-3 as applicable.

C. Supplier shall include a suitable amount of paint for each finish coat for field touch-up work. MSDS sheets shall be provided for each type of paint supplied.

PART III - EXECUTION

Not Applicable.

PART IV - ATTACHMENTS

ATTACHMENT NO. 1 - ENGINE GENERATOR PERFORMANCE DATA SHEET. ATTACHMENT NO. 2 - EMISSION REQUIREMENTS. FACILITY PARAMETERS ATTACHMENT NO. 3 - ELECTRICAL REQUIREMENTS FOR MECHANICAL EQUIPMENT END OF SECTION 15400


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ATTACHMENT NO. 1

ENGINE GENERATOR PERFORMANCE DATA SHEET

E N G I N E Engine Continuous Capacity bhp * Electrical efficiency * Manufacturer / Model No. * Type Reciprocating Gas Engine Lubrication Oil Exhaust (flue) gas temperature at 100% load ° F * Exhaust (flue) gas temperature at 75% load ° F Exhaust (flue) gas temperature at 50% load ° F Exhaust (flue) gas temperature at 30% load ° F

Exhaust gas flow (dry) lb/hr / SCFM * Engine Starter type: Electric Battery * Engine Jacket Cooling Btu/hr- In-Out temp.° F * Engine Lube Oil Cooling Btu / hr- In-Out temp.° F *


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G E N E R A T O R Generator Continuous Capacity/Nominal Power output * KW / * KW Manufacturer / Model No. * / * Type Permanent Magnet Lubrication * Power factor: 0.8 PF Voltage: 13,200 V Amps: * amps Frequency: 60 hz Poles * Phase 3 phase RPM: * Connection: WYE (STAR) * Pitch: * Insulation class “H” Excitation Requirements Efficiency At Full Load * Reactances (% at KVA rating) * Direct axis synchronous reactance: * Direct axis transient reactance: * Direct axis sub-transient reactance: * Short circuit current values: * Three phase: * Line to Line: * Line to Neutral: * Electrical data * Auxiliary power requirements * Space heaters (Watts & Volts): * Cooling fan(Watts & Volts): * Total Weights: * Shipping / Erection Lbs * Operating / Flooded Lbs * Overall Dimensions * Note: Supplier to Confirm all listed information and to furnish information marked with *


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ATTACHMENT NO. 2 FACILITY INFORMATION

I T E M D E S C R I P T I O N V A L U E Location Philadelphia, PA Outside air design temperature (SUMMER) 89 °F DB / 74 °F WB Outside air design temperature (WINTER) 11°F DB Indoor air temperature range 60 °F to 104 °F

Latitude / Longitude

Elevation above sea level at first floor. 50 ft

EMISSION REQUIREMENTS ON DISCHARGE OF THE ENGINE

ALL CONCENTRATIONS BELOW CORRECTED TO 3% OXYGEN ON A DRY BASIS

TECHNICAL DATA gr/BHP-Hr PPM

NOx: g/bhp-hr * * CO: g/bhp-hr * * VOC (NMHC): g/bhp-hr * * THC: g/bhp-hr * * Exhaust Oxygen 9.1 % Minimum efficiency at 100% capacity

at 15 percent excess air

at 5 percent excess air.

F U E L - NATURAL GAS Fuel Pressure Required at the Engine: Psig * Natural Gas Firing Rate at Engine: SCFM * Fuel Oil Firing Rate: GPH (MAX/MIN) Not Applicable Natural Gas heat value (HHV) Min/Max Btu/Cu ft

950/1030

Turn Down * Jacket water heat rejection Btu/Hr * Oil cooler heat rejection Btu/Hr * Heat rejection to atmosphere Btu/Hr * Location: (x) Indoors ( ) Outdoors


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ATTACHMENT NO. 3 ELECTRICAL REQUIREMENTS FOR MECHANICAL EQUIPMENT

D E S C R I P T I O N I N F O R M A T I O N D E S C R I P T I O N

I N F O R M A T I O N

Purchaser’s Aux. Power Supply:

480V, 3 ph., 3 wire, 60 Hz, 100 kA SC.

Lighting:

NA

Area Classification Per NEC & FM Seller shall confirm Rating of equipment

Class: General Purpose Division: Group: Temp Rating

Heat Tracing NA

Motors 460V, 3 ph, 60 Hz, TEFC, severe duty, energy efficient, type per motor data sheet

Electr. Equipment Nameplates

White lamicoid with black lettering. Screwed in place

Grounding Skid - Ground Lugs on frame by Seller Motors – Separate ground conductor with power supply

Control System By Seller as defined in Specification.

Control Power Derived by Seller from engine batteries

Convenience Receptacles:

NA

Raceway and Fittings Rigid galvanized steel unless otherwise required

Wiring Flame retardant, UL VW-1

Motor Controllers By Purchaser Control Terminations

Spade

Branch Feeders By Purchaser Wire numbers Yes Equipment Enclosures and Control Stations

Nema 12, unless otherwise Required (see below)

Certifications: UL listed components

Documentation:

Power requirements/ load summary, single line diagram, schematics, panel layouts, interconnect wiring diagrams, bills of materials, raceway routing, and test reports

Note: Electrical system and equipment shall be designed and installed in accordance with NFPA 70 (National Electrical Code)


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15402 SELECTIVE CATALYTIC REDUCTION SYSTEM

PART I - GENERAL

1.1 DESCRIPTION

A. The Supplier shall design, fabricate, assemble, factory test, deliver and provide startup and commissioning and training for two (2) Selective Catalytic Reduction (SCR) Systems equipped with a CO oxidation catalyst. The SCR system shall be complete with all components and design features, as specified herein for installation at SEPTA's Midvale Facility Combined Heat and Power (CHP) Plant, located in Philadelphia, PA. SEPTA is referred to herein as “Owner.”

B. The SCR system shall be the Supplier's standard and shall be designed in accordance with the

latest applicable codes and standards. C. It is the intention of this specification that the Supplier shall be solely and entirely responsible

for the design, procurement of materials and components, fabrication and assembly, inspection and testing, preparation for shipment, delivery and guarantee of the performance of the equipment, as well as the commercial liability of the entire SCR system, including subsequent startup, operation and maintenance support, as required by the Owner. The individual equipment packages of the SCR system shall be integrated by the Supplier to form a completely functional system such that the Engineer need only to design the interconnecting utilities, piping, wiring and appurtenances to form a complete, functional, and reliable system.

D. Supplier's proposed design shall be fully defined and shall be accompanied by drawings and

data to describe in sufficient detail the construction and general arrangement to allow for an acceptable evaluation. Completed Data Sheets with the proposal are required before the proposal can be accepted. The Supplier shall, as a minimum, furnish drawings, data and descriptive information for the SCR system as specified herein.

1.2 WORK INCLUDED

A. The SCR systems shall be installed indoors in the exhaust duct of two (2), natural gas fueled, engine generator set (refer to specification 15400). The SCR system shall reduce the exhaust emissions to the level as listed in Attachment No. 2. The scope of equipment supplied shall be as specified herein, and in the Equipment Data Sheets on which the operating conditions and special requirements are listed.

B. In the event the Engine exhaust temperature exceeds 975 °F (including all exhaust temperature

tolerances) thus causing ammonia slip above local and state limits at any load point, an additional oxidizing catalyst or a pre-cooler shall be provided to cool the exhaust prior to the SCR catalyst and to limit the ammonia slip to the level acceptable by EPA. The SCR catalyst shall be able to handle the elevated flue gas temperatures during the engine low load operations.


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C. Supplier’s scope of supply shall include, but not necessarily be limited to, the following:

1. Horizontal catalyst/oxidation reactor vessel, including catalyst. 2. Mixer assembly with injection tubes. 3. Urea storage tank, with valving and instrumentation. 4. Metering/Injection system complete with metering pump, dosing box, and atomizing air

compressor. 5. Engine exhaust gas continuous sampling system. 6. Flexible connections, as required. 7. Urea injection control and instrumentation system. 8. PLC controls with indicators, alarms, shutdown annunciators and communications interface

the plant control system. 9. All necessary trim, pipe, valves instruments and fittings within the boundaries of equipment

furnished by Suppliers (interconnecting tubing is by others). 10. Bolts, nuts, and gaskets at system flanged interfaces. 11. Electrical wiring, conduit and all electrical components within the boundaries of

manufacturer's scope of supply. 12. Prime and finish painting of equipment, components and structure, auxiliary equipment and

piping, and other exposed steel surfaces. 13. Shop testing. 14. Startup and two-year operational spare parts. 15. Special tools required for erection, operation, or maintenance. 16. On-site technical support and supervision during installation and start-up. 17. Operator Training.

1.3 WORK BY OTHERS

A. Installation of Supplier’s furnished equipment. B. Concrete foundations, structural steel, anchor bolts, washers, and nuts. C. Utility piping from Supplier’s interface to Owner's facilities and equipment. D. Exhaust gas ductwork. E. Ductwork and SCR vessels insulation. F. Field installed tubing, wiring, and conduit from the Supplier’s interface points.

1.2 1.4 UTILITIES AVAILABLE

A. Electricity: 480 Volt, 3 phase, 60 hertz 120 Volt, 1 phase, 60 hertz C. Municipal Water Supply: 30-50 psig at 65° F

1.3


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1.5 CODES, STANDARDS AND REGULATIONS

A. All materials, design, fabrication, assembly and test procedures shall be in accordance with the requirements of all applicable codes, standards or regulations having jurisdiction over the work.

B. Reference to any code, standard or regulation shall mean the latest published editions, including addenda, supplements and revisions thereto, which are in effect when the purchase order is awarded.

C. In the event of conflict between codes, standards or regulations, the conflict shall be referred to the Engineer for resolution.

D. The organizations having jurisdiction include, but are not limited to, the following:

1. ANSI American National Standards Institute 2. ASME American Society of Mechanical Engineers 3. EPA Federal, State and Local Environmental Protection Agencies 4. IBC International Building Code, New Jersey Edition 5. ISA International Society of Automation. 6. NEC National Electrical Code. 7. NEMA National Electric Manufacturer’s Association. 8. NFPA National Fire Protection Association. 9. OSHA Regulations of the Occupations Safety and Health Administration. 10. UL Underwriter's Laboratories Inc. 11. The state, county or municipal laws and regulations governing the location where the

equipment is to be installed.

1.4 1.6 INSPECTION

A. The Engineer reserves the right to inspect the equipment during fabrication at the Manufacturer's

plant. Dates and times shall be mutually agreeable to the Manufacturer and the Engineer. B. Inspection by the Engineer, or lack of, shall in no way relieve the Manufacturer of its

responsibility to meet the requirements of the Codes and this specification.

1.5

1.7 QUALITY ASSURANCE

F. The Supplier shall be responsible for satisfactory total operation of the SCR and its certification. This supplier shall have had experience with three (3) or more installations of SCRs of comparable size and complexity in regards to coordinating, engineering, testing and supervising. Each of these installations shall have been in successful operation for three (3) or more years. Prior to review of submittals, the Engineer reserves the right to:

1. Have the Supplier submit a list of locations of similar installations.


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2. Inspect any of these installations and operations of the SCR system, and question the user concerning the installations without the presence of the Supplier.

O. Factory authorized representative shall be capable of providing emergency maintenance and repairs at the project site within four (4) hours maximum of notification.

P. Supplier shall be responsible for coordination of all sub-suppliers, and for overall guarantees relating to the mechanical and electrical compatibility of equipment, including the proper functioning of instrumentation, control and the interaction of the overall system.

Q. Manufacturer's quality plan shall be available for review and shall specify how Manufacturer shall ensure that:

1. All engineering, design, drafting, calculations, specifications, and other related work performed by Supplier, his sub-suppliers, or his subcontractors is ensured of being accurate, technically correct, and in compliance with all specifications, codes, standards, and other technical requirements of the specification.

2. All applicable Standards and Engineering specifications, documents, and other requirements are communicated to and complied with by sub-suppliers and subcontractors.

3. All materials can be verified as to origin and conformance to requirements. 4. Fabrication is in accordance with approved drawings and procedures. Non-conforming

work is subject to corrective action or replacement. 5. Non-conforming items are not shipped without Owner's authorization. 6. Verification equipment is correctly calibrated and adjusted.

1.8 SHOP TESTING

E. The SCR system shall be shop tested in accordance with Supplier’s standard shop performance test requirements. The Engineer reserves the right to witness all, or any portion of the tests. The Supplier shall notify the Engineer fifteen (15) days prior to date of testing. All costs associated with shop testing, including fuel, electricity, etc. shall be included as part of the Supplier’s scope.

F. The Supplier shall make all necessary adjustments or modifications required if shop and/or field testing identifies performance or design deficiencies.

G. Certified copies of all shop tests and examinations performed by the Supplier shall be provided to the Engineer for record purposes. All test reports shall be countersigned by the inspecting authority where required by code.

1.9 FIELD TESTING AND PREPARATION FOR START-UP

O. SCR shall be tested thoroughly for both control panel integrity and satisfactory equipment operation. Each test shall be conducted in a safe and professional manner avoiding interference with normal building operations. Documentation of tests shall be forwarded to the Engineer or Owner's Representative in the form of a test report. The Owner's Representative may waive the right to be present for the testing, but this shall not relieve the Supplier from his testing


43

obligations. Six (6) copies of report shall be supplied and shall include, as a minimum, the following:

1. Project name; system description. 2. Date of test. 3. Name of Supplier\Equipment manufacturer. 4. Technician performing test. 5. Test performed, and results.

1.10 SUBSTITUTIONS

A. Unless approved in advance by the Engineer, there shall be no substitutions for equipment, materials or components specified or previously approved.

1.11 SUBMITTALS REQUIRED WITH EACH PROPOSAL

Failure to submit any of the following information may be cause for rejection of proposal.

B. Total net pricing (FOB site), estimated freight costs broken out and proposal validity date.

C. Quotes for any Optional equipment.

D. Complete fabrication and delivery schedule, including, but not limited to approval drawing submittal delivery after order; finalization of detail engineering, release for manufacturing, equipment delivery to jobsite after approval of drawings. All deliveries to be quoted as the best achievable.

E. Guaranteed performance as specified herein.

F. Completed Data Sheets per attachments.

G. Statement of compliance with Bid specification. Technical clarifications and exceptions to the specification.

H. A certificate by the Supplier that the SCR, accessories, and components will withstand the seismic forces and seismic load, as listed by the IBC, and that the SCR will be fully operational after the seismic event at the project site.

I. Scope of supply, including materials of construction, component listing identifying the manufacturer of specialty valves and components and all work by others.

J. Proposed general arrangement drawings (plan and elevation views), P&ID, shipping and operating weights of major components, and space requirements for erection and maintenance.

K. Utility requirements, electrical, air, exhaust gas flow, etc.


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L. The Supplier shall provide a complete and detailed description and design features of the SCR including construction, controls (identifying all local and remote control devices), and safety precautions. The Supplier shall provide a summary of design features and their associated competitive advantage(s).

M. The Supplier shall identify specific design ideas that will minimize field installation work and overall project cost that is not specified herein.

N. The Supplier shall provide detailed information regarding his ability to service the SCR both during startup and subsequent operation. The information shall, as a minimum, include the following: is service organization part of corporate group or done through agents, are service personnel specialized in particular type of equipment.

O. The Supplier shall provide a complete list of components that will be shipped loose for field installation.

1.12 SUBMITTALS REQUIRED AFTER PURCHASE ORDER

A. All non-proprietary design drawings, calculations, manuals, data sheets, etc., as a minimum, shall be submitted in accordance with this specification for review, approval, and final certification as required. The Supplier shall submit an initial drawing schedule, identifying drawing titles and numbers within two (2) weeks of issuance of the purchase order. All submittals shall be submitted to the Engineer as follows:

1. For Approval – Seven (7) legible prints of sizes larger than 11” x 17” to be provided including CD(s) containing general arrangement drawings, as required for plant layout of equipment, in AutoCAD Version 2000 or higher or convertible to AutoCAD.

2. After Final Approval – Two (2) certified sets of sizes larger than 11” x 17” to be provided including CD(s) containing general arrangement drawings, as required for plant layout of equipment, in AutoCAD Version 2000 or higher or convertible to AutoCAD.

3. Operating and Maintenance Manuals – Eight (8) sets. 4. All Supplier drawings shall have the project name (“SEPTA Wayne Junction Combined

Heat and Power Plant”), Engineer's name (“To Be Determined”), and the Owner’s purchase order number indicated near the drawing title.

5. Drawings shall be submitted for approval prior to fabrication of the equipment or development of software. Unless otherwise identified in writing in the purchase order, fabrication shall not commence until these drawings are returned "Proceed" or "Proceed as Noted."

B. Prior to fabrication, submit for approval the following:

1. Data Sheets; including auxiliary equipment motors, pumps, etc. 2. P&ID’s 3. Equipment Layouts; SCR and auxiliary equipment 4. Wiring Diagrams and schematics 5. Control and Power Panel Layouts


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6. List of equipment and items shipped loose for field installation Contractor 7. Performance calculations 8. O&M Manuals

a. Submit, preliminary copies of Maintenance and Operating manuals of the SCR and auxiliaries including technical data sheets, catalog information, wiring diagrams, and information, such as telephone number, fax number, and web sites, for ordering replacement parts.

C. O&M Manuals

1. Two weeks prior to the final inspection, submit four (4) copies of the updated Maintenance and Operating Manual to the Engineer:

a. Include complete "As installed" diagrams and arrangements, which indicate all items of equipment and their interconnecting wiring.

b. Include complete diagrams of the internal wiring for each of the items of equipment, including "As installed" revisions of the diagrams.

c. The wiring diagrams shall identify the terminals to facilitate installation, maintenance, operation and testing.

d. Complete lists of spare parts and special tools recommended for two (2) years of normal operation of the complete system.

e. MSDS Sheets for all Supplier furnished Chemicals, fills, etc. f. Start-up instructions g. Rigging and installation instructions

D. Certifications:

1. Prior to shipment of SCR Supplier shall submit to Engineer, certified report of shop tests.

2. After the completion of installation, the manufacturer statement that the SCR and auxiliaries have been properly installed, adjusted and tested.

E. Drawing Requirements (not all inclusive):

1. Equipment layouts shall include arrangement drawings in plan and elevation, with all components identified. Product and service tie-ins shall be identified by size, type and dimensions for locating tie-ins. Access clearances for service of equipment and removal of components shall also be shown. Mechanical interfaces to other systems or utilities shall be clearly identified and dimensioned, including size and type of connection. Detailed location and characteristics of all terminal points, electric connection requirements, etc. shall be provided.

2. Piping and Instrumentation Diagrams (P&IDs):

a. Interconnecting, terminal, and trim piping including flow directions, Supplier's line designation and line sizes.

b. All Supplier furnished valves, flanges, silencers, trim, instruments, controls, vents, and drains with trim list identification.


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c. Settings, design temperatures and pressures, and safety valve set pressures. d. Motor HP, GPM, and TDH (ft) for Supplier furnished pumps.

3. Elevations and sections shall be provided as necessary to show full details of tie-ins, service access and control components.

4. Outline drawings with locations of electrical boxes, conduits and grounding pads. 5. Electrical drawings, schematics and electrical interconnecting diagrams. 6. Electrical data for all power consumers and mechanical utility requirements. 7. Weights and overall dimensions and detailed floor loadings shall be shown. Provide unit-

mounting details.

1.13 SOUND AND VIBRATION

A. The Supplier shall make every effort to design and manufacture the equipment in a manner such that sound generation and vibration is held to a minimum.

B. The Supplier shall state the sound level in their proposal for the equipment, as measured in accordance with ANSI Standards S1.2, "Method for the Physical Measurement of Sound" and S 1.4, "Specification for General Purpose Sound Level Meter".

1.14 SAFETY

A. All mechanical equipment shall be fully guarded and interlocked with machine operations; i.e., exposed gears, chains, belts, sprockets and hazardous moving parts to meet current OSHA standards in effect at the time of delivery. Guard doors shall include electrical interlocks to stop or prevent machine operations if the guard door is opened. In order to comply with OSHA requirements for lockout/tag out, padlockable devices shall be provided to isolate and safely release electrical, pneumatic and other potential sources of energy release.

B. The Supplier shall warrant that all equipment complies with the appropriate standards for machine guarding and design set out in United States Code of Federal Regulations (CFR) Title 29, Chapter XVII, Part 1910, Subpart O.

1.15 COMMISSIONING AND STARTUP

A. The Supplier shall provide the necessary field startup services to fully commission the equipment to achieve performance guarantees. This service shall include, but not be limited to, verification of proper installation, performance of all tests and procedures as stated in the startup and installation manuals, verification of the proper operation of the control panels to perform as designed, performance of all necessary adjustments and calibrations of all SCR sensors and


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meters and necessary technical assistance to assure that the Supplier’s equipment meets the performance guarantees. The Supplier shall make all reasonable attempts to insure that the same service technician is utilized for startup, training and commissioning for each of the Supplier’s equipment packages for the duration of the project.

1.16 TRAINING

B. The Supplier shall provide on-site training for operating and maintenance personnel. This service shall include operating instructions and training for Owner's personnel. Instructions shall include, but not be limited to, training materials, hands-on and classroom instruction and complete review of all manuals. Classroom training shall be performed in a maximum of 8-hour daily sessions. The hands-on instructions shall include start-up, operation (normal and expected transients), shutdown and maintenance of all systems.

1.17 SPARE PARTS

C. With his proposal, the Supplier shall identify all spare parts, including source, cost and identification of the manufacturer and associated model number, critical to initial startup that are recommended for the Engineer/Owner to have on-hand to minimize unplanned construction delays or equipment downtime, as well as a standard priced spare parts list for replacement of components as needed. The Supplier shall recommend spare parts expected for replacement during startup and two (2) years of operation.

1.18 SPECIAL TOOLS

D. The Supplier shall furnish one (1) set of special tools required for the SCR system proposed.

1.19 WARRANTY

D. The Manufacturer shall warrant that all materials and equipment furnished under this contract will be new and of good quality, free from defects in design, workmanship, and materials.

E. Each item of equipment, or part thereof, proving to be defective within the specified period of the warranty shall be replaced, free of defect, without cost to the Owner.

F. The warranty period shall be the Manufacturer's standard warranty period, but not less than a minimum of twelve (12) months after startup, or 18 months after delivery of the SCR at the site (whichever comes first).

1.20 PERFORMANCE GUARANTEES

A. The Supplier shall provide performance guarantees for the SCR including auxiliaries.


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1.21 PRODUCT DELIVERY AND HANDLING

E. The SCR shall be delivered FOB to the job site. Supplier shall furnish rigging and installation instructions for unloading, and transporting it to final location.

F. The Supplier shall be responsible for the shipment of the SCR to the job site. Supplier shall be responsible for packaging and all precautions necessary for shipments to arrive at destinations in the condition shipped when handled by commercial carriers.

G. The SCR system shall be factory assembled, and skid mounted, to the greatest extent possible.

H. Supplier shall coordinate the delivery of SCR with the installing contractor. Installing Contractor shall be responsible for the receiving and unloading of the equipment at the job site. Manufacturer shall confirm shipping clearances and shall provide the status of shipments in transit upon request.

PART II - PRODUCTS

2.1 GENERAL

A. The Supplier shall provide a complete SCR system comprising all equipment and components required to control and monitor engine exhaust emission as required by Federal, State and Local Authorities and as specified in Attachment No. 2. The SCR system shall be of a type and capacity recommended by the SCR manufacturer based on the Engine requirements. Acceptable Manufacturers, subject to compliance with requirements of this specification, are as follows:

a. Miratech b. Steuler c. Peerless Mfg. d. Johnson Matthey

E. Asbestos or asbestos filled materials shall not be used for any component.

F. The SCR system shall be guaranteed to achieve reduction of emissions to levels below the maximum site emissions from a minor stationary source located in a Severe Non-Attainment area as defined by Title V of the Federal Clean Air Act of 1990, as well as the emissions reduction criteria stipulated by the Pennsylvania Department of Environmental Protection.

G. Urea is the only reducing agent that will be accepted for use in the SCR system.

H. Supplier shall ensure the total back pressure imparted on the engine exhaust by the SCR System, and other in-line exhaust components shall be less than the engine manufacturer recommends..


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2.2 DETAILED DESIGN

I. SCR REACTOR VESSEL 1. The SCR catalyst reactor housing shall be fabricated from non-scaling heat resistant

stainless steel, of rigid reinforced construction. The SCR catalyst reactor housing shall be equipped with ANSI flanges arranged for front entry and top exit. The SCR housing and all components in contact with engine exhaust shall be suitable for continuous operation at the maximum engine exhaust temperature without scaling, deformation or any other physical damage for the life of the system.

2. The SCR reactor housing shall be equipped with insulation supports. Insulation shall be supplied and installed by others.

3. The SCR reactor housing shall be designed to be mounted horizontally in the engine exhaust gas duct and be supported from overhead. The SCR supporting steel shall be provided by Supplier.

4. The reactor housing shall be equipped with sample gas ports, maintenance and inspection doors for easy access and catalyst bed loading and unloading, instrumentation connections and other connections as deemed necessary by the Supplier.

5. The SCR vessel catalyst core shall consist of an adequate number of layers of catalyst material, with room for one (1) additional layer of material in the reactor housing. Each layer of catalyst material shall be of a modular design. Catalyst modules shall be of size and weight to facilitate manual loading.

6. The catalyst shall be type as recommended by the SCR manufacturer and shall be designed for operation at the maximum and minimum exhaust temperatures achievable by the engine.

J. SCR SYSTEM ACCESSORIES 1. The SCR system shall include a static exhaust gas mixer to be mounted upstream of the

SCR catalyst reactor housing. The mixer shall einsure full and complete mixing of the atomized injected reducing agent with the engine exhaust gas under all engine load conditions. The static mixer shall be fabricated from non-scaling heat resistant stainless steel. The static mixer shall be equipped with a stainless steel injection lance, through which the atomized reducing agent is introduced into the exhaust stream. The static mixer shall be equipped with ANSI flanges at both ends.

2. The static mixer shall be equipped with insulation supports. Insulation shall be supplied and installed by others.

3. The SCR system shall be supplied with a reducing agent storage, injection and control system which shall included but not necessarily limited to the follow: Urea storage tank, metering/injection pump, dosing box, atomizing air compressor, and all appurtenances required to form a complete and operable system. The capacity shall by as recommended by the SCR supplier.

4. The reducing agent metering and control system shall be capable of insuring, that the maximum ammonia slip to atmosphere from the SCR system does not exceed the limits specified in Attachment No. 2 under all engine operation conditions. Use of an oxidation catalyst mounted downstream of the SCR catalyst to eliminate excess ammonia slip to atmosphere is prohibited.


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5. Compressed air system, for urea atomization shall be provided by the Supplier. 6. The Urea/water solution shall be directed into the exhaust gas stream by means of a

metered injection nozzle system. 7. The Supplier shall provide one (1) nominal 6,000 gallon, polyethylene storage tank for

urea/water solution. The tank shall be installed outdoors and be of vertical design. As a minimum, the tank shall be equipped with inlet, outlet, re-circulation, vent, drain nozzles, trim and instruments as listed in Attachment No. 1. All spare or un-used tank connection shall be supplied with blind flanges.

K. PIPING/TUBING 1. All Urea solution and compressed air pipe/tube materials and components shall be

stainless steel. Minimum tube size shall be 1/2 inch nominal. Minimum tubing thickness is 0.063 of an inch.

2. Stainless steel tubing sizes shall be limited to 1” and below. Carbon steel, cast, ductile, or malleable iron piping material shall not be used.

3. All stainless steel Urea piping shall be welded. Threaded connections shall be minimized. Pipe threads shall conform to ANSI B2.1, Taper Pipe Threads. Taper threaded connections are unacceptable in stainless steel.

1.6 2.3 INSTRUMENTATION AND CONTROLS

A. PLC based, closed loop analysis and reactant injection system to maximize reactant injection efficiency by continuously sampling and analyzing the treated exhaust gas.

B. The SCR control system shall be equipped with an interface display and with a serial interface to permit communication and monitoring of the SCR system from the plant balance of plant control system (PCS). The Supplier shall provide and configure the Modbus/TCP or other Ethernet based (compatible with the PCS) communications interface, provide programming of all parameters required to effectively monitor and control the SCR system from the PCS.

C. Completely pre-wired Control panel, built in accordance to manufacturer standards, with UL listed components, shall be provided.

D. The SCR control system shall be equipped to provide the following functions: 1. Continuous monitoring of the temperature downstream of the SCR (SCR discharge

connection) 2. Continuous monitoring of the urea flow rate (gal/hr)

The Temperature and Urea flow information shall be continuously stored in an electronic data storage for the EPA compliance record.

1.7 2.4 CLEANING, PACKAGING AND TAGGING


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K. All equipment, components and subassemblies shall be thoroughly cleaned of all water, sand, grease, oil and other foreign materials prior to shipment.

L. All flanged openings shall be covered with 3/8” thick plywood flange protectors; threaded openings shall be protected with plastic end caps or plugs.

M. All caps, plugs and flange covers shall be sealed with tape to provide a dust-tight closure.

N. The equipment shall be suitably skidded, crated, boxed, sealed or otherwise protected from damage during shipment.

O. Each separate shipping crate, box or skid shall be clearly and indelibly labeled with equipment tag numbers. Letters shall be a minimum of 1” high.

P. Each piece of equipment shall be identified with an equipment number and shall have a 304 stainless steel nameplate permanently attached to it.

Q. The nameplate shall contain the following information:

6. Equipment number. 7. Purchase order number and date fabricated. 8. Manufacturer’s name and address. 9. Manufacturer’s serial number and model number. 10. Equipment Data: Maximum working pressure and temperature, operating volume, etc.

R. All information shall be embossed on the nameplate or otherwise permanently affixed.

S. Motor nameplates shall be the responsibility of the Supplier and shall contain the motor manufacturer’s standard information.

T. The cleaning and packaging requirements of this section are minimum standards to be followed. The Supplier shall submit in writing, his standard procedures for cleaning and packaging for Engineer’s review. In addition, he shall submit written recommendations for field storage, both indoor and outdoor.

1.8 2.5 PAINTING

A. All carbon steel surface and equipment shall be primed and finished painted in accordance with manufacturer’s standards. In the absences of specific manufacturer’s standards, prime paint with a Zinc rich primer (dry film thickness - 2.0 mils min, 2.5 mils max), finish coat shall be of Aliphatic Polyurethane (dry film thickness - 2.0 mils min, 2.5 mils max) or standard manufacturer epoxy paint.

B. Stainless steel components shall not be painted.


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PART III - EXECUTION

Not Applicable

PART IV - ATTACHMENTS

ATTACHMENT NO. 1 - SCR SYSTEM DATA SHEETS. ATTACHMENT NO. 2 - EMISSION DATA AND FACILITY PARAMETERS. ATTACHMENT NO. 3 - ELECTRICAL REQUIREMENTS FOR MECHANICAL EQUIPMENT.

END OF SECTION 15402

1.9 ATTACHMENT NO. 1 -SCR SYSTEM DATA SHEETS Service: Two (2) Selective Catalytic Reduction system (SCR) for two (2) 4,000-4,400 kW engine generator

sets. The SCR system shall reduce the exhaust gas emissions to the level as listed in Attachment No. 2.

Scope: Supplier shall supply, as a minimum, SCR system components as follows: (2) SCR Reactor housing for horizontal gas flow (with support steel and insulation supports)

loaded with SCR catalyst material (2) Static Mixer (1) 6000 gallon Urea Storage Tank with level transmitter and tank trim (2) Urea injection system, pumps, dosing box, atomizing air compressor Associated electrical equipment and control system

Note: Supplier to furnish information marked with * with the BID


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Operating Data Specified Information Information by Supplier

Natural Gas Engine Manufacturer

By Supplier *

Natural Gas Fuel Consumption

By Engine Supplier *

Load, [%] HP/ kW By Engine Supplier * Exhaust flow rate, wet basis By Engine Supplier * Exhaust flow rate, dry basis By Engine Supplier * Engine exhaust gas temperature

By Engine Supplier °F *

Consumption of Urea By SCR Supplier * Consumption of water By SCR Supplier * Pressure drop across SCR By SCR Supplier * Pressure drop across Static Mixer

By SCR Supplier *

Guarantee for SCR catalyst By SCR Supplier (operating hours)

*

SCR REACTOR DIMENSIONS:

Description Specified Information Information by Supplier

Length / Width / Height N/A * Cross section approx. N/A * Reactor material Stainless Steel * Weight without catalyst material

N/A *

Weight of Catalyst material N/A * Inlet/outlet flange Type/Size ASME B16.5 *


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1.1 ATTACHMENT NO. 1 - SCR SYSTEM DATA SHEET (CONTINUED)

1.2 SCR-CATALYST MODULE

1.3 Description 1.4 Specified Information 1.5 Information by Supplier

1.6 Make / Model / Manufacturer

1.7 By SCR Supplier 1.8 *

1.9 Catalyst Module 1.10 (*) layers Catalysts + (1) spare layer

1.11 *

1.12 Catalyst type /material 1.13 By SCR Supplier 1.14 * 1.15 Catalyst module dimensions

1.16 Incl. stainless steel wire mesh

1.17 *

1.18 Length / Width / Height 1.19 By SCR Supplier 1.20 * 1.21 Catalyst module quantities


1.24 Arrangement 1.25 By SCR Supplier 1.26 * 1.27 Total catalyst surface 1.28 By SCR Supplier 1.29 * 1.30 Guarantee life of catalyst

1.31 By SCR Supplier (operating hours)

1.32 *

1.33 Min / Max Catalyst Bed Temp


1.36 Min / Max Temp at Urea Injection


1.39 Min/Max exhaust gas Temp. at SCR exit


1.42 Min / Max press drop across catalyst


1.45 Ammonia Slip (ppmvd) 1.46 < 10 ppmvd 1.47 *


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1.48 CO-CATALYST MODULE

1.49 Description 1.50 Specified Information 1.51 Information by Supplier

1.52 Make / Model / Manufacturer


1.55 Catalyst Module 1.56 (*) layer(s) 1.57 * 1.58 Catalyst type /material 1.59 By SCR Supplier 1.60 * 1.61 Catalyst module dimensions

1.62 Incl. stainless steel wire mesh

1.63 *

1.64 Length / Width / Height 1.65 By SCR Supplier 1.66 * 1.67 Catalyst module quantities


1.70 Arrangement 1.71 By SCR Supplier 1.72 * 1.73 Total catalyst surface 1.74 By SCR Supplier 1.75 * 1.76 Guarantee life of catalyst

1.77 By SCR Supplier (operating hours)

1.78 *

1.79 Min / Max Catalyst Bed Temp


1.82 Min / Max Temp at Urea Injection


1.85 Min / Max press drop across catalyst



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ATTACHMENT NO. 1 - SCR SYSTEM DATA SHEET (CONTINUED)

SCR STATIC MIXER DIMENSIONS Description Specified Information Information by Supplier

Length / Width / Height N/A * Cross section approx. N/A * Material Stainless Steel * Weight N/A * Inlet/outlet flange Type/Size ASME B16.5 *

UREA SUPPLY, METERING and INJECTION SYSTEM:

Metering pump w/speed controlled drive (Capacity to be confirmed by Supplier). Injection lance nozzle with high temperature protection, to be mounted into the static mixer. Injection lance material including set of stainless steel fittings. 80 microns (Supplier to confirm) filter to precipitate suspended particulate from Urea solution with SS screen. Air compressor with accessories for atomization of urea solution.

1.87.1 ELECTRICAL and CONTROL SYSTEM

Automatic urea metering and control system shall be equipped with closed loop gas analysis system that shall inject urea in accordance with engine load. SCR Supplier shall furnish temperature sensors for field installation by Contractor to measure the operating temperature across the SCR catalyst and to release the urea injection upon the catalyst temperature exceeding the required minimum operating temperature for the exothermal reaction of the NOx oxidation. The temperature sensors shall de-energize the injection system upon the Engine shut down. Completely pre-wired UL listed Control panel, built in accordance to manufacturer standards, shall be provided.

UREA STORAGE TANK:

Manufacturer: * Model Number: * Type: Vertical Capacity: 6000 gal (Nominal) Dimensions: * Material: Polyethylene Manhole: 16” Dia. Flanged w/cover * Mounting : * Tank wall thickness: * Level Transmitter (LT) Required: (X) Yes ( ) No LT Manufacturer:* Model Number: * __________ Tank Connections (sizes and type to be confirmed by Supplier):

Fill (w/internal dip tube if located on top): 1-1/2” NPT * System Return (w/internal dip tube if located on top): 1” NPT *

Level Transmitter: 2“ NPT *


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Drain: 1” NPT Overflow: 2” NPT Pump Suction: 1” NPT

Vent: 2” NPT Spare connection on the top of the Tank: 2” NPT (w/blind flange)


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ATTACHMENT NO. 1 - SCR SYSTEM DATA SHEET (CONTINUED)

UREA METERING PUMP:

Manufacturer: * Model Number: * Type: * Horsepower: * Flowrate Required: * gpm Pressure Required: * Pump Speed: * Spm Pump Material: * housing / * internals / * Non wetted parts All necessary piping/tubing and associated hardware between urea tank and urea injection nozzle shall be provided including, but not limited to, th following:

Pump air mufflers, strainers/filters, check valves and ball type shut-off valves. Valve Material: 304 SS or 316 SS * Pipe/Tube Material: 304 SS or 316 SS

UREA ATOMIZING AIR COMPRESSOR:

Manufacturer: * Model Number: * Type: * Horsepower: * Flowrate Required: * scfm Pressure Required: * Speed: * rpm Materials of Construciton: *

1.10


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ATTACHMENT NO. 2 - EMISSION DATA

E M I S S I O N D A T A

EMISSION REQUIREMENTS (see note)

PERFORMANCE DATA

Nitrogen Oxides (Nox) Grams/BHP-hr Lbs/ hr Annual Emission Rate for Each Unit (ton/yr) Annual Combined Emissions (ton/yr)

0.15 1.99 8.72 17.44

Carbon Monoxide (CO) Grams/BHP-hr Lbs/ hr Annual Emission Rate for Each Unit (ton/yr) Annual Combined Emissions (ton/yr)

0.15 1.99 8.72 17.44

Volatile Organic Compounds (VOC) Grams/BHP-hr Lbs/ hr Annual Emission Rate for Each Unit (ton/yr) Annual Combined Emissions (ton/yr)

0.09 1.19 5.23 10.46

Sulfur Dioxide (SO2) Grams/BHP-hr Lbs/ hr Annual Emission Rate for Each Unit (ton/yr) Annual Combined Emissions (ton/yr)

0.002 0.022 0.10 0.20

Particulate Matter (PM-2.5) Grams/BHP-hr Lbs/ hr Annual Emission Rate for Each Unit (ton/yr) Annual Combined Emissions (ton/yr)

0.03 0.37 1.62 3.24

NOTE: Above values are based on PADEP


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F A C I L I T Y P A R A M E T E R S

I T E M D E S C R I P T I O N V A L U E

Location Philadelphia, PA Outside air design temperature (SUMMER) 89 °F DB / 74 °F WB Outside air design temperature (WINTER) 11°F DB Indoor air temperature range 60 °F to 104 °F

Latitude / Longitude 40.00/74.10

Elevation above sea level at first floor. 50 ft


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1.11 ATTACHMENT NO. 3- ELECTRICAL REQUIREMENTS FOR MECHANICAL EQUIPMENT

D E S C R I P T I O N I N F O R M A T I O N D E S C R I P T I O N I N F O R M A T I O N

Purchaser’s Power Supply:

480 V, 3 ph, 3 wire, 60 Hz 65 KA 120V, 1 ph., 2 wire, 60 Hz

Lighting: Foot candles: Type:

NA

Area Classification Per NEC & FM Seller shall confirm Rating of equipment

Class: General Purpose Division: Group: Temp Rating

1.87.1.1.1.1.1 Heat Tracing

NA

Motors TEFC, Severe Duty, Energy Efficient

Electr. Equipment Nameplates

White lamicoid with black lettering. Screwed in place

Grounding Package – Ground Lugs on frame by Seller Motors – Separate ground conductor with power supply

Control System By Seller as defined in Specification.

Control Power

By Purchaser Convenience Receptacles:

NA

Raceway and Fittings

Rigid galvanized steel unless otherwise required

Wiring Flame retardant, UL VW-1

Motor Controllers By Supplier Control Terminations Spade Branch Feeders By Purchaser Wire numbers Yes Equipment Enclosures and Control Stations

Nema 12, unless otherwise Required

Certifications: UL listed components

Documentation:

Power requirements/ load summary, single line diagram, schematics, Schematics, Panel Layouts, interconnect wiring diagram, bills of materials, raceway routing and test reports.

Note: Electrical system and equipment shall be designed and installed in accordance with NFPA 70 (National Electrical Code)


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16346 MEDIUM VOLTAGE GENERATOR SWITCHGEAR Part 1 - GENERAL

1.1 SCOPE

A. The Seller shall furnish, test, and deliver (1) 13.2 kV generator switchgear line-up (SG-CG1301) as specified herein and as shown on the attached drawing E-2. The installation of this equipment will be by Others.

B. The 13.2 kV service entrance switchgear will consist of 15 kV indoor, metal-clad, circuit breaker switchgear with Main-Tie-Main circuit breakers, generator circuit breakers (3), and feeder circuit breakers (3). The switchgear will include manual closed transition (with synch check) bus tie transfer controls.

C. The Seller shall furnish batteries and redundant battery chargers for 125VDC breaker control power for the 13.2 kV generator switchgear.

D. The Seller shall furnish an Arc Flash Hazard Analysis Study per the requirements set forth in NFPA 70E - Standard for Electrical Safety in the Workplace. The arc flash hazard analysis shall be performed according to the IEEE 1584 equations that are presented in NFPA70E-2004, Annex D. The Seller shall prepare and factory install Arc Flash Hazard Warning labels. Arc Flash Hazard Warning labels shall include: PPE Level, work distance, short circuit data, incident energy, and flash protection boundary information.

1.2 REFERENCES

A. Metal-clad switchgear components shall be designed, manufactured and tested in accordance with the latest applicable standards of NFPA 70, NEMA SG-4 and SG-5, IEEE, UL, and but not limited to, ANSI 37.20.2.

1.3 ATTACHMENTS

A. DRAWINGS

1. E2, CHP Switchgear Single Line Diagram

B. DOCUMENTS 1.

1.4 SUBMITTALS

A. The following information shall be submitted to the Engineer (PDF and Autocad): 1. Master drawing index


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2. Floor plan (detailing structural steel design, conduit openings, etc.) 3. Switchgear front views, sections, and floor plans 4. Switchgear side views with equipment and bus arrangements 5. Switchgear compartment (unit) layouts and terminal block arrangements. 6. Device and switch development drawing (showing relay terminals, switch developments,

meter terminals, auxiliary relay terminals, etc) 7. Single line diagrams 8. Three line diagrams (that are required by the Utility): MUST BE IN UTILITY

FORMAT. 9. Elementary diagrams (that are required by the Utility): MUST BE IN UTILITY

FORMAT. ALL RELAY INPUTS AND OUTPUTS MUST BE SHOWN ON THE SAME SHEET. LADDER TYPE DIAGRAMS ARE NOT ACCEPTABLE. BREAKER MECHANISM AND TRUCK MOUNTED SWITCHES, LOCKOUT RELAY AND TEST SWITCH DEVELOPMENTS, ETC. MUST ALSO BE SHOWN

10. Control system architecture and communications diagrams 11. Wiring diagrams for enclosure auxiliaries 12. AC & DC station service wiring diagrams 13. Internal interconnection wiring diagrams. 14. Field interconnection wiring diagrams 15. Battery sizing calculations 16. Arc flash study and Labels 17. Device Internals and switch developments 18. Sub-plate assembly drawings 19. Shipping split interconnection wiring diagrams 20. Protective relay manuals, setting information, etc. 21. Nameplate schedule 22. Component list 23. Product data sheets 24. Conduit entry/exit locations 25. Assembly ratings including:

a. Short-circuit rating b. Voltage c. Continuous current d. Basic impulse level for equipment over 600 volts

26. Major component ratings including: a. Voltage


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b. Continuous current c. Interrupting ratings

1.5 SUBMITTALS - FOR INFORMATION

A. The following product information shall be submitted:

1. Descriptive bulletins 2. Product sheets.

1.6 SUBMITTALS - FOR CONSTRUCTION

A. The following information shall be submitted for record purposes:

1. Final as-built drawings and information. 2. Wiring diagrams 3. Certified production test reports 4. Installation information including equipment anchorage provisions 5. Seismic certification.

B. Submit six (6) copies of the above information.

1.7 QUALIFICATIONS

A. The manufacturer of the assembly shall be the manufacturer of the major components within the assembly.

B. The manufacturer of this equipment shall have produced similar electrical equipment for a minimum period of five (5) years.

1.8 REGULATORY REQUIREMENTS

1.01 A. Listing by Underwriters Laboratories (UL) or Canadian Standards Association (CSA) shall be provided.

1.9 DELIVERY, STORAGE AND HANDLING

A. Equipment shall be handled and stored in accordance with manufacturer's instructions. One (1) copy of these instructions shall be included with the equipment at time of shipment.

B. Shipping groups shall be designed to be shipped in sections not to exceed facility handling and installation. Units shall be shipped complete with all accessories required for assembly. All wiring that extends between shipping sections must be terminated in


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terminal blocks at interface point with a wiring harness that will be field installed between sections. See drawings for any shipping size restrictions.

C. Switchgear shall be equipped to be handled by crane. Where cranes are not available, switchgear shall be suitable for skidding in place on rollers using jacks to raise and lower the groups.

D. Switchgear being stored prior to installation shall be stored to maintain the equipment in a clean and dry condition. If stored outdoors, switchgear shall be covered and heated.

1.10 OPERATION AND MAINTENANCE MANUALS

A. Six (6) copies of the equipment operation and maintenance manuals shall be provided. The Seller shall also provide a CD rom which contains all manuals and drawings in PDF format.

B. A preliminary operation and maintenance manual (PDF or hardcopy) shall be submitted for review prior to shipment.

C. Operation and maintenance manuals shall include the following information: 1.1. Instruction books and/or leaflets

2. Recommended renewal parts list 3. Complete set of drawings. 4. Detailed Sequence of operation 5. Maintenance and testing instructions.

1.11 EXTRA MATERIALS

A. Potential transformer fuses: (6) of each type installed

B. Spare indicating lights: six (6) of each type installed

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

1. Medium voltage circuit breakers – ABB, Eaton/Cutler Hammer, GE, Siemens, Square D


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2. Batteries – ALCAD, GNB, SBS

3. Battery chargers – LaMarche, GNB, SBS

4. Potential Transformers – ABB, GE

5. Surge Arresters – ABB, GE

2.2 RATINGS

A. 15 kV Switchgear described in this specification shall be designed for normal operation on a 13.2 kV, three-phase, 3 wire, low resistance grounded (400A), 60-hertz system. In the event of a loss of the utility, the system will not operate isolated from the utility.

B. UL labeled equipment shall be provided. In the event that UL listing is not available, the Seller shall obtain third party certification as required in order to obtain the necessary approvals of the local authority having jurisdiction.

C. Each circuit breaker shall have the following ratings:

Switchgear I.D. SG-CG1301 Maximum Voltage 15 kV Operating Voltage 13.2 kV BIL Rated 95 kV Continuous Current 1200 Amps Short-Circuit Current 18 kA (At Rated Maximum KV) Closing and Latching Capability 37 kA rms 3 Sec. Short Time Rating 23 kA Nominal 3-Phase MVA Class 1000 MVA Rated Interrupting Time Five cycles

2.3 CONSTRUCTION

A. The switchgear assembly shall consist of individual vertical sections housing various combinations of circuit breakers, potential transformers, metering, and controls, bolted to form a rigid metal-clad switchgear assembly. Metal side sheets shall provide grounded barriers between adjacent structures and solid removable metal barriers shall isolate the major primary sections of each circuit. Rear covers shall be furnished for each vertical section for circuit isolation and ease of handling. Lifting handles shall be provided.

B. The stationary primary contacts shall be silver-plated and recessed within insulating tubes. A metal or lexan shutter shall automatically cover the stationary primary disconnecting contacts when the breaker is in the disconnected position or out of the cell.


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Provide rails to allow withdrawal of each circuit breaker for inspection and maintenance without the use of a separate lifting device.

C. All space heaters within each assembly shall be controlled by one thermostat and furnished with a single pole circuit breaker for supply disconnect. The entire circuit shall be wired to an accessible terminal block provided for a single connection for the internal power source.

2.4 SEISMIC REQUIREMENTS

A. Design equipment and anchorages in accordance with the requirements of IBC 2006 and the following criteria: seismic design category c, sds = 0.31g, ip = 1.5. For equipment mounted on the second floor, z = 23 feet, h = 43 feet.

2.5 BUS

A. The main bus shall be copper and have flame-retardant and track-resistant epoxy insulation. The bus supports between units shall be flame-retardant, track-resistant, glass polyester for 15 kV class. The switchgear shall be constructed so that all buses, bus supports and connections shall withstand stresses that would be produced by currents equal to the momentary ratings of the circuit breakers. Main buses shall be rated 1200 amperes. Main bus shall have provisions for future extension. All bus joints shall be silver-plated, bolted and insulated with easily installed boots. The bus shall be braced to withstand fault currents equal to the close and latch rating of the breakers. The temperature rise of the bus and connections shall be in accordance with ANSI standards and documented by design tests.

B. A ¼ x 2 inch copper ground bus shall extend the entire length of the switchgear.

2.6 WIRING/TERMINATIONS

A. The switchgear manufacturer shall provide suitable terminal blocks for secondary wire terminations and a minimum of 10% spare terminal connections shall be provided. One control circuit cutout device shall be provided in each circuit breaker housing.

B. Switchgear secondary wire shall be (minimum) #14 AWG (#12 for CT circuits) type SIS rated 600 volt, 105 degrees C, furnished with wire markers at each termination. Wires shall terminate on terminal blocks with marker strips numbered in agreement with detailed connection diagrams. Control wiring shall be terminated with spade type lugs. Current transformer wiring shall be terminated with ring type lugs and lock washers. Wiring shall be stamped every 3-4” with From –To designations.


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C. Incoming line and feeder cable lugs of the type and size indicated on the one-line diagram drawings shall be furnished. Insulating boots for customer cables shall also be provided.

2.7 CIRCUIT BREAKERS

A. The circuit breakers shall be horizontal draw-out type, capable of being withdrawn on rails. The breakers shall be operated by a motor-charged stored energy spring mechanism, charged normally by a universal electric motor and in an emergency by a manual handle. The primary disconnecting contacts shall be silver-plated copper.

B. Each circuit breaker shall contain three vacuum interrupters separately mounted in a self-contained, self-aligning pole unit, which can be removed easily. The vacuum interrupter pole unit shall be mounted on glass polyester supports. A contact wear gap indicator for each vacuum interrupter, which requires no tools to indicate available contact life, shall be easily visible when the breaker is removed from its compartment. The breaker front panel shall be removable when the breaker is withdrawn for ease of inspection and maintenance.

C. The secondary contacts shall be silver-plated and shall automatically engage in the breaker operating position, which can be manually engaged in the breaker test position.

D. Interlocks shall be provided to prevent closing of a breaker between operating and test positions, to trip breakers upon insertion or removal from housing and to discharge stored energy mechanisms upon insertion or removal from the housing. The breaker shall be secured positively in the housing between and including the operating and test positions.

E. Close and trip circuits shall be separately fused. Fuse blocks shall be dead front, pull-out type.

F. Undervoltage relays shall be provided and monitor close and trip circuit voltage. Contacts (normally open, closed when energized) shall be provided and wired out to terminal blocks for the Customer’s use.

G. Each breaker shall be complete with control switch and red and green indicating LEDs to indicate breaker contact position (ElectroSwitch Series 24 with pistol grip handles).

H. Each breaker shall have a minimum of 4 normally open and 4 normally closed auxiliary contacts (mechanism and truck operated) wired to accessible terminal blocks for the Buyer’s use.

I. Remote control (trip and close) of the mains, tie, and feeder (not generator) breakers shall be provided via the SEL relays or remote mimic panel (by Others). A common


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local/remote control switch (ElectroSwitch Series 24 with oval grip handle) shall be provided. It shall be located on the tie breaker compartment door. Mimic panel controls interfaces shall be wired to common terminal blocks located in the upper section of the tie breaker compartment.

J. Breaker status contacts shall be wired to the SEL relays.

2.8 SURGE ARRESTERS

A. Station class, metal oxide, surge arresters shall be provided for the incoming mains. They shall be rated for 10 kV. They shall be connected to the line side of the breaker and must be located in the entrance cable compartment.

2.9 PROTECTIVE RELAYS

A. The switchgear manufacturer shall furnish and install, in the metal-clad switchgear, the quantity, type and rating of protection and synchronism check relays as indicated on the drawings and described hereafter in this specification. Protection relays shall have auxiliary inputs and outputs as required to interface controls, alarms, trips, etc. with the Plant Control System (PCS) and to provide SCADA outputs (analog and digital) as required by the Utility. Protection relays shall also have auxiliary inputs and outputs as required for hard wired signals from field electrical mechanical device contacts (such as transformer level and temperature devices, etc.).

B. The Seller shall provide relay setting software and manuals for all microprocessor based relays.

C. In general, microprocessor based multi-function and solid state relays shall be provided. Unless otherwise approved, microprocessor based multi-function protective relays shall be manufactured by Schweitzer and Beckwith.

D. The main service entrance and feeder circuit breakers shall be equipped with a SEL 351A relays with dual redundant Ethernet ports.

E. Generator circuit breakers shall be equipped with a Beckwith M3425A generator protection relay (with Ethernet, Modbus TCP/IP option.

F. SEL 587Z bus differential relays shall be provided for protection of each bus.

G. Bus tie circuit breaker synch check shall be a Basler BE1-25 relay.

H. Under/over voltage alarm relays shall be provided for each bus. They shall be Basler type BE1-27/59.


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I. The Seller shall wire trip, alarm and relay failure contacts (for the Purchasers use) to terminal blocks located in a common section.

J. Relays shall operate from the 5-ampere secondary output of current transformers.

K. The primary current transformer rating being used for phase and ground protection feeding the device shall be programmable for current transformers with primary current ratings from 5 through 5,000 amperes.

L. Current and potential test blocks (ABB FT1) shall be provided for all metering and protection circuits including trip and close circuits.

M. The Seller shall confirm all current and potential transformer ratings.

N. Lock out relays shall be provided as indicated on the one line diagrams. Lockout relays shall be ElectroSwitch Series 24 hand reset. Contacts from all lockout relays shall be wired to terminal blocks located in a common section for the Purchaser’s use.

2.10 AUXILIARY DEVICES

A. Current transformers shall be furnished as indicated on the one-line diagram drawings. The thermal and mechanical ratings of the current transformers shall be coordinated with the circuit breakers. Their accuracy rating shall be equal to or higher than ANSI standard requirements. The standard location for the current transformers on the bus side and line side of the 15 kV breaker units shall be front accessible to permit adding or changing current transformers without removing high-voltage insulation connections. Shorting terminal blocks shall be furnished on the secondary of all the current transformers.

B. Voltage and control power transformers of the quantity and ratings indicated in the detail specification shall be supplied. Voltage transformers shall be mounted in draw-out drawers contained in an enclosed auxiliary compartment. Rails shall be provided for each drawer to permit easy inspection, testing and fuse replacement. Shutters shall isolate primary bus stabs when drawers are withdrawn.

C. Switchgear cubicle strip heaters and thermostats shall be provided. The Owner will provide one (1) 120V source of power. The Seller shall wire all strip heaters to a common point.

D. A manual bus (main-tie-main) transfer control system shall be provided. The bus tie will be operated normally open. The transfer control system shall permit closed transition transfers (closing of bus tie and tripping of selected main or closing of selected main and tripping of bus tie). The system shall be designed using discrete control relays, synch check relay (across the tie breaker), interlocks, control switches, indicating lamps, mimic


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diagram, etc. PLC and protective relay (internal logic) based transfer schemes are NOT acceptable. Operational , maintenance, and re-transfers shall be manual, closed transition (momentary paralleling), transfers. A selector switch (device 10) shall be provided (Electro-Switch Series 24 with oval grip handle). It shall be used to select which breaker is to be tripped (e.g. Main 1, Tie, or Main 2). Spare contacts from this switch shall be wired out for the Purchasers use. It shall be located on the tie breaker compartment door. A nameplate with the sequence of operation description shall also be provided.

E. Satec AX-8, analog I/O expanders shall be provided as indicated on the project one line. I/O expanders shall have 8 outputs (4-20 ma). The Seller shall wire these signals to terminal blocks located in the upper section of the tie breaker for the Purchasers use.

F. Provide a SEL 3610 port server and Fiber/Ethernet switch and wire all relays and meters to the port server.

2.11 BATTERIES AND BATTERY CHARGER

A. The Seller will furnish one (1) 125 volt DC flooded cell lead acid battery system for 15 kV switchgear breaker trip and close control power. The battery system should be sized to carry the switchgear continuous load for 8 hr after loss of charger output, and in addition, shall be capable of tripping and closing all of the medium voltage circuit breakers twice at the end of the period. Batteries will be sized to provide concurrent tripping of all breakers and continuous load. Batteries shall be 20 yr. lead acid type, complete with electrolyte, fully charged, and arranged for shipment with electrolyte in cells. Provide a two-step rack and spill containment system that minimizes space allocation requirements. Batteries are to be provided with necessary electrical connections between cells and between rows of cells and include two flexible connectors with bolted-type terminals for output leads.

B. The Seller shall also provide a DC distribution panelboard with a suitable number of branch feeders breakers.

C. The Seller shall furnish redundant (2) battery chargers. Battery chargers shall be static-type silicon rectifier type equipped with automatic regulation and provisions for manual and automatic adjustment of the charging rate. It shall automatically maintain output voltage within 0.5 percent from no load to rated charger output current, with 480 V ac input-voltage of plus or minus 10 percent and input-frequency of plus or minus 3 Hz.

D. Other features of charger include the following: Note, Alarms shall be monitored by the plant control system. The Seller shall wire these contacts to terminal blocks located in a common section for the Purchasers use.

B. DC ammeter C. DC voltmeter


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D. Ground indication 1.02 Alarms for loss of AC, low battery, and ground

2.12 SCADA RTU INTERFACE

A. SCADA outputs as required by SEPTA or the Utility. As a minimum, the following data and controls are required.

B. Wire all breaker status and control interfaces, analog signals, etc. as indicated on the contract drawings and specification to terminal blocks located in a common section (upper section of the tie breaker). All customer field interconnection cables associated with interfacing with the SCADA RTUs will be routed to this location.

1.03 Utility SCADA RTU (discrete, hard wired)

1. Entrance breakers (52M1, 52M2) position 2. Generator breaker position (EG01, EG02, Future EG03) 3. Instantaneous kW from Generators – 13.2 kV 4. Instantaneous kVar from Generators – 13.2 kV 5. Instantaneous bus voltage 13.2 kV supply 6. SCADA Trip – trip generator circuit breakers 1.04

2.13 CUSTOMER METERING

A. Provide customer metering devices where shown on the drawings.

B. Customer metering devices shall be multifunction power monitoring meters with Ethernet (Modbus/TCP) data communications. Unless otherwise approved, multi-function power monitoring meters shall be Satec PM172E meters.

C. Control power for meters shall be 125V dc.

2.14 SWITCHGEAR ENCLOSURES

A. The switchgear shall be designed with a NEMA 1 construction for indoor service. Structures shall be manufactured so that future expansion on either end is possible.

B. Each vertical section of outdoor switchgear if applicable shall be provided with space heaters. Tubular type heaters operated at half voltage for long life shall be supplied. 500-volt or 250-volt rated heaters shall be used at 240 or 120 volts, respectively.


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C. All the space heaters within each assembly shall be controlled by one thermostat and furnished with a single pole circuit breaker for supply disconnect. The Seller shall provide the power source.

D. Heaters shall be wired to provide temporary heating during storage.

2.15 NAMEPLATES

A. Engraved nameplates shall be furnished for all main and feeder assemblies as indicated on the drawings. Nameplates shall be laminated plastic, black characters on white background, and secured with screws. Characters shall be 3/16-inch high, minimum. Nameplates shall give item designation and circuit number as well as frame ampere size and appropriate trip rating. Furnish master nameplate giving switchgear designation, voltage ampere rating, short-circuit rating, manufacturer's name, general order number, and item number. Cubicle nameplates shall be mounted:

1. On the front face 2. On the rear panel 3. Inside the assembly, visible when the rear panel is removed

B. Control components mounted within the assembly, such as fuse blocks, relays, pushbuttons, switches, etc., shall be suitably marked for identification corresponding to appropriate designations on manufacturer's wiring diagrams.

C. The manufacturer shall not remove, reuse, alter, or replace original equipment nameplates or equipment tags associated with equipment or components supplied by the manufacturer’s suppliers and sub-suppliers.

D. Signage in accordance with the requirements of the National Electrical Code (NEC) and National Electrical Safety Code (NESC) shall be provided.

2.16 MIMIC BUS

1.05 A. The 15 kV switchgear shall be equipped with a red laminate mimic bus representation displayed on the front of the switchgear. This representation shall illustrate the arrangement of the devices and apparatus contained in the cubicles displayed.

2.17 FINISH

A. Switchgear shall be painted gray (ANSI 61) with the manufacturer’s standard process for indoor equipment.

2.18 ACCESSORIES


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A. The switchgear manufacturer shall furnish accessories for test, inspection, maintenance, and operation, including:

1. One -- Maintenance tool for manually charging the breaker closing spring

and manually opening the shutter 2. One -- Levering crank for moving the breaker between test and connected

positions 3. One -- Test jumper for electrically operating the breaker while out of its

compartment 4. One – Ground and test device 5. One -- Portable lifting device for lifting the breaker on or off the rails 6. One -- Test cabinet for testing electrically operated breakers outside housing

1.19 CORONA FREE DESIGN

a. The switchgear shall be corona free by design and shall be tested for partial discharges in accordance with EEMAC standard G11-1. The corona discharges measured during the tests shall be less than 100 picocoulombs.

PART 3 - EXECUTION

3.1 FACTORY TESTING

A. The following standard factory tests shall be performed on the circuit breaker element provided under this section. All tests shall be in accordance with the latest version of ANSI standards.

1. Alignment test with master cell to verify all interfaces and interchangeability 2. Circuit breakers operated over the range of minimum to maximum control

voltage 3. Factory setting of contact gap 4. One-minute dielectric test per ANSI standards 5. Final inspections and quality checks

B. The following production test shall be performed on each breaker housing: 1.1. Alignment test with master breaker to verify interfaces 2.2. One-minute dielectric test per ANSI standards on primary and secondary circuits 3.3. Operation of wiring, relays and other devices verified by an operational sequence

test 4.4. Final inspection and quality check.


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C. The manufacturer shall perform a complete integrated functional test of the control system and switchgear. Factory tests as outlined above may be witnessed by the Purchaser’s representative. The manufacturer shall notify the Purchaser two (2) weeks prior to the date the tests are to be performed.

D. The manufacturer shall provide three (3) certified copies of factory test reports.

3.2 INSTALLATION (BY OTHERS)

A. The Installation Contractor shall install all equipment per the manufacturer's recommendations and contract drawings.

3.3 FIELD QUALITY CONTROL

A. Provide the services of a qualified factory-trained manufacturer's representative to assist the Installation Contractor in installation and startup of the equipment specified under this section for a period as defined in the purchase order. The manufacturer's representative shall provide technical direction and assistance to the contractor in general assembly of the equipment, connections and adjustments, and testing of the assembly and components contained therein.

B. The Seller shall provide three (3) copies of the manufacturer's field start-up report.

3.4 FIELD ADJUSTMENTS

A. The multi-function protective relays shall be set in the field by a qualified testing company, retained by the Installation Contractor, in accordance with settings designated in a coordination study of the system.

3.5 FIELD TESTING (BY OTHERS)

A. The Installation Contractor will test all equipment in accordance with the manufacturer’s recommendations.

3.6 MANUFACTURER'S CERTIFICATION

A. A qualified factory-trained manufacturer's representative shall certify in writing that the equipment has been installed, adjusted and tested in accordance with the manufacturer's recommendations.

B. The Contractor shall provide three (3) copies of the manufacturer's representative's certification.

3.7 TRAINING


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A. The Seller shall provide a training session for up to five (5) Purchaser’s representatives for a period as defined in the purchase order at a job site location determined by the Purchaser.

B. The training session shall be conducted by a manufacturer's qualified representative. Training program shall include instructions on the assembly, circuit breaker, protective devices, control systems, and other major components. The Seller shall provide four (4) sets of training documents.


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DATA SHEET DATE: EQUIPMENT.: MEDIUM VOLTAGE METAL CLAD SWITCHGEAR EQUIPMENT NO.: “ SG-CG1301 – 13.2 KV GENERATOR SWITCHGEAR”

Site Conditions THIS SECTION IS TO BE COMPLETED

BY See Specification THE EQUIPMENT SUPPLIER AND

RETURNED WITH THE QUOTATION Enclosure NEMA 1 12 3R Other Enclosure

Indoor Outdoor Outdoor non-walkin Louvered Filtered Gasketed

Ratings Ratings MVA Class 500 MVA MVA Class MVA Voltage Class 15 kV Voltage Class

kV BIL 95 kV BIL

kV Frequency 60 Hz Frequency

Hz Operating Voltage 13,200 V Operating Voltage

kV Close and Latch Capability 37 kA (rms)

Close and Latch Capability kA (rms)

Interrupting Rating 18 kA (rms) Interrupting Rating kA (rms)

Main Bus Main Bus

Copper Aluminum Insulated Copper Aluminum Insulated 1200 amp 2000 amp 4000 amp 1200 amp 2000 amp 4000 amp

Circuit Breakers Circuit Breakers

Air Magnetic Vacuum Air Magnetic Vacuum Main Breaker Rating 1200 A Main Breaker Rating A Feeder Breaker Rating 1200 A Feeder Breaker Rating A Control Power Control Power Required


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Closing 125 VDC Closing VDC

Tripping 125 VDC Tripping VDC

Miscellaneous power by Seller 120V, 1 Ph.

No. of sources req’d by Seller: Voltage and ampacity req’d:

Incoming Supply (see One-Line) Incoming Supply

Cable Copper Top Entry Cable Copper Top Entry Bus Duct Aluminum Bottom Entry Bus Duct Aluminum Bottom Entry

XXX(X) XXX kcmil, copper, 15 kV, 133% EPR insulated cables and stress cones per phase

Size:

Outgoing Feeders (see One-Line) Outgoing Feeders

Cable Copper Top Entry Cable Copper Top Entry Bus Duct Aluminum Bottom Entry Bus Duct Aluminum Bottom Entry

Control Cables Control Cables

Top Entry Bottom Entry Top Entry Bottom Entry Potential Xfmr & Control 14 AWG (min.)

Potential Xfmr & Control AWG (min.)

Current Xfmr Secondary 12 AWG (min.)

Current Xfmr Secondary AWG (min.)

Bus Transfer Scheme (Refer to Specification for details)

Bus Transfer Scheme (Refer to Specification for details)

Automatic Manual Automatic Manual Tie Breaker Normal Position: Open Closed

Tie Breaker Normal Position: Open Closed

Accessories And Special Features Accessories And Special Features Space Heaters Space Heaters Oper. and Maint. Tools and Accessory Set Oper. and Maint. Tools and Accessory Set Hinged Rear Doors Hinged Rear Doors Kirk Key Interlocks Kirk Key Interlocks


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Customer Metering Customer Metering -

Control Power Auto Transfer Control Power Auto Transfer Surge Arresters Surge Arresters Trip Voltage Monitor Relays Trip Voltage Monitor Relays Separate Close and Trip Power Fuses Separate Close and Trip Power Fuses Control Power Transformers (CPTs) Control Power Transformers (CPT) Compart for Utility Metering Equipment Compartment for Utility Metering Equipment Maint. tool for manual spring charging Maint. tool for manual spring charging Levering crank Levering crank Test jumper Test jumper Breaker lifting yoke Breaker lifting yoke Ground and test device Ground and test device Portable lifting device Portable lifting device Test cabinet Test cabinet Touch up paint Touch up paint Door Nameplates Door Nameplates

White w/ Black Letters Screw Mounted

White w/ Black Letters Screw Mounted

Interior Nameplates Interior Nameplates

White w/ Black Letters Adhesive Mounted

White w/ Black Letters Adhesive Mounted

Exterior Finish Exterior Finish

ANSI 61 Light Gray ANSI 24 Dark Gray

ANSI 61 Light Gray ANSI 24 Dark Gray

Other Other 1.88 Protective Relays 1.89 Protective Relays SEL –351A (mains and feeders), SEL 587Z (bus diff), Beckwith M3425A (generators), SEL 751A synch check, Basler BE1-27/59 (bus voltage)


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1.90 Battery 1.91 Battery Flooded cell, lead acid Manufacturer and type Support time – 8 hrs Support time – 8 hrs Battery Charger Battery Charger Redundant chargers Manufacturer and type

C. END OF SECTION 16341

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