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PELRINE & BUCHANAN'S MARITIME TRADING WORLDWIDE LTD. |
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A. The basic unit includes the engine, generator and fuel tank mounted to the deck, which occupies the majority of the container’s interior (refer to the attached General Arrangement Drawing). The switchgear cabinet is adjacent to the generator and is coupled to the generator terminal box by buss way. The exhaust silencers are situated above the engine. Service items such as filters and batteries are located on either end of the engine and are accessible through the double doors in both sides of the container. The unit is self-contained and designed to be transported over the road on a standard two-axle ISO container chassis. The completed unit’s maximum gross weight is 50,500 pounds, inclusive of coolant, oil and 200 gallons of fuel (without trailer). Loading will not exceed 17,000 pounds per axle based on a 2-axle trailer weight of 10,000 pounds
B. External connections are provided for normal servicing of the generator set. These connections include fuel transfer ports, engine oil drain and radiator coolant drain. The secondary containment area drain can be used for normal “make ready” cleanup or in the unlikely event of an engine oil, fuel or coolant rupture. The external fuel connection can be utilized to transfer fuel from a bulk fuel storage tank. All drains have plugs installed with the exception of the rainwater drain.
C. The power rating is applicable to heavy-duty Diesel generator sets and is based on ISO 8528 rating methods. Ratings and emissions compliance are optimized for 1800 RPM (60 Hz.) operation.
A. The heavy-duty diesel engine is model TBD620V12, manufactured by Deutz Corporation. It is turbocharged and intercooled, operates on the four-stroke cycle, and is in a 90o vee configuration. The TBD620V12 is EPA certified at 1800 RPM and TA LUFT/2 approved for 1500 RPM operation.
B. All fluids are pumped by engine driven pumps. This includes the fuel system, lube oil system, jacket cooling system and a separate charge air cooling system.
C. The lube oil system includes a gear type lube oil pump, oil cooler, spin-on oil filters and acentrifugal type filter. A 24 VDC waste oil sump pump is installed to assist with routine oil change maintenance.
D. A Racor Turbine Series fuel filter is installed on the engine. The Racor filter incorporates centrifugal separation along with a pleated media filter to remove water and solids. The Racor duplex filters are installed in parallel so they can be serviced while the generator set is online. A 24 VDC fuel priming pump assists with initial start up after the container is moved.
E. The Woodward PRO-ACT II electronic governor provides engine speed control. It provides steady state frequency regulation better than ± 0.5%.
F. The starting system consists of two 8D lead acid batteries supplying 24 VDC to the engine mounted starter. The heavy-duty, maintenance-free batteries will be in polyethylene battery boxes. The electric system has a master battery disconnect switch in the negative circuit. A 10 amp, float type battery charger is installed in the container and requires 120 VAC customer furnished power in the standby mode. An engine-mounted, battery-charging alternator maintains the charge on the batteries while the engine is running.
G. The air intake system is fitted with dry type air filters with replaceable paper elements and restriction indicators. Combustion air for the engine is drawn into the container through fixed louvers and then through the heavy-duty air cleaners.
H. A gauge panel is installed with mechanical gauges for oil pressure, water temperature, and fuel pressure.
I. An automatic lube oil level regulating system is installed. The system has a 20-gallon rectangular tank to allow oil make-up while the engine is running.
J. Dual 4000-watt jacket water heaters will be mounted on the engine block to maintain the engine in a warm, ready to start state. The water will circulate by convection to maintain the appropriate temperature while the engine is not running. The heaters are equipped with isolation valves and operate on 208VAC customer supplied power.
K. The exhaust system consists of a stainless steel flexible exhaust connection mounted on the turbocharger outlet. This connects to the critical grade exhaust silencer, which provides typical sound attenuation of 25 to 30 dB(A). The outlet of the silencer is protected from debris or rain with a weighted rain cap.
A. The MAGNAMAX generator is manufactured by Marathon Electric Manufacturing Corporation and is a single bearing design. The generator meets NEMA MG 1, parts 16 and 22, in design, performance and factory test procedures. The generator is rated 1500 kW, 1875 kVA standby and 1430 kW, 1788 kVA prime, 60 hertz, 1800 RPM, 3 phase, and 0.8 lagging power factor. The voltage will be 480 volt, but the units are capable of running at 380 VAC, 50 Hz or 480 VAC, 60 Hz.
B. The generator is equipped with a permanent magnet generator excitation system. Both the PMG and the rotating brushless exciter will be mounted outboard of the bearing. The system shall supply a minimum short circuit support current of 300% of the rating for 10 seconds. The exciter uses a three-phase full wave rectifier assembly.
C. The stator shall be a 2/3-pitch design to eliminate the third harmonic. The stator and rotor shall be insulated with NEMA Class H or better, synthetic, non-hygroscopic materials. The generator temperature rise will be 130 degrees C over a 40 degree C ambient at the standby rating.
D. Voltage regulation shall be ¼% from no load to full load and 5% frequency variation. Regulator drift shall be less than ½% per 40 degree C ambient temperature change.
E. The programmable digital voltage regulator, Marathon model DVR2000C, is located in the control cabinet.
F. Strip heaters are installed to minimize condensation forming in the generator. These are supplied with 120 VAC power.
A. The generator is direct coupled to the engine flywheel housing and driven through a flex plate attached to the engine flywheel. The engine/generator assembly is mounted on the container floor with vibration isolators sized for the weight and duty.
A. The cooling system consists of two radiator cores located in the container walls. One core serves the engine cooling water circuit and the other the charge air-cooling circuit. Hydraulic motors drive the two (2) high capacity fans. The variable speed fans are thermostatically controlled.
B. Air is drawn through fixed louvers in the sides of the container and through the radiator cores and exhausted through fixed guards. The radiated heat of the engine-generator compartment does not heat the cooling air. Additional outside air is drawn through louvered openings at the engine end of the container to provide airflow across the engine generator set. The fans are of sufficient capacity to accommodate volume requirements of the radiator cores, the generator and switchgear as well as to dissipate the engine’s radiated heat.
C. Radiator drain lines have accessible valves. Radiator fill port and sight glass are accessible through and located near the rear cargo doors.
D. The cooling system is designed to provide the rated heat rejection for prime power operation at 113°F ambient, and for standby power operation at 109ºF.
A. The Generator Control Panel is designed in accordance with NEMA and ANSI standards. The enclosure is freestanding and made of aluminum/steel construction. Each unit has the following standard features:
i. A Basler DGC2000 controller
ii. A Basler GPR generator protection relay with switches and controls.
iii. On-board synchronization and load sharing capability.
iv. Synchroscope and sync lights
v. Master circuit breaker open/closed indicator lamps and operating switch.
B. The Woodward Governor Company synchronizing and load sharing modules offer a reliable and proven paralleling system working with the Woodward PRO-ACT II electronic governor. The Woodward AGLC allows the system to achieve preset baseload settings, automatically or manually while in the utility mode. The Woodward SPMA acts as a synchronizer for paralleling with an existing grid, utility, or other units. The Woodward Load Sharing Module provides for multiple generator sets to be paralleled and share load.
A. The 2500-ampere circuit breaker is a GE Power Break II with an interrupting capacity of 150,000 symmetrical amperes. The main breaker is an electrically operated, stored energy unit equipped for synchronizing and remote operation. The main circuit breaker is fixed in the freestanding generator control cabinet. The breaker cabinet door has lock-out/tag-out provisions.
B. The electrical connections between the generator and the breaker are oversized bus bars on each phase. The minimum spread between buss bars is 6" for ample spacing. The bus bars continue from the breaker and terminate in the power connection box on the outside of the container. This box is used to house the connection to the customer’s power cables.
C. Customer interface connections are located in a separate section of the power connection box and include power, paralleling, and control signals. Control circuit breakers are included as needed. The customer’s power cables are connected to the bus bars by standard lugs. The access door installed on the exterior side of the container for the cables is capable of being locked with the customer’s power cables installed for added safety.
D. A separate power supply is required to maintain the generator set in the standby mode when the engine is not running. Off-line power, 110/208 VAC via standard, twist-lock receptacle for supply of engine heater, generator strip heaters, battery charger, internal AC lighting, and convenience receptacles must be supplied when the generator set is in the standby mode.
E. Control signals for paralleling RS1500DD units with other power systems can be accessed via heavy-duty industrial DIN-rail terminal strips mounted in the power connection box.
F. Control signals for the remote start/stop and status monitoring of the unit can be accessed via heavy-duty industrial DIN-rail terminal strips. All customer control inputs are dry contacts. All customer status outputs are dry normally open contacts. These signals include:
i. Remote Start/Stop input (maintained contact)
ii. Remote Start input (momentary contact)
iii. Remote Stop input (momentary contact)
iv. Engine Running/Stopped status dry contact output
v. Low Fuel Level status dry contact output
vi. Remote breaker trip input.
vii. Remote emergency stop input
viii. Breaker closed, dry contact.
ix. Breaker tripped, dry contact.
x. Summary alarm, dry contact.
xi. Low battery voltage, dry contact.
xii. Low oil pressure pre
alarm, dry contact.
xiii. High coolant temperature, dry contact.
G. Grounding and bonding pads are located on the container chassis in two (2) locations, one below the power connection box and another diagonally near the rear side of the container. Full current grounds are provided from the generator set to the container chassis. Bonding straps are installed from the power connection
box, control cabinet, fuel tank and engine skid to the container chassis.
A. The container housing the engine-generator set is custom-built for the application and is fabricatedto ISO specifications for an ocean going shipping container. It is fabricated from heavy gauge corrugated steel and hollow section to provide a rigid support for the entire generator set. The container is manufactured in accordance with Lloyds of London certification, or equal, and it has a CSC nameplate to signify meeting three-high ocean shipping standards. Since the container meets ocean shipping standards, it has ISO corner castings for twist lock fastening and overhead lifting, and nothing protrudes beyond the corner castings.
B. The container engine compartment includes multiple access doors for operator safety with internal release hardware to open door even if padlocked from outside. There are standard container lockable doors on the rear of the container. All doors provide full height access with positive closing/locking mechanisms and heavy-duty hinges.
C. The acoustic treatment is designed to meet a mean average ambient noise rating of 74 dB(A) at 7 meters. The acoustic attenuation is comprised of an acoustic infill of resin bonded mineral fiber of suitable density and thickness. The attenuation lining is non-hygroscopic, non-carcinogenic, noncombustible, and compliant with BS476.4 standard. The walls and roof are lined with the acoustic insulation that is retained by aluminum perforated metal.
D. Air inlet silencers with suitable corrosion-resistant fixed blade weather louvers cover the openings for compartment ventilation, radiators, and combustion air intakes. The aluminum louvers are mounted to the container with a gasket to prevent corrosion caused by galvanic reaction.
E. The container includes a seal-welded floor to provide environmental spill containment of up to 110% of the total fluids (fuel, engine coolant, lube oil, and hydraulic fluid). The seal-welded bottom is treated with spray-in type resilient coating to prevent leakage of fluids from the container at every possible point. Containment area drain plugs are included. The container is designed so that there is no inherent entry of rainwater into the fluid containment area.
F. A connection box is provided for customer power connections located at the generator end of the container adjacent to the circuit breaker. The hinged door over the connection box is secured with a locking device.
G. Internal lighting consists of fluorescent fixtures, powered by 120VAC shore power and by 24VDC battery power via a timer-controlled switch. Switch boxes for the lights and 120V GFI receptacles are located adjacent to each door.
H. The exhaust outlet from the internally mounted exhaust silencer consists of rain caps to prevent rainwater from entering the piping while the engine is not running. The rain caps are mounted< flush with the top of the container. The rain caps are oriented so that exhaust is deflected toward radiator fans to blow it away from the combustion air intakes.
I. One portable personnel ladder is included with the optional trailer for container access. There are attachment points for the ladder located below each of the seven (7) access doors.
J. The container dimensions are standard ISO 40 foot length, width, and “high cube” height. The exterior dimensions are:
i. Length: 480 inches (40 ft)
ii. Width: 96 inches (8 ft 0 in)
iii. Height: 114 inches (9 ft 6 in)
A. The painting system is applied in accordance with standard paint specification. This includes all carbon steel parts being commercially sandblasted clean prior to coating.
B. The container interior and exterior is primed per manufacturer's recommendation. A finish coat isthen applied. The container bottom is protected with ten (10) to fifteen (15) mils of a heavy dutysealing coating.
C. The engine and generator are coated gray, (RAL 7015), controls are white, accessories and components are finished to the manufacturer’s standard.
D. Items fabricated are finished to standard coating and finishing specification.
E. Finishing materials are applied in accordance with the manufacturer’s recommendations and conform to local environmental regulations with regard to OSHA requirements and VOC emissionsat the time of application.
F. Owner furnished logo decals or sign placards are applied as required.
A. The unit is provided with a steel, UL-listed, 1100 useable gallon fuel tank. The tank is sized to achieve 8 hours of operating time at prime rating prior to re-filling. To facilitate easy filling, a 1" fill port shall be provided and terminated on the outside wall of the container.
B. The penetrations from the tank exterior into the fuel tank are through the tank top and they are fully within the spill containment area. All fittings are NPT standard. The tank includes a slanted 4-inch fill neck with removable screen located within the 2-inch containment basin on top of the tank for overflow spill protection, and has an adjacent fuel level gauge.
C. The fuel tank vent is routed to the outside of the container and incorporates a check valve. The fuel tank 6" emergency pressure/vacuum vent is located on top of the tank and is within the spill containment area.
D. The fuel supply line to the engine terminates 1" above the tank bottom, and has a check valve. The fuel returns into a separate baffled section of the tank and terminates 1" above the tank bottom. A pick up port is provided for transferring fuel out of the tank.
E. There are 6-inch clean out ports located at the top of each baffled section of the fuel tank.
A. One copy of the standard documentation package is provided. This package consists of:
i. General Arrangement Drawing that includes overall dimensions, dry and wet weights, fluid types and capacities, lift-and-load data, tie-down provisions, interface descriptions and locations, clearances, and other basic mechanical or electrical information needed by the customer to successfully install the unit.
ii. Electrical Schematics and Wiring Diagrams
iii. Operation and Maintenance manuals.
B. A document box is provided. The box has a hinged top with non-skid surface so that it can be used as a step to assist with manual refueling of the tank
