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858-485-1622

PART-1 STANDBY DIESEL ENGINE/GENERATOR – ACTIVE PARTICULATE FILTER SYSTEM

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1.1 SCOPE

  1. ACTIVE DIESEL PARTICULATE FILTER SYSTEM (A-DPF) – Provide an automatic, regenerating diesel particulate filter that meets CARB Level 3+ verification standards. The system will consist of a combination Passive DPF(P-DPF)/silencer and load bank that will provide automatic filter regeneration on an as required basis. The A-DPF housing design to include a minimum exhaust silencing insertion loss of 30-35dBA. No moving parts are permitted in the A-DPF. The DPF shall be the Johnson Matthey SDPF-H model or CRT(+)-H model and Simplex load bank, or an equivalent pre-approved by the specifying engineer.
  2. A UL listed, Data logger/filter monitor (F-M) shall be supplied. The F-M unit and associated mounting and sensing hardware will measure both inlet temperature and pressure of the P-DPF. It will record/store those measurements for a minimum of 5 years, based on 5 second sampling intervals. In addition to the storage of these temperature and pressure time stamps, the unit will be capable of multiple set point alarms and storing those alarms in the device. The data logger/filter monitor shall be a Johnson Matthey F-M Module or an equivalent pre-approved by the specifying engineer.
  3. The P-DPF data-logger/filter monitor (F-M) shall work in conjunction with the Active Load Bank Controller (ALBC). The ALBC shall include inputs for two dry signals from the F-M. The first input is a “Warning” of high exhaust back pressure and the second input is an “Alarm” of high back pressure. During generator start-up, the ALBC shall perform an Active Pressure Check of the P-DPF under various loads. The ALBC shall step up a user defined kW load. Each step will hold for a user defined amount of time prior to moving to the next step. Once the maximum programmed load is reached, the controller will begin stepping down in the same manner until the load reaches the programmed load level set point which will be maintained until the generator is turned off or a signal is received from the F-M to increase load. If at any point during the Active Pressure Check, or thereafter, a pressure Warning or Alarm signal is received from the F-M, the ALBC will begin increasing load to a user defined kW window by user defined time delays. The ALBC will maintain this load level until the Warning or Alarm signal drops out and a user defined time period has passed to prevent cycling. If the Alarm signal from the F-M is present for more than a user defined time, then the ALBC will step the load down to zero load and signal a fault condition dry contact output. This output will indicate a condition where high back pressure persistence could cause damage to the generator. If at any time the signal from the generator identifying a shutdown/cool-down mode is received, the load bank shall step down to zero load and hold there until the signal is removed, or the generator is no longer running.

1.2 CONSTRUCTION

  1. The P-DPF section of the system will have a minimum external shell construction thickness of 3/16”, constructed with carbon or stainless steel metal, fully welded, leak tight and capable of continuously operating at pressures of 60” water column or greater. The P-DPF must be capable of self-support from supplied lifting lugs or mounting brackets, both of sufficient strength to provide both lift and anchoring of the unit in a safe and practical manner. Filter elements and catalyst elements must be individual, not combined into one element and each easily removed and replaced by removing and replacing one band-clamp and one locking nut. Access hatch(es) that enable access to these elements must weigh less than 40 lbs. so as a single operator can open and close the access hatch(es).
    • Inlet and Outlet connections will be ANSI 150# Class Flat-Face flanges.
    • Multiple Inlet and Outlet sampling ports and at least one Inlet and one Outlet port capable of being tapped for installation of temperature and pressure sensors.
    • An internal means of handling thermal stress/expansion must be provided. This can take the form of sliding mounting brackets or sliding mounting channel.
    • Connections flanges are not to be used as a means of support or to handle weight or thermal stresses.
    • Gaskets and bolting that are supplied by others must be capable of 950 F continuous service, as is the construction of the P-DPF itself.
    • No frangible sound absorbing materials to be used upstream of catalyst and filter sections.
    • This exhaust system, including any and all interconnecting duct/pipe shall be designed and installed to be gas tight and thus prevent leakage of combustion exhaust.
    • The exhaust system that connects the P-DPF from the engine and past the P-DPF to the final discharge point shall be designed to compensate for all flue gas induced thermal expansion.
    • The exhaust system supports and roof penetrations shall be suitable for the specified roof construction and shall comply with the manufacturer’s installation instructions.
  2. The manufacturer shall provide “to scale” drawings depicting the actual unit, including “center of gravity” call out, the total weight of the unit and connection details.

1.3 EXTERNAL INSULATION BLANKET

  1. Thermal Blanketing
  2. The thermal blanket shall be composed of woven Treo fiber insulation that is lightweight, water-repellent and sound absorbent. The outer surface of the insulation blanket shall be of silicone impregnated fiberglass material and be installed using stainless steel spring and hook latching.
  3. The fiber insulation shall be noncombustible, asbestos free and contain no resinous or inorganic binders and conform to Mil-I-24244, USCG subpart 164.009.
  4. The maximum material operating temperature shall meet or exceed the operating temperature range of the genset exhaust.
  5. Materials must pass requirements for fire testing according to ASTM E84, NFPA 701 and UL 1709.
  6. Kevlar thread to be used to stitch sections of blanketing together, when needed.
  7. The thermal insulation blanket shall be manufactured by InsulTech LLC, or an equivalent pre-approved by the specifying engineer.

PART-2 PERFORMANCE

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2.1 EMISSIONS

  1. PM2.5 removal to be in excess of 85%,
  2. CO removal to be in excess of 80%,
  3. HC removal to be in excess of 70%.
  4. Discharge of NO2 from NO to NO2 conversion not to exceed 20% of inlet NO value.

2.2 REGENERATION

  1. Unit shall be capable of rapid regeneration at engine loads of 50% or greater, and the total duration of regeneration after reaching the maximum engine allowable back pressure must be less than 6 hours - while at optimal regeneration temperature.
  2. Inorganic oil ash does not regenerate, so unit must be able to hold ash at least 1000 hours of operation without exceeding maximum allowable engine back pressure due to engine oil ash build-up.

PART-3 EXPERIENCE

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3.1 MINIMUM QUALIFICATIONS

  1. The P-DPF manufacturer must have 10+ years of successful experience in providing CARB verified diesel particulate filters.
  2. The P-DPF manufacturer must have 100+ CARB verified units successfully installed in California
  3. The load bank manufacturer must have 25+ years of successful experience in providing load bank for generator set applications.

PART-4 WARRANTY

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4.1 WARRANTY

  1. The P-DPF shall be factory warranted for a period of 5 years from shipment. This includes repair and/or replacement of factory defects and other faults or failures that are not due to normal wear and tear or mistreatment, abuse or abnormal conditions.
  2. The F-M shall be factory warranted for a period of 1 year from shipment. This also includes repair and/or replacement of factory defects and other faults or failures that are not due to normal wear and tear or mistreatment, abuse or abnormal conditions.
  3. The load bank shall be factory warranted for a period of 1 years from shipment. This includes repair and/or replacement of factory defects and other faults or failures that are not due to normal wear and tear or mistreatment, abuse or abnormal conditions.

PART-5 PRODUCTS

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5.1 MANUFACTURERS

  1. Product specification requirements shall be met by using Johnson Matthey P-DPF, Johnson Matthey F-M, InsulTech LLC blanketing, Simplex load bank or an equivalent pre-approved by the specifying engineer. Equivalent submittals shall specify manufacturer’s model number, and other pertinent identification, and attest that the alternate material is in compliance with all specification requirements and be submitted to the specifying engineer 14 days ahead of bid.

PART-1 STANDBY DIESEL ENGINE/GENERATOR – PASSIVE PARTICULATE FILTER

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1.1 SCOPE

  1. PASSIVE DIESEL PARTICULATE FILTER (P-DPF) – Provide a passive regenerating diesel particulate filter that is CARB Level 3+ verified, and has a minimum capacity to allow twenty-four (24) /thirty (30) minute cold starts before the filter back pressure exceeds the maximum allowable back pressure for the engine while at 100% load capacity. A single housing design to include a minimum exhaust silencing rating for an overall octave insertion loss of 30-35dBA. No moving parts or electrical parts will be will be permitted in the P-DPF. The DPF shall be the Johnson Matthey CRT(+)-H model, or equivalent that is pre-approved by the specifying engineer.
  2. A CARB verified data logger/filter monitor (F-M) shall be with UL-Listing. The F-M unit and associated mounting and sensing hardware will measure both inlet temperature and pressure of the P-DPF, and record/store those measurements for a minimum of 5 years, based on 5 second sampling intervals. In addition to the storage of these temperature and pressure time stamps, the unit will be capable of multiple set point alarms and storing those alarms in the device for a minimum of 5 years. The F-M unit shall run on either 12VDC or 24VDC power, and have a minimum of two relay outputs. The F-M unit shall be capable of being remotely monitored with supplied software. The F-M shall be a Johnson Matthey CRTdM or equivalent that is pre-approved by the specifying engineer.

1.2 CONSTRUCTION

  1. The P-DPF section of the system will have a minimum external shell construction thickness of 1/8”, constructed with carbon steel or 304 stainless steel metal (specified by engineer), fully welded, leak tight and capable of continuously operating at pressures of 60” water column or greater. The P-DPF must be capable of self-support from supplied lifting lugs or mounting brackets, both of sufficient strength to provide both lift and anchoring of the unit in a safe and practical manner. Filter elements and catalyst elements must be individual, not combined into one element and each easily removed and replaced by removing and replacing one band-clamp and one locking nut. Access hatch(es) to enable access to these elements must weigh less than 40 lbs. so as a single operator can open and close the access hatch(es).
    • Inlet and Outlet connections will be ANSI 150# Class Flat-Face flanges.
    • Multiple Inlet and Outlet sampling ports and at least one Inlet and one Outlet port capable of being tapped for installation of temperature and pressure sensors.
    • An internal means of handling thermal stress/expansion must be provided. This can take the form of sliding mounting brackets or sliding mounting channel.
    • Connections flanges are not to be used as a means of support or to handle weight or thermal stresses.
    • Gaskets and bolting that are supplied by others must be capable of 950 F continuous service, as is the construction of the P-DPF itself.
    • No frangible sound absorbing materials to be used upstream of catalyst and filter sections.
    • This exhaust system, including any and all interconnecting duct/pipe shall be designed and installed to be gas tight and thus prevent leakage of combustion exhaust.
    • The exhaust system that connects the P-DPF from the engine and past the P-DPF to the final discharge point shall be designed to compensate for all flue gas induced thermal expansion.
    • The exhaust system supports, and/or roof penetrations shall be suitable for the specified roof construction and shall comply with the manufacturer’s installation instructions.
  2. The manufacturer shall provide “to scale” drawings depicting the actual unit, including “center of gravity” call out, the total weight of the unit and connection details.

1.3 EXTERNAL INSULATION

  1. Thermal Blanketing
    • If thermal blanketing is required (specified by engineer), then the thermal blanket shall be composed of woven Treo fiber insulation that is lightweight, water-repellent and sound absorbent. The outer surface of the insulation blanket shall be of silicone impregnated fiberglass material and be installed using stainless steel spring and hook latching.
    • The fiber insulation shall be noncombustible, asbestos free and contain no resinous or inorganic binders and conform to Mil-I-24244, USCG subpart 164.009.
    • The maximum material operating temperature shall meet or exceed the operating temperature range of the genset exhaust.
    • Materials must pass requirements for fire testing according to ASTM E84, NFPA 701 and UL 1709.
    • Kevlar thread to be used to stitch sections of blanketing together, when needed
    • The thermal insulation blanket shall be manufactured by InsulTech LLC, or equivalent that is pre-approved by the specifying engineer.

PART-2 PERFORMANCE

section1_1

2.1 EMISSIONS

  1. PM2.5 removal to be in excess of 85%.
  2. CO removal to be in excess of 80%.
  3. HC removal to be in excess of 70%.
  4. Discharge of NO2 from NO to NO2 conversion not to exceed 20% of inlet NO value.

2.2 REGENERATION

  1. Unit shall be capable of rapid regeneration at engine loads of 50% or greater, and the total duration of regeneration after reaching the maximum engine allowable back pressure must be less than 6 hours - while at optimal regeneration temperature.
  2. Inorganic oil ash does not regenerate, so unit must be able to hold ash at least 1000 hours of operation without exceeding maximum allowable engine back pressure due to engine oil ash build-up.

PART-3 EXPERIENCE

section1_1

3.1 MINIMUM QUALIFICATIONS

  1. The P-DPF manufacturer must have 10+ years of successful experience in providing CARB verified diesel particulate filters.
  2. The P-DPF manufacturer must have 200+ CARB verified units successfully installed in California.

PART-4 WARRANTY

section1_1

4.1 WARRANTY

  1. The P-DPF shall be factory warranted for a period of 5 years from shipment. This includes repair and/or replacement of factory defects and other faults or failures that are not due to normal wear and tear or mistreatment, abuse or abnormal conditions.
  2. The F-M shall be factory warranted for a period of 1 year from shipment. This also includes repair and/or replacement of factory defects and other faults or failures that are not due to normal wear and tear or mistreatment, abuse or abnormal conditions.

PART-5 PRODUCTS

section1_1

5.1 MANUFACTURERS

  1. Product specification requirements shall be met by using Johnson Matthey P-DPF, Johnson Matthey F-M, InsulTech LLC blanketing or equivalent preapproved by the specifying engineer. Equivalent submittals shall specify manufacturer’s model number, and other pertinent identification, and attest that the alternate material is in compliance with all specification requirements and be submitted to the specifying engineer 14 days ahead of bid to be illegible for acceptance as pre-approved.