Facility Power Readiness NFPA changes overview

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Facility Power Readiness&

NFPA changes overview

Brian Mauriello, VP Sales & MarketingBen Charney, Aftermarket Sales Mgr.

Kinsley Power Systems

Long Term Care Mutual Aid Plan Meetings (CT Regions: 1, 4, 5)Oct 23‐25, 2012

FOR A COPY OF THIS POWERPOINT, email [email protected]

Privately held, family value driven (est. 1964)• 91 Employees (40 Generator Technicians)• Highest number of EGSA certified and factory certified technicians in NE (all makes)• Coverage area: NJ – PA – NY – CT – MA – RI – VT – NH – ME

Exclusively dedicated to emergency power generation sales, service, rental and support• Plentiful replenishment maintenance/service parts inventory• Equipment lifecycle maintenance / service & unplanned repairs• 24/7/365 support•Rental ready assets ‐ 20kw to 2MW at all branch locations, 2 hour deployment from first call

Total systems solution• Specify/design through to ongoing maintenance/service• Generator, ATS, Switchgear integrated power solution

Strong business relationships with 9,700+ active customers• All industries/applications (8.5kw to multi‐megawatt installations)

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Our Company

14 Connecticut South Dr. East Granby, CT 06026860.844.6100 direct860.844.6136 fax

63 Railroad AvenueAlbany, NY 12205518.458.8614 direct518‐458‐1738 fax

205 Adams StreetBedford Hills, NY 10507914.218.9922 direct914.218.9941 fax

605 Cambridge AvenueSyracuse, NY 13208315.455.8440 direct315.455.8069 fax

2205 Kenmore AvenueTonawanda, NY 14207716.876.2324 direct716.876.2326 fax

Locations

The Key is Preventative Maintenance:

Two services per year, one major,one minor. Gen & ATS

For diesel units, conduct an annualload bank test.

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The main concern: Emergency Generators function when needed.

• Are your units maintained regularly?

• Are you load banking your dieselgenerators?

• Do you have a sufficientquantity/quality of fuel on site?

• Do you know the specific facilityelectrical loads that will be receivingemergency power?

•Do you know who to call for emergencyrental back up power?

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Are You Ready for an Outage?

When the power fails and your generator performs as it should?

• Maximum run time for any standby rated generator is 240 hours . After 10 days of continuous run, any unit will need service. Filters will begin to clog, fluids will break down.

• Monitor system for leaks every (6) hours of continuous run.

• After any individual outage where a generator runs for 50 hours, call your generator service provider for a Level 1 inspection.

• Make sure that you are aware of your refueling needs. Have your fuel delivery company on standby.

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What Do You Do…..

The manufacturer recommends keeping a quantity for (2) services, on hand of the following parts:• Belt, Alternator, Fan• Element, Air Cleaner• Filter(s), Fuel• Fuses• Maintenance (tool) Kit• Oil Filter•Thermostat• Water separator filter, Fuel • Spark plug pack (nat. gas)

Keep these parts well labeled in a suitable container that’s easily accessible!

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Recommended Spare Parts

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How to prepare if a Rental is needed

• Keep an area clear for setting up rental equipment and routing of cables (if cablescross any path ways you will need cable trays to protect them and prevent peoplefrom walking on them).

• Establish a connection point to your facility (if you connect using the breaker andcontrol wiring from your standby system then a generator tech can make theconnections. If wiring directly to an ATS or distribution panel you will be requiredto hire an electrician).

• Most rental equipment of >100 KW will require the user to fill the fuel system andremove the fuel before transporting. As most tanks are normally rated for 8 hoursof full load operation. You should have a local fuel supplier pre‐arranged to keepthe system adequately filled during outages.

• Extension cords will be required to run the rental battery charger and block heatercircuits. (These can be heavy gauge custom made shoreline connections!).

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How to prepare if a Rental is needed (cont’d)

• NFPA 110 is directed at an emergency power supply system (EPSS) that has somelevel of impact on life safety, the system is required to be permanently installed.

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You find an emergency planning information sheet by visiting the website:

www.mutualaidplan.org/CT

The following information describes how the 2010 edition of NFPA 110 will affect healthcare organizations . The new NFPA 110 standards were realigned for continuity among NFPA documents (i.e. NFPA 99 and NFPA 101, 2012 Edition changes). The previous editions of NFPA 110 were difficult to follow.

NFPA 99, Health Care Facilities Code®, 2012 Edition; NFPA 99 covers the essentialelectrical system for Health Care Facilities.

NFPA 101, Life Safety Code®, 2012 Edition; NFPA®'s Life Safety Code is the mostwidely used source for strategies for occupant safety throughout the life cycle of abuilding. It is the only document that addresses life safety in both new and existingstructures. From egress, sprinklers, and alarms to emergency lighting, smoke barriers,and special hazard protection, the LSC covers it.

NFPA 110, Standard for Emergency and Standby Power Systems, 2010 Edition; NFPA110 covers construction, installation, maintenance and operational testingrequirements as these pertain to performance of an Emergency Power Supply System(hereafter ‘EPSS’).

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NFPA Latest Revisions


Significant revisions to the NFPA 110 (2010 edition) include the following:

• Clarification that the standard is intended to apply to those EPSS’s classed aseither Level 1 or Level 2 systems. Applying the requirements of this standard tosystems classed as optional standby is not mandatory.

• Revision of the application section to indicate that the operation testing androutine maintenance requirements of Chapter 8 cover new and existing EPSSs.

• Revisions to the requirements of Chapter 7 for acceptance testing thatdistinguish what is required for new and unoccupied buildings and facilitiesversus the requirements for existing occupied buildings and facilities. In addition,requirements for test duration, step‐testing intervals, and requireddocumentation have been modified.

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Significant revisions to the NFPA 110 (2010 edition) include the following (cont’d):

• Revisions to the definitions of Automatic Transfer Switch (ATS) andNonautomatic Transfer Switch for consistency with NFPA111, Standard on StoredElectrical Energy Emergency and Standby Power Systems and for correlation withrelevant product standards covering the construction of transfer switches.

• Revisions to the requirements of Chapter 8 on operational testing‐ durations fordiesel and spark‐ignited generators. In addition, the 36‐month (triennial) testrequirement has been revised to clarify the maximum duration, the minimumacceptable EPSS loading or operating condition, and the method of test initiation.

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Clarification that the standard is intended to apply to those EPSSs classed as either Level 1 or Level 2 systems:

‐ The requirements of NFPA 110 are not intended to apply to a standby system unlessit is an emergency power supply system (EPSS) designated as either Level 1 or Level 2.Furthermore, it is not intended that NFPA 110 apply only to required standby systems;however, until a requirement specifically includes all emergency, legally requiredstandby, and optional standby EPSSs, its application to voluntary systems is optional.When a system (that is not required) is installed at the discretion of the owner, thechoice to apply the requirements of NFPA 110 is also at the discretion of the owner.For voluntary use, the system needs to be designated as either Level 1 or Level 2 andall applicable requirements for the selected level will apply. There is the possibility thata code or standard may not designate an EPSS level, in which case the responsibility ofthe authority having jurisdiction (AHJ) is to either designate the EPSS level or approvea design/installation that assigns the EPSS level.

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Clarification that the standard is intended to apply to those EPSSs classed as eitherLevel 1 or Level 2 systems (cont’d):

‐ NFPA 110 does not determine which occupancies require a Level 1 system or whichof its loads are critical to life safety:

• Level 1 is the appropriate classification where the system operation has a directimpact on life safety and failure of the system will compromise the necessarylevel of safety.

• In contrast, Level 2 is the appropriate classification where the operation of thesystem is less critical to life safety because contingencies for continued operationof a facility or function without a power supply are part of an establishedprocedure.

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Revisions to the definitions of Automatic Transfer Switch (ATS ):

• Automatic Transfer Switch (ATS); Self‐acting equipment for transferring theconnected load from one power source to another power source.

• Bypass‐Isolation Switch; A manually operated device used in conjunction withan automatic transfer switch to provide a means of directly connecting loadconductors to a power source and disconnecting the automatic transfer switch.

• Nonautomatic Transfer Switch; A device, operated manually by a physical actionor electrically by either a local or remote control, for transferring a common loadbetween a normal and alternate supply.

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• The scope of NFPA 110 extends to the load terminals of the transfer switch since that is the limit of the performance aspect of the power source. The requirements within NFPA 110 are based on this criterion. Delivering the reliable power to other systems is a distribution concern not covered by this standard. See Exhibit 1.

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• The systems covered by NFPA 110 are used as backups to a primary power source. Inorder to switch from one source to the other during a power outage, a transfer switchis necessary. See Exhibit 4.

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Chapter 7 revisions:

• Operating Temperature:

‐ Generator engine operating temperatures and the battery temperatures are nolonger specified by NFPA 110.

What does this mean?Refer to the generator’s manufacturer recommendations.

‐ The minimum room temperature is 40°F for both indoor and outdoorapplications. Generators located outdoors must be enclosed to protect thegenerator from rain and snow, and maintains proper operating temperature.

What does this mean?Outdoor generator must be equipped with the necessary accessories to meetNFPA 110, Level 1.

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• Operating Temperature (cont’d):

‐ Generator accessories such as block heaters, battery charger, battery heater,alternator (strip) heater, etc. installed within an outdoor enclosure allows the EPSSto operate when called upon. A frozen water jacket or battery chilled below itsability to start an engine must be avoided. Heating these components allows theequipment to perform (start and transfer load) when called upon. See Exhibit 3.

- Exhibit 3. EPS Located in Heated‐ and Secured Outdoor Enclosure.

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• Testing:

‐ Installation acceptance test is conducted after completion of the installationwith all emergency power supply system (EPSS) accessories and supportequipment in place and operating. Depending on the status of the facility, thereare two options for starting the first part of the test;

• In a new and unoccupied building or facility, turn off normal power to thebuilding or facility.

• In an existing occupied building or facility, either simulate a normal powerfailure by operating at least one transfer switch test function or turn offnormal power.

What does this mean?The installation operational acceptance test is the final approval test for all theEPSSs and it must be passed before the EPSS is considered to meet NFPA 110.

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• Testing (cont’d):

‐ Loading percentages in regards to generator testing are changed to ‘not lessthan’ (NLT) rather than absolute percentages, such as 25%, 50%, and 75%. Theengine start function is confirmed by verifying operation of the start circuit of alltransfer switches supplying EPSS loads. After a cool down period of NLT 5minutes, the second part of the test (a two‐hour full‐load test) is conducted. Thebuilding load may be used but must be supplemented by a load bank if necessaryto get to 100 % of the generator nameplate kW rating. This part, which previouslyrequired a 100% block load step, may now be NLT 30% for the first 30 minutes,NLT 50% for the next 30 minutes, and finally 100% for the final 60 minutes.

What does this mean?Some inspectors were citing noncompliance if the test loading did not match thegenerator rating. This is commonly the case when a generator is oversized forfuture expansion – so now, the organization will not be penalized for a test thatrepresents the current building load.

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• Monthly Exercise:

‐ Generators in service shall be exercised at least once monthly, for a minimumof 30 minutes, using one of the following methods:

• Loading that maintains the minimum exhaust gas temperatures asrecommended by the manufacturer.

• Under operating temperature conditions and at not less than (NLT) 30percent of the EPSS nameplate kW rating.

What does this mean?Every monthly test, the generator has to warm up before you start the 30‐minuteclock. The monthly load tests must operate the generator at NLT 30% of the EPSSnameplate kilowatt (kW) rating (not the amperage rating) for a minimum of 30minutes at normal operating temperatures (until the coolant temperature and oilpressure stabilize).

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• Paralleling Gear Maintenance:

‐ Maintenance of paralleling gear is now stipulated and similar to ATSmaintenance. Previously, manufacturers’ recommendations on paralleling gearmaintenance prevailed. Generator battery conductance testing will now beaccepted in lieu of specific gravity readings.

What does this mean?The manufactured suggested maintenance does not supersede NFPA 110requirements and battery conductance testing should be part of yourmaintenance.

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• Record Keeping:

‐ All test records must be permanent, meaning they must be kept forever, andelectronic records are permitted. The permanent record shall include thefollowing: (1) The date of the maintenance report. (2) Identification of theservicing personnel. (3) Notation of any unsatisfactory condition and thecorrective action taken, including parts replaced. (4) Testing of any repair for thetime as recommended by the manufacturer testing.

What does this mean?NFPA 110 requires maintenance documents to be maintained as long as thefacility remains in operation and the maintenance organization should provide adetailed report after each service (inclusive of load bank reports).

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• Repairs:

‐ NFPA 110 has detailed instructions for required testing of generators afterrepairs are made to the emergency power supply system (EPSS), includingtransfer of all automatic transfer switches (ATS) for NLT 30 minutes.

What does this mean?After the repairs are made, you must test the complete systems for no less than 30 minutes (any generator/switch/swgr repair). The purpose is to ensure the system has been repaired and is capable of being called upon reliably in the future.

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• Storage area:

‐ Storage of generator parts/accessories was previously not permitted in theemergency power generator rooms, and some authorities fully enforced thisrequirement. Storage requirements have been relaxed.

What does this mean?Parts, tools, and manuals for routine maintenance and repairs are now allowed tobe located in the generator room.

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• Testing :

‐ At the conclusion of the operational acceptance testing, or after completion ofrepairs, the first routine monthly test must be made immediately after thepassing of the acceptance test. The operational test shall be initiated at an ATSand shall include testing of each EPSS component on which maintenance orrepair has been performed, including the transfer of each automatic and manualtransfer switch to the alternate power source, for a period of not less than 30minutes under operating temperature.

What does this mean?After a new emergency power system installation or after completion of repairs,the facility’s acceptance test must take place within the same day. Referencesection 8.3 Maintenance and Operational Testing, paragraphs 8.3.2 and 8.3.2.1.

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• Testing (cont’d):

‐ Fuel oil (No. 2 Diesel) quality testing is now a required annual test, usingmethods that are approved by American Society for Testing and Materialsstandards (ASTM).

What does this mean?Maintenance contract should include annual fuel analysis testing which will helpeliminate potential fuel storage and fuel life issues.

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• Testing (annual):

‐ When a monthly load test is incapable of achieving the 30% nameplate kWrating, then the generator must have an annual load test, which will now only berequired to operate for 90 minutes instead of the previously required twocontinuous hours.

What does this mean?It is important to remember that meeting 30% of the electrical service (buildingutility) amperage rating is not the same as meeting 30% of the kW rating. Theannual test consists of the generator operating at NLT 50% nameplate rating for30 minutes, then NLT 75% nameplate rating for 60 minutes (for a cumulative 90continuous minutes).

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• Testing (annual cont’d):

‐ Exercising the breakers between the generators and the transfer switchesannually is required.

What does this mean?Exercising the circuit breakers between the generator and the transfer switches isrecommended once a year at the beginning of a monthly load test. Test must beconducted at the beginning of the load test once per year, and document thatyou did it.

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• Testing (triennial):

‐ NFPA 110 requires a three‐year four‐hour load test and requires that the ATS istransferred during the annual load test. The annual load test (only if yourmonthly load test is incapable of achieving the 30% nameplate kW) and thethree‐year four‐hour load test are permitted to be combined, provided theaforementioned conditions of both tests are met.

What does this mean?Your annually 90 minutes test (at NLT 50% nameplate rating for 30 minutes, thenNLT 75% nameplate rating for 60 minutes, for 90 continuous minutes) and three‐year four‐hour load test can be combined (1 hour, 30 minutes then 2 hour, 30minutes).

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• Weekly Inspection:

‐ Weekly inspection does not require running of the EPSS. Generators are notrequired to be tested weekly; however, they are required to be inspected weekly.

What does this mean?Weekly inspections required. NFPA 110 specifies minimum requirements, and amanufacturer may have recommendations that exceed those requirements. Ifyou are going to do a weekly run test, it’s recommended you start the generator,get it to normal operating temperature (without transferring the loads).

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Summary:

‐Many codes and standards refer to the class and type of emergency powersupply system (EPSS) as defined in NFPA 110. NFPA 110 recognizes that EPSSs areutilized at many different facilities for many different purposes. Requirements forone situation may not be appropriate in another situation; therefore, NFPA 110recognizes two levels of classification. Once the system is identified as eithercritical to life and safety (Level 1) or less critical (Level 2), the user will be able todetermine which requirements apply to that system. Once determined, therequirements of those tests are now further defined and clarified. Randominspection and testing are not a basis for maintaining the dependability of theemergency power supply system (EPSS). The continued reliability of the EPSS isdependent on an established program of routine maintenance and operationaltesting.

Be certain that your maintenance provider is fully compatible with the newestNFPA requirements, so that you can be assured your records will show your fullcompliance to these regulations.

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Reference:

‐ Reference the following NFPA 110 (2010) sections for clarification;• Installation Acceptance Test, Section 7.13• Manuals, Special Tools, and Spare Parts, Section 8.2• Maintenance and Operational Testing, Section 8.3• Local authorities should always be consulted to determine specificrequirements• Readers are encourage to refer NFPA 110, 2010 Edition in its entirety, visitwww.nfpa.org/110 for complete NFPA110.

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Monthly Exercise What does this mean?Generators in service shall be exercised at least once monthly, for a minimum of 30 minutes, using one of the following methods:Loading that maintains the minimum exhaust gas temperatures as recommended by the manufacturer.Under operating temperature conditions and at not less than (NLT) 30 percent of the EPSS nameplate kW rating.

Every monthly test, the generator has to warm up before you start the 30‐minute clock. The monthly load tests must operate the generator at NLT 30% of the EPSS nameplate kilowatt (kW) rating (not the amperage rating) for a minimum of 30 minutes at normal operating temperatures (until the coolant temperature and oil pressure stabilize).

Operating Temperature What does this mean?Generator engine operating temperatures and the battery temperatures are no longer specified by NFPA 110. The minimum room temperature is 40°F for both indoor and outdoor applications. Generators located outdoors must be enclosed to protect the generator from rain and snow, and maintains proper operating temperature.

Refer to the generator’s manufacturer recommendations.Outdoor generator must be equipped with the necessary accessories to meet NFPA 110, Level 1.

Paralleling Gear Maintenance What does this mean?Maintenance of paralleling gear is now stipulated and similar to ATS maintenance. Previously, manufacturers’ recommendations on paralleling gear maintenance prevailed. Generator battery conductance testing will now be accepted in lieu of specific gravity readings.

The manufactured suggested maintenance does not supersede NFPA 110 requirements and battery conductance testing should be part of your maintenance.

Record Keeping What does this mean?

All test records must be permanent, meaning they must be kept forever, and electronic records are permitted. The permanent record shall include the following: (1) The date of the maintenance report. (2) Identification of the servicing personnel. (3) Notation of any unsatisfactory condition and the corrective action taken, including parts replaced. (4) Testing of any repair for the time as recommended by the manufacturer testing.

NFPA 110 requires maintenance documents to be maintained as long as the facility remains in operation and the maintenance organization should provide a detailed report after each service (inclusive of load bank reports).

Repairs What does this mean?NFPA 110 has detailed instructions for required testing of generators after repairs are made to the emergency power supply system (EPSS), including transfer of all automatic transfer switches (ATS) for NLT 30 minutes.

After the repairs are made, you must test the complete systems for no less than 30 minutes (any generator/switch/swgr repair). The purpose is to ensure the system has been repaired and is capable of being called upon reliably in the future.

Storage What does this mean?Storage of generator parts/accessories was previously not permitted in the emergency power generator rooms, and some authorities fully enforced this requirement. Storage requires have been relaxed.

Parts, tools, and manuals for routine maintenance and repairs are now allowed to be located in the generator room.

NFPA Latest Revisions—Relevant Summary


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Testing What does this mean?Loading percentages in regards to generator testing are changed to ‘not less than’ (NLT) rather than absolute percentages, such as 25%, 50%, and 75%. The engine start function is confirmed by verifying operation of the start circuit of all transfer switches supplying EPSS loads. After a cool down period of NLT 5 minutes, the second part of the test (a two‐hour full‐load test) is conducted. The building load may be used but must be supplemented by a load bank if necessary to get to 100 % of the generator nameplate kW rating. This part, which previously required a 100% block load step, may now be NLT 30% for the first 30 minutes, NLT 50% for the next 30 minutes, and finally 100% for the final 60 minutes. Fuel oil (diesel/#2) quality testing is now a required annual test, using methods that are approved by American Society for Testing and Materials standards (ASTM).

Some inspectors were citing noncompliance if the test loading did not match the generator rating. This is commonly the case when a generator is oversized for future expansion – so now, the organization will not be penalized for a test that represents the current building load. Maintenance contract should include annual fuel analysis testing which will help eliminate potential fuel storage and fuel life issues.

Testing (Annual) What does this mean?When a monthly load test is incapable of achieving the 30% nameplate kW rating, then the generator must have an annual load test, which will now only be required to operate for 90 minutes instead of the previously required two continuous hours.

While a mathematical conversion between amperage and kilowatt can be calculated, it is important to remember that meeting 30% of the amperage rating is not the same as meeting 30% of the kW rating.The new revised annually test consists of the generator operating at NLT 50% nameplate rating for 30 minutes, then NLT 75% nameplate rating for 60 minutes, for 90 continuous minutes. There’s a requirement that you exercise the breakers between the generators and the transfer switches annually.Exercising the circuit breakers between the generator and the transfer switches is a requirement. It’s recommended once a year at the beginning of a monthly load test, do it at the beginning of the load test once per year, and document that you did it.

Testing (Triennial) What does this mean?NFPA 110 requires a three‐year four‐hour load test and requires that the ATS is transferred during the annual load test. The annual load test (only if your monthly load test is incapable of achieving the 30% nameplate kW) and the three‐year four‐hour load test are permitted to be combined, provided the aforementioned conditions of both tests are met.

Your annually 90 minutes test (at NLT 50% nameplate rating for 30 minutes, then NLT 75% nameplate rating for 60 minutes, for 90 continuous minutes) and three‐year four‐hour load test can be combined (1 hour, 30 minutes then 2 hour, 30 minutes).

Weekly Inspection What does this mean?Weekly inspection does not require running of the EPSS. Generators are not required to be tested weekly; however, they are required to be inspected weekly.

Weekly inspections required. NFPA 110 specifies minimum requirements, and a manufacturer may have recommendations that exceed those requirements. If you are going to do a weekly run test, it’s recommended you start the generator, get it to normal operating temperature (without transferring the loads).

NFPA Latest Revisions—Relevant Summary


Documents

Facility Power Readiness NFPA changes overview