INSPECTION AND TESTING OF EMERGENCY GENERATORS

Transcription

1 INSPECTION AND TESTING OF EMERGENCY GENERATORS Certificatin requirements NFPA 101(12), Sec requires that emergency generatrs prviding pwer t emergency lighting systems be installed, tested and maintained in accrdance with NFPA 110, Standard fr Emergency and Standby Pwer Systems. NFPA 101(12), Sec als requires that, where required fr cmpliance with the Cde, emergency generatrs and standby pwer systems be installed, tested and maintained in accrdance with NFPA 110. NFPA 101(12), Sec. 2.2 references the 2010 editin f NFPA 110. Buildings that fall under Chapter 18 f NFPA 101(12) and are equipped with r in which patients require the use f life-supprt systems (e.g. hspitals, nursing hmes with residents n ventilatrs) must als meet the applicable prvisins f the 2012 editin f NFPA 99, Standard fr Health Care Facilities [see NFPA 101(12), Sectins , , and ]. Prvisins dealing with maintenance and testing f emergency generatrs can be fund in NFPA 99(12), Sec This sectin starts ut by referencing NFPA 110, but als deals with such issues as: Testing intervals Test cnditins Persnnel qualificatins Maintenance and testing f circuitry Maintenance f batteries Each facility shuld have a cpy f these standards. They can be rdered frm NFPA at r Natinal Fire Preventin Assciatin ( State licensure requirements MSFC(15), Sectins and als requires that emergency generatrs be inspected, tested and maintained in accrdance with the 2010 editin f NFPA 110. Maintenance and testing Applicable standards Requirements fr rutine maintenance and peratinal testing f emergency generatrs can be fund in: Chapter 8 f the 2010 editin f NFPA 110 Sectins , and f the 2012 editin f NFPA 99 Maintenance and testing General 1) Maintenance and testing is critical t the cntinued reliability f yur emergency generatr and must be perfrmed in accrdance with manufacturer s recmmendatins, instructin manuals, and the minimum requirements f NFPA 110 and the authrity having jurisdictin (AHJ) [see: NFPA 110(10), Sectin 8.1.1]. 2) Yur facility shuld have at least tw sets f instructin manuals fr all majr generatr cmpnents. One set shuld be kept in a secure, cnvenient lcatin near the equipment. The ther set shuld be kept in a different secure lcatin [see: NFPA 110(10), Sectin 8.2.2]. These manuals must, at a minimum, cntain the fllwing: a) A detailed explanatin f the peratin f the emergency pwer supply system b) Instructins fr rutine maintenance c) Detailed repair instructins d) An illustrated parts list and part numbers e) Illustrated and schematic drawings f electrical wiring systems, including perating and safety devices, cntrl panels, instrumentatin and annunciatrs

2 Page 2 f 6 3) Special tls and testing devices necessary fr rutine maintenance must be available fr use when needed [see: NFPA 110(10), Sec ]. 4) Rutine maintenance, inspectin and peratinal testing f the emergency generatr and assciated cmpnents must be verseen by a prperly trained persn [see MSFC(15), Sec ; NFPA 99(12), Sec (C); NFPA 110(10), Sec ]. Evidence f such training shuld be kept in the designated emplyees persnnel file. In the absence f a prperly trained persn n-site, an utside vendr may need t be cntracted t versee the perfrmance f all r part f these services. 5) NFPA 110 des nt establish a specific date and time f day fr required testing. Thse are t be determined by management and are typically scheduled s as t prvide minimum disruptin f facility peratins. [see NFPA 110(10), Sectins and ]. NFPA 99(12), Sec (A), hwever, requires that generatr sets be tested 12 times a year, with testing intervals f nt less than 20 days nr mre than 40 days. Weekly inspectins T meet federal certificatin and state licensure requirements, health care facilities must inspect their emergency generatrs weekly [see NFPA 110(10), Sec ]. At a minimum, this weekly inspectin shuld include a check f the fllwing: 1. Fuel (check main and day tank fuel supply levels; day tank flat switch; piping, hses and cnnectrs; perating fuel pressure; and fr any bstructins t tank vents and verflw piping 2. Lubricatin system (check fr prper il level and il perating pressure; lube il heater) 3. Cling system (check clant level, water pump(s), jacket water heater, belts, hses, fan) 4. Exhaust system (check drain cndensate trap and fr pssible leakage) 5. Battery system [lk fr pssible crrsin; check specific gravity, electrlyte level and battery charger maintenance-free batteries require rutine visual inspectin and maintenance in accrdance with manufacturer s instructins] 6. Electrical system (cnduct a general inspectin f wiring and cnnectins; check circuit breakers/fuses) 7. Prime Mver/Generatr (Check fr debris, freign bjects, lse r brken fittings; check guards and cmpnents; lk fr any unusual cnditin f vibratin, leakage, nise, temperature r deteriratin Nte: This is nt an all-inclusive list. The equipment manufacturer may have additinal maintenance requirements that will likely include mnthly, quarterly, semi-annual and annual inspectins and checks. Mnthly testing 1) T meet federal certificatin and state licensure requirements, health care facilities must exercise their emergency generatrs under lad at least mnthly [see NFPA 110(10), Sec ]. a) Diesel generatr sets are required t be exercised at least nce mnthly, fr a minimum f 30* minutes, using ne f the fllwing methds [see NFPA 110(10), Sec ]: i) Lading that maintains the minimum exhaust gas temperatures recmmended by the manufacturer (it is unlikely that minimum exhaust gas temperatures will be reached if the generatr isn t carrying a lad equivalent t at least 30 percent f the generatr s nameplate kw rating).

3 Page 3 f 6 ii) Under perating temperature cnditins and at nt less than 30 percent f the generatr s nameplate kw rating. A 100 kw generatr, fr example, wuld need t be exercised under a lad f at least 30 kw t meet this requirement. (1) Nrmal perating temperatures are set by the manufacturer. Smething t cnsider when scheduling yur mnthly tests is that yur particular generatr may nt reach perating temperature in 30 minutes* and that running the generatr fr shrt perids f time may be harmful t the engine. Yu als want t make sure that the generatr runs lng enugh t ensure that all engine parts are prperly lubricated. *Nte: Warm-up and cl-dwn times d nt cunt tward the required 30 minutes. iii) An alternate methd is prvided fr diesel-pwered generatrs that d nt meet the testing requirements utlined in 1.a abve. This culd ccur when, fr example, a large generatr in relatin t the lad is installed (e.g. either t accunt fr the largest mtr cnnected t the generatr r t accmmdate future expansin f the facility). Such generatrs can be exercised mnthly with the available lad and exercised annually with supplemental lads at 50 percent f nameplate kw rating fr 30 cntinuus minutes, fllwed by 50 percent f nameplate rating fr 30 minutes and at nt less than 75 percent f the nameplate kw rating fr 60 minutes, fr a ttal test duratin f 1.5 cntinuus hurs [see NFPA 110(10), Sec ]. b) Spark-ignited generatr sets (e.g. gasline-pwered, natural gas-pwered r prpanepwered) must be exercised at least nce a mnth with the available lad fr 30 minutes r until the water temperature and il pressure have stabilized. c) Where equivalent lads are used fr testing, it is imprtant t nte that such lads are required t be autmatically replaced with the emergency lads in case f failure f the nrmal pwer [see NFPA 110(10), Sectins and ]. d) Where a generatr set is used fr standby pwer, peak lad shaving r perated during a pwer utage, such use is allwed t be substituted fr a rutine mnthly test, prvided the generatr is perated in accrdance with the standards and the apprpriate data are recrded. 2) The mnthly test is required t be initiated by simulating a pwer utage using the test switch(es) n the autmatic transfer switch(es) r by pening a nrmal breaker [see NFPA 110(10), Sec ]. Opening a nrmal breaker shall nt be required. 3) Lad tests must include cmplete cld starts [see NFPA 99(12), Sec (B); NFPA 110(10), Sec ]. 4) Time delays must be set as fllws [see NFPA 110(10), Sectins 6.2 and 8.4.5]: a) Time delay n start: 1 secnd minimum (0.5 secnd minimum fr gas turbine units). This is t prevent nuisance starts and pssible subsequent lad transfer in the event f harmless mmentary pwer dips. *Nte: NFPA 101(12), Sec requires that emergency lads be picked up within 10 secnds.

4 Page 4 f 6 b) Time delay n transfer t emergency: n minimum required. c) Time delay n restratin t nrmal pwer: 5 minutes minimum (t give the primary surce sufficient time t stabilize befre retransfer f the lad, a delay f between 15 and 30 minutes is recmmended) [see NFPA 110(10), Sec. A.6.2.8]. d) Time delay n shutdwn: A minimum time delay f 5 minutes must be prvided fr unladed running f the generatr prir t shutdwn t allw fr engine cldwn small (15 kw r less) air-cled prime mvers are exempt frm this requirement [see NFPA 110(10), Sec ]. *Nte: Sme generatr manufacturers recmmend a lnger cldwn perid. If s, NFPA 110(10), Sec requires that the manufacturer s recmmendatins be fllwed. 5) Dcumentatin f the mnthly testing f yur emergency generatr(s) shuld, at a minimum, include the fllwing infrmatin: a) Identificatin f generatr tested (e.g. Generatr #1) b) Date generatr was installed/placed in service c) Generatr standby nameplate rating in kw d) 30% f generatr standby nameplate rating in kw e) Fuel type (e.g. diesel, gasline, etc.) f) Nrmal perating temperature g) Date f test h) Signature r initials f persn perfrming the test i) Identificatin f ATS(s) used t initiate the test j) ATS transfer time (0 t 10 secnds)*** k) Time delay fr cldwn (minimum 5 minutes required) l) Elapsed run time (supprt with hur meter start and stp times m) Oil pressure during test n) Operating temperature during test ) Engine exhaust temperature during test, if applicable p) kw (lad under test) q) Identificatin f unsatisfactry cnditins and crrective actin taken (including parts replaced) *Nte: NFPA 99(12), Sec specifies that the 10-secnd criterin des nt apply during the mnthly testing f the generatr. This prvisin, new t the 2012 editin f the standard, recgnizes that additinal time may be needed during nrmal mnthly testing t allw fr paralleling with nrmal pwer. It is imprtant t nte that, if the 10-secnd criterin is nt met during the mnthly test, a prcess must be prvided t annually cnfirm the capability f the life safety and critical branches t cmply with the requirement in NFPA 99(12), Sec that pwer be restred within 10 secnds after interruptin f nrmal pwer. Mst health care facilities experience a pwer utage at least nce a year. As a suggestin, a facility culd recrd the transfer time during an actual utage and use that dcumentatin t cnfirm cmpliance with Sec It is imprtant t be prepared in case smething ges wrng during testing. It is strngly recmmended that yur facility have a plicy in place that makes prvisins fr a prtable generatr r ther alternate pwer surce fr situatins in which the emergency generatr malfunctins r, wrse yet, is ut f service.

5 Page 5 f 6 3-year testing Level 1 emergency pwer supply systems (EPSS) thse installed where failure f the equipment t perfrm culd result in lss f human life r serius injuries are required t be tested at least nce within every 36 mnths in accrdance with the fllwing [see NFPA 110 (10), Sec ]: Testing must be cntinuus fr the duratin f the generatr s assigned class, but is nt required t exceed 4 hurs: The test must be initiated by perating at least ne transfer switch test functin and then by perating the test functin f all remaining ATSs r initiated by pening all switches r breakers supplying nrmal pwer t all ATSs that are part f the EPSS being tested. The minimum lad fr a diesel-pwered emergency pwer supply (EPS) must be nt less than 30 percent f the standby nameplate kw rating f the generatr. A supplemental lad is allwed t be used t meet r exceed the 30 percent requirement. The minimum lad fr a diesel-pwered EPS must be that which maintains the minimum exhaust gas temperatures as recmmended by the manufacturer. The minimum lad fr spark-ignited EPSs must be the available EPSS lad. The test required in is allwed t be cmbined with ne f the mnthly tests required by Sec and ne f the annual tests required by Sec as a single test. Where the test required by Sec is cmbined with the annual lad bank test, the first 3 hurs must be nt less than the minimum lading required by Sec and the remaining hur must be nt less than 75 percent f the standby nameplate kw rating f the generatr. Autmatic transfer switches (ATS) 1. Transfer switches are required t be perated mnthly [see NFPA 110(10), Sec ; see als: MSFC(15), Sec ]. 2. This mnthly test must cnsist f electrically perating the transfer switch frm the nrmal/standard psitin t the alternate psitin and then a return t the nrmal/standard psitin [see MSFC(15), Sec ; NFPA 110(10), Sec ]. In many cases, a Transfer Test switch r buttn is prvided and can be used t perfrm this test. Where this feature des nt exist, it may be necessary t manually discnnect nrmal pwer in sme fashin t the transfer switch (see sme wrds f cautin n testing belw). 3. Transfer switches must als be inspected n a rutine basis (mnthly is recmmended) t check cnnectins, check fr evidence f verheating r excessive cntact ersin (terminals and cnnectrs are nrmal clr), listen fr unusual sunds, t ensure that the switches are maintained free frm accumulated dust and dirt, and ensure that all cvers are tight and drs securely clsed [see MSFC(15), Sec ; NFPA 110(10), Sec ]. 4. EPSS circuit breakers fr Level 1 system usage, including main and feed breakers between the EPS and the transfer switch lad terminals, are required t be exercised annually with the EPS in the ff psitin [see NFPA 110(10), Sec ]. Circuit breakers rated in excess f 600 vlts fr Level 1 system usage are required t be exercised every 6 mnths and tested under simulated verlad cnditins every 2 years [see NFPA 110(10), Sec ]. 5. Because they are such a key cmpnent in the successful peratin f yur emergency generatr, it is recmmended that yu cnsider having infrared testing f yur transfer switch(es) cnducted annually t check fr lse cnnectins.

6 Page 6 f 6 Sme wrds f cautin n testing 1. Shutting ff pwer, especially shutting ff the main breaker, can expse a persn t pssible shck, electrcutin and/r arc flash hazards. It is imprtant, therefre, that anyne perfrming a test in this fashin be adequately trained and take prper safety precautins, including the wearing f prper persnal prtective equipment (PPE). T reduce the safety risks, it is strngly recmmended that facilities nt already s equipped cnsider adding a switch fr testing f their transfer switches. 2. The explanatry infrmatin in NFPA s 2012 Health Care Facilities Handbk t Sec (B), which addresses test cnditins (including cld starts and apprpriate autmatic and manual transfer f essential electrical system lads), prvides mre fd fr thught: Testing criteria required by (B) might range frm manually discnnecting pwer t the pwer sensrs n transfer switches t manually pening the main incming feeder breakers. It is very imprtant that each test methd be fully understd by all staff thrugh apprpriate ntificatin and that the cnsequences f each methd (if smething fails t functin) be weighed carefully. A prcedure fr returning t the nrmal pwer surce shuld als be established in the event a failure ccurs during testing. There is a false assumptin that discnnecting a facility s mains is the best methd f testing the standby generatr(s) and essential electrical system. One must always cnsider the pssibility that failure f the discnnecting means r sme ther unexpected cntingency might make it difficult r impssible t restre nrmal pwer. It is prbably better t initiate engine start by interrupting pwer just ahead f the transfer switch(es) n an alternating r rtating basis in rder t make sure each transfer switch has an intact engine start circuit. DOCUMENT yur inspectins and tests NFPA 110(10), Sec requires the establishment f a written schedule fr rutine generatr maintenance and testing [see als: MSFC(15), Sec ]. A sample schedule can be fund in Annex A f the standard [see Figure A.8.3.1(a)]** r may even be available frm the equipment manufacturer [see als: 2012 Health Care Facilities Handbk Annex B, Figure B.6.2]. **Because there is a lt riding n the successful peratin f a facility s emergency generatr, it is strngly recmmended that the schedule fr Level 1 EPSS be fllwed when establishing yur maintenance schedule. A written recrd f generatr inspectins, tests, exercising, peratin and repairs must be maintained n the premises and be available fr review by the fire inspectr n request. This recrd must, at a minimum, include: the date f the reprt, name(s) f the persn(s) prviding the service, identificatin f unsatisfactry cnditins and crrective actin taken (including parts replaced), and any testing f repairs recmmended by the manufacturer [see MSFC(15), Sec ; NFPA 99(12), Sec ; NFPA 110(10), Sectins and ]. A sample maintenance lg can be fund in Annex A f NFPA 110 [see NFPA 110(10), Figure A.8.3.1(b)] r may even be available frm the equipment manufacturer [see als:]. A sample testing lg can als be fund in Annex A f NFPA 110 [see NFPA 110(10), Figure A.8.4.1(a) r may even be available frm the equipment manufacturer. As an alternate, yu can use these samples t create yur wn lgs. It is imprtant that at least tw peple in yur facility knw where yur lgs are kept t increase the likelihd that they can be readily prvided if requested during an inspectin. It is recmmended that these lgs be maintained fr at least three years.