Cynergy Electric Company, Inc.
   
 

Design/Build

 
 
Fairfax CountyDepartment of Public Works Generator System Rehabilitation
Contract No. CN06402003 Project No. 402/100351
Alpha Construction Upper Marlboro, MD  William McGovern (301) 420-8420

Cynergy performed a $2.4 million design/build contract for Alpha Construction for the replacement of three existing generators, remote radiators and generator switchgear. The existing generators were thirty year old EMD 900RPM units with an air start system, remote radiators, off skid mounted control panels and generator switchgear. The project entailed the design of a complete replacement system at three different pumping stations with new 1800 RPM generators, generator switchgear, day tanks and remote radiators. The customer also wanted remote SCADA monitoring of certain generator, day tank and switchgear data. Principle features of the project were as follows:

  • Provide one 1750KW 4160 volt diesel engine generator
  • Provide one 1500KW 4160 volt diesel engine generator
  • Provide one 1000KW 480 volt diesel engine generator
  • Replace the 4160 volt primary feeders between the existing outdoor switchgear and new generator switchgear at two locations
  • Install new 4160 volt feeders between the generators and generator switchgear
  • Demolish three existing 60,000 lbs. diesel engine generators including remote radiators, associated equipment, piping, wiring and accessories
  • Provide temporary emergency power during construction, including on-grade engine generators with wiring and accessories
  • Provide three remote radiators and radiator piping between the generator and radiator
  • Provide three new 200 gallon automatic day tanks
  • Provide new 48VBC battery systems for the 4160 volt switchgear
  • Provide two new 4160 volt generator switchgear with vacuum breaker
  • Provide one 480 volt generator switchgear with 4000 amp breaker
  • Provide mechanical modifications, jacket water piping, exhaust piping and fuel oil piping
  • Provide new controls, wiring and accessories for the equipment
Temporary 4160 volt generator plants had to be installed at two of the locations before the existing system could be removed. This was accomplished by using a 480 volt generator and 2500 KVA step up transformer. Temporary generator controls had to be installed to interface with the existing station switchgear. The generator, switchgear, fuel system, etc. were all connected to the customer’s monitoring system. Miscellaneous installation items included; fuel day tank, batteries, remote radiator circuits and low voltage circuits to the parasitic equipment in support of the generator, control circuits, etc. Commissioning and field testing were a large component in the project. Third party testing was provided for all medium voltage equipment, generator and cables. Factory field services were provided for the generator. Hands on training, classroom training and operation and maintenance manuals were provided for all operational systems.

 

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