2390 kw natural gas emergency power...

SOBEYS Inc.: Huntington Road Distribution Centre, Vaughan

2390 kW Natural Gas Emergency Power System

Operational Performance Tests Report

Performed in accordance with CSA282-05 Section 10

( from October 10th through October 18th, 2008 )

By: POWER GENySYS

October 19, 2008

218 Goulding Ave., North York, Ontario, M2R 2P5 w w w . p o w e r g e n y s y s . c o m

Tel.: (416) 224-9339 Fax: (416) 224-9336

October 19, 2008 DDACE Power Systems 1 Moyal Court, Concord, ON L4K 4R8 Attention: Mr. Jan M. Buijk, B.Sc.,

VP and General Manager RE: Sobeys Distribution Centre, Huntington Road, Vaughan Emergency Power Supply Generator Dear Mr. Buijk, POWER GENySYS was retained by DDACE Power Systems to provide independent performance verification of the Jenbacher JGS616 natural gas fuelled emergency power generator system installed at Sobeys Huntington Road Distribution Centre in Vaughan Ontario. POWER GENySYS was also requested to provide opinion as it relates to the equipment’s suitability as a life safety emergency generator set, in accordance with the requirements set out in CSA Standard C282-05 “Emergency Electrical Power Supply for Buildings”. It is not the purpose of this report to confirm the entire installation is compliant with the Standard, but only to offer commentary as it relates to the performance of the generator set portion of the Standard. Ultimately, it will be the Authority Having Jurisdiction (AHJ), (ie. the City of Vaughan Building Department or the City of Vaughan Fire Department) that will grant the Occupancy Permit for the new Distribution Centre based on their acceptance of the emergency generator and its associated installation. The CSA 282 Standard was amended in October 2005, and now allows generator sets, fuelled by a reliable source of pipeline natural gas, to provide emergency electrical power supply for buildings. As of June 2006, the Ontario Building Code was amended to reference, thus adopting this new CSA 282-05 Standard. The undersigned was the project engineer responsible for the very first installation of a pipeline natural gas generator set in Ontario, that serves as the emergency electrical power supply for the Villa Colombo Vaughan, Long Term Care facility in Kleinburg. Further, the undersigned was responsible for the testing and successful demonstration of this “new” technology to the City of Vaughan Building Department. Occupancy was granted by the City of Vaughan for that nursing home in September 2006. In order for the system installed at Sobeys to be accepted by the AHJ, the system has to be subjected to “Initial Installation Performance Tests”, and meet the performance requirements as defined in Section 10 of the CSA 282-05 Standard. DDACE Power Systems performed the tests, with the assistance of GE Jenbacher, where POWER GENySYS witnessed these tests to subsequently provide independent verification. Due to the nature of the site (which is still under construction), some restrictions were imposed by Sobeys’ Health and Safety Department. As a result of these restrictions, the testing as defined in Section 10 of the Standard had to be performed over a number of days.

The full load four hour testing as per 10.3.1 of the Standard occurred on October 10th, 2008 between 17:30 and 22:30. Although the calculated emergency building load as defined by the Standard was 384kW, DDACE noted that they are contractually obligated to perform the four hour full load test at the nameplate rating of the generator set (2390 kW). Photographic evidence of this testing at the required time intervals has been included in the final report for reference. The Crank Cycle testing as per 10.4 of the Standard and the Safety & Shutdown demonstration as per 10.5 of the Standard occurred on October 11th, 2008 between 14:12 and 15:08. Video evidence of the Crank Cycle testing and photographic evidence of the Safety & Shutdown demonstration has been included in the final report for reference. The Cold Start Full load testing as defined in Section 10.2.3 of the Standard was performed and verified over two days. On October 14th, 2008 between 19:53 and 20:58, four cold starts were performed and recorded. The 384 kW calculated emergency block load, was simulated using both the building emergency lighting and a resistive load bank (total actual load applied was approximately 450 kW which exceeds the requirement). After the fourth cold start, the engine was kept running for one hour in accordance with 10.2.2 of the Standard. After one hour of operation, normal power was restored to the building. After the generator set control panel sensed normal power was available for 5 minutes, the undersigned witnessed the satisfactory “seamless” transfer of the load from emergency power to normal power (mains parallel) and immediately began unloading the generator. After unloading the generator and opening of the generator breaker [ 52-G ], the control panel displayed that the system was in cool down mode for a period of one minute, after which the genset automatically shut down. Photographic evidence of this testing at the required time intervals has been included in the final report for reference. While the testing that occurred on Oct 14th was compliant with the Standard as it relates to the time to connect emergency lights and ability of the generator to handle the block load, Sobeys Electrical Contractor noted that the nature in which the generator cold start tests were performed on Oct 14th, was potentially detrimental to the life of the emergency lighting system. DDACE Power Systems subsequently agreed to, and then further optimized the Jenbacher JGS616 starting sequence to alleviate this concern. The Cold Start portion of the testing was performed again on October 18th. Seven (7) successful start tests were performed between 06:30 and 07:30 and recorded by DDACE and GE Jenbacher. However, these tests were not witnessed. An additional Four (4) start tests were performed, in the presence of POWER GENySYS, DDACE, GE Jenbacher, Sobeys and their representation between 12:30 and 13:30. For each start that was demonstrated, the emergency lights were illuminated in less than 15 seconds after the power failure was simulated. Each time after the load was applied, steady state frequency and voltage from the generator was observed well within the required 10 seconds. Video and photographic evidence of this testing is attached for reference. The Oct 18th testing demonstrated the Cold Start occurred within the 15 seconds and at a frequency that eliminated any possibility of long term damage to the emergency lighting system., Clause 6.4.2 of the Standard requires that the generator be capable of maintaining the emergency supply voltage and frequency such that on the one-step application of full load, the engine generator set continues operating and returns to stable voltage and frequency within 10 seconds. In conclusion the Jenbacher JMS616 package was successfully subjected to all testing as required by Section 10 of the standard, “Initial installation performance tests”. Sufficient data has been recorded, assembled and documented in this report in such a manner that the AHJ has everything required to review and assess whether the GE Jenbacher emergency generator and its associated equipment meets the requirements of the C282-05 standard.

We are confident that upon review of the data provided AHJ will consider the generator set performance to be in accordance with the requirements under CSA282-05 and once also satisfied with other requirements related to the equipment installation, will issue the occupancy permit. Other requirements of the CSA 282-05 Standard, not related to the generator and associated equipment performance, such as fuel supply, etc. are not a part of this report but will be identified and presented in a separate report prepared by DDACE Power Systems. If further clarification is required, please contact the undersigned at (416) 224-9339. Yours truly,

Vito Casola, P.Eng., President POWER GENySYS

CSA 282-05: Emergency Electrical Power Supply for Buildings Owner: Sobeys Inc.

Project: Sobeys Distribution Centre

Address: Huntington Road, Vaughan, Ontario

Summary of Site Specific Testing (per CSA 282-05 “Section 10 “Initial Installation Performance Tests”) Yes No Notes: Was the engine “cold”? √ Engine temperature at 62.9°C and oil temperature

was 44.1°C. Parameters maintained with only the block heaters in operation and the oil pump providing pre-lubrication for 5 min. out of every 30 min.

Was the emergency load at its normal operating level?

√ Building load and load bank combination was set at 450kW (exceeding the Full Load Test requirement).

Was the power failure simulated by opening all of the breakers that supply normal power to the building?

√ The single building main breaker was opened.

Was the emergency power supply connected to “life safety equipment” within 15 seconds of a normal loss of power?

√ Emergency power supply connected Four consecutive times to “life safety equipment” in 14.24s, 14.25s, 14.32s and 14.32s.

After the one-step application of emergency load, did the engine generator set continue operating AND return to stable voltage and frequency within 10 seconds?

√ After one-step application of 450kW resistive load, the engine-generator set continued operation and stabilized in a maximum time of 7.6 s.

On application or removal of load, was the resulting engine generator voltage and frequency only deviate within a range suitable for the connected equipment?

√ Application of load was at 59.2 Hz within the emergency lighting spec of 50Hz. Voltage deviation within specs.

Did the voltage and frequency stay within the +/- 2% rated values after the recovery of the one-step application of emergency load?

√ Refer to test report, section 10.3.1.

Were the engine internal temperatures maintained throughout the course of the full load testing?

√ Refer to test report, section 10.3.1. Full load testing was at a load of 2390kW, exceeding the 384kW as required by the Standard.

Upon the restoration of normal power, did the system automatically transfer load from the Emergency source to the normal source?

√ Refer to test report, section 10.3.1.

Did the crank cycle test demonstrate the batteries have sufficient cranking time for a total of 60 seconds?

√ Refer to test report, section 10.4

Did all safety/shutdown devices respond as specified in Table 1 of the Standard?

√ Refer to test report, section 10.5

Did the ventilation system maintain the room temperature within the allowable tolerances specified in Clauses 6.7 & 6.8?

√ Refer to test report, section 10.3.1. Room air temperature actually dropped over the course of the 4 hour full load testing.

Did the Owner’s representative witness the tests and received instructions on the proper performance of the work specified in table 2 to 4 of the Standard?

Currently, it is assumed that DDACE Power Systems will provide all necessary service and maintenance support for Sobeys. If the Owner retains his own representative to perform ongoing system maintenance, training for that new individual shall be provided.

TEST FORM: EMERGENCY GENERATOR SYSTEMS

CSA 282-05: Emergency Electrical Power Supply for Buildings

Owner: Sobeys Inc. Project: Sobeys Distribution CentreAddress: Huntington Road, Vaughan, Ontario

Ref. CSA-282-0510.2.1 Cold Start Test NOTE: "Full Load Test" as defined by CSA 282-05 (Clause 6.1.1.2) is the full load normally served by the10.2.2 Operate for 1hour after cold start, then restore power, then Emergency Power System plus 10%.

auto transfer load from emergency to normal, then shut down generator set As per the project specific requirements, this is 200 kW of lighting and 200 hp fire pump connected to soft-start10.3.1 4 hour Full Load Test Therefore, test load (Full Load) will be (200+149) * 1.1 = 384 kW

10.4 Cycle Crank Test10.5 Verify Safety Shutdowns and Alarms

10.2.1 Cold Start Full Load Test (CSFLT) TEST Run No. 1 2 3 4 1 2 3 414-Oct-08 19:36 to 20:58 Start Time (measured by hand) 14.86 14.35 14.18 14.74

Start Time (measured by Fluke 199 Scopemeter) 14.24 14.24 14.32 14.32Start Time (measured by Video) 13.80 13.20 12.99 13.64 na 14.20 na na

Time delay on start (60 milliseconds) 0.06 0.06 0.06 0.06 0.06 0.06 0.06 0.06Cranking time until engine starts and runs (measured by video) 11.25 10.83 10.94 11.52 na 9.75 9.22 naTime required to come up to operating speed (measured by video) na na na na na 14.24 14.32 naTime required for each life safety switch placed into emergency position 14.86 14.35 14.18 14.74 14.25 14.25 14.33 14.33Time req. to achieve steady-state condition, with all switches in emerg. Pos (video). 7.55 7.40 6.61 6.96 384kW step. 3.81 4.44 3.43 na 122kW stepTime delay for the connection of other loads, later than the life safety equipment Not tested, but time delay of other loads will be One minute after transfer of life safety loadsTime delay on retransfer 5 minutesTime delay on engine cooldown and shutdown 1 minute

10.2.2 Cold Start Full Load Test immediately continued for 1 hour (TEST Run No. 4 from Oct 14th)

Interval Photo File Name ( hh:mm:ss ) ( kW ) ( Hz ) L1-L2 L2-L3 L3-L1 L1 L2 L3 ( °C ) ( bar ) ( °C ) ( bar ) ( °C )LightsOut Sobeys CSFLT - 04.AVI 19:53:13 0 Not recorded, this portion of the test was re-done on Oct 18th 47.8 3.78 58.9 1.42 ~ 26 18.6Cold Start Sobeys CSFLT - 04.AVI 19:53:14 450 Not recorded, this portion of the test was re-done on Oct 18th 48.3 3.96 60.2 1.43 ~ 26 18.61 min. Sobeys 10.2.2 - 01, 02 19:56:24 534 60.0 485 487 485 686 650 681 58.8 4.13 64.6 1.43 ~ 26 18.65 min. Sobeys 10.2.2 - 03, 04 20:00:33 564 60.0 486 488 487 701 657 675 62.4 4.08 73.9 1.48 ~ 26 18.810 min. Sobeys 10.2.2 - 05, 06 20:05:21 680 60.0 486 488 487 836 786 816 64.6 4.06 79.0 1.52 ~ 26 19.215 min. Sobeys 10.2.2 - 07, 08 20:11:36 706 60.1 486 488 487 874 826 843 66.3 4.05 80.4 1.55 ~ 26 19.430 min. Sobeys 10.2.2 - 09, 10 20:25:00 706 60.0 486 488 486 873 825 843 67.2 4.03 80.6 1.56 ~ 26 19.645 min. Sobeys 10.2.2 - 11, 12 20:40:06 706 60.0 486 487 486 873 824 844 67.3 4.03 80.7 1.54 ~ 26 19.760 min. Sobeys 10.2.2 - 13, 14 20:55:00 707 60.1 485 487 486 874 825 842 67.5 4.02 80.7 1.55 ~ 26 19.5Load Transfer Sobeys 10.2.2 - 15, 16, 17 ~ 20:56:00 707 - 645 no data recorded, video shows transfer from Emergency mode to Mains parallel (Normal power) - CLICK here for link to Video (Sobeys 10.2.2 - 29.AVI)Mains Parallel Sobeys 10.2.2 - 18 to 21 20:56:55 645 - 0 no data recorded, images show the ramping down of the load from the generator to 645kW to 0 kWCooldown/Stop Sobeys 10.2.2 - 22 to 28 20:57:32 0 no data recorded, images show the engine cool down cycle period and shutdown.

10.2.2 Cold Start Test portion, repeated (TEST Run No. 3 from Oct 18th)

Interval Photo File Name ( hh:mm:ss ) ( kW ) ( Hz ) (V) (A) ( °C ) ( bar ) ( °C ) ( bar ) ( °C )LightsOut Sobeys CST3 - 02.AVI 12:45:14 67 59.2 481 14.5s a/ loss of pwr. 240 43.9 4.16 62.8 1.47 ~ 26 nrSteady State Sobeys CST3 - 02.AVI 12:45:22 125 60.1 481 22.0s a/ loss of pwr. 220 48.3 3.96 60.2 1.43 ~ 26 nr

note: 2.5 second overshoot & recovery recorded when emergency load initially applied10.3.1 Full Load Test 10-Oct-08 ( 5:30 pm to 10:30 pm )

Interval Photo File Name ( hh:mm:ss ) ( kW ) ( Hz ) L1-L2 L2-L3 L3-L1 L1 L2 L3 ( °C ) ( bar ) ( °C ) ( bar ) ( °C )Start ~ 17:30:00 040% load Sobeys 4hrFLT - 01.JPG 17:35:06 1051 60 not recorded ~ 26 18.885% load Sobeys 4hrFLT - 02.JPG 17:45:14 2047 60 not recorded ~ 26 18.9Full Load Sobeys 4hrFLT - 03, 04 17:59:16 2390 60 482 484 482 2879 2849 2872 69.3 3.98 84.9 1.26 ~ 26 19.25 min Sobeys 4hrFLT - 05, 06 18:05:02 2393 60 482 484 482 2882 2848 2871 68.8 3.98 84.4 1.27 ~ 26 19.410 min Sobeys 4hrFLT - 07, 08 18:10:26 2390 60 482 483 482 2877 2846 2866 68.8 3.98 84.4 1.27 ~ 26 19.315 min Sobeys 4hrFLT - 09, 10 18:15:25 2391 60.1 482 484 482 2881 2849 2868 68.8 3.98 84.4 1.27 ~ 26 19.230 min Sobeys 4hrFLT - 11, 12 18:30:26 2390 60.1 482 484 482 2882 2850 2868 68.8 39.8 84.3 1.27 ~ 26 19.145 min Sobeys 4hrFLT - 13, 14 18:45:43 2390 60.1 482 484 482 2880 2849 2868 68.8 39.8 84.4 1.27 ~ 26 19.060 min Sobeys 4hrFLT - 15, 16 19:00:24 2390 60 482 484 482 2879 2848 2869 68.8 39.8 84.4 1.27 ~ 26 18.975 min Sobeys 4hrFLT - 17, 18 19:15:48 2390 60.1 482 484 482 2880 2848 2869 68.8 3.97 84.3 1.27 ~ 26 18.990 min Sobeys 4hrFLT - 19, 20 19:30:33 2387 59.9 482 484 482 2874 2843 2865 68.9 3.98 84.4 1.27 ~ 26 18.8105 min Sobeys 4hrFLT - 21, 22 19:45:47 2391 60 482 484 482 2881 2848 2871 68.9 3.98 84.4 1.27 ~ 26 18.7120 min Sobeys 4hrFLT - 23, 24 20:00:04 2390 60 482 484 482 2878 2845 2868 68.9 3.98 84.4 1.27 ~ 26 18.8135 min Sobeys 4hrFLT - 25, 26 20:15:25 2390 60 482 484 482 2878 2845 2869 68.9 3.98 84.5 1.27 ~ 26 18.5150 min Sobeys 4hrFLT - 27, 28 20:30:13 2389 59.9 482 484 482 2878 2846 2865 68.9 3.98 84.5 1.26 ~ 26 18.4165 min Sobeys 4hrFLT - 29, 30 20:46:20 2390 60 482 484 482 2880 2849 2867 68.9 3.98 84.4 1.27 ~ 26 18.3180 min Sobeys 4hrFLT - 31, 32 21:00:24 2391 60 482 484 482 2880 2849 2867 68.8 3.98 84.3 1.27 ~ 26 18.1205 min Sobeys 4hrFLT - 33, 34 21:15:17 2390 60.1 482 484 482 2880 2846 2864 68.8 3.98 84.2 1.26 ~ 26 17.9220 min Sobeys 4hrFLT - 35, 36 21:30:28 2392 60 482 484 482 2887 2851 2872 68.8 3.98 84.3 1.27 ~ 26 17.9235 min Sobeys 4hrFLT - 37, 38 21:45:29 2393 60.1 482 484 482 2882 2846 2868 68.8 3.98 84.3 1.27 ~ 26 17.8240 min Sobeys 4hrFLT - 39, 40 22:00:28 2391 60 482 484 482 2887 2852 2873 68.8 3.98 84.3 1.26 ~ 26 17.8255 min Sobeys 4hrFLT - 41, 42 22:15:10 2393 60.1 482 484 482 2883 2849 2870 69 3.98 84.4 1.25 ~ 26 17.9

10.4 Cycle Crank Testing NOTE: The Starting System consists of (4) x 12 Volt Batteries @ 1000 CCA (Cold Cranking Amps) 100% Battery Capacity = 24.0 Volts11-Oct-08 ( 2:12 pm to 2:15 pm ) 2 pairs of Batteries (each pair connected in series) are connected in parallel to provide 24 Volts to two Starter Motors 80% Battery Capacity = 19.2 Volts

Battery Voltage prior to Crank Cycle Test 26.368 Volts SEE Videos:1st 30 second crank ( battery voltage during cranking ) Cranked for 30 seconds ( Voltage ranged between 19 and 20 Volts ) Sobeys CCT - 001.AVI

Time following 1st crank when batteries reach 80% capacity 0.0 sec. after crank stop: 19.8 V or > 80%; 0.5 sec. after stop: 22.1 V; 1.0 sec. after stop: 24.3 VTime following 1st crank when batteries reach 100% capacity 0.6 seconds after crank stop

2nd 30 second crank ( battery voltage during cranking ) Cranked for 30 seconds ( Voltage ranged between 14.5 and 19.5 Volts ) Sobeys CCT - 002.AVITime following 2nd crank when batteries reach 80% capacity 0.0 sec. after crank stop: 19.3 V or > 80%; 0.5 sec. after stop: 19.3 V; 1.0 sec. after stop: 24.1 VTime following 2nd crank when batteries reach 100% capacity 0.75 seconds after crank stop

10.5 Safety & Shutdown demonstration

Table 1 Description Confirmed NOTES: SEE Photos:1 Overcrank NA Cranking is programmed to terminate at 360 rpm2 Low engine temperatures (i.e., too low for relaible start) Started genset; changed low engine temp setpoint; genset stopped Sobeys 10.5.2 - 01 to - 063 High engine temperature pre-alarm NA4 High engine temperature Started genset; changed high engine temp setpoint; genset stopped Sobeys 10.5.4 - 01 to - 066 Low lube oil pressure Started genset; changed lube oil pressure setpoint; genset stopped Sobeys 10.5.6 - 01 to - 067 Overspeed Started genset; changed overspeed setpoint; genset stopped Sobeys 10.5.7 - 01 to - 068 Low fuel gas pressure Disconnected wire from pressure transducer and recorded alarm Sobeys 10.5.8 - 01 9 Emergency electrical power supply system supplying load Sobeys 10.5.9 - 01 to -03

10 Control switch not in automatic position Photos of DIA.NE Control Panel (control switch in Manual & AUTO) Sobeys 10.5.10 - 01 to -0411 Low voltage in battery Adjusted Reostat inside Genset Mounted Control Panel Sobeys 10.5.11 - 01 to -0513 Contacts for local and remote common alarm Photos of Control Relays inside DIA.NE Control Panel Sobeys 10.5.13 - 01 to -0314 Audible alarm silencing switch NA19 Low coolant pressure Started genset; changed low coolant pressure setpoint; genset stopped Sobeys 10.5.19 - 01 to -0623 Underfrequency/underspeed Started genset; changed underfrequency setpoint; genset stopped Sobeys 10.5.23 - 01 to -0624 Overcurrent Run Mains Parallel; changed overcurrent setpoint; genset stopped Sobeys 10.5.24 - 01 to -0925 Undervoltage Started genset; changed undervoltage setpoint; genset stopped Sobeys 10.5.25 - 01 to -0526 Overvoltage Started genset; changed overvoltage setpoint; genset stopped Sobeys 10.5.26 - 01 to -0627 Main disconnect open Opened / Closed Mains Breaker; record DIA.NE status/alarms Sobeys 10.5.27 - 01 to -04

Witnessed by: Signature: Company / Position: Date:

1 Vito Mike Casola, P.Eng. POWER GENySYS / President Oct. 19, 2008

2 Harout Makdessian, P.Eng. DDACE Power Systems / Manager, Engineering Oct. 19, 2008

3 Mark Greenhill, P.Eng. DDACE Power Systems / Manager, Projects Oct. 19, 2008

Battery Charge Rate

Battery Charge Rate

Room Air Temp

Room Air TempDescription Time kW Output Frequency

Battery Charge Rate

Room Air Temp

Description Time kW Output Frequency Amperage Oil Temp Oil Pressure

Voltage

Oil Pressure

Jacket Temp.

Jacket Temp.

Cold Start Tests (Oct 18th)

Jacket Pressure

Oil Pressure

Jacket Temp.

Jacket PressureOil Temp

Jacket PressureVoltage Amperage Oil Temp

Cold Start Full Load Tests (Oct 14)

Voltage

Amperage

Description Time kW Output Frequency

CLICK to link evidence photos

218 Goulding Ave., North York, ON, M2R 2P5 T: 416.224.9339 C: 416.616.7507

18-Oct-08 12:23 to 13:20

18-Oct-08

Sobeys DC, Vaughan: GE Jenbacher JGC616 Emergency Generator

CSA-282-05 Testing: Section 10.2.2 - Cold Start Full Load Test (1 hour)

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CSA-282-05 Testing: Section 10.2.1 - Additional Cold Start Tests

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CSA-282-05 Testing: Section 10.3 - Full Load Test (4 hour)

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CSA-282-05 Testing: Section 10.5 Safety Shutdown & Alarms: Table 1 It.2

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CSA-282-05 Testing: Section 10.5 Safety Shutdown & Alarms: Table 1 It.8&9

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2390 kw natural gas emergency power...

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