Architect of the Capitol Ford House Office Building H2-263 Second and “D” Streets, S.W. Washington, D.C. 20515
General Contractor: Consigli Construction Co. 1250 H Street, NW Suite 975
Washington, DC 20005
Cynergy performed a $4,385,829 contract with the Consigli Construction Company to renovate and upgrade the AOC Rayburn House Office Building Emergency Generator System.
Key features of the new system included: • Two 2000KW diesel 480V generators • 6000A paralleling switchgear with emergency feeders • 3200A and 2500A copper busways • Five 150A transfer switches • 225A by-pass transfer switch • Two 2000A switchboards • 3000A load bank cabinet • Remote monitoring panel for system • 325 gallon day tank for each generator
• 8000 gallon underground main tank • Exhaust silencers • New grounding system • Panelboards
• Lighting fixtures and misc. starters, safety switches, transformers and VFD’s • Monitoring systems • Fire alarm system
The facility had to remain operational 24/7 during construction. All service outages had to be limited to off hours, which were coordinated and preapproved by the owner. A detailed construction sequence was developed and preapproved before any outage could begin. Some new system components were installed prior to the removal and replacement of the generators; the new paralleling switchgear, and also the load bank (connected to the switchgear). The new system at large all had to be commissioned and placed into operation prior to the transfer of existing circuits from the old to new system. Logistics of the project were difficult at best. The building’s occupants serve Congress and other government operations so no noise could be made during normal business hours. The new generator room was located on the basement level and the existing generator room was two floors above; some 800 feet away. The new generators weighed 40,000 pounds; a large crane was used to make the lifts, and Cynergy’s team of master riggers performed all the rigging operations. Before the generators could be placed into the room, an existing space had to be retrofitted with new exhaust and intake ventilation systems, sound attenuated panels, CMU walls, new roll-up door, passageway door, etc. Much of this work was performed by the general contractor. The new generators had unit mounted radiators, so new fans and dampers were installed, and discharge duct work, used for cooling, was equipped with vibration isolation. New fuel piping was installed for supply, return, normal and emergency vents, and the fueling system included monitoring. Miscellaneous installation items included concrete housekeeping pads, grounding systems, framing supports for mechanical piping, structural steel to support the new busways, control circuits, painting walls and epoxy coating the floor, and more. Commissioning, including operational demonstration of all systems and field testing, were a large component in the project. A third party conducted all NETA required testing on equipment, ground systems and cables. Factory field servicing was provided for the switchgear, generators, transfer switches and control systems. Hands on training and operation and maintenance manuals were provided for all operational systems. Other items provided by Cynergy included an arc flash, short circuit & coordination study. Construction scheduling, quality control, safety and security were important elements of the entire project. Cynergy used Procore™ project management software to help manage the project.