(R2)Specifications_Generator_Set_0002.pdf

Specification for Engine-Generator Sets for

Elephant Butte Power Plant and Caballo Dam

BACKGROUND

The Elephant Butte Field Division (EBFD) is comprised of two sites, Elephant Butte Powerplant (EB) located at 4696 Hwy 51, Truth or Consequences, New Mexico and the Caballo Dam, (CAB) located at

Caballo Dam Rd, Caballo, New Mexico, 30 minutes south of Elephant Butte by vehicle, via I-25 S. EBFD has a need for two Emergency Backup Engine-Generators to replace existing equipment which provide station service to the Elephant Butte Powerplant and Caballo Dam during maintenance and emergency operations. Emergency conditions may result in unscheduled loss of station service power from nominal sources. The Bureau of Reclamation requires that Powerplant and Dam critical loads continue to receive power via secondary power sources (e.g., batteries and generators) and the ability for the operator to monitor generator conveniently for proper operation. (FIST 1-2, Appendix F, B. (7))

SCOPE

The contractor shall remove the existing generator at EB and provide two new Engine-Generator sets to include all installation labor, materials for installation, equipment, commissioning, training, and as-built drawings.

REQUIREMENT

The Contractor shall furnish and install two new Engine-Generator sets complete with accessories as specified below. Reclamation will only accept new generators. No re-manufactured generators or equipment shall be quoted.

EB POWER PLANT GENERATOR

Elephant Butte Power Plant (EB) is located at 4696 Hwy 51, Truth or Consequences, NM 87901.

The EB set shall be suitable for outdoor installation, including tan-colored weatherproof housing. The set shall be complete with engine, engine-cooling- system, propane fuel-storage system, exhaust-system, starting-system, main generator, and control equipment. Design and installation shall comply with NESC and NFPA 58 guidelines.

Generator must have ample and sufficient power and capacity to provide a continuous standby electric power output from the main generator and minimum standby rating of 240 kilowatts (0.8 power factor) at 240/120 volts, 3 phase, 60 hertz, 4,500 ft. above sea level (with propane derate).

The synchronous or rated speed of the set shall not exceed 1,800 revolutions per minute and comply with EPA emission standards.

The new EB Generator will be placed on existing concrete pad with a usable area measuring 14’ X 26‘, Length X Width (see figures 2 and 3).

The EB Generator shall be mounted on a common bedplate with vibration isolators, or equivalent rigid steel frame with vibration isolators.

EB Required Mechanical Components

1. Be a battery started type.

2. Develop sufficient horsepower to drive the Generator and Engine auxiliaries at 100-percent rated full-load output Amperes of the Generator and use not more than 80 percent of the maximum engine horsepower at rated speed.

3. Provide a minimum standby rating of 240 kilowatts (minimum power factor of 0.8) from the

Generator, after propane fuel derate.

4. Provide output of 3-phase, 240/120V, 60Hz.

5. Must have an exhaust system equipped with a residential noise level muffler which will minimize engine noise and carries exhaust gases away from the set, through the top of the external housing and shall maintain housing weatherproofing integrity, utilizing an exhaust rain cap, if necessary to prevent water intrusion.

6. Must have a coolant -jacket heater for cold-weather starting.

7. Generator shall run on a propane fuel system.

8. Provide a propane tank, valves, regulator, tubing, and connections for use of the EB Engine-

Generator utilizing propane as the fuel source.

9. The propane tank shall contain 24 hours of fuel capacity at full load.

10. Propane tank shall be double walled for proper containment rating.

11. The Contractor must provide first fill of propane to commission Generator Set.

EB Required Electrical Components

1. Generator must have an automatic-trip, main line circuit breaker with rating of at least 800 amps, installed in the circuit at the generator to provide for overcurrent and short circuit protection.

2. Generator shall have HMI to monitor operation of the Engine-Generator.

3. Generator must have voltmeter on with indication of the voltage presently being supplied to the station-service load.

4. Must have an ammeter on per phase to check the current presently being used by the station-service load.

5. Must have a frequency meter set to check the frequency being furnished by the Engine-

Generator.

6. Must have IEEE approved connectors connecting existing 3 phase cables and neutral cable to

Engine-Generator sets.

7. Must have Modbus TCP communication capability for future EBFD integration. Listing of all

Modbus points shall be provided at commissioning.

EB Nameplates

1. The Engine-Generator set shall have name plates showing the manufacturer's name, equipment type (such as model number or specification number), kW rating, voltage, frequency, serial number, date of manufacture, and other pertinent data.

2. The Original Equipment Manufacturers (OEM) part number, serial number or component original data plate/information shall not be removed, defaced, or obscured.

EB Information

1. Contractor shall provide warranty information and a manufacture spare parts list to include manufacture part numbers.

EB Additional Equipment

2. Contractor shall provide remote operation and monitoring equipment for EB Engine-Generator via Remote HMI from Powerplant Control Room via Ethernet. This will be installed by the

Government.

3. Contractor shall provide one spare each of all filters and drive-belts for EB Engine-Generator.

Additional Details of EB Concrete pad and connections.

Figure 1. Existing EB Generator Housing with 3-phase Connections disconnected from Generator (2 cables per phase) and 120VAC box for coolant jacket heater is shown.

Figures 2 & 3. EB Photos of existing Generator Set and Load Bank (north-facing and east-facing, respectively). The Load Bank is moveable, and the concrete pad area is outlined in red. The posts on the pad may be removed. The solar panel maintains battery charge on the current system and may be re-mounted as well, with the coordination of the COR.

CAB DAM GENERATOR

Caballo Dam Control Station is located on Caballo Dam Rd, Caballo, NM 87931.

The CAB generator set shall be suitable for outdoor installation, including tan-colored weatherproof housing. The set shall be complete with engine, engine-cooling-system components, fuel-system components, exhaust-system components, starting-system components, main generator, and control equipment. Design and installation shall comply with NESC and NFPA 58 guidelines.

The set shall have ample and sufficient power and capacity to provide a continuous standby electric power output from the main generator and minimum standby rating of 25 kW (0.8 power factor) at

240/120 volts, 3 SINGLE phase, 60 hertz, 4,300 ft. above sea level (with propane derate).

The synchronous or rated speed of the set shall not exceed 1,800 revolutions per minute and comply with EPA emissions standards.

The new generator will be placed on the existing pad which measure Length X Width (feet): 10’L X 8’ W.

The set, including engine and main generator, shall be mounted on a common bedplate with vibration isolators, or equivalent rigid steel frame with vibration isolators.

CAB Required Mechanical Components

1. Must be a battery started type.

2. Develop sufficient horsepower to drive the Generator and Engine auxiliaries at 100-percent rated full-load output Amperes of the Generator and use not more than 80 percent of the maximum engine horsepower at rated speed.

3. Provide minimum standby rating of 25 kilowatts (minimum power factor 0.8), after propane fuel derate.

4. Provide output of 3-SINGLE phase, 240/120V, 60Hz.

5. Must have an exhaust system equipped with a residential noise level muffler which will minimize engine noise and carry exhaust gases away from the set, through the top of the external housing and shall maintain housing weatherproofing integrity, utilizing an exhaust rain cap, if necessary, to prevent water intrusion.

6. Must have a coolant-jacket heater for cold-weather starting.

7. Shall supply all required connectors, required gas lines, and connect to existing propane fuel container (see Figure 5).

8. The Generator shall run on a propane fuel system.

9. The Contractor shall provide first fill of propane to commission Generator Set.

CAB Required Electrical Equipment

1. Generator shall have an automatic-trip, main line circuit breaker with rating of at least 800 amps, installed in the circuit at each generator to provide for overcurrent and short circuit protection.

2. Generator shall have HMI to monitor operation the of Engine-Generator.

3. Must have a voltmeter with indication of the voltage presently being supplied to the station-service load.

4. Must have ammeter per phase to check the current presently being used by the station-service load.

5. Must have a frequency meter to check the frequency being furnished by the Engine-Generator.

6. Must have Modbus TCP communication capability for future EBFD integration. Listing of all

Modbus points shall be provided at commissioning.

7. Must have IEEE approved connectors connecting 3 phase cables and neutral cable to Engine-

Generator sets. (See Figure 4 for existing connector reference photograph)

CAB Nameplates

1. The Engine-Generator set shall have name plates showing the manufacturer's name, equipment type (such as model number or specification number), kW rating, voltage, frequency, serial number, date of manufacture, and other pertinent data.

2. The Original Equipment Manufacturers (OEM) part number, serial number or component original data plate/information shall not be removed, defaced, or obscured.

CAB Information

1. Contractor shall provide warranty information on all equipment and a manufacture spare parts list to include manufacture part numbers.

CAB Additional Equipment

2. Shall provide Remote operation and monitoring Equipment for CAB Engine-Generator via

Remote HMI from Caballo Control Room via Ethernet. (Government will install)

3. Provide one spare each of all filters and drive-belts for each Engine-Generator set, EB and CAB, respectively.

Additional Details of CAB Connections & Equipment

Figure 4. Existing CAB connections to existing Generator. (CAB Generator will be removed by Government prior to contractor installation.)

Figure 5. Existing propane tank stamped “500 gal. water capacity.

Below Requirements Apply to both EB and CAB Generator Sets

Table 1. Required Submittals

Number Description Date Due

1 Schedule 14 days after award Combined showing each generator

Delivery and

Installation.

2 Drawing of Layout of Generator 14 days after award For Each Generator Set

3 Commissioning Plan 14 Days prior to installation

For Each Generator Set

4 Warranty 7 days after commissioning and acceptance

For Each Generator Set

5 Parts List 7 days after commissioning and acceptance

For Each Generator Set

6 As-builts 14 days after commissioning and acceptance.

For Each Generator Set

Full payment will not be made until all submittals are accepted and approved by COR.

ASBUILT DRAWINGS AND DATA

1. Provide Drawings of Engine-Generator set, including electrical and mechanical systems of as-built and installed systems within 14 days of installation and acceptance.

2. Electrical drawings shall illustrate all wiring terminations and the controls necessary to accomplish the integrated operation of the Engine-Generator set.

3. All keys and software access to allow the Bureau maintenance personnel to reprogram controllers and governor as needed, shall be provided.

4. A listing of all Modbus points shall be provided at commissioning.

REMOVAL AND INSTALLATION

1. Removal and Installation shall occur during non-irrigation season. The exact dates will be provided by Reclamation once irrigation season is determined, generally ending in October.

Installation and commissioning must be completed before February 2025.

Contractor shall submit schedule for delivery and installation as stated under “Required

Submittals Table” the Government will review, discuss, and approve schedule before the

Contractor comes on site.

2. The contractor shall be responsible to supply crane and operator to remove the EB Engine-

Generator set and to install both the EB and CAB Engine-Generator sets.

a. Crane contractor and operations must abide by Federal and State DOT, OSHA regulations.

b. The Contractor shall move the old EB generator set to the Elephant Butte Lower Yard at the direction of the COR. (Travel is within Reclamation property and less than 0.35 miles over pavement and gravel road.)

c. The Government will remove the existing CAB generator prior to Contractor installation.

3. The Contractor shall provide all equipment for removal and disconnecting of the housing/hardware, connections, and Engine-Generator set at EB.

a. The existing EB Generator Set is a Cummins 350 kW Standby Emergency AC Generator

i. CECO (Cummins Engine CO.) P.N. 3052031

ii. Model No. CC534C

iii. Serial No. 119601

4. The Contractor shall connect the new equipment to 3-phase Engine-Generator cables and supply any additional cabling, wiring, and connectors needed for the installation of the new

Generators. The existing 3 phase connection at EB is 500 MCM cable, (2 cables per phase) available at the concrete pad shown in figure 1. The existing wired connection at CAB is shown in figure 4.

5. The Contractor shall install and connect a 120VAC receptacle from the existing circuit for the new coolant jacket heater.

6. Shall position the Engine-Generator sets, housing doors, and controls so the operator has at least three feet (3 ft.) for access and egress to controls and maintenance items with housing door open.

7. The entire assembly of Engine-Generators and housings shall be bolted to the concrete pads.

8. Contractor will provide Reclamation with an estimated schedule 14 days after award of the supply and installation of Generator Sets. This will be reviewed, discussed, and approved by the

Contracting Officers Representative (COR). Once schedule is set any issues that affect the timeline will be communicated to COR.

COMMISSION & TESTING

1. The Contractor shall prepare (and submit with schedule, as described in Table 1) a step-by-step commissioning plan to test all control operations, protective devices, and integration, including:

i. Pre-Startup checks/tests & Report

1. Fitting, hose, and guard checks

2. Fluid Levels check.

3. Exhaust & emissions systems check.

4. Battery system testing

ii. Manual Engine-Generator Start-Up and Shut-Down Tests & Report – no load.

1. Startup operation (Locally at unit)

2. Emergency shut-down operation via emergency stop (Locally at unit)

iii. Operational Engine-Generator Tests & Reports

1. The commissioning plan shall include a minimum 2-hour test with load bank. The contractor may use the provided EBFD-supplied resistive load bank for EB Engine-Generator set load bank test.

i. (EBFD-supplied EB load bank details: Make: SIMPLX;

Model: Merlin-250 250kW @1PF, 240/480V, 3PH/3-wire, 60Hz)

2. The commissioning plan shall include a minimum 4-hour test with the real load.

3. Vibrational measurements

4. Performance Standard Tests

5. Protective Relay Calibration

iv. System “trip” functional tests

1. System self-protective tests including warnings and shutdown testing due to over-heat, low oil pressure, low coolant, short circuit, and emergency shutdown.

TRAINING

1. Training shall include a Question & Answer session, equipment walk-through, and hands-on training and should not take more than half a day.

2. Contractor shall provide reference material on the following:

a. How the system operates including information about programming, pre-check, startup, and shutdown procedures.

b. Operations, including fault protection modes, troubleshooting, recovery, and mitigations.

c. System maintenance requirements and recommendations on all serviceable fluids, filters, gaskets, and other associated parts.

d. Future installation and integration of Remote HMI.

3. EBFD will provide a conference room for the Question & Answer session.

4. The Contractor shall coordinate with the COR in scheduling the Question & Answer session, equipment walk-through, and hands-on training.

Site Conditions

Normal work hours are Monday through Thursday, except federal holidays, 7:30 a.m. to 4:00 p.m. If the

Contractor plans to work outside the regular schedule work hours, a request must be made to the COR for approval 72 hours in advance.

The Government has electricity at 120 VAC available for Contractors use. No charge will be made for power obtained from Government source. The Contractor is responsible to provide generators, transmission lines, and distributing power to points of use.

Non-potable water is available on-site at no charge to the contractor. The Contractor is responsible to provide any needed equipment to convey the water to needed site.

At EB, a running-water restroom is available 250 feet from the EB worksite. At CAB, a pit latrine is available 575 feet from CAB worksite. A running-water restroom is available 1 mile from CAB worksite.

The contractor shall be responsible for all clean up and for disposal of waste materials or rubbish from transportation and installation of the generator set. The disposal of waste materials and rubbish shall be in accordance with this paragraph and all applicable Federal, State, and local regulations, standards, codes, and laws. Also, the requirements contained in the Bureau’s “Reclamation Safety and Health

Standards” are applicable to clean up and to dispose waste materials and rubbish. If there is a conflict between the requirements contained in this paragraph, the Bureau’s “Reclamation Safety and Health

Standards”, and other Federal, State, or local regulations, standards, codes, and laws, the more stringent requirements shall prevail. (Contractor cannot dispose of waste in Reclamation dumpster.)

Any damage caused to the existing site or equipment to due to installation of the generators shall be repaired to existing condition. This includes roads, walls, fences, gates, nearby equipment.

SAFETY AND HEALTH

The Contractor shall take proper safety and health precautions to protect the workers, Government employees, the public and the property of others.

The Contractor shall comply with all federal, state, and local laws and standards as well as the Bureau of

Reclamation Manual Reclamation Safety and Health Standards (RSHS), 2009 edition, may be downloaded at http://www.usbr.gov/ssle/safety/RSHS/rshs.html.

REQUIRED QUOTE SUBMITTALS

The following information shall be included with offeror;

1. Description of the generator engine sets for each site to include sufficient detail to evaluate compliance with the stated specifications. Including any brochures and/or cut sheets to confirm the generator sets meet the needs of the requirement.

2. Contractor shall have a minimum of 5 years’ of experience installing generator sets. Please provide a minimum of three recent similar projects within the last 6 years. Projects shall include description of project to include size of the generator installed and use, company name, contact, and phone number.

3. Estimated schedule for supply and install after receipt of award.

4. Expressed Warranty generator sets and installation.

5. Contractor shall provide information on vendors that carry authorized parts and service to Truth or Consequences, NM.

This will be a best value buy considering technical capability, schedule, warranty, and price all factors being equal.

If the Contractor fails to include the above required information in their quote, the quote can be found nonresponsive and not be considered for award.

http://www.usbr.gov/ssle/safety/RSHS/rshs.html

Amendment 1

Engine-Generator Sets for Elephant Butte Power Plant and

Caballo Dam

1. Is the ISO container shown in your picture a temporary rental generator?

No, the large yellow/tan ISO container is unrelated dry storage for

Elephant Butte Power Plant, (ref. Figures 2 & 3 in the Specification).

2. Which side of the existing Cummins generators are the power cables on?

They are fed up from beneath the generator, through a vault in the concrete, on the far side of Figure 2, (left side of Figure 3).

3. The current generator batteries are charged with that solar system, not sure if they are charging directly or using an inverter to feed AC to a “normal” AC fed battery charger…we just need to clarify that standard battery chargers run on a normal AC circuit.

They are charging directly using a DC WindyNation P30L PWM solar charge controller, which may be reused by the contractor.

EB POWER PLANT

1. Is there a requirement to upgrade the location and installation of the new propane tank for compliance with the current codes?

The Contractor must comply with NESC and NFPA 58 (See Specification document, Section “CAB DAM GENERATOR”, paragraph 2).

NFPA 58, 6.4.1.3 provides minimum 10 ft. distance from buildings because it will be at least 25 ft away from other tanks. The allotted space for installation is also greater than 25 ft. from the nearest building.

2. Is an automatic transfer switch required? No

3. For items 2 through 5 under the "EB required Electrical components", typically, a switchboard line up would reflect the required information (ammeter, voltmeter, frequency meter). Please confirm if this is correct.

This statement is correct for items 3 through 5.

The HMI in item 2 must also be TCP communication capable (see item 7). Some manufacturers provide the data on an HMI digital readout screen. The method that the contractor decides to use to display the amps, volts, and frequency data AND provide the same data in TCP format should be an industry-accepted method.

4. Is there a load center that is energized from the generator to provide power to the jacket heater, battery charger?

No. The existing power source for the jacket heater is an existing 120VAC circuit. The existing power source for the battery charger is the solar panel. (Figure 3) and a DC Windy Nation P30L PWM solar charge controller, all three of which may be reused.

5. Does the scope of work involve reconnecting the load bank to the new generator?

The requirement is to include a minimum 2-hour test with a load bank. In the Specification document, Commission & Testing section, 1.iii.1, The Contractor may use the EBFD-supplied resistive load bank (which would require connecting it) or the Contractor can supply their own load bank for testing.

6. Please note, modifications to the propane gas line from the propane tank to the generator may be required.

Acknowledged

CABALLO DAM

1. Please confirm the generator is 240/120V 3 phase. Based on the photo, it appears to be 240/120V 1 phase generator (2 wires and ground).

The old CAB Engine Generator is single phase, and the Spec has been modified to reflect this.

2. Please note, modifications to the propane gas line from the propane tank to the generator may be required.

Acknowledged.

3. Please note, the existing tank may be replaced with a new one, depending upon the required input of the new generator.

If a new one is required due to run time requirement of the generator, then the Contractor should present their calculations and upon validation, the government will decide whether to approve a replacement or change/waive the CAB run time requirement.

4. Is there a requirement to ensure the installation and modification to the gas lines to the existing propane tank is compliant with the current codes?

Yes, thank you for asking. Specification document, Section “CAB DAM GENERATOR”, paragraph 2, states that, “Design and installation shall comply with NESC and NFPA 58 guidelines.”

5. Please refer to comment 1.c regarding the requirement of ammeter, voltmeter, and frequency meter as it applies to this generator.

This statement is correct for items 3 through 5.

The HMI in item 2 must also be TCP communication capable (see item 7). Some manufacturers provide the data on an HMI digital readout screen. The method that the contractor decides to use to display the amps, volts, and frequency data AND provide the same data in TCP format should be an industry-accepted method.

Contractor shall note any deviation, exception or additional costs outside the specification on their quote.