J.2.1 Statement of Work_V2.pdf

SENSITIVE BUT UNCLASSIFIED

SBU - CONTRACTING AND ACQUISITIONS

U.S. Department of State Bureau of Overseas Buildings Operations Office of Facilities Management

FACILITIES MANAGEMENT DIVISION

OBO/OPS/FAC/PS - CFSP

STATEMENT OF WORK

ASSET PROCUREMENT AND LOGISTIC SERVICES

Baghdad Diplomatic Support Center Procurement of Replacement 50Hz Power Plant Medium Voltage Generators and Site Delivery

U.S. Embassy, Baghdad, Iraq

June 18, 2024

STATEMENT OF WORK

ORIGINAL RECORD

1.0 INTRODUCTION

1.1 The U.S. Embassy, Baghdad, Iraq, Diplomatic Support Center (BDSC) in coordination with Overseas Buildings Operations (OBO) requires equipment procurement and logistic services to acquire and deliver to site replacement medium voltage metal enclosed/packaged generator systems. A total of nine (9) each packaged and enclosed systems are required for this action. This requirement also includes all logistic and coordination services required to deliver the systems to site. Upon delivery and receipt at site, the US Government will take possession of the equipment and store it on compound.

The contractor shall include with their proposal a separate cost identified as an option for dealer start up and commissioning services that may be considered with future installation activities undertaken by the US Government. This scope of work and activity DOES NOT include any construction services or requirements.

1.1.1 This activity includes contractor services to purchase replacement equipment, execute, manage, and oversee scheduling and production activities, provide manufacturer submittal and shop drawing details, equipment assembly and fabrication drawings and details, O&M equipment servicing and install manuals, test reports and summaries, equipment replacement part and supply manuals, during fabrication and production provide progress updates and scheduling services and coordinate and execute all logistic activities required to deliver the equipment to site. This shall include all customs and local freight forwarder activities, coordination with Post and host country authorities, and freight movements. All shipments shall be arranged and booked door to door. All shipments shall be completed via unsecure commercially available means without transit security restrictions.

1.1.2 The Contractor shall furnish all equipment and services necessary to manage, plan, and implement all requirements for material, procurement, shipping and supervisory oversight necessary to execute and successfully complete this activity in accordance with any ordering documents, specifications and instructions. This scope of work also includes logistics services and all associated procurement activity management functions.

1.1.3 There will be no government furnished equipment or property.

1.2 All deliverables generated under this contract shall be marked appropriately and correctly for security classification by the contractor as part of this contract. The contractor is advised that all services provided and deliverables to the US Government shall be made in accordance with the terms and conditions of the RFP and the resultant contract, inclusive of the July 2018 Diplomatic Security, Security Classification Guide.

1.3 All equipment furnished by the contractor shall be designed, built, fabricated or assembled at a site, city and country that is accessible to the US Government inspection personnel, including COR, CO and other designated staff that may be engaged with quality assurance or control activities. US Government access to contractor facilities and locations shall be made without undue host country visa or security restrictions.

Equipment and components manufactured within the continental United States shall be disclosed within the contractor proposal, including factory/head quarters addresses. The contractor shall also disclose within their proposal and the contractor furnished submittal documentation the names and addresses of foreign suppliers of major components that will make up the new generator systems. This shall include but not be limited to the diesel engines, medium voltage alternators and medium voltage switchgear and circuit breaker components.

All testing and commissioning activities, including individual components and fully assembled system level and completed assembly testing and commission shall be executed at a site accessible to US Government representatives and all testing and commissioning facilities shall be disclosed by the contractor within their proposal in response to the CO RFP and included within submittal documents.

2.0 ACTIVITY OBJECTIVES

2.1. The intent of this activity is to procure and deliver to site replacement 50Hz power plant metal enclosed diesel driven medium voltage generator systems. The diesel generator specification, climate/environmental data and weather rated, drop over enclosure details and system features are included within this statement of work. This information is presented as attachments and/or within this document. This information shall serve for informational purposes to describe the equipment details and requirements. All equipment and systems furnished for this activity shall be designed, configured, capable of meeting a twenty (20) year minimum sustained life expectancy under all physical, electrical and environmental conditions, as defined by manufacturer requirements and design, along with manufacturer specifications and applied equipment consensus standards. Additional performance requirements and standards are included within this scope of work.

3.0 SCOPE OF WORK

3.1 The contractor shall furnish a technical and cost proposal to purchase and delivery to U.S.

Embassy, Baghdad, Iraq, Baghdad Diplomatic Support Center (BDSC), nine (9) each metal enclosed weather rated and protected diesel driven generator sets. This scope of work includes equipment details and contract requirements.

3.2 The contractor shall procure and furnish fully functional and complete generator systems with weather rated drop over type enclosures. All equipment furnished and utilized to fabricate, produce, or otherwise assemble the final products shall be new parts, and components. The use of rebuilt, refurbished, recycled, “new old stock”, or used parts, equipment or systems is not authorized. The contractor shall document complete system functionality after completion of all fabrications and assembly line production.

Commissioning and testing shall be documented via manufacturer test reports, quality control documentation and certification documentation attesting to fully functional equipment meeting or exceeding all performance requirements and specifications.

3.3 All new generators and enclosures shall be fabricated and manufactured furnished as suitable for use with the applied environmental conditions per the attachment and this scope of work. Additionally, the new diesel engines and alternators shall be procured via sources that can provide local operations and maintenance and repairs services, including providing spare, repair and maintenance parts and supplies, fluids, etc. that are factory approved for use with O&M and repair related services, as available in Iraq. Additionally, the diesel engines and all fuel system components, hardware, etc. shall be furnished and compatible with the diesel fuel available from local fuel suppliers, including suitable and verified for use with high sulfur content #2 diesel fuel oil.

3.3.1 Each new generator system shall be rated and designed in accordance with ISO 8528 and per manufacturer ratings. Each generator system shall be rated as prime running power/prime power. With unlimited hours of usage for varying load conditions. Average variable load factor shall be 70% of the prime power rating with 10% overload available but limited to 1 in 12 hours and not to exceed 25 hours per year. The 10% overload shall be in accordance with ISO 3046-1. To ensure maximum life expectancy and mean time to overhaul, the new generator systems shall be capable and permissible to provide an average power output over a 24-hour operational period not to exceed 70% of the prime power rating.

3.4 Each enclosed diesel generator systems shall be factory assembled and furnished with a full functional and integral air filtering and ventilation system and associated controls, designed and applied so that exposure to weather will not interfere or prohibit successful or full function of the ventilation system or the internal components and parts that make up the generator system an power distribution/control and protection systems, on board fuel pumping and controls, starting battery and charger, critical grade exhaust silencer, exhaust silencer and piping and exhaust pipe system insulating jackets and supporting hardware, local and remote control, annunciation and metering packages, medium voltage output circuit breaker, protective relaying systems and paralleling capabilities and station service power to operate lighting and controls, including enclosure ventilation dampers, central heaters, equipment (including medium voltage alternator) space/condensation heaters, block heaters, fuel pumps, interior lighting, door controls, etc.. Additionally, each generator system shall include a diesel engine OM filter minding and condition monitoring system with on board diagnostic capabilities and a complete manufacturer furnished and designed engine and alternator control module and operator console.

1.4.1 Each generator system shall include a factory designed and assembled enclosure incorporating removable panel sections to facilitate any equipment servicing, repair or replacement activities. Each panel shall be fastened to the structural enclosure framing using grade 5 hardware and fasteners. Each panel shall be factory designed with applied weather resistant gasketing and sealing surfaces to prevent airborne dust and rainwater infiltration. All gasketing material shall be UV protected/resistant and field replaceable.

Each panel shall include self-supporting features to allow placement and hardware installation. All panels shall incorporate lifting handles and tie off hooks for rigging placement. All panels shall be finished and protected with exterior and interior finishes as specified within the scope of work and specifications. Enclosure panels exposed to the interior shall be white or light gray (ANSI 61) and all exterior panels, and frames or other enclosure parts exposed at the exterior shall be colored light tan. The contractor submittal documents shall include color samples for Government approval. The completed enclosure system shall be devoid of all manufacturer markings or emblems except for OSHA required caution and warning signage or labels for operations and servicing instructions and nameplate data.

1.4.2 All enclosure panels shall integrate and be design and constructed for acoustical noise control with an assembled dba rating coordinated with the engine/generator design. The enclosure system shall be UL220 listed and approved. All enclosure panels and seals shall be designed and constructed/protected as a waterproof assembly so that exposure to weather will not interfere with successful or functional capabilities of the complete generator system, including output/power distribution and control and ventilation systems. The completed enclosure assembly shall be designed and rated for a continuous applied wind speed of 150mph.

1.4.3 The contractor shall design the equipment enclosure system taking into consideration freight handling and shipment requirements or constraints on shipment/packaging volume, weight and dimensions, coordinated with shipment means and modes, including any surface or air carrier equipment provisions. If it is determined by the contractor that enclosure and equipment systems will require field reassembly, those instructions and requirements shall be documented within the contractor submittal packages, identifying the provisions and requirements for disassembly/freight handling purposes and field reassembly. All shipments shall be packaged, braced, and otherwise protected from handling damages and to prevent interior or content damages due to rough handling.

Each generator system must be cable of being transported by truck or by aircraft. It can be assumed that meeting the aircraft requirements will also satisfy the ground transport requirements.

The generator system and all components installed in the enclosure or enclosure sections shall be designed to be restrained under the following aircraft loading conditions:

Horizontal (Fore and Aft) 3.0G Horizontal (Lateral) 1.5G Vertical (down) 4.5G Vertical (up) 2.0G

The generator system shall withstand these loadings without loss of deployed serviceability. The above loadings are to be applied independently and coordinated with aircraft and freight handler/owner requirements.

Each generator or system section must be capable of being placed on standard cargo pallets. Specific cargo pallets, additional bracing or supports required for aircraft ground handling requirements shall be included within the contractor fabrication and design details.

Each generator frame, system and enclosure, including any disassembled sections must have top and bottom corner tie down points to facilitate securing them in a aircraft using the specific aircraft loading and cargo securing systems.

The generator enclosure or enclosure sections must be vented to allow for potential cargo bay rapid decompression: 8.3 psig in 0.5 seconds. Decompression is to be considered a low risk event and therefore the survivability of the shelter is to be only dealt with as a safety concern (i.e. the generator does not need to remain operational).

The generator enclosure shall have a permanent data plate installed indicating the weight, CG and any lifting and or tie down restrictions.

A Certification Plan shall be provided verifying each generator system is capable of meeting the transportability requirements.

1.4.4 The enclosure panels shall be designed and applied with openings or access panels for exterior oil and coolant drain points with valves located on the interior side of the enclosure.

3.5 Product and Equipment Submittals

Submittals for approval shall include the following. Submittals shall be provided, bound and presented, hardcopy, five (5) each with electronic media and files for all submittal documents. All electronic media files shall be MS Office and AutoCad along with Adobe pdf files for all submittals. Media shall include three (3) each read/writable DVD disks. All electronic media and information provided shall be accessible from the removable media devices without use of proprietary read/write software. All submittal data and information shall be “open source”.

o Manufacturer shop/assembly/fabrication drawings and enclosure fabrication and steel joinery details, including interior acoustic controls/panels, steel members and sheet metal, exterior sheet metal, sealing and waterproofing, doors and frames, ventilation louvers, wall, roof and base/flooring support framing, anchorage and lifting points.

o Generator and alternator elevations and plan drawings, elementary and control wiring, schematics, harness and connector layouts and placements, connector pin out and wiring terminal drawings.

o All manufacturer equipment wiring diagrams shall also clearly identify all field or customer furnished wiring and termination points.

o Enclosure finishes and corrosion protection, including type, color, application instructions, coating standards.

o Exterior and interior equipment plan and elevation drawings with shipping splits identified and estimated weights. Include interior equipment layout plan and elevation views, clearances for OM activities, access points.

o Outline drawings showing conduit entry areas and enclosure anchoring information, including seismic constraints.

o Elementary and control wiring diagrams, including engine harness and engine control console and system management diagrams. Include physical wiring layouts, connector locations and identifications and connector pinout diagrams.

o Single line diagram.

o Sequence of operation. Include relay setup and setting instructions, circuit breaker removal and replacement, paralleling control setup and modification, including automatic and manual functions, ventilation controls, including automatic and manual override for louver operators and linkage.

o Interior equipment layouts/placement/elevations/plan views, routing and penetrations, fire protection details including sealing, fire alarm and annunciation details, shop drawings, fabrication and assembly diagrams and complete bill of material listing items by manufacturer’s name, part number and description for all components, parts and assemblies that make up the complete metal enclosed generator system, include engine, generator, conduit and wiring, conduit fittings, circuit breakers, generator auxiliary components, protective relaying systems and modules, OM filter monitoring system, ventilation and air filtration systems and components, including louvers, filters, filter media, fans and all associated controls, system monitoring and control hardware and interface modules/control station.

o Complete nameplate and status annunciator panel schedule.

o Manufacturer catalog and technical literature for major components, e.g.

generator, alternator, main output circuit breaker, protective relaying system, regulator.

Operation and maintenance manuals shall contain:

o Complete Set of Drawings, final/production and fabrication/assembly submittal physical and wiring diagrams, enclosure fabrication and assembly details.

o Detailed Interconnect spreadsheet with wiring diagrams o Complete Bills of Material and parts manuals.

o Installation and maintenance instruction Manuals for Major Components including circuit breakers and protective relays/control modules, generator engine and alternator, generator system wiring diagrams and connector location and pin call out diagrams, generator control panel, governor and paralleling controls, mechanical and air filtration systems, etc. including programming, troubleshooting, repair, setup, and operation instructions. Spare part manuals for generator engine and alternator and governor assembly shall also be furnished.

o O&M manuals shall be provided in electronic format, Adobe pdf, and hard copy, 5 sets, for final submission, three sets plus 2 electronic pdf file submission for pre-production technical review.

3.6 Generator Set, Output Circuit Breaker and Medium Voltage Switchgear, Protective

Relaying and Paralleling/Synchronization

Circuit breaker shall be draw out type. Circuit breakers shall be designed, manufactured, and tested in accordance with ANSI C37.06 and NEMA SG4. Circuit breakers shall be designed and manufactured with vacuum type interrupters.

The output switchgear shall include for each breaker cubicle cell, movable terminal shutters that isolate live terminal upon disconnection and removal of the breaker from its cubicle position. The switchgear shall include a movable overhead gantry crane designed to lift breakers freely from the finished floor elevation and place them onto draw out cubicle racks. Additionally, the switchgear shall include a breaker lift truck configured to lift and place circuit breakers into position without the use of an overhead gantry.

The switchgear assembly shall be a NEMA 1 design, indoor type, with hinged cubicle doors with latching/hold open provisions and thumb screw and lockable door hardware.

The switchgear assembly shall be metalclad, designed and furnished in accordance with the following:

ANSI/IEEE C37.20.2 - Standard for Metal-Clad and Station-Type Cubicle Switchgear.

ANSI/IEEE C37.04 and .06 - Standard ratings and preferred ratings for Outdoor AC Medium-Voltage Circuit Breakers.

ANSI/IEEE C37.11 - Requirements for electrical control for AC High-Voltage Circuit Breakers rated on a symmetrical current basis or a total current basis.

ANSI/IEEE C37.09 - Standard Design and Production Testing

ANSI Z55.1 - Gray Finishes for Industrial Apparatus and Equipment.

ANSI/IEEE C57.13 - Requirements for Instrument Transformers.

NEMA SG4 - Alternating Current High Voltage Circuit Breakers.

The switchgear and circuit breakers shall be rated for an ambient temperature range of –

30 degrees to +40 degrees Celsius.

The switchgear and circuit breakers shall be tested for the highest IBC-2021 seismic standard as described by ANSI/IEEE 693-1984.

The switchgear and circuit breakers shall be rated to withstand a wind load of 90 mph imposed upon the structure supporting the terminal connection per ANSI C37.04 Section 6.2.

The switchgear and circuit breakers shall be rated for use at altitudes up to 3300 ft. above sea level per ANSI C37.04 Section 4.2.2. For altitudes over 3300 ft., the rated dielectric strength and rated maximum voltage and current shall be multiplied by altitude correction factors to obtain values at which applications may be made.

The switchgear shall be metal-clad switchgear with dead front design and shall consist of an enclosure containing circuit breaker(s), components and wiring, all factory assembled (except for necessary shipping splits) and operationally checked as an integrated switchgear and controls assembly. The assembly shall be self-supporting, and floor mounted on a level surface. The integrated switchgear assembly shall withstand the effects of closing, carrying and interrupting currents up to the assigned maximum short circuit rating.

The switchgear enclosure assembly shall include a lightning protection system furnished and installed by the contractor and integrated with the generator output and electrical grounding and bonding systems. The lightning protection system shall be detailed and depicted as part of the project design and included with any manufacturer shop drawings, including connection, splicing, and terminating requirements for any switchgear modules or shipment splits.

The contractor shall furnish switchgear spare parts to include rebuild kits for each type of power circuit breaker furnished and installed. One (1) spare power circuit breaker shall be furnished as well, for each style and rating of power breaker furnished and installed.

Other spare parts shall also include PLC control boards, power and control fuses, indicating lamps and sockets, control switch handles and operations and maintenance supplies, including spare circuit breaker contacts, operating and cell switches, operating handles, cleaners and lubricants/greases and oils. Additionally, for any key operated lockout devices or interlocks, 4 sets of spare keys shall be provided for each lock. Key fobs shall also be provided identifying key identifier and use purpose. All spare parts and key shall be turned over to the Post facility manager. If during the course of equipment/system installation, testing, commissioning, troubleshooting, etc., spare parts are utilized to correct a found problem, the contractor shall replenish the spare part stock at no additional cost. All spare parts and kits shall be full and complete at the time of project completion and equipment being placed into service.

Switchgear Details:

Maximum Design Voltage: 15.0 kV.

Impulse Withstand (Basic Impulse Level): 95 kV.

Power Frequency Withstand: 36kV, 1 minute test.

Main Bus Ampacity: 3,000 amps, continuous and confirmed per contractor calculated design requirements including total future city power input capacity and calculated with maximum generator plant output when operating generators in a continuous mode.

Momentary Current Ratings: Equal to the circuit breaker close and latch rating.

Circuit Breaker Interrupt Rating: 50 KAIC and as confirmed per design requirements.

Surge Arrestors shall be distribution class and provided as shown on contract drawings.

Switchgear Enclosure General Requirements

Structure. The enclosure shall be free-standing, and floor supported, with front and rear access.

An adequate number of anchor bolt holes shall be designed to place the base in direct contact with the foundation when bolted. The flatness of the floor surface upon which the equipment is installed shall deviate no more than 0.125 inches per 10 feet in any direction. All doors shall be formed of 11-gauge steel. The support frame and structure shall include integral leveling capabilities design to support the completed switchgear assembly including all equipment and operator personnel loads.

All steel parts, except galvanized (if used), shall be cleaned and a zinc-phosphate (outdoor equipment) or iron phosphate (indoor equipment) pre-treatment applied prior to paint application.

Paint shall be determined at the pre-award/bid site visit. All painting, regardless of color, shall meet ANSI and applicable ASTM requirements for polyester powder, applied electrostatically through air.

Following paint application, parts shall be baked to produce a hard, durable finish. The average thickness of the paint film shall be 2.0 mils. Paint film shall be uniform in color and free from blisters, sags, flaking and peeling.

Adequacy of paint finish to inhibit the buildup of rust on ferrous metal materials shall be tested and evaluated per paragraphs 5.2.8.1-7 of ANSI C37.20.2-1987. Salt spray withstand tests in accordance with ASTM #D-1654 and #B-117 shall be performed on a periodic basis to provide conformance with the corrosion resistance standard of at least 2500 hours minimum (outdoor equipment) or 600 hours minimum (indoor equipment).

Bus. The main bus is to be rated 3,000 amps and as per calculated per factory contractor design effort and be fully insulated for its entire length with an epoxy coating. The conductors shall be tin plated copper and be of a bolted design. Access to this compartment is gained from the front or rear of the structure by removing a steel barrier. Provide standard provisions for future extension, as applicable. Lugs shall be provided per cable schedule and shall be compression type.

Wiring. AC voltage sensing wiring shall be SIS #14 AWG. CT wiring shall be SIS #12 AWG.

All DC control wiring shall be a minimum of #18 SIS AWG. Current transformer circuit terminations shall be ring tongue type and include shorting terminal blocks.

Control wires shall be numbered every eight (8) inches or less and visible next to the terminals.

Also, the wiring shall be permanently marked with wire termination designations. These designations shall include the device and connection point where the wire is terminated. All control wire markings shall be printed directly on the wire insulation and be permanent. Low level signal circuits shall be separated and provided with shielded wire to minimize electromagnetic interference. Shielded wire shall be grounded at one point. Ethernet cabling shall be unshielded category 5 or higher.

Wiring between each section shall not be spliced and shall be free of abrasions and tool marks.

Connections between cubicles shall use labeled connection plugs. Wires shall be placed in wire duct or harnessed and shall be supported to prevent sagging or breakage from weight or vibration. Inter-cubicle wiring harnesses shall be contained in overhead steel wire troughs.

Communication cables and current transformer circuits shall be hard wired.

All wiring to hinged doors, except communication and current transformer circuits, shall be run through door terminal blocks or connection plugs. Terminal blocks shall be provided for all external connections and placed in an accessible area not exposed to hazardous bus or cables, if possible. Current transformer circuits shall be connected through shorting terminal blocks.

All wiring and terminal markings, numbering and designations shall correspond to elementary and point to point control wiring diagrams and schematics, as furnished with the equipment submittals.

Nameplates. Engraved laminated plastic nameplates, having white letters on black background, shall identify major components, vertical sections, and circuit breakers. Nameplates shall mimic single line diagram notation and naming conventions. Nameplates shall be attached with self-tapping screws. Additionally, a mimic single line bus diagram shall be embossed onto the switchgear exterior cubicle doors and enclosure panels.

Components

Metering Instrumentation. Analog metering instrumentation consisting of industrial switchboard type meters, 4-1/2" square, 1% accuracy. Current and potential transformer ratios shall be selected and coordinated for nominal and rated values for ammeters, voltmeters, and kW meters.

Instrument Switches. Instrument switches shall be of the rotary type. Each switch shall be supplied with a titled escutcheon plate, suitably marked for each position. The switches shall have positive means of maintaining contact, which shall be silver to silver with a wiping action.

Current Transformers. Current transformers shall be furnished with VA burden and relay class ratings suitable to supply the metering and protective devices without affecting accuracy.

Potential Transformers. Two (2) open-delta connected draw-out potential transformers shall be provided in turns ratio and VA burden rating to be compatible with the controls and voltage sensing as applied. Transformers shall have integrally mounted primary and secondary fuses.

Alarm and Status Indication. Visual and audible alarm and status indication lights, including spares, shall be furnished as indicated by customer. Visual alarms shall be reset only after the fault condition has been corrected. The audible alarm shall include a silencing circuit which after activation shall permit audible annunciation of subsequent failures. Lamp test shall be an integral feature of this indicator. Each illuminated indicator tile shall be 24 mm x 24 mm.

Control Fuses. Fuses shall be mounted in locations where they are readily accessible. Pull-out type fuses shall be provided for all primary circuits and shall be of the current limiting type.

Protective Relays. Door mounted protective relays shall be utility grade with semi-flush mounting. They shall have standard built-in test features and targets.

Electromagnetic and PLC Control Relays Including Paralleling/Synchronization System

All control relays and synchronization system shall be suitable and adequately rated for their intended service in the control system. All relays and synchronization for control circuit duty shall be plug-in type with retaining clips and transparent plastic covers. Relays shall be clearly marked for control voltage. When possible, all relays shall have light-emitting diodes to indicate that the coil is energized. Separate lockout relays shall be provided.

Contractor design shall specify relay requirements, types, configurations and include itemized/tabulated settings for all protective, control and lockout relays, PLC and mechanical based. This shall also include setup and setting for the arc flash reduction relay and system.

Relays as required shall include synchronization, over current, voltage and as required generator and generator feeder protective relaying at the new switchgear.

Protective relaying system shall also be included for future utility input feeder cubicles and power transfer systems between future utility and paralleled generator buses.

Switchgear cubicle sections designated for specific purposes for future or spare use, shall also be furnished and installed with relaying and control systems so that they can be utilized in the event of an emergency or future connectivity requirement.

Circuit Breakers

All circuit breakers controls shall monitor the trip coil status and control voltage (close/trip).

Controls shall prevent closing circuit breakers when the trip voltage is not available.

All circuit breakers shall include 2 each trip/close coils operable at 220VAC/50Hz single phase station service AC voltage.

Furnish circuit breakers with one vacuum interrupter per phase. Breakers of same type and rating shall be completely interchangeable. The circuit breaker shall be operated by means of a stored energy mechanism which is normally charged by a universal motor but can also be charged by the manual handle supplied on each breaker for manual emergency closing or testing. The closing speed of the moving contacts is to be independent of both the control voltage and the operator. Provide a full front shield on the breaker. A minimum of 6 auxiliary contacts and 5 MOC and 5 TOC type contacts, shall be provided for external use. The racking mechanism to move the breaker between positions shall be operable with the front door closed and position indication shall be visible with door closed.

An interlocking system shall be provided to prevent racking a closed-circuit breaker to or from any position. An additional interlock shall automatically discharge the stored-energy operating mechanism springs upon removal of the breaker out of the compartment.

A Circuit Breaker Trip Switch shall be provided with open/closed/tripped indicating LEDs.

Refer to other scope sections for circuit breaker requirements.

Protective Relaying and Monitoring

Protection functions shall be included at a minimum and per factory design requirements.

Additionally, all generator and switchgear relaying and controls shall be coordinated with an integrated for all operations and functionality with generator synchronization, protective relaying, and engine/generator control systems. Multifunction/PLC relays shall be configurable to allow disabling of features and protective capabilities/function. Multifunction relays are acceptable for use.

Instantaneous overcurrent (50) Instantaneous and definite time overcurrent for ground (50/51GN) AC Inverse Time Overcurrent (51) Negative sequence overcurrent (46) Phase differential (87G) with a dedicated set of CT’s , generator (87) Differential protective relay Over and under voltage (59/27) Reverse power for anti-motoring (32) Voltage restrained phase overcurrent (51V) Voltage phase reversal (47) Over and under frequency (81) Synchronizing relay (25) Field relay, over/under excitation (40)

Current and Voltage Test blocks shall be provided to facilitate testing of the relay. A separate Lockout Relay (Device 86) shall be provided for each protective relay. In conjunction with the generator differential (87G) protection above, which includes dedicated CT’s in the switchgear as noted, another set of matching CT’s shall be shipped loose with the switchgear to install on the generator for connection to the protective relay.

Power Management Applications

Master controls applications shall include Load Bus Optimization and Generator Load Demand.

Generator manufacturer electronic control panel shall also be furnished and configured and setup to interface engine control module and electrical controls and metering.

Load Bus Optimization shall control up to 128 individually prioritized and separately controlled distribution loads via power transfer switches and/or electrically operated circuit breakers. Loads shall be added or removed from the bus according to the available headroom on the bus.

Generator Load Demand shall control up to 32 individually prioritized and separately controlled engine-generator sets. Engine-generator sets shall be added or removed from the bus according to dynamic measurements of power consumption and engine-generator efficiency set-points.

Main bus monitoring shall include a discrete Bus Under/Overvoltage Relay, a discrete Bus Under/Over-Frequency Relay and a Main Bus Power Watt Transducer.

Metering and monitoring network devices and design standards shall include IEC 62443-3, NERC CIP and IEEE 1613, providing a secure network with security management. Encrypted connections and configuration files shall provide data confidentiality with connection verification required for access. Simple general-purpose security for industrial applications shall include IEC 62443-4-2 Level 1 and Level 2 for medium and high security options. The controls network shall remain isolated.

Security features shall include definition of at least three distinct security levels (monitor, control, manage) and a unique user name and password for each individual. Each individual account shall also be assigned to a security level thereby defining the scope of their access and control. Logging into or out of the system shall be an event entered into the alarm history. Each operator-triggered alarm shall be logged as an alarm history entry with the operator identity included. If an individual is logged in to the system with no activity for 30 minutes, the individual shall be automatically logged out.

All HMI and LCD screens shall include security lockout provisions to prevent unauthorized access to control and operational functions or adjustment to protective relaying and metering set points or active/passive control of generator set operations and output circuit breaker position.

All HMI or LCD type screens shall be designed and applied with dust tight and weatherproof seals and anti-scratch surface protection. All HMI and associated screens and enclosures shall be IP67 minimum rated.

Synchronizing and Paralleling

The contractor shall refer to the attached specification, 26 23 13, dated 10 March 2024 for details and requirements concerning each generator synchronizing and paralleling system. This specification shall be used along with other specifications, statement of work or contract documents, manufacturer submittals, fabrication and shop drawings.

Arc Flash Reduction/Maintenance System

The new generator and switchgear systems shall include arc flash reduction relaying and control systems for all generator medium voltage sections. This shall include reduction application at generator output and at MV output circuit breaker cubicle, metering section and output cable terminals.

The manufacturer shall furnish and install a complete arc flash reduction system that is fully compatible with the assembled and complete generator and switchgear system. All control switches and relaying adjustment capabilities shall be installed to prevent unauthorized adjustment or operation of the systems.

Arc Flash, Shock Hazard and High Voltage Warning and Labeling

The contractor shall furnish warning signage and notice that specify arc flash levels, safety distance and required PPE. Labeling shall be furnished in accordance with NFPA 70, 2020 version, NFPA 70E – 2021. Labels and marking shall meet these requirements and ANSI/NEMA Z535.4-2011. All labeling shall meet these requirements and be suitable for continuous service exposed to the environment in which they are applied to.

Labeling shall be posted/installed at ALL generator main entrance, generator enclosure maintenance doors and access hatches, switchgear and instrument transformer and control enclosure doors and at each cubicle that makes up the switchgear lineup. Labels shall be applied such that they are easily and readily viewable from the finished elevation of the switchgear enclosure flooring, at a height range of 4’-0” to 6’-0”.

All arc flash labeling shall be written in the English language.

Arc flash labeling shall contain the following minimum information:

1. Available incident energy level (cal/mm2) and corresponding working distance.

2. Minimum arc rating of clothing/PPE. Arc rating shall be appropriate for the hazard energy level present.

3. Nominal system voltage

4. Equipment identification/number

5. Arc flash boundaries, including limited, restricted, and prohibited boundaries.

6. Arc flash study date

High voltage warning and danger sings shall be applied to all exterior switchgear doors and equipment/cabling access compartment doors. Signs shall be designed and applied to meet OSHA and ANSI Z535.4-2011 requirements and NFPA 70 and 70E requirements.

Manufacturer applied arc flash, high voltage and shock hard warning signs and tags shall be applied to all switchgear cubicle doors, including circuit breaker, relaying and wiring, stations service, instrument transformer and G&T cubicles. Signs shall be design and applied to meet OSHA and ANSI Z535.4-2011 requirements and NFPA 70 and 70E requirements.

Circuit Breaker and Switchgear Accessories

Two (2) each portable circuit breaker lifting devices shall be provided for circuit breaker removal if interior lifting mechanisms are not furnished..

A circuit breaker racking handle shall be provided.

All tools or tool kits necessary to remove and replace circuit breakers, instrument transformers and other equipment from the switchgear line shall be furnished. Also, all tools necessary for servicing the switchgear and all associated components and hardware shall be furnished.

A remote racking system shall be provided and installed. Remote cabling shall be of sufficient length to allow remote operator operations from outside the switchgear “vault”.

The generator output switchgear system and enclosure shall be designed to provide visible indication of energized bus as viewable from each cubicle. Additionally, circuit breaker position (open/closed/racked out) shall be indicated on each cubicle front panel door.

Generator and Switchgear Station Service

The new switchgear system and enclosure shall include a shore power distribution, power and lighting provisions. The contractor shall furnish and install a power distribution panel to supply all ventilation, lighting and power outlet requirements. The power panel shall also be designed and capable to provide power for all alternating current requirements for control, as designed, for the new switchgear and provide power for the battery chargers and all cubicle space heaters.

All new station service equipment and systems, including branch circuit wiring, devices and bonding and grounding shall be installed per the NEC as required per the OBO Electrical Code Supplement.

The new power panel shall be accessible separate from the switchgear lineup, surface mounted, NEMA 1 enclosure. Panel bus shall be fully rated, copper, including ground and neutral bars. All circuit breakers shall be bolt-on style. A fully rated main breaker shall be included with panel, along with a transient voltage surge suppression module. The TVSS, if externally mounted from the panel, shall be located adjacent to the panel with TVSS leads maintained as short as possible.

All interior wiring shall be THHN/THWN, 90 degree C, copper conductors with EMT conduit and steel compression fittings.

All new lighting shall be surface mounted LED, industrial grade with wire guards to protect fixture lens. All new interior lighting, including engine and alternator service bay lighting shall be design by the manufacturer for maximum engine BTU heat gain plus maximum ambient temperature.

All new power outlets shall be NEMA 6-20R, 2P, 3W, 250V, 20A rated, surface mounted in metallic outlet boxes. All covers shall be raised cover style, including any quad configured outlet positions. Each outlet shall be installed and wired separately, on its own circuit, without shared neutrals.

Switchgear Environment and Enclosure

The contractor shall utilize as needed the attached Iraq climate data for environmental data necessary to be integrated into the engine/generator enclosure design and air filtering and ventilation systems, including engine-based components (air filter/prefilter) and for electrical and mechanical equipment application and design environmental requirements. Minimum environmental requirements and conditions shall include an ambient temperature of 40 degree Celsius with 100% condensing humidity. The attached climate data is provided as informational purposes only and is used at the contractor’s own risk. The contractor shall also utilize their own research, records and data for all design and fabrication and assembly purposes.

Other requirements of the statement of work and the following requirements shall apply to the enclosure fabrication, assembly and manufacturer design.

The generator system enclosure shall be a NEMA 3R, factory designed drop over style metallic system to include integral ventilating systems, entrance and equipment doors for access to power and control wiring output terminations, and fuel delivery/fill systems, lighting and power services with all interior generator enclosure equipment, fixtures, appliances, etc. configured and installed to allow for OM and maintenance operations.

o The switchgear enclosure shall include the following features:

The enclosure shall be 3-hour fire rated with fire rated entrance doors possessing lockable and panic door hardware sets. All enclosure ventilation louvers shall be designed and rated for factory designed ventilation flow with the generator system operating at full load output at the maximum outside air design temperature.

Entrance and egress door(s) shall also be installed to meet any applicable fire code requirements for emergency egress/personnel requirements.

The contractor shall furnish and install door lock construction key cores as required.

All penetrations for equipment or utility services that enter or exit the new enclosure shall be designed and installed to meet enclosure temperature/ventilation and water infiltration requirements.

For shipping splits and reassembly, the generator enclosure and framing shall be designed with integral forklift pockets and lifting eyes. Lifting eye and pockets shall be designed to lift the entire/completed enclosure, including the weight and install of all equipment and any fluids, with the exception of the diesel fuel load. Steel material and framing specification, welding, fabrication and joining techniques and assembly shall meet factory design requirements.

Exterior finish for the new generator enclosure shall be a polyester powder coating meeting at a minimum AAMA 621 standard with a minimum 10 year durability cycle. Color selection will be made at the time of order. If other exterior coating/processes are available that exceed the AAMA 261 standard, the contractor shall include details in their technical proposal and shall include details with the product shop manual/drawing submission, including manufacturer product details and application process, durability specifications, etc..

Enclosure shall be Dust and Fog Resistant. All ventilated openings shall be filtered to inhibit the ingress of dust and included with coalescing media. The ventilated covers shall be externally removable to allow safe maintenance of the filter media without providing access to live parts. All external doors and covers shall be gasketed.

All generator exterior entrance and access doors shall be hinged with hold open hardware furnished and installed. Hold open hardware shall be furnished and installed to keep captive active door leaves at the 90 and 180 degree open positions.

The generator enclosure, including engine and alternator sections shall include LED technology exit and emergency lighting equipment and systems. All exit and emergency lighting shall meet 640 lumen output minima, including operation via normal and battery power. All battery backup fixtures shall be capable of remaining fully functional four (4) hours after illumination. All emergency and exit lighting shall meet building code, UL and

NFPA requirements. All lighting fixtures shall also include wire guard protection.

The completed enclosure shall be sized, designed and configured to accommodate the generator and switchgear assembly and allow for full operator and maintenance personnel access to meet manufacturer clearances and approaches to perform all OM functions. Generator and switchgear and aisles shall be designed to meet applicable NEC 70, NFPA 70E and OSHA requirements.

All equipment shall be laid out and positioned to meet all applicable codes, including NFPA fire code, OSHA, including equipment access clearances and applicable OBO code supplements. All equipment, hardware, components, wiring, devices, etc. furnished and installed and that make up the generator room system shall be UL listed for their intended uses. All electrical work, fabrication and assembly shall meet NFPA 70, 70B and 70E.

Switchgear enclosure section entrance doors shall be sized and configured to allow field removal and replacement of any interior components that make up the switchgear system without having to remove the entrance room door assemblies.

The new generator output switchgear section assembly, including all low voltage and medium voltage systems shall be bonded and grounded in accordance with the NEC. This shall also include bonding and grounding integration for generator feeder circuits and feeder distribution circuits and pad mounted switches. All exterior grounding connections using bare copper stranded conductors and ground rods shall be connected and interconnected using exothermic techniques except for terminal connections to equipment/equipment enclosures, ground lugs, bus, etc. All grounding and bonding conductors shall be copper and all ground rods shall be copper clad.

The generator and switchgear enclosure shall include an OBO approved fire alarm detection and annunciation system. This shall include heat/smoke detection, manual pull station and audible/visual annunciation appliances. The new generator enclosure fire alarm system shall be integrated into the Post system as separate zones. The new fire alarm system shall be installed in accordance and in compliance with applicable building code provisions and NFPA 72.

The generator section switchgear/control room section of each generator enclosure shall include a ventilation system with required fans, ducting/plenum, motorized louvers and operating mechanisms, motor drives and motors and humidstat and automatic control. Ventilation system shall operate upon engine start and remain active during engine operations. Ventilation system shall shutdown upon engine shutdown.

Additionally, the humidstat shall control room ventilation during non-run engine times. Upon engine start up, the control system shall override and humidstat function and initiate louver opening function.