22-SMM-041_C6_RFP_N6449822R4033.pdf

CODE

(Hour)

PAGE(S)

until 05:00 PM local time 29 Apr 2022

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G F 80 - 94

95 - 111 H 112 - 117 sean.m.mccolgan@navy.mil

RATING PAGE OF PAGES

7. ISSUED BY

(Date)

IMPORTANT - Award will be made on this Form, or on Standard Form 26, or by other authorized official written notice.

Previous Edition is Unusable 33-134 STANDARD FORM 33 (REV. 9-97)

Prescribed by GSA FAR (48 CFR) 53.214(c)

1 117

(If other than Item 7)

15A. NAME 16. NAME AND TITLE OF PERSON AUTHORIZED TO

AND

ADDRESS

SIGN OFFER (Type or print)

OF

OFFEROR

AMENDMENT NO. DATE

15B. TELEPHONE NO (Include area code) 17. SIGNATURE15C. CHECK IF REMITTANCE ADDRESS

IS DIFFERENT FROM ABOVE - ENTER

SUCH ADDRESS IN SCHEDULE.

18. OFFER DATE

1. THIS CONTRACT IS A RATED ORDER

UNDER DPAS (15 CFR 700)

2. CONTRACT NO.

N64498 8. ADDRESS OFFER TO

See Item 7

9. Sealed offers in original and 1 copies for furnishing the supplies or services in the Schedule will be received at the place specified in Item 8, or if handcarried, in the depository located in

CAUTION - LATE Submissions, Modifications, and Withdrawals: See Section L, Provision No. 52.214-7 or 52.215-1. All offers are subject to all terms and conditions contained in this solicitation.

10. FOR INFORMATION

CALL:

A. NAME (NO COLLECT CALLS)

SEAN MCCOLGAN 215-897-3071

11. TABLE OF CONTENTS

SOLICITATION/ CONTRACT FORM

SUPPLIES OR SERVICES AND PRICES/ COSTS

2 - 4

X I CONTRACT CLAUSES

DESCRIPTION/ SPECS./ WORK STATEMENT X

PACKAGING AND MARKING

5 - 32 33 - 34

J LIST OF ATTACHMENTS

INSPECTION AND ACCEPTANCE

DELIVERIES OR PERFORMANCE

35 - 36 37 - 38

X K

REPRESENTATIONS, CERTIFICATIONS AND

OTHER STATEMENTS OF OFFERORS

CONTRACT ADMINISTRATION DATA 39 - 47 X

SPECIAL CONTRACT REQUIREMENTS

OFFER (Must be fully completed by offeror) X M

L INSTRS., CONDS., AND NOTICES TO OFFERORS

EVALUATION FACTORS FOR AWARD

NOTE: Item 12 does not apply if the solicitation includes the provisions at 52.214-16, Minimum Bid Acceptance Period.

is inserted by the offeror) from the date for receipt of offers specified above, to furnish any or all items upon which prices are offered at the price set opposite each item, delivered at the designated point(s), within the time specified in the schedule.

13. DISCOUNT FOR PROMPT PAYMENT

(See Section I, Clause No. 52.232-8)

14. ACKNOWLEDGMENT OF AMENDMENTS

(The offeror acknowledges receipt of amendments

AMENDMENT NO. DATE

to the SOLICITATION for offerors and related documents numbered and dated):

FACILITY

12. In compliance with the above, the undersigned agrees, if this offer is accepted within calendar days (60 calendar days unless a different period

SOLICITATION, OFFER AND AWARD

X

(X) SEC. DESCRIPTION (X) SEC. DESCRIPTION PAGE(S)

PART I - THE SCHEDULE

26. NAME OF CONTRACTING OFFICER (Type or print) 27. UNITED STATES OF AMERICA 28. AWARD DATE

EMAIL:TEL: (Signature of Contracting Officer)

CODE CODE

B. TELEPHONE (Include area code) C. E-MAIL ADDRESS

AWARD (To be completed by Government)

19. ACCEPTED AS TO ITEMS NUMBERED 20. AMOUNT 21. ACCOUNTING AND APPROPRIATION

22. AUTHORITY FOR USING OTHER THAN FULL AND OPEN COMPETITION:

10 U.S.C. 2304(c)( ) 41 U.S.C. 253(c)( ) (4 copies unless otherwise specified)

23. SUBMIT INVOICES TO ADDRESS SHOWN IN ITEM

24. ADMINISTERED BY (If other than Item 7) CODE 25. PAYMENT WILL BE MADE BY CODE

PART IV - REPRESENTATIONS AND INSTRUCTIONS

PART III - LIST OF DOCUMENTS, EXHIBITS AND OTHER ATTACHMENTS

48 - 78

PART II - CONTRACT CLAUSES

NAVAL SURFACE WARFARE CENTER PHILA

CODE 0223, SEAN MCCOLGAN

SEAN.M.MCCOLGAN@NAVY.MIL

5001 SOUTH BROAD STREET, BUILDING 4

PHILADELPHIA PA 19112

215-897-3071

FAX:

TEL:

FAX:

TEL:

NOTE: In sealed bid solicitations "offer" and "offeror" mean "bid" and "bidder".

SOLICITATION

6. REQUISITION/PURCHASE NO.5. DATE ISSUED

30 Mar 2022

4. TYPE OF SOLICITATION

SEALED BID (IFB)

NEGOTIATED (RFP)

[ X ]

3. SOLICITATION NO.

N6449822R4033

Section B - Supplies or Services and Prices

ITEM NO SUPPLIES/SERVICES QUANTITY UNIT UNIT PRICE AMOUNT

0001 1 Each First Article Test (FAT) Unit

FFP

In Accordance With (IAW) Section C, Statement of Work (SOW), FAT unit, testing and reports. Price is inclusive of shipping.

NOTE: The requirements in DFARS 252.211-7003, Item Identification and Valuation, are applicable for this line item. The contractor shall provide DoD unique identification or a DoD recognized unique identification equivalent.

FOB: Destination

PSC CD: 6115

NET AMT

0002 1 Each OPTION Production Unit #1

FFP

IAW Section C, SOW, Ship Service Diesel Generators. Price is inclusive of shipping.

NOTE: The requirements in DFARS 252.211-7003, Item Identification and Valuation, are applicable for this line item. The contractor shall provide DoD unique identification or a DoD recognized unique identification equivalent.

0003 1 Each OPTION Production Unit #2

FFP

IAW Section C, SOW, Ship Service Diesel Generators. Price is inclusive of shipping.

NOTE: The requirements in DFARS 252.211-7003, Item Identification and Valuation, are applicable for this line item. The contractor shall provide DoD unique identification or a DoD recognized unique identification equivalent.

0004 1 Each OPTION Production Unit #3

FFP

IAW Section C, SOW, Ship Service Diesel Generators. Price is inclusive of shipping.

NOTE: The requirements in DFARS 252.211-7003, Item Identification and Valuation, are applicable for this line item. The contractor shall provide DoD unique identification or a DoD recognized unique identification equivalent.

0005 1 Lot Contract Data Requirements Lists (CDRLs)

FFP

IAW Section C, SOW, Technical Data (CDRLs). *NOT SEPARATELY

PRICED*

Section C - Descriptions and Specifications

STATEMENT OF WORK (SOW)

Statement of Work (SOW) LCC 19 USS Blue Ridge Diesel Generator Set Procurement

1.0 Introduction

1.0.1 The Naval Surface Warfare Center Philadelphia Division (NSWCPD) is a Department of Defense entity responsible for research and development, test and evaluation, engineering and fleet support organization for the Navy’s ships, submarines, military watercraft and unmanned vehicles. This requirement is for NSWCPD Code 442, which is responsible for the steam and diesel electrical power systems on board LCC 19 USS Blue Ridge.

1.0.2 This contract is for non-personal services. It does not create employment rights with the U.S.

Government whether actual, inherent, or implied.

1.0.3 Government/Contractor Relationship

1.0.3.1 The services to be delivered under this contract are non-personal services and the parties recognize and agree that no employer-employee relationship exists or will exist under the contract between the Government and the Contractor's personnel. Therefore, it is in the best interest of the Government to provide both parties a full understanding of their respective obligations.

1.0.3.2 The Contractor employees shall identify themselves as Contractor personnel by introducing themselves or being introduced as Contractor personnel and displaying distinguishable badges or other visible identification for meetings with Government personnel. In addition, Contractor personnel shall appropriately identify themselves as Contractor employees in telephone conversations and in formal and informal written correspondence.

1.0.3.3 Contractor personnel under this contract shall not engage in any of the inherently

Governmental functions listed at FAR Subpart 7.5 or DFARS Subpart 207.5.

1.0.4 Employee Relationship:

1.0.4.1 The services to be performed under this contract do not require the Contractor or its personnel to exercise personal judgment and discretion on behalf of the Government.

Rather the Contractor's personnel will act and exercise personal judgment and discretion on behalf of the Contractor.

1.0.4.2 Rules, regulations, directives, and requirements that are issued by the U.S. Navy and

NSWCPD under its responsibility for good order, administration, and security are applicable to all personnel who enter a Government installation or who travel on

Government transportation. This is not to be construed or interpreted to establish any degree of Government control that is inconsistent with a non-personal services contract.

1.0.4.3 Inapplicability of Employee Benefits: This contract does not create an employer-employee relationship. Accordingly, entitlements and benefits applicable to such relationships do not apply.

1.0.4.4 It is the Contractor's, as well as the Government's, responsibility to monitor contract activities and notify the Contracting Officer if the Contractor believes that the intent of this Section has been or may be violated.

1.0.4.4.1 The Contractor shall notify the Contracting Officer in writing via letter or email within three (3) calendar days from the date of any incident that the Contractor considers to constitute a violation of this Section. The notice should include the date, nature, and circumstances of the conduct; the name, function, and activity of each Government employee or Contractor official or employee involved or knowledgeable about such conduct; identify any documents or substance of any oral communication involved in the conduct; and the Contractor's estimated date when, absent a response, cost, schedule or performance will be impacted.

1.0.4.4.2 The Contracting Officer will, within five (5) calendar days after receipt of notice, respond to the notice in writing. In responding, the Contracting Officer will either:

a. Confirm the conduct is in violation and when necessary direct the mode of further performance,

b. Countermand any communication regarded as a violation,

c. Deny that the conduct constitutes a violation and when necessary direct the mode of further performance, or

d. In the event the notice is inadequate to make a decision, advise the Contractor what additional information is required, and establish the date by which it should be furnished by the Contractor.

1.1 BACKGROUND

The legacy diesel generator sets currently installed on the LCC 19 ship are undersized, high maintenance, failure prone and do not meet the 7Th Fleet requirements. NSWCPD Code 442 has been tasked with replacing them with a shock qualified brushless replacement that will give the ship a low maintenance and reliable electric plant to support the remainder of the service life for the LCC which is currently slated for 2039.

This purchase specification defines the requirements in their entirety. The system supplier shall provide all technical documentation as defined by these requirements.

1.2 SCOPE OF WORK

The Contractor shall provide a quantity of up to three (3) Ship Service Diesel Generators to serve as replacements of existing generators. Each Diesel Generator shall comply with the ABS NVR as pertaining to MIL-G-21296 and the requirements of this specification. Where there may be a conflict, this specification shall take precedence. The generator sets shall be shock qualified to the requirements of MIL-S-901D either through previous qualification testing, extension qualification, requests, partial testing, or full testing. Each new diesel generator shall be able to provide at least 2000 kW (electrical) at 450 VAC, 60 Hz, 0.8 power factor, when operating continuously as defined in Section 3.1.2.

If a generator set is not previously qualified or does not have shock testing completely waived by the Technical Code, the First Article Test (FAT) will be established as CLIN 0001, and the production units will be established as options under CLINs 0002-0004. Any generator set used as the FAT unit will be turned over to the government and will not be considered a production unit.

2.0 APPLICABLE DOCUMENTS

2.0.1 MIL-STD-1399, Electric Power, Alternating Current

2.0.2 MIL-G-21296B, Generator Set, Diesel Engine Direct and Alternating Current, 60 Hz (Naval

Shipboard Use)

2.0.3 MIL-S-901D, Shock Tests, H.I. (High-Impact) Shipboard Machinery, equipment, And Systems, Requirements For

2.0.4 MIL-STD-461E, DOD Interface Standard Requirements for the Control of electromagnetic

Interference Characteristics of Subsystems and Equipment

2.0.5 NAVSEA 0908-LP-000-3010, Shock Design Criteria for Surface Ships, Rev. 1, dated September

2.0.6 NAVSEA T9300-AF-PRO-020, Design Practice and Criteria Manual for Surface Ships Chapter 300

2.0.7 ABS NVR, American Bureau of Shipping, Rules for Building and Classing Naval Vessels

2.0.8 ASNI C50.10, C50.13 or C50.14

2.0.9 Basler Tech Manual for DECS 250N

These documents can be referenced at https://quicksearch.dla.mil/

The Contractor shall reference and utilize the latest version available when performing tasks within this PWS.

3.0 REQUIREMENTS

3.1 SCOPE OF SUPPLY

The following components shall be furnished by the Supplier:

a. Diesel Engine– Continuous power, four (4) stroke diesel generator set.

b. Generator - Continuous power, AC generator with rotating brushless exciter, Sea-Water Cooled.

c. Permanent Magnet Alternator, three (3) phase alternator attached to the bearing end (non-drive end) of the generator for field flashing, generator excitation, and to support generator control equipment.

d. Main and Auxiliary terminal boxes

3.1.1 SCHEDULE FOR LONG LEAD TIME MATERIAL

Delivery of all Diesel Generator Sets, inclusive of all ancillaries listed in the Scope of Supply, shall be delivered to the Yokosuka, Japan area on or before April 1st, 2025. All qualification efforts must also be completed or waived with approval from the government prior to this date.

3.1.2 DESIGN STANDARDS AND CRITERIA

3.1.2.1 Generator Rating

Each generator shall be capable of the following rating: 2000 kW (electrical) at 60 Hz, 3 phase ungrounded delta or wye, 0.8 power factor and shall meet the overload ratings per section 3.1.2.5.2.

3.1.2.2 Diesel Engine Ratings

The propulsion engine shall be V16, 4-stroke-cycle diesel.

3.1.2.3 Size Requirements

3.1.2.3.1 Overall Genset Assembly

The combined dimensions of the engine and the generator, while coupled together, shall not exceed the following maximum size restrictions:

-Maximum Dimensions: 275 in. in length, 125 in. in height and 110 in. in width.

-The combined weight of the engine and generator shall not exceed 85,000 pounds.

3.1.2.3.2 Diesel Engine Only

The diesel engine (including exhaust bellows) shall be sized between the following minimum and maximum dimensions.

-Minimum Dimensions: 145 in. in length, 90 in. in height, 72 in. in width.

-Maximum Dimensions: 175 in. in length, 108 in. in height and 88 in. in width.

3.1.2.3.3 Generator Only

There are no generator-specific minimum or maximum dimensions as long as the overall generator set assembly meets the requirements of 3.1.2.3.1.

3.1.2.4 Operational Conditions

Design climatic conditions at which the Generator must operate are given in Section 3.1.3,

3.1.3.2.1 and 3.1.3.2.2.

It shall be assumed that the existing prime mover shall maintain lubrication and shall experience no loss of fluids under ship motion conditions as specified in Section 3.1.3, 3.1.3.2.1 and 3.1.3.2.2.

3.1.2.5 Generator Detailed Requirements

3.1.2.5.1 Generator Requirements

a. Minimum Continuous Power Output: 2000 KW

b. Generator Speed: 1800 RPM

c. AC Generator Specifications:

The Generator shall be a marine, three phase, synchronous generator meeting the electrical requirements defined in Table 1. The generator shall be totally enclosed water air cooled and arranged for ungrounded delta or ungrounded WYE connection. The generator shall meet the requirements of ANSI C50.10 and C50.13 or C50.14 (as applicable).

Application Ship Service Voltage 450 VAC Continuous rating 2000 KW Phases 3 Frequency 60 Hz Sub-transient Reactance (Xd”) 19.2% or lower Enclosure Totally enclosed, water-air-cooled Insulation Class H or Higher Power Factor 0.8, Lagging

Table 1: Generator Electrical Requirements

3.1.2.5.2 Load and Overload

The Generator shall be capable of delivering rated kW load at rated power factor continuously at the rating conditions specified.

The Generator shall be capable of delivering 110 percent of rated kW load at rated power factor for 30 minutes of each 8 hour period without part failure or deterioration of the Generator life.

The generator set shall be capable of accepting full rated load a maximum of 20 seconds after engine cranking is initiated.

The rated power conditions shall be based on the ambient conditions and be in accordance with ABS NVR, American Bureau of Shipping, Rules for Building and Classing Naval Vessels, Part 4, Chapter 2, Section 1 Diesel Engines.

3.1.2.5.3 Short Circuit

Each Generator shall be capable of withstanding, without damage to the unit, a single phase or three phase short circuit fault at the generator terminals for a period of time determined by I2t=180, where I is the sustained value of line current on a per unit basis and t is time in seconds.

The sustained value of current during a short circuit shall not be less than 3.2 times greater than rated levels.

3.1.2.5.4 Voltage Balance

Under any condition from no load to rated load, the variation in output voltage between phases shall not exceed 5%.

3.1.2.5.5 Waveform

The deviation factor of the open-circuit terminal voltage on any phase shall not exceed 5%. The total harmonic distortion of the output voltage waveform shall not exceed 1% over the operating range from no load to rated load (assuming linear load condition only), nor shall any single component of the output voltage harmonic distortion exceed 0.3%.

3.1.2.5.6 Windings

The armature windings shall be secured by slot wedges. Field coils shall be secured so that they cannot become loose or damaged by vibration or produce vibration due to shifting of the coil position.

The generator windings shall be impregnated with solventless resin under vacuum and pressure to provide the windings with the required mechanical strength, dielectric insulation and imperviousness to humidity, oil, fuel-oil, diesel fumes and industrial chemicals.

Damper bars (amortisseur windings) shall be interconnected between poles. All winding connections shall be silver brazed.

Details of the insulation system (slot liners, individual wire insulation, turn insulation, Vacuum Pressure Impregnation (VPI) insulation of formed coils or assembled windings, etc.) shall be provided.

Slot pitch shall be such that the machines will be compatible with all Ship Service/Emergency Diesel Generator (SS/EDGs).

3.1.2.5.7 Terminal Boxes

Terminal box(es) will be mounted on the generator frame/enclosure to facilitate shipboard installation of interconnecting cabling.

3.1.2.5.7.1 Main Power Terminal Box(es)

a. The generator shall be provided with one or more main terminal boxes meeting the following requirements:

b. Each terminal box shall be located in accordance with Mechanical interface specification reference and shall accommodate all main power cables and cable terminations.

c. Phases shall be separated from ground and each other by barriers of insulating material.

Identification of phase ends shall be provided.

d. Terminal boxes shall be provided with a removable access cover having reusable gaskets and removable non-magnetic plates to accommodate cable transits or stuffing tubes.

e. Three sets of three current transformers (three on each phase for a total of nine), complete with protective devices, mounted on the generator and located in each main generator terminal box.

The current transformers will be required to set to a ratio of 5000:5.

f. A,B,C Phase labelling/stamping properly labelled in both main and auxiliary terminal boxes for buswork and Current Transformers (CTs).

3.1.2.5.7.2 Auxiliary Terminal Boxes

The generator shall be provided with one or more auxiliary terminal boxes that shall be used as a connection termination point for all incoming auxiliary cables associated with the generator, including, but not limited to: the exciter leads, PMA leads, main voltage sensing leads, CT connections, stator RTD connections, speed sensor (magnetic pickup) connections, bearing and air temperature alarms, and generator heater connections. They shall also house the CT protection devices and any relays, fuses/fuse holders etc. necessary to facilitate any of the above requirements in this section. These boxes shall be electrically isolated from the main power terminal box. Wherever possible, auxiliary terminal boxes shall be segregated by <30V and >30V to allow easier servicing of low voltage components.

The auxiliary terminal boxes shall be provided with a removable access cover having reusable gaskets and removable non-magnetic plates to accommodate cable transits or stuffing tubes.

Terminal boxes with greater than ten (10) cables shall use a multi-cable transit.

3.1.2.5.8 Rotor Construction

A salient pole rotor shall be provided with keys in conjunction with a shrink fit to prevent movement of the spider on the shaft. A pin through the shaft or welding shall not be used to prevent axial displacement. Spiders constructed of individual flutes welded to the shaft may be used if pre-heat and stress-relieving procedures are employed in accordance with NAVSEA Publication S9074-AR-GIB-010/278.

Field poles and pole shoes of a salient pole rotor shall not be secured by dowels or in such a manner as to prevent removal and replacement. The stress resulting from the method of securing poles to the spider shall be less than half the elastic limit of the material at rated speed.

Generators shall be integral shaft-field pole (cylindrical rotor) synchronous generators. The assembled rotor (with field windings, brushless exciter, and permanent magnet alternator installed) shall be dynamically balanced in accordance with the requirements of MIL-STD-167- 1.

3.1.2.5.9 Bus Assemblies

Bus bars and bus connections shall be of copper, silver surfaced at the contact areas up to 1 inch past the joint area. The entire bus may be silver plated at the discretion of the Contractor. Silver surfacing shall be accomplished by plating using 99.9 percent pure silver and shall conform to the requirements of QQ-S-365 except that the silver plate shall be not less than 0.005 mm (0.0002-inch) thick. Threaded surfaces shall have silver thickness of at least 0.005 mm (0.0002 inch).

3.1.2.5.10 Generator Bearing

Generator bearing shall be force-fed, sleeve-type, journal bearing, split through the horizontal with liners. The design shall permit removal and replacement of the bearing liners without removing the rotor from the frame or removing the coupling from the drive end. Free-end bearings shall be self-aligning and mounted/secured to generator frame vice foundation.

The lubrication system shall prevent oil or oil-laden vapor from leaking or migrating from the oil seal, bearing housing, or split lines into the generator under normal conditions or the inclined operating conditions described in sections 3.1.3.2.1 and 3.1.3.2.2. Measuring of shaft currents during first article testing will be performed to determine if grounding is necessary.

The generator shall have a separate oil circuit from the prime mover.

3.1.2.5.11 Generator Cooling

The generator shall be cooled by double wall, air-to-water heat exchangers in accordance with MIL-C-19836. Coolers will be designed for seawater with temperatures of 100 degrees Fahrenheit and shall assume a fouling factor of 1.10. Protective zincs shall be used. Ship service coolant system design pressure range of 69 kPA (10 lbs/in2) to 758 kPA (110 lbs/in2) shall be assumed. The equipment cooling system shall be capable of withstanding a hydrostatic pressure test of 1137 kPA (165 psig). Operation of cooler at design flow shall be possible over the specified range of coolant inlet temperature.

Condensation from the cooler shall drain to outside of the machine without contacting the electrical windings.

3.1.2.5.12 Generator Cooler Connections

Water connections to cooler heads or water boxes shall be integral to the heads or welded.

Brazed pipe connections are prohibited. Connecting flanges shall be edge drilled and tapped for threaded pressure tap connections. Flanges must be associated in a manner that places them, with respect to the prime mover, in a general location such that existing generator cooler piping will require minimal changes for all applications. Connections to and from cooler shall be properly and visibly labelled inlet and outlet.

3.1.2.5.13 Generator Anti-Condensation Heaters

Electric heaters shall be installed in the generator enclosure in sufficient quantity and size to prevent condensation of moisture on the generator windings when the Generator is secured. The heaters shall be thermostatically controlled and protected to prevent damage to windings due to excessive heating. The heaters shall be replaceable without requiring the removal of more than access covers. The heaters must accept 120V, 1 Phase, 60Hz power.

3.1.2.5.14 Generator Frame and Enclosure

The generator frame shall have feet large enough to accommodate holding-down bolts, dowel pins, and jackscrews (where used) for attachment to the sub-base. The Generator shall be constructed so that the frame of the generator shall not extend below the lower face of the sub base. Mounting/foundation requirements are per the Mechanical Interface Specification.

Enclosure access shall be by removable sections, panels or hinged doors permitting access to both ends of the rotor and to the anti-condensation heaters. Access openings shall permit air cooling of the generators (at a reduced power level of 80%) in case of a failure in the water cooling-system. All access openings shall be provided with drip shields at their upper edges and shall have re-usable watertight gaskets.

3.1.2.5.15 Lifting Means

Eyebolts, lugs, holes or equivalent means shall be provided to permit lifting of the generator and attached accessories as a unit. These lifting means shall be appropriate for the rigging of the generator through ship for installation.

3.1.2.5.16 Nameplate Data

Nameplate details shall conform to all aspects of ABS NVR.

3.1.2.5.17 Cooler Condensation Baffles

The generator frame shall be constructed or fitted with baffles so that condensation from the water-to-air heat exchanger will not drop on the generator windings. The condensation shall be drained to the outside of enclosures.

3.1.2.5.18 Temperature Gauges and Monitors

Platinum resistance temperature detectors (RTDs) shall be provided for remote indication and monitoring of generator bearings, stator winding, and cooling air temperatures (100 ohms at 0 degrees C). Additionally, four (4) removable probe type RTDs shall be provided; this total quantity is comprised of each generator bearing having an installed RTD and a spare RTD.

Thermostatically controlled DP/DT switches shall be provided for remote indication of over temperature conditions of the generator bearing and cooling air temperature.

Installed dial type thermometers shall be provided for local continuous readings of air-box temperature.

3.1.2.5.19 Journal and Thrust Bearings

All bearings shall be outfitted with Resistance Temperature elements as required by ABS 3-3- 2/6.

3.1.2.5.20 Generator Stator Windings

Stator winding temperature indication shall be provided by means of two (2) platinum embedded RTDs per phase. The second RTD in each phase shall serve as a reserve in the event that the first RTD fails.

3.1.2.5.21 Generator Air Temperature

RTDs and continuous reading dial type thermometers shall be located so as to measure the temperature of air into and out of the generator heat exchanger. Gauges of the dial type thermometers shall be mounted on the generator enclosure in a location that is easily read from a position adjacent to the generator sub-base.

3.1.2.5.22 Parallel Generator Operation

The Generator shall be capable of operating continuously in parallel with any combination of other Generator Sets as defined in this specification. The Generator Set shall be capable of operating in parallel with shore power for purposes of load transfer. When operated in parallel with other generators, the Generator shall be capable of maintaining its share of the total load within ±5% of a value that is proportional to the ratio of the Generator rating to the total of all paralleled generator ratings.

3.1.2.5.23 Permanent Magnet Alternator (PMA)

A permanent magnet alternator (PMA) shall be supplied. The PMA shall be mounted so it does not interfere with accessibility to the main generator windings for inspection and cleaning. The PMA assembly shall be mounted opposite the drive end of the generator, and shall be accessible for maintenance through removable covers in the end shield. The PMA will have electrical characteristics to support the Government provided Basler, DECS 250N type, digital voltage regulator. Specific details of Basler, DECS 250N Digital Excitation Control System can be found in the Basler Tech Manual for DECS 250N.

3.1.2.5.24 Voltage Regulation

Excitation/Voltage Regulation Requirements The Generator shall utilize a brushless excitation system compatible with redundant automatic voltage regulators, see the Basler Tech Manual for DECS 250N. The provided PMA shall provide the power for the exciter field, voltage regulators, and respective control equipment.

A rotating rectifier assembly shall be used to provide direct current excitation to the generator field. The rectifier assembly shall be mounted on the end of the exciter opposite the drive end of the generator, and shall be accessible for maintenance through removable covers in the end shield to facilitate diode replacement. The output of the rotating rectifier assembly shall be directly connected to the main generator field by leads that run through the shaft.

3.1.2.5.25 Short Circuit Capability

The excitation and voltage regulation system shall provide sufficient excitation to the generator under both single phase and three phase short circuit conditions to meet the requirements specified herein. Normal voltage shall be restored upon removal of the short.

3.1.2.5.26 Design and Construction

The overall dimensions of the Generator shall be in accordance with the Mechanical interface specification reference. The design and construction should be such that the generator can be used in multiple applications, using necessary peripherals and/or adapters as specified in the Mechanical interface specification reference.

3.1.2.5.27 Accessibility

The Contractor shall include in the reliability and maintainability program the procedures to be used to assure accessibility and adequate pull spaces for equipment maintenance after equipment installation.

3.1.2.5.28 Operating Life

The Generator shall have an operating life not less than 160,000 hours over a period of not less than 35 years. This life shall be predicated on the following:

a. Hours at rated load 20,000

b. Hours at 60 percent load 95,000

c. Hours at 40 percent load 45,000

The Generator shall withstand not less than 100,000 starts/stops during its operating life.

3.1.2.5.29 Electrostatic Discharge (ESD) Control Program

This program is to be established in accordance with MIL-STD-1686 and DOD-HDBK 263.

This program is applicable to ESD sensitive parts listed in MIL-STD-1686 and is applicable from contract award date.

The program includes all procured electrical/electronic equipment, parts and assemblies that were certified and qualified using the electrostatic discharge sensitivity (ESDS) classifications 1, 2 and 3 designators and testing requirements specified under MIL-M-38510 and MIL-STD-883.

3.1.2.6 Diesel Engine Detailed Requirements

The diesel engine shall be a 4-cycle, turbocharged, V16 configuration. Engine driven fuel, lubricating oil and cooling water pumps shall be provided. The engine shall be supplied with regulating and overspeed governors.

The system shall include the engine with interface connections; combustion air inlet/exhaust gas connections; engine base and subbase with resilient mount system for noise isolation;

turbocharger(s) jet assist system, piping, wiring, conduit and fittings attached to engine; and mating electrical connectors.

3.1.2.6.1 Combustion Air Inlet Filter System

3.1.2.6.1.1 Emergency Stop Air Shutoff Device

The engine combustion air intake system shall be modified to provide an emergency stop air shutoff device. This device shall also have a contact available for control system status.

3.1.2.6.1.2 Ducted Connections to turbocharger

The combustion air intake system shall be modified to allow for directly ducted connections to the turbochargers.

There shall be two (2) options for consideration.

3.1.2.6.1.2.1 Modify the Air Intake housing to facilitate use of Continuous Rated engine intake filters and a direct connection to the combustion air intake system.

3.1.2.6.1.2.2 Remove the Air Intake housing and provide an inlet connection in the vertical direction to interface with the combustion air intake system. In this option, the Government would be responsible for the intake filters.

3.1.2.6.1.3 For each of the options as described in 3.1.2.6.1.2, there shall be a detailed parts list, and illustration provided. In addition if either of the proposed options were used on prior shock qualified Grade A installations per MIL-STD-901D, the Contractor shall notify the Government of such qualification, as well as the original shock test procedures and resultant reports.

3.1.2.6.2 Exhaust Expansion Joint

Exhaust expansion joint shall be sufficiently flexible to accommodate thermal growth and the shock excursion of the SSDG on its mounts.

3.1.2.6.3 Engine Fuel Service System

The engine fuel system shall be complete and self-contained within the generator set package requiring no additional shipyard supply other than the interconnecting piping and valves between the engine and the fuel day tank.

The system shall include the fuel control system, engine mounted pump(s), duplex strainer, duplex filter-water separator, control valves, manifold, nozzles, piping, piping components, instrumentation and wiring, and relief valves.

3.1.2.6.4 Engine Cooling System

The engine cooling system shall be a freshwater type, closed circulation type complete with on skid heat exchanger.

The system shall include all prime mover jacket water and Separate Circuit After Cooler cooling systems components including engine mounted pump, pre-heat unit, control valves, cooler, piping, expansion tanks, instrumentation, and mating electrical connectors.

Jacket water heater and generator heaters shall have the same voltage.

3.1.2.6.5 Engine Lubricating Oil Service System

The engine lubricating oil system, including any oil pre-lube system required prior to starting, shall be complete and self-contained within the generator set package requiring no additional shipyard supply.

The system shall include sumps, pumps, heat exchangers, prelubrication system, relief valves, pressure and temperature regulating valves, ventilation system to dissipate crankcase fumes, oil mist separator, centrifugal oil filters, and fill and drain connections.

3.1.2.6.6 Starting System

The starting system shall use an electrically actuated starting system. Two (2) starters shall be provided interfacing with the engine. Each starter shall use 24VDC and be capable of providing eight (8) consecutive starts.

The Contractor shall provide a written description of the planned mounting configuration, as well as drawings detailing the mounting plan. Controls shall be provided for remote and local starting.

3.1.2.6.7 Lubrication System

An engine Prelubrication System shall be included on the engine subbase. The system shall include at a minimum all the pump(s), piping and foundations necessary. The system shall be capable of providing lubrication to the engine on an intermittent basis.

The Contractor shall provide cable mounts and hold downs as necessary, prior to shipment, thus allowing the Government to secure cabling during engine installations. The Contractor shall provide the Government a detailed parts list, description, and illustration, including location, of the Prelubrication System.

3.1.2.6.8 Electrical Enclosures

The Contractor shall provide functionally equivalent items to the following:

(i) Instrument Panel

(ii) Auxiliary Panel

(iii) Prelube Motor Control

(iv) AC Power Distribution Box

(v) Jacket Water Heater Control Box

The Contractor shall provide interfacing cable connections as well as cable ways and cable supports for each of the items mentioned above. All connections of the items mentioned above shall be located at a central location for interface with off unit items. The Contractor shall provide the Government a detailed parts list, description, and illustration of the intended cabling connections and location.

3.1.2.6.9 Crankcase Ventilation System

The Contractor shall modify the on engine Crankcase Ventilation System to provide for crankcase pressure balancing and oil fume removal as a self-contained system.

The Contractor shall provide the Government a detailed parts list, description and illustration to the Government.

3.1.2.6.10 Combustion Air Intake System

The engine combustion air intake system shall provide an emergency stop air shutoff device.

The combustions air intake system shall be modified to allow for directly ducted connections to the turbochargers. The Contractor shall provide, at a minimum, the Government two options for consideration (see section 3.1.2.6.1.2 for details). For each option, the Contractor shall provide the Government with a written description, detailed parts list, and illustration.

3.1.2.6.11 Cylinder Temperature Monitoring System

The Contractor shall provide outfitting the Cylinder Temperature Monitoring System and provide details of vibration monitoring locations and available sensor options for use with the engine.

3.1.2.6.12 Vibration Monitoring System

The Contractor shall provide outfitting for installation of a Vibration Monitoring System and provide details of vibration monitoring locations and available sensor options for use with the engine and generator.

3.1.2.6.13 Serviceability

The Contractor shall provide easily accessible means for the serviceability of the engine.

3.1.2.7 Environmental Qualifications

The Supplier is required to provide previously completed documentation (if applicable) or a schedule and timeline for accomplishing testing or qualification extension requests.

3.1.2.7.1 Shock

The equipment shall meet shock Grade A, hull mounted, Class II, heavy weight, type A requirements of MIL-S-901D. The Contractor shall submit a test plan for government approval (CDRL A002) prior to testing, notification of testing before testing occurs (CDRL A010) and test report (CDRL A003) after testing is completed. If testing has previously been completed, documentation of shock qualification shall be provided to the government to waive this testing requirement. If applicable, a shock qualification extension request may be provided to the government for approval (including the previously completed test report and government approval) to potentially waive or reduce the testing requirement.

3.1.2.7.2 Vibration-Externally Generated

The equipment shall be designed to meet requirements of MIL-STD-167-1 and MIL-STD-740-2.

3.1.2.7.3 Vibration-Internally Generated

Each rotating equipment shall be designed to meet requirements of MIL-STD-167-1.

3.1.2.7.4 Vibration-Torsional

The unit shall be designed in accordance with MIL-STD-167-2A.

3.1.2.7.5 Electromagnetic Qualification Status

The Contractor shall provide the electromagnetic qualification status of all electrical, electronic and electromechanical equipment (CDRL A004). The status shall cover electromagnetic interference (EMI) per MIL-STD-461E, and electromagnetic pulse (EMP).

3.1.2.7.5.1 Electromagnetic Interference (EMI)

The equipment shall be designed in accordance with MIL-STD-461E.

3.1.2.7.5.2 Direct Current Magnetic Field Environment

The equipment shall be designed in accordance with MIL-STD-1399.

3.1.2.8 Testing

All tests shall be performed as required by ABS NVR for the generator and the following paragraphs also apply. If there are conflicts between these cited requirements, they shall be identified in writing to the Government; however, the more stringent requirement shall prevail.

3.1.2.8.1 General Requirements

All tests or inspections shall be described in detailed test procedures to be prepared by the Supplier and approved by the Government and shall be documented in reports to be prepared by the Supplier and approved by the Government. The Supplier shall notify the Government at least 25 days prior to the commencement of any test. The Government may elect to witness any or all tests.

3.1.2.8.2 Responsibility for Inspection

The Supplier is responsible for the performance of all inspection and testing requirements as specified herein. Except as otherwise specified in the contract or order, the Supplier may use his own or any other facilities suitable for the performance of the inspection requirements specified herein, unless disapproved by the Government. The Government reserves the right to perform any of the inspections set forth in the specification where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

3.1.3 GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION

3.1.3.1 General

This section covers standards of design, materials, workmanship, installation, and inspection procedures.

Requirements of other sections of these specifications, or of referenced documents which are in excess of the requirements of this section, shall have precedence over the requirements of this section.

3.1.3.2 Principles of design and construction

3.1.3.2.1 Environmental conditions

3.1.3.2.1.1 Climatic conditions

Equipment shall be installed in machinery spaces, refer to ABS 3-3-1/9 for ambient temperature.

Electric plant machinery shall be designed to operate with seawater cooling temperature of 28 degrees F minimum and 100 degrees F maximum. In addition, those electric plant components taking air from the weather shall be designed to operate satisfactorily in any weather air ambient temperature between minus 20 degrees F and 125 degrees F with a relative humidity of zero to 100 percent.

3.1.3.2.2 Ship motion

Equipment and machinery shall be designed and installed to operate and to maintain satisfactory lubrication, without loss of oil from machinery or hydraulic systems, under the following conditions:

a. When the ship is permanently trimmed down by the bow or stern as much as 5 degrees from the normal horizontal plane.

b. When the ship is permanently listed up to 15 degrees to either side of the vertical.

c. When the ship is pitching 10 degrees up or down from its normal horizontal plane.

d. When the ship is rolling up to 45 degrees to either side of the vertical.

3.1.3.2.3 Protection of personnel

Protection of personnel against operating hazards shall be provided. Shafting, couplings, gears, flexible shafts, automatic stanchion operating mechanisms, hot equipment surfaces (125 degrees F or higher), and similar items shall have adequate guards installed for protection of personnel.

Such protective guards shall be removable without dismantling the machinery surrounded.

Guards shall be constructed of sheet or expanded metal as light as is consistent with required protection. Guards fitted on parts requiring frequent attention shall have doors, covers, or other ready means for access, secured by wing nuts or other simple fastenings.

Protective guards shall also be installed as barriers to prevent personnel from inadvertently contacting energized and exposed electrical circuits, components, and terminals which present shock and high voltage hazards.

The following warning sign shall be used where voltages between 20 and 500VDAC or VAC are present:

DANGER SHOCK HAZARD (in accordance with drawing, NAVSHIPS No. RE-2699757, where AC or DC voltages are between 30 volts and 500 volts).

3.1.3.2.4 Protection of equipment

Equipment shall be protected against the hazard of personnel brushing against or being thrown against the equipment, particularly under heavy sea conditions, and inadvertently causing damage to exposed components or resulting in maladjustment of exposed functional controls such as push buttons, knobs, and switches. Equipment and electric cables shall also be protected against similar hazards from accidental movement or shifting of equipment and material in exposed locations. Protection shall be provided by equipment arrangement to afford such protection or by installation of enclosures, screens, or guard rails. Such enclosures, screens, or guard rails shall be designed to withstand a static load of 500 pounds and of being used safely as handholds if so configured. The protective method utilized shall not inhibit access to the equipment as required for normal operational and maintenance procedures.

3.1.3.2.5 Electromagnetic Interference (EMI) reduction

All Contractor-furnished electrical and electronic equipment shall meet the applicable EMI requirements of Sect. 406. All low frequency system cables shall be installed in conformance to the requirements of publication, S9407-AB-HBK-010. Equipment shall be installed in accordance with the EMI and IMI requirements of MIL-STD-1310, as modified by Sect. 406.

3.1.3.2.6 Electromagnetic Pulse (EMP) protection

Any equipment, structures, or systems which are located in EMP exposed areas, as defined in Sect. 407, shall conform to requirements specified in Sect. 407.

Electromagnetic environment safety.- Protection from electromagnetic radiation to ordnance (HERO), personnel (HERP), and fuel (HERF) shall be provided in accordance with the criteria in publication, NAVSEA OP3565, as modified to the limits of OPNAVINST 5100.23B dated 3 Jan 1991 (for personnel protection).

3.1.3.2.7 Preservation and preventive maintenance program

The Supplier shall establish a preventive maintenance program and shall prepare a preventive maintenance plan for all machinery and equipment to be installed on a ship. The program shall encompass the preventive maintenance to be performed from the time of receipt of the machinery and equipment until delivery to the ship, including inactive equipment maintenance required pending installation and activation of an item of machinery or equipment aboard the ship. Specific preventive maintenance requirements for each piece of machinery and equipment shall be obtained or developed by the supplier. Specific maintenance requirements shall include, but not be limited to, a simple but complete description of the action to be taken and the schedule (periodicity) and other circumstances relating to when it should be accomplished. Utilization of existing Navy Planned Maintenance System (PMS) documentation is authorized and encouraged where applicable in the preparation of these requirements. The initial preventive maintenance plan shall include the Suppliers planned approach to and organization for the total preventive maintenance program, a listing of machinery and equipment that the program will be applicable to and the specific preventive maintenance requirements.

3.1.3.2.8 Electrostatic Discharge (ESD) Control

The Supplier shall implement the electrostatic discharge control requirements in accordance with MIL-STD-1686A dated 8 August 1988 and DOD-HDBK-263 for ESD sensitive parts listed therein. For GFE, the ESD program shall commence at the receipt inspection of equipment; for CFE, the program shall start at contract award.

The Contractor's ESD control program shall cover the requirements as specified in Table 1 of MIL-STD-1686A dated 8 August 1988 including, all CFE procured electrical/electronic equipment, parts and assemblies that were certified and qualified using the Electrostatic Discharge Sensitivity (ESDS)Classifications 1, 2, and 3 designators and testing requirements specified under Mil. Spec. MIL-M-38510H dated 31 August 1989 and MIL-STD-883C dated 29 November 1989.

The Contractor shall maintain and abide by all ESD labeling or markings that the manufacturer has applied for the identification of ESD sensitive parts/assemblies.

3.2 Commonality of Systems, Subsystems, and Components

N/A.

3.3 Manufacturing Phase-Out or Discontinuation of Production, Diminishing Sources, and Obsolete Materials or Components

The Contractor shall notify the contracting officer immediately upon determining the unavailability of obsolete materials or components. The Contractor may recommend a solution to include the impact on the contract price and delivery. The Contractor shall not initiate any item redesign or incur any additional costs without the express, written authorization of the contracting officer.

3.4 Diminishing Manufacturing Sources and Material Shortages Management

(DMSMS) Contract Requirements

3.5 Parts Obsolescence

4.0 DATA REQUIREMENTS

4.0.1 Exhibit A – CDRL A001, Engineering Manual

4.0.2 Exhibit B – CDRL A002, Shock Test Plan

4.0.3 Exhibit C – CDRL A003 Shock Test Report

4.0.4 Exhibit D – CDRL A004, Electromagnetic Qualification Status

4.0.5 Exhibit E – CDRL A005, Counterfeit Prevention Plan

4.0.6 Exhibit F – CDRL A006, Request for Variance

4.0.7 Exhibit G – CDRL A007, Request for Waiver

4.0.8 Exhibit H – CDRL A008, Material Certification

4.0.9 Exhibit J – CDRL A009, Small Business Utilization Report

4.0.10 Exhibit K – CDRL A010, Notification of Test Trials

4.0.11 Exhibit L – CDRL A011 Monthly Status Report

4.0.12 Exhibit M – CDRL A012 Installation Control Drawings

5.0 SECURITY REQUIREMENTS

5.1 OPERATIONS SECURITY (OPSEC)

5.1.1 The Contractor shall protect critical information associated with this contract to prevent unauthorized disclosure. The NSWC Philadelphia Division's (NSWCPD) Critical Information List (CIL)/ CIIL (Critical Indicators and information list) will be provided on site, if warranted.

Performance under this contract requires the Contractor to adhere to OPSEC requirements. The Contractor may not impose OPSEC requirements on its subcontractors unless NSWCPD approves the OPSEC requirements. During the period of this contract, the Contractor may be exposed to, use, or produce, NSWCPD Critical Information (CI) and/or observables and indicators which may lead to discovery of CI. NSWCPD’s CI will not be distributed to unauthorized third parties, including foreign governments, or companies under Foreign Ownership, Control, or Influence

(FOCI).

5.1.2 CUI correspondence transmitted internally on the Contractor's unclassified networks or information systems, and externally, shall be protected per NIST SP-800-171, Protecting…