Attachment_I_-_Statement_of_Work.pdf

(RFQ)

Provide Generator for Chiller, Bldg 1 at

USDA

Fruit & Tree Nut Research Lab

21 Dunbar Rd.

Byron, GA 31008

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1. INTRODUCTION

The U.S. Department of Agriculture proposes to install a 208 volt, 3 phase, 60 Hz emergency backup generator system at the USDA-ARS

Laboratory in Byron, Ga. The project consists of providing standby power to the laboratory facilities chiller electrical system mounted on top of auditorium at Building 1. The chiller has a minimum circuit amps of 744 amps with a manufacturer’s recommend fuse size of 800 amps.

Contractor shall install a factory tested diesel fueled engine-generator set and automatic transfer switch complete in accordance with these specifications. The set shall be built by manufacturers regularly engaged in the production of such equipment.

See Appendix 1 Figure 1 for placement location for new generator and switch gear.

This work will include, but is not limited to, the following:

1. Contractor to provide all material, labor, equipment, supplies, transportation, and supervision to complete the project.

2. Determining proper size, providing and installing new generator, automatic transfer switch, wiring and other related components necessary for complete and functional system. The diesel engine-generator set shall meet the criteria contained in this specification.

3. Observing and insuring equipment and installation meets all applicable Federal, State and local building and safety codes that relate to this work.

4. Provide new concrete slab for generator, patching and sealing of any cuts, trenches, or required penetrations through existing walls, sidewalk or parking areas.

5. Coordinate with utility providers and owner to maintain uninterrupted utility services to Building 1 during contract execution.

2. REFERENCES

National Electrical Manufacturers Association (NEMA)

NEMA MG 1-Standards for Motors and Generators

NEMA ICS 6-Standard for Industrial Controls and Systems Enclosures

Underwriters Laboratories (UL)

UL 142 -Standard for Safety Steel Aboveground Tanks for Flammable and

Combustible Liquids

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3. DELIVERY

A representative for the Contractor will need to be onsite to receive delivery of all shipments.

4. SUBMITTALS

The following items shall be submitted for the engine-generator set:

4.1 Approval drawings and data

a. Engine tabulation sheet showing the name of the manufacturer, type and model number, number of cylinders and maximum horsepower at rated speed of generator. See APPENDIX 2 FORM ENGINE / GENERATOR

SCHEDULE.

b. Generator tabulation sheet showing the name of the manufacturer, type and model number, kilovolt-ampere at rated speed and voltage at 0.8 power factor, and per cent voltage regulation (no load to full load). See APPENDIX 2 FORM ENGINE / GENERATOR SCHEDULE.

c. Schematic and wiring diagrams for all equipment installed in this project.

d. Product Specifications for transfer switch.

e. Product Specifications for fuel tank.

4.2 Final Drawings and manuals

a. Provide operation and service manuals for the engine- generator set and transfer switch electronically (PDF preferred format).

b. Provide f inal drawings showing the complete, scaled layout of all equipment, piping, wiring and conduit location and sizes electronically (PDF preferred format).

4.3 Warranty

a. Provide the manufacturer’s warranty provisions for the equipment installed under this contract.

b. Provide a one year written warranty for workmanship by the

Contractor.

5. Statement of Work (SOW)

5.1 Engine-Generator set

Set components shall be environmentally suitable for the locations shown and shall be the manufacturer's standard product offered in catalogs for commercial or industrial use.

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The engine-generator set shall be an enclosed outdoor unit. All components comprising the unit shall be capable of full feature operation in ambient temperatures ranging from -30 degrees F to 110 degrees F. Provide a generator strip heater for moisture control when the generator is not operating.

The engine-generator set shall come with engine, cooling system, weather enclosure, starting system, control system, vibration isolators, generator, exhaust system components, grounding lugs and all other accessories required to make a complete unit. The engine-generator set, enclosure and transfer switch shall be painted with the engine-generator manufacturer’s standard paint system and color.

The engine-generator set shall be mounted to a common base of sufficiently rigid steel to maintain alignment during operation, shipping and lifting.

The mounting arrangement and weather enclosure shall allow convenient access to the oil drain and all other critical maintenance areas.

5.2 The engine-generator set shall have the following features:

5.2.1 Engine

a. Generator capacity shall be adequate to serve the connected loads.

The initial voltage dip shall not exceed 20 percent. If there is a fire pump connected to the generator, the voltage dip shall be limited to the NFPA requirements for voltage dip for fire pumps.

b. Engine shall operate on Grade 2D or B 20 diesel fuel.

c. Shall have a minimum of four cylinders, capable of operating the generator at full-rated load without using more than 90 per cent of the maximum engine horsepower.

d. Shall have a battery operated starting system with a positive solenoid starting motor.

e. Shall have electronic type governor which maintains an output frequency within 2.0 hertz of the rated synchronous speed for all load ratings from no load to full-rated load.

f. Shall have automatic, forced feed type of lubrication system, replaceable oil filter, and replaceable dry element air filter.

g. The lubrication oil supply for the prime mover shall be kept to at least 75 percent of its optimum operating temperature, and a separate electric pump shall maintain a positive continuous flow of lubricant to all bearings.

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5.2.2 Cooling System

a. The cooling system shall be a closed recovery, liquid coolant system. It shall contain a unit mounted radiator, belt driven fan, thermostatic temperature control and an engine mounted circulating pump.

b. The cooling system shall have a drain valve install at the lowest point in the system for draining and flushing.

c. Engine water cooling system shall be either remote or engine-mounted, so arranged that pressure on the head of the engine block will not exceed six psig. Where remote-mounted radiators create static pressure in excess of six psig, provide a separate pump, receiver tank and piping to the radiator to prevent rupturing each gasket by excessive pressure.

d. The radiator fan shall be covered with a shrouded safety guard and screen which are removable for maintenance.

e. The radiator shall be mounted with vibration isolators capable of supporting the entire weight of the radiator and isolating the radiator from severe engine vibration.

f. The cooling system shall maintain a steady-state engine temperature at the full –rated load of generator output.

5.2.3 Exhaust System

a. Shall have a flexible exhaust connector, condensation trap and drain valve installed inline before the muffler.

c. Shall have a critical muffler. The weight of the muffler shall not be supported by the engine.

d. Shall have exhaust piping installed with long radius elbows and supported on the vertical and horizontal runs as recommended by the manufacturer of the exhaust components.

e. Shall have metal guards and insulation for shielding the exhaust pipes and muffler to protect personnel from injury.

f. The exhaust system shall be designed in such a manner that the back pressure to the engine will, in no case, exceed 20 inches water gauge.

g. Engine exhaust mufflers (silencers) shall be provided for each engine-generator set to ensure acceptable noise levels with the minimum muffler grade being residential grade.

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5.2.4 Batteries and Battery Charger

a. Batteries shall be furnished and installed on the engine-generator set as recommended by the manufacturer of the unit. The batteries shall be the lead-acid type, rated for 12 volts.

b. The batteries shall be secured in a mounted rack attached as an integral part of the engine-generator set. The batteries shall be connected to the engine’s electrical system with cables of the engine manufacturer’s recommended size and type.

c. The battery shall be capable of charging to 90 percent of full capacity within 24 hours and have a minimum expected life of 6 years on float charge.

d. The battery charger shall provide float and equalize charge, each independently adjustable. Output of the charger shall be rated at

12 volts, with a minimum output current of at least 6 amperes and tapering to 0 amperes.

e. The battery charging unit shall operate from the normal service power of 120 volts, single phase, 60 hertz.

f. The input and output circuits of the battery charger shall be protected with a circuit breaker or fuses.

g. The battery charger shall be located in a weather-proof enclosure.

h. The battery charger shall have two alarm contacts, one for battery under-voltage and one for battery over-voltage, wired to a terminal block within the engine-generator control panel.

5.2.5 Generator

a. Shall have windings and insulation rated for continuous operation at full-rated output of the generator without exceeding the rated temperature as defined by NEMA standard MGI 22.40. The winding insulation shall be class B, F or H as defined by NEMA standard

MGI 1.65.

b. The generator, exciter and voltage regulator shall be designed to match the torque-curve of the diesel engine.

c. Shall have a brushless excitation system that is directly connected with the generator rotor and stator and uses heavy-duty silicon diodes connected to the rotor shaft.

d. Shall have a regulation system which responds to immediate load drops by adjusting the frequency and voltage to maximize motor starting capability.

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e. Shall have frequency regulation to insure frequency variation does not exceed plus or minus 0.25 percent of its mean value for constant loads from no load to full load.

f. Upon application of 100 percent of the nameplate rating in one step, less applicable de-rating factors for site conditions, the resulting transient voltage dip shall not exceed 30 percent of the rated voltage and the voltage recovery time shall not exceed 5 seconds. Random voltage regulation shall not exceed plus or minus

1 percent of the mean value for constant loads from no load to full load.

g. The voltage regulator shall provide under-frequency and over-frequency protection and 3 phase voltage sensing.

h. Over-voltage protection shall be provided by a manual reset type circuit breaker or similar device which immediately de-energizes the exciter field and causes an engine shutdown and fault alarm.

5.2.6 Auxiliary Engine-Generator Equipment

Auxiliary engine-generator equipment shall consist of engine-generator controls, circuit breaker for protection of the generator, and an automatic transfer switch. All external control and power circuits using wire of 10 AGW or less shall be terminated on a input/output terminal block. Engine-Generator controls shall use solid state circuitry and shall be mounted on the engine-generator set with vibration dampers to protect the controls from damage.

5.2.6.1 The following switches, gauges and indicators shall be mounted, labeled, visible and adjustable from the face of the control panel:

a. A three position selector switch labeled MANUAL-OFF-AUTOMATIC and pushbuttons labeled START and STOP. They shall operate as follows:

(1) MANUAL – Provides manual start-up or shut-down of the engine-generator in response to the START/STOP pushbuttons.

(2) OFF – Shall prevent manual or automatic operation of the engine-generator set and thereby provide a safety lockout for periodic maintenance of the engine-generator. The Contractor shall provide the selector switch with a lock system suitable for use of a padlock in the OFF position.

(3) AUTOMATIC – Shall be capable of starting and operating the engine-generator in response to a signal from the automatic transfer switch.

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b. A voltage rheostat and gauge to fine-tune the line to line (or leg to leg) voltage output from the generator to within 3 percent of the rated output voltage.

c. Battery charge rate voltmeter

d. Battery charge rate ammeter

e. Engine hour meter

f. Engine oil pressure gauge

g. Engine oil temperature gauge

h. Engine coolant temperature gauge

i. AC current voltmeter

j. AC current ammeter

k. AC voltmeter phase selector switch with an off position

l. AC ammeter phase selector switch with an off position

m. A fault reset switch

n. Frequency meter

5.2.6.2 Illuminated Annunciation Lights

Illuminated annunciation lights shall be mounted and labeled on the control panel to indicate the following conditions:

a. Engine-generator running

b. Over-crank shutdown

c. Over-speed shutdown

d. Pre-warning for high coolant temperature

e. High coolant temperature

f. Pre-warning for low oil pressure

g. Low oil pressure shutdown

h. Transferred to standby power source

i. Selector switch not in automatic mode

j. High battery voltage

k. Low battery voltage

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5.2.6.3 Alarm Contacts

Individual alarm contacts shall be provided and wired to a terminal block in the engine-generator control panel via conduit from the respective devices. These contacts shall close under the following conditions:

a. Engine-generator running

b. Engine-generator shutdown

c. Engine-generator over crank shutdown

d. Engine-generator over-speed shutdown

e. Engine-generator pre-warning for high coolant temperature

f. Engine-generator pre-warning for low oil pressure

g. Engine-generator high coolant temperature shutdown

h. Engine-generator low oil pressure shutdown

i. Transfer switch transferred to the standby power source

j. Engine-generator selector switch not in the automatic mode

k. High battery voltage

l. Low battery voltage

5.2.6.4 Cranking Controls

The cranking controls shall operate in response to the manual and automatic starting of the engine-generator set. The cranking controls shall contain the following:

a. A cranking limiter to prevent a simultaneous engine cranking and running condition.

b. An oil-pressure bypass switch to bypass the engine oil pressure protective switch for the duration of the cranking interval to permit engine-generator startup.

c. A cranking cycler that is factory preset to provide a minimum of four repeated cycles of engine cranking with a 10 second ON period and a 10 second OFF period. Each cycle shall provide individually adjustable ON and OFF cranking.

5.2.6.5 Exercising Control

The exercising control shall require manual initiation and shall operate in conjunction with the automatic transfer switch and the

SOW Page 9 of 17 automatic mode of the engine-generator control. The exercising control shall permit immediate assumption of a standby load at any point in the exercising cycle without causing a fault condition.

5.2.6.6 Shutdown (fault) Controls

These controls shall be located in the engine-generator control panel and shall provide shutdown of the engine-generator system upon recognition of one or more of the following conditions:

a. High engine coolant temperature.

b. Low engine coolant level.

c. Low oil pressure.

d. Engine over-speed

e. Failure to start after the stipulated number of cranking attempts.

5.5.6.7 Output Contacts

Two additional dry signal output contacts shall be provided to be normally open when the engine-generator stops operation and to close and remain closed throughout the duration of engine-generator operation. The contacts shall have the same rating as the alarm contacts.

5.2.6.8 Circuit Breaker

A circuit breaker shall be provided for the output circuit protection of the engine-generator. The circuit breaker shall be a thermal-magnetic type with a molded case and provide automatic trip and manual reset. The breaker shall be easily accessible.

5.2.6.9 Automatic Transfer Switch

The automatic transfer switch shall be fully automatic so that when any one or all phases of the normal service power fails, the engine-generator set shall be started. When the generator has attained rated voltage and frequency, the load shall be automatically transferred to the generator source. Upon restoration of normal utility provided power, the load shall be automatically transferred to the utility provided source.

The normal service power will be supplied from the building electrical service. Operating current for actuation of the switch shall be obtained from the source to which the load is to be transferred. The transfer switch shall be contained in a NEMA Type 1 enclosure.

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The automatic transfer switch shall have the following features:

a. Mechanical interlocks to allow lock out of the device for maintenance purposes.

b. A start time-delay, adjustable of up to at least 5 seconds, shall be provided to prevent startup due to momentary power outages or voltage dips.

c. A transfer time-delay, adjustable up to 120 seconds, shall be provided to allow the engine-generator set to stabilize prior to load transfer.

d. A run time-delay, adjustable up to 30 minutes, shall be provided to allow the engine-generator set to run loaded for a minimum amount of time and prevent stopping the engine after running a short period of time. This control may be located either in the transfer switch or within the engine-generator control panel, at the option of the Contractor.

5.2.6.10 Electrical

a. Contractor shall disconnect the Smart Meter shown in APPENDIX

1 Drawings Figure 2 from the main disconnect switch in electrical service panel located in Room 162. Wire shall be extended through abandoned 4 inch conduit in electrical panel to pad mounted transformer and connected to low voltage bushings.

b. Conductors emerging from underground shall be installed in rigid metal conduit, intermediate metal conduit, or Schedule 80 rigid nonmetallic conduit from 18” below grade or the minimum cover distance to the point of termination above ground. The bottom of the pipe shall be protected by a bushing or other effective means.

5.2.6.11 Weather Enclosure

A weather-proof enclosure shall be provided around the engine-generator equipment. The enclosure shall have the following features:

a. Manufactured from a minimum of 14 gauge metal material.

b. Bolted to the engine-generator base with a barrier between the engine-generator base and bottom of the enclosure to prevent rodents from entering the enclosure.

c. Painted with the engine-generator manufacturer’s standard color.

d. Have fixed louvers for ventilation.

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e. Removable side panels and hinged control panel door with key locks utilizing the same key. Contractor shall provide four sets of keys.

5.2.6.12 Fuel tank

Provide a generator manufacturer’s designed sub-based, double walled fuel tank and containment with a tank capacity capable of supplying generator fuel needs for 48 hours at 100% load. The tank shall meet UL 142 Standards.

5.2.6.13 Delivery, Storage and Handling

Properly protect materials and equipment in accordance with the manufacturers recommended storage procedures, before, during, and after installation. Protect stored items from the weather and contamination. During installation, piping and similar openings shall be capped to keep out dirt and other foreign matter.

6. ON-SITE ACCEPTANCE TEST

The complete installation shall be load bank tested for compliance with the specification following completion of all site work. Testing shall be conducted by representatives approved by the manufacturer, with required fuel supplied by USDA. The USDA shall be notified in advance and shall have the option to witness the tests.

a. Installation acceptance tests to be conducted on-site shall include a "cold start" test, a four hour full load test, and a one-step rated load pickup test.

7. ON-SITE TRAINING

Conduct training course for operating staff as designated by the CO.

The instructions shall cover pertinent points involved in operating, starting, stopping, servicing the equipment, as well as all major elements of the operation and maintenance manuals. Additionally, the course instructions shall demonstrate all routine maintenance operations such as oil change, oil filter change, and air filter change.

8. COMPLETION INSPECTION

8.1 Punch-Out Inspection

Near the completion of work, Contractor shall conduct an inspection to ensure all requirements of this SOW has been accomplished before notifying the CO that the work is ready for the Government Pre-Final inspection.

8.2 Final Acceptance Inspection

The Contracting Officer Representative (COR) will perform the pre-final inspection to verify that the work is complete and ready to operate. Additional Government personnel including, but not limited

SOW Page 12 of 17 to, those from ARS Facility Engineer user groups may also be in attendance. A Government Final Punch List may be developed as a result of this inspection. Ensure that all items on this list have been corrected before notifying the Government. Correct any items noted on the Final inspection in a timely manner. These inspections and any deficiency corrections required by this paragraph must be accomplished within the time slated for completion of the entire work or any particular increment of the work if the project is divided into increments by separate completion dates.

9. ACCEPTANCE

Final acceptance of the engine-generator set will not be given until the Contractor has successfully completed all tests and after all defects in installation material or operation have been corrected.

10 ATTACHMENTS

APPENDIX 1: Drawings

APPENDIX 2: Form

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APPENDIX 1

Drawings

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Figure 1

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Figure 2

APPENDIX 2

Form

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ENGINE / GENERATOR TABULATION SCHEDULE

Service Load [ ] [kVA] [kW]

Power Factor [0.8] [ ] lagging

Motor Starting kVA (maximum) [ ] kVA

Maximum Speed 1800 rpm

Engine‐Generator Application stand‐alone

Engine Cooling Type water/ethylene glycol

Heat Exchanger Type [fin‐tube] [shell‐tube]

[Governor Type] [Isochronous]

Frequency Bandwidth percent steady state + [ ] [0.4] [0.25]

[Governor Type] [Droop]

Frequency Regulation (droop) (No load to full load) [[3] [ ] percent max.)]

Frequency Bandwidth percent (steady state) + [ ] [0.4] [0.25]

Voltage Regulation (No load to full load) + 2 percent (max.)

Voltage Bandwidth (steady state) + [0.5] [1] [2] percent

Frequency [50] [60] Hz

Voltage [ ] volts

Phases [3 Phase, Wye] [3 Phase, Delta] [1 Phase]

Minimum Generator Reactance [ ] percent Subtransient

Nonlinear Loads [ ] kVA

Max Step Load Increase [ ] [100] percent of Service Load at [ ] PF

Max Step Load Decrease (w/o shutdown) [ ] [100] percent of Service Load at [ ] PF

Max Time to Start and be Ready to Assume Load [10] [ ] seconds

Max Summer Indoor Temp (Prior to Genset

Operation)

[ ] degrees CF

ENGINE / GENERATOR TABULATION SCHEDULE

Min Winter Indoor Temp (Prior to Genset

Operation)

[ ] degrees CF

Min Winter Indoor Temp [ ] degrees CF

Max Allowable Heat Transferred To Engine

Generator Space at Rated Output Capacity

[ ] kWMBTUH/hr

Max Summer Outdoor Temp (Ambient) [ ] degrees CF

Min Winter Outdoor Temp (Ambient) [ ] degrees CF

Installation Elevation [ ] above sea level