Attachment_B_Technical_Specifications.docx

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SECTION 11 86 02 - GROUND POWER UNIT SPECIFICATIONS

PART 1 - GENERAL

1.1 DESCRIPTION

A. This specification covers design criteria, manufacturing standards, equipment testing and installation for solid-state 400 Hz frequency converter aircraft ground power units (GPU).

B. Provide GPU consisting of modular construction. Solid-State components designed for 50/60 Hz input to 400 Hz output shall be used. The GPU shall include all input/output devices and ancillary control devices necessary to meet the design requirements specified herein. The GPU shall be the manufacturer’s latest design, or current production model, that complies with the specification.

C. The solid-state, 400 Hz / 28.5 Volt DC output GPU shall be complete with components and accessories coordinated so that the complete unit shall function as specified. The GPU enclosure and accessories shall be manufacturer's standard design. All components shall be new, unused and suitable for the purpose intended.

1.2 DEFINITIONS

A. The term “Ground Power Unit”, “400Hz,” “Frequency Converter” and “GPU” as used within this specification and throughout the contract documents is understood to mean the components, subcomponents and subsystems that constitute a complete, operable, and maintainable Ground Power Unit and as referred to herein, are synonymous.

B. The term “Power Supply Cables,” “Input Supply Power,” as used within the specification and throughout the contract documents is understood to mean the electrical cables conduits, enclosures and conductors including supports and final connections between the Ground Power Unit and the power panel located on the rotunda column.

C. The term “Aircraft Connector Cables,” “400hz cables,” as used within the specification and throughout the contract documents is understood to mean the electrical cable and conductors originating from the Ground Power Unit and used to connect to the aircraft.

D. The terms, “Seller”, “Contractor”, "Provider" and “Manufacturer” as referred to herein, are synonymous. The term Owner, shall include the Owner, or his authorized representative.

1.3 BASIS OF DESIGN

A. In its base Bid, the Bidder shall include for supply and installation of 400Hz power units that comply with this Specifications per the equipment schedule and plan included. This shall include removal of the existing units, installation of the new units, re-establishing power and communication cables, commissioning, and other activities and materials in order to provide a complete and operable installation.

B. Alternate #1: If accepted in addition to the base Bid, bidder shall supply and install new power supply cabling from the existing rotunda mounted panel to the proposed GPU. Power Supply Cabling shall consist of disconnect or J-box and electrical conductors, appropriately sized for GPU. GPU contractor shall be responsible for the design and installation of the electrical service, conduits, conductors, j-boxes, etc., down line of the disconnect to the GPU location. Conduits shall be installed for electrical cabling on all fixed walkways and the outer most tunnel of the bridges. With the exception of cabling in the existing festoon and under the rotunda, all cabling shall be installed in conduit. Flexible conduits shall be provided where conduit runs cross flexible connects of the bridge and/or walkways. This shall include installing the cable within the existing under bridge cable management system or festoon.

C. Alternate #2: If accepted in addition to the base Bid, bidder shall supply and install new aircraft supply cable management system. This may be in the form of a cab mounted cable hoist or an under-cab cable reel. The hoist shall be equipped with a 3-phase brake motor and up/down limit switches on the hoist cable drive mechanism. The location of the hoist(s) shall be top upper left of the cab bubble for single hoist. For dual hoists, second hoist shall be located top upper left of the outer most tunnel. Cable hoists shall be manufactured by AmeriBridge Services, Oshkosh Aerotech or J & B Aviation. Cable Reel systems shall be manufacturer by ITW GSE or other approved manufacturers. This shall include the necessary controls and interconnections to provide a complete and operable system.

D. Alternate #3: If accepted in addition to the base Bid, bidder shall supply and install new aircraft connector cables. Aircraft connector cables shall be manufactured or recommended by the system manufacturer, which conform to the electrical characteristics of the system and meet the power requirement of the aircraft. Molded 400Hz cables shall consist of single jacketed 260Amp, 4 wire, balanced with center neutral 400Hz cable with a molded connector complete with on/off and up/down modular switches and replacement contact section. The length of supplied cables shall be sufficient to reach the aircraft connections regardless of whether the PBB is servicing L1 or L2 door (where applicable) for all aircraft in the planning mix. New cables shall be installed in existing or proposed cable management system.

1.4 REFERENCES

A. The equipment shall conform to all applicable federal, state, and municipal codes and regulations that apply to the installation site. The design of all parts and subassemblies shall be in accordance with good commercial practices to assure safe, efficient, and practical designs in keeping with standards that have been adopted by the passenger loading bridge industry. Applicable documents include, but are not limited to, the following. The latest approved version or edition, by the authority having jurisdiction, of the following codes, references and standards shall apply. If the authority having jurisdiction has not approved or adopted a particular code, reference, or standard, the latest published edition shall be applicable.

1. American Institute of Steel Construction (AISC)

2. Society of Automotive Engineers (SAE) Standards

3. American Society of Mechanical Engineers (ASME) Standards

4. National Fire Protection Association (NFPA-415)

5. Life Safety Code (NFPA-101)

6. National Electrical Code (NEC) – NFPA 70

7. National Electrical Manufacturers Association (NEMA) Standards

8. Occupational Safety and Health Administration (OSHA)

9. American Society for Testing and Materials (ASTM)

10. American Insurance Association (AIA)

11. Standard for Power Units Other Than Class 2 (UL 1012)

14. OIAA Design Construction Handbook

B. In the event of conflict between a reference and another reference or this specification, request clarifications. All responses are final and will be at no additional cost to the Owner.

1.5 GENERAL REQUIREMENTS

A. 100% Buy American Compliant. Equipment is designed, manufactured, and built in American using goods and materials purchased in coordination with the Buy American Act 49 USC section 50101.

B. The GPU and all components thereof shall be constructed in accordance with all codes and standards and local laws and regulations applicable to the design and construction of this type of equipment, which are generally accepted and used as good practice throughout the industry, including without limitation, NFPA, Underwriter's Laboratories, OSHA, SAE Publications, American National Standards, Military Standards, etc. The design of all parts and subassemblies shall be in accordance with good commercial practice and shall be the responsibility of the manufacturer to assure safe, efficient and practical design in keeping with requirements peculiar to this type system.

C. Manufacturers are required to satisfy all requirements of this specification. Should the Manufacturer desire to deviate from any portion, either because the specification is in error, violation of any law or regulation, or is in need of modification to permit a more satisfactory functional and economical design, they must submit a written request for such deviation. The Manufacturer shall not contract, purchase or cause to be delivered, equipment which does not meet all requirements of this document as specified, without obtaining prior written approval.

D. The Manufacturer shall be responsible for verifying installation locations and methods and shall notify the Engineer of any conflicts or code violations prior to manufacture of the GPU units. Verifications shall include field verifications and coordination with the Passenger Boarding Bridge to which this equipment will be fixed. Modifications to eliminate conflicts or code violations will be coordinated with and approved by the Engineer. Modifications shall be made at no additional cost to the Owner.

E. The Manufacturer shall furnish and install all necessary equipment to provide a complete, operable and maintainable unit.

F. The GPU shall be designed as an overhead assembly to be mounted under a passenger loading bridge outmost tunnel. Should alternate mounting configurations or physical attributes, other than those specified herein, or indicated on the project drawings, be proposed, manufacturers shall submit alternates for approval prior to bid date. Alternate mounting, configurations, or attributes shall be provided at no additional cost to the Owner.

G. EMI/RFI: Unit shall be designed so as not to affect aircraft radio/navigation equipment. It shall be applicable throughout the entire aircraft radio frequency range. Provisions shall be designed into the unit to protect it from voltage fluctuations which might result from the operation of aircraft radio frequency equipment.

H. The equipment and its accessories shall be designed and constructed with reliability of operation a primary consideration. The GPU shall be designed for a minimum life of 15 years with routine servicing and periodic servicing.

1.6 SUBMITTALS

A. Drawings, sketches, details, and materials shall be submitted in the English language, with United States Units, including dimensions, volumes, weights, and forces. The use of the metric or SI units is not acceptable.

B. Pre-Manufacture Submittals: The following submittals shall be made as necessary to meet the project schedule and shall be submitted to and approved prior to releasing the GPU units to production.

1. The manufacturer shall submit shop drawings, technical specifications, and descriptive product data for review and approval. An index prepared in chronological order listing drawings, sketches, details, and material submitted shall be provided.

2. Product data for selected models including specialties, accessories, and the following:

a. Engineering Certification:

1) Manufacturer shall submit Engineering Certification stating that the GPU and all components thereof are constructed in accordance with this specification, as well as all codes and standards and local laws and regulations applicable to the design and construction of passenger boarding bridges, including without limitation, NFPA, Underwriter's Laboratories, and OSHA.

b. Shop Drawings: Provide schematics and interconnection diagrams; conduit/cable entrance locations and requirements; and nameplate legends. Differentiate between manufacturer-installed wiring and field-installed connections.

3. Installation Details: Provide complete installation details including, without limitation, installation details of all appurtenances. Show installed configuration as well as any pertinent details regarding interface to other equipment and systems, include electrical connection service points.

C. Post-Installation: Submit equipment Vendor/Manufacturer commissioning report for review.

1.7 QUALITY CONTROL

A. Comply with quality control requirements specified within Division 01 of the project specification.

B. NFPA Compliance: Comply with applicable portions of NFPA 70 and NFPA 415 for components and completed and installed products.

C. NEMA Compliance: Motors, enclosures and electrical accessories shall comply with NEMA standards and be so rated.

D. UL Compliance: Equipment shall be UL, or ETL listed and shall be labeled by a nationally recognized testing laboratory at the time of bid. Submit verification with bid submittals.

E. Regulatory Requirements: The equipment shall be designed to conform to all applicable Federal, State and Municipal Codes and regulations as applicable to the project site which are in effect at the time of manufacture.

F. Installation Support: Provide a qualified manufacturer’s technical representative and service personnel during the entire PBB, PCA and GPU installation, testing and commissioning process. This representative shall be an employee of the manufacturer.

1.8 WARRANTY, MAINTENANCE AND SPARE PARTS

A. Provide a full parts, labor and remote support warranty for the new units and ancillaries. Labor warranty shall be performed by factory trained service technicians. Warranty shall run two (2) years from the completion and sign-off of the substantial completion. All warranty services shall be at the site of the installation. Provider shall be responsible for all travel and sustenance expenses necessary for warranty services.

B. Shipping and handling charges for warranty parts are the responsibility of the Provider.

C. Warranty Services shall be commenced with on-site representation, by qualified repair technicians, within 48 hours from the request of the Owner.

D. Provide, a five-year warranty for installed paint systems, beginning at completion and sign-off of Substantial Completion.

1.9 OPERATION AND MAINTENANCE MANUALS

A. Provide six (6) bound copies and electronic copies of the approved, comprehensive Operation and Maintenance Manual for each model GPU unit fourteen (14) days prior to Substantial Completion.

B. The content of the manuals shall be limited to information and data that specifically apply to products provided and shall include routine normal and special operating instructions and sequences. Also included shall be routine maintenance procedures and guides for troubleshooting, disassembly and reassembly instructions, and recommended spare parts list including current prices and sources.

C. Wiring diagrams and schematics shall be incorporated into the manuals to clearly show features such as controls, switches, instruments, points of connection, and indicators by name and location.

D. Operation and Maintenance Manuals: Include in ATA 101 format a general description, theory of operation and specification, schematics and wiring diagrams, start-up instructions, installation and maintenance procedures, parts list, recommended spare parts list, troubleshooting guides, controls and accessories information.

1. Special Tools List: Provide a list of any special tools required to perform any field performable maintenance tasks.

2. Spare Parts List: Provide manufacturer's recommended spare parts list.

PART 2 - PRODUCTS

2.1 GENERAL

A. In this Specification, the term “or Authority approved equal” may be used to indicate that the Contractor shall have the option of proposing an alternative to what has been specified. The Contractor’s alternative must be equal to or exceed the performance, functionality and safety requirements of the Specification.

B. Only a single GPU type from a single supplier is permitted to be used throughout this project.

2.2 MANUFACTURERS

A. The manufacturer shall be a qualified source, who has been regularly engaged in the engineering, manufacturing and installation of commercial aviation GPU equipment and components for a minimum of five (5) years and with a minimum of one hundred (100) units installed.

B. Qualified manufacturers and installers will have completed no less than five (5) jobs of similar size and scope within the last five (5) years.

C. The manufacturer shall have proven technical capabilities and adequate manufacturing facilities together with sufficient financial depth and stability to permit prompt and satisfactory execution of the contract.

D. ACCEPTABLE MANUFACTURERS/SUPPLIERS

1. FCX Systems, Inc. Morgantown, WV

2. ITW GSE Inc. Palmetto, FL

3. Oskosh Aerotech, Ogden UT

4. Unitron, LP, Dallas TX

2.3 MATERIALS

A. Where components are not otherwise indicated, provide standard components published by manufacturer as included in standard pre-engineered GPU systems and as required for a complete system. All equipment and parts furnished shall be the manufacturer's latest listed and published stock models. The equipment and parts shall meet all the applicable requirements of the specifications.

2.4 SYSTEM REQUIREMENTS

A. General

1. There shall be a horizontal 400Hz power source (GPU) provided at each Passenger Boarding Bridge (PBB), in accordance with the criteria provided in this specification.

B. Technical and Performance Requirements

1. The GPU shall be a stationary, horizontal 400Hz power source that shall be fixed under the Passenger Boarding Bridge (PBB) near the point of connection to the aircraft.

2. It shall consist of a static rectifier group converting the 480V, 3-phase, 60Hz power into 200/115V 400Hz power.

3. It shall be an independent system having a power rating that meets the power requirement of any type of aircraft docked with the PBB as per information in the contract drawings.

4. Switchboards and control boxes shall incorporate equipment, materials and components that perform all operational functions, are lockable, are resistant to external impacts, and are covered entirely with dust and waterproof enclosures. Supply cables for the equipment shall be carried by means of a sliding cable recovery carriage along the moving parts of the bridge.

5. Electrical characteristics of the system.

a. Input voltage: 480V ±10%

b. Input frequency: 60Hz ± 5%

c. Outlet power:

1) min. 1 x 90KVA unit (1 x 90KVA Connectors) where 90KVA is indicated in the equipment schedule.

2) min. 1 x 180KVA unit (2 x 90KVA Connectors) where 180KVA is indicated in the equipment schedule.

d. Output frequency: 400Hz ± 0.3%

e. 115/200V voltage with precision regulation with a tolerance of ±2% .

f. Voltage modulation shall not exceed 2.5% under any load condition.

g. Outlet voltage shall return to ±0.5% of pre-set value within 25 milliseconds after sudden block loading / unloading and application of the nominal load.

h. System must be capable of supplying a surcharge of 150% for minimum 30 seconds and of 125% for minimum 10 minutes.

i. System must be capable of supplying 150% of nominal current for 30 seconds until the protection circuits operate against three-phase short circuit.

j. Total harmonic content shall not exceed 3% of fundamental and individual harmonic at not more than 2% of fundamental for stable loads.

k. Crest factor shall be 1.414 ±0.07.

l. Maximum voltage modulation factor: 2.5V peak to valley (0.5%)

m. Power factor of the system shall be checked continuously so as to keep it between 0.8 and 1.

n. Yield of the system shall be minimum 92% under a load of 100%.

o. The noise level shall not exceed 70dB (A).

6. Equipment and switchboards shall be of NEMA 4 minimum protection class and resistant to a wind load of 120 mph.

7. Each GPU shall be provided with an integrated display console, TCP/IP/Ethernet Interface (Modbus), internal communication ports USB, RS485 and RS 232 and external Ethernet and USB ports.

8. Each GPU shall be provided with an Emergency power ‘Off’ Switch, Input / output voltage, current and frequency monitor, elapsed time meter and summary fault indicator and aircraft universal safety interlock circuit disconnect, dual for 180 KVA units.

9. One mobile checking and calibration device conforming to the 400Hz system that meets the power requirement of the largest aircraft shall be provided for checking and calibration of systems.

10. Unit shall interlock with the PBB to prevent PBB horizontal operation while GPU unit is operating. This shall apply to all units as well as all PBB's. Appropriate messages shall be displayed at the PBB operator's console to indicate unit's run status is preventing PBB operations.

PART 3 - EXECUTION

3.1 GENERAL

A. Contractor shall prepare a detailed work plan prior to starting work for review and approval. At no time, shall the contractor impact more than one aircraft gate unless approved in writing by the owner.

B. Prior to removal of the existing Ground Power Units, contractor shall complete a field investigation and confirm that the existing power and communication cabling and supports are sufficient for reinstallation. Contractor shall document any noted deficiencies and provide proposed solutions for review and approval.

C. To the greatest extent possible, contractor shall utilize existing cabling. In the event that the existing cabling is unsuitable for reconnection, contractor shall replace cabling back to the nearest existing enclosure. Should an enclosure not be available, contractor shall request approval for installation of a splice enclosure and provide a detail for review. All enclosures shall be rated for exterior use and painted to match the appearance of the bridges and GPU.

D. Contractor shall remove the existing ground power units in such a fashion as to not damage or mar the existing cabling and supports. Any damage caused by the contractor shall be repaired to the satisfaction of the owner at the contractor’s expense prior to installation of the new equipment.

E. Installations shall be performed in strict compliance with the Manufacturer's written Installation Procedures.

1. Manufacturer shall submit a copy of their Installation Procedures for approval, prior to installation.

F. Contractor shall engage with equipment Vendor/Manufacturer to provide site commissioning services to:

1. Verify that the installation was done correctly and in accordance with manufacturer’s instructions.

2. Perform visual inspections for correctness of wiring, phase sequence, tightness, availability of keys, interlocking wiring, input/output voltages and frequencies.

3. Provide full load testing (via load bank) for a minimum of one hour to confirm system capacity is within operating limits and provide any calibration and/or adjustment as necessary, Confirm no hot spots upon completion of full load test.

4. Using load bank, perform block load testing from 0 to 50%, 50% to 100%, 100% to 50%, 50% to 0. Confirm voltage variations at each block load test is within specified limits.

5. Provide minimum 4-hour training to airport operations/maintenance staff.

6. Document test results and submit commissioning report for review.

Method of measurement

4.1 method of measurement The 90 kVa Fixed Ground Power Units will be paid on a per unit basis. Each unit shall be measured based on each unit and shall include low-voltage electrical power conductors and cables, grounding and bonding, hangers and supports, conduits, boxes, identification tags, enclosed switches, testing and incidentals necessary to complete the installation of the ground power unit.

The 180 kVa Fixed Ground Power Units will be paid on a per unit basis. Each unit shall be measured based on each unit and shall include low-voltage electrical power conductors and cables, grounding and bonding, hangers and supports, conduits, boxes, identification tags, enclosed switches, testing and incidentals necessary to complete the installation of the ground power unit.

The Power Supply Cables will be paid on a per unit basis. Each unit shall be measured as a complete installation at a gate connecting the rotunda main panel with the GPU. This shall include the removal of the existing power cables, procurement and installation of new cables in the existing cable management system, final connections to the rotunda panel and GPU, testing and incidentals necessary to complete the installation.

The Aircraft Supply Cable Management System will be paid on a per unit basis. Each unit shall be measured as a complete installation at a gate. This shall include the removal of the existing cable hoists, procurement and installation of new cable management system, reinstalling existing or proposed aircraft supply cables, control boxes and associated interconnections, testing and incidentals necessary to complete the installation.

The Aircraft Supply cables will be paid on a per unit basis. Each unit shall be measured as a cable originating from the GPU for the purpose of supplying power to the aircraft. This shall include removal of the existing cables, procurement and installation of new cables, installing proposed cables in the existing or proposed cable management system, testing and incidentals necessary to complete the installation.

Basis of Payment

5.1 basis of payment

1. Payment will be made using the following:

1. 90 kVa Fixed Ground Power Unit (and supporting infrastructure) – Per Unit

2. 180 kVa Fixed Ground Power Unit (and supporting infrastructure) – Per Unit

3. Alternate #1 – Power Supply Cable Replacement – Per Unit

4. Alternate #2 – Replacement of Aircraft Supply Cable Management System – Per Unit

5. Alternate #3 – Replacement of Aircraft Supply Cables – Per Unit

END OF SECTION