Attachment F - P-1401 Final DB RFP 0001.pdf

FINAL DB RFP 0001

This document is to provide supplemental information to the Final DB RFP (Attachment A). The purpose is to clarify or give more specific details concerning the base bid and both bid options. Many of the following requirements are tied to specific clauses in the 6.0 Engineering Systems Requirements (ESR) D50 and G40 sections but also relate to other sections where related work is described.

1. Continuation Sheet

RFP – PART 3, Chapter 6, ESR D50 -ELECTRICAL, “GENERAL SYSTEMS REQUIREMENTS”:

Add the following:

Provide a selective coordination study, Fault current analysis, and Arc Flash Hazard report for all new equipment to include each subpanel directly connected to this new work in accordance with UFC 3-501- 01, “Electrical Engineering”. Show that the system is selectively coordinated to the greatest extent possible within the scope of work. Make recommendations on how to further coordinate the system downstream. The contractor/DOR must include all field investigation/field verification for the information necessary to conduct the studies. The studies must be conducted by a qualified professional engineer. Install approved arc flash labels on equipment. Install fault-current labels on all switchboards, enclosed circuit breakers in accordance with the NEC.

Circuit breakers must be equipped with Arc Reducing Maintenance (ARM) switch, or equivalent in accordance with NEC 240.87.

RFP – PART 3, Chapter 6, ESR D50 -ELECTRICAL, “SYSTEM DESCRIPTION”:

Delete any requirement for a minimum kW size for a temporary generator as it relates to the base bid or any bid option. The actual size of the temporary generator used in the Contractor’s construction sequence is entirely up to the Contractor and their DOR. Based upon historical loading and load profile, propose a size unit considering temperature, type of load to maintain operation at the required frequency and voltage range to ensure the vital functions of the facility continue to operate during the construction sequence.

Include this in your proposal in addition to where and how you will make your connections to the existing system to minimize downtime. The temporary generator must have the following attributes:

1 The temporary generator unit supplied must be housed in a weatherproof enclosure with a level 2 sound attenuated enclosure to minimize sound pressure levels in the immediate area of the project. The air intake and air output must be designed to limit the sound levels during operations at full load. The exhaust muffler/silencer must be located within the level 2 enclosure and escape the unit up and away from the facility.

2 The Contractor must ensure that the alternator and step loading of the generator output maintain and support this facility during the duration of the construction. The voltage and frequency behavior of the generator set must be in accordance with ISO 8528 operating limit values for performance class G2. The contractor is responsible for making all connections to each system to isolate the distribution system during construction. Contactor is responsible for maintaining generator voltage and frequency within acceptable ranges.

RFP – PART 3, Chapter 6, ESR D50 -ELECTRICAL, “SYSTEM DESCRIPTION” and D509002 EMERGENCY LIGHTING AND POWER under Base Bid:

Do not demolish and replace the existing generator parallelling switchgear and controls. The manufacturer/system integrator for this system is Caterpillar through Carter Machinery Company and currently controls/parallels and monitors three Caterpillar diesel generators. Refurbish the existing generator parallelling control switchgear to modernize its HMI, PLCs and remote annunciator/monitoring system, including redundant main processors, and necessary relays to bring the equipment back up to 100% operational integrity, in accordance with, UFC 3-540-01, “Engine-Driven Generator Systems for Prime and standby Power Applications”. Refurbishing must be accomplished by a service provider licensed by the original manufacturer/fabricator and include, inspection, repairs as required, cleaning and recalibration, alignment verification and testing of all circuit breakers, controls and, 24V DC Battery system. Provide a new circuit breaker in the refurbished paralleling gear for a connection point for a portable load bank. Program the system for its operation. Provide a permanent mechanism like a docking station/connection box on the building exterior for cables to be extended to a future portable load bank.

Extend full size conductors in conduit to the connection box. The outdoor connection box must be in a NEMA 3RX enclosure. Coordinate connection methodology with the activity. Paralleling switchgear sequence of operations must be in accordance with the following FUNCTIONAL SEQUENCE OF

OPERATIONS:

Functional Sequence of Operations

A. The System Controls shall be designed and integrated with the other specified control components to provide a completely functional total system which shall automatically perform the following generally described sequence of operations:

1) Automatic/Standby (Utility) Mode

A. The utility main breaker is closed serving utility power to its load bus and the ATS is the normal position serving utility power to its load bus.

B. The generator main breakers, emergency tie breaker, and distribution breaker are open.

C. The automation is standing by to act in response to a utility failure.

2) Emergency Mode

A. Utility Failure at utility switchboard

1) Utility protective relaying senses utility voltage or frequency out of tolerance.

2) The utility main breaker is opened.

3) A run request is sent to the generator plant.

4) The first generator up to voltage and frequency is closed to the bus.

5) The emergency tie breaker is closed.

6) The remaining generators are synchronized and paralleled to the bus as they come up to voltage and frequency.

7) The system is now in Emergency Mode.

B. Utility Failure at ATS

1) The automatic transfer switch senses utility voltage or frequency out of tolerance.

2) A run request is sent to the generator plant.

3) The first generator up to voltage and frequency is closed to the bus.

4) The distribution breaker in the generator paralleling switchboard is closed.

5) The remaining generators are synchronized and paralleled to the bus as they come up to voltage and frequency.

6) The system is now in Emergency Mode.

C. Utility Failure at utility switchboard and at ATS

1) Utility protective relaying and ATS senses utility voltage or frequency out of tolerance.

2) The utility main is opened.

3) A run request is sent to the generator plant.

4) The first generator up to voltage and frequency is closed to the bus.

5) The emergency tie breaker is closed.

6) The remaining generators are synchronized and paralleled to the bus as they come up to voltage and frequency.

NOTE: The distribution breaker in the generator paralleling switchboard closes based on its load shed level and the number of generators online (see Load Shed section).

7) The system is now in Emergency Mode.

D. Utility Restoration at utility switchboard and Exit from Emergency Mode

1) Utility protective relaying senses utility voltage and frequency within tolerance.

2) Following a 30-minute time delay (which can be abbreviated by the operator) to assure that the utility power source is stable, the generator plant is passively synchronized and paralleled to the utility source by closing the utility main breaker.

3) The generator plant is soft ramp unloaded until the utility source is nominally serving the entire system load.

4) The emergency tie breaker is opened.

5) The generator mains are opened.

6) The generators are allowed to run for their programmed cool down period.

7) The system is now back in Automatic/Standby (Utility) Mode.

E. Utility Restoration at ATS and Exit from Emergency Mode

1) The automatic transfer switch senses the utility source is within acceptable operational tolerances.

2) Following the internal retransfer timer in the ATS, the ATS transfers back to utility power and the run signal from the ATS is removed.

3) The generator main breakers are opened.

4) The generators are allowed to run for their programmed cool down period.

5) The system is now back in Automatic/Standby (Utility) Mode.

3) Closed Transition to Emergency Mode

A. Entry

1) The operator places the System Mode Selector Switch into the Closed Xfer to Emergency position.

2) A run request is sent to the generator plant.

3) The first generator up to voltage and frequency is closed to the bus.

4) The remaining generators are synchronized and paralleled to the bus as they come up to voltage and frequency.

5) Once the capacity of all the generators that are on the bus exceeds the load on the utility a five minute warmup timer will begin.

6) Following the warmup timer (which can be abbreviated by the operator), the generators are paralleled across the emergency tie breaker. They are then soft ramp loaded until the generator plant is serving nominally the entire load on the bus and the utility main breaker is opened.

7) The system is now running in Emergency Mode.

B. Exit from Emergency Mode

1) The operator removes the System Mode Selector Switch from Emergency position and returns it to the Auto position.

2) Following a 30-minute time delay (which can be abbreviated by the operator), the generator plant is passively synchronized and paralleled to the utility source.

3) The generator plant is soft ramp unloaded until the utility source is nominally serving the entire system load.

4) The emergency tie breaker is opened, and then all the generator main breakers are opened.

5) The generators are allowed to run for their programmed cool down period.

6) The system is now back in Automatic/Standby (Utility) Mode.

Load Shed Control

A. The System Controls shall include a Load Shed Control function to control the loads served by the generator plant. The Load Shed Control shall have one Essential Load Shed Priority Level for each generator in the system plus one Non-Essential Load Shed Priority Level (which is always shed in the Emergency Mode of operation). The Load Shed Control shall control the distribution circuit breaker in the generator paralleling switchboard. The distribution circuit breaker to be controlled is electrically operated. The distribution circuit breaker shall be field selectable to be assigned to any of the available Load Shed Priority Levels. Provide the following controls for each Essential Load Shed Priority Level:

1) Shed Delay Timer, adjustable from O to 1024 seconds

2) Add Delay Timer, adjustable from O to 1024 seconds

3) Load Shed Override Selector (shed/auto/add)

4) Status indicators to show whether the Priority Level is Added or Shed

5) Four form C dry contacts for load shed/add control of an external breaker/ATS

B. Provide the following controls for each Non-Essential Load Shed Priority:

1) Load Shed Override Selector (shed/auto/add)

2) Status indicators to show whether the Priority Level is Added or Shed

3) Four form C dry contacts for load shed/add control of an external breaker/ATS

C. Additionally, the Load Shed Controls shall have:

1) Load Shed Control Switch (On/Off)

2) User-settable Load Shed % (as a function of on-line generator capacity)

3) User-settable Load Shed Time Delay

4) User-settable Load Add % (as a function of on-line generator capacity)

5) User-settable Load Add Time Delay

6) User-settable Bus Under frequency Set point

7) User-settable Bus Under frequency time delay

8) Bus Under frequency Reset Pushbutton

9) Bus Under frequency indicator

Conditional Load Shed

Upon entrance into Emergency Mode of operation, the Load Shed Control shall shed all Essential and Non-Essential loads. As generators come to the bus, Essential Priority Level loads shall be added conditionally based on the number of generators on-line. When the first generator closes to the bus and the emergency tie breaker is closed, Priority Level 1 loads shall be added; Second generator, priority 2, etc. After a time delay that allows all operational generators to come to the bus, Load Shed Mode shall shift to Load Sensitive Mode.

Load Sensitive Load Shed

After all generators have been given sufficient time to come to the bus, load shed shall shift to "Load Sensitive" mode. The system shall compare current generator on-line capacity (in kW) to current load requirements. If surplus capacity is greater than the calculated Load Add setpoint, after the Load Add Time Delay the next Load Shed Priority will be added. This calculation will continue until all Sheddable Loads are added, or until surplus capacity is less than the calculated Load Add setpoint. If surplus capacity is less than the calculated Load Shed setpoint, after the Load Shed Time Delay the next Load Shed Priority will be shed. This calculation will continue until all Sheddable Loads are shed, or until surplus capacity is greater than the calculated Load Shed setpoint. The Load Shed Control, in its automatic shedding and adding of loads, shall not override any manual load shed/add operation.

If emergency mode is initiated from just the ATS the distribution breaker in the generator paralleling switchboard shall close once the first generator closes to the bus. If emergency mode is initiated from just the utility protective relays the distribution breaker in the generator paralleling switchboard shall not close during emergency mode. If emergency mode is initiated from both the ATS and the utility protective relays, the distribution breaker in the generator paralleling switchboard shall close based upon its load shed level which is operator settable at the touchscreen.

Should the load bus frequency fall below the user selected bus underfrequency setpoint for a period longer than the bus underfrequency time delay, then all Priority Level loads shall be shed, and load addition shall not resume until the operator has depressed the Bus Underfrequency Reset button. The bus underfrequency protection shall override any manual load add operation.

Generator Demand Priority Control

The System Controls shall include a Generator Demand Priority Control function to automatically match the on-line generator capacity to the loads to avoid unnecessary operation of all the generators when the loads are low.

A) The following controls shall be provided for each generator:

1) User-settable Generator Priority Selector

2) Status indicator for the Generator Priority Selected

3) Status indicator for generator On-line or Off-line

B) The Generator Demand Priority Control shall have the following controls:

1) Generator Demand Priority Control Switch (On/Off)

2) User-settable Generator Remove % (as a function of a single generator capacity)

3) User-settable Generator Remove Delay

4) User-settable Generator Add % (as a function of a single generator capacity)

5) User-settable Generator Add Delay

Upon entrance into Closed Transition to Emergency Mode, all generators shall be started, paralleled to the bus, and load transferred to the generators. After the Remove Time Delay, generators shall be removed from the bus as a function of the generator percentage loading by the user selected Generator Remove time delay. Generators shall be removed from the bus in descending priority. Should the generator percentage loading increase to the user selected Generator Add limits for the user selected Add Delay, the next generator will be started, synchronized and paralleled to the bus. Generators shall be added to the bus in ascending priority order. Should the generator plant ever reach 95% loading, the next priority generator shall be started and added to the bus with no time delay.

RFP – PART 3, Chapter 6, ESR D50 -ELECTRICAL, “SYSTEM DESCRIPTION” and D509002 EMERGENCY LIGHTING AND POWER under Base Bid for the UPS work:

Replace the two existing 500kVA UPS and provide two 250 kVA static, double conversion units, each using a 12-pulse minimum PWM IGBT rectifier forming a parallel redundant configuration Uninterruptible Power Supply (UPS) system in accordance with TSEWG TP-19, “Static Uninterruptible Power Supply” DoD supplemental Technical Documents. Each module must be a free-standing separate system and have load sharing controls for operating in parallel. Add the following UPS system requirements:

1. Each UPS must have an input harmonic reduction filter and output filter. Each 250kVA UPS module must contain a dedicated 15-minute, at full load, battery system using forced air ventilated battery cabinets with VRLA AGM maintenance free batteries connected in multiple strings using “quick connect” hardware and a DC in-line breaker in each cabinet. Provide UPS battery monitoring system for enhanced diagnostics. Battery systems must be configured so that failure of a single battery module or string cannot reduce UPS input voltage. Batteries must have a minimum 10-year warranty available.

2. The new UPS systems must each be supplied with an HMI interface and system monitoring screen. Interface the new UPS modules to operate with the generator set controls using step loading functions to ensure the system can safely transfer to and from utility power, generator power, and back again. Provide and replace the UPS 1 and 2 system remote monitoring panels located in building NH-94 to allow for remote monitoring of the system. Confirm adequacy and utilize existing battery room exhaust fans.

3. Provide each UPS with its own internal static bypass switch and single output. The two parallel-redundant UPS system must supply a new maintenance bypass switchboard. An external bypass circuit will connect to the maintenance bypass switchboard interlocked with a tie breaker from the bus connected to the UPS outputs.

4. Replace all the wiring into and out of the UPS system. Extend full size neutral conductors where required for operation. Conduits may be reused if proven to be free of obstructions and able to support new conductors. The existing overhead cable tray for the DC bus may be reused, but DC rated power cable and battery system breakers must be replaced with new. The DC ampacity of the DC link must transfer full load power at the rated voltage with a maximum of 1% total voltage drop due to conductor losses.

5. Serve UPS and bypass from circuit breakers in existing switchboard Main 1. Install five new, enclosed, 1600A minimum frame size circuit breakers with 800A trip units having LSI trip functions. New enclosed circuit breakers must have shunt trip capability to operate and work in tandem with UPS EPO switches. EPO switches must be installed near each door from the UPS room.

6. Provide a new maintenance bypass switchboard with circuit breakers connecting the outputs from each UPS. Provide interlocked breakers for connecting maintenance bypass circuit and tie breaker from the switchboard bus. Connect output from these breakers through 2000A frame circuit breaker with shunt trip and new 4 wire feed to existing MLO panel UDP.

7. Provide new circuit breakers with Arc Reducing Maintenance (ARM) switch, in accordance with

NEC 240.87.

EMERGENCY LIGHTING AND POWER -EMERGENCY POWER under Bid option (i):

Add the following requirements:

1. Generator #3 must be supplied with a generator control system compatible with paralleling gear logic and protection with specified generator protection and as recommended by the manufacturer.

2. Install new generator #3 as open construction in the Quonset hut. Contractor to evaluate and correct the maintenance and access space for the open generator.

3. Contractor must replace Gen 3’s exhaust system including piping, muffler, and structure penetrating thimble. Repair or replace the generator intake and heat rejection air throughout the Quonset Hut walls including ductwork extension. Provide a control system to open and close the louvers when not in use. Extend power for water-jacket heater, lube-oil heater, and battery charger. Existing circuits may be reused, if feasible; but new circuits must be extended from existing panels, where necessary, for the new generator operation. Provide a skid mounted day tank suitable for a minimum of 24 hours of run time at full load. Reconnect the day tank to the existing diesel underground storage tank that serves Gen 3. Modify the existing fuel monitoring system, fuel lines, jockey pumps to serve the new generator.

4. Replace existing ventilation louvers, complete with new motorized dampers and limit switches, for continued satisfactory operation. Provide unit heaters to maintain the temp at 40 degrees F during winter. Extend existing utilities as required to support the installation complete.

5. Procure a licensed structural engineer to develop and implement a plan of equipment extraction from the existing freestanding metal structure Quonset Hut housing the electrical equipment in option (i) and (ii) associated with the replacement and redesign of the generator 3 (600kW) and unit substation 2. This requirement extends to bid option 2, as well. The structural engineer must study the existing installation and create an action plan and construction sequence to safely extract/replace the equipment in a manner to allow the metal Quonset Hut structure to be restored to its weather-resistance and structural integrity after the project work is completed. The structural engineer must be a professional engineer familiar with the modification of existing metal structures and removing and re-installation of large equipment safely and effectively inside similar structures. The contractor must make all recommended safety and structural modifications in the explicit manner specified by the structural engineer throughout the construction of the project. All procedures and special equipment used in this process must be approved by the Activity and their Security personnel. The design services, field work and other engineering services/surveys for each of the two bid options must be prorated and split between the two options. No additional services or cost will be allowed to the Contractor based upon whether either bid option is awarded or both.

EMERGENCY LIGHTING AND POWER -EMERGENCY POWER under Bid option (ii):

1. New Secondary Unit Substation configuration will not be used. Reference G40 for installation of pad mount 750kVA transformer outside the Quonset hut. Install new switchboard inside the Quonset hut.

2. Remove the existing unit substation from inside the Quonset hut and install new switchboard.

Remove 35kV cabling from inside the Quonset hut and reroute to new pad mount transformer.

3. Note that switchboard Main 2 has a 2000A circuit to the Automatic transfer switch (ATS), a 200A circuit to elevator disconnect switch and 250A circuit to panel existing “DU” and must be reconnected. It is anticipated that the circuit to the ATS will be replaced with new while the other two existing circuits can be reconnected to the new switchboard Main 2. Confirm with placement of Main 2.

4. Rearrange the new electrical equipment in the Quonset Hut to obtain all necessary NEC and maintenance clearances.

5. Procurement of a licensed structural engineer as discussed above applies to bid option (ii) too.

RFP – PART 3, Chapter 6, ESR G40 - SITE ELECTRICAL UTILITIES - Bid option (ii):

New Secondary Unit Substation configuration will not be used. Install the pad mount 750kVA transformer outside the Quonset hut. Reference G50 and Install new switchboard inside the Quonset hut.

RFP – PART 3, Chapter 6, ESR G40 -SITE ELECTRICAL UTILITIES -G4010 ELECTRICAL

DISTRIBUTION:

Modify the 34.5kV circuit and primary switches in a manner to remain outside and not be routed through the Quonset hut. Utilize new 35 kV, copper 1/C #1/0 EPR cables with 133% insulation levels and a copper shield for extensions to the existing pad mount switchgear. Provide secondary service cable in 5-inch conduit duct bank, from the pad mount transformer to the new switchboard in the Quonset hut.

RFP – PART 3, Chapter 6, ESR G40 -SITE ELECTRICAL UTILITIES -G401001 SUBSTATIONS:

Delete requirement. Change to “NOT USED”.

RFP – PART 3, Chapter 6, ESR G40 -SITE ELECTRICAL UTILITIES -G401002 TRANSFORMERS:

1. Install new pad mount transformer, coordinate location with the Activity and coordinate the 34.5kV primary installation with the local utility authority. Locate new transformer adjacent to the Quonset Hut in an approved location free from underground utilities and other underground structures. Contractor must survey the exact location to prove installation. Approved location may be up to 120ft from the existing hut at no additional charge to the Government. Grade for the installation of the transformer and primary extension must be re-finished to match existing grade.

2. Transformer must be dead front design with ANSI specific front plate spacing, 3-two-position load break switches to permit closed transition loop feed and sectionalizing, rated 300A, fixed primary bushings and 600A dead break connectors in accordance with local requirements.

Provide bayonet fuses in series with partial range current limiting fuses. Include three surge arrestors. Provide transformer with biodegradable, less-flammable liquid, in accordance with UFC 3-550-01. Edit UFGS 26 12 19.10 for procurement specification.

3. Provide utility authority compliant, elevated transformer pad with the top 12-inch minimum above grade and 2 levels of rebar. Extend two 5” concrete-encased PVC primary conduits to the transformer from the existing 35 kV underground distribution system. Stub two empty 5” PVC conduits 5 ft from pad for future extension. Cap ends.

RFP – PART 3, Chapter 6, ESR G40 -SITE ELECTRICAL UTILITIES -G401009 METERING:

Provide a new AMI 208V, 3-phase, Shark 270 Meter in a stainless-steel enclosure in accordance with local metering requirements. Connect the new meter to the utility reporting system in accordance with the Base requirements.