DATA SHEET_21126300.pdf

DOC # 2112-6300

SPECIFICATION FOR PROCUREMENT OF 1500KVA ISOLATION TRANSFORMER

1 SCOPE. This document specifies the minimum requirements for the procurement of a transportable 1500kVA, 480VAC isolation transformer for supplying AC shore power to naval vessels and temporary loads in a marine industrial environment.

2 APPLICABLE REFERENCES. Equipment shall comply with applicable requirements of the following references and with all specifications of this document. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption is obtained.

2.1 FED-STD-H28A - Screw Thread Standards for Federal Services

2.2 29 CFR 1915 - Occupational Safety and Health Standards

2.3 ASTM D 3951 - Standard Practice for Commercial Packaging

2.4 AWS D14.4 - Specification for Welded Joints in Machinery and Equipment

2.5 NEMA ICS 6 - Enclosures for Industrial Controls and Systems

2.6 NFPA 70 - National Electrical Code

2.7 NFPA 79 - Electrical Standard for Industrial Machinery

2.8 UL STD 1561, Dry-Type General Purpose and Power Transformers

2.9 NEMA ICS 1 – Industrial Control & Systems: General Requirements

2.10 NFPA 70E – Standard for Electrical Safety in the Workplace

3 REQUIREMENTS.

3.1 GENERAL REQUIREMENTS. The equipment shall consist of a single transportable unit that meets all specifications of this document and is new and unused. Unit provided shall not be an “experimental” or “prototype” unit.

3.1.1 NEW DEVELOPMENT. If, during the contract period, any new developments are generated that would improve the efficiency, accuracy or productivity of the equipment and its related equipment or decrease its operation costs, the contractor shall notify the Contracting Officer. Reports of such developments shall be addressed to the Contracting Officer.

3.1.2 SAFETY AND HEALTH REQUIREMENTS. Covers, guards, or other safety devices shall be provided for all parts of equipment that present safety hazards. Safety devices shall not interfere with operation of the equipment. The devices shall prevent unintentional contact with the guarded part and shall be removable to facilitate inspection, maintenance, and repair of the parts. Additional safety and health requirements shall be as specified in other paragraphs of this specification.

3.1.3 OSHA APPROVED CERTIFICATION. The equipment installation and its component parts shall be in compliance with the applicable OSHA regulations in accordance with CFR Title 29, Chapter XVII, Part 1910 and installed in accordance with NEC/NFPA requirements.

Approval shall be as specified under the “Approval” and “Acceptance” criteria in the OSHA regulations Subpart “O” Machinery and Machine Guarding paragraph 1910.212 and Subpart “S” Electrical paragraph 1910.303 and paragraph 1910.399. After equipment delivery and prior to testing, the contractor shall provide an OSHA Certification Report. Failure to provide this certification report will delay acceptance of the equipment and could result in rejection for failure to comply with the terms of the contract. This OSHA Certification Report documents the results of all tests performed, provides an assessment of the equipment performance for compliance with the contract requirements, and forms a basis for recommending a safety certification. The report, test, and evaluation shall be a composite of those inspection requirements specified in the contract. The report shall be prepared in an orderly manner to clearly and accurately set forth the collected data and conclusion resulting from these inspection requirements and opinions. Subjective conclusions shall be clearly identified. The report shall include, but is not limited to, the following:

3.1.3.1 List of all tests performed along with corresponding witnesses.

3.1.3.2 List of data used for evaluation.

3.1.3.3 Tabulation of all discrepancies related to specification performance requirements.

3.1.3.4 Description of limitations revealed by data utilized.

3.1.3.5 Actions taken to mitigate each discrepancy and limitation.

3.1.3.6 Recommendations for subsequent actions.

3.1.3.7 Summary of conclusions.

3.1.3.8 Manufacturer Certification that equipment has been manufactured and installed to OSHA CFR 1910.399 (per definition of “acceptable”).

3.1.4 AUDIBLE NOISE LEVEL. Audible noise emitted by the equipment shall not exceed 85 dB at any point 2 feet (24 inches) or further from the enclosure.

3.1.5 ENVIRONMENTAL PROTECTION. The equipment shall be designed and constructed, so that under the operating service, transportation, and storage conditions described herein, the equipment shall not emit materials hazardous to the ecological system as prescribed by federal, state, and local statutes in effect at the time of bid.

3.1.6 HAZARDOUS SUBSTANCES. The equipment shall not contain asbestos or polychlorinated biphenyl (PCB) compounds. The equipment shall not contain lead or lead compounds with the following exceptions: lead inside electronic components, lead solder, and lead-acid batteries.

3.1.7 FERROUS PARTS. Exposed ferrous parts such as screws, bolts, nuts, washers, etc., shall resist corrosion in a salt-laden, moist, variable temperature atmosphere. Protection such as chrome plating, galvanizing or other electrical/chemical process, or stainless steel is acceptable.

3.1.8 DISSIMILAR METALS. Dissimilar metals shall not be used in direct contact with each other without suitable means for preventing electrolytic corrosion.

3.1.9 LUBRICATION. Bearings (except sealed-for-life and self-lubricating type), mating gears and sliding parts shall be provided with means for lubrication.

3.1.10 PRE-FABRICATION DRAWING. Prior to commencing fabrication of the transformer, contractor shall provide a drawing of the equipment for review/approval. Drawing shall clearly reflect the center of gravity and shall reflect all pertinent information regarding the specified requirements.

3.1.11 EXCEPTIONS. Exceptions to these specifications will be considered. If the contractor takes exceptions to any part of these specifications, all exceptions shall be listed in a manner where each exception references the specification paragraph to which the exception applies.

Exceptions shall be submitted as part of the bidding proposal.

3.2 CONSTRUCTION. The equipment shall be constructed of parts that are new, without defects, and free of repairs. The equipment construction shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to damage from environmental hazards (such as dust, debris, or residue) shall be sealed or otherwise protected. The structure shall withstand all forces encountered during the operation of the equipment to its maximum rating and capacity without permanent distortion or failure. Any loose or spattered solder, flux, metal chips, insulation scrap, or other foreign material shall be removed from the equipment.

3.2.1 WELDING, BRAZING AND SOLDERING. Cold solder joints, incomplete joining of solder and metal, excess or insufficient solder or damaged insulation shall be considered reason for rejection of the equipment. Flux for soldering shall be rosin or rosin and alcohol. No acid, acid salts or acid core solder shall be used in preparation for soldering of electrical connections.

Weldments shall comply with reference 2.4.

3.2.2 FASTENING DEVICES. Screws, pins, bolts, and similar internal and external parts shall be installed with means for preventing change of tightness. Parts subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently installed. Fastening devices shall be tightened to torque limits as established by the manufacturer's standard for tightening to preclude loosening by normal operation or vibration.

3.2.3 SURFACES. Surfaces of parts shall be free from debris that could impede operation or cause damage to parts. External surfaces shall be smooth. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function.

3.2.4 THREADS. All threaded parts used on the equipment and its related attachments and accessories shall conform to reference 2.1.

3.2.5 PLUMBING. All metallic valves, pipes, and tubes shall be brass, galvanized steel, or stainless steel to prevent corrosion.

3.2.6 WIRING. All conductors and terminals shall be conservatively sized for their respective loads and be marine grade. Terminals shall be protected with adhesive-lined heat shrink tubing wherever possible. Wiring shall be rated at 105°C or higher. Wiring shall be installed in a manner which prevents stress on cable, wires and connections. When wires or cables must pass through a frame, by irregular surfaces, sharp edges, or heat dissipating parts, they shall be routed and protected to prevent damage or degradation of the equipment. All wiring and bus bars shall be copper. Adequate spacing shall be maintained throughout to avoid excessive bending of cabling and wiring, to maintain adequate separation and creep distance between electrical potentials and between these potentials and ground. In no instance shall clearances and creep distances be less than those prescribed under NEMA ICS 1-2000.

3.2.7 CONNECTIONS. AC electrical connections within the equipment shall be complete and shall be made via terminals on the components, terminal/circuit boards and bus bars.

Conductors shall not be spliced between terminations. Bus bars that carry primary or secondary current shall be silver or tin plated at connection points. Connections and terminals shall be supported and spaced without dependence upon the wiring in the components and braced as necessary to assure withstanding the distortion forces associated with available short-circuit currents. Proper identification of wiring, bus bars, terminals and circuits for function, polarity, phasing, etc., shall be adhered to throughout the equipment. Identification shall be in the form of wire markers, color coding, permanently engraved plates, or permanent markings on the devices. Allow adequate spacing to permit ease in disconnecting wiring and cabling during trouble-shooting and repair. In no instance shall clearances and creep distances be less than those prescribed under NEMA ICS 1-2000.

3.2.8 EQUIPMENT. All equipment and their respective installations shall conform to relevant NEMA, ANSI and NFPA standards for the intended application. Given the operating environment of the equipment, current carrying components and adjacent components shall be insulated to prevent tracking.

3.2.9 VENTILATION. Adequate cooling or ventilation shall be provided on the equipment to preclude premature deterioration of the equipment or any component thereof when utilized under the ambient and operating conditions specified herein.

3.2.10 MEASURING/INDICATING DEVICES. All measuring and indicating devices such as dial indicators, pressure gages, temperature indicators, and other similar devices used on the equipment shall be graduated in the U.S. Customary System of Units (US). Marking on all measuring and indicating devices shall be permanently and legibly engraved or etched on a non-glare background. All dials and other indicating devices shall be securely mounted in place.

3.2.11 MAINTAINABILITY. The equipment shall be designed and constructed to permit Maintenance Personnel to easily service the equipment using a minimal number of tools. All parts subject to wear, breakage, or distortion shall be accessible for adjustment, replacement or repair. Consistent with required maintenance and design of the equipment, the contractor shall provide any special tools required to service the unit. The equipment shall be equipped with access covers to facilitate inspection, cleaning, and repair or replacement of internal parts.

3.2.12 INTERCHANGEABILITY. All parts of the end item shall be manufactured to definite standards and tolerances that will provide for the interchangeability of respective parts between end items of the same model without modification of the part or the equipment. All replacement parts shall be available commercially within the continental United States.

3.2.13 CONTROLS AND INSTRUMENTATION. Operator controls, instrumentation and indicators shall be mounted convenient to operating personnel. Such devices shall be clearly and legibly marked for function and identification. Controls shall be fitted with suitable handles, pushbuttons, or control knobs, as applicable.

3.3 COMPONENTS. The equipment shall consist of, but not be limited to, the following described principle components, attachments, and accessories necessary to meet the operational and performance requirements specified herein. Any additional components necessary for the operation of the equipment shall also be furnished in accordance with the manufacturer's standard practice. To the largest extent practical, all hardware, material, and components shall be of US or Canadian origin.

3.3.1 GENERAL DESIGN. Transformer shall be a dry type, air cooled design.

3.3.2 POWER OUTPUT REQUIREMENTS. The transformer shall be an air cooled dry type with a 1:1 winding design and a power rating of 1500kVA. The designed electrical ratings are for both the input (primary) and output (secondary) of the transformer. Power connections are 3-phase, 480 VAC power at 60 Hz. The transformer shall have 3 selectable taps for nominal voltage (100%, 102.5%, and 105%) with a +/- 1% tolerance. Natural circulation shall be used to cool the transformer. The natural circulation of the enclosure must be adequate to cool the transformer in order to prevent any overheating from occurring when operating at its full load in any of the conditions described in section 3.3.3.

3.3.3 PERFORMANCE. Transformer shall perform continuously under any load condition including full rated load. Design and construction of the transformer shall be considerate of operating and storing the equipment, without added protection, under any combination of the following ambient conditions without loss of capacity or damage to equipment:

3.3.3.1 Elevation: 50 feet below to 100 feet above mean sea level

3.3.3.2 Temperature: -10° F to 100° F

3.3.3.3 Relative Humidity: 0 % to 100 %

3.3.3.4 Wind Velocity: 0 to 100 miles per hour

3.3.3.5 Unusual Service Conditions: salt water spray, direct exposure to sunlight, contaminated industrial environment including dust, fumes, smoke and blast grit, and inclement weather including wind driven rain and snow.

3.3.4 ELECTRICAL RATINGS:

3.3.4.1 Minimum full load rating: 1500KVA

3.3.4.2 Nominal input voltage: 480VAC phase-to-phase, 3 phase, 60Hz

3.3.4.3 Nominal output voltage: 100%, 102.5%, or 105% of input voltage, selectable via taps.

3.3.4.4 Output voltage tolerance: +/- 1% of nominal output voltage.

3.3.4.5 Impedance: 4.2% maximum

3.3.4.6 SCA: Windings and bus bars shall be braced for up to 100,000A of short-circuit current.

3.3.4.7 Droop/compensation voltage: 3% maximum

3.3.5 CONTROL AND INDICATION. All controls and indicators/gauges shall be clearly accessible/visible while maintaining a no category Arc Flash Personal Protection Equipment requirement and shall include the following:

3.3.5.1 Control handle and status indicator for main circuit breaker.

3.3.5.2 Control power circuit breakers and/or fuses.

3.3.5.3 Control and status indication for any accessories (e.g. fans, heaters).

3.3.5.4 Output current, voltage and frequency indication.

3.3.5.5 Unit shall contain a temperature monitoring system that monitors for transformer hot spots, with maximum allowable temperature shown on the indicator(s).

3.3.6 GROUNDING. Input and output shall be configured as an ungrounded setup where the phases and neutral are completely isolated from ground. Exposed, non-current carrying metal parts on the equipment shall be maintained at earth ground potential. None of the primary circuits in the equipment shall be connected to ground. An accessible ground stud or lug on the outside of the equipment enclosure shall provide means for grounding the equipment for safety to personnel.

3.3.7 MAIN CIRCUIT BREAKER. The transformer shall be provided with a primary circuit breaker installed between the input power connection point and the primary transformer windings. The circuit breaker shall be rated for 100,000A (minimum) short circuit interrupting capacity. The circuit breaker overcurrent set point shall be adjustable to the following values (minimum): 1200A, 1600A, 1800A, 2000A. The circuit breaker shall provide a remote trip capability as described below.

3.3.8 LOCKOUT REQUIREMENTS. A physical means shall be provided to prevent energization of the AC output bus bars, such that the equipment can be locked out for energy control purposes using a standard padlock. This isolation means shall mechanically prevent energization. The main circuit breaker designed with a lockout may be used as the lockout device.

3.3.9 REMOTE TRIP. An Amphenol Star-line series 7 pin receptacle with environmental cover using pins 2 and 5 for the remote trip contacts and pin 3 for ground shall be provided for connection of a remote trip device (Amphenol Star-Line series part number ZPEM-12 12- 310SN-03 or equivalent). The remote trip circuit shall trip the main circuit breaker upon closing of an external contact (“shunt trip”). The remote trip circuit shall be 120VAC (nominal). The power source for the remote trip circuit shall be derived from the primary input power via an auxiliary step-down transformer built into the provided equipment.

3.3.9.1 Amphenol Star-line series 7 pin receptacle shall be accessible on the exterior of the equipment enclosure to allow for remote trip connection while maintaining a no category Arc Flash category for Personal Protection Equipment requirement.

3.3.10 CONNECTION POINTS. Connection points shall be provided as follows.

3.3.10.1 Two (2) connection points shall be provided, one for input power and one for output power. Connection points shall be capable of handling the power requirements of section 3.3.2 and 3.3.4.

3.3.10.2 Connections shall be placed to prevent excessive stress or bending of power cables.

3.3.10.3 Connection points shall be able to accommodate 4 ea 500 kcmil type W cables with lugs (single hole, ½ inch hardware) per phase.

3.3.10.4 Connection point shall be able to accommodate 2 ea 800 kcmil type W cable with lugs (double holes spaced 1.75” apart, ½ inch hardware) per phase.

3.3.10.5 Connection points shall be fully enclosed. Each connection point enclosure shall be provided with a minimum of (1) access door. The connection point enclosures shall be placed near the top of the enclosure and extend outward from the main body of the enclosure, such that the government can install cable entrances on the bottom of each connection point enclosure.

3.3.10.5.1 Bus bar connection points shall be designed to be cleaned in place without disassembly.

3.3.10.5.2 Connection points composed of multiple stacked bus bars shall be bolted together to maintain contact between parallel stacked bus bars. The stacked bus bars shall not rely on the cable lug connection hardware to maintain contact between parallel stacked bus bars.

3.4 MAIN ENCLOSURE. The requirements for the main enclosure are as follows:

3.4.1 MATERIAL. All components of the equipment shall be contained within one common enclosure. Surface shall be suitable for soap and water cleaning.

3.4.2 SIZE. The enclosure shall be of the minimum size that allows for adequate ventilation of components with dimensions no greater than a length of 15 feet, a width of 6 feet, and a height of 8 feet.

3.4.3 WEATHERPROOFING. The enclosure shall be NEMA 3RX rated or equivalent and shall maintain its NEMA 3RX rating when cables are connected to the input and output bus bars. The enclosure shall be of weatherproof construction to include flooring with appropriate drains installed. Additionally, the bottom of the enclosure shall be designed to prevent dust and moisture from ground water to be drawn inside. All openings to the interior of the transformer enclosure shall be adequately sealed to prevent entry by rodents (e.g. screens on all permanent openings).

3.4.4 TRANSPORTABILITY. The transformer enclosure with installed equipment shall be designed to be safely lifted and transported without being trailer mounted. Vertical, horizontal, and cross bracing (as applicable) shall be of adequate size and thickness to withstand any reasonable stress that may be imposed when in transit as well as during normal operation.

3.4.5 DOORS AND COVERS. The sides of the enclosure shall be fitted with hinged doors to permit full access to the installed equipment for routine inspection, in-place maintenance, trouble shooting, and removal of components. Door hinges and latches shall be of stainless steel construction and shall be conservatively sized to handle repeated use, abuse, and stress. Each door/cover shall be designed and equipped with appropriate gaskets/seals to protect the inside of the enclosure against the outside environment. Door gaskets/seals shall be robust and selected to survive repeated opening and shutting of doors.

3.4.6 LIFTING PROVISIONS. The enclosure shall be provided with certified crane lift points and forklift tine guides as follows:

3.4.6.1 QUANTITY OF LIFT POINTS. For design purposes, only 2 diagonally opposed lift points shall be considered to support the weight of the equipment, regardless of the total number of lift points used.

3.4.6.2 DESIGN LOAD. Vertical Design Load shall be taken as the base equipment weight plus 10%. The base equipment weight is what the assembled item weighs, as delivered, plus the maximum possible weight of all fluids or materials that the item is capable of containing when used as designed.

3.4.6.3 WORKING LOAD LIMIT. Working Load Limit (WLL) shall be calculated by multiplying the portion of the Vertical Design Load applied to each of the two diagonally opposed lift points by a factor of 1.155 (to account for a minimum rigging gear sling angle of 60° above horizontal).

The WLL shall be used for all lift point design calculations and while based on only two lift points supporting the load, applied to each lift point installed.

3.4.6.4 LIFT POINT CALCULATIONS. The lift points, and the equipment structure to which the lift points are attached, shall be checked by a qualified engineer for adequacy per the requirements presented here. Analysis of the equipment structure shall also include buckling analysis per AISC, Allowable Stress Design methodology, as needed, to verify integrity of the structure, considering the loadings imposed by the orientation of the WLL as described herein.

Calculations supporting the lift point design shall be submitted for review prior to acceptance of the equipment. Allowable stresses for the lift points shall be based on the following:

YS = Yield Strength (minimum) UTS = Ultimate Tensile Strength (minimum)

UTSORYSMINIMUMALLF

(Allowable bending/tensile stress. Use the minimum value.)

ALL

ALL

F

=τ (Allowable shear stress)

*5.1 UTS

BEARING =σ (Allowable bearing stress based on projected area of shackle pin.)

3.4.6.5 LIFT POINT ORIENTATION. Orientation of lift points shall be such that when loaded, the direction of lifting load will be in the plane of the padeye plate ± 5°. Location of lift points shall be symmetrical with respect to the equipment center of gravity (CG). Lift points shall also be in a common horizontal plane above the CG. Location of lift points shall consider that each leg of lifting gear will be of equal length. The equipment shall lift level within 3°. If the equipment is intended to be stackable, provisions in the design shall be made to prevent damage to the lift points of the lower item if the upper item is not landed accurately or symmetrically. When lift points are installed on the supporting structure by welds that carry the lifted load, welding shall be performed and visually inspected in accordance with AWS D1.1.

3.4.6.6 LIFTING PROCEDURE. The equipment shall be capable of being lifted in its entirety without any disassembly and without degrading the weather resistance of the equipment enclosure (as specified in 3.4.4).

3.4.6.7 TINE GUIDE OPENINGS. The equipment shall be provided with box-section tine guides meeting ASME standards for forklifts, tine-guide openings in the base for safe handling and transport by forklift truck from each side. The box sections shall extend through the entire length or width of the equipment, completely enclosing the forklift tines. They shall be fabricated from heavy metal/channel having a definite thickness to withstand the stresses imposed. Box sections shall have internal cross-sectional dimensions of at least 6 inches high by 12 inches wide. Tine guide openings shall extend approximately 2 to 3 inches beyond the furthest outward point of the exterior of the enclosure. Center-to-center dimension of the tine guide openings shall not exceed 48 inches. Tine guides shall be centered about the unit’s center of gravity. They shall be welded to the base and so spaced apart, center-to-center, that while transporting the equipment, a forklift truck can pass over pavement obstructions causing dynamic stresses representing five (5) times the equipment's weight without causing the box sections to fracture or part from the base.

3.5 LABELING REQUIREMENTS. The equipment shall be labeled as follows:

3.5.1 INSTRUCTION PLATES. Wording and numbers on all control panels, instruments, charts and plates shall be permanently and legibly displayed in bold face, English language characters on a contrasting background. Stencil the design load weight and electrical capacity (KW) on at least one side of the enclosure.

3.5.2 CAUTION/WARNING PLATES. Corrosion resistant "Caution" or "Warning" plates shall be securely attached to the equipment in prominent, visible locations. All safety precautions to be observed by the operator or maintenance personnel shall be permanently marked on the plates.

3.5.3 IDENTIFICATION PLATE. A corrosion resistant identification plate shall be securely and conspicuously placed on the equipment. It may be the manufacturer's standard, but, as a minimum, it shall contain the following information:

3.5.3.1 Nomenclature.

3.5.3.2 Contractor's name.

3.5.3.3 Manufacturer's model designation.

3.5.3.4 Manufacturer's serial number.

3.5.3.5 Electrical characteristics (rated voltage, amperage, frequency, phases, etc).

3.5.3.6 Contract number.

3.5.3.7 Date of manufacture.

3.5.4 LUBRICATION PLATE. If parts of the equipment require periodic lubrication, a corrosion resistant lubrication plate shall be securely attached to the equipment providing, at a minimum, the following information:

3.5.4.1 Points of application.

3.5.4.2 Service interval.

3.5.4.3 Type of lubricant.

3.5.4.4 Viscosity.

3.5.5 ARC FLASH. Appropriate arc flash placards and stickers shall be placed on the covers of all enclosures where an arc flash hazard exists. The arc flash warning placards/stickers shall include Flash Hazard Boundary, Cal/cm2 Flash Hazard at 18 inches, Class Level of Electrical Safety Equipment, and Shock Hazard Voltage Level when covers are removed.

3.5.6 LIFT SKETCH DATA PLATE. A corrosion resistant data plate shall be securely and conspicuously placed on the equipment that provides a diagram of the proper lifting method for the equipment using the lift points, including the design load weight of the equipment and rated load of each lift point.

3.6 TECHNICAL DATA. Provided technical data, written in the English language, shall contain, as a minimum, the following information:

3.6.1 General introductory information including pictures displaying the identity and location of components.

3.6.2 Specifics of "as built" transformer characteristics.

3.6.3 Itemized start up checklist and detailed operating procedure.

3.6.4 Listing of safety/protective systems.

3.6.5 Listing of control systems and printed circuit cards and components included in or affecting each.

3.6.6 Description of major components, and a parts list of all components with applicable vendor information, CAGE code, etc.

3.6.7 Schematic, arrangement, description of function, and test and adjustment for each circuit card.

3.6.8 All required maintenance information.

3.6.9 Relay function reference table listing each device, its function and part number.

3.6.10 Troubleshooting suggestions.

3.6.11 Test data and documentation with certification signature(s) reflecting the satisfactory accomplishment of tests performed in paragraphs 4.2 and 4.4.

3.6.12 List of major drawings.

3.6.13 Drawings of the following:

3.6.13.1 A schematic diagram, of the complete electrical system.

3.6.13.2 Printed circuit card interconnection diagram.

3.6.13.3 Complete wiring diagram of all components.

3.6.13.4 Sections and details, incorporating part numbers of devices, to enable simplification of maintenance.

3.6.13.5 Exploded view of entire unit as well as all major components

3.6.13.6 Assembly drawing.

3.6.14 One or more disk(s) containing all technical data listed from (a) through (m) above in Adobe PDF format.

3.7 TRAINING QUALIFICATIONS. The contractor shall provide one or more qualified representatives who are conversant in English and are thoroughly familiar with all aspects of equipment installation, calibration, maintenance, and operation for the training of facility personnel. Representative(s) shall possess U.S. citizenship and be of good standing and repute. All printed training aids shall be supplied at no additional cost to the government, be in the English language, and become the property of the U.S. Government.

3.8 ON-SITE TRAINING – CIVILIANS. Within 30 days after receipt of a written request by the receiving activity, the services of a qualified training representative(s) shall be provided.

The representative(s) shall train personnel on site at the receiving activity. Training service shall not be less than one (1), eight hour work day to instruct personnel of the journeyman mechanic's level in the proper operation and maintenance of the equipment.

4 QUALITY ASSURANCE PROVISIONS. The contractor shall conform to quality assurance, inspection and testing criteria as follows:

4.1 RESPONSIBILITY FOR INSPECTION. The contractor shall be responsible for the performance of all inspection requirements (examinations and tests) as specified herein. The contractor shall be responsible for ensuring that the equipment provided meets all requirements of Section 3. The Government reserves the right to perform additional inspections and to reject the equipment provided if these inspections show that the equipment does not meet all requirements of Section 3.

4.2 TEST SCHEDULE COORDINATION AT ORIGIN. The contractor shall be responsible for coordinating testing schedules at the origin of the contracted work. Contact the receiving activity, through the Contract Administration Office a minimum of thirty (30) working days prior to performing the scheduled tests of paragraph 4.4, in order to provide the receiving activity the opportunity to observe the testing.

The contractor shall notify the receiving activity along with a written copy of the notification.

Only supplies that completely conform to the specifications shall be offered for inspection and test. The contractor's test schedule shall allow consecutive inspection and test of the supplies offered. The Government reserves the right to charge the contractor for any Government re-inspection cost when supplies are not ready at the time requested by the contractor or when necessitated by prior rejection.

4.3 EXAMINATION. The equipment shall be examined to determine compliance with all requirements of this specification. The supplies offered for delivery shall be examined for design, construction, components, electrical equipment and workmanship to determine conformance with the requirements of this specification.

4.4 TESTS AT ORIGIN. At a minimum, the following tests shall be carried out by the manufacturer or manufacturer’s representative prior to delivery of the equipment.

4.4.1 INSULATION RESISTANCE TESTS. Perform insulation resistance tests from each phase to ground using a calibrated 1000VDC megohmmeter on the input and output bus bars.

The resistance between current carrying members and ground shall not be less than 500 megohms at any point tested. This test shall be performed a minimum of two (2EA) times, once prior to load testing and again following load testing.

4.4.2 OPERATIONAL TEST. Energize the transformer. Verify accuracy of installed metering and ensure that output power complies with paragraph 3.3.4.

4.4.3 LOAD TEST. Accomplish a load test as follows. During the test, observe that output voltage, current and frequency remain in compliance with paragraph 3.3.4, that installed metering continues to function properly, and that the equipment’s internal temperature does not exceed safe operating levels.

4.4.3.1 Apply load in 20% increments until 100% of full load capacity is reached. Operate for a minimum of ten (10) minutes at each load step. Record output voltage, current and frequency at each step.

4.4.3.2 Operate the transformer at 100% of full load for a period of at least three (3) hours.

4.4.3.3 Remove load in 20% increments until transformer is unloaded, then secure power to the transformer.

4.4.4 AUDIBLE NOISE TEST. While operating at full load, perform audible noise testing to ensure conformance with paragraph 3.1.4.

4.4.5 LIFT POINT TESTING. Each lift point shall be load tested to 200% of WLL and held under load for 2 minutes. Acceptance criteria shall be: no bending, cracking, or permanent deformation of the lift points or associated supporting structure. Documentation shall be provided on the fabricator’s company letterhead stating that each lifting pad has successfully passed the 200% test. The fabricator shall mark the lift points in a permanent manner with the WLL, test date, and test load applied. All weights shall be marked in pounds.

4.5 TEST AND EVALUATION REPORT. A test and evaluation report shall be prepared by the contractor documenting all readings and results that were recorded during the performance of paragraphs 4.2 and 4.4, including any defects found, repairs that were made and documentation of the subsequent retesting. This test and evaluation report shall be provided to the Government along with the equipment.

4.6 WARRANTY. Contractor shall provide a warranty period in writing covering all parts and labor associated with the repair of the transformer.

4.6.1 When possible, all repairs covered by warranty shall take place on site.

4.6.2 Warranty shall commence from the date of acceptance of the transformer.

4.6.3 Warranty period shall be no less than three (3) years from date of acceptance.