Attachment_A.pdf

1 Attachment A

Attachment A- Low Engine Speed (Preferred SOW)

1.0 SCOPE

1.1 The Mobile Utilities Support Equipment (MUSE) Division, Port Hueneme exchange contract objective is to utilize existing resale and/or core value of twenty-eight (28) power plants to receive multiple 1400 kW power plants in exchange. The Contractor shall provide NEW, diesel engine driven, commercially available, self-contained and transportable power plants which will not be used as military tactical equipment. The power plants shall be rated at minimum of 1400 kW at 60 Hertz (Hz) Continuous Power (COP), 4160/3300 volts, three-phase, four-wire, wye, 60/50 Hz, 0.8 power factor (pf) lagging. The kW rating at 50 Hz shall be Contractor determined.

The generator shall be a brushless-type with a permanent magnet (PMG) exciter. The power plant shall consist of a skid mounted, housed engine-generator unit, a skid mounted, housed switchgear-control unit, a skid mounted auxiliary unit and all necessary power cables, interconnecting control cables and piping required for operation and specified equipment.

1.2 The following twenty-eight (28) total power plants are offered as an exchange (Attachment C contains the Detailed Description of Old Power Plants):

-750kW (4160VAC/130Amp/60Hz) 5 power plants -1500kW (4160VAC/260Amp/60Hz) 10 power plants (includes control skid) -2000kW (4160VAC/347Amp/60Hz) 7 power plants (includes control skid) -2500kW (4160VAC/430Amp/60Hz) 6 power plants (includes control skid)

The government will transfer ownership of OLD generators in lots. The first lot, approximately 30%, will be transferred upon approval of the design. The second lot, approximately 30%, will be transferred upon successful completion of testing of new power plant/s, the remaining units, approximately 40% will be transferred upon delivery and acceptance of the new power plant units.

All twenty-eight (28) total power plants and associated collateral equipments must be removed from MUSE, at the Contractor’s own expense, within 3 months’ time of transfer of ownership.

2.0 APPLICABLE DOCUMENTS (applicable to each power plant delivered under this contract)

2.1 Government Documents. The following documents form a part of this contract to the extent specified herein. Unless otherwise specified, the effective dates of all referenced documents shall be the dates referenced in the Department of Defense Index of Specifications and Standards (DODISS) in effect at the time of solicitation issuance.

Military:

MIL-STD-129P (w/Change 4), Department of Defense Standard Practice: Military Marking for Shipment and Storage, 19 September 2007

MIL-STD-461F, Department of Defense Interface Standard: Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment, 10 December 2007

MIL-STD-705C, Military Standard, Generator Sets, Engine Driven, Methods of Tests and Instructions, 24 April 1989 (Applicable to Table I tests only)

MIL-STD-889B, Military Standard: Dissimilar Metals, May 1993

MIL-STD-1472G, Department of Defense Design Criteria, Human Engineering, January 2012

2 Attachment A

MIL-F-16884J, Military Specification, Fuel Naval Distillate, 31 May 1995

MIL-T-5624R, Military Specification, Turbine Fuel, Aviation, March 1995

MIL-L-2104F, Military Specification, Lubricating Oil, Internal Combustion Engine, 11 march 1992 (Including Amendment-1, 28 September 1992)

MIL-PRF-009000K(SH), Performance Specification, Lubricating Oil, Shipboard Internal Combustion Engine, High Output Diesel, 27 April 2011.

Copies of the above document are available from the Defense Automated Printing Service, Standardization Documents Order Desk, (215) 697-6257/6396 or via their website: http://dodssp.daps.dla.mil.

Federal:

Title 23 Code of Federal Regulations, part 658, Federal Highway Administration, Department of Transportation

Title 29 CFR Part 1910, Occupational Safety and Health Administration (OSHA)

Title 40 Code of Federal Regulations, Part 63, National Emission Standards for Hazardous Air Pollutants for Source Categories

Defense Transportation Regulation (DTR), Department of Defense (DOD) Regulation 4500.9-R, Part VI, June 2002

FED-STD-H28A, Screw-thread Standards for Federal Services

Copies of the above document are available from the U.S. Department of Commerce, National Technical Information Services, 5285 Port Royal, Springfield, VA 22161 or via their website: http://public.transcom.mil

2.2 Other Publications. The following documents form a part of this contract to the extent specified herein.

Effective dates of the referenced documents shall be the dates referenced in effect at the time of solicitation issuance.

COMMERCIAL:

American Society of Mechanical Engineers

ASME Y14.1 2005 (Rev 2010) Decimal Inch Drawing Sheet Size and Format

ASME Y14.100 2004 (Rev 2009) Engineering Drawing Practices

ASME Y14.2 2008 Line Conventions and Lettering

ASME Y14.3 2003 (Rev 2008) Multiview and Sectional View Drawings

ASME Y14.38 2007 Abbreviations and Acronyms for Use on Drawings and Related Documents

ASME Y14.4 1994 (Rev 2004) Dimensioning and Tolerancing

ASME Y14.44 2008 Reference Designations for Electrical and Electronics Parts and Equipment

ASME Y32.2.3 1949 (Rev 1999) Graphic Symbols for Pipe Fittings, Valves and Piping

ASME BPVC-VIII-1 2010 Section VIII-Rules for Construction of Pressure Vessels Division 1

3 Attachment A

American Welding Society (AWS)

AWS D1.1/D1.1M:2010 Structural Welding Code – Steel

AWS D1.2 Structural Welding Code – Aluminum

AWS D1.6 Structural Welding Code – Stainless

Institute of Electrical and Electronic Engineers (IEEE)

IEEE Std 1 (2000) General Principles for Temperature Limits in the Rating of Electric Equipment and for the Evaluation of Electrical Insulation

IEEE Std 43 (2000) Testing Insulation Resistance of Rotating Machinery

IEEE Std 100 (2000) Standard Dictionary of Electrical and Electronics Terms

IEEE Std 115 (2009) Guide for Test Procedures for Synchronous Machines, Part I — Acceptance and Performance Testing, Part II —Test Procedures and Parameter Determination for Dynamic Analysis

IEEE Std 142 (2007) Recommended Practice for Grounding of Industrial and Commercial Power Systems

IEEE Std 315 (1975) Graphic Symbols for Electrical and Electronics Diagrams (Including Reference Designation Letters)

IEEE Std 446 (1995) Recommended Practice for Emergency and Standby Power Systems for Commercial and Industrial Applications

IEEE Std C2 (2007) National Electric Safety Code

IEEE Std C37.21 (2005) Standard for Control Switchboards

IEEE Std C37.23 (2003; R2008) Standard for Metal-Enclosed Bus

IEEE Std C57.12.01 (1998: R2005) General Requirements for Dry-type Distribution and Power Transformers, Including Those with Solid-cast and/or Resin Encapsulated Windings

IEEE Std C57.13 (1993; R2008) Standard Requirements for Instrument Transformers

The Society for Protective Coatings (SSPC)

SSPC QP 3, (2000) Standard Procedure for Evaluating Qualifications of Shop Painting Applicators

2.3 References.

NOTE: Issue date of references included in project specifications need not be more current than provided by the latest guide specification.

American Society for Testing and Materials International (ASTM)

ASTM B 8 - 11 Standard Specification for Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, or Soft

ASTM B 117 - 11 Standard Practice for Operating Salt Spray (Fog) Apparatus

ASTM D 523 - 08 Standard Test Method for Specular Gloss

4 Attachment A

ASTM D 975 - 11 Diesel Fuel Oils

ASTM D 1200 - 10 Viscosity by Ford Viscosity Cup

ASTM D 2247 - 11 Standard Practice for Testing Water Resistance of Coatings in 100% Relative Humidity

ASTM D 2794 – 93 (2010) Standard Test Method for Resistance of Organic Coatings to the Effects of Rapid Deformation (Impact)

ASTM D 3276 - 07 Standard Guide for Painting Inspectors (Metal Substrates)

ASTM D 3359 - 09e2 Standard Test Methods for Measuring Adhesion by Tape Test

ASTM D 3925 – 02 (2010) Standard Practice for Sampling Liquid Paints and Related Pigmented Coatings

ASTM D 4417 - 11 Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel

ASTM E 85, Surface Burning Characteristics of Building Materials

International Electrical Testing Association (NETA)

NETA ATS, Electrical Power Distribution Equipment and Systems

National Fire Protection Association (NFPA)

NFPA 30, Flammable and Combustible Liquids Code

NFPA 37, Standard for the Installation and Use of Combustion Engines

NFPA 70, National Electrical Code. Equipment shall be suitable for use in systems in compliance to Article 700, 701, and 702.

NFPA 110, Emergency and Standby Power Systems.

NFPA 255, Standard of Test Surface Burning Characteristics of Building Materials

National Electrical Manufacturers Association (NEMA)

NEMA ICS 18-2001 (R2007) Motor Control Centers

NEMA MG 1-2009, (R2010) Motors and Generators

NEMA MG 2-2007, Safety Standard and Guide for Selection, Installation, and Use of Electric Motors and Generators

NEMA TR 1-1993, (R2000) Transformers, Regulators and Reactors

NEMA WC 58-2005, (R2008) Portable and Power Feeder Cables for Use in Mines and Similar Applications

Underwriters Laboratories (UL)

UL 142, (2006) Standards for Steel Aboveground Tanks for Flammable and Combustible Liquids UL 489, (2009) Molded-Case Circuit Breakers, Molded-Case Switches, and Circuit-Breaker Enclosures UL 506, (2008) Standard for Specialty Transformers UL 508, (1999) Standard for Industrial Control Equipment

5 Attachment A

UL 508C, (2002; Rev thru 2004) Standard for Power Conversion Equipment

UL 723, (2008) Test for Surface Burning Characteristics of Building Materials

UL 891, (1998; Rev thru 2005) Switchboards

UL 1236, (2006) Battery Chargers for Charging Engine-Starter Batteries UL 1437, (2006) Standard for Electrical Analog Instruments - Panel Board Types UL 1561, (2011) Standard for Dry-type General Purpose and Power Transformers

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY

(MSS)

MSS SP-58 (2002) Pipe Hangers and Supports - Materials, Design and Manufacture

MSS SP-69 (2002) Pipe Hangers and Supports - Selection and Application

MSS SP-80 (2003) Bronze Gate, Globe, Angle and Check Valves

International Organization for Standardization (ISO)

ISO 8528 (2005) Reciprocating Internal Combustion Engine Driven Alternating Current Generator Sets.

All work performed shall conform to applicable sections of the latest revision of the preceding standards, in addition to industry standard practices.

3.0 GENERAL REQUIREMENTS

3.1 Power Plant Requirements. The Contractor shall provide fully operational product(s); completely packaged, medium voltage, transportable, power plant(s). Power plant(s) shall be NEW, provide utility grade generator protection and be driven by a commercially available diesel engine. Power plant capacity is determined by COP ratings as defined by ISO 8528, Part 1, Section 13.3.1. The power plant(s) shall be designed for continuous operation at rated output under conditions specified, to supply three-phase, three wire ungrounded service and three-phase, four wire grounded service at 4160/3300 volts (nominal), 900/750 rpm, 60/50 Hz, 0.8 pf lagging. The power plant(s) shall be designed for operation as a single unit (isolated load), in parallel with other power plants of like characteristics, or in parallel with commercial 60 or 50 Hz utility power (infinite bus). The short circuit rating of the power plant switchgear shall be 250 MVA at 4.16 kV. The power plant(s) shall be complete with accessories and auxiliary equipment as required to deliver fully functional power plant(s) and specified in the SOW. Other items normally supplied for the intended application and required for operation under conditions specified in this SOW shall be included.

3.1.1 The control system of the power plant(s) shall be UL 508 listed and labeled.

3.1.2 All power plant components shall be fully self-contained within a weatherproof enclosure.

3.1.3 Power plant engines shall meet the highest Environmental Protection Agency (EPA) Tier Level of current emissions requirements as original engine manufacturer best industry standards are capable to reach without the aid of any third party equipment or special fuel usage. The Contractor shall provide emissions compliant engine(s) as per the application and category of the engine(s) provided. The engine emissions Tier level provided shall not be below Tier 2 for stationary application Limited Time Running Power (LTP) in accordance with ISO 8528-1.

3.1.4 The power plant shall be designed to provide automatic (mains failure), automatic base load (peak shaving) and manual operations in island and load sharing modes with similar power plants.

6 Attachment A

3.1.5 Provide factory and acceptance testing to include a forty-eight (48) hour load test at varying load and at 0.8 pf lagging 60 Hz followed by an eight (8) hour load test at varying load and at 0.8 pf lagging in the 50 Hz configuration (production power plant only). Generate comprehensive reports that reflect Original Equipment Manufacturer (OEM) certified test results.

3.1.6 Provide forty (40) hours of technician training to Government personnel

3.1.7 Each power plant shall be identical.

3.1.8 Each power plant shall be capable of LTP, Prime Power (PRP), and Continuous Power (COP) operations as described in ISO 8528-1. Each power plant performance class shall meet Performance Class G3 in accordance with

ISO 8528.

3.1.9 Each power plant shall be capable of single step load pick up of 100% nameplate COP kW and power factor with the engine-generator set at operating temperature, less than or equal to 1500 feet above sea level in a 50 degree Centigrade ambient temperature.

3.1.10 Software, computer hardware, and interconnecting devices (cables, adapters, etc.) shall be provided to the Government to operate, adjust parameters, troubleshoot and monitor the power plant(s). The furnished software licenses shall be perpetual. Power plant(s) shall be able to operate and Government personnel shall be able to effectively perform adjustments to parameters in the field, without the need to purchase additional software.

3.2 Description

3.2.1 Engine-generator Unit. The engine-generator unit shall be a skid mounted, factory aligned (by the Contractor), housed unit complete with all components, parts, accessories and equipment required for operation and as specified in this SOW. The engine-generator unit shall include, at a minimum, the following:

a. A diesel engine directly coupled to an AC generator

b. An engine starting system

c. An engine cooling system (except radiator(s))

d. An engine combustion air supply system (filtered)

e. An engine speed governing system

f. An engine exhaust system

g. An engine pre-lubrication/pre-heat system

h. Engine control and monitoring panel

i. Engine fuel system delivery and return system

j. Generator cooling system (filtered)

k. House ventilation system(s)

l. House lighting system(s)

m. Station power and lighting transformer

n. Motor control center

The engine and generator shall be mounted on a common skid base. Accessories and auxiliary equipment shall be mounted on the engine, the skid base, or as specified in this SOW. The engine-generator unit shall be designed to maximize free and clear space around the engine, engine accessories, and generator as a unit to allow for personnel access.

3.2.2 Switchgear-control Unit. The switchgear control unit shall be skid mounted, housed unit complete with all components, parts and accessories and equipment required to operate, control, and monitor the output of the generator, station power and outgoing power circuit and as specified in this SOW. The switchgear control unit shall include, at a minimum, the following:

a. Switchgear, including the power plant control center

b. Station power transformer(s)

c. Station power distribution panelboards

7 Attachment A

d. Control power system

e. Heating, ventilation, and air conditioning system(s)

f. House lighting system(s)

g. Battery and battery charging system(s)

h. Automatic transfer switch for shore and station power

3.2.3 Auxiliary Unit. The auxiliary unit shall be a skid mounted, housed unit complete with components, parts, accessories and equipment required for operation and as specified in this SOW. The radiator unit shall include, at a minimum, the following:

a. Radiator fan drive including electric motors, pulleys, fans and belts.

b. Disconnect switches as required by NFPA 70

c. Radiator(s).

d. Fuel day tank and fuel transfer system.

e. Air compressor and receiver tank.

3.3 Weights and Dimensions. Shipping weights and dimensions shall not exceed the following:

Dimensions (inches) Weight (Lbs) Length Width Height Engine-generator Unit 80,000 360 102 138 Switchgear Control unit 25,000 192 102 138 Auxiliary Unit 25,000 360 102 138 Exhaust Silencer (as required) 240 102 72

The weight of fuel, coolant, and lubricants other than what is required to preserve and/or protect the power plant during transport or storage and the weight of the exhaust silencer shall not be included in the shipping weight. The weight of control and power cables, shipping braces and tools stored or installed in the respective shipping locations as dictated by the configuration design shall be included in the shipping weight. The loading shall be distributed laterally and balanced with respect to the longitudinal centerline of each unit.

3.4 Production Power Plant. The Contractor shall furnish one complete power plant (Production Power Plant) for inspection, validation, and testing to verify contract compliance. After acceptance of the production power plant by the Government, the production power plant shall remain at the Contractor’s facility until required production unit testing is complete. The production power plant shall be used as the paralleling test unit for subsequent production units, and as a model to which other units can be compared to ensure that each power plant is identical.

The first production power plant shall be complete to the extent necessary to allow proper demonstration of parallel operation and as specified in this SOW.

3.4.1 Restoration. The production power plant, prior to shipment, shall be restored to the original condition, at the time of Government acceptance, with the exception of normal wear incurred during testing. The restoration shall include, as a minimum, paint touch-up or repainting as required and the installation of new lubricating oil and air intake filters.

3.5 Materials, Components, and Parts. Except where the specification specifically indicates otherwise, the Materials, components, and parts installed in, on, or as part of the power plant shall meet the following requirements:

a. Standard commercial industrial products.

b. Installed in conformance with application and installation recommendations of the manufacturer and the manufacturer of the materials, components, and parts which they are installed in, on or near.

c. Identical so the materials, components and parts are interchangeable from one power plant to another.

d. Suitable for the extremes of pressure, temperature, mechanical stresses, voltage and current to which they might be exposed.

e. Suitable for the operational and maintenance environment in which they are located or may be subject to.

8 Attachment A

f. Capable of withstanding, without damage, the impacts generated by rail transit, as specified.

g. Not adversely affected by fluids and vapors to which they would likely be exposed to. This especially applies to gaskets, seals, and insulation (electrical, thermal, and sound).

h. New and unused, except as required for normal factory tests and for tests specified in this SOW.

i. Free from defects.

j. Not be furnished if they have been repaired or modified to correct deficiencies.

k. Conform to the requirements of this purchase description.

l. Be of current production and not scheduled for obsolescence by the manufacturer.

3.5.1 Manufacturer’s Recommendations. Materials, components and parts shall be installed using the application and installation recommendations and requirements of their manufacturer. Materials, components and parts shall not be installed where they may be adversely affected by the conditions of operation, maintenance, transportation and storage specified. Nonconformance with this requirement may constitute grounds for reinstallation or rejection of the materials, components, and parts concerned.

3.5.2 Interchangeability. Power plant(s) furnished under this SOW shall be identical. Materials, components, and parts shall be interchangeable from one power plant to another. Two or more materials, components, and parts of the same class, size, and type (form, fit and function) installed within, on or as part of a power plant shall be identical, interchangeable and of the same manufacturer. For example; control relays all from the same manufacturer.

3.5.3 Mechanical: General Requirements.

3.5.3.1 Hardware. Hardware shall be as follows with the number of different sizes to be kept as low as practical.

Nuts, bolts, and screws shall have standard screw threads and heads as required by FED-STD-H28A. Non-standard screw threads and heads shall not be used unless approved by the Contracting Officer (KO) or authorized Navy Technical Representative (NTR).

3.5.3.1.1 Blind Hardware. A nut or bolt shall not be located such that it cannot be grasped by the thumb or forefinger of one person’s hand or by a common hand tool. The use of threaded type inserts (similar to Nutsert (TM)) may be used for the mounting of switchgear components.

3.5.3.1.2 Sheet Metal Screws. Sheet metal screws shall NOT be used.

3.5.3.1.3 Hinges. All Hinges used throughout the power plant shall be constructed of corrosion proof metal.

3.5.3.1.4 Valves. Valves used throughout the power plant shall be ball or globe type and constructed of corrosion proof metal where practical.

3.5.3.2 Welding. Welding procedures shall conform to a nationally recognized code applicable to the materials being joined. Welding shall be accomplished by welders certified by the American Welding Society and fully cognizant of the code to which they are conforming to. Copies of the applicable codes shall be in the Contractor’s possession. Surfaces to be welded shall be free from foreign matter which would be injurious to the weld. Welds shall be equal to or greater than the full design strength of the materials being joined. Welds shall retain the full design strength of the materials being joined. Welds shall transmit imposed stresses without permanent deformation or failure when subjected to proof or service testing. Structural welding shall conform to AWS D1.1/D1.1M:2010.

Welds which, upon inspection by the Government, are found not to conform to the code to which they were welded shall be cause for rejection and contract testing will not commence until they are repaired. The engine manufacturer’s standard welding procedures are acceptable in construction of the diesel engine and cataloged components.

3.5.3.3 Contact of Dissimilar Metals. Intimate contact of dissimilar metals which cause galvanic corrosion shall be avoided. When such contact cannot be avoided, interposing insulating material in conformance with MIL-STD- 889B shall be provided to minimize the corrosive effect.

3.5.3.4 Assembly of Light Metal Alloys. Attachments to aluminum and magnesium alloys shall be by:

9 Attachment A

a. Machine bolts with nuts.

b. Steel bushings with tapped holes.

c. Stud bolts with National Coarse Threads on both ends which screw into aluminum or magnesium.

d. Helical-coil type threaded inserts.

e. Thread (coarse thread series) in the light metal alloy as permitted by the NTR.

f. Rivets for installing house surfaces (interior, exterior, roof, and ceiling).

3.5.3.5 Corrosion Resistant Metals and Treatments.

3.5.3.5.1 Metals. The following are the only corrosion resisting metals that will be acceptable:

a. Type 316 stainless steel

b. Copper

c. Aluminum alloys which do not contain more that 0.4 percent copper

d. Brass

e. Bronze

f. Beryllium-copper

g. Copper-nickel alloys

h. Nickel-copper alloys

3.5.3.5.2 Treatments. The following are the only corrosion resisting treatments that will be acceptable:

a. Sherardizing

b. Galvanizing

c. Electrodepositing with cadmium, chromium, copper, nickel, silver or zinc.

d. Aluminizing

e. Anodizing

f. Alonizing

3.5.3.6 Thermal and Sound Insulating Material. Thermal and sound insulating material used in power plant shall conform to the following requirements:

a. Non-hygroscopic, non-toxic and free from perceptible odors.

b. Resistant to attack by vermin, insects, rodents and fungus.

c. Unaffected by battery electrolyte or petroleum derivatives.

d. Maintain its shape, position and integrity under conditions of vibration and temperatures specified.

e. Protected from abrasion.

f. Replaceable in the field.

g. Fire retardant, with a flame spread rating of 75 or less, and a smoke developed rating of no more than

150 when tested in accordance with ASTM E 84.

3.5.3.7 Rigid Metal Piping and Fittings. Rigid metal piping and fittings shall be used throughout the power plant.

Rigid metal piping and fittings shall be designated and installed to withstand vibration or deflection without damage.

Rigid metal piping systems shall be designed to prevent air pockets (in liquid piping systems) and undrained, trapped liquids. Rigid metal piping shall be securely strapped and supported. Where required to isolate, prevent vibrations and resist shock, rigid metal piping shall be resiliently mounted. Pressure sensitive adhesive pads shall not be used. Do not use snap rings in conjunction with liquid lines containing petroleum products. Liquid piping systems shall have provision(s) for venting trapped air after repair or replacement of any component, part or subassembly. Drain piping shall terminate external to one common side of the power plant at the skid base, be plugged with threaded pipe plug(s) and be the lowest point per respective system. Drain piping shall include normally closed, ¼ turn valves located internal to the power plant skid base. Drain lines for engine systems required to be open during operation shall not have valves.

3.5.3.8 Flexible Piping, Hoses and Fittings. Flexible piping, hoses, tubing and fittings shall be used in piping systems to:

10 Attachment A

a. Isolate vibrations

b. Allow for expansion and contraction

c. Provide ease of connection, installation and maintenance

d. Connect to engine cooling system to the radiator(s)

In no case will flexible piping or hoses make up the whole of the piping system. When used, flexible piping, hoses, tubing and fittings shall meet the following requirements:

a. Designed for the temperatures they are or may be subjected to in the particular system in which it is installed.

b. Designed for mediums that they will transport.

c. Have a bursting pressure rating not less than four times the maximum operating pressure of the system in which it is installed.

d. Shall be reinforced.

e. If exposed to sunlight, shall be rated for exposure to direct sunlight.

The installation of flexible piping, hoses, tubing and fittings shall prevent physical damage caused by mechanical movement or abrasion from adjoining components or structures under vibratory conditions during operation, maintenance or transit. Flexible piping, hoses, tubing and fittings shall be installed per the manufacturer’s recommendations and requirements for the operational and maintenance environments as specified in this SOW.

Piping bends shall be free from kinks, creases and flattening. Piping runs and bends shall be parallel to the geometric lines of the power plant and the component(s) they are mounted to. Flexible hoses with synthetic liner and metal braid covering will be acceptable to use with fluids not adversely affecting the hose material. Pressure sensitive adhesive pads shall not be used for securing flexible piping or hoses. Do not use ordinary rubber, plastic or other unreinforced, unprotected or combustible tubing. Do not use brazed joints.

3.5.3.9 Belt Drives. Drive belts shall be multi-“V” type, ganged, belt(s). A “Gates Power-band” is an example of this type of belt. V-belt drives shall be selected for continuous duty and conform to the Rubber Manufacturers Association (RMA), with a minimum service factor of 1.5. Idler pulleys shall be installed using the recommendations and requirements of the drive belt manufacturer.

3.5.3.10 Ease of Servicing, Operation and Maintenance. Parts, assemblies and accessories shall be arranged in the power plant to permit accessibility for adjustment, repair and replacement without disturbance to other elements in the power plant where practical. Maintenance, disassembly or assembly operations shall be accomplished by common tools. If special test equipment and/or tools are required for servicing, such items shall be furnished with the power plant. The engine-generator unit enclosure shall be readily removable without disconnecting components or systems except as specified. Pipe unions shall be used in fluid systems for ease of installation and removal of pumps and other components for repair, maintenance and replacement. Liquid reservoirs (e.g., fuel day tank, lubricating oil sump or coolant expansion tank(s)) shall drain to the exterior of the power plant. Hand access openings (except access openings to the exterior of the power plant) shall meet the requirements of MIL-STD-1472F where practical.

3.5.3.11 Fasteners

3.5.3.11.1 Fasteners, Mechanical. Each fastener (e.g., screw, stud or bolt) shall use lock-washers to prevent loosening due to vibration. Lock-washers, other than those on the engine and catalogued components, shall be captive on nuts, machine screws, cap screws or bolts when the nominal size is less than ¼ inch diameter. Fasteners and associated hardware (e.g., nuts and lock-washers) shall be made of corrosion resistant material or shall be provided with a corrosion resistant treatment as specified in Section 3.5.3.5. Unused length of threads or studs (or screws/bolts used as studs) shall not exceed the diameter of the stud except as required by component OEM for catalogued components. Do not use lock plates, locknuts, lock wire or castlellated nuts with cotter pins. Do not wedge, peen or stake parts which may require removal or adjustment. Do not use rivets as specified.

3.5.3.11.2 Fasteners, Electrical. Lock-washers shall be provided for each fastener used in making an electrical connection for components not catalogued by OEM. Each fastener, lock-washer and associated hardware shall be

11 Attachment A made of corrosion resistant material or shall be treated to be made corrosion resistant as specified in Section 3.5.3.5.

Fasteners (bolts, screws and studs) shall not carry electrical current; they shall serve to secure electrical current carrying parts (e.g., lugs, terminals) in firm contact with each other. Where flow of current through a stud cannot be avoided, the stud and its associated hardware (e.g., nuts and lock-washers) shall be made of highly-conductive, corrosion resistive material. Studs shall not turn in their mountings when nuts are tightened or loosened to the required torque. Do not use lock-washers that depend on friction or spring action for this purpose. Unused length of thread on studs (or screws used as studs) shall not exceed the diameter of the stud except for catalogued components

OEM.

3.5.4 Electrical: General Requirements

3.5.4.1 Electrical Components.

Electrical enclosures for items such as control panels, panelboards, etc., shall conform to the requirements of NEMA Type 4 enclosures. Enclosures that require additional protection, i.e., enclosures at or near engine oil and coolant systems shall be rated to the environment that it is configured within or as specified in this SOW. Electrical hardware used to route engine thermocouple wires may be excluded from this requirement, subject to prior approval by the NTR.

3.5.4.2 Buses, Bus Connections and Medium Voltage Cables. Power plant 4160/3300 volt buses shall be single, solid copper, with rectangular cross section and rounded edges to avoid high dielectric stresses. Ferrous metal shall not be used for carrying electrical current. Buses shall be non-segregated and shall be supported on high strength reinforced epoxy insulators. Bus shall meet the requirements of IEEE C37.23. Buses and bus connections shall have a continuous current rating as determined by the insulation rating (see Section 3.5.4.2.1), shall be rated no less than 600 amperes and momentary rating to withstand not less than 40,000 amperes/RMS current for 10 cycles on a 60 Hz basis (0.167 seconds) without damage to or permanent deformation of the metal or insulation. Each bus splice shall be made with either a splice plate of the same material as the bus or by a lap-type splice. Bus splices shall not cause undue stress on supports and shall ensure rigidity and pressure contact. The use of medium voltage cables in the power plant’s switchgear shall be limited to the potential transformer (PT) leads and cables associated with the power plant’s surge capacitors, lightening arrestors and station power transformer. In these applications, high voltage cables shall be routed and separated from adjacent conductors and ground to avoid dielectric stresses which may cause partial discharge (corona). Unsupported lengths of cable over three feet in length are shall not be acceptable. Sharp bends are not acceptable, and the minimum bending radius of cable shall conform to the respective cable manufacturer’s criteria. In all cases where high voltage cables are routed through metal walls, they shall be positively segregated from the walls and each other using insulating material of the appropriate voltage class.

3.5.4.2.1 Bus Electrical Insulation. 4160/3300 volt buses shall have an insulating covering that, by itself, will meet the insulation class requirement for 5kV and shall be rated for not less than 105 degrees Celsius. Electrical insulation for buses shall be non-hygroscopic, flame retardant, track resistant, low power factor, non-toxic, and resistant to attack by rodents, insects, mildew, and fungus. Bus connections shall be insulated with removable, molded insulation boots. Bus connections shall not be taped.

3.5.4.3 Wiring and Cable. Unless otherwise allowed or specified, wiring shall be in accordance with and conform to the applicable sections of ASTM B-8-11 and NFPA 70.

3.5.4.3.1 Wiring, Low Voltage (600 volts or less). Except as otherwise permitted or specified, the following requirements govern low voltage wiring. Wire shall be stranded, single conductor, copper with gray SIS insulation.

For the purpose of this SOW, the use of type SIS wire shall meet the requirements of NFPA 70 for type XHHW-2 wire. Acceptable exceptions to the foregoing are as follows:

a. Strip heater wiring (generator and switchgear) shall be stranded, single conductor, copper, TFE insulated, terminated at the strip heater(s) using long barreled, un-insulated, crimp type, ring tongue lug.

b. Special purpose wiring (e.g., paired, shielded, calibrated, instrumentation, etc.) as required by unique components.

12 Attachment A

c. Other wire sizes and insulation provided as part of an off-the-shelf component wired by the component manufacturer.

d. Flexible cord suitable for the installed ambient temperature shall be used as a disconnecting means between the motor control center and the engine-generator unit lighting, receptacle and exhaust fan circuits as specified.

3.5.4.3.2 Wiring Methods. Wiring shall be located, installed and secured to prevent damage or deterioration that could result from contact with sharp corners and edges, pinching, twisting, sharp bends or fatigue, resulting from vibration or repeated bending. Wiring shall not transmit mechanical forces to electrical connections and terminals, and shall be located/installed to prevent contact with high temperature or moving parts, chemicals or fluids. Wiring not run in conduits shall be neatly bundled throughout cabinets and compartments. Wiring harnesses/bundles not run in wire-ways shall be secured to structural members at a minimum of every six inches of all bends. Nylon, self-locking clamps (not self-adhesive) shall be used for this purpose. Wire breakouts to terminals of components shall be at right angles to the wire bundle and shall present a neat, uniform appearance and shall be no shorter than four inches and not longer than eight inches. Wiring shall not be spliced or tapped at any point throughout the length of the run between terminations. Should any wire require a break or splice, it shall be made in a junction box with terminal strips/blocks mounted internally. No more than two wires shall terminate at a single connection point.

3.5.4.3.3 Wire Identification. Each wire over four inches in length shall be identified within two inches of its termination by a contrasting color “shrink sleeve” on which the identification code has been permanently, machine imprinted with contrasting characters. The wire identification shall be as large as practical, and shall not impair the characteristics of the wire insulation. The wire identification shall be identical to the engineering drawing convention. A different series of numbers or different color of the identification code shall be used to distinguish communication wiring, AC and DC circuitry. Circuit identifications on all power plants shall be identical (i.e., standardized). Wiring diagrams and schematics shall reflect all wiring identification.

3.5.4.3.4 Electric Motors. Electric motors shall be totally enclosed, fan cooled (TEFC) or “Wash Down” rated. AC motors over ¼ HP shall be three phase, three wire, squirrel cage induction motors, 480 volt (nominal). DC motors shall be rated for 120 volts DC. AC and DC motors shall have a minimum service factor of 1.15. Electric motors shall conform in allowable temperature rise and marking to NEMA MG 1, at a 1.0 service factor.

3.5.4.3.5 Electrical Conduit and Fittings. Pull and junction boxes and conduit shall be used throughout the power plant as required by NFPA 70 and as specified below. Conduit terminations shall have insulated bushings and shall be properly reamed to eliminate any sharp edges. Liquid-tight flexible metallic conduit or cord as required by NFPA 70 may be used between junction boxes, electrical motors, pressure switches, temperature switches and other remote mounted equipment or components to prevent transmission of mechanical forces or vibration. Flexible liquid-tight metallic conduit shall not be used as the equipment grounding conductor for conduit runs. Metal conduits/raceways shall be solidly grounded (bonded) as per NFPA 70.

3.5.4.3.6 Terminal Lugs. Terminal lugs for conductors rated 600 volts or less, size AWG #10 or smaller, shall be of the insulated ring tongue, compression crimp type style unless supplied as part of a catalogued assembly. Terminal lugs for conductors size AWG #8 and larger, or which are rated for more than 600 volts shall be un-insulated, rectangular tongue, NEMA spaced two-hole style compression crimp type lugs unless supplied as part of a catalogued assembly. Compression crimp type lugs shall be installed using the proper manufacturer required tools.

All terminal lugs shall be installed using the proper manufacturer recommended tools. Terminal lugs shall be the proper size for both the conductor and the terminal stud or bolt. Except in cases where the conductor size is AWG #6 or smaller, any medium voltage connection which is not suitable for two-hole terminal lugs shall be modified to accept NEMA spaced two-hole lugs unless supplied as part of a catalogued assembly.

3.5.4.3.7 Terminal Blocks. With the exception of connections made at electric motors, all connections shall be made at component terminations or at NEMA rated terminal blocks (strips) securely mounted to and within enclosures.

Terminals on components or terminal blocks shall not have more than two lugs attached to any single terminal.

Terminal blocks shall be individually labeled (i.e.; TB-1, TB-2, etc.) and each terminal block position shall be sequentially numbered (1 through number of positions) on a marking strip. Wiring diagrams and schematics shall include terminal board connections. Lettering size shall be as large as practical. Connections made inside integral junction boxes for electric motors shall be made by splicing motor lead pigtails as specified by the motor

13 Attachment A manufacturer and this SOW. Each splice shall be covered with a reusable, UL listed wire connector. Contractor shall provide 10% additional spare NEMA rated terminal board terminals except as provided as part of catalogued equipment installed.

3.5.4.3.8 Medium Voltage Wiring and Cable. Medium voltage wire and cable shall be single conductor, unshielded, stranded copper with type XLP insulation and jacket rated for 5kV/8kV and 105 degree Celsius conductor temperature. Cable ends shall be terminated using compression crimp lugs. NEMA spaced two-hole lugs shall be used on wire and cable size AWG #6 and larger.

3.5.4.3.9 Medium Voltage Wire and Cable Routing. All single conductor medium voltage cables shall be routed and separated to avoid contact with each other, adjacent medium voltage cables and ground. Single conductor medium voltage cables shall not be bundled with or pass within six inches of any low voltage wiring. Where passage through walls or current transformers is required, provisions shall be made to isolate the cable from the wall or sides of the current transformer(s). The minimum bending radius of the cable shall conform to the respective cable manufacturer’s criteria, or NFPA 70, whichever is the most restrictive. Cables routed from the generator shall be supported on reinforced stand-off insulators at the appropriate intervals to elevate cables from potentially oily or wet surfaces.

3.5.4.3.10 Medium Voltage Wire and Cable Identification. Marking shall be provided approximately two to four inches from each termination using a contrasting color, heat shrink sleeve and a contrasting color, machine imprinted permanent characters as large as practical in height. All markings shall be perpendicular to the wire.

3.5.4.4 Instrument Transformers. Current and potential transformers used for instrumentation, controls and relaying shall meet the requirements of IEEE C57.13 and shall be rated by the manufacturer for operation at 60 and 50 Hz. Potential transformers used in circuits at the generator output potential shall be of the 5kV insulation class.

3.5.4.4.1 Current Transformers. Current transformers shall be the doughnut (window) type. With the exception of the current transformer on the generator neutral, current transformers rated for the generator output potential shall be rated as required by the coordination study and shall be capable of withstanding the short circuit current supplied by the generator without saturation detrimental to security of protective relay operation. The current transformer on the generator neutral used to operate the ground fault relay shall be connected in a wye configuration, shall be of the accuracy class required by the coordination engineer and shall be rated to operate at 60 and 50 Hz.

3.5.4.4.2 Potential Transformers. Potential transformers shall be rated not less than 1.5 times the burden to which they are connected, shall have a 120 volt secondary, shall be connected open-delta line to line, shall be the accuracy class as required by the coordination engineer and shall be rated to operate at 60 and 50 Hz.

3.5.4.5 Limit Switches and Pushbuttons. Limit switches shall be the sealed type. Pushbuttons shall be the heavy duty type and oil-tight.

3.5.4.6 Control Relays. Relays for control and alarm circuitry (other than protective relays) and emergency lighting shall be the totally enclosed or hermetically sealed type. Time delay relays, if used, shall be the solid state, electronic type. Open type (telephone) relays shall not be used.

3.5.4.7 Resistors and Rheostats. Tapped resistors shall be used in preference to the adjustable (slide wire) type.

Where adjustable resistors are used, the wire shall be of sufficient size to prevent damage though corrosion at the contact point. Rheostats and potentiometers shall be of the wire wound type located only in ventilated areas and not less than three inches from adjacent wiring components.

3.5.4.8 Semiconductor Devices. Semiconductor devices shall be the hermetically sealed type. Except for zener diodes and as specified, semiconductor devices shall have peak repetitive voltage ratings equal to the peak transients to which they may be subjected to in the power plant. In addition, semiconductor devices shall be capable of withstanding or protected against transient voltage and current peaks experienced during testing. The use of circuits which require semiconductor devices matched or paired characteristics is prohibited. This specification shall not apply to OEM catalogued devices such as; engine controller, power plant controller and multifunction protective relay.

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3.5.5 Gasket Materials. Gasket material used for weather proofing shall be closed cell, ozone proof, resistant to sunlight, chemicals, petroleum derivatives, moisture and vapors encountered in a marine environment. Backing adhesives shall be equally immune to degradation. Where used to provide a weatherproof seal on removable panels, doors or access covers, gasket material shall cover the entire mating surface with no gaps or breaks. Corner joints shall either be continuous or be joined in such a manner as to prevent a through path for wind driven rain. Gasket material thickness shall be selected as required to provide a minimum of 25% compression deflection of the material with no greater than 15 pounds per square inch (psi) surface pressure. The use of silicone sealants or other compounds to provide supplementary sealing in addition to gasketing is prohibited. The non-adhesive side of the gasket material shall be coated with a long lasting release agent such as Teflon (if not already provided by the product manufacturer) to prevent sticking and tearing when panels, doors or access covers are opened or removed.

3.6 Safety Requirements.

3.6.1 General Safety. Aspects of the power plant design and configuration shall comply with all criteria of the Occupational Safety and Health Standards, Part 910, Chapter XVII of Title 29 of the Code of Federal Regulations (29 CFR 1910) effective on the date of contract award. The power plant design and configuration shall conform to the criteria of MIL-STD-1472 Section 3.15 “Hazards and Safety” et seq. The following subparts and sections of 29 CFR 1910 contain criteria which are specifically applicable.

a. Subpart D “Walking-Working Surfaces”

b. Subpart E “Means of Egress”

c. Subpart H “Hazardous Materials”

Sect. 1910.106 “Flammable and Combustible Liquids”

d. Subpart J “General Environmental Controls”

Sect. 1910.144 “Safety Color Code for Marking Physical Hazards” Sect. 1910.145 “Specifications for Accident Prevention Signs and Tags”

e. Subpart M “Compressed Gas and Compressed Air Equipment” Sect. 1940.169 “Air Receivers”

f. Subpart N “Materials Handling and Storage”

g. Subpart O “Machinery and Machine Guarding”

Sect. 1910.212 “General Requirements for All Machines” Sect. 1910.219 “Mechanical Power Transmission Apparatus”

h. Subpart S “Electrical”

3.6.1.1 Personnel Safety. Location on and within the power plant that could be occupied by operating and maintenance personnel (hereinafter referred to as “personnel”) shall comply with the applicable requirements of 29 CFR 1910, Subparts D and E. Exterior doors shall have provisions for opening from inside, even when locked from the outside. Any location within the power plant where personnel could reasonably be expected to enter during operation of the power plant shall have at least two means of egress, remote from each other and arranged to minimize the possibility that both may be blocked by any one fire or other emergency condition. Exit aisle-ways shall be configured to provide headroom of not less than 80 inches between walking surface and any projection from the ceiling.

3.6.1.2 Physical Hazard Identification. Physical hazards throughout the power plant shall be color coded in accordance with the criteria of 29 CFR 1910.144. Danger signs, caution signs, directional signs and informational signs shall be installed in appropriate and conspicuous locations throughout the power plant in accordance with the criteria of 29 CFR 1910.145.

3.6.1.3 Equipment Guards. Parts and components subject to high operating temperatures, energized electrically or moving, which present a hazard to operating personnel, shall be insulated, enclosed or guarded. Equipment guards shall not impair the proper functioning of any part of the power plant. Shafts and shaft couplings shall have guards of rigid construction to prevent bodily contact with the shaft or coupling. Equipment guards shall be readily removable.

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3.6.2 Insulation Matting. Insulation matting shall be provided for the switchgear control unit floor. Matting shall be a minimum of 30 inches wide and of sufficient length to cover the entire floor area between the switchgear-control house doors. Should the medium voltage disconnects be located in an area of the switchgear-control house other than the path covered by this matting, additional matting shall be rolled and stored in the switchgear-control unit during shipment. Insulation matting shall have a minimum dielectric strength of 10,000 volts. Switchgear-control unit doors shall be capable to open fully as specified in this SOW with insulation matting in place for normal operation.

3.6.3 Noise Exposure. Any location within or around the power plant exterior at which the noise level exceeds 85 dBA, (when measured on a standard sound level meter at microphone heights of both three and five feet above the walking or standing surface), and which could possibly be occupied by personnel during power plant operations, shall have conspicuous warning signs…