Attachment_B.pdf

1 Attachment B

ATTACHMENT B- MEDIUM TO HIGH ENGINE SPEED- ALTERNATIVE 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 conform to dimensional requirements as described in this SOW.

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

-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 GENERAL REQUIREMENTS:

2.1 The Contractor shall provide completely packaged, medium voltage, transportable, 1400kW Continuous Power (COP) rated power plant(s). The power plant(s) shall be new, provide utility grade protection, and be driven by a commercially available diesel engine. The power plant’s capacity shall be in accordance with ISO 8528-1 Section 13, Power Rating Definitions, and this SOW.

2.2 Each power plant shall be fully self-contained within a standard sized Intermodal Container that conforms to International Organization for Standardization (ISO) intermodal container specifications; for amplifying information see paragraph 10.30.

2.3 Each power plant’s engine shall meet, or exceed, Environmental Protection Agency (EPA) emissions requirements for mobile off highway equipment for the year of its acceptance; without the aid of additional equipment or special fuel usage; for amplifying information see paragraph 9.0.

2.4 Each power plant shall be designed to provide automatic and semi-automatic operations, local and remote monitoring, and local and remote control functions; for amplifying information see paragraph 9.0.

2.5 Each power plant shall be capable of, and be built to provide: Limited-time Running Power (LTP), Prime Power (PRP), and Continuous Power (COP) operations as defined in ISO 8528-1 Section 13, and this SOW.

2.6 Each power plant shall be capable of a single step load pick up of 100% LTP kW rating and power factor with the engine-generator set at engine manufacturer recommended temperature. For amplifying testing requirements, see paragraph 11.0.

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2.7 The contractor shall provide a complete Operation and Maintenance data package for each power plant delivered; for amplifying information see paragraph 14.0.

2.8 The contractor shall provide Government technicians factory training, and upon successful completion of the training, a recognized certification to support the finished product; for amplifying information see paragraph 17.0.

2.9 The contractor shall provide a warranty per contract clause.

3.0 DESIGN REVIEW MEETINGS AND GOVERNMENT INSPECTIONS

3.1 The Government and the Contractor shall hold four design review meetings.

3.1.1 The first meeting shall be the Post Award meeting which shall be held at the Governments facility in Port Hueneme, CA. At this time the Government and Contractor shall review all submittal documents, and shall agree upon the general layout of each power plant and major components. This meeting shall be held within forty-five

(45) business days after award of contract. Contractor shall provide four sets of the following information required for the Post Award meeting for review in portable document format (PDF):

a. Manufacturer’s product literature and performance data, sufficient to verify compliance to specification requirements.

b. The Contractor shall furnish information showing manufacturer’s model numbers, dimensions and weights for the engine, generator, enclosure, and major auxiliary equipment.

c. A paragraph by paragraph specification compliance statement, describing the differences, if any, between the specified and the proposed equipment.

d. Inspection system plan.

e. Manufacturer's certification of prototype testing of engine and generator.

f. Manufacturer's published warranty documents.

g. Engineering drawings showing plan and elevation views with certified overall dimensions and weight as well as wiring interconnections.

h. Interconnection wiring diagrams showing all external connections required; with field wiring terminals marked in a consistent point-to-point manner.

i. Manufacturer's installation instructions.

j. Manufacturer's published de-rating information.

k. All drawings and wiring schematics must be available in AutoCAD format and all component catalog cut-sheets must be available in PDF format.

3.1.2 The second meeting shall be a 25% design review of each power plant, the component make up and overall layout of each power plant and shall be held no later than thirty (30) business days after the Post Award meeting.

This meeting shall be held at the Contractor’s facility.

3.1.3 The third meeting shall be a critical design review of the power plant’s drawings and component list, which shall take place no more than thirty (30) business days after the 25% design review meeting. The critical design review meeting shall be held at the Government’s facility in Port Hueneme, CA.

3.1.3.1 The Contractor shall be 50% completed with engineering drawings of the power plant at the time of this meeting. This is to include the plan and elevation drawings (all four sides) of the power plant, a simple one-line and three-line drawing, control drawings, and the proposed component list of parts and accessories for the power plant.

3.1.4 The fourth meeting shall be the final design approval of each power plant delivered under this contract, which shall take place no more than thirty (30) business days after the critical design review meeting. This meeting shall be held at the Contractor’s facility. The final approved design shall be strictly adhered to during the construction of each power plant.

3.1.4.1 At this time the Contractor shall be 100% complete with all engineering drawings and component parts list.

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3.1.5 During the course of the design stages, if for any reason the Contractor is not prepared with the required items per design review meeting, the Contractor shall give the government prompt notification, and a projected date when the documentation will be available for review.

3.1.6 During the design approval stages of the power plant, the Contractor shall NOT proceed with production until all design drawings and components are approved by the Government. Accuracy and functionality of the drawings to meeting the requirements of the specifications shall be the sole responsibility of the Contractor.

Government approval of designs or drawings will not effect a waiver of any contract requirement including performance specifications.

3.2 Production Meetings. The Government reserves the right to conduct as required on site progress inspections during productions. The Contractor shall conduct progress meetings with the Government once every two weeks via telephone conference. The contractor shall provide meeting minutes with 7 calendar days after meeting.

4.0 APPLICABLE DOCUMENTS:

4.1 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.

4.1.1 Military:

MIL-HDBK-138B, Container Inspection Handbook for Commercial and Military Intermodal Containers, January 2002

Copies of the above document is available from the Defense Automated Printing Service, Standardization Documents Order Desk, Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094 or via their website:

http://dodssp.daps.mil.

4.1.2 Federal:

Defense Transportation Regulation (DTR), Department of Defense (DOD) Regulation 4500.9-R, Part VI, June 2002 Copies of the above document is 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

4.1.3 Naval Facilities Engineering Command (NAVFAC) Publications:

NAVFAC P-300, Management of Civil Engineering Support Equipment, Sept 2003

Copies of the above NAVFAC Publication may be obtained by writing to the Naval Inventory Control Point, 700 Robbins Ave., Philadelphia, PA 19111-5098 or via the following website: http://www.nll.navsup.navy.mil.

4.2 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.

4.2.1 COMMERCIAL:

4.2.1.1 American National Standard Institute (ANSI)

ANSI C37.90 Relays and Relay Systems Associated with Electric Power Apparatus

ANSI C39.1 Requirements for Electrical Analog Indicating Instruments

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ANSI C57.13 Requirements for Instrument Transformers

4.2.1.2 American Welding Society (AWS)

AWS D1.1 Structural Welding Code – Steel

AWS D1.6 Structural Welding Code – Stainless

AWS D1.2 Structural Welding Code – Aluminum

4.2.1.3 Institute of Electrical and Electronic Engineers (IEEE)

IEEE C2 National Electric Safety Code (2002)

IEEE C27 Switchgear assemblies including metal-enclosed bus

IEEE C37 Circuit Breakers, Switchgear, Substations, and Fuses

IEEE C39 Electrical Analog Indicating Instruments

IEEE C57.13.1 (1981) Guide for Field Testing of Relaying Current Transformers

IEEE C62 Guides and Standards For Surge Protection

IEEE 446 Recommended Practice for Emergency and Standby Power Systems for Commercial and Industrial Applications

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 48 (1996; R 2003) Test Procedures and Requirements for Alternating-Current Cable Terminations 2.5 kV through 765 kV

IEEE Std 81 (1983) Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface Potentials of a Ground System (Part 1)Normal Measurements

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

IEEE Std 115 (1995; R 2002) Test Procedures for Synchronous Machines: Part I: Acceptance and Performance Testing; Part II: Test Procedures and Parameter Determination for Dynamic Analysis

IEEE Std 120 (1989) Master Test Guide for Electrical Measurements in Power Circuits

4.2.1.4 The Society for Protective Coatings (SSPC)

SSPC AB 2 (1996; R 2000) Cleanliness of Recycled Ferrous Metallic Abrasive

SSPC AB 3 (2003) Newly Manufactured or Re-Manufactured Steel Abrasives

SSPC Guide 12 (1998) Guide for Illumination of Industrial Painting Projects

SSPC Guide to VIS 1 (1989) Guide to Visual Standard for Abrasive Blast Cleaned Steel

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SSPC PA 1 (2000) Shop, Field, and Maintenance Painting

SSPC PA 2 (1996; R 2002) Measurement of Dry Coating Thickness With Magnetic Gages

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

SSPC SP 10 (2000) Near-White Blast Cleaning

SSPC SP COM (2000) Surface Preparation Commentary for Steel and Concrete Substrates

SSPC VIS 1 (2002) Guide and Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning

4.3 REFERENCES.

4.3.1 American Society for Testing and Materials International (ASTM)

ASTM D 975 (2004be1) Diesel Fuel Oils

ASTM D 1200 (1994; R 1999) Viscosity by Ford Viscosity Cup

ASTM D 3276 (2000) Painting Inspectors (Metal Substrates)

ASTM D 3925 (2002) Sampling Liquid Paints and Related Pigmented Coatings

ASTM D 4417 (2003) Field Measurement of Surface Profile of Blast Cleaned Steel

4.3.2 International Electrical Testing Association (NETA)

NETA ATS Electrical Power Distribution Equipment and Systems

4.3.3 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 99 Essential Electrical Systems for Health Care Facilities

NFPA 110 Emergency and Standby Power Systems. The power plant shall meet all requirements for Level 1 systems. Level 1 prototype tests required by this standard shall have been performed on a complete and functional power plant, component level type tests will not substitute for this requirement.

4.3.4 National Electrical Manufacturers Association (NEMA)

NEMA SG-5 Power switchgear assemblies

NEMA MG-1-1998 part 32. Alternator shall comply with the requirements of this standard.

Other applicable ANSI or NEMA standards that have not been listed.

4.3.5 Department of Transportation (DOT)

49 Code of Federal Regulations, part 658

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4.3.6 Occupational Safety and Health Administration (OSHA)

Standards as applicable.

4.3.7 International Organization for Standardization (ISO)

ISO 668 Series 1 freight containers - Classification external dimensions and ratings [Amd. 1993 (E)] ISO 830 Terminology in relation to freight container (Amd. 1988)

ISO 1161 Series 1 freight containers - Corner fittings Specification (Amd. 1990)

ISO 1496-1 Series 1 freight containers - Specification and testing.

part 1: General cargo containers for general purposes (Amd.2 - 1998)

ISO 1894 General purpose series 1 freight containers - Minimum internal dimensions (2nd edition - 1979)

ISO 6346 Freight containers - coding, identification and marking - 1995(E)

ISO 8528-1 Specification for application, ratings, and performance (1993)

ISO 8528-5 Specification for performance class G-3.

4.3.8 Underwriters Laboratories (UL)

UL 508 The entire control system of the generator set shall be UL508 listed and labeled.

UL 891 (1998; Rev thru Feb 2003) Dead-Front Switchboards for 600v and below.

UL 1236 (2002) Battery Chargers for Charging Engine-Starter Batteries

UL Classified Enclosure based on PCIB-QRNZ Evaluation

4.3.9 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

4.3.10 The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

Canadian Standards Association 282, 1989 Emergency Electrical Power Supply for Buildings

Canadian Standards Association C22.2, No. 14 – M91 Industrial Control Equipment.

European Norm 50082-2 Electromagnetic Compatibility – Generic Immunity Requirements, Part 2: Industrial.

European Norm 55011 Limits and Methods of Measurement of Radio Interference Characteristics of Industrial, Scientific and Medical Equipment.

Federal Communications Commission Part 15, Subpart B.

International Electrotechnical Commission 8528 part 4. Control Systems for Generator Sets

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International Electrotechnical Commission Std 801.2, 801.3, and 801.5 for susceptibility, conducted, and radiated electromagnetic emissions.

4.4 References. All work performed shall conform to the following in order of precedence:

4.4.1 Applicable sections of the latest revision of the preceding standards.

4.4.2 Industry best practices.

4.4.3 This SOW.

5.0 QUALIFICATIONS OF CONTRACTORS:

5.1 The Contractor shall provide all labor, supervision, tools, materials, facilities, transportation, and weight-handling equipment required to complete all aspects of this contract.

5.2 The Contractor shall inspect, test, label, and install the various associated equipment and components in accordance with manufacturer’s recommendations, referenced standards, and all other terms and conditions of the contract.

5.3 The Contractor shall provide management oversight to meet performance, and schedule objectives in accomplishing all work.

5.4 All work shall be performed by skilled craftspeople of the appropriate trade. All work shall be done in accordance with the Contractors’ best practices, industry consensus standards and codes, and this contract.

5.5 The Contractor shall be responsible for the quality of the work. The Contractor’s work effort shall result in a product that is reliable in the field and acceptable by the Government as demonstrated by inspection, testing, and quality conformance inspections.

5.6 All surface preparation and coating shall be performed in accordance with the coating manufacturer’s instructions, recommendations, and SSPC good painting practice.

5.7 All welding shall be performed by an American Welding Society Certified Welder. A machinist certified by a state or nationally accredited institution shall perform all machine work.

5.8 Only certified Power Generation technicians shall work on engine or generator control systems. Technician certifications shall be an inspectable item upon contract award.

6.0 PLACE OF PERFORMANCE:

6.1 The Contracting Officer’s Representative (COR) shall be given access during regular working hours to inspect or witness the progress of work at any time during production and/or the testing process.

6.2 For the sake of this contract, regular working hours at principle places of performance is Monday through Friday, 0800-1600, exception for federal holidays.

7.0 PERIOD OF PERFORMANCE:

7.1 The period of performance begins upon the date of acceptance of the contract, and shall not exceed 24 months.

8.0 CONTRACT DATA REQUIREMENTS:

(Applicable to each power plant delivered under this contract)

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8.1 The Contractor shall submit monthly status reports via email and/or facsimile to the COR. These reports shall indicate the status of each power plant. The reports shall indicate progress, delays, test results, and any other pertinent facts concerning the power plants or the contract. Monthly status reports shall be submitted in the Contractor’s preferred format. Status reports shall be submitted to the government no later than the first working day of each month.

8.2 The Contractor is required to provide a Milestone chart, in the Contractors preferred format, to the COR no later than ten calendar days after contract award. The milestone chart shall be updated and submitted monthly thereafter, unless major changes to the schedule are anticipated. The Milestone chart shall, at a minimum, indicate:

8.2.1 Purchase order release dates, delivery schedules, test dates.

8.2.2 Proposed start date of major milestones and events.

8.2.3 Proposed completion date of major milestones and events.

8.2.4 All proposed start and completion dates shall be placed in chronological order.

8.2.5 The Contractor shall provide a complete list of all long lead items, (more than three weeks lead time) and shall provide purchase order release dates. The government reserves the right to review these purchase orders for the purpose of determining risk to proposed schedule.

8.3 The Contractor is required to submit a Final Test Report, in the Contractors preferred format, to the COR upon acceptance of each power plant. The report shall indicate a breakdown, and the results of, all acceptance testing listed in paragraph 11 of this contract.

8.4 The contractor shall provide protective relay software to support the requirement of section 10.1.6

8.5 The contractor shall provide a certification as required by 10.7.4.

8.6 The contractor shall provide data as required by paragraph 14.0.

9.0 POWER PLANT Parameter Schedule:

9.1 The power plant shall have a gross weight of less than 67,200 pounds.

9.1.1 Gross weight shall include all fluids necessary to operate; oil and coolant at operating level, ¼ tank of diesel fuel.

9.2 The power plant shall be constructed suitable for transportation, without special permits, in the following modes:

9.2.1 Marine: In the ship cell guides of vessels, and on the deck of vessels, secured by vertical and diagonal wire lashings.

9.2.2 Road: On flat bed, secured by twistlocks or equivalent at the bottom corner fittings.

9.2.3 Rail: On flat cars or special container cars secured by twistlocks or equivalent at the bottom corner fittings.

9.2.4 Air: On C-5 aircraft secured by adequate tie-downs to provide support shipment during take-off and landing.

9.3 All power plant components and assemblies shall be new.

9 Attachment B

9.4 The power plant shall be designed for standard industrial usage and NOT as military tactical equipment and shall be diesel engine driven.

9.5 The power plant shall have a net COP rating capacity of 1400kW at a 0.8-power factor and supply a wye connected 4160/2400 voltage (v), three phase, 60-Hertz (Hz) alternating current (AC) output.

9.5.1 The power plant shall have a PRP rating in accordance with ISO 8528.

9.5.2 The power plant shall have a LTP rating in accordance with ISO 8528.

9.6 Gross kW rating of the power plant shall not be more than the figure obtained by multiplying the delivered shaft-horsepower rating of the engine by 0.746 and by the overall efficiency of the generator at the corresponding load. The overall efficiency of the generator shall allow for power required to operate the exciter, including power consumed in losses, windings, and friction for the generator, rotating exciter, and ancillary set loads.

9.7 Auxiliary equipment shall be designed for continuous duty at 110 percent of rated LTP power capacity of the power plant, unless otherwise specified in this SOW.

9.8 Each power plant shall include standard assemblies and incorporate commercial off-the-shelf optional assemblies to meet performance specifications.

9.9 The engines shall meet, or exceed, Federal Environmental Protection Agency (EPA) emissions requirements for “emergency standby” operations for this size power plant for the year of its acceptance, without the aid of additional equipment or special fuel usage.

9.10 The control system shall incorporate standard off-the-shelf technology for manual and automatic operation in an isolated condition (single power plant), in parallel with multiple like power plants (Island Operation), or parallel with a utility (Utility Paralleling).

9.11 The power plant shall include manual and automatic controls for start/stop, synchronizing/paralleling, load sharing, utility grade generator set protection scheme.

9.12 Semi-automatic paralleling to be both speed (frequency) and voltage matching for placing a genset onto a "live" network whether the network is utility source power or powered by a genset source isolated from the utility.

9.13 "Utility Paralleling" logic shall automatically soft load the genset, once the genset breaker closes in synchronism with the utility, to a preset "base load level" providing a fixed kW contribution to the utility grid with generator var / power factor control functions operative.

9.14 "Island Operation", for an isolated load network, shall involve control logic for sharing of active (kW) and reactive (kVAR) loads among duplicate on-line site generator sets, to include the ability to automatically soft load and unload the gensets.

9.15 The maintainability of all power plants and accessories will be one of the prime considerations during the design effort required by this contract. Removal and replacement of components shall not require the use of special tools or processes. The design shall give prime consideration to accessibility of equipment for maintenance.

Captive installation hardware shall be approved by the government COR prior to use.

9.16 The Contractor shall determine the interface and human factor requirements. The Contractor shall propose locations for all components, controls, and indicators. The Contractor shall furnish the proposed equipment locations to the Government at the "Initial Design Review". The COR has final design approval authority for the locations of all equipment and components.

9.17 The power plant must incorporate the following operational characteristics:

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9.17.1 “Black start” capability.

9.17.2 Manual and Automatic start/stop.

9.17.3 Semi-Automatic and Automatic synchronizing/paralleling.

9.17.4 Isochronous load sharing.

9.17.5 Utility grade generator set protection. See paragraph 10.14.2.

9.17.6 Local and remote communication management capabilities.

9.17.7 Local and remote monitoring of engine and generator parameters including starting and stopping the unit.

9.18 Engine-Generator Parameter Schedule

Power Rating 1400 kW COP

Overload Capacity 10% of LTP Rating

Service Load COP, PRP, and LTP maximum duty cycles as defined in ISO 8528

Motor starting KVA Manufacturers standard

Power Factor 0.8 Lagging

Engine Generator Applications Stand Alone, Parallel with infinite bus, parallel with infinite bus and other like power plants, parallel with like power plants on an isolated bus (Island)

Maximum Rated speed 1200 or 1800 RPM

Heat Exchanger Type Removable Finned Tube

Governor Type Isochronous

Frequency Bandwidth

(Steady State) ISO 8528 Class G3

Governor Type Droop

Frequency Regulation (Droop) Adjustable, 0% to 3%

Frequency Bandwidth (Steady State) ISO 8528 Class G3

Voltage Regulation (No Load To Full Load) ISO 8528 Class G3

Voltage Bandwidth (Steady State) ISO 8528 Class G3

Frequency 60/50 Hertz

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Voltage 4160Y/2400 3300Y/1900 Volts

Phases 3 Phase, Wye

Minimum Generator Subtransient Reactance 0.10 Percent

Non Linear Loads 20% COP

Max Step Load Increase 100% LTP, 0.8 PF

Transient Recovery Time With Step Load Increase (Voltage) ISO 8528 Class G3

Transient Recovery Time With Step Load Increase (Frequency) ISO 8528 Class G3

Maximum Voltage Deviation with Step Load Increase ISO 8528 Class G3

Maximum Frequency Deviation with Step Load Increase ISO 8528 Class G3

Maximum Step Load Decrease (Without Shutdown, or breaker trip) 100% LTP

Maximum Time to Start and Assume Load 10 Seconds

Maximum Outdoor Ambient Temperature 40 Celsius

Minimum Outdoor Ambient Temperature -5 Celsius

Relative Humidity 60%

Installation Elevation 0 to 1,000 Meters, Mean Sea Level

Alternator Temperature Rise 80 C above ambient, at COP

Alternator Insulation Class Class H

10.0 TECHNICAL REQUIREMENTS:

10.1 Description: The power plant shall be complete with all necessary auxiliary equipment and controls and meet the following criteria:

10.1.1 The power plant shall be tested, certified, and packaged using off-the-shelf components, controls, interlocks, and safety features to permit operation at LTP, PRP, COP power applications.

10.1.2 The power plant shall permit operation in isolated conditions as a stand-alone single unit, in parallel with similar units, or in parallel with a utility.

10.1.3 The power plant shall permit multi unit parallel operations with isochronous and droop capabilities.

10.1.4 Manufacturer’s standard and/or optional equipment will be used to assemble the power plant.

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10.1.5 The Contractor shall incorporate an engine protection scheme as described in NFPA 110, Level one (1), minimum.

10.1.6 The Contractor shall incorporate as the utility grade generator set protection scheme a fully functional General Electric 489 Generator Management Relay.

10.1.7 The alternator shall produce a clean AC voltage waveform, with not more than 5% total harmonic distortion at full linear load, when measured from line to neutral, and with not more than 3% in any single harmonic, and no 3rd order harmonics or their multiples.

10.1.8 The voltage regulation system shall include provisions for reactive load sharing and electronic voltage matching for paralleling applications. Motorized voltage adjust potentiometer is not acceptable for voltage matching.

10.1.9 A battery monitoring system shall be provided which initiates alarms when the DC control and starting voltage is less than 25VDC or more than 32 VDC.

10.1.10 The control system shall include all interfaces necessary for proper operation with the paralleling equipment provided under this contract. The generator set supplier shall be responsible for complete compliance to all specification requirements for both the generator set and the paralleling equipment.

10.1.11 All components and parts shall be installed in accordance with it’s manufacturer’s requirements and recommendations, nationally recognized consensus standards, and this SOW.

10.1.12 All electrical and mechanical device in the engine room shall be oil and dust tight.

10.1.13 All non OEM control wiring shall be point to point labeled on each end of the wire.

10.1.14 All wire terminations shall be either ring type, spade type, or compression.

10.1.14.1 CT control wiring terminations shall be ring type connections, and shall utilize shorting blocks where applicable.

10.1.14.2 PT control wiring shall be spade type connections.

10.1.14.3 Splices shall not be made in wires between terminal connection point.

10.2 Sound Criteria:

10.2.1 External noise level shall not exceed levels for manufacturer’s published specifications.

10.2.2 Entire packaged system shall be sound attenuated as required to achieve sound levels below 95 decibels (Dba), at seven meters measured from any direction from the power plant, with the power plant operating at the LTP rating.

10.2.3 All ratings are “A” - weighted, free-field, 6 feet above grade and single power plant operation.

10.2.4 The Contractor shall conduct a sound test, witnessed by the Government, with the power plant operating at COP rating, and will be required for approval of shipment.

10.2.5 The power plant shall be provided with a sound-attenuated housing which allows the power plant to operate at full rated load in the ambient conditions specified in paragraph 10.4.5, les applicable engine derates.

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10.3 Operation and Maintenance: All components, assemblies, engine/control management, and safety/protection devices shall be accessible for maintenance, repair, and replacement without disturbance to other generator set equipment.

10.4 Environmental Operation Conditions: The power plant shall be capable of operation under any, or a combination, of the following conditions. Power plant capacity de-rates, if applicable, shall apply below – 17.8 C, above 40 C, below 0 Meters (0 Feet) MSL, and above 457 Meters (1500 Feet) MSL. The contractor shall inform, in writing, the government what the power plants are capable of operating at with the applicable derating factors.

10.4.1 Exposure to salt–laden air, and salt-water spray encountered at seaside locations.

10.4.2 Exposure to sand/dust-laden air encountered at arid, desert locations.

10.4.3 Exposure to continuous wind conditions ranging up to 40 miles per hour (64km/hr) with gusts up to 100 miles per hour (160km/hr).

10.4.4 Exposure to wind driven rain impinging on the power plant at angles up to 75 degrees from the vertical in any direction at three inches per hour.

10.4.5 Exposure to outdoor conditions ranging from operation under direct sunlight at outdoor ambient air temperature of 50 deg C (122 deg F) to operation in complete shade at outdoor ambient air temperature of –30 deg C (-22 deg F).

10.4.6 At any altitude from mean sea level (MSL) to 5,000 feet (1,523m) above mean sea level.

10.5 Transportability: The power plant, complete with accessories, when properly prepared for shipment, will be suitable and capable of being transported in a “wet” state (oil and coolant at operating level, with ¼ tank of fuel).

Technical manuals shall contain explicit instructions and illustrations to prepare units for shipment. Instructions for bracing of components shall be included as required in Paragraph 17.

10.5.1 The power plant shall be designed to sustain a 3g impact along the longitudinal axis without suffering structural damage. The power plant shall be capable of being fully operational following impact without the need for repairs. A 3g test is not required.

10.5.2 If applicable, blocking and bracing required to support components within the set during transport shall be incorporated into the set design and provided.

10.5.3 If applicable, blocking or bracing required only for transport shall be completely removable.

10.5.4 If applicable, shipping braces shall be stored in designated locations within the power plant when not in use and installed with common hand tools.

10.5.5 If applicable, all bracing shall be permanently marked to facilitate correct installation.

10.5.6 If applicable, all bracing shall be painted red.

10.6 Materials and Components: All materials and components shall be the standard off-the-shelf industrial grade products manufacturers regularly provide, and shall include optional features to the extent necessary to comply with requirements of this contract.

10.6.1 All material and components shall be new and unused. “One Trip” ISO containers shall be acceptable.

10.6.2 Equipment containing PCBs, asbestos, or mercury shall not be used.

10.7 Engine: The power plant shall utilize a diesel engine designed for LTP, PRP, and COP power applications.

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10.7.1 The engine shall be diesel, 4 cycle, liquid cooled. The horsepower rating of the engine at its minimum tolerance level shall be sufficient to drive the alternator and all connected accessories.

10.7.2 Two cycle engines are not acceptable.

10.7.3 The engine shall be capable of burning fuel oil conforming to CID A-A-52557, grade DF-2; MIL-F-16884H Fuel, Naval Distillate F-76 and MIL-PRF-5624 grade JP-8.

10.7.4 An emissions certification data sheet shall be provided with the engine. It shall certify that the engine meets or exceeds EPA mobile off highway regulations for the year of generator set acceptance as configured for operation without the use of additional items or special fuels. This shall be a data deliverable and can be found in paragraph 17.0.

10.7.5 The engine shall be certified using fuel oil conforming to CID A-A-52557, grade DF-2.

10.7.6 Provide vibration isolators, as required to limit objectionable vibration to levels less than that required by component part manufacturers, quantity as recommended by the manufacturer.

10.7.7 Engine accessories and features shall include:

10.7.7.1 An electronic governor system conforming to ISO 8528 “G3” specifications.

10.7.8 The power plant shall include a cooling system(s) rated for operation as specified in sections 9.18 and 10.4.

10.7.8.1 The cooling system shall be filled with an extended life propylene glycol mixture by the equipment manufacturer.

10.7.9 Rotating parts shall be guarded against accidental contact.

10.7.10 Electric starter(s) shall be capable of three complete cranking cycles without overheating.

10.7.11 Positive displacement, mechanical, full pressure, lubrication oil pump.

10.7.12 Full flow lubrication oil filters with replaceable spin-on canister elements and dipstick oil level indicator shall be provided. Separate by-pass filtration shall be provided. By-pass filtration shall be selected and installed as recommended by the engine manufacturer.

10.7.13 An engine driven, mechanical, positive displacement fuel pump.

10.7.14 Fuel filter with replaceable spin-on canister element.

10.7.15 Fuel cooler, suitable for operation as specified in sections 9.18 and 10.4.

10.7.16 Heavy duty type replaceable dry element air cleaner with restriction indicator.

10.7.17 Flexible supply and return fuel lines.

10.8 Coolant heater: Provide a thermostatically controlled coolant heater system. The coolant heater shall be UL listed and labeled.

10.8.1 Flexible hoses to and from the coolant heater shall be silicone hose connections. Steel tubing shall be used for connections into the engine coolant system wherever the length of pipe run exceeds 12 inches. The coolant heater installation shall be specifically designed to provide proper venting of the system. The coolant heaters shall be installed with stainless steel ball valves to isolate the heater for replacement of the heater element.

10.8.2 The coolant heater shall be provided with a thermostat.

15 Attachment B

10.8.3 The coolant heater(s) shall be sized as recommended by the engine manufacturer to warm the engine to a minimum of 100F (38C) in a 0 F (-17.8 C) ambient, in compliance with NFPA110 requirements, and the temperature required for starting and load pickup requirements of this specification.

10.9 Engine Assemblies: As a minimum, the mechanical system(s) shall include:

10.9.1 Lubricating oil import/export assembly sized to provide complete filling or draining of the lubrication system within 30 minutes with 70� F oil.

10.9.2 Prelubrication system with automatic control to provide for lubrication of the engine in accordance with manufacturer’s specifications and recommendations.

10.9.3 Lube oil sump heaters with automatic control. External sump heating pads shall NOT be accepted.

10.9.4 Jacket water system coolant import/export assembly sized to provide for complete filling or draining of the coolant system within 30 minutes with 70� F coolant.

10.9.5 Jacket water heater system with automatic control.

10.9.6 Local double-walled fuel day tank with a minimum capacity to support four (4) hours of engine operation at the LTP rating. The tank shall incorporate removable level switches for automatic transfer operation, tank rupture alarm, and a full length site glass. Level switch connections shall be made utilizing pin and sleeve connectors to allow for rapid removal of the level switches prior to shipment. Provide a minimum of 4 inches of sediment space below the fuel pick up that supplies the engine.

10.9.7 Automatic and manually controlled fuel transfer assembly, incorporating filtering and fuel water separation to the day tank. Transfer system automatically controlled via level switches in day tank with a manual override capability. Transfer pump shall incorporate a pressure relief valve to prevent possible pump damage. Provide safeties and install fuel system in accordance with NFPA 30, NFPA 37, and this SOW.

10.9.8 Provide a Volts Direct Current (VDC) fuel priming system.

10.9.9 Engine mounted fuel/water separator filters.

10.9.10 Provide an Engine crankcase breather. The breather system shall comply with the engine manufacturer’s recommendations and requirements, and meet EPA requirements. If an open breather system is provided vent to exterior of the enclosure to prevent spent gases from re-entering the power plant.

10.9.11 Volts Direct Current (VDC) electric starter(s) shall be used.

10.10 ENGINE MONITORING DEVICES: As a minimum, the following engine parameters shall be monitored:

10.10.1 Engine speed in revolutions per minute (RPM).

10.10.2 Battery voltage.

10.10.3 Oil pressure and temperature.

10.10.4 Engine jacket Coolant temperature and level (visual site glass).

10.10.5 Engine hours.

10.10.6 Bank exhaust temperatures.

10.10.7 Fuel level.

16 Attachment B

10.10.8 Engine Aftercooler circuit temperature and level (visual sight glass).

10.11 GENERATOR (AC Alternator): The generator shall be capable of producing 1400 kW at 0.8-power factor and supply a wye connected 4160/2400-volt, three phase, 60-Hz AC output. For the LTP, PRP, or COP rating the alternator winding total temperature shall not exceed 155 C in a 40 C ambient. The overall efficiency of the generator shall allow for power required to operate the exciter, including power consumed in losses, windings, friction of the generator, rotating exciter and ancillary set loads. The generator shall be enclosed within a drip-proof, fully guarded housing with strip heaters provided.

10.11.1 The AC alternator shall be; synchronous, 2/3 pitch, revolving field, drip-proof construction, single bearing, air cooled by a direct drive fan, and directly connected to the engine with flexible drive disc. All insulation system components shall meet NEMA MG1 temperature limits for Class H insulation system. Actual temperature rise measured by resistance method at LTP, PRP, and COP ratings shall not exceed 80 degrees Centigrade in a 40 C ambient.

10.11.2 The AC alternator shall be capable of delivering rated output (kVA) at rated frequency and power factor, at any voltage not more than 5 percent above or below rated voltage.

10.11.3 A permanent magnet generator (PMG) shall be included to provide a reliable source of excitation power for optimum motor starting and short circuit performance. The PMG and controls shall be capable of sustaining and regulating current supplied to a single phase or three-phase fault at approximately 300% of rated current for not more than 10 seconds.

10.11.4 Provide two embedded resistance temperature detectors per phase and temperature indication equipment.

The control system shall annunciate high alternator temperature as a fault condition, and initiate an orderly timed shutdown sequence.

10.11.5 Provide anti-condensation heater(s) for the alternator.

10.12 SWITCHGEAR: Utility grade, metal-enclosed interconnect switchgear conforming to NEMA (1) gasketed requirements shall be used. Switchgear shall have a minimum basic insulation level (BIL) of 95 kilovolts.

Assembly and mounting of components shall be in a logical sequence, separated by voltage class. All electrical assemblies and wiring methods applied shall be incorporated in accordance with industry standards. The switchgear cubicles shall have automatic humidistat(s) and thermostat(s) controlled electric strip heaters to prevent condensation.

10.12.1 The following components shall be utilized in the overall switchgear assembly:

10.12.1.1 Drawout circuit breaker or contactor,

10.12.1.2 Load interrupt switch,

10.12.1.3 Surge capacitors,

10.12.1.4 Lightning arrestors,

10.12.1.5 C100 CT’s for protective relaying,

10.12.1.6 Potential Transformers (Generator and Load side)

10.12.1.7 Neutral ground reactor.

10.12.1.8 Control Power Transformer (CPT); sized by the contractor to provide sufficient capacity to provide control power to all associated components with a 50% reserve capacity for future component upgrades.

17 Attachment B

10.13 INSTRUMENTATION: The generator set shall incorporate controls for manual and automatic start/stop, synchronizing/paralleling, load sharing, associated engine and generator management/monitoring, safety shutdown protection, emergency stop control, AC metering, kilo-watt hour measurement and visual/sound fault annunciation.

Indicating instruments and assemblies shall be switchboard type incorporating shock resistant mounting. All instrumentation shall be stable and readable during normal operation of the generator set.

10.14 PROTECTIVE/SAFETY DEVICES: At minimum, the following Mechanical and Electrical warnings and or shutdowns shall be provided to protect critical service requirements:

10.14.1 Mechanical: low oil pressure, high coolant temperature, low coolant level, low fuel level alarm and shutdown, over crank, overspeed, engine system emergency shutdown, fuel tank rupture basin alarm and shutdown.

10.14.2 Electrical: A fully functional General Electric 489 Generator Management Relay, to include overcurrent (51), frequency (81 O/U), reverse power (32), over voltage (59), under voltage (27), instantaneous overcurrent (50), generator temperature (49), ground fault (51G), emergency shutdown/lock out (86), phase sequence (47), generator percent differential (87G).

10.14.2.1 A Synchronizing check (25) shall be incorporated into the protection scheme.

10.14.3 A relay coordination study and short circuit calculations shall be performed with results and recommended relay settings provided. The studies shall be in accordance with IEEE 141, IEEE 242,IEEE 399, IEEE 1584, ANSI C37.010, and NFPA 70E.

10.14.3.1 The contractor is solely responsible for inputting all relay settings into the protective device.

10.14.4 A neutral ground reactor shall be provided to limit the ground fault between the wye point of the generator and ground to no more than the bolted three phase fault current. Neutral grounding resistors shall NOT be accepted.

The generator shall be effectively grounded in accordance with IEEE 142.

10.15 LOAD CENTER: The power plant shall be equipped with a load center to supply conduits and wiring for interior lighting, generator strip heaters, battery charger, fuel transfer control, jacket water heaters, lube oil heaters, duplex receptacles, and as specified.

10.15.1 Load center shall not be series rated and shall have at a minimum a 100-amp main breaker. All branch circuit breakers shall be sized for proper voltages/amperages required by the accessories.

10.15.2 The placement of this breaker panel shall be shown on drawings.

10.15.3 Load centers that are not UL listed shall not be accepted.

10.15.4 All internal wiring and conduit runs to the various ancillary equipment supplied with the package shall be wired in accordance with NFPA 70 and other codes as applicable.

10.15.5 A 4160/120-240 volt station service, step-down transformer shall provide set power. The transformer shall be sized to provide sufficient power to associated components with a 50% reserve capacity for future component upgrades. The station service transformer shall be connected between the generator and the load interrupt switch.

10.15.6 A distribution block shall be supplied as a means for the connection of external commercial power.

10.15.7 The Contractor shall provide an automatic transfer switch as a means to safely transfer between the dual services, commercial and set (generator). The transfer switch shall be a separate device from the load center panel.

The preferred source shall be commercial power.

10.15.8 The transfer switch shall be placed ahead of the load center and shall be the single entry point for commercial power or set power.

18 Attachment B

10.16 24VDC CONTROL POWER SYSTEM:

10.16.1 Control power voltage shall be 24VDC. Batteries shall be sized to allow proper operation of all VDC loads and provide power plant starting and control requirements within the ambient conditions specified.

10.16.2 Battery bank isolation switches for positive and negative shall be provided to interrupt DC system at source for maintenance. Connections will be made to prevent any current flow with open switches.

10.17 STARTING SYSTEM:

10.17.1 BATTERIES:

10.17.1.1 Batteries shall be valve regulated lead acid type sized as required.

10.17.1.2 Battery size shall be BCI Group No. 8D minimum, and shall be rated not less than 220 amp hours.

10.17.1.3 Necessary cables and clamps shall be provided.

10.17.1.4 The Battery bank shall be sized to safely handle all loads applied to it, to include starting the engine.

10.17.1.5 Batteries shall fit inside an enclosure and provide protection of the battery and cables. (Batteries under the generator are not acceptable.)

10.17.2 BATTERY TRAY:

10.17.2.1 A battery tray shall be provided for the batteries and shall conform to NEC 480-7 (b). It shall be constructed and so treated as to be resistant to deterioration by battery electrolyte.

10.17.2.2 Further, construction shall be such that any spillage or boil-over of battery electrolyte shall be contained within the tray to prevent a direct path to ground.

10.17.3 BATTERY CHARGER:

10.17.3.1 A UL listed/CSA certified voltage regulated, current limiting, automatic, DC battery charger shall be provided for the power plant. The battery charger shall be suitable for use as a power supply or a battery eliminator with a temperature compensation feature.

10.17.3.2 The Contractor shall ensure correct AC input voltage and DC output voltage, as required by battery system.

10.17.3.3 Battery charger’s amperage output shall not be less than ten (20) amperes.

10.17.3.4 The battery charger’s enclosure shall be sealed and gasketed, in a drip-proof cabinet.

10.17.3.5 The battery charger shall be wall mounted and hard wired within the power plant’s enclosure.

10.17.3.6 The battery charger shall be equipped with float and equalize charge settings.

10.17.3.7 The float and equalize rates of the charger shall be adjustable in the field.

10.17.3.8 The Contractor shall attach to the battery charger a label with the correct settings for float and equalize charging, as required by battery system.

10.17.3.9 The battery charger shall include A/C input and D/C output integral over current protective devices.

19 Attachment B

10.17.3.10 The output current shall limit at 110% of full load and shall have 0.25% regulation with a �10% AC line fluctuation.

10.17.3.11 Operational monitors shall provide visual output along with individual contacts for remote indication of:

Loss of AC power Low battery voltage High battery voltage Power ON (no relay contact)

10.17.3.12 Battery charger shall include an Analog DC voltmeter and zero center DC ammeter, equalize charge timer.

10.18 PERSONNEL DOORS:

10.18.1 All doors shall be strategically located in areas to allow ease of maintenance on the power plant and allow good access to and visibility of instruments, controls, engine gauges, etc.

10.18.2 The enclosure shall have pre-hung acoustical doors manufactured by enclosure manufacturer for personnel access to engine room and any other service area required. Door depth must match enclosure wall depth. Door hardware shall include, at a minimum, 2 heavy-duty strap hinges and 1 handle and 1 heavy duty door closure per door.

10.18.3 All door hardware shall…