16T0030P00001.docx

N64498-16-T-0030

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

450VAC SWITCHBOARD TECHNICAL SPECIFICATION DOCUMENT Naval Surface Warfare Center - Philadelphia

Document Number: 8027_0000

November 24th, 2015

Technical Specification (TS) Documents This Technical Specification comprises the following separate engineering documents:

A. TS Document #1: Technical Requirements Form B. TS Document #2: Engineering Specification N64498-16-T-00300001d Specification Document Number: 8027_0000 Date: February 2016 C. TS Document #3: Technical Data Sheets - To Be Completed by Contractor

Table of Contents

TS Document #1: Technical Requirements Form

The Following Documents Form Part of the Technical Specification

Equipment Information:

The Following Equipment is to be procured under this Technical Specification

Technical Requirements Form Revision Information:

TS Document #2: Engineering Specification

TITLE SHEET

Government Name and Address: Naval Ship Systems Engineering Station (NAVSSES), Philadelphia, PA.

Project Name: 450VAC Switchboard

Engineering Specification Revision Information:

1 Scope of this Specification

1. This Specification provides the technical requirements for the design, performance, inspection, testing, and warranty of (2) 450VAC Switchboards. This Specification forms part of the technical requirements form (TS Document #1) for the procurement of this equipment and shall be read in conjunction with all documents listed herein. The 450VAC Switchboards consists of the following equipment specified herein:

0. (2) Indoor switchgear enclosures consisting of:

a. Vertical metal enclosed sections bolted together

b. Bus bars

c. Distribution sections

d. Auxiliaries sections

e. Handles

0. Draw-out / molded case circuit breakers with electronic trip units

0. Metering

0. Current transformers

0. Heaters

0. Terminal boards

1. This Specification is broken down into the following sections:

1. Scope of this Specification

1. Overview

1. Applicable Codes, Standards, and Regulations

1. Rating, Conditions of Service, and Performance Warranty

1. Work Included: Contractor’s Responsibility

1. General Requirements

1. Design and Construction Requirements

1. Performance Requirements

1. Inspections and Tests

1. TS Document #3: Technical Data Sheets (to be completed by the Contractor)

1. Throughout this Specification the following terms apply:

2. “Government” refers to Naval Ship Systems Engineering Station (NAVSSES), Philadelphia, PA.

2. “Contractor” refers to the party or parties submitting a bid for supplying the equipment specified herein. The selected Contractor shall be the Manufacturer and Supplier of the 450VAC Switchboard.

2. “Manufacturer” refers to the party, or parties, that manufacture a part or parts of the equipment or material.

2 Overview

1. The Contractor supplied 450VAC Switchboard shall provide an interface between Government supplied equipment under test. The 450VAC Switchboard shall be located at the NAVSSES Building 633 complex in Philadelphia, PA 19112.

1. The conceptual 450VAC Switchboard diagram is depicted in Figure 1. The electrical power source supplying the 450VAC Switchboards are Government furnished three phase switch-mode variable frequency power inverters.

Figure 1: Conceptual 450VAC Switchboard Diagram

1. Each 450VAC Switchboard shall provide the required equipment and supporting systems to interface Customer provided electrically ungrounded Source and Load feeders, to include but not limited to:

1. Indoor switchgear enclosures consisting of:

a. Vertical metal enclosed sections bolted together

b. Bus bars

c. Distribution sections

d. Auxiliaries sections

e. Handles

2. Draw-out / molded case circuit breakers with electronic trip units

3. Metering, Ground fault protection

4. Current transformers

5. Heaters

6. Terminal boards

1. The 450VAC Switchboard Contractor shall provide the following services as specified herein:

3. The Contractor shall submit a Progress Report to report schedule data for all End Items listed on in Section 2 paragraph C, In Accordance With (IAW) CDRL A001 Contractor’s Progress, Status and Management Report of this Technical Specification document. The planning and scheduling of this effort shall be proposed as discrete tasks.

3. The Contractor shall deliver General Arrangement drawings IAW CDRL A002, Commercial Drawings/Models and Associated Lists, 450VAC Switchboard General Arrangement Drawings, of this technical specification document. The general arrangement drawings shall include both Plan and Elevation views. The drawings shall include all electrical (controls, instrumentation and power) connection locations. The Contractor shall provide foundation layouts with dimensions and weights of equipment with alignment drawings and procedures

3. The Contractor shall submit 450VAC Switchboard drawings IAW CDRL A003, Commercial Drawings/Models and Associated Lists, 450VAC Switchboard Drawings, of this technical specification document. The Contractor shall provide manufacture assembly, installation assembly, mechanical schematics, protection systems, and electrical/electronic diagrams with complete materials list.

3. The Contractor shall submit Electrical Single Line Drawings IAW CDRL A004, Product Drawings/Models and Associated Lists, 450VAC SWITCHBOARD Electrical Single Line Drawings, of this technical specification document. All electrical, instrumentation, and controls wiring interconnections shall be clearly identified.

3. The Contractor shall provide COTS manuals and supplemental data with all equipment and components for which manuals or data are available. Copies of COTS manuals and supplemental data shall be delivered IAW CDRL A005, Commercial Off-The-Shelf (COTS) Manuals and Associated Supplemental Data, 450VAC Switchboard Manuals, of this Technical Specification document. All manuals for the components shall be submitted in both electronic and paper formats.

3. The Contractor shall prepare a Test Plan IAW CDRL A006, Test Procedures; Factory Acceptance Test, of this Technical Specification document.

3. The Contractor shall prepare a Test Report for all successfully completed tests. The Contractor shall prepare a Test Report, in Contractor format, IAW CDRL A007, Test Inspection/Report, of this Technical Specification document, to document the result of the Factory Acceptance Testing (FAT). These tests shall include, but not be limited to, Tests identified in Section 9 of this Technical Specification.

3. The Contractor shall package the description of procurement according to all current commercial standards and codes. The Contractor shall prepare a Packaging Plan for the description of procurement. The Packaging Plan shall be delivered to and approved by the Government prior to delivery of the description of procurement. The packaging plan shall detail the precautions the Contractor plans to use to protect and preserve the description of procurement against corrosion, deterioration and physical damage during shipment and handling. The Packaging Plan shall be prepared and submitted IAW CDRL A008 Packaging Plan and Lifting Arrangement Drawings of this technical specification document.

3. The Contractor shall submit Lifting Arrangement Drawings IAW CDRL A009 Commercial Drawings/Models And Associated Lists; Lifting Arrangement Drawings. The requirements for these drawings are specified further in sections 6.6 and 7.4 of this technical specification document.

3 Applicable Codes, Standards, and Regulations

3.1 General

A. Unless otherwise specified, the equipment shall be designed, constructed, and tested in accordance with the applicable provisions of the following standards. The latest edition of the referenced document (including any amendments or corrections) applies, at the time of contract award.

B. Where a standard is referred to and conflicts with a part of this Specification, the Government shall be consulted in writing for immediate resolution.

C. When an equivalent standard to those identified in this Specification are proposed by the Contractor, the Contractor shall notify the Government in writing for immediate resolution.

3.2 Industry Standards

A. American National Standards Institute (ANSI)

1. ANSI Z55.1, Gray Finishes for Industrial Apparatus and Equipment

B. ASTM INTERNATIONAL (ASTM)

1. ASTM A 167, Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip

2. ASTM A 780, Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

3. ASTM D 149, Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies

4. ASTM D 1535, Specifying Color by the Munsell System

5. ASTM D 709, Laminated Thermosetting Materials

C. INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

1. IEEE C2, National Electrical Safety Code

2. IEEE C37.13, Standard for Low-Voltage AC Power Circuit Breakers Used in Enclosures

3. IEEE C37.20.1, Standard for Metal-Enclosed Low-Voltage Power Circuit-Breaker Switchgear

4. IEEE C37.21, IEEE Standard for Control Switchboards

5. IEEE C37.90.1, Surge Withstand Capability (SWC) Tests for Relays and Relay Systems Associated with Electric Power Apparatus

6. IEEE C57.12.29, Pad-Mounted Equipment – Enclosure Integrity for Coastal Environments

7. IEEE C57.13, Standard Requirements for Instrument Transformers

8. IEEE Std 100, The Authoritative Dictionary of IEEE Standards Terms

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

D. INTERNATIONAL ELECTRICAL TESTING ASSOCIATION (NETA)

1. NETA ATS, Acceptance Testing Specifications

E. NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

1. NEMA C12.1,Electric Meters; Code for Electricity Metering

2. NEMA ICS 6, Standard for Industrial Controls and Systems Enclosures

3. NEMA LI 1, Industrial Laminated Thermosetting Products

4. NEMA PB 2.1, General Instructions for Proper Handling, Installation, Operation and Maintenance of Dead front Distribution Switchboards Rated 600 Volts or Less

5. NEMA ST 20, Standard for Dry-Type Transformers for General Applications

6. NEMA SG-5, Power Switchgear Assemblies

F. NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

1. NFPA 70, National Electric Code (NEC)

2. NFPA 70E, Standard for Electrical Safety in the Workplace

G. UNDERWRITERS LABORATORIES (UL)

1. UL 1558, Metal-Enclosed Low-Voltage Power Circuit Breaker Switchgear

2. UL 467, Standard for Grounding and Bonding Equipment

3. UL 2735, Standard for Safety Electric Utility Meters

3.3 Lifting and Rigging Standards

A. NAVSEA Technical Publication S9074-AR-GIB-010/278, Table VII, Machinery Class M2, Category A B. NAVFAC P307, Management of Weight Handling Equipment

4 Rating, Conditions of Service, and Performance Warranty

4.1 Equipment Ratings, Materials, and Workmanship

1. The 450VAC Switchboard equipment provided shall meet all requirements specified herein.

1. Materials used for work performed under this contract shall be new and suitable for the intended service conditions of the equipment.

1. Work shall be performed by skilled mechanics in the various crafts and be executed in a first class and workmanlike manner in accordance with recognized good practice in the industry.

4.2 Conditions of Service

1. All 450VAC Switchboard equipment shall be located indoors in the facility Building 633 Complex located at NAVSSES Philadelphia, PA.

4.3 450VAC Switchboard Acceptance, Performance Warranty and Defects Liability A. Customer Acceptance of the 450VAC Switchboard equipment shall follow the successful completion of all factory tests identified in Section 9 including the review and approval of all test reports by the Government, and receipt of the Contractor supplied Test Certifications.

B. The Contractor shall warrant that the equipment supplied shall be entirely suitable for the intended service and is free from faults in design, and is of sufficient capability to meet the specified Performance Requirements.

C. The equipment provided shall have a design life of no less than thirty (30) years with nominal maintenance and repair, to be consistent with the design life of commercially available utility distribution equipment.

D. The Contractor shall warrant the 450VAC Switchboard equipment for a period of twelve (12) months from the date of Acceptance by the Government that all equipment furnished by the Contractor shall be free from defects in design, material, and workmanship.

E. The Contractor warranty shall cover all parts, labor and repairs related to the 450VAC Switchboard equipment.

F.

5 Work Included: Contractor’s Responsibility

5.1 Overall System Requirements

A. The Contractor shall provide a 450VAC Swithboard interface compatible with their specified interface requirements as required in this Specification.

B. The Contractor shall have complete responsibility for the provision of all equipment and accessories necessary for the successful operation of the 450VAC Switchboard whether or not specifically identified in this Specification.

5.2 Scope of Supply

A. The Contractor’s work shall include the furnishings of all design, fabrication, inspection, testing, documentation, and special tools of the 450VAC Switchboard equipment.

B. The Contractor’s work shall include, but not be limited to, the following:

1. Equipment as specified herein.

2. Spare Parts as specified herein.

3. Factory field service / training as specified herein.

5.3 Engineering Design and Status Reporting

A. The Contractor shall provide, at a minimum, the following submittals for Government review and approval of the 450VAC Switchboard design:

1. Mechanical design to include overall 450VAC Switchboard dimension and weight of the individual equipment and lifting arrangements. This shall be included in CDRL A002 submittals.

2. Thermal management design to meet the performance specified herein. This shall include any special arrangements due to sensor selection and placement and associated components. This shall be included in CDRL A003 submittals.

3. Electrical power design to meet the performance specified herein. This shall include the circuit breaker and bus-bar derived ratings. This shall be included in CDRL A004 submittals.

4. Controls and instrumentation design to meet the performance specified herein. This shall include all sensor and meter wiring schematics. This shall be included in CDRL A003 submittals.

5. Reliability analysis to include individual component, subsystem and overall system reliability determinations. This analysis shall be based on component reliability information and previously developed system configuration for system reliability assessments. This shall be included in CDRL A003 submittals.

6. The Contractor shall submit monthly Progress Reports in accordance with Section 2.D.

6 General Requirements

6.1 Equipment Drawing and Technical Data Submittal Requirements A. The Contractor shall deliver, but not be limited to, all submittals identified in Section 2.D and Section 5.3..

B. The sequence of drawing and technical data submission shall be such that all information is available prior to the Government’s review. All drawings shall form part of the contract after the Government’s review and approval.

C. All drawings shall be submitted in digital format as PDF files suitable for mark-up with comments and printing. The title block shall contain the name of the Government, contract name and number, and the Government’s equipment tag number.

D. Review of the Contractor’s drawings by the Government shall not relieve the Contractor of any part of their obligation to meet all requirements noted in the contract documents or the responsibility of correctness of such drawings.

E. The Contractor shall make all necessary changes in design that are required to make the work conform to the provisions of the contract without additional cost to the Government.

F. All final submitted drawings shall be brought to an As-Built status and be endorsed with the wording “As Built” in the revision block.

6.2 Installation Instructions, Operating, and Maintenance Manuals

1. 450VAC Switchboard Operating and Maintenance (O&M) Manuals shall be supplied by the Contractor to provide all information deemed necessary for the Government to operate and maintain the 450VAC Switchboard throughout its design life.

1. The documentation shall contain Manufacturer contact information, warranty information, instructions, drawings (reduced as necessary, but clearly legible), parts lists, catalogs, and any other instructions that may be needed or be useful in the installation, planned maintenance, corrective maintenance, dismantling, assembling and for identification when ordering replacement parts. The manuals shall be provided in searchable, digital format and in paper hardcopy format. Hardcopy format shall be assembled and bound between hardcovers to Letter size (8.5 inch by 11 inch). Where the Contractor’s and/or Subcontractor’s standard brochures are included, they shall be clearly marked to indicate the part that has actually been furnished.

1. Each set of Manuals may be divided into separate volumes for:

1. Installation Instructions

2. Operating Instructions

3. Maintenance Manuals with list of spare parts

1. The Contractor shall provide COTS manuals and supplemental data with all equipment and components for which manuals or data are available. Copies of COTS manuals and supplemental data shall be delivered IAW CDRL A005, Commercial Off-The-Shelf (COTS) Manuals and Associated Supplemental Data, 450VAC Switchboard Manuals, of this technical specification document. All manuals for the components of the system shall be submitted in a single three-ring binder or multiple binders, as necessary.

6.3 Nameplates, Markings, and Notices

A. Nameplates, notices and the like shall be permanently attached to the equipment to bring the attention to the following:

1. Notices required by statutory regulations such as maximum safe working load.

2. Warning notices such as “DANGER”.

3. Equipment nameplates with the Manufacturer’s model and data B. Suitable nameplates shall also be attached to meters, indicators and control switches furnished with the equipment.

C. Nameplates and notices shall be of appropriate size and the information contained thereon be easily read from all operating positions. They shall be affixed to the equipment so that they cannot be removed or destroyed through wear and tear.

D. Stampings and engravings shall be of sufficient depth so that the letters, numbers, and wording shall not be worn away by the prevailing environmental conditions.

E. Nameplate material shall be of stainless steel or approved equivalent.

F. 450VAC Switchboard equipment nameplates shall have all necessary information to facilitate identification and installation and shall include but not be limited to (as applicable):

1. Name of Manufacturer

2. Contract number (when applicable)

3. Equipment tag number

4. Manufacturer’s serial number

5. Design and performance information as applicable

6. Date of Manufacture

7. Voltage

8. Current

9. Number of phases

10. Frequency

11. Total weight

6.4 Cleaning, Painting and Protective Coatings

1. Painting and protective coatings shall be in accordance with the Contractor’s applicable standard painting Specification for industrial indoor use

6.5 Special Tools, Devices, and Test Equipment

A. The Contractor shall supply a complete list and recommended quantities of test equipment and any special tools required to install and maintain the 450VAC Switchboard equipment. The list of recommended special tools and test equipment shall be noted in the Maintenance Manuals.

B. The Contractor shall deliver one set of necessary special tools and devices required for the installation, operation, and maintenance of the plant or equipment supplied. These shall be new, of first-class quality, crated separately from other equipment and materials, and be clearly marked as to their intended use.

6.6 Assembly, Packaging, and Shipping

A. Unless otherwise specified, the equipment shall be packed in accordance with the best commercial practice for shipment and transportation. Any damage received in transit due to defective or insufficient packing or defective methods of packing shall be corrected by the Contractor at their expense and within a reasonable time when called upon to do so.

B. The Contractor shall package the description of procurement according to all current commercial standards and codes. The Contractor shall prepare a Packaging Plan and Lift Arrangement Drawings for the description of procurement. The Packaging Plan and Lift Arrangement Drawings shall be delivered to and approved by the Government prior to delivery of the description of procurement. The Packaging Plan and Lift Arrangement Drawings shall detail the precautions the Contractor plans to use to protect and preserve the description of procurement against corrosion, deterioration and physical damage during shipment and handling. The Packaging Plan and Lift Arrangement Drawings shall be prepared and submitted IAW CDRL A009 Commercial Drawings/Models And Associated Lists; Lifting Arrangement Drawings of this technical specification document.

6.7 Spare Parts

6.7.1 Maintenance Spares and Consumables

A. The Contractor shall submit to the Government for review and approval, their recommended list of spare parts, assemblies, and consumables to be delivered to the Government for efficient maintenance of the equipment being supplied. The quantity of spares and consumables shall be based on one (1) year of operation.

B. The Contractor shall itemize any spare parts, assemblies, and consumables, other than spare parts and consumables specifically included under the contract, that are recommended for the Government to acquire for forty-eight (48) months of operation of the equipment after Acceptance of the 450VAC Switchboard (as identified in Section 4.3). These spares, assemblies, and consumables shall be fully itemized. Prices shall be quoted in $US currency, including packaging, and delivery into the Government’s warehouse.

6.7.2 Construction Spares

A. The Contractor shall supply on-site Construction Spares to include spare parts, assemblies, and consumables to cover normal predictable losses, wastage, and damage during installation, testing, and commissioning.

B. The Contractor shall supply a list of the itemized Construction Spares to the Government for review and approval.

6.7.3 Spare Part and Consumables Packaging and Identification

1. All spares parts and consumables supplied shall be listed in the Maintenance Manuals.

1. Spares, assemblies, and consumables supplied shall be packed and delivered separately to the Government, and be identified using the part numbers listed in the maintenance manuals.

1. Spare Part and Consumable Packages shall be clearly labeled with the following information:

1. Government’s contract number

2. Name of equipment supplied

3. Name of spare part(s)

4. Name of spare part(s) supplier(s)

5. Manufacturer’s spare part(s) number

6. Number of items

7 Design and Construction Requirements

1. The 450VAC Switchboard Contractor shall be ISO-9001 Certified and shall submit current Certification documentation upon Contract Award.

7.1 General Arrangement

A. The Contractor supplied 450VAC Switchboards shall be designed for bottom entry of cabling and shall be accessible through the front and back sides for hookup.

B. The Contractor supplied 450VAC Switchboards shall be constructed of vertical metal enclosed sections bolted together to form a rigid assembly and shall be front and rear aligned.

C. The Contractor supplied 450VAC Switchboards shall have front accessible circuit breakers.

D. The Contractor supplied 450VAC Switchboards shall have vertical insulating barriers between the front device section, the main bus section, and the cable compartment with full front to rear vertical insulating barriers between adjacent sections.

E. The Contractor supplied 450VAC Switchboards shall be completely factory engineered and assembled, including protective devices and equipment indicated with necessary interconnections, instrumentation, and control wiring.

F. The Contractor supplied 450VAC Switchboards shall be outdoor NEMA ICS 6 Type 3.

G. The Contractor supplied 450VAC Switchboards shall be equipped with insect/rodent screen and filter to permit air circulation.

H. Each Contractor supplied 450VAC Switchboard’s enclosures shall be bolted together with removable bolt-on side and hinged rear covers, and sloping roof downward toward rear.

I. Each Contractor supplied 450VAC Switchboard’s rear doors shall be provided with stainless steel pad lockable vault handles with a three point latch.

J. Each Contractor supplied 450VAC Switchboard’s bases, frames and channels of enclosure shall be corrosion resistant and shall be fabricated of ASTM A 167 type 304L stainless steel.

K. Each Contractor supplied 450VAC Switchboard’s bus bars shall be copper with silver or tin-plated contact surfaces. Phase bus bars shall be insulated with an epoxy finish coating powder providing a minimum breakdown voltage of 16,000 volts per ASTM D 149.

L. Each Contractor supplied 450VAC Switchboard’s main section shall consist of an individually mounted draw-out or molded case circuit breaker as specified herein.

M. Each Contractor supplied 450VAC Switchboard’s distribution sections shall consist of an individually mounted draw-out or molded case circuit breaker as specified herein.

N. Each Contractor supplied 450VAC Switchboard’s auxiliary sections shall consist of indicated instruments, metering equipment, control equipment, transformer, and current transformer compartments as required.

O. Each Contractor supplied 450VAC Switchboard’s handles for individually mounted devices shall be of the same design and method of external operation. Label handles prominently to indicate device ampere rating, color coded for device type. Identify ON-OFF indication by handle position and by prominent marking.

P. Each Contractor supplied 450VAC Switchboard’s draw-out or molded case circuit breakers shall have short-circuit current rating of 100,000 RMS amperes symmetrical at 480 volts AC. Each breaker shall be provided with a four-position operation (CONNECTED, TEST, DISCONNECTED, WITHDRAWN) where each position is clearly identified by an indicator on the circuit breaker front panel.

Q. Each Contractor supplied 450VAC Switchboard’s circuit breakers shall have a microprocessor-based device designed to monitor and display parameters of the circuit breaker electronic trip units.

R. Each Contractor supplied 450VAC Switchboard’s shall have a multi-function meter to display a selected phase to neutral voltage, phase to phase voltage, percent phase to neutral voltage THD, percent phase to phase voltage THD; a selected phase current, neutral current, percent phase current THD, percent neutral current; selected total PF, kW, KVA, kVAR, FREQ, kVAh, kWh.

S. Each Contractor supplied 450VAC Switchboard shall have a ground fault detection monitor. The Ground Detection monitor shall be a Bender EDS460-D or equivalent.

T. Each Contractor supplied 450VAC Switchboard shall have 120-volt heaters in each vertical section to control moisture condensation and shall be controlled by a thermostat and humidistat located in the section. A single external source of Customer provided 120V power will be provided to each Switchboard.

U. Each Contractor supplied 450VAC Switchboard shall have a voltage rating of 480 volts AC, 3-wire, 3-phase operated at frequencies of 20 Hz to 70 Hz and corresponding voltages of 120 to 500V. The circuit breakers shall operate at those frequency and voltage ranges and do not need to provide overcurrent protection when outside atypical frequency and voltage ranges. The contractor may provide protection override function during operations outside normal voltage and frequency ranges.

V. Each Contractor supplied 450VAC Switchboard shall have a continuous current rating of 2,000 RMS amperes.

W. Each Contractor supplied 450VAC Switchboard shall have a short-circuit current rating of 100,000 RMS symmetrical amperes.

X. Each Contractor supplied 450VAC Switchboard shall have a circuit breaker lifting device and built in rail for circuit breaker installation and removal.

7.2 General

A. All 450VAC Switchboard equipment shall be compatible with the interfaces as specified herein.

B. The Contractor shall provide Instrumentation and Control for the safe operation of the 450VAC Switchboards locally and remotely as specified herein.

C. The 450VAC Switchboard shall be fully tested at the factory prior to shipment per the Testing Requirements specified in Section 9.

D. The 450VAC Switchboards shall be as completely factory assembled as possible within shipping and handling limitations in accordance with this Specification.

E. The 450VAC Switchboards shall have sufficient accessibility for all replaceable parts.

F. The 450VAC Switchboards shall be designed to ensure personnel safety in accordance with NFPA 70E.

G. The 450VAC Switchboards shall be sized to continuously deliver the full power as specified herein.

H. The 450VAC Switchboards shall incorporate provisions for installing grounding devices with sufficient accessibility during maintenance periods. A single grounding location per vertical section shall be identified.

I. The 450VAC Switchboards enclosure front of each cubical shall be hinged doors or removable lift-off panels.

J. Each 450VAC Switchboard enclosure shall be adequately secured but shall not be used for structural strength.

K. Each 450VAC Switchboard enclosure shall have adequate ventilation openings as required.

L. The 450VAC Switchboards shall have adequate clearance between live bus work and disconnect devices in accordance with industry standards.

M. Each 450VAC Switchboard’s top of the enclosure shall prevent dripping water or falling objects from entering the switchboard enclosure or damage instrumentation on the front panels.

7.2.1 Instrumentation and Control

7.2.1.1 Control Functions

A. Each 450VAC Switchboard control equipment shall provide, at a minimum, the following control and instrumentation functions:

1. Local switchboard control for each circuit breaker shall include:

a. Circuit Breaker Open/Close/Trip operation

b. Heater ON/OFF/AUTO selection switch

c. Switchboard Local/Remote switch which will transfer the breakers close functionality between local and remote. Both local and remote Breaker open functionality shall be active independent of the position of the LOCAL/Remote switch.

2. Local switchboard indication shall include:

a. Switchboard local/remote indication

b. Switchboard power available indication

c. Each Circuit Breaker Open/Close/Trip position indication

d. Each Circuit Breaker withdrawn position indication

e. Each Circuit Breaker current (A)

f. Each Circuit Breaker apparent power (VA)

g. Long time trip event

h. Short time trip event

i. Instantaneous trip event

j. Shunt trip event

k. Long time trip delay in progress event

l. Ground fault event

m. Heaters on indication

3. Remote switchboard control for each circuit breaker shall include:

a. Circuit Breaker Open/Close operation

4. Remote switchboard indication shall include:

a. Switchboard local/remote indication in the form of a dry contact closure

b. Switchboard power available indication in the form of a dry contact closure

c. Each Circuit Breaker Open/Close/Trip position indication in the form of a dry contact closure

d. Each Circuit Breaker withdrawn position indication in the form of a dry contact closure

e. Each Circuit Breaker current (A) as a 0-20mA output

f. Each Circuit Breaker apparent power (VA) as a 0-20mA output

g. Ground fault event in the form of a dry contact closure

5. Each circuit breaker shall have:

a. Adjustable short time pick up setting

b. Adjustable long time pickup setting

c. Adjustable instantaneous pickup setting

6. Each 450VAC Switchboard shall incorporate a power meter displaying the following information:

a. Each Line-Line Voltage

b. Each Line-Ground Voltage

c. Each phase Current

d. Total Real, Reactive, Apparent Power and Power Factor. The power meter shall be provided with digital communication capabilities to allow direct status communication (Ex: Modbus).

7. Ground fault detector shall be connected to the main bus(es).

8. Each AC Switchboard shall provide independent high bandwidth current and voltage sensors to be utilized by the Customer. These sensors shall have a dedicated termination board for Customer interface. The following are the required voltage and current measurements with associated sensors:

a) Three phase to phase voltage measurements per AC Switchboard main buses utilizing the LEM CV 3-1000 or equivalent sensor

b) Three phase to neutral voltage measurements per AC Switchboard main buses utilizing the LEM CV 3-1000 or equivalent sensor

c) Three phase current measurements for each Source Feeder per AC Switchboard identified in Figure 1, utilizing the LEM LT 2005-T or equivalent sensor.

9. The sensor interfaces and physical sensors shall be designed such that these sensors can be easily removed for inspection and calibration.

10. The switchboard shall be designed to accept momentary hardwired contact closure commands for remote open and close operation.

7.2.1.2 Control Panels

A. All power connections above 30A shall be pressure (crimp) type connectors with a NEMA pad, including terminations for Government’s connections.

B. Wire connections, other than factory soldered connections, shall be made with non-insulated straight shank, crimp type, plated, terminals.

C. Each terminal block and each point used on terminal block shall be labeled with tape or stick on labels.

D. All circuit boards shall be accessible for quick and easy replacement without special tools.

E. Components shall be accessible through lockable hinged door.

F. No electrically-energized components shall be accessible with doors closed.

G. Hardware shall be properly designed and/or treated to resist corrosion.

H. Power bus shall be conservatively rated and so designed for fault current rating and maintenance-free operation.

I. All interconnecting wiring, equipment and terminal board points shall be properly identified using identification marking.

J. Modular construction shall be used to minimize maintenance and change-out required during the troubleshooting process where necessary.

K. Thermostatically controlled space heaters shall be provided to control environmental conditions when necessary.

L. All panels and equipment shall be designed to ensure safety of operating and maintenance personnel.

M. All controls and instrumentation shall be galvanically isolated from the main 450VAC Switchboard input power which is ungrounded.

7.2.1.3 Controls Connection Cubicle

A. Each Instrumentation and Control Connection Cubicle shall be adequately sized to permit the proper termination of the low voltage control and instrument wires and cables in accordance with the requirements of the 450VAC Switchboard and national and local electrical codes. The instrumentation and controls cubicle should provide open, unused space for customer installation of DIN rail to install Allen Bradley Flex I/O interface modules for Remote I/O monitoring and control. The customer allocated space for the PLC interface shall be 24”x24” that would fit two rows of DIN rail.

B. All Instrumentation and Control wiring for remote control and monitoring shall be run to the Control Connection Cubicle with outgoing connections available on DIN mounted terminal blocks..

C. Each Instrumentation and Control Connection Terminal Box shall incorporate a ground lug.

D. Instrumentation and Control Terminal blocks shall be rated at 600 VAC.

E. Instrumentation and Control wires and cables shall be rated at 600 VAC and be a minimum of #18 AWG.

7.3 Connections and Terminals

7.3.1 Power Interface Terminals

A. The power interface termination area shall be adequately sized to permit the proper bend radius of the cable and the proper termination of 400 mcm cables.

B. The power interface terminals may be copper with silver or tin plating to reduce corrosion.

C. The power interface terminals shall be designed to accommodate a two-hole lug connection for the power cables.

D. A ground bus or termination interface shall be provided at the power interface section and have provisions to be bonded to site structure. The ground bus shall be galvanically isolated from the main 450VAC Switchboard input power which is ungrounded.

E. The ground bus work shall be copper with silver or tin plating to reduce corrosion.

F. The conductors shall be oriented and labeled from left to right for the A, B, and C phase terminations. The terminations shall be made on high copper alloy blocks and conform to standard NEMA patterns.

G. The Contractor shall specify the make and model number of the high copper alloy lugs that should be used for the cables being terminated on each of the termination blocks and the required tightening torque for the bolts on the termination pad.

H. The Contractor shall specify the make and model number of the high copper alloy ground conductor lugs that should be used for the ground wires and the tightening torque required for the bolts on the termination pad.

I. Power interface terminals shall provide a termination pad that is clearly marked for the connection of grounding conductors.

7.3.2 Installation

A. The Contractor shall provide Installation Drawings IAW CDRL A003, Product Drawings/Models and Associated Lists, 450VAC Switchboard Drawings.

B. The installation drawings shall provide sufficient detail including clearances and tolerances required for installation.

7.4 Delivery, Lifting and Rigging

A. The Contractor shall deliver each 450VAC Switchboard to NAVSSES Building 633 complex in Philadelphia, PA 19112 using standard industry packaging and delivery practices.

B. The Contractor shall provide lift arrangement drawings, in accordance with A009 Commercial Drawings/Models And Associated Lists, for all components and assemblies to be lifted on site at NAVSSES, Philadelphia PA.

C. The lift arrangement drawings shall provide sufficient detail in order to develop lift plans and for review and approval for all crane and rigging operations necessary to move and position the 450VAC Switchboard on-site.

D. The lift arrangement drawings shall identify the location, configuration and rating of all lifting points, shall provide a lift diagram as needed to depict any restrictions on lift angles at lift points and shall identify associated rigging hardware.

E. The lift arrangement drawings shall also include, or be accompanied by, engineering calculations.

F. The lift arrangement drawings for four-point configurations (if required) shall be designed to meet the requirements of NAVFAC P307 'Management of Weight Handling Equipment' as follows:

1. Slings, shackles, and attachment points in a four leg assembly for a four-point lift shall be sized based on either pair of diagonally opposing legs carrying the entire load, unless the assembly is equipped with devices that automatically adjust for equal distribution of the load such as engineered equalizer plates.

2. Chain hoists can be used for equalizing loads only if used in conjunction with load indicating devices.

G. Welds of lifting pads, jacking and handling features on the components and assemblies shall be inspected in accordance with NAVSEA Technical Publication S9074-AR-GIB-010/278, Table VII, Machinery Class M2, Category A.

H.

8 Performance Requirements

8.1 450VAC Switchboard Performance Requirements

8.1.1 450VAC Switchboard Technical Data Sheets

1. Each 450VAC Switchboard main bus bars shall be silver or tin plated with a continuous current rating of 2000 Amps.

1. Each 450VAC Switchboard shall have a maximum short circuit withstand of 100kA

1. Each 450VAC Switchboard shall have a main bus bracing of 100kA.

1. Each 450VAC Switchboard shall have a maximum voltage of 480Vac, 3ph, ungrounded

1. Each 450VAC Switchboard shall support variable frequency operations of 20 to 70Hz. NOTE: Nominal operation is 60Hz +/-3%. Any other atypical operation outside 60Hz +/-3% does not require overcurrent protection of the circuit breaker and would be closely monitored.

1. Each 450V Switchboard shall support variable voltage operations of 120 to 500V. NOTE: Nominal operation is 450V +/-3%. Any other atypical operation outside 60Hz +/-3% does not require overcurrent protection of the circuit breaker and would be closely monitored.

1. Each 450VAC Switchboard shall have a one minute withstand voltage of 2000V.

1. Each 450VAC Switchboard’s auxiliary voltage for all controls and metering shall be self-derived by the main input power.

1.

8.1.2 450VAC Switchboard Performance A. The 450VAC Switchboard shall be rated to meet the following input characteristics:

1. Nominal input voltage rating of 450Vac, 3ph, ungrounded with the following characteristics:

a. Line-to-line voltage unbalance of 3%

b. Average line-to-line voltage from nominal: +/- 5%

c. Voltage modulation: 2%

d. Maximum transient voltage: +/- 16%

e. Support operational frequencies of 20 to 70 Hz

2. Maximum total harmonic distortion of 5%

3. Maximum single harmonic of 3%

4. Maximum deviation factor: 5% B. Each circuit breaker shall provide long-time, short-time and instantaneous protection to the load.

8.1.3 Environmental Conditions

1. The 450VAC Switchboard shall be installed in an industrial indoor facility located in Building 633 Complex located at NAVSSES Philadelphia, PA.

9 Inspections and Tests

9.1 Categories and Scope of Tests

A. The Contractor shall prepare a Test Report, in Contractor format, for all successfully completed tests. The Contractor shall prepare a Test Report, in Contractor format, IAW CDRL A007, Test/Inspection Report, FAT Test Report, of this technical specification document, to document the result of the Factory Acceptance Testing (FAT). The final test report will be submitted only after failures (if any) have been corrected, and the applicable test has been repeated to verify adequacy of the correction.

1. The Contractor shall perform their standard tests and those applicable from industry standards such as but not limited to IEEE C37.20.1 and IEEE C37.21

2. The Contractor’s test plan shall include pass/fail criteria for each test.

3. The Contractor shall provide operational Training of the 450VAC Switchboard of this technical specification document.

B. The Factory and Acceptance Testing (FAT) shall demonstrate the End Items ability to perform its intended function in the intended operating environment. FAT shall also demonstrate compliance with the End Items drawing package and performance specifications. The Contractor, IAW the purchase specification, shall perform the FAT. The Contractor shall notify the Government no later than 15 working days prior to FAT as to when and where the test will take place. As a minimum, at least one Government representative shall witness each phase of the FAT. All Contractor or supplier-performed Proof-load, Environmental and Reliability Tests, when applicable, shall be completed prior to start of the FAT.

C. Should any test item fail to conform to the specified requirements, the Contractor shall perform a failure analysis identifying the cause(s) of such failure along with the corrective action(s) to be taken. This analysis and corrective actions shall be supplied to the Government for review and approval.

D. If previously tested items are changed or modified, the Contractor shall perform a complete retest to demonstrate conformance with specified requirements.

E. The Contractor shall submit a certified test report for each test, including a summary of results, to the Government. The test report shall be complete with the Contractor’s acknowledgement certifying the test data and verifying conformance to the specified requirements.

F. The Contractor shall submit calibration data sheets for all instrumentation and circuit breakers.

G. The Factory Acceptance Testing shall include standard industry testing UL/IEC/IEEE for the type and class of equipment. These test may include but not limited to the following three primary categories in accordance with guidance from IEEE Std C37.20.1 Section 6:

1. Design Tests. For the test below, arrangement construction shall consist of an indoor vertical section of circuit breaker compartments plus an additional representative structure so that the main bus extends through both sections and includes main bus splice.

a. Dielectric tests. Power frequency withstand test shall be performed to demonstrate the ability of the insulation system to withstand 2.2kVrms, 60Hz. The voltage is to be increased gradually from zero to 2200Vrms within 5-10secs and shall be held there for 1min.

b. Rated continuous current tests. The continuous current rating of the switchboard shall be 2000A. Test shall be performed at ambient temperature for such a period of time that the temperature rise of any monitored point has not increased by more than 1degree Celsius over one hour period. The total temperature shall not exceed Tables 3 and Table 4 of IEEE STD C37.20.1 to be considered passing.

c. Short-time withstand current tests shall be made to demonstrate the thermal and mechanical capability of the buses and connections in LV switchgear to withstand the rated short-time current of the assembly. This test may be conducted as a single phase test. The circuit breaker shall be closed and the overcurrent trip device shall be made inoperative.

d. Short-circuit current withstand tests shall be made to demonstrate the mechanical adequacy of the structure, buses, and connections when the bus is subjected to a high current for a specified time. The current for these tests is to be equal to the short-circuit rating of the circuit breakers intended for use in the tested switchgear.

e. Mechanical endurance tests. Low-voltage switchgear with draw-out / molded case circuit breakers shall be subjected to at least 500 mechanical endurance test cycles for each frame size and type of circuit breaker. A test cycle, consists of operations between connected, test and disconnected positions to demonstrate proper sequential operation and to establish satisfactory function as specified in section 6.2 of IEEE STD C37.20.1.

f. Flame-resistance tests. Sheet, molded, or cast insulating material used in a switchgear assembly shall not be classified as flame resistant unless they have a minimum average ignition time of 60 s and a maximum average burning time of 500 s when tested in accordance with method II of ASTM D229-2001.

g. Rod entry test. This test shall prevent the insertion of a straight rod having a diameter of 13 mm into the opening.

h. Coating (paint) qualification test. The coating qualification test shall be performed to ensure the adequacy of finishes to inhibit the buildup of rust on ferrous metal materials used for enclosures.

i. Certified factory test reports, signed and dated by the person who conducted the test, shall be provided to the Customer prior to shipment.

2. Production tests for LV switchgear shall include power frequency dielectric tests, mechanical tests, grounding of instrument transformer case tests, and electrical operation and control wiring tests.

a. Dielectric tests. Power frequency withstand tests shall be made on each LV switchgear in accordance with the general requirements of 6.2 of IEEE STD C37.20.1. Tests shall be made between each phase and ground with the other phases grounded at 2200V. Apply a test voltage of 1800V between neutral and ground.

b. Mechanical tests shall be performed to ensure the proper functioning of mechanical interlocks, etc. These tests shall ensure the interchangeability of removable elements designed to be interchangeable.

c. Grounding of instrument transformer case test. The effectiveness of grounding of each instrument transformer case or frame shall be checked by a low potential source such as 10V or less using bells, buzzers, or lights.

d. Electrical operation and control wiring tests shall include wiring continuity, insulation test, polarity verification and sequence test in accordance with section 6.3.4 of IEEE STD C37.20.1.

3. Conformance tests Field dielectric tests

a. The Contractor shall demonstrate the operation:

i. Demonstrate each circuit breaker local and remote operational control of Open/Close/Trip and Open/Close…