Medium_Voltage_Load_Bank_Specification_8024_final.pdf

MEDIUM VOLTAGE LOAD BANK

TECHNICAL SPECIFICATION DOCUMENT

Naval Surface Warfare Center - Philadelphia

Document Number: 8024_0001

June 22nd, 2015

Medium Voltage Load Bank Specification

Document Number: 8024_0000

Date: June 22nd, 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 C. TS Document #3: Technical Data Sheets - To Be Completed by Contractor

Date: June 22nd, 2015

Table of Contents Technical Specification (TS) Documents

TS Document #1: Technical Requirements Form

TS Document #2: Engineering Specification

1 Scope of this Specification

2 Overview

3 Applicable Codes, Standards, and Regulations

3.1 General

3.2 Industry Standards

3.3 Military Standards

3.4 Lifting and Rigging Standards

4 Rating, Conditions of Service, and Performance Warranty

4.1 Equipment Ratings, Materials, and Workmanship

4.2 Conditions of Service

4.3 Load Bank Acceptance, Performance Warranty and Defects Liability

5 Work Included: Contractor’s Responsibility

5.1 Overall System Requirements

5.2 Scope of Supply

5.3 Engineering Design and Status Reporting

6 General Requirements

6.1 Equipment Drawing and Technical Data Submittal Requirements

6.2 Installation Instructions, Operating, and Maintenance Manuals

6.3 Nameplates, Markings, and Notices

6.4 Cleaning, Painting and Protective Coatings

6.5 Special Tools, Devices, and Test Equipment

6.6 Assembly, Packaging, and Shipping

6.7 Spare Parts

7 Design and Construction Requirements

7.1 General Arrangement

7.2 General Electrical

7.3 General Cooling System

Date: June 22nd, 2015

7.4 General Instrumentation and Control

7.5 Connections and Terminals

7.6 Installation

7.7 Delivery, Lifting and Rigging

8 Performance Requirements

8.1 LOAD BANK Performance Requirements

8.2 Load Elements

8.3 Environmental Conditions

8.4 Audible Noise

9 Inspections and Tests

9.1 Categories and Scope of Tests

10 TS Document #3: Technical Data Sheets - To Be Completed by the Contractor

10.1 General LOAD BANK Characteristics

Date: June 22nd, 2015

TS Document #1: Technical Requirements Form The Following Documents Form Part of the Technical Specification

Item # Document Title Revision #

1 Technical Requirements Form 1

2 Engineering Specification 1

3 Technical Data Sheets - To Be Completed by Contractor 1

Equipment Information:

The Following Equipment is to be procured under this Technical Specification

Item # Quantity Description Equipment Tag #

1 1 LB_MVAC_001 MVAC LB

Technical Requirements Form Revision Information:

Rev # Date Revision Issue Description Rev Approval

June 1st, Release for Procurement 05/18/2015

Date: June 22nd, 2015

TS Document #2: Engineering Specification

TITLE SHEET

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

Project Name: MEDIUM VOLTAGE LOAD BANK

Engineering Specification Revision Information:

Rev # Date Revision Issue Description Rev Approval

1 June 22nd, Release for Procurement 06/15/2015

Date: June 22nd, 2015

1 Scope of this Specification A. This Specification provides the technical requirements for the design, performance, inspection, testing, and warranty of a Medium Voltage Load Bank. 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.

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

1. Scope of this Specification

2. Overview

3. Applicable Codes, Standards, and Regulations

4. Rating, Conditions of Service, and Performance Warranty

5. Work Included: Contractor’s Responsibility

6. General Requirements

7. Design and Construction Requirements

8. Performance Requirements

9. Inspections and Tests

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

C. Throughout this Specification the following terms apply:

1. “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 Load Bank.

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

Date: June 22nd, 2015

2 Overview A. The Medium Voltage Load Bank (Load Bank) shall be rated for outdoor use and will be located at the NAVSSES Building 633 complex in Philadelphia, PA 19112.

The following table provides a summary of the Load Bank specified in this document.

Table 1: Overview of Load Bank Requirements

Resistive (kW) Inductive (kVAR) Reactive (kVAR)

Item Qty Equipment

Tag Voltage

(V)

Power Rating (kW)

Load Resolution

(kW)

Power Rating (kVAR)

Load Resolutio n (kVAR)

Lagging Power Factor

(pf)

Power Rating (kVAR

Load Resolution

(kVAR)

Leading Power Factor

(pf)

1 1

LB_MVAC_

2.6kV

AC, 0-

60Hz

3MW

See Section

See

Section 8 See

Section 8 See

Section 8

B. The Load Bank Contractor shall provide the following services as specified herein:

1. 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.

2. The Contractor shall deliver General Arrangement drawings IAW CDRL E001, Commercial Drawings/Models and Associated Lists, Load Bank 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 Load Bank drawings IAW CDRL E002, Commercial Drawings/Models and Associated Lists, Load Bank Drawings, of this technical specification document. The Contractor shall provide manufactures assembly, installation assembly, protection systems, thermal management, and electrical/electronic diagrams with complete materials list. This submittal shall include data related to the temperature performance of the resistive elements to be utilized. Data should be based on measured real data of the resistive load element material thermal performance and include, but not be limited to, the environmental conditions consistent with the Load Bank physical location specified herein.

4. The Contractor shall submit Electrical Single Line Drawings IAW CDRL E003, Product Drawings/Models and Associated Lists, Load Bank Electrical Single Line Drawing and Controls Drawing, of this technical specification document. All electrical and controls site interconnections shall be clearly identified. This drawing shall also be accompanied with a narrative description of the Load Bank controls and associated operation.

5. 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 E004, Commercial Off-The-Shelf (COTS) Manuals and Associated Supplemental Data, Load Bank Manuals, of this

Date: June 22nd, 2015 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. The Contractor shall prepare a Test Plan IAW CDRL T001, Test Procedures; Factory Acceptance Test, of this Technical Specification document.

7. The Contractor shall prepare a Test Report for all successfully completed tests. The Contractor shall prepare a Test Report, in Contractor format, IAW CDRL T002, Preparation of 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.

8. 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 A002 Packaging Plan and Lifting Arrangement Drawings of this technical specification document.

9. The Contractor shall submit Lifting Arrangement Drawings IAW CDRL E005 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.

Date: June 22nd, 2015

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

Environments

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

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

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

5. 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)

Date: June 22nd, 2015

1. UL 467, Standard for Grounding and Bonding Equipment

2. UL 2735, Standard for Safety Electric Utility Meters

3.3 Military Standards

A. MIL-STD-1399-680, Department of Defense Interface Standard Section 300, Medium

Voltage Electric Power, Alternating Current

3.4 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

Date: June 22nd, 2015

4 Rating, Conditions of Service, and Performance Warranty

4.1 Equipment Ratings, Materials, and Workmanship

A. The Load Bank equipment provided shall meet all requirements specified herein.

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

C. 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

A. All Load Bank equipment shall be located outdoors in the facility Building 633 Complex located at NAVSSES Philadelphia, PA.

4.3 Load Bank Acceptance, Performance Warranty and Defects Liability A. Acceptance of the Load Bank 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 twenty five (25) 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 Load Bank 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 Load Bank equipment.

Date: June 22nd, 2015

5 Work Included: Contractor’s Responsibility

5.1 Overall System Requirements

A. The Load Bank Contractor shall provide an interface compatible with their specified interface requirements as required in this Specification.

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

C. The LOAD BANK Contractor shall be ISO-9001 Certified and shall submit current Certification documentation upon Contract Award.

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 Load Bank 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 Load Bank design:

1. Mechanical design to include overall Load Bank dimension and weight of the individual equipment and lifting arrangements. This shall be included in CDRL E001.

2. Thermal management design to meet the performance specified herein. This narrative and associated calculations shall be included in CDRL E002.

3. Electrical power design to meet the performance specified herein. This narrative and associated calculations shall be included in CDRL E003.

4. Controls and instrumentation design to meet the performance specified herein. This narrative and associated design shall be included in CDRL E003.

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 narrative shall be included in CDRL E001.

6. The Contractor shall submit a Progress Report to report as identified in Section 2.

Date: June 22nd, 2015

6 General Requirements

6.1 Equipment Drawing and Technical Data Submittal Requirements A. The Contractor shall deliver general arrangement drawings IAW CDRL E001, Product

Drawings/Models and Associated Lists, Load Bank 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

B. The Contractor shall submit Load Bank drawings IAW CDRL E002, Product Drawings/Models and Associated Lists, Load Bank Drawings, of this technical specification document. The Contractor shall provide manufactures assembly, installation assembly, mechanical schematics, protection systems, and electrical/electronic diagrams with complete materials list. This information shall be sufficient to provide the Government with a complete understanding of the equipment being supplied. The drawings shall include at a minimum the following requirements:

1. LOAD BANK thermal management

2. LOAD BANK electrical input power

C. The Contractor shall submit Electrical Single Line and Controls System Drawings IAW CDRL E003, Product Drawings/Models and Associated Lists, Load Bank of this technical specification document. The drawings shall show the relative electrical interconnections of the Load Bank sections. All site interconnections shall be clearly identified. The drawings shall also include all controls and instrumentation connections internal and external to the Load Banks.

D. 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.

E. 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.

F. 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.

G. 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.

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

Date: June 22nd, 2015

6.2 Installation Instructions, Operating, and Maintenance Manuals A. Load Bank 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 Load Bank throughout its design life.

B. 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.

C. 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

D. 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 E004, Commercial Off-The-Shelf (COTS) Manuals and Associated Supplemental Data, Load Bank 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. The Load Bank terminals and wires shall be labeled with markings that remain visible after connections are made. AC bus bars shall include phase identifiers and DC bus bars shall include positive and negative bus identifiers.

F. All conductors shall be oriented and labeled from left to right for phase A, B, and C terminations, in the case of AC Load Banks and positive and negative bus identifiers in the case of DC Load Banks. The terminations shall be made on high copper alloy blocks that have termination configurations conforming to standard NEMA patterns.

Date: June 22nd, 2015

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

H. Internal components such as relays, contactors, terminal blocks shall have identification markers that relate to the component identifications shown in the drawings.

I. Load Bank 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

A. Painting and protective coatings shall be in accordance with the Contractor’s applicable standard painting Specification for industrial outdoor 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 Load Banks. 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 Load Bank shall be as completely factory assembled as possible within shipping and handling limitations in accordance with this Specification.

C. 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

Date: June 22nd, 2015 prepared and submitted IAW CDRL E005 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 Load Bank (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 A. All spares parts and consumables supplied shall be listed in the Maintenance Manuals.

B. 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.

C. 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

Date: June 22nd, 2015

7 Design and Construction Requirements

7.1 General Arrangement

A. The Load Bank shall be installed at Building 633, NAVSSES Philadelphia, PA.

B. The Load Bank shall be arranged and installed to an existing roof mounted structural steel grate platform. Details on this platform will be available upon Contract award.

C. The Load Bank shall be outdoor minimum NEMA ICS 6 Type 4.

D. The Load Bank shall be constructed of metal enclosed sections bolted together to form a rigid assembly and shall be front and rear aligned.

E. The Load Bank base, frame and channel of enclosure shall be corrosion resistant and shall be fabricated of ASTM A 167 type 304L stainless steel.

F. The Load Bank enclosures shall be bolted together with removable bolt-on side and hinged rear covers, and sloping roof downward toward rear.

G. The Load Bank enclosure shall be adequately secured but shall not be used for structural strength.

H. The Load Bank rear doors shall be provided with stainless steel pad lockable handles with a three point latch.

I. The Load Bank 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.

J. The Load Bank shall be completely factory engineered and assembled, including protective devices and equipment indicated with necessary interconnections, instrumentation, and control wiring.

K. The Load Bank shall be designed for bottom entry of cabling and shall be accessible through the front and back sides for hookup.

L. The Load Bank shall have vertical insulating barriers between the cable compartment and the load element section with full front to rear vertical insulating barriers between adjacent sections.

M. The Load Bank shall have adequate clearance between live buswork and disconnect devices in accordance with industry standards.

N. The Load Bank shall have adequate ventilation openings as required and be equipped with insect/rodent screen and filter to permit air circulation.

O. The Load Bank shall have sufficient accessibility for all replaceable parts.

P. The Load Bank shall be designed to ensure personnel safety in accordance with NFPA 70E.

7.2 General Electrical

A. The Load Bank shall be compatible with the interfaces as specified herein.

B. The Load Bank shall have a separate 480-volt auxiliary power for all fans, control equipment.

This external power will be provided by the Customer.

Date: June 22nd, 2015

C. The Load Bank auxiliary sections shall consist of fuses, load contactors, terminal strips, thermostat/humidistat, control equipment, auxiliary transformer (as required), and current transformer compartments as specified.

D. The Load Bank shall have 120-volt heaters in each section to control moisture condensation and shall be controlled by a thermostat and humidistat located in the section.

E. The Load Bank shall have a continuous current rating as specified in Section 8.

F. The Load Bank shall be fully tested at the factory prior to shipment per the Testing

Requirements specified in Section 9.

G. The Load Bank, including all ancillary systems, shall be sized to continuously deliver the rated power as specified in Section 8 under all environmental conditions consistent with the specified installation location.

H. The Load Bank shall incorporate provisions for installing grounding devices with sufficient accessibility during maintenance periods.

I. The Load Bank shall be provided with a grounding bus bar on the bottom of the cable termination section and means to bond the unit to structural ground on the outside.

J. The Load Bans shall be, at a minimum, protected against; full or partial loss of one or multiple load elements, loss of control power, facility power supply over-voltage and under-voltage, over current (over-load), internal short circuits, loss of cooling, ground fault, and over temperature. Safe system shutdown is acceptable upon multiple load element faults.

K. The Load Bank shall be designed to limit any damage resulting from component failures or electrical faults to the smallest equipment subdivision within which the failure/fault occurred.

L. The Load Bank shall be sufficiently free of radiated and conducted electromagnetic interference (EMI), Radio Frequency Interference (RFI), and Telephone Interference, so as to not result in mis-operation of instrumentation, control and communications equipment, and be compliant with IEC-61800-3.

M. The Load Bans wiring shall be based on a copper alloy with a minimum cable insulation rated at 90 degrees Celsius.

N. The Load Bank shall integrate an Input Contactor to isolate the Government supplied input source from the Load Banks.

O. The design for the Load Bank shall not include any input transformers for the specified rated input voltage in Table 1.

P. The ratings of the Input Contactor shall be compatible with the individual Load Bank power/voltage/current steady state and transient ratings.

Q. The Input Contactor shall be designed to ensure personnel safety in accordance with NEMA ICS 7.1, IEEE 1566, and NFPA 70E.

R. The Load Bank shall have means to isolate Auxiliary power used for control and heater power when accessing Load Bank panels.

S. The Load Bank shall provide a dedicated power termination box, adequately sized to permit the proper termination of the power cables in accordance with requirements specified herein.

T. The Load Bank power termination box shall be located so the cover plate, which shall be securely bolted to the box, can be easily removed.

U. The Contractor shall specify the make and model number of the copper 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.

Date: June 22nd, 2015

7.3 General Cooling System

A. The Load Bank shall be air cooled.

B. The Load Bank design shall ensure that proper thermal isolation is provided between load element compartments and adjacent controls and cabling compartments to ensure that cable insulation and control components will not be damaged due to overheating from adjacent load elements.

C. The Load Bank exhaust airflow shall be through the top of the Load Bank, with an offset from vertical no greater than 30 degrees. The exhaust offset shall be adjustable with a deflector in either direction, or the exhaust hood shall be able to be rotated to adjust direction of exhaust.

D. The Load Bank intake and exhaust airflow design shall ensure that insulation resistance is not impacted by operation of the Load Bank in severe weather with heavy rain or snow.

E. The Load Bank shall be designed such that the number of cooling fans are energized in accordance with the commanded load.

F. The Contractor shall propose the following two cooling system options:

1. Cooling system that complies with Section 7.3.E.

2. Cooling system that integrates Variable Speed Drives for each of the cooling fans that are temperature controlled.

G. The cooling system option shall be selected upon Contract Award.

7.4 General Instrumentation and Control

A. The Load Bank shall provide Instrumentation and Control for the safe operation of the Load

Bank locally and remotely as specified herein.

B. The Load Bank control system shall be responsible for the monitoring, protecting and controlling a safe operation of the Load Bank.

C. The Load Bank control equipment (contactors, fuses, circuit breakers, protection circuitry) shall be panel mounted and adjacent to the load elements and within the main Load Bank enclosure.

D. The Load Bank load element increment shall be independently protected by its own branch circuit fuses or breaker.

E. The Load Bank input contactors shall be designed for maximum continuous voltage with maximum load.

F. The Load Bank control equipment shall include auxiliary contacts for all Load Bank contactors to provide position status for a Government furnished PLC based control system.

G. The Load Bank auxiliary contacts shall be wired to terminal boards for Government provided control circuit interfaces.

H. The Load Bank operational control permissives shall be capable of being disabled by the Government. This shall include operation of the Load Bank with removed or failed load segments.

I. The Load Bank shall have a digital power meter with an Ethernet output to transmit the analog values defined below. The communication protocol used by the Ethernet output should be an industry standard protocol capable of communicating with a wide range of PLC manufacturers, including Allen Bradley Controllogix PLC product line. If an Ethernet output is not possible, a 4-20 mA analog outputs would also be acceptable. If the analog output option is chosen, then terminal blocks/termination points shall be provided for wiring access to the Government supplied PLC. The digital power meter shall provide a minimum of the following signals:

1. Input voltage (RMS or Average as applicable)

2. Input current (RMS or Average as applicable)

Date: June 22nd, 2015

3. Frequency (Hz) as applicable

4. Real Power (kW)

5. Reactive Power (kVAR) as applicable

6. Apparent Power (kVA) as applicable

7. Power Factor (lagging/leading) as applicable

J. The Load Bank shall provide a Hardwired Emergency Stop push button that would safely open the input contactor of the Load Bank. The Emergency Stop push button shall be designed in accordance with IEEE 1566.

K. Anti-condensation heaters shall be provided in required areas to prevent damage or malfunction due to moisture. Interlocks and thermostatic/humidistat controls shall be provided so that heaters operate at desired temperature/humidity when the Load Bank is off.

L. Integral fans shall be provided with associated controls to maintain Load Bank temperatures within the required temperature limits. The Contractor shall identify the cooling system options of operating the installed number of fans proportional to the applied load.

M. All electrical measurements shall be electrically isolated from the main power.

N. Interposing relays shall operate the load segments contactors. These interposing relays shall interface with a Government supplied PLC derived dry contact with internally derived control power.

O. Auxiliary dry contacts shall be provided from the main input contactor, each load segment contactor and auxiliary fan(s), for monitoring operating status by the Government supplied

PLC.

P. The Load Bank shall provide independent high bandwidth phase to ground voltage sensors (or voltage dividers with associated processing rack) at the input interface to be utilized by the Government. These sensors shall be pre-installed and pre-wired to a dedicated termination board for Government interface. The following voltage transducers shall be installed in the Load Bank:

Table 2 – LOAD BANK Sensors

Equipment Tag

Measurement Sensor Model Quantity of sensors

LB_MVAC_0

VAC

Zimmer HST Series

7.4.1 Instrumentation and Control Signals

A. The Load Bank shall provide, at a minimum, the following protection monitoring signals, which shall be indicated by LEDs on a LOCAL dedicated control panel interface:

1. Main power available

2. Auxiliary power available

3. Heater power available

4. Low airflow fault

5. Intake over temperature fault

6. Exhaust over temperature fault

7. External trip (input contactor)

8. Electrical fault (load element)

Date: June 22nd, 2015

B. The Load Bank shall provide, at a minimum, the following protection monitoring signals, which shall be available to be transmitted via Ethernet, dry contact, or 4-20 mA analog signal from the LOAD BANK to the Government PLC for REMOTE monitoring:

1. Main power available

2. Auxiliary power available

3. Heater power available

4. Main airflow rate

5. Intake air temperature

6. Exhaust air temperature

7. Fan status

8. All alarm signals

9. All fault signals

C. The Load Bank shall provide, at a minimum, the following LOCAL controls on a LOCAL dedicated control panel interface:

1. Main power EMERGENCY STOP push button

2. Auxiliary power ON/OFF switch

3. Heater power ON/OFF switch

D. The Load Bank shall provide, at a minimum, the following REMOTE control signals, which shall be available to be transmitted via dry contacts from the LOAD BANK to the Government PLC for REMOTE monitoring:

1. Auxiliary power ON/OFF command

2. Fan operation ON/OFF command

3. Main input contactor ALL LOAD OFF command

4. All individual load segment control ON/OFF commands

7.4.2 Computer Interface Software Application

A. The Contractor shall provide any required software, algorithms, and licenses required to provide the ability to monitor the Load Bank control system code online for troubleshooting purposes.

B. The Contractor shall provide an Interface Description Document (IDD), or equivalent, detailing the protocols used and how to extract and interpret the data from the Instrumentation and Control data ports. A template for the IDD will be provided by the Government upon contract award.

7.4.3 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. Components shall be accessible through lockable hinged door.

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

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

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

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

Date: June 22nd, 2015

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

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

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

L. All controls and instrumentation shall be galvanically isolated from the main Load Bank input power which is ungrounded.

7.4.4 Connection Terminal Blocks

A. Each Instrumentation and Control Connection Terminal Blocks 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 Load Bank and national and local electrical codes.

B. All Instrumentation and Control wiring shall be run inside the enclosure with outgoing connections in the form of "Klippon" (or equivalent) terminals.

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.

7.5 Connections and Terminals

7.5.1 Power Interface Terminals

A. The Load Bank 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.

B. The input power interface termination box shall accommodate, at a minimum the cable types and quantities specified in Table 3, and shall provide adequate clearance for the bending radii of these cables.

Table 3 - LOAD BANK Power Cable Termination Box

Equipment Tag Cable Type Cable Quantity

LB_MVAC_001 LS5KVTSGU-250 16

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.

E. The ground bus shall be galvanically isolated from the main Load Bank input power which is ungrounded.

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

G. All conductors shall be oriented and labeled from left to right for phase A, B, and C terminations, in the case of AC Load Banks and positive and negative bus identifiers in the case of DC Load Banks. The terminations shall be made on high copper alloy blocks that have termination configurations conforming to standard NEMA patterns.

Date: June 22nd, 2015

H. 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.

I. 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.

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

7.6 Installation

A. The Contractor shall provide Installation Drawings IAW CDRL E002, Product

Drawings/Models and Associated Lists, Load Bank Drawings.

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

7.7 Delivery, Lifting and Rigging

A. The Contractor shall deliver the Load Bank 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 CDRL E005

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 Load Bank 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.

Date: June 22nd, 2015

8 Performance Requirements

8.1 LOAD BANK Performance Requirements

A. The Load Bank shall be designed as three single phase load banks. The Load Bank applies load between the Supply and Return points of each Phase.

B. Each of the three Load Bank phases shall be rated at 2600Vac line to neutral.

C. The Load Bank shall be designed to meet the Resistive/Inductive configuration per phase depicted in Figure 1.

D. The Load Bank shall integrate two identical inductance elements. The inductive element shall be rated at L=1.874 mH, with a 50% turns winding tap. The intermediate tap on each inductor coil shall allow four adjustments of the total load bank inductance.

E. The Load Bank shall be designed for a frequency range operation of 0-60Hz. The continuous current rating at DC is 600 Amps.

F. The Load Bank shall provide, for each phase, a controlled parallel path to short all resistive elements. This path shall be rated for 600Adc maximum.

G. Each phase of the Load Bank shall consist of seven independently controlled load segments, as depicted in Figure 1. The base resistance value is R=67.6 Ohms.

H. The Load Bank total dissipated power for each single phase load bank will never exceed

3MW.

I. Each of the Load Bank segments shall have the following maximum continuous current ratings:

1. Segment R – 50Amps AC.

2. Segment R/2 – 100Amps AC

3. Segment R/4 – 150Amps AC

4. Segment R/8 – 300Amps AC

5. Segment R/16 – 600Amps AC

6. Segment R/32 – 1000 Amps AC

J. The Contractor shall propose two options for Load Bank:

1. Each of the quantity 3 LB_MVAC_001 units as independent units.

2. All three units integrated into a single three phase Load Bank capable of loading each individual phase.

K. Selection of the Load Bank configuration, per above, shall be made upon Contract Award.

Phase Supply

Phase Return

L/2

L/2

R R/2 R/4 R/16R/8 R/8 R/32

Figure 1: Medium Voltage Load Bank Configuration – Per Phase

Date: June 22nd, 2015

8.2 Load Elements

A. The load elements shall be contained in one or more cases or trays, which shall be removable in their entirety as a unit, if service ever becomes necessary.

B. The load cases shall be constructed and installed to permit removal of one unit without having to remove any other unit.

C. Load elements shall be individually serviceable and replaceable in the field without major disassembly of the Load Bank. The entire length of each element shall be rigidly supported and insulated as required to preclude a broken resistance wire from creating a short circuit to an adjacent wire or ground.

D. To ensure long term reliability, the Load Bank shall be designed so that at rated load, load elements operate at not more than 50% of the maximum continuous temperature rating of the load element used.

E. The Load Bank segments shall be fused and controlled by separate magnetic contactors that are independently terminated at a terminal strip for ease of Government access.

8.3 Environmental Conditions

A. The Load Banks shall be outdoor rated and capable of operating in an environment as specified in Section 4.2.A and 7.3

8.4 Audible Noise

A. Maximum audible noise from the Load Banks and associated system components shall comply with commercial standards related to personnel safety for audible noise and noise performance in the octave band for all operating conditions shall be provided.

B. Demonstration of proposed noise performance shall be presented by the Contractor in the form of analysis or historical data from similar system components.

C. Performance shall be verified during on-site commissioning tests as specified in Section 9.

Date: June 22nd, 2015

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 T002, Test Inspection/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.

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

3. The Contractor shall provide operational Training of the Load Bank of…