Specifications_for_15-MTC-234.doc

ELECTRICAL DISTRIBUTION CONTAINER (edc) SPECIFICATION I. Background:

The Navy wishes to procure an Electrical Distribution Container (EDC) related to a sea-based test. The EDC and its contents are required to have approval per the American Bureau of Shipping (ABS) Guide For Building And Classing High Speed Naval Craft 2007, Part 4 Craft Systems And Machinery. The EDC will be designed to receive input power from a 1 MW-rated diesel generator and convert the power to make it suitable for the operation of a group of 600VAC loads. The contractor will not be required to supply the diesel generator. The primary function of the EDC is to create 600 VAC output power through two 500kVA transformers and their corresponding distribution equipment.

II. Scope:

The required services are necessary to enable a sea-based test onboard a Navy vessel. The vendor shall provide equipment, as manufactured by the appropriate OEM, as described herein. The orientation of the equipment and pass-throughs described herein can be referenced in Appendix A.

III. Requirements:

Container Specifications

The contractor shall provide a container with the following specifications:

1. Container shall fit the exterior dimensions of a high-cube 20’ ISO shipping container

a. Shall contain standard ISO mount top and bottom corner fittings per the requirements in ISO 1161

b. Shall contain forklift pockets as described in ISO 1496-1

2. Container design shall include traceable best practices for mitigating shock and vibration hazards typical of road and rail transmission

a. The contractor shall provide, to the Navy, the steps taken to mitigate shock and vibration hazards that may occur during transportation

3. Container shall be suitable for outdoor use

4. Exterior shall be painted white for UV resistance and low solar loading

5. Walls and structural members shall be of steel construction and consistent with design requirements for freight containers as described in ISO 1496-1

6. Interior floor shall be of a metal structure of suitable thickness for mounting two transformers weighing 2600 lb. each

7. The container shall be insulated for use in an outdoor environment, and an appropriate ignition barrier, as described in the 2012 International Building Code Section 2603.4.1.6, shall be used to isolate the insulation from the interior of the container.

8. Container and floor exterior shall have sufficient corrosion treatment and resistance to allow placement on wet surfaces including dirt, sand, and minor saltwater interaction.

9. Interior walls shall be of suitable construction to wall mount 6 disconnects, weighing 150 lb. each, and one main distribution panel, weighing 150lb. each

10. Structure shall be provided in center of container as shown in Appendix A drawings to allow for future installation of four wall mounted components weighing up to 150 lb. each.

11. Personnel Door

a. 36” wide personnel door shall be provided to allow for transportation of items into container and personnel access for maintenance and installation

b. Personnel door shall be located on the aft of the container as indicated in the attached documentation

12. Double Doors

a. Doors on forward side of container shall be provided to allow installation and removal of transformers.

13. Doors shall secure in accordance with the ISO standard and shall be able to accept a padlock or have another means of keyed entry

14. Climate control system shall be installed for cooling and dehumidification inside the container

Container Contents

1. The contractor shall provide, in the EDC, two (2) Federal Pacific 500kVA transformers. These transformers must come specifically from Federal Pacific. No equivalents will be acceptable. The transformers shall have the following operating characteristics:

a. 480VAC Delta Primary – Shall have the ability to accept three 300MCM cables per phase as specified in Appendix A

b. 600VAC Wye Secondary – Can accept three 4/0 cables per phase as specified in Appendix A

c. 150C Temperature Rise – vented enclosure, dry type, no supplemental cooling

d. Aluminum Coils

e. K Factor equal to 1

f. Less than or equal to 2600lbs each

g. Enclosure Dimensions: 73.75” H x 53.375” W x 42.375” D (including NEMA 3R or better weather shields) as shown in Appendix A

h. Floor Mount suitable of carrying 2600lb load per transformer

i. NEMA 3R enclosure or better

j. Primary Taps: +2/-4 @ 2.5%

k. Cables feeding the primary side of the transformers shall penetrate the container on the port side

l. There shall be 12” of free space between the two transformers and 6” of space between the wall and the transformer to allow for proper ventilation and heat management, as shown in Appendix A

2. The contractor shall provide six (6) Eaton disconnects, part number DH365FRK. No equivalents will be acceptable.

a. Cables originating from the load side of every disconnect and exiting the container shall penetrate the container on the starboard side

b. On the disconnect that is not wired to the secondary side of the transformers, the cable that feeds the line side shall penetrate the container on the port side

3. The contractor shall provide one (1) 208VAC 3 phase 4 wire Eaton Main Distribution Panel (MDP). The MDP must be manufactured be Eaton. No equivalents will be acceptable. The MDP shall have following characteristics:

a. Voltage

i. 208Y/120V 3-Phase, 4 Wire

b. Enclosure

i. NEMA 3R

c. Bus Rating and Type

i. Copper

ii. 225A

d. Ground Bar

i. Shall be capable of accepting Aluminum or Copper Cable

ii. Bus Bar shall be copper

e. Short Circuit Rating

i. 10k A.I.C. Fully Rated

f. Neutral Bar

i. Factory Installed

ii. Shall have the ability to accept Copper and Aluminum cables from #6-600MCM

iii. Rated to 450A

g. Trim

i. Complete Enclosure, trim included

h. Mounting

i. Surface Mount

i. Enclosure Size

i. 18 single phase branch circuits available on panel bus bar

j. Main Breaker

i. Eaton FDE Series

ii. 125A

iii. 3 Poles

iv. 65k A.I.C @ 240VAC (60Hz)

v. Electronic non-interchangeable trip unit

vi. Wire size: #4-4/0

vii. UL489 Rated

viii. Dimensions no greater than 6” H x 4.13” W x 3.38” D

ix. Top Cable Entry

x. Ground Fault Circuit Interrupter (GFCI) protected

k. Circuit Breakers

i. Breakers listed below shall come pre-installed in panels

1. Load should be divided equally between phases

2. The breakers shall not have Ground Fault Circuit Interrupting capability

3. The panel shall have blank covers in unused breaker locations

ii. Eaton BAB Breaker series

iii. Circuit breaker ratings and poles as listed below

1. No spare breakers required

2. Rated to 240VAC

3. 10k A.I.C. Rated @ 240VAC

4. UL 489 Rated

5. Lug Kit shall accept #14-#4 cable (Copper/Aluminum)

6. One 3 Pole 40A Breaker

7. One 3 Pole 30A Breaker

8. Two 3 Pole 20A Breakers

9. Three single pole 20A Breakers

l. Cable Penetrations

i. The cable that delivers power to the panel shall penetrate the container on the port side

ii. The cables that originate from the panel and leave the container via Amphenol bulkhead penetrations described herein shall penetrate the container on the starboard side

4. The contractor shall provide an air conditioner and dehumidifier with the following characteristics:

a. The air conditioner shall be capable of providing no less than 2 tons of refrigeration

b. Dehumidification performance at optimal ambient operating conditions shall be no less than 10 pounds of water per hour

c. Shall run on 3-phase 208VAC

d. Max current draw shall be less than or equal to 20A

e. Shall fit inside footprint of standard 20’ ISO container along with all other equipment described herein

f. Programmable thermostat shall be located inside EDC

5. The contractor shall provide Amphenol bulkhead penetrations (connectors) listed herein and described in Appendix A. No equivalents will be acceptable.

a. The contractor shall provide four (4) 300MCM 4-Wire Amphenol Receptacles & Panel Mount Covers each, Part Numbers ZREP-C28-18P & ZP-C-2528-10, respectively

b. The contractor shall provide seven (7) 4/0 4-Wire Amphenol Receptacles & Panel Mount Covers each, Part Numbers ZREP-C24-38P & ZP-C-2524-10, respectively

c. The contractor shall provide three (3) 3AWG 4-Wire Amphenol Receptacles & Panel Mount Covers each, Part Numbers ZREP-C20-42P & ZP-C-2520-10, respectively

d. The contractor shall provide one (1) 10AWG 4-Wire Amphenol Receptacle & Panel Mount Cover each, Part Numbers ZREP-12-14P & ZP-C-2512-10, respectively

e. All bulkhead connectors shall be of part number and manufacturer as described in Appendix A

f. Chassis shall not be grounded to any pin

g. Receptacles & covers shall not exceed the footprint of the exterior wall dimensions

h. Receptacles shall be installed such that the corresponding ‘long’ Amphenol plug, as shown in Appendix A, can be mated with the receptacle and proper wire bend radius can be maintained

i. Receptacles shall be installed such that cables can be run along the ground

j. Receptacle and cover ‘R’ as referenced in Appendix A shall be installed on the aft side of the container

i. Twenty feet of cable ‘Q’ as referenced in Appendix A shall be soldered to receptacle ‘R’, and coiled and secured on the wall adjacent to receptacle ‘R” such that the weight of the cable does not exert force on the connector itself

6. The contractor shall provide terminals for all connecting cables to transformer input and outputs.

The terminals shall be Thomas & Betts, Part Number ADR35-21, or equivalent, as shown in Appendix A.

7. The contractor shall provide a RoxTec Data Acquisition Pass Through for data transmission, as shown in Appendix A, with the following specifications:

a. The contractor shall provide three (3) RoxTec weld-in fiber optic penetrations for data transmission, Part Number SLR-75. No equivalents will be acceptable.

b. 3.504” OD, 3.012” ID steel sleeve shall be welded into bulkhead to allow for installation of custom cable gland for fiber optic cable penetration.

c. Steel sleeve shall not extrude past EDC footprint

d. Total of 3 sleeves shall be welded into container

i. One shall be installed on the port side

ii. One shall be installed on the starboard side

iii. One shall be installed aft by the personnel door

8. The contractor shall provide interior lighting to the following specifications:

a. 4’ light fixture(s)

b. Energy-efficient design with total lighting output equivalent or better than four T8 32W fluorescent bulbs

c. Switch to control lighting shall be located inside container

9. The contractor shall provide interior service outlets to the following specifications:

a. Two single 120VAC service GFCI outlets wall mounted and centrally located

b. Both shall be fed from single pole GFCI 20A breaker

10. The contractor shall provide grounding capability to the following specifications:

a. Each enclosure inside the EDC shall be bonded to a common ground

b. The interior ground shall be bonded to the container chassis

c. There shall be a threaded ½”-13 x 4” grounding stud on the exterior of the container that is bonded to both the container chassis and the interior common ground and shall not exceed the footprint of the ISO container described herein

d. ½”-13 steel nut shall be provided on the grounding stud

11. The contractor shall provide cabling with the following specifications:

a. Wire size and type shall comply with provided single line diagram as shown in Appendix A

b. All interior wiring shall be routed through cable tray or suitable conduit per National Electric Code (NEC) and not obstruct personnel walkways

i. Cable trays as shown in Appendix A do not have to appear exactly as shown in the drawings and images.

c. Line items H, I, J, O, P and Q in the parts list of Appendix A shall be Government Furnished Equipment (GFE). The manufacturer is responsible for supplying all other cables.

12. Validation of Test

a. For the transformers described herein, the contractor shall provide all test data, in accordance with DI-QCIC-81891 (Acceptance Test Report), that demonstrates the transformer’s ability to function under full load

b. All 480VAC and 600VAC power connections shall be tested for integrity of insulation and proper electrical connectivity, and a certificate of test shall be provided

13. The contractor shall provide a structure to accommodate a data acquisition system with the following specifications:

a. A 22U, 19” ‘half height’ rack mount shall be installed to allow for the integration of future data acquisition equipment

b. The contractor shall provide a dedicated 120VAC GFCI 20A Outlet for a Data Acquisition System (DAS), as shown in Appendix A

14. The contractor shall provide labeling on all equipment, including transformers, disconnects, the distribution panel, and all Amphenol connectors consistent with the provided and approved drawing package provided in Appendix A.

Government Furnished Property (GFP) The following material shall be provided, by the Navy to the contractor, as Government Furnished Equipment (GFE):

Table 1 - Government Furnished Equipment, MIL-SPEC Cables

The length of the cables to be provided in Table 1 shall be determined after the final drawing package has been approved by the Navy. The contractor shall connect the GFP listed in Table 1, in accordance with the diagrams provided in Appendix A.

All Government Furnished Information, provided by the Navy to the contractor, can be seen in Appendix A.

Schedule Requirements The contractor shall provide all deliverables described herein no later than (NLT) 16 weeks after contract award.

Data Requirements:

· Operation and Maintenance Manual in accordance with DI-MISC-81414 (Operation and Maintenance Instructions for Research and Development (R&D) Equipment)

· Factory Acceptance Test Results in accordance with DI-QCIC-81891 (Acceptance Test Report)

· Calibration and Certification Report in accordance with DI-QCIC-80278B (Calibration and Measurements Requirements Summary)

· Installation and Connection Requirements and Drawings in accordance with DI-MISC-81321A (Equipment Installation Instructions). The contractor shall include total container weight and center of gravity coordinates as part of this data package.

· Wiring Diagram in accordance with DI-SESS-81000E (Product Drawings/Models and Associated Lists)

· Mechanical Drawings in accordance with DI-SESS-81000E (Product Drawings/Models and Associated Lists)

· Bill of Materials in accordance with DI-SESS-81000E (Product Drawings/Models and Associated Lists) Delivery:

All deliverables shall be delivered to the following address:

NAVSSES Code 325

ATTN: John Heinzel

5001 S Broad St

Philadelphia, PA 19112