RFQ N0042123Q0281.pdf

INFRASTRUCTURE, SAFTEY, & ENVIRONMENTAL

ERIC PEHMOELLER

47440 EMORY RD

PATUXENT RIVER MD 20670

TEL: 860-681-3284 FAX:

1301083872

REQUEST FOR QUOTATIONS

(THIS IS NOT AN ORDER) 1

PAGE OF PAGES

1. REQUEST NO. 2. DATE ISSUED RATING

N0042123Q0281 17-May-2023 5a. ISSUED BY

8. TO: NAME AND ADDRESS, INCLUDING ZIP CODE

IMPORTANT: This is a request for information, and quotations furnished are not offers. If you are unable to quote, please so indicate on this form and return it to the address in Block 5a. This request does not commit the Government to pay any costs incurred in the preparation of the submission of this quotation or to contract for supplies or services. Supplies are of domestic origin unless otherwise indicated by quoter. Any representations and/or certifications attached to this

Request for Quotations must be completed by the quoter.

11. SCHEDULE (Include applicable Federal, State, and local taxes)

ITEM NO.

(a)

SUPPLIES/ SERVICES

(b)

QUANTITY

(c)

UNIT

(d)

UNIT PRICE

(e) (f)

SEE SCHEDULE

AMOUNT

% No. %

NOTE: Additional provisions and representations [ ] are [ ] are not attached.

13. NAME AND ADDRESS OF QUOTER (Street, City, County, State, and ZIP Code)

14. SIGNATURE OF PERSON AUTHORIZED TO

SIGN QUOTATION

15. DATE OF

QUOTATION

16. NAME AND TITLE OF SIGNER (Type or print) (Include area code)

TELEPHONE NO.

AUTHORIZED FOR LOCAL REPRODUCTION STANDARD FORM 18 (REV. 6-95)

PREVIOUS EDITION NOT USABLE Prescribed by GSA FAR (48 CFR) 53.215-1(a)

THIS RFQ X[ ] IS [ ] IS NOT A SMALL BUSINESS SET-ASIDE

6. DELIVER BY (Date)

SEE SCHEDULE

AND/OR DMS REG. 1

UNDER BDSA REG. 2

4. CERT. FOR NAT. DEF.3. REQUISITION/PURCHASE

REQUEST NO.

NAWCAD PROCUREMENT GROUP

21983 BUNDY ROAD, BLDG 441

PATUXENT RIVER MD 20670

9. DESTINATION (Consignee and address, including ZIP Code)

7. DELIVERY

[ ]X FOB

DESTINATION

[ ] OTHER

(See Schedule)

07-Jun-2023(Date)

PLEASE FURNISH QUOTATIONS TO THE ISSUING OFFICE IN BLOCK 5a ON OR BEFORE CLOSE OF BUSINESS:10.

240-538-7195MICHAEL WOODS

(Name and Telephone no.) (No collect calls)5b. FOR INFORMATION CALL:

d. CALENDAR DAYSc. 30 CALENDAR DAYSb. 20 CALENDAR DAYS12. DISCOUNT FOR PROMPT PAYMENT a. 10 CALENDAR DAYS

N0042123Q0281

Section A - Solicitation/Contract Form

SOLICITATION/CONTRACT

SOLICITATION/CONTRACT

U.S Government ~ Tax Exempt

ISSUED BY:

Name: Michael Woods Email: michael.d.woods102.civ@us.navy.mil

MANDATORY SITE VISIT:

A site visit is required for this solicitation to be eligible for award. The contractor shall visit the project site; collect required data about existing structures, surroundings, appurtenance and all items that will be affected by this project or related to this project; and verify existing conditions.

The contractor shall be responsible for the verification of the actual site condition and the accuracy of this information to ensure adequacy of the design and successful construction.

The site visit is scheduled for 22 May 2023 at 9:30 AM EST at NAVAL AIR STATION PATUXENT RIVER, MD Building 101.

Must contact Eric Pehmoeller, eric.a.pehmoeller.civ@us.navy.mil or (860) 681-3284, to provide notice of attendance by 2:00 PM EST on 18 May 2023.

Requests for Information (RFI) after Mandatory Site Visit:

All RFI’s shall be submitted after attendance of the mandatory site visit by 12:00 PM EST on Thursday, 25 May 2023.

Time of Completion:

Work shall be prosecuted diligently and shall be completed for use within the time indicated in the award document. Duration time is calendar days not workdays. Completion date will be 120 days from date of award.

Reference Your Quote:

TECHNICAL POC:

Name:

Email:

PAYMENT/INVOICING ISSUES: PLEASE CONTACT COMPTROLLER BELOW.

N64142 NAWCAD

COMPTROLLER

INTERNAL ENTITLEMENTS TEAM BLDG 440 ROOM 25

47122 LILJENCRANTZ ROAD

PATUXENT RIVER, MD 20670-1549

INTERNAL ENTITLEMENTS TEAM 301-342-9586

EMAIL: PAXR_ACCT_INTERNAL_ENTITLEMENTS@NAVY.MIL

WAWF Invoicing Help & Instructions:

Visit the website at https://wawf.eb.mil/ and you can find help via the link "Vendors - Getting Started Help" under the New User section.

EARLY AND PARTIAL SHIPMENTS ARE ACCEPTABLE

VENDOR – IF ELECTRONIC EQUIPMENT, PLEASE MARK BOX/PACKAGE

CONTAINING ELECTRONIC EQUIPMENT WITH THE “DO NOT SCAN” STICKER

RECEIVING DOC HOURS ARE MONDAY THROUGH FRIDAY, 0630-1500 ES

Section B - Supplies or Services and Prices

ITEM NO SUPPLIES/SERVICES QUANTITY UNIT UNIT PRICE AMOUNT

0001 1 Job AD9 H111 Water Side

FFP

H111 Water Side Install Four 400 HZ Converters FOB: Destination

PURCHASE REQUEST NUMBER: 1301083872

PSC CD: Z2AA

NET AMT

Section C - Descriptions and Specifications

STATEMENT OF WORK

NAVAL AIR WARFARE CENTER/AIRCRAFT DIVISION (NAWCAD)

NAVAL AIR STATION PATUXENT RIVER

REFERENCE WORK Request# 1386(23-0128)

HANGAR 111 WATER SIDE INSTALL FOUR 90KVA 400HZ FREQUENCY CONVERTERS

TYPE OF PROJECT: CONSTRUCTION

1.0 GENERAL

1.1 General Description:

Project Title: HANGAR-111 WATER SIDE INSTALL of FOUR 400HZ FREQUENCY CONVERTERS.

Project Description: installation which will completely restore 400 Hz frequency converter power to Water Side of hangar 111.

1.2 General Conditions:

1. Work shall be performed in accordance with scope of work.

2. No foreign nationals allowed.

3. Government tenant to provide staging area for materials and equipment near work area.

4. Government tenant to provide access to area for workers, material deliveries, and equipment.

5. Prior to any work starting on-site the contractor will provide a narrative technical proposal outlining how the contractor will perform the project, how the project will be phased, and what measures will be taken by the contractor so that construction of the project will have minimal effect on the building operations.

6. All work to be in accordance with and not limited to the following:

a. OSHA and Army Corp of Engineers Safety Manual, EM-385-1-1 Safety requirements, Current Edition.

b. Safety and Health Standards for Construction Industry (29 CFR PART 1929 2007)

c. OPNAVINST 5090.1D

d. COMAR, Title 26.13

e. NASPAXRIVINST 5090.5A

7. Request Brandon Lundburg for Safety Planner. (301-342-5330)

8. Notify the base fire department 10 days in advance for a burn permit, soldering, grinding or open flame requirement.

9. Secured fire alarm. Contractor shall notify the contracting officer representative 10 days in advance.

10. Submit an Inventory Adjustment Form for each piece of equipment removed and each piece of equipment installed to the NAWCAD point of contact (POC).

11. The contractor shall visit the project site; collect required data about existing structures, surroundings, appurtenance and all items that will be affected by this project or related to this project; and verify existing conditions. The contractor shall be responsible for the verification of the actual site condition and the accuracy of this information to ensure adequacy of the design and successful construction.

1.3 Location: NAVAL AIR STATION PATUXENT RIVER, MD Hangar 111.

1.4 Time of Completion: Work shall be prosecuted diligently and shall be completed for use within the time indicated in the award document. Duration time is calendar days not workdays. Completion date will be 120 days from date of award.

Contractor is required to furnish proof of any cause for delay and shall request an extension of the completion date in writing through the Contracting Officer.

1.5 Site Visit: See solicitation for site visit details. Contractor shall verify all conditions, dimensions and methods on site(s) at time of site visit.

1.6 Payment: Payment will be made in one lump sum after completion and acceptance of the work by the Government Representative. Progress payment decisions will be on a case-by-case basis. All invoices shall be submitted through WAWF.

1.7 Government Furnished Materials/Utilities: All material, equipment, labor, and supervision will be supplied by the contractor with exceptions as noted below. Exceptions: Government shall provide existing on site aircraft cables and support stands for the cables. Contractor to provide installation of aircraft cables including cable supports and adapt the location of the stands as needed to provide a complete usable system.

The contractor shall provide and maintain, at his/her expense, the necessary service lines from existing Government outlets to the site of the work.

Utilities specified above will be furnished at no cost to the contractor. In the event that the Government is unable to provide the required types of utilities, the contractor shall, at his/her expense arrange for the required utilities. No foreign nationals allowed.

1.8 Execution of Work: Work shall be performed during normal duty hours 0600-1630, Monday through Friday. Work performed after normal working hours shall be coordinated with the NAWCAD POC.

No work shall be performed on Government holidays or weekends unless expressly allowed by the Officer in Charge, NAWCAD Contracts.

1.9 Contractor's Production Report: The contractor is required to submit a "Contractor Production Report”. The form shall be completed daily and be provided electronically to the NAWCAD POC, by 10:00 AM the following day.

The existing commands in Hangar 111 require knowledge of work being performed. Information regarding working in/ through building spaces, power outages (large or small) and the effect on the building and mission needs to be communicated. Therefore; the contractor shall have to provide a written schedule of daily work, three weeks before starting the project. The schedule is to provide the following information:

• The date, phasing, time of day and duration that work will be performed for each of the tasks and outages.

• Room/area locations in which the work will be performed and which the outage will effect.

• Additional information is to be provided as per the contracting officer's requirements. The schedule is to be updated with the contracting officer POC on a daily basis.

1.10 Submittals: The Government Representative shall approve submittals prior to the start of work.

The contractor shall submit the following cut sheets with the cost proposal within 15 days after award:

1. All material and equipment including but not limited to: 400Hz system equipment and material required for installation of systems.

2. Activity Hazard Analysis in accordance with EM 385-1-1.

3. Fall protection plan.

4. Manufacturer’s Data/Catalog Cut sheets for equipment/materials.

5. Work Schedule.

6. Inventory Adjustment Form.

7. Prior to any work starting on site the contractor will provide an updated technical narrative outlining how the contractor will perform the project, how the project will be phased, and what measures will be taken by the contractor so that construction of the project will have minimal effect on the building operations.

8. Preconstruction Submittals Within 36 days of contract award but not less than 30 days prior to commencing any work on site, the Contractor shall submit the following for review and approval.

(a) Shop Drawings

(b) Nameplates

Nameplate illustrations and data shall be approved by the Contracting Officer before installation.

(c) Provide a one-line drawing showing branch/feeder circuits and include equipment. Provide the following information on drawing:

(i) Approximate conduit length

(ii) Conductor sizes: provide conductor sized per NEC 70, show voltage drop calculations, note adjustments to conductor size for installation having more than three current-carrying conductors and correction for ambient temperature.

(iii) Conduit size and material type (EMT, PVC, RMC etc...).

(iv) Major junction/splice boxes: indicate sizes of boxes and if any splicing of conductors.

(v) Fire seal assembly insulation drawings and their ratings. Provide existing wall fire rating for wall that are being penetrated.

(d) Product Data

Six copies of annotated descriptive data to show the specific model, type, and size of each item. Catalog cut sheets shall also indicate the UL listing. The data shall be highlighted to show model, size, and options that are intended for consideration. Data shall be adequate to demonstrate compliance with all contract requirements. Product data for all equipment shall be combined into a single submittal. Provide an equipment list identifying the type, quantity, make, and model number of each piece of equipment to be provided under this submittal. The equipment list shall include the type, quantity, make and model of spare equipment and those shown on the shop drawings.

(e) Operation and Maintenance (O&M) Instructions

Six copies of the Operation and Maintenance Instructions. The O&M Instructions shall be prepared in a single volume or in multiple volumes, with each volume indexed, and may be submitted as a Technical Data Package. Manuals shall be approved prior to training. The Interior Fire Alarm and Mass Notification System Operation and Maintenance Instructions shall include the following:

(i) Five copies of the Manufacturer Data Package.

(ii) Operating manual outlining step-by-step procedures required for system start-up, operation, and shutdown. The manual shall include the manufacturer's name, model number, service manual, parts list, and preliminary equipment list complete with description of equipment and their basic operating features.

(iii) Maintenance manual listing routine maintenance procedures, possible breakdowns and repairs, and troubleshooting guide. The manuals shall include conduit layout, equipment layout and simplified wiring, and control diagrams of the system as installed.

(iv) A final Equipment List shall be submitted with the Operating and Maintenance (O&M) manual.

8. As-Built Shop Drawings The drawings shall show the system as installed, including deviations from both the project drawings and the approved shop drawings. These drawings shall be submitted within two weeks after the final Government test of the system. At least one set of the as-built (marked-up) drawings shall be provided at the time of, or prior to the final Government test. Contractor may choose to work with NAWCAD ISE team to create the final drawings.

Refer any questions to NAWCAD POC.

1.11 Clean-Up of Site, shall be performed on a daily basis. Contractors are not permitted to use Government dumpsters or other contractor’s dumpsters for disposal of debris. Daily and final clean up required. The contractor shall ensure that all trash and debris created by this project is cleaned up and removed off site. Customer to provide area for a dumpster TBD for duration of job.

1.12 Foreign Object Debris (FOD), is any particle or substance, alien to an aircraft or system, which could potentially cause damage. Contractor and their employees shall controlling and containing FOD generated by the construction.

1.13 Hot Work: A hot work permit is required as needed. A permit may be obtained through the Government inspector with 48 hours prior notice. Hot work in electrical or mechanical room space will require a gas-free test prior to the Government fire inspector granting approval. In accordance with the Government fire inspector's requirements, the contractor shall perform this test daily. The Government fire inspector shall approve the instrument used.

1.14 Dust Control: The amount of dust resulting from demolition shall be controlled to prevent the spread of dust to occupied portions of the construction site and to avoid creation of a nuisance in the surrounding area. Use of water shall not be permitted when it will result in, or create, hazardous or objectionable conditions such as ice, flooding and pollution.

1.15 Inspection of Work: Contractor shall inspect all work in accordance with FAR 52.246-12 "Inspection of Construction."

1.16 Lockout/Tagout: The contractor shall apply, monitor and remove (upon completion of work) proper lockout and tag out devices on all equipment undergoing repairs in accordance with the latest version of the U.S. Army Corps of Engineers Safety and Health Requirements Manual, EM-385-1-1.

1.17 Warranty: All equipment and parts furnished and installed by the contractor shall be warrantied against defects and workmanship for a period of not less than one year from the date of acceptance at no additional cost to the Government. Manufacturer's warranty for all parts will take effect upon the expiration date of the contractor's one-year warranty.

1.18 NOTE: Any changes shall be submitted back to a contracting official for approval prior to execution of any changes.

1.19 Attached Drawings and documents (Attachment 1): The following referenced drawings, sketches, pictures, reports and other documents accompany this statement of work and are a part thereof. Drawings are the property of the Government and shall not be used for any purpose other than that contemplated by the statement of work.

1. Categorical Exclusion (CATEX)

2. Drawing 1 Site Location

3. Drawing 2 Hangar 111 Location Of Work

4. Drawing 3 Existing Conditions

5. Drawing 4 Existing Conditions One-Line Drawing

6. Drawing 5 New Equipment Installation Location

2.0 DETAI LE D DESCRIPTION

Project Description: This is a construction project intended to provide four new 90KVA 400Hz double output frequency converter units and one spare aircraft cables. The contractor shall provide all labor, material, equipment, and other incidental work required to complete this project. Other incidental work required includes any and all items necessary to ensure a complete, usable and maintainable final product including the demolition work not specifically stated elsewhere in this Statement of Work (SOW). Work includes, but is not limited to, the following:

Note: Lockout/tag out required when removing/installing, working on or relocating electrical devices.

Note: All debris requires removal from building the same day as produced.

DEMOLITION

2.1

1. See Hangar 111 existing equipment location drawing.

2. All affected walls and wall penetrations with regards to this SOW shall be patched or sealed. Fire stop sealant is to be applied as per NFPA code.

3. Properly dispose of all equipment and materials.

4. Remove the 400 Hz frequency converter.

5. Remove the 400 Hz distribution panel.

6. Remove four dual line drop compensators.

7. Remove the aircraft cables from the dual line drop compensators and reuse/install cables to the four new 400Hz 90KVA converter units.

8. Contractor may adapt/remove electrical feeders (conduit, fitting supports and conductors) as required to install the new four - 400 Hz 90KVA frequency converter feeders.

9. Remove electrical feeders (conduit, fitting supports and conductors) not repurposed in the new installation.

a. Electrical feed from 480 VAC distribution panel to the 400 Hz frequency converter.

b. Electrical feed from 400 Hz frequency converter to the 400 Hz distribution panel.

c. Electrical feeds from the 400 Hz distribution panel to the four dual line drop compensators.

INSTALL

2.2 All affected walls and wall penetrations with regards to this SOW shall be patched or sealed. Fire stop sealant is to be applied as per NFPA code.

a) Patch and prep walls to a Level 4 finish suitable for paint.

b) Prime coat and then apply two coats of interior latex paint to the partition walls. Each coat shall be applied evenly and cover the substrate completely. Finish surfaces shall show solid even color, free from runs, brush marks or other defects. The customer shall choose the colors and the sheen shall match the existing walls.

2.3 Electrical

a) Provide the required and complete 480 VAC electrical feeds (sized and installed as per manufacturer requirements for the equipment) from the existing 480VAC Panel in electrical room #126/104544

b) Provide new and/or certified reconditioned circuit breakers UL listed for existing 480VAC panel.

c) Contractor may use EMT with compression fittings and/or rigid conduit.

i) Rigid Steel Conduit

(1) Provide hot dipped galvanized rigid steel conduit complying with NEMA RN 1ANSI C80.1, UL 6 and UL 5 as applicable.

(2) Use threaded fittings for rigid steel conduit. Use solid gaskets. Ensure conduit fittings with blank covers have gaskets, except in clean, dry areas or at the lowest point of a conduit run where drainage is required. Provide covers with captive screws and are accessible after the work has been completed.

ii) Electrical Metallic Tubing (EMT)

(1) Ensure EMT is in accordance with UL 797, UL 5, and ANSI C80.3 and is zinc coated steel. Provide zinc-coated couplings and connectors compression type with insulated throat. Crimp, spring, or setscrew type fittings are not acceptable.

d)

e) Provide seal tight flexible metallic conduit connections between conduit and the final connection to the new 90KVA 400Hz double output frequency converter units.

f) Install existing aircraft cables which were removed from the dual drop compensator into new unit (cables provided by government and are on site). Contractor to test each cable to insure functionality. Note: Provide one new spare aircraft cables matching existing cable length. Contractor shall include in their price replacement of two failed existing cables with new cables if needed.

g) Reuse/relocate as needed the four existing aircraft cable storage racks to insure an efficient and complete installation.

h) Provide main electrical gear/equipment at existing locations of dual drop compensator locations. Provide floor mounting frames for 400 Hz. frequency converter sized as needed to fix existing locations and provide leveling of units. Note floor is sloped in many of the hangar locations.

i) The contractor shall locate outlets, panels, equipment, light fixtures, conduit, etc..., in the field with the contracting officer POC. No electrical equipment/device shall be located so that the lowest part of the box, conduit or equipment is below 20” above hangar finished floor.

j) The contractor is to perform their installation as per the latest National Electrical Code (NEC)/ National Fire Protection Association (NFPA 70) and all applicable NFPA codes which are applicable to this Scope of Work. Additionally as per manufacturer’s requirements.

k) Contractor is to review and follow all building codes (to include but not be limited to NEC/NFPA 70 Chapter 5 special Occupancies) with regards to location, installation and construction of equipment, conduits and devices installed within aircraft hangar.

l) All equipment, large junction boxes, disconnects and panels, shall be properly marked using engraved plastic signage appropriate for the environment in which the equipment is located. Include equipment name, voltage, name of panel from which the equipment is fed, location of feeder panel, and circuit breaker number.

m) Provide grounding and bonding throughout the installation as required by the latest National Electrical Code NFPA 70.

n) Provide four new 90KVA 400Hz double output frequency converter units and one new spare aircraft cables as follows:

i) REFERENCES used update and latest revisions.

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 519 (2014) Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems IEEE 1159 (2009) Recommended Practice on Monitoring Electric Power Quality IEEE C2 (2017; Errata 1-2 2017; INT 1 2017) National Electrical Safety Code IEEE C62.41.1 (2002; R 2008) Guide on the Surges Environment in Low-Voltage (1000

V and Less) AC Power Circuits IEEE C62.41.2 (2002) Recommended Practice on Characterization of Surges in Low-

Voltage (1000 V and Less) AC Power Circuits

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC 60947-4-1 (2018; INT 1 2020; Corr 1 2020) Low-voltage Switchgear and Control gear, Part 4-1: Contactors and Motor Starters - Electromechanical Contactor and Motor Starters

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2018) Enclosures for Electrical Equipment (1000 Volts Maximum) NEMA ST 20 (2014) Dry-Type Transformers for General Applications

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2020; ERTA 20-1 2020; ERTA 20-2 2020; TIA 20-1; TIA 20-2; TIA 20-3; TIA

20-4) National Electrical Code

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE AS5756/6 (2013; Rev A; Stabilized (S) 2013) Cable, 3-Phase Power, Electric

Portable, Multi-conductor, 90 Degree C, 600V, Ozone Resistant, Split Phase

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-PRF-24021 (1998; Rev K; Notice 1 2014) Electric Power Monitors, External

Aircraft MIL-STD-461 (2015; Rev G) Requirements for the Control of Electromagnetic

Interference Characteristics of Subsystems and Equipment MIL-STD-704 (2004; Rev F; Notice 1 2008; Notice 2 2013) Aircraft Electric Power

Characteristics MIL-STD-1399-300 (2008; Rev B) Electric Power, Alternating Current

UNDERWRITERS LABORATORIES (UL)

UL 489 (2016) UL Standard for Safety Molded-Case Circuit Breakers, Molded- Case Switches and Circuit-Breaker Enclosures UL 506 (2017) UL Standard for Safety Specialty Transformers UL 1012 (2010; Reprint Apr 2016) UL Standard for Safety Power Units Other than Class 2 UL 1449 (2014; Reprint Jul 2017) UL Standard for Safety Surge Protective Devices

ii) SUBMITTALS

(1) SD-02 Shop Drawings

Frequency Converter Drawings;

(2) SD-03 Product Data

Frequency Converter;

(3) SD-06 Test Reports

Work Plan;

Routine Factory Test Plan;

Special Factory Test Plan;

Performance Test Plan;

Test Schedule;

Routine Factory Tests;

Special Factory Tests;

(4) SD-07 Certificates Qualifications of Manufacturer;

UL Listing;

(5) SD-09 Manufacturer's Field Reports Initial Inspection and Tests;

Performance Tests;

Training Syllabus;

(6) SD-10 Operation and Maintenance Data Frequency Converter, Data Package 5;

Preliminary Operation and Maintenance Manuals, Data Package 5;

Remote Monitoring and Control Panel, Data Package 5;

(a) QUALITY ASSURANCE

iii) Frequency Converter Drawings

Furnish scaled drawings of enclosure outline including front, top, side views, and overall dimensions. Provide external power and control wiring and cable connections. Provide single line, schematic, and wiring diagrams. Drawings shall include details of input and output circuit breakers, contactors, rectifiers, surge protectors, and control devices.

Drawings shall include conduit entry and exit locations.

iv) Qualifications of Manufacturer Submit a certification that the manufacturer has a minimum of five (5) years' experience in the design, manufacturing, and testing of 400 Hz solid state frequency converters at the same or equivalent kVA and voltage ratings for direct connection to aircraft electrical loads. When specifications require multiple converters operating in parallel, the manufacturer shall provide specific experience with equal or greater kVA rated converters.

The certification shall state that the manufacturer is experienced in manufacturing and testing solid state converters of an equivalent or greater kVA rating.

Experience in manufacturing motor generator sets does not qualify as equivalent.

Experience in manufacturing portable engine-driven 400-hertz power units does not qualify as equivalent. The manufacturer shall be experienced in producing units for installation in permanent buildings in environmentally closed spaces or in weatherproof enclosures as applicable. The manufacturer shall also document that converters are designed for connection to non-linear loads typically encountered in the aircraft and shipbuilding industries. The manufacturer shall furnish documented experience with converters in various environmental conditions including exterior flight line, hangar, and environmentally enclosed spaces within buildings.

v) Work Plan Submit a written schedule of dates of routine and special factory tests, installation, field tests, and operator training for the converter system. Furnish a list of instrumentation equipment for factory and field test reports.

vi) Routine Factory Test Plan Submit 7 copies of test plans and procedures at least 21 calendar days prior to the tests being conducted. Provide detailed description of test procedures, including test equipment and setups, to be used to ensure the converter meets the performance specification and explain the test methods to be used. As a minimum, the test procedures shall include the tests required under the paragraph

ROUTINE FACTORY TESTS.

vii) Performance Test Plan Submit 7 copies of test plans and procedures at least 15 calendar days prior to the start of field tests. Provide detailed description and dates and times scheduled for performance of tests, and detailed description of test procedures, including test equipment (list make and model and provide functional description of the test instruments and accessories) and setups of the tests to be conducted to ensure the converter meets the performance specification. Explain the test methods to be used. As a minimum, the test procedures shall include the tests required under the paragraph FIELD QUALITY CONTROL. Test reports shall include power quality measurement data collected in accordance with IEEE 1159.

viii) UL Listing Submit with the initial submittal to verify qualification of manufacturer.

Frequency converter shall be identified with a UL or nationally recognized testing laboratory (NRTL) label prior to shipping.

ix) Currently Listed Products Submit UL or NRTL certification or UL file number for the actual frequency converter to be shipped.

x) Proposed Listed Products Submit UL or NRTL certification or UL file number for same or similar rating or product size range of like design unit.

xi) Routine Factory Tests Report Submit within 45calendar days after completion of tests. Receive approval of test prior to shipping unit. Certify tests were conducted on each converter in accordance with the requirements set forth in paragraph ROUTINE FACTORY TESTS and certify converter satisfactorily operated within specified limits.

Report shall include copies of the test procedures, test data, and results.

xii) Special Factory Tests Report Certify tests were conducted on a converter of the same design, construction and kVA and voltage rating to be provided and in accordance with the requirements set forth in paragraph SPECIAL FACTORY TEST and certify converter operated without malfunctioning within specified limits. Report shall include copies of the test procedures, test data, and results.

Performance Tests Report Submit report of test results as specified by paragraph FIELD QUALITY CONTROL within 15 calendar days after completion of tests. Certify tests were conducted on each converter in accordance with the paragraph FIELD QUALITY CONTROL and certify converter satisfactorily operated within specified limits.

Report shall include copies of the test procedures, test data, and results.

2.4 MAINTENANCE

a) Operation and Maintenance Manuals

Submit frequency converter operation and maintenance manuals in accordance with Section 01 78 23 OPERATION AND MAINTENANCE DATA.

b) Additions to Operation and Maintenance Manuals

i) In addition to requirements of Data Package 5, include the following on the actual frequency converter provided:

(1) A "one-line diagram" from service entrance to 400 Hz utilization panel or point.

(2) A weatherproof, tear-resistant plastic data sheet with operating instructions for each unit including startup, shutdown [, and paralleling] procedures.

(3) Routine and field acceptance test reports.

(4) UL or NRTL certification or UL file number.

c) Preliminary Operation and Maintenance Manuals Prior to scheduling Field Performance Tests, 2 copies of a Preliminary Operation and Maintenance Manual must be submitted to and approved by the Contracting Officer.

d) Extra Material

Furnish recommended manufacturer's spare parts list and schedule of prices for each type of converter and other equipment specified in this section. This list shall include the following:

i) Power semi-conductors

ii) Power filter capacitors

iii) Plug-in logic cards

iv) Output switching modules

v) Fuses

vi) Indicator lamp/LED

vii) Ventilation system filters

2.5 PRODUCTS

a) FREQUENCY CONVERTER

Provide frequency converter consisting of modular construction solid-state components for 60 to 400 Hz conversion, input/output devices, and ancillary control devices. Frequency converter shall be a standard product of the manufacturer and shall be the manufacturer's latest design that complies with the specification requirements. The 400 Hz frequency converters provided under this contract shall be products of the same manufacturer. The unit shall have a calculated MTBF exceeding 24,000 hours as calculated when the converter is provided with yearly servicing and maintenance. The converter shall be UL or third party listed to comply with UL 1012. Circuit breakers operating at 400 Hz shall be designed and UL tested for 60 Hz operation and de-rated for 400 Hz operation. Provide startup and shutdown instructions posted on the front of the unit using engraved plastic plate. Provide a plastic encapsulated schematic diagram attached to the inside of the unit in clear view of maintenance personnel.

b) Electrical Characteristics

i) Input Voltage

480/277 VAC, three phase, four wire, grounded, 60 Hz. Converter shall provide rated output voltage when input voltage is varied plus or minus 10 percent. Input neutral currents shall not exceed 21 percent of any individual phase current at no load and at full load.

ii) Input Power Factor Between 0.8 lagging and unity, under all conditions of steady state line and load variations specified herein.

iii) Surge Protection The converter shall be capable of sustaining an input surge described in and tested in accordance with UL 1449, and IEEE C62.41.1 and IEEE C62.41.2, Location Category B and continue to operate with no alarms within the specified tolerance.

iv) Inrush Current The inrush current shall not exceed 100 percent of the rated full load input current. Inrush current limitation is based on a frequency converter that does not require a transformer at the input to the unit. Should the contractor choose to provide a frequency converter with a transformer at the input to the unit, the contractor shall be responsible for increasing the size of the upstream feeder breaker(s) and increasing the size of conductors and raceways in accordance with NFPA 70.

v) Input Current Distortion Input current THD shall not exceed 12 percent of the fundamental with nominal input voltage at full load. Individual harmonic content shall not exceed 8-percent of the fundamental.

vi) Output Voltage 200Y/115 V, three phase, 400 Hz, grounded system. Adjustable to plus or minus 10 percent of the rated voltage. The limits overvoltage and under voltage shall be as defined in MIL-STD-704plus or minus 2 percent. The phase rotation of the output voltage shall be clockwise sequence of A-B-C.

Converters shall be designed for compatibility with ship and aircraft power monitors complying with MIL-PRF-24021.

vii) Power Output 90 kVA at 0.8 power factor lagging.

viii) Load Range Operate into a linear load with a power factor between 0.5 lagging and 0.8 leading and into a non-linear load with not less than 15 percent current THD, composed of not less than 6 percent of the 3rd harmonic and not less than 7 percent of the 5th harmonic.

ix) Efficiency The 90 kVA units shall have a minimum efficiency of 87 at 50 percent load and 91 at 100 percent load. For a frequency converter that requires a transformer at the input to the unit, reduce the specified efficiencies by 2 percent.

x) No Load Input Losses The frequency converter shall have no-load input losses no greater than 7 percent of the output kW rating. For a frequency converter that requires a transformer at the input to the unit, increase the specified no load input losses by 2 percent.

xi) Overload Satisfactory overload operating time is based on no more than one overload in any 4 consecutive hours of operation:

Percent of Full Load Satisfactory Operating Time 110 percent 60 minutes 125 percent 5 minutes 150 percent 2 minutes

200 percent 20 seconds

After minimum operating time is achieved, unit shall interrupt output power. Unit shall be capable of sustaining the overload without damage until the protective device interrupts the overload.

xii) Short Circuit When a bolted line-to-line fault, or a bolted three phase fault is applied to the unit, unit shall be capable of sustaining the short circuit current without damage until the protective device interrupts the fault.

xiii) Output Voltage THD

(1) Balanced load :

(a) Output voltage THD: Not to exceed 3 percent line-to-line and line-to-neutral for linear loads as specified in the paragraph LOAD RANGE.

(b) Output voltage THD: Not to exceed 5percent line-to-line and line-to-neutral for non-linear loads as specified in the paragraph LOAD RANGE.

(c) Maximum single harmonic distortion: Not to exceed 2 percent of the fundamental at the nominal voltage for linear loads as specified in the paragraph LOAD RANGE.

(d) Maximum single harmonic distortion: Not to exceed 3 percent of the fundamental at the nominal voltage for non-linear loads as specified in the paragraph LOAD RANGE.

xiv) Unbalanced load: Output voltage THD not to exceed 4 percent, line-to-neutral with 15 percent unbalanced linear load.

c) Output Voltage Amplitude Modulation

Output voltage amplitude modulation shall not exceed 1/2 percent of nominal voltage at no load to full load.

d) Frequency Stability Control output frequency of the 400 Hz converter within plus or minus 0.5 percent for all operating conditions, including maximum and minimum specified input voltages, ambient temperature and relative humidity. The frequency regulation shall operate independent of supply frequency and load changes.

e) Phase Angle Regulation Displacement angle between adjacent voltage phases shall be 120 degrees plus or minus 2 degrees with balanced load and plus or minus 4 degrees with three phase 15 percent unbalanced load. A 15 percent unbalanced load is defined as:

i) Phase A at full rated single phase load.

ii) Phase B at 85 percent of Phase A.

iii) Phase C at 85 percent of Phase A.

f) Transient Output Voltage Recovery In accordance with MIL-STD-704.

g) Environmental Rating

The converter shall operate from no load to rated full load under the following conditions:

i) Ambient temperatures ranging from 0 degrees C to 55 degrees C.

ii) Relative humidity from 0 to 95 percent noncondensing.

iii) Ambient pressures from sea level to 3,000 feet

h) Monitoring and Control Panel Provide converter with a control panel that is equipped with the following controls, indicators, instrumentation, data logging, diagnostics, and alarm functions.

i) Controls

i) Start/stop pushbutton.

ii) Lamp/light emitting diode (LED) test - A push-to-test button or switch to test indicator lamps/LEDs.

iii) Alarm reset.

iv) Emergency power off - A separate pushbutton for emergency power off.

v) Circuit breaker.

vi) Output contactor ON/OFF

vii) Output voltage adjust.

j) Indicators

i) Input power available - Lamp/LED to indicate that the supply voltage is available.

ii) Output power On/Off - Lamp/LED to indicate that the converter output voltage is available.

iii) System alarm - Lamp/LED to indicate that a fault has been detected. This indicator shall be latched in the "ON" position whenever an alarm condition described in paragraph ALARM ANNUNCIATOR, is detected and shall remain "ON" until the alarm reset pushbutton is pressed.

iv) Indicating lamp/LED to indicate that the alarm silence switch is in the disable position.

v) Elapsed time meter (hours)

vi) Output contactor "ON".

vii) Aircraft interlock bypass - Lamp/LED to indicate that the Aircraft Interlock has been bypassed.

k) Digital Instrumentation

Provide true rms, plus/minus one percent accuracy, microprocessor-based meter with a simultaneous three-line LCD display Provide a digital display that has, at a minimum, the following functions:

i) Output phase-to-phase voltage.

ii) Output phase-to-neutral voltage.

iii) Output phase current.

iv) Output neutral current.

v) Output frequency.

l) Alarm Annunciator

The unit shall be capable of detecting and displaying the following abnormal conditions:

i) Input over voltage.

ii) Input under voltage.

iii) Output under voltage.

iv) Output over voltage.

v) Output overload.

vi) System alarm.

vii) Control logic failure.

viii) Over temperature.

ix) Logic power supply failure.

m) Input/Output Devices

Provide fully-rated, three-pole, UL approved devices for control of 60 Hz input and 400 Hz output from the converter. Devices and cables operating at 400 Hz shall be de rated in accordance with IEEE 519.

n) Circuit Breaker Conform to requirements of UL 489. Units operating at 400 Hz shall be de rated for 400 Hz operation.

o) Input Circuit Breaker Provide converter with a UL listed input circuit breaker as an integral part of the converter. Breaker shall be operable from the front of the converter. Breaker shall have a short-circuit current rating to match existing 480 volt feeder panel, existing branch circuit breakers amperes symmetrical minimum.

p) Output Contactor Provide converter output with an automatic magnetically-held contactor with interlock circuit. Output contactor shall be of sufficient capacity to handle rated load, overload, and available short circuit current. Contactor shall open when any circuit identified in the paragraph PROTECTIVE CONTROL causes the system to shut down. Output contactor shall be electrically interlocked with ON/OFF circuitry so that when the frequency converter is shut down, the contactor shall open immediately and remain open.

q) Output Circuit Breaker Provide converter output with a non-automatic manual circuit breaker with appropriate frame size and a shunt trip coil de-rated for 400 Hz operation. Circuit breaker shall be tripped by the unit's OFF circuit local or activated and when any circuit identified in the paragraph PROTECTIVE CONTROL causes the system to shut down. Output breaker shall be operable from the front of the unit.

r) Aircraft Interlock Circuit

Interlock circuit shall determine the presence or absence of the 28 VDC feedback signal from the aircraft. Interlock circuit shall not allow the output disconnect to close if the 28 VDC signal is not present. If the output disconnect is closed when the 28 VDC is lost, disconnect shall open within 2 seconds. Converter shall contain terminal block points for the connection of two 12 AWG wire from the aircraft cable assembly for the interlock circuit. Interlock circuit shall not draw more than 20 milliamperes from the aircraft's 28 VDC circuit. For testing purposes, provide a switch inside the converter with two positions:

i) Normal - For aircraft loads.

ii) Bypass - For testing with dummy load or no load, or for use with aircraft with no 28 VDC.

s) Protective Controls

Provide circuitry for the following protective controls.

i) Input under voltage.

ii) Input over voltage.

iii) Loss of phase.

iv) Loss of input power.

v) Door interlock - When any access door is opened, the interlock circuitry shall open the 60Hz input device and 400 Hz output device and not allow the input or output device to close. For maintenance purposes, provide a bypass switch to defeat the interlock circuitry.

vi) Output overvoltage - Protect by tripping output devices for instantaneous overvoltage of 30 percent or more and for 10 to 30 percent overvoltage lasting more than 0.25 second.

vii) Output under voltage - Protect by preventing the closing of the output disconnect until the output voltage is 95 percent of the rated output. If, after closing, the voltage decreases to below 90 percent for longer than 5 seconds, provide relaying to trip output devices utilizing a field-adjustable time-delayed circuit with a range of 4 to 10 seconds.

viii) Output frequency - Protect by tripping output devices for frequency change in excess of plus or minus 5 percent of the rated output frequency (400 HZ).

ix) Output overload.

x) Converter over temperature protection.

t) Automatic Line Drop Compensation Provide automatic line drop compensation - 0 to 7 percent adjustable internally.

u) Built-In Test Equipment Frequency converter shall include built-in test equipment which monitors both primary circuits and protection circuits of the unit. Provide visual indication to assist diagnosis of unit failures to a modular level. Provide visual indication of converter status using cabinet mounted light emitting diodes.

v) Magnetic Devices Provide Class 180 power magnetic transformer and inductors in accordance with NEMA ST 20 and UL 506. The limits of Class 180 shall not be exceeded at the maximum specified ambient temperature and at 100 percent load.]

w) Acoustical Noise

Maximum continuous acoustical noise level shall be 68 dBa (A weighted scale).

x) Assembly Construction

Provide enclosures suitable for indoor environments in accordance with NEMA 250, Type 12K. Arrange to provide required louvers, cooling air, entry and exit provisions for equipment within enclosures. Construct unit(s) so that components, with the exception of control and monitoring components, are totally enclosed within the enclosure. Electronic circuits including power circuits shall be modular construction readily accessible for maintenance, repair and module replacement from the exterior of the enclosure. Provide permanent identification tags for wiring. Uniquely identify each wire. Use the same identification system in the wiring diagrams in the Operation and Maintenance Manual. Provide each enclosure with a finish coat over a substrate which has been provided with a rust inhibiting treatment. Color shall be the manufacturer's standard color.

y) Nameplates

z) Aircraft Power Cables

i) Reuse and adapt as needed the existing Dual Line Drop Compensator cables

ii) Inspect cables for physical damage.

iii) Test with Megohm tester all conductors as per manufacturer’s instructions and provide a written report.

2.6 SOURCE QUALITY CONTROL

a) Converter Test Schedule

The Government reserves the right to witness tests. Provide frequency converter test schedule for tests to be performed at the manufacturer's test facility. Submit required test schedule and location, and notify the Contracting Officer 30 calendar days before scheduled test date. Notify Contracting Officer 15 calendar days in advance of changes to scheduled date.

Test Instrument Calibration.

i) The manufacturer shall have a calibration program which assures that all applicable test instruments are maintained within rated accuracy.

ii) The accuracy shall be directly traceable to the National Institute of Standards and Technology.

iii) Instrument calibration frequency schedule shall not exceed 12 months for both test floor instruments and leased specialty equipment.

iv) Dated calibration labels shall be visible on all test equipment.

v) Calibrating standard shall be of higher accuracy than that of the instrument tested.

vi) Keep up-to-date records that indicate dates and test results of instruments calibrated or tested. For instruments calibrated by the manufacturer on a routine basis, in lieu of third party calibration, include the following:

(1) Maintain up-to-date instrument calibration instructions and procedures for each test instrument.

(2) Identify the third party/laboratory calibrated instrument to verify that calibrating standard is met.

b) Routine Factory Tests

Routine tests shall be performed by the manufacturer on each of the actual frequency converter(s) prepared for this project to ensure that the design performance is maintained in production. Submit test reports, by serial number and receive approval before delivery of equipment to the project site.

For tests which require full load, use 1.0 power factor unless otherwise noted. All measurements shall be true RMS measurements. Measurements shall be obtained in accordance with IEEE 1159. Tests shall include the following:

i) Input current and power factor: Operate converter at low, nominal and high input voltage at full load. Measure and record input voltage, input power factor and input current in each phase and neutral if the neutral conductor is connected to the converter input.

ii) Output voltage, output voltage THD, output current, output power factor, and voltage regulation: Operate converter at nominal input voltage for:

(1) 50 percent of rated capacity with 0.8 lagging power factor linear load.

(2) 100 percent of rated capacity with 0.5 lagging power factor, 0.8 lagging power factor, 1.0 power factor, and 0.8 leading power factor linear loads.

(3) 50 percent of rated capacity with the non-linear load as specified in the paragraph

LOAD RANGE.

(4) 100 percent of rated capacity at low and high input voltage.

(5) 100 percent of rated capacity with the non-linear load as specified in the paragraph LOAD RANGE.

Operate for not less than 10 minutes at each test condition in (1), (2), (3) and (4) above and not less than 30 minutes at test condition in (5) above. Monitor and record output voltage, output voltage THD, output current, output current waveform, output power factor and frequency at the beginning and end of each test condition. Monitor and record output voltage single harmonic distortion for each test condition in (2) and (5) above at the beginning and end of each test condition. Verify output remains within specified regulation limits.

iii) Efficiency: Operate at nominal input voltage at half load and full load at 1.0 power factor. Measure and record input voltage, input current, input power factor, output voltage, output current, and output power factor. Calculate the unit efficiency.

iv) No load losses: Operate at no load and nominal input voltage. Measure and record input voltage, input current, input power, input power factor, and output voltage.

v) Burn-in Test: Before delivery, burn-in all units under full load conditions for at least 24 hours by cycling units 6 hours "ON" under full load conditions and 3hours "OFF" at no load conditions for at least 4 complete "ON" cycles. Burn-in test shall be performed with the converter enclosure doors closed and all ventilation in the final operating condition.

vi) Include harmonic frequency spectrum analysis depicting Harmonic Order and Harmonic Magnitude at the unit’s input and output terminals during full load THD test in test reports.

vii) Automatic line drop compensation: Operate converter at nominal voltage at:

(1) No-load.

(2) 50 percent of rated capacity with a 0.8 lagging power factor linear load.

(3) 50 percent of rated capacity with the specified non-linear load.

(4) 100 percent of rated capacity with a…