SON_B810 and B845 Generator Installations_Beale AFB.pdf

STATEMENT OF NEED FOR DESIGN-BUILD PROJECT

BAEY 240021 (B810) & BAEY 240022 (B845) –

Replace 20 kW Generator and Associated Equipment

9 CES Building

Bldg.810 & Bldg. 845

BAEY 240021 & BAEY 240022

Air Combat Command

BEALEAIRFORCEBASE

CALIFORNIA

9TH CIVIL ENGINEER SQUADRON

24 May 2024

DIVISION REVISIONS

Number Date Description

01 Initial Release i

BAEY 240021 (B810) & BAEY 240022 (B845) – Replace 20 kW Generators and Associated Equipment 011001-3

DIVISION 01 – GENERAL REQUIREMENTS

SECTION 011001 – STATEMENT OF NEED FOR DESIGN-BUILD

PART 1 - INTRODUCTION

1.01 BACKGROUND

The 9th Contracting Squadron has a requirement for the design and construction of BAEY 240021 (B810) and BAEY 240022 (B845) to remove the existing failed generator, replace and install new Cummins 20kW generator with adequately sized tank and a new compatible Bypass Automatic Transfer Switch (BTPC). Contractor shall furnish all supervision, labor, tools, equipment, materials, operations, and incidentals as required and will perform all necessary connections to the generator and ATS so that they are fully operational IAW all current NFPAs, DAFMANs, UFCs, State and local codes and regulations. The contractor is also responsible for applying for the Air Quality permits from Feather River Air Quality in coordination with 9 CES Environmental Section for compliance. Additionally, the contractor will coordinate with 9 CES/Environmental Section to initiate an Authority to Construct, and AF103. The contractor will relocate the existing generator and associated equipment to the 9th Civil Engineer Squadron Compound upon coordination with the Base Project Manager. All installation(s) shall be completed in accordance with the manufacturer’s instructions for installing the equipment, with a start-up and turn-over of O&M manuals after installation. The contractor shall field verify existing underground utilities related to the project including all necessary field measurements for detailed references by the 65% approval submittal.

1.02 DESIGN-BUILD FIRM REQUIREMENTS

The Design-Build Firm shall perform all necessary studies, meetings, analyses, coordination, work plan development, contract document preparation and subsequent construction for the project. The project site general locations are shown on the attached location map. The work plan shall include all related items as required to safely accomplish all necessary work. The submittal shall contain narratives, site plans/layouts and preliminary details (PDF) with product submittals for electrical components. Include a one-line diagram for all new electrical work.

1.03 DESIGN-BUILD FIRM ENGINEERING SERVICES

The Design-Build Firm shall have an engineering staff within the firm and/or shall partner with or have a direct relationship with a professional engineering firm who shall furnish all services, materials, supplies, and supervision required to fully investigate and execute this project. The survey and work plan of engineering features of the work shall be accomplished by the appropriate licensed design professional(s) who are experienced with these types of system. The final work plan shall be stamped and signed by the registered professional engineer(s) responsible for the plan in their respective areas of expertise and, if applicable, a principal of the firm registered in engineering as applicable.

1.04 COMPLETE AND USABLE

The Design-Build Firm shall provide a work plan for a complete and usable system within the negotiated and accepted contract construction cost and meeting all requirements of this

BAEY 240021 (B810) & BAEY 240022 (B845) – Replace 20 kW Generators and Associated Equipment 011001-4 statement of need. The government will not accept requests for additional funds except for changes in project scope, unforeseen site conditions or as directed by the Contracting Officer.

The Design-Build Firm shall be financially and technically responsible for resolving any work plan errors or omissions in its products.

PART 2 - TECHNICAL DESCRIPTION OF PROJECT

2.01 GENERAL

A. The Design-Build Firm (hereafter referred to as the Contractor), is required to provide all services necessary for the complete work plan and construction of this project.

B. This 9 CEN Statement of Need (SON) addresses all work within and support of project number BAEY 240021 and BAEY 240022.

2.02 CLIN 001 – BASE BID: REQUIRED WORK FOR BUILDING 810 - GENERATOR REPLACEMENT

PROJECT:

A. Construction: Work Plan for 20kW Generator

i. Provide adequate work plan for the new Cummins 20kW generator, 3 wire, remote start, 120/208 VAC, 60Hz, to include battery.

ii. Provide one-line diagrams for the work plan and construction.

B. Demolition:

i. Remove existing generator and tank. Provide rental unit to provide backup emergency power in the event of an emergency outage.

ii. Remove all existing conduit and conductors from the generator to the ATS, and ATS to the 100A, 120/208 VAC main disconnect switch. Note: If upon testing, it is determined that the existing cabling/conduit is in compliance with current standards and is functional, it may remain in place as it is a direct burial.

iii. Remove existing ATS.

iv. Remove existing main disconnect switch.

C. Install Cummins 20kW generator, 3 wire, remote start, 120/208 VAC, 60Hz, to include battery charger.

i. This system is designated as an emergency system or Critical Operations Power System (COPS). As a result, it must comply with NFPA 70 Article 701 \3\ (systems required by law) and NFPA 110 Level 2 (used when failure is less critical to human life and safety) /3/criteria.

ii. Install Current Transformers (CT) on the neutral side of the generator windings. Use these CT’s as an input to a generator protective relay for overcurrent protection.

1. Wye-wound generators require only a resistor or reactor from the wye point of the generator to ground. Install a CT in this circuit for ground fault protection.

BAEY 240021 (B810) & BAEY 240022 (B845) – Replace 20 kW Generators and Associated Equipment 011001-5

2. Install hazard identification signs as specified in NFPA 704, Standard System for the Identification of the Hazards of Materials for Emergency Response, on stationary aboveground tanks.

iii. Provide remote manual stop function on the outside of the building that houses the generator according to UFC 3-540-01.

D. Install Cummins Compatible Onan ATS, 150A, open transition, four-pole with bypass capability.

i. Provide switchboard or switchgear construction with drawn out power or insulated case circuit breakers for the main power distribution equipment.

ii. Provide working around each circuit breaker when in its withdrawn position in accordance with NFPA 70, Table 110.26 (A)(1).

iii. Provide free-standing metal clad or metal enclosed switchgear as required for generator voltage rating, load capacity, fault capacity (withstand/interrupting ratings), paralleling requirements and operating scenarios.

iv. Provide an open transition transfer scheme unless facility operating procedures require paralleling with the utility. Closed transition transfer is rarely required for standby power applications. Closed transition will require coordination with the local utility and will require designing for the higher available short circuit current of the combined parallel power sources.

1. Use of a double-throw design within line of sight from the ATS to facilitate ATS replacement without mission impact is acceptable. /2/

E. Install manual transfer switch to connect portable generator in the event that the emergency back-up generator fails.

i. The facility should be designed with a permanently installed generator and a connection for a portable generator, do not connect the conductors for both generators directly onto the emergency side of the associated ATS. Install a double-throw switch upstream of the ATS; connect the permanently installed generator and the portable generator connection to this double-throw switch, with the output of the switch connected to the ATS emergency source connection.

F. Install load bank connections on the emergency side of the ATS, with cam-lock connectors.

i. Single-pole (cam-lock style) connectors and receptacles that are double-locking in accordance with the National Electrical Code (NEC) and NEMA 3R-rated are permitted with limitations. For standby generators, paralleled connections are prohibited. A single connector per phase must be used for each load and meet the following requirements:

1. Connectors and receptacles must be rated 200 amperes or less, UL listed, and

Canadian Standards Association (CSA) certified.

2. Connector and receptacle contacts must be made of high-conductivity copper base alloy.

BAEY 240021 (B810) & BAEY 240022 (B845) – Replace 20 kW Generators and Associated Equipment 011001-6

3. Connector and receptacle must provide a double-locking means to ensure a minimum 600 lb./in2pressure on contact.

4. Connector contacts must be recessed. A thermoplastic rubber or neoprene-insulated jacket must extend past the ends of both the male and female contacts and meet the strain relief requirements listed below.

5. Receptacles must be provided with NEMA 3R color-coded (for phase and ground identification) snap-back covers (150 amperes and less) or protective caps.

6. Cable plugs must be provided with color-coded (for phase and ground identification) protective caps with lanyards.

7. Tapping tees are not permitted.

8. Connectors and cable plugs must be fully rated for intended use.

9. Cable-to-plug connections must be crimped. Set-screw connections are not allowed because of their tendency to loosen due to heating/cooling, high load, and vibration.

10. The only approved cable strain relief is vulcanized style terminations.

ii. Install all previously removed conduit and conductors with NEW approved cabling

IAW with the current Beale Installation Specific Guide (ISG)

iii. Install Automatic External Defibrillators (AED) due to the proximity of medical services in the event of an emergency.

iv. Perform Arc Flash analysis and install warning labels.

v. Perform integrity test of generator system set tank.

vi. Ensure equipment grounds are tested.

vii. Ensure that the generator and ATS are initially tested IAW with all current NFPA, DAFMAN, UFC references, to include initial load bank testing.

viii. Due to the mission this generator supports, all NFPA testing will be IAW with NEC

Article 701, Legally Required Standby Systems, and NFPA 110, Level 1 criteria.

ix. Ensure the Electrical Power Production shop and the Electrical Sub-AMP manager are present for all testing and commissioning.

x. Ensure that 9 CES is provided all warranty and close out documents.

G. The contractor will be provided escort(s) while performing all phases of this work.

H. All installation(s) shall be completed in accordance with manufacturer’s instructions.

2.03 CLIN 002 – BID OPTION 1: REQUIRED WORK FOR BUILDING 845 - GENERATOR

REPLACEMENT PROJECT:

A. Construction: Design for 20kW Generator:

i. Provide adequate design for the new Cummins 20kW generator, 3 wire, remote start, 120/240 VAC, 60Hz, to include battery.

ii. Provide one-line diagrams for the work plan and construction.

B. Demolition:

i. Remove existing generator and tank. Provide rental unit to provide backup emergency

BAEY 240021 (B810) & BAEY 240022 (B845) – Replace 20 kW Generators and Associated Equipment 011001-7 power in the event of an emergency outage.

ii. Remove all existing conduit and conductors from the generator to the ATS, and ATS to the 100A, 120/240 VAC main disconnect switch. Note: If upon testing, it is determined that the existing cabling/conduit is in compliance with current standards and is functional, it may remain in place as it is a direct burial.

iii. Remove existing ATS.

iv. Remove existing main disconnect switch.

C. Install Cummins 20kW generator, 3 wire, remote start, 120/240 VAC, 60Hz, to include battery charger.

i. This system is designated as an emergency system or critical operations power system (COPS). As a result, it must comply with NFPA 70 Article 701 \3\ (systems required by law) and NFPA 110 Level 2 (used when failure is less critical to human life and safety) /3/criteria.

ii. Install Current Transformers (CT) on the neutral side of the generator windings. Use these CT’s as an input to a generator protective relay for overcurrent protection.

1. Wye-wound generators require only a resistor or reactor from the wye point of the generator to ground. Install a CT in this circuit for ground fault protection.

iii. Ensure generator set tank is set sized to accommodate a minimum local 24-hour capacity tank based on the full-load fuel consumption rate of the engine.

1. Install hazard identification signs as specified in NFPA 704, Standard System for the Identification of the Hazards of Materials for Emergency Response, on stationary aboveground tanks.

iv. Ensure set tank has leak detection and overfill alarms.

v. Provide remote manual stop function on the outside of the building that houses the generator according to UFC 3-540-01.

D. Install Cummins Compatible Onan ATS, 150A, open transition, four-pole with bypass capability.

i. Provide switchboard or switchgear construction with draw out power or insulated case circuit breakers for the main power distribution equipment.

ii. Provide working around each circuit breaker when in its withdrawn position in accordance with NFPA 70, Table 110.26 (A)(1).

iii. Provide free-standing metal clad or metal enclosed switchgear as required for generator voltage rating, load capacity, fault capacity (withstand/interrupting ratings), paralleling requirements, and operating scenarios.

iv. Provide an open transition transfer scheme unless facility operating procedures require paralleling with the utility. Closed transition transfer is rarely required for standby power applications. Closed transition will require coordination with the local utility and will require designing for the higher available short circuit current of the combined parallel power sources.

BAEY 240021 (B810) & BAEY 240022 (B845) – Replace 20 kW Generators and Associated Equipment 011001-8

1. Use of a double-throw design within line of site from the ATS to facilitate ATS replacement without mission impact is acceptable. /2/

E. Install manual transfer switch to connect portable generator in the event that the emergency back-up generator fails.

i. The facility should be designed with a permanently installed generator and a connection for a portable generator, do not connect the conductors for both generators directly onto the emergency side of the associated ATS. Install a double-throw switch upstream of the ATS;

connect the permanently installed generator and the portable generator connection to this double-throw switch, with the output of the switch connected to the ATS emergency source connection.

F. Install load bank connections on the emergency side of the ATS, with cam-lock connectors.

i. Single-pole (cam-lock style) connectors and receptacles that are double-locking in accordance with the National Electrical Code (NEC) and NEMA 3R-rated are permitted with limitations. For standby generators, paralleled connections are prohibited. A single connector per phase must be used for each load and meet the following requirements:

1. Connectors and receptacles must be rated 200 amperes or less, UL listed, and Canadian Standards Association (CSA) certified.

2. Connector and receptacle contacts must be made of high-conductivity copper base alloy.

3. Connector and receptacle must provide a double-locking means to ensure a minimum 600 lb./in2pressure on contact.

4. Connector contacts must be recessed. A thermoplastic rubber or neoprene-insulated jacket must extend past the ends of both the male and female contacts and meet the strain relief requirements listed below.

5. Receptacles must be provided with NEMA 3R color-coded (for phase and ground identification) snap-back covers (150 amperes and less) or protective caps.

6. Cable plugs must be provided with color-coded (for phase and ground identification) protective caps with lanyards.

7. Tapping tees are not permitted.

8. Connectors and cable plugs must be fully rated for intended use.

9. Cable-to-plug connections must be crimped. Set-screw connections are not allowed because of their tendency to loosen due to heating/cooling, high load, and vibration.

10. The only approved cable strain relief is vulcanized style terminations.

ii. Install all previously removed conduit and conductors with NEW approved cabling IAW with the current Beale Installation Specific Guide (ISG)

iii. Install Automatic External Defibrillators (AED) due to the proximity of medical services in the event of an emergency.

iv. Perform Arc Flash analysis and install warning labels.

v. Perform integrity test of generator system set tank.

vi. Ensure equipment grounds are tested.

BAEY 240021 (B810) & BAEY 240022 (B845) – Replace 20 kW Generators and Associated Equipment 011001-9

vii. Ensure that the generator and ATS are initially tested IAW with all current NFPA, DAFMAN, UFC references, to include initial load bank testing.

viii. Due to the mission this generator supports, all NFPA testing will be IAW with NEC Article 701, Legally Required Standby Systems, and NFPA 110, Level 1 criteria.

ix. Ensure the Electrical Power Production shop and the Electrical Sub-AMP managers are present for all testing and commissioning.

x. Ensure that 9 CES is provided all warranty and close out documents.

G. The contractor will be provided escort(s) while performing all phases of this work.

H. All installation(s) shall be completed in accordance with manufacturer’s instructions.

2.04 ADDITIONAL REQUIREMENTS

A. Construction Phasing Plan: This repair by replacement generator project shall include a construction phasing plan.

1. The Construction Phasing Plan shall be defined for both the demolition and installation of the generator system to enable them to work effectively as determined and avoid issues during construction.

2. During the installation and testing of the new generator system, there shall be provision of back up emergency power to enable the systems the generator supports to remain 100% functional during the entire construction period.

B. Investigation Report: The contractor shall provide an initial submittal of an investigation report five (5) days after the government has reviewed all comments and questions from referenced inspections of all affected areas related to the design and after retrieving all information from RFI’s received.

1. The contractor shall investigate all site conditions to include the existing utilities and provide an initial necessary work plan analysis along with the required calculations towards the project.

2. The contractor shall be responsible for physically investigating all areas, accessible or not. Non-accessible areas can be opened by base personnel, with prior coordination.

The contractor shall provide the Contracting Officer Representative (COR) seven (7) days written notice prior to any scheduled inspection of concealed spaces which require government assistance.

3. The contractor shall be required to perform all necessary field measurements for detailed references, to verify dimensions and confirm all information shown on government furnished reference material.