TECHNICAL ORDERING DATA (18 PAGES).docx

SPECIFICATIONS REQUIREMENTS

DC LOAD BANK

1. SCOPE

1.1. Scope. This purchase description specifies the minimum requirements for the procurement of transportable, remote controllable, electric load bank with characteristics and capacities as set forth herein.

1.2. Intended use. The load bank provided shall be suitable for use pier side in load testing various DC power generating equipment found on board naval vessels.

1.3. Quantity required. The following quantity and size load bank to be provided are as follows:

a. Quantity of one (1 ea.) – 1625 KW (5000 amps at 325 VDC) load bank, direct current (VDC), resistive type

2. APPLICABLE DOCUMENTS

2.1. Government documents.

2.1.1. Specifications, standards, and handbooks.

STANDARDS FEDERAL

FED-STD-H28A - Screw Thread Standards for Federal Services. (Latest edition) (Application for copies should be addressed to the DLA IS Defense Supply Center, Phil - General & Industrial Item of Supply, 700 Robbins Avenue, Philadelphia, PA 19111-5096)

2.1.2. Other government documents and publications. The following other government documents and publications form a part of this purchase description to the extent specified herein.

CODE OF FEDERAL REGULATIONS (CFR)

U.S. DEPARTMENT OF LABOR, OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

29 CFR 1910 - Occupational Safety and Health Standards. (Latest edition) (Application for copies should be addressed to the U.S. Department of Labor, 200 Constitution Ave, Washington, D.C. 20210)

2.2. Non-government publications. The following documents form a part of this purchase description to the extent specified herein.

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM D 3951 - Standard Practice for Commercial Packaging. (Latest edition) (Application for copies should be addressed to the American Society for Testing and Materials, ASTM International, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959)

AMERICAN WELDING SOCIETY INC (AWS)

AWS D14.4 - Specification for Welded Joints in Machinery and Equipment (Latest edition) (Applications for copies should be addressed to the American Welding Society Inc, 550 N. W. LeJeune Road, Miami, FL 33126)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 6 - Enclosures for Industrial Controls and Systems. (Latest edition) NEMA MG 1-2009, Revision 1-2010 - Motors and Generators (Application for copies should be addressed to the National Electrical Manufacturers Association, 1300 N 17th Street, Suite 1752, Rosslyn, VA 22209)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 - National Electrical Code (Latest edition) NFPA 79 - Electrical Standard for Industrial Machinery. (Latest edition) (Application for copies should be addressed to the National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02169-7471)

2.3. Order of precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption is obtained.

3. REQUIREMENTS

3.1. General requirements. The equipment shall be a transportable unit that is new and unused, capable of performing its intended function in accordance with the operation and performance requirements specified herein. The equipment shall be complete, so that when connected to the utilities identified herein, it can be used for any function for which it is designed and constructed. Products such as experimental units do not qualify as meeting the requirements specified herein.

3.1.1. New development. If during the contract period, any new developments are generated that would improve the efficiency, accuracy or productivity of the equipment and its related equipment or decrease its operation costs, the contractor shall notify the Contracting Officer. Reports of such developments shall be addressed to the Contracting Officer with a copy addressed to:

Ruben Arauz or Jim Weaver Puget Sound Naval Shipyard & IMF Shop 51, Building 427, Door 6 1400 Farragut Avenue Bremerton, WA 98314-5001

3.1.2. Safety and health requirements. Covers, guards, or other safety devices shall be provided for all parts of equipment that present safety hazards. Safety devices shall not interfere with operation of the equipment. The devices shall prevent unintentional contact with the guarded part and shall be removable to facilitate inspection, maintenance and repair of the parts. Machine parts, components, mechanisms, and assemblies furnished on the unit shall comply with all specific requirements of "OSHA Safety and Health Standards (29 CFR 1910), General Industry" that are applicable to the equipment itself. Additional safety and health requirements shall be as specified in other paragraphs of this specification. The design and manufacture shall be in accordance with all applicable OSHA safety standards.

3.1.3. OSHA approved certification. The equipment installation and its component parts shall be in compliance with the applicable OSHA regulations in accordance with CFR Title 29, Chapter XVII, Part 1910 and installed in accordance with NEC/NFPA requirements. Approval shall be as specified under the “Approval” and “Acceptance” criteria in the OSHA regulations Subpart “O”, Machinery and Machine Guarding paragraph 1910.212 and Subpart “S” Electrical, paragraph 1910.303 and paragraph 1910.399. After equipment delivery, and prior to testing, the contractor shall provide an OSHA Certification Report. Failure to provide this certification report will delay acceptance of the equipment, and could result in rejection for failure to comply with the terms of the contract. This report documents the results of all tests performed, provides an assessment of the equipment performance for compliance with the contract requirements, and forms a basis for recommending a safety certification. The report, test and evaluation shall be a composite of those inspection requirements specified in the contract. The report shall be prepared in an orderly manner to clearly and accurately set forth the collected data and conclusion resulting from these inspection requirements, opinions and subjective conclusions shall be clearly identified. The report shall include, but is not limited to, the following:

a. List of all tests performed and by whom witnessed.

b. List of data used for evaluation.

c. Tabulation of all discrepancies related to specification performance requirements.

d. Description of limitations revealed by data utilized.

e. Actions taken to mitigate each discrepancy and limitation.

f. Recommendations for subsequent actions.

g. Summary conclusions.

h. Manufacturer Certification that equipment has been manufactured and installed to OSHA CFR 1910.399 (per definition of “acceptable”).

3.1.4. Audible noise level. Audible noise emitted by the equipment shall not exceed 85 dB at the following locations:

a. Each side measured at one (1) foot from the enclosure;

b. The intake end and two corners measured at 26 feet from the enclosure; and

c. The exhaust end and two (2) corners measured at a distance of 26 feet from the enclosure The Audible noise shall be measured on the "A" weighted scale of a standard sound level meter under all operating and load conditions. Measurements shall be taken at each of the corners and at equal distant intervals of not more than three (3) feet along each side and end. For each measurement, the microphone shall be located on a straight line perpendicular to the surface or corner being measured. The height shall correspond to the point of highest noise level emitted from the surface or corner at the location and distance from the equipment specified herein.

3.1.5. Environmental protection. The equipment shall be designed and constructed, so that under the operating service, transportation and storage conditions described herein, the equipment shall not emit materials hazardous to the ecological system as prescribed by federal, state, and local statutes in effect at the time of bid.

3.1.6. Reclaimed materials. The equipment may contain reclaimed materials to the maximum extent possible provided such materials will not jeopardize the intended use, performance or design life of the equipment. Reclaimed materials shall have been collected or recovered from solid waste and reprocessed to become a source of raw materials, as opposed to virgin raw materials. None of the above shall be interpreted to mean that the use of used, rebuilt or re-manufactured products are allowed under this specification.

3.1.7. Mercury restriction. The equipment shall contain neither mercury nor mercury compounds, or be exposed to free mercury during manufacture.

3.1.8. Asbestos restriction. Asbestos and materials containing asbestos shall not be used on or in the equipment.

3.1.9. Polychlorinated biphenyl (PCB) restriction certification. The use of polychlorinated biphenyl on or in the equipment is prohibited. Written certification from the manufacturer that the equipment contains no detectable PCBs (less than two (2) parts-per-million) shall be provided. The certification shall be on manufacturer’s letterhead and signed by a company official who is empowered to provide same. A PCB label plate stating the PCB compliance certification shall be supplied and attached to the equipment.

3.1.10. Cadmium restriction. The use of cadmium and materials containing cadmium on or in the furnished equipment is prohibited.

3.1.11. Lithium restriction. The use of lithium and materials containing lithium on or in the furnished equipment is prohibited.

3.1.12. Methylene chloride restriction. The use of methylene chloride and materials containing methylene chloride on or in the furnished equipment is prohibited.

3.1.13. Lead restriction. The use of lead and materials containing lead on or in the furnished equipment is prohibited.

3.1.14. Ferrous parts. Exposed ferrous parts such as screws, bolts, nuts, washers, etc., shall resist corrosion in a salt-laden, moist, variable temperature atmosphere. Protection such as chrome plating, galvanizing or other electrical/chemical process, or stainless steel is acceptable.

3.1.15. Aluminum parts. Aluminum parts for use outdoors shall be anodized or chemically treated followed by two coats of weather-resistant exterior paint.

3.1.16. Dissimilar metals. Dissimilar metals shall not be used in direct contact with each other without suitable means for preventing electrolytic corrosion.

3.1.17. Lubrication. Bearings (except sealed-for-life and self-lubricating type), mating gears and sliding parts shall be provided with means for lubrication. Reservoirs of splash-type systems shall be fitted with oil level sight gauges. Automatic "force feed" and manually operated force feed systems shall be supplied with a filter. Manually operated systems shall have control handles mounted in an accessible location convenient to the operator. Oil holes, grease fittings and filler caps shall be easily accessible.

3.1.18. Workmanship. Workmanship of the equipment and its accessories shall meet all requirements specified herein.

3.1.19. Pre-fabrication drawing. Prior to commencing fabrication of the load bank, contractor shall provide a drawing of the equipment for review/approval. Drawing shall clearly reflect the center of gravity and shall reflect all pertinent information regarding the specified requirements.

3.2. Construction. The equipment shall be constructed of parts that are new, without defects and free of repairs. The equipment construction shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to damage from environmental hazards (such as dust, debris, or residue) shall be sealed or otherwise protected. The structure shall withstand all forces encountered during the operation of the equipment to its maximum rating and capacity without permanent distortion or failure. Any loose, spattered solder, flux, metal chips, insulation scrap or other foreign material shall be removed from the equipment.

3.2.1. Castings and forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, or filling with solder or paste shall be used for reclaiming any defective part. Such processes may be used only for enhancing surface finish and appearance.

3.2.2. Welding, brazing and soldering. Welding, brazing or soldering shall be employed only where those operations are included in fabrication of the original design. These operations shall not be employed as repair measures for defective parts. Any excess material used for such operations shall be thoroughly removed from the part(s) upon completion of the operations. Solder connections shall show evidence of good bonding in metal-to-metal contact. Cold solder joints, incomplete joining of solder and metal, excess or insufficient solder or damaged insulation shall be considered reason for rejection of the equipment. Flux for soldering shall be rosin or rosin and alcohol. No acid, acid salts or acid core solder shall be used in preparation for soldering of electrical connections. Weldments shall comply with AWS D14.4.

3.2.3. Fastening devices. Screws, pins, bolts, and similar internal and external parts shall be installed with means for preventing change of tightness. Parts subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently installed. Fastening devices shall be tightened to torque limits as established by the manufacturer's standard for tightening to preclude loosening by normal operation or vibration.

3.2.4. Surfaces. Surfaces of castings, forgings, molded parts, stampings and welded parts shall be cleaned and free from sand, dirt, fins, sprues, flux or other harmful or extraneous materials. External surfaces shall be smooth. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. Except as otherwise specified herein, the condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practices.

3.2.5. Painting. The equipment shall be painted in the manufacturer's standard color provided it results in a highly wear resistant finish which guarantees continued protection to the surfaces covered against all service conditions. Prior to painting, Surfaces shall be properly prepared and primed. Enclosure shall have a minimum of one coat of primer, two coats of paint and be suitable for soap and water cleaning. The use of paint containing lead is prohibited. The paint formulation shall contain no hazardous materials.

3.2.6. Threads. All threaded parts used on the equipment and its related attachments and accessories shall conform to FED-STD-H28A.

3.2.7. Digital readouts. Digital readouts shall display data in illuminated figures clearly legible at a distance of 10 feet and give direct horizontal readings without requiring any calculation or interpolation. Each digit of the readout display shall be of the in-line type.

3.2.8. Ventilation. Adequate cooling or ventilation shall be provided on the equipment to preclude premature deterioration of the equipment or any component thereof when utilized under the ambient and operating conditions specified herein.

3.2.9. Measuring/indicating devices. All measuring and indicating devices such as dial indicators, pressure gages, temperature indicators, depth stops, and other similar devices used on the equipment shall be graduated in the U.S. Customary System of Units (US). Marking on all measuring and indicating devices shall be permanently and legibly engraved or etched on a non-glare background. All dials and other type indicating devices shall be securely mounted in place. This unit shall be located so to allow reading from the operator's stationary workstation.

3.2.10. Maintainability. The equipment shall be designed and constructed to permit Maintenance Personnel to easily service the equipment using a minimal number of tools. All parts subject to wear, breakage, or distortion shall be accessible for adjustment, replacement or repair. Consistent with required maintenance and design of the equipment, the Contractor shall provide any special tools required to service the Unit. The equipment shall be equipped with access covers to facilitate inspection, cleaning, and repair, or replacement of internal parts.

3.2.11. Interchangeability. All parts of the end item shall be manufactured to definite standards and tolerances that will provide for the interchangeability of respective parts between end items of the same model without modification of the part or the equipment. All replacement parts shall be available commercially within the continental United States.

3.2.12. Controls and instrumentation. Operator controls, instrumentation and indicators shall be mounted convenient to operating personnel. Such devices shall be clearly and legibly marked for function and identification. Controls shall be fitted with suitable handles, pushbuttons, or control knobs, as applicable. Gauges and instruments shall be designed for re-calibration.

3.3. Components. The equipment shall consist of but not be limited to the following described principle components, attachments, and accessories necessary to meet the operational and performance requirements specified herein. Any additional components necessary for the operation of the equipment shall also be furnished in accordance with the manufacturer's standard practice.

3.3.1. Design. The load bank shall be a forced air horizontal intake and exhaust air flow, convection cooled, remote controlled, transportable unit (not trailer mounted) complete with resistor elements, control panel, relays, contactors, circuit breakers, wiring remote control console, interconnecting multi-conductor cables, and safety devices to protect personnel and the equipment. The load bank shall be designed for individual control and operation from a single remote control console. The load bank shall be designed for continuous operation and related performance at variable ambient temperatures from -10°F up to 104°F, salt and/or dust laden atmosphere and possible adverse weather conditions of wind driven rain, snow or sleet.

3.3.2. Resistance load segments. The resistance (kW) load segments shall employ 600 volts (minimum) double insulated, non-breakable, grid type resistors of corrosion-resistant steel with negligible resistance change from cold start to maximum operating temperature. Every resistor element shall have insulation to ground in excess of 100 megohms when read with a 500 Volt megger. The resistors shall be mounted where they are readily accessible and individually removable for inspection and maintenance. Provisions shall be incorporated into the load bank to permit personnel to easily disconnect all circuits to the resistors prior to removal of the assembly and to reconnect all circuits after the assembly is reinstalled. The individual resistors shall be rigidly supported in the assembly to prevent sagging and adverse movement. There shall be no evidence of hot spots and arcing on the resistor grids during operation. Individual resistance load segments shall be circuit arranged to permit the operator to apply and remove resistance load at increments no greater than 200A at 300 VDC.

3.3.3. Contactors. An arrangement of magnetic contactors, located in-circuit between the main circuit breaker and the load segments, shall provide on-off control of power to the individual resistive load segments as initiated by the remote control provided. Each contactor shall be selected to have parameters proven to be adequate in handling/interrupting all DC voltages and currents to be encountered in the circuit during normal and overload conditions. Each contactor shall be labeled in a manner, which identifies it to its applicable load segment. Each contactor shall be 600 volts minimum insulated, 2-pole (minimum), magnetic latch type and current de-rated as necessary to assure continued operation and performance. The contactor main poles shall incorporate arc barriers and suppression devices as required to safely interrupt full load current. The interlock contacts shall be insulated from the contactor and ground. Each contactor shall either have an associated over-current sensing unit or an in-line fuse that will break the circuit in the case of an overload current. Fuse/over-current values shall exceed full load current by a large enough margin to avoid nuisance trips when operating at full load, but shall afford adequate protection for the contactor, load segment and internal wiring as determined by the manufacturer. Each contactor shall be labeled to identify the associated load segment.

3.3.4. Pilot relays. Pilot relays shall be employed in the control circuitry of the load bank to electrically interface the control switches on the remote control with the load bank device to be controlled. Each control switch on the remote control shall affect its assigned control function by energizing the applicable pilot relay(s) in the load bank. The power devices being controlled shall include auxiliary contacts. Minimum breakdown voltage between all elements of each relay and ground shall be 1000 volts RMS. The relays shall be mounted on a shock and vibration absorbing assembly or individually shock-mounted to withstand the forces associated with transporting the load bank within a naval facility.

3.3.5. Main circuit breaker. The load bank shall include a NEMA rated, trip-free, 2-pole (minimum), 600 volts DC (minimum), main circuit breaker located in-circuit between the input bus bars and all load segment contactors. The main circuit breaker shall have a frame size of not less than 125% of the maximum load bank current under all loads and temperature conditions to be encountered. Current interrupting capacity shall be no less than 100 kAIC, and the circuit breaker shall include instantaneous and inverse time over-current trips. Over-current trip coordination shall be incorporated between the main circuit breaker and the over-current devices for the individual load segments to preclude nuisance tripping of the main circuit breaker for over-current conditions in each load segment which can be safely interrupted by the load segment contactor(s). The main circuit breaker shall be controllable (on/off/reset control) from the remote control unit, and shall be listed or labeled by a Nationally Recognized Testing Laboratory (NRTL) (e.g. UL). Each breaker motor shall operate from the separate control power within the load bank and shall include its own over-current protection.

3.3.6. Load terminals. The load bank shall be fitted with two input load bus bar terminals, designed and labeled as positive and negative. Each bus bar terminal shall be sized to continuously carry full rated current of the load bank circuit without exceeding safe temperatures and be braced to 100 kAIC (minimum). Each bus bar terminal shall be copper (silver or tin plated at connection points) and configured to accept two-hole type lugs. See Figure 1 for measurements of the two-hole lug configuration and spacing requirements. Adequate spacing shall be present between bus bar terminals to allow for 900 MCM lugs to be placed onto both sides of each bus bar while ensuring adequate room to work in tightening the lugs to the bussing. Bus bar terminals shall also be able to accept a sufficient number of 500 MCM load cables (assume 500A per 500 MCM) to handle full load current. Bus bar terminals shall comply with a national consensus standard for bus bars.

Figure 1

3.3.7. Load capacities. The load bank shall provide the following minimum continuous duty, ungrounded load capacities:

a. 5000A (minimum) load over a range of 210 to 325 VDC and every voltage between without having to change cable connection points.

b. 1500A (minimum) load over a range of 80 to 325 VDC and every voltage between without having to change cable connection points.

3.3.8. Performance. The load bank supplied under these specifications shall perform continuously under any load condition including full rated load. Design and construction of the load bank shall be considerate of operating and storing the equipment, without added protection, under any combination of the following ambient conditions without loss of capacity:

a. Elevation: 50 feet below to 100 feet above mean sea level

b. Temperature: -10° F to 100° F

c. Relative humidity: 0 % to 100 %

d. Wind velocity: 0 to 100 miles per hour

e. Unusual service conditions: salt water spray, direct exposure to sunlight, contaminated industrial environment including dust, fumes, smoke and blast grit, and inclement weather including wind driven rain and snow.

3.3.9. Overvoltage. The load bank shall have adequate electrical/thermal withstand characteristics/capacities to assure against degradation and damage when operating with applied voltages of up to 10% above specified values, thereby protecting against overvoltage conditions due to errors in instrumentation and when testing the output voltage ranges of power generating equipment under full load conditions.

3.3.10. Control Power. The load bank shall be designed to provide for operation of the fan(s), space heater(s), main circuit breaker, load contactors, and associated control and indicator functions from a single external source of 480VAC, 3-phase, 60Hz control power. The load bank shall include one or more static power supply(s) with all factors of transformation, rectification, and regulation necessary to effect and maintain proper operation of the load bank. The remote console shall be fully operable up to 30’ (feet) from the load bank. Voltages on the remote console shall not exceed 50 volts. Voltages on all contactor coils and the circuit breaker motor shall not exceed 125 volts. The method of connection for the 480VAC control power shall either be input bus bars for lug connection, or "Camlok" type flange mounted connections. If lug type connections are used, they will be located in a special recessed compartment of the load bank enclosure for protection and safety of personnel. If "Camlok" type connections are used, a mating set of connectors will be provided with the load bank for use in fabricating a power cable. The load bank shall include a 3-pole, 600VAC circuit breaker (listed or labeled by a Nationally Recognized Testing Laboratory (NRTL) (e.g. UL)), appropriately sized for the maximum expected control power load that provides on-off control and over-current protection for equipment powered from the 480VAC control power connection.

3.3.11. Protective Capabilities. The load bank shall have the following protective capabilities:

a. High Temperature. High temperature detectors shall function to trip open the main circuit breaker and to energize the "high temperature" light on the remote control in the event of over temperature in the exhaust air stream. Not less than four detectors shall be provided. One detector shall be located in each quadrant of the exhaust air stream within the load bank. Each detector shall independently cause the required function. Each detector shall be set to activate before temperatures within the load bank exceed safe operating levels or the exhaust air temperature exceeds 150°F.

b. Air Flow. A directional air flow switch sensor shall be incorporated into the air stream and shall function to trip open the main contactor in the event air flow through the load bank is reversed, interrupted or reduced below a safe value.

c. Interlocks. A network of interlock switches on the load bank doors, shutters, and interlock contacts in the fan motor circuit shall function to open and lock out the main contactor in the event: a door is open, a shutter is not fully open, the fan motor is de-energized. Each door shall have the capability of preventing hypersensitivity of the interlock feature. In addition, all interlock switches on each load bank door shall be capable of being locked into a bypass mode for maintenance personnel to observe the load bank under operating conditions.

d. Trip protection. An under voltage release circuit shall automatically function to trip open the main circuit breaker in the event that either control voltage within the load bank is interrupted, or is reduced to a level which prevents the circuit breaker from being opened by the remote control switch. The protective circuit shall maintain to trip open the breaker until the problem is corrected and normal on-off control is restored.

e. Cooling Fan(s). The load bank shall be adequately cooled or ventilated to prevent deterioration, degradation, or failure of the unit and any part thereof when operating at the duty cycle and under conditions specified herein, for the intended functional life of the load bank. Moisture entering intake air ducts shall not cause deterioration or failure of any component part of the load bank. Electronic parts and control units shall be insulated from the heat generating load segments and ventilated as necessary to preclude damage or faulty operation. Electric motor driven stainless steel fan(s) shall be provided. The fan motor shall be the 3-phase, ball bearing, induction motor type with adequate horse power rating so as not to be overloaded under any condition of the load bank operation with ±10% variation in motor voltage. Directional arrows on the outside of the load bank enclosure shall indicate correct fan rotation and correct airflow. The temperature of the exhaust air, emitting from the discharge end of the load bank, shall not exceed 150° F under all ambient and operating conditions. The fan motor shall be designed and circuit arranged to operate from the 480 VAC control power within the load bank. The motor circuit shall include a 3-pole magnetic starter(s) with 3-pole running over current protection for each voltage. The fan motor shall be positioned in the load bank so as not to be subjected to excessive temperatures. The fan motor shall be capable of being controlled from the remote control.

3.3.12. Space Heaters. The load bank shall include electric internal heaters large enough to maintain the internal temperature above 50°F in all environments. The heaters shall be circuit arranged to operate from the load bank's external 480VAC, three phase, 60 Hertz control power supply. An on/off switch shall control power to the heaters; also, the heaters shall be controllable via thermostat to maintain the internal temperature at a specified level. The thermostat may be mounted internal to the load bank (it may also be incorporated into the remote control functionality, but this is not required). If thermostat(s) is/are mounted internal to the load bank, ensure thermostat(s) are reasonably accessible for adjustment. The heaters will be configured to turn off when any DC load is applied to the load bank. Each heater shall have a manual disconnection mechanism (e.g. quick disconnect plugs) for maintenance purposes. If the resistive load elements are contained in multiple compartments within the common enclosure, each compartment shall include its own individual internal heater(s) and associated individual control devices and manual disconnect(s) as described above.

3.3.13. Remote Control Console. The load bank shall be equipped with a portable remote control having a total weight not to exceed 40 pounds. The cover shall completely seal the inside of the remote control from the outside environment when in place. Controls and indicators shall be designed to be dust tight at all times. A permanently inscribed instruction plate, attached to the inside of the removable cover, shall provide complete instructions for operating the load bank. The remote control shall be equipped with quick disconnect, multi-pin, polarized type receptacle for connecting the console to the load bank via the remote cable. This arrangement shall permit the console to be used with each identical load bank for operation at a minimum distance of not less than 30 feet. Remote control console shall be NEMA 4 rated (minimum).

a. Controls and Indicators. The remote control shall permit the operator to individually control and interpret status and able to load and unload in increments not greater than 200 Amperes at 300 VDC. Load controls shall be marked to reflect the ampacity rating of the segment at 300VDC and at 200VDC (e.g. 200A@300VDC, 133A@200VDC). Controls and indicators shall include but are not limited to:

A. CONTROL SWITCHES

(1) Fan motor

(2) Main circuit breaker

(3) Resistance load steps (one for each load segment)

B. INDICATOR LIGHTS

(1) Fan “on-off”

(2) Main circuit breaker "open-closed" Resistance load step “on-off” (one for each step)

(3) High temperature

b. Control cables. The load bank shall be furnished with a standard (non-proprietary type) remote control cable for connecting the remote control to the load bank. The control cable shall be fitted on each end with a quick disconnect, multi-pin, polarized plug designed to connect to the mating receptacle on the load bank or control as applicable. The remote control cable shall be furnished in three (3 ea.) 10' (feet) plug-in sections. The control cable shall have not less than five spare conductors. The cable shall be multi-conductor flexible type with an outer jacket of neoprene that retains its flexibility in an ambient temperature range of 32°F to 120°F. The cable shall be UL listed/approved for use in an outdoor marine environment and capable of being manually coiled for storage within the load bank enclosure without cracking the outer sheath or damaging the cable. Conductors shall be not less than No. 18 AWG, and insulated for not less than 600 volts. The same purpose control cables, for each identical load bank shall be interchangeable among the load banks. All sections of the remote control console cables shall be capable of being series connected permitting the remote control console to be operated up to a total of 310 feet from the connected load bank.

3.3.14. Enclosure. All components of the equipment shall be contained within one common NEMA 3R (minimum) enclosure of aluminized structural and sheet steel. A high quality painted surface (as described in paragraph 3.2.5) shall minimize corrosion. A louvered access door or similar provisions shall be made for power cable entrance of temporary cabling that provides an adequate means of ensuring inadvertent or accidental contact with energized part(s). The enclosure(s) shall be of drip-proof construction and of minimum size consistent with good design practices and ventilation of components. All enclosures shall be of weatherproof construction to include sheet steel flooring with drains having removable, hinged covers for use and continuous outdoor storage in variable temperature, humidity and inclement weather conditions. Additionally, the bottom of the enclosure shall be designed to prevent dust and moisture from ground water to be drawn inside. All openings to the interior of the load bank enclosure shall be adequately sealed to prevent entry by rodents (e.g. screens on all permanent openings). The load bank enclosure with installed equipment shall be designed to be safely lifted and transported (see 3.3.14(g)) without being trailer mounted. Vertical, horizontal, and cross bracing (as applicable) shall be of an adequate size and thickness to withstand any reasonable stress that may be imposed when in transit as well as during normal operation.

a. Doors and covers. The sides of the enclosure shall be fitted with hinged doors to permit full access to the installed equipment for routine inspection, in-place maintenance, trouble shooting and removal for overhaul and repair. Hinged doors shall have padlock provisions (contractor not responsible for providing padlocks), and view portal(s) shall be provided to allow for visual inspection of indication, measurement, thermal monitoring, and circuit breaker instrumentation, as applicable. Each recessed compartment on the load bank shall be fitted with a suitable hinged cover to provide added protection to the equipment installed therein when not in use. Each door/cover shall be designed with a gasket to protect the inside of the enclosure against the outside environment.

b. Louvers. As necessitated by the kW rating and required heat dissipation of the load bank provided, the enclosure shall be fitted with multi-vane louver(s) on the side of the enclosures (not on top), having stainless steel shafts and bearings, for intake and exhaust airflow. The louver(s) shall automatically open when the cooling fan is operated and shall automatically close when the fan is de-energized. All ventilation openings shall be fitted with an overall, removable screen of 1/2 inch, corrosion-resistant metal wire mesh.

c. Receptacle. A receptacle shall be mounted in a recessed compartment of the enclosure for connecting the remote cables. The receptacle shall be the multi-pin, quick disconnect, polarized type designed to mate to the corresponding plug on the applicable control cable. The receptacle shall be identified for function.

d. Interior lighting. The load bank shall be provided with internal lighting controlled from a separate on-off switch. Power for illumination shall be derived from the control power source and transformed to the proper operating level. Power for illumination shall be designed to be available both concurrent with and independent of the energization of the control transformer.

e. Grounding. The enclosure shall include a ground stud or lug of appropriate size to permit grounding of the load bank enclosure for personnel safety.

f. Remote control console and cable storage. The enclosure shall provide an accessible, assigned area for storing the remote control console and control cables when these items are not being used.

g. Tine guide openings. The equipment shall be provided with box-section meeting ASME standards for forklifts, tine-guide openings in the base for safe handling and transport by forklift truck from each side. The box sections shall extend through the entire length or width of the equipment, completely enclosing the forklift tines. They shall be fabricated from heavy metal channels having a definite thickness to withstand the stresses imposed. Box sections shall have internal cross-sectional dimensions of at least 6 inches high by 12 inches wide. Tine guide openings shall extend approximately 2 to 3 inches beyond the furthest outward point of the exterior of the enclosure. Center-to-center dimension of the tine guide openings shall not exceed 48 inches. Tine guides shall be centered about the unit’s center of gravity. They shall be welded to the base and so spaced apart, center-to-center, that while transporting the equipment, a forklift truck can pass over pavement obstructions causing dynamic stresses representing five (5) times the equipment's weight without causing the box sections to fracture or part from the base.

3.4. Electric utilities. The equipment shall be designed and constructed to be complete for operation on Single Service 480 volts (±10%), 3 phase, grounded or ungrounded power, 60 Hertz. The utility power to operate the controls, cooling fans, etc, shall be entirely separate from the load bank load circuits. All power running through the load boxes will be ungrounded.

3.4.1. Electrical equipment. Electrical components including motors, starters, relays, switches, and wiring shall conform to and be located in accordance with applicable NEMA, ANSI and NFPA standards for the intended application. Given the operating environment of the equipment, current carrying components and attendant components shall be insulated to inhibit tracking.

3.4.2. Wiring. Inter-unit connecting wiring within the load bank shall be rated at 105°C. The preformed wire and cable method shall be used in wiring the load bank; point-to-point method is prohibited. Wiring shall be installed in a manner which prevents stress on cable forms, wires and connections. When wires or cables must pass through a frame, by irregular surfaces, sharp edges or heat dissipating parts, they shall be routed and protected to prevent damage or degradation of the equipment.

3.4.3. Electric power disconnect. Supply circuit disconnect devices shall be provided and installed on the equipment as specified in paragraph 3.3.5 and 3.3.10.

3.4.4. Motors. Motors shall conform to NEMA MG-1, rated for continuous duty and shall be equipped with ball bearings of the sealed and permanently lubricated type.

3.4.5. Control circuits. Main and auxiliary control circuits shall operate on a circuit of 120 volts or less derived from isolation transformer(s) integral with the equipment.

3.4.6. Electrical connections. Electrical connections within the equipment shall be complete and shall be made via terminals on the components, terminal/circuit boards and bussing. Splices between terminations are not permitted. Connections and terminals shall be supported and spaced without dependence upon the wiring in the components and braced as necessary to assure withstanding the distortion forces associated with available short-circuit currents. Proper identification of wiring, bussing, terminals and circuits for function, polarity, phasing, etc., shall be adhered to throughout the equipment. Identification shall be in the form of wire markers, color coding, permanently engraved plates, and permanent markings on the devices. Adequate spacing shall be maintained throughout to avoid excessive bending of cabling and wiring, to maintain adequate separation and creepage distance between electrical potentials and between these potentials and ground, and to permit ease in disconnecting wiring and cabling during trouble-shooting and repair. In no instance shall clearances and creepage distances be less than those prescribed under NEMA ICS, Part ICS 1-111.

3.4.7. Grounding. Exposed, non-current carrying metal parts on the equipment shall be maintained at common, zero ground potential. None of the primary circuits in the equipment shall be connected to ground. A ground stud or lug on the equipment shall provide means for grounding the equipment for safety to personnel. A NEMA type "grounding plug" that effectively grounds the equipment shall be acceptable for cord connected equipment.

3.4.8. Solid-state components. Solid-state design shall be employed throughout for electronic components. Use of selenium and other similar aging devices shall be permitted only in the application of voltage surge protection to other solid-state components. Each solid-state device shall be selected and installed to have characteristics and withstand ratings compatible with its intended function and application in assuring long life and reliability. Solid-state components shall not be adversely affected when subjected to radiated and conducted power line transients and surges typically experienced in a production type, industrial environment. Series and parallel connections of solid-state devices without forced sharing circuitry for voltage and current, respectively, is not permitted. Cathode ray tubes are excluded from this requirement.

3.5. Physical size limitations. The maximum external dimensions of the load bank shall not exceed 96” (inches) length, 96” (inches) width, and 120” (inches) height.

3.6. Instruction plates. Wording and numbers on all control panels, instruments, charts and plates shall be permanently and legibly displayed in bold face, English language characters on a contrasting background. Stencil the weight and electrical capacity (KW) on at least one side of the enclosure located on or near the base. The lettering shall be a minimum of 2" in height.

3.6.1. Caution/warning plates. Corrosion resistant "Caution" or "Warning" plates shall be securely attached to the equipment in prominent, visible locations. All safety precautions to be observed by the operator or maintenance personnel shall be permanently marked on the plates. The caution/warning plates shall include Flash Hazard Boundary, Cal/cm2 Flash Hazard at 18 inches, Class Level of Electrical Safety Equipment, and Shock Hazard Voltage Level when covers are removed.

3.6.2. Identification plate. A corrosion resistant identification plate shall be securely and conspicuously placed on the equipment. It may be the manufacturer's standard, but, as a minimum, it shall contain the following information:

Nomenclature Contractor's Name Manufacturer's Model Designation Manufacturer's Serial Number Electrical Utilities (Volts, H.P., Amps, Frequency, Phases, etc.), as applicable Other Utilities (GPM, CFM, PSI, etc.), as applicable Contract Number Date of Manufacture

3.6.3. Lubrication chart or plate. A lubrication plate or chart shall be securely attached to the equipment. If a chart is furnished, it shall be placed in a transparent plastic folder or laminated between permanently sealed clear plastic sheets. The following information shall be furnished on the chart or plate:

Points of application Service interval Type of lubricant Viscosity

3.7. Technical data / O&M manuals. Four (4 ea.) hard copies and one (1) electronic copy of the operation and maintenance (O&M) manuals shall be provided with the machine. O&M manuals shall contain technical information, specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language. Technical data shall contain at a minimum:

3.7.1. Data shall enable an average journeyman mechanic to operate, program, maintain, and repair the equipment.

3.7.2. Complete instructions and information for all equipment, components, assemblies, subassemblies, attachments, and accessories.

3.7.3. Operating instructions including programming requirements, pre-operational checks, start up, shut down and emergency shutdown procedures.

3.7.4. Maintenance and service instructions, including all preventive maintenance schedules, and lubrication charts.

3.7.5. Trouble-shooting guides.

3.7.6. Parts list containing: illustrations, part numbers, part nomenclature, original manufacturer, cross reference numbers, and recommended spare parts, including quantities.

3.7.7. Energy control procedure, in accordance with 29 CFR 1910.147, to bring equipment to a zero energy state for maintenance.

3.7.8. All mechanical and electrical schematics with a table of contents showing discrete components, block diagrams, wiring diagrams with inputs and outputs identified, system electrical interface documents, and drawings for the specific model of all machine equipment/drives/controls supplied.

3.7.9. All final “as-built” contract drawings shall be provided on CD or DVD disc(s). The format of the drawing files shall be in AutoCAD version 2010 or older. Files shall have DWG or DXF extensions.

3.8. Spare parts. (The spare parts quote shall be considered optional, listed and priced as a separate line item under Section B of Contract). The government hereby establishes an option to purchase spare parts for the items required under this contract. The offeror shall furnish a spare parts list as part of the proposal. If this option is exercised, the spare parts purchased shall be delivered concurrent with the equipment being supplied. The list shall contain the following information:

a. Description of recommended spare part(s).

b. Recommended quantity for one year's support, assuming normal usage, after warranty.

c. Prime manufacturer(s) and part number(s);

(1) Cross-reference number applicable to the location or function in the equipment or system being procured.

d. Unit price.

e. Manufacturer's lead time (if in excess of 30 days).

Unit prices submitted in the spare parts list shall be valid for 365 days after the effective date of the contract. During that period, the government may exercise its option at any time. The government need not purchase all parts or all quantities on the spare parts list.

3.9. Exceptions. Exceptions to these specifications will be considered. If the contractor takes exceptions to any part of these specifications, all exceptions shall be listed in a manner where each exception references the specification paragraph to which the exception applies. Exceptions shall be submitted as part of the bidding proposal.

4. QUALITY ASSURANCE

4.1. Responsibility for inspection. The contractor shall be responsible for the performance of all inspection requirements (examinations and tests) as specified herein. The contractor may use his own or any other facilities suitable for the performance of the inspection requirements specified herein, unless disapproved by the government. The government reserves the right to perform any inspections set forth in the specification where such inspections are deemed necessary to ensure the supplies and services meets the specifications.

4.1.1. Responsibility for compliance. All items shall meet the requirements of Section 3. The inspections set forth in this specification shall become part of the contractor's overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of ensuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling inspection, as part of manufacturing operations, is an acceptable practice to ascertain conformance to requirements, however, this does not authorize submissions of defective material, either indicated or actual, nor does it commit the government to accept defective material.

4.2. Classification of inspections. The inspection requirements specified herein are classified as follows:

a. Quality conformance inspection (see 4.3)

b. Acceptance test (see 4.4)

4.3. Quality conformance inspection. Quality conformance inspection shall be applied to each item prior to being offered for acceptance under the contract.