A07_Attachment_0002_Recapitalization_Purchase_Description_6115-0132_Amendment_0002.pdf

Attachment 0002

PD 6115-0132

Recap PD Vr59

15 June 2016

PURCHASE DESCRIPTION

GENERATOR SETS, TRAILER MOUNTED

DEPLOYABLE POWER GENERATION & DISTRIBUTION SYSTEM (DPGDS)

PRIME POWER UNIT (PPU)

DIESEL FUEL DRIVEN, ALTERNATING CURRENT

800 KILOWATTS

GENERAL SPECIFICATION FOR

1. SCOPE

1.1. Scope. This Purchase Description (PD) covers the general requirements for the recapitalization of the MEP-PU-810A/B Deployable Power Generation and Distribution System (DPGDS) Prime Power Unit (PPU). The recapitalized MEP-PU-810A/B is a trailer-mounted PPU which will have a total output of no less than 800 kilowatts (kW), consisting of two skid-mounted diesel-engine driven generator sets (hereinafter referred to as “set” or “sets”) which produce 2200/3800 VAC at 50 Hz, 2400/4160 VAC at60 Hz and are housed in a common enclosure. Each set can operate independently or in parallel, and operate in parallel with legacy MEP-PU-810A/B units.

Each set has individual brushless alternators, fuel systems, engine management systems, 24 volt DC cranking systems, hydraulic cooling systems, power management and protection systems, and other devices as required for independent operation. Each generator set engine/alternator assembly may be removed from the trailer without affecting operation of the other set.

1.2. Classification. Each set is classified as Type II: Prime; Mode I (50/60 Hz); Class 2A (Utility, Compatible with Commercial Power Distribution Systems) as specified in MIL-STD-1332, and produces no less than 400kW at 60 Hz (334 kW at 50 Hz).

1.3. Set Rating. Each set is rated at 0.8 power factor (PF), lagging, and produces the following output voltages:

a. 2400/4160 volts at 60 Hz, 3-phase, 4 wire, wye connected

b. 2200/3800 volts at 50 Hz, 3-phase, 4 wire, wye connected

Beneficial comments (recommendations, additions, deletions) and any pertinent data which may be of use in improving this document should be addressed to: DoD Project Manager Expeditionary Energy & Sustainment Systems Attn: SFAE-CSS-E2-MEPS -OPM 5850 Delafield Road, Ft.

Belvoir, VA 22060-5809 by using the Standardization Document Improvement Proposal (DD Form 1426) appearing at the end of this document or by letter.

AMSC N/A FSC 6115

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

Draft RECAP PD Vr59 15 June2016

1.4. Configurations. Both the MEP-PU-810A and MEP-PU-810B configurations are functionally identical, except for mobility, and share as many common components as practicable.

The recapitalized MEP-PU-810 units shall maintain these configurations and capabilities, and shall meet the requirements as specified herein. However, the model numbers of the recapitalized MEP- PU-810 units will change from MEP-PU-810A to MEP-PU-810C and from MEP-PU-810B to MEP- PU-810D. The MEP-PU-810 units are configured as follows:

a. The MEP-PU-810A(C) model configuration is mounted on a two axle wagon-style chassis equipped with surge actuated hydraulic brakes, lunette-ring hitch towbar, and is designed for low speed mobility (up to 20 mph), towed by vehicles without trailer brake controllers. The MEP-PU- 810A is certified for air transport on US Air Force C-5, and C-17 aircraft.

b. The MEP-PU-810B (D) model configuration is mounted on a single axle chassis equipped with air actuated brakes, 5th wheel kingpin hitch, and is US Department of Transportation (DOT) compliant for transport at highway speeds (up to 55 mph), towed by truck/tractor vehicles. The MEP- PU-810B is certified for air transport on US Air Force C-5 and C-17 aircraft.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are needed to meet the requirements specified in sections 3 and 4 of this PD. This section does not include documents cited in other sections of this PD or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirement documents cited in sections 3 and 4 of this PD, whether or not they are listed in paragraphs 2.2 and 2.3.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

FEDERAL SPECIFICATIONS

A-A-52557 - Fuel Oil, Diesel; for Posts, Camps and Stations

A-A-52624 - Antifreeze, Multi Engine type

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A-A-55804 - Rods, Ground (with Attachments)

A-A-59616 - Pipe Fittings: Bushings, Locknuts, and Plugs; Iron, Steel and Aluminum; (Threaded); 125-150 Pounds

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-PRF-2104 - Lubricating Oil, Internal Combustion Engine, Combat/Tactical Service

MIL-PRF-10924 - Grease, Automotive and Artillery

MIL-PRF-21260 - Lubricating Oil, Internal Combustion Engine, Preservative Break-in

MIL-DTL-5624 Turbine Fuel, Aviation, Grade JP-4, JP-5,and JP-5/JP-8 ST

MIL-PRF-46167 - Lubricating Oil, Internal Combustion Engine, Arctic

MIL-A-53009 - Additive, Antifreeze Extender, Liquid Cooling Systems

MIL-DTL-22992- General Specifications for connectors, plugs and receptacles, electrical, waterproof, quick disconnect, heavy duty type

MIL-DTL-53039 - Coating, Aliphatic Polyurethane, Single

Component, Chemical Agent Resistant

MIL-DTL-53072 - Chemical Agent Resistant Coating (CARC) System Application Procedures and Quality Control Inspection

MIL-DTL-64159 - Camouflage Coating, Water Dispersible Aliphatic

Polyurethane, Chemical Agent Resistant

MIL-DTL-83133 - Turbine Fuel, Aviation, Kerosene Type, JP-8 (NATO F-34), NATO F-35, and JP-8+100

(NATO F-37)

MIL-L-85470 - Inhibitor, Icing, Fuel System, High Flash NATO

Code Number S-1745

MIL-L-85762 - Lighting, Aircraft, Interior, Night Vision Imaging

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System (NVIS) Compatible

FEDERAL STANDARDS

FED-STD-595 - Colors Used in Government Procurement

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130 - Identification Marking of U.S. Military Property

MIL STD 209 - Lifting and Tie-down Provisions

MIL STD 461 - Requirements for the Control of Electromagnetic

Interference Characteristics of Subsystems and Equipment

MIL-STD-464 - Electromagnetic Environmental Effects, Requirements for

Systems

MIL-STD-705 - Generator Sets, Engine Driven Methods of Tests and Instructions

MIL-STD-810 - Environmental Engineering Considerations and Laboratory Tests

MIL-STD-882 - System Safety

MIL-STD-889 - Dissimilar Metals

MIL-STD-1472 - Human Engineering

MIL-STD-1474 - Noise Limits

MIL-STD-1791B - Designing for Internal Aerial Delivery in Fixed

Wing Aircraft

MIL-STD-2169 - High-Altitude Electromagnetic Pulse (HEMP) Environment (Secret)

DEPARTMENT OF DEFENSE HANDBOOKS

MIL-HDBK-705 - Generator Sets, Engine Driven Methods of Tests and Instructions

Draft RECAP PD Vr59 15 June2016

MIL-HDBK-831 - Preparation of Test Reports

ALLIED ENGINEERING PUBLICATION

AEP-7 - Chemical, Biological, Radiological and Nuclear

(CBRN) Contamination Survivability Factors in the Design, Testing and Acceptance of Military

(Copies of these documents are available online at https://assist.dla.mil/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094)

2.2.2 Other Government documents, drawings, and publications. The following Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, shall be those cited and in effect on the date the solicitation.

ARMY PUBLISHING DIRECTORATE (APD)

2.2.2.1 Documents

TOP 1-2-609 Instructional Material Adequacy Guide and Evaluation

Standard AR 700-101 - Joint Operating Procedures Management and

Standardization of Mobile Electric Power Generating Sources

AR 750-43 - Army Test, Measurement and Diagnostics

Equipment (TMDE) Program

FM 3-11.4 - Multiservice Tactics, Techniques, and Procedures for Nuclear, Biological and Chemical (NBC) Protection

FM 3-11.5 - CBRN Decontamination – Multiservice Tactics, Techniques and Procedures for Chemical, Biological, Radiological and Nuclear Decontamination

(Copies of these documents are available from http://www.apd.army.mil/)

Draft RECAP PD Vr59 15 June2016

2.2.2.2 Drawings.

0116-1298 - Battery Disconnect Switch

69-776 - Tank, Ether, Cold Start

69-777 - Bracket, Tank, Ether

0116-2900 - Nameplate Identification

88-22842 - Plate, Identification

13229E5666-31 - ID Plate

13230E7022- IUID Plate

95-8165 - Vehicle Receptacle Assembly (Installation Drawing

NATOSTANAG 4074)

(Copies of these drawings required by contractors in connection with specific acquisition functions should be obtained from the contracting activity or as directed by the Contracting Officer.)

2.2.2.3 Catalogs and Manuals.

TM 9-6115-484-14/ TM 9-6115-746-13 will be provided as government furnished equipment in electronic format at time of contract award.

SC 5180-90-CL-N26 Department of the Army, Tool Supply Catalog, Mechanic's

Kit, General Automotive SC 5180-01548-7634 General Mechanic's Automotive Tool Kit

FM 3-4 NBC Protection

(Copies of specifications, standards, handbooks, drawings, publications, and other Government documents required by contractors in connection with specific acquisition functions should be obtained from the contracting activity or as directed by the Contracting Officer.)

2.3 Non Government publications. The following documents form a part of this Purchase Description (PD) to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. Unless otherwise specified, the issues of the documents that are DoD adopted can be found at: https://assist.dla.mil Unless otherwise specified, the documents not found at: https://assist.dla.mil are cited in the solicitation (see 6.2)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

Draft RECAP PD Vr59

ANSI/NCSL Z540.2 - U.S. Guide to the Expression of Uncertainty In

Measurement Test Equipment

ANSI/ISO 10012 - Quality Assurance Requirements for Measuring

ANSI/AGMA - 9005 Industrial Gear Lubrication

ANSI/NCSL Z540.1-3 - Requirements for the Calibration of Measuring and

Test Equipment

(Copies of these documents are available from http://www.ansi.org/)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM D5363 - Anaerobic Single-Component Adhesives (AN) ASTM D975 - Oils, diesel fuels ASTM D1655 - Aviation Turbine fuels

(Copy of this documents are available from http://www.astm.org /)

INSTITUTE OF ELECTRICAL AND ELECTRONIC ENGINEERS (IEEE)

IEEE 315 - Graphic Symbols for Electrical and Electronics Diagrams

IEEE 386 - IEEE Standard for Separable Insulated Connector Systems for Power Distribution Systems above 600 V

IEEE 1299 - IEEE Guide for the Connection of Surge Arresters to Protect Insulated, Shielded Electric Power Cable Systems

IEEE C62.11 - IEEE Standard for Metal-Oxide Surge Arresters for AC Power Circuits (> 1 kV)

(Copies of this document are available from http://www.ieee.org/)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

MG1 Definite Purpose Synchronous Generators for Generating Set Applications

Draft RECAP PD Vr59 15 June2016

MG2-2014 Safety Standard and Guide for Selection, Installation, and Use of Electric Motors and Generators

(Copies of this document are available from http://www.nema.org/)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 National Electrical Code

(Copy of this document is available from http://www.nfpa.org/)

SOCIETY OF AUTOMOBILE ENGINEERS (SAE)

SAE J514 - Hydraulic Tube Fittings

SAE J614 - Engine and Transmission Dipstick Marking

SAE J1362 - (R) Graphical Symbols for Operator Controls and Displays on Off-Road Self-Propelled Work Machines

SAE J2360 - (R) Automotive Gear Lubricants for Commercial

And Military Use SAE J2014 - Pneumatic Tires for Military tactical wheeled vehicles.

SAE J726 - Air Cleaner Test Code

(Copies of these document are available from http://www.sae.org/)

UNDERWRITERS LABORATORIES (UL)

UL 94 - UL Standard for Safety Tests for Flammability of Plastic Materials for Parts in Devices and Appliances

UL 943 Standard for Safety for Ground-Fault Circuit Interrupters (GFCIs

UL 1053 - Ground fault Sensing and Relaying Equipment

UL 60950 - UL Standard for Safety Information Technology

Equipment – Safety – Part 1: General Requirements

(Copies of these document are available at: http://www.ul.com)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

Draft RECAP PD Vr59

ISO - 5011 Inlet Air Cleaning Equipment for Internal Combustion Engines and

Compressors – Performance Testing

ISO- 8528-1thru 5 Reciprocating Internal Combustion Engine Driven Alternating Current Generating Sets

ISO 3046 Reciprocating Internal Combustion Engine Performance

ISO 11158 Lubricants, industrial oils and related products (class L) ISO/IEC 15434 Barcode Specification

ISO/IEC 15418 Information technology - Automatic identification and data capture techniques - GS1 Application Identifiers and ASC MH10 Data Identifiers and maintenance

(Copies of these documents are available at: http://www.iso.org)

2.4 Order of precedence. In the event of a conflict between the text of this document and the references cited herein (except for related associated specifications or specification sheets), the text of this document takes precedence. Nothing in this document, however supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 Description. The MEP-PU-810 C/D Power Prime Unit (PPU) houses medium voltage generation equipment in self-contained, trailered packages. Each PPU contains an integral Primary Distribution Center (PDC) that provides control, instrumentation and primary switchgear for power plant operations. The PPU generates primary power at 4160 volts at 60 Hz and 3800 volts at 50 Hz.

Each PPU contains two independently controlled generator sets that can operate independently or in parallel, in isochronous speed and voltage droop modes. The PPU can operate on the fuels as specified in 3.7.3. The PPU shall be able to operate under all conditions as specified herein without any warnings or alarms. The PPU shall be able to interface and be compatible with existing DPGDS distribution equipment without modification. The unit shall meet the requirements as specified herein and on drawings:

3.1.1 PD Sheets

PD 6115-0132/1 MEP- PU-810 C Generator Set, MEP 800 PPU, 800kW, 50/60Hz

PD 6115-0132/2 MEP- PU-810 D Generator Set, MEP 800 PPU, 800kW, 50/60Hz

3.2 Drawings. Required interface drawings as specified herein, are end product drawings.

No deviation from the prescribed drawing requirements is permissible without prior approval of the contracting officer. Where tolerances could cumulatively result in incorrect fits, the contractor

Draft RECAP PD Vr59 15 June2016 shall provide tolerances within those prescribed on the drawings to ensure correct fit, assembly, and operation of the set. Any data (e.g. shop drawings, layouts, flow sheets, processing procedures, etc.) prepared by the contractor or obtained from a vendor to support fabrication and manufacture of the production item shall be made available, upon request, for inspection by the contracting officer or the designated representative.

3.2.1 Size and weight. The PPU size shall not exceed the requirements as outlined in PD sheets (see 3.1.1). The wet operational weights (see 6.4.29) of the recapitalized PPUs shall not exceed the weight of the existing PPUs by more than 10%. (O). If the unit weight is increased, analysis must be performed on the axle and wheel assemblies of both units to ensure design integrity (PD 6115-0132/1, PD 6115-0132/2)

3.2.2 Reliability. The minimum acceptable mean time between essential function failure (MTBEFF) (see 6.4.16) for all sets shall be 750 hours with an 80% lower confidence limit, when demonstrated IAW paragraph 4.7.24 and 4.7.25.

3.3 First Article. The contractor shall furnish three recapitalized First Articles of each model for inspection/test as specified herein for determination of conformance to this PD. The government will provide 3 of each PPU model type (A and B) as GFE to the contractor for the recapitalization effort.

3.4 Materials. Power Units shall be fabricated from compatible metals and materials that are inherently corrosion resistant or are treated to prevent the various forms of corrosion and deterioration that may be encountered in the storage and operating environments specified herein.

Dissimilar metals shall not be used in intimate contact with each other unless protected against galvanic corrosion. Dissimilar metals and methods of protection are referenced and detailed in MIL-STD-889. Use of polyvinyl chloride (PVC) is prohibited. Materials selected shall be free from perceptible odors and noxious fumes; fire retardant conforming to UL-94; and unaffected by battery electrolyte or petroleum (fuels, lubricants and coolants) products specified herein. All rubber compositions shall be resistant to ozone deterioration and shall be formulated with an anti-ozonant system. The use of ozone depleting chemicals (ODCs) or materials that produce ODCs during manufacture is prohibited. Materials used shall comply with the Pollution Prevention Act of 1990 (42 U.S.C. 13101- 13109) (PPA) and various executive orders…e.g. elimination of Cadmium.

3.5 Design. (See 3.1).

3.5.1 Engine. The engine(s), including all sub systems and components, shall comply with applicable Environmental Protection Agency (EPA) minimum Tier II Non Road emissions regulations and meet the requirements as specified herein. The engines shall be Prime rated for continuous operation. Engine shall be supportable by the manufacturer for a minimum of ten years.

3.5.1.2 Oil temperature. Oil temperature in the oil sump shall stabilize as specified by the engine manufacturer under all operating conditions specified herein.

Draft RECAP PD Vr59 15 June2016

3.5.1.3 Timing marks. When timing marks are utilized to perform proper servicing, adjustment, or replacement of engine components, the timing marks shall be clearly visible without removal of any set component or set structural member.

3.5.1.4 Lubricating system. The set shall meet all requirements specified herein using lubricants specified in paragraph 3.7.4. The lubricating system shall be provided with seals, gaskets, and bearing clearances to permit use of arctic lubricating oil conforming to MIL-PRF- 46167 and MIL-PRF-2104. The lubricating system shall be compatible with MIL-PRF-21260 preservative oil.

a. The lubricating system shall allow the soldier to safely check and add oil while the set is operating, or in the “OFF” condition.

b. An oil-drain assembly shall allow complete drainage of the crankcase/oil-sump outside of the housing into a suitable container. The system shall contain a ¼ turn ball type valve to control oil flow. The system shall exit the set through a ¾ NPT couple with a removable ¾ internal square pipe plug IAW A-A-59616.

All piping, valves, fittings and tubing of the lubricating system shall have the ability to disconnect and be easily accessible for maintenance.

c. The oil filler opening shall permit oil filling from a standard 8 quart capacity can with spout and flow control valve, NSN 7420-00-255-5996.

d. The oil-level bayonet gage shall be readily accessible, double-marked to accurately indicate full and 1 quart low oil-level, with the set while off or operating in any position from level to a 15 degree incline. The bayonet gage shall be marked IAW SAE J614.

e. A captive filler cap shall be provided except in the case where the cap and dipstick are integral.

f. A full-flow oil filtration system shall be provided. The oil filter shall be of the spin-on, disposable, type.

g. The lubricating systems for the generator sets shall permit sampling of lubricant while the set is running. A valve shall interface with the engine oil pan or oil gallery and be spring-loaded to a self-close position when the valve actuation handle is released. The valve arrangement shall interface with an oil sampling bottle NSN 8125-01-193-3440. Sampling of lubricant shall not activate the low oil pressure shutdown at any possible lubricant sampling rate.

h. Marking shall be provided at the fill port and oil drain IAW paragraph 5.9.5 of

MIL-STD-1472. The oil drain pipe shut-off valve shall be provided with an arrow showing direction of operation of flow.

Draft RECAP PD Vr59 15 June2016

i. The crankcase ventilation system shall be closed. Oil condensate shall flow back into the crankcase.

3.5.1.5 Manual turning. Provision shall be made to permit manual turning of the engine crankshaft for inspection and maintenance actions as required for the engine and/or generator.

Reference to the crank angle can be made with the set fully assembled. Manual turning by barring on the flywheel ring gear, the generator coupling, or the generator fan is not permitted.

3.5.1.6 Wet stacking. The generator set shall inherently minimize the effects of continuous light load operation when measured and analyzed as specified in paragraph 4.7.36. The set shall not wet stack or incur failure during sustained light load operations (100 hours at 25% rated load).

3.5.1.7 Engine maximum power. The minimum acceptable engine maximum power shall be the power necessary to produce at least 110 percent of rated load as defined in 13.3.2 of ISO 8528-1 and ISO 3046 under all operating conditions as specified herein.

3.5.1.8 Automatic belt tensioning. All drive belts shall incorporate automatic belt tensioners.

3.5.1.9 Air filtration. The air cleaner shall be of the dry type with disposable barrier-filter elements IAW ISO 5011. The air filter shall be serviceable and not require replacement for 500 hours (T).

3.5.1.10 Fuel consumption. Fuel consumption using JP-8 shall be no greater than 30 gals per hour per engine at rated load (60 gph, 100% load two engines) using JP-8/F-24 fuel, with an objective of 27 gals per hour.

3.5.2 Exhaust system. The engine exhaust and cooling air if modified from current design shall exit the set separately. Engine exhaust after discharge shall not re-enter the set. Both the engine exhaust and cooling air shall exit from the top of the set, in an upward direction. A means to prevent rain from entering the engine exhaust and cooling air outlets, or a means to drain rain from the engine exhaust and cooling air systems without accumulation or without damage to set components shall be provided. If a rain cap is used, it shall be captive.

3.5.3 Cooling system. The cooling system for each PPU set consists of two separate cooling systems, which contains two Radiator/ Air-To-Air-After-Cooler (ATAAC) assemblies in an "A" frame configuration. Each radiator is connected respectively to each 3456 EPG Engine. One coolant circuit cools the engine block. The other circuit cools the pressurized filtered intake air after by use of an ATAAC. The air is carried in the 4.00-inch diameter pipes that pass through the top of the interior trailer wall. The engine block is cooled with a water and anti-freeze mixture from a coolant to air heat exchanger. The coolant is carried in a combination of 2.50 and 3.00-inch pipes that pass through the center of the interior trailer wall. While it is not the government’s intention to change the cooling system, offerors may replace and or modify the cooling system and ATAAC as necessary for their proposed solution to meet the specifications outlined in this PD.

The cooling and ATAAC system shall be sized to allow the generator set (s) to operate in all operational environments specified herein. If the existing system is modified from current

Draft RECAP PD Vr59 15 June2016 configuration, provisions to drain the coolant outside of the PPU into a suitable container shall be provided. The radiator cap shall be captive and not interfere with the radiator fan. The radiator fill port shall be accessible through the set roof. A coolant site gauge shall be used to monitor the amount of coolant in the system and shall be visible from ground level. Hydraulic fittings shall comply with SAE J514. If the cooling and ATAAC assembly is maintained it shall be flushed and serviced to include corrosion control.

3.5.3.1 Hydraulic System. Offerors may replace and or modify the hydraulic system as necessary for their proposed solution to meet the specifications outlined in this document.

Hydraulic pump(s), if provided, shall be driven by a drive pad on the diesel engine.

3.5.3.1.1 Hydraulic Motors. If hydraulic motors are provided for powering the fans within the PPU, the motors shall contain pressure ports for maintenance purposes for the hydraulic-driven fans for each engine. Currently there are three hydraulic fan motors per engine. (vent, radiator and charge air).

3.5.4 Cranking system. The cranking system shall be 24 volts direct current (DC), negative ground. The set shall not be damaged (see 6.4.2) in the event that the polarity of the battery cables is reversed. It shall not be possible to crank the set with the battery polarity reversed.

3.5.4.1 Batteries. The batteries shall be replaced. The battery shall be relocated from their current location to a location internal to the PPU housing. The batteries selected shall be of a standard commercial size, maintenance free Valve-Regulated Lead-Acid (VRLA) type and located side by side. The batteries used shall be on the TACOM preferred list (battery.army.mil / Preferred Power Sources List). The batteries shall have sufficient reserve to permit the set to start under all conditions between -32C (-25F) to 52C (125F) ambient temperatures. No battery shall be selected that requires a battery-specific charger. Terminal post location shall be on top of the battery.

3.5.4.2 Battery tray and retainer. A battery tray and retainer shall be provided to retain the batteries within the set during all operation, transportation and handling modes. Retention of the batteries shall permit easy removal/installation of the batteries. If a bar is used as the retainer, it shall be insulated to prevent accidental shorting across the battery terminals. In addition, batteries shall be protected from external environmental conditions. The battery tray and retainer shall be resistant to battery electrolyte. A means shall be provided to allow drainage of spilled electrolyte out of the set without contact with any set component except the battery tray and retainer. Battery access for maintenance, removal and test, shall be IAW paragraph 5.9.9.4 and Figure 39 of MIL-

STD-1472.

3.5.4.3 Battery cable. Battery terminal connectors shall be provided on one end of each cable and both ends of battery interconnecting cable, if used. A red non-conductive protective cover shall be provided on the positive battery terminal and for the terminals used with the interconnecting cable, if used. Battery cables shall be marked to indicate polarity.

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3.5.4.4 Cranking (starting) motor. A means shall be provided to prevent starting of the motor and engagement of the drive mechanism during running of the set or when coming up to rated speed after the cranking motor disengages.

a. If a single terminal cranking motor is used, the negative terminal of the set batteries shall be directly connected to the cranking motor case (housing) by a removable wire of sufficient size to carry the cranking current.

b. If a two terminal (isolated case) cranking motor is used, the negative terminal of the cranking motor shall be directly connected to the negative terminal of the battery by a removable wire of sufficient size to carry the cranking current.

c. If the engine assembly is electrically isolated from the skid base by resilient mounts, a ground strap(s) shall be provided to electrically bond the engine assembly to the skid base. The ground strap shall be a braided strap of sufficient size to carry the cranking current.

3.5.4.5 Battery Disconnect Switch. A switch shall be provided for each set of batteries that will remove the negative terminal of the batteries from the return path of the circuit. The switch shall be marked “OFF” and “ON” to indicate the state of the batteries. This switch ensures that no residual currents drain the batteries when the generator set is off. An example of this type of switch can be found from drawing # 30554-0116-1298 (Appendix D).

3.5.5 Battery charging system. A new battery charging system shall be provided. The new charging system shall have temperature compensating characteristics compatible with Absorbed Glass Mat (AGM), Gel Cell and maintenance free batteries specified herein. The battery charging system shall not be damaged by continuous application of a short or open circuit to its output. The battery charging system shall be capable of maintaining the batteries in a state of full charge after four hours of operation, once the starting cycle in paragraph 3.7.1.1 is complete, in addition to providing the required control power (see 3.5.12.1.2). The battery charging system shall be capable of charging dead batteries without activating any protective device, or damage to the battery. Battery chargers shall be able to connect to shore power (120/230 VAC, 50/60 hertz) when PPU’s are in storage mode.

3.5.6 Grounding. All AC electrical components of the set shall be isolated from ground, except as otherwise specified herein. The equipment ground terminal (GND) shall be connected by an accessible, removable connection to the neutral output terminal "N" (see 3.5.23.1). Neutral connection of "WYE" connected current transformer secondary may be connected to circuits leading to the output terminal "N". Direct current components utilizing chassis or case grounding shall not be used except for cold starting aids, cranking motor, control panel indicators for the engine, and electric fuel pumps.

3.5.7 Starting aids. The starting aid system shall not be required for set starting at temperatures at or above -6C (20F). The engine may be equipped with starting aids to meet starting and operating requirements as specified herein. All starting aids shall automatically activate at the

Draft RECAP PD Vr59 15 June2016 appropriate temperatures as specified herein, with the activation of the start cycle. The starting aid system shall include a means to self-check operation and indicate system malfunction.

3.5.7.1. Standard starting aids (ether or glow plugs). For temperatures between -6ºC (20ºF) and -32ºC (-25ºF) standard starting aids shall be used. If ether is selected, the starting aid system shall be automated to inject a measured shot of ether based on ambient temperature and cranking conditions. The systems shall be compatible with the ether tank and solenoid depicted on drawings 30554-69-776, 30554-69-778 and ether bottle bracket depicted on drawing 30554-69-777 (Appendix D) . They shall be permanently installed in each set in a location that permits installation and removal of the ether tank/bottle without the use of tools. The measured shot of ether shall be as recommended by the engine manufacturer. An electrical interlock shall be provided such that the ether starting aid will be inoperative unless its switch is automatically activated concurrently with cranking of the engine. The ether tank/bottle shall not be a component of the set and shall be furnished only on Test Articles (see 3.2). Production sets shall be furnished without ether tanks/bottles for shipping.

3.5.7.2. Winterization kit. For temperatures below -25ºF (-32ºC), a winterization kit located internal to the set, shall be provided. The kit shall be easily installed or removed without removing major components to the set. The kit wiring shall be included in the generator set wiring harnesses. The kits shall not require external sources of fuel or electricity. The kits shall be provided with all Test Articles. When required (see 6.2), production sets shall be furnished with winterization kits. The winterization kit shall provide an indication of “ready to crank” when the winterization kit has completed its cycle. Automatic troubleshooting shall be incorporated into the winterization kits or digital control system. No special tools for maintenance of the winterization kits shall be allowed.

3.5.8 Governing system. The governing system shall provide the frequency performance as specified herein. The frequency characteristics shall meet the quality standard of ISO 8528-5.

Loss of input signal to the governing system shall cause the engine to shut down.

3.5.8.1 Frequency regulation. The governor shall have an adjustable speed droop from 0 to 5 percent of rated frequency. The frequency regulation of zero droop (isochronous mode) shall not exceed ± 0.25 percent (steady state) of frequency setting from no load to full load. The governing system shall also automatically monitor and regulate the output frequency within the limits specified herein.

3.5.8.2 Short-term frequency stability (30 sec). At every constant load from no load to rated load, the speed governing system shall maintain frequency within a bandwidth equal to 0.5 percent of rated frequency. The governing system shall not permit repetitive periodic frequency variation, commonly called hunting, even if within the allowable 0.5 percent band.

3.5.8.3 Frequency drift. With the PPU operating at constant load and voltage, a change in the ambient temperature of 60° F in a 4-hour period shall not cause the frequency to change by more than 1 percent.

Draft RECAP PD Vr59 15 June2016

3.5.8.4 Frequency transient performance. With a sudden 50 percent change in load between no load and rated load, the speed governing system shall re-establish stable engine operating conditions within 4 seconds. The maximum transient frequency change above the new steady state frequency (overshoot) shall be not more than 4 percent of rated frequency. The maximum transient frequency change below the new steady state frequency (undershoot) shall be not more than 4 percent of rated frequency. In addition, the circuit breaker shall not trip when the load is suddenly increased and decreased from no load to rated full load and from rated full load to no load in one step.

3.5.9 Generator and voltage control system. The generator and voltage control system, i.e.

generator, exciter, voltage regulator, power conditioners, and/or other accessories necessary to control the output voltage, shall meet the requirements as specified herein. The voltage characteristics shall meet the quality standard of ISO 8528-5. The failure of any individual module shall not induce failure into any other module(s), e.g. voltage regulator failure inducing a generator excitation failure.

3.5.9.1 Generator. All generators shall use the EnduraSeal insulation vacuum impregnation process (VPI). The generators shall be of the drip-proof, guarded machine type specified, designed, constructed, and installed in accordance with NEMA MG-1 and MG-2, and shall be adequate to meet all performance requirements specified herein. No damage (see 6.4.2) shall result from running the set at the minimum speed attainable by the frequency adjust device (see 3.5.18.2) setting for a period of one hour with the excitation system energized and the generator set temperature stabilized in an ambient of 52C (125F). Phase sequence shall be A-B-C and L1 to L2 to L3. The generator shall be in electrical and mechanical balance at all speeds up to 125 percent rated speed, and shall be capable of operation at 125 percent rated speed for fifteen (15) minutes without damage. The generator shall withstand operation at 125 percent rated load. Rotating rectifiers shall be replaceable without removal of the generator from the overall set housing, and without removal of the generator housing (stator). If current SR4B generators are used they shall be removed and refurbished.

3.5.9.1.1 Generator bearings. Generator bearings shall be replaced as part of the refurbishment. The bearings shall be sealed and permanently lubricated. The oil or grease for the generator shall not congeal or degrade at any operational temperatures as specified herein.

3.5.9.1.2 Generator system leads. The generator system (see 3.5.9) leads shall be brought out of the generator frame through non-abrasive bushings or grommets and then through non-abrasive clamps, block or holders that isolate each lead and hold each lead securely in place. Leads shall be identified with a permanent marking. Marking shall be such that wires can be easily identified to ensure the proper terminations can be made. These requirements shall be applicable to any power conditioner.

3.5.9.1.3 Generator strip heaters. The generator strip heaters shall be supplied on each generator. Strip heaters shall be powered by an adjustable switch/thermostat relay which is

Draft RECAP PD Vr59 15 June2016 connected to the breaker panel located inside the PPU. The heaters shall be energized when the system is not in operation and shore power (120/230 VAC) is available. The heaters shall have the ability to connect to shore power when the PPU is in storage mode.

3.5.9.1.4 Coils, windings, and insulation. The insulation of all coils and windings shall be class H as classified in NEMA Standard No. MG1-1.66 with temperature limits as specified herein (see 3.5.9.1.5.). The EnduraSeal vacuum pressure impregnation process shall be used.

3.5.9.1.5 Temperature rise. Allowable temperature rise of coils, windings and mechanical parts, when the generator and auxiliary items are installed in the set shall not exceed the following:

Class H

Insulated component

Coils, Windings, and connections (Measured in rise in resistance method)

125C (257F)

Generator bearings 50C (90F)

Poles, cores, and other mechanical parts in contact with insulation

Same as for the insulation in which the parts are in contact

3.5.9.1.6 Dielectric strength. Generator windings shall meet the applicable IEEE and NEMA MG1 guidelines.

3.5.9.1.7 Phase balance (voltage). The maximum difference in the 3 line-to-neutral voltages shall not be more than 1% of rated line-to-neutral voltage.

3.5.9.1.8 Identification, marking and information. The generator housing shall be marked IAW paragraph 3.19.2.

3.5.9.2 Voltage transient performance.

a. With the PPU initially operating at rated frequency and rated voltage, and following any sudden change in load from no load to half load, the instantaneous voltage shall not drop to less than 80 percent of rated voltage and shall reach stable conditions within 3 seconds. No overshoot or undershoot of the final voltage may exceed the initial voltage transient in amplitude.

b. The above requirements shall also apply when load is suddenly changed from half load to no load, except that the initial voltage transient shall involve a voltage rise not to exceed 130 percent of rated voltage.

c. With the PPU initially operating at no load, rated voltage, and rated frequency, the instantaneous voltage shall not drop to less than 60 percent of the no load rated voltage

Draft RECAP PD Vr59 15 June2016 when a balanced 3-phase, 0.4 power factor or less, lagging static load having an impedance of 0.5 per unit is applied to the output terminals of the PPU. The generator shall recover to not less than 95 percent of rated voltage within 5 seconds and shall stabilize at or above this voltage.

3.5.9.3 Voltage waveform.

3.5.9.3.1 Deviation factor. The deviation factor for the line-to-line and line-to-neutral voltage waveform for each voltage test point shall be less than 5 percent.

3.5.9.3.2 Harmonic content. From no load to full load, the Root Mean Square (RMS) value of the sum of all the harmonic components in the output voltage waveform line-to-line, and also line-to-neutral, shall not exceed 5 percent of the RMS value of the rated voltage. The RMS value of any single component shall not exceed 3 percent of the RMS value of the rated output voltage under the above condition. In addition, there shall be no spikes or notches in the waveform

3.5.9.4 Short circuit. The generator and voltage excitation system, operating as a unit, shall withstand two consecutive single-phase line-to-line, or line-to-neutral, and symmetrical 3-phase short-circuits at 5-minute intervals at the set output load terminals when operating at rated load (see 6.4.22) and frequency without reduction in dielectric strength to a point where it does not meet the requirements in paragraph 3.5.9.1.5. The sustained short circuit current shall not be less than 300 percent of rated output current. 3-phase short circuits shall be held for a minimum of for 10 seconds and single-phase short circuits shall be for 5 seconds.

3.5.9.5 Flexural vibrations and critical speeds. The sets shall be free from dangerous flexural vibration (see 6.4.3) and dangerous torsional critical speeds (see 6.4.4) between the minimum low idle speed and 115 percent of rated speed.

3.5.10 Overspeed. The generator set shall operate at 125 percent of rated speed for 15 minutes without damage (see 6.4.2). Rated speed of the sets shall be that required for the sets to produce rated frequency at rated load. Should the proposed design be mechanically incapable of obtaining the 125 percent overspeed condition, then the test shall be conducted at the maximum engine speed obtainable.

3.5.11 Low Power Factor. The generator set shall operate at a power factor of 0.4 lagging and experience no failures or damages.

3.5.12 Controls , instrumentation, and other functions. All the instruments, controls and devices necessary to start, operate, and monitor the PPU and each generator set under all operating conditions shall be contained within the Primary Distribution Center (PDC). Instruments, controls and devices shall not be damaged by any operational or storage conditions as specified herein. All wires shall enter the PDC through multi-pin re-connectable connectors (“Cannon” type preferred).

The PDC shall contain all control panels required to operate the PPU. A weather proof Access cover(s) shall be provided to protect the control panel during operation and storage, and shall be self-supporting in the open position. The control panels shall be hinge-mounted to provide access

Draft RECAP PD Vr59 15 June2016 to protective devices, and swing out of the PDC to not less than 90 degrees. All instruments, controls, and panel lights shall be on the control panels, except as specified herein (see 3.5.12).

All indicating instruments shall be readable in bright sunlight. All instruments and controls shall be permanently labeled IAW paragraph 5.5 of MIL-STD-1472.

3.5.12.1 Primary Distribution Center (PDC). The PDC is a sub-assembly of the PPU which provides an operator station for local control of the PPU and each generator set. The PDC contains the set output contactors, fuses, bus bars, output terminals and communications portals. The PDC also houses the PPU control system and individual generator set control systems. The PDC is removable for maintenance operations which require access to 4160V components located in the rear of the unit. The PDC shall contain internal strip heaters connected to an adjustable temperature thermostat which shall be easily accessible inside the PDC. The thermostat shall have an adjustable temperature range from 0 to 100 degrees. The strip heaters are required to control condensation/moisture during extreme temperature operations. The heaters shall be capable of being powered by both shore power (120/230 VAC) and generator power when system is operational.

3.5.12.1.1 Digital Control System (DCS). The independent Electronic Modular Control Panel

II (EMCPII) systems for each generator set and the common Programmable Logic Controller (PLC) shall be upgraded in each PPU to the current state of the art technologies in order to meet the performance requirements specified within. The new DCS’s for each generator shall consist of an electronic governing system, voltage regulation, and electrical output protective circuits to control each generator set independently. The DCS shall utilize solid-state electronics with self-diagnostics to provide complete automatic control and to monitor each generator set’s performance including, but not limited to, the engine, generator, output power and protective system. The new PLC’s shall have the capability to communicate and permit up to no less than sixteen (16) PPUs (32 generator sets) to operate in parallel. All PPUs shall share real (kW) and reactive (kVAR) loads. Control circuitry shall incorporate reverse power protections and permissive parallel devices while a generator set is paralleling into the electrical system. The DCS for each generator shall control the generator output contactor during auto, manual, utility operational modes to prevent any damage to the generators.

3.5.12.1.2 DC control power. A circuit breaker shall be connected in the DC supply to protect all control circuits. All DC control devices shall be suitable for operation at 16 to 32 volts under all conditions. DC voltage transients resulting from operation of the AC circuit interrupter or any other set mounted device shall not exceed 150 volts measured across any DC component. Total operating DC current for the control shall not exceed 5 amps when the set is operating. All other (non-control) components shall be designed such that a circuit breaker will protect the individual components from damage.

3.5.12.1.3 Master switch. A four-position switch or functionally equivalent device shall be provided to be used for each generator set start-up and shut down operations. The switch shall be protected against failure from sand and dust penetration and contain self-cleaning contacts. Any

Draft RECAP PD Vr59 15 June2016 device(s) used shall perform the following functions in the following sequence to control the generator set as follows:

a. Position one. Position one shall be marked “OFF” to stop the set. When the switch is in the “OFF” position, all generator set circuits which are energized from the battery shall be de-energized except the auxiliary fuel pump. The panel lights and the malfunction indicator lamps shall be controlled by a separate mechanical switch and shall be designed to automatically “shut-off” after 10 minutes.

b. Position two. Position two shall be marked “AUTO”. In this position, all circuits required for normal operation and starting under normal and extreme conditions in the auto mode shall be energized. The unit shall be capable of starting and stopping remotely in the auto mode.

c. Position three. Position three shall be marked “MANUAL”. In this position, all circuits required for normal operation and starting under extreme conditions shall be energized. When the switch is in this position the generator set shall electrically crank, come up to rated speed and voltage, and reach a ready-to-load state automatically without any additional actions on the part of the operator except frequency and voltage control adjustments

d. Position four. Position four shall be marked “COOL DOWN”. When the switch is actuated to position four, the system will sense the unit is in cool down mode and open the generator breaker associated with that engine if it’s closed.

The unit will run for 5 min. for engine temperatures to stabilize and then will automatically shut down the unit.

3.5.12.1.4 AC circuit contactor switch. A control switch shall be provided for each vacuum contactor to permit opening and closing of the AC output circuit interrupter (see 3.5.22). LEDs on the control panel shall illuminate to indicate the current position of the output circuit contactor. A green LED will be used to indicate open and a red LED will be used to indicate closed.

3.5.12.1.5 Remote Terminal Unit/Programmable Logic Controller (PLC) Functions. The control system shall permit up to no less than sixteen PPUs to operate in parallel in the auto, manual and utility mode. The PLC shall automatically start and stop generator sets connected to the bus depending on the load requirements. All PPUs shall share real (kW) and reactive (kVAR) loads in accordance with 3.7.2. Control circuitry shall be designed to prevent a reverse power situation while a PPU is paralleling into the electrical system. In a power plant configuration when multiple PPUs are paralleled, they shall be capable of being remotely monitored (see 3.5.12.1.7) and controlled by a separate computer logic device such as a PC (through a standard communications Ethernet connection) . The remote control device shall replicate the functions of the on-board control panel.

Draft RECAP PD Vr59 15 June2016

3.5.12.1.6 Economizing mode. The PPUs shall contain an economizing mode feature that provides automatic load management function when the operating PPUs are in the automatic mode. The Programmable Logic Controller (PLC) within the PPU will monitor the load on the common bus, start the generator set and place generator sets on-line and remove generator sets off-line depending on load demand. The load management threshold shall be adjustable and be based on both (kW/kVA) of the rated capacity of each of the on-line generator sets. The system will always maintain one generator set on-line. When the PPUs operate in the automatic mode, the default setting for economizing is on. The economizing feature shall be capable of being disabled at the DCS or remotely when connected to a PC/computer. When economizing is disabled, the PLC will not take generator sets off-line if the per unit load falls below the threshold. However, the PLC will place an additional generator set on-line if the threshold is exceeded even when economizing is disabled. Generators will be placed on line based on lowest engine hours and removed based on highest hours.

3.5.12.1.7 Remote functions. A remote control capability shall be provided to control the PPU from a remote location a maximum of 250ft away. The necessary interfaces shall be provided where control of starting and stopping, AC circuit interrupter, Emergency Stop and Battleshort functions, along with set operational monitoring as specified herein, shall be accomplished from a remote site.