W9127819R0074_SOW_26Jun19.pdf

STATEMENT OF WORK

This Statement of Work describes the specifications for the procurement and installation of three (3) phase 480V, 800A double throw disconnect switch and switchgear trip elements for the J Strom Thurmond Lake Office station service feed and installation of a government furnished 3 phase 480V, 500KVA Emergency Diesel Generator.

LIST OF GOVERNMENT FURNISHED EQUPMENT

1. Switchgear Breaker (without trip element) Eaton Magnum DS, DS6083WEA-3HP6 Estimated $40,000

2. Diesel Generator Cummins DFEH-8578821, 3 phase 480V, 500KVA Estimated $100,000

3. Cable

XHHW-2, 600V, 750 KCMIL

Estimated $4,000

4. PLC

Eaton 8103, ELC2-PV28NNDR Estimated $30,000

1.0 GENERAL

J Strom Thurmond, US Army Corps of Engineers, is a hydroelectric power plant that operates with seven (7) 54 MW generators on the Savannah River in Clarks Hill, SC. The project has recently undergone a 480 V Motor Control Center and Station Service Switchgear upgrade to Eaton branded equipment. The project provides the station service feed to the Project Manager’s Office. There is one feed from the Station Service Switchgear Bus 2 to provide power to the Project Manager’s Office and it is necessary to install another feed from Station Service Switchgear Bus 1. The project has a 480 V emergency diesel generator on site that has never been operated, installed, or commissioned. It is necessary to install the diesel generator and terminate to the pre-designated breaker in Station Service Switchgear 2.

2.0 SCOPE

2.1 480 V PMO Feeder Installation

The station service setup at Thurmond is an Eaton Magnum DS three phase 480V double bus setup. The two busses are tied together via a tie breaker. The existing setup for the Project Manager’s Office (PMO) station feed is a single feed from Bus 2. See drawings in Appendix A of current switchgear setup. This request for proposal is for the installation of a new feeder from Station Service bus 1 to feed the PMO office transformer. The 65 FT of 750 KCMIL necessary to complete this task will be provided by the government. A three phase, three position disconnect switch will need to be purchased and installed by the contractor. The new three position disconnect and enclosure must meet the specifications of section 3.0 Materials. The disconnect switch will have a Bus 1 Feed, Bus 2 Feed, and an off position. A new 400 A digitrip element will need to be purchased for the switchgear 2. The trip element will need to meet the specifications listed under section 3.0 Materials. The three position disconnect switch will be installed in the switchgear gallery as shown in the drawings in Appendix A. The existing feed to the PMO will be removed from Station Service bus 2 and relocated to the new disconnect switch. The contractor will install new Government furnished feeder cables from Station Service Switchgear 1 and 2 to the new disconnect switch.

The contractor is required to comply with EM385-1-1 and the onsite Hazard Energy Control Program (HECP) to include a 90 minute onsite training session with quiz. All HECP requirements will be followed when working with electrical clearances. USACE personnel will be responsible for de-energizing the equipment, and the contractor will observe a zero voltage state when working on the equipment. The contractor is required to give at least a week notice for when the equipment will need to be de-energized and work will begin. The contractor will be responsible for installing the new 400 A digitrip in place of the existing 200 A trip in breaker 2b of Bus 1 in the Eaton Magnum DS station service switchgear. The contractor will terminate the new cable in the breaker 2b. The contractor will be responsible for running new cable in new RMC conduit that will feed into the existing cable tray. The contractor will pull the cable through the existing conduit and new conduit the contractor sets up to the new disconnect switch on the upstream wall in the switchgear gallery. The contractor will be responsible for installing the new disconnect and terminating the new feeder cable.

2.2 480 V Diesel Generator Installation

The Cummins DFEH-8578821 diesel generator is furnished by the government. The diesel generator will be moved by the contractor to its location on the transformer deck. See moving plans submittal in the submittal section. The dimensions of the deck are listed in the drawings of appendix A. The generator is 16,040 lbs dry and will be located on the unloading deck. The power plant staff can assist in lifting the generator on a loading platform on the unloading deck with the power house crane. The project does not have a means to lift or move the generator to the transformer deck location and it will be the contractors responsibility to move it to the new location. The required 350 Kcmil cable will be furnished by the government. The 350 Kcmil cable will be run by the contractor in parallel to achieve the required 600 A rating. It will be necessary to make vertical core drills through 18-24 inches of concrete from the Transformer deck directly below to the Station Service Switchgear. GPR results must be done on both sides of the surface and be approved by USACE before penetrations begin. The contractor must provide weather sealing on the penetrations on the transformer deck to prevent leakage. Plant raw water and conduit as-built drawings must be reviewed before final drills begin. The contractor will provide the necessary diesel fuel for commissioning and leave a full tank before when the contract is completed. The contractor must commission the generator and have a certified Cummins diesel technician on site during commissioning. The guidelines listed in the diesel generator installation guide must be followed. The contractor will be responsible for mounting the diesel to the deck and placing vibration isolators per the manual. The contractor will make a penetration large enough for 4 inch conduit and two ¾ inch conduit through the deck. The contractor will run the parallel 350 Kcmil conductors from the output of the diesel generator to the switchgear bellow. The contractor will be responsible for running conduit and terminating on the predesignated 600 A breaker in the switchgear bus 2 position 5C. The contractor will run the remote start for the diesel generator to the remote start output of the station service switchgear. The remote start control wiring will be run in its own ¾” conduit.

The contractor will also run the power for the heaters and battery charger through a ¾” conduit.

2.3 Option 1: Program Eaton Switchgear PLC

This option lays out the plans for the contractor to design a program for the existing Eaton PLC in the 480V Station Service Switchgear. The program will be designed by the contractor to act like a transfer switch. When 480 V station feed goes down for more than 10 seconds, the program will shed all loads and start the diesel generator. When the diesel generator is up to rated voltage the program will sequentially close in essential loads. After power is restored the program will shut off the diesel generator and close back in the plant loads.

3.0 Material Specifications

3.1 480 V Three Position Disconnect Switch

Three Phase non-fusible rated 800A or above. Must be a three pole double throw safety switch. It must have lugs big enough to support 750 KCMIL connections. Must be a NEMA 1 rated or above enclosure.

a. Conduit Fill percentages shall not exceed those specified in the NEC. Conduit to be installed under this contract shall be run exposed for connecting circuits between items of equipment. Conduit, fittings, and accessories shall be installed in accordance with details shown on the drawings and as specified herein.

All conduit bends shall have a radius of not less than 10 times the inside diameter of the conduit.

b. All conduit shall be galvanized rigid.

c. No threadless fittings or running-thread couplings shall be used on conduit

d. Metal conduits shall be cut only with a tool approved for the purpose. Roller-type pipe cutters shall not be used on conduits. All cuts shall be square and the conduit opening shall not be constricted. After cutting and threading, conduit ends shall be reamed to remove rough edges and burrs, and the entire conduit shall be thoroughly cleaned to remove all cuttings, dirt, and oil from its interior. Threads shall be clean cut. Threaded joints in metal conduit and terminations in cast boxes shall have the threads coated with an approved joint compound, and shall be screwed tight to make the joint watertight and to provide electrical continuity of a given conduit system. Suitable watertight conduit hubs and bushings shall be provided where conduit terminates within a box, terminal cabinet, or accessory that has no threaded hub or fitting to receive threaded conduit.

e. All conduit shall be installed in a manner to ensure against trouble from the collection of trapped condensation, and all runs shall be arranged to avoid traps wherever possible.

f. Pull boxes shall be furnished and installed, complete with covers, in conduit runs as required by NFPA 70 and good practice in the trade, regardless of whether the boxes are specified on the drawings

g. Conduit shall be installed with a minimum of bending and cutting. Conduits not dimensioned as to location shall be installed approximately where shown on the drawings with limited adjustment to avoid interference with other work. Conduit shall be rigidly attached with approved supports and anchors to the surface over which it is run. The maximum spacing of supports for the exposed conduit shall be 8 feet. Supports for exposed conduit on concrete surfaces shall be fastened securely to the concrete with approved anchors. Wooden, fibrous, or similar plugs inserted into the concrete will not be accepted.

h. The entire metallic conduit system installed in the powerhouse by the contractor shall be electrically continuous and thoroughly grounded. No welding or brazing of the grounding conductor to the conduit will be allowed. All grounding connections to the conduit shall be made by means of grounding bushings or by an approved pressure type connector.

3.2 Ground-Penetration Radar (GPR)

Ground-penetrating radar test must be performed prior to all core drilling. GPR test must be done on both sides of concrete. GPR results must show rebar on picture results. Energized equipment must be distinguished from rebar on picture results of GPR. The contractor is responsible for showing were the GPR testing was done with pictures and showing where the proposed penetration will be.

3.3 Diesel Commissioning

All guidelines shown in the “Installation Manual” A040Z642 (Issue 4) by Cummins Power Generation must be followed.

Load testing will be performed with plant loads and must be scheduled a week in advance when no scheduled generation is planned on the loads being tested.

3.4 Digitrip Switchgear Element

Must be compatible with the existing Eaton Magnum DS switchgear with a plug and play design.

4.0 General Contractor on Site Requirements

(a) The Contractor shall be responsible for furnishing employee identification and for requiring each employee to display such identification as may be approved and directed by the Contracting Officer, unless otherwise specified below. All Contractor personnel, prior to engaging in work on project premises, shall be issued an identification card by the Contractor. The I.D. cards shall include the following information:

Name of Contractor Name of Employee Birth date Height Weight Hair color Eye color Recent photo

All prescribed identifications shall be returned immediately to the Contractor upon release of any employee. The Contractor shall supply a complete listing of all personnel and their titles who will be working on the project. This listing shall be revised at a minimum of once weekly and revisions provided. When required by the Contracting Officer, the Contractor shall obtain and submit fingerprints of all persons employed by it or to be employed at the powerhouse.

Contractor personnel shall wear ID badges at all times where they are easily visible, except in situations where this would pose a safety hazard.

b) On site work will be 0630 - 1500 EST Monday through Thursday and off on Federal Holidays.

5.0 Submittals

5.1 Schedule For Work

The contractor shall submit a schedule for accomplishing the work in this contract.

The schedule will not be used by the Government to select a Contractor; rather it will be used to insure that the Contractor is capable of accomplishing the necessary work in the allotted time periods. The Contract duration shall be 180 days after award.

5.2 List of qualifications

The contractor must submit documentation showing at least 5 years of experience with work related to the contract scope. In the submittal the contractor must show they have a Cummins diesel certified contractor that will oversee the generator commissioning.

5.3 List of Materials

A full list of materials that will be used and the specifications showing that section

3.0 has been met.

5.4 GPR Data

Prior to core drilling. GPR results showing rebar and any obstructions where penetrations will be, must be submitted to USACE for approval.

5.5 Accident Prevention Plan

The Contractor shall comply with the safety and health provisions contained herein in addition to those provisions contained in Contract Clause "ACCIDENT PREVENTION" of EM 385-1-1.

5.6 Activity Hazard Analyses

a. The Contractor shall develop Activities Hazard Analyses as part of the Accident Prevention Plan. The procedures shall define how the Contractor will implement the Activity Hazard Analysis in accordance with the criteria in EM 385-1-1 as further described:

b. In accordance with the requirements of EM 385-1-1, the Contractor shall, prior to the beginning of each major phase of work, prepare an Activity Hazard Analyses for that work phase. This analyses shall address the hazards for each activity to be performed in that work phase and shall detail procedures and safeguards necessary to eliminate the hazards or reduce the risks to an acceptable level.

c. The Contractor shall develop this analyses to identify the sequence of work, the specific safety and health hazards anticipated, and the control measures to be implemented to minimize or eliminate each hazard. The Activity Hazard Analyses shall be job specific and shall address the following major points:

(1) Activity being performed (i.e., identify major phase).

(2) Sequence of work.

(3) Hazards to be controlled.

(4) Control measure(s) to mitigate the hazards.

d. A work phase in the analyses is defined as a major operation involving a type of work that presents hazards that must be abated or controlled and that have not been experienced in previous operations, or when a new subcontractor or work crew is to perform work.

e. The analyses for each major work phase will be discussed by the Contractor and Construction Officer's representative. Work shall not proceed on that phase until the Contractor's Activity Hazards Analyses have been accepted by the Contracting Office

5.7 Diesel Generator Moving Plans

The contractor is required to list plans for how to move the diesel generator from the unloading deck to the permanent location on the transformer deck. The contractor will be required to submit the weight and dimensions of the crane (if used) and equipment used to lift and move the generator. This submittal will be required to be approved by USACE at least two weeks before moving the generator.

5.8 Contractor’s Quality Control Plan

The Contractor shall maintain an effective quality control system. The Contractor's system shall encompass all actions involving selection of construction material sources and suppliers, on-site and off-site fabrication of Contractor furnished items to be included in the work, on-site and off- site production of construction materials, work placement procedures, workmanship, inspection, and testing. The system shall provide the necessary supervision, inspection, and tests of all items of work, including that of its suppliers and subcontractors, that will assure the compliance of all work with applicable requirements and drawings in respect to the Contractor furnished equipment, materials, workmanship, construction, finish, functional performance, and identification. The Contractor's system shall encompass all management and supervisory actions taken by its staff that affect quality of the finished construction work, including all inspection controls and tests required for compliance with the contract, except for those inspections and tests specifically reserved to be accomplished by the Government.

6.0 ACCEPTANCE

All parts supplied under this SOW will be covered by the contractor for a one (1) year period.

If deficiencies are found under this scope the contractor will be responsible for repairs or replacement parts without further cost to the government. On site work must begin within 60 days of contract award, and must be completed within 180 days after award of contract.

Appendix A Drawings

As-Builts (2018-08-16)-1