Scope_of_Work-Diesel_Generator_Replacement_Revised_2Jun17.pdf

Project Scope of Work

Title: Replace Standby Generators

Building/Location: DFAS, Limestone, ME

Date: 28 February 2017 (Revised 11 May 2017) Prepared By: Michael Kinney (DFAS LI COR)

1. GENERAL SCOPE: The work covered in this Scope of Work, as well as the related drawings consists of furnishing all personnel, labor, materials, tools, equipment, transportation, supervision, delivery, complete installation and other items and services necessary to perform all services identified herein to accomplish all work identified in the SOW to replace two Standby Generators at DFAS Limestone, Maine.

2. PRINCIPLE FEATURES: The principle features of work include removing, disposing and replacing two existing 400kW Cat diesel generators sets with Equal to or Equivalent 400kw, 500 kVA Diesel Fueled, Standby Generators per SOW. All work must meet all applicable Local, State, Federal, UFC, NFPA and NEC Codes.

3. SUPERVISOR: The contractor shall have a designated supervisor on site at all times during work.

4. PERIOD OF PERFORMANCE: The Contractor shall be allowed a total of 90 calendar days upon notice to proceed to accomplish this project, as described herein. All work shall be completed within 365 days regardless of contract award date. Note. No work will occur during the months of August, September and October 2017 due to FY17 closeout activities.

5. NOTIFICATION OF COMMENCEMENT: The Contractor shall confirm the construction start date with the Contracting Officer at least 48 hours prior to intention to start construction.

6. SITE CONDITIONS: Contractor shall inspect and verify known site conditions and determine if the inside location of the replacement Standby Generators are adequate for safe and efficient operations listed in the SOW prior to award of project. The contractor is responsible to determine if the existing raised concrete pads are sufficient in size to accommodate the replacement generators.

Also, the contractor shall determine if the two existing smoke stacks will need to be temporarily disassembled and moved to facilitate removal and installation of new generators and reinstalled. The contractor will coordinate with the Contracting Office when scheduling visits to the site prior to construction activities. The building shall be available for contractor use and others supporting this project. The building will remain occupied and operational during the project with DFAS staff coverage during the hours of (6:00am to 4:30pm) Monday – Friday as coordinated by the COR.

7. CONSIDERATIONS: The contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract for the Maine Air National Guard via a secure data collection site. The contractor is required to completely fill in all required data fields using the following web address:

https://afcmra.hqda.pentagon.mil/

Reporting inputs will be for the labor executed during the period of performance during each Government fiscal year (FY), which runs October 1 through September 30. While inputs may be reported any time during the FY, all data shall be reported no later than October 31 of each calendar year, beginning with 2013. Contractors may direct questions to the help desk at: usaf.pentagon.saf-aq.mbx.cmra-help-desk-air-force@mail.mil

8. CLEANUP: Contractor shall clean up the job site daily. The Contractor shall provide their means for removing debris from the work site. The Contractor shall use their equipment to clean the work area. The Contractor shall clean the area as many times as necessary after the job is complete to ensure there is no evidence of the work that just occurred.

9. SAFETY: The Contractor shall be responsible for managing the project(s) and maintaining a work site compliant with EM 385-1-1 Safety and Health Requirements Manual. Also, Contractors and Subcontractors must review and sign The DFAS Limestone Contractor Safety and Health Agreement before commencing on-site work. This form will be provided at the Pre-Con meeting after award of contract.

10. SECURITY REQUIREMENTS:

1. Contractor shall comply with all DFAS Personnel security requirements and must submit an initial security background investigation form (DFAS Form 9035), (OF 306) along with a completed fingerprint card (SF-87 Form or SF258) for submission to have a DFAS background investigation for all contractor personnel involved in the project who will be on-site. Contractor must submit security clearance paperwork to DFAS Limestone ASAP after the contract is awarded or at least 30 days prior to the construction start date. After the initial paperwork is submitted to DFAS Limestone and forwarded to DFAS HQ, an electronic questionnaire (e-QUIP) must be completed by each person to be properly vetted. No contractor or sub-contractor will be allowed access to DFAS facilities unless properly vetted. No contractor or sub-contractor will be allowed unescorted access to DFAS facilities unless properly vetted. All contractors must comply with DFAS established policy concerning Violence in the Workplace and general rules of behavior while on site at DFAS Limestone.

11. SUBMITTALS: Provide submittals for government approval as listed below for the project.

Submit the prerequisite Quality Control Plan, Accident Prevention Plan with a detailed Activity Hazard Analysis, Project Schedule, Schedule of Values, etc., each of which must be submitted and approved prior to starting work at the site. Ensure all appropriate plans, certifications, MSDS’s, etc.

are maintained on the project site and are available for Government review at any time. Provide information for each submittal for government approval as listed below.

a. Manufacturer’s Data: Manufacturer's O&M descriptive and technical data and installation and maintenance instructions.

b. Warranty information: Provide a written manufacturer’s warranty.

c. Copy of project “As-Builds” will be provided to the COR upon project completion.

d. Within thirty (30) days from Substantial Completion the Contractor shall have all punch-list items and close-out documents, etc. completed.

12. WARRANTY: Installer shall warrant in writing that the work shall be free of faults or defects, in accordance with the requirements in this Scope of Work for a period one year after project completion; materials and products used in the project shall have manufacturer’s warrantees respective of the item used.

13. SCOPE of WORK:

a. Background: The selected contractor shall provide in complete and 100 percent working order, two- new replacement 400kW/500kVA Diesel Fueled packaged on base, generator system(s) located in the DFAS Limestone Energy Plant, Generator Room. The contractor shall provide all necessary materials, appurtenances and labor to provide for a standby power system that will automatically start and transfer from commercial power to standby power within four to seven seconds upon commercial power failure in order to maintain operation of critical circuits of the DFAS Limestone facility.

b. Current Configuration: The facility has two existing 480 volt, 3 phase skid mounted-open 400Kw Caterpillar diesel generators with twenty-four hour, belly tanks configured inside the facility generator room which have a cold air louvered intake system and tie-in to recently upgraded ASCO switchgear system identified above. The ASCO switchgear works in conjunction with five Automatic Transfer Switches which supplies standby power to the designated facility emergency circuits.

Additionally, three 300 gallon diesel fuel reserve tanks are connected to the generator belly tanks located next to the generator room and provide fuel for extended run time if needed. Existing diesel generator removal will require the removal of cool air intake shrouds and exterior wall louvers to facilitate removal from the generator. After generator removal, the louvers shall be reinstalled and any openings must be immediately secured and not remain open overnight without DFAS or contractor presence for building security reasons.

c. Site preparation and specific requirements: New replacement 400Kw, 500kVA, 60Hz diesel-fueled generators set(s) shall be capable of producing the rated 400 kW and 500kVA when operating at the local altitude and temperature range. Both generator sets shall include appropriate mounting bases, cable controls, operating gauges, electrical connections to operating systems, ASCO switchgear and diesel supply lines. Both generator sets shall be capable of running individually or simultaneously. The generator sets shall be started and accelerated to rated speed immediately upon loss of normal power after and adjustable time delay not to exceed 7 seconds. The generator set shall accept load in one step, up to the engine capability to recover to rated speed. The generator manufacturer will provide data to verify the generator set will operate as required in the ambient conditions of 130 feet Altitude, minimum temperature of minus 40 degrees Fahrenheit and maximum temperature 130 degrees Fahrenheit. Both generators will feature an extreme arctic (jacket water heater) and battery heater package to ensure operations during extreme cold weather conditions. The base shall be designed to rigidly support the engine generator set, ensure permanent alignment of rotating parts and be arranged to provide easy access to allow changing of lube-oil and engine coolant. The base will be constructed of steel and ensure that all alignment is maintained during shipping and normal operations. The base shall permit skidding in any direction for installation and shall withstand and mitigate the effects of vibration of the engine and generator. Anchor bolt holes shall also be provided. Standard pad isolation to guard against vibration of the base and foundation shall also be included.

The Contractor shall provide signage warning occupants of construction areas and pathways around work areas.

d. The contractor shall protect existing interior/exterior walls. Any damage to existing mechanical room walls and floors resulting from contractor’s activities shall be repaired by the contractor.

e. Contractor will be responsible for the cost and arrangement of dumpsters for disposal and removal of any construction debris in performance of this requirement.

f. Lights shall be used only in areas where work is actually being performed.

g. New 400kW Diesel Standby Generators will be installed where the two existing 400kW Caterpillar generators are currently located in “The Generator Room” inside the facility.

h. Current diesel generators to be removed are Caterpillar 3408, SRA, 603 HP, 400kW (open) units with both approximately 600 hours on each unit. Serials numbers are 6DAO1244 and 6DAD1245 respectively. Both units were initially installed in 1987, have no known defects and are in full operational order. A monetary contract credit based upon fair market value as determined by the Contracting Officer credit is required.

i. ASCO switch gear will remain in the “Switch Gear Room” interior to the facility. Existing ASCO Switchgear and ATS (5) breakers will be inspected, tested and reutilized for the project. Any serviceability issues with the ATS’s must be identified and reported to the Contracting Officer and COR. ASCO ATS number is JO7ATS3026ON506, ATS serial number is 445287-003RE. ASCO Switch Gear reprogramming shall be required by the contractor to incorporate the replacement generators by a qualified ASCO technician.

j. Current Diesel (Two) Generators will be completely drained of fuel (24 Hour Tanks) and removed from the facility. The Diesel Generators will become the property of the contractor and properly disposed of off-site site by the contractor. All fuel lines, electrical lines and conduit will be inspected and replaced if necessary to ensure safe and efficient operation of the new generators. The exhaust system will be modified if necessary and retrofitted by the contractor to accommodate the new generators.

k. The contractor's equipment shall be of commercial quality, size, and type suitable for accomplishing the various phases of work specified and operated from existing sources of government-furnished electrical power and water. All electrical equipment used by the contractor shall meet all safety requirements of this contract and shall be UL2200,UL508,UL142,UL498, NFPA70,99,110 and 708 compliant approved. It shall be the responsibility of the contractor to prevent the operation or attempted operation of electrical equipment, or combinations of equipment, which require power exceeding the capacity of existing building circuits. All equipment shall have guards to prevent marking and scratching of facility furnishings, or building surfaces. The contractor's equipment shall be in good repair and able to operate efficiently and safely. Any and all lifting devices or cranes shall be properly maintained with a certified operator and competent person on-site when in use. The contracting officer or representative may inspect the contractor's equipment and/or tools at any-time and direct the removal of any improper or unsafe equipment/tools. These items shall be removed from the job by the contractor and replaced with satisfactory equipment.

l. The contractor shall at all times provide adequate supervision of his employees to ensure complete and satisfactory performance of all work in accordance with the terms of the contract. The contract manager, or alternate representative, will be on the site and available at all times when the work of the contract is being carried out to receive instructions from the contracting officer or his representative (COR). The contractor shall provide additional telephone and pager numbers where the contract manager and alternate can be reached during other than normal duty hours should the contracting officer deem it necessary. Access to locked rooms in areas where construction is required will be provided by the COR or their designated representative.

14. Salient Features: The contractor shall provide all necessary materials, appurtenances and labor to provide for a standby power system as identified in para 13.c. above. The new 400kW Diesel fueled generators will have the minimum requirements identified below.

* Engine rated at (680 to 700) HP at rated at least 450 Kw for operation on Diesel Fuel

* Voltage: 480

* Phase 3

* Frequency 60 Hz

* Fuel Tank size (Diesel) 230 to 250 gallons

* Cooling method: Radiator

* Engine RMP 1800 to 2300

* Circuit Breaker Size at least 800A

* Shunt Trip

* Analog Voltage Regulator

* Emergency Stop

* Power factor 0.8

* Electric Starter

* Rating Type Standby

* Leads: 12

* Phase: 3

* Bearings: Single Bearing

* Excitation Type: Self Excited

* EPA certified

* Permanent magnet excited alternator, protective coating and strip heater

* Pad type Isolator

* Control panel: EMCP 4.1 with internal digital voltage regulator and electronic engine governor.

* Generator Running relay.

* Audible alarm siren; volt free contacts for alarm

* Block coolant heater; Low Coolant Temperature alarm and Low Coolant shutdown circuit

n. Factory Testing: The contractor will be responsible for factory testing verification. Prior to delivery to the site the generator manufacturer will have conducted factory testing. The generator sets shall be tested and a Performance Assurance Certification shall be completed at the factory on the unit. A certified copy of the test of the engine-generator performance shall be provided to the Contractor for review. Factory tests shall include, but not be limited to the following.

* Full load at rated power factor will be applied;

* Full load at unity, 1.0 PF;

* Recordings of the maximum load carrying capabilities of the engine generator set:

*Maximum single block load pick-up capability;

*Kilowatts;

*Amperes;

*Voltage;

*Kilovolt amperes;

*Resistance of exciter field and stator;

*Insulation test, generator field, exciter armature, exciter field, generator armature;

*Dielectric test, generator armature, generator field, exciter armature, exciter field;

*Lube oil pressure;

*Time stamp *Coolant temperature;

*Battery charge rate;

*Heaters, jacket water or equivalent circulating water heater system and/or lube oil;

*Safety shutdowns and automatic controls;

*Annunciator panel, charger, pumps as supplied;

*Phase sequence on three phase;

*Frequency;

*Full load and .4PF to verify the motor starting capability;

*Full rated load at rated PF and maximum load to verify engine power and maximum capability;

*kVA, kilowatts, amperes, voltage, frequency and voltage transience at half and rated load *frequency at: no load, full load rated and maximum output;

*Regulator range – adjust, phase sequence, phase voltage balance;

*Stator and exciter field resistance;

*All safety shutdown and automatic controls;

*Testing shall include portions of MIL-STD-705.

15. Field Testing and Start up:

Prior to start-up the Contractor shall arrange to have the system inspected by an authorized Caterpillar factory representative. All features and functions of the system shall be field tested after installation and start-up. Tests shall include, but not be limited to 100% rated load bank test for 4 hours minimum. A final field test report showing all results will be submitted to the Owner. The start-up of the engine generator set and automatic transfer switch will be performed by an authorized representative of the manufacturer. Start-up, following field testing will include instructions to Owner’s employees on normal maintenance and operation of the generator set. Upon completion of start-up the Contractor shall provide to the Owner a minimum of two copies of an Operations and Maintenance manual(s) and all associated documentation.

END OF SCOPE OF WORK