Inactive Total Small Business Set-Aside (FAR 19.5)

SCOPE OF WORK The Contractor shall provide all management, supervision, labor, personnel, equipment, tools, training, materials, and supplies necessary to purchase, deliver, setup, test, and make oper... SCOPE OF WORK The Contractor shall provide all management, supervision, labor, personnel, equipment, tools, training, materials, and supplies necessary to purchase, deliver, setup, test, and make operational one (1) new 375kW diesel engine generator sets. At the time of contract award, the Contracting Officer (KO) will identify the on-site Government point of contact (POC) who will monitor performance to ensure services are received and carried out in accordance with (IAW) the requirements in this SOW. All references in this SOW to “Contractor personnel” include both Contractor employees and subcontractors. The generator sets shall be shipped to and stored at the DLA Distribution Susquehanna, New Cumberland, PA site. The Government will provide a suitable area for the Contractor to unpack, setup, test, and make operational the generator sets. Contractor personnel shall be escorted by Government personnel at all times while onsite. Setup and test dates shall be coordinated with the POC. EQUIPMENT SALIENT CHARACTERISTICS/DESCRIPTION The 375kW diesel engine generator sets for standby power supply shall have the following basic features; a liquid cooled diesel engine, unit-mounted cooling system, unit-mounted control and monitoring, outdoor enclosure, a synchronous AC alternator, multiple output voltages, and system controls with all necessary accessories for a complete operating system. The genset shall operate at rated power output at the listed ambient temperature (104?F) and elevation (1500 Ft). The generator is meant to be mobile in nature, so the generator is to be installed on a DOT approved trailer with pintle hitch. The generator set shall also have the following specific features listed below. ENGINE Engine Rating and Performance Each engine shall operate on No. 2-D diesel conforming to ASTM D975; shall be designed for non-road applications; and shall be complete with ancillaries. The engine shall be a standard production model described in the manufacturer's catalog data, which describes and depicts each engine-generator set and all ancillary equipment in sufficient detail to demonstrate specification compliance. The engine shall be a liquid cooled, diesel fueled, turbocharged, after-cooled engine of 4-cycle design and have adequate horsepower to achieve rated 375kW generator output (minimum standby rating @480V, 3-phase and 208V, 3-phase) at an operating speed of 1800 RPM. Power ratings shall be in accordance with EGSA 101P. ENGINE OIL SYSTEM Full pressure lubrication shall be supplied by a positive displacement lube oil pump. The engine shall have a replaceable oil filter(s) with internal bypass and replaceable element(s). The engine shall operate on mineral based oil. Synthetic oils shall not be required. The oil shall be cooled by an oil cooler which is integrated into the engine system. ENGINE COOLING SYSTEM The engine shall be cooled with a unit mounted radiator, fan, water pump, and closed coolant recovery system. The coolant system shall include a coolant fill box which will provide visual means to determine if the system has adequate coolant level. The radiator shall be designed for operation in 120 degrees F, (49 degrees C) ambient temperature. A radiator fan guard shall be installed for personnel safety that meets UL and OSHA safety requirements. ENGINE STARTING SYSTEM Starting system shall be manufacturers recommended dc system utilizing a negative circuit ground. Starting motors shall be in accordance with SAE ARP892. The engine’s cranking batteries shall be lead acid. The batteries shall be the largest available by the manufacturer for this generator size. The batteries supplied shall be in accordance with SAE J537 and meet NFPA 110 cranking requirements of 90 seconds of total crank time. Battery specifications (type, amp-hour rating, cold cranking amps) shall be provided in the submittal. The generator set shall have an engine driven, battery charging alternator with integrated voltage regulation. ENGINE FUEL SYSTEM The engine fuel system shall be designed for operation on #2 diesel fuel and cold weather diesel blends. The fuel system for each engine generator set shall conform to the requirements of NFPA 30 and NFPA 37 and contain the following elements. Pumps The engine shall be provided with an engine driven pump. The pump shall supply fuel at a minimum rate sufficient to provide the amount of fuel required to meet the performance indicated within the parameter schedule. The fuel flow rate shall be based on meeting the load requirements and all necessary recirculation. Filter a. A minimum of one full flow fuel filter shall be provided for each engine. The filter shall be readily accessible and capable of being changed without disconnecting the piping or disturbing other components. The filter shall have inlet and outlet connections plainly marked. Relief/Bypass Valve a. A relief/bypass valve shall be provided to regulate pressure in the fuel supply line, return excess fuel to a return line, and prevent the build-up of excessive pressure in the fuel system. Check Valve a. The engines suction line shall be fitted with a check valve to secure prime for the engines injection pump. All fuel system components shall be installed at the point of manufacture. ENGINE CONTROLS Engines that are equipped with an electronic engine control module (ECM) shall monitor and control engine functionality and seamlessly integrate with the genset controller through digital communications. ECM monitored parameters shall be integrated into the genset controllers, NFPA 110 alarm and warning requirements. All ECM fault codes shall be displayed at the genset controller in standard language – fault code numbers are not acceptable. For engines without ECM functionality or for any additional genset controller monitoring, sensors shall be conditioned to a 4-20ma signal level to enhance noise immunity and all sensor connections shall be sealed to prevent corrosion. Engine speed shall be controlled with an integrated isochronous governor function with no change in alternator frequency from no load to full load. Steady state regulation shall be 0.25%. ENGINE EXHAUST & INTAKE The engine exhaust shall meet all current federal and local emission requirements for diesel generator sets. The manufacturer shall provide written documentation indicating conformance with current emissions standards. The manufacturer shall supply its recommended stainless steel, flexible connector to couple the engine exhaust manifold to the exhaust system. A rain cap will terminate the exhaust pipe after the silencer. All components must be properly sized to assure operation without excessive back pressure when installed. The manufacturer shall supply an exhaust silencer as standard that enables the genset to meet site noise requirements of 91 dBA at 23 feet, assuming no installed sound barriers. For gensets with weather-protective enclosures, all exhaust piping from the turbo-charger discharge to the silencer shall be thermally wrapped to minimize heat dissipation inside the enclosure. The engine intake air shall be filtered with engine mounted, replaceable, dry element filters. Genset mufflers shall be factory mounted. 3.8 ALTERNATOR Genset shall be provided with alternator, multiple voltage selector switch, voltage adjustment potentiometer, and other components necessary to provide the voltage and phase configurations indicated below. Provide power systems to supply field selectable (via selector switch) electrical power as follows: 480Y/277V, 3 Phase, 4 Wire, 60 Hz. 208Y/120V, 3 Phase, 4 Wire, 60 Hz. 120/240V, 1 Phase, 3 Wire, 60 Hz. The alternator shall be of the synchronous type, one or two bearing, conforming to NEMA MG 1, equipped with winding terminal housings in accordance with NEMA MG 1, equipped with an amortisseur winding, and directly connected to the engine. Three phase alternators shall be 12 lead, broad range capable of supporting voltage reconnection. Single phase alternators shall be four lead and dedicated voltage designs (600v) shall be six lead. All leads must be extended into a NEMA 1 connection box for easy termination. A fully rated, isolated neutral connection must be included by the generator set manufacturer. The alternator shall meet temperature rise standards of UL2200 (120 degrees C). The insulation system material shall be class "H" capable of withstanding 150 degrees C temperature rise. The alternator shall be protected against mechanical, electrical and thermal damage due to vibration, 25 percent overspeeds, or voltages and temperatures at a rated output capacity of 100 percent. To ensure precision protection and repeatable trip characteristics, these functions must be implemented electronically in the generator control panel -- thermal magnetic breaker implementation are not acceptable. A tropicalized resin coating shall be applied to the alternator windings to provide protection against the entrance of moisture. Generator ancillary equipment shall meet the short circuit requirements of NEMA MG 1. Submit each generator kW rating and short circuit capacity (both symmetric and asymmetric). EXCITER A. The generator exciter shall be of the brushless type. Semiconductor rectifiers shall have a minimum safety factor of 300 percent for peak inverse voltage and forward current ratings for all operating conditions, including 110 percent generator output at 104 degrees F (40 degrees C) ambient. The exciter and regulator in combination shall maintain generator- output voltage within the limits specified. VOLTAGE REGULATOR A. The generator shall be provided with a solid-state voltage regulator, separate from the exciter. The regulator shall maintain the voltage within a bandwidth of the rated voltage, over a steady-state load range of zero to 100 percent of rated output capacity. Regulator shall be configured for safe manual adjustment of the engine generator voltage output without special tools, during operation from 90 to 110 percent of the rated voltage over the steady state load range of zero to 100 percent of rated output capacity. Regulation drift shall not exceed plus or minus 0.5 percent for an ambient temperature change of 36 degrees F (20 degrees C). The voltage regulator shall have a maximum drop of 2 percent of rated voltage over a load range from 0 to 100 percent of rated output capacity and automatically maintain the generator output voltage within the specified operational bandwidth. SAFETY SYSTEM A. Devices, wiring, panels, etc., shall be provided and installed as a complete system to automatically activate the appropriate signals and initiate the appropriate actions. The safety system shall be provided with a self-test method to verify its operability. Alarm signals shall have manual acknowledgement and reset devices. The alarm signal systems shall reactivate for new signals after acknowledgment is given to any signal. The systems shall be configured so that loss of any monitoring device shall be dealt with as an alarm on that system element. 1. Audible Signal a. The audible alarm signal shall be continuously activated upon alarm and silenced upon acknowledgment. 2. Visual Alarm Signal a. The visual alarm signal shall be a panel light. The light shall be normally off, activated to be blinking upon alarm. The light shall change to continuously light upon acknowledgement. If automatic shutdown occurs, the display shall maintain activated status to indicate the cause of failure and shall not be reset until cause of alarm has been cleared and/or restored to normal condition. Shutdown alarms shall be red; all other alarms shall be amber. 3. Alarms and Action Logic a. Shutdown b. Simultaneous activation of the audible signal, activation of the visual signal, stopping the engine, and opening the generator main circuit breakers shall be accomplished. 4. Problem a. Activation of the visual signal shall be accomplished. 5. Alarm Panel a. Provide an alarm panel with shutdown and alarm functions in accordance with NFPA 110 Level 2. ENGINE GENERATOR SET CONTROLS AND INSTRUMENTATION A. Devices, wiring, local panels, etc., shall be provided and installed as a complete system to automatically activate the appropriate signals and initiate the appropriate actions. The generator control system shall be a fully integrated control system. The generator controller shall provide integrated and digital control over all generator functions including: engine protection, alternator protection, speed governing, voltage regulation, and all related generator operations. The generator controller must also provide seamless digital integration with the engine’s electronic engine control module (ECM) if so equipped. B. The control system shall provide an environmentally sealed design including encapsulated connections. The use of non-encapsulated boards, edge cards, and pc ribbon cable connections are considered unacceptable. CONTROLS A. A local control panel shall be provided with controls in accordance with NFPA 110 Level 2, mounted on the engine generator set. Engine Generator Set Metering and Status Indication A. A local panel shall be provided with devices in accordance with NFPA 110 Level 2, mounted on the engine generator set. PANELS Each panel shall be of the type necessary to provide specified functions. Panels shall be mounted on the engine generator set base by vibration/shock absorbing type mountings. Instruments shall be mounted flush or semi-flush. Convenient access to the back of instruments shall be provided to facilitate maintenance. Instruments shall be calibrated using recognized industry calibration standards. Each panel shall be provided with a panel identification plate which clearly identifies the panel function as indicated. Each instrument and device on the panel shall be provided with a plate which clearly identifies the device and its function as indicated. Panels can be combined into a single panel. Enclosures 1. Enclosures shall be designed for the application and environment, conforming to NEMA ICS 6. Analog 1. Analog electrical indicating instruments shall be in accordance with ANSI C39.1 with semi- flush mounting. Unit-mounted instruments shall be the manufacturer's standard with an accuracy of not less than 2 percent. The instrument's operating temperature range shall be minus 4 to plus 130 degrees F (minus 20 to plus 54 degrees C). Distorted generator output voltage waveform of a crest factor less than 5 shall not affect metering accuracy for phase voltages, hertz, and amps. Electronic 1. Electronic indicating instruments shall be true RMS indicating, solid state, microprocessor controlled to provide all specified functions. Control, logic, and function devices shall be compatible as a system, sealed, dust and water tight, and shall utilize modular components with metal housings and digital instrumentation. An interface module shall be provided to decode serial link data from the electronic panel and translate alarm, fault and status conditions to set of relay contacts. Instrument accuracy shall be not less than 2 percent for unit mounted devices throughout a temperature range of minus 4 to plus 130 degrees F (minus 20 to plus 54 degrees C). Data display shall utilize LED or back lit LCD. Additionally, the display shall provide indication of cycle programming and diagnostic codes for troubleshooting. Parameter Display 1. The control panel(s) shall display all user pertinent unit parameters including: engine and alternator operating conditions; oil pressure and optional oil temperature; coolant temperature and level alarm; fuel level; engine speed; DC battery voltage; run time hours; generator voltages, amps, frequency, kilowatts, and power factor; alarm status and current alarm(s) condition per NFPA 110 Level 2. 3.16 CIRCUIT BREAKER The generator shall be provided with one (1) mainline 480V, 800AT, 3-pole, 100% rated, electronic trip, LSI circuit breaker. The UL listed mainline circuit breaker must be mounted in a NEMA rated enclosure. The line side connections are to be made at the factory. 3.17 ENGINE / ALTERNATOR HOUSING The engine/alternator shall be isolated from the generator frame with rubber isolators. The packaging shall not require the addition of external spring isolators. The generator shall include a unit mounted 120 volt convenience outlet. 3.18 ENCLOSURE The genset shall be packaged with a weather-protective enclosure. The engine generator set enclosure shall be corrosion resistant, fully weather resistant, contain all set components, and provide ventilation to permit operation at rated load under secured conditions. Provide doors for access to all controls and equipment requiring periodic maintenance or adjustment. Provide removable panels for access to components requiring periodic replacement. The enclosure shall be capable of being removed without disassembly of the engine-generator set or removal of components other than exhaust system. The enclosure shall reduce the noise of the generator set to within the limits specified in paragraph 3.7C. The color shall be manufacturer’s standard. The genset silencer shall be mounted inside the enclosure. Silencers mounted on the top of the generator enclosure are not acceptable. Gensets with silencers mounted inside the main generator compartment shall have the silencer thermally wrapped to minimize heat stress on the surrounding components. 3.19 FUEL TANK The packaging shall include a double wall, sub-base mounted, UL142 listed fuel tank. The tank shall be sized to provide a minimum of 16 hours run time at 100 percent rated load (standby). The tank shall include normal and emergency vents, secondary containment emergency vent and rupture basin sensor and fuel level indication. The tank shall include a local fuel fill port with a screw-on cap. The fuel fill port shall be accessible without opening the enclosure. The fuel tank shall use a fuel sensor to provide indication of fuel level. The controller shall have a warning indication on low fuel level and provide shutdown functionality for low, low fuel level. The fuel tank shall be supplied by the engine-generator set manufacturer and be installed before shipment. TRAILER A. Each generator is to be installed on a DOT approved trailer with electric brakes, a heavy duty center mounted jack, and light package. LOOSE ITEMS Loose parts that require site mounting and installation shall be itemized and packaged to prevent damage. Extra Materials Provide two sets of special tools and two sets of filters required for maintenance. Special tools are those that only the manufacturer provides, for special purposes, or to reach otherwise inaccessible parts. One handset shall be provided for each electronic governor when required to indicate and/or change governor response settings. Supply two complete sets of filters in a suitable storage box in addition to filters replaced after testing. VIBRATION ISOLATION The engine-generator set shall be provided with manufacturer’s standard vibration isolation in accordance with the manufacturer’s standard recommendation. Submit torsional analysis including prototype testing or calculations which certify and demonstrate that no damaging or dangerous torsional vibrations will occur when the prime mover is connected to the generator, at synchronous speeds, plus/minus 10 percent. Submit vibration isolation system performance data for the range of frequencies generated by the engine-generator set during operation from no load to full load. FINISHES Indoor and Outdoor Enclosures and Components shall have Manufacturer's standard finish over corrosion-resistant pretreatment and compatible primer. Applicable Documents The following documents of the issue in effect on the date of award form a part of this purchase description to the extent specified within: Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use. ASME B15.1 NFPA 37 NFPA 70 NFPA 110 requirements for Level 2 emergency power supply system UL 2200 Comply with applicable state and local government requirements. 4.0 EQUIPMENT SETUP AND TESTING The Contractor’s factory-authorized service representative shall unpack, inspect, and setup the Genset. Examine/inspect equipment for compliance with requirements for installation and other conditions affecting packaged engine-generator performance. Setup equipment to comply with packaged engine-generator manufacturers' written installation and alignment instructions and with NFPA 110. Install electrical wiring and devices furnished by equipment manufacturers that were not specified to be factory mounted. After equipment setup the Contractor shall inspect components, assemblies, connections, and equipment installations, before starting the genset. The Contractor shall verify equipment is operating properly before contacting the Government and beginning the field testing. The Contractor shall perform the following inspections and field tests and prepare test reports: Ensure the engine starts (both hot and cold) within the specified time. Verification of engine parameters within specification. Verify no load frequency and voltage, adjusting if required. Test all automatic shutdowns of the engine-generator. Perform a load test of the electric plant, ensuring full load frequency and voltage are within specification by using building load or load bank. Perform a load test for 1.5 hours using building load. In addition to the load bank test, load the generator at 30% for 30 minutes, 50 % for 30 minutes, and 100% for 60 minutes. The Contractor shall perform the following additional tests and inspections: Perform tests recommended by manufacturer, electrical test, visual and mechanical inspection, for "AC Generators and for Emergency Systems" specified in NETA Acceptance Testing Specification. Certify compliance with test parameters. NFPA 110 Acceptance Tests: Perform tests required by NFPA 110 that are additional to those specified herein, including but not limited to, single-step full-load pickup test. Battery Tests: Equalize charging of battery cells according to manufacturer's written instructions. Record individual cell voltages. Measure charging voltage and voltages between available battery terminals for full-charging and float-charging conditions. Check electrolyte level and specific gravity under both conditions. Test for contact integrity of all connectors. Perform an integrity load test and a capacity load test for the battery. Verify acceptance of charge for each element of the battery after discharge. Verify that measurements are within manufacturer's specifications. System Integrity Tests: Methodically verify proper installation, connection, and integrity of each element of engine-generator system before and during system operation. Check for air, exhaust, and fluid leaks. Voltage and Frequency Transient Stability Tests: Use recording oscilloscope to measure voltage and frequency transients for 50 and 100 percent step-load increases and decreases, and verify that performance is as specified. Harmonic-Content Tests: Measure harmonic content of output voltage under 25 percent and at 100 percent of rated linear load. Verify that harmonic content is within specified limits. Leak Test: After setup, charge system and test for leaks. Repair leaks and retest until no leaks exist. Operational Test: After electrical circuitry has been energized, start units to confirm proper motor rotation and unit operation. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment. Remove and replace malfunctioning units and retest as specified above. Retest: Correct deficiencies identified by tests and observations and retest until specified requirements are met. Report results of tests and inspections in writing. Record adjustable relay settings and measured insulation resistances, time delays, and other values and observations. Attach a label or tag to each tested component indicating satisfactory completion of tests. The Government POC or designee shall observe all equipment testing. Test instruments shall have been calibrated within the last 12 months, traceable to standards of NIST, and adequate for making positive observation of test results. Make calibration records available for examination on request. DELIVERABLES/SUBMITTALS The Contractor shall submit three (3) sets of owner’s manuals specific to the equipment supplied and they must accompany delivery of the equipment. General operating instructions, preventive maintenance, wiring diagrams, schematics and parts exploded views specific to this model shall be included. Also include a list of tools and replacement items recommended to be stored at site for ready access. Include part and drawing numbers, current unit prices, and source of supply. Product Data: The manufacturer shall have printed literature and brochures describing the standard series specified, not a one of a kind fabrication. For each type of packaged engine generator indicated. Include rated capacities, operating characteristics, and furnished specialties and accessories. In addition, include the following: Thermal damage curve for generator. Time-current characteristic curves for generator protective device. The Contractor shall factory test each engine-generator set, other system components, and accessories manufactured specifically for this SOW before shipment to the Government. Perform the following tests at rated loads and power factors: Test components and accessories furnished with installed unit that are not identical to those on tested prototype to demonstrate compatibility and reliability. Full load run. Maximum power. Voltage regulation. Transient and steady-state governing. Single-step load pickup. Safety shutdown. Report factory test results within 10 days of completion of test. The generator set shall be tested and performance assurance certification shall be completed at the factory on the unit. The test metering shall have an accuracy of 1% or better and the metering used in testing shall be regularly calibrated and traceable to the National Bureau of Standards. The certified test of the engine-generator performance shall be provided. All tests shall be performed in accordance with the following test methods: IEEE 115 or MIL STD 705. Additional factory tests shall include but not be limited to the following: Full rated load at rated PF and maximum load, to verify engine power, overland and maximum capability KVA, kilowatts, amperes, voltage, frequency and voltage transients at ½ 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 Insulation test, generator field, exciter armature, exciter field, generator armature or stator Dielectric test, generator field, exciter armature, exciter field, generator armature or stator All safety shutdown and automatic controls Standard testing shall include portions of MIL-STD-705, Methods: 301.1b insulation resistance test 302.1a high potential test 401.1a winding resistance test 410.1a open circuit saturation curve test 503.1b start and stop test 505.2a overspeed protective device test 507.1c phase sequence test (rotation) 508.1c phase balance test (voltage) 510.1c rheostat range test 511.1c regulator range test 511.2b frequency adjustment range test 513.2 indicating instrument test (electrical) 515.1a low oil pressure protective device test 515.2a over temperature protective device test 516.1 controls, direction of rotation 640.1c maximum power test The Contractor shall provide replacement parts described below that match products installed and that are packaged with protective covering for storage and identified with labels describing contents. Fuses: One for every 10 of each type and rating, but no fewer than one of each. Indicator Lamps: Two for every six of each type used, but no fewer than two of each. Filters: Two sets each of lubricating oil, fuel, and combustion-air filters as indicated by paragraph 3.21B. Shop Drawings: Detail equipment assemblies and indicate dimensions, weights, loads, required clearances, method of field assembly, components, and location and size of each field connection. Dimensioned outline plan and elevation drawings of engine-generator set and other components specified. Wiring Diagrams: Power, signal, and control wiring. CONTRACTOR FURNISHED TRAINING A. The Contractor shall provide approximately four (4) hours of training on the operation of this equipment to approximately 6-10 Government employees. Training shall take place at DLA Distribution Susquehanna, Pennsylvania in New Cumberland, PA. Training shall include as a minimum; start-up, equipment operation, clean-up, and general maintenance