2023_08_03stationbatterymonitorbidspecification_2_1 SNW edits.pdf

MASSACHUSETTS BAY TRANSPORTATION AUTHORITY

POWER SYSTEMS MAINTENANCE

Bid Specification for Procuring Installation & Commissioning of Station

Battery Monitors.

Prepared by Sean N. Walters

March 2, 2023 REVISED August 7, 2023, Addendum 1

STATION CONTROL BATTERY MONITORING SYSTEM

A. BATTERY MONITOR

1. The battery monitor system shall allow for remote monitoring of each cell through the

SAS/SCADA system. The system provided shall be compatible with the existing equipment currently in use at MBTA. It shall be rack mounted adjacent to the batteries.

2. On-Line Battery Monitoring System

1. Provide an on-line battery monitoring system that can monitor the performance of each battery cell at each of the MBTA traction power substations, store the performance data locally, and distribute this information to two central PCs. Each monitor shall be supplied complete with all required battery cell wiring for connecting each battery post to the monitor, associated connection hardware, current transducers, temperature transducers, fuses, and any other hardware needed to complete the assembly of the battery monitoring system at each substation. The system shall also include the necessary software to be installed at the two central PCs that are capable of managing the remote battery monitors and able to auto poll each system on a programmed schedule from a modem connection, Ethernet connection, or a combination thereof. This software shall be capable of receiving and archiving the measured data from each monitor, recalling and sorting it, printing and/or plotting it, and facilitating the observance of trends in the data which signify deteriorating conditions in a proactive manner. The software shall have a real time monitoring mode to allow a graphic presentation of real time voltage, temperature, and discharge data during a discharge test or live discharge event. Each substation battery monitor shall have the capability of sending an alarm automatically to the central PCs when an alarm condition has been detected, OR Each substation battery monitor system shall also be capable of integrating with the substation automation system to provide all status, polling, archiving data as described above and shall be capable of integrating fully with the battery monitoring software.

2. Detailed specifications for each battery monitors are summarized as follows and shall equal or exceed the product specifications of Alber corp’s MPM-100 Multi-

Purpose Monitor:

(a). String Capacity: Each monitor shall have the capacity to monitor 60, 2-volt cells connected in series to provide a string voltage of 120 volts.

(b). Input Power: The monitor shall be DC powered from the 120 volt station battery system.

(c). Operating Temperature Range: 41 to 104 degrees Fahrenheit.

(d). Humidity: 0 to 80% RH (non-condensing) at 5 to 31 degrees Celsius; 0 to 50%

RH (non-condensing) at 32 to 40 degrees Celsius.

3. Cell Voltage:

a. 0 to 4.000 volts; 0.1% of reading +_1mV.

b. 0 to 16.0 volts; +-20mV.

4. Cell Voltage Channel:

a. 2V range: (0-4V), 0.1%+_1mV

b. 4V range: (0-8V), 0.1%+-2mV.

c. 6V range: (0-8.5V), 0.1%+-2mV.

d. 8V range: (0-10V), 0.1%+-10mV.

e. 12V range: (0-16V), 0.1%+-10mV.

5. Cell Resistance: 0 to 32,000micro Ohms, 5% of reading +-1micro-ohm.

Inter-tier Resistance: 0 to 5milliOhms, 5% of reading +-5 micro-ohms.

String Voltage: 0 to 150 volts, 0.1% of reading +-0.1V.

Discharge Current: 0 to 4000Amps, +-5% of full scale using current transformer.

Temperature: 0 to 80 degrees Celsius, +-1 degree Celsius.

Float Current: 0 to 5000mA, +-50mA.

Communication:

a. One USB port

b. One modem serial port

c. One RJ-45 connection port or RS-232 connection port.

d. Protocols: MODBUS, DNP3, IEC 61850 and SNMP

Local Data Storage:

a. E2 nonvolatile memory for calibration constants, alarm levels, telephone numbers, and setup information.

b. 100 alarm events in revolving nonvolatile memory.

c. 32K bytes of discharge data in nonvolatile memory.

d. 1.6K bytes resistance test records.

e. 1.65K bytes historical data.

f. Flash memory for firmware upgrades.

3. Measurement Capability

(a). Individual cell voltage

(b). Individual cell DC resistance accomplished by applying a momentary load at user defined intervals.

(c). Individual intertier resistance measurements performed at user defined intervals.

(d). Total overall battery voltage per string.

(e). Ambient or pilot cell temperature per string for temperature trending.

(f). System discharge logging of the overall voltage, individual cells, discharge current, and temperatures.

(g). Float current per string.

4. System Hardware Requirements

(a). LEDs indicating alarms, communications, and processor status.

(b). Wiring harnesses with supplied connectors to be terminated in the field during installation.

(c). Individual fused leads to each battery cell/jar for resistance test load cables, and resistor terminated leads for voltage sense.

(d). Ring connector terminals at each connection.

(e). Ambient temperature probes, electrolyte temperature probes, shunt and shunt adapters, current/float cable assemblies, float current measurement transducer for each string, float charging current probes, external network interface equipment including necessary cables, and current and voltage transducers.

(f). “U” wall mount bracket for mounting each monitor to a concrete wall.

(g). One USB port for connection of a laptop for local data viewing or service.

5. System Software Requirements

(a). The software shall operate on the Windows 7 Professional, Windows 2000, and XP compatible software for data analysis, display, archiving, and trending.

(b). The software shall be responsible for maintaining a database of all information gathered from the monitors for future analysis and reporting.

(c). The software shall be configurable for wither a central, local or service computer application. The central configuration shall be responsible for permanently removing any data that may reside in the monitor E2 memory. The local configuration will not permanently remove data from E2 memory and will allow it to remain for the central computer. The service configuration will allow service technicians to call for real time analysis from any accessible phone line.

(d). The software shall be able to auto-poll multiple monitoring systems on a programmed schedule.

6. Password Protection: The battery monitoring system shall require a password to allow any programming or calibration changes either via remote connection or local connection.

7. System Performance

(a). The battery monitoring system shall monitor, display, and record the battery bank voltage, battery discharge current, individual cell voltages, configured temperature, individual cell resistance, and inter-tier resistances. All these parameters shall be continuously monitored in real time during normal operation and during all battery discharges, except for resistance test, which is a user programmable event.

(b). The battery monitoring system shall transfer all battery parameters specified above at the remote central computer at user defined intervals.

(c). The system shall automatically display, record, and provide a print-out of all alarm conditions, as and when they occur, at the remote central computer. The reporting shall include the following parameters:

(a). Individual cell voltage high and low alarm

(b). Individual internal resistance high alarm.

(c). Individual internal resistance warning as a percentage of alarm threshold.

(d). Inter-tier resistance high alarm.

(e). Overall voltage high and low alarm.

(f). Temperature high and low

(g). Individual cell voltage low alarm during discharge.

(h). Discharge string current.

(i). Discharge time alarm set in hours/minutes.

(j). Float current high alarm.

(k). Each alarm record shall include defined limits, alarming parameter, show the time and date of the event, and the peak value reached during the violation.

(l). Each parameter alarm shall be configurable for a latching or non-latching alarm contact function.

(m). As user defined, the system shall automatically page or fax a report to responsible personnel when any alarm thresholds are violated.

(n). The system shall provide and maintain a complete, real-time discharge event log and a dynamic on-line display of battery voltage, individual cell voltages, battery string current, and ambient temperature whenever the battery is in a discharge mode. In addition to the numerical display, the system shall provide a graphical display of the battery voltage and cell voltages versus time that allows playback of the discharge event.

(o). Store historical record of the internal cell resistance of each cell.

(p). Display the actual real time numbers (or stored snapshots) of all battery parameters at the remote central computer. Additionally, the display shall provide individual graphical representation of all battery parameters in relation to alarm thresholds.

(q). Provide automatic voltage logging of overall voltage, individual cell voltages, and temperature at user defined intervals for trending analysis.

8. System Report Generation Capabilities

(a). Alarm condition reporting – tabular, fax, or pager.

(b). Cell/jar out-of-limits summary report – tabular.

(c). Individual cell voltages over time – graph or tabular.

(d). Individual cell resistance values over time – graph or tabular.

(e). Total battery voltage over time – graph or tabular.

(f). Battery temperature / room temperature over time – graph or tabular.

(g). Discharge report: total battery voltage decay vs. time – graph or tabular.

(h). Discharge report: cell voltage decay vs. time – graph or tabular.

(i). Discharge hit summary report – tabular.

(j). Discharge hit interval summary report – tabular.

(k). General summary report of battery and monitor status of all systems to the battery or string level base on user set thresholds.

(l). Detail summary reports of battery and monitor status of all systems with a line graph trend of any parameter that violated a threshold.

9. User’s Guide

(a). Each substation with a battery monitor installation shall have one set of MBTA’s manuals, which include the following information as a minimum:

(a). Installation and commissioning instructions

(b). Operating instructions

Site Acceptance Tests: The battery monitor system supplier shall prepare site acceptance test procedures, which shall be used to validate the functionality and performance required by this specification.

System Installation, Start-up, Commissioning and Training

The battery monitoring supplier shall provide a field start-up engineer to supervise the system installation at each battery monitor locations. Supervision of the installation does not necessarily imply full time presence during all installation work. However, the start-up engineer must be present during critical times of the installation process, which includes as a minimum, the initial site planning visit, initiation of work to familiarize installation workers with the methods and procedures to perform the work, and a daily presence at the site thereafter to confirm that the work is proceeding as planned.

After installation, the battery monitoring supplier shall provide a field engineer to start up each battery monitor location and perform all required site acceptance tests to demonstrate that the system meets the functionality and performance of this specification. Before initiating each acceptance test, the field engineer shall co-ordinate with the MBTA to schedule this event at a mutually agreed time and date. A copy of the acceptance test procedure shall be provided to the MBTA a minimum of five (5) days before the start of each test. A signed copy of the completed acceptance test shall be provided for the MBTA’s records for each monitor location. Acceptance testing shall also take place at the two remote central computers to ensure that the vendor’s monitoring software is performing as required in this specification. A copy of the acceptance test procedure for the central computers shall be provided to the

MBTA a minimum of five (5) days before the start of each test. A signed copy of the completed acceptance report for each of the central computers shall be provided for the

MBTA’s record.

Factory Acceptance Tests: Each battery monitor and its software shall be factory tested before shipment to the MBTA to demonstrate the functionality and performance required by this specification. The vendor shall provide written certification for each of the factory acceptance tests, complete with the signature(s) and date(s) for the responsible staff performing the acceptance tests. In addition, a written copy of the full factory test procedure shall be submitted to the MBTA indicating the results of each test and the associated acceptance criteria for assigning a “pass” or “fail” outcome.

B. BATTERY ELECTROLYTE SENSOR

1. The battery level sensor shall you eliminate unnecessary remote site visits and will eliminate the required quarterly inspection of battery electrolyte level in your battery string.

2. The Alber ELSi2 shall be provided.

3. The ELS2 Electrolyte Level Sensor is a non-invasive level sensor with incorporated temperature monitoring designed for quick installation and easy set up. This device complies with the NERC PRC-005 requirements for electrolyte level inspection. With this sensor, you eliminate unnecessary remote site visits and will eliminate the required quarterly inspection of battery electrolyte level in your battery string. An ELS2 system will include one sensor module to be attached to each cell for monitoring electrolyte level and temperature. Each of these modules will be connected back to a system interface module called the ELSi2 for processing of data for alarm analysis and reporting.

C. NAMEPLATES

1. Each major component of equipment shall have, as a minimum, the manufacturer's name, address, and catalog number, model, style or type on a nameplate securely attached to the item in an area easily accessible to normal visual demands by maintenance and service personnel. Nameplates for electrical apparatus shall conform to the applicable industry standards for the specified equipment.

2. Each battery charger, panel board, terminal box, enclosure, and all panel mounted, and individually mounted equipment and devices shall be provided with nameplates for proper identification. Panel and door mounted devices shall also be identified in the rear with the designations indicated on manufacturer's connection diagrams. Internally mounted devices shall be similarly identified with nameplates and manufacturer's connection diagram designations.

3. Nameplates for panel and door mounted relays, meters, control and instrument switches, fuses and auxiliary devices and individually mounted circuit breakers, disconnect switches, etc., shall have 1/4 inch, minimum, lettering. For protective and auxiliary relays, the nameplate inscription shall include device number and function. Nameplates for fuses shall note the type and rating of fuse, polarity and identify the circuit.

4. All nameplates shall be laminated plastic with dull white surface and black core unless otherwise specified. Letters shall be engraved through outer layer to expose black core. All exposed edges shall be beveled. Nameplates shall be fastened with machine screws. Use of self-tapping screws or adhesives will not be permitted.

D. EQUIPMENT EXPERIENCE, AVAILABILITY, AND SERVICEABILITY

1. The vendor shall demonstrate that the proposed equipment has a proven reliability record in a dc traction power substation environment by furnishing a minimum of three references with names of contact persons and phone numbers at the referenced transit authorities in the United States. The subject equipment must have been in service at the referenced facility for a minimum of five (5) years.

2. The equipment vendor shall preferably have a service center and/or an affiliated field service battery installation and repair contractor within 250 miles of Boston

MA in order to be able to provide technicians, spare parts and accessories on short notice to enable the MBTA to minimize any disruption to the operating system in the event of any battery system problems. The vendor shall provide the location and names of facilities / field service contractors within this radius.

E. DELIVERY

1. The equipment vendor shall be responsible for all shipping and handling charges for the delivery of all materials furnished under this contract. All deliveries associated with the installation of station batteries shall be to the specific locations specified in Table 1 in Appendix A. In some cases, the vendor shall ship directly to a substation, and in other cases the delivery shall be made to the MBTA’s South

Boston Switching Station located at 696 East First Street in South Boston. All deliveries shall be coordinated with the MBTA’s Project Engineer. The delivery truck in all cases MUST be equipped with an operable hydraulic tail gate in order to accommodate drop offs both at street grade as well as at elevated truck docks.

2. The vendor shall coordinate the timing for each delivery with the MBTA’s Project

Engineer for a mutually convenient delivery time. A minimum advance notice of

48 hours is required before each delivery.

Deliveries made to specific substations shall involve bringing all furnished materials directly to the operating floor in close proximity to where the existing battery set is located. The logistics involved for each delivery location can vary depending on site specific conditions.

F. EQUIPMENT WARRANTIES

1. A written copy of the manufacturer’s warranty for batteries and charger/eliminator shall be included with the bid proposal.

2. For station battery monitors, the MBTA requires a full guarantee during the first

18 months from date of delivery acceptance at the respective drop-off location.

Thereafter the warranty should be pro-rated for the remaining 19 years of the designed battery service life.

3. For the battery charger/eliminators, the MBTA requires a one-year full guarantee from in-service date or 18 months from date of shipment, whichever occurs first.

Thereafter the warranty should be pro-rated for the remaining 19 years of the designed battery charger service life.

G. PAYMENT

1. Vendor may request partial payment for materials delivered and received in good condition as determined by the MBTA. Each invoice shall reflect a ten

(10) percent retainage by the MBTA, which shall be payable upon satisfactory acceptance of the installed material by the MBTA’s Project

Engineer.

H. LIQUIDATED DAMAGES

Not Applicable.

APPENDIX A

TABLE 1.

SUBSTATION MODEL NUMBER LOCATION DATE OF

INSTALLATION

DATE OF

COMMISSION

Lincoln Switching

High Street

North Quincy

Wollaston

Quincy Center

Kenmore

Dewey

Washington Village

Cabot

Columbia