Attachment (A) NSLSII-EEG-SOW-SPC-001.pdf

Brookhaven National Laboratory Number: NSLSII-EEG-SOW-SPC-001

Brookhaven Science Associates Version: 2

National Synchrotron Light Source II (NSLS-II) Effective: 04MAR2024

NSLS-II Cryo Generator & ATS

Statement of Work and Technical Specification QA Category: A-2

Document Reviewed and Approved By:

Prepared by Derek Pulis NSLS-II Electrical Engineering Group Leader

Approved By Scott Buda NSLS-II Electrical Engineer

Approved By Robert Lee ESH Manager

Approved By Judith Harris NSLS-II Quality Assurance Engineer

Approved By James Rose Deputy Director, NSLS-II Accelerator Div

Approved By Timur Shaftan Director, NSLS-II Accelerator Div

Approved By Philip Bernath Contracts Administrator

Reviewers (These are additional people who are not approving through SharePoint.)

Reviewed By Michael Monteleone Staff Electrical Engineer ii National Synchrotron Light Source II

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VERSION CONTROL SHEET

VERSION DESCRIPTION DATE AUTHOR APPROVED BY

1 First Issue 05JAN2024 D. Pulis See cover page.

Sections 2,3,4,5 were updated. References Section was separated and inserted into Section 2. Sections 2-5 shifted to 3-6.

Section 3 Technical Requirements: order of subjects were changed and consolidated.

Section 6 Technical Specifications – the specifications were reduced and this section was condensed.

04MAR2024 D. Pulis See cover page.

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Contents

1 Introduction and Overview

2 References

2.1 Reference Documents

2.2 Conflicts

3 Technical Requirements

3.1 Contractor Responsibilities

3.1.1 Design, Engineering and Manufacturing Documentation

3.1.2 Progress Reporting

3.1.3 Testing

3.1.4 End Item Documentation (EID)

3.1.5 Warranty

3.1.6 Shipping

3.1.7 Setup

3.2 Vendor Training

3.3 Work Plan

4 Deliverables

5 Value Engineering

6 Technical Specifications

6.1 Electrical

6.1.1 Generator

6.1.2 Automatic transfer switch (ATS)

6.2 Regulatory Requirements

6.3 Mechanical

6.4 Environmental Requirements

6.5 Fuel Tank

6.6 Starting System

6.7 Enclosure

6.8 Controls and Monitoring

6.9 Control Panel― Integral Functionality:

6.10 Digital Monitoring Capability:

6.11 Alarms and Shutdowns:

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Definitions/Acronyms

ANSI American National Standards Institute

ATP Acceptance Test Procedure

ATS Automatic Transfer Switch

ASME American Society of Mechanical Engineers

BMM Beamline for Materials Measurements

BNL Brookhaven National Laboratory

BSA Brookhaven Science Associates

DOE Department of Energy

DWG Drawing

EID End Item Documentation

EPA U.S. Environmental Protection Agency.

ESH Environment, Safety, and Health

FAT Factory Acceptance Test

GeV Giga (109) electron Volts

IEC International Electrotechnical Commission

IEEE Institute of Electrical and Electronics Engineers

ISO International Organization for Standardization

NEC National Electric Code

NFPA National Fire Protection Association

NRTL Nationally Recognized Test Lab

NSLS-II National Synchrotron Light Source II

PPE Personnel Protection Equipment

QA Quality Assurance

SAT Site Acceptance Test

SAT Site Acceptance Test

SOW Statement of Work

SPC Technical Specification

UL Underwriters Laboratories

NSLSII-EEG-SOW-SPC-001: NSLS-II Cryo Generator & ATS Statement of Work and Technical Specification 1

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1 INTRODUCTION AND OVERVIEW

This Statement of Work (SOW) and Technical Specification (SPC), hereinafter called “the SOW/SPC,” is the basis for the procurement, delivery, installation and setup with acceptance testing of a 500 kW Generator & 1,000 A Automatic Transfer Switch (ATS) to be installed at NSLS-II. BSA will provide the pad (cement foundation). BSA shall install and connect all conductors to the Generator and ATS. Contractor shall provide expertise and guidance on all connections The 500 kW Generator & 1,000 A ATS described in this document, hereafter referred to as the “Equipment”. Since installation of the Generator is an integral part of this document, the title of this combined Specification and SOW refers to the manufacturing requirements, testing, installation and certification.

2 REFERENCES

2.1 Reference Documents

• BNL-QA-101

• NFPA 110, Standard for Emergency and Standby Power Systems, 2019

2.2 Conflicts

In the event of a conflict between the SOW/SPC and any reference documents, the Contractor shall immediately notify the BSA Representative. Failure to notify the BSA Representative of a document conflict shall not relieve the Contractor’s responsibility to ensure full compliance with all requirements.

3 TECHNICAL REQUIREMENTS

3.1 Contractor Responsibilities

In accordance with the applicable specifications, referenced documents, and instructions as defined in this SOW/SPC, the Contractor shall be responsible for the design, engineering, purchase of all materials, manufacturing, assembly, delivery and setup of the Equipment.

3.1.1 Design, Engineering and Manufacturing Documentation

To ensure compliance with this document, and all the referenced documents, the Contractor shall provide the following documentation to BNL for review in the first progress report, prior to start of production.

▪ Specifications, sourcing and catalog cut sheets for all commercially purchased components

▪ Assembly drawings and Part Lists

▪ Manufacturing schedule (Gantt type chart) showing the timeline for each major activity necessary to meet the overall BNL schedule requirements in Section 5

3.1.2 Progress Reporting

Within two (2) weeks after award of contract, Monthly progress reports shall be emailed to the BNL technical representative. If additional information is needed, a conference call or video conference meeting between the Contractor and BNL shall be held at a mutually agreed upon time. Minutes of a conference call can qualify for a progress report.

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3.1.3 Contractor Required Inspection and Testing

The Equipment shall be tested at the Contractor’s facility to demonstrate full compliance with the SOW/SPC. The tests shall be conducted on the Equipment at the Contractor’s facility according to the FAT, prior to shipment to BNL.

All test data shall be documented and submitted to the BSA prior to shipment of the Equipment, for review and approval by BSA in writing.

3.1.4 End Item Documentation (EID)

At a minimum, the Contractor shall provide an electronic copy, and one hard copy, of the EID package with the delivery of the equipment. The EID package shall consist of the following documentation:

• Manufacturer and model

• Operation and Maintenance Manual

• Bill of Materials

• Overall length, width, and height

• Emissions certification showing the generator meets all emission standards of the EPA

• Generator fuel consumption in gal/hour at 100% of kilowatt rating

• Generator center of gravity XYZ locations

• Generator circuit breaker manufacturers information

• Recommended trip settings for all adjustable settings

• Short circuit interrupt rating

• Certificate of Conformance

• Factory Acceptance and Site Acceptance Test Reports

3.1.5 Warranty

• The Contractor shall provide a warranty for the Equipment, against failure and defects for a period of 1 year (min) from completion of Site Testing.

3.1.6 Shipping

• The Equipment shall be properly braced and cushioned so that it will not shift during handling and shipment.

• Each packing crate shall be fitted with ShockWatch and TiltWatch sensors or an equivalent approved by BSA.

• The Equipment shall be delivered to:

Brookhaven National Laboratory Central Receiving 98 Rochester Street Upton, New York 11973

• BNL requires a minimum of five (5) business days’ notice prior to the date and time of the carrier’s arrival at the BNL site.

• The BNL receiving department hours of operation are Monday through Friday between 9:00 AM and 3:00 PM Eastern Time Zone.

• The container shall be appropriately labeled with the listing of contents, destination, gross weight, location of center of gravity, purchase order number, and contact information.

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3.1.7 Setup

Vendor Responsibilities

• The equipment will be removed from all packaging and crating.

• All controls connections will be made.

• Cabling connections between Generator and ATS will be made.

• Site Acceptance Testing (SAT): Testing to ensure proper completion of work, compliance and/or system readiness to service (operations). Testing shall be as per NFPA 110, Standard for Emergency and Standby Power Systems, 2019, Section 7.13 Installation Acceptance.

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BNL Responsibilities

• Concrete pad shall be Installed by BSA (reference section 6.3 Mechanical)

• BNL Riggers shall offload truck and place Generator and ATS onto concrete pad.

• 480 VAC connections from substation to ATS and from ATS to facility performed by BSA (contractor shall provide expertise and guidance).

• 110 VAC power for battery charger, if required.

• Disposal of waste packing material shall be the responsibility of BSA personnel.

3.2 Vendor Training

BNL is a restricted access site. Persons that are not US citizens will require screening and approval.

Contact BSA Technical Representative for special instructions and requirements.

Perform all routine work on weekdays, excluding BNL holidays, between 8:00 a.m. and 5:00 p.m., unless otherwise specified or approved. BNL holiday list is available upon request.

All Contractor and Subcontractor employees must attend the Contractor/Vendor Orientation (CVO) Training Course and be approved by BSA to work on the BNL site. The CVO class and the badging will take approximately 4 hours. Classes are 2-3 times per week. Coordinate the initial visit with BSA technical representative to ensure the class is being held and so personnel can obtain temporary initial access to the site.

3.3 Work Plan

The Contractor will develop and deliver a written Job Hazard Analysis to the BSA Technical Point of Contact, for each task specified herein, identifying the safety risks and safety precautions taken to mitigate each hazard.

The Contractor will participate in a work permit process to review the known and anticipated hazards and ensure compliance with BNL safety requirements.

An example job hazard analysis can be provided upon request.

Work Plan - the Contractor shall develop a detailed written work plan for installation that includes all onsite installation activities in a step-by-step format. This plan is a prerequisite for obtaining a work permit and must be approved by BSA prior to the start of installation activities. The completed work plan shall be submitted to the BSA prior to delivery of the Equipment, and this work plan shall be attached to a Work Permit. The work plan shall include, at a minimum:

• Prerequisites: preparatory actions to be performed before work can be started and any administrative and physical requirements.

• Precautions: precautions that must be observed during performance of work.

• Identification for hold points and other monitoring.

• Scheduling, coordination, and notification.

• Work controls for mitigating identified hazards based on the following hierarchy, as practical.

o Elimination/substitution of hazards.

o Engineering controls.

o Administrative controls and work practices and/or personal protective equipment

(PPE)

An example work plan can be provided upon request.

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4 DELIVERABLES

Schedule in weeks after award of contract

Generator/ATS Design Review Draft Week 2

Generator/ATS Design Review Week 4

Contractor Walkdown of Installation Site Week 40

Factory Acceptance Test Draft Week 42

Work Plan Draft Week 42

Work Plan Week 48

Factory Acceptance Test Week 50

End Item Documentation Week 52

Equipment Delivery Week 52

Installation Week 53

Site Acceptance Test Week 53

Site Acceptance Test Report Week 54

Monthly progress update shall be coordinated as per section 3.1.2, Progress Reporting.

5 VALUE ENGINEERING

The Contractor is encouraged to make recommendations for changes that might lead to an improvement in performance, reliability, quality, safety, or reduction in cost. Simplicity in operation, ease of maintenance, and an improvement in the performance and reliability of the specific functions beyond the requirements of this specification are objectives which shall be considered in the production of each component type. Where it appears a substantial improvement in simplicity of design, performance, ease of maintenance or reliability will result from the use of materials, parts, and processes other than those specified, it is desirable that their use be investigated. When investigations point to advantages that may be realized, the recommendation for change shall be presented to BSA for review.

6 TECHNICAL SPECIFICATIONS

6.1 Electrical

6.1.1 Generator

• Generator shall be ≥ 500 kW, 480 Vac, 3 Phase, 4 Wire, 60 Hz (Wye).

• Steady-State Voltage: <5% of rated output voltage from no load to full load.

• Steady-State Frequency: <1% of rated frequency from no load to full load.

• Transient Voltage: <10% variation for 50% step-load increase or decrease.

• Transient Frequency: < 5% variation for 50% step-load increase or decrease.

• Start Time shall be < 10 seconds from ATS “Start Command”. NFPA 110 (Type 10, Level 2)

6.1.2 Automatic transfer switch (ATS)

• ATS shall be 480 Vac, ≥ 1,000 A, 3 Phase, 4 Wire, 60 Hz (Wye) o NOTE: Generator is only 500 kW (750A)

• Shall be equipped with terminals for the following connections:

o Utility: Three (3) 535 kcmil conductors per phase (1,000 A total max) o Generator: Two (2) 535 kcmil conductors per phase (750 A total max) o Load: Three (3) 535 kcmil conductors per phase (1,000 A total max)

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• Must be Make-Before-Break.

• Synchronize generator phase to utility prior to switching.

• Shall send the Generator a “Start Command” when voltage drops below a preset level within 1 second.

• Shall be include provisions for a remote emergency stop pushbutton.

• Shall be located outdoors - NEMA-3R

• Adjustable time delay (0-30 minutes) on transfer back to normal source to allow normal source to stabilize after restoration.

• This time delay shall be automatically bypassed if the generator fails.

• Shall provide provision to choose between a time delay before transferring back to normal source following restoration of power and running indefinitely until manually switched back to normal source

• Adjustable time delay (0-10 minutes) on engine shutdown to provide unloaded running of the diesel engine before shutdown for additional cool down.

o “ATS Bypass” toggle switch. Two positions:

▪ "NORMAL" - This will allow automatic transfer to Generator power and automatic transfer back to Utility power.

▪ "BYPASS" The "BYPASS" position shall lock the ATS in Utility power. This will allow the Diesel Engine to be tested without ATS functions.

o “Engine Test” toggle switch. Three positions:

▪ "OFF" The "off" position shall disable diesel engine from starting and automatic transfer switch from operating and shall immediately shutdown engine if running in "auto" or "engine test."

▪ "AUTO" The "auto" position shall place the diesel engine, automatic transfer switch, and associated controls in an automatic mode.

▪ "TEST" The " test" position shall exercise the diesel generator and ATS by simulating a normal power source failure, transferring the load to the generator.

o “Transfer Back Inhibit” toggle switch. Two positions:

▪ INHIBIT - This will allow automatic transfer to Generator power but will prevent the transfer back to Utility power. Transfer back to Utility would occur once the inhibit switch is toggled OFF (to NORMAL state).

▪ NORMAL - This will allow automatic transfer to Generator power and automatic transfer back to Utility power.

6.2 Regulatory Requirements

The generator covered by these specifications shall be designed, tested, rated, assembled and installed in accordance with all applicable standards of ANSI, NEC, ISO, U.L., IEEE, IEC and NEMA

• UL2200 – Listed.

• UL508A – Listed.

• UL 489 – Listed - Molded-Case Circuit Breakers, Molded-Case Switches, and Circuit-Breaker Enclosures.

• NEMA MG1 – Motors and Generators

• NFPA 70 – National Electrical Code.

• NFPA 99 – Essential Electrical Systems for Health Care Facilities.

• NFPA 110 (Type 10, Level 2) – Emergency and Standby Power Systems.

• NFPA 37 – Standard for the Installation and Use of Stationary Combustion Engines and Gas Turbines.

• Engine exhaust emissions: Comply with U.S. EPA requirements and applicable state and local regulations.

• The generator will need to meet the applicable emission standards outlined in 40 CFR 1039;

• Suffolk County Department of Health Services: Article 12 – Toxic and Hazardous Materials Storage and Handling Controls

6.3 Mechanical

The equipment shall be located in the area shown below. The cement concrete pad and fencing shall be installed by BNL. Details shall be provided after contract award.

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6.4 Environmental Requirements

• Engine-generator system shall withstand the following environmental conditions without mechanical or electrical damage or degradation of performance capability.

• Ambient Temperature: + 15°F to + 110°F

• Altitude: Sea level to 500.0 feet.

6.5 Fuel Tank

• Shall provide 24-hour capacity.

• Integral Fuel Tank mounted under the engine as a subbase.

• Diesel Fuel Grade #2 (DF2)

• Shall be compliant with Suffolk County Department of Health Services: Article 12 – Toxic and Hazardous Materials Storage and Handling Controls

• Tanks used for the storage of flammable or combustible materials must meet, or exceed, the design manufacturing standards of UL#142/80, API 650, API 620, and carry the appropriate label.

• The tank must be designed and constructed in a manner consistent with the requirements of NFPA 30 and the New York Uniform Fire Prevention and Building Code, where applicable (including properly sized emergency venting for both primary and secondary tank containment systems).

• The tank must be of double-walled construction (e.g. basin or rupture tank) and must utilize continuously welded seams.

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• A static pressure test must be conducted on the generator tank system as per the manufacturer’s specifications and must meet any one of the following standards: API 650/653, PEI RP200, STI SP001, UL142

• Metal fuel tanks and containment structures shall be electrically grounded.

• If the interior of the secondary containment structure (interstitial area) is not readily visible to the facility operator, i.e. does not contain a cut-out or equivalent method for inspecting the interstice, a leak detection system is required with audible and visual alarm capabilities. This system must also have a means of testing/confirming operability during routine inspections.

• The tank must have a positive means of preventing overfilling. A sight gauge satisfies this requirement.

A high-level alarm is not necessary if the tank is filled locally, and the sight gauge is clearly visible to the operator who is filling the tank. If an electronic high-level alarm is installed, it must have an audible and visual alarm and a means of testing/confirming operability during routine inspections.

• The tank must have individual weather-tight Spill Boxes for the fill and emergency vent with a minimum volume of 7.5-gallons and the Spill Box must have a hasp for applying a Master Lock.

• The tank must be elevated above local grade to prevent corrosion associated with ground/concrete contact, to permit complete inspection of the tank and to facilitate the detection of fuel leaks.

6.6 Starting System

A DC electric starting system with positive engagement shall include a storage battery and battery charger equipped with float and equalize charge settings.

• Starting motor: A DC electric starting system with positive engagement shall be furnished.

• Battery: A storage battery set shall be provided.

• Battery Charger: A voltage regulated battery charger shall be provided.

• Shall be equipped with provisions to automatically switch between the float and equalize charge modes.

• Shall provide indication of battery charger malfunction, low battery voltage, and high battery voltage.

6.7 Enclosure

• The complete diesel engine generator set, including generator control panel, engine starting batteries and fuel oil tank, shall be enclosed in a factory assembled, sound attenuated enclosure mounted on the fuel tank base.

• A weather resistant, sound attenuated enclosure of steel with electrostatically applied powder coated baked polyester paint. It shall consist of a roof, side walls, and end walls. Fasteners shall be either zinc plated or stainless steel.

• Outdoor Enclosures and Components: Manufacturer's standard finish over corrosion-resistant pretreatment and compatible primer.

6.8 Controls and Monitoring

All engine and control panel shall be accessible through manufacturer’s configuration software. The following maintenance functionality shall be integral to the generator set control.

• Engine running hours display

• Service maintenance interval (running hours or calendar days)

• Remote Communications shall be provided – RS485 or similar

• Provide 30V, 10A dry contacts for “Run” and “Fault” conditions

6.9 Control Panel― Integral Functionality:

The Contractor shall provide a list of all control panel functions. The control panel should have the capabilities list below. Exceptions must be noted at time of proposal.

• LCD alarm with text-based alarm/event descriptions

• Generator status

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• Unbalanced load indication

• Remote start/stop control

• Local run/off/auto control

• Cooldown timer

• Speed adjusts

• Emergency stop push button

6.10 Digital Monitoring Capability:

The Contractor shall provide a list of all digital monitoring capabilities available at the local control panel and remotely. The system should monitor the conditions listed below. Exceptions must be noted at time of proposal.

• Engine status

• Engine oil pressure

• Engine oil temperature

• Engine coolant temperature

• Engine Speed (RPM)

• Engine battery voltage

• Engine run time

• Generator AC voltage (Line to Line, Line to Neutral)

• Generator AC current (Avg and Per Phase)

• Generator AC Frequency

• Generator kW (Total and Per Phase)

• Power Factor (Avg and Per Phase)

• Total kW-hr

6.11 Alarms and Shutdowns:

The Contractor shall provide a list of all alarms and shutdowns. The controller should monitor and provide alarm indication and subsequent shutdown for the conditions listed below. All alarms and shutdowns are accompanied by a time, date, and engine hour stamp that are stored by the control panel for multiple past and recent events. Exceptions must be noted at the time of proposal.

• Low oil pressure alarm/shutdown

• High engine temperature alarm/shutdown

• Low coolant level shutdown

• Overspeed shutdown

• Over crank shutdown

• Emergency stop shutdown

• Low coolant temperature alarm

• Low battery voltage alarm

• High battery voltage alarm

• Battery charger failure alarm

• Generator phase sequence

• Generator over voltage

• Generator under voltage

• Generator over frequency

• Generator under frequency

• Generator overcurrent