12157-08-001 Replace 125 VDC Batteries at ETF-B and ETF-C Plants SOW.pdf

12157-08-001

SOW NO. 12157-08-001

12 March 2008

Approved for public release;

Distribution unlimited

STATEMENT OF WORK

FOR

REPLACE 125 VDC BATTERIES AT ETF-B AND ETF-C PLANTS

ARNOLD ENGINEERING DEVELOPMENT CENTER

ARNOLD AIR FORCE BASE, TENNESSEE 37389-9998

TABLE OF CONTENTS

Section/Paragraph Page

1. SCOPE

1.2 Background and Statement of Need

2. APPLICABLE DOCUMENTS

2.1 Government Documents

2.2 Non-Government Documents

3 REQUIREMENTS

3.1 Safety Requirements

3.2 Quality Assurance

3.3 Hazardous Material Identification and Material Safety Data

3.4 Hazardous Waste

3.5 Submittals

3.6 Schedule

3.7 Job Conditions During Execution

3.8 Installation

3.9 Standards of Performance

4 Test, Demonstration, Inspections, and Training 5 Shipping and Storage

5.1 Preparation for Delivery

5.2 Other

STATEMENT OF WORK

1. SCOPE

1.1 Provide all services, plant, labor, transportation, per diem, materials, supplies, and equipment to design, manufacture, deliver, install, checkout, and place in service four replacement 125 VDC systems at Arnold Air Force Base, Tennessee. Each system shall consist of 60 flooded-cell lead acid batteries with charger and monitoring system. Work also includes removal of old batteries from AEDC. Major Items of work include, but are not limited to, the followings tasks at facilities 929, 922, 903, and 879:

1.1.1 Remove existing 125 VDC battery banks, battery chargers, and battery rack in designated facilities from AEDC.

1.1.2 Provide temporary uninterruptible 125 VDC power capable of supplying 200 ampere-hours at Bldg. 929 and 903, 50 ampere-hours at building 903, and 120 ampere-hours and building 879. Connection for temporary power shall be made while existing system is operational.

1.1.3 Install new 125 VDC battery banks, battery chargers, and battery rack in designated facilities.

1.1.4 Install accompanying battery monitoring system in each facility.

1.2 Background and Statement of Need: The station batteries at each of the four locations provide 125 VDC to operate electrical circuit breakers, relaying, and controls for electric motors driving pumps and fans. These batteries are mission essential for maintaining continuous control and operation of the switchgear.

The monitors are needed to enhance and simplify battery maintenance operations. The batteries at each location are:

Facility 929 - 60 cells, 2V flooded cell lead acid.

Facility 922 - 60 cells, 2V flooded cell lead acid.

Facility 903 - 60 cells, 2V flooded cell lead acid.

Facility 879 - 60 cells, 2V flooded cell lead acid.

2. APPLICABLE DOCUMENTS - The Contractor shall comply with the latest revisions and provisions of the following documents to the extent referenced herein.

2.1. Government Documents:

2.1.1 Standards:

A. AEDC Safety, Health, and Environmental Standards:

1. B1 Master Work Permit, 2007

2. B2 Lockout Tagout, 2007

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3. B3 Control of Hazardous Areas, 2007

4. B6 Low Voltage Electrical Systems and Related Work

Practices, 2007

5. E6 Hazardous Material Management Program, 2007

6. F2 Personal Protective Equipment, 2007

B. Code of Federal Regulations:

1. 40 CFR 261 Hazardous Waste Management Systems:

Identification and Listing of Hazardous Waste, 2007.

2. 40 CFR 262 Standards Applicable to the Generators of Hazardous Wastes, 2007.

3. 40 CFR 263 Standards Applicable to the Transporters of Hazardous Wastes, 2007

4. 40 CFR 266 Standards for the Management of Specific Hazardous Wastes and Specific Types of Hazardous Wastes Management Facilities

C. U.S. Army Corp of Engineers:

1. EM-385-1-1 Safety and Health Requirements Manual, 2003

2.1.2 Drawings: The following drawings will be provided for reference purposes. The referenced drawings show location of the batteries and related items but their accuracy and applicability cannot be guaranteed by the Government. The contractor shall field verify all information and obtain approval from the Systems Engineer for location of new equipment prior to finalizing the design.

A. Aerospace Testing Alliance:

1. 3-20-E222 Air Supply Building Single Line Diagram Facility

2. 3-20-E249 Refrigeration Control Building Single Line

Diagram Facility 922

3. 3-40-E306 Single Line Diagram Exhaust Building Facility 903

4. 3-40-E311 Partial Power Plan Ground Level-West Facility

B. DMJM-Norman:

1. 3-20-E239 Air Supply Building Power Details & Schedules

MCC-1, MCC-2, MCC-3 & EPP-1 Facility 929

2. 3-20-E228 Air Supply Building Power Plan Ground Level

North Facility 929

3. 3-20-E254 Refrigeration Control Building Schedule and

Details Facility 922

4. 3-20-E251 Refrigeration Control Building Miscellaneous

Power Plan Facility 922

5. 3-40-E322 Exhauster Building, Power Details and Schedules, MCC-1, MCC-2, MCC-3, and EPP-1 Facility 903 C. Sverdrup and Parcel, INC.

1. A-038 High Altitude Engine Test Facility Exhauster Building Basement Floor Plan Facility 879

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2.2. Non-Government Documents:

2.2.1 Standards:

A. Institute of Electrical and Electronic Engineers (IEEE):

1. IEEE C2-02 National Electrical Safety Code.

2. IEEE 450-02 Recommended Practice for Maintenance, Testing, and Replacement of Vented Lead-Acid Batteries for Stationary Applications

3. IEEE 484-02 Recommended Practice for Installation Design and Installation of Vented Lead-Acid Batteries for Stationary Applications

4. IEEE 485-03 Recommended Practice for Sizing Lead-Acid Batteries for Stationary Applications

5. IEEE 1491-05 Guide for Selection and Use of Battery Monitoring Equipment in Stationary Applications.

B. National Fire Protection Association (NFPA):

1. NFPA 70-05 National Electrical Code.

2. NFPA 70E-04 Standard for Electrical Safety in the Workplace.

3. NFPA 110-05 Emergency and Standby Power Systems

3. REQUIREMENTS

3.1. Safety Requirements:

3.1.1. All work, including design, construction, and installation, shall be accomplished in compliance with AEDC Safety Standards A6 with all supplements and appendices, B1, B2, B3, and NFPA 70E Article 320.

3.2 Quality Assurance:

3.2.1 Materials:

A. Provide materials, components, parts, and equipment to be incorporated into the work, which are manufactured in accordance with recognized and accepted standards such as IEEE, ASTM, NEMA or similar. Where possible, use materials, components, parts, and equipment which have been tested and listed by an independent agency such as UL. Reject damaged and inferior materials, components, parts, and equipment. All materials used shall be new and unused.

B. The Government reserves the right to inspect all material for discrepancies, damage, and inferiority once the material arrives on-site.

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3.3 Hazardous Material Identification and Material Safety Data:

3.3.1 Procedures:

A. The Contractor shall provide information on the hazardous materials he brings on AEDC property prior to beginning on-site work. Hazardous materials may include solvents, paints, adhesives, acids, or any other substance, which could be included within the definitions in paragraph 2.

B. The information required is:

1. Company name, point of contact, and phone number.

2. Brief statement indicating how the hazardous material will be used within the scope of the contract.

3. List of all hazardous materials to be used (product name, manufacturer’s name, and address).

4. Amount of each material to be stored on site and where it will be stored.

5. Where the product Material Safety Data Sheets (MSDS) will be maintained.

C. All unused products are the responsibility of the Contractor and shall be removed from AEDC property at the completion of the project.

D. The Contractor shall coordinate with the Government representative and the Hazardous Waste Operations Group (454-3628) if any hazardous waste is to be generated.

3.3.2 Definitions:

A. Hazard communication standard. A chemical right-to-know law under OSHA that requires chemical manufacturers and importers to assess the hazards of chemicals they make or import and to distribute this information to inform workers of the hazards associated with these chemicals. This written information is a Material Safety Data Sheet

(MSDS).

B. Hazard classes. Hazardous materials that have been grouped into classes by the Department of Transportation (DOT). These classes include explosives, flammables, oxidizers and organic peroxides, compressed gases, corrosives, and poisons.

C. Hazardous material. Any substance that may be harmful when used.

Specific substances have been designated as hazardous under the Clean Water Act, the Resource and Conservation and Recovery Act, and the hazardous air pollutants under the Clean Air Act.

D. Hazardous waste. Any waste that may cause or significantly contribute to serious illness or death or that may pose a substantial threat to human health or the environment, if not properly managed. Hazardous wastes may be solids, liquids, semi-solids, or compressed gases.

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3.4 Hazardous Waste: Where hazardous waste (as identified or listed in 40 Code of Federal Regulations 40 CFR 261) is generated, follow the procedures in AEDC Safety Standard E18, Chemical and Petroleum Products Waste Management, for storing and turning in hazardous waste. These procedures include the requirement to complete Forms GC-565 and GC-1337 to be furnished by the Government representative.

3.5 Submittals:

3.5.1 All submittals shall be made to the contracting officer.

3.5.2 Listing: At the end of this section is a summarized listing of the submittals required for the work. The listing is included for the convenience of users of the contract documents.

3.5.3 Transmittal Timing: Prepare and transmit each submittal to the Contracting Officer sufficiently in advance of the scheduled performance of related work and other applicable activities. Transmit different kinds of submittals for the same unit of work so that processing will not be delayed by the Government's need to review submittals concurrently for coordination.

3.5.4 Review Time: Allow sufficient time so that contract performance will not be delayed as a result of the time required to properly process submittals, including time for re-submittals, if necessary. Allow 10 working days for initial Government processing of each submittal. No extension of time will be authorized because of the Contractor's failure to transmit submittals to the Government sufficiently in advance of the work.

3.5.5 "Approval" submittals: Submittals requiring approval by the Contracting Officer are so designated in the applicable sections and the submittal list at the end of this section. When brand names or equal are specified, any "equal" submitted will require approval. Any submittal requesting a deviation will require approval.

Do not install any equipment or material requiring approval submittals until approvals are received from the Contracting Officer.

3.5.6 "Information Only" Submittals: Submittals not requiring the Contracting Officer's approval are considered to be "information only" submittals.

3.5.7 Miscellaneous Submittals: These submittals include the following:

A. Inspection and test reports. Furnish three copies of such reports.

B. Record drawings.

C. Operating and maintenance data. Furnish three bound copies of operating data and maintenance manuals.

D. Materials and tools. Refer to individual sections of the statement of work for required quantities of spare parts, extra and overrun stock, Page-5 maintenance tools and devices, keys, and similar physical units to be submitted.

E. Certifications and test reports. Furnish three copies of such submittals.

3.5.8 Summarized Submittal Table:

No. Paragraph Reference Submittal Description App Info 1 3.5.7.A Inspection and Test Reports X 2 3.5.7.B Record Drawings X 3 3.5.7.C Operating and Maintenance Data X 4 3.5.7.D Materials and Tools X 5 3.5.7.E Certifications and Test Reports X 6 3.6.1 Design and Installation Schedule X 7 3.6.5 Plans X 8 3.6.7 Documentation X 9 3.6.9 Manuals X 10 3.6.10 Software X

3.6 Schedule:

3.6.1 Design and Installation Schedule: Within 10 working days following Notice to Proceed, submit to the Contracting Officer a schedule showing dates and durations of each major milestones. Include at a minimum the following:

A. Site investigation started/completed.

B. Plans submitted.

C. Start of procurement of monitors and backup power supplies.

D. Start of installation of each battery, battery charger, and monitoring system.

E. Completion of installation of each battery, battery charger, and monitoring system.

F. Start of checkout/verification on each battery, battery charger, and monitoring system.

G. Completion of each checkout/verification.

H. Scheduled turn over to the Government of entire system.

3.6.2 Site Inspection: The contractor shall schedule and conduct a site investigation of each of the site locations prior to starting design. At that time he shall obtain from the Systems Engineer approved locations for all equipment to be installed, location to obtain normal power for the monitoring system, and location of cabinets to connect to the LAN.

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3.6.3 Authority: The Commander, Arnold Air Force Base is responsible for all aspects of operations and readiness of the base. He has designated the Battery Systems Engineer to maintain documentation and control of the various station batteries on the base. The Systems Engineer will review and approve this design prior to start of on-site installation work.

3.6.4 Design Reviews: The contractor shall provide a design installation package, including drawings and installation specifications/instructions, for Government review and approval prior to scheduling field installation. No formal on-site design reviews are anticipated, but the Government reserves the right to schedule and hold such reviews to resolve lingering issues. The contractor shall be required to attend and support such reviews if scheduled.

3.6.5 Plans: Submit plans and details to the Contracting Officer for each 125 VDC battery bank, battery charger, and battery monitoring system to be installed under this contract. Plans shall be standard drawings not less than “D” size with title blocks. Plans shall be on paper and electronic media using AutoCAD™ format. Plans shall show locations of monitors, batteries, chargers and supporting devices. Details shall show wiring, points of connection, and modifications to existing systems and interfaces to the AEDC local area network (LAN). Submit drawings at least 20 days prior to start of installation and do not begin installation of any system until receiving Government approval.

3.6.6 Preconstruction Conference: Within 20 working days of approval of the final design, the contractor shall convene a pre-construction conference at AEDC. At this conference, the contractor shall be briefed on scheduling outages, security, safety, and other housekeeping issues at AEDC.

3.6.7 Documentation: Furnish a CD-ROM of all final documentation including as-built drawings as well as specifications and cut sheets for each battery, charger, monitor and inverter. As-built drawings shall show details of installed equipment and all locations of new equipment. Drawings shall be in AutoCAD™ format.

The CD-ROM shall include every associated component file of the drawings and other documentation, including raster images, jpeg, tif, excel, and any related items required to view, modify, or manipulate the electronic files. Submit to the Contracting Officer for approval prior to applying for final payment.

3.6.8 Final Design Documentation: Final design documentation shall become property of the Government without encumbrances or restrictions.

3.6.9 Manuals: Submit three copies on paper and an electronic copy (Microsoft® Word® 2000 or later or Adobe® Acrobat® format) of an operations and maintenance manual for each VDC battery bank, battery charger, and battery monitoring system installed. The manufacturer’s standard manual for each item is acceptable provided it is annotated for the AEDC installation. The manuals shall include, as a minimum, detailed operation and maintenance (corrective and preventive) instructions, troubleshooting guides, Bill of Materials for all parts, emergency contact information and any other information required to safely and efficiently operate and maintain all parts of the systems.

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3.6.10 Software: Provide the system manufacturer’s standard software as required to be installed on AEDC workstations and laptop computers to permit communications and monitoring of the system. Any restrictions on software use shall be approved by the Systems Engineer.

3.6.11 Construction Completion Conference: Following construction completion and prior to final acceptance of the work the Contractor shall in conjunction with the Contracting Officer convene a construction completion conference. At this conference all unresolved issues (punch list) will be addressed. Upon resolution of punch list items and submittal of final as-built drawings, the work shall be turned over to Arnold Air Force Base personnel.

3.7 Job Conditions During Execution:

3.7.1 Place all sanitary waste in Contractor provided dumpsters.

3.7.2 Plan and execute this project in a manner to minimize downtime. Furnish new components and devices, complete, with all necessary materials for installation to meet this objective. Schedule all work in advance with the Government representative.

3.7.3 Keep work area clean and free from waste and debris. Dispose of waste as directed by the Government representative.

3.7.4 Do not close or obstruct existing egress to any building or site exit without written permission from the Government representative.

3.7.5 Do not close, block, or otherwise obstruct streets, walks, or other occupied or used facilities without written permission from the Contracting officer.

3.7.6 Cease operations immediately for any unsafe conditions and notify the Government representative. Do not resume operations until authorized by the Government representative.

3.7.7 Provide temporary barricades and other forms of protection as required to protect Government personnel and the general public from injury due to the work. Remove protections at the completion of work.

3.7.8 Do not interrupt existing utilities or commence power outages without signed authorization from the Government representative.

3.8 Installation:

3.8.1 A portable backup battery of sufficient capacity shall be provided by the contractor while the existing battery is out of service. The backup battery shall be moved from site to site as the work progresses.

3.8.2 All permanent electrical connections to the permanent battery, cells, monitors, and other equipment shall be made with ring-tongue lugs or other secure type

Page-8 connectors. Alligator clips or other temporary connections are not acceptable for the final installation.

3.8.3 Installation shall be performed in accordance to IEEE C2 and 450 and the NEC.

3.8.4 Provide communication wiring from each monitor to the LAN cabinet using unshielded CAT 6 horizontal cables within rigid metallic conduit. All communication wiring and fiber shall conform to TIA/EIA 568.B. The approximate lengths of cable and conduit runs needed are as follows:

Facility 879 – 200 feet Facility 903 – 300 feet Facility 922 – 150 feet Facility 929 – 200 feet

3.8.5 Strictly observe AEDC lockout tag-out procedures and all other Safety, Health, and Environmental standards during the on-site performance of this contract.

For situations not covered by AEDC Standards follow the guidance of CoE EM- 385-1-1.

3.8.6 Lead acid batteries shall be secured and placed on pallet(s) and taken to Power Control (bldg. 1525) for pick-up. Jay West (x7250) is the point of contact at Power Control. Batteries shall be on pallets; do not place any of the batteries in boxes.

3.9 Standards of Performance:

3.9.1 Battery: Each battery shall consist of 60 flooded lead-calcium cells within transparent jars interconnected with proper connectors provided by the battery manufacturer to provide a nominal battery rating of 125 volts. Cell jars shall be transparent to allow for visual inspection of plates. Cell jars shall have electrolyte high and low levels indicated on each side. Each cell shall have posts extending above the cap for the purpose of system monitoring and cell voltage measurements. Batteries shall be installed so that the sides of each plate are visible from the front of the rack. The battery posts can not have copper inserts.

Each cell shall have acid withdrawl tubes in order to be able to take temperature and specific gravity readings. Replace the existing cables between the charger and the batteries. Each battery shall have an ampere-hour capacity adequate for an 8-hour period as follows:

A. Bldg. 929, 200 ampere-hours

B. Bldg. 922, 200 ampere-hours

C. Bldg. 903, 50 ampere-hours

D. Bldg. 879, 120 ampere-hours

Batteries shall have a minimum 20-year pro-rated life and a 5-year no cost replacement warranty. Battery manufacturer must have a minimum of twenty

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(20) years or more experience making batteries of this size and type. The specific gravity of each battery shall be 1.215 at 77 degrees Fahrenheit. The contractor shall provide all necessary inter-cell connectors and stainless steel hardware for the battery system. All cell connections shall be coated with a light coat of NO-OX-ID grease for corrosion protection. Each cell shall be equipped with vent type flame arrestors of the fused aluminum type. Each battery shall be equipped with spill containment. All battery cells, at system turnover shall meet the minimum manufacturer’s specifications for inter-cell resistance, cell voltage, specific gravity, and electrolyte levels. Battery capacity at the end of installation, and before system turnover, shall be a minimum of 95% of manufacturer’s rating, when tested at a minimum of the two (2) hour rate.

3.9.2 Battery Rack: Seismic rated battery racks shall be provided and shall have bolted steel frame and rails finished with two coats of electrolyte-resistant paint of standard manufacturers color. Racks shall be bolted down and connected to the building ground system. Racks shall be no more than two steps high and top steps shall be low enough to permit maintenance to be done at floor level. Rails shall have a top covering of plastic at least 1.6 mm or 1/16 inch thick. Paint, rubber, and plastic shall resist corrosion and action of the electrolyte. Where recommended by the manufacturer, the installation shall include a cell lifter.

Rack layout must conform to space requirements for each location:

A. Bldg. 929, 209” L x 21” W

B. Bldg. 922, 209” L x 21” W

C. Bldg. 903, 62” L x 21” W

D. Bldg. 879, 147” L x 22” W x 55” H

3.9.3 Battery Charger: The battery charger shall be a constant voltage output of 130 VDC nominal, with a 115-140 V float adjustment range, and 124-150 V equalize adjustment range. Float and equalize voltage adjustment potentiometers shall be located on the front of the charger such that they can be changed without opening the charger. The output regulation shall be ±1.0% of DC voltage setting maintained against the combined variations of line, load and temperature. The output transient response shall be ±5.0% maximum of DC voltage setting maintained with step load changes from 20% to 100%. Recovery shall be to ±2.0% of DC voltage typically within 200ms. Recovery to steady state DC voltage setting shall be typically within 500ms. Charger shall be equipped with a soft-start feature to prevent overshoot of DC voltage setting at turn-on. The electric current limiting circuitry shall be continuously adjustable from 90% to 120% of rated load. The filtered output ripple voltage shall be 30 mVrms or less.

Charger shall also be able to operate as DC power supply without batteries.

Input and output breaker shall be rated and installed for the charger. Warrant the installed system against defects in manufacture and installation for a minimum of two years, unconditional, warranty from date of installation and government acceptance.

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A. Alarm Indicators

• Over Voltage

• Under Voltage

• Under Current

• AC Power Failure

• Ground Detection

B. Meters

• Voltmeter (DC)

• Ammeter (DC)

C. Battery Charger I/O Ratings (Location Specific):

VAC In (3 phase)

VDC Out IDC Out

Bldg 929 480 135 200 Bldg 922 480 135 200 Bldg 903 480 135 50 Bldg 879 480 135 120

3.9.4 Battery Monitoring System: Mount and install battery monitoring systems and inverters in accordance with IEEE 1491.The monitoring system required is the BTech Model S5H-102060-CO-WM for lead/acid batteries or approved equal by the System Engineer. Provide emergency backup power for the battery monitor from each battery. Use a rack-mounted Wilmore, Model 1654 1000 volt-ampere (VA) inverter. Contractor shall be responsible for mounting the monitors and inverters. Warrant the installed system against defects in manufacture and installation for one year from date of turn over to the Government.

4 TEST, DEMONSTRATION, INSPECTIONS, AND TRAINING:

4.1 Provide tests, demonstrations, and inspections in accordance with IEEE 450 to verify the operational integrity of each completed system. The Government representative and the System Engineer shall witness all tests, demonstrations, and inspections made to prove the system integrity.

4.2 Test/Inspection Reports: The Contractor shall submit for review the records of all tests required by this Statement of Work. This includes but is not limited to battery load bank testing after installation has been completed, but before final hookup to system is done. Other data required is intercell connection resistances, individual cell specific gravities, and voltages both before the load tests and after the cells have been returned to the fully charged state. All test reports shall be submitted within 7 days after the test is completed.

4.3 The Contractor shall be required to demonstrate and validate the operation and performance of the new electrical systems. The tests, inspections, and demonstrations in this section are in addition to all others specified in this text.

4.4 Provide training for three people on use of the software at a LAN connected PC.

Also provide training for accessing monitor data using a laptop.

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5. SHIPPING AND STORAGE

5.1 Preparation for Delivery: The Contractor shall provide all preservation, packaging, and packing to ensure safe delivery of the components to AEDC.

The contractor shall transport all required materials, supplies, tools, and equipment to AEDC and shall be solely responsible for off-loading and storing them. The Government will provide a lay-down area for storage but cannot guarantee the security of items stored there. The contractor shall be responsible for the security of all items until the system is turned over to the Government and may elect to transport items on an as-needed basis.

5.2 Other: The Government will provide loading/unloading space for vehicles, tools, equipment, batteries, and other project materials. Sensitive electronic equipment shall be kept indoors.

END OF SOW

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