PWS.pdf

Fleet Numerical Meteorology and Oceanography Center Statement of Work

Cleaning and Repair of Eaton UPS #1 and UPS #2

BACKGROUND:

During Bldg. 708 installation of heat curtains surrounding the Eaton Uninterruptable Power Supplies (UPS) units, the contractor drilled multiple holed through aluminum support rails above UPS #1 and UPS #2. While drilling these holes, metal shavings fall into the top of both UPS cabinets. The metal shavings inside UPS #2 worked their way down to UPS Power Module (UPM) #1 causing it to fail. Both UPS units currently have metal saving inside, leaving us vulnerable to additional and unpredictable electrical component failure if and/or when metal shavings randomly relocate to an undesirable location.

Note: The preventive maintenance (PM) service is also a concern, as Eaton is unwilling to accept the liability and associated risk under current conditions. Once this scope of work is complete, Eaton is expected to approve a full parts and labor UPS PM Service contract.

SCOPE:

This scope includes the cleaning, repair (including the procurement of all repair equipment, parts and material) and firmware upgrades of the following two (2) Eaton Model# 9395, 3-phase, 750KVA UPS units installed at FLENUMMETOCCEN, Building 708, 7 Grace Hopper Avenue, Stop 1, Monterey CA 93943-5501:

1. UPS #1: Serial # EJ085BAA02, Model 9395-825-825-CE, Battery Type VRLA Sealed, 200

2. UPS #2: Serial # EJ085BAA03, Model 9395-825-825-CE, Battery Type VRLA Sealed, 200

REQUIRMENTS:

1. The contractor shall be either Eaton or an authorized Eaton Corporation Reseller capable of providing full repair services.

2. The contractor shall provide certified Eaton repair/replacement equipment, components and parts in accordance with Eaton manufacturer’s recommendations.

3. The contractor shall provide certified Eaton field service personnel qualified to perform work.

4. The contractor shall provide proprietary Eaton UPS firmware service, and upgrades to the UPS with the latest available version.

5. The contractor shall perform all work in accordance with Eaton manufacturer’s recommendations.

6. The contractor shall be responsible for submitting site visit request to the Security Department of all personnel requiring access to the FLENUMMETOCCEN compound.

7. The contractor shall provide a certified electrician to make electrical connections between the load bank and the UPS before and after testing.

8. The contractor shall determine all applicable steps, checks, and procedures for the load bank testing and furnish a copy of such in advance to the Government for review and approval prior to starting work.

9. The contractor shall keep the work area clean and orderly at all times, and remove trash and debris from site at the end of each work shift.

10. The contractor shall remove and dispose of all unneeded components, parts, materials and/or equipment from site upon project’s completion.

11. The contractor shall confirm to the Government that the UPS system is restored to full operation upon project completion.

12. The contractor shall provide all project reports, documentation and test results to the Government within 7 days after project completion.

13. The contractor shall answer any questions related to the cleaning and repair that the Government may have.

PERIOD OF PERFORMANCE:

Note: All work shall be accomplished within five (5) consecutive workdays, from a Thursday to the following Wednesday (excluding Saturday and Sunday), preferably during normal working hours, 8:00 am to 5:00 pm.

1. The Government will provide a schedule with repair dates and working hours.

2. UPS #2 work shall be performed over a two (2) day period, Thursday through Friday.

3. UPS #1 work shall be performed over a two (2) day period, Monday through Tuesday, immediately after the UPS #2 work.

4. After UPS #1 and UPS #2 work has been completed, the four (4) hour firmware upgrades shall be performed and shall take place the next day, Wednesday, during normal working hours.

TASKS:

Pre-Installation Tasks:

1. Perform a pre-inspection of the UPS for Suitability and Compliance of Intended Upgrade Procedure.

2. Verify replacement parts, components and equipment are the correct type and quantity prior to starting work.

3. Perform Facility Environment Cleaning in Bldg. 708 UPS room location (Floors, Walls, Equipment, etc.) to remove and dispose of metal shavings and debris.

UPS #2:

Electrically isolate and bypass UPS #2 from the critical power system. Take UPS #2 offline first, since one (1) of three (3) UPM’s is not functioning. The present conditions only allow the unit to operate at 500 KVA rather than the designed 750 KVA. The Government desires UPS #2 to be 100% operational before transferring all critical load from UPS #1 to UPS #2.

Once UPS #2 is electrically isolated, the following shall be performed on UPS #2 while UPS #1 remains online and conditioning the critical load to Bldg. 700:

1. Remove and dispose of (1) Mini CSB, (18) Rectifier/Invert Modules, (6) Battery/Neutral Power Modules, (6) IO boards, (3) AC and DC oil filled capacitor pan assemblies, and (1) front panel air filter pad.

2. Perform UPS #2 inspection and document findings and recommendations in support of the FLENUMMETOCCEN Eaton 9395-825 UPS systems.

3. Perform a deep cleaning to remove and dispose of accessible metal shavings and debris that are present in UPS #2.

4. Remove the fan trays, clean, inspect, and reinstall.

5. Procure, furnish, plan and install (1) Mini CSB, (18) Rectifier/Invert Modules, (6) Battery/Neutral Power Modules, (6) IO boards, (3) AC and DC oil filled capacitor pan assemblies, and (1) front panel air filter pad with new factory components.

6. Additional parts requiring replacement, if any, shall be quoted at time of discovery.

7. When the cleaning and parts replacement is complete, UPS #2 shall be energized.

8. Perform Eaton manufacturer’s recommended checks as performed during startup of a new UPS.

9. Perform UPS #2 calibration and 750 KVA load bank test. (See Calibration and Load Bank Testing requirements below)

10. Once UPS #2 is deemed ready for load, UPS #1 and UPS #2 shall be put in parallel.

Note: At this point, the system shall then be left in parallel overnight as added assurance that UPS #2 is properly functioning prior to transferring all critical load from UPS #1 to UPS #2.

UPS #1:

Electrically isolate and bypass UPS #1 from the critical power system. The same procedure for UPS #2 shall be followed, with the exception of the (1) mini-CSB replacement that occurred in UPS #2; the mini- CSB replacement is not needed in UPS # 1.

Once UPS #1 is electrically isolated, the following shall be performed on UPS #1 while UPS #2 remains online and conditioning the critical load to Bldg. 700:

1. Remove and dispose of (18) Rectifier/Invert Modules, (6) Battery/Neutral Power Modules, (6) IO boards, (3) AC and DC oil filled capacitor pan assemblies, and (1) front panel air filter pad.

2. Perform UPS #1 inspection and document findings and recommendations in support of the FLENUMMETOCCEN Eaton 9395-825 UPS systems.

3. Perform a deep cleaning to remove and dispose of accessible metal shavings and debris that are present in UPS #1.

4. Remove fan trays, clean, inspect, and reinstall.

5. Procure, furnish, plan and install (18) Rectifier/Invert Modules, (6) Battery/Neutral Power Modules, (6) IO boards, (3) AC and DC oil filled capacitor pan assemblies, and (1) front panel air filter pad with new factory components.

6. Additional parts requiring replacement, if any, shall be quoted at time of discovery.

7. When the cleaning and parts replacement is complete, UPS #1 shall be energized.

8. Perform Eaton manufacturer’s recommended checks as performed during startup of a new UPS.

9. Perform UPS #1 calibration and 750 KVA load bank test. (See Calibration and Load Bank Testing requirements below)

10. Once UPS #1 is deemed ready for load, UPS #1 and UPS #2 shall be put in parallel, unless it is determined and recommended by Eaton Field Technician to move immediately into the firmware upgrades. (See Firmware Upgrades requirements below)

Calibration and Load Bank Testing:

1. Perform UPS calibration.

2. Supply a 750 KVA load bank, required cables and a certified electrician to make electrical connections between the load bank and the UPS before and after testing.

3. It is the responsibility of the contractor to provide, stage and remove the load bank, and associated load bank cabling.

4. Cabling shall be of adequate length to position the load bank in area suitable for heat rejection, and in an area where heat can safely dissipate away from personnel, buildings and sensitive equipment.

5. Eaton field service personnel shall perform the UPS load bank test verifying the UPS performance at various load steps per the manufacturer’s recommendations.

UPS Firmware Upgrades:

1. Eaton Field Service Personnel shall provide the latest available Eaton firmware version.

2. Eaton field service personnel shall place both UPS #1 and UPS #2 in bypass to allow firmware upgrades.

3. Eaton Field Service Personnel shall install and verify the UPS firmware upgrades.

Note: the UPS units must be bypassed at the same time to allow the firmware revision to operate in parallel. Once a firmware upgrade is performed on one unit, it cannot be put in parallel until the second unit is upgraded to the same firmware revision.