Battery_System_Technical_Specification_Document_Final.pdf

BATTERY SYSTEM

TECHNICAL SPECIFICATION DOCUMENT

Naval Surface Warfare Center - Philadelphia Division

Document Number: 9917_0000

Rev. B

January 9, 2017

Battery System Technical Specification

Date: 9 Jan 2017

Technical Specification (TS) Documents

This Technical Specification comprises the following separate engineering documents:

A. TS Document #1: Technical Requirements Form

B. TS Document #2: Engineering Specification

C. TS Document #3: Technical Data Sheets - To Be Completed by Contractor

Table of Contents

Technical Specification (TS) Documents

TS Document #1: Technical Requirements Form

TS Document #2: Engineering Specification

1 Scope of this Specification

2 Overview

3 Applicable Codes, Standards, and Regulations

3.1 General

3.2 General Standards

3.3 Lifting and Rigging Standards

4 Rating, Conditions of Service, and Performance Warranty

4.1 Equipment Ratings, Materials, and Workmanship

4.2 Conditions of Service

4.3 Battery Acceptance, Performance Warranty and Defects Liability

5 Work Included: Contractor’s Responsibility

5.1 Overall System Requirements

5.2 Scope of Supply

5.3 Engineering Design and Status Reporting

5.4 Security Requirements

6 Work Included: Government’s Responsibility

6.1 Overall System Requirements

6.2 Scope of Supply

6.3 Analyses

7 General Requirements

7.1 Equipment Drawing and Technical Data Submittal Requirements

7.2 Installation Instructions, Operating, and Maintenance Manuals

7.3 Nameplates, Markings, and Notices

7.4 Special Tools, Devices, and Test Equipment

7.5 Assembly, Packaging, and Shipping

7.6 Spare Parts

8 Design and Construction Requirements

8.1 General Arrangement

8.2 General Design

8.3 Connections and Terminals

8.3.1 Instrumentation and Control

8.5 Delivery, Lifting and Rigging

9 Performance Requirements

9.1 Battery System Performance Requirements

10 Inspections and Tests

10.1 Categories and Scope of Tests

11 TS Document #3: Technical Data Sheets - To Be Completed by the Contractor

11.1 General Battery System Characteristics

11.2 Drawings and Design Documents (as applicable)

12 Annual Maintenance and Testing………………………………………………………………...37

12.1 Maintenance and Testing Requirements…………………………………………………………..37

TS Document #1: Technical Requirements Form

The Following Documents Form Part of the Technical Specification

Item # Document Title Revision #

1 Technical Requirements Form 1

2 Engineering Specification 1

3 Technical Data Sheets - To Be Completed by Contractor 1

Equipment Information:

The Following Equipment is to be procured under this Technical Specification

Item # Quantity Description Equipment Tag #

1 1 Battery System

Technical Requirements Form Revision Information:

Rev # Date Revision Issue Description Rev Approval

TS Document #2: Engineering Specification

TITLE SHEET

Government Name and Address: Naval Surface Warfare Center –

Philadelphia Division, Philadelphia, PA.

Project Name: Battery System

Engineering Specification Revision Information:

Rev # Date Revision Issue Description Rev Approval

1 Scope of this Specification

A. This Specification provides the technical requirements for the design, performance, inspection, testing, and warranty of (1) Battery System. This Specification forms part of the technical requirements form (TS Document #1) for the procurement of this equipment and shall be read in conjunction with all documents listed herein. The Battery System consists of the following equipment specified herein:

1. Indoor enclosure to accommodate a Battery System as specified herein.

2. Valve Regulated Lead Acid (VRLA) batteries with minimum of 20 year design life rated to

350 kWhr and capable of supplying1400 kW for 15 minutes and 2200 kW for 5 minutes.

3. Battery monitoring system for each cell.

4. HVAC and exhaust system.

5. Leak detection system.

6. Fire alarm and suppression system.

7. Hydrogen detection system.

8. Lighting and receptacles.

9. Battery input disconnecting means.

10. Battery output disconnecting means.

11. Instrumentation, metering and remote monitoring.

12. Control wiring and accessory devices.

13. Battery handling and maintenance device(s).

14. Auxiliary systems as specified herein for a safe operation of the system that meets the national and local building, fire and electrical codes.

B. This Specification is broken down into the following sections:

1. Scope of this Specification.

2. Overview.

3. Applicable Codes, Standards, and Regulations.

4. Rating, Conditions of Service, and Performance Warranty.

5. Work Included: Contractor’s Responsibility.

6. Work Included: Government’s Responsibility.

7. General Requirements.

8. Design and Construction Requirements.

9. Performance Requirements.

10. Inspections and Tests.

11. TS Document #3: Technical Data Sheets (to be completed by the Contractor).

C. Throughout this Specification the following terms apply:

1. “Government” refers to Naval Surface Warfare Center - Philadelphia Division, (NSWC

PD), Philadelphia, PA.

2. “Contractor” refers to the party or parties submitting a bid for supplying the equipment specified herein. The selected Contractor shall be the Manufacturer and Supplier of the battery System.

3. “Manufacturer” refers to the party, or parties, that manufacture a part or parts of the equipment or material.

2 Overview

A. The Contractor supplied Battery System shall provide an interface to Government supplied bi-directional 355VDC power distribution system components to supply battery-based backup power and conditioning for the DC bus. The battery System shall be located at the NSWC PD Building

633 complex in Philadelphia, PA 19112. The Contractor shall deliver the battery System as a turn-key package, requiring minimal on-site assembly or reassembly.

B. The conceptual Battery System diagram is depicted in Figure 1. The following shall be government furnished:

1. Battery System foundation.

2. Battery System enclosure rigging and mounting.

3. External exhaust connections from the supplied ventilation/HVAC system.

4. Input power cabling from 450VAC, 3ph, 60Hz facility power source to the Battery System enclosure auxiliary loads. A single source feeder will be provided.

5. Power cabling from Battery System bus interface to facility 355VDC switchboards.

6. Controls wiring between Battery System and facility alarming system.

7. Remote instrumentation and control cabling between Battery System and the Battery System remote interface.

8. External auxiliary systems as specified herein for a safe operation of the system that meets the national and local building, fire and electrical codes as specified herein.

C. The Battery System Contractor shall provide the required equipment and supporting systems as specified herein, to include but not be limited to:

1. Lifting and handling points instruction.

2. Standalone indoor environmentally controlled enclosure to accommodate the Battery System as specified herein constructed in accordance with standards specified in Section 3.2.

3. VRLA batteries to meet the 233-355VDC, 1400 kW for 15 minutes and 2200kW for 5 minutes requirement.

4. Battery racks and disconnecting means that comply with NEC Article 480 requirements.

5. 355VDC output bus cabling termination provisions for two output disconnect switches to interface with facility 355VDC switchboards.

6. High bandwidth voltage and current sensors to be utilized by government at the Battery System input and output terminals.

7. 450VAC power interface that distributes the single GFE provided 450VAC feeder for all Battery

System auxiliary loads.

8. 240/120VAC power panel for enclosure lighting and receptacles.

9. Lighting and receptacles to meet maintenance requirements.

10. Duct and fan exhaust to connect to exhaust system interface.

11. Battery Charger System to provide controlled float charge system with monitoring and controls necessary to provide necessary conditioning, protection, and cycling to meet protection, recharge time, and battery life requirements. Means to disconnect charger from battery circuit shall be provided.

12. Battery monitoring and control system with provisions for local and remote monitoring of:

a. Battery charger system .

b. Battery charger disconnect.

c. Fire alarm and suppression system.

d. Hydrogen sulfide detection.

e. Water leak detection.

f. Ambient air temperature monitoring.

g. Individual cell voltage and temperature, battery string voltage and temperature, and battery current in amperes and ampere-hours.

13. Internal control wiring and single junction box interface for remote indication and control.

14. Emergency stop pushbutton to isolate charger input and battery output.

15. Battery output disconnect contactors rated for the full voltage and load.

16. Battery lifting and handling equipment.

17. Battery spill containment.

18. Any special tooling including software required to operate, maintain and repair the battery system.

19. Spares for equipment parts that may cause a single point of failure of the system and/or require replacement within the first 5 years of operations.

20. Battery System site installation drawings.

21. Battery System external structural, mechanical, electrical and controls site connection/ installation.

BATTERY MGT SYSTEM

BATTERY CHARGER

FAN

EXHAUST

4 BATTERY STRINGS

440V

PP

240/ 120 V

PP

440 V SOURCE (SUPPLIED BY GOV’T)

240/120V SOURCE (SUPPLIED BY GOV’T)

355V SWBD

(SUPPLIED BY GOV’T)

CNTRL

JB

CONTROL SIGNAL WIRING

(SUPPLIED BY GOV’T)

EXHAUST DUCTING TO OUTSIDE

(SUPPLIED BY GOV’T)

HVAC SYSTEM (Provided by Vendor)

355V OUTPUT BUS

DISC. SWITCHES

DOOR

DOOR

355V SWBD

(SUPPLIED BY GOV’T)

Figure 1: Conceptual Battery System Diagram

D. The Battery System Contractor shall provide the following services as specified herein:

1. Progress Report. The Contractor shall submit a Progress Report to report schedule data for all End Items listed on in section 2 paragraph C, In Accordance With (IAW) CDRL A001

Contractor’s Progress, Status and Management Report of this technical specification document. The planning and scheduling of this effort shall be proposed as discrete tasks.

2. System Drawings. The Contractor shall submit Battery System drawings IAW CDRL A002

Design Data and Calculations: As Built Design Datasheet and Dimensions and A005 Design

Data and Calulations: Piping and Instrumentation Drawings, of this technical specification document. The Contractor shall provide manufactures assembly, installation assembly, mechanical schematics, machine design, protection systems, and electrical/electronic and controls diagrams with complete materials list.

3. General Arrangement drawings. The Contractor shall deliver General Arrangement drawings IAW CDRL A004 Product Drawings/Models and Associated Lists: General

Arrangement Drawing. The general arrangement drawings shall include both Plan and

Elevation views. The drawings shall include all electrical (controls, instrumentation and power) connection locations. The Contractor shall provide foundation layouts with dimensions and weights of equipment with alignment drawings and procedures for installation.

4. Electrical Single Line Drawings. The Contractor shall submit Electrical Single Line

Drawings IAW CDRL A006, Product Drawings/Models and Associated Lists: Electrical

One-Line Drawings. The electrical system single line diagrams shall show the relative electrical and controls interconnections of the Battery System, battery enclosure auxiliaries, and battery system instrumentation and controls. All electrical and control site interconnections shall be clearly identified. This drawing shall also be accompanied with a narrative description of the Battery System controls and associated operation.

5. Lifting Arrangement Drawings. The Contractor shall submit Lifting Arrangement

Drawings IAW CDRL A013 Packaging Plan and Lifting Arrangement Drawing:

Packaging Plan and Proceduures. The requirements for these drawings are specified further in sections 3.3 and 8.4 of this technical specification document.

6. Manuals and Supplemental Data. The Contractor shall provide COTS manuals and supplemental data with all equipment and components for which manuals or data are available. Copies of COTS manuals and supplemental data shall be delivered IAW CDRL

A010, Commercial Off-The-Shelf (COTS) Manuals and Associated Data: Battery System

Installation, Operation, and Maintenance Manuals. All manuals for the components of the system shall be submitted in a single three-ring binder or multiple binders, as necessary.

Supplemental data shall include but not be limited to Electrochemical Impedance Spectroscopy

(EIS) measurements of at a minimum 50 independent samples of the provided battery cell that constitutes the building block of the Battery system. This specific Supplemental Data shall be provided on an impedance vs. frequency plot and also as recorded data of the EIS results.

7. Test Plan. The Contractor shall prepare a Test Plan IAW CDRL A007 Test Procedures:

Test Procedure Documentation to include Factory Acceptance Testing (FAT) and On-Site

Acceptance Testing (OSAT) of this Technical Specification document as identified in section

10.1.

8. Test Report. The Contractor shall prepare a Test Report, in Contractor format, for all successfully completed tests. The Contractor shall prepare a Test Report, in Contractor format, IAW CDRL A008 Test/Inspection Report: Performance and Acceptance Testing which includes; Preparation of Test Report, FAT & OSAT Test Report, of this technical specification document, to document the result of the F A T a n d OSAT. The final test report will be submitted only after failures (if any) have been corrected, and the applicable test has been repeated to verify adequacy of the correction.

9. Packaging Plan. The Contractor shall package the Battery System according to all current commercial standards and codes. The Contractor shall prepare a Packaging Plan for the Battery System. The Packaging Plan shall be delivered to and approved by the

Government prior to delivery of the description of procurement. The packaging plan shall detail the precautions the Contractor plans to use to protect and preserve the Battery System against corrosion, deterioration and physical damage during shipment and handling. The

Packaging Plan shall be prepared and submitted IAW CDRL A013 Packaging Plan and

Lifting Arrangement Drawing: Packaging Plan and Procedures of this technical specification document.

10. Calibrations Certificates. The Contractor shall prepare a calibration certificate IAW

CDRL A009 Calibration Certificates, traceable to the National Institute of Standards and

Technology (NIST) for all supplied instrumentation, and tooling, and shall be calibrated in accordance with its Instrument Calibration Procedure (ICP). If an ICP does not exist then best commercial practices shall be used. A calibration sticker must be attached to the item which indicates serial number of the item, date that the calibration was conducted and date when the items need to be re-calibrated. In addition, a calibration certificate must be provided on signed Company letterhead certifying that calibration was successfully performed on the item and as a minimum it shall contain the following information:

a. Part Number

b. Nomenclature

c. Date that the calibration was conducted

d. Date when the items need to be re-calibrated

e. Item Serial Number

f. Contract Number

Copies of calibration certificate documentation shall be delivered IAW CDRL A009, Calibration

Certificate, of this SOW, and provided as part of the Technical Support Package (TSP) for the

Battery System.

3 Applicable Codes, Standards, and Regulations

3.1 General

A. Unless otherwise specified, the equipment shall be designed, constructed, and tested in accordance with the applicable provisions of the following standards. The latest edition of the referenced document (including any amendments or corrections) applies, at the time of contract award.

B. Where a standard is referred to and conflicts with a part of this Specification, the Government shall be consulted in writing for immediate resolution.

C. When an equivalent standard to those identified in this Specification are proposed by the

Contractor, the Contractor shall notify the Government in writing for immediate resolution.

3.2 General Standards

A. NFPA 70, National Electric Code (NEC)

B. NFPA 70E, Standard for Electrical Safety in the Workplace

C. UFC 3-520-5, Unified Facilities Criteria (UFC) Stationary Battery Areas

D. UFC 3-530-1, Unified Facilities Criteria (UFC) Interior and Exterior Lighting and Controls

E. UFC 3-600-1, Unified Facilities Criteria (UFC) Fire Protection Engineering for Facilities

F. IEEE STD 1187, Recommended Practice for Installation Design and Installation of VRLA

Storage Batteries for Stationary Applications

G. OSHA 29 CFR 1926, Safety and Health regulations for Construction

H. ANSI Z55.1, Gray Finishes for Industrial Apparatus and Equipment

I. IEC 62040-3, Battery system - Method of Specifying the Performance and Test Requirements

J. NFPA 101, NFPA Life Safety Code

K. IBC, International Building Code

L. UFC 1-200-01, Unified Facilities Criteria (UFC) General Building Requirements

3.3 Lifting and Rigging Standards

A. NAVSEA Technical Publication S9074-AR-GIB-010/278, Table VII, Machinery Class M2, Category A

B. NAVFAC P307, Management of Weight Handling Equipment

4 Rating, Conditions of Service, and Performance Warranty

4.1 Equipment Ratings, Materials, and Workmanship

A. The battery equipment provided shall meet all requirements specified herein.

B. Materials used for work performed under this contract shall be new and suitable for the intended service conditions of the equipment.

C. Work shall be performed by skilled mechanics in the various crafts and be executed in a first class and workmanlike manner in accordance with recognized good practice in the industry.

4.2 Conditions of Service

A. All Battery System equipment shall be located on a dedicated foundation inside the

Building 633 Complex at NSWC PD Philadelphia, PA.

4.3 Battery Acceptance, Performance Warranty and Defects Liability

A. Acceptance of the battery shall follow the successful completion of all Factory and On-Site

Acceptance Tests identified in Section 9 including the review and approval of all test reports by the Government, and receipt of the Contractor supplied Test Certifications.

B. The Contractor shall warrant that the equipment supplied shall be entirely suitable for the intended service and is free from faults in design, and is of sufficient capability to meet the specified Performance Requirements.

C. The VRLA batteries shall have a design life of no less than twenty (20) years with nominal maintenance and repair.

D. The Contractor shall warrant the battery for a period of twelve (12) months from the date of Acceptance by the Government (system start-up) that all equipment furnished by the

Contractor shall be free from defects in design, material, and workmanship.

E. The Contractor warranty shall cover all parts, labor and repairs related to the Battery

System equipment.

F. The Contractor shall provide Service Protection Plan to warrant the Battery System for the first year.

5 Work Included: Contractor’s Responsibility

5.1 Overall System Requirements

A. The Contractor shall provide a Battery System with specified interface requirements as detailed in this Specification.

B. The Contractor shall have complete responsibility for the provision of all equipment and accessories necessary for the successful operation of the battery System whether or not specifically identified in this Specification.

5.2 Scope of Supply

A. The Contractor’s work shall include the furnishings of all design, fabrication, inspection, testing, documentation, and special tools of the Battery System.

B. The Contractor’s work shall include, but not be limited to, the following:

1. Equipment delivered and installed ready for government interface connection as specified herein.

2. Spare Parts as specified herein.

3. Factory field service / training as specified herein.

5.3 Engineering Design and Status Reporting

A. The Contractor shall provide, at a minimum, the following submittals for Government review and approval of the battery design basis in accordance with CDRL A004, Commercial Off-

The-Shelf (COTS) Manuals and Associated Supplemental Data:

1. Mechanical design to include overall battery enclosure, battery racks, and arrangement of all batteries and subcomponents identified in the specification. The dimension and weight of the individual equipment and lifting arrangements shall also be provided.

2. Thermal management design to meet the performance specified herein.

3. Electrical power design to meet the performance specified herein.

4. Controls and instrumentation design to meet the performance specified herein.

5. Battery charger design to meet the performance specified herein.

6. Battery Characterization data to include, but not be limited to, the following information about the individual VRLA batteries used in the design, and identical characterizations on a battery string basis, and overall battery:

a) Discharge Rates (1/2C, C, 2C, 4C at a minimum)

b) Impedance vs Discharge

c) Short Circuit capability

d) Equivalent Battery Impedance

e) Alloy type

f) Type of separator

g) Ampere-hour rating per cell

h) Cell Nominal/Minimal voltage

i) Cold Cranking Amperes

j) Cycle and Shelf life

k) Maximum charge current/voltage

7. Battery Failure Mode and Effect Criticality Analysis (FMECA) design submittal.

8. Reliability analysis to include individual component, subsystem and overall system reliability determinations. This analysis shall be based on component reliability information and previously developed system configuration for system reliability assessments.

9. The Contractor shall submit a Progress Report to report schedule data for all End Items listed on in section 2 paragraph C, In Accordance With (IAW) CDRL A001 Contractor’s

Progress, Status and Management Report of this technical specification document. The planning and scheduling of this effort shall be proposed as discrete tasks.

5.4 Security Requirements

A. Contractor requires access to spaces/areas that contain RD. No direct access to RD required.

B. Contractor shall be responsible to ensure that all representatives have CONFIDENTIAL clearance and are not foreign nationals.

C. Contractor Personnel Identification. In the performance of this contract, contractor employees shall identify themselves as contractor personnel by introducing themselves or being introduced as contractor personnel and by displaying distinguishing badges or other visible identification for meetings with Government personnel. Contractor personnel shall appropriately identify themselves as contractor employees in telephone conversations and formal and informal written correspondence.

D. An Active CONFIDENTIAL) Facility Clearance (FCL) is required for performance on this contract. There are no safeguarding requirements required.

6 Work Included: Government’s Responsibility

6.1 Overall System Requirements

A. The Government shall provide the interfaces and auxiliary systems of the Battery

System compatible with specified interface requirements as required in this Specification.

6.2 Scope of Supply

A. The Government’s work shall include the furnishings of all design, construction, fabrication, of the battery System auxiliaries as specified herein.

6.3 Analyses

A. The Government shall provide the following documents for the battery design:

1. Installation Drawings external to the battery System including the power sources and loads, integrated HVAC system, fire alarm/suppression system, hydrogen detection and exhaust systems.

2. Physical Layout Design of Battery System enclosure within the facility.

7 General Requirements

7.1 Equipment Drawing and Technical Data Submittal Requirements

A. The Contractor shall provide the installation drawings internal to the Battery System including the power sources and loads, integrated HVAC system, fire alarm/suppression system, hydrogen detection and exhaust system. The structure shall be designed in accordance with applicable building standards for structures housing VRLA batteries, including but not limited to NFPA 70, NFPA 101, IBC, UFC 1-200-01, UFC 3-520-5, and account for the following additional provisions:

1. Enclosure dimensions not to exceed 50’ – 0” in length, 25’-0” width, and 17’-0” height.

2. Construction. The enclosure ceiling and walls shall have nominal insulation and waterproof surface.

3. Enclosure interior walls shall be acid/alkali resistant.

4. Enclosure floors shall be acid/alkali resistant and non-conductive.

5. Enclosure shall be 1-hour fire rate construction. Ceiling and roof construction shall comply with UL Design P-501.

6. The occupancy of the enclosure shall be rated as F-1, Factory/Industrial, Moderate Hazard.

7. Enclosure shall allow for, at a minimum, 36” access along each battery cell and battery disconnect device. The ceiling shall have, at a minimum, a 9’-0” clearance.

8. An integrated 2,000 pound roof crane shall be provided. The clearance from the floor of the enclosure to the crane pick shall be at a minimum 9 feet.

9. Cradle and equipment necessary for battery insertion and removal shall be provided, if necessary.

10. An integrated ladder shall be provided for access to rooftop equipment.

11. Hollow metal steel doors shall be provided with a single leaf door and a pair of doors.

Doors shall be equipped with panic/fire devices.

12. The batteries shall be installed in a battery rack system.

13. The Battery System shall include battery spill containment.

14. The enclosure shall have an integrated fire-protection system that can be tied onto a centralized building fire alarm system.

15. The enclosure shall have an integrated hydrogen monitoring system.

16. The enclosure shall have an integrated ground fault detection system.

17. The enclosure shall have an integrated (liquid) leak detection system.

18. The enclosure shall have an integrated ventilation system consistent with UFC 3-520-05 and IEEE 1187 with a minimum airflow of 10 cfm per square foot of enclosure area.

19. Electric heating for the enclosure shall meet UFC 3-520-05.

20. The ventilation system shall provide a minimum of 10 cfm/sqft with adjustable speed controls.

21. 450Vac and 240/120Vac power distribution panels shall be provided.

22. Service critical and non-critical loads such as emergency lighting, fire suppression system, general lighting, and receptacles shall be connected to 240/120VAC, 3 phase, 60

Hz, 100Amp supply.

23. Physical Layout Design of battery equipment and auxiliaries inside the dedicated enclosure.

B. The drawings shall include at a minimum the following requirements:

1. Battery System thermal management

2. Battery System electrical power

3. Battery System controls and instrumentation

C. The sequence of drawing and technical data submission shall be such that all information is available for Government’s review prior to manufacturing. All drawings shall form part of the contract after the Government’s review and approval.

D. All drawings shall be submitted in digital format as PDF files suitable for mark-up with comments and printing. The title block shall contain the name of the Government, contract name and number, and the Government’s equipment tag number.

E. Review of the Contractor’s drawings by the Government shall not relieve the Contractor of any part of their obligation to meet all requirements noted in the contract documents or the responsibility of correctness of such drawings.

F. The Contractor shall make all necessary changes in design that are required to make the work conform to the provisions of the contract without additional cost to the Government.

G. All final submitted drawings shall be brought to an As-Built status and be endorsed with the wording “As Built” in the revision block.

7.2 Installation Instructions, Operating, and Maintenance Manuals

A. Battery System Operating and Maintenance (O&M) Manuals shall be supplied by the

Contractor to provide all information deemed necessary for the Government to operate and maintain the Battery System throughout its design life.

B. The documentation shall contain Manufacturer contact information, warranty information, instructions, drawings (reduced as necessary, but clearly legible), parts lists, catalogs, and any other instructions that may be needed or be useful in the installation, planned maintenance, corrective maintenance, dismantling, assembling and for identification when ordering replacement parts. The manuals shall be provided in searchable, digital format and in paper hardcopy format. Hardcopy format shall be assembled and bound between hardcovers to letter size (8.5 inch by 11 inch). Where the Contractor’s and/or

Subcontractor’s standard brochures are included, they shall be clearly marked to indicate the part that has actually been furnished.

C. Each set of Manuals may be divided into separate volumes for:

1. Installation Instructions

2. Operating Instructions

3. Maintenance Manuals with list of spare parts

7.3 Nameplates, Markings, and Notices

A. Nameplates, notices and the like shall be permanently attached to the equipment to bring the attention to the following:

1. Notices required by statutory regulations such as maximum safe working load.

2. Warning notices such as “DANGER”.

3. Equipment nameplates with the Manufacturer’s model and data

B. Suitable nameplates shall also be attached to meters, indicators and control switches furnished with the equipment.

C. Nameplates and notices shall be of appropriate size and the information contained thereon be easily read from all operating positions. They shall be affixed to the equipment so that they cannot be removed or destroyed through wear and tear.

D. Stampings and engravings shall be of sufficient depth so that the letters, numbers, and wording shall not be worn away by the prevailing environmental conditions.

E. Nameplate material shall be of stainless steel or approved equivalent.

F. Battery System equipment nameplates shall have all necessary information to facilitate identification and installation and shall include but not be limited to (as applicable):

1. Name of Manufacturer

2. Government’s contract number

3. Equipment tag number

4. Manufacturer’s serial number

5. Design and performance information as applicable

6. Date of Manufacture

7. Voltage

8. Current

9. Total weight

7.4 Special Tools, Devices, and Test Equipment

A. The Contractor shall supply a complete list and recommended quantities of test equipment and any special tools required to install and maintain the Battery System such as lift for batteries and jumpers for battery bypass. The list of recommended special tools and test equipment shall be noted in the Maintenance Manuals (CDRL A010). The Contractor shall provide the basis of the determination of the quantities recommended, such as Mean Time

Between Failure (MTBF).

B. The Contractor shall deliver one set of necessary special tools and devices required for the installation, operation, and maintenance of the plant or equipment supplied. These shall be new, of first-class quality, crated separately from other equipment and materials, and be clearly marked as to their intended use.

7.5 Assembly, Packaging, and Shipping

A. Unless otherwise specified, the equipment shall be packed in accordance with the best commercial practice for shipment and transportation. Any damage received in transit due to defective or insufficient packing or defective methods of packing shall be corrected by the

Contractor at their expense and within a reasonable time when called upon to do so.

B. The Battery System shall be as completely factory assembled as possible within shipping and handling limitation in accordance with this specification.

C. The Contractor shall package the Battery System according to all current commercial standards and codes. The Contractor shall prepare a Packaging Plan and Lift Arrangement

Drawings for the Battery System. The Packaging Plan and Lift Arrangement Drawings shall be delivered to and approved by the Government prior to delivery of the description of procurement. The Packaging Plan and Lift Arrangement Drawings shall detail the precautions the Contractor plans to use to protect and preserve the Battery System against corrosion, deterioration and physical damage during shipment and handling. The Packaging Plan and

Lift Arrangement Drawings shall be prepared and submitted IAW CDRL A002 of this technical specification document.

D. The Contractor shall provide a 2 week notice on when the equipment will be delivered along with the shipping carrier’s information.

E. The Contractor shall deliver the equipment in a flatbed truck that is accessible with crane or fork lift.

7.6 Spare Parts

A. Maintenance Spares and Consumables

The Contractor shall submit to the Government for review and approval, their recommended list of spare parts, assemblies, and consumables to be delivered to the

Government for efficient maintenance of the equipment being supplied in accordance with

CDRL A012 Proposed Spare Parts List. The quantity of spares and consumables shall be based on five (5) years of operation.

B. Construction Spares

1. The Contractor shall supply on-site Construction Spares to include spare parts, assemblies, and consumables to cover normal predictable losses, wastage, and damage during installation, testing, and commissioning.

2. The Contractor shall supply a list of the itemized Construction Spares to the Government for review and approval.

C. Spare Part and Consumables Packaging and Identification

1. All spares parts and consumables supplied shall be listed in the Maintenance Manuals.

2. Spares, assemblies, and consumables supplied shall be packed and delivered separately to the

Government, and be identified using the part numbers listed in the maintenance manuals.

3. Spare Part and Consumable Packages shall be clearly labeled with the following information:

1. Government’s contract number

2. Name of equipment supplied

3. Name of spare part(s)

4. Name of spare part(s) supplier(s)

5. Manufacturer’s spare part(s) number

6. Number of items

8 Design and Construction Requirements

A. The Battery System Contractor shall be ISO-9001 certified and shall submit current certification documentation upon Contract Award.

B. All Contractor on-site representatives must be United States citizens who are able to interface/handle up to Confidential-Restricted Data (CRD) (NORFORN or NNPI) and equipment/network data.

8.1 General Arrangement

A. The Battery System Contractor shall provide the required equipment and supporting systems as specified herein to meet the battery performance requirements as specified in section 9.

B. The Contractor supplied Battery System enclosure shall be delivered in whole or in part with necessary installation requiring mechanical connections completed by Contractor in order to deliver a turn-key package ready for facility connections.

C. The Contractor supplied Battery shall be designed with necessary redundancy of auxiliary power supplies, cooling fans, etc. so that a single point of failure of these auxiliary components does not interrupt the output power of the unit.

D. The Contractor supplied Battery power interface section shall be designed for top entry of cabling and shall be accessible through the front and back sides for hookup.

E. The Contractor supplied Battery System shall provide three disconnect devices as necessary to safely disconnect the full battery for maintenance replacement and repair. Two fused disconnect devices shall be used to independently isolate the two government furnished

355VDC switchboards. The third disconnect device shall be used to isolate the two parallel switches from the battery output shunt trip contactor. The fourth disconnect device shall isolate the battery charger as detailed in section 9.1.3 (b)(8).

F. The contractor supplied Battery System shall provide a disconnect device with remote shunt trip capability rated to interrupt the full load.

G. The Contractor shall supply a lifting system for use to repair and replace the battery cell and/or string as necessary.

H. The Contractor supplied battery strings shall have disconnecting means for isolation in accordance to NEC and other industry standards.

I. The Contractor supplied Battery System shall be installed in a vendor provided enclosure.

The enclosure shall be waterproof and watertight to prevent water ingress. The enclosure shall be installed on an existing government provided carbon steel “Tee-Pad” with the following maximum dimensions: 25 feet wide by 50 feet long at a 20’-0” elevation. This platform will support the components to which the battery output will be connected. The

Battery System enclosure shall be designed to the specified IBC, NFPA and NEC requirements.

J. The Contractor supplied Battery System shall be designed to withstand 30 minutes without

HVAC cooling while the unit is on batteries.

K. The Contractor shall provide means to exhaust heat provided by a non-sparking fan with upward discharge to reject heat when the unit is on battery power. Discharge shall be ducted to prevent water ingress from the roof. The power to the exhaust system shall be installed in the 120/240V critical load panel. An interface flange for duct interface to the exterior of the building shall be provided.

L. The Contractor shall provide the required equipment and supporting systems as specified herein, to include but not be limited to:

1. A standalone indoor enclosure to accommodate the Battery System as specified herein.

2. All associated internal wiring within enclosure and auxiliary systems.

3. Fire alarm and suppression system with visual and audible alarms that may be tied to a centralized fire alarm system. A dry contact shall be provided for additional remote monitoring when the alarms are active.

4. Adequate ceiling mounted lighting to provide sufficient light for operation and all maintenance tasks, with a switch at each entrance/exit.

5. Two egress doors with keyed locks and emergency exit push bars.

6. Emergency lighting and exit signs at each door.

7. 120VAC, 20A GFI protected convenience receptacles every 10 feet of each accessible wall.

8. All auxiliary systems as specified herein within enclosure boundary for a safe operation of the system that meets the national and local building, fire and electrical codes as specified herein.

9. Air inlet located no higher than the tops of the battery cells of the lowest tier.

10. HVAC and exhaust system to maintain temperature between 65 and 80 Deg F at all times.

M. The Government shall provide the required equipment and supporting systems as specified herein, to include but not be limited to:

1. HVAC source power and exhaust system interface for power and exterior ducting.

2. All auxiliary systems as specified herein external to enclosure boundary for a safe operation of the system that meets the national and local building, fire and electrical codes as specified herein.

3. 120/240Vac single phase, 125Amp power panel for all 120/240Vac house loads.

4. 480Vac, 3 phase, 60 Hz, 250Amp s power panel for all 480V house loads.

5. Connect the battery System enclosure fire alarm system into the Building 633 Complex at

NSWC PD Philadelphia, PA fire alarm system with visual and audible alarms.

8.2 General Design

A. The Contractor shall provide a Battery System that is compatible with the interfaces as specified herein.

B. The Contractor shall provide Instrumentation and Control for the safe operation of the Battery

System locally and remotely as specified herein.

C. The Battery System shall be as completely factory assembled as possible within shipping and handling limitations in accordance with this Specification.

D. The Battery System shall have sufficient accessibility for all replaceable parts.

E. The Battery System shall be designed to ensure personnel safety in accordance with NFPA

70E.

F. The Battery System shall be sized to continuously deliver the full power as specified herein.

G. The Battery System shall incorporate provisions for installing grounding devices with sufficient accessibility during maintenance periods.

H. The Battery enclosure shall be adequately secured but shall not be used for structural strength.

I. The Battery enclosure shall have ventilation openings at the sides where required.

J. Adequate clearance shall be provided between live bus work and disconnect devices in accordance with industry standards.

K. Installation hardware that includes but is not limited to:

1. Bus work, cables, cable trays, cable supports, connectors, terminal plate kits, anchoring bolts, tooling, and grounding

2. Special tooling required for installation

3. Manual battery disconnect switches to safely isolate each proposed battery string .

8.2.1 Instrumentation and Control

A. The Contractor shall provide temperature sensors for each battery cabinet and ambient room temperature wired to a terminal strip to be remotely monitored via a Government supplied

PLC or incorporated in the local/remote monitoring station.

B. The Contractor supplied Battery System shall provide MODBUS TCP/IP interface for remote monitoring. The Battery shall be provided with digital communication capabilities to allow direct status communication for remote battery operations.

C. The Contractor supplied Battery System shall provide both local and remote touchscreen monitoring capability of the battery monitoring system to monitor the status and health of the

VRLA batteries to include but not limited to individual battery cell voltage and temperature, battery current in amperes, percent charge, and discharge time remaining.

D. The remote control and indication touchscreen shall be designed to operate at a distance of

450 ft (via fiberoptic connection) from the physical Battery installation. The remote control station will be in the Government’s control room.

E. The Contractor supplied Battery System shall provide local and remote time stamped log of all Battery actions, including but not limited to, battery charge cycles, fault logs, event logs and shunt tripping of contactors.

F. The Contractor supplied Battery System shall supply but not limited to, signals and functions hardwired relay contacts for the following. The control and indication signals shall be wired to terminal strip(s) within a single junction box to provide easy wiring access to the remote system:

1. Low battery alarm

2. Battery System alarm

3. Battery System Mode –Normal, Battery Charging, Battery Discharging

4. Hydrogen detection system

5. Fire detection system alarm

6. Air flow Alarm

7. Smoke detection alarm

8. Ground fault detection

9. Water leak detection

10. Fire suppression system activation

11. Accept a hardwired, dry contact shutdown command for remote monitoring and control via a Government supplied PLC.

G. Remote Battery System Emergency Power Off shall be provided in test site control center.

H. Local Battery System Emergency Power OFF shall be provided at the battery enclosure entries.

I. Local and Remote Battery indication / monitoring shall include a minimum of:

1. Battery charger normal input power available/active/inactive

2. Battery charger input power available/active/inactive

3. Battery charger output power active/inactive

4. Battery charger historical event log

5. Battery charger historical alarm log

6. Battery charger status, normal input power voltage, current, frequency, apparent power, real power, power factor

7. Battery output power, voltage, current, battery time remaining, battery temperature

8. Fire alarm system activated status

9. Fire suppression system activated status

10. Enclosure temperature monitoring

11. Individual Battery cell monitoring data (voltage/current/temperature/resistance at a minimum)

8.3 Connections and Terminals

8.3.1 Instrumentation and Control

A. All power connections above 30A shall be pressure (crimp) type connectors with a NEMA pad, including terminations for Government’s connections.

B. Wire connections, other than factory soldered connections, shall be made with non-insulated straight shank, crimp type, plated, terminals.

C. Each terminal block and each point used on terminal block shall be labeled with tape or stick on labels.

D. All circuit boards shall be accessible for quick and easy replacement without special tools.

E. Components shall be accessible through lockable hinged door.

F. No electrically-energized components shall be accessible with doors closed.

G. Hardware shall be properly designed and/or treated to resist corrosion.

H. Power bus shall be conservatively rated and so designed for fault current rating and maintenance-free operation.

I. All interconnecting wiring, equipment and terminal board points shall be properly identified using identification marking.

J. Modular construction shall be used to minimize maintenance and change-out required during the troubleshooting process where necessary.

K. Thermostatically controlled heating and cooling system shall be provided to control environmental conditions when necessary.

L. All panels and equipment shall be designed to ensure safety of operating and maintenance personnel.

M. The instrumentation and control connection terminal junction box(es) shall be adequately sized to permit the proper termination of the low voltage control and instrument wires and cables in accordance with the requirements of the battery System and NEC.

N. All Instrumentation and Control wiring shall be run in conduit to terminal boxes with outgoing connections in the form of "Klippon" (or equivalent) terminals.

O. Each Instrumentation and Control Connection Terminal Box shall incorporate a ground lug.

P. Instrumentation and control terminal blocks, wires, and cables shall be rated at 600 VAC and wires shall be a minimum of #18 AWG.

8.3.2 Power Interface Terminals

A. The power interface termination area shall be adequately sized to permit the proper termination of the output bus as follows:

1. Bus bar to accommodate two-hole lug connection for power cable terminations to ensure lug position and compression is maintained.

2. Copper with silver or tin plating to reduce corrosion.

3. NEMA 4 rated enclosure to provide containment of exposed bus bar and disconnect switch. Locking provisions shall be provided to meet safety requirements.

4. Sufficient bracing to meet short circuit/bolted fault requirements.

5. Power cables shall be routed and supported with exit directly above the termination area through ceiling with necessary transit interface to meet insulation and environmental integrity of the enclosure.

6. The conductors shall be oriented and labeled from left to right for the Positive (+) and

Negative (-) terminations. The terminations shall be made on high copper alloy blocks and conform to standard NEMA patterns.

B. Minimum grounding requirements shall be provided as follows:

1. A ground bus or termination interface shall be provided at the power interface section and have provisions to be bonded to site structure.

2. Power interface terminals shall provide a termination pad that is clearly marked for the connection of grounding conductors.

3. The Contractor shall specify the make and model number of the high copper alloy lugs that should be used for the cables being terminated on each of the termination blocks and the required tightening torque for the bolts on the termination pad.

4. The Contractor shall specify the make and model number of the high copper alloy ground conductor lugs that should be used for the ground wires and the tightening torque required for the bolts on the termination pad.

8.3.3 Installation

A. The Contractor shall provide Battery System Installation Drawings upon delivery, including one-lines and isometric drawings necessary for validation of the installation.

B. The installation drawings shall provide sufficient detail including clearances and tolerances required for installation.

8.5 Delivery, Lifting and Rigging

A. The Contractor shall deliver the battery System to NSWC PD Building 633 complex in

Philadelphia, PA 19112 using standard industry packaging and delivery practices.

B. The Contractor shall provide lift arrangement drawings, in accordance with CDRL A015 Lift

Arrangement Drawings for all components and assemblies to be lifted on site at NSWC PD, Philadelphia, PA.

C. The lift arrangement drawings shall provide sufficient detail in order to develop lift plans and for review and approval for all crane and rigging operations necessary to move and position the Battery System on-site.

D. The lift arrangement drawings shall identify the location, configuration and rating of all lifting points, shall provide a lift diagram as needed to depict any restrictions on lift angles at lift points and shall identify associated rigging hardware.

E. The lift arrangement drawings shall also include, or be accompanied by, engineering calculations.

F. The lift arrangement drawings for four-point configurations (if required) shall be designed to meet the requirements of NAVFAC P307 'Management of Weight Handling Equipment' as follows:

1. Slings, shackles, and attachment points in a four leg assembly for a four-point lift shall be sized based on either pair of diagonally opposing legs carrying the entire load, unless the assembly is equipped with devices that automatically adjust for equal distribution of the load such as engineered equalizer plates.

2. Chain hoists can be used for equalizing loads only if used in conjunction with load indicating devices.

G. Welds of lifting pads, jacking and handling features on the components and assemblies shall be inspected in accordance with NAVSEA Technical Publication S9074-AR-GIB-010/278, Table VII, Machinery Class M2, Category A.

9 Performance Requirements

9.1 Battery System Performance Requirements

9.1.1 Battery Technical Data Sheets

A. The battery main bus bars shall be silver plated with a continuous current rating of 2000

Amps.

B. The battery shall have a maximum short circuit withstand of 100kA

C. The battery shall have a main bus bracing of 100kA

D. The battery shall have a one minute withstand voltage of 2000V

E. The battery shall incorporate temperature compensated battery charging to prolong the life of the battery modules.

F. The battery shall incorporate, at a minimum, a three stage (bulk, absorption, and float) charging technique for the battery modules.

9.1.2 Battery System Performance

A. The battery System shall meet the following output characteristics:

1.…