Facility_UPS_System_Specification_FINAL_010615.pdf

FACILITY UNINTERRUPTIBLE POWER SUPPLY (UPS)

SYSTEM

TECHNICAL SPECIFICATION DOCUMENT

Naval Surface Warfare Center - Philadelphia

Document Number: 8105_0000

January 6th, 2015

Facility UPS Technical Specification

Date: 6 January, 2015

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

Date: 6 January, 2015

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 Transformer Standards

3.4 Military Standards

3.5 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 UPS 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

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 Cleaning, Painting and Protective Coatings

7.5 Special Tools, Devices, and Test Equipment

7.6 Assembly, Packaging, and Shipping

7.7 Spare Parts

Date: 6 January, 2015

8 Design and Construction Requirements

8.1 General Arrangement

8.2 General

8.3 Connections and Terminals

8.4 Delivery, Lifting and Rigging

9 Performance Requirements

9.1 Facility UPS 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 UPS Characteristics

11.2 Drawings and Design Documents (as applicable)

Date: 6 January, 2015

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 FACILITY UPS SYSTEM

Technical Requirements Form Revision Information:

Rev # Date Revision Issue Description Rev Approval

6 January, 2015 Approved for Release

Date: 6 January, 2015

TS Document #2: Engineering Specification

TITLE SHEET

Government Name and Address: Naval Surface Warfare Center - Carderock Division, Ship Systems Engineering Station (NAVSSES), Philadelphia, PA.

Project Name: Facility UPS System

Engineering Specification Revision Information:

Rev # Date Revision Issue Description Rev Approval

1 6 January, Approved for Release

Date: 6 January, 2015

1 Scope of this Specification A. This Specification provides the technical requirements for the design, performance, inspection, testing, and warranty of (1) Facility UPS 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 Facility UPS System consists of the following equipment specified herein:

1. Integrated multi-modular converter based UPS, 1100KVA/450VAC/60HZ

2. Valve Regulated Lead Acid (VRLA) batteries with minimum of 10 year design life rated to full UPS load for 30 minutes of backup power

3. Battery monitoring system for each cell

4. HVAC and exhaust system (provided by others)

5. Fire alarm and suppression system (provided by others)

6. Hydrogen detection system (provided by others)

7. Lighting and receptacles (provided by others)

8. UPS input disconnecting means (provided by others)

9. Maintenance Bypass and Service Panel (MBSP) with kirkey interlock

10. Instrumentation, metering and remote monitoring

11. Control wiring and accessory devices (provided by others)

12. Indoor enclosure to accommodate a 1100KVA UPS system as specified herein and accommodations to integrate an additional 1100KVA UPS system and associated auxiliaries in the future (provided by others)

13. Auxiliary systems as specified herein for a safe operation of the system that meets the national and local building, fire and electrical codes (provided by others)

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 - Carderock Division, Ship

Systems Engineering Station (NAVSSES), 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 Facility UPS System.

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

Date: 6 January, 2015

2 Overview A. The Contractor supplied Facility UPS System shall provide an interface between Government supplied 450Vac input and load switchboard. The Facility UPS System shall be located at the NAVSSES Building 633 complex in Philadelphia, PA 19112.

B. The conceptual Facility UPS System diagram is depicted in Figure 1. The electrical power source supplying the Government supplied 450Vac input and load switchboard shall be terrestrial utility 13.8kV/450V, 3 phase, 4 wire, 60Hz transformer. The following shall be government furnished equipment:

1. Facility UPS System indoor enclosure on raised steel platform

2. Facility UPS System equipment rigging and mounting

3. Input and output power cabling between 450Vac Facility Switchboard 3 and Facility UPS

System enclosure

4. Input power cabling to 450Vac mechanical power panel for enclosure auxiliary loads

5. Remote communication cabling to Facility UPS System enclosure

6. UPS inputs disconnecting means

7. 480Vac three phase mechanical load panel and all associated wiring

8. 30KVA 450-120/240Vac transformer and 120/240Vac single phase critical load house panel and all associated input wiring

9. HVAC and exhaust system

10. Fire alarm and suppression system

11. Hydrogen detection system

12. Lighting and receptacles

13. Control wiring and accessory devices

14. Standalone indoor enclosure to accommodate a 1100KVA UPS system as specified herein and accommodations to integrate/parallel an additional 1100KVA UPS system and associated auxiliaries in the future

15. All 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 Facility UPS System Contractor shall provide the required equipment and supporting systems as specified herein, to include but not be limited to:

1. 1100KVA Integrated multi-modular converter based UPS and VRLA batteries

2. Maintenance Bypass and Service Panel (MBSP) with kirkey interlock and 100A out breaker critical loads house panel

3. Battery cabinet disconnecting means

4. Battery monitoring system

5. Power and controls wiring between UPS and battery cabinets

6. Controls wiring between UPS, battery and MBSP

7. UPS and battery instrumentation and controls for local and remote monitoring

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

1. 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 first submittal of the plan shall establish a baseline schedule that must remain frozen and

Date: 6 January, 2015 visible throughout the period of performance. Any requested changes to the baseline must be submitted in writing to the Procuring Contracting Officer (PCO) and the Electric Drive Test Facility (EDTF) Program Manager (PM) for approval with a description of justification and what consideration will be offered to the Government. The planning and scheduling of this effort shall be proposed as discrete tasks.

2. The Contractor shall deliver general arrangement drawings IAW CDRL A002, Product Drawings/Models and Associated Lists, UPS System General Arrangement Drawings, of this technical specification document. 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

3. The Contractor shall submit UPS system drawings IAW CDRL A003, Product Drawings/Models and Associated Lists, UPS System Drawings, of this technical specification document. The Contractor shall provide manufactures assembly, installation assembly, mechanical schematics, machine design, protection systems, and electrical/electronic diagrams with complete materials list.

4. The Contractor shall submit Electrical Single Line Drawings IAW CDRL A004, Product Drawings/Models and Associated Lists, UPS Electrical Single Line Drawings, of this technical specification document. The electrical system single line diagrams shall show the relative electrical interconnections of the UPS, battery cabinet and MBSP. All site interconnections shall be clearly identified.

5. 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 A005, Commercial Off-The-Shelf (COTS) Manuals and Associated Supplemental Data, UPS System Manuals, of this technical specification document. All manuals for the components of the system shall be submitted in a single three-ring binder or multiple binders, as necessary.

6. The Contractor shall prepare a Test Report for all successfully completed tests. The Contractor shall prepare a Test Report, in Contractor format, IAW CDRL A006, Preparation of Test Reports, FAT Test Report, of this technical specification document, to document the result of the Factory Acceptance Testing (FAT). 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.

7. 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 A007, Preparation of Test Report, OSAT Test Report, of this technical specification document, to document the result of the On-Site Acceptance Testing (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.

8. The Contractor shall package the description of procurement according to all current commercial standards and codes. The Contractor shall prepare a Packaging Plan for the

Date: 6 January, 2015 description of procurement. 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 description of procurement against corrosion, deterioration and physical damage during shipment and handling. The Packaging Plan shall be prepared and submitted IAW CDRL A008 Packaging Plan and Lifting Arrangement Drawings of this technical specification document.

E. The following services shall be government furnished:

1. Facility UPS System enclosure design

2. Facility UPS System auxiliaries design

3. Facility UPS System installation drawings

4. Facility UPS System structural, mechanical, electrical and controls installation

UNINTERRUPTABLE POWER SUPPLY #1

1.1MVA

RECT

INV

STATIC

SW

BATT

CONVBATTERY

UPS#1 NORMAL

UPS#1 OUTPUT

MAINTENANCE ISOLATION

3200A

OUTPUT#1

1600A

MANUAL BYPASS & SERVICE PANEL (MB&SP)

KIRK KEY INTERLOCK

FUTURE

UNINTERRUPTABLE POWER SUPPLY #2

1.1MVA

RECT

INV

STATIC

SW

BATT

CONVBATTERY

MAINTENANCE BYPASS

3200A

OUTPUT#2

1600A

FUTURE

UPS#2 NORMAL

FUTURE

UPS#2 OUTPUT

UPS OUTPUT

FUPS-2

FAC UPS1

120V HOUSE

PANEL

240Y/120V, 100A, 3PH, 4W

FUPS-1

FAC UPS1

450V MECH

PANEL

450V, 250A, 3PH, 4W

FACILITY UPS SYSTEM

450VAC, 60Hz

2.2MVA

450VAC

FAC UPS1

NON-CRITICAL

MECH LOADS240/120VAC

FAC UPS1

CRITICAL

HOUSE LOADS

FED BY

FAC-SWBD1

COMMUNICATION

AND PARALLING

LINK

UPS BYPASS

0A

30KVA, 1PH

450V PRI

240/120V SEC

FUTURE

FAC UPS2

MECH PANEL

450V, 250A, 3PH, 4W

FUTURE

450VAC

FAC UPS2

NON-CRITICAL

MECH LOADS

(FUTURE

FEEDER

SUPPLIED BY

GOVERNMENT)

(FEEDER

SUPPLIED BY

GOVERNMENT)

(FEEDER

SUPPLIED BY

GOVERNMENT)

(FEEDER

SUPPLIED BY

GOVERNMENT)

KK

(COMMUNICATION LINE

SUPPLIED BY GOVERNMENT FOR

REMOTE EPO AND FACILITY UPS

SYSTEM MONITORING)

Figure 1: Conceptual Facility UPS System Diagram

Date: 6 January, 2015

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. ANSI Z55.1, Gray Finishes for Industrial Apparatus and Equipment D. IEC 62040-3, UPS - Method of Specifying the Performance and Test Requirements E. NFPA 101, Life Safety Code F. IBC, International Building Code G. UFC 1-200-01, Unified Facilities Criteria (UFC) General Building Requirements H. UFC 3-520-5, Unified Facilities Criteria (UFC) Stationary Battery Areas I. UL-1778, Uninterruptable Power Systems

3.3 Transformer Standards

A. ANSI C57.13, Requirements for Instrument Transformers

3.4 Military Standards

A. MIL-STD-1399-300B, Department of Defense Interface Standard Section 300B, Electric

Power, Alternating Current

3.5 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

Date: 6 January, 2015

4 Rating, Conditions of Service, and Performance Warranty

4.1 Equipment Ratings, Materials, and Workmanship

A. The UPS 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 Facility UPS System equipment shall be located inside a dedicated enclosure inside the

Building 633 Complex at NAVSSES Philadelphia, PA.

4.3 UPS Acceptance, Performance Warranty and Defects Liability A. Acceptance of the UPS shall follow the successful completion of all factory and on-site 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 equipment provided, with the exception of the VRLA batteries, shall have a design life of no less than fifteen (15) years with nominal maintenance and repair, to be consistent with the design life of commercially available utility distribution equipment.

D. The Contractor shall warrant the UPS 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 UPS system equipment.

F. The Contractor shall provide Service Protection Plan to warrant the UPS system.

Date: 6 January, 2015

5 Work Included: Contractor’s Responsibility

5.1 Overall System Requirements

A. The Contractor shall provide a Facility UPS System interface compatible with their specified interface requirements as required 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 Facility UPS 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 UPS.

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

1. Equipment 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 UPS design:

1. Mechanical design to include overall UPS inverter, battery cabinet and MBSP dimension and weight of the individual equipment and lifting arrangements.

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 Characterization to include the following information about the individual VRLA batteries used in the design, and identical characterizations on a battery string basis, and overall battery basis:

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

b) Short Circuit capability

c) Equivalent Battery Impedance

6. UPS Failure Mode and Effect Criticality Analysis (FMECA) design submittal.

7. 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.

8. 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 first submittal of the plan shall establish a baseline schedule that must remain frozen and visible throughout the period of performance. Any requested changes to the baseline must be submitted in writing to the Procuring Contracting Officer (PCO) and the Electric Drive Test Facility (EDTF) Program Manager (PM) for approval with a description of

Date: 6 January, 2015 justification and what consideration will be offered to the Government. The planning and scheduling of this effort shall be proposed as discrete tasks.

6 Work Included: Government’s Responsibility

6.1 Overall System Requirements

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

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 Facility UPS system auxiliaries as specified herein.

6.3 Analyses

B. The Government shall provide the following analyses for the UPS design:

1. Installation Drawings for an indoor structure to house the Facility UPS System including an integrated HVAC system, fire alarm/suppression system, hydrogen detection and exhaust systems and be rated F-1 Factory/Industrial Moderate Hazard occupancy as defined in the International Building Code (IBC). 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 provide the following additional provisions:

a) The structure shall provide an integrated 2000 pound overhead lift

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

c) If applicable, the roof of the structure shall be accessible via an integrated exterior roof ladder

d) Non-critical electrical service to the structure shall be provided by a single 450Vac, 3 phase, 60 Hz, 250Amp supply for non-critical mechanical loads. The 450Vac power panel and enclosure connected loads shall be provided and installed by the government.

e) Critical electrical service to the structure shall be self-derived for the critical loads such as emergency lighting, fire suppression system, emergency exhaust system, etc.

The 120Vac power panel and enclosure connected loads shall be provided and installed by the government.

2. Physical Layout Design of UPS equipment and auxiliaries inside the dedicated enclosure.

7 General Requirements

7.1 Equipment Drawing and Technical Data Submittal Requirements A. The Contractor shall deliver general arrangement drawings IAW CDRL A002, Product

Drawings/Models and Associated Lists, UPS System General Arrangement Drawings, of this technical specification document. The general arrangement drawings shall include both Plan and Elevation views. The drawings shall include all electrical (controls, instrumentation and

Date: 6 January, 2015 power) connection locations. The Contractor shall provide foundation layouts with dimensions and weights of equipment with alignment drawings and procedures

B. The Contractor shall submit UPS system drawings IAW CDRL A003, Product Drawings/Models and Associated Lists, UPS System Drawings, of this technical specification document. The Contractor shall provide manufactures assembly, installation assembly, mechanical schematics, machine design, protection systems, and electrical/electronic diagrams with complete materials list. This information shall be sufficient to provide the Government with a complete understanding of the equipment being supplied. The drawings shall include at a minimum the following requirements:

1. UPS System thermal management

2. UPS System electrical input power

3. UPS System controls and instrumentation

C. The Contractor shall submit Electrical Single Line Drawings IAW CDRL A004, Product Drawings/Models and Associated Lists, UPS Electrical Single Line Drawings, of this technical specification document. The electrical system single line diagrams shall show the relative electrical interconnections of the UPS, battery cabinet and MBSP. All site interconnections shall be clearly identified.

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

E. 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.

F. 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.

G. 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.

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

I.

7.2 Installation Instructions, Operating, and Maintenance Manuals A. Facility UPS 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 UPS 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

Date: 6 January, 2015 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

D. 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 A005, Commercial Off-The-Shelf (COTS) Manuals and Associated Supplemental Data, UPS System Manuals, of this technical specification document. All manuals for the components of the system shall be submitted in a single three-ring binder or multiple binders, as necessary.

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. Facility UPS 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. Number of phases

10. Frequency

11. Total weight

7.4 Cleaning, Painting and Protective Coatings

A. Painting and protective coatings shall be in accordance with the Contractor’s applicable standard painting Specification.

Date: 6 January, 2015

7.5 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 Facility UPS System such as lift for power modules and batteries. The list of recommended special tools and test equipment shall be noted in the Maintenance Manuals.

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.

7.6 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 Contractor shall package the description of procurement according to all current commercial standards and codes. The Contractor shall prepare a Packaging Plan and Lift Arrangement Drawings for the description of procurement. 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 description of procurement against corrosion, deterioration and physical damage during shipment and handling. The Packaging Plan and Lift Arrangement Drawings shall be prepared and submitted IAW CDRL A008 of this technical specification document.

7.7 Spare Parts

7.7.1 Maintenance Spares and Consumables

A. 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. The quantity of spares and consumables shall be based on one (1) year of operation.

B. The Contractor shall itemize any spare parts, assemblies, and consumables, other than spare parts and consumables specifically included under the contract, that are recommended for the Government to acquire for forty-eight (48) months of operation of the equipment after Acceptance of the UPS (as identified in Section 4.3). These spares, assemblies, and consumables shall be fully itemized. Prices shall be quoted in $US currency, including packaging, and delivery into the Government’s warehouse.

7.7.2 Construction Spares

A. 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.

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

Date: 6 January, 2015

7.7.3 Spare Part and Consumables Packaging and Identification A. All spares parts and consumables supplied shall be listed in the Maintenance Manuals.

B. 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.

C. 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 Facility UPS System Contractor shall be ISO-9001 Certified and shall submit current

Certification documentation upon Contract Award.

8.1 General Arrangement

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

1. 1100KVA Integrated multi-modular converter based UPS

2. UPS input disconnecting means

3. Valve Regulated Lead Acid (VRLA) batteries with minimum of 10 year design life rated to full load for 30 minutes of backup power

4. 100A out circuit breaker for self-derived power to critical loads panel

5. Battery monitoring system

6. Battery module disconnecting means

7. Maintenance Bypass and Service Panel (MBSP) with kirkey interlock

8. UPS and battery instrumentation for local and remote monitoring

9. UPS and battery controls for local operations

10. Control wiring and accessory devices between UPS, battery cabinet and MBSP

11. The MBSP shall accommodate a 1100KVA UPS system as specified herein and provide accommodations to integrate/parallel an additional 1100KVA UPS system in the future NOTE: The following shall not be procured at this time:

a) Second 1100kVA UPS unit with batteries

b) Second UPS input disconnecting means

c) Second UPS Maintenance Bypass interface

d) Second UPS battery monitoring

e) Second UPS controls and monitoring

B. The Contractor supplied Facility UPS shall be modular in construction, and have at a minimum, an independent bypass module, independent modular power modules, and independent battery modules.

C. The Contractor supplied Facility UPS shall contain modular based power conversion blocks with built in N+1 redundancy. The Facility UPS shall be fully operational upon a failure of a

Date: 6 January, 2015 single power conversion block. The Facility UPS shall be capable of isolating a single power conversion block failure to ensure continuous operation of the unit.

D. The Contractor supplied Facility UPS 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.

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

F. The Contractor supplied Facility UPS power conversion shall be designed for non-interrupted maintenance bypass to service UPS and batteries over the life.

G. The Contractor supplied Facility UPS System batteries shall be Valve Regulated Lead Acid (VRLA) batteries with minimum of 10 year design life.

H. The Contractor supplied Facility UPS and battery cabinet shall provide disconnect device(s) as necessary to safely disconnect the battery modules from the power conversion modules for maintenance replacement and repair.

I. The Contractor supplied Facility UPS battery strings shall have DC disconnects for isolation.

J. The Contractor supplied Maintenance Bypass and Service Panel shall have a minimum of (1)

2000AT circuit breaker for maintenance bypass and (1) 2000AT circuit breaker for maintenance isolation of the UPS that are interlocked mechanically (kirk keys) and electrically (auxiliary contacts).

K. The Contractor supplied Facility UPS System shall provide the capability to parallel two UPSs of the same family that compare, adjust and match the output voltages and frequencies of the two UPS outputs, so that they share the same load when paralleled to a common output load bus.

L. The Contractor supplied Facility UPS System shall be installed in a Government provided indoor enclosure supported a 25 feet wide by 50 feet long raised steel platform.

M. The Facility UPS System enclosure shall be designed to the specified IBC, NFPA and NEC requirements.

N. The Contractor supplied Facility UPS System shall be designed to withstand 30 minutes without HVAC cooling while the unit is on batteries. Means to exhaust heat may be used via the 120/240V critical load panel within the enclosure.

O. The Contractor shall provide temperature sensors for each Facility UPS 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.

P. The Contractor shall provide a battery monitoring system for the health of each installed cell that includes but not limited to voltage, temperature, resistance and current of each cell.

Q. The Contractor supplied Facility UPS system shall provide MODBUS TC/IP interface for remote monitoring.

R. The Contractor supplied Facility UPS System shall provide local and remote monitoring capability to monitor the status and health of the Facility UPS and associated VRLA batteries to include but not limited to individual cell voltage, temperature, current and resistance.

S. The Contractor supplied Facility UPS System shall provide local and remote time stamped log of all Facility UPS actions, including but not limited to, battery charge cycles, fault logs, event logs and shunt tripping of circuit breakers.

Date: 6 January, 2015

T. The Contractor supplied Facility UPS System shall provide a touchscreen display for local monitoring, control and operation.

U. The Contractor supplied Facility UPS System shall provide a touchscreen display for remote monitoring.

V. The Contractor supplied Facility UPS System shall supply but not limited to, signals and functions hardwired relay contacts for the following. These signals should be wired to a terminal strip to provide easy wiring access to the remote system:

1. Line failure alarm

2. Low battery alarm

3. UPS alarm

4. UPS Mode – Bypass, Normal, Battery

5. Converter failure alarm

6. Fire detection system alarm

7. Fire suppression system activation

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

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

1. 480Vac three phase mechanical load panel and all associated wiring

2. 450-120/240Vac 30KVA delta-wye transformer for single phase critical load house panel

3. 120/240Vac single phase critical load house panel

4. HVAC and exhaust system

5. Fire alarm and suppression system

6. Hydrogen detection system

7. Lighting and receptacles

8. All 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 X. The Government shall provide a standalone indoor enclosure to accommodate a 1100KVA

UPS system as specified herein and provide accommodations to integrate the associated auxiliaries of a second 1100KVA UPS system in the future.

NOTE: The following shall not be procured at this time:

1. Second UPS enclosure auxiliaries including HVAC, exhausting, hydrogen detection and all other such auxiliaries Y. The Government shall provide two egress doors with keyed locks and emergency exit push bars.

Z. The Government shall provide enclosure emergency lighting and exit signs at each door.

AA. The Government shall provide enclosure HVAC system with built in redundancy for the heating ventilation and air conditioning requirements of the UPS and battery cabinets.

BB. The Government shall provide means an exhaust system to reject heat when the unit is on battery power. The power to the exhaust system shall be installed in the 120/240V critical load panel.

CC. The Government shall supply the Facility UPS System enclosure fire alarm system tied into the Building 633 Complex at NAVSSES Philadelphia, PA fire alarm system with visual and audible alarms.

Date: 6 January, 2015

DD. The Facility UPS System enclosure shall provide fire suppression with visual and audible alarms.

EE. The Facility UPS System enclosure shall provide hydrogen detection and exhaust system for the VRLA batteries with local and remote visual and audible alarms.

FF. The Government shall supply the Facility UPS System enclosure with adequate ceiling mounted lighting with a switch at each exit door.

GG. The Government shall supply the Facility UPS System enclosure with 120Vac convenience receptacles every 10 feet of each accessible wall.

HH. The Government shall supply the Facility UPS System with a 480Vac, 3 phase, 60 Hz, 250Amp main power panel and connect the enclosure non-critical mechanical loads such as but not limited to HVAC systems, etc. and all associated wiring.

II. The Government shall supply the Facility UPS System with a 120/240Vac single phase, 125Amp main critical panel and all associated wiring for all 120/240Vac house loads.

8.2 General

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

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

Facility UPS System locally and remotely as specified herein.

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

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

E. The Facility UPS System shall be designed to ensure personnel safety in accordance with

NFPA 70E.

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

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

H. The Facility UPS enclosure front of each cubical shall be hinged doors or removable lift-off panels.

I. The Facility UPS enclosure shall be adequately secured but shall not be used for structural strength.

J. The Facility UPS enclosure shall have ventilation openings at the top and bottom where required.

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

8.2.1 Instrumentation and Control

8.2.1.1 Control Functions

A. The Facility UPS System control equipment shall provide, at a minimum, the following control and instrumentation functions:

1. Local Facility UPS control shall include a minimum of:

a) UPS mode of operation

i. Normal

Date: 6 January, 2015

ii. Bypass

iii. Battery

b) Battery Charger On/Off

c) Output load On/Off

2. Local Facility UPS indication shall include a minimum of:

a) Facility UPS normal input power available/active/inactive

b) Facility UPS bypass input power available/active/inactive

c) Facility UPS battery input power available/active/inactive

d) Facility UPS output power active/inactive

e) Facility UPS historical event log

f) Facility UPS historical alarm log

g) Facility UPS normal input power voltage, current, frequency, apparent power, real power, reactive power, power factor

h) Facility UPS bypass input power voltage, current, frequency, apparent power, real power, reactive power, power factor

i) Facility UPS output power voltage, current, frequency, apparent power, real power, reactive power, power factor, efficiency

j) Facility UPS battery voltage, current, apparent power, real power, reactive power, power factor, minutes of battery time remaining

k) Facility UPS battery cell temperature

l) Facility UPS battery charger status

3. Remote UPS Emergency Power Off shall be provided in test site control center.

4. Remote Facility UPS monitoring shall include a minimum of:

a) Facility UPS normal input power available/active/inactive

b) Facility UPS bypass input power available/active/inactive

c) Facility UPS battery input power available/active/inactive

d) Facility UPS output power active/inactive

e) Facility UPS historical event log

f) Facility UPS historical alarm log

g) Facility UPS normal input power voltage, current, frequency, apparent power, real power, power factor

h) Facility UPS bypass input power voltage, current, frequency, apparent power, real power, power factor

i) Facility UPS output power voltage, current, frequency, apparent power, real power, power factor, efficiency

j) Facility UPS battery voltage, current, power factor, minutes of battery time remaining, battery temperature

k) Facility UPS battery charger status

l) Fire alarm system activated status

m) Fire suppression system activated status

n) Enclosure temperature monitoring

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

Date: 6 January, 2015

8.2.1.2 Operator Interface (both Local and Remote)

A. The Facility UPS local display shall provide complete control and monitoring UPS system.

B. The Remote control and indication shall be designed to operate at a distance of 450 feet (via fiber optic connection) from the physical Facility UPS installation.

C. The Remote control interface shall be located in the Government’s Control Room.

8.2.1.3 Communications

A. The Facility UPS shall be provided with digital communication capabilities to allow direct status communication for remote Facility UPS operations.

8.2.1.4 Control Panels

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 space heaters 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.

8.2.1.5 Connection Terminal Box

A. Each Instrumentation and Control Connection Terminal Box 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 Facility UPS and NEC.

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

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

D. Instrumentation and Control Terminal blocks shall be rated at 600 VAC.

E. Instrumentation and Control wires and cables shall be rated at 600 VAC and be a minimum of #18 AWG.

Date: 6 January, 2015

8.3 Connections and Terminals

8.3.1 Power Interface Terminals

A. The power interface termination area shall be adequately sized to permit the proper termination of the following input power cables: seven (7) sets of four (4) one (1) conductor 500kcmil cables and seven (7) sets of 250kcmil ground cables.

B. The power interface terminals may be copper with silver or tin plating to reduce corrosion.

C. The power interface terminals shall be designed to accommodate a two-hole lug connection for the power cables.

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

E. The ground buswork shall be copper with silver or tin plating to reduce corrosion.

F. The conductors shall be oriented and labeled from left to right for the A, B, and C phase terminations. The terminations shall be made on high copper alloy blocks and conform to standard NEMA patterns.

G. 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.

H. 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.

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

8.3.2 Installation

A. The Contractor shall provide Facility UPS, battery and MBSP Installation Drawings upon delivery.

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

8.4 Delivery, Lifting and Rigging

A. The Contractor shall deliver the Facility UPS system to NAVSSES 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 A008

Packaging Plan and Lift Arrangement Drawings, for all components and assemblies to be lifted on site at NAVSSES, 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 UPS 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.

Date: 6 January, 2015

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,…