NABR_PV_BATTS_-_SOW-REV_1.doc

National Park Service

Southeast Utah Group – Natural Bridges National Monument Statement of Work: Supply, Install and Recycle Batteries for Photovoltaic System Delivery Location: Natural Bridges National Monument, Utah May 2015

PROJECT SPECIFICATIONS

PART 1 GENERAL

1.1

DESCRIPTION AND REQUIREMENTS

A.

General. Supply, install and recycle batteries for an off grid Photovoltaic (PV) System at Natural Bridges National Monument. The PV system in conjunction with backup diesel generators provides all electrical service at the headquarters for Natural Bridges. The existing 216 (2 volt nominal) flooded lead acid batteries (C&D CPV 1880) batteries are to be removed and recycled (approximately 260 pounds each). They are to be replaced with 216 (2 volt nominal) flooded lead acid batteries with a higher amp hour rating. The new batteries shall provide a minimum of 2,100 amp hours (at 24 hours) per cell. The work of this contract will include disconnecting, loading, and transporting the existing batteries to a certified recycler. The work will also include delivery, un-loading, installation, wiring, and acceptance testing of the new batteries.

B.

Qualifications. Due to the technical nature and safety concerns of working with PV batteries, which includes disconnecting and connecting the battery bank and load testing the batteries, the Contractor shall have a minimum of seven years of experience in the field of battery testing or PV experience related to battery installation and maintenance. The on-site supervisor shall have at least two years of battery testing or PV experience related to battery installation and maintenance. Provide any other information on technical qualifications and training of the installation crew with the required submittal.

C.

Delivery Location and Instructions: Natural Bridges is located approximately 40 miles west of Blanding Utah, four miles off Highway 95. All roads are asphalt including the delivery location parking area and access to the battery building. The Contractor is required to provide all equipment for off-loading the batteries and moving the batteries. The Park will not provide any equipment. Deliveries will be accepted Monday thru Thursday from 7:00 to 4:30. No deliveries will be accepted on Friday, Saturday, Sunday or Federal Holidays.

D.

Overall Period of Performance and Installation Time. The overall period of performance for this project is 140 calendar days (20 weeks) from award. Included in the overall time is the installation phase. Due to the need to be expeditious in the installation phase, the period of performance is 21 calendar days (3 weeks) from the time the existing batteries are disconnected till the time the new batteries are installed and operating. If the option line to perform acceptance testing is exercised an additional 14 calendar days will be added to overall time of 140 calendar days.

E.

Warranty. Minimum terms include a 12 month full replacement period, and limited 48 months pro-rated warranty.

F.

Site Tour. All prospective Contractors are highly encouraged to visit the facilities. There will not be a formal date set for a site tour, however interested parties can visit the site with appointment, at any time up to two weeks before the bid due date. The Contractor must set up an appointment with the facility manager Kristy Ferguson at 435-692-1234-21 to visit the site.

G.

Special Battery Delivery Requirements. The Contractor is required to provide a fork lift or other piece of equipment to off load and move all batteries. The Park will not provide any equipment for moving batteries. The Contractor shall schedule with the facility manager, Kristy Ferguson at 435-692-1234-21 for delivery and inspection of the batteries. Designated Park personnel must inspect the batteries before offloading of the batteries can begin. If upon inspection of the truck and batteries reveals that the batteries are not adequately secured, they are tipped over, they are banged up, or they are damaged in any way the Park will record the serial numbers of all batteries in the delivery and refuse acceptance of all batteries. The Contractor shall provide all new batteries, re-furbishing the damaged batteries will not be accepted. The new battery delivery will again be inspected for the same requirements.

H.

Battery Recycling. The existing Park batteries shall be recycled. The recycling of the batteries must be documented via chain of custody. The Contractor shall submit with the bid proposal their plans for battery recycling, including the name and any certifications of the proposed recycler. The recycler must be a recycling facility authorized by the U.S. Environmental Protection Agency, or to a battery manufacture for delivery to a secondary lead smelter.

I.

Battery Layout. Due to the Park requiring the battery size be increased in capacity, it is essential that a battery layout plan be established to ensure the batteries can fit in the existing building. The battery building floor plan is included with this contract. The Contractor shall submit their proposed battery layout with critical dimensions shown with the bid proposal. At a minimum the battery layout shall maintain a three foot walkway to allow for maintenance, and the layout shall meet the requirements of the National Electric Code (NEC) with emphasis on articles 480 and 690 for battery based PV installations.

J.

Battery Interconnects and Leads. The Contractor is responsible for all labor and material for connecting the batteries together, and all wiring and connections up to the J-boxes in the battery room. The contractor is responsible for providing all new battery interconnects and battery terminal covers with the installation. Stainless steel hardware is required for all bolted connections. The existing battery leads are defined as the cabling running from the batteries to the J-box in the battery room and are #2 welding cables and not the 1/0 DLO cables shown on the as built drawings. All battery leads are to be replaced with a minimum of two parallel 1/0X-flex cable or equal. DLO (diesel locomotive) cable or welding cable are not an acceptable equal. The new battery leads shall be rated for 90C. All battery cables and leads must have properly rated heavy duty lugs compatible with fine strand, flexible batter cable. The Contractor shall provide calculations in their submittal showing that the proposed leads, meet the amperage and all other requirements necessary for the proposed batteries. These calculations shall include derating for multiple conductors in the raceway as well as temperature derate on the conductors per NEC 310.15(B)(3)(a) & 310.15(B)(2)(a). Voltage drop on the inverter to battery cables shall be clearly shown in the calculations and shall not exceed 2%. The Contractor shall submit complete information showing how the batteries are to be connected including: parts, wires, bolts, bolt torque information, and any other information necessary for the complete wiring of the batteries. This submittal shall be included with the bid proposal.

K.

Battery Containment. The Contractor shall remove and legally dispose, outside of the Park, the existing battery containment. The Contractor shall supply and install a new containment system for the new batteries. The containment system must have a minimum 4” high curb, and be liquid tight. The Contractor shall submit cut sheets and general information on the containment system they are proposing with the bid proposal.

L.

Acceptance Testing. The testing procedures will follow attachment #1, of the Battery Council International’s (BCI) standard section 14 “Determination of capacity of lead-acid industrial storage batteries for motive power service”. See PART 3 EXECUTION, 3.2 ACCEPTANCE TESTING, for specific requirements on testing for this specification.

1.2

SUBMITTALS

A. Submittals. Submit electronic cut sheets and required documentation in PDF format. The following submittal list is provided as an aid, if a submittal is required in the specifications but not on this list, it is still required.

1. General Plan. Brief description of work to be performed, number of employees on the job, and timeline. Submit with the bid proposal.

2. Qualifications. Provide documentation on meeting the required seven years and other pertinent information on qualifications. Submit with the bid proposal.

3. Battery Specifications Cut Sheet. Submit with bid proposal

4. Battery Warranty. Submit with bid proposal

5. Battery Recycling. Provide documentation on recycler. Submit with bid proposal

6. Battery Room Layout. Provide detailed drawing of battery configuration. Submit with bid proposal

7. Battery Interconnects and Leads. Provide documentation and calculations on all connections from the batteries to the J-box. Submit with bid proposal

8. Battery Containment System. Provide details. Submit with bid proposal

9. Safety Plan. Submit within two weeks after award

10. Acceptance Testing. Provide complete report within one week after testing 1.3

PROJECT CONDITIONS

A.

Staging Areas. The Contractor can stage equipment at the battery/PV building and yard. The Park will provide for covered and heated space for temporary storage of the batteries.

B.

Work days and hours. The work shall be performed from Monday through Friday from 7:00 am until 5:30 pm. No work is to be performed on Federal Holidays, or outside the set work hours without the approval of the Contracting Officers Representative (COR).

C. Lodging. Due to the remote location, on-site government housing is available to the Contractor. Government housing includes beds, kitchen with dishware/ pots/ pans, and showers. Government housing does not include food, towels, and bedding. Government housing also includes an option for a trailer pad for the Contractor to bring their own trailer onsite. The Park will supply all power and utilities to the Contractor if they decide to utilize this option.

D.

Phone Service. Cell phone coverage is unavailable. The Contractor is allowed to use Park phones for business, and limited personal usage.

E.

Crew Size. Due to safety concerns the minimum crew size is two people.

F.

Trash. The Contractor shall pick up and dispose of all trash and debris from the work of this contract and discard outside of the Park in a legal manner.

G.

Site Power during Installation. During the battery installation the Park will run on diesel power. The Contractor shall coordinate with Kristy Ferguson to coordinate the switch over from PV to diesel power to begin work. The Contractor shall ensure that complete shut off of power to the batteries has been accomplished before beginning work. The Contractor shall implement lock out - tag out procedures. Once the installation phase begins and the Park is running on diesel generators, it is essential that the Contractor remain on the job until the installation of the new batteries is completed. The maximum time allowed for the installation phase is 21 calendar days. If the acceptance testing option is exercised an additional 14 calendar days will be added.

H. Preconstruction Meeting. Prior to or at the beginning of on-site work a preconstruction meeting will be held. The meeting will be held at the job site. The Contractors on-site foreman shall attend. The foreman shall bring to the meeting and have read a copy of these specifications and be knowledgeable about this contract, the ensuing work, the safety plan and be prepared to answer questions. Topics of discussion will also include Park rules and regulations, labor standards, paperwork requirements for payment and other job specific requirements.

PART 2 PRODUCTS

2.1

BATTERY REQUIREMENTS

A. Salient Features

1. Type: Flooded lead acid battery made specifically for renewable energy storage

2. Cycle Type: Heavy duty deep cycle battery

3. Voltage: 2 volt nominal

4. Amp hour rating minimum: 2,100 at 24 hours at 1.75 volts per cell, at 77F

5. Expected life minimum: 3,000 cycles at 50% depth of discharge or better

6. Safety Venting Caps: Batteries shall be provided with safety venting caps which include flame arrestors

7. Manufacture Certification: ISO 9001 B. Approved product. Though this battery is no longer available, as an example, an approved battery meeting the salient features is the C&D Technologies CPV 2500. Batteries meeting the salient features may be submitted for approval.

PART 3 EXECUTION

3.1

SAFETY

A.

Warning. Batteries are potentially dangerous and proper precautions must be observed in all battery handling and maintenance. Work on batteries shall be performed only with proper tools and shall utilize the protective equipment listed. Battery work shall be performed by personnel knowledgeable with PV batteries and trained in the safety precautions involved.

B.

Protective Equipment. The following protective equipment shall be worn by personnel who perform battery work, or have these items on-site:

1. Goggles and face shields

2. Acid – resistant gloves

3. Protective aprons

4. Have availability to portable or stationary water facilities for rinsing eyes and skin in case of contact with electrolyte. This requirement is fulfilled with on-site facilities

5. Bicarbonate of soda solution mixed 100 grams bicarbonate of soda to 1 liter of water, to neutralize acid spillage.

6. Class C fire extinguisher 20 pound minimum, or manufacture recommended extinguisher

7. Adequately insulated tools

C.

Precautions. The following protective procedures shall be observed during this work:

1. Use caution when working on batteries since they represent a shock hazard.

2. Prohibit smoking and open flames, and avoid activities that increase the chances of arcing in the immediate vicinity of the battery.

3. Verify that the acceptance test equipment leads are clean, in good condition, and connected with sufficient length of cable to minimize the risk of accidental arcing in the vicinity of the battery.

4. Verify that all connections to acceptance test equipment include appropriate short-circuit protection.

5. Verify that the battery area ventilation is operating per its design.

6. Verify unobstructed egress from the battery area.

7. Do not wear metallic jewelry while working on the batteries.

8. Neutralize static buildup just before working on the battery by contacting the nearest effectively grounded surface.

9. Verify that the battery monitoring system is operational.

10. Utilize insulated tools where appropriate.

D. Safety Plan Submittal. Within two weeks after award, submit for acceptance an accident prevention program. The COR will review the proposed program for compliance with the requirements of these specifications. Under no circumstances is onsite work allowed to be performed until this program has been reviewed. THE PLAN SHALL SPECIFICALLY ADDRESS THE SIX ITEMS BELOW, LISTED AND NUMBERED IN THE SAME ORDER. ALL OTHER SAFETY PLANS WILL BE REJECTED!!!! Ensure that all employees have access to a copy of this plan on-site.

1. Name of responsible on-site supervisor to carry out the safety program.

2. Local Contact Information. Provide a list, which includes telephone numbers and addresses, of the nearest: ambulance, physician, hospital, fire department, and police.

3. Emergency Equipment. Provide a list of Contractor first aid kit locations. At a minimum the Contractor shall have at least one first aid kit onsite. Provide a list of Contractor fire extinguisher locations and type. At a minimum the Contractor shall have at least one 20 pound class C fire extinguisher.

4. Hazardous work phases and materials. Briefly outline each phase of the work, and identify any hazardous materials, associated hazards, and the methods proposed to ensure protection of property and safety of the public, Park personnel, and the Contractor's employees. At a minimum address the following for this project: lock out tag out, handling and installing PV batteries.

5. Personal Protective Equipment (PPE). Provide a statement requiring the aforementioned PPE be worn by employees.

6. Crew Safety Training. Due to the remoteness of this job, each crew member will be required to have current emergency medical training. Training shall include first aid and CPR, and be at least an 8 hour course. Training shall be provided by the Red Cross, the American Heart Association or equivalent. OSHA-10 or 30 are also required for training for at least one person on the crew.

3.2

ACCEPTANCE TESTING

A.

Acceptance testing shall be performed no sooner than six months after battery installation and no later than 9 months.

B.

The testing procedures will follow attachment #1, the Battery Council International (BCI) standard section 14 “Determination of capacity of lead-acid industrial storage batteries for motive power service”, with the following changes:

1. Section 2.2.1. Change 80% to 50% to reflect use in a PV system.

2. Section 5.5. Delete this section and replace with the following: The battery voltage shall be recorded at 30 minute intervals until it reaches a value of 1.80 volts times the number of cells, at which time the individual cell voltages shall be recorded. The battery voltage shall then be recorded at 5 minute intervals until it reaches the final voltage of 1.75 volts. The elapsed time in hours to final voltage shall be recorded. No cell shall be allowed to drop below 0.00 volts (reading backwards). The Contractor shall jumper across any cell as it reaches zero volts with a jumper cable capable of handling the current at which the discharge is taking place.

3. Battery manufacture recommendations for conducting this type of testing shall also be referenced and take precedence where they are different from the prescribed procedure.

C.

Document all testing results in a neat and organized manner and provide as a submittal.

D.

Provide a final report summarizing the testing documentation and making recommendations on replacement of any of the new batteries. Submit within one week of completion of testing.

PART 4 MEASUREMENT AND PAYMENT

A.

Measurement and payment will be made according to the bid schedule.

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