Attachment_2_-_SAQMMA16R0482_SOW.pdf

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STATEMENT OF WORK FOR MODULAR POWER SYSTEM

(GENERATORS) TO POWER X-RAY SCANNING EQUIPMENT IN

EGYPT

1.0 PURPOSE and BACKGROUND

1.1 The purpose of this document is to procure ten (10) Modular Power

Systems (MPS) according to the design requirements and specifications below and have them delivered and installed on existing cement pads at eight (8) specific locations in Egypt. The cement pads are built to accommodate a 40 foot container. The MPS will be used to provide emergency site power, as well as prime power at one site

(Koustal), for American Science and Engineering (AS&E) X-Ray scanning equipment installed under a State Department (DoS)

Nonproliferation and Disarmament (NDF) fund project with the

Government of Egypt (GoE).

2.0 SCOPE

2.1 This document addresses deliverables as well as an illustrative design requirements and specifications for the MPS system, including the generator, Uninterruptible Power Supply (UPS) and required electrical distribution panels (paragraphs 4 through11). Offeror may propose an equivalent MPS system that meets the salient characteristics required for proper operation in the environment and for the purpose intended without specifically meeting every description listed in paragraphs 4 through 11 below

2.2 The Contractor shall coordinate with the site contractor, Darko

Constructions Co. (Darko), to coordinate with the GoE for customs and tax free entry into Egypt of the MPS and assistance in transport to the specific sites. The Contractor shall cover the cost of transport to the site and placing of the MPS at the location on the specific sites where designated by Darko. Darko will connect the power cables from the UPS to the scanning equipment and arrange for the GoE to connect the utility power to the MPS, except at the site at Koustal where the MPS will be the main power source to the scanning equipment. Contact information for Darko is:

Shady Aboul Fotouh: CEO

Darko Constructions Co.: 4, El Nabawy El Mohandes, Agouza, Giza, Cairo, Egypt.

Phone +202-33038519

Fax +202-33475421

Mobile +20100-1111996

Email: shady_fotouh@darko-eg.com darko_con@yahoo.com mailto:shady_fotouh@darko-eg.com mailto:darko_con@yahoo.com mailto:darko_con@yahoo.com

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Web site:

http://www.darko-eg.com http://www.darko-eg.net

Once all connections are made, the Contractor shall start up and test the MPS for final acceptance by the authorities of the GoE.

2.3 Contract Requirements:

The site locations in Egypt with the number of MPS and power ratings required for manufacture under this contract are as follow:

Hamdi Tunnel West Side one MPS 300kVA conf.1

Salam (Peace Bridge) West Side one MPS 300kVA conf.1

Al Salloom (Libyan border) one MPS 300kVA conf.5

Sharm El Sheikh one MPS 300kVA conf.5

Koustal (Sudan border) two MPSs 300kVA conf.3B

Port Fouad two MPSs 300kVA conf.1,5

Hamdi Tunnel East Side one MPS 300kVA conf.1

Salam (Peace Bridge) East Side one MPS 300kVA conf.1

2.4 All personnel performing on-site/in country involved in the customization, maintenance, repair and installation of the MPSs are subject to approval by the Government of Egypt.

2.5 The Contractor shall provide an initial warranty and a service contract for parts and regular maintenance of the MPS provided under the base contract and the option quantities for one (1) year beyond the date of initial installation.

3.0 REFERENCE INFORMATION

3.1 Reference Documents:

3.1.1 National Electrical Code, NFPA 70, 2014

3.1.2 MPS One Line Diagram, 255-2513-1 (provided by AS&E)

mailto:info@darko-eg.net http://www.darko-eg.com/ http://www.darko-eg.net/ http://www.darko-eg.net/

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3.2 Abbreviations and Definitions used:

3.2.1 ATS – Automatic Transfer Switch

3.2.2 DG – Diesel Generator

3.2.3 NEC – National Electrical Code

3.2.4 NEMA – National Electrical Manufacturers Association

3.2.5 NFPA – National Fire Protection Association

3.2.6 UPS – Uninterruptible Power Supply

4.0 GENERAL REQUIREMENTS

4.1 The Modular Power System (MPS) shall be enclosed in a container designed and manufactured to comply with the environmental conditions at the above sites to be weatherproof from rain and sand storms.

4.2 Container should have an adequate HVAC system to maintain a stable operating temperature.

4.3 The MPS shall be capable of providing isolated power from either an external (utility) source or an internal source.

4.4 The MPS shall consist of the following components at a minimum:

4.4.1 A 50Hz diesel generator (10 MPS, each with a generator

of 300KVA power.)

4.4.2 An appropriately sized and rated ATS to transfer from utility power to diesel backup power.

4.4.2.1 ATS requires auxiliary contacts for load bank connection.

4.4.3 A UPS to provide power to critical loads. (10 MPS, each with a UPS of 300KVA power).

4.4.4 A distribution panel for critical loads.

4.4.5 A distribution panel for non-critical loads.

4.4.6 A radiator mounted load bank to prevent engine wet stacking.

4.4.7 A surge protection device (TVSS) to protect against excessive current.

4.4.8 Associated circuit protection devices, etc. to achieve compliance with applicable electrical codes.

4.4.9 All components shall be integrated, pre-wired and mounted on the same surface.

4.5 All user terminations, controls, panels and service points shall be easily accessible and clearly labeled.

4.6 The MPS shall be protected from oxidation and corrosion.

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4.7 The Offeror shall indicate on their proposal how they will provide service and maintenance support for one year for installation at the above sites.

4.8 The Contractor shall provide training in proper setup, operation and maintenance of the power system.

4.9 Factory Acceptance Testing must occur in the US or manufacturer location prior to shipment. This test shall be conducted on the first ready to ship unit. No further testing would be required at factory location on the remainder of the systems. The Contractor is responsible to conduct a Site Acceptance Test on each unit to confirm that each system meets its stated technical specifications as a condition for final acceptance.

5.0 ELECTRICAL REQUIREMENTS

5.1 All components and equipment shall meet all applicable U.S.

Standards and local standards.

5.2 The MPS shall be designed to allow easy connections to be made to utility power as well as output power.

5.2.1 Customer connections will be made via stub-up locations beneath the distribution panels, allowing direct connection to the individual breakers.

5.3 The output section of the MPS shall consist of two distribution panels, one for 380V critical loads and one for 380V non-critical loads with circuit protection devices as shown on the one line diagram.

5.4 The MPS shall be designed for a nominal utility main of 380V, 50Hz, +/- 10%, 5 wire.

5.5 The DG output shall be 380V, 50Hz, 5 wire.

5.6 The DG output shall be connected to the ATS through appropriate circuit protection devices.

5.7 The ATS shall be for 10 MPS 600A service entrance rated, contactor type, 380V, 50Hz, 3 phase, 3 pole, with auxiliary contacts in NEMA 1 enclosure. There must be a Bypass Isolation Switch for the ATS.

(Note: The ATS does not need to be service entrance rated provided the utility mains for all site configurations are connected to an upstream service rated disconnect device.)

5.8 The ATS for Koustal only shall alternate automatically with time control and in case of failure of one.

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5.9 The UPS shall be an online double-conversion system, rated for a continuous output of 10 MPS 300kVA, minimum, with IGBT rectifiers.

5.10 The UPS shall be configured to provide a 400V, 50Hz, +1%, -5%, output for an input of 380V, 50Hz, +/- 10%.

5.11 The UPS shall be able to provide uninterrupted power to 10 MPS

300KVA critical load for up to 6 minutes in the event of a total line side outage.

5.12 The UPS shall have a bypass feature to allow direct connection of the critical loads to the load side of the ATS in the event of UPS overload or failure.

5.12.1 External maintenance bypass will provide 380V from utility, not the 400V from the output of the UPS intended for the critical loads.

5.13 The MPS shall have internal service lighting connected to the load side of the ATS.

5.14 As an option, battery powered backup lighting shall be provided and mounted internal to the unit to aid in locating controls. These lights should be able to be switched on and off manually to avoid depletion of the batteries.

5.15 As an option, the MPS should have the capability to transmit status and error messages to an external computer via Ethernet.

5.16 A radiator mounted load bank will be used to prevent wet stacking when the critical loads are not applied.

5.16.1 The load bank will be sized to provide 50% generator capacity in the absence of any critical loads.

5.16.2 The load bank will utilize an automatic load controller connection to a current transformer downstream of the ATS. The load will automatically transfer to the load bank in the absence of a critical load.

5.16.3 Automatic load dump via auxiliary contacts on the ATS will allow the load to be transferred from the load bank if the ATS is connected to utility.

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5.17 Surge protection device shall be connected in parallel to the non-critical distribution panel.

5.17.1 Response time should be less than 0.5 nanoseconds.

5.17.2 Device shall have 125kA per mode and 250kA per phase.

5.17.3 Fault current shall be 200kAIC.

5.17.4 Device shall be housed in a NEMA 1 Standard enclosure

6.0 DIESEL ENGINE-DRIVEN GENERATOR

6.1 Provide ten (10) alternating-current standby diesel engine-driven generators for the power requirement set out in paragraph 2.2 above. All generators will be standby for emergency power except for the two generators destined for the

Koustal site. These will be prime power. The generators at the Koustal site will alternate for a total operating time of approximately 224 hours a month

(approximately 8 hours per day with 4 hours on each MPS). All other generators will probably not operate more than 40 hours a month, but must be capable of up to 12 hours continuous power in case of prime power loss.

6.1 380/220 -volt, 3-phase, 4-wire, 50 Hz; equipped with 4-cycle, 6 -cylinder, 1500 RPM, liquid-cooled, with unit mounted radiator, diesel engine; connected directly to 4-pole revolving-field type single-bearing generator through semi-flexible steel disk coupling.

6.2 Each generator shall have a main distribution panel and appropriately sized sub-panels for critical and non-critical loads.

6.3 Intake air filters shall be dual element radial seal design made of densely pleated filter paper with built in pleat support and positive pleat spacing.

6.3.1 One piece molded urethane end caps with integral seal.

6.3.2 Heavy-duty metal inner and outer wraps.

6.3.3 Baked on enamel outer filter wrap.

6.4 A dust ejector shall be upstream of the intake air filter and eject waste to the exhaust system downstream of the muffler.

6.5 Starting system shall be 24V-DC electric with negative ground.

6.5.1 Components sized so they are not damaged during a full engine cranking cycle at maximum ambient temperature.

6.5.2 Heavy duty cranking motor that automatically engages and releases from engine flywheel without binding.

6.5.3 Cranking cycle as required by NFPA 110 for system level specified.

6.5.4 Lead acid battery with sufficient capacity to provide specified cranking cycle three times in the ambient temperature range.

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6.5.5 Factor mounted on-engine charging alternator with solid state voltage regulation.

6.5.6 Current-limiting, automatic-equalizing and float-charging type battery charger designed for lead-acid batteries.

6.6 Equip set with associated control equipment to automatically start engine, transfer load to standby power upon failure of normal power source, transfer load back to normal power upon its restoration, and stop engine.

6.7 Cushion-mount engine-generator on heavy steel base with vibration isolators to reduce possibility of torsional vibration. Equip engine with low-oil pressure, high-water temperature, and automatic overspeed safety shutdown devices.

6.8 Equip generator with exciter and voltage regulator to maintain voltage within 1/2% of rated value.

6.9 Generator shall be brushless type. Generator shall be connected directly to fly wheel by semi-flexible steel disk coupling.

6.10 Provide unit capable of voltage recovery, within regulated range, of 5 seconds following a sudden load increase from 0 percent to 100 percent of rated load, and with voltage dip not to exceed 19.5% upon application of rated load at rated power factor.

6.11 Frequency regulation shall not exceed 11.5-hertz from no load to rated load.

6.12 Minimum of 14.9% subtransient direct axis reactance.

6.13 Minimum 1009 skVA motor starting capability at a 30% voltage dip.

6.14 The excitation system shall enable the generator to sustain 300% of rated current for ten (10) seconds at prime rating during a fault condition and shall improve the immunity of the voltage regulator to non-linear distorting loads.

6.15 Construction shall prevent mechanical, electrical, and thermal damage due to vibration, overspeed up to 125 percent of rating, and heat during operation at 110 percent of rated capacity.

6.16 For the output waveform at no load the voltage harmonic content measured line-to-line or line-to-neutral shall not exceed 5% THD and

3% for single harmonics.

6.17 The telephone influence factor shall not exceed 50.

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6.18 Thermostatically controlled unit arranged strip heater to maintain stator windings above dew point.

6.19 The insulation system of the generator shall be UL 1446 Recognized

Class H with tropicalization and antiabrasion

7.0 GENERATOR SET MOUNTED CONTROLS

7.1 Provide a fully solid-state, microprocessor based, generator set control. The control panel shall be designed and built by the engine manufacturer. The control shall provide all operating, monitoring, and control functions for the generator set. The control panel shall provide real time digital communications to all engine and regulator controls via SAE J1939.

7.2 Environmental: The generator set control shall be tested and certified to the following environmental conditions:

7.2.1 40C to 70C Operating Range

7.2.2 100% condensing humidity, 30C to 60C

7.2.3 IP22 protection for rear of controller; IP55 when installed in control panel

7.2.4 5% salt spray, 48 hours, +38?C, 36.8V system voltage

7.2.5 Sinusoidal vibration 6G's RMS, 24-1000Hz

7.2.6 Electromagnetic Capability (89/336/EEC, 91/368/EEC, 93/44/EEC, 93/68/EEC, BS EN 50081-2, 50082-2)

7.2.7 Shock: withstand 15G

7.3 Functional Requirements: The following functionality shall be integral to the control panel.

7.3.1 The control shall include a minimum 5.5 inch, 480 x 320 pixel, and white backlit graphical display with text based alarm/event descriptions.

7.3.2 The control shall include a minimum of 6-line data display

7.3.3 Generator set overview screen displaying critical generator set mechanical and electrical data on a single screen.

7.3.4 Audible horn for alarm and shutdown with horn silence switch

7.3.5 Standard ISO labeling

7.3.6 Multiple language capability

7.3.7 Remote start/stop control

7.3.8 Local run/off/auto control integral to system microprocessor

7.3.9 Cooldown timer

7.3.10 Speed adjust

7.3.11 Lamp test

7.3.12 Emergency stop push button

7.3.13 Voltage adjust

7.3.14 Voltage regulator V/Hz slope - adjustable

7.3.15 Password protected system programming

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7.4 Digital Monitoring Capability: The controls shall provide the following digital readouts for the engine and generator. All readings shall be indicated in either metric or English units

7.4.1 Engine

7.4.1.1 Engine oil pressure

7.4.1.2 Engine oil temperature

7.4.1.3 Engine coolant temperature

7.4.1.4 Engine RPM

7.4.1.5 Battery volts

7.4.1.6 Engine hours

7.4.1.7 Engine crank attempt counter

7.4.1.8 Engine successful start counter

7.4.1.9 Service maintenance interval

7.4.1.10 Real time clock

7.4.1.11 Engine exhaust stack temperature

7.4.1.12 Engine main bearing temperature

7.4.2 Generator

7.4.2.1 Generator AC volts (Line to Line, Line to Neutral and Average)

7.4.2.2 Generator AC current (Avg and Per Phase)

7.4.2.3 Generator AC Frequency

7.4.2.4 Generator kW (Total and Per Phase)

7.4.2.5 Generator kVA (Total and Per Phase)

7.4.2.6 Generator kVAR (Total and Per Phase)

7.4.2.7 Power Factor (Avg and Per Phase)

7.4.2.8 Total kW-hr

7.4.2.9 Total kVAR-hr

7.4.2.10 % kW

7.4.2.11 % kVA

7.4.2.12 % kVAR

7.4.2.13 Generator bearing temperature

7.4.2.14 Generator stator winding temperature

7.4.3 Voltage Regulation

7.4.3.1 Excitation voltage

7.4.3.2 Excitation current

7.5 Alarms and Shutdowns: The control shall monitor and provide alarm indication and subsequent shutdown for the following conditions. All alarms and shutdowns are accompanied by a time, date, and engine hour stamp that are stored by the control panel for first and last occurrence:

7.5.1 Engine Alarm/Shutdown

7.5.1.1 Low oil pressure alarm/shutdown

7.5.1.2 High coolant temperature alarm/shutdown

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7.5.1.3 Loss of coolant shutdown

7.5.1.4 Overspeed shutdown

7.5.1.5 Overcrank shutdown

7.5.1.6 Emergency stop shutdown

7.5.1.7 Low coolant temperature alarm

7.5.1.8 Low battery voltage alarm

7.5.1.9 High battery voltage alarm

7.5.1.10 Control switch not in auto position alarm

7.5.1.11 Battery charger failure alarm

7.5.2 Generator Alarm/Shutdown

7.5.2.1 Generator over voltage

7.5.2.2 Generator under voltage

7.5.2.3 Generator over frequency

7.5.2.4 Generator under frequency

7.5.2.5 Generator reverse power (real and reactive)

7.5.2.6 Generator overcurrent

7.5.2.7 Generator current balance

7.5.3 Voltage Regulator Alarm/Shutdown

7.5.3.1 Loss of excitation alarm/shutdown

7.5.3.2 Instantaneous over excitation alarm/shutdown

7.5.3.3 Time over excitation alarm/shutdown

7.5.3.4 Rotating diode failure

7.5.3.5 Loss of sensing

7.5.3.6 Loss of PMG

7.6 Inputs and Outputs

7.6.1 Programmable Digital Inputs: The controller shall include the ability to accept programmable digital input signals. The signals may be programmed for either high or low activation using programmable Normally Open or Normally Closed contacts.

7.6.2 Programmable Discrete Outputs: The control shall include the ability to operate sixteen (16) discrete outputs, integral to the controller, which are capable of sourcing up to 300mA.

7.7 Maintenance: All engine, voltage regulator, control panel and accessory units shall be accessible through a single electronic service tool. The following maintenance functionality shall be integral to the generator set control.

7.7.1 Engine running hours display

7.7.2 Service maintenance interval (running hours or calendar days)

7.7.3 Engine crank attempt counter

7.7.4 Engine successful starts counter

7.7.5 40 events are stored in control panel memory

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7.7.6 Chronological status event log capable of displaying a sequence of event leading up to a generator set shutdown

7.7.7 Programmable cycle timer that starts and runs the generator for a predetermined time. The timer shall use 7 user-programmable sequences that are repeated in a 7-day cycle. Each sequence shall have the following programmable set points:

7.7.7.1 Day of week

7.7.7.2 Time of day to start

7.7.7.3 Duration of cycle

7.8 Remote Communications: The control shall include the option for

Modbus TCP communications via Ethernet 10BASE-T and Modbus

RTU communications via RS-485 half duplex with configurable baud rates from 2.4k to 57.6k.

7.9 Remote Monitoring Software: The control shall provide the option for

Monitoring Software with the following functionality

7.9.1 Monitor up to ten (10) generator sets, plus ATS and UPS.

7.9.2 Provide access to all date and events on generator set

communications network

7.9.3 Provide remote control capability for the generator set(s)

7.9.4 Ability to communicate via Modbus TCP, Modbus RTU or remote modem

8.0 ENCLOSURE REQUIREMENTS

8.1 A new steel construction high cube ISO-type container.

8.1.1 Modified with cutouts for personnel doors, intake louvers exhaust silencer installation and load cable access.

8.1.1.1 Cargo doors remain intact for access

8.1.2 Provide and install 14-gauge sheet steel floor

8.1.2.1 Cleaned and prime painted RAL 9001 (white)

8.1.2.2 Floor coated with painted non-skid (Gray)

8.1.3 Interior walls and roof covered with sound panels consisting of mineral wool fibre insulation covered with 22 gauge galvanized perforated sheet steel. Wall construction is Non-Combustible with a Zero Flame and Zero Smoke Spread per ASTM E 136 and

ASTM E84. Achieving sound level is approximately 80 db (A) at 7 meters/25-feet when measured approximately 5 feet from the ground free field condition around the package wall.

8.1.4 Personnel doors with slam latches and emergency exit push buttons internal

8.2 Engine and UPS Room

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8.2.1 Load cable access to be recessed and located on exterior of container on the curb side with lockable access door

8.2.2 Contain connections for remote start, load share lines, jacket water and strip heaters & battery charger

8.2.3 Stainless steel door hardware for all doors

8.2.4 MPS shall have grounding pads in accordance with national electrical codes.

8.2.5 Air discharge through turn hood located in front of the enclosure

8.2.6 Air inlet with Aluminum washable air filters, sound attenuated ducts and screened openings. Aluminum washable filters are a multi-layer expanded aluminum mesh secured in an aluminum frame, rated with an ASHARE 52.1-92 average synthetic dust weight arrestance of 67% at 520 fpm for the 1” series filter. Filters are UL approved and surpassed the Federal Specification FF-

300A. Filters are washable and reusable.

8.2.7 Install supplied generator set on a multi-gallon base tank in accordance with fire safety codes. Base tank and any additionally needed side tanks shall permit 24 hours of runtime at 100% load

8.2.7.1 A rail system can be used for easy removal of engine

generator set

8.2.8 Provide grounding between generator and container

8.2.9 Provide and install weather protective document box within unit

8.2.10 Provide and install required safety labels

8.3 Fuel System

8.3.1 (Standard) Double wall UL 142 listed, diesel fuel tank with the maximum capacity permitted by codes to be located on floor of container. Skid proof coating & spill containment around perimeter of the tank.

8.3.1.1 1 – 2” (50.8 mm) fuel filler (External fill with low fuel level strobe)

8.3.1.2 1 – ¾” (19.1 mm) fuel return & 1 – ¾” (19.1 mm) fuel pick up

8.3.1.3 1 – 1” (25.4 mm) fuel cell vent

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8.3.1.4 1 – 1” (25.4 mm) fuel containment basin vent

8.3.1.5 1 – 1” (25.4 mm) fuel cell drain

8.3.1.6 1 – 1” (25.4 mm) fuel containment basin drain

8.3.1.7 1 - Fuel level gauge

8.3.1.8 2 – 1 ½” (38.1 mm) fittings for customer use

8.3.1.9 1 – 1 ½” (38.1 mm) in rupture tank for switch

8.3.2 Alarms

8.3.2.1 1 - Leak detection alarm

8.3.2.2 1 - Low fuel level alarm

8.3.2.3 1 – Critical low fuel level alarm

8.3.3 All supply and return fuel lines pipe will be scheduled 40 black pipe and isolated from container to withstand any vibration.

8.3.4 Necessary structure for over the road use—baffles, material, design, etc. – not designed to carry more than 200 gallons of fuel during transportation

8.3.5 The fuel tank will be cleaned and prime coated then finish painted in standard industrial epoxy paint. The color will be White (RAL#

9001).

8.4 Drain groups

8.4.1 Lube oil drain at container exterior

8.4.2 Radiator drain at container exterior

8.4.3 Shut off valves located inside of container

8.5 Exhaust

8.5.1 Supply and install exhaust silencer

8.5.1.1 Designed to be internally mounted with proper heat

protection. The high temperature insulation conforms to the requirements of Military Specification MIL-1-16411

Type II, ASTM-C-1086 and Coast Guard Specification for

Incombustible Materials #164.009 and MIL-I-24244.

8.5.2 Internal exhaust flexes and pipes will be thermally wrapped

8.5.3 Exhaust outlet through the roof and located to prevent re-circulation of exhaust air

8.6 Cooling

8.6.1 Radiator to be factory installed on genset

8.6.2 Exhaust air to be directed through turning vane through front of container

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8.7 Electrical

8.7.1 380 VAC, three phase, AC distribution panel with main breaker and with cover and ground bar

8.7.2 One (1) complete interior lighting system in accordance with standards of Illuminating Engineering Society of North America

(IES). Emergency lighting must be per National Fire Protection

Association, NFPA 101, Life Safety Code.

8.7.3 Install and cable batteries and rack

8.7.4 GFI receptacles will be installed in locations in accordance with national electrical codes. General purpose receptacles shall be

Schuko Type F, 220V, 50Hertz, 16 Ampere duplex type.

8.8 Heating Ventilation and Air Conditioning

8.8.1 Provide HVAC unit/units located on the wall of the container sufficient for environmental condition per UPS manufacturer recommendation working 24 hours. HVAC design and requirements for containers shall meet standards set by

International Building Code (IBC), American Society of

Mechanical Engineering (ASME), and American Society of

Heating, Refrigeration and Air Conditioning Engineers

(ASHRAE).

8.8.2 HVAC unit will be designed to operate in marine environment

8.8.3 HVAC unit will be provided with a programmable thermostat

9.0 UPS SYSTEM

9.1 The UPS shall operate in the following modes.

9.1.1 On-Line (Normal) - The load shall always powered by the inverter, with stabilized voltage and frequency, using the energy from the mains power supply (INPUT). If there is a fault in the INPUT, the

UPS shall switch to the batteries in zero time and the batteries shall supply energy to the inverter to keep the load powered (for the backup time of the batteries). When the INPUT is restored the batteries shall be automatically recharged by the rectifier.

9.1.2 Stand-By-On - The load shall be powered from the by-pass line (if the power supply line is within the specified limits); if there is a fault on the power supply line, the load shall switch automatically onto the inverter, powered by the battery. In Stand-By- On mode, the rectifier remains powered and keeps the batteries charged. If

15 | P a g e the by-pass line voltage or the frequency moves out of the specified limit, the load shall be automatically switched onto the inverter output. With Stand-By On operation, the energy dissipated by the system shall be reduced, leading to considerable savings.

9.1.3 Stand-By Off - Standby-Off the load shall not be powered. In the event of an input mains failure the UPS shall be powered from the inverter using the energy stored in the batteries.

9.1.4 Battery System - Each unit shall draw the energy from its own battery. At the end of its backup time each UPS shall shutdown.

The load shall then remain unpowered if the duration of the power source outage is greater than the backup time of the connected battery system. When the power source is restored the system shall restart automatically. Each UPS shall recharge its own battery system.

9.1.5 Overload - If the load condition to the system is not reduced, the

UPS system shall switch onto the by-pass line. When the overload is removed, the UPS shall automatically return to normal operation. If the overload is continuous, this shall trigger the external protection devices located at the UPS input on the by-pass line. In this case the load shall remain unpowered.

9.2 The IGBT rectifier shall be capable of receiving utility input and rectifying it to produce Direct Current (DC) power at levels sufficient enough to supply the load via the inverter and charge the batteries.

9.2.1 Input Protection - The rectifier shall include protection against primary power surges, (except for lightning transients) and under or over voltage conditions. This protection is provided via fuses, Circuit Breakers, and Microprocessor Control of the rectifier.

9.2.2 Filtering - Sufficient filtering of the rectifier/charger output shall be provided to prevent damage to the battery. Ripple voltage shall not exceed ≤1% RMS.

9.2.3 In-Rush Limiting - When the primary power is applied to the rectifier, the current surge shall be limited to no more than nominal input current when the UPS is operating at 380VAC input.

9.2.4 Power Walk-In - When the utility power is applied to the rectifier, the current shall be <25% of the full load current and shall gradually increase to full load rating within 10 seconds (adjustable 0-30 sec.).

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9.2.5 Automatic Restart - Upon restoration of utility AC power after a power outage, the rectifier shall automatically restart and assume the inverter and battery recharge loads.

9.2.6 Charger - An integral charging circuit shall be capable of recharging the batteries during normal operation to ensure maximum life from the battery system.

9.2.7 Charger Capacity - The charger shall have sufficient capacity to recharge a fully discharged battery to 90% capacity within ten times discharge time.

9.2.8 Battery Test - The UPS shall periodically check the battery system for an open cell. If the UPS detects an open cell, an alarm condition shall be displayed and an audible alarm shall sound.

9.3 The inverter section of the power converter module shall utilize

Insulated Gate Bipolar Transistors (IGBT's). This solid-state device that incorporates digital signal processing (DSP) pulse width modulation

(PWM) technology capable of accepting the output of the rectifier or the battery system voltage and delivering AC power within specified limits to the critical load bus. The inverter shall be microprocessor controlled and include all necessary timing logic and control circuits.

9.4 The inverter shall automatically startup when a start command is generated and shall be stable and ready to deliver power to the load.

9.4.1 Inverter Protection - Inverter IGBT's shall be protected by current limiting circuits. The inverter shall be capable of running indefinitely with the batteries disconnected. For rapid removal of the inverter from the critical load, the inverter’s control electronics shall instantaneously turn off the inverter when the inverter’s capacity is exceeded. Simultaneously, the static transfer switch shall transfer the load to utility power without interruption to maintain continuous power to the critical load.

9.4.2 Inverter Oscillator - The inverter shall contain an oscillator capable of operating and maintaining the output frequency of the inverter within specified limits. The inverter oscillator shall be capable of frequency synchronization and phase locking to the bypass utility power source frequency. When operating as a slave to the utility power and a failure occurs in the slaving signal, the inverter oscillator shall automatically revert to a free running state and maintain the specified limits. The oscillator shall not drift more than 0.05% while operating at maximum rated operating temperature.

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9.4.3 Phase Balance - Electronic controls shall be provided to regulate each phase so that an unbalanced load will not cause the output voltage to go outside of the specified voltage unbalance or phase displacement limits.

9.5 AC Input Characteristics

9.5.1 Nominal Voltage: 380Y/220 VAC, 3 Phase, 50Hz

9.5.2 Nominal Voltage Range: +15/-10% from nominal voltage

during battery recharge.

9.5.3 Voltage Range on battery: +15% / -40%

9.5.4 Frequency Range: 45 - 65 Hz

9.5.5 Power Factor: > 0.99 at full load, nominal conditions.

9.5.6 Current Harmonic Distortion (THDi): < 3%

9.5.7 Inrush current: Less than nominal input current for less than one cycle

9.5.8 Input Surge Protection: UPS shall be equipped to withstand surges per ANSI/IEEE C62.41.

9.5.9 Rectifier Walk-in: Progressive from 0 to 30 seconds (adjustable)

9.5.10 Rectifier Walk-in Delay Timer: Progressive start of rectifier from 0 to 120 seconds (adjustable.

9.6 AC Output Characteristics

9.6.1 Voltage: 400Y/230 VAC, ± 1% steady state variation phase-to-phase voltage volts AC, 3 Phase, 50Hz

9.6.2 Frequency: 50Hz, + 2%,50Hz, + .05% when free running.

9.6.3 Voltage regulation: ±1% for balanced load, ±3% for 100% unbalanced load.

9.6.4 Voltage Distortion: Maximum 2% total (THD).

9.6.5 Voltage Transient (Step Load) Response: + 5% for 100% step load change.

9.6.6 Voltage Recovery Time: Return to within 1% of nominal value within 20 milliseconds.

9.6.7 Phase Angle Displacement: 120 degrees + 1º for balanced load;

120º, + 1º for 100% unbalanced load.

9.6.8 Non-Linear Load Capability: Output voltage total harmonic distortion shall be less than 2% when connected to a 100% non-linear load with a crest factor not to exceed 3%.

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9.6.9 Slew Rate: 1 hertz/second maximum.

9.6.10 Power Factor: 0.9 at the rated volt amperes (VA).

9.6.11 Inverter Overload Capability: 110% of rated load for 60 minutes, 150% of rated load for 1 minute.

9.6.12 Bypass Overload Capability: 110% for 60 minutes, 125% for 10 minutes, 150% for 1 minute.

9.6.13 Output Waveform: Sinusoidal

9.6.14 Efficiency: (DC-AC): Minimum - 95% at Full Load, (AC-AC):

Minimum – 93% at Full Load

9.7 Battery

9.7.1 Battery Voltage: 420 volts DC minimum before cutoff, 540 volts float.

9.7.2 Maximum DC Current: Maximum DC current at cutoff voltage shall be 478.7 Amps

9.8 The System shall withstand any combination of the following external environmental conditions without operational degradation.

9.8.1 Operating Temperature Range: 32ºF (0ºC) to 104ºF (40ºC) for the electronics, however the batteries should not be exposed to prolonged periods of temperature above 77ºF (25ºC). For every 15ºF

(8ºC) above 77ºF battery life is cut in half, and may void the battery warranty.

9.8.2 Storage Temperature Range: -25ºF (-32ºC) to 122ºF (50ºC) however batteries should not be exposed to temperatures above 77ºF (25ºC).

For every 15ºF (9.5ºC) above 77ºF battery life is cut in half, and may void the battery warranty.

9.8.3 Relative Humidity: Continuous operation with a relative humidity up to 90% non-condensing at 77°F (25°C).

9.8.4 Altitude: Normal operation without de-rating is 3,281 feet.

9.8.5 Audible Noise: Audible noise generated by the UPS shall not exceed 65 dBA when measured at 1 meter in front of the power converter using scale “A” of a standard ASA sound level-measuring device.

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9.9 The UPS unit shall incorporate the necessary controls, instruments and indicators to allow the operator to monitor the system status and performance, as well as take any appropriate action. The UPS shall meet, at a minimum the following requirements:

9.10 LED Control Panel Functions

9.10.1 Menu Selection

9.10.2 Mimic Screen

9.10.3 Function Indicator LED’s

9.10.4 Function Selection Keys

9.10.5 EPO Button

9.11 Graphic Display - A graphic display shall be on the UPS door, which provides the user to have a close-up, detailed overview in real time of the status of the UPS. The user shall be able to switch the UPS on and off, consult electrical mains, output, battery measurements and perform the main UPS settings. The display shall be divided into four main areas, each with its own specific role.

9.11.1 General Information: Area of the display where the set date and time and, according to the screen, UPS model or title of the menu which is active at that moment is displayed permanently.

9.11.2 Data Display/Menu Navigation: Main display area designed for displaying the UPS measurements (constantly updated in real time) and for consulting the various menus which the user shall select using the designated function keys.

9.11.3 UPS Status/Errors-Faults: Area where the UPS operating status is displayed. The first line shall always be active and constantly display the status of the UPS at that moment. The second only becomes active in the presence of an error and/or fault with the

UPS and shall display the type of error/fault encountered.

9.11.4 Key Function: Area divided into four boxes, each relative to the function key below its area. According to the menu which is active at that moment, the display shall indicate the function belonging to the corresponding key in the appropriate box, access main menu, go back to previous menu or display, scroll, confirm selection and silence function keys.

9.11.5 Menu Display

9.11.5.1 System Diagram

9.11.5.2 Measures

9.11.5.3 Waveforms

9.11.5.4 Commands

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9.11.5.5 Battery Test

9.11.5.6 Command

9.11.5.7 Bypass

9.11.5.8 System

9.11.5.9 Stand-By Mode ON

9.11.5.10 Smart Mode ON

9.11.5.11 Customizing

19.11.5.11.1 Date/Time

29.11.5.11.1 Normal Output Voltage

39.11.5.11.1 Battery Capacity

9.11.5.12 History

9.11.5.13 Firmware

9.11.5.14 Language

9.11.6 LED Status Indication

9.11.6.1 Bypass Line

9.11.6.2 Main Power

9.11.6.3 On Battery

9.11.6.4 Load on Bypass

9.11.6.5 Normal Output

9.11.6.6 Alarm for Internal Fault

10.0 MECHANICAL REQUIREMENTS

10.1 Individual MPS components shall be mounted on a steel frame base with holes in base for floor mounting.

10.1.1 The flooring under the DG shall be protected by a metal drip pan to collect any liquids that may drip from the engine and/or radiator.

10.2 Panels and controls shall be enclosed in a NEMA 1 enclosure.

10.3 Appropriate filtering, venting and/or ducting shall be provided for cooling air and combustion air.

11.0 ENVIRONMENTAL REQUIREMENTS

11.1 The MPS shall be suitable for continuous operation in a desert environment.

11.2 The MPS shall withstand a sandy, salty atmosphere.

11.3 The MPS shall be capable of operation in an ambient operating temperature of –18 deg. C (0 deg. F) to 55 deg. C (131 deg. F) with relative humidity at 95%.

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11.4 Ambient noise measured at a distance of 20 feet in any direction from the MPS should be no greater than 80dBA. This requirement should be met with the DG operating at full rated load.

12.0 SHIPPING PREPARATION REQUIREMENT

12.1 All exposed fittings that are external to the container as well as door handles, knobs, etc. shall be removed and stored inside the container for protection.

12.2 All door and ventilation openings that have been made in the container shall be covered with plywood in order to protect them from damage.

12.3 Shipping will be from manufacturer location to Egypt and then each of the containers should be delivered to their respective sites.

13.0 GENSET TESTING

13.1 Certified test report from the factory confirming full load acceptance at

0.8 power factor and generator transients.

13.2 Witness test performed at enclosure manufacturer at 100% load for a minimum of 2 hours using resistive load bank supplied by enclosure manufacturer.

13.2.1 All costing for customers witnessing personnel not included in quote (i.e. air, hotel, food).

14.0 APPROVED SOURCE(S) OF SUPPLY

14.1 The Contractor must have service representation within Egypt.

14.2 Project engineer must be certified to work on maintaining the systems.

14.3 The Contractor must be an approved company with references of similar systems in Egypt.

14.4 The Contractor must have local representation in Egypt with trained

Field Service engineers and availability of required spare parts.

14.5 During the Maintenance, the Contractor shall provide all required supplies including parts of generators and other components in the MPSs. The

Contractor shall have 98% part availability and be able to deliver to each required location within 24 hours.

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15.0 PERIOD OF PERFORMANCE

15.1 See Section F-006 for detail information

16.0 ATTACHMENTS

16.1 Generator Configuration Drawing 1

16.2 Generator Configuration Drawing 3B

16.3 Generator Configuration Drawing 5