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59 -- 1200 kva battery-free single module ups system (OB1839370) (2006-11-21)

THIS IS AN URGENT REQUIREMENT!!! Brookhaven Science Associates is seeking an
all-inclusive price quote by 4:00 pm (local time) on Wednesday, November 22,
2006 for the following: UPS-1200
1200 kVA Battery-free Single Module UPS System, Automatic Transfer and Bypass
Isolation Switch, Switchgear and Weatherproof Walk-in Enclosure. 1.01 SCOPE

A. Furnish and deliver F.O.B. Upton NY a single conversion battery-free
uninterruptible power supply system (UPS) as described herein that provides
uninterruptible power within specified tolerances during failure or
deterioration of the normal power supply, automatic transfer switch, 480 Volt
switchgear, and equipment enclosure.

B. Include start-up services for all Equipment.

C. Rigging, installation labor and installation materials (including all
interconnections between detached pieces of Equipment) shall be the
responsibility of the Owner.

D. Control wiring connections between shipping splits of a single piece
of Equipment shall be made by manufacturer?s field service technicians.

E. Time is of the essence and the UPS unit, enclosure, transfer switch,
and switchgear shall be shipped for delivery to BNL by December 29, 2006. The
unit shall be compatible with a Caterpillar 2250 Diesel Generator as an
engineered uninterruptible battery-free power solution.

1.02 SYSTEM DESCRIPTION

A. The Equipment shall include a single conversion, line interactive
battery-free uninterruptible power supply (UPS) comprised of the following
major elements integrated into a single unit:

1. A single UPS module containing input breaker, static disconnect
switch, static bypass switch, bi-directional AC to DC converter (UPS
Converter) and line inductor;

2. A minimum of four flywheel energy storage modules (FES), each
containing two flywheels, two bi-directional AC/DC converters (BDC) and DC
disconnect means, controls and accessories necessary for the FES to provide
the specified energy storage for the UPS.

3. All controls and accessories necessary for the Equipment to function
properly as specified;

4. Options detailed elsewhere in the specification when included on the
specification bill of materials.

B. The UPS module shall provide at least 21 seconds ride-through time at
rated load without using chemical batteries.

C. The UPS shall be rated 1200 kVA / 960 kW output power.

D. The maintenance bypass (MBP) shall be designed as to integrate in the
same line up and as part of the UPS module. The MBP shall not increase the
depth or height of the UPS and shall not increase the length of the UPS by
more than 22 inches.

E. See specification for Automatic Transfer Switch, 480V Switchgear, and
Enclosure specification attached herein.

1.03 QUALITY ASSURANCE

A. The UPS together with any specified options shall be tested at the
factory for proper operation. The UPS module and FES shall be functionally
tested, and burned in for a minimum of 72 hours.

B. UPS design and construction shall conform to the following North
American standards as applicable:

1. UL1778, Standards for Uninterruptible Power Supply Equipment.

2. UL1004, Electric Motors.

3. FCC Rules and Regulations 47, Part 15, Subpart J, Class A.

4. IEEE 587-1980/ANSI C62.41 1980, Category A & B Recommended practice on
surge voltages in low power circuits.

5. NFPA 70
National Electric Code.

6. OSHA safety standards for electrical equipment and service of
electrical equipment.

7. CSA C22.2 No.107.1 Commercial and Industrial Power Supplies.

8. Industry Canada ICE-003, Canadian EMC.

9. Year 2000 compliance as defined in BSI standard DISC PD2000-1, A
definition of Year 2000 Conformity Requirements Document.

C. All Equipment shall be new and of current design and manufacture.

1.04 DELIVERY, STORAGEAND HANDLING

A. Deliver Equipment in fully enclosed vehicles after specified
environmental conditions have been permanently established in spaces where
Equipment is to be placed.

B. Store Equipment in spaces with environments controlled within
manufacturer?s ambient temperature and humidity tolerances for non-operating
Equipment.

1.05 PROPOSAL

A. Provide firm price, and confirmation of December 29, 2006 delivery
time, in accordance with the requirements of this specification.

B. Provide a bill of materials listing the products and services and
quantities of each.

C. Provide a paragraph by paragraph specification compliance that clearly
identifies whether the proposed Equipment and services comply with the
specification. If the proposal complies fully with the requirements of a
paragraph, the notation ?Comply? shall be applied to the paragraph and no
notations associated with that paragraph shall relieve the supplier from
complying with the requirements of the paragraph. Any Deviation or Exception
must be marked with the legend ?Deviation? or ?Exception?, respectively, and
explained sufficiently to allow the purchaser or its agents to clearly
evaluate the effect and consequences of the Deviation or Exception.

D. Include all other information required by this specification to be
part of the proposal.

1.06 SUBMITTALS

A. Provide general arrangement drawings showing all exterior
enclosure dimensions, cable access, shipping splits, and clearances. Show
sizes, weights, and relationships between individual shipping units, the
location and designation of all field wiring termination areas, and the
maximum number and permissible size range of power conductors which can be
accommodated for each power termination, heat rejection, cooling and humidity
requirements, air flow, and location of air inlets and outlets.

B. Provide assembly and mounting details for all Equipment and
shipping splits.

C. Provide electrical, mechanical, and environmental
specifications for the proposed Equipment including weights and dimensions of
shipping splits.

D. Provide the same paragraph-by-paragraph response to these
specifications in sufficient detail to clearly show all deviations. Clearly
identify any changes in this compliance compared to the compliance supplied
with the proposal. The submittal may be rejected if it contains any deviations
or exceptions not included in the proposal.

E. Provide electrical one-line drawings showing all power and
control interconnect wiring. Include number of and type of power conductors
that must be connected between shipping splits, Filed power wiring amperages,
arrangement and ratings of all input and output protection devices in the
Equipment, and control wire size and type; Equipment enclosure lighting and
HVAC panelboard; and 480 Volt switchgear with main circuit breakers and input,
and maintenance bypass circuit breakers.

F. Provide interconnect drawings or wire lists detailing the
termination points, and terminal designations for all field wiring between
Equipment being supplied. This drawing will either contain wiring requirements
or shall be keyed to the one-line drawing in a manner that clearly determines
wiring requirements.

G. Provide six copies of all submittal drawings at least 30 days
prior to shipment.

1.07 MANUALS

Provide 6 sets of user manuals containing safety, handling, storage,
installation, operation and normal maintenance instructions. The manuals
should also contain specifications, requirements, descriptions, and features
for all Equipment. Ship user manuals with Equipment.

1.08 WARRANTY AND MAINTENANCE CONTRACT

The manufacturer shall warrant the Equipment against defect in workmanship and
materials for a minimum of two years from date of acceptance to the Owner.

PART 2 ? PRODUCTS (UPS SYSTEM)

2.01 ACCEPTABLE MANUFACTURERS

The approved manufacturer for the UPS is Active Power, Inc. No substitutions
are permitted.

2.02 CONSTRUCTION

A. All materials used shall be new, of current manufacture, high quality,
free from defects and shall not have been in previous use except as required
for factory testing.

B. All Equipment except for remote annunciation panels, remote EPO panels
or computer monitoring equipment shall be contained in freestanding enclosures
that meet NEMA1 and IP20 standards as a minimum. No rear or side access or
code clearance shall be required for installation, service or repair. Front
access clearance (as opposed to code clearance) shall not exceed 48 inches.
Remote annunciation panels and remote EPO panels shall be wall mounted in
Building 515 at a location identified by the Owner.

C. All enclosures shall line up and match. The depths of all enclosures
shall be the same. Each enclosure may be composed of one or more shipping
splits. Each enclosure shall be completely segregated from other enclosures to
inhibit propagation of arcs and debris from internal faults. Barriers between
enclosures shall channel airflow between enclosures if required.

D. Standard cable access shall be from the top using raceway,
conduit or cable tray. Power Cable access shall be sufficient to accommodate
cable sizes from 500 MCM to 750 MCM whether run in raceway, conduit or on
cable tray. It shall be assumed that one set of cables is included in each
raceway or conduit. Sufficient clearance inside the Equipment shall be
provided to allow cable pulling, bending and termination without damage to the
Equipment and without requiring removal of Equipment parts other than access
panels and personnel shields that are intended to be removed for internal
access and are designed for easy removal by a single person. Lugs and hardware
for attaching standard NEMA two-hole lugs shall be provided by others.

E. Construction of Equipment shall facilitate lifting and
rigging. Clearance shall be provided in the base of Equipment to allow lifting
by forklift or pallet jack. Means shall be provided to lift Equipment by crane
without damage. The installing or rigging contractor shall provide appropriate
slings and spreader bars. The Equipment shall be sufficiently robust that when
packaged for shipment it shall be appropriate for shipment by common carrier
truck, rail, ship or airplane. Shipping splits shall be constructed and crated
to withstand normal international shipping and handling without damage.
Crating shall contain shock and tilt indicators to indicate when the Equipment
has been subject to excessively rough handling during shipping

F. All wiring shall be in accordance with UL standards. All power
conductors, transformer and choke windings shall be copper. All bus bar
connections shall be between copper, silver-plated copper or tin-plated copper
surfaces and shall be between compatible metals. Connections shall be properly
torqued and marked.

G. All control wiring between shipping splits of a single line up
of equipment shall be fitted with connectors constructed and identified to
prevent connection to the wrong location or in the wrong orientation.
Connectors shall have proper restraints to prevent loosening.

H. All field control wiring terminations shall be made to
terminal blocks or appropriate receptacles for plug-in connections. All data
bus connections shall be made with connectors. Receptacles and connectors
shall have appropriate restraints to prevent plugs from loosening.

I. All serial communications busses within the UPS module or between the
UPS module and FES module that are required to maintain operation shall be
redundant.

J. All Power interconnections between shipping splits of a single piece
of Equipment shall be supplied and equipped with termination or connection
hardware.

K. All field replaceable components except bus bar shall be
marked with the part designations shown on Equipment drawings and parts lists.
Label all terminal blocks and other wiring termination means with a
designation for the termination location and individual termination point
within the location.

L. PCBs shall not be used nor shall any components be used that
require toxic or hazardous materials documentation for transportation.

M. The UPS shall use modular, field replaceable power electronic sub
assemblies that are designed to allow ease of replacement.

N. All fuses in the main power paths of the UPS shall be monitored for
continuity. Blown fuses shall be alarmed.

O. Fans shall be redundant so that failure of any single fan shall not
cause the overheating of the UPS, capacity reduction, shut down or transfer to
bypass. Every fan shall be monitored to give positive indication of fan
failure without causing erroneous fan failure indications. All fan failures
shall be indicated on the UPS control panel. Any fan shall be replaceable
while the UPS operates on maintenance bypass.

P. Semiconductor power stages and power magnetic components, including
power transformers, shall be monitored for over-temperature conditions. Other
components shall also be monitored if necessary to prevent over temperature
failures. Ambient UPS temperature shall also be measured at a point of intake
into the UPS cabinet. All over temperature conditions shall be indicated on
the UPS control panel. High ambient temperature shall not shut down the UPS
unless it causes an internal component over-temperature.

Q. Control power shall be internally derived from redundant sources.
Control power supplies shall be redundant so that failure of a single supply
shall not affect UPS performance during operation. The static bypass switch
shall have separate power supplies and controls from the remainder of the UPS
module so that a complete failure of the other UPS controls and power supplies
shall not prevent the static bypass from operating. Control power from
external sources shall not be required during operation or normal start-up
sequences. Control power supplies shall be monitored for failure and failure
shall be indicated.

2.03 UPS MODULE

A. DESCRIPTION

The UPS module shall be a single conversion design. The input to the UPS
module shall be connected to an electrically operated input breaker. The
output of the breaker shall connect to the input of the static disconnect
switch and the static bypass switch. The output of the static disconnect
switch shall connect to the line side of a line inductor. The load side of the
line inductor shall be connected to the utility side of UPS converter. The
other side of the UPS converter shall connect to the DC bus of the UPS module.
The DC bus shall connect to 4 flywheel energy storage modules (FES). The load
side of the line inductor shall also be connected to the load side of the
static bypass switch and to the output of the UPS module. The UPS module shall
have the space and means to include a 1600 amp output circuit breaker.

B. OPERATION

1. The UPS shall operate continuously while maintaining specified output
power quality whenever the AC input power is within specified steady state
limits. The UPS shall operate properly from turbo-charged diesel generator
sets equipped with electronic isochronous governors and three-phase sensing
voltage regulators provided the generator sets are rated to support the
critical load at rated UPS power plus UPS losses and recharging power for the
FES. The UPS shall not require over sizing of engine generator sets to
accommodate UPS input harmonics. The UPS shall be compatible with the
Caterpillar 2250 generator set.

2. In normal mode operation, the input breaker, static disconnect switch,
and output breaker are closed and the static bypass switch is open. The input
source supplies real power to the UPS module to support the load and to keep
the energy storage charged. The utility converter shall exchange reactive
current through the line inductor to regulate the output voltage. The utility
converter shall also supply reactive current and harmonic current required by
the load. The static disconnect switch shall be phase controlled to block
reverse power from flowing from the utility converters to the input source.
UPS output voltage shall remain within 10 degrees of the input voltage during
steady state operation at all load levels between no load and full load and
shall not deviate by more than 15 degrees at the overload level that triggers
an instantaneous transfer to bypass. It shall not be necessary for the UPS to
draw power from the FES modules to support 100% step loads in normal mode
operation.

3. When input frequency or voltage deviates outside pre-determined
limits, the static disconnect switch and input circuit breaker shall open. At
the same time the utility converter shall draw power from the FES modules to
maintain uninterrupted power to the load within specified tolerances. The load
shall continue to be supplied power from the FES until they are fully
discharged or until the input returns within specified tolerances and the UPS
resynchronizes, reconnects and ramps the load back onto the supply. The UPS
shall resynchronize in the direction of the smaller angular difference and the
maximum frequency slew rate shall be adjustable. The default slew rate shall
be one Hz per second and shall accomplish resynchronization in less than 2.5
seconds when the frequency of the returned source is the same as the frequency
prior to the input disturbance. The synchronization process shall not use
phase jumps that appear to the load as high slew rate frequency changes. When
the UPS module reconnects to the input the current walk-in shall be linear and
without steps.
4. If the input does not return to within normal limits before the stored
energy in exhausted, or if the UPS has not resynchronized to the input one of
the following customer selectable choices shall occur:

a. The UPS shall shut down without damage or clearing fuses and the
output voltage shall cleanly transition to zero without spikes or surges.
This shall be the default setting.

b. An alternate firmware setting shall cause the UPS to attempt to
maintain power to the load by making a break transfer to bypass if the bypass
source is available. In this case, the Converters shall shut down and the
bypass shall turn on after a programmable delay provided the bypass source is
within limits specified herein. The delay shall be programmable over a minimum
range of 0 seconds to 2 seconds.

5. When the UPS has walked in following reconnection to the utility
source or following a discharge of stored energy for any reason, the UPS shall
recharge the FES modules. The recharge current shall ramp up to a level
corresponding to the preset, programmable recharge rate and, when the
flywheels approach full charge the recharge current shall ramp down. The
recharge power shall not be stepped on and off. The recharging current limit
shall be set independently of the input current limit. However, if the input
current limit is reached, recharging shall be reduced as required until it
reaches the minimum allowable level. The maximum recharge rate shall be one
that results in additional input current less than 20% of nominal full load
input current. The maximum recharge setting shall allow the minimum flywheel
configuration to be recharged in less than 5 minutes with 2 FES modules. The
minimum allowable recharge rate shall increase the full load input current by
less than 10% with 2 FES modules.

6. An alternate recharging mode shall be initiated by the Automatic
Transfer Switch potential-free contact closure. This contact closure activates
an alternate set of operating parameters (diesel operation, e.g.) for the UPS.
Alternate charging current and input current limit, among other parameters,
are activated by this contact when set in the field configurable firmware
settings. Other parameters that may have alternate settings activated by this
external input shall include, without limitation, walk-in rate, slew rate,
input voltage window, and input frequency window.

7. The bypass shall be designed for automatic and manually initiated,
automatically executed operation. Transfers to bypass shall occur without
interruption of load current or voltage except when a break transfer upon
complete discharge is selected as outlined above. The UPS shall automatically
transfer to bypass in normal mode or discharge mode if it is overloaded in
excess of specified time-load profile limits, if the output voltage deviates
beyond specified parameters or if an internal failure occurs that will
imminently render the UPS unable to support the load. Bypass transfer shall be
inhibited whenever programmable, preset conditions are not met. Those
conditions shall include the following:

a. Phase differential between bypass source and UPS output less than 15
degrees as a default value with a programmable range from 15 degrees to 179
degrees.

b. Frequency differential between Bypass source and UPS output less than
0.5 Hz as a default with a programmable range of 0.5 Hz to 2 Hz.

c. Voltage differential between UPS output and bypass source of +10% to -
15% and programmable to smaller differential values.

8. The number of re-transfers from bypass to UPS in any 10-minute period
due to overload conditions shall be programmable from 0 to 3. If the maximum
number or retransfers is reached, the UPS shall remain in bypass on the next
transfer and shall require operator intervention at the UPS control panel to
return to normal mode operation. Manual transfers to bypass shall be inhibited
unless the bypass is within specified parameters and is synchronized to the
output with less than 15 degrees phase differential.

9. Means shall be provided to prevent a shorted SCR condition of the
static bypass switch or static disconnect switch from back feeding power from
the UPS to the input when the input source has failed (anti-backfeed
protection). Indication shall be provided whenever the anti-backfeed
protection is activated to indicate a shorted SCR. When the anti-backfeed
protection is activated, the input circuit breaker shall be opened whenever an
input source failure is detected. Stand-alone anti-backfeed logic shall
prevent a shorted SCR from connecting UPS output power to a failed utility
even if the primary UPS logic fails.

10. The UPS controls shall be programmable for either automatic or manual
starting. It shall be possible to start the UPS, charge the energy storage and
check the UPS for correct internal operation without energizing the output.
The customer may choose manual or automatic restart operation via a field
selectable firmware setting. In manual mode operator intervention shall be
required to start the UPS and energize the output. In automatic mode, the UPS
shall start and energize the load automatically when it detects input power
within specified tolerances. In automatic mode the UPS shall energize the
output via bypass while the UPS starts. The UPS shall then transfer
automatically from bypass to normal mode operation.

11. For service purposes means shall be included to brake the flywheels to
a stop from full speed in less than 30 minutes.

C. UPS MODULE ADDITIONAL CONSTRUCTION REQUIREMENTS

1. The UPS module shall have built in surge suppression. Surge
suppressors shall have indicators to detect when the devices are no longer
capable of providing surge suppression

2. The UPS Module shall be protected against overloads and short circuits
on its output. All power semiconductor devices shall have appropriate over
current protection and shall have appropriate current limiting means to
prevent cascading failures. Extensive internal monitoring and diagnostics
shall be included to minimize UPS damage from internal failures.

3. The UPS Module shall have a withstand rating of at least 65,000 amps.
A complete copy of the specifications is available upon request by submitting
an email request to the attention of JoAnna Black at [Please use the link below].
Telephonic inquiries will not be accepted.

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