1602000 J.pdf

SECTION J

DOCUMENTS, EXHIBITS, AND OTHER ATTACHMENTS

TABLE OF CONTENTS

ATTACHMENT NUMBER ATTACHMENT TITLE

J-1602000-01 Definitions and Acronyms

J-1602000-02 SCADA Support Service Agreement

J-1602000-03 Electrical Power Distribution Equipment Tables & Current Maintenance Frequencies

J-1602000-04 Diesel Generator Maintenance Program Building 72

J-1602000-05

MG Maintenance and Testing

J-1602000-06 Avtron Load Bank Maintenance and Testing

J-1602000-07 Transportable Rectifier Testing

J-1602000-08 Fast Load Shed (FLS) PM & Maintenance

J-1602000-01 Definitions and Acronyms

Definitions High Voltage Transmission

Transmission of electrical loads greater than 69 kilovolts (KV).

Low Voltage Distribution

Distribution of electrical loads less than or equal to 600 volts (V).

Medium Voltage Distribution

Distribution of electrical loads ranging from greater than 600 V up to and including 69 KV.

Acronyms ANSI American National Standards Institute ASHRAE American Society of Heating, Refrigerating and Air-Conditioning

Engineers ASME American Society of Mechanical Engineers NEC National Electrical Code NFPA National Fire Protection Association NETA MTS National Electrical Testing Association, Maintenance Testing

Specifications

J-1602000-02 SCADA Annual Support/Service Agreement Requirements

SCADA Premium Support/Service Agreement

Contractor shall provide Annual Support/Service Agreement for Remote Assistance from the Industry Leading Experts.

Power Monitoring Expert software is a power management solution for energy suppliers and consumers. It allows us to manage energy information from metering and control devices installed in our facility and other remote locations. The product offers control capabilities and comprehensive power quality and reliability analyses to help reduce energy-related costs.

• Premium Support. Premium Support provides proactive support that improves the system performance, increases system utilization and helps reduce the cost of ownership.

• Senior Technical support Engineer Dedicated to Site. Senior technical support engineer is assigned as a single point of contact for the site to answer all inquiries and expedite problem resolution by building an exclusive knowledge of the system.

• Real Time Maintenance. Alerts the senior technical engineer assigned to the site of any issues occurring in the system.

• Comprehensive Support for Entire Engineered Solution.

• Includes configurations, graphical interfaces, PLC programming and tailored software solutions provided by Square D engineering services.

• Also includes support for Square D supplied 3rd party products integrated to provide engineering solution such as communication interfaces, satellite antennas, and remote input devices.

• Assistance with Power System Controls, Sequence of Events Recording, Active Pager Module, Water, Air, Gas, Electric, Steam, and other engineered solutions.

• Monthly System Status Update. A monthly report detailing the current status of the system and any performance issues is sent via email by the senior technical support engineer.

• 24 x 7 Support for PowerLogic Systems. The 24x7 service provides around the clock support for PowerLogic systems. Gives us the help we need when needed the most. Calls received after normal business hours are routed via a paging service to a senior technical support engineer who will return the call within one hour.

J-1602000-03 Electrical Power Distribution Equipment Tables & Frequencies

Refer to separate pdf file: J-1602000-03

NOTE: J-1602000-03 is intended to provide a detailed list of the electrical distribution equipment, excluding the building services, to be inspected, tested and maintained.

TABS:

• Transformers

• MV Disco Switches

• MV Breakers

• LV Breakers

• Battery System

• Protective Relays

• MG Sets 3rd Party

• Regulators

• Load Tap Changers

• MV MG Starter

• MG Set

• Oil Samples

• Powerware UPS

• Avtron Load Bank

• Variable Speed Drive

• Transportable Rectifier Testing

• Test Equipment Calibration

• SCADA Service Agreement

• Summary

• Maintenance Frequencies

J-1602000-04 Diesel Generator Maintenance Program Building 72

Refer to separate file: J-1602000-04

NOTE: J-1602000-04 - Diesel Generator Maintenance Program B72

BLDG LOC MFR MODEL SERIAL KW HP

Building 72 Milton CAT 3516B FDN01082 (DG1) 2000

Building 72 Milton CAT 3516B FDN01081 (DG2) 2000

J-1602000-05

Contractor shall perform preventive maintenance and testing of two (2) Motor Generators.

Contractor Requirements. Contractor shall be familiar with, firsthand knowledge of, and previous experience having worked with and on this equipment. Contractor shall be knowledgeable and experienced with providing electric motor repairs, electric motor rewinds, custom controls and panels, system integration, machine rebuilds, and diagnostic services for commercial and industrial applications.

MG #175 – Teco Westinghouse 750 KW Synchronism Motor Generator MG #238 - Teco Westinghouse 750 KW Synchronism Motor Generator

Perform On-Site PM and Testing as follows

MG Set #175 Roll out tower bearings, document conditions, dimensions of shaft journals, and bearing bores.

Perform Oil Sample of used oil per ASTM D 1816/ASTM D 3612, remove, dispose and replenish lubricating oil.

Megger and Polarization Index testing on the rotor and stator of the AC and DC machines.

Visually check brushes and brush holders.

Contractor shall furnish lubricating oil to lubricate bearings.

MG Set #238 Roll out tower bearings, document conditions, dimensions of shaft journals, and bearing bores.

Perform Oil Sample of used oil per ASTM D 1816/ASTM D 3612, remove, dispose and replenish lubricating oil.

Megger and Polarization Index testing on the rotor and stator of the AC and DC machines.

Visually check brushes and brush holders.

Contractor shall furnish lubricating oil to lubricate bearings.

J-1602000-06 AVTRON Load Bank Maint. and Testing

AVTRON Load Bank Maintenance and Testing

Contractor shall perform preventive maintenance and testing of one (1) Avtron Load Bank

Contractor is advised that preventative maintenance and testing shall be performed on-site by an authorized Avtron Service Technician

Contractor is responsible for the first $750.00 worth of parts required for repairs per visit.

Avtron 600KW Load Bank, Direct Current (VDC), resistive type

Perform Annual PM and Testing per O&M requirements

• Walk-Around Inspection. Inspect overall condition of structure and housing for, debris, leaks, proper panel security, loose or broken fittings, loose or misplaced wires and guards and check all switches are in proper working order. Repair as necessary.

• Insulation Test. Insulation test shall exceed 10 megohms at rated circuit voltage.

• Operation Test. Load bank shall be energized at no load and all control and indicator functions checked for proper operation.

• Louvers. Check for proper operation (able to open and close freely).

• Strip Heaters. Check for proper operation. Maintain >32°F temperature inside load bank at all times.

• Power Test. Load Bank shall be energized and full rated power applied to its input load terminals. The results of observations and measurements made during and at the conclusion of these tests shall confirm for the load bank:

• No evidence of heat damage or deterioration.

• No evidence of sagging, distortion, hot spots or arcing on the resistors.

• No trip-out or faulty operation of the load bank.

• No evidence of excessive pitting, contact bounce, contact chatter, or failure to promptly extinguish the arc.

• Minimum change in load segment characteristics from cold to maximum operating temperatures.

• Load capacities, incremental step loading to conform to specifications.

• KW and KVAR markings on remote console are accurate and comply with requirements.

• Dielectric Test. Load Bank shall be subjected to test which demonstrate dielectric withstand capabilities of all current carrying components between each other and ground. This test shall be performed for all levels of voltage and, where necessary, those components, which might be damaged by higher voltage levels, shall be properly isolated prior to testing.

• Megging. Load Bank will be subjected to megger tests using a 500 Volt Megger. With all contacts and circuits closed, the resistance between current carrying members and ground shall not be less than 100 megohms at any point tested when heated from normal operation.

• Protective Features Test. Load Bank shall be energized and the protective features shall be tested for proper operation. The tests on each feature which functions to trip open the main circuit breaker shall be accomplished in a manner which will assure that it is the feature being tested which actually trips the breaker under the simulated condition.

J-1602000-06 AVTRON Load Bank Maint. and Testing

• High Temperature. Temperature detectors are provided in each resistive stack and shall drop all load in the event an over-temperature condition.

• Air Flow. Directional air flow switch sensor are incorporated into the air stream in the event air flow through the load bank is reversed, interrupted, or reduced below a safe value.

• Interlocks. Interlock are supplied on the hinged single point load connection area. The interlock will be wired to a terminal block for interconnection to a Government supplied main circuit breaker. The load banks shall be provided with bolt on exterior panels that can be removed for routine maintenance.

• Cooling Fans. Load bank is adequately cooled or ventilated to prevent deterioration, degradation, or failure of the unit and any part thereof when operated at the duty cycle. Fan motors for the resistive load bank is a 3-phase, ball bearing, induction motor type with adequate horsepower rating so as not to be overloaded under any condition of the load bank operation.

Check operation of fan(s) for proper operation, damage to blades, vibration and repair and/or lubricate as required.

• Malfunctions. Report any malfunction and make necessary repairs.

• Detailed Report. Upon completion of annual PM and testing provide Government with a detailed report of findings, repairs and recommendations.

J-1602000-07 Rectifier Inspection and Testing Requirements

Contractor shall perform inspection and testing of Transportable Rectifiers.

Contractor Requirements. Contractor shall provide on-site engineering support (16 hours of on-site engineering support) to inspect and test rectifier. Contractor shall be familiar with, have firsthand knowledge of, and previous experience having worked with and on this equipment.

Contractor shall be knowledgeable and experienced with SCR Rectifier Systems, Thyristor Assemblies, PLC controls, HMI panels, and diagnostic services for commercial and industrial applications.

Perform On-Site Inspection and Testing on transportable rectifiers

1. LOTO:

a. Secure power to rectifier, open all doors and perform a visual inspection of entire unit.

b. Breakers, transformer, and relays shall have current test dates before being tested (testing by others)

i. Provide date of recent testing and PM located on test labels attached

2. Primary Section:

a. Inspect 15 KV PT fuses for control power.

b. Inspect condition of Fuses and PT.

c. Inspect overall condition of KVA transformer

d. Identify significant amount of rust or peeling paint in HV section.

e. Inspect HV cable for security and visually check for signs of Corona

f. Inspect HV cable for abnormal wear

3. Exterior:

a. Inspect entire rectifier for abnormal damage to enclosure, door hinges, exterior paint, rust, rain, or water intrusion.

b. Inspect dura-line receptacles are not cracked or worn from use and are serviceable

c. Inspect RS232/RJ45 port is not damaged or rusted, (corrosion control individual contact pins if required)

d. Inspect remote console control cable is not damaged

e. Visually check ground connection(s)

f. Inspect all appropriate labeling and warning labels are legible, labeling identifying appropriate PPE requirements, Weight, CG, etc.

g. Inspect all doors close to prevent weather intrusion, doors properly secure, locking pawls move free and easily, and control alarms operate properly.

4. Air filters:

a. Contractor shall remove filters and clean them.

5. Interior:

a. Visual inspection of electronics and other controls appear to be in serviceable working condition.

b. Visual check capacitors for any damage or abnormalities

c. Visual inspection of breaker(s) are in the connected position

d. Using a multi-meter check all control fuses are installed and in working order

e. Visual inspection of DC Filter system

6. Transformer:

a. Inspect transformer exterior that there are no external oil or gas leaks.

b. Visual inspect pressure gauge has correct readings and not defective.

c. Visual inspection of oil level is appropriate for current condition.

d. Reset Max temperature telltale indicator.

e. Contractor shall provide a transformer oil sample and provide results.

7. Cooling system:

a. Contractor shall test Polyethylene Glycol and water mixture and provide results.

b. Visual inspection of proper level of coolant, fill as required

8. Remote operation:

a. Allen Bradley Panel View Remote Control Box (suitcase).

i. Inspect case for damage and positioned in a dry location

ii. RS232/RJ45 communications cable is installed

iii. 120 volt power source available

b. Connect RS232/RJ45 cable and verify communication is operational.

c. Functional test all features and controls.

i. Analog and digital metering is working properly

ii. Ramp voltage up and down

iii. Start and stop fans

iv. Start and stop rectifier

v. Open and close breaker(s)

vi. Operate circuit breaker trip function

vii. Visual inspection of status indicators is consistent with local status

9. Local Operation:

a. Apply power to rectifier

b. Verify no alarms

c. Verify audible alarm is working with rectifier change of state

d. Cycle AC breaker and verify charging motor is operating

e. Verify ventilation louvers and blowers are working properly

f. Verify volts are approximately ‘0’

g. Verify status of breaker is consistent with local status

h. Verify all displays are functioning properly

i. Verify control power is available at PLC

j. Operate each operation and control to verify proper results

k. Verify all indicator lamps are working

l. Verify regen is working and switch is on continuous

m. Verify breaker charging motor operation on DC breaker

n. Verify DC Breaker can Open and Close with local and remote controls

o. Verify remote trip operates correctly

p. Verify AC Breaker can Open and Close with local and remote controls

q. Verify strip heaters are operational within the entire rectifier.

r. Voltage control pot rotates smoothly throughout range and does not appear to have dead spots.

s. Calibrate panel volt meter to the best readings possible.

t. Install ground detector (furnished by government) and verify >10 meg

i. Close each DC breaker without any load connected and verify no change in status on ground detector

ii. Open DC breaker verify no change on ground detector status

iii. During load box testing monitor ground detector and verify no change in status

iv. Turn on Regen and check for AC Ripple

10. Emergency Stop:

a. Verify Emergency Stop works.

When an emergency stop is triggered the following actions should automatically occur in order to return the power supply to a safe state:

1. SCR gating is stopped

2. Switchgear is opened

3. Regen Resistors are engaged

4. Emergency shutdown procedure is not intended to be the normal shutdown sequence.

11. Relay controls:

a. UV relay picks up at < or = 200 VDC

12. Load testing:

a. Verify DC output voltage is within + or - 2 volts of digital display

b. Using government furnished load box test rectifier as follows and document using attached test report sheet.

i. Check AC Ripple…

ii. Check with a DC amp meter and verify each DC cable carrying a balanced load.

iii. Annotate outside temperature and humidity levels.

iv. Annotate start and stop time of test

v. With assistance from government personnel test rectifier, refer to attached test sheets for test requirements. Test rectifier at the following voltages, 210 VDC, 265 VDC and 365 VDC.

vi. Perform one hour endurance test and annotate results.

vii. Annotate max VDC this unit can provide

c. If a load box is not available utilize the full capability of the rectifier’s Regen to perform load test for 60 minutes

d. AC Ripple is considered to be within specifications when ~1-3 volts @ any applied load, 1% RMS max

e. Verify output voltage is steady and reliable.

f. Verify Remote trip functions properly

13. Test reports:

a. Provide a detailed report of overall condition of rectifier within 5 working days after completion of testing. Each topic listed above shall be addressed in report.

b. Provide a copy of Rectifier load test results

c. If parts are required to repair rectifier that are above and beyond what government can furnish, contractor shall provide a separate quote to the contracting officer before proceeding with repairs.

Load Box KW set Point

(do not adjust)

Once voltage is set

(do not adjust) Volts Actual Anticipated Amp Rating Amps

Actual Ripple

(AC Volts)

213 210 375

420 210 750

639 210 1125

847 210 1500

1061 210 1875

1280 210 2250

1496 210 2625

1713 210 3000

(do not adjust)

Once voltage is set

(do not adjust) Volts Actual Anticipated Amp Rating Amps

Actual Ripple

(AC Volts)

158 265 285

257 265 570

388 265 855

517 265 1140

646 265 1425

778 265 1710

906 265 1995

1046 265 2300

(do not adjust)

Once voltage is set

(do not adjust) Volts Actual Anticipated Amp Rating Amps

Actual Ripple

(AC Volts)

80 365 210

160 365 420

211 365 630

280 365 840

354 365 1050

425 365 1260

496 365 1470

575 365 1700

1 hour endurance test with Ripple Checks every 10 minutes

Volts set at 210 VDC, load box set at 1700Kw Load Box KW starting point

1700 KW

Volts 210 Volts Actual

Increase KW on Load box to achieve this Amp rating

(+/- 5)

Amps Actual

Ripple (AC Volts)

+10 min 210 3000

+20 min 210 3000

+30 min 210 3000

+40 min 210 3000

+50 min 210 3000

+60 min 210 3000

J-1602000-08 Fast Load Shed (FLS) PM & Maintenance

SCOPE:

1. Contractor shall provide all labor, materials, tools, equipment, transportation and supervision necessary to perform all work associated with performing semi-annual PM and maintenance on FLS hardware and equipment, maintenance to include cleaning and vacuuming.

2. Work is expected to be completed during normal business hours, Monday thru Friday, 8:00AM

– 5:00PM EST, exclusive of holidays. Contractor is expected to have unescorted access to the

CIA.

3. Onsite Maintenance Actions;

a. Overall System Health Evaluation

b. Check historical log for abnormalities to include but not limited to system errors, and device communication alarms.

c. Hardware inspection

d. Provide a list of software drivers that should or could be updated.

e. Verify Cabinet Heating and Fans are working properly

• Check thermostat set points

f. Verify RT430 GPS clock r is working properly

g. HMI Workstations Diagnostics and Cleaning (3-locations)

h. HMI Workstation Backup (3-locations)

• Utilize imaging software and create image snapshot

• Government shall provide Software and External Hard Drive

i. Workstation and FLS Rack Cleaning

• Clean all cabinet filters.

• Vacuum inside each cabinet and workstations.

• Government shall provide key to access worstations.

j. System Review with Customer

4. Within 14 days after completion contractor shall provide a detailed field service report of findings and recommendations.

5. Equipment to be covered under this contract:

a. Software

• GE Simplicity Server Dev/Runtime Software

• GE 8 series setup

• Kepware IEC61850 OPC Driver

• Custom Developer HMI Application

• GE IGS Modbus OPC Driver

b. Hardware

• Dell Workstations & Monitor located in Power Plant Control Room and building 43 conference room

• GPS Clock (GE RT430)

• GE Components provided in Rack; Power Plant

• GE Components provided in Rack; Franklin Substation

• GE Components provided in Rack; Substation 2

• GE Components provided in Rack; Substation 3

• GE Components provided in Rack; Substation 4

• GE Components provided in Rack: building 43

6. Government Responsibilities;

a. Provide an individual authorized to resolve questions and coordinate site access and activities, such as: switching for outages and providing operators and/or electricians during the implementation of this agreement.

b. Provide an uninterrupted flow of work and a safe work environment.

c. Provide security for equipment, tools and instruments stored at the job site at all times.

d. Provide accurate and complete drawings and documentation for hardware and software.

e. Responsible for performing on-going minor maintenance to the system, to maintain supplied equipment in a condition that allows a 3rd party to carry out the scope of work described herein.

f. Government shall ensure that all personnel maintaining the system have been adequately trained.

ATTACHMENT NUMBER