33 99 00 General Substation Equipment-R1.docx

SECTION 33 99 00

GENERAL SUSBSTATION EQUIPMENT

PART 1 General

1.01 SUMMARY

A. This specification covers the technical requirements for the provision of electrical equipment, materials and labor necessary to erect, construct, install and test a complete functional 60/12kV substation.

B. The terms “disconnect switch” and “air switch” are used interchangeably and designate both motor and manual operated 60kV high voltage disconnect switches. Specific reference to the type of switch being addressed shall use the descriptor “motor operated” or manually operated” preceding the switch designation.

C. It is not intended to specify all technical requirements nor to set forth those requirements adequately covered by applicable codes and standards. The high-voltage portion of the substation shall include the transmission dead-end structure, the high-voltage disconnect switches and their support structures, instrument transformers, surge arresters, shield wire and mast structures, phase conductors, insulators, termination hardware, foundations, supports, raceways, grounding system and incidentals and miscellaneous components for a completely functional and operating substation.

D. The Contractor shall furnish all high-quality outdoor equipment meeting the requirements of this specification and related industry standards.

1. Work to be provided by the Contractor for the high voltage portion of the substation includes, but is not limited to, the following sub-items in locations and quantities shown on the Contract Drawings:

a. Dead end structure with associated appurtenances.

b. Support structures for disconnect switches, bus support insulators, surge arresters, VT’s, and associated items.

c. Lot of high-voltage post insulators, surge arresters, steel-reinforced aluminum cable, tubular aluminum pipe and associated substation hardware and fittings to make up the complete circuit from the 60kV transmission line termination point external and adjacent to the substation boundary to the Customer 12kV metering cabinet.

d. Grounding system.

e. Raceways for low-voltage power cables, control cable and fiber optic cable from components within the substation to the Substation Control Building control room.

f. Supply of labor and materials, including miscellaneous metalwork, brackets and hangers not specifically mentioned elsewhere, that are necessary to make the high-voltage substation complete and functional.

1.02 RELATED SECTIONS

A. The related sections referenced herein provide specific requirements that the electrical equipment and/or systems covered by this specification must comply with. In addition, there are general project sections within the overall package of total specifications that must be followed to support the design and installation of the project. These sections include requirements that address administrative and contractual issues, submittals, concrete and steel, civil/grounds and earth, environmental and seismic conditions/parameters and similar items.

B. Where specific requirements, conditions and/or parameters are stated in this specification those items will take precedent over the project general requirements.

C. The specific Related Sections include the following:

1. Section 01300, Submittal Procedures

2. Section 26 05 10: Common Electrical Equipment

3. Section 26 05 19: Low-Voltage Electrical Power Conductors and Cables

4. Section 26 05 23: Control-Voltage Electrical Power Cables

5. Section 26 05 26: Grounding

6. Section 26 05 33: Manholes Boxes Raceways and Fittings

7. Section 26 05 43: Underground Raceway System

8. Section 26 56 00: Yard Lighting

9. Section 33 71 50: Aluminum Bus and Bus Hardware

10. Section 33 72 39: Substation Protection, Control, and Metering Panels

11. Section 33 73 10: Transformer Installation

12. Section 33 77 13: 60kV and 12kV Group Operated Air-Break Disconnect Switches

13. Section 33 77 19: 60kV SF6 Circuit Breaker Installation

1.03 REFERENCES

1. The version/revision of the references listed below, including any addenda, attachments, and errata associated with them shall be the established and approved version/revision of these documents in effect at the time of issue of the Contract.

1. The equipment furnished shall be in accordance with, but not limited to, the following codes and standards:

1. American Concrete Institute (ACI)

a. ACI 318-05: Building Code Requirements for Structural Concrete

2. American Institute of Steel Construction (AISC)

a. AISC 360-05: Specification for Structural Steel Buildings

b. AISC 341-05: Seismic Provisions for Structural Steel Buildings, including Supplement No.1

c. AISC 303-05: Code of Standard Practice for Steel Buildings and Bridges

3. American Society of Civil Engineers (ASCE)

a. ASCE/SEC 48-05: Design of Steel Transmission Pole Structures

b. ASCE 7-05: Minimum Design Loads for Buildings and Other Structures

4. American Society of Testing and Materials (ASTM)

a. A123A 123M: Standard Specification for Zinc (Hot Dip Galvanized) Coatings on Iron and Steel Products

b. A143A 143M: Standard Practice for Safeguarding Against Embrittlement of Hot-Dip Galvanized Structural Steel Products and Procedure for Detecting Embrittlement

c. A153/A 153M: Standard Specification for Zinc Coating (Hot Dip) On Iron and Steel Hardware

d. A385: Standard Practice for Providing High-Quality Zinc Coatings (Hot-Dip)

e. A780: Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

f. ASTM B221-08: Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes

g. ASTM B232/B232M - 01e1: Standard Specification for Concentric-Lay-Stranded Aluminum Conductors, Coated-Steel Reinforced (ACSR)

h. E376: Standard Practice for Measuring Coating Thickness by Magnetic-Field or Eddy Current (Electromagnetic) Examination Methods

5. American Welding Society (AWS)

a. D1.1: Structural Welding Code - Steel

6. California Building Standards Code

7. Institute of Electrical and Electronic Engineers (IEEE)

a. C29.1: Test Methods for Electrical Power Insulators

b. C29.9: Wet Process Porcelain Insulators (Apparatus, Post Type)

h. C37.36b: Guide to Current Interruption with Horn Gap Air Switches

i. C37.37 : Loading Guide for AC High Voltage Air Switches including supplement C37.37a

j. C2: National Electrical Safety Code

k. C37.30: Standard Requirements for High-Voltage Switches

l. C37.34 : Test Code for High-Voltage Air Switches

m. C37.36b: IEEE Guide to current interruption with Horn gap air switches

q. C62.11: Standard for Metal-Oxide Surge Arresters for AC Power Circuits (>1 kV)

r. C62.22 : Guide for Application of Metal-Oxide Surge Arresters for Alternating-Current Systems

8. National Electrical Manufacturers Association (NEMA)

a. 107: Methods of Measurement of Radio Influence Voltage (RIV) of High-Voltage Apparatus

b. WC57: Standard for Control Cables (ICEA S-73-532)

c. TT-1: Standard for tapered tubular steel structure

d. SG 6: Power Switching equipment

9. Steel Structures Painting Council (SSPC)

a. SP1: Solvent Cleaning

b. SP3: Power Tool Cleaning

c. PA1: Shop Field and Maintenance Painting

d. PA2: Measurement of Dry Paint Thickness with Magnetic Gages

10. Underwriters Laboratories Inc. (UL)

a. 44: Rubber Insulated Wires and Cables

11. Factory Mutual (FM)

a. Loss Prevention Data Sheet 5-10 Protective Grounding

12. National Electrical Safety Code (NESC) G. In addition to the above codes and standards, Contractor shall comply with all applicable Federal, State and local laws, codes, and regulations.

H. The material and services furnished shall comply with and not prevent the City’s compliance with all applicable requirements of CalOSHA.

I. In the event of any apparent conflict among standards, codes, or this specification, Contractor shall refer the conflict to the City for written resolution.

1.04 SUBMITTALS

1. Submittals shall be made in accordance with Section 7, “Submittal Management,” of the Standard Provisions and Section 20, “Submittal and Quality Requirements,” of the Special Provisions. Submittals shall adhere to the schedule requirements defined in Article 20.01.04.

1. Submittals shall be submitted in accordance with Sections 01300 and 26 05 00.

1. Contractor shall furnish the following documentation for approval:

1. Technical data and parameters/ratings of the proposed equipment

2. Outline drawings.

3. Manufacturer’s drawings and literature for the proposed equipment

4. Wiring and schematic diagrams

5. Design test reports.

6. Production test reports

7. Operation and maintenance instructions

8. Size, spacing, elevation drawings for the high voltage disconnect switch

9. Support structure manufacturer’s shop drawings and calculations (for all types of structures furnished)

10. Anchor bolts details and patterns

11. Assembly and erection details

12. Structure member details, connections and disconnect mounting details.

13. Certified design calculations and foundation design drawings.

14. Approved and as built drawings

1. All Design Drawings and Calculations shall be prepared and sealed by an appropriate discipline Professional Engineer licensed in the State of California.

1.05 Project Specific Site and Utility Data.

A. All equipment, materials, and the installation shall be provided to be suitable for the site environment as described below:

1. Altitude: Below 3000 feet

2. Maximum outdoor air temperature design basis: 115 degrees F

3. Minimum outdoor air temperature design basis: 0 degrees F

4. Degree of outdoor pollution: Light

5. Outdoor air conditions: Dust/Sand

6. Outdoor relative humidity: 100%

7. Maximum wind velocity design basis: 115 mph

8. CBC Site Class: D

9. CBC Risk Category: IV

10. Seismic Importance Factor 1.5

11. 60kV Transmission system maximum operating voltage:66kV

12. 60kV Transmission system average operating voltage: 60kV

13. 60kV Transmission system minimum operating voltage: 54kV

14. Lightning Frequency: 0.25 flashes/square km/year

1.06 QUALITY ASSURANCE

1. Manufacturers shall have an active quality control program in compliance with ISO-9001.

1. Provide electrical equipment, materials, details of construction, installation, and testing to provide a complete system in conformity with all applicable standards, codes, and requirements as specified herein and required by prevailing ordinances, and regulations.

P. Referenced codes and standards establish the minimum requirements for the Work. Wherever these specifications require higher grades of materials or workmanship than required by the codes and standards, these specifications apply.

Q. Should the specified reference standards conflict with these Specifications, request clarification from the City before proceeding.

R. All materials, supplies, and equipment shall be new, undamaged, and unused standard products of reputable manufacturers and suitable for the intended use. Products that have been discontinued shall not be acceptable.

1.07 DELIVERY, STORAGE, AND HANDLING

1. Manufacturer’s recommendations for the supplied item(s) shall be followed.

1.08 WARRANTY

1. Manufacturer’s standard warranty shall apply, except for the 72.5kV switches and motor operators which shall be warranted for (5) years from the date of energization. A copy shall be included with delivery of the item(s).

1.09 SPECIAL TOOLS AND SPARE PARTS

1. The Contractor shall provide a detailed list with quoted prices for special tools and recommended spare part requirements.

1. The Contractor shall provide a list of recommended spare parts identifying each one and the specific sub-assembly to which it applies.

1. The Contractor shall indicate the expected life of the parts requiring replacement and the minimum recommended inventory of the spare parts for installation, start-up, and for continuous operation, and maintenance for a period of five (5) years. Contractor shall state whether the recommended spare part is a stock item or a special item and shall furnish the name and location of the nearest supplier with the approximate lead time required for delivery.

1. The Contractor shall furnish all special tools necessary for installation, start-up, operation, maintenance and adjustment of the equipment furnished by the Contractor.

1. The Contractor shall identify all special tools furnished, including the function of each tool and the specific equipment for which it is intended for use. Contractor shall also indicate whether the tool is required for installation, operation, maintenance or adjustment.

1.10 DEFINITIONS

A. If used/stated in this specification, the terms listed below are defined as stated:

1. City/SVP: This term shall denote the Silicon Valley Power Utility that is part of the City of Santa Clara.

2. Owner/Purchaser/Client: These terms shall denote City/SVP.

3. Contract Drawings: This term shall denote drawings prepared by the City/SVP and/or its representative and/or its design company and provided to supplement the requirements stated in this specification for the design and installation of the equipment, devices, components, etc. covered by this specification.

4. Contractor Drawings: This term shall denote drawings to be prepared by the Contractor to support the requirements of this specification and the overall design of the Juliette Substation Expansion Project.

5. Manufacturer’s Drawings: This term shall denote the drawings to be prepared by the entity manufacturing the equipment, devices, components, etc. in accordance with the requirements of this specification to define the design and/or installation of these items.

PART 2 Products

MANUFACTURERS

A. The listing of specific manufacturers does not imply preference of their products.

B. Products in compliance with this specification and manufactured by others not named will be considered only if 1) pre-approved by the City during the bid process or 2) specifically requested by the Contractor due to supply chain/schedule issue and manufacturing change affecting the associated item and approved by the City.

C. Manufacturers for equipment, devices and components are included in the subsections below that provide the requirements for the equipment, devices and components.

D. Where no manufacturers are listed, the Contractor shall include proposed manufacturer(s) for the equipment, devices and components with their response to the Request for Bids for review and approval by the City.

DEAD-END, DISCONNECT SWITCH AND MAST STRUCTURES

A. The dead-end steel structures, disconnect switch supports and shield wire mast structures, collectively referred to as the STRUCTURES, shall be fabricated and furnished in accordance with the requirements of the steel structure design as stated below.

B. Steel Structure Design

1. General

a. The configurations and dimensions of the STRUCTURES shall be referred to the Contract Drawings for the substation.

b. The dead-end steel structures shall resist the tensions and loads imposed on it by the transmission line conductors and static shield wires. Where applicable, the performance of the installed and supported high-voltage disconnect switch shall not be affected by the deflections of the dead-end steel structure.

c. Furnish detailed shop and erection drawings of the STRUCTURES for the City’s review. Recommended torque values for all assembly bolts and anchor bolts shall be included in the detailed drawings.

d. Fabricate the STRUCTURES in conformance with the Contract Drawings.

2. Structure and Support Details

a. Provide ground brackets on all columns, welded near the base, for bolted connection to the buried ground grid (Provide means to connect CADWELD type LA equipment connector).

b. Include provisions for securely fastening fiber optic cables to each dead-end structure as applicable, provide 7/16-inch diameter holes from the top of the structure down the t side to the fiber optic splice box panel every 24 inches, on the side of the structure where the cable loop and splice box are sown on the Contract Drawings. Provide compatible cable clamps as manufactured and recommended by the OPT-GW manufacturer. Provide a cable support for a (5) foot diameter loop of OPT-GW cable (50) feet long.

c. Include provisions for securely fastening cables extending from the buried ground grid to the above grade grounding conductors to each structure; where applicable. Use cable-to-flat type connectors similar to Andersen GC140 bolted to structure at periodic intervals no more than 4 feet apart.

d. All field connections shall be bolted to the structure. Field welding shall not be allowed.

e. Provide split lock washers for all bolted connections, except connections using pre tensioned high strength bolts.

f. Furnish bolts, nuts and locking devices at 5% over the actual required quantities with a minimum of one extra per structure or support.

3. Anchor bolt design

a. Anchor bolts shall be hot dip galvanized to a minimum depth of 6 inches below the concrete surface.

b. Provide leveling nuts for all anchor bolts.

c. Provide a steel template for each anchor bolt cluster suitable for maintaining desired spacing of anchor bolts during installation of concrete foundation (not required if prefabricated anchor bolt cage is provided).

d. The distance from the top of the concrete to the bottom of the steel base plate shall be 1 inch plus one anchor bolt diameter.

e. Bolt holes for the anchor bolts shall be oversized 5/16 inch for anchor bolts less than and equal to ¾ inch diameter. Bolt holes for anchor bolts shall be oversized 1/2 inch for anchor bolts greater than ¾ inch diameter.

4. Design Loads

a. As a minimum, the following shall be used for the STRUCTURES design.

b. Ice and Wind: The STRUCTURES will be loaded with all equipment, structure dead weight and a coating of radial ice on both equipment and ice. The degree of loading due to ice shall be considered as low in accordance with the geographical area shown in the loading map in NESC C2. A wind pressure shall be applied on the ice-coated equipment and to the structure per ASCE 7-05 and ASCE 48-05 using a basic wind speed of 90 miles per hour.

c. Extreme Wind: The STRUCTURES will be loaded with all equipment and structure dead weight without ice. A wind pressure shall be applied to the equipment and structure. Wind pressures shall be determined using ASCE 7-05 and ASCE 48-05 with a basic wind speed of 90 miles per hour.

d. Short Circuit: A horizontal force equal to 100 % of the cantilever strength of the insulator shall be applied perpendicular to the top of the insulator. No horizontal or vertical forces from ice or seismic shall be considered on the equipment. Short circuit reaction plus extreme wind shall be applied to each structure as applicable.

5. Wire Load

a. Design the appropriate structure assuming that the wires are terminating only on one side of the structure. The effects of wires terminated on both sides of the structure with transverse wind and maximum line angle shall also be considered.

6. Disconnect Switch Support

a. The Contractor shall provide a structural steel support for the high voltage disconnect switch which is separate from the dead-end steel structure. The disconnect switch elevation shall be as shown in the Contract Drawings.

b. The rated cantilever strength shall be taken as the standard strength of the insulator mounted.

7. Deflection

a. The dead-end structure shall be considered as a line terminal structure requiring both NEMA class A requirement and NEMA class B requirement with respect to deflections.

8. Material

a. All steel shall conform to ASTM specifications and shall be suitable for welded and galvanized structures

b. All steel material shall conform to one of these ASTM specifications

i. Structure: A-36, A-53 Grade B, A-500 Grade B, A-572, A-588, A-992, A-595, A-633 Grade E and A-871

ii. Anchor Bolts: ASTM A1554 grade 55 with A563A heavy hex nuts

iii. Connection Bolts: A-325 Type I Hot dip galvanized C. Fabrication

1. Fabrication tolerances shall conform to AISC 303 and AWS D1.1

1. Dynamically loaded Welds shall conform to AWS D1.1 section 9

1. All other welds shall conform to AWS D1.1 section 8 D. Weld Consideration

1. Shaft base plates and shaft/splice plates shall have complete joint penetration welds.

2. All circumferential welds shall have 100 % joint penetration

3. Longitudinal welds, other than slip joint, shall have 60 % penetration for all material ¾ inch thick or less and 80 % penetration for thicker than ¾ inch.

4. For longitudinal welds in slip joints, the penetration in the male or female section shall be 100 % for a minimum length of six inches. In the female section, it shall be more by the length of the slip section.

5. The components shall be marked prior to galvanizing. Stamped marks shall be clearly visible after galvanizing.

6. Welders qualified in accordance with AWS D 1.1 shall perform all welding.

E. Protective Coating

1. All material to be coated shall be completely fabricated prior to coating process.

2. Preparation and fabrication of galvanized STRUCTURES shall be in accordance with ASTM A-385

3. Members shall be galvanized in accordance with ASTM A-123

4. Safeguards against embrittlement shall be provided in accordance with ASTM A-143

5. Galvanized coating thickness shall be measured as per ASTM E-376

6. Damaged hot dipped galvanized STRUCTURES shall be repaired as per A-780

7. Fasteners shall be galvanized as per ASTM A-153

8. Anchor bolts shall be galvanized for the threaded length plus six inches.

72.5-kV DISCONNECT SWITCH A. Disconnect switches to conform to the following as well as all requirements of section 33 77 13.

B. The disconnect switches shall be of three-pole; single-throw; vertical break; motor-operated or manual operated (as indicated on the Contract Drawings). Manual-only switches shall be provided with a geared drive mechanism. Motor-operated switches shall be equipped with a drive disconnector, a swing-arm socket, and a removable swing-arm handle. Both types of switches shall be equipped with auxiliary switches. Main switch contacts shall be capable of energizing and de-energizing the connected equipment capacitive charging current in unloaded conditions without damage or wear.

C. The disconnect switches shall be mounted on the dead-end steel structure or separately on a disconnect switch support as indicated on the Contract Drawings. The operating rod shall extend to a suitable length based on the location of the operating handle or control panel.

D. Disconnect switch blades shall be of copper material with silver alloy contact surfaces on the exposed make-and-break contacts. Replaceable arcing horns at the jaw end of the disconnect switch shall be furnished.

E. The disconnect switch shall be rated for 72.5 kV, 350 kV BIL, 2000 A, 60 Hz, with 100 kA short circuit momentary rating.

F. Jaw contacts shall be high pressure, high thermal capacity, and self-aligning silver contacts featuring self-cleaning (wiping) action. Harmful abrasion and scoring of contact surfaces shall be avoided. The construction shall also make it feasible to crush all ice while closing, thus establishing metal-to-metal connection along the entire contact surface.

G. The design shall overcome the tendency of the blade to be forced out of the jaw when the disconnect switch is subjected to short-circuit current forces.

H. The contact springs shall be stainless steel and shall not be in the path of current.

I. Hinge contacts shall be the same type as used for the jaw. Alternate sealed construction reviewed by the City may be supplied if pressure and resistance are constant throughout the life of the disconnect switch, and if any required adjustments can be made without disassembly of the disconnect switch.

J. Blade Counter Balance: For ease of blade movement, spring-type counter balance shall be used on vertical break and vertical reach disconnect switches where required. This mechanism shall be located in a weather and corrosion-proof housing. Initial lubrication shall be lifetime.

K. Rotating insulator bearing shall be in a weather and corrosion-proof enclosure. The thrust bearing components shall be corrosion free, sealed, and lubricated for lifetime. The bearing base shall be equipped with four leveling screws, which can horizontally and vertically adjust, and securely lock the disconnect switch in any leveled position.

L. All bolted connections will utilize stainless steel hardware. The bolt hole pattern of the disconnect switch shall be made suitable for mounting on the dead-end structure or separate support.

M. Connection provisions for portable grounds shall be provided at the line and load sides. Provisions to consist of a 6 inch long, ¾ inch diameter grounding stud, with a NEMA 3-inch x 3-inch, 4-hole pad.

N. The average operating life of the disconnect switches shall not be less than forty (40) years. The preferred mechanical operation shall be 1000 close-open operations, with 900 close-open operations without terminal loading and 100 close-open operations with terminal loading. The terminal loading shall be as per table-4 of ANSI C37.32.

O. The outdoor high-voltage air switch shall meet the performance requirements of this specification while operating within the specified operating environment.

P. Provide a mechanical and electrical key-interlock system to provide the following functionality: each 70kV circuit breaker must be open in order to open it’s associated high-side air switch, and both breaker high-side air switches must be open in order to allow operation of the incoming manual-operated air switch. Coordinate with the circuit breaker manufacturer Q. The radio influence voltage level shall be less than 500 micro-volts at 1 MHz. There shall be no visible or audible corona when tested as per IEEE Standard C37.34 at 110 % of line to neutral voltage. Grading rings or shields shall be used where necessary to attain the desired RIV level. RIV shall be measured using the NEMA standard circuit and in accordance with NEMA Publication 107.

R. Disconnect Switch Operating Mechanism

1. All non-current carrying ferrous components shall be hot-dipped galvanized steel, except bolts and nuts which shall be stainless steel. However, the proximity effect of the rated current of the disconnect switch shall be considered when selecting materials for noncurrent carrying parts, in order not to cause undue heating.

2. The operating mechanism linkage shall consist of hot-dipped galvanized steel rods of adjustable lengths to facilitate final settings.

3. The horizontal and vertical rods shall be supported by suitable self-aligning bearings.

4. Direct coupling of the vertical rod is desirable, where not possible an outbound bearing shall be used (universal couplings are not acceptable).

5. The design of the mechanism shall take into account the thermal expansion and contraction of the components, thus avoiding increased forces for operating the disconnect switch. If necessary, compensating devices shall be used.

6. The operating mechanisms shall be equipped with positive limiting devices to prevent operation of the handle after the completion of a cycle and a braidless grounding device for grounding the operating rod to the City’s grounding system. The grounding device must be located on operating rod above operating handle and must have current-carrying capability equal to or greater than 500 kcmil bare stranded copper cable.

7. The mounting height of disconnect switch operating mechanisms (both manual and motor operated) shall be such that the operating handle or hand crank is 4’ above grade except that the base of the motor mechanisms shall not be less than 18" above grade.

8. Motor-operated disconnect switch operating mechanisms where shown on the drawings shall be suitable for use on a 125VDC power supply to be provided by the City. The control circuit shall be fused at the operating mechanism cabinet. Contractor shall show required remote breaker rating on wiring diagrams.

9. The motor shall be a high-torque motor, able to open or close the disconnect switch in not more than 10 seconds.

10. The motor shall be controlled by across the line type reversing magnetic starters, interlocked electrically and mechanically.

11. Motor shall be equipped with overload protection. If this device is operated, it shall permit completion of the cycle (opening or closing) and after completion, it shall prevent commencing a subsequent operating cycle. A contact closing for overload shall be available for alarm initiation.

12. An electromagnetic brake shall be used if required to limit overtravel of the mechanism. It shall be the type which is required to be energized before the brake can be released.

13. The operating cycle shall be set to ensure total completion of a cycle (opening or closing).

14. The operating mechanism shall be equipped with an emergency crank for operating the motor operated disconnect switch manually. The crank shall be insertable from the outside into the operating mechanism, without opening the cabinet. The opening shall be closed with a rain and dust protective cover having padlocking arrangements. When the crank is used, it shall automatically disengage the brake and open the motor control circuits. The auxiliary switches shall not be disengaged by this operation. Coupling between operator and operating rod shall be designed so that it can be conveniently disengaged and the power mechanism tested without operating the disconnect switch. The manual effort required to operate the disconnect switch shall not exceed 35 lb. measured at the end of the handle.

15. The operating mechanism shall be equipped with one "open", one "close", and one “stop” pushbutton, accessible after opening the cabinet door. All external interlocks shall be effective if local air switch operating pushbuttons are used.

16. Contractor shall provide an auxiliary relay to indicate that motor operated disconnect switch is ready for remote operation. Monitoring shall include power supply, disconnect switch in remote position, overloads condition, and other interlocks as required.

17. The cabinet shall be equipped with an electrical heater to prevent condensation, rated 240V but operated at 120V.

18. The operating mechanism housing shall consist of a rigid frame strong enough to transmit the most severe operating reactions to the supporting structures.

19. The enclosure shall be NEMA Type 4X. The cover shall be aluminum sheet, not less than 1/8 in. thick, and shall have padlocking provisions. An undrilled removable plate shall be provided in the bottom for a maximum of two ‑4-inch IPS galvanized steel conduits.

20. The control mechanism enclosure shall be located with the crank hub approximately 4 ft above ground.

21. The enclosure shall be equipped with a ground lug for No. 4/0 AWG to 500 kcmil copper grounding cable.

22. The gear drive train of the mechanism shall be enclosed, sealed, and lubricated for lifetime. The gears shall be nodular iron, designed to assure long life and minimum wear. The gear shafts shall be supported by stainless steel antifriction bearings, sealed and lubricated for lifetime.

23. The mechanism shall be equipped with a mechanical position indicator visible from the outside.

24. Arrows shall indicate required direction of motor rotation.

25. Provision for remote close and open and a local/remote selector switch shall be provided.

26. All the as-built drawings of the disconnect switch shall be conveniently stored inside the enclosure in a protective sleeve.

S. Auxiliary Switches

1. Contractor shall provide (10) electrically independent, adjustable auxiliary contacts which shall indicate the disconnect switch positions independently of the position of the operator. The specified number of auxiliary contacts are required for both manually-operated and motor-operated switches, in the case of motor-operated switches the quantity of contacts will be in addition to those required for motor control.

2. Each assembly of auxiliary switches shall be provided with a weatherproof metal housing with conduit hubs and removable cover containing the specified single-throw auxiliary control switches. The auxiliary switches shall be connected with a direct-action operating mechanism to indicate fully open and fully closed positions of the disconnect switch. Auxiliary switch contacts shall be rated 10 amperes continuous, 125 volts dc.

3. Five (5) of the single-throw contacts shall be normally open (form A) and the other five (5) shall be normally closed in the fully open position (form B). In the fully closed position, the auxiliary switches will change from normally open to normally closed and vice versa. The contacts shall be adjustable and convertible from normally open to normally closed, etc., without disassembly of the auxiliary switch assembly.

T. Disconnect Switch Insulators

1. All disconnect switch insulators shall be NEMA station post-type porcelain in accordance with applicable ANSI C29.1 and C29.9.

2. Insulators shall be made of dense, wet process porcelain, homogeneous, and completely vitrified, with a continuous uniform standard color glaze.

3. The mechanical and electrical qualities of the glaze, cement, and metal parts of the insulator shall not be affected by contaminants specified in section 1.05 of this specification for the life of the equipment.

4. Contractor shall submit proof of factory quality control checks and tests made on the insulators selected for the purchase order, if such insulators have already been supplied on other purchase orders. Where insulators of new design are offered, they shall be tested in accordance with ANSI C29.1 and the results submitted as part of Contractor's proposal information.

U. Corrosion Resistance

1. Stainless steel, galvanized steel, bronze and other non‑ferrous surfaces do not require coating.

2. All unpainted parts and hardware shall be non-magnetic stainless steel.

3. Painted surfaces color shall be ANSI 61, light gray.

V. Terminals

1. Terminal pads of the disconnect switch shall be of high conductivity copper and shall be electroplated silver to a thickness of not less than 0.127 mm (0.005 inch).

2. The flat surfaces of single-tang terminal pads shall be horizontal and shall be aligned for straight-away take-off.

3. Each terminal pad shall have four 14.3mm (9/16 inch) diameter holes drilled with 45mm (1-3/4 inch) center line spacing per applicable ANSI and NEMA Standards and suitable for use with copper or aluminum conductors.

4. When current rating dictates the use of terminal pads with other hole drilling, the same shall be in accordance with applicable ANSI and NEMA Standards and shall be submitted to the City for approval.

W. Electrical Wiring Requirements

1. The control components and position indicating and monitoring contacts shall be wired to a terminal board within the motor operator housing of each motor operated disconnect switch and connection box on the manually operated disconnect switch.

2. Terminal boards shall be provided for all equipment controls, instruments, and relays requiring external connection. They shall be rated not less than 25 amperes, 600 volts and provided with barriers, marking strips and terminal screws. Each terminal point shall be marked with the designations shown on manufacturer’s Control Wiring Diagrams.

3. A reasonable number of spare terminals shall be provided; however, not less than 20 percent of terminals on each block shall be spare. Not more than one wire shall be connected to one terminal block point. However, where jumper wires are necessary, two wires may be connected for internal wiring.

4. Terminals for external connections shall be arranged for consecutive connection of conductors within one cable in accordance with manufacturer’s wiring diagrams and the applicable Contract Drawings. One external wire will be connected to each outgoing terminal point. Ample, unobstructed access space shall be provided in front of all terminals.

5. Control, position indication and monitoring wiring shall be 600 volt, #12 AWG minimum, 7 strand, copper wire with heat, moisture and flame resistant crosslinked polyethylene insulation in accordance with NEMA WC57. The wiring shall pass the flame test conducted in accordance with UL 44, Section 54. Where flexibility is required, 19-strand wire shall be used. Wiring shall be free of abrasions and tool marks. All wiring shall be adequately supported to prevent sagging and breakage caused by vibration in transit. Minimum bending radius of the wires shall not be less than 4 times its overall diameter. A maximum of 12 wires shall be in a bundle so as to facilitate tracing of wires. Wire markers on both ends of the bundle shall be used. With the wiring bundled, the wire markers shall be at end and readable.

6. Contractor's and the City’s wiring shall be terminated on manufacturer’s terminal boards or equipment with ring-type non-insulated terminals or approved equal.

7. Control, position indication and monitoring wiring will be #12 AWG stranded copper cables terminated with terminals similar to those described above. Terminals shall be of adequate size to accommodate control wiring connections.

8. All units shall be wired in accordance with manufacturer’s Control Wiring Diagrams as reviewed and commented on by the City. Wiring shall provide for both local and remote control of electrically operated air switches and for remote position indication/monitoring of all air switches.

9. If accidental short-circuiting of certain wires can result in closing or opening of the air switch, these wires shall not be terminated on adjacent terminals.

10. Wiring required to interconnect shipping sections shall be terminated on terminal board in one section, with the loose wires of the other section in accordance with this terminal board marking.

11. Control, position indication and monitoring wiring shall be isolated completely from power buses, cables, and connections by means of metal conduit, steel ducts, armored cable, or other suitable barriers.

POST INSULATORS, CONDUCTORS, AND TERMINATIONS

A. Provide substation materials as itemized in the List of Materials on the Contract Drawings.

B. Tubular aluminum pipe shall be of 6063-T6 alloy material per ASTM B221.

C. ACSR cable shall conform to ASTM B232 D. AAC cable shall conform to ASTM B231.

VOLTAGE TRANSFORMERS

Nominal System Voltage Rating: 70kV60kV Maximum System Voltage: 77kV72.5kV BIL Rating: 350kV Frequency: 60 Hz Voltage Ratio: 350/600:1300/500:1 Secondary-Voltage Rating: 115/69V Number of Secondary Windings: Two (X and Y) Thermal Rating: 1000VA 2000VA Total Accuracy/Standard Burdens: 0.3 WXYZ (X, Y)0.3 through Z

SURGE ARRESTERS

A. The 60 kV incoming lines shall be provided with station class, metal oxide surge arresters in accordance with ANSI Standard C62.11. Each surge arrester shall have a maximum continuous line-to-ground operating voltage (MCOV) of 42 kV.

GROUNDING

A. All buried grounding connections shall be by the exothermic weld process. Connections to equipment shall utilize mechanically crimped plated copper lugs of the size matching the provision. Where the provision accommodates a two-hole lug two-hole lugs shall be provided.

B. All structures, surge arresters, and equipment are to be grounded at two points, as diagonally opposite as possible.

NAMEPLATES

A. Nameplates shall be provided in accordance with Specification No. 26 05 53.

B. A corrosion resistant nameplate with clearly legible lettering shall be permanently attached to each assembled piece of equipment at an easily visible place. It shall provide all necessary information pertaining to the equipment, but as a minimum, the following must be included: manufacturer's name, type of equipment, serial number, shop order number and date, project identification number, ratings, and weight. Any special maintenance instructions shall also be shown at this or other suitable location.

FACTORY ACCEPTANCE TESTING

A. All equipment and materials shall be subjected to and pass the production tests required by all of the applicable prevailing standards – including but not limited to IEEE, ANSI, NEMA, and ASTM.

PART 3 EXECUTION

INSTALLATION

A. Substation Equipment

1. Install the STRUCTURES on the foundations prepared in accordance with the Contract Drawings and specifications. Level and align the STRUCTURES to make them plumb and square. Touch up with cold-galvanize paint any minor abrasions.

2. Install the disconnect switches either on the dead-end structures or on separate supports as indicated in the Contract Drawings. Level, adjust, align, and verify operation of the disconnect switch in accordance with the manufacturer’s installation instructions and requirements.

3. Install all components and wiring in accordance with the manufacturer’s installation instructions.

4. Install (2) ground cables to each piece of substation equipment located at diagonally-opposed corners of the equipment, except 70kV instrument transformers require a single connection.

5. Install shield wires from the dead-end structure to the shield wire mast structure.

FIELD TESTING AND COMMISSIONING

A. Contractor shall provide support to City-hired testing firm as required to test individual components and the complete substation after installation. Contractor’s support includes but is not limited to coordination, access, scheduling, connecting, disconnecting, providing clearances, providing test power, and providing safe working conditions during construction.

CLOSEOUT ACTIVITIES

A. Provide all documents (including redlines) showing modifications or changes to the equipment as a result of field testing results and/or installation requirements.

B. Provide all certified copies of all field testing and commissioning results signed by the preparer(s) that performed the tests and the person(s) that have reviewed/approved the results.

END OF SECTION

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