Electrical SOW Design Recommendations for the GSA Elevator Upgrade design.pdf

SENSITIVE BUT UNCLASSIFIED

Electrical SOW Design Recommendations for the GSA Elevator Upgrade Design Revised 08/05/2020 - Final Version from THB

1. Put a qualified electrical engineering company under contract to research, develop, and produce a comprehensive and accurate design for a complete set of electrical construction documents to upgrade all electrical systems and equipment supplying normal and emergency power to all south side elevators.

• Investigate, research and document all existing electrical equipment, all existing electrical devices, all existing lighting fixtures, all exit signs, and all existing conduits and conductors that are part of the existing normal power system to, for and in all elevator machine rooms, all elevators, elevator hoist ways and elevator pits on the south side.

• Produce Prints, Drawings and Specifications to supply all renovated elevators in this project with an upgraded normal power system that is completely compliant with the latest edition of the National Electrical Code, and to install a new emergency power system supplied by the existing emergency generator 17 that is fully compliant with the latest editions of NFPA 70 (National Electrical Code), NFPA 110 (Emergency Power Systems) and the IBC (International Building Code) .

• Provide Prints and Drawings that clearly show the full extent and all specific details of the electrical equipment and conductors that are: a) Existing to Remain, b) Existing To Be Salvaged and shall be turned over to the government, c) Existing To Be Removed, and d) New Work.

• Incorporate future work requirements from the emergency power design requirements and drawings shown in the recently completed Phase 1C and 2 Elevator Emergency Power Upgrade project into the new emergency power system design.

2. Upgrade normal power conductors and conduits to all south side elevator machine rooms, and upgrade conductors to all equipment in all elevator machine rooms, hoist ways and pits.

• Remove all old existing conductors and conduits supplying normal power to all south side elevators. Electrical Vault 5 on the 8th floor supplies normal power to every elevator - except for elevator 45 - on the south side of the building. Vault 5 was fully modernized in 2016, but only the beginning of each of the feeder circuits were upgraded. Therefore, the majority of the normal power feeders are 60 years old antique conductors (with cloth-covered insulation) that are more than 30 years past their reliable and useful life.

• Calculate for voltage drop to all elevators and provide new copper conductors that are NEC compliant. It is clear that the existing smaller conductor ampacity sizes (one 3-phase set of cloth-covered 500MCM) going up to 900 feet did not account for the significant power loss from voltage drop. This is especially the case in elevator cores #1 and #3 where under-voltage is contributing to a significantly higher failure rate for both AC-DC motor generators and for DC motors.

• New elevator controllers and the National Electrical Code require consistent 480-volts of power with less than a 3 percent voltage drop.

• The renovations for Phases 1A, 1B and 1C upgraded all normal power wiring to the renovated elevators. All the new conduit and conductors were sized and engineered to eliminate voltage drop.

• Replace and upgrade to modern copper conductors all these ancient, cloth-covered and under-sized conductors that presently supply normal power to all south side elevators. This will provide long-term future reliability, eliminate voltage drop, and ensure continuity of elevator operations during normal and during emergency situations.

• See additional information on Table 1.

Electrical SOW Design Recommendations for GSA Elevator Upgrade Design – Continued

3. Replace and upgrade all existing electrical equipment in all south side elevator machine rooms, elevator hoist ways and elevator pits. Most existing electrical equipment, existing devices, existing lighting and existing wiring in the elevator machine rooms elevator hoist ways, and elevator pits is 60 years old and is well past its reliable life expectancy of 30 years. Each of the following items needs to be assessed, replaced, and/or upgraded:

Upgrade all existing electrical equipment, existing fixtures and existing devices in all elevator machine rooms

• Upgrade all existing 480-Volt switchboards

• Upgrade all existing panelboards

• Upgrade all existing disconnect switches

• Upgrade the hardware and software control systems for the four existing Automatic Transfer Switches

• Provide and install new Automatic Transfer Switches (ATS) where none already exist

• Require that all new Automatic Transfer Switches shall be Russelectric to match the 48 existing ATSs

• Replace all existing light fixtures, all existing exit signs, all existing switches, all existing receptacles, and connect all these items to emergency power.

• Protect all receptacles in all locations with Ground Fault Circuit Interrupter receptacles.

• Install a dedicated emergency circuit for all exit lights and a few strategic lights to always remain on and unswitched in each elevator machine room.

• Install a separate emergency power circuit for all general illumination lights and require one, 3-way light switch at all entry doors in every elevator machine room.

• Replace all existing branch circuit and feeder conductors for normal or emergency power.

Upgrade all electrical equipment in elevator hoist ways and elevator pits

• Upgrade all existing lighting and all existing exit lights in all hoist ways and elevator pits

• Require all hoist way and all associated pit lights to be switched as a group from two locations: one switch near the entrance to the pit and one switch just inside the hoist way at the upper floor

• Replace all existing duplex receptacles in all elevator pits. Require that all duplex receptacles be protected by one or more receptacles that are the Ground Fault Circuit Interrupter type.

4. Design and install a complete Level 1 Emergency Power System (EPSS) for the south side elevators. Justifications for supplying all renovated elevators with emergency back-up power:

• It is required by the latest edition of the International Building Code (IBC). The IBC defines this building as a high-rise building. Consequently, it is a mandatory requirement to have a Standby Power System for all elevators that are being upgraded. (See email from the Fire Protection Engineer.)

• This Standby Power ensures that people are not trapped in elevators – especially during a power failure and/or an emergency – as the elevators will always go to the home floor and allow passengers to exit. Without emergency power during a normal power failure, passengers could be trapped.

• NFPA 110 specifies the requirements for a Level 1 Emergency Power Supply System (EPSS), and generator 17 meets and exceeds these specifications.

• It allows for independent fire fighter operation during an emergency when normal power fails.

• It enables VIPs and key personnel serving in multiple 24/7 operations centers in the building to move reliably and efficiently through the building during a power failure.

• It permits elevator technicians and other essential personnel to move critical equipment and people during a power failure.

• It supplies emergency power to elevator car emergency lighting, to all elevator machine room and hoist way lighting, and is supplies emergency power for all elevator status monitoring systems.

• All renovated elevators and all their associated electrical systems on the north side were supplied with normal power backed up by emergency power.

5. Require that emergency generator 17 shall supply all emergency, back-up power, which shall be controlled by Automatic Transfer Switches and distributed by switchboards and panelboards, to all south side passenger and freight elevators, to all elevator cooling systems, to all lighting and to all general power for all elevator machine rooms, all hoist ways, all pit areas and to all their associated electrical systems in the electrical design.

• A great deal of effort, money and time has been invested in installing, testing, and commissioning the 1C emergency generator (AKA generator #17).

• Generator 17 is a true Level I, Emergency Power Supply System (EPSS) generator (as defined by NFPA

110) that is dedicated for the sole purpose of supplying emergency power to all elevators and their associated machine rooms equipment and independent elevator cooling systems on the south side.

• Generator 17 has a load capacity of 1,725,000 watts. At present, its entire load for four elevators on the north side is only 25,000 watts, which is less than 2 percent of its power capacity! It was not designed nor intended to utilize indefinitely such a small percentage of its potential load capacity. To not utilize it more fully would be tragic, and it would make no sense.

• Require that every elevator and all its associated equipment in every location shall be supplied by normal power backed up by emergency generator power supplied by generator 17.

• Require that all Automatic Transfer Switches shall, upon the loss of normal power, initiate generator 17 to start and run, and to transfer all elevators and all associated elevator machine room electrical equipment to emergency power from generator 17.

• Require that the generator 17 starting and control circuit coming from the ATSs shall be installed in a minimum of ¾-inch Electrical Metallic Tubing.

• Require that generator 17 supply emergency power to all independent cooling systems for all elevator machine rooms on the south side.

• Require that the existing emergency power feeds and the Russelectric Automatic Transfer Switches for elevators 22, 23, 31 and 44 be disconnected and removed, and that generator 17 emergency power shall be installed and connected instead. Turn over to the government each of the four ATSs.

• Mandate in the Specifications that all new distribution panelboards and all new panelboards include Power Quality Meters (PQM) that are connected to the Foreseer Electrical Monitoring System.

6. Comply with all mandatory emergency power systems requirements in the latest edition of NFPA 70, The National Electrical Code. Due to the fact that generator 17 is a Level 1 Emergency Power Supply System, require that the Electrical Engineer of Record research and apply all applicable NEC requirements, especially Article 700.

• Specify and require Surge Protective Devices (SPD) on all new distribution panelboards and all new panelboards that supply normal power backed up by emergency power to all elevator machine room equipment, especially all elevator controllers. The reliability and life span of elevator controllers will be greatly increased with SPDs. Require that the SPDs indicate when they no longer provide surge protection.

Require that the SPDs be connected to the Foreseer Monitoring System.

• Specify that a Coordination Study be conducted on the emergency power system overcurrent protective devices. Ensure that all parts of the emergency system meet the NEC requirements and are properly coordinated. This includes the ground fault settings for one or more main circuit breakers installed in the panelboard at generator 17.

• Research the applicable requirements regarding 2-hour rated Fire Resistive Cables for the conductors and conduits for the emergency power feeder from generator 17 up the outside wall of the courtyard and to the main emergency distribution panelboard. As part of the Phase 1C Renovation, the Electrical Engineer of Record determined and specified 2-hour Fire Resistive Cables in a very similar application for the existing emergency panelboard HPM8S1 supplied by Generator 17.

7. Put an HVAC engineering company under contract to assess the existing independent cooling systems for all elevator machine rooms on the south side to determine if these cooling systems are adequate and energy efficient or not. Produce design construction documents to address all identified issues.

• The electronics in all upgraded elevator controllers require an operating temperature of 75 degrees or lower to not malfunction and to increase their reliable life span.

• Require a fully integrated design that shall supply all independent cooling systems for all elevator machine rooms on the south side with adequate power from generator 17.

• Require a temperature controller and/or sensor be connected to the Foreseer Monitoring System.

8. Request that the electrical engineer evaluate and determine the appropriate location to install a new set of conduits and conductors from generator 17 up the outside of the courtyard wall to the mechanical room on the south side.

• Mandate that the installation of vertical conduits and the shroud cover duplicate the method and execution of similar conduit installations in other sections of the generator 17 courtyard wall by installing a shroud that shall be similar in shape, design, material and color that will disguise the conduits up the courtyard wall. See additional information in the Phase 1C and 2 Elevator Emergency Power Upgrade documents.

• Mandate that all conduits and all shroud anchors shall only be installed in the mortar joints of the exterior limestone wall.

• Note the third bullet of number 6 above.

9. Require the Electrical Engineer of Record to perform Electrical Coordination and Short Circuit Studies as required by the National Electrical Code for emergency power systems.

• Perform an electrical Coordination Study and a Short Circuit Study of all relevant parts of the normal power systems supplying power from Vault 5 all the way through each circuit breaker or fuse to each elevator controller.

• Design an emergency power system that will comply with all NFPA 70 National Electrical Code requirements that shall be electrically coordinated. This will ensure that electrical faults on branch circuits or lower-level feeder circuits do not cause large portions of the emergency power system to go offline.

10. Require key emergency power system equipment to be connected to and monitored by the existing Eaton Foreseer Electrical Monitoring System already in widespread use in the building. The Foreseer system provides real time and historical electrical power readings and data on all the emergency power systems, the Uninterruptible Power (UPS) systems and an extensive coverage of the normal power systems in the building.

• Require all new emergency power panelboards and distribution panelboards to have Power Quality Meters, either as part of the panelboards or as a separate unit, which shall be connected to and display all major power readings for the PQMs in Foreseer. Duplicate similar windows already in use in the Foreseer system.

• Require all power and status information that is displayed in the new and existing Automatic Transfer Switches that are or will be part of the new emergency power system to be connected to and display all power and status information in the Foreseer Monitoring System.

• Require the status of all new Surge Protective Devices be displayed in the Foreseer system.

• Update the existing windows in the Foreseer system for generator 17 to include activating any spare circuit breakers and other status information.

• Require that all necessary technical and technician support, including hardware, software and programming for adding all new panelboards and ATSs to the Foreseer Monitoring System be included in the requirements of the Specifications and in the Prints.

• Require that all communication fiber and other cables that are installed as part of these requirements shall be installed in a minimum ¾-inch Electrical Metallic Tubing.

11. Prepare and produce drawings, calculations, and specifications for this emergency and normal power distribution system design need to include all of the following requirements:

• Cannibalize and salvage all Direct Current (DC) motors, all AC to DC generators, and all existing elevator controllers from all renovated elevator systems and physically hand over all these items to the Government for use as spare parts.

• Upgrade all existing elevator motors and elevator controllers to Alternating Current (AC) motors controlled by Variable Frequency Drive (VFD) controllers.

• Remove and upgrade all existing normal (utility) power switchboards, panelboards, disconnect switches, light fixtures, switches, receptacles and any other associated electrical equipment or devices.

• Remove and replace all branch circuit and feeder conductors that are not modern THHN copper conductors in all elevator machine rooms, hoistways and elevator pits.

• Assess and investigate all parts of the existing emergency power systems supplying emergency power to elevators 22, 23, 31 and 44. Remove all existing Generator 2 emergency power conduits, conductors and the four Russelectric ATSs supplying emergency power to these elevators.

• Install Automatic Transfer Switches (ATSs) for all south side elevators to provide emergency power when normal power fails or is not available.

• Require that all Automatic Transfer Switches shall only be Russelectric Inc. ATSs to match 48 existing Russelectric ATSs in use in the building. Sole source justification available upon request.

• Design and Install a new emergency power distribution system that includes 480-volts panelboards, 208-volts panelboards, Automatic Transfer Switches and all other necessary equipment or devices.

• Provide emergency power for independent cooling equipment for each elevator machine room.

• Identify each specific section of normal power conduit and conductors that need to be removed and upgraded

• Provide specific electrical or other requirements for special elevators 22 and 24

• Upgrade lighting and conductors if any elevator cars are designated historic.

• Supply two dedicated 120-volts, 20-amps branch circuits that are supplied by central Uninterruptible Power System (UPS) power to the elevator Lift Net Monitoring system, nearby associated equipment and one other Elevator Shop computer.

12. Require a commissioning plan for all normal and emergency electrical systems and equipment, all HVAC systems and equipment and all elevator systems and equipment. This plan could include qualified third parties, government experts or a combination of factory technicians and engineers.

• Require that all the following electrical equipment and systems shall be included in the commissioning plan and specific field tests are mandated, specified, performed and documented using qualified factory technicians or specialized electrical engineers.

• Verify all Automatic Transfer Switches and testing to verify their control of generator 17.

• Test all Panelboards and verify all Power Quality Meters display all power readings correctly.

• Test and verify the correct settings and functioning of all circuit breakers in all new switchboards.

• Verify the correct functioning of all Surge Protective Devices.

• Verify the correct settings on all adjustable trip circuit breakers.

• Verify the correct functioning of each independent cooling system and their ability to restart after transferring to emergency power.

• Verify that all required equipment, power readings and status information is connected to and displayed in the Foreseer Electrical Monitoring System.

13. Additional Requirements

• Require all electrical equipment and circuits to be labeled, to specify the one or more sources and locations of power, and to specify the specific loads.

• Steel fittings only shall be used for the installation of all electrical metallic tubing (EMT).

• All electrical work shall be inspected an authorized government official during various stages of the rough-in installation and at the completion of the job. This is in addition to any inspections conducted by GSA.

• All new Automatic Transfer Switches shall be Russelectric. These ATSs need to match the 48 already in use in the building. Sole source justification available upon request.

Page Break

Table 1 – Details of Existing Normal Power to South Side Elevators Elevator Bank or Group to Be Renovated on

South Side

Core

Vault 5 Panelboard Which

Feeds Entire Group

Feeder Circuit Size

Existing G.

Rigid

Conduit Size

New Conductors to Big Box by Column

P-16

New Conductors to Boxes in or Near Vault 5

Purpose Other Than

Passenger

14, 15, 16, 17 1 MDP-1 400A 3” Yes 14 - Freight

18, 19, 20 2 MDP-1 400A 3” Yes 22 - Special

21, 22, 23 2 MDP-2 400A 3” Yes 23 - Freight

24, 25, 26 3 MDP-4 400A 3” Yes 24 - Special

27, 28 3 MDP-5 400A 3” Yes

29, 30, 31 4 MDP-4 400A 3” Yes 31- Freight

43, 44 N/A MDP-1 400A 3” Yes 44 - Freight

45 N/A Probably Vault 3 - - - - 45-Freight Separate feed from 5th floor