Appendix C - Equipment Specifications A25-1118.pdf

AMES LAB – MD150 SUBSTATION PREPURCHASE February 14, 2025

SECONDARY UNIT SUBSTATIONS WITH SWITCHGEAR SECONDARY 261116.11 - 1

SECTION 261116.11 - SECONDARY UNIT SUBSTATIONS WITH SWITCHGEAR SECONDARY

PART 1 - GENERAL

1.1 SUMMARY

A. Section Includes:

1. Manufactured units.

2. Medium-voltage metal-clad switchgear section.

3. Dry-type transformer section.

4. Secondary distribution section terminal compartment.

5. Secondary distribution section switchgear.

1.2 DEFINITIONS

A. NETA ATS: Acceptance testing specification.

B. RTD: Resistance temperature detector (IEEE C37.2 Device No. 26).

1.3 ACTION SUBMITTALS

A. Product Data: For each type of product.

1. Include rated capacities, operating characteristics, and furnished specialties and accessories.

B. Shop Drawings: Detail equipment assemblies and indicate dimensions, weights, loads, required clearances, method of field assembly, components, and location and size of each field connection.

1. Wiring Diagrams: Power, signal, and control wiring.

2. Dimensioned plans and elevations showing major components and features.

a. Include a plan view and cross section of equipment base, showing clearances, manufacturer's recommended workspace that accounts for breaker service and removal, and locations of penetrations for grounding and conduits.

3. One-line diagram.

4. List of materials.

5. Nameplate legends.

6. The material, size and number of bus bars, and current rating for each bus, including mains and branches of phase, neutral, and ground buses.

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7. Short-time and short-circuit current ratings of secondary unit substations and components.

8. Ratings of individual protective devices.

9. Mimic-bus diagram.

C. Time-Current Characteristic Curves: For overcurrent protective devices.

D. Primary Fuses: Submit recommendations and size calculations.

E. Field quality-control reports.

1.4 INFORMATIONAL SUBMITTALS

A. Factory test reports.

1.5 DELIVERY, STORAGE, AND HANDLING

A. Deliver in shipping splits in sizes that can be moved past obstructions in delivery path.

B. Coordinate delivery of secondary unit substations to allow movement into designated space.

C. Store secondary unit substation components protected from weather and so condensation does not form on or in units. Provide temporary heating in accordance with manufacturer's instructions.

D. Handle secondary unit substation components in accordance with manufacturer's instructions. Use factory-installed lifting provisions.

1.6 WARRANTY

A. Manufacturer Warranty: Provide manufacturer warranty for defects in material and workmanship for 12 months from date of commissioning or 18 months from date of shipment, whichever comes first. Complete forms in Owner's name and register with manufacturer.

PART 2 - PRODUCTS

2.1 MANUFACTURER

A. Square D; Schneider Electric

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2.2 SYSTEM DESCRIPTION

A. Description: Medium-voltage, primary incoming section; transformer section; and low-voltage secondary switchgear section; and including coordinated circuit breakers, fusible switches, and metering components.

1. Electrical Components, Devices, and Accessories: Listed and labeled in accordance with NFPA 70 by qualified electrical testing laboratory recognized by authorities having jurisdiction and marked for intended location and application.

2. Comply with IEEE C2.

3. Comply with IEEE C37.121.

2.3 MANUFACTURED UNITS

A. Indoor Unit Arrangement: Separate secondary distribution equipment connected with busway.

B. Connections between primary device and transformer must be bus, and between transformer and secondary must be flexible bus braid unless noted otherwise.

C. Indoor Enclosure: Steel.

D. Skid Mounted: Mount each shipping group on an integral base frame as a complete weatherproof unit.

E. Unit Substation Enclosures Finish:

1. Factory-applied finish in manufacturer's standard color, including under surfaces treated with corrosion-resistant undercoating.

2.4 MEDIUM-VOLTAGE METAL-ENCLOSED SWITCHGEAR SECTION

A. Metal-enclosed, air-interrupter switchgear, with fuses, complying with IEEE C37.20.3.

1. Switchgear must be arc resistant, complying with IEEE C37.20.7, Type 1.

B. Ratings: Comply with IEEE C37.04; and suitable for application in three-phase, 60 Hz, solidly grounded-neutral system.

1. System Voltage: 4.16 kV nominal; 4.76 kV maximum.

2. Design Level of Available-Source Fault Current: Integrated short-circuit rating consistent with value of fault current indicated.

3. Main-Bus Rating: 600 A, continuous.

C. Interrupter Switches: Stationary, gang operated, and suitable for application at maximum short-circuit rating of integrated switchgear assembly.

1. Rating: 600 A continuous duty and load break.

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2. Two-Time Duty-Cycle Fault Closing: 40 000 A, asymmetrical.

3. Switch Action: No external arc and no significant quantities of ionized gas released into enclosure.

4. Switch Construction: Supported entirely by interior framework of structure, with copper switchblades and stored-energy operating mechanism.

5. Phase Barriers: Full length of switchblades and fuses for each pole; designed for easy removal; allow visual inspection of switch components if barrier is in place.

6. Protective Shields: Cover live components and terminals.

a. Fuse Mounts: Single-frame mounted and de-energized when switch is open.

7. Mechanical Interlock: Prevent opening of switch compartment door unless switchblades are open, and prevent closing switch if door is open.

8. Window: Permits viewing switchblade positions when door is closed.

9. Accessory Set: Tools and miscellaneous items required for interrupter switchgear test, inspection, maintenance, and operation. Include fuse-handling tool as recommended by switchgear manufacturer.

D. Fuses: Sizes recommended by secondary unit substation manufacturer, considering fan cooling, temperature-rise specification, and cycle loading.

1. Current-Limiting Fuses: Full-range, fast-replaceable, current-limiting type that will operate without explosive noise or expulsion of gas, vapor, or foreign matter from tube.

2. Indicator integral with each fuse to show when it has blown.

3. Spares: Include three fuses in use and three spare fuses in storage clips in each switch.

2.5 DRY-TYPE TRANSFORMER SECTION

A. Description: IEEE C57.12.01, IEEE C57.12.51, and dry-type, two-winding, secondary unit substation transformer.

B. Primary Incoming Section: Transformer cover-mounted bushings. The bushings must meet thermal, mechanical, and dielectric requirements as specified for transformer section.

C. Style:

1. Indoor, ventilated, cast coil/encapsulated coil, with primary and secondary windings individually cast in epoxy; with insulation system rated at 185 deg C with an 80 deg C average winding temperature rise above a maximum ambient temperature of 104 deg F.

D. Cooling System:

1. Class AA, air cooled, complying with IEEE C57.12.01.

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E. Insulation Materials: IEEE C57.12.01, rated 220 deg C.

1. Insulation Temperature Rise: 150 deg C, maximum rise above 104 deg F.

F. Basic Insulation Level (BIL):

1. Primary: 30 kV

2. Secondary: 10kV

G. Full-Capacity Voltage Taps:

1. Four nominal 2.5 percent taps, two above and two below rated primary voltage.

2. Four nominal 2.5 percent taps below rated primary voltage.

H. Impedance: 5.75 percent.

2.6 SECONDARY DISTRIBUTION SECTION TERMINAL COMPARTMENT

A. Low-Voltage Terminal Compartment: Bus duct flange for close coupling with busway.

2.7 SECONDARY DISTRIBUTION SECTION SWITCHGEAR

A. The secondary distribution section must be drawout, low-voltage switchgear, complying with IEEE C37.20.1 and UL 1558.

1. Section barriers between main and tie circuit-breaker compartments must be extended to rear of section.

B. Switchgear Structure:

1. Match and align front and back of switchgear.

2. Isolate line bus from load bus at each main and tie circuit breaker with bus isolation barriers.

3. Allow the following circuit-breaker functions to be performed when compartment door is closed:

a. Operate manual charging system.

b. Open and close circuit breaker.

c. Examine and adjust trip unit.

d. Read breaker nameplate.

4. Locate instrumentation transformers within breaker cell, and make front accessible and removable.

C. Switchgear Bus:

1. Use bus bars to connect compartments and vertical sections. Cable connections are not permitted.

2. Main Phase Bus: Uniform capacity the entire length of section.

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3. Neutral Bus: 100 percent of phase-bus ampacity, except as indicated. Equip bus with pressure-connector terminations for outgoing circuit neutral conductors.

Include braces for neutral-bus extensions for busway feeders.

4. Vertical Section Bus Size: Comply with IEEE C37.20.1, including allowance for spare circuit breakers and spaces for future circuit breakers.

5. Phase- and Neutral-Bus Material:

a. Hard-drawn copper of 98 percent minimum conductivity, with copper feeder circuit-breaker line connections.

6. Use copper for connecting circuit-breaker line to copper bus.

7. Contact Surfaces of Buses: Silver plated.

8. Feeder Circuit-Breaker Load Terminals: Silver-plated copper bus extensions equipped with pressure connectors for outgoing circuit conductors.

9. Ground Bus: Hard-drawn copper of 98 percent minimum conductivity, with pressure connector for feeder and branch-circuit ground conductors, minimum size

1/4 by 2 inch.

10. Neutral bus equipped with pressure-connector terminations for outgoing circuit neutral conductors. Neutral-bus extensions for busway feeders are braced.

11. Neutral Disconnect Link: Bolted, uninsulated, 1/4 by 2 inch copper bus, arranged to connect neutral bus to ground bus.

12. Provide for future extensions from either end of main phase, neutral, and ground bus by means of predrilled bolt-holes and connecting links.

D. Circuit-Breaker Compartment:

1. Drawout Features: Circuit-breaker mounting assembly equipped with a racking mechanism to position circuit breaker and hold it rigidly in "connected," "test," and

"disconnected" positions. Include the following features:

a. Interlocks: Prevent movement of circuit breaker to or from "connected" position when it is closed, and prevent closure of circuit breaker unless it is in

"connected," "test," or "disconnected" position.

b. Circuit-Breaker Positioning: Permit racking of an open circuit breaker to or from "connected," "test," and "disconnected" positions only when compartment door is closed unless live parts are covered by a full dead-front shield. Permit manual withdrawal of an open circuit breaker to a position for removal from structure. When compartment door is open, status for connection devices for different positions includes the following:

1) Test Position: Primary disconnects disengaged, and secondary disconnect devices and ground contact engaged.

2) Disconnected Position: Primary and secondary devices and ground contact disengaged.

2. Primary Disconnect: Mount on stationary part of compartment. The disconnect must consist of a set of contacts extending to rear through an insulating support barrier, and of corresponding moving finger contacts on power circuit-breaker studs, which engage in only "connected" position. The assembly must provide

SECONDARY UNIT SUBSTATIONS WITH SWITCHGEAR SECONDARY 261116.11 - 7

multiple silver-to-silver full floating, spring-loaded, high-pressure-point contacts with uniform pressure on each finger. Load studs must connect to bus extensions that terminate in solderless terminals in rear cable compartment.

3. Secondary Disconnect: Floating terminals mounted on stationary part of compartment that engage mating contacts at front of breaker. Disconnecting devices must be gold plated, and engagement must be maintained in "connected" and "test" positions.

E. Circuit Breakers:

1. Comply with IEEE C37.13 and UL 1066.

2. Ratings: For continuous, interrupting, and short-time current ratings for each circuit breaker; voltage and frequency ratings same as switchgear.

3. Operating Mechanism: Mechanically and electrically trip-free, stored-energy operating mechanism with the following features:

a. Normal Closing Speed: Independent of both control and operator.

b. Slow Closing Speed: Optional with operator for inspection and adjustment.

c. Stored-Energy Mechanism: Manually charged.

d. Operation counter.

4. Trip Devices: Solid-state, overcurrent trip-device system consisting of one or two current transformers or sensors per phase, a release mechanism, and the following features:

a. Functions: Long-time-delay, short-time-delay, and instantaneous-trip functions, independent of each other in both action and adjustment.

b. Temperature compensation that ensures accuracy and calibration stability from 23 to 104 deg F.

c. Field-adjustable, time-current characteristics.

d. Current Adjustability: Dial settings and rating plugs on trip units, or sensors on circuit breakers, or a combination of these methods.

e. Three bands, minimum, for long-time- and short-time-delay functions;

marked "minimum," "intermediate," and "maximum."

f. Pickup Points:

1) Five minimum, for long-time- and short-time-trip functions. Equip short-time-trip function for switchable I-squared-t operation.

2) Five minimum, for instantaneous-trip functions.

g. Ground-fault protection with at least three short-time-delay settings and three trip-time-delay bands; adjustable current pickup.

1) Arrange to provide protection for four-wire circuit or system.

5. Trip Indication: Labeled, battery-powered lights or mechanical targets on trip device to indicate type of fault.

6. Auxiliary Contacts:

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a. Contacts and switches required for normal circuit-breaker operation, sufficient for interlocking and remote indication of circuit-breaker position.

b. Spare auxiliary switches, at least two, unless other quantity is indicated. Each switch must consist of two Type A and two Type B contacts wired through secondary disconnect devices to a terminal block in stationary circuit-breaker compartment.

7. Padlocking Provisions: For installing at least three padlocks on each circuit breaker to secure its enclosure and prevent movement of drawout mechanism.

F. Mechanical Interlocking of Circuit Breakers: Uses a mechanical tripping lever or equivalent design and electrical interlocks.

G. Key Interlocks: Arranged to prevent opening or closing interlocked circuit breakers, except in a specified sequence. Include mountings and hardware for future installation of key interlocks.

2.8 LOW-VOLTAGE INSTRUMENT SECTION

A. Instrument Transformers: Comply with IEEE C57.13.

1. Potential Transformers: Secondary voltage rating of 120 V and NEMA C 12.11

Accuracy Class of 0.3 with burdens of W, X, and Y.

2. Current Transformers: Burden and Accuracy Class suitable for connected relays, meters, and instruments.

B. Multifunction Digital-Metering Monitor: Microprocessor-based unit suitable for three- or four-wire systems.

1. Inputs from sensors or 5 A current-transformer secondaries, and potential terminals rated to 600 V.

2. Switch-selectable digital display with the following features:

a. Phase Currents, Each Phase: Plus or minus 1 percent.

b. Phase-to-Phase Voltages, Three Phase: Plus or minus 1 percent.

c. Phase-to-Neutral Voltages, Three Phase: Plus or minus 1 percent.

d. Three-Phase Real Power: Plus or minus 2 percent.

e. Three-Phase Reactive Power: Plus or minus 2 percent.

f. Power Factor: Plus or minus 2 percent.

g. Frequency: Plus or minus 0.5 percent.

h. Integrated Demand, with Demand Interval Selectable from 5 to 60 Minutes:

Plus or minus 2 percent.

i. Accumulated energy, in MWh, plus or minus 2 percent; stored values unaffected by power outages for up to 72 hours.

3. Communications module suitable for remote monitoring of meter quantities and functions. Interface communication and metering requirements in accordance with

Section 260913 "Electrical Power Monitoring."

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4. Mounting: Display and control unit that is flush or semiflush mounted in instrument compartment door.

C. Control Power Supply:

1. From medium-voltage instruments section.

2. Control power transformer supplying 120 V control circuits through secondary disconnect devices.

D. Control Wiring: Factory installed, complete with bundling, lacing, and protection; and complying with the following:

1. Flexible conductors for No. 8 AWG and smaller, for conductors across hinges and for conductors for interconnections between shipping units.

2. Conductors sized in accordance with NFPA 70 for duty required.

E. Maintenance Tools: Furnish tools and miscellaneous items required for circuit-breaker and switchgear test, inspection, maintenance, and operation.

1. Racking handle to manually move circuit breaker between "connected" and

"disconnected" positions.

2.9 IDENTIFICATION DEVICES

A. Compartment Nameplates: Engraved nameplate for each compartment, mounted with corrosion-resistant screws.

2.10 SOURCE QUALITY CONTROL

A. Factory Tests:

1. Perform design and routine tests in accordance with standards specified for components. Conduct transformer tests in accordance with IEEE C57.12.90.

Conduct switchgear and switchboard tests in accordance with NEMA C 37.51.

2. Perform the following factory-certified tests on each secondary unit substation:

a. Resistance measurements of all windings on rated voltage connection and on tap extreme connections.

b. Ratios on rated voltage connection and on tap extreme connections.

c. Polarity and phase relation on rated voltage connection.

d. No-load loss at rated voltage on rated voltage connection.

e. Exciting current at rated voltage on rated voltage connection.

f. Impedance and load loss at rated current on rated voltage connection and on tap extreme connections.

g. Applied potential.

h. Induced potential.

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PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine areas and space conditions for compliance with requirements for secondary unit substations and other conditions affecting performance of the Work.

B. Examine roughing-in of conduits and grounding systems to verify the following:

1. Wiring entries comply with layout requirements.

2. Entries are within conduit-entry tolerances specified by manufacturer, and no feeders will have to cross section barriers to reach load or line lugs.

C. Examine walls, floors, roofs, and concrete bases for suitable conditions for secondary unit substation installation.

D. Verify that ground connections are in place and that requirements in Section 260526

"Grounding and Bonding for Electrical Systems" have been met. Maximum ground resistance must be 5 ohms at secondary unit substation location.

E. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 INSTALLATION

A. Comply with applicable portions of NECA 400, NECA 410, NECA 430, and NEMA SG 11.

B. Install secondary unit substations on concrete equipment bases.

C. Maintain minimum clearances and workspace at equipment in accordance with manufacturer's instructions and NFPA 70.

3.3 IDENTIFICATION

A. Identify system components, wiring, cabling, and terminals.

1. Install number of signs required to be readable from each accessible side, but space signs a maximum of 30 ft. apart.

B. Operating Instructions: Place printed operating instructions for secondary unit substations, including key interlocking, control sequences, elementary single-line diagram, and emergency procedures with maintenance materials.

3.4 CONNECTIONS

A. Ground equipment in accordance with Section 260526 "Grounding and Bonding for

Electrical Systems."

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1. At Interior Locations: For grounding to grounding electrodes, use bare copper cable not smaller than No. 4/0 AWG. Bond surge arrester and neutrals directly to transformer enclosure and then to grounding electrode system with bare copper conductors. Keep leads as short as practicable with no kinks or sharp bends. Make joints in grounding conductors and loops by exothermic weld or compression connector.

3.5 FIELD QUALITY CONTROL

A. General Field Testing Requirements:

1. Comply with provisions of NFPA 70B, "Testing and Test Methods" Chapter.

2. Perform each visual and mechanical inspection and electrical test. Certify compliance with test parameters.

3. After installing secondary unit substation but before primary is energized, verify that grounding system at substation is tested at specified value or less.

4. After installing secondary unit substation and after electrical circuitry has been energized, test for compliance with requirements.

5. Visual and Mechanical Inspection:

a. Verify equipment nameplate data complies with Contract Documents.

b. Inspect bolted electrical connections for high resistance using one of the following two methods:

1) Use a low-resistance ohmmeter to compare bolted connection resistance values to values of similar connections. Investigate values that deviate from those of similar bolted connections by more than 50 percent of lowest value.

2) Verify tightness of accessible bolted electrical connections by calibrated torque-wrench method in accordance with manufacturer's published data or NETA ATS, Table 100.12. Bolt-torque levels must be in accordance with manufacturer's published data. In absence of manufacturer's published data, use NETA ATS, Table 100.12.

6. Remove and replace malfunctioning units and retest.

7. Prepare test and inspection reports. Record as-left set points of all adjustable devices.

B. Switchgear Field Tests:

1. Visual and Mechanical Inspection:

a. Inspect physical and mechanical condition.

b. Inspect anchorage, alignment, grounding, and required area clearances.

c. Verify unit is clean and shipping bracing, loose parts, and documentation shipped inside cubicles have been removed.

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d. Verify that fuse and circuit-breaker sizes and types correspond to Drawings and coordination study as well as to address of circuit breaker that is used to identify it in microprocessor-communication software.

e. Verify that current and voltage-transformer ratios correspond to Drawings.

f. Confirm correct operation and sequencing of electrical and mechanical interlock systems.

1) Attempt closure on locked-open devices. Attempt to open locked-closed devices.

2) Make key exchange with devices operated in off-normal positions.

g. Verify appropriate lubrication on moving current-carrying parts and on moving and sliding surfaces.

h. Inspect insulators for evidence of physical damage or contaminated surfaces.

i. Verify correct barrier and shutter installation and operation.

j. Exercise all active components.

k. Inspect mechanical indicating devices for correct operation.

l. Verify that filters are in place and vents are clear.

m. Inspect control power transformers as follows:

1) Inspect for physical damage, cracked insulation, broken leads, connection tightness, defective wiring, and overall general condition.

2) Verify that primary- and secondary-fuse or circuit-breaker ratings match Drawings and comply with manufacturer's recommendations.

3) Verify correct functioning of drawout disconnecting and grounding contacts and interlocks.

C. Large Dry-Type Transformer Section Field Tests:

1. Visual and Mechanical Inspection:

a. Inspect physical and mechanical condition.

b. Inspect anchorage, alignment, and grounding.

c. Verify that resilient mounts are free and that any shipping brackets have been removed.

d. Verify unit is clean.

e. Verify that as-left tap connections are as specified.

D. Low-Voltage Power Circuit-Breaker Field Tests:

1. Visual and Mechanical Inspection:

a. Inspect physical and mechanical condition.

b. Inspect anchorage, alignment, and grounding.

c. Verify that all maintenance devices are available for servicing and operating breaker.

d. Verify unit is clean.

e. Verify that arc chutes are intact.

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f. Inspect moving and stationary contacts for condition and alignment.

g. Verify that primary and secondary contact wipe and other dimensions vital to satisfactory operation of breaker are correct.

h. Perform mechanical operator and contact alignment tests on both breaker and its operating mechanism in accordance with manufacturer's published data.

i. Verify cell fit and element alignment.

j. Verify racking mechanism operation.

k. Verify appropriate lubrication on moving current-carrying parts and on moving and sliding surfaces.

l. Perform adjustments for final protective-device settings in accordance with coordination study provided by end user.

m. Record as-found and as-left operation counter readings.

E. Nonconforming Work:

1. Equipment will be considered defective if it does not pass tests and inspections.

2. Remove and replace defective units and retest.

F. Prepare test and inspection reports.

3.6 CLEANING

A. After completing equipment installation and before energizing, inspect unit components.

Remove paint splatters and other spots, dirt, and debris. Repair damaged finish to match original finish. Vacuum interiors of secondary unit substation sections.

END OF SECTION 261116.11