Attachment 1_SOW.pdf

Statement of Work Micro Gin Motor Control Center Upgrade

Micro Gin Motor Control Center1 with PLC2 and HMI3

General Information (A):

A1: The USDA ARS Cotton Ginning Research Unit in Stoneville, MS has a requirement for the supply and installation of one Motor Control Center (MCC) and Programmable Logic Controllers (PLC) with

Human-Machine Interface (HMI) control console to replace the existing hardwired devices and controls.

Commissioning will be the joint responsibility of contractor and USDA personnel.

A2: Existing service is provided by three on site transformers providing 480 volts via a delta configuration with a corner grounded “B” phase. The current service configuration will not change.

Special consideration must be applied to the application of variable frequency drives with the grounded

“B” phase.

A3: Installation must include removal and demolition of existing devices (see Installation Comments in Appendix), cable trays and wiring. Supply must include all devices and controls, wiring, connectors, conduit and cable trays. All wiring and hardware must meet applicable local and national codes.

Contractors must provide a new 600-amp service panel at back wall on northwest end of building 26.

Alternate: Current 480-volt service is provided by one 600-amp panel at the east building end wall.

Contractor may consider providing service from the 600-amp panel to the new MCC, to be located at the west end of the building.

A4: Due to the complexity and age of the existing configuration, it is strongly encouraged that interested vendors attend the scheduled site visit.

A5: Contractor must provide all equipment and supplies necessary for installation. USDA personnel will be available to receive equipment shipments. USDA furnished forklift, scissor lift and boom lift will be available for use in equipment installation.

A6: The MCC and all components must be designed, manufactured and tested in accordance with the latest applicable standards of NEMA, ANSI and UL 845.

A7: The manufacturer of this equipment must have produced similar electrical equipment previously.

A8: The MCC must bear a UL label. Upon request, certified copies of production test reports must be supplied demonstrating compliance with these standards.

A9: Equipment must be handled and stored in accordance with manufacturer’s instructions. One (1) copy of the instructions must be included with the equipment at time of shipment.

1 Eaton.com/design guides 2 Modicon 340 Controllers setup Guide 3 Cimon.com, How to Choose an Industrial HMI

A10: Equipment operation and maintenance manuals must be provided with each assembly shipped and must include instruction leaflets, instruction bulletins and renewal parts lists where applicable, for the complete assembly and each major component.

Specifications (B):

B1 - Voltages: 480 volt, 60HZ 3 phase. Control voltage transformer must provide 24V DC. 120- and 240-volt single phase provided by existing 45 kVa transformers.

B2 - Total connected horsepower: 332.75. Design for 400 total connected horsepower. See section 2 of the Appendix for full motor and motor control method tables.

B3 - Wiring: Nema Class I, Type A

B4a MCC: The motor control center must be 600-volt class suitable for operation on a three-phase

60 HZ Delta system with a corner grounded B phase. System operating voltage is 480 volt, 60HZ 3 phase.

Control voltage 24V DC.

B4b - Structures: Totally enclosed, dead-front, free-standing assemblies. Height and depth TBD

(access to motor control room limited at 74” height). Horizontal wireway at top isolated from the horizontal bus via metal barriers, readily accessible through hinged cover. Structures must also contain a horizontal wireway at bottom open to the full rear of the structure. Adequate space for conduit and wiring to enter the top or bottom must be provided without structural interference.

B4c - Compartments: Mounted control units must be incrementally arranged within each vertical structure. A vertical wireway with adequate cross-sectional area must be adjacent to each vertical unit and must be covered by a hinged door.

Each unit compartment must be provided with an individual front door. Adequate space must be provided in MCC for four (4) future additional compartments.

B4d - Safety Interlock: An operating mechanism must be mounted on the primary disconnect of each starter unit. It must be mechanically interlocked with the unit door to prevent access, unless the disconnect is in the “OFF” position. Padlocking accommodation must be provided to positively lock the disconnect in the “OFF” position with up to three (3) padlocks with the door open or closed.

B4e - Bus: Each structure must contain a main horizontal bus and vertical compartment feeding bus(es) with minimum ampacity of 600 amperes. Both horizontal and vertical buses must be fully rated and not tapered. Each bus must be individually fully rated.

B4f - Ground bus: A ground bus must be furnished firmly secured to each vertical section structure and must extend the entire length of the motor control center. The ground bus must be located in the bottom horizontal wireway. Each structure must contain vertical ground bus rated at 300 amperes. The vertical ground bus must be directly connected to the horizontal ground bus.

B4g - Motor Controllers: Combination starter units must be full-voltage, non-reversing and must utilize

High-magnetic Motor Circuit Protection (HMCP) devices for short circuit protection.

Magnetic starters through size 3 must be equipped with a minimum of one (1) normally open auxiliary contact. Coils must be of molded construction. All coils to be color coded, marked with voltage, frequency and part number.

Overload relays must be of the solid-state type, equivalent to Eaton C440.

Variable frequency drives (VFD) must be provided in MCC(s) as per attached schedule. VFD must be same as or equivalent to Schneider Altivar ATV340, Eaton Power XL DX1 or Mitsubishi FR-A800 series. Drives must have communication cards capable of communication using EtherNet/IP. Alternate: Contractor must provide quote to control all motors by VFDs.

B4h - EtherNet/IP Devices: Motor Control Center assemblies must be provided with a factory assembled

EtherNet/IP field bus communications network providing direct connectivity between MCC devices and the system PLC and/or HMI. EtherNet industrial switches must be provided as required and must have sufficient ports available to connect to each.

EtherNet/IP device and have at least 2 open ports for a user connection and a PC connection for maintenance. If required, the switch must be capable of connecting to multiple sections.

The EtherNet/IP system must include a complete 600V Cat 5 tested cabling system in accordance with the

ODVA Network Specification. Non-standard, non-shielded cable will not be accepted. It is permissible to daisy chain EtherNet/IP devices using a 2-port switch configuration. All cabling must be securely supported and attached to the MCC structure in accordance with manufacturer’s recommendations.

EtherNet/IP communications modules must be provided at each device interfacing to the EtherNet/IP field bus. The communications modules must be installed in the unit device compartment and must be directly connected to the EtherNet/IP EtherNet cable. Each device must be provided with the appropriate factory fabricated cable for interfacing the communications module with the associated EtherNet/IP device.

Preferred Alternate: A remote I/O cabinet may be provided at the MCC in lieu of installing communication modules in each individual compartment.

B4i - Enclosure, Nameplates & Finish: The type of enclosure must be in accordance with NEMA standard type 1A with gasketed doors. All enclosed steel, wireways and unit doors must be gasketed.

Each unit will have a 1.0 x 2.5-inch engraved nameplate. The lettering must be 3/16-inch high, black on a white background.

The control center must be painted according to the Manufacturer’s standards once approved by end user.

Such standards typically include phosphatizing pretreatment and polyester urethane, thermosetting powder paint. Manufacturer’s standard color must be used. All structural steel and panels will be painted.

PLC (C):

C1: Examples of acceptable PLCs are Schneider M340, Allen Bradley COMPACTLOGIX 5380, Siemens

SIMATIC S7-1500 or Omron NX1P2.

C2: Requires robust input/output capacity, high-speed processing and secure communication protocols.

C3: I/O capacity must support both digital (discrete) signals such as motors, air valves and on/off switches, and analog signals for continuous measurement as in temperature, pressure and flow rates, via

4-20mA and RTD sensors. See section 2 of Appendix.

C4: Built-in mathematical processing and loop control such as proportional-integral-derivative (PID), feedforward control and alarming functions.

C5: Must support standard industrial Ethernet protocols such as EtherNet/IP (or Profinet in the case of the Siemens SIMATIC S7-1500 unit).

C6: Must integrate smoothly with HMIs, SCADA software and smart field instruments (transmitters, actuators & valves, data loggers, etc.)

C8: Ability to make online program edits without interrupting facility operation.

C9: High-speed CPU(s) and adequate memory to handle complex batch sequencing, data logging and rapid response times.

C10: Must be able to withstand harsh facility conditions (air-borne fiber and dust), wide operating temperatures, humidity and electrical noise or interference.

C11: See section 3 of Appendix for additional comments and specifications.

HMI (D):

D1: HMI must provide real-time visualization (process graphics, instantaneous analog updates and clear trend charts for tracking variables over time).

D2: Priority-based alarms with audible and visual alerts for abnormal states, and historical alarm logs with time stamps.

D3: Password protected security and access control, role-based user authentication, and audit trails.

D4: Clear visual emergency stop and interlock status display, sequential motor start/stop stations with visual run indication, and setpoint adjustments with confirmation prompt.

D5: Storage for production batches, run times and cycle counts with recipe management for loading production parameters and export capabilities for compliance and quality control. As this is a research facility, the order of machine operations, feeds, and operating speeds should be able to be changed from the control panel without the need for an external computer connection.

D6: NEMA 4X industrial grade for dust and moisture, reliable communication protocols such as

EtherNet/IP or Profinet to link with PLC.

D7: HMI must be of the size and resolution to clearly display fifty (50) motor start/stop stations on one to two screens. For example, 21.5” panel at minimum Full HD 1920x1080 resolution.

D8: See section 4 of Appendix for additional comments and specifications.

Factory Testing (E): Motor control centers must have been tested to prove adequate mechanical and electrical capabilities. All factory tests required by the latest ANSI, NEMA and UL standards must be performed. A certified test report of all standard production tests must be available to the owner upon request. The manufacturer must notify the owner two (2) weeks prior to the date the tests are to be performed.

Installation (F): Contractor must provide the services of a qualified factory-trained manufacturer’s representative to perform installation of the equipment specified.

Contractor must follow the installation instructions supplied by the manufacturer.

Control wiring must be as shown on the contract drawings except as modified by the approval and submittal process. Interface all local and remote devices into the control wiring and operational systems for each load.

Training (G): The Contractor must provide a training session for up to five (5) owner’s representatives for 2 normal workdays at the job site or other office location chosen by the owner.

A manufacturer’s qualified representative must conduct the training session.

The training program must consist of the following:

o Review of the MCC one-line drawings and schedules o Review of the factory record shop drawings and placement of the various cells o Review of each type of starter cell, components within, control, and power wiring o Review contactor coil replacement and contact replacement procedures o Discuss the maintenance timetable and procedures to be followed in an ongoing maintenance program o Provide three-ring binders to participants complete with copies of drawings and other course material covered

Field Adjustments and Testing (H): The Contractor must perform field adjustments of the short circuit and overload devices as required to place the equipment in final operating condition. The settings must be in accordance with the contract and approved studies and standards including manufacturer’s leaflets.

Contractors must provide a field report on tests performed, test values experienced, etc., and provide a copy of the report to the customer upon request.