Attachment-No-4-Field Testing Report of ASCO 5kV Switchgear-Dated May-14-2025-Rev-01.pdf

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James J. Peters VA Medical Center

Field Testing Report of ASCO 5kV Switchgear

Attachment # 4

Testing Completed by:

Gabriel Paoletti, P.E.

Assisted by:

Amir Elgabari – VA Chief of Projects & Planning

Mohammad Hossain – VA Healthcare Engineer

Date: May 14, 2025 – Rev 01

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Contents Purpose / Background:

Executive Summary

Equipment Tested

Testing Procedure

48vDC Power Supply

24vDC Power Supply

Dual DC Power Supply

AC Simulated Fault Current Power Supply

48/24vDC Component Energizing

Control Wiring Review

Generator Breaker Trip Circuit Review

Generator Breaker Close Circuit Review

Field Testing Report of ASCO 5kV Switchgear Summary

Conclusion

Project Required Testing

Reference Materials:

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Purpose / Background:

The field testing was to determine the condition of the 5kV Switchgear obtained from the VA

Manhattan site for use at the VA Bronx for the EMD Generator Replacement Project.

The 5kV switchgear was manufactured by ASCO Power Technologies, L.P. in Florham Park, NJ in 2013 /

2014. All equipment has been in proper storage and H.O. Penn performs routine testing on the two

(2) generators. The entire bill of material includes two (2) 4160 Volt Generators built by CAT, 5kV

Circuit Breakers supplied by Schneider, Relays supplied by SEL, and PLCs, Control Relays and auxiliary equipment supplied by other manufacturers. The PLCs, relaying and wiring was designed to connect and parallel three (3) generators with the utility, while initially the VA Bronx facility will only be connecting two (2) generators.

Initial input from Schneider / ASCO was to effectively replace all components except for the 5kV circuit breakers.

This field testing performed functional testing of the relay protection schemes, the 5kV circuit breaker charging, closing and trip functions, verification of the 86 Lock-out Relay operation; and powering up all PLCs, Touch-screen displays, control devices, relays, etc. with the required 48vDC and 24vDC.

We have reached out to H.O. Penn and Schneider / ASCO on March 5th, 2025, regarding any extended warranties that might be available for all the equipment.

Responses were that extended warranties for this existing equipment supplied by the VA-Manhattan prior project would not be available.

Executive Summary

On 01/06/2025, two representatives from Schneider / ASCO performed a visual inspection of all sections. During their visit, they did not indicate any issues with any components, based on their visual inspection. A visual inspection does indicate that all equipment appears in satisfactory condition.

The conclusion of the Field Testing included within this report indicates that all critical components are in satisfactory condition and are fully operational, including the wiring, insulation and all other aspects of the equipment.

Recommendations for refurbishment and upgrading of this equipment is included within the

Conclusion of this report.

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Equipment Tested

The following components and associated internal wiring were fully tested on two dates (02/27/25 &

03/04/25) and were found to be fully operational.

Section Components Master ✓ Potential Transformers

✓ Touchscreen Display

✓ Control Station

✓ Alarm Annunciator

Section 2 / Generator 1 (PSG-1) ✓ SEL 351S Protective Relay

✓ Alarm Annunciator

✓ Control Station

✓ Test Switches

✓ One (1) 5kV Circuit Breaker: Charge, Close and Trip

✓ Bus Insulation

Section 3 / Generator 2 (PSG-2) ✓ SEL 700G Protective Relay

✓ Alarm Annunciator

✓ Control Station

✓ Test Switches

✓ One (1) 5kV Circuit Breaker: Charge, Close and Trip

✓ Bus Insulation

Section 4 / Generator 3 (PSG-3) ✓ SEL 700G Protective Relay

✓ Alarm Annunciator

✓ Control Station

✓ Test Switches

✓ One (1) 5kV Circuit Breaker: Charge, Close and Trip

✓ Bus Insulation

Section 5 / Two 5kV Circuit Breakers

(PS-1/PS-2)

✓ Two (2) SEL 351S Protective Relay

✓ Two (2) Control Station

✓ Two (2) Test Switches

✓ Two (2) 5kV Circuit Breaker: Charge, Close and Trip

✓ Bus Insulation

Section 6 / Two 5kV Circuit Breakers

(PS-3/PS-4)

✓ Two (2) SEL 351S Protective Relay

✓ Two (2) Control Station

✓ Two (2) Test Switches

✓ Two (2) 5kV Circuit Breaker: Charge, Close and Trip

✓ Bus Insulation

Section 7 / Two 5kV Circuit Breakers

(PS-5/PS-6)

✓ Two (2) SEL 351S Protective Relay

✓ Two (2) Control Station

✓ Two (2) Test Switches

✓ Two (2) 5kV Circuit Breaker: Charge, Close and Trip

✓ Bus Insulation

Section 8 / Two 5kV Circuit Breakers

(PS-7/PS-8)

✓ Two (2) SEL 351S Protective Relay

✓ Two (2) Control Station

✓ Two (2) Test Switches

✓ Two (2) 5kV Circuit Breaker: Charge, Close and Trip

✓ Bus Insulation

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NOTE: As shown above, and visually observed during the Field Testing, there are PT’s in Section 1

(Master), Section 2 (Generator 1), Section 3 (Generator 2), and Section 4 (Generator 3).

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Testing Procedure

48vDC Power Supply

The first step was to provide a 48vDC power supply to simulate the eventual 48vDC station batteries.

This voltage is for the circuit breaker charging, trip and close, as well as other controls. -PTB4 and –

PTB5 had an additional open tap screen to allow us to connect our 48vDC without disturbing the existing wiring. This was applied as shown below to each Section.

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24vDC Power Supply

The second step was to provide a 24vDC supply to simulate the 24vDC battery bank that will be within the generator unit. This provides for starting of the generator as well as other controls, PLCs, relays, etc. within the switchgear. This was connected as shown below.

Note: As shown for -PTB1 and -PTB2, they are a common bus and we were able to connect our 24vDC supply to terminals #21 (+24vDC) and #51 (-24vDC), without disturbing the existing wiring.

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Dual DC Power Supply

A DC power supply was utilized to provide both the 48vDC and 24vDC simulated voltage, as shown below. We were also able to measure the 5kV circuit breaker charging current via the DC ammeter.

All circuit breakers charging current was less than 5 amperes – DC.

AC Simulated Fault Current Power Supply

To simulate fault current through the protective relays, a Westinghouse AC current source Test Set was utilized. This allowed for simulating the secondary fault current from the CTs (5 Amp full load secondary CT ratings) through each of the protective relays. This verified that the protective SEL relays, 86 lock-out relays, all control wiring between the relays and the circuit breakers, and the circuit breaker tripping functions were fully operational.

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Simulate Fault Current Injection was accomplished via the Switchgear Test Switches, by inserting the simulated fault current each phase, as shown below.

48/24vDC Component Energizing

By applying the 48vDC and 24vDC, we were able to observe all the PLCs, relaying, alarm annunciator, metering and controls to become energized. We were also able to activate the touch-screen display, as shown below. All electronic devices appeared fully operational.

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Control Wiring Review

During the first testing cycle on 02/27/25, we were able to simulate a trip on all eight (8) Feeder

Circuit Breakers and close these circuit breakers therefore allowing for the Protective Relay to initiate the trip function. This included sections 5, 6, 7 and 8. We were also able to energize all PLCs, touchscreen displays, relays, annunciators, etc. on this date.

For the Generator Sections 2, 3 and 4, due to the pre-wired controls, we were able to simulate the

Generator relays to initiate a trip signal, but we could not close the circuit breaker due to potential external required “close signals.” It was determined that we would review the systematic diagrams to determine where we could apply an external “close signal.”

Generator Breaker Trip Circuit Review

A review of the generator trip circuit indicated that the wiring of relay “CBTR” was such that a continuous 48vDC was being applied to the C-86 Lock-out relay, which was then closing the circuit to the “CB Shunt Trip.” This wiring was preventing us from closing any of the generator breakers.

This is shown below, where the contacts #3 and #7 are normally closed, therefore the CB Shunt Trip is continuously energized across terminals #9 and #10.

This wiring was corrected by connecting the wire at #7 to #5, therefore no longer providing a continuous trip signal to the “CB Shunt Trip.” Following this wiring change, all three (3) Generator breakers could be closed and tripped via the simulated fault current. The CBTR relay was identified on the schematic drawings and the wiring change was clearly labeled as shown below.

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The 1st photo below shows the wire connected at the #7, and the 2nd photo shows the corrected wiring with the #7 wire moved to the #5 terminal. This appears to have been a potential wiring error, therefore the wiring was left as shown in the 2nd photo (connection to Terminal #5), therefore allowing for future testing and operating of the Generator circuit breakers.

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Generator Breaker Close Circuit Review

A review of the generator close circuit indicated that an external signal was designed into the controls. As shown below, for the circuit breaker to close, 48vDC must be applied to terminal #7 of

NK-PSG-1. To accomplish this, the C-86 Lockout relay must be reset, which was accomplished by the wiring correction above. The CBCL “Circuit Breaker Close” relay must be energized by an external signal at RTUTB:7 and RTUTB: 8. In addition, 27DCC must be energized, which occurs when the 48vDC is present, and the DALM relay be energized. All components are shown below, except for the circuit to energize the DALM relay.

The circuit to energize the DALM relay is shown below, we need an external signal at RTUTB: 13 and

RTUTB: 14.

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Therefore, we need to apply an external signal at RTUTB:13 – RTUTB:14 to energize DALM, and an external signal at RTUTB:7 – RTUTB:8 to simulate the external close signal. As shown below, Terminal

Board “RTUTB” is on the right-hand side of the inside cabinet.

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Fail safe switches, which could only be activated (closed) with the Red-Handle raised were utilized to ensure that the external signal was only applied when intended.

Two separate switches were installed, with color coding to indicate the DALM close signal (blue) and the REMOTE CLOSE signal (yellow), as shown below.

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Field Testing Report of ASCO 5kV Switchgear Summary

Conclusion

The conclusion is that all critical components are in “like-new” condition and are fully operational, including the wiring, insulation and all other aspects of the equipment.

Project Required Testing

The above testing should also be performed during the following stages of the EMD Generator

Project.

a. 3rd party testing all existing equipment within the VA supplied ASCO 5kV Switchgear at the Storage facility prior to removal. All testing shall match the Field Testing identified in Attachment #4 - Field Testing Report of ASCO 5kV Switchgear: Dated May 14, 2025

(This report).

b. Shipment of the existing equipment to the facility of the Equipment Refurbisher.

c. Similar testing as performed as in "a" above to verify that no equipment has been damaged in shipment to the Equipment Refurbisher's facility.

d. At the Refurbishment facility, perform the following:

1) Replace all PLCs

2) Replace Touch-screen displays

3) Replace control relays

4) Replace protective relays and all other equipment to result in the operating modes required within these specifications.

5) Equipment which has not effectively changed in design since the original equipment was supplied, can be re-utilized after inspected and tested. This could include “Control Switches, Test Switches, Terminal Boards, Mounting hardware, and other miscellaneous components.

e. Following all modifications to the individual switchgear sections, connect all sections via the umbilical cords and perform the following testing:

1) Perform all testing similar to that performed as described in the Attachment

#4 - Field Testing Report of ASCO 5kV Switchgear: Dated May 14, 2025 (This report).

2) Perform Factory Acceptance Testing (FAT) as outlined in Drawings

f. Deliver and install all sections of the 5kV Switchgear as specified.

g. Perform all testing similar to that performed as described in the Attachment #4 - Field

Testing Report of ASCO 5kV Switchgear: Dated May 14, 2025 (This report).

h. Perform Site Acceptance Testing (SAT) as outlined in Drawings

i. Contractor shall complete all primary, secondary, metering, control and any other connections to complete ensure a fully operational emergency generator system.

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j. Contractor shall have a 3rd party also complete testing of all assembled equipment, including the 5kV Circuit Breakers, etc. to verify a fully operational emergency generator system.

Reference Materials:

Attachment #1 - Elementary 5kV Gear: 107 Sheets (ASCO Power Technologies, L.P. Drawings No.

572708

Attachment #2 - ASCO CAT Submittal: March 1, 2017: 61 Sheets (H.O Penn / CAT Power Systems

Document Transmittal Dated March 1, 2017 and associated drawings)

Attachment #3 - HO Penn Equipment in Storage: 86 Pages (H.O Penn / ASCO - List of Equipment to be supplied for this project that is currently in storage.

Attachment #4 - Field Testing Report of ASCO 5kV Switchgear: Dated May 14, 2025: 17 Pages (This report).

Please provide any questions and/or feedback.

Gabe Paoletti, P.E.

Cell: 609-970-3875