B01_08_SOW_-_MTAO_Excitation_System_Upgrade_2.pdf

Excitation System Upgrade Solicitation No. 140R6025Q0047

STATEMENT OF WORK

1.0 Background

The Canyon Ferry and Yellowtail Powerplant generating units both utilize a static excitation system. The Canyon Ferry excitation system is Eaton ECS2100 model and was installed in

2011. The Yellowtail excitation system is a Cutler Hammer ECS2100 model and was installed in 2005. The existing front-end hardware is beyond the serviceable life and no longer supported.

2.0 Definitions

CO: Contracting Officer

COR: Contracting Officer Representative

HMI: Human Machine Interface

IDP: Interactive Display Panel

ECM: Excitation Control Module

SIM: Sensor Input Module

FCIM: Firing Control Interface Module

BCM: Bridge Control Module

STATEMENT OF WORK

1.0 Background

2.0 Definitions

3.0 Principal Components of Work

4.0 Use of Site / Site Security

5.0 Existing Equipment

6.0 New Replacement Equipment Requirement

7.0 Statement of Work

8.0 Drawings

9.0 Safety

10.0 Special Work Permit

11.0 Schedule

12.0 Training

Excitation System Upgrade Solicitation No. 140R6025Q0047

3.0 Principal Components of Work

The major portion of this work shall be furnishing all new components as outlined in this

Statement of Work and delivering those components to site once all preliminary work and components are available and complete. Under coordinating schedules, the contractor removes all existing control components, install the modern equipment, implement, and provide latest configuration and setting files, test, and commission the exciters for each generating unit at each facility. The contractor is to provide all labor, tools, parts, materials, designs, drawings, manuals, software, configuration files and transportation to and from Canyon Ferry and

Yellowtail Powerplant.

4.0 Use of Site / Site Security

A. The work is located at Canyon Ferry and Yellowtail Powerplant.

a. Canyon Ferry is located at 4000 Riverside Rd. Helena, MT 59602 approximately 20 miles east of Helena, in Lewis and Clark County, Montana.

b. Yellowtail Powerplant is located approximately 43 miles southwest of Hardin, in Big

Horn County, Montana.

B. Do not interfere with work of other contractors or the Government in vicinity, or with reservations made by the Government.

C. Contractor authorized work hours:

1. Canyon Ferry Powerplant:

a. Monday through Thursday 6:30 a.m. to 5:00 p.m.

2. Yellowtail Powerplant

a. Monday through Thursday 7:00 a.m. to 5:30 p.m.

3. Alternate work schedules may be approved, including Friday and weekend work, with written notice provided 7 working days in advance when the proposed work is contemplated outside of the normally authorized work hours at each facility. Approval of requests are not a basis for future request approval.

4. Night work will not be allowed at either facility.

5. No work will be allowed during Federal holidays or Sundays at either facility.

D. Site Security Requirements:

1. At least 10 days prior to arrival provide a list of employees and/or vehicles arriving at the job site. Provide approved identification information for each employee and vehicle.

Update the list at least 10 days prior to arrival for any person or item not previously listed.

2. All contractor and subcontractor employees must be U.S. citizens or possess valid documentation authorizing them to work in the United States.

3. The Government may perform background checks on any or all workers and deny access to any worker.

4. All vehicles company owned and privately owned are subject to search. All company owned and privately owned equipment, bags, boxes, etc. are subject to search.

5. The Government will control access to the worksite to authorized persons with proper identification.

6. Privately owned contractor and subcontractor vehicles shall park at a site designated by the COR or a site designated representative.

Excitation System Upgrade Solicitation No. 140R6025Q0047

7. In case of emergency, all contractor and subcontractor personnel will follow emergency instructions provided by the Reclamation Representative.

8. All firearms and dangerous weapons are prohibited in federal facilities by all persons not specifically authorized by Title 18, United States Code, Section 930.

9. Any violations of security requirements and/or restrictions may result in prohibiting contractor and subcontractor access to the federal facility at any time.

5.0 Existing Equipment

A. System configuration files and code will be made available after award to facilitate system retrofit. It is anticipated that a configuration file will exist for each component for each unit.

B. Canyon Ferry (3-unit facility)

1. 3 separate excitation control systems (1 each generating unit)

2. Single channel configuration

3. Multi control board design

4. Utilize BESTCOMs

5. PanelMate HMI for IDP1500

6. Single bridge

C. Yellowtail (4-unit facility)

1. 4 separate excitation control systems (1 each generating unit)

2. Dual channel configuration

3. Multi control board design

4. Utilize BESTCOMS

5. PanelMate HMI for IDP1500

6. Dual bridges

6.0 New Replacement Equipment Requirement

A. Control Module Design: Single

B. Voltage Regulation accuracy minimum: 0.1%

C. Utilize existing control board terminations and connectors.

D. Control module to fit within existing control board footprint without additional modification to equipment not being replaced.

a. Utilize retrofit L-bracket to ensure existing mounting provisions and cabling can be utilized.

E. Simulation Tool

F. Autotuning of the PID controller

G. IRIG-B signaling input and available time stamping

H. Time Response performance screen

7.0 Statement of Work

It is the intent of this work to perform a front-end upgrade of the existing ECS-2100 voltage regulators to the DECS-2100 voltage regulators by retrofitting new control boards and HMIs on

Yellowtail generator units 1-4 and Canyon Ferry generators 1-3. This may include the bridge control module(s). In addition to supplying the required hardware, software, and configurations, Excitation System Upgrade Solicitation No. 140R6025Q0047 work will include removal of existing hardware, installation, commissioning, and training of new hardware. The existing bridge control module(s) for retrofit to the BCM-2 will be identified at the time of award. See section 11.0 Schedule as it pertains to availability of units to perform work.

This requirement must meet the following criteria:

1. Research of the existing Generator Control System to finalize Installation Details.

2. Provide the current version of Basler BESTCOMS™ Pro Controller configuration tool

3. Replacement equipment must fit within existing equipment footprint that is to be replaced.

4. Auto tuning of control loops

5. Must use existing rectifier bridge

6. Compatible with existing analog to digital I/O boards

a. Plug and play replacement

b. Use of signaling converters in terms of media or protocol in order to facilitate retrofit with new hardware to be compatible with existing analog to digital I/O is not permitted.

7. Removal of the existing ECS-2100 control equipment and installation of the new Basler

Electric DECS-2100 Front-End Retrofit.

8. Supply any additional cabinet wiring, which may be needed, regarding the installation of the new Basler Electric Exciter System.

9. Provide the “Interface Design” of the new Systems including:

a. Provide all revisions to the existing Elementary System Drawing Package of the

Generator Control and Voltage Regulator Systems.

b. Connection details for all new devices as supplied by contractor to be installed in the new Regulator Control Panel.

c. System Connection Drawings.

d. Wiring Lists of wires to be removed, wires to be reused and new wire to be added.

e. Interface details for direct connection of the new excitation equipment to the existing Control System and details on existing equipment to be removed from service.

f. Voltage Regulator Control System Settings.

g. Digital Documentation Package to include.

▪ a. Instruction Manuals for all equipment of the new Basler Electric Systems.

▪ b. As Built Digital Drawings (per above in items 9a – 9f), supplied in

AutoCAD (dwg format).

10. Provide On-Site Turnkey Services by Basler factory trained Technical Expert with regard to the Installation, Connection and Interconnection of the new Basler Electric Systems.

a. Remove the ECS2100 equipment.

b. Install the new DECS-2100 Front-End retrofit in the existing exciter cabinet.

c. Provide System Checkout / Testing of all new equipment, devices and interconnection cables.

11. Provide System Startup Services

a. Shut-down (Unit at standstill) checks with external equipment – DCS, Remote

Switches, etc.

Excitation System Upgrade Solicitation No. 140R6025Q0047

b. Off-Line (Rated Speed No-Load) Set-Up and Testing of the new Voltage Regulator

Control System.

c. On-Line (With Load) Set-Up and Testing of the new Voltage Regulator Control

System

12. Provide the “final” System Startup Report with regard to the commissioning of the new

Basler Electric Type DECS-2100 System, including software settings/configurations.

13. On-Site Commissioning Tests

a. Pre-Excitation System Checks (Unit @ Standstill)

▪ Wire Checks / Ground Checks of the new System

▪ Control I/O Testing & Sequence Testing

▪ Loss of PT Signal Transfer Testing

▪ Excitation Simulation Checks (Dummy Load Test)

▪ Current & Voltage Signal Injection

▪ Unit Annunciation Alarm Checks

▪ DCS Interface Checks

▪ System “Trip” Tests

▪ DECS Module Software Setup

b. Off-Line, Full Speed No-Load System Checks

▪ AVR “Automatic Voltage Regulator” Start Sequence

▪ FCR “Field Current Regulator” Start Sequence

▪ AVR Step Response Testing & FCR Step Response Test

▪ Off-Line OEL Overexcitation Limiter Stability Step Test

▪ Saturation Curve Testing

c. On-Line System Tests

▪ AVR Step Response Test & FCR Step Response Test

▪ On-Line OEL Overexcitation Limiter Stability Step Test

▪ UEL Under-excitation Limiter Settings & Stability Step Test

14. Install new configuration files and validate settings.

15. Test new configurations and settings.

16. Ensure functionality of install configurations, settings, and code where applicable before system startup and commissioning.

17. Provide onsite technical assistance during system startup and commissioning.

18. Provide all as-left configurations, settings, files, and code following commissioning.

19. Provide new nameplate for each cubicle door.

20. Provide training as required. See section 12.0

8.0 Related Drawings

A. Drawings are for informational purposes only.

B. See Appendix A of drawing list and drawings.

Excitation System Upgrade Solicitation No. 140R6025Q0047

9.0 Safety

The Contractor shall comply with all federal, state and local laws and standards as well as the

Bureau of Reclamation manual Reclamation Safety and Health Standards (RSHS). The

Contractor should plan to download or view the electronic version of the RSHS manual at no charge from the Bureau of Reclamation web site at:

https://www.usbr.gov/ssle/safety/RSHS/rshs.html

The required safety documents are a written safety plan (site specific) and a job hazard analysis. These documents will be approved by the Government, prior to the start of onsite work. RSHS Appendix A and Appendix B provide excellent descriptions of how to write a safety plan and how to write a job hazard analysis. The site safety plans shall be submitted at least 90-days before site work is to start.

The contractor will be required to participate in each facility’s hazardous energy control program (F-HECP). Program documentation and material will be made available after award.

At the beginning of the site work (each facility separate), the contractor will be provided an orientation by a Bureau representative on the F-HECP Lockout/Tag procedure.

Prior to commencing work the contractor will be required complete a Special Work Permit

(SWP). This will be completed in conjunction with a Bureau representative. The SWP will detail the specific equipment that is intended to be worked on. Due to the coordinating schedules covering multiple units and facilities, there will be multiple SWP throughout the execution of the work.

10.0 Contractor Qualifications

Must be Basler factory trained technicians to perform all work. The technicians should be able to provide Basler certifications or Basler Identification.

11.0 Special Work Permit

At each powerplant location the powerplant supervisor and powerplant operator will prepare a special work permit regarding the site work. The contractor will be required to sign and abide by the instructions in a special use permit spelling out what areas of the power plant and dam the contractor will be allowed to work in. It is critical that the contractor remain in work areas necessary to accomplish the work requirement. The special use permit will also identify any unusual hazards that might exist in the construction areas.

In the case of a fire alarm, drill or actual fire, all contractor personnel must report to the designated muster area.

https://www.usbr.gov/ssle/safety/RSHS/rshs.html

Excitation System Upgrade Solicitation No. 140R6025Q0047

12.0 Schedule

Work to be performed is to be coordinated with planned unit outages. Unit outages and sequencing may change after award. It is anticipated that only one unit will be available per week to facility commissioning and startup. Government may adjust outages and unit work to facilitate up to 2 units at a time based on request by contractor and after demonstrating successful commissioning and startup functions. It is not anticipated that unit commissions at each facility can or will occur within a single week.

January February March April

Installation wk wk wk wk wk wk wk wk wk wk wk wk wk wk wk wk

Canyon Ferry

Install - 1st

Install - 2nd

Install - 3rd

Yellowtail

Install - 1st

Install - 2nd

Install - 3rd

Install - 4th

13.0 Training

A training class shall be provided after the retrofits have all been completed and the equipment returned to operational state. This training shall be hosted once at Yellowtail and once at Canyon

Ferry. The training shall accommodate up to 8 individuals at each location, minimum. Training shall minimally address the following topics:

1. DECS2100 Equipment overview

2. Functionality and detail description of the individual components

3. Theory of Operation

4. Interactive Display Panel screen access, navigation, features, descriptions of function, alarms and control actions.

5. Maintenance functions and schedules associated with new hardware.

6. BestCOMs Software

a. Overview of the software and purpose

b. Navigation of the software for routine tasks

c. Connecting to the hardware

d. Troubleshooting and configuration

e. Simulation and Testing