Building 65 Unit Substations SOW with Attachments 1 (1).pdf

Statement of Work (SOW) for

Building 65 Unit Substations Repair and Replacement

1. INTRODUCTION

1.1. The Structural Validation Branch (AFRL/RQVV) validates aerospace structures technology in Building 65, Wright-Patterson Air Force Base, for the Aerospace Systems Directorate (AFRL/RQ). The Branch utilizes several unit substations internally to the building which service a large deal of research loads, typical lighting and outlets, HVAC, and process cooling loads.

1.2. AFRL/RQVV also utilizes several secondary midsize panelboards to further distribute the power from one of these unit substations. Several of these panelboards need upgraded panels due to environmental conditions, breaker condition, location, and spare parts considerations.

2. DESCRIPTION

2.1. Substation 14 is a 3500KVA unit substation that converts 12.47KV to 480/277V 3 phase power. It is an early 2000’s vintage unit with bolt on bus secondary breakers that are currently testing outside of manufacture specification, and replacement breakers are no longer available.

Additionally, there is a distribution panel attached to the end of Sub 14 that has several breakers that failed during maintenance testing, along with others that tested outside manufacturing specifications. Lastly, the fan thermal controller has failed and is throwing constant temperature alerts and has been disconnected as it is constantly alarming without a fault present.

2.2. Substation 12 is a 1000KVA unit substation that converts 6.9KV to 480V 3 phase power. It is a 70’s vintage General Electric unit that has been scabbed together with secondary gear from a previous unit. Many of the secondary breakers in the unit have degraded in performance and currently test outside of manufacture specifications, and replacement breakers are no longer available.

2.3. PDP 480 TFE is a 1200A Cutler Hammer Panelboard of 70’s vintage that has several breakers testing outside of manufacturing specifications and requires a waterproof enclosure due to types of equipment near the unit.

2.4. Panel H is a 400A GE Panelboard of 2000’s vintage that is currently installed in an inaccessible location and needs relocated to be compliant with the NFPA 70 National Electric Code.

2.5. PDP 480 1EW2 is a 400A GE Panelboard of 2000’s vintage that has several breakers testing outside the manufacture specifications and utilizes breakers not consistent with the rest of building 65 and needs relocated to be compliant with the NFPA 70 National Electric Code.

3. GENERAL SCOPE

3.1. The contractor shall replace the fan controller, 2x bolt on bus large breakers, 1x bolt on buss medium breaker, and 8x stab on breakers of various sizes in Substation 14.

3.2. The contractor shall provide and install a new switchboard to replace Substation 12 main gear, Substation 12 480V distribution gear, Panel P, and Panel A4 in 115E.

3.3. The contractor shall provide a new 2000A Feed to the new switchboard in Section 3.2 from an existing breaker in Substation 11.

3.4. The contractor shall provide and install a new panelboard to replace existing 240V section of Substation 12 distribution gear in 115E.

3.5. The contractor shall provide and install 2 new panelboards to replace Panel H, these new panelboards will be relocated within M103E, and all new feeds will be provided to branch circuits.

3.6. The contractor shall provide and install a new panelboard to replace existing 480V PDP 480 TFE on the Test Floor, relocate an existing 480V panelboard, and provide and install a new 75KVA 480Y to 208Y transformer that will feed 2x 100A 208/120V Panelboards.

3.7. The contractor shall provide and install a new panelboard to replace existing 480V PDP 480 1EW 2 in the East Warehouse.

3.8. The contractor shall demolish existing gear that is no longer required in and around the locations of the new panels identified in Sections 3.2-3.7.

3.9. The period of performance for this work is 18 months from time of award.

4. APPLICABLE DOCUMENTS

4.1. NEC NFPA 70, National Electric Code National Fire Protection Association 70.

4.2. National Electrical Manufacturers Association (NEMA) standard 250.

4.3. American National Standard Institute/National Electrical Testing Association (ANSI/NETA)

Standard for Acceptance Testing Specifications for Electrical Power Equipment and Systems.

4.4. NFPA 70E, Standard for Electrical Safety in the Workplace.

4.5. OSHA 29 CFR 1910, Occupational Safety and Health Association Code of Federal Regulations, Part

1910.

4.6. DAFMAN 91-203, Department of the Air Force Manual 91-203 Air Force Occupational Safety, Fire, And Health Standards

4.7. Wright Patterson Air force Base Installation Facilities Standards (IFS) January 2023

4.8. RQ OI 32-10, Electrical Power Systems Operating Instructions in Building 65

4.9. Any documents listed above that are published by the DoD/USAF may be provided upon request.

5. GENERAL GUIDANCE

5.1. The contractor shall follow all applicable OSHA, NEC, and Air Force safety instructions during this contract effort.

5.2. The contractor shall ensure all installation methods do not compromise the integrity or exceed the weight limits of the existing structure or installations.

5.3. The contractor shall identify any existing installations that require relocation and report them to AFRL/RQVV, prior to any work being completed. If able to be relocated, a minimum of 10 business days be provided to the government to move said installations.

5.4. All installation of new conductors must have an insulation resistance test, completed on each leg, prior to energization. Evidence of these tests shall be delivered to AFRL/RQVV prior to completion of this contract.

5.5. All installation of new conductors shall have a maximum size of 500 mcm per the IFS.

5.6. All new breakers larger than 225A shall have an electronic trip unit from the factory per the RQOI.

5.7. All new breakers and panels shall be tested in compliance with NETA ATS-2021 and a report delivered to AFRL/RQVV prior to completion of this contract.

6. Panel Location References

6.1. Substation 14 is in the main sub room (1ET) on the ground floor.

6.2. Substation 12 is in the FIRST lab Room 115E on the ground floor, this room also contains Panel P, Panel A4, and the 240V transformer and distribution gear.

6.3. PDP 480 TFE is located on the main test floor along the East wall behind the waterjet cutter.

6.4. Panel H is located on the mezzanine above the FIRST lab, on the West wall between the crane rail and the wall. Most of the loads fed by this panel exist in the same space.

6.5. PDP 480 1EW 2 is in the machine shop along the East wall underneath the staircase behind the hydraulic pump.

6.6. Substation 11 is in the second-floor electrical room (2ET), this room also contains the MV air switch currently feeding Substation 12.

6.7. See Attachment 1 for more information about the existing gear or their locations.

7. DETAILED SCOPE OF WORK

7.1. SUBSTATION 14 RETROFIT

7.1.1. PE Bolt on Breakers

7.1.1.1. The contractor shall retrofit the two existing secondary breakers marked MCC-1 and MCC-2 by replacing them with draw out MasterPact NW 20 H1 2000A breakers with cradles. This includes all wired and bus connections internal to the unit. These breakers shall be interchangeable with the secondary breakers in Substations 1- 9 in the same room. These breakers shall have an electronic trip unit with LSIG settings and Ammeter readings.

7.1.1.2. Front doors surrounding these breakers shall be either trimmed out in a code compliant matching surround or they shall be replaced with new doors made to fit the new breaker surround.

7.1.2. MEL Bolt on Breakers

7.1.2.1. The contractor shall upgrade the existing secondary breaker marked FIRE PUMP to a current generation Square D breaker. The new breaker shall have interrupt rating (480v KA rating) and adjustability (I.E. LSI/LSIG/etc…) equal to or greater than the existing breakers to be replaced.

7.1.2.2. Front doors surrounding this breaker shall be either trimmed out in a code compliant matching surround or they shall be replaced with new doors made to fit the new breaker surround.

7.1.3. Distribution I-Line Breakers

7.1.3.1. The contractor shall replace 8x secondary breakers in the distribution gear on the end of

Substation 14 with current generation Square D I-Line breakers. The new breakers shall have interrupt rating (480v KA rating) and adjustability equal (IE LSI/LSIG/etc…) to or greater than the existing breakers to be replaced **

7.1.3.2. The contractor shall cover any exposed spaces created by this breaker replacement with panel space covers to match the existing.

**NOTE – The existing breaker labeled ACCOMP-1 is currently a temporary replacement and the specs for this breaker shall be equivalent to the replacement of breaker ACCOMP-2

7.1.4. Thermal protection fan Controller

7.1.4.1. The contractor shall retrofit the existing fan controller and associated wiring on the transformer fans with a Square D Model 98A Digital Temperature Controller.

The existing is a Model 98 Digital Temperature Controller that has failed.

7.1.4.2. The contractor shall replace any thermocouples or temperature probes found to be failed along with the controller.

7.1.4.3. The contractor shall test the temp controller system in compliance with NETA ATS-2021 and a report shall be provided to the government (AFRL/RQVV).

7.2. SUBSTATION 12 REPLACEMENT

7.2.1. The contractor shall provide a new Square D QED-2 Switchboard with the specs:

- Enclosure and all breakers shall be rated at 480Y/277V 3Ph 4W 60Hz Wye Grounded SCCR: 65kA.

- Fully Rated NEMA 1 Enclosure

- Main Breaker 2000AS/2000AT/3P RK with LSIG and ZSI

- Ground Bar and Mains rated at 2000A Copper: Silver Plated

- 144 Inches of Mounting Space

- Wired for ZSI compatibility

- The following breakers shall be used to replace breakers in the existing panel, and to merge loads from existing Panel P:

o 1x – 600A 3P LJ Frame Breaker with LSIG settings and ZSI o 3x – 400A 3P LJ Frame Breakers with LSIG settings and ZSI o 2x – 250A 3P JJ Frame Breakers with LSI settings and ZSI o 2x – 125A 3P HJ Frame Breakers o 2x – 100A 3P HJ Frame Breakers o 1x – 60A 3P HJ Frame Breaker o 9x – 30A 3P HJ Frame Breakers

- The following breakers shall be included as spare breakers:

o 1x – 800A 3P MJ Frame Breaker with LSIG settings and ZSI o 2x – 400A 3P LJ Frame Breakers with LSIG settings and ZSI o 2x – 250A 3P JJ Frame Breaker with LSI settings and ZSI o 2x – 125A 3P HJ Frame Breakers o 2x – 100A 3P HJ Frame Breakers o 2x – 60A 3P HJ Frame Breakers o 1x – 30A 3P HJ Frame Breaker

- This Panel shall be labeled PDP 480 115E.

7.2.2. The contractor shall install this panel in the location shown in Attachment 2 behind (West of) the existing Substation 12.

7.2.3. The contractor shall add wireway above and to the North of the panel as shown in Attachment

2. The purposes of these are to: reduce outage times required for feeds being added, and to increase the amount of wall space available for pulling existing loads. This wireway shall be connected to the existing panels with 6” and 4” pipe nipples as shown.

7.2.3.1. This installation shall occur prior to the removal of Substation 12 to permit the transitions of loads from one live panel to another. See Section 8 of this document for an anticipated workflow of shifting these loads.

7.2.3.2. This panel shall be installed atop a raised 4” concrete housekeeping pad. Pad shall be built in accordance with common industry practices.

7.2.4. The contractor shall remove the existing panel labeled A4 and the associated disconnect to the left of this panel. Both panels shall be returned to the government (AFRL/RQVV).

7.2.5. The contractor shall remove the existing 480V Delta to Wye 277V Transformer that is hung in the air and return it to the government (AFRL/RQVV). The contractor shall refeed the existing 480Y/277V Lighting panel with a new feed from PDP 480 115E.

7.2.6. The contractor shall refeed all remaining existing 480V loads, currently fed by Unit Substation 12 and Panel P, to PDP 480 115E.

7.2.6.1. Any power outages will need to be coordinated with the government (AFRL/RQVV) at least

2 weeks in advance. See Section 8 of this document for an anticipated workflow of shifting these loads.

7.3. 2000A FEED TO PDP 480 115E

7.3.1. The contractor shall provide a new 2000A Feed to provide power to the new panel (PDP 480 115E) in section 7.2. This feed shall be fed from the currently spare 2000A breaker in Substation 11.

7.3.1.1. This new feed shall be installed with the following requirements:

- Conduit shall be of a Rigid threaded metallic conduit, with grounding bushing installed and connected at penetrations to all panels and tap boxes.

- Conductors shall be copper with an XHHW-2 type jacket and sized per the

75° C column of Table 310.15(B)(16) of the NFPA 70 National Electric Code.

- Conductors shall be a maximum size of 500MCM in accordance with the

WPAFB IFS 2023.

7.3.1.2. This power feed shall be accompanied by a Zone Selective Interlock compatible communication feed between Substation 11 and the new panel (PDP 480 115E).

7.3.1.3. The general location for the path of this new feed is shown in Attachment 3

7.4. NEW PANEL PDP 240 115E

7.4.1. The contractor shall provide a new Square D I-Line Panelboard:

- Enclosure and all breakers within shall be rated at 480V 3Ph 3W 60Hz

- Fully Rated NEMA 1 Enclosure

- Main Breaker 600AS/600AT/3P LJ with a Micrologic 6.0A

- Ground Bar and Mains rated at 600A Copper: Tin Plated

- 72 Inches of Mounting Space

- The following breakers shall be used to refeed loads in the existing sub 12

240V section.

o 2x – 200A 3P JJ Frame Breakers o 1x – 30A 3P HJ Frame Breaker

- The following breakers shall be included as spare breakers.

o 1x – 200A 3P JJ Frame Breaker o 1x – 125A 3P HJ Frame Breakers o 6x – 100A 3P HJ Frame Breakers o 4x – 60A 3P HJ Frame Breakers o 3x – 30A 3P HJ Frame Breakers

- This Panel shall be labeled PDP 240 115E.

7.4.2. The contractor shall install PDP 240 115E as shown in Attachment 4 of this document.

7.4.3. The contractor shall relocate the existing T225 240 115E to above PDP 240 115E as shown in

Attachment 4 of this document. Supports shall be sized to support the full weight of the transformer.

7.4.4. The contractor shall provide a new 350A 480V feed to T225 240 115E from PDP 480 115E.

7.4.5. The contractor shall provide a new 600A 240V feed to PDP 240 115E from T225 240 115E.

7.5. RELOCATE AND REPLACE PANEL H

7.5.1. The contractor shall provide TWO new Square D NF panelboards with the following specs:

- Specs, location, and load sharing shown in Attachment 5

- Enclosure and all breakers within shall be rated at 480V/277 3Ph 4W 60Hz

Wye Grounded SCCR: 65kA.

- Fully Rated NEMA 12 Enclosure

- Main Breaker 250A 3P JJ Circuit with Micrologic 6

- Ground Bar and Mains rated at 250A Copper: Tin Plated

- 42 Breaker Spaces panel. These shall be split among the two panels.

o 1x – 80A 3P EJB Breaker o 2x – 60A 3P EJB Breakers o 2x – 40A 3P EJB Breakers o 1x – 25A 3P EJB Breaker o 3x – 20A 3P EJB Breakers o 7x – 15A 3P EJB Breakers o 1x – 80A 3P EJB Breaker o 2x – 30A 3P EJB Breakers o 1x – 25A 3P EJB Breakers o 3x – 20A 3P EJB Breakers o 1x – 15A 3P EJB Breaker o 12x – 20A 1P EJB Breakers

7.5.2. The contractor shall install TWO new 400A 480Y/277V 3Ph 4W feed to these panels from the new panel (PDP 480 115E) in section 7.2. These new feeds shall be installed with the following requirements:

- Conduit shall be of a Rigid threaded metallic conduit, with grounding bushing installed and connected at penetrations to all panels and tap boxes.

- Conductors shall be copper with an XHHW type jacket and installed per the 75° C column of Table 310.15(B)(16) of the NFPA 70 National Electric Code

7.5.3. The name of the new panels shall be known as PNL 480 M103E 1 & PNL 480 M103E 2 on all nameplates and breaker labels.

7.5.4. All loads currently existing on Panel H shall be transferred to PNL 480 M103E 1 & 2 by running new conduit and wire for each load. Existing conduits may be used for VAV 1&2.

7.6. Replace Panel PDP 480 TFE

7.6.1. The contractor shall remove and replace the existing panel with a Square D I-Line panelboard with the following specs:

- Enclosure and all breakers within shall be rated at 480V 3Ph 3W 60Hz Wye

- Fully Rated NEMA 12 Enclosure

- Main Breaker 600AS/600AT/3P LJ Circuit with a Micrologic 6.0A trip unit o Zone Selective Interlocking back to PDP 480 115E

- Ground Bar and Mains rated at 600A Copper: Tin Plated

- 99 Inches of Mounting Space panel.

o 1x – 200A 3P HJ Frame Breaker o 2x – 125A 3P HJ Frame Breakers o 1x – 100A 3P HJ Frame Breakers o 1x – 60A 3P HJ Frame Breaker o 2x – 30A 3P HJ Frame Breakers o 1x – 20A 3P HJ Frame Breaker o 2x – 400A 3P LJ Frame Breakers with LSI settings o 3x – 100A 3P HJ Frame Breakers o 2x – 70A 3P HJ Frame Breakers o 2x – 60A 3P HJ Frame Breakers o 2x – 30A 3P HJ Frame Breakers

7.6.1.1. This Panel shall be installed atop a raised 4” concrete housekeeping pad. Pad shall be built in accordance with common industry practices.

7.6.2. Upon removal, all breakers currently installed in this panel shall be returned to the government (AFRL/RQVV).

7.6.3. The contractor shall relocate T75 208 1EW 1 (See Section 7.7) to the South most alcove on the East wall of the test floor. See Attachment 6 for locations. This transformer shall be named T75 208 TFE 3. This transformer shall be fed by PDP 480 TFE and shall feed PNL 208 TFE 4 and PNL 208 2EM 2.

7.6.4. The contractor shall remove T45 208 TFE transformer (immediately to the left of Panel PDP 480 TFE) and return it to the government (AFRL/RQVV).

7.6.5. The contractor shall remove T75 277 TFE transformer from the wall and return it to the government (AFRL/RQVV).

7.6.6. The contractor shall relocate the 480Y/277V 125A panel from the existing column to the South most alcove on the East wall of the test floor. See Attachment 6 for locations.

7.6.7. All existing wiring shall be evaluated for reuse, any wires recommended for replacement shall be brought to the attention of the government (AFRL/RQVV).

7.7. Replace Panel PDP 480 1EW 2

7.7.1. The contractor shall remove and replace the existing panel with a Square D I-Line panelboard with the following specs:

- Specs and Location are included in Attachment 7

- Enclosure and all breakers within shall be rated at 480V 3Ph 3W 60Hz Wye

Grounded SCCR: 65kA.

- Fully Rated NEMA 12 Enclosure

- Main Breaker 400AS/400AT/3P LJ Circuit with a Micrologic 6.0A trip unit

- Ground Bar and Mains rated at 400A Copper: Tin Plated

- 72 Inches of Mounting Space panel.

o 1x – 250A 3P JJ Frame Breaker with LSI settings o 1x – 100A 3P HJ Frame Breaker o 1x – 30A 3P HJ Frame Breakers o 2x – 225A 3P JJ Frame Breakers o 1x – 100A 3P HJ Frame Breaker o 2x – 60A 3P HJ Frame Breaker o 3x – 30A 3P HJ Frame Breakers

7.7.2. All existing wiring shall be evaluated for reuse, any wires recommended for replacement shall be brought to the attention of the government (AFRL/RQVV).

7.7.3. The existing breakers in PDP 480 1EW 2 shall be returned to the Government (AFRL/RQVV).

7.7.4. Transformer T75 208 1EW 1 and PNL 208 1EW 1 shall be removed and any active loads shall be transferred to PNL 208 1EW 2. The transformer shall be reutilized in Section 7.6.

7.7.5. The new location for PDP 480 1EW 2 will require a splice to be added to the existing feed conductors. The box required for the splice is already present and may be utilized for the splice.

7.7.5.1. The splice shall be crimped with a hydraulic crimper and sealed with cold shrink.

7.7.5.2. The conductors used in the extension shall be of the same type and size as the existing conductors feeding the current panel.

7.8. Remaining Demo

7.8.1. The contractor shall remove the following equipment once it has been decommissioned through completion of other tasks. Demo of any gear shall include all conduits terminated into the gear back to the next tap box/panel or to their end in the case of abandoned in place feeds.

7.8.1.1. Substation 12 in its entirety, including both distribution panels attached to the North end of the secondary section.

7.8.1.2. Medium Voltage feeder conduit, cable, hangers, and all hardware for the feeder of Substation 12 back to above the FIRST lab. All cables shall be disconnected from Air switch, and terminated in a ta

7.8.1.3. Panel A4 and Fused disconnect (immediately to the South of A4) shall be removed from 115E and turned back over to the government (AFRL/RQVV).

7.8.1.4. Panel P in its entirety

7.8.1.5. Panel H in its entirety

8. SCHEDULE

8.1. It is important that this replacement effort has minimum effects to the mission of AFRL in Building

65. A phased approach with coordination with building occupants is anticipated in the following order. Alterations to this scheduled will be considered but must be brought to the attention of the government (AFRL/RQVV) at least 60 days in advance of the work being completed. NOTE: Items in RED will be subject to weekend power outages.

8.1.1. Equipment Procurement – Expected to be longest schedule driver in this project.

8.1.2. Housekeeping Pad Pours – These can almost be done immediately as no demo would be required from current state.

8.1.3. PDP 480 115E 2000A Feeder Install – The majority of this run can be done during the work week except for landing the conduits and wires into Substation 11.

8.1.4. Panel A4 and Disconnect Removal – Current Loads have been removed from this panel.

8.1.5. PDP 480 115E Install – Placement of this unit will not impact operation of Substation 12.

8.1.6. PDP 480 115E Power Up – Will require weekend outage of Substation 11 to land wiring.

8.1.7. PDP 480 TFE Install – New panel will utilize a feed from PDP 480 115E, wiring may need replaced. This panel can schedule a weeklong outage to accomplish during the week.

8.1.8. T75 208 1EW 1 Removal – Transformer to be relocated and used in 8.1.9.

8.1.9. T75 208 TFE 3 Install – Location of new transformer will split feed 2x 100A 208Y/120V Panels.

8.1.10. PDP 240 115E Panel and Remaining Sub 12 Loads – Need moved in a coordinated order to make sure critical loads are not powered down during the work week. Weekend work shall be required here.

8.1.11. PNL 277 TFE Relocate – 4 Wire install requires PDP 480 TFE before removal of Delta to Wye Transformer. This panel can schedule a weeklong outage to accomplish during the week.

8.2. The following tasks are less order critical as they do not require any prework to be completed.

8.2.1. Substation 14 Retrofits – This unit is available for upgrades and would need to be completed on a weekend power outage.

8.2.2. PDP 480 1EW 2 Replacement – This panel replacement is independent of the other items on this list and shall be scheduled separately.

9. List of Parts to Return to Government (Reference)

9.1. The following list shall serve as a compendium of all equipment removed during the scope of this contract that shall be returned to the Government (AFRL/RQVV) prior to completion of the contract.

9.1.1. Substation 14 – All Removed Breakers

9.1.2. Substation 12 – All of the following

- All Breakers in North Most Distribution Sections (GE Thermo-mag) in 115E.

- 480V Delta to 480/277V Wye Transformer hanging in air in 115E.

- Panel A4 and Attached Disconnect in 115E.

9.1.3. Panel P – Panelboard and all Breakers

9.1.4. Panel H – Panelboard and all Breakers

9.1.5. Panel PDP 480 TFE – All of the following:

- All Breakers

- 45kVA 208/120Y Transformer

- 75kVA 480V Delta to 480/277V Wye Transformer

9.1.6. Panel PDP 480 1EW 2 – All Breakers.

10. Attachment List

10.1. Attachment 1: General layout of building and Equipment

10.2. Attachment 2: Details of PDP 480 115E

10.3. Attachment 3: Details of 2000A Feeder Run

10.4. Attachment 4: Details of PDP 240 115E

10.5. Attachment 5: Details of PDP 480 M103E 1&2

10.6. Attachment 6: Details of PDP 480 TFE

10.7. Attachment 7: Details of PDP 480 1EW 2