Swbd_SpecLibertyPW3A.pdf

Technical Specification Enclosed Vertical Switchboard with Rear

Hinged Door and Associated Devices Liberty Substation, Panel CHG15

Revised May 22, 2015

- TECHNICAL SPECIFICATION

VERTICAL SWITCHBOARD AND ASSOCIATED DEVICES

TABLE OF CONTENTS

1. GENERAL

2. MATERIAL

3. CONSTRUCTION

4. TESTS

5. PAINT

6. DESIGN AND MANUFACTURING PROGRESS REVIEW MEETINGS

7. DRAWINGS, DATA, AND ELECTRONIC MEDIA

8. INSPECTION

9. DELIVERY CONTACTS & LOCATION

10. CONTRACT DRAWINGS

1. GENERAL: All equipment furnished under this procurement shall be in accordance with the best modern practice and shall conform to the latest applicable standards of the American National Standards Institute, Inc. (ANSI), the Institute of Electrical and Electronic Engineers, Inc. (IEEE), and the National Electrical Manufacturers Association (NEMA), as to design, construction, performance, and tests unless otherwise specified herein. In the event of contradictory requirements between the ANSI, NEMA, or IEEE standards and these requirements, the terms of these requirements shall apply.

A. The Contractor shall construct the control switchboards at the contractor's plant and shall deliver the control switchboards to the specified delivery location ready for installation. Switchboard sections shall each be constructed as separate panels. All incoming and outgoing cables shall enter the equipment from below via cable trench.

B. Devices to be furnished under this procurement, as described in the arrangement drawings, shall be mounted as shown and wired in accordance with the schematic and wiring diagrams provided under this contract.

C. This specific order also includes unloading by the supplier, with delivery being specified as “FOB Destination Within Consignee’s Premises.”

2. MATERIAL: Equipment required for the switchboard(s) shall include all items specified on the material list.

A. Materials shown on all attached drawings including the arrangement plan and switchboard assembly drawings which are not identified as Government or Western-furnished are typical and shall be furnished by the Contractor. The Contractor may furnish materials other than those shown subject to approval by the Contracting Officer.

(1) If the Contractor proposes to furnish materials different from those shown on the drawings, the Contractor shall mark two sets of prints of all affected drawings (including arrangements, material lists, schematics, and wiring diagrams) and submit them to the Contracting Officer for approval in accordance with the drawings and data paragraph.

B. Government/Western-furnished material will be sent to the contractor as stated in Table B. The Contractor shall inventory and acknowledge by letter receipt of Western-furnished devices within 10 days.

C. The Contractor shall ship spare parts (both Contractor-furnished and Government/Western-furnished) with the switchboards.

D. Switchboard Wiring:

(1) All wiring within each switchboard panel shall be furnished as switchboard type stranded No.

14 AWG copper conductor, with gray SIS insulation rated for 600-volt service and which passes the VW-1 vertical flame test. The stranding for general switchboard wiring shall be class K (41/30) stranded.

(2) The wiring between the heavy duty 125 volt direct current terminal blocks and to the source side of the 125 volt direct current circuit breakers shall be sized according to the 50 Ampere rating of the 125 volt direct current breaker supplying the switchboards.

(3) All terminations of wire shall be made with pre-insulated, pressure-crimp type ring-tongue terminal connectors, applied with a compression tool that requires full compression before releasing.

a. To insure positive electrical connections, and to avoid damage to the ferrule, it is mandatory that the proper crimping tool be used in accordance with the instructions for its use. The proper terminal and crimping tool shall be used for each wire size.

b. Ring tongue terminal connectors shall be equal to the pre-insulated PLASTI-GRIP

Terminal, as manufactured by TYCO (AMP) Incorporated, Harrisburg, PA, 17105, phone 717-564-0100.

c. The crimping tool, used to apply these terminal connectors, shall be equal to the TETRA-

CRIMP Tooling as manufactured by TYCO (AMP) Incorporated, and as recommended by the manufacturer of the ring tongue terminal connectors being furnished and installed by the Contractor.

(4) A wire-way duct system, consisting of overhead horizontal wire-ways and vertical wire-ways in the side-sheets, with removable covers shall be provided for the wiring within a panel.

These wire-ways shall allow cabling from side to side of the panels, and vertically from the floor to the top of each switchboard panel.

a. All wiring within the wire-ways shall be completely accessible for operation, maintenance, removal, and replacement. The wire-way system shall be designed with capacity for wire for all devices, present and future, that can practicably be mounted on the panel.

b. The removable covers shall be completely accessible for removal and replacement. No wiring within or external to the wire-ways shall be attached to the covers.

(5) Exposed wiring (e.g., not inside a wireway) shall be kept to a minimum. Where used, exposed wiring shall be formed into compact groups bound together and firmly supported.

Exposed wiring shall be run straight, horizontally, or vertically with short-radius right-angle bends.

(6) Hinge wiring shall be twisted around the longitudinal axis of the wire, wherever possible, instead of being bent laterally.

(7) Each wire shall be protected from abrasion where it leaves a channel or wire-way. Grommets shall be provided at all holes and all elliptical slots furnished for wires and cables, including holes provided for Western-furnished wires and cables.

(8) Splices will not be permitted in the wiring.

(9) All connections shall be made at device studs or terminal blocks. A maximum of two connections per terminal will be used. All wiring between various devices shall be performed by the most direct method rather than looping back and forth across the switchboard panel.

(10) Wiring from switchboards to other indoor or outdoor equipment shall be made using multi-conductor control cables. These cables will be provided and connected by others.

(11) Wiring between panels of a switchboard section shall be routed from device to device via the overhead cable wire-way.

(12) The Contractor shall provide labeled and pre-terminated jumpers for the connections between shipping splits.

(13) Circuit/conductor designations (i.e. wire names) as shown on the schematic and wiring diagrams shall be machine lettered, stamped, engraved, or neatly marked with permanent black ink on a white heat shrink marking sleeve at every wire termination other than those at a terminal block. Terminal block marking shall be as specified in section E(6) below.

a. The heat shrink sleeves shall be suitable for use by being slipped onto each conductor, over solderless-type lugs or connectors which have already been applied to the conductor, and heat shrunk to fit the conductor using a heat gun. After shrinking, the marker sleeve shall be tight enough to stay in place regardless of conductor position and loose enough to permit the marker to be slid and twisted so it can be read after the conductor is terminated. The heat shrink tubing shall be suitable for being "printed" in a typewriter or printer with a multiple strike inked textile ribbon.

b. The wire names and callbacks shall be machine printed or neatly hand printed with indelible ink, black on white background, and shall be in accordance with the designations shown on the wiring diagrams.

c. The heat shrink marking sleeves shall be equivalent to:

Phoenix Contact 800388 or Tyco/Raychem RNF-100

E. Terminal blocks:

(1) Terminal blocks for control wiring shall be rated at least 600 volts and 25 amperes. The blocks shall be molded-block type to accommodate ring lugs one-half inch wide (diameter) at the terminal screws, and have screws with serrated or grooved contact surfaces or have lock-washers. The blocks shall be furnished with molded insulated barriers between terminals and have a removable white marking strip. The blocks shall have 12 termination points each. Examples of terminal blocks meeting the above requirements are:

Buchanan Catalog No. B112

General Electric Company Type EB25B12W Marathon 1512STD Connectron Inc. Type KU12

(2) The arrangement and location of the blocks shall be such that incoming and outgoing cables can be supported and all wiring to the blocks shall be completely accessible without having to remove other devices for accessibility. Refer to the wiring diagrams.

(3) Terminal blocks shall be provided for each switchboard panel to facilitate interconnections of wiring between adjacent switchboard panels, other switchboards, and outdoor (power) equipment. These blocks shall be mounted on the side sheets and be grouped according to the interconnecting cable destination. Refer to the wiring diagrams.

(4) At least two heavy-duty terminal blocks with barriers shall be furnished and installed on the side sheets of each vertical switchboard panel, one on each side, near the top for terminating the direct current (DC) main supply external and inter-panel cables. Refer to the arrangement and wiring diagrams.

(5) Current Shorting blocks shall be provided for each switchboard panel to facilitate interconnections of wiring between adjacent switchboard panels, other switchboards, and outdoor (Current) equipment. These blocks shall be mounted on the side sheets and be grouped according to the interconnecting cable destination. Refer to the arrangement and wiring diagrams.

(6) Circuit/conductor designations as shown on the schematic and wiring diagrams shall be machine lettered, stamped, engraved, or neatly marked with permanent black ink on the white marking strip on the terminal block.

(7) The terminals shall be arranged so that the conductors in each cable are grouped together to the fullest extent possible. Terminals for common circuits shall be jumpered and one conductor run to adjacent panels to reduce the number of conductors. Adjacent terminals on the same terminal block shall be used for the three-phase leads and neutral from each set of current transformers. Refer to the wiring diagrams.

(8) Western's cable termination practice is to terminate all conductors of a multi-conductor shielded cable at the same terminal block. One conductor in each cable is an inactive conductor which is to be grounded at both ends of the cable. Spare conductors and the shield are to be grounded at the switchboard ground bus. All DC circuits shall be run radially, that is, the positive and negative (or "out" and "in") leads shall be run in the same cable.

Refer to the wiring diagrams.

a. The neutral conductors from instrument transformers shall be grounded according to the schematic and wiring diagram drawings. Each such ground connection shall be made directly and individually to the switchboard ground bus of the switchboard panel indicated on the schematic and wiring diagram drawings.

F. Nameplates:

(1) The Contractor shall furnish and mount nameplates as shown on the arrangement drawings, nameplate list drawings, wiring diagrams, and Control Standards Nameplate Details drawing 31 4015.

(2) The switchboard panel designation shall also be placed on the inside of each switchboard panel, using a nameplate identical to that located at top of the exterior side of the panel.

(3) Nameplates, stencils, KROY-type labels, or neat lettering giving the Government device function number and wiring diagram location designation shall also be placed inside of the panels adjacent to each device.

3. CONSTRUCTION:

A. Structural and Mechanical Features: The equipment shall have the following structural and mechanical features:

(1) Rigid, self-supporting, sheet-steel, dead-front type features. The switchboards shall be designed for the “Moderate” seismic qualification level requirements as defined/required by IEEE Std 693-2005, Annex L. The panels or cubicles shall be qualified by static analysis. Per paragraph L.1.2 of IEEE Std 693-2005, an acceleration of 0.75g shall be used for static analysis.

(2) Vertical or Duplex Panel (instrument and relay) with necessary framing, bracing, and brackets: The individual panels which comprise the switchboard panel shall have an overall height of 7 feet 6 inches (90 inches) excluding the base. Side sheets shall have 4-inch wide wire channels. Panel dimensions shall be as shown on the arrangement drawings.

(3) Panels shall be of sheet steel, visually smooth and flat with no obvious waves, no lighter than No. 11 United States Standard gage.

(4) Easily removable panels.

(5) A wire-way system with removable covers, as described in section 2.D(4) above.

(6) The bases shall be 2-inch by 4-inch by 1/4-inch thick steel tube, or as otherwise specified to match existing equipment. Bases shall be provided with anchor and grout holes where applicable. Ends of bases and other openings, if any, shall be covered. Bases shall be bolted to the panel, to allow future relocation of the panel without moving the bases. The switchboard section shall be self-supporting and shall not require additional horizontal or vertical support.

(7) The interior structural framework shall be constructed according to the contractor’s standard practice and shall be approved by Western. The frame work is intended to support 19 inch rack mounted relays and sub-panels as shown on the drawings. The contractor shall provide detailed drawings of the framework for approval prior to construction of the panels.

(8) Individual sub-panels shall be fabricated according to the drawings and mounted on the framework as shown on the panel arrangement drawings. The contractor shall provide final detailed switchboard shop fabrication detail drawings of each sub-panel for approval prior to fabrication of the sub-panels. Blank sub-panels to fill unused space shall be provided by the contractor. Blank sub-panels shall be constructed such that their vertical dimension is an integer multiple of 1-3/4 inches in order to maintain consistency with the standard sub-panel dimensions. Mounting holes for the blank sub-panels shall be spaced similar to the standard sub-panels with corresponding dimensions.

(9) The panel shall be fully enclosed with a flat roof, overhead light and a rear hinged door as shown in the arrangement drawings. This enclosure shall be constructed according to the contractor’s standard practice and the arrangement drawings. This new panel will be located at the end of an existing row of enclosed panels that have a height of 92 inches (including the base) and depth of 24 inches, so it is important that the new panel is flush with and matches the existing panels in these dimensions. The overall panel width across the front and rear shall be 48 inches as shown in the arrangement drawings. The contractor shall design and fabricate the new panel according to the specifications herein and LIB 4007 and be consistent with the existing panels in terms of appearance, structural integrity and functional utility. The contractor shall provide detailed drawings of the panel enclosure, door, hinging, overhead light, structural framework etc. for approval prior to construction.

B. Electrical Features: The following electrical features shall be furnished:

(1) Duplex ground-type, with Ground-Fault Circuit-Interrupter (GFCI), convenience outlets will be installed as shown on the arrangement drawings provided by Western. The outlets shall be 2 pole, 3 wire, 20 amperes, 125 volts (NEMA type 5-20R). Separate 120 volt, single-phase, alternating-current (AC) circuits shall be provided for the convenience outlets located within the switchboard. These circuits shall be wired to outgoing terminal block points.

(2) A separate 120 volt, single-phase, alternating-current (AC) circuit shall be provided for the convenience receptacle(s). These circuits shall be wired to outgoing terminal block points.

(3) Where copper bus or other bare metal is used for 125 volt direct-current, control bus circuit connections, it shall be wrapped with insulating tape or otherwise suitably insulated according to the Contractor's standard.

(4) Copper bus contact surfaces, unless silver plated, shall use copper based on a current density of not more than 200 amperes per square inch.

(5) Grounding bus shall be copper and in accordance with Paragraph 7.1.4 of ANSI C37.21. The grounding bus, complete with solderless lugs or terminals for connecting a No. 4 AWG grounding cable, shall be located at the bottom of each switchboard panel.

a. A minimum of 24 drilled and tapped holes with 10-32 screws shall be provided on each ground bus for each panel. Refer to the wiring diagrams for the actual number used.

Jumper straps shall be provided for connecting the ground bus to the ground bus on adjacent switchboard panels if a solid jumper bar cannot be included.

(6) One overhead light fixture with two 20-watt fluorescent lamps for interior lighting. The light will be controlled by one way light switch, which will be located inside a recessed box near the non-hinged side of the rear door as shown in the arrangement drawings. The switch shall be “T” rated, 20 amperes, 120 volts.

4. TESTS: The switchboard control equipment, including wiring, control switches, indicating meters, transducers, indicating lights, electro-mechanical relays, DC circuit breakers, fuses, and test switches shall be subjected to the following tests, at the expense of the control switchboard contractor. Static relays shall be isolated from all tests, as described below, to avoid damage to or improper operation of sensitive components.

A. The Contractor shall prepare a schedule for the tests shown below. The Contractor shall be responsible for all testing connections. The Contractor shall have performed all testing prior to the arrival of the Western inspector. As stated in section 6.A(2)d, One Hundred- Percent Design and Manufacturing Progress Review Meeting, Western will witness repeats of selected Operation and Control Wiring Tests.

B. The Contractor shall furnish two copies of pre-inspection test reports which detail (as a minimum):

type of test performed, date, test performed by, equipment tested, failures or unusual results, missing equipment, and corrective measures taken. These test reports shall be provided to the Western representative at the beginning of the One Hundred-Percent (Final) Design and Manufacturing Progress Review Meeting.

C. The Contractor shall furnish two copies of final test reports which include the pre-inspection test report data and the results of the final inspection tests. These reports shall detail (as a minimum):

type of test performed, date, test performed by, equipment tested, failures or unusual results, missing equipment, and corrective measures taken. The final test reports shall be sent to the address given below for drawings and data at the time of equipment shipment.

D. Tests shall be performed in the order given below.

(1) Continuity and Operation: The correctness of the control wiring and logic of the control switchboards shall be verified by actual electrical operation of the component control devices, as follows:

a. All AC current and potential circuits shall be checked by applying three-phase currents or potentials at the external cable connection terminal blocks, and verifying the phase angle and magnitude of each quantity at the terminals of each device in the circuit being tested.

b. If the circuit includes static relay components, the static relays shall be isolated via test switches or by lifting wires from the relay terminals. AC quantities shall be verified at the inputs to the static relay test switches or at the lifted wires.

c. All DC control circuits shall be checked by operation of devices, including control switches, indicating lights, electro-mechanical relays, DC circuit breakers, and test switches. If the control circuits include static relay components, the operation of static relay contacts shall be simulated at the relay terminals or the relay test switch, with the static relays isolated from the DC circuits via test switches or by lifting wires from relay terminals.

d. Remote devices such as power circuit breakers shall be simulated at the external cable termination blocks in the Control Switchboards. The simulation equipment shall accurately simulate power circuit breaker trip and close coil currents, as well as auxiliary contact operation.

(2) Polarity and Calibration: Indicating meters and transducers shall be tested by applying AC currents and potentials to ensure that they indicate the proper quantities and direction.

Polarity and calibration tests may be performed at the same time as the Continuity and Operation tests.

5. PAINT: The switchboard shall be prepared for painting by the contractor's standard cleaning and priming system. The Contractor shall furnish the paint supplier's paint specifications and a paint chip/sample in the switchboard instruction manuals to facilitate future matching of colors.

A. Painting Exterior Surfaces of Switchboards. The switchboard exterior shall be painted with ANSI 61, light gray, semigloss enamel, or as otherwise specified to match existing switchboards. The paint for switchboards to be installed where there are no existing switchboards shall match Cardinal Industrial Finishes color number 6403-60401 (web site address of www.cardinalpaint.com).

B. Painting Interior Surfaces of Switchboards. The switchboard interior shall be contractor's standard white.

C. Providing "Touch-up" Paint. The Contractor shall provide one pint of the gray and one pint of the white paint for on-site touch-up, or the equivalent amounts (16 ounces each) in aerosol spray cans.

Material Safety Data Sheets (MSDS) shall be provided per relevant contract clause.

6. DESIGN AND MANUFACTURING PROGRESS REVIEW MEETINGS

A. Purpose: Design and Manufacturing Progress Review Meetings are required to ensure that all parties http://www.cardinalpaint.com/ understand all technical requirements of this contract and that construction of the switchboards is of highest quality and is accomplished in a timely manner.

(1) If there is any question regarding technical matters which could impact the scope of this contract, the Contractor shall contact the Contracting Officer’s Representative for resolution.

(2) Schedule: The Design and Manufacturing Progress Review Meetings shall occur as follows:

a. Initial Meeting: The Contractor shall conference call to Western's Desert Southwest Regional Office (DSW) to participate in this meeting. The conference call shall occur approximately 7 calendar days after award of this contract. The Contractor shall contact Western's technical contact person to coordinate the meeting. Western's technical contact for this project is listed in section 7 (c). The meeting topics shall include, but not be limited to, the following:

I. Scope of the work.

II. Schedule of future Design and Manufacturing Progress Review Meetings. The Contractor shall furnish a schedule of design and manufacturing meetings to Western for approval.

III. Drawing and Data Submittal Schedule.

IV. Special contract features such as Government inspection, shipment of equipment by air-ride van, and late delivery of equipment, and procedures for completing contract modifications, if and when required.

V. The Contractor shall provide its plan to obtain all Contractor-furnished equipment and material, shall identify who will fabricate the steel, and state any known situations which may hinder his completion of the work.

b. Forty-Percent Design and Manufacturing Progress Review Meeting. This meeting shall occur approximately 5 calendar days after the Contractor submits Switchboard Structural Detail and Arrangement Drawings for approval, as identified in Table B of the Drawings and Data paragraph of this specification. The Contractor shall conference call to Western's DSW office to participate in this meeting. The meeting topics shall include, but not be limited to the following:

I. Identify all Government-furnished equipment not received by the contractor.

II. Discuss Contractor-proposed revisions to Western's Material list.

III. Review all aspects of the Contractor's Switchboard Structural Detail and Arrangement Drawings.

IV. The Contractor shall provide evidence of having ordered all Contractor-furnished equipment and material. The Contractor shall provide a plan for obtaining all outstanding equipment and material.

c. Seventy Five Percent Design and Manufacturing Progress Review Meeting. This meeting shall either be held at the Contractor's manufacturing facility, or the meeting may be held via telephone conference call, as agreed upon by both parties. Prior to a telephone conference call meeting, the Contractor shall provide photographs (prints or digital) showing all equipment mounted in the switchboards. Digital photographs should be e-mailed to Andrea Cope at cope@wapa.gov. This meeting shall occur after all electrical equipment and material has been mounted on the switchboard. The meeting topics shall include, but not be limited to, the following:

I. Western will inspect the assembled switchboard steel, paint and the mounting of electrical equipment, or review Contractor-provided photographs.

II. Western will work to resolve any outstanding equipment deliveries, and review the Contractor's schedule and plan for testing the switchboards.

III. The Contractor shall identify all outstanding electrical equipment and material, and provide dates for outstanding equipment delivery.

IV. The Contractor shall provide his schedule and plan for testing the switchboards in accordance with Paragraph 4 of these specifications.

V. The Government will furnish a detailed written inspection report to the Contractor which will identify all manufacturing deficiencies and recommendations for correction.

d. One Hundred-Percent (Final) Design and Manufacturing Progress Review Meeting: This meeting shall be held at the Contractor's facility and shall occur when the equipment is to be inspected. Western shall witness repeats of selected Electrical Operation and Control Wiring tests.

I. The Contractor shall notify Western 10 calendar days prior to the inspection date. Inspection shall begin no later than 9 calendar days prior to the NLT delivery date (or the vendor’s projected delivery date) and shall be scheduled to commence to ensure that Western personnel are not required to inspect or travel on weekends or holidays (unless requested and agreed to in advance by the Contracting Officer and Contracting Officer Representative).

II. The Government will furnish a detailed written inspection report to the

Contractor, which will identify any manufacturing deficiencies. This report will be provided to Western's Construction Engineer at the substation site to ensure that all deficiencies have been corrected by the Contractor prior to shipment of the switchboards.

7. DRAWINGS AND DATA

A. Western will provide the specification drawings (i.e., the control switchboard arrangement drawings which include the material list or BOM), schematic diagrams, wiring diagram layout drawings and the nameplate lists for this work as indicated in Table B.

B. Western will provide wiring diagrams unless the contractor is providing them under a separate agreement.

C. Addresses for Contractor-furnished Drawings and Data:

(1) Identify each data and/or drawing submittal with the contract or delivery order number, the mailto:cope@wapa.gov

Item Number (from Table B) and with “Liberty Substation Panel CHG15”.

(2) Though electronic submittal is preferred, when/if data or drawings must be submitted physically and are shipped via U.S. Postal Service Express Mail, Next-Day Service, ship them to the street address, not to the post office box number.

(3) Send the drawings and data outlined in Table B to:

a. A copy of all correspondence shall be sent to the Contracting Officer’s Representative (COR information to be provided after award):

b. Technical submittals may be addressed directly to the technical contact person, using the following addresses (with a copy of the transmittal letter to the COR):

E-mail Address: cope@wapa.gov

Post Office Box Address: Street Address:

U.S. Department of Energy U.S. Department of Energy Western Area Power Admin. Western Area Power Admin.

ATTN: G5320, Andrea Cope ATTN: G5320, Andrea Cope P.O. Box 6457 615 South 43rd Ave.

Phoenix, AZ 85005-6457 Phoenix, AZ 85009-5313

D. The Government and contractor shall furnish drawings as outlined in Table B (Wiring Diagrams WAPA provided) below.

mailto:cope@wapa.gov

TABLE B - INTERMEDIATE DELIVERY SCHEDULES

(Government providing Wiring Diagrams)

Item No.

Party Responsible

Deliverable Quantity Delivery Schedule:

(Not later than)

A Government Specification drawings (arrangements and material, BOM)

1 elec. copy Included with the Solicitation

B Contractor Proposed Switchboard arrangements and material (marked prints) Note 2

1 elec. copy 7 days ADO/ACANote 1

C Government Government-approved Switchboard arrangements and material

1 elec. copy 7 days after Government receives Item B

D Contractor Proposed Switchboard Structural and Shop Fabrication Detail Drawings

1 elec. copy 20 days ADO/ACANote 1

E Government Government-approved Switchboard Structural & Shop Fabrication Details

1 elec. copy (mark-ups of Item D)

10 days after Government’s receipt of Item D.

F Government Schematic diagrams and wiring diagrams

1 elec. copy 60 days prior to shipment of switchboards

G Government GFE referenced in Para. 2(a) As Available 60 days prior to shipment of switchboards

H Contractor Schematic diagrams and wiring diagrams (marked prints)Note 2

1 elec. copy 10 days after Contractor’s receipt of Item F

I Government Government-approved revisions to schematic diagrams and wiring diagrams.

1 elec. copy 10 days after Government’s receipt of Item H

J Contractor Final drawings (contractor-prepared Switchboard Structural & Shop Fabrication Detail drawings, & Switchboard Arrangement Drawings)

1 elec. copy 10 days before shipment of Equipment.

K Contractor Instruction books and renewal parts lists

5 sets Same as for Item J

L Contractor Digital Photographs 1 elec. copy At shipment of switchboards M

Contractor Marked prints of all Government-furnished drawings showing final revisions / clean up, and test reports

2 sets of marked prints, 1 elec. copy of report

At shipment of switchboards (1 set with equipment & 1 set to COR)

1. ADO means After Delivery Order is sent to the Contractor ACA means After Contract Award (when Contracting Officer signs award document)

2. Required to show deviations of proposed Contractor-furnished materials or wiring changes from those shown on the Government-furnished drawings. If the Contractor proposes no deviations, instead of providing mark-ups, the Contractor may send notice stating that no deviations are proposed and that the drawings will have no changes.

"Days" are "calendar days".

“GFE” is Government-furnished/Western-furnished Equipment

E. Technical Requirements for Contractor-furnished drawings:

(1) Switchboard Structural and Shop Fabrication Detail Drawings. The drawings shall show plan views and structural details including internal views of panels. The drawings shall show locations and dimensions of auxiliary devices, terminal blocks, and wire-ways. The internal views shall show all devices in their relative physical locations and whether they are located on the panels, side sheets, brackets, or top.

a. The drawings shall show such details as needed to verify the requirements of section 3

(Switchboard Construction) and to enable future switchboard vendors to provide switchboards which match-up with this equipment. The drawings shall include sufficient detail for shop use in fabricating the switchboards.

NOTE: Dimensions shown on sub-panel Standard Drawings are to be used in actual sub-panel construction. Arrangement drawings show sub-panel location and devices to be mounted.

(2) Wiring Diagrams: The Contractor is required to review and propose corrections or modifications to Western-provided switchboard wiring diagrams. The Contractor shall propose changes, corrections, or modifications to the wiring diagrams in accordance with the following guidance:

a. Western allows two separate systems for wiring diagrams. One is the feedline method and the second is the tabulation method. With the evolution to digital relays, the tabulation method has been used primarily to save space. The two systems can be mixed on wiring diagrams.

b. The schematic diagrams describe the proper naming of wires (wire designations).

Control switchboard location codes consist of two letters. The location codes begin at the upper left hand corner of the panel (as viewed from inside, or rear of, the vertical board). The location names move from left to right and from top to bottom. When placing wire designations on the wiring diagram, the wire designations should be enclosed in parentheses (262PL) and should be closest to the terminal or terminal number, followed by the destination.

c. Destination codes will be composed of the alpha (letter) code for the location in the panel, followed by the alphanumeric terminal designation with no space or comma between [e.g, 1-(262PL) AB27]. The only exception is in the event of an alpha numeric location code, in which case a dash will precede the terminal number [e.g, 1-(262PL) TB1-6]. Use commas to separate switchboard designations from destination codes [e.g, 1-(262PL) CHA3,PP6]. Use semi-colons to separate multiple wires on the same terminal [e.g, 1-(262PL) AB27; DE6].

d. Draw cables with thicker lines where multiple conductors have entered the line.

Individual conductors will branch in at an angle from the cable, and perpendicular to the terminal block. Show color-coding by breaking the line and inserting a lower case color-code letter.

e. Switchboard Wiring Practice:

I. Route wiring between devices within a switchboard directly from device to device (not through a terminal block). Route wiring between left hand (LH) and right hand (RH) racks within a single switchboard through the wireway duct system (one wire per signal).

II. Route wiring between devices in adjacent switchboard sections through the appropriate side sheet terminal blocks (not directly from device to device)

Example 1: Wire a device on Panel 1 to a device on Panel 2.

Solution: From the device on Panel 1 to terminal block on Panel 1 to terminal block on Panel 2 to device on Panel 2.

Example 2: Wire a device on Panel 1 to a device on Panel 3.

Solution: From the device on Panel 1 to terminal block on Panel 1 to terminal block on Panel 3 to device on Panel 3.

III. When more than two switchboard sections are required: Generally the switchboard lineup cannot be shipped as one unit, and shipping splits should be considered in the wiring. If the sections have to be shipped in three separate sections, wires shall not be routed across these splits.

Example: Wire a device on Panel 1 to a device on Panel 3.

Solution: From the device on Panel 1 to terminal block on Panel 1 to terminal block on Panel 2 to terminal block on Panel 3 to device on Panel 3.

IV. Do not terminate more than two wires at any point.

V. Wire by most direct and efficient route (radially, not looping back and forth).

VI. Show case grounding of all devices, where applicable.

VII. Cable from the switchyard, other switchboard lineups, the RTU, and AC and DC distribution boards will enter the cabinet from below if a cable trench is used, or from above if a cable tray is used. Contractor will contact Western design engineer to verify which method is to be used.

VIII. Terminal blocks are provided at the top of each switchboard section for common wiring.

Examples: Sync Circuits (ASR, MSR, ASI, MSI and VO), RTU positive, annunciator positive (1ANP), etc.

IX. Run a bus with two appropriately sized wires (using heavy duty terminal blocks) through all switchboard sections to connect 125 V DC (positive and negative) to the DC circuit breakers (see Standard Drawing 31 6010, Panel Dc Circuit Bus).

X. Ensure cable designations comply with requirements shown on Standard

Drawing 31 4005.

XI. All DC circuits connecting to a device at a power circuit breaker, Motor- Operated Disconnect, transformer, or reactor must be run radially. Route positive and negative leads of a circuit in the same cable. AC and DC circuits are routed in separate cables.

XII. Leave one (1) conductor in each cable as a spare. Ground each spare conductor and cable shield at both ends. Refer to Standard Drawing 31 6000.

XIII. Wire transducer outputs directly from the transducer rack to the programmable automation controller or RTU using shielded twisted-pair cable.

XIV. Terminate all annunciator points (even unused points) to terminal blocks on the side sheets.

f. The contractor shall implement Western-approved corrections or changes and document them using Western’s drafting standards. Should a new drawing be needed, the drawings shall be prepared using Western Title Blocks. If/when a Western drawing is formally revised, Western personnel will initial the revision blocks of all revised drawings.

F. Format Requirements for Contractor-prepared drawings:

(1) General Requirements:

a. Drawings shall be prepared using computer aided drafting (CAD) equipment. The

Contractor shall submit only "electronic format" versions of Contractor prepared drawings, unless otherwise stated in Table B above. Freehand sketches, manually prepared drawings, and plots of CAD drawings will not be accepted.

b. Drawings shall be provided with the Contractor's name, the Contractor's drawing number, and the Government contract number in the upper right corner of the drawings, as shown on drawing 61 9005.

(2) Contractor-Prepared CAD Drawings: The Contractor shall provide all Contractor-prepared deliverable drawings prepared on a Contractor CAD System. All Contractor prepared drawings shall be delivered as AutoCAD “.dwg” format or AutoCAD ASCII ".dxf" format electronic files.

a. Contractor-prepared electronic drawing files shall conform to the following requirements:

I. All “.dwg” or ".dxf" graphics files shall be compatible with the 2004/LT2005

Release format as specified by AutoCAD, Autodesk Corporation.

II. All AutoCAD “.dwg” drawing files shall be prepared using the following AutoCAD color assignment schedule in order to meet Western's drafting standards for pen weights for Size D drawings, for half-size reduce the pen widths by half and set all the pen numbers to 1:

ENTITY COLOR PLOTTER TYPICAL PLOTTER PEN

PEN NO. LINETYPE PEN WIDTH WIDTH RANGE

(INCHES) (MM)

5 (blue) 1 0 .011 0.23-0.34 7 (white) 2 0 .016 0.35-0.44 2 (yellow) 3 0 .021 0.50-0.55 1 (red) 4 0 .027 0.64-0.74 3 (green) 5 0 .032 0.76-0.89

III. All text on AutoCAD ".dwg/.dxf" drawing files shall be prepared using the following AutoCAD color assignment schedule in order to meet Western's drafting standards for pen weight:

TEXT HEIGHT ............ENTITY . COLOR

.080............................. 5 ............ Blue .100............................. 5 ............ Blue .120............................. 7 ............ White .140............................. 2 ............ Yellow .175............................. 1 ............ Red .200 & above ............... 3 ............ Green

IV. If Western text lisp routines are used on Model Space/Paper Space drawings, the text will be scaled according to the Viewport Scale. When plotted the text heights will be correct.

V. All AutoCAD ".dwg/.dxf" drawing files shall be prepared using the Western provided Symbol Libraries, Text Font Libraries, and Sample Borders. All symbols shall be placed as inserted AutoCAD blocks. If additional symbols are developed the colors for the constituent entities shall be explicitly set. Symbol colors shall not be set using the layer "0" features. Care must be exercised when exploding blocks with attributes, as the attribute values are lost. TIP: Use Western lisp UNBLOCK.LSP, this will retain Attribute values.

VI. The standard text fonts for Western drawings are RM90 and SP90. Some special characters are available through the lowercase letters in the SP90 text font. They are as follows:

KEYBOARD ENTRY ASSOCIATED CHARACTER

c = Centerline symbol d = Delta symbol e = Plus, minus symbol f = Diameter symbol g = Degree symbol h = Is proportional to symbol i = Pi symbol l = Lambda symbol m = Ohm symbol o = Luminous or magnetic flux symbol p = Phase symbol u = Mu symbol v = Angle symbol w = Westinghouse symbol

VII. AutoCAD Text Specials. Special "%%" Characters The AutoCAD special "%%" characters of AutoCAD shall not be used. Use SP90 special characters instead.

b. The "Electronic Versions" of new, CAD, drawings shall be CAD drawing files provided on compact disks (CDROMs) or via email, in the following format types:

I. Electronic format. Any CAD drawing files provided in Electronic Format shall be the AutoCAD “.dwg” file format. CDROM files shall be ISO 9660 format or UDF- Universal Disk Format.

II. The Contractor shall take reasonable precautions to provide virus free electronic media or emailed files to Western. This shall include but not be limited to:

(a). Have up-to-date antivirus software and signatures on all systems associated with creating the files and putting the files on the compact disks (CDROMs)or DVDs, or sending them via email.

(b). Avoid putting executable type files or autorun functions on the storage media or in emailed files.

(c). Performing virus checking and removal of the stored files on the storage media or on outgoing emails with up-to-date antivirus software.

(d). "Write protect" all electronic media prior to providing the media to Western.

(e). If malicious code is detected on any systems associated with creating the files, compact disks (CDROMS), DVDs, or sending emails to Western, notify the COR.

III. All compact disks, DVDs, or other media containing CAD drawing files shall be clearly labeled to describe the format used and a listing of the drawing files, file names, contained on the media.

G. Final Contractor-furnished Drawings and Data

(1) Final drawings of the approval drawings:

a. The final drawings shall show all changes and revisions made up to the time they are transmitted. Contractor's revision notes shall be below the bottom margin.

b. The Contractor shall provide the final drawings which shall prepared using computer aided drafting (CAD). The drawings shall be submitted in electronic format only.

If any changes are required after the final drawings have been transmitted, the Contractor shall provide two marked prints of each affected drawing showing the changes.

(2) Instruction Books and Renewal Parts Lists. Copies of books for the operation and maintenance of the control, metering, and relaying equipment shall be furnished as required by Table B. Included shall be:

a. Manufacturer's instruction pamphlets and parts identification lists for each device.

b. Low-voltage circuit breaker tripping curves (for Contractor-furnished breakers).

c. Include the paint sample/ship and MSDS required above.

d. The operation and maintenance instruction pamphlets, curves, etc., shall be bound together with a contents sheet provided at the front of each bound volume. The contents sheet shall list the index sheet tab number, the Government bill of material item number, the manufacturer and model number, and the manufacturer's instruction leaflet number for each device. Identical devices may be grouped under the first bill of material item number referencing that device if the contents sheet lists the other item numbers. The data for each item shall be separated from the data for other items by a reinforced divider tab index sheet made of 110 pound index stock.

e. The Government will furnish copies of the instruction pamphlets for the Government-furnished devices as stated in Table B. These shall be included in the instruction books furnished by the Contractor.

(3) Digital Photographs

a. The digital photographs shall be 7.1 megapixel or higher resolution, “.jpg” or PDF format, showing the arrangement of the equipment and the construction of the switchboard panel. The photographs shall include front and rear views of the switchboards. The photographs shall show:

I. The switchboards essentially completed and wired;

II. The device nameplates clearly enough to read the nameplates and switch escutcheons;

III. "Head-on" perpendicular views, rather than oblique views.

(4) Marked prints of all drawings:

a. The Contractor shall maintain a marked set of prints showing all minor corrections to the

Government-furnished drawings. This set of marked prints is to be forwarded to the address above according to Table B, and a copy of each marked print is to be shipped with the equipment.

8. INSPECTION: Refer to the Design and Manufacturing Progress Review Meetings section.

9. DELIVERY CONTACTS & LOCATION:

A. Contacts: Refer to contract clause WES-F-1001 – Advance Shipping Notification regarding the pre-delivery coordination contacts to be made by the shipper and the days and time-window when deliveries can be made. If the required arrangements/ notifications are not made, the Government may not be able to receive and/or unload the equipment.

(1) Persons to be contacted for this contract are:

COR: To be determined Office Telephone/email

Alternate: To be determined Office Telephone/email

(2) A field delivery contact person and alternate field delivery contact person will be specified in each individual delivery order or provided by the COR.

(3) The contractor shall make contact with field delivery contact personnel at least ten (10) calendar days prior to shipping to verify delivery location, delivery date/time and detailed driving directions.

(4) Location/site: Items shall be delivered and all transportation charges prepaid by the contractor, F.O.B. Destination (see contract clause 52.247-34) to:

US DOE/Western Area Power Administration Liberty Substation

33.24.55 N LAT 112.29.45 W LONG

Liberty, AZ 85326

Directions: From Phoenix, take I-10 West to Jackrabbit Trail Road, Exit 121, and go south apprx. 2 miles to Dunlap Road;

West on Dunlap one mile to Liberty Sub entrance at Tuthill Road

10. CONTRACT DRAWINGS: The following drawings are included in the contract as appendices to these specifications.

A. Standard and Reference Drawings:

31 6000 Shielded Cable Grounding 31 6010 Panel DC Circuit Bus 31-4015 Nameplate Details 31-4005 Wiring diagram and Cabling Methods 61-9005 Format for Manufacturer’s Drawings

B. Substation Drawings

LIB 4007 Enclosed Switchboard CHG15 Arrangement Note: LIB 4007 includes the overall panel dimensions and the bill of materials (BOM)

**** End of Technical Specifications **

Technical Specification