fpebreakerreplacement 2 JOD.pdf

FPE Circuit Breaker Replacement – 1/1/2020

1.0 General

This specification covers the design, testing and manufacturing requirements for forty nine (49) replacement medium voltage vacuum circuit breakers. The circuit breakers shall be mechanical and electrical replacements for Federal Pacific DST-II-500 MVA air circuit breakers. The replacement vacuum circuit breakers shall be interchangeable between different types of cells of the same voltage, MVA and ampere class without cell modifications except as noted. It is recognized that there is no “exact replacement” for any type circuit breaker except for a duplicate of the original. However, fit and function are to be maintained and only minor reversible cell modifications are allowed. Awarded contractor will prepare a breaker installation plan showing milestones and tasks for MBTA review and approval before starting any work.

2.0 Scope of Work

Provide all project management, factory and field engineering, supervision, labor, material, tools, rental, test equipment and transportation as defined by this specification for a complete vacuum breaker replacement of the existing medium voltage switchgear circuit breakers listed in Section

8.0 “Equipment List”.

3.0 Applicable Standards

All medium voltage replacement circuit breakers shall be designed, manufactured and tested in accordance with the latest applicable sections of:

IEEE/ANSI C37.59

IEEE/ANSI C37.04

IEEE/ANSI C37.06

IEEE/ANSI C37.09

IEEE/ANSI C37.20.2

ANSI C37.55-1989

IEEE/ANSI C37.100-1992

ANSI/NFPA 70 (NEC)

NETA/ANSI ATS-2013

4.0 Ratings

Power circuit breakers shall be draw-out type, nominal 13.8 kV class, three pole, employing vacuum interrupters, designed for 60 Hz operation and rated on a symmetrical current basis in accordance with ANSI C37.06 as follows:

a. Rated continuous current 1200 A

b. Rated maximum voltage 15.0 kV

c. Nominal voltage 13.8 kV

d. Rated voltage range factor (K) 1.3

e. Rated withstand test voltage:

Low frequency (rms) 36 kV

Impulse, crest 95 kV

f. Nominal MVA class 750 MVA

g. Rated short circuit current at maximum voltage (rms) 28 kA

h. Maximum symmetrical interrupting capability (rms) 36 kA

i. Rated short time current (3 sec.) - 36 kA

j. Closing and latching capability, crest 97 kA

k. Rated interrupting time 5 cycles

5.0 Power Circuit Breakers

5.1 Breaker Assembly

a. The primary disconnecting devices shall consist of self-aligned assemblies. The female contacts shall be constructed of bridging segments of fatigue-resistant zirconium copper alloy with silver tungsten arching tips or similar approved high quality material, designed to ensure high-pressure contact and guaranteed not to distort or fail under the mechanical stresses and heating due to duties specified for circuit breakers. All contact surfaces shall be heavily silver-plated.

b. Control wiring connections between stationary structure and the removable breaker shall be provided with automatic, self-coupling contacts.

c. Mechanical interlocks shall be provided on each circuit breaker to prevent the withdrawal of the removable element when the breaker is in the closed position and to prevent the insertion of a closed breaker from the test to the operating position. The interlocks shall also discharge the spring of the stored energy operating mechanism before the breaker removable element can be fully withdrawn from its housing.

d. Each circuit breaker shall be mounted on a mobile frame. The frame shall be permanently attached to the circuit breaker and shall be equipped with four (4) steel wheels for rolling the circuit breaker on the floor of the substation. All breakers are required to be a direct roll-in design which allows moving the breaker over the concrete substation floor into the switchgear unit without the need for portable ramps or wedges or cradles. Circuit breakers of same rating shall be mechanically and electrically interchangeable.

e. The frame shall be constructed from steel. All frame designs shall be plated with a corrosive resistant finish and shall be constructed to place all non-conducting metal surfaces to ground potential. No ground wires shall be required to tie the frame components to ground.

f. Control wiring shall be SIS, cross-linked polyethylene, #14 AWG minimum except for short runs such as coil and motor leads. Wiring shall be provided with ring-type compression terminals with insulated sleeves at each termination. All wiring shall be identified at each termination by printing on wire jacket or on an insulating sleeve. Adhesive wire markers are not acceptable. Wiring for all internal components shall be wired to a readily accessible terminal block/s.

g. Mechanical interlocks shall be provided on each circuit breaker to prevent the withdrawal of the removable element when the breaker is in the closed position and to prevent the insertion of a closed breaker from the test to the operating position. The interlocks shall also discharge the spring of the stored energy operating mechanism before the breaker removable element can be fully withdrawn from its housing.

5.2 Operating Mechanism

a. Shall be of the stored energy type, suitable for operation from a 125 Vdc supply.

Operating circuits shall successfully close the breaker over a voltage range of 90 to 145 Volts and trip the breaker over a voltage range of 70 to 145 Volts. The operating mechanism shall be provided with a mechanism charging motor cut-off switch mounted on the breaker.

b. A removable handle shall be provided for manual charging and closing of the breaker for maintenance and adjustment.

c. The mechanism shall have front accessible manual close and trip operators that are directly connected to the breaker operating mechanism and are an integral part of the electrical close and trip coils.

d. The new circuit breaker operating mechanism shall be a “true Trip-Free” design.

When the trip function is mechanically engaged and held and the close function is initiated either electrically or mechanically, the contacts shall not close. The contact travel shall be restricted to 10% of the total travel and shall be in compliance with the requirements of IEEE/ANSI C37.06.

e. The circuit breaker elements shall, under normal operating conditions, have a minimum scheduled maintenance interval of five(5) years or 10,000 operations, whichever comes first, and shall require no re-lubrication to the mechanism during this period.

5.3 Auxiliaries

a. Auxiliary Contacts - In addition to auxiliary switches required for control, interlock, indication, and alarm circuits, provide each circuit breaker with a minimum of four "a" and four "b" spare auxiliary switch contacts wired to outgoing wiring terminal block for Authority's use. Auxiliary switches mounted on stationary structures are acceptable.

b. Auxiliary switches and breaker control circuit wiring connected through the secondary disconnecting devices shall be operable when the breaker is racked to the test position so that the breaker can be closed and tripped, electrically or mechanically, with primary disconnecting devices open.

c. The circuit breaker shall have a low inertia, rotary operated auxiliary switch connected to the main pole shaft assembly. Connections shall be made via insulated ring-tongue terminals.

d. Existing circuit breakers utilize FPE Drawing 1500B0044 to achieve operating scheme. See drawing G and T DST – 2 in COMMBUYS.

5.4 Indicators

a. Circuit breakers shall have an easily accessible means for contact wear indication.

b. A non-resettable 5-digit register type operations counter shall be mounted on each circuit breaker.

c. Each breaker shall have a mechanical status indicator to show the state of the stored energy mechanism. The mechanism shall state “charged” or “Discharged”.

d. Each breaker shall have a mechanical status indicator to show the state of the breakers main contacts. The mechanism shall state “Open” or “Closed”.

5.5 Racking Mechanism

a. Each circuit breaker or cubicle shall be equipped with a cranking device for moving the removable breaker element to and from its operating position. The cranking device shall be permanently attached to either the stationary housing or to the removable breaker unit. Suitable guide rails which prevent misalignment shall be provided for centering the breaker in proper position when inserting or withdrawing the removable element.

The racking-in mechanism shall be manually operated, threaded shaft type, employing a removable crank. Lever type rack-in mechanism will not be acceptable.

b. Circuit breakers shall have the capability of racking between the connected, disconnected, and test position with the cubicle door closed.

c. A positive stop shall be provided for the test position and fully connected position.

d. Provisions shall be made for padlocking the removable element in the operating and fully disconnected positions.

e. Provisions shall be made to the front of the cubicle's hinged door to provide a sliding shutter to cover the aperture utilized for the cranking device. The circuit breaker shall be able to be racked or cranked from the "test" position to the "operating" position with the breaker compartment door closed.

6.0 Warranty

The vendor shall warrant to the MBTA that the apparatus or services to be furnished hereunder shall be newly manufactured and of the highest quality and free from defects in material, workmanship, and title. The warranty shall be effective for a period of twelve (12) months after date of energization or eighteen (18) months after the date of shipment, whichever is less. If applicable, extended warranties and associated costs shall be supplied with the bid.

7.0 Field Testing

Each breaker shall be tested in accordance with ANSI/NETA ATS-2013, section 7.6.1.3 requirements. Each cell shall be functioned checked to verify proper operation of the protective and operational scheme. Any pre-energization tests or inspections required for warranty purposes shall be performed. The costs and expenses associated with field testing shall be included in the Bidders’ proposal.

8.0 Equipment List

New vacuum circuit breakers shall be delivered to the following substations;

Brkr Qnty Station Address

7 Columbia Old Colony Ave-JFK Pass. Station/ Dorchester

9 High Street 45 High Street / Boston

10 Cabot Foundry Street / Boston

8 Reservoir Strathmore Road / Brookline

8 Riverside Grove Street / Newton

7 Wonderland 1380 North Shore Road / Revere

9.0 Vendor Qualifications

The supplier or manufacturer must meet the following qualifications to be considered for the award of the contract.

a. The vendor shall supply evidence of ANSI certification of the circuit breaker element and the completed assembly prior to delivery.

b. The vendor shall have a minimum of 10 years’ experience in the maintenance of medium voltage switchgear. Provide address and telephone number of the service office nearest to the jobsite with the bid proposal.

c. All vendors are required to verify nameplate data, control wiring requirements and cell-to-breaker interface.

d. The vendor shall provide references for completed 15kV FPE switchgear breaker replacement projects.

10.0 Design and Certification (Type) Testing

The vacuum circuit breaker supplied shall have type tests performed on its base design.

Extrapolation of test values based on individual components is unacceptable. The tests shall be performed on the complete assemblies. All type tests will be performed in the actual switchgear cell or an equivalent structure where permitted by ANSI C37.09. Written test reports, data logs and digital reproductions of the pulse used to perform the BIL test are required to be on hand for review by the buyer. Non-compliance with these base type tests or the failure to produce evidence of such test shall result in the immediate disqualification of the vendor without obligation to the buyer.

The following:

a. BIL - <60KV for 4.76KV applications, 95KV for 8.25 and 15KV applications as a minimum> crest with 1.2 sec x 50 sec x 50% wave shape per ANSI C37.09.4.5.4.

The tests shall be conducted per IEEE STD 4. This test shall be performed in a breaker cell or cell equivalent in an environmentally controlled “semi-clean room” area with controlled humidity levels. No adjustment shall be required for humidity.

Corrections for barometric pressure and ambient temperature shall be applied to the test parameters. The breaker shall pass a total of 54 shots.

b. Mechanical operations tests of each breaker design shall be performed in a switchgear cell designed to accommodate MOC switches. The maximum number of auxiliary MOC devices shall be installed in the switchgear cell to ensure that the vacuum breaker has sufficient power to operate the auxiliary devices, successfully closes and latches during each operation and that no fatigue or failure occurs. The system shall pass the number of operations as listed in “the first scheduled maintenance point” of 10,000 life expected mechanical operations per ANSI C37.06- 1987 Table 8.

c. Momentary tests per IEEE/ANSI C37.20.2.5.2.4 shall be performed of the completed vacuum replacement breaker including the vacuum breaker element, bushings, primary disconnects (finger clusters), all bus in the breaker unit, and all insulators and braces per ANSI C37.09, 4.6.2.4. This shall prove the mechanical strength and integrity of the conductor and frame assembly of the complete new vacuum replacement breaker. This test must be performed in a switchgear cell designed to accommodate the circuit breaker being tested. Anti-rotation devices may be added to the cell if required to prevent rotation. If anti-rotation devices are used in the test breaker, then they shall be installed in all the switchgear cells intended to accommodate the new breakers.

d. Short-time current tests at K*I current shall be performed to confirm the breakers I2t capability. The test shall be performed in a switchgear cell.

e. Continuous rated current testing per ANSI C37.04-1979 without exceeding 65oC hotspot rise with a maximum ambient not to exceed 40oC. This test shall be performed in a breaker cell or a cell structure of the same equivalent volume, dimensions and ventilation as the original switchgear structure.

f. Low Frequency Withstand - <19kV RMS for 4.76kV applications, 36kV RMS for 8.25kV and 15kV applications> per ANSI 37.09, 4.5.3.1

g. All production tests as stated in ANSI C37.09-1979.5.

11.0 Execution

a. The vendor shall utilize their factory trained and certified field engineer to perform the inspection, field testing, and installation of each breaker at the customer’s site.

Field-testing shall comply with ANSI/NETA ATS-2013 standards.

b. The vendor shall perform operational tests to confirm proper operation of the breaker within a MBTA cubicle.

c. The vendor shall provide training on the vacuum technology and new replacement breaker operation and maintenance.

d. The vendor shall provide a separate O&M Manual for each station the breakers will be located. The manual shall include a B.O.M’s, technical drawings, vendor cut sheets, etc. The manual shall be approved prior to breaker energization.

e. Six (6) sets of breaker accessories shall be delivered, one (1) set to each station;

racking handle and manual charging handle.

f. Lead-time for breakers expected to be less than 20 weeks, once executed contract and Purchase Order are in place. Contractor will confirm the lead-time to the

MBTA.

12.0 Delivery

Shipping shall be FOB job site. Maximum truck length shall be 22 feet, a hydraulic gate will be required at multiple sites. The MBTA shall provide a boom truck at Reservoir and Riverside substations to facilitate off-loading. A lifting cradle for the breakers, provided by the contractor, shall be utilized to facilitate delivery at the aforementioned stations.

END OF SPECIFICATION