Attachment_03_GOVERNMENT_RESPONSES_TO_VENDOR_SUBMITTED_QUESTIONS.docx

GOVERNMENT RESPONSES TO VENDOR SUBMITTED QUESTIONS

1. Please Provide any 1-line drawings for the current drive systems:

a. Feeder transformer all the way to the motor

b. Controls and I/O

Government Response:

The figure above shows the existing power cabling diagram for the Whirltower drive system except that the existing motor is now rated at 2350HP, 600V, 3150A. In manhole 87D the 12.47KV feeder from Station C consisting of 3#2/0 MV105 15KV, 1#2 600V Gnd. cables is Tee spliced with one tail feeding the 480V pad mount transformer next to the manhole and the other feeding the drive system. The feeder cable from Station C to manhole 87D shall be upgraded to 3#4/0 cu, 15KV, MV105, 133% EPR insulation, copper tape shielded cable and 1#2/0 600V cu Gnd. This feeder distance is approximately 500 feet. The 15KV connections at C station and the drive shall be 15KV terminators, taped 15KV Tee splices shall be used in MH 87D. The UG feeder conduit size is 4”. For additional information see attached files (GovResponse_1a.pdf and GovResponse_1b.pdf). NOTE: these drawings should be used for reference only. They represent the original Reliance drive installation in 1997 for the 1500 HP motor and may contain some mark-up to show changes when the existing 2350 HP motor was installed in 2001 but do not necessarily represent the exact current configuration.

2. Will the new drive and controllers interface with the current data collection system?

Government Response: Yes. The existing control console with the speed control pot, direction switch, start/stop switches, etc. which connect to the existing drive’s PLC will remain as will the data collection system which measures blade test information and the blade pitch controls. Additionally, the existing whirl tower data acquisition system (DACS) drawings indicate that the DACS provides input to the Reliance drive through PLC digital input Slot 7. The inputs are used to identify the blade under test and establish limits. The contractor shall maintain the existing interface connections as part of their design. A new HMI for the drive system shall be provided to allow monitoring, maintenance and setup of the new drive.

3. For the electrical power feed to Building 1792, please confirm 2/0 cable size and quantity.

Government Response: See Government response to question 1 above.

4. Can we get a copy of the current Reliance Automax PLC and I/O drawings and controls logic?

Government Response: The diagram above shows the existing PLC/HMI configuration. Detailed I/O drawings and control logic diagrams will be provided to the contractor after contract award. Refer to response to question 1 for basic I/O drawings. The attached file (GovResponse_4.pdf) shows partial configuration information regarding the Reliance drive as configured for the old 1500 HP motor. NOTE: This information is FOR REFERENCE ONLY. Some of the parameters do not apply to the existing 2350 HP motor.

5. Can you provide a one-line diagram for the Whirltower motor drive system currently in use, as well as pictures of the name plates on the transformer and switchgear, motor drive and DC motor.

The motor information is given above, field current is rated at 60A, 200V.

The transformer switch is an FPE 14.4KV, 600A model D-28167 air switch fused at 250A. This switch can be reused with the fuses changed to match the rating of the new drive transformer. Refer to attached name plate pictures (switchgearIDplate.jpg, transformerIDplate.jpg, driveIDtag.jpg, whirltowerMotorDataPlate.jpg).

The existing drive transformer is an FPE dry type, rated at 12470KV primary, 575/575Y secondary, 2000KVA total.

The existing iron core reactors are rated at 250uH, 1000A continuous, 2000A/1 min.

The SCR bridges in the existing drive are rated at 1000A, 600V continuous, 2000A/1min. The existing drive is configured for 4 quadrant operation allowing for forward/reverse operation and regenerative braking. The new drive shall be configured the same way. Parallel SCR bridges will be required to achieve the 4000HP continuous drive rating. The delta/wye secondary of the new drive transformer shall feed the new drive and the parallel SCR bridges shall be configured as 0 degree and 30 degree to reduce power system harmonics. The following figure shows a more physical layout of the system drive components and cabling.

6. When do you intend to upgrade to the 4000HP motor?

Government Response: This date has not been determined but will coincide with the requirements to test larger helicopter blades in the future.

7. How often do you expect the motor to be overloaded to 6000HP in the future?

Government Response: The drive shall be rated for 4000HP continuous and 6000HP for 1 minute. High power test conditions which occur at maximum blade pitch test settings are limited to the amount of time it takes to get stable blade tracking and pitch moment readings which is typically one to 2 minutes. The 6000HP test condition is to allow for future growth capability, the 4000HP requirement is to accommodate new test requirements expected in the near future.

A typical production test of blades lasts 15 minutes where the blades are spun at rated blade RPM and incrementally at increased pitch setting where blade performance is measured. The blades will be stopped to allow the operators to make adjustments to the blades as required and the blades will then be retested until they pass the test or are rejected. The test blades will then be demounted from the stand and another set will be mounted for testing which requires about 30 minutes.

8. Who is doing the protection coordination and arc flash studies on base for the installation of the new equipment?

Government Response: The Government is responsible for the settings of the relay on the Blade Test feeder to manhole 87D. The contractor is responsible for sizing the fuses for the transformer disconnect and the sizing of all overcurrent protective devices in the drive. The Government will provide the feeder relay protection curves to the contractor to allow them to coordinate their protective devices with the utility system.

9. In section 3.3.6 you specify a mean time between failure of 1000 hours, but you also expect the system to run 2000 hours per year. Is 1000 hours a typo?

Government Response: The contractor shall provide drive system reliability data for their proposed product. The drive will be subject to the terms of the warranty in the contract. The reliability data provided will be used as an evaluation criteria by the Government. See the Government response to question 7 for a description of typical operation of the facility.

10. We need to ensure you have enough HVAC capacity in the building for the new drive and transformer. Could you confirm your HVAC capacity.

The above figure shows the layout and dimensions of the existing control building. There is no HVAC in the equipment room. There are two roof mounted exhaust fans in the equipment room which work in conjunction with the filter bank to provide ventilation for the equipment. The contractor shall evaluate the ventilation requirements for their equipment and determine if the existing exhaust fans are adequate. The CFM of the existing roof mounted exhaust fans is not available without inspecting the fans, but they are high volume as they were originally sized based on the 1500HP MG-Set formerly located where the existing drive transformer is located. The control cabinets for the 1960 vintage MG-Set were located along the wall where the existing drive is located. The existing drive system replaced the MG-Set and the existing ventilation system was not altered to accommodate the solid state DC drive. It is expected that the existing ventilation in the equipment room will be adequate for the new equipment, but if higher volume fans are required the contractor shall provide them. As stated in paragraph 3.3.1.6 Environmental Conditions: “The equipment room in Building 1792 is not temperature or humidity controlled. If the Contractor’s design requires controlled environmental conditions, the Contractor shall include the necessary equipment as part of their design.”

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