PWS 2A 2B Control System Replacement DRAFT 2020 June 16.docx

Barrier IIA&B – Pulse Generating Control System Replacement Supply and Installation Performance Work Statement

CHICAGO DISTRICT

LEADERS IN CUSTOMER CARE

CHICAGO SANITARY AND SHIP CANAL (CSSC)

BARRIER IIA (OPTIONAL BARRIER IIB)

PULSE GENERATING CONTROL SYSTEM REPLACEMENT

SUPPLY & INSTALLATION FY20

Performance Work Statement (PWS)

Certified Final: Ready to Advertise Rev AMD-00?

June 12, 2020 Amendment Revision Log

AMD-00?

Table of Contents

PROJECT SCOPE

The Contractor shall furnish and install a complete, working, fully functional and cohesive Pulse Generating Control System (PGCS) for Barrier IIA and (Optional Barrier IIB) facility that will allow for an operational, safe, effective and efficient Pulse Generating System and provide additional functionality as described in this PWS while maintaining minimal functionality as currently installed. The PGCS will consists of Insulated Gate Bi-Polar Transistor (IGBT) Assembly Control, High Voltage Power Supply (HVPS) Control, High Voltage Polarity/Position Switch Control (HVPPS), Power Monitoring System (PMS) Control, IGBT and HVPS Cooling Control System (CCS), Generator Operation Monitoring, Database Control and any Supportive Systems for a complete PGCS to include a weather station, canal monitoring, and AHU Air Handler Unit Control (for Barrier IIB only). In addition, the Contractor shall furnish and install a complete, working, fully functional and cohesive remote control system for the integration of the existing generators control at Barriers IIA and IIB with the existing control at the Permanent Barrier I Facility (PB1). These control systems are part of an integrated system at the existing Barriers IIA, IIB and PB1 Aquatic Nuisance Species Dispersal Barrier facility in Romeoville, Illinois located on the Chicago Sanitary Shipping Canal (CSSC). The Contractor shall provide a fully functional and complete working PGCS and remote generator control in compliance with the requirements of the Performance Work Statement (PWS) and contract documents that provides an operational, efficient and effective Pule Generating Systems for Barrier IIA and (optional) Barrier IIB.

The PGCS shall include all necessary PGCS equipment that controls each Pulse Generating Unit (PGU) in the Barrier facility. In each Barrier facility of IIA and IIB there are a total of (3) three PGUs each with the control systems and supportive control systems mentioned in the previous paragraph; there are (2) two 1.5MW PGUs (commonly known as Pulser 1 and Pulser 2) and (1) one 350KW PGU (commonly known as Pulser 3). Therefore, for clarity each Barrier IIA and IIB have 3 PGUs as mentioned previously for a total of (6) PGUs. The Contractor shall remove all existing PGCS components and equipment with the exception of the items that will be reused as detailed in the plans (One Line Diagrams). Any removed components and equipment shall be disposed of per the contracting officer.

The PGCS shall be installed per this Performance Work Statement and Plans. These provided Government documents detail the majority of work. However, there may be some work that requires additional details and the Contractor is responsible to obtain these additional details and implement in the installation of the PGCS.

Currently, the existing Barrier Facilities converts 480 Volts (V) alternating current (AC) power into a pulsed DC power as described below where the existing PGCS is able to operate the PGUs at an adjustable range within the prescribed parameters for Volts, pulse frequency, and pulse duration allowed by the equipment. The existing PGCS equipment capabilities provides the PGUs with pulsed voltages of any value from 0-2,000V and 0-1000V and peak pulse currents up to 7,500 Amps (A) and 3,000 Amps (A) for the 1.5MW and 350KW PGUs output respectively with a pulse frequency up to 100 Hertz (Hz) within increment adjustments of 0.5Hz and a pulse duration of 0-100 milliseconds (ms) within increment adjustments of 150 microseconds (µs). The new PGCS shall also provide these capabilities; more detail for this control is provided further in this PWS and the Appendix A, B, C, D, E and F.

The Contractor shall provide a PGCS that includes control stations for the PGUs at Barriers IIA and IIB facilities respectively as well as a control station that allows for control of each Barrier IIA & IIB PGU in the PB1 facility; more detail for this control is provided further in this PWS and the Appendix A, B, C, D, E and F. The Contractor shall provide a PGCS that allows each Barrier IIA and IIB PGU to be capable of being synchronized or interleaved with all other PGUs at PB1 and Demonstration Barrier facilities. Consistent with the synchronization system currently being used at the barriers, each PGU shall use the leading edge of a pulse from a Global Positioning System (GPS) signal with a given offset based on a percentage of the operating frequency to achieve synchronization or interleaving with other PGUs on site to include the PGUs in Barriers IIA and IIB, the PB1 barrier facility and the Demonstration Barrier. More detail for this control is provided further in this PWS and the Appendix A, B, C, D, E and F.

The Contractor shall coordinate with other contractors who may be working at Barrier IIA, IIB, PB1 and Demonstration Barrier facilities. The Contractor shall work within the existing site conditions, including the structural building and support systems built under separate contracts. If this is not possible the contractor shall include any and all alterations in the initial proposal.

Existing Infrastructure to Support Barrier IIA and IIB PGCS The following components of the Barrier IIA and IIB are existing and to be integrated into the new PGCS and generator remote control, including: PGU equipment to include but not limited to the IGBT assemblies, the high voltage power supplies, capacitive storage banks; the cooling system equipment for the PGUs; the underwater electrodes and the cabling from the electrodes to the ground surface; the building with its supporting electrical (other than PGCS equipment); the mechanical systems HVAC for Barrier IIB only; the facilities generators; and the corresponding control systems for the aforementioned components.

The Contractor shall utilize the existing infrastructure (cooling system, electrical, and physical building layout) for the PGCS, associated systems and remote generator control. If the existing infrastructure is insufficient, it is the contractor’s responsibility to include any alterations and costs of those alterations in the proposal prior to bidding.

The Barrier IIA and IIB facilities details to include dimensions and other details are set forth in Appendix B Drawings.

Similarly for Barrier IIA and IIB the 1.5MW PGU’s (commonly known as Pulser 1 and Pulser 2) major equipment include but are not limited to: a 3.4KV, 30KA ABB/Astrol IGBT assembly; a 1.5MW 480VAC to 3.2KVDC HVPS; and a 0.1135F capacitor bank comprised of fifty (50) 3300V, 2270 microfarad capacitors. The 350KW PGU’s (commonly known as Pulser 3) major equipment include but are not limited to: a 2.0KV, 10KA ABB/Astrol IGBT assembly; a 350KW 480VAC to 2.0KVDC HVPS; and a 0.05675F capacitor bank comprised of fifty (25) 3300V, 2270 microfarad capacitors. More detail for this control is provided further in this PWS and the Appendix A, B, C, D, E and F.

Barrier IIA has two (2) 25KV, 6.5KA, 3 Position HVPPSs (High Voltage Polarity/Position Switch). One HVPPS allows switching between Pulser 1 and Pulser 2 while the other allows switching between Pulser 2 and Pulser 3; effectively making Pulser 2 the backup for either Pulser 1 or Pulser 3. The 3 positions will include an off and switching between PGUs as detailed in previous sentence. The HVPPS has an auto lube system, and electrical motor to change positions and control feedback for HVPPS position. Barrier IIB has two (2) 25KV, 6.5KA, 6 Position HVPPSs. One HVPPS allows switching between Pulser 1 and Pulser 2 while the other allows switching between Pulser 2 and Pulser 3; effectively making Pulser 2 the backup for either Pulser 1 or Pulser 3. The 6 positions will include an off and switching between PGUs as detailed in previous sentence and allow for polarity switching of all PGUs. The HVPPS has an auto lube system, and electrical motor to change positions and control feedback for HVPPS position. Barrier IIB similarly to Barrier IIB has two (2) HVPPSs with the same specifications as IIA. However, Barrier IIB uses all 6 positions of the HVPPS. More detail for this control is provided further in this PWS and the Appendix A, B, C, D, E and F.

Barrier IIA and IIB both have two (2) closed loop liquid cooling systems for the PGUs. There is a deionized (DI) water system for the IGBT assemblies and a water/glycol system for the HVPSs. There are multiple sensors to include but not limited to flow, temperature, conductivity and pressure for each system as well as circulation pumps, piping and valves; it is expected for this equipment to be reused in the new PGCS. More detail for this control is provided further in this PWS and the Appendix A, B, C, D, E and F.

There are two (2) underwater electrode (steel bar assemblies) arrays per Barrier IIA and Barrier IIB; there is a “narrow” array and a “wide” array. They are referred to as narrow and wide due to the orientation of the underwater electrodes. The narrow array has electrodes that are spaced closer together while the wide array has electrodes that are spaced further apart. Further details are set forth in Appendix D. The narrow array consist of 24 - 5”x5” electrodes approximately 156’ long while the wide array consist of 18 – 5”x5” electrodes approximately 156’ long with each electrode spanning the width of the canal and resting on underwater concrete sleepers. The narrow array has two major groupings with 12 electrodes per major grouping while the wide array has 9 electrodes per major grouping. The two groupings for each array will provide each array with a cathode and an anode. Each electrode has one 250kcmil, 5KV, HDPE cable (known as the electrode cables) attached to each end (see additional details in Appendix F). Therefore, there are a total of 48 cables for narrow array and 36 cables for the wide array. The electrode cables are routed through several conduits that feed from the underwater electrodes through the CSSC embankment up to the bus bar raceway and the electrode cables are attached to the bus bar. The bus bar is routed through the raceway where it is attached to a HVPPS, thereby each array is fed by one of the two HVPPSs. The (2) two underwater electrode arrays will generate an independent pulsed direct current (DC) electric field in the CSSC powered by the PGUs.

Barrier IIA has one (1) 3MW emergency generator that was originally sized to with the capability of running both the narrow and wide array for the IIA facility. However, it is recorded the generator struggles with running both arrays simultaneously. Therefore, it was decided to run only one (1) array on emergency generator power. The default array is the narrow array and the existing PGCS monitors the operation of the emergency generator and shuts down the wide array if in use while on emergency generator power. The new PGCS shall provide the same functionality; more detail for this control is provided further in this PWS and the Appendix A and B.

Barrier IIB has two (2) 2MW emergency generators that have the capability of running both the narrow and wide array for the IIB facility. However, this is accomplished by applying a power limit to each PGU with the existing PGCS. The new PGCS shall provide the same functionality; more detail for this control is provided further in this PWS and the Appendix A and B.

In addition, the control for the existing emergency generators is currently located locally at the Barrier IIA and IIB facilities. The Contractor shall integrate the existing emergency generator controls at IIA and IIB with the existing controls in the PB1 facility to allow for control and monitoring of the existing IIA and IIB emergency generators in the PB1 facility. More detail for this control is provided further in this PWS and the Appendix A and B.

No additional equipment will be furnished as Government Furnished Equipment unless otherwise directed by the Government. The contractor shall provide all equipment required to have a complete and functional Pulse Generating Control System and PB1 remote control capability of existing emergency generators at Barriers IIA and IIB. The contractor’s proposal shall not include or assume the government shall furnish equipment not already installed at the project site.

Existing Fish Dispersal Barriers.

The Barrier II facility provides a pulse generating system that is located at the US Army Corps of Engineers’ Electric Dispersal Barrier system in the Chicago Sanitary & Ship Canal (CSSC) near Romeoville, Illinois. Barrier II was designed as two halves, each actually an independent barrier (Barrier IIA and Barrier IIB). This was done to provide redundancy, so that if one half is off-line for maintenance, (whether scheduled or unscheduled), the other half can be operational. The Dispersal Barriers send rapidly pulsed DC current through electrodes in the canal which creates an electric field in the water that deters the passage of invasive fish; thereby creating an operational and effective Pulse Generating System. The Dispersal Barriers system includes several major facilities and structures, including: the Barrier IIA, Barrier IIB, Demonstration Barrier, and the Permanent Barrier I facilities.

Barrier IIA is located in the CSSC approximately 1,150 feet downstream of the Demonstration Barrier which is located at river mile 296.5. Barrier IIA utilizes three Pulse Generating Units each comprised of a rectifier, capacitor bank, and IGBT pulsed power assembly to generate a pulsed DC in the water. Barrier IIA has 42 electrodes that span over 130 feet upstream-to-downstream on the canal bottom.

Barrier IIA has two sub-parts known as the wide and narrow arrays. The narrow array extends over approximately 50 feet upstream-to-downstream in the canal and is where the maximum electric field strength of the barrier can be generated. The operating parameters for the narrow array are normally a DC voltage in the water with a maximum field strength at the water surface of 2.3 volts/inch from a source of a DC voltage of @2,200V, @8,000A peak pulse current, a frequency of 34 Hz with a pulse duration of 2.3mS. However, these operating parameters can be adjusted. The wide array extends over approximately 80 feet upstream-to-downstream, but can’t generate field strengths as high as the narrow array. The operating parameters for the wide array are normally a DC voltage in the water with a maximum field strength at the water surface of 1 volts/inch from a source of a DC voltage of @800VDC, @2000A peak pulse current, a frequency of 34 Hz with a pulse duration of 2.3mS. The wide array is downstream of the narrow array. Barrier IIA was placed into full time operation in 2009.

Barrier IIB is located in the CSSC, approximately 800 feet downstream of the Demonstration Barrier and 220 feet upstream of Barrier IIA. Barrier IIB utilizes equipment with very similar specifications and quantity to the equipment in Barrier IIA. It has the same type, number, and spacing of electrodes as Barrier IIA, and similar operating parameters. Barrier IIB was placed into service in April 2011.

The Demonstration Barrier is located in the CSSC at approximately river mile 296.5. It consists of twelve steel cables secured just above the canal bottom. The upstream-to-downstream length of the barrier is 54 feet. A rapidly pulsed DC current is sent through the cables creating an electric field in the water that extends to the water surface. The Demonstration Barrier utilizes 4 Pulse Generating Units each comprised of a rectifier, capacitor bank, and an Insulated Gate Bipolar Transistor (IGBT) pulsed power assembly to generate pulsed DC voltage in the water with a maximum field strength at the water surface of 1 volt/inch, a frequency of 5Hz with a pulse duration of 4mS. There are two 125KVA and two 25KVA Pulse Generating Units. The Demonstration Barrier has been operational since 2002.

The Permanent Barrier I (PBI) facility is located between Barrier IIB and the Demonstration Barrier. The Permanent Barrier I facility building construction is complete. However, the construction of one of the two 4.3MW pulse generating units is currently underway and is expected to be complete in late fall of 2020.

DRAWINGS AND EQUIPMENT DETAILS

Drawings The following plan sets and drawings are applicable to the extent specified in the PWS:

One Line Diagrams (Drawings):

One Line Diagrams.pdf (attached as Appendix A)

Existing Control Logic Diagrams (Drawings):

Existing Control Logic Diagrams.pdf (attached as Appendix B)

Plan Layout (Drawings):

Plan Layout.pdf (attached as Appendix C)

2A Cooling System As-Builts (Drawings):

2A Cooling System As-Builts.pdf (attached as Appendix D)

2B Cooling System As-Builts (Drawings):

2B Cooling System As-Builts.pdf (attached as Appendix E):

Examples (Drawings, Format, Layouts):

Examples.pdf (attached as Appendix H)

Equipment Details The following equipment details are included as a part of this contract:

Cooling System Product Data, Shop Drawings, and Design Analysis

2A-2B Cooling System Data.pdf (attached as Appendix F)

This document contains support information for the cooling system as currently designed. The contractor shall field verify all equipment parts and layout prior creating their proposal and system design.

Electrode Cable Details

Electrodes and Cable Details.pdf (attached as Appendix G)

Conflict Precedents The order of precedents for resolving conflicts between documents will be as followed:

(1) Performance Work Statement

(2) Specifications as provided in Section 4 of the PWS

(3) Drawings as provided in Section 2 of the PWS

(4) All other specifications as defined in Section 6 of the PWS

(5) All Contractor provided drawings, documents and references.

PERFORMANCE REQUIREMENTS

General The Contractor shall furnish the labor, management, personnel, services, tools, meters, parts, materials, supplies, data, software, hardware, programming software-firmware, Computer Hardware Resources, control equipment, control sensors, Computer Software Configuration Items and equipment for the work set forth in this Performance Work Statement, except as otherwise specified herein. Consistent with the requirement of the Performance Work Statement, the Contractor shall procure, install, coordinate, set-up, start-up, test and commission a fully functional, operational, and working PGCS comprised of integrating six (6) independent existing Pulse Generating Units with associated equipment with new control systems that include an Insulated Gate Bi-Polar Transistor (IGBT) Assembly Control, a High Voltage Power Supply (HVPS) Control, a High Voltage Polarity/Position Switch Control (HVPPS), an Power Monitoring System (PMS) Control, an IGBT and HVPS Cooling System Control, a Generator Operation Monitoring, a Database Control and Supportive Systems to include a weather station, a canal monitoring, and an AHU Air Handler Unit Control (for Barrier IIB only). In addition, the Contractor shall similarly furnish and install a complete, working, fully functional and cohesive remote control system for the integration of the existing generators control at Barriers IIA and IIB with the existing control at the Permanent Barrier I Facility (PB1). The Contractor shall provide the work as listed previously in the paragraph to allow for a fully operational, efficient and effective Pule Generating System.

Meetings At a minimum the contractor shall host or attend the following meetings:

Progress Meetings.

A progress meeting will be conducted by the contractor weekly, and may be performed telephonically unless the contractor is on-site. The day for conducting meetings will be mutually agreed to between the Contractor and the Government within 10 calendar days after receipt of the notice to proceed. Unless the Contracting Officer's Representative (COR) specifically indicates in writing otherwise, the contractor shall prepare meeting agendas and meeting minutes for each meeting.

Each progress meeting will consist of a written agenda of topics and issues to be discussed during the meeting and followed up with draft meeting minutes prepared by the Contractor. The draft meeting minutes will be emailed out to all attendees one day after the meeting for review and approval. The review and approval process will allow for mutual acceptance of the draft minutes as written, or editing to add, delete, and/or correct items that were covered in the weekly meeting. The edited draft meeting minutes will be published and handed out by the Contractor at each following week's progress meeting. If all attendees agree the minutes have been properly edited; then those minutes become the official final minutes of the previous week's progress meeting. The contractor shall create and maintain an attendance sheet that will become an attachment to the official final meeting minutes.

The progress meeting agendas will at a minimum contain the following items:

6. Requests for Information (RFIs) / Requests for Comments (RFCs)

7. Pay estimate

8. Other

During the period beginning with on-site installation activities and ending with completion of the Performance Verification and Endurance Tests, the progress meeting agendas shall also include the following topics:

9. Status of safety plan and accident prevention

10. Review of any Punch/Discrepancy List Items

11. Review of the QCS program

12. Status and review of testing

During the first progress meeting the agenda format will be reviewed and agreed to by all parties in attendance.

Prepare and distribute the updated agenda for the meeting prior to the scheduled day, and any information in dispute will be addressed at the meeting.

Preliminary Technical Data Package Charrette Meeting.

No later than 60 days after the contract is awarded, the Government will provide comments on the Preliminary Concept Technical Package submitted with the Contractor’s proposal. Within 20 days after receiving the Government comments, the contractor shall schedule and host a charrette meeting with the Government, on site in the PB1 Building 1st floor conference room, to discuss the comments and the conceptual design. The purpose of the meeting will be to provide an opportunity for collaboration between the contractor and the Government to develop a path forward to create a PGCS and remote generator control that successfully meet the needs of the Government and fulfills the contract requirements. The meeting will be attended in person by all parties. All personnel required to make binding decisions on behalf of the Contractor must be present.

Charrette Meeting Notes.

The contractor shall provide meeting minutes of all topics discussed, with their resolutions, to the COR, for review and acceptance, within seven business days of the completion of the charrette meeting.

Conceptual Technical Data Package Submittal (TDP-2).

Within 60 days after the charrette meeting, the Contractor shall submit to the COR, for review and approval, the Conceptual Technical Data Package Submittal which shall consist of a revised Preliminary Concept Technical Package addressing any issues and modifications discussed at the charrette meeting. Additionally, the Contractor shall submit a complete (includes all submittals required by any section of the PWS) submittal register for government review and approval. Once approved the contractor shall maintain the submittal register and make the updated register available to the government upon request.

Technical Data Package 3 (TDP-3) Review Charrette Meeting.

Within 90 days after submission of the TDP-3, the Government will provide its comments on the submittal. Within 20 days after receiving the Government comments, the contractor shall schedule and host a charrette meeting with the Government on site, in the PB1 Building 1st floor conference room to discuss the comments and the conceptual design. The purpose of the meeting will be to provide an opportunity for collaboration between the contractor and the Government to develop a path forward to create a PGCS and remote generator control that successfully meets the needs of the Government and fulfills the contract requirements. The meeting will be attended in person by all parties. All personnel required to make binding decisions on behalf of the Contractor must be present. Within 60 days after the charrette meeting, the Contractor shall submit to the COR, for review and approval, any revisions to the Technical Data Package 3 documents discussed at or arising out of the charrette meeting.

Preconstruction Conference.

Prior to commencement of any construction/installation work on the site, a meeting shall be held with the Contracting Officer to discuss and develop: the administration of the safety program; preparation of the schedule; shop drawings, and other submittals. Major subcontractors who will engage in the work must also attend.

Schedule In addition to the requirements set forth in PWS Section 3.2 the contractor shall follow all requirements in PWS Section 6.

Period of Performance The Period of Performance shall be three years.

Preliminary Schedule A preliminary schedule is required to be provided as part of the bid package. The schedule shall include all major features of work. Additionally, the schedule shall show the appropriate review period for submittals, as required by the relevant CDRL or 90 days for Technical Data Packages, whichever is greater, for each Government review.

Schedule after Award The Contractor shall develop, maintain, and submit for Government approval within 30 days after contract award, an integral master project schedule identifying critical path events for all requirements to be performed by the Contractor in accordance with the contract. The schedule shall include an event-driven schedule/network that includes all tasks (from project award through testing, training and close-out) and logic necessary for the management of work, task flows, task interdependencies, major milestones, key events and all deliverables required under the contract. The Contractor shall cost load the schedule for all activities associated with Milestone E. The Contractor shall develop the schedule using a commercially available project tracking software, (Primavera P6 or equivalent), and submit it in electronic and Adobe PDF format to the Government. The schedule shall not exceed the Period of Performance (POP) as awarded.

Inclusions.

The Contractor’s project schedule shall include (not an all-inclusive list): unique activity numbers, activity description, activity durations, baseline, actuals and critical path. Furthermore, the Contractor shall identify tasks (i.e. submittal reviews, testing, etc.) performed by the Government and delivery of products or information provided by the Government on the project schedule.

Revisions.

A revised schedule shall be submitted for Government approval with all proposals, Engineering Change Order (ECO), contract modifications and Period-of-Performance (POP) extension requests. A current schedule reflecting progress shall be submitted with all invoices or on a monthly basis. If a schedule is revised for any reason contributable to contractor delay, the Contracting Officer may require consideration commensurate with the additional Government incurred costs. An updated submittal register shall be provided with every schedule update.

If, in the opinion of the Contracting Officer, the Contractor falls behind the approved schedule, take steps necessary to improve its progress including those that may be required by the Contracting Officer, without additional cost to the Government. In this circumstance, the Contracting Officer may require the Contractor to increase the number of shifts, overtime operations, days of work, and/or the amount of construction plant, and to submit for approval any supplementary schedule or schedules as the Contracting Officer deems necessary to demonstrate how the approved rate of progress will be regained.

Period of Performance Extension Requests POP extension requests shall be submitted for Government approval when the contractor realizes that they will not be able to complete all required work by the POP date. Approval of POP extension requests are not guaranteed. At a minimum, the following information is required for all POP requests: updated project schedule, explanation of the reason for the delay, and if it was a Government or Contractor delay. If a schedule is revised for any reason contributable to contractor delay, the Contracting Officer may require consideration commensurate with the additional Government incurred costs.

Pulse Generating Control System The Contractor shall provide and install a fully functional Pulse Generating Control System (PGCS) for Barrier IIA and (optional) IIB facilities for the effective and efficient operation of 3 PGUs in each barrier that meets the performance specifications and requirements set forth in this PWS, per Appendix A, B, C, D, and E and within actual as-constructed conditions. The Contractor shall provide and install PGCSs that includes Insulated Gate Bi-Polar Transistor (IGBT) Assembly Control, High Voltage Power Supply (HVPS) Control, High Voltage Polarity/Position Switch Control (HVPPS), Power Monitoring System (PMS) Control, IGBT and HVPS Cooling System Control, Generator Operation Monitoring, Database Control and any Supportive Systems for a complete PGCS to include a weather station, canal monitoring, and AHU Air Handler Unit Control (for Barrier IIB only) to continuously maintain the pulsing of (DC) direct current power in the Chicago Sanitary Ship Canal. These PGCSs will be installed within two separate barrier facilities IIA and (optional) IIB independently of each other and allow for local control in each facility as well as remote control from the PB1 facility.

For purposes of information only, the Government has observed canal conditions between 600µS/cm (ambient) at 86˚F for summer months and 2800µS/cm (ambient) at 34˚F in winter (additional historical data can be made available after contract award). For purposes of information only, the Government has observed at the existing barriers that the peak current increases by approximately 1,500A when a metal hulled vessel passes through the barriers (additional detailed data can be made available after contract award).

Pulse Generating Control System Operation The Pulse Generating Control System Operation shall include, but is not limited to, the following operations for the purpose of generating the required DC electrical pulses through the underwater electrodes. The PGCS shall provide operation per this PWS and at a minimum replace the existing operation of the equipment and control at Barriers IIA and IIB:

(a) The PGCS currently operates with parameters for the 1.5MW PGU of 2,000V with a pulse duration of 2.3ms at 34Hz and for the 350KW PGU parameters of 800V with a pulse duration of 2.3ms at 34Hz.

(b) The PGCS shall be able to operate the PGU’s at an adjustable range within the full range of parameters for Volts, pulse frequency, and pulse duration allowed by the equipment.

(c) Provide and install IGBT Assembly control for the existing IGBT assembly, existing IGBT assembly supportive devices and new IGBT assembly devices. The PGCS shall monitor the operation of the IGBT assembly and subsequently alter the PGCS control with minimal operation as currently in place and as required. The existing 1.5MW PGU IGBT assembly is rated 3.4kV/30kA and capable of being operated at peak output rectangular currents of the following: 6,500A peak at 100% duty cycle, 10,000A peak at 40% duty cycle, 20,000A peak at 10% duty cycle, and 30,000A peak at 4% duty cycle; however due to limitations of other PGU equipment the current is thought to be limited to approximately 2000A RMS current with peak pulse currents approximately 7200A and the peak pulse current shall never be greater than 30kA with resulting shutdown of equipment and alarms. The existing 350KW PGU IGBT assembly is rated 2kV/10kA and capable of being operated at peak output rectangular currents of the following: 2,700A peak at 100% duty cycle, 4,300A peak at 40% duty cycle, 8,400A peak at 10% duty cycle, and 10,000A peak at 8% duty cycle; however due to limitations of other existing PGU equipment the current is thought to be limited to approximately 600A RMS current with peak pulse currents approximately 2145A and the peak pulse current shall never be greater than 10kA with resulting shutdown of equipment and alarms. Currently, the IGBT assembly is controlled with an IGBT controller on board the assembly and communicates with the existing PGCS with fiber optic serial protocol. The IGBT assembly controller provides signals to the on board gate drivers to “switch” the IGBT modules and in addition provides diagnostic monitoring to trigger alarms and failures. There are a total of (4) four fiber optic communication lines; 3 output signals to the PGCS and 1 input signal from the PGCS to the IGBT controller. The 3 output signals include the following; 1 feedback signal-switching status on/off-(EXT_TRIGG_FP), 1 status signal-short circuit status-(STATUS_1), and 1 status signal-gate drive unit failure status-(STATUS_2). The input signal-(TRIGG_IN-IP)-on/off (pulse generator) is provided via the existing function generator; this signal is a pulse train of light supplied to the IGBT controller that will provide the pulse duration (pulse width) and pulse frequency. The pulse train is currently provided by the existing “Keysight” oscilloscope for each PGU in Barrier IIA and “Bitscope” in Barrier IIB and can be reused in IIA and new oscilloscopes equal to the “Keysight” oscilloscope shall be provided for each PGU in Barrier IIB. More information can be provided regarding the IGBT controller after award of the contract. The Contractor shall replace each of the existing IGBT assembly controller on board the IGBT assembly with a new controller for each IGBT assembly for a total of (6) six new controllers. The new IGBT assembly controllers shall provide the same operability and functionality as the current controllers with an industrial communication system such as Ethernet that can be paired easily with an industrial off the shelf PLC and associated software. In addition, the Contractor shall provide the most up to date short circuit protection and gate failure detection systems available for the assemblies. The existing IGBT controllers are manufactured and/or supported by Astrol Electronics in Switzerland and Astrol currently can provide replacement IGBT controllers that have Ethernet communication control scheme. In the event of a switching error, short circuit or gate drive failure the Contractor shall shut down the power to the IGBT assembly and operation thereof in the most efficient and fast method as possible to reduce possible arc time. There shall be capability for the new IGBT controller to communicate directly with the HVPS controller to shorten this time. The Contractor shall interface the PGCS with a new IGBT assembly on-board controller (IGBT controller) to provide control and feedback between the PGCS and the IGBT assembly controller. The Contractor shall include in the PGCS devices for measuring current and voltage on upstream and downstream of each of the IGBT assemblies to replace the existing measuring devices for the purpose of detecting measuring voltage, current, over-voltages, under-voltages, over-currents and under-currents; these devices can be dual used between PGU control and the (Power Monitoring System) PMS control. The Contractor shall include in the PGCS devices for measuring current and voltage on each of the IGBT assembly capacitor banks to replace the existing measuring devices. The purpose of these devices is to monitor the voltage and current on the capacitor bank and to use these values to display upon the GUI (Graphical User Interface) screens such that the operator can verify the presence of stored energy or lack thereof on the capacitors as well as initiating an alarm in the event of high voltage and high current. The Contractor shall include in the PGCS a device for sensing water leaks in the IGBT assembly area to replace the existing device. The purpose of this device is to detect any water that could possibly leak from the IGBT assembly cooling system and shut down the power and operation to the PGU and annunciate an alarm on the GUI screen. The Contractor shall include in the PGCS a device for sensing light generated by electrical arcs in the IGBT assembly area. The purpose of this device is to detect flashes of light generated by arc faults in the IGBT assembly area and to shut down power to the IGBT assembly and operation thereof in the most efficient and fast method as possible to reduce possible arc time. The Contractor shall include in the PGCS controls to drain the capacitor banks using the existing relay and bleed resistors (fast discharge). The purpose of this control is allow the user to drain the energy from the capacitor banks in a faster method than the bleed resistors (slow discharge) that aren’t wired to the relay. The control for fast discharge bleed resistor relay shall be interlocked to prevent draining with the fast discharge resistors while the IGBT assembly is energized. The Contractor shall also provide for draining the capacitors with simply dissipating the stored energy in the water of the canal. The Contractor shall provide new solar radiation sensors or can reuse the existing to provide adequate sensing of solar radiation for the IGBT assembly operation. The Contractor shall coordinate with the IGBT assembly manufacturer to ensure proper control and operation of the IGBT assembly in this application. The Contractor shall have the IGBT assembly evaluated for condition and operability after modifications and prior to reinstatement of service by either the manufacturer of record, representative of manufacturer of record or the manufacturer of the IGBT assembly controller. The Contractor shall evaluate all (6) six IGBT assemblies to determine the condition of existing assembly components, component life span expected, component likelihood of failure, evaluation of all protective devices and systems to determine effectiveness and evaluation of internal communications and external communications. The evaluation shall be provided to the Government in a clearly articulated report. The Contractor shall assume for estimation purposes any required repairs or replacements will be an additional cost to the Government and not included in the initial proposal. The Contractor shall provide an estimate of repairs and replacements to the Government prior to any repairs or replacements for approval and payment. After approval, the Contractor shall provide the repairs and replacements.

(d) Provide and install HVPS control for the existing HVPS (High Voltage Power Supply), existing HVPS supportive devices and new HVPS assembly devices. The PGCS shall monitor the operation of the HVPS and subsequently alter the PGCS control with minimal operation as currently in place and as required. The Contractor shall interface the PGCS with the existing HVPS on-board controller (HVPS controller) to provide control and feedback between the PGCS and the HVPS controller. The HVPS controller has 16 discrete contacts for input into the PGCS that include alarms and annunciation from the HVPS. In addition, the HVPS controller has a DB9 RS232 communication port that shall allow for control from the PGCS to include things like alarm information and control parameters like DC set-point voltage for the voltage output of the HVPS (See One Line Diagram Drawings and Existing Control Logic Diagrams). Lastly, the HVPS controller has 3 discrete inputs such that the PGCS can utilize to provide a fault to the HVPS controller and ultimately shut down the HVPS. Additional information pertaining to the HVPS and the HVPS controller can be provide after award of contract. The Contractor shall coordinate with the HVPS manufacturer to ensure proper control and operation of the HVPS in this application. The Contractor shall evaluate all (6) six HVPSs to determine condition of existing assembly components, component life span expected, component likelihood of failure, evaluation of all protective devices and systems to determine effectiveness and evaluation of internal communications and external communications. The evaluation shall be provided to the Government in a clearly articulated report. The Contractor shall assume for estimation purposes any required repairs or replacements will be an additional cost to the Government and not included in the initial proposal. The Contractor shall provide an estimate of repairs and replacements to the Government prior to any repairs or replacements for approval and payment. After approval, the Contractor shall provide the repairs and replacements.

(e) Provide and install HVPPS (High Voltage Polarity/Position Switch) control for the existing HVPPS, existing HVPPS supportive devices and new HVPPS assembly devices. The PGCS shall monitor the operation of the HVPPS and subsequently alter the PGCS control with minimal operation as currently in place and as required. The Contractor shall interface the PGCS with the existing HVPPS controllers to provide control and feedback between the PGCS and the HVPPS controllers to allow for proper control and alarm annunciation between the HVPPS controllers and the PGCS. The HVPPS controllers include a switch position controller and lube controller. The switch position controller includes command position that actuate a small motor on the HVPPS assembly that rotates the HVPPS between positions in addition it includes position feedback from cam switches and micro-switches on the HVPPS assembly to indicate position of the HVPPS. The HVPPS has 6 positions and only 4 of the 6 positions are currently being used for Barrier IIA and all 6 positions for Barrier IIB; see paragraph “Existing Infrastructure to Support Barrier IIA and IIB PGCS” at this beginning of this document for additional information. The HVPPS shall never actuate while under electrical load. The lube controller provides control for the lubing mechanism on board the HVPPS assembly; the HVPPS requires lubing before actuation. The HVPPS shall have a local/remote switch to allow for actuation of the HVPPS either by GUI screen interface or local control switch which directly control the existing HVPPS controller. The local/remote switch shall be located to allow for safe operation without the need of electrical PPE. The Contractor shall coordinate with the HVPPS manufacturer to ensure proper control and operation of the HVPPS in this application. The Contractor shall evaluate all (4) four HVPPSs to determine the condition of existing assembly components, component life span expected, component likelihood of failure, evaluation of all protective devices and systems to determine effectiveness and evaluation of internal communications and external communications. The evaluation shall be provided to the Government in a clearly articulated report. The Contractor shall assume for estimation purposes any required repairs or replacements will be an additional cost to the Government and not included in the initial proposal. The Contractor shall provide an estimate of repairs and replacements to the Government prior to any repairs or replacements for approval and payment. After approval, the Contractor shall provide the repairs and replacements.

(f) Provide and install Power Monitoring System (PMS) control, PMS devices and existing PMS supportive devices. The PGCS shall monitor the voltage and current as described further and subsequently display or alter the PGCS control with minimal operation as currently in place and as required. The PMS shall include equipment and devices to interface with the PGCS to allow for control and annunciation of the PMS and the PGCS. The PMS shall include devices that monitor voltage and current upstream and downstream of the IGBT assemblies to replace the existing equipment. The PMS shall include devices to monitor the current through each of the electrode cables to replace the existing system that feed the underwater electrodes and display this information on the PGCS GUI screens for display and trending; the values shall be in real time. In addition, the values from the PMS shall be stored in the PGCS database for reference; the average and peak quarter hour value shall be recorded and backed up for 2 weeks. Therefore, the PMS has 48 (forty eight) electrode cables that will be monitored for each of the narrow array electrode configurations and 36 (thirty six) electrode cables for each of the wide array electrodes configurations. Note: each barrier IIA and IIB have both a narrow and a wide array. The Contractor shall remove the existing electrode cable current transformer from each of the cables as mentioned previously. The Contractor shall replace the current transformers with a current sensor. The PMS shall be capable of monitoring the pulsed currents on each cable as required by the PGU equipment. The PMS shall be designed to limit interference from electrical noise in the most effective way possible.

(g) Provide and install IGBT assemblies and HVPSs cooling control, IGBT assembly and HVPS cooling devices, IGBT assembly and HVPS existing supportive devices. There is a complete existing cooling system for IGBT assemblies and the HVPSs. The PGCS shall monitor the operation of the equipment as previously mentioned and subsequently alter the PGCS to provide required cooling of the equipment with minimal operation that is currently in place and as required. All equipment, devices and piping shall be reused with the exception of a portion of the existing control system. The portion of the existing control system that shall remain are the existing temperature, flow, conductivity, pressure sensors and pump control equipment with all other control components to be removed. There are existing cooling devices that the Contractor can incorporate into the PGCS or the Contractor can substitute similar devices for the existing devices if submitted and approved by the Government. The cooling control for the IGBT assemblies and HVPSs shall be such that to meet the requirements of the IGBT assembly and HVPS manufacturer requirements. The IGBT assemblies are required by the manufacturer to have required a minimum water flow for the complete switch of 70L/min (1.5MW PGU) and 20L/min (350KW PGU); a water pressure between 4-6 bar (58-87psi), use of demineralized water, no copper parts in the cooling system, a conductivity no greater than 1µS/cm and a maximum inlet temperature of 40˚C (104˚F) and ambient operation between 10-40˚C at less than 65% RH. More information regarding the IGBT assembly can be provided upon award of the contract. The HVPSs have an existing air to water heater exchanger to provide cooling for the HVPS enclosure. There is a blower in the cooling section of the HVPS that pulls heated air the heat exchanger. Cooling water supplied by the existing cooling system circulates through the heat exchanger. The HVPS manufacturer requires the water be supplied at 22GPM (1.5MW PGU) and 15GPM (350KW PGU) with a maximum temperature of 35˚C (95˚F). The Contractor shall coordinate with the IGBT assembly and HVPS manufacturers to ensure proper control and operation of the equipment in this application.

(h) Provide and install Generator Operation Monitoring…