SOW - Upgrade Paralleling Switchgear B330.pdf

STATEMENT OF WORK (SOW)

Contract Number: (completed by the CO at time of award) Task Order Number: (completed by the CO at time of award if a TO) IFCAP Tracking Number: (Completed by the requestor. This is the 2237

Number)

Follow-on to Contract and Task Order Number:

(If this is a follow-on order to a previous contract or TO, insert the contract number or the TO number to which it is a follow-on. If this is not for a follow-on, state “Not Applicable”)

1. Contracting Officer’s Representative (COR).

Name: Amy Pratt Section: Engineering Projects Address: 4100 W third St, Dayton, OH 45428 Phone Number: 937-939-1556 Fax Number: 937-267-3943 E-Mail Address: Amy.boatman@va.gov

2. Contract Title: Upgrade Paralleling Switch Gear B330

3. Background:

There are two programmable logic controllers (PLC’s) for the paralleling switchgear in building 330 to provide a redundancy for such a critical system. One of the PLC’s is completely inoperable thereby removing the redundancy thus putting the facility’s inpatient tower in a very vulnerable position. The second PLC and the operator interface panel (OIP) are in legacy mode and are no longer repairable. Maintenance personnel have frequently experienced lost communications as well as viewing capabilities and control access. This equipment is vital to our emergency power backup system which serves the inpatient tower. The complete system made up of the PLC’s, HMI, operating system(OS), and controls are antiquated, obsolete and no longer serviceable.

4. Scope.

The contractor shall remove and replace the existing discontinued GE Fanuc 90-30 series PLC hardware and Genius communications (obsolete) with the latest Rx3i PLC hardware and EGD communications. Replace the existing Operator Interface Panel (OIP) with a new 15” Siemens touch screen with a new Wonderware “E” Box processor running the latest Wonderware software.

The active portion of the control’s replacement is estimated to take approximately one to two weeks and will require an outage of the controls. A portable generator to carry the entire load will need to be brought in. Estimated size is 2MW at 480V-3Ph. The system will require load banking to verify correct operation.

The contractor shall be certified in Russelectric (Siemens) switchgear and be familiar with Caterpillar genset controls. The contractor shall also be an expert in programming the PLC with the latest edition of Proficy software as well as Wonderware for configuring the OIP. Contractor shall provide all labor, materials, software and programming, and testing to modernize the paralleling switchgear controls that serves Building 330.

Contractor shall coordinate integration activities with Russelectric (Siemens) and Caterpillar. Contact information listed here:

Russelectric, A Siemens Business Ohio CAT 99 Industrial Park Road 1281 Brunker Dr South Shore Park Troy, OH 45373 Hingham, MA 02043-5250 614-580-4346 781-749-6000 blotfi@ohiocat.com Stephen.fox@siemens.com Babak Lotfi Stephen Fox

5. Specific Tasks for Switchboard (34763-S-ESBR)

ITEM A:

Bid Item 1, Base Bid - Provide temporary backup service in place of the facility generators during construction activities. Document all settings and values on indicators and controls prior to any removal of components. Remove PLC processors, power supplies, input/output cards, other communication cards, and chassis. Install new PLC racks complete with all necessary hardware and programmed for identical operation as previous program. Perform all testing and commissioning. Provide training to VA FMS staff and all Operation and Maintenance manuals. Remove temporary backup service and restore all connections to facility generators. Commission new PLC controls and operator interface with facility generators.

1) Provide a 2000kW portable diesel generator(s) in place for backup service. Temporary generator(s) is to serve as a backup system for the loads while the controls are being replaced in the emergency generator switchgear. Provide a plan on where the connections are to be made from the portable generator(s) and how they will serve the building in the event that there is a loss of normal power. Run all necessary cabling and controls for backup operation. Train staff on use and operation in the event that an event would occur during off hours. Have plan in place for servicing and refueling. Remove all sources of power from paralleling switchgear and prevent facility generators from starting through lockout/ tagout devices. Shunt all dead bus bars to ground and test for any stray voltage present.

2) Prior to commencing any work, record all setpoint values and other settings. Replace the existing discontinued GE Fanuc 90-30 series PLC hardware and Genius communications (obsolete) with the latest Rx3i PLC hardware and EGD communications. Replace the existing OIP with a new 15” Siemens touch screen with a new Wonderware “E” Box processor running the latest Wonderware software.

3) Replace the existing discontinued PLC’s and PLC communication with current GE Rx3i PACs and communications. Provide the conversion process and programming to replace the following in such a way to minimize downtime.

a) Replace the (1) existing GE Fanuc PLC (Primary) in the Master Control Cubicle (34763-S- ESBR) with a Rx3i PLC, using a CPE305, Central Processing Unit, Power Supply, and Backplane.

i) Provide a Siemens DC to DC power supply retrofit kit and circuit protection for installation to feed the PLC above.

b) Replace the existing GE Fanuc PLC (Alternate) in the Master Control Cubicle (34763-S- ESBR) with a Rx3i PLC, using a CPE305, Central Processing Unit, Power Supply, and Backplane.

i) Provide a Siemens DC to DC power supply retrofit kit and circuit protection for installation to feed the PLC above.

c) Replace the (1) existing GE Fanuc expansion PLCs (Primary) in the (CC) control cubicle with a Rx3i expansion PLCs. A total of (1) expansion racks will be replaced. Provide a Siemens DC to DC power supply and protection hardware for installation to feed the new expansion racks.

d) Replace the existing (4) GE Fanuc PLCs in the Generator Control Cubicles (C1-C4) with Rx3i PLCs using CPU305 Central Processing Unit, Power Supply, and Backplane. Provide a Vicor to Puls DC to DC power supply retrofit kit and circuit protection for installation to feed the replaced PLC.

i) (1) 34763-S-ESBR Cubicle C1

ii) (1) 34763-S-ESBR Cubicle C2

iii) (1) 34763-S-ESBR Cubicle C3

iv) (1) 34763-S- ESBR Cubicle C4

e) The Rx3i PLCs will use EGD communications for communications with all other PLCs in the system (replaces Genius Bus communications).

The communications for the Rx3i PLCs and all other PLCs will be configured in a ring topology for redundancy, each PLC will have a Moxa-managed Ethernet switch and will be configured in a Moxa TurboRing topology, which allows for any one device, or anyone link to fail, and the entire system remain operational.

f) Replace all IO cards in the Primary & Alternate PLC's.

g) Provide (1) Moxa Ethernet/Serial Modbus Gateways in each Generator control cubicle (4 Total) for communications between the Generator protocol converter and the Engine PLC via Ethernet.

h) Provide the programming to convert the existing PLC logic and configuration to GE Proficy ME. The Logic and configuration to be loaded on the Rx3i Devices. These logic routines for control are converted in an automated process and the logic will be converted and remain as it currently operates. The configuration is converted in an automated process and then manually modified for the new communications protocol and hardware.

4) Replace the (1) existing Wonderware OIP on the door of the Master Control Cubicle (CC) 34763-P-ESBR with 15" Siemens Touch panel with a Wonderware “E” Box PC running the latest version of the Wonderware Intouch software. Provide (1) 3k Tag RT License for running the Intouch software.

a) The new touch screen with bezel and mounting plate shall fit into the existing door. Provide Scada Engineering to load the existing graphics to the new unit.

5) Test/check hardware and all inputs and outputs on PLC’s with bench test before installing onsite. Recheck after installation onsite. Test for seamless redundancy of PLC’s without causing errors. PLC program shall be identical to existing logic. Any opportunity for improvements or necessary changes shall be made through the RFI process as well as documented in the program comments and the O&M’s.

6) Test/check control system after installation in switchgear. Check communication interface with generators. This segment reflects technical support and aid from the Russelectric field service team and OhioCAT. during the startup of emergency generator switchgear. Use technical support to verify alarms, shutdowns, speed, and voltage control, load-sharing, and synchronization.

7) Provide a 2000 KW resistive load bank to perform a resistive load bank test for two (2) hours on each emergency standby generator after upgrades.

Remove load bank after 2-hour test and commissioning of paralleling generators and their corresponding switchgear.

6. Performance Monitoring: All work will be inspected by COR and SME.

7. Security Requirements: The Contractor must check in and out with the COR before and upon completion of any work on campus. The contractor must check with COR prior to energizing or de-energizing lines or equipment. The COR is the only individual allowed to energize or de-energize lines or equipment unless the COR delegates the authority.

The C&A requirements do not apply, and a Security Accreditation Package is not required.

8. Government-Furnished Equipment (GFE)/Government-Furnished Information

(GFI): N/A

9. Other Pertinent Information or Special Considerations:

a. Identification of Possible Follow-on Work.

b. Identification of Potential Conflicts of Interest (COI).

c. Identification of Non-Disclosure Requirements.

d. Packaging, Packing and Shipping Instructions. All packing slips and shipping labels will include the PO#. If there are equipment/supplies a shipping confirmation should be provided to the COR and delivered to Dayton Veterans Affairs Medical Center 4100 W Third St Building 143, Dayton, OH 45428

e. Inspection and Acceptance Criteria.

10. Risk Control: Must be licensed and bonded with OSHA certifications.

11. Place of Performance: Tasks under this SOW shall be performed in VA facilities located within the Dayton VA Center

The Dayton VA is located at 4100 W. 3rd St. Dayton, OH 45428 and work is to be performed at the following locations:

Building 330

12. Period of Performance: 425 Calendar days from issuance of NTP.

Any work at the Government site shall be conducted on any day or time as required. All work outside of normal business hours, including holidays and weekends shall be scheduled and coordinated with the Contracting Officer (CO) and the COR. The work to be done will occasionally need to be performed outside of normal business hours to be accomplished during the ‘non peak’ hours as described below. For reference, the Federal holidays are shown below.

There are eleven (11) Federal holidays set by law (USC Title 5 Section 6103) that VA follows:

Under current definitions, four are set by date:

New Year's Day January 1 Juneteenth June 19 Independence Day July 4 Veterans Day November 11 Christmas Day December 25

If any of the above falls on a Saturday, then Friday shall be observed as a holiday.

Similarly, if one falls on a Sunday, then Monday shall be observed as a holiday.

The other six are set by a day of the week and month:

Martin Luther King's Birthday Third Monday in January Washington's Birthday Third Monday in February

Memorial Day Last Monday in May Labor Day First Monday in September Columbus Day Second Monday in October Thanksgiving Fourth Thursday in November

13. Delivery Schedule: Monday – Friday 0800-1630 HOURS. Shutdown events for making or breaking electrical/control connections or equipment testing must be scheduled through the COR during hospital nonpeak hours.