Statement_of_Specification_1.pdf

SH Condensing System and Gov Modernization

BUREAU OF RECLAMATION

NORTHERN CALIFORNIA AREA OFFICE

STATEMENT OF SPECIFICATION

SHASTA POWER PLANT DIGITAL GOVERNOR

MODERNIZATION

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Initial Shasta main unit design, engineering, and programming of new hardware and software to modernize digital governor for first main unit. Including adding synchronous condense and rough zone mode to existing governor controls.

1. Payment: Lump sum price. Qty 1 ea.

B. Subsequent Shasta main unit design, engineering, and programming of new hardware and software to modernize digital governor for remaining four main units. Including adding synchronous condense and rough zone mode to existing governor controls.

1. Payment: Lump sum price. Qty 4 ea.

C. Main unit governor control PLC and equipment upgrade

1. Payment: Lump sum price. Qty 5 lot

D. Initial Shasta station service unit design, engineering, construction drawings and programming of new hardware and software to modernize digital governor for first station service unit.

1. Payment: Lump sum price. Qty 1 ea.

E. Subsequent Shasta station service unit design, engineering, construction drawings and programming of new hardware and software to modernize digital governor for remaining station service unit.

1. Payment: Lump sum price. Qty 1 ea.

F. Station service unit governor control Programmable Logic Controller (PLC) upgrade equipment

1. Payment: Lump sum price. Qty 2 lot

G. Commissioning services for each unit

1. Payment: Lump sum price. Qty 7 ea.

H. Governor Maintenance Software

1. Payment: Lump sum price. Qty 1ea.

I. Recommended spare parts

1. Payment: Lump sum price. Qty 1 lot

1.02 BACKGROUND

A. Shasta power plant digital governors have been in service for over 20 years. The current hardware is obsolete and no longer supported by manufacturers. To extend the service life of the digital governors a modernization of hardware will need to occur.

1.03 SCOPE

A. Perform all the necessary work to design, engineer, program and supply all hardware needed to modernize the existing digital governors and add synchronous condense and rough zone modes to existing digital governors at Shasta powerplant.

1.04 OBJECTIVE

A. Modernize all digital governors PLC’s and Human Machine Interface (HMI) to extend current lifecycle by 15-20 years. This will include all design, engineering, and programming necessary to modernize governors with update to date hardware.

1.05 DIGITAL GOVERNORS

A. All original mechanical governors were replaced with L&S Automated Control Digital Governors in 2004-2005 timeframe.

1.06 Type of Contract

The government will award a Firm-Fixed Price contract.

1.07 Period of Performance

All work must be completed no later than two years from the date of award.

1.08 Administration Information

A. Recognized Holidays:

New Year’s Day Independence Day Martin Luther King Jr.’s Birthday Labor Day President’s Day Columbus Day Memorial Day Veteran’s Day Juneteenth National Independence Day Thanksgiving Day

Christmas Day

B. Hours of Operations

The contractor is responsible for conducting business between the hours of 7am to 5pm Monday through Friday except Federal holidays or when the Government facility is closed due to local or national emergencies, administrative closings, or similar Government directed facility closings. For other than firm fixed price contracts, the contractor will not be reimbursed when the government facility is closed for the above reasons. The Contractor must at all times maintain an adequate workforce for the uninterrupted performance of all tasks defined within this PWS when the Government facility is not closed for the above reasons. When hiring personnel, the Contractor must keep in mind that the stability and continuity of the workforce are essential.

C. Place of Performance

The work to be performed under this contract will be performed at:

Shasta Power Plant 16349 Shasta Dam Blvd Shasta Lake CA 96019

PART 2 TECHNICAL REQUIREMENTS

1.09 MINIMUM LEVEL OF PERFORMANCE

A. Upgrade the digital governor PLCs and HMIs for the five generator units and two service units at Shasta power plant. The upgraded governors will include Modicon M580 BMEP581020 PLCs and Magelis HMIGTO5310 touchscreen panels, also manufactured by Schneider Electric. Primarily to minimize unit downtime, L&S will utilize Schneider Electric’s Evolution PLC I/O Chassis to house the new PLC components. The Evolution PLC I/O Chassis fits the identical footprint as the current Quantum backplate with the additional advantage of allowing the connection of field wiring to M580 I/O without disturbing existing connections by use of pre-wired I/O adapter cable.

To prepare for the upgrade from the obsolete Quantum 140CPU65150 PLC to the Modicon M580 PLC, L&S will first design and engineer the layout of one generator unit and one service unit. A similar design and engineering process will then be employed for the subsequent four generator units and second service unit. This process will take less time per unit as they will be identical to the initial generator and service units.

A significant design change as part of upgrading from the Quantum 140CPU65150 PLC to the Modicon M580 PLC will be to eliminate the now defunct Modbus Plus communication network which currently controls communication between the Quantum 140CPU65150 PLC, Momentum High Speed Counters and the Bitronics PowerPlex RTS Digital Transducer used to assist in the auto synchronizing process. The existing

Bitronics PowerPlex RTS Digital Transducer will be replaced with a new SEL-751 Feeder Protection Relay, programmed by L&S, which will perform auto-synchronizing tasks by measuring generator frequency and bus frequency, making the need for a bus frequency Momentum High Speed Counter no longer necessary. The other existing Momentum High Speed Counter will be replaced with a new X80 TMC Frequency Input Module to measure the speed signal coming from the pickups and PT interface.

Given the hardware and resulting PLC code changes, the current PLC software cannot simply be migrated. The programing changes to the individual hardware components require intimate knowledge of the internal code. In addition, the vibration sensing code will be migrated to the Modicon M580 and verified.

L&S will program, and bench test the Modicon M580 BMEP581020 PLC and Magelis HMIGTO5310 touchscreen panel so that the upgraded hardware operates correctly.

The generator synchronous condense mode programming will be modified for the main units 1-5 to include the ability to control and protect the units during condensing and rough zone operations. The governor programing will initiate and maintain and air bubble during condensing operations and have automatic protection to restore units to Speed No Load operations from condensing mode in the event of loss of cooling flow to seal rings or any other loss of controls for condensing operations. In addition, the governor programming will be modified to control the air admittance valve for rough zone operations during normal governor operations.

1.10 SERVICE WORK TO BE PERFORMED

A. Design, engineering, and programing will consist of the integration and installation engineering of new governor PLC components for the Shasta Generator main and service units, programming the Modicon M580 controller with the latest software version followed by testing to ensure accurate operation. In addition, programming and documentation updates related to Synchronous Condense Mode and rough zone air admission will be added to main units only. L&S will provide a list of PLC update materials for United State, Bureau of Reclamation (USBR) review. The following documentation will also be provided with the design and construction package.

1. Description of System Operation Updates

2. Updated Layout Drawings

3. Updated Elementary Drawings

4. Updated Communication Drawings

5. Installation and integration engineering consists of drawing updates showing the new hardware mounting and wiring Owner and Maintenance Manual Updates

6. Installation procedure to be used by NCAO staff for installation of all new hardware

7. Factory Testing

1.11 NEW HARDWARE EQUIPMENT

A. Contractor will provide all necessary hardware to upgrade the digital governors to a Modicon M580 PLC system

1.12 COMMISSIONING AND TRAINING

A. Commissioning services will be performed by one (1) field service representative per L&S Electric’s standard Site Acceptance Test (SAT) procedures and Site Acceptance Test (SAT) documentation, which is based on the FAT documentation.

B. Provide onsite training to Operations and Craft on modernized governors and new condensing Mode operations also include rough zone operations during normal governor control mode.

1.13 Governor Maintenance Software

A. Software will be provided to allow access and modifications to the governor PLC software and HIM applications.

1.14 SPARE PARTS

A. Contractor must provide all recommended spare parts.

1.15 DELIVERY ADDRESS

A. Shasta power plant is located at:

US Bureau of Reclamation Shasta Power Plant 16349 Shasta Dam Blvd.

Shasta Lake, CA 96019

END OF SECTION