A.01.13_SPECIFICATIONS.docx

DIVISION 26 - ELECTRICAL

SECTION 26 29 23

BONNEVILLE HATCHERY WELLS - VARIABLE FREQUENCY DRIVE SYSTEMS UNDER 600 VOLTS

PART 1 GENERAL

Provide 480VAC Variable Frequency Drives for existing Hatchery Well Pumps, H1 (300HP), H4 (250HP), H5 (300HP), and H7 (100HP). Ensure the drives are functionally identical. Provide drives of a single manufacturer and supplier.

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 519 (2014) Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems

IEEE C62.41.1 (2002; R 2008) Guide on the Surges Environment in Low-Voltage (1000 V and Less) AC Power Circuits

IEEE C62.41.2 (2002; C 2012) Recommended Practice on Characterization of Surges in Low-Voltage (1000 V and Less) AC Power Circuits

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2014) Enclosures for Electrical Equipment (1000 Volts Maximum)

NEMA ICS 1 (2000; R 2015) Standard for Industrial Control and Systems: General Requirements

NEMA ICS 2 (2000; R 2005) Industrial Control and System Controllers, Contactors, and Overload Relays Rated 600 Volts

NEMA ICS 3.1 (2009; R 2014) Guide for the Application, Handling, Storage, Installation and Maintenance of Medium-Voltage AC Contactors, Controllers and Control Centers

NEMA ICS 6 (1993; R 2011) Industrial Control and Systems: Enclosures

NEMA ICS 7 (2014) Industrial Control and Systems: Adjustable-Speed Drives

INTERNATIONAL ELECTRICAL TESTING ASSOCIATION (NETA)

NETA ATS (2013) Standard for Acceptance Testing Specifications for Electrical Power Equipment and Systems

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2014; AMD 1 2013; Errata 1 2013; AMD 2 2013; Errata 2 2013; AMD 3 2014; Errata 3-4 2014; AMD 4-6 2014) National Electrical Code

UNDERWRITERS LABORATORIES (UL)

UL 489 (2013; Reprint Mar 2014) Molded-Case Circuit Breakers, Molded-Case Switches, and Circuit-Breaker Enclosures

UL 508C (2002; Reprint Nov 2010) Power Conversion Equipment

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-STD-461 (2007; Rev F) Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

47 CFR 15 (2014) Radio Frequency Devices

1.2 SYSTEM DESCRIPTION

1.2.1 Performance Requirements

a. Electromagnetic Interference Suppression Certify computing devices, as defined by 47 CFR 15, MIL-STD-461 rules and regulations, comply with the requirements for class A computing devices and labeled as set forth in part 15.

b. Electromechanical and Electrical Components Ensure electrical and electromechanical components of the Variable Frequency Drives (VFD) do not cause electromagnetic interference to adjacent electrical or electromechanical equipment while in operation.

1.2.2 Electrical Requirements

a. Power Line Surge Protection Provide each VFD with surge protection in accordance with IEEE C62.41.1, IEEE C62.41.2 and IEEE 519. Provide the surge protection within the cabinet to protect the unit from damaging transient voltages. Mount surge arrestor near the incoming power source and properly wire to all three phases and ground. Do not use fuses for surge protection.

b. Sensor and Control Wiring Surge Protection Ensure I/O functions as specified are protected against surges induced on control and sensor wiring installed indoors. Protect the inputs and outputs in both normal mode and common mode using the following two waveforms:

(1) A 10 microsecond by 1000 microsecond waveform with a peak voltage of 1500 volts and a peak current of 60 amperes.

(2) An 8 microsecond by 20 microsecond waveform with a peak voltage of 1000 volts and a peak current of 500 amperes.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.

SD-02 Shop Drawings

Schematic Diagrams; G Interconnecting Diagrams; G Installation Instructions; G

Submit drawings for Government approval prior to equipment construction or integration. Record modifications to original drawings made during construction immediately for inclusion into the as-built drawings.

SD-03 Product Data

Variable Frequency Drives; G Equipment Schedule; G Spare Parts; G Human Interface Module; G Communications Adapter; G Include data indicating compatibility with motors being driven.

Matrix Filter; G

SD-06 Test Reports

Factory Test Results; G VFD Factory Test Plan; G Proposed Test Plan; G Performance Verification Tests; G

SD-08 Manufacturer's Instructions

Installation Instructions; G

SD-10 Operation and Maintenance Data

Variable Frequency Drives; G

Provide service and maintenance information including preventive maintenance, assembly, and disassembly procedures. Submit additional information necessary to provide complete operation, repair, and maintenance information, detailed to the smallest replaceable unit. Provide routine preventative maintenance instructions, and equipment required. Provide instructions on how to modify program settings, and modify the control program. Provide instructions on drive adjustment, trouble-shooting, and configuration. Provide instructions on process tuning and system calibration.

1.4 QUALITY ASSURANCE

1.4.1 Schematic Diagrams

Show circuits and device elements for each replaceable module. Schematic diagrams of printed circuit boards are permitted to group functional assemblies as devices, provided that sufficient information is provided for government maintenance personnel to verify proper operation of the functional assemblies.

1.4.2 Interconnecting Diagrams

Show interconnections between equipment assemblies, and external interfaces, including power and signal conductors. Include for enclosures and external devices.

1.4.3 Equipment Schedule

Provide a schedule of equipment to be supplied. Provide a cross reference in the schedule between manufacturer data and identifiers indicated in shop drawings. Include the total quantity of each item of equipment supplied in the schedule. For complete assemblies, such as VFD's, provide the serial numbers of each assembly, and a sub-schedule of components within the assembly. Provide recommended spare parts listing for each assembly or component.

1.4.4 Installation Instructions

Provide installation instructions issued by the manufacturer of the equipment, including notes and recommendations, prior to shipment to the site. Provide operation instructions prior to delivery.

1.4.5 Factory Test Results

Document test results and submit to Government within seven working days after completion of test.

1.5 DELIVERY AND STORAGE

Store equipment delivered and placed in storage with protection from the weather, humidity and temperature variations, dirt and dust, or other contaminants.

1.6 WARRANTY

Warranty the variable speed drives furnished under this contract against defects in materials and workmanship for a minimum period of one year from the date of acceptance of the drives by the Bonneville Project. Provide delivery of parts and/or service to the Government with 24 hours of notice by the Government to the Contractor as part of the warranty.

1.7 MAINTENANCE

1.7.1 Spare Parts

Provide one set of spare parts in accordance with the manufacturer's spare parts list. Supply all spare parts in moisture resistant packaging and corrugated boxes or other containers suitable for long-term storage. Label boxes or storage containers on the outside with a listing of the part name, number, description, and date it was furnished for each spare part. Ensure the label is in a clear waterproof envelope, lamination, or other protective cover. Spare parts are to include, but not be limited to:

a. Three (3) – Indicating lights assemblies of each type and rating.

b. One (1) – Control relay of each type and rating.

c. One (1) – Control switch of each type and rating.

d. One (1) – Selector switch of each type and rating.

e. One (1) – Pushbutton of each type and rating.

f. One (1) – Electronic display of each type.

g. Five (5) – Fuses of each type and rating for each VFD panel.

h. Twenty five (25) – Terminal blocks of each type.

1.7.2 Maintenance Support

During the warranty period, Provide on-site, on-call maintenance services by Contractor's personnel on a per-call basis with 36-hour response. Provide support for the maintenance of all hardware and software of the system supplied. Send various personnel of different expertise on-site depending on the nature of the maintenance service required. Include costs for travel, local transportation, living expenses, and labor rates of the service personnel while responding to the service request. The provisions of this Section are not in lieu of, nor relieve the Contractor of, warranty responsibilities covered in this specification. Should the result of the service request be the uncovering of a system defect covered under the warranty provisions, all costs for the call, including the labor necessary to identify the defect, shall be borne by the Contractor.

PART 2 PRODUCTS

2.1 VARIABLE FREQUENCY DRIVES (VFD) Ensure all new equipment is compatible with Allen Bradley Controllogix systems using the EtherNet/IP communications protocol, with documented capability for control and monitoring over Ethernet. Provide all hardware of a quantity, style, and mode of operation as specified herein. Ensure the VFD includes the following minimum functions, features, and ratings:

a. Input circuit breaker per UL 489 with a minimum of 25,000 amps symmetrical interrupting capacity and door interlocked external operator. A fused disconnect switch is also permitted.

b. Converter stage per UL 508C changes fixed voltage, fixed frequency, ac line power to a fixed DC voltage. Ensure the converter utilizes a full wave bridge design incorporating diode rectifiers. Silicon Controlled Rectifiers (SCRs) are not acceptable. The converter will be insensitive to 3-phase rotation of the ac line and will not cause displacement power factor of less than .95 lagging under any speed and load condition.

c. Inverter stage changes fixed DC voltage to variable frequency, variable voltage, ac for application to a standard NEMA design B squirrel cage motor. Ensure the inverter is a sinusoidal PWM type Drive with sensor-less Dynamic Torque Vector Control capability.

d. Ensure the VFD is capable of supplying 110 percent of rated full load current for one minute for Variable Torque and 150 percent for Constant Torque applications at maximum ambient temperature.

e. Ensure the VFD is able to withstand voltage variations of -15 percent to +10 percent and imbalance no greater than 3 percent without tripping or affecting VFD performance. System frequency will be 60 Hz with a maximum frequency variation of +/- 5 percent. Ensure line notching, transients, and harmonics on the incoming line do not affect VFD performance.

f. Ensure the VFD does not increase voltage distortion above 5 percent at the input terminals of the VFD or line filters. If measurements show otherwise, make all modifications to the drive necessary to meet this requirement.

g. Ensure acceleration and deceleration time is independently adjustable from one second to 360 seconds.

h. Provide VFDs that are self-adjustable to accept an input voltage range between 380-500V AC, three phase, +/- 10 percent. Ensure the displacement power factor is 0.98, lagging, over the entire speed range. Ensure the efficiency of the drive is a minimum of 97.5 percent at full load and speed.

i. Use hardwired I/O provided via separate I/O cards that mount in the control enclosure and plug into the main control board of the VFD. Ensure these cards provide both analog and digital inputs and outputs.

j. Ensure the drive output voltage varies with frequency to maintain a constant V/Hz ratio up to base speed (60 Hz) output. Supply constant or linear voltage outputs at frequencies greater than base speed (60 Hz).

k. Ensure the controllers are capable of producing an output frequency over the range of 0.1 to 120 Hz.

l. Ensure the VFD has both low frequency limit and high frequency limit functions. Each will be programmable from 0 to 60 Hz with 1 Hz resolution. Ensrue minimum and maximum output frequency is adjustable over the following ranges: 1) Minimum frequency 3 Hz to 50 percent of maximum selected frequency; 2) Maximum frequency 40 Hz to 60 Hz.

m. Ensure the controller efficiency at any speed is not less than 96 percent.

n. Accomplish protection of power semiconductor components without the use of fast acting semiconductor output fuses. Ensure subjecting the controllers to any of the following conditions will not result in component failure or the need for fuse replacement:

(1) Short circuit at controller output

(2) Ground fault at controller output

(3) Input undervoltage

(4) Input overvoltage

(5) Loss of input phase

(6) Instantaneous overload

(7) Sustained overload exceeding 115 percent of controller rated current

(8) Over temperature.

o. Provide VFDs with selectable slip compensation, which will sense output current and adjust output frequency, to improve motor speed fluctuations. This will allow 1 percent or less (depending in the slip value selected) speed regulation without the use of a speed feedback device. This function is to be adjustable over a range of 0 to 15.00 Hz.

p. Ensure the VFD is able to reset itself up to 10 times (adjustable with adjustable intervals of 2-20 seconds) after over-current, over-voltage, overheating, and overload faults.

q. Include external fault reset capability with the VFD. Include all the necessary logic to accept an external fault reset contact.

r. Provide critical speed lockout circuitry to prevent operating at frequencies with critical harmonics that cause resonant vibrations. Provide a minimum of three user selectable bandwidths.

s. Ensure the VFD is microprocessor based with an LCD display to monitor operating conditions. The Drive display section will allow for local operation and setting of Drive function codes and display fault indication and reasons associated with the fault.

t. Provide the following operator control and monitoring devices mounted on the front panel of the VFD:

(1) Digital speed potentiometer

(2) Hand-Off-Auto (HOA) switch

(3) Power on (READY) light, green

(4) Drive run (RUN) light, red

(5) LCD local display (HIM - Human Interface Module).

u. Provide EtherNet/IP communications adapter for communicating with the PLC.

v. Provide VFDs that are able to support Modbus protocols by adding an appropriate communications adapter from the VFD manufacturer.

w. Provide VFD parameterization and monitoring software. Provide two sets of the manufacturer’s latest software to be licensed to the government.

2.2 ENCLOSURES

a. Provide equipment enclosures conforming to NEMA 250, NEMA ICS 7, and NEMA ICS 6.

b. VFD enclosure shall be NEMA 250 Type 12.

2.2.2 Pilot Devices

Pilot devices (control units and stations) shall be heavy-duty, oil-tight, and shall be manufactured by type per NEMA ICS 1, pilot lights push to test transformer type.

a. Control Switches. Ensure control station switches are of the panel mounted, heavy duty, oiltight construction with double break silver contacts. Contacts will have the rating designation of A600 in accordance with Table 2-125-1 of NEMA ICS 2. The type of switch furnished will be determined by the contact arrangement or as indicated. Clearly mark each control escutcheon plate to show each operating position. Engrave switch identification numbers on the escutcheon plates or on separate nameplates. Ensure the escutcheon and nameplate markings are as shown.

b. Pushbuttons. Ensure pushbuttons are of the oil-tight type, to NEMA ICS 2 standards. Where applicable, in enclosures rated NEMA 4X, they are to be to NEMA 4 requirements. Each pushbutton is to have an individual nameplate, furnished by the manufacturer, with the pushbutton function clearly indicated. All functions are to be as indicated on the drawings. Furnish contacts, rated for NEMA A600, rated either at 24 volts DC or 120VAC, for 10 amps continuous current and with a "make" current of 60 amps and a "break" current of 6 amps to perform the function. Contact blocks are to be of the oil-tight type. All push button operators that are exposed to the weather are to be installed with weather resistant boots.

c. Indicating Lights. Ensure indicating lights are 30.5 mm, NEMA 250 Type 4, full voltage type. Lights are to be LED type, push to test, and be complete with color caps as indicated.

2.2.3 PANEL WIRES AND CABLES

a. Ensure all wires and cables conform to NEMA 250, NEMA ICS 7, and NFPA 70.

b. All field wiring is to land on terminal blocks in the VFD enclosures. No field wiring is to land on individual devices in the VFD panels.

c. All control wire within control panels is to be stranded copper wire (type XHHW) with 600V insulation.

d. Ensure line voltage color coding of insulation is: black for power, white for 120V neutrals, red for AC controls which derive their source from within the panel, yellow for AC controls which derive their source external to the panel, blue for low voltage DC controls, green for grounding conductors.

e. Instrumentation wiring for DC analog circuits is to be stranded #18 AWG, minimum size copper conductor with FEP conductor insulation with foil or stranded wire shielding and overall Gray FEP jacket. Shop or factory wire panels to identified terminal blocks equipped with screw type lugs. Wire troughs are to be a minimum of one inch wide and three inches deep with removable snap-on covers and perforated walls for easy wire entrance. Ensure wire troughs are constructed of non-metallic materials with voltage insulation in excess of the maximum voltage carried therein.

2.3 NAMEPLATES

Provide each item of equipment mounted in each control cabinet with an engraved nameplate or with other suitable means of identification. Make the nameplates out of laminated sheet plastic or of anodized aluminum approximately 1/16-inch thick, engraved to provide white letters on a black background. Provide equipment of the withdrawal type with nameplates mounted on the removable equipment in locations visible when the equipment is in place. Fasten the nameplates to the panels in proper position. Submit samples of engraved nameplates with a schedule of nameplate sizes and lettering for approval. The Contractor will be permitted to supply and attach to each control cabinet assembly a nameplate or trademark.

2.4 SOURCE QUALITY CONTROL - VFD FACTORY TEST PLAN

To ensure proper performance upon delivery, subject each VFD to 100 percent factory tests. To ensure quality, subject each VFD to a series of in-plant quality control inspections before approval for shipment from the manufacturer's facilities. Provide test plans and test reports.

2.5 MATRIX FILTER

Provide input harmonic filters in order to conform with IEEE 519, limiting full load current distortion to less than 5 percent THID. It shall accept a 480V AC, 60 Hz, 3-phase input voltage with a maximum source impedance of 6 percent and a minimum source impedance of 1.5 percent. Ensure the filter has a service factor of 1.00 and an operating temperature of -40 to 50 degrees Celsius.

PART 3 EXECUTION

3.1 INSTALLATION

Installation will be performed by the government.

3.2 FIELD QUALITY CONTROL

Test specified products as a system for conformance to specification requirements prior to scheduling the acceptance tests. Conduct performance verification tests in the presence of Government representative, observing and documenting complete compliance of the system to the specifications. Submit a signed copy of the test results, certifying proper system operation before scheduling tests.

3.3 COMMISSIONING

Provide start-up services by a field engineer of the manufacturer. Drive programming and setting of parameters is the responsibility of the Contractor. The Government may furnish some parameters to the Contractor prior to start-up as required for PLC/SCADA interface. Coordinate and schedule factory start-up services in writing with the Government two weeks in advance.

3.4 ACCEPTANCE TESTING

Inspect and test applicable equipment covered by this specification in accordance with NETA ATS.

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