DRAFT_SOW_Switchgear.pdf

US Army Corps of Engineers The Dalles Lock and Dam

DQ3 & DQ4 Oil Switch Replacement Project DQ2 Area 5kv Medium Voltage Switchgear Specifications

GENERAL

This Section provides a summary of the various Contract work elements and their relationship to each other. This summary describes work activities within Contract completion date. This Section does not provide the technical detail for particular work activities, but describes the work as a whole, providing overall perspective to the separate tasks and their interrelationships. Use this Section in conjunction with all the Specification Sections and the Drawings to establish the total work requirements.

SCOPE OF WORK

This contract covers the purchase of electrical 5kv switchgear and is broken into two subparts, each with optional items. The bid should be broken out into sections to clearly indicate to the customer the price for base primary, primary plus options, primary plus secondary, and secondary plus options. It shall be assumed that any combination of the above bid breakouts can be combined as part of the award of this contract and no extra cost shall be incurred as a result by the Government.

The primary part is switchgear Section ‘A’ with a customer exercised optional item of a factory installed digital multifunction relay and associated equipment.

The secondary part is a switchgear section ‘B’ with a customer exercised optional item of a factory installed digital multifunction relay and associated equipment.

CONTRACT DRAWINGS

a. The Drawings that accompany these Specifications are a part thereof.

b. Reference publications will not be furnished.

c. Immediately check furnished Drawings and notify the Government of any discrepancies.

SUBMITTALS REQUIRED (Types of)

a. Shop Drawings

a. Drawings that shall include:

i. Wiring diagrams and installation details of equipment indicating proposed location, layout and arrangement, accessories, and other items that must be shown to ensure a coordinated installation. Wiring diagrams must identify circuit terminals and indicate the internal wiring for each item of equipment and the interconnection between each item of equipment. Include control schematics and external connections. Point to point connection and wiring diagrams must show all terminal blocks and connections between blocks and equipment. Drawings must indicate adequate clearance for operation, maintenance, and replacement of operating equipment devices. Submittals must include the nameplate data, size, and capacity. Submittals must also include applicable federal, military, industry, and technical society publication references.

b. Test Reports

a. Metal Enclosed Switch-Breaker Production Tests

b. Acceptance checks and tests

c. Factory acceptance test of all current transformers and potential transformers included in the equipment.

c. Closeout Submittals

a. Warranty

b. Assembled Operation and Maintenance Manuals

c. equipment test

d. Product Data

Catalog cuts, illustrations, schedules, diagrams, performance charts, instructions and brochures illustrating size, physical appearance, and other characteristics of materials, systems, or equipment for some portion of the work.

e. Manufacturer's Instructions

Preprinted material describing installation of a product, system, or material, including special notices and Safety Data Sheets (SDS) concerning impedances, hazards, and safety precautions.

f. Operation and Maintenance Data

Data that is furnished by the manufacturer, or the system provider, to the equipment operating and maintenance personnel, including manufacturer's help and product line documentation necessary to maintain and install equipment. This data is needed by operating and maintenance personnel for the safe and efficient operation, maintenance, and repair of the item. This Data is intended to be incorporated in an operations and maintenance manual or control system.

g. Certificates of compliance Submit an electronic copy of certificates required for demonstrating proof of compliance of materials with specification requirements. Each certificate must be signed by an official authorized to certify on behalf of the manufacturing company, contain the name and address of the Contractor, the project name and location, and the quantity and date or dates of shipment or delivery to which the certificates apply. Copies of laboratory test reports submitted with certificates must contain the name and address of the testing laboratory and the date or dates of the tests to which the report applies. Certification shall not be construed as relieving the Contractor from furnishing satisfactory material if, after tests are performed on selected samples, the material is found not to meet the specific requirements.

SUBMISSION OF OPERATION AND MAINTENANCE MANUAL DATA

a. Submit Operation and Maintenance (O&M) Data specifically applicable to this Contract and a complete and concise depiction of the provided equipment, product, or system, stressing and enhancing the importance of system interactions, troubleshooting, and long-term preventative maintenance and operation. Organize and present information in sufficient detail to clearly explain O&M requirements at the system, equipment, component, and subassembly level. Include troubleshooting data with error indications and the possible cause. Include an index preceding each submittal.

b. Each system or piece of equipment must be covered in a single manual regardless of the number of suppliers or subcontractors involved. Data submitted for the manual is in addition to that furnished as shop drawings. At least 30 days prior to scheduled testing, submit one copies of above data for each electrical, mechanical, and electromechanical system or equipment.

c. Mark draft copies as "Draft." The Government will return one electronic copy if "Approved" or "Returned for Correction". If "Returned for Correction" resubmit the corrected manual with one set of additional data, for the manuals retained by the Government, within 30 days of the date the prior submittal was returned. Within 30 days of approval, submit one additional, complete copies identical to the "Approved" copy (for a total of two copies) and two electronic copies, in accordance with paragraph entitled Electronic O&M Manual.

Package Quality

Provide data for equipment in hard copy and electronic format. Documents must be fully legible and all pages of the original material must be included. Poor quality copies and material with hole punches obliterating the text or drawings will not be accepted.

Manufacturer's Data

One master hard copy of the approved O&M manual(s) must contain all original documents including, but not limited to: standard catalog cuts, manufacturer's data, parts sheets, and illustrations. Non-permanent copies will not be accepted. Mark out all non-applicable data, such as description of other models and optional equipment not included. If reference is made to other drawings or data they must be included. List equipment covered; the manufacturer; and name, address, and telephone number of the local representative.

Electronic O&M Manual

Subsequent to approval of the hard copy O&M Manual(s), submit two permanently labeled, CD-ROM (CD-R disks only). Assemble the electronic information in a single PDF file with data organized identically to the approved master hard copy.

TYPES OF INFORMATION REQUIRED IN O&M DATA PACKAGES

Operational Section

Include manufacturer's recommended procedures and instructions for correctly operating the equipment.

a. Operating Instructions Include specific instructions, procedures, and illustrations for the following phases of operation for the installed model and features of each system.

b. Safety Precautions

List personnel hazards and equipment or product safety precautions for all operating conditions.

c. Operator Prestart

Include procedures required to install, set up, and prepare each system for use.

d. Startup, Shutdown, and Post-Shutdown Procedures

Provide narrative description for Startup, Shutdown, and Post-shutdown operating procedures including the control sequence for each procedure.

e. Normal Operations

Provide narrative description of Normal Operating Procedures. Include control diagrams with data to explain operation and control of systems and specific equipment.

f. Emergency Operations

Include Emergency Procedures for equipment malfunctions to permit a short period of continued operation or to shut down the equipment to prevent further damage to systems and equipment. Include Emergency Shutdown instructions for fire, explosion, spills, or other foreseeable contingencies. Provide guidance and procedures for emergency operation of all utility systems including required valve positions, valve locations, and zones or portions of systems controlled.

g. Operator Service Requirements

Include instructions for services to be performed by the operator such as lubrication, adjustment, inspection, and recording gage readings.

h. Environmental Conditions Include a list of Environmental Conditions (temperature, humidity, and other relevant data) that are best suited for the operation of each product, component, or system. Describe conditions under which the item equipment should not be allowed to run.

i. Manufacturer's Data and Parts Catalogs

Include all original standard catalog cuts, manufacturer's data, parts sheets, or illustrations. Parts catalogs must include identification, nomenclature, part numbers, required parts, recommended spare parts stocked, and spare parts supplied. Data must match equipment furnished.

Standard catalog data will not be acceptable unless irrelevant parts are marked out and relevant parts are clearly identified.

Preventive Maintenance Section

Include the following information for preventive and scheduled maintenance to minimize corrective maintenance and repair for the installed model and features of each system. Include potential environmental and indoor air quality impacts of recommended maintenance procedures and materials.

a. Lubrication Data Include preventative maintenance lubrication data, in addition to instructions for lubrication provided under paragraph entitled Operator Service Requirements:

a. A table showing recommended lubricants for specific temperature ranges and applications.

b. Charts with a schematic diagram of the equipment showing lubrication points, recommended types and grades of lubricants, and capacities.

c. A Lubrication Schedule showing service interval frequency.

b. Preventive Maintenance Plan and Schedule Include manufacturer's schedule for routine preventive maintenance, inspections, tests, and adjustments required to ensure proper and economical operation and to minimize corrective maintenance. Provide manufacturer's projection of preventive maintenance work-hours on a daily, weekly, monthly, and annual basis including craft requirements by type of craft. For periodic calibrations, provide manufacturer's specified frequency and procedures for each separate operation.

Corrective Maintenance Section (Repair)

Include manufacturer's recommended procedures and instructions for correcting problems and making repairs.

a. Troubleshooting Guides and Diagnostic Techniques Include step-by-step procedures to promptly isolate the cause of typical malfunctions. Describe clearly why the checkout is performed and what conditions are to be sought. Identify tests or inspections and test equipment required to determine whether parts and equipment may be reused or require replacement.

b. Wiring Diagrams and Control Diagrams

Wiring diagrams and control diagrams must be point-to-point drawings of wiring and control circuits including factory-field interfaces. Provide a complete and accurate depiction of the actual job specific wiring and control work. On diagrams, number electrical and electronic wiring and pneumatic control tubing and the terminals for each type, identically to actual installation configuration and numbering.

c. Maintenance and Repair Procedures

Include instructions and a list of tools required to repair or restore the product or equipment to proper condition or operating standards.

d. Removal and Replacement Instructions

Include step-by-step procedures and lists of required tools and supplies for removal, replacement, disassembly, and assembly of components, assemblies, subassemblies, accessories, and attachments. Provide tolerances, dimensions, settings, and adjustments required. Instructions must include a combination of text and illustrations.

e. Spare Parts and Supply Lists

Include lists of spare parts and supplies required for maintenance and repair to ensure continued service or operation without unreasonable delays. Special consideration is required for facilities at remote locations. Identify spare parts and supplies that have a long lead-time to obtain.

Appendices Section

Provide information required below and information not specified in the preceding paragraphs but pertinent to the maintenance or operation of the product or equipment. Include the following:

a. Product Submittal Data Provide a copy of all SD-03 Product Data submittals required in the applicable Technical Sections.

b. Manufacturer's Instructions

Provide a copy of all SD-08 Manufacturer's Instructions submittals required in the applicable Technical Sections.

c. O&M Submittal Data

Provide a copy of all SD-10 Operation and Maintenance Data submittals required in the applicable Technical Sections.

d. Parts Identification

Provide identification and coverage for all parts of each component, assembly, subassembly, and accessory of the end items subject to replacement. Include special hardware requirements, such as requirement to use high-strength bolts and nuts. Identify parts by make, model, serial number, and source of supply to allow reordering without further identification. Provide clear and legible illustrations, drawings, and exploded views to enable easy identification of the items. When illustrations omit the part numbers and description, both the illustrations and separate listing must show the index, reference, or key number that will cross-reference the illustrated part to the listed part. Group parts by components, assemblies, and subassemblies in accordance with the manufacturer's standard practice. Parts data may cover more than one model or series of equipment, components, assemblies, subassemblies, attachments, or accessories, such as typically shown in a master parts catalog.

e. Warranty Information

List and explain the various warranties and clearly identify the servicing and technical precautions prescribed by the manufacturers or Contract documents in order to keep warranties in force. Include warranty information for primary components such as the compressor of air conditioning system.

f. Testing Equipment and Special Tool Information

Include information on test equipment required to perform specified tests and on special tools needed for the operation, maintenance, and repair of components.

g. Testing and Performance Data

Include completed prefunctional checklists, functional performance test forms, and monitoring reports. Include recommended schedule for retesting and blank test forms.

h. Contractor Information

Provide a list that includes the name, address, and telephone number of the General Contractor and each subcontractor who installed the product or equipment, or system. For each item, provide the name, address, and telephone number of the manufacturer's representative and service organization that can provide replacements most convenient to the project site. Provide the name, address, and telephone number of the product, equipment, and system manufacturers.

FAILURE TO SUBMIT OPERATIONS AND MAINTENANCE DATA

Failure to furnish O&M Manual data as required is justification to hold or adjust the retained percentage. Moreover, failure to furnish O&M Manual data as required may result in a final unsatisfactory overall performance rating, despite the nature of all other ratings.

DELIVERY, STORAGE, AND HANDLING

a. Provide written notification to the Government 14 calendar days prior to shipment of equipment.

b. Wrap all finished painted surfaces and metal work or provide other means of protection from damage during shipment. Prepare all parts for shipment so that slings for handling may be attached readily while the parts are in a railway car or transport truck.

c. Each shipping section of the switchgear shall be properly matchmarked to facilitate reassembly, and shall be provided with removable lifting channels with eye bolts for attachment of crane slings to facilitate lifting and handling. The equipment shall be shipped as completely assembled and wired as feasible so as to require a minimum of installation work. Switchgear groups and metal-enclosed buses which are disassembled into sections for shipment shall have the associated parts properly matchmarked to facilitate installation by the Government. Any relay, indicating instrument, or other device which cannot withstand the hazards of shipment when mounted in place on the switchgear shall be carefully packed and shipped separately. These pieces shall be marked with the number of the panel on which they are to be mounted and fully identified so they can be readily mounted and connected. Wiring to any relay shipped separately shall be completed and on removable terminal blocks for ease of field installation.

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.

ASSOCIATION OF EDISON ILLUMINATING COMPANIES (AEIC)

AEIC CS8 (2007) specification for Extruded Dielectric Shielded Power Cables Rated 5 through 46 kV.

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA WC 70 (2009) Power Cable Rated 2000 V or Less for the Distribution of Electrical Energy----S95-658 NEMA WC 74/ICEA S-93-639 (2012) 5-46 kV Shielded Power Cable for Use in the Transmission and Distribution of Electric Energy

ASME INTERNATIONAL (ASME)

ASME B1.1 (2003; R 2008) Unified Inch Screw Threads (UN and UNR Thread Form)

ASTM INTERNATIONAL (ASTM)

ASTM A123/A123M (2013) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products ASTM A153/A153M (2009) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware ASTM A653/A653M (2013) Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process ASTM A780/A780M (2009) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings ASTM D1535 (2013) Specifying Color by the Munsell System ASTM D709 (2013) Laminated Thermosetting Materials

ASTM B3 (2013) Standard Specification for Soft or Annealed Copper Wire ASTM B33 (2010; R 2014) Standard Specification for Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM B8 (2011) Standard Specification for Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, or Soft

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 100 (2000; Archived) The Authoritative Dictionary of IEEE Standards Terms IEEE C2 (2012; Errata 2012; INT 1-4 2012; INT 5-7 2013; INT 8 2014) National Electrical Safety Code IEEE C37.121 (2012) American National Standard for Switchgear-Unit Substations

- Requirements IEEE C37.20.3 (2013) Standard for Metal-Enclosed Interrupter Switchgear

IEEE C37.20.4

IEEE C57.12.01 (2005) General Requirements for Dry-Type Distribution and Power Transformers Including Those with Solid-Cast and/or Resin-Encapsulated Windings IEEE C57.12.28 (2014) Standard for Pad-Mounted Equipment - Enclosure Integrity IEEE C57.12.29 (2014) Standard for Pad-Mounted Equipment - Enclosure Integrity for Coastal Environments

IEEE C57.12.50 (1981; R 1998) Ventilated Dry-Type Distribution Transformers, 1 to 500 kVA, Single-Phase, and 15 to 500 kVA, Three-Phase, with High-Volt 601 to 34,500 Volts IEEE C57.12.80 (2010) Standard Terminology for Power and Distribution Transformers IEEE C57.12.91 (2011) Standard Test Code for Dry-Type Distribution and Power Transformers IEEE C57.124 (1991; R 2002) Recommended Practice for the Detection of Partial Discharge and the Measurement of Apparent Charge in Dry-Type Transformers IEEE C57.13 (2008; INT 2009) Standard Requirements for Instrument transformers IEEE C57.13.1 (2006; R 2012) Guide for Field Testing of Relaying Current Transformers IEEE C57.98 (2011) Guide for Transformer Impulse Tests IEEE 383 (2003; R 2008) Standard for Qualifying Class 1E Electric Cables and, Field Splices for Nuclear Power Generating Stations 2004

INTERNATIONAL ELECTRICAL TESTING ASSOCIATION (NETA)

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

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA PB 2 (2011) Deadfront Distribution Switchboards ANSI/NEMA PB 2.1 (2013) General Instructions for Proper Handling, Installation, Operation and Maintenance of Deadfront Distribution Switchboards Rated 600 V or Less NEMA 250 (2014) Enclosures for Electrical Equipment (1000 Volts Maximum) NEMA ICS 6 (1993; R 2011) Enclosures NEMA LI 1 (1998; R 2011) Industrial Laminating Thermosetting Products

NEMA SG5

NEMA SG6

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 891 (2005; Reprint Oct 2012) Switchboards UL 467 (2007) Grounding and Bonding Equipment

UL 44 (2014; Reprint Feb 2015) Thermoset-Insulated Wires and Cables

DEFINITIONS

Unless otherwise specified or indicated, electrical and electronics terms used in these specifications, and on the drawings, must be as defined in

IEEE 100.

DRAWINGS

Drawings must include, but are not limited to the following:

a. An outline drawing, with front, top, section, and side views showing incoming, and outgoing sections.

b. One-line diagram showing metal enclosed switch-breaker and ampere rating of bus bars. Include control schematics for the medium voltage circuit breaker.

c. Elementary diagrams and wiring diagrams with terminals identified, and indicating prewired interconnections between items of equipment and the interconnection between the items.

d. Time-current characteristic curves (on full size logarithmic paper) for the metal enclosed switch-breaker.

e. Switchgear markings and NEMA nameplate data.

f. Circuit breaker types, interrupting rating, and trip devices, including available settings.

g. Three-line diagrams and elementary diagrams and wiring diagrams with terminals identified, and indicating prewired interconnections between items of equipment and the interconnection between the items.

STANDARD PRODUCTS

Provide materials and equipment that are products of manufacturers regularly engaged in the production of such products which are of equal material, design and workmanship. Products must have been in satisfactory commercial or industrial use for two years prior to bid opening. The two year period must include applications of equipment and materials under similar circumstances and of similar size. The product must have been on sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the two year period. Where two or more items of the same class of equipment are required, these items must be products of a single manufacturer; however, the component parts of the item need not be the products of the same manufacturer unless stated in this section.

MATERIAL AND EQUIPMENT MANUFACTURING DATE

Products manufactured more than three years prior to date of delivery to site must not be used, unless specified otherwise.

SEISMIC REQUIREMENTS

Provide seismic tested equipment as follows:

a. The equipment, its anchorage and major components must be suitable for, and certified to meet, all applicable seismic requirements of the 2012 edition of the International Building Code (IBC) and ASCE 7-10, Minimum Design Loads for Buildings and Other Structures. A design spectral response acceleration parameter at short periods (SDS) of 0.49g, Risk Category IV and a Seismic Design Category D must be used. Guidelines for the installation consistent with these requirements must be provided by the switchgear manufacturer and be based upon testing of representative equipment.

b. Mounting recommendations must be provided by the manufacturer based upon approved shake table tests used to verify the seismic design of the equipment.

c. The equipment manufacturer must certify that the equipment can withstand, that is, function following the seismic event, including both vertical and lateral required response spectra as specified in above codes.

d. The equipment manufacturer must document the requirements necessary for proper seismic mounting of the equipment. Seismic qualification must be considered achieved when the capability of the equipment, meets or exceeds the specified response spectra.

WARRANTY

The equipment items must be supported by service organizations which are reasonably convenient to the equipment installation in order to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract. A one year warranty of all parts and materials is required.

PRODUCTS

General

a. The equipment furnished and the work performed under this Contract must be in conformance with the applicable provisions of ANSI & IEEE standards. Furnish documentation substantiating that the circuit breaker design and assembly are ANSI certified.

b. All materials, components, and equipment shall conform to the requirements of these specifications. Materials, components, and equipment shall be free from defects and imperfections, of recent manufacture, and shall have mechanical and electrical properties suitable for the intended use. All materials, components, and equipment not manufactured by the Contractor must be products of other recognized reputable manufacturers meeting the requirements of subparagraph Qualifications. Insofar as practicable, devices and equipment used for the same or similar services shall be of the same make and type, and shall be interchangeable when of the same rating.

QUALITY ASSURANCE

a. Manufacturer: For equipment required for the work of this section, provide products which are the responsibility of one manufacturer when possible.

b. Manufacturer shall have had produced similar electrical equipment for a minimum of 5 years.

c. Manufacturer shall be ISO 9001 certified.

Medium Voltage Metal Enclosed Switch-Breaker

The metal enclosed switch-breaker must consist of a deadfront, completely metal-enclosed vertical section with a non-fused load interrupter switch in series with a fixed-mounted vacuum circuit breaker. The 5kV switch-breaker must have a continuous current rating of 600A at 4160V, circuit breaker short circuit rating of 25kA Sym RMS, circuit breaker closing and latching capability of 40kA Asym RMS/65kA peak, and a switch fault close of 40kA Asym RMS/65kA peak. Provide as an option to the customer a digital multifunction relay to be described later under the Multifunction Relay section.

The following features must be supplied with each switch-breaker:

a. A minimum high-impact viewing window that permits full view of the position of all three switch blades through the closed door. The window must not be more than 58-inches above the switch pad level to allow ease of inspection.

b. High voltage parts within the circuit breaker compartment must be isolated with grounded metal barriers.

c. A grounded metal barrier bolted closed in front of the switch to prevent inadvertent contact with any live part, yet allow for a full-view inspection on the switch blade.

d. Provisions for padlocking the switch in the open or closed position.

e. Green OPEN, Red CLOSED switch position indicators.

f. A hinged cover with rustproof quarter turn nylon latches over the switch operating mechanism to discourage casual tampering.

g. Vertical section construction must be of the universal frame type using die-formed and bolted parts. All enclosing covers and doors must be fabricated from steel whose thickness must be equal to or greater than those specified in ANSI/IEEE C37.20.3. No owner removable hardware for covers or doors must be thread-forming type. To facilitate installation and maintenance of cables and bus in each vertical section, a split removable top cover must be provided. A G90 grade galvanized base shall isolate equipment from contact with the concrete pad providing protection from rust. Heavy-duty hot dipped galvanized anchor clips shall be provided to anchor the switchgear to the concrete pad.

h. Eccentric or concentric knockouts are not allowed in the enclosure. All holes for conduits need to be drilled and punched in the field.

System Voltage

The system will be a 4160v AC system, 60 hertz, 3-phase, 3-wire plus ground.

Wiring/Terminations

a. One terminal pad per phase must be provided for attaching cable terminal lugs for a maximum of two conductors per phase of the sizes indicated on the drawings. Sufficient space must be allowed for electrical stress relief termination devices.

b. Small wiring, fuse blocks and terminal blocks within the vertical section must be furnished as required. Each control wire must be labeled with wire markers. Terminal blocks must be provided for customer connections to other apparatus.

Load interrupter switch cubicles

a. Each load interrupter switch shall have a manual quick-make quick-break over-toggle type mechanism that does not require the use of a chain or a cable for operation, and utilizes a heavy-duty coil spring to provide opening and closing action.

b. The speed of opening and closing the switch shall be independent of the operator, and it shall be impossible to tease the switch into any intermediate position.

c. The interrupter switch shall have separate main and break contacts to provide maximum endurance for fault close and load interrupting duty.

d. The interrupter switch shall have insulating barriers between each phase and between the outer phases and the enclosure.

e. A maintenance provision shall be provided for slow closing the switch to check switchblade engagement and slow opening the switch to check operation of the arc interrupting contacts.

Surge Arresters

Surge arresters must be intermediate class, metal-oxide type, 6 kV duty-cycle voltage rated, 5.1 kV maximum continuous operating voltage, suitable for surge protection of the switches. The surge arresters must meet the applicable provisions of IEEE C62.11 and NEMA LA 1.

Enclosure

Enclosures must be of a totally enclosed, dead-front, freestanding construction. All enclosures must be constructed to prevent inadvertent access to energized parts and the ingress of solid foreign objects.

Enclosures must be constructed to a minimum of Type 1 as defined in NEMA 250.

The enclosure must be constructed such that all points are solidly bonded to the cubicle ground connection. Interior surfaces must receive not less than one coat of corrosion-resisting paint in accordance with the manufacturer's standard practice. All bolts, studs, machine screws, nuts, and tapped holes must be in accordance with ASME B1.1. Finish enclosure with baked enamel.

Finish color is ASTM D1535 light gray No. 61. Enclosures should not be taller than 100 inches.

Bus Bars

Ensure bus bars are silver-plated copper with silver-plated contact surfaces.

Plating is a minimum of 0.0002 inch thick. Make bus connections and joints with hardened steel bolts. Rate the through-bus at the full ampacity of the main throughout the switchboard. Provide minimum one-quarter by 2-inch copper ground bus secured to each vertical section along the entire length of the switchboard. The bus must have bus phase marking to identify the phases. The standard phasing within equipment housing for AC power circuits must be A-B-C from left to right when facing the front of the equipment, A-B-C from top to bottom, and A-B-C from front to back.

Bus Supporting Systems

All bus shall be supported utilizing a high strength and high creep support providing 10.5-inch of creep between phases and ground. The molded fins shall be constructed of high track resistant cycloaliphatic epoxy or approved equal.

All standoff insulators on the primary switches and fuse mountings shall be cycloaliphatic epoxy or approved equal.

Circuit Breaker using Electronic LSI Trip Units

a. Each circuit breaker must be operated by a manually charged spring stored energy mechanism and be able to operate without external control power.

b. Each circuit breaker must have three vacuum interrupter assemblies.

c. Each vacuum interrupter must have a contact wear indicator to indicate the contact wear. The breaker front panel must be removable when the bolts are removed for ease of inspection and maintenance of the mechanism.

d. Each breaker must contain red and green indicating tabs to indicate breaker contact position.

e. Breaker tripping devices must be a microprocessor based trip unit that is self-powered and self-protecting with a front panel display and LED indicators that display the operating state and fault type. The trip unit must have an arc reduction maintenance switch (ARMS) to provide a temporary instantaneous-only setting for the load side of the breaker.

See section Electronic LSI Trip Unit for additional detail.

Electronic LSI Trip Units

Equip breakers with a solid-state LSI tripping system consisting of three current sensors and a microprocessor-based trip unit that provides true rms sensing adjustable time-current circuit protection. The ampere rating of the current sensors shall be based on the kva demand and the sensor settings shown on the drawings. The trip unit ampere rating are as indicated on the drawings.

Provide the electronic trip units with the following features at a minimum.

a. Breakers have long delay pick-up and time settings.

b. Breakers have short delay pick-up and time settings and instantaneous settings.

c. Provide main breaker with bell alarm contact.

Circuit Breaker using Digital Multifunction Relay Protection Option

a. Each circuit breaker must be operated by a motor-charged spring stored energy mechanism. The spring must be able to be charged manually in an emergency or during maintenance procedures.

b. Each circuit breaker must have three vacuum interrupter assemblies.

c. Each vacuum interrupter must have a contact wear indicator to indicate the contact wear. The breaker front panel must be removable when the bolts are removed for ease of inspection and maintenance of the mechanism.

d. The breakers must be electrically operated by 120/240 Vac close and AC capacitor trip.

e. Each breaker must be complete with pistol grip control switch and red and green indicating lights to indicate breaker contact position.

f. The control voltage must be derived from a control power transformer mounted in the switchgear.

g. Breaker tripping devices must be a microprocessor based relay trip unit with a front panel display that will display quantities and messages selectable by government programming, and indicators that display the operating state, fault type, as well as the trip unit function elements.

The trip unit must have an arc reduction maintenance switch (ARMS) to provide a temporary instantaneous-only setting for the load side of the breaker. See section titled Arc Reduction Maintenance Switch (ARMS) for details.

h. Each relay must have not less than 2 output contacts configurable as normally opened or normally closed. Relay contacts must be rated for the Project operating power supply, which will nominally be 125 VDC.

Digital Multifunction Relay Circuit Breaker Protection Option

As an option to the Government, each vacuum circuit breaker may be provided with an external digital multifunction relay system that will trigger a trip response from the circuit breaker instead of using an internal to the breaker electronic LSI trip unit. The system should include all current transformers (CT), potential transformers (PT), control power transformers, test blocks, CT shorting blocks, terminals and fuses external to the circuit breaker. All external system devices should be sized to accommodate the system voltage, frequency, and short circuit ratings. All CT’s should be based on the sensor ratings as indicated on the drawings and should not be sized so that they are at their maximum operational limit from the factory. Each digital multifunction relay shall provide the following functions and features:

a. Relays for phase time overcurrent, instantaneous overcurrent and ground fault protection, ANSI 50/51, 50/51G, or 50/51N, shall be incorporated into a single device having all the features and functions herein specified.

b. The relay shall be a solid-state microprocessor-based multifunctional type that operates from a 5 ampere (or 1 ampere depending on the model) secondary output of current transformers. The relay shall provide ANSI 50/51N protective functions for each of the three (3) phases, and ANSI 50/51N or 50/51G ground fault protection functions as shown on the plans or as determined by the coordination study. The relay shall be configurable between true rms or fundamental sensing for each phase and ground. Ground element shall be capable of being utilized in residual, zero sequence, ground source connection schemes, or deactivated.

c. The primary current transformer rating being used for phase and ground protection feeding the device shall be programmable for current transformers with primary current ratings from 1 through 50,000 amperes

d. The relay shall provide the following protection and control functions:

a. Phase overcurrent (50/51): Three inverse time overcurrent (51-1, 51-2, 51-3) functions and three instantaneous overcurrent (50-1, 50-2, 50-3) functions with adjustable time delay

b. Ground overcurrent (50R/51R): Two inverse time overcurrent (51R-1, 51R-2) functions and two instantaneous overcurrent (50R-1, 50R-2) functions from calculated values with adjustable time delay

c. Ground overcurrent (50X/51X): Two inverse time overcurrent (51X-1, 51X-2) functions and two instantaneous overcurrent (50X-1, 50X-2) functions from measured values with adjustable time delay

d. Auto reclosing (79)

e. Breaker failure protection with adjustable time delay (50-BF)

e. Both the phase and ground protection curves shall be independently field-selectable. Curves shall be selectable from the following:

a. IEEE: Moderately inverse, very inverse, extremely inverse

b. IEC: A, B, C or D

c. Thermal: Flat, lt, I2t, I4t

d. Thermal curves shall be similar to those on low voltage trip units for close coordination with downstream devices.

f. The relay shall have five contact outputs that may be programmed for any protection function operation output.

g. The relay shall have a front panel display of relay condition, and 7 programmable LEDs that can be used for trip condition or breaker status.

h. The relay shall have a LCD display with LED background illumination capable of displaying the following information with metering accuracy of +/- half (0.5) percent of measured value (ln) for ln < 2 ln and +/-one (1) percent of measured value (ln) for ln > 2:

a. Individual RMS and fundamental phase currents

b. Ground RMS and fundamental current

c. Maximum, minimum and average RMS and fundamental current for each phase and ground since last reset

d. Positive, negative and zero sequence currents

i. Relay shall have the following features:

a. Breaker wear monitoring

b. Trip coil-monitoring and IRIG-B.

c. Real-time clock for stamping of events, trips and minimum/maximum values with 1 mS time resolution.

d. User interface for programming and retrieving data from the front of the unit without additional equipment.

e. Four contact inputs that are user programmable.

f. Continuous self-testing of internal circuitry.

g. Self-diagnostic capability and a relay healthy alarm output.

h. Programmable lockout/self-reset after trip function.

i. Programmable set points for device curve selection.

j. Programmable inputs, such as current transformer ratios.

k. Settings change shall be password protected for security.

j. Relay shall be suitable for operating temperatures from -20 degrees to 60 degrees C. Relay shall be suitable for operating with humidity from 0 to 95% relative humidity (non-condensing).

k. Relay shall record information on the last 20 faults including:

a. Date, time, and currents at the time of fault.

l. Relay shall record 3600 cycles of waveform data for the current.

m. Relay shall record the last 300 events into an event log with date and time stamping.

n. Relay shall have the following communications ports available as specified:

a. Rear communications port(s) that supports Modbus TCP and DNP 3.0

TCP/UDP.via Ethernet RJ45 connector.

b. A USB front communication port for programing and interrogation of the relay via personal or laptop computer

c. Communication ports shall have the ability to transmit all information contained in the relay such as currents, set points, cause of trip, magnitude of trip current, and open-close trip status over the connected network.

o. Relay shall store four setting groups which can be called for via communications, front panel operation or contact input.

p. Relay trip contacts shall not change state if power is lost or an undervoltage occurs. These contacts shall only cause a trip upon detection of an overcurrent or fault condition based upon programmed settings.

q. A relay healthy alarm output shall be normally energized and shall drop out if a relay failure is detected in the self-test function or if control power is lost.

r. The relay shall be suitable for operating on control power with a nominal input voltage of 48 to 125 Vdc or 120 Vac to 240 Vac (50 or 60 Hz).

s. The relay shall be provided with removable terminals for complete unit removal and replacement. The CT terminal block shall provide self-shorting of the CT circuits.

t. The Relay shall be fully programmable through the face of the relay. In addition a means to be able to program the Relay through a communication port need to be provided.

u. The Relay shall be provided with conformal coating to be able to be used in harsh environments.

Arc Reduction Maintenance Switch (ARMS)

a. The metal enclosed switch-breaker section must have an ARMS switch for load side protection. The load side ARMS will activate the instantaneous-only setting of the circuit breaker for downstream protection.

b. Each ARMS must have a blue lamp for indication when maintenance mode is on, and a two position maintained selector switch for turning the maintenance mode on and off. On circuit breakers using only the Electronic LSI Trip Unit for protection, a blue LED built into the trip unit will be sufficient as indication. On circuit breakers using a multifunction relay for protection, the ARMS indication light must be driven by a relay output, indicating that the relay has changed settings, in lieu of being driven from a contact in the ARMS switch.

Insulated Barriers

Where insulated barriers are required by reference standards, provide barriers in accordance with NEMA LI 1, Type GPO-3, and 0.25 inch minimum thickness.

Terminal Boards

Provide with engraved plastic terminal strips and screw type terminals for external wiring between components and for internal wiring between removable assemblies. Terminal boards associated with current transformers must be short-circuiting type. Terminate conductors for current transformers with ring-tongue lugs. Terminal board identification must be identical in similar units. External wiring must be color coded consistently for similar terminal boards.

Control Switches

a. All control switches must be of the rotary switchboard type with handles on the front and the operating contact mechanisms on the rear of the panels. Each switch must be provided with ample contact stages to perform the functions of the control system. Contacts must be self-aligning and must operate with a wiping action. A positive means of maintaining high pressure on closed contacts must be provided.

Compression springs or pivotal joints must not carry current. The covers or plates on the switches must be readily removable for inspection of contacts. All control switches must be suitable for operation on 600-volt AC circuits. All such switches must be capable of satisfactorily withstanding a life test of at least 10,000 operations with rated current flowing in the switch contacts. The switches must be capable of continuously carrying 20 amperes without exceeding a temperature rise of 30 degrees C. The single-break inductive load interrupting rating of switches must be not less than 10 amperes for 125 volts DC.

b. Control and instrument switches must be suitable for the intended use.

The switches must have modern handles or keys of pistol grip and must be black color unless otherwise specified.

c. Control switches for electrically-operated circuit breakers must be three position momentary-contact type with spring return to neutral position, and must have modern-black, heavy duty pistol grip handles.

Circuit breaker control switches must have mechanical operation indicators to show the last manual operation of the switches, and must have slip contacts when so indicated or required.

Escutcheons

Each control switch must be provided with an escutcheon clearly marked to show each operating position. The switch identifications must be engraved on the escutcheon plates or on separate nameplates. The escutcheon and nameplate markings shall be subject to approval.

Indicating Lamp Assemblies

Indicating lamp assemblies must be of the switchboard type, insulated for 120-volt AC service, with appropriate colored caps. Color caps must be made of material which will not be softened by the heat from the lamps. Lamps must be long-life light emitting diode type with a minimum normal life span of 50,000 hours. Indicating lights must be visible from at least 20 feet away. Lamps must be replaceable from the front of the panels and any special tools required for lamp replacement must be furnished. Insofar as practicable, all color caps must be similar and interchangeable, and all lamps must be of the same type and rating.

Manufacturer’s Nameplates

Each item of equipment must have a nameplate bearing, as a minimum, the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place; the nameplate of the distributing agent will not be acceptable. Include additional information as applicable to fully identify the equipment. Nameplates must be made of noncorrosive metal. As a minimum, provide nameplates for transformers, circuit breakers, switches, and switchboards.

Factory Inspection and Test

Each item of equipment supplied under this Contract must be given the manufacturer's routine factory tests and also other tests, as specified below, to insure successful operation of all parts of the assemblies. The factory test equipment and test methods used must conform to the applicable requirements of ANSI, IEEE and NEMA standards, and must be subject to approval.

Equipment Test Schedule

The Government reserves the right to witness Factory tests. Provide equipment test schedules for tests to be performed at the manufacturer's test facility.

Test Instrument Calibration

a. The manufacturer must have a calibration program which assures that all applicable test instruments are maintained within rated accuracy.

b. The accuracy must be directly traceable to the National Institute of Standards and Technology.

c. Instrument calibration frequency schedule must not exceed 12 months for both test floor instruments and leased specialty equipment.

d. Dated calibration labels must be visible on all test equipment.

e. Calibrating standard must be of higher accuracy than that of the instrument tested.

f. Keep up-to-date records that indicate dates and test results of instruments calibrated or tested. For instruments calibrated by the manufacturer on a routine basis, in lieu of third party calibration, include the following:

(1) Maintain up-to-date instrument calibration instructions and procedures for each test instrument.

(2) Identify the third party/laboratory calibrated instrument to verify that calibrating standard is met.

Metal Enclosed Switch-Breaker Production Tests

IEEE C37.20.3. Furnish reports of production tests performed on the actual equipment for this project. Required tests must be as follows:

a. Production Tests

(1) Dielectric

(2) Mechanical operation

(3) Circuit breaker operated over the range of minimum to maximum control voltage if applicable.

(4) Electrical operation and control wiring.

(5) Factory setting of contact gap.

(6) Test all functions of the circuit breaker tripping mechanism when using the customer chosen protection device.

UL Listing

The materials and equipment to be furnished under this specification shall be UL listed. The label or listing of the Underwriters Laboratories, Inc., shall be accepted as evidence that the materials or equipment conform to the applicable standards of that agency. In lieu of this label or listing, a statement from a nationally recognized, adequately equipped testing laboratory indicating that the items have been tested in accordance with required procedures and that the materials and equipment comply with all requirements of the governing authority will be accepted.

Warning Labels

Warning labels shall be installed in accordance with NFPA 70E and shall include voltage levels.

INSULATED WIRE AND CABLE

General

All wire and cable used for power, control, metering, and relaying systems must be provided by the Contractor and must conform to the requirements specified herein. Characteristics, including conductor size, stranding, number of conductors, rated circuit voltage, cabling, and other requirements for each type of service, must be as indicated on the drawings, or as specified under the detailed requirements of these specifications for the particular construction or use, unless otherwise stated.

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