Gavins Relays Specifications.pdf

Gavins Point – Generator and Transformer Modular Relay Replacement

1. General Project Description

2. Work Requirements

2.1. DESIGN DOCUMENTATION

2.1.1. Protection Systems:

2.1.2. Relay Settings:

2.1.3. Government Assistance:

2.2. FABRICATE AND SUPPLY COMPLETE RELAY PANELS

2.2.1. Relay Purchase:

2.2.2. Panel Fabrication:

2.3. BENCH TESTING / TEST PROCEDURES

2.3.1. Installation:

2.3.2. Bench Testing of Protective Settings:

2.3.3. Commissioning Test Procedures:

2.3.4. Functional Testing:

2.4. COMMISSIONING / TELEPHONE SUPPORT

2.4.1. Support:

2.5. PROJECT MANAGEMENT / KICKOFF MEETING

2.5.1. Kickoff Meeting:

3. Contract Deliverables:

4. Government Furnished Equipment and Materials:

5. Schedule:

6. Submittals:

6.1.1. Contractor Shall Submit:

6.1.2. Submittal Form:

6.1.3. Meaning of Approvals:

7. Warranty:

8. APPENDIX A – DRAWINGS FOR REVISION / REPLACEMENT

APPENDIX B – Photos

1. General Project Description Contractor shall provide relay panels ready to install for the three hydro-generators and three GSU transformers located at the Gavins Point Dam near Yankton, SD. Work shall include detailed electrical design, wiring diagrams, relay supply, panel fabrication, relay settings, documentation, testing, support and commissioning services.

2. Work Requirements

2.1. DESIGN DOCUMENTATION

2.1.1. Protection Systems:

Prepare design documentation for the replacement/modification of the six relay panels in the Gavins Point powerhouse. The drawings listed in Appendix A shall be required for upgrade / replacement. Designs for the generator protection shall include the following for each generator: primary “A” Set and back-up “B” Set protection using two Schweitzer 300G Relays, flexitest switches, lockout relays, dc circuit breakers, communication cables, etc. All 300G relays shall have 2nd and 3rd output expansion decks. Designs for the GSU transformer protection shall include the following for each transformer: primary and back-up protection using “A” & “B” set Schweitzer 387E Relays, flexitest switches, lockout relays, dc circuit breakers, communication cables, etc. A Schweitzer 2032 communication device with output contacts shall connect to the twelve generator relays and shall be programmed to communicate with the Omaha District SCADA system.

Designs shall be standardized to the extent possible. Designs shall include 30%, 90%, and final design phases. Each design phase shall include comment periods with review comments provided by the Power Plant Office and District Office.

Panel Fabrication may begin after approval of the final design. The following drawings shall be submitted for review and approval:

• Panel layouts and Bill of Materials

• Name plate list

• Revised Protection one lines

• Revised ac/dc schematics with terminal block references

• Internal panel wiring diagrams

• Panel-to-panel wiring diagrams

2.1.2. Relay Settings:

The Contractor shall provide all relay setting sheets. Design documents shall be provided detailing the relay settings and their basis along with step by step calculations. Settings shall be provided with the 90% and final designs. The settings will undergo the same review and approval process as the wiring packages. Settings shall be submitted in SEL AcSelerator database format along with hardcopy binders. Two copies of complete documentation shall be maintained in hardcopy binders containing all design, setting, and schematic information for each plant.

2.1.3. Government Assistance:

The Government will assist the Contractor in coordinating relay designs and settings with the transmission operator, Western Area Power Administration.

2.2. FABRICATE AND SUPPLY COMPLETE RELAY PANELS

2.2.1. Relay Purchase:

The contractor shall purchase approved microprocessor relays, test switches, test blocks, communication devices, and associated equipment for a complete protection system. Relay and device procurement may begin after approval of the 90% design package. All protection relays, communication processors, computing platforms, I/O devices, communication cables, transceivers shall be manufactured by Schweitzer Engineering Laboratories.

2.2.2. Panel Fabrication:

Fabricate and prepare relay panels complete and ready to replace existing panels within the power plants. Panels shall include all relays and devices pre-wired with all intra-panel wiring including jumper leads for all wiring to land within the cubicle. Drawings shall indicate where inter-cubicle wiring shall land. Relay panels shall be designed according to the needs of the projects. The relay board panel of the existing tunnel type control panels will be faced with a new panel mounted onto the exsisting structure. The exsiting panel will be channeled out and modified to except the new panel and relays. The new control panels will be equipped for panel mount relays. Additionally, some existing relays, meters, ect will remain. The contractor shall coordinate with the plant and provide cuts outs/mounting holes for the remaining equipment.

2.2.2.1.Panel Specifications:

Material shall be cold-rolled steel sheet ASTM 1008 (A-366), commercial quality, matte finish, stretcher leveled. Panels shall be constructed from 11 gauge steel and have a pretreatment of 8 stage sprayed Zinc phosphate. Paint shall be polyester (powder electrostatic) with 2–3 mils. Outside and inside color shall be the same. Color shall be ANSI 61 or ANSI 70 as coordinated with the project. Any blanks shall be covered using filler plates.

2.2.2.2.Panel Consumables:

Terminal blocks shall be Marathon 12 pole (PN 1512STD); Shorting terminal blocks shall be Marathon 4 pole (PN 1504SC); Wire terminals shall be insulated ring terminals—Panduit-type PV or equal; Fuses and fuse holders shall be Bussman type; Wiring: Internal wiring shall be SIS 600 V, 150°C Gray; Size AWG 12 for currents; AWG 14 for potentials, control and digital I/O; Wiring shall be routed in Panduit wire duct (vertical and horizontal); Test Blocks / Control Switches / Lock Out Relays (LORs): Test blocks shall be ABB type FT-1; Control switches (if needed) shall be Electroswitch series 24; LORs shall be Electroswitch with internal indicator lights.

2.3. BENCH TESTING / TEST PROCEDURES

2.3.1. Installation:

Prepare installation procedures and drawings for the installation of new relay systems and control panels by government power plant electricians.

2.3.2. Bench Testing of Protective Settings:

All protection settings shall be loaded into relays and verified to have been loaded properly. Setting files shall be issued as documentation prior to shipment and in appropriate SEL format (SEL-5010 / SEL-5030). Panels of relays shall be bench tested prior to shipping to the Project Office. The Contractor shall provide relay tests sheets using EnoServe RTS relay test program. Any customization required to the standard RTS test routines shall be supplied to the Corps of Engineers.

2.3.3. Commissioning Test Procedures:

The Contractor shall provide step by step commissioning test procedures for each relay system. Procedures shall be adequate to test all protection functions according to NERC criteria. Acceptance Test Reports shall be submitted to the customer prior to panel arriving at site and also included in instruction manuals.

2.3.4. Functional Testing:

The Contractor shall provide functional test procedures for each relay system as installed in the power plant. Procedures shall be adequate to test all functional test requirements according to NERC criteria. On a per-panel basis, functional testing shall be performed from the interface terminal blocks per the following:

• Current and voltage injection to verify proper operation of relays, meters, etc.

• Verification of performance against ac and dc schematics, including controls switches, LORs, and pulsing of all relays, inputs, outputs, test switches, indicating lights, etc.

2.4. COMMISSIONING / TELEPHONE SUPPORT

2.4.1. Support:

The contractor shall provide up to 40 hours telephone support during and following the installation of relay panels. Support will be required during normal business hours. The Contractor shall not exceed hours of support without contract modification.

2.5. PROJECT MANAGEMENT / KICKOFF MEETING

The Contractor shall provide a project management services. The project manager shall prepare and provide monthly progress reports for the duration of the contract.

Reports shall include a simple gannt chart identifying major tasks and milestones. It shall include a description of the work completed over the previous month and the work to be completed during the upcoming month. The document should address any concerns or requirements to meet the proposed milestones. The document shall provide submitted and projected invoice information along with a running total of paid invoices. Hours of telephone support shall be tracked and approved

2.5.1. Kickoff Meeting:

The Contractor shall attend a 8 hour kickoff meeting (excluding travel time) to discuss design requirements and gather necessary information and documentation.

3. Contract Deliverables:

All drawings, manuals, specifications, etc shall be delivered both as a hard and soft copy.

The following shall be delivered:

• Design drawings (each design phase)

• Equipment specifications

• Equipment installation procedures and drawings

• Complete Panels

• Relay and equipment settings

• RTU configuration and related documents

• As-built documentation. All drawings are to be provided in Microstation version 8.0

• Commissioning/Testing procedures

4. Government Furnished Equipment and Materials:

The government will provide all existing COE documentation related to the control panel replacements as available. The Contractor shall maintain and FTP site for the government to post electronic data as requested by the Contractor.

At a minimum the following information will be provided: :

• Name plate lists

• Available Drawings: Protective one-line diagrams, AC/ DC schematics, wiring diagrams in Microstation Format (some drawings may be hardcopy only)

• Existing Panel Layout and Bill of Material Drawings: (Hard Copy Only)

• Generator ratings, reactance’s and field tests

• Existing exciter settings, transformer ratings, fault studies, and coordination studies as available.

5. Schedule:

Contractor shall provide a project schedule. It shall contain the following milestones:

• Project kickoff

• 30% design

• 90% design

• Design complete

• Fabrication start

• Fabrication complete

• Factory testing

• Delivery

6. Submittals:

6.1.1. Contractor Shall Submit:

• Schedule

• 30%Design

• 90% Design

• Final Design

• All Equipment Specifications

• Relay Settings

• Commissioning procedures

• Functional Testing Procedures

• Equipment Manuals

• As Builts in Microstation

6.1.2. Submittal Form:

The attached submittal form (ENG Form 4025) shall be used for transmitting the submittal. This form may be reproduced by the Contractor and shall be properly executed by filling out all the heading blank spaces and identifying each time submitted. Special care should be exercised to ensure proper listing of the specification paragraph and/or sheet number of the contract drawings pertinent to the date submitted for each item. The Contractor shall provide copies for each submittal to the location stated below.

6.1.3. Meaning of Approvals:

Action Codes will be as indicated on the back of ENG Form 4025. The Contracting Officer will mark an Action Code on each submitted ENG Form 4025 prior to returning a copy to the Contractor. The approval of a submittal by the Contracting Officer shall not be construed as a complete check, but will indicate only that the general method of prosecution and detailing is satisfactory.

Approval will not release the Contractor of the responsibility for any error that may exist, as the Contractor is responsible for satisfactory prosecution and detailing of all work.

6.1.3.1.When Not Approved The Contractor shall make all corrections required by the Contracting Officer and promptly furnish a corrected submittal in the form and number of copies as specified in the initial submittal.

6.1.3.2.Submittal Delivery The Contractor shall provide a completed copy of ENG Form 4025 with 3 copies of each submitted item to the Contracting officer at the Gavins Point Project

U.S. Army Corps of Engineers Gavins Point Project P.O. Box 710 Yankton, SD 57078-0710

Two copies of all submittal shall be submitted to the following address:

Attn: Lucas Kirkpatrick (OD-SM) U.S. Army Corps of Engineers 1616 Capitol Ave Omaha, NE 68102

7. Warranty:

Contractor shall provide standard industry warranty for all equipment installed. This will cover at minimum one year of service. It will include all equipment, costs and work associated with replacement of defective part.

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8. APPENDIX A – DRAWINGS FOR REVISION / REPLACEMENT

MGOPN-83E301.10 SINGLE LINE DIAGRAM

MGOPN-83E304.4 THREE LINE DIAGRAM SHEET 1

MGOPN-83E305.2 THREE LINE DIAGRAM SHEET 2

MGOPN-83E306.2 THREE LINE DIAGRAM SHEET 3

MGOPN-83E311.4 UNIT 1 CONTROL DIAGRAM

MGOPN-83E311A.3 UNIT 1 CONTROL DIAGRAMS SHEET 2

MGOPN-83E312.4 UNIT 2 CONTROL DIAGRAM

MGOPN-83E312A.3 UNIT 2 CONTROL DIAGRAMS SHEET 2

MGOPN-83E313.5 UNIT 3 CONTROL DIAGRAM

MGOPN-83E313A.3 UNIT 3 CONTROL DIAGRAMS SHEET 2

MGOPN-83E335.3 TRANSFORMER 1 BAY CONTROL DIAGRAM

MGOPN-83E336.3 TRANSFORMER 2 BAY CONTROL DIAGRAM

MGOPN-83E337.3 TRANSFORMER 3 BAY CONTROL DIAGRAM

MGOPN-83E906.5 RELAY BOARD ASSEMBLY

MGOPN-83E907.4 RELAY BOARD NAMEPLATE SCHED & BILL OF MAT

MGOPN-83E907A.1 RELAY BOARD BILL OF MATERIALS SHEET 1

MGOPN-83E907B RELAY BOARD BILL OF MATERIALS SHEET 2

MGOPN-83E906.5 RELAY BOARD ASSEMBLY

MGOPN-83E922.7 TRANSFORMER 3 RELAY BOARD WIRING PANEL 1RB

MGOPN-83E924.6 GENERATOR 3 RELAY BOARD WIRING PANEL 2RB

MGOPN-83E925.4 GENERATOR 3 RELAY BOARD REAR PANEL WIRING -

PANEL 2RBR

MGOPN-83E927.7 TRANSFORMER 2 RELAY BOARD WIRING PANEL 3RB

MGOPN-83E929.8 GENERATOR 2 RELAY BOARD WIRING PANEL 4RB

MGOPN-83E930 GENERATOR 2 RELAY BOARD REAR PANEL WIRING -

PANEL 4RBR

MGOPN-83E934.5 GENERATOR 1 RELAY BOARD WIRING PANEL 4RB

MGOPN-83E935.3 GENERATOR 1 RELAY BOARD REAR PANEL WIRING -

PANEL 4RBR

MGOPN-83E937.6 TRANSFORMER 1 & HV BUS RELAY BOARD WIRING

PANEL 3RB

APPENDIX B – Photos The following pictures are examples of the generator and transformer panels. The attached photos are from Generator 1 and of the GSU transformer Relay Boards. These are For-Information-Only. The contractor must field verify the existing layout.

Picture 1: GEN 1 AT 6RB BOTTOM HALF Picture 2: GEN 1 AT 6RB TOP HALF Picture 3: TRANSFORMER 1 AT 7RB BOTTOM HALF Picture 4: TRANSFORMER 1 AT 7RB TOP HALF Picture 5: TRANSFORMER 2 AT 3RB BOTTOM HALF Picture 6: TRANSFORMER 2 AT 3RB TOP HALF Picture 7: TRANSFORMER 3 AT 1RB BOTTOM HALF Picture 8: TRANSFORMER 3 AT 1RB TOP HALF

Picture 1: GEN 1 AT 6RB BOTTOM HALF

Picture 2: GEN 1 AT 6RB TOP HALF

Picture 3: TRANSFORMER 1 AT 7RB BOTTOM HALF

Picture 4: TRANSFORMER 1 AT 7RB TOP HALF

Picture 5: TRANSFORMER 2 AT 3RB BOTTOM HALF

Picture 6: TRANSFORMER 2 AT 3RB TOP HALF

Picture 7: TRANSFORMER 3 AT 1RB BOTTOM HALF

THE AUTO-SYNCHRONIZER LOCATED ABOVE WILL BE REINSTALLED

Picture 8: TRANSFORMER 3 AT 1RB TOP HALF