NORTHERN INDIANA COMMUTER TRANSPORTATION DISTRICT
TRACTION POWER REHABLITATION
SPECIFICATION
FOR
MADISON SUBSTATION
PREPARED FOR NICTD
BY:
LARAMORE, DOUGLASS & POPHAM, INC.
Consulting Engineers
20N. Wacker Drive, Suite: 1500 Chicago, IL 60606
DISTRICT
NORTHERN INDIANA COMMUTER TRANSPORTATION DISTRICT MADISON SUBSTATION REHABLITATION TABLE OF CONTENTS
EXHIBIT 1 DRAWINGS AND TECHNICAL SPECIFICATION
DIVISION 1 – GENERAL PAGES
SECTION 01010 SUMMARY OF WORK 01010-1 THRU 01010-9 SECTION 01011 DRAWING LIST 01011-1 THRU 01011-2 SECTION 01012 WORK SEQUENCE AND CONSTRAINTS 01012-1 THRU 01012-3 SECTION 01027: SCHEDULE OF VALUES 01027-1 THRU 01027-2 SECTION 01300: SUBMITTALS 01300-1 THRU 01300-10 SECTION 01310: PROGRESS SCHEDULE AND REPORTS 01310-1 THRU 01310-5 SECTION 01700: PROJECT CLOSEOUT 01700-1 THRU 01700-4
DIVISION 16 – ELECTRIAL
SECTION 16010: GENERAL PROVISIONS ELECTRICAL 16010-1 THRU 16010-3 SECTION: 16011: BASIC ELECTRICAL MATERIALS AND METHODS 16011-1 THRU 16011-12 SECTION 16125: TRACTION POWER CABLES 16125-1 THRU 16125-12 SECTION 16126: TRACTION POWER CABLE LUGS 16126-1 THRU 16126-2 SECTION 16127: CABLE TAGS 16127-1 THRU 16127-1 SECTION 16601: GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT 16601-1 THRU 16601-17 SECTION 16602: RECTIFIER TRANSFORMER 16602-1 THRU 16602-7 SECTION 16603: I500 VOLT DC SILICON RECTIFIER 16603-1 THRU 16603-9
TABLE OF CONTENTS Page 1 DISTRICT
EXHIBIT 1 DRAWINGS AND TECHNICAL SPECIFICATION (Continued)
DIVISION 16 – ELECTRIAL PAGES
SECTION 16604: 1500 VOLT DC SWITCHGEAR 16604-1 THRU 16604-11 SECTION 16605: ANODE BUS DUCT 16605-1 THRU 16605-5 SECTION 16606 STATION CONTROL CABINET 16606-1 THRU 16606-5 SECTION 16607: TRACTION POWER EQUIPMENT REMOVAL & INSTALLATION 16607-1 THRU 16607-8 SECTION 16608: TRACTION POWER EQUIPMENT TESTING 16608-1 THRU 16608-16 SECTION 16609: IN-LINE TEST ON RECTIFICATION EQUIPMENT AND SURGE AND DESTRUCTIVE TEST ON DIODES 16609-1 THRU 16609-13 SECTION 16610: SERVICE ENGINEER 16610-1 THRU 16610-2 SECTION 16612: TRACTION POWER SUPPORT 16612-1 THRU 16612-3 SECTION 16613: MODIFICATION, TESTING AND REPROGRAMMING OF SCADA RTU 16613-1 THRU 16613-4
TABLE OF CONTENTS Page 2 DISTRICT
SECTION 01010
SUMMARY OF WORK
PART 1 GENERAL
1.01 GENERAL DESCRIPTION OF SOUTH SHORE LINE & THE PROJECT SITE
A. The South Shore Line is owned and operated by Northern Indiana Commuter Transportation District (District) and has approximately 75 route miles extending from South Bend Regional Airport in South Bend , Indiana at Mile Post (MP) 0 to METRA’s Kensington Station in Chicago, IL at MP 75.4. District uses a 15-mile section between Kensington Station and METRA’s Randolph Street terminal in Chicago, Illinois to complete the electric train operation.
B. Traction power to trains at 1500 volt DC is supplied from ten (10) traction power substations owned and operated by District along the South Shore line having a 2 MW rectifier at each substation, except at Eastport where there is a 4 MW rectifier to support the maintenance facility requirements. Local Utility supplies 34.5 kV, three phase, 60 Hertz to the substations from their high voltage transmission system
C. The work on this project shall consist of replacing major traction power equipment at Madison Substation located at approximately 59.14 MP along the South Shore Line all in accordance with the Construction Contract documents, technical specifications and drawings included as part of Contract Documents.
1.02 SUMMARY OF WORK
A. This section contains a general summary of work to be performed under this contract. If any conflict exists between the work described in this summary and the work defined in other specification sections or the drawings, those documents shall take precedence.
B. The Contractor shall provide all labor, material, equipment, incidentals and general conditions necessary to perform all the work as indicated in the contract documents and as required for a complete project.
C. Contractor shall comply with all applicable codes, ordinances, rules, regulations, orders and legal requirements. Contractor shall obtain and pay for all applicable permits and fees. Contractor shall provide all required mobilization, traffic control and protection. Under no circumstances shall the Contractor be entitled to any time extension or monetary damages due to any delay in issuing any permits.
D. Contractor shall inspect the site and verify all existing conditions, dimensions, access and obstructions prior to commencement of the work.
SUMMARY OF WORK 01010-1 DISTRICT
E. The work under this Contract includes furnishing, labor, materials, equipment, tools and incidentals for performing all operations necessary to replace major traction power equipment at Madison Substation as follows:
1. Remove and dispose outdoor oil filled transformer, anode bus duct, silicon power rectifier, dc switchgear, ac relay panel, dc feeder cables: from rectifier to dc switchgear; from dc switchgear to indoor disconnect and bypass switches; and return cable from rectifier to the negative bus. The control and auxiliary power cables associated with the aforementioned traction power equipment shall be disconnected, removed from trays and conduits and disposed. The new cables shall be similar in type, size and number of conductors as the existing cables. The new cables shall be installed using the same routing, trays, conduits as of the existing ones.
2. Furnish, install, test and commission the following traction power equipment in the same corresponding location from where the existing equipment is removed.
a. One (1) outdoor 34.5 kV dry type rectifier transformer and its primary cable.
b. One (1) set of anode bus duct for connecting rectifier transformer to a rectifier
c. One (1) 3000 kW, 1500 volt dc silicon diode rectifier.
d. One (1) 1500 volt dc switchgear line up.
e. A standalone Station Control Cabinet (SCC) for providing a complete microprocessor based protection and a fully digital measurement processing and functionally control in a single unit for all the traction power equipment of the Substation. The SCC shall be installed at the ac relay panel location.
f. 5 kV dc feeder cables from dc switchgear to indoor disconnect and bypass switches
g. 5 kV dc feeder cables from indoor disconnect switches to outdoor disconnect switches.
h. 5 kV dc return cables from rectifier to the negative bus and from the negative bus to the rail.
i. All control and auxiliary power cables associated with the traction power equipment.
SUMMARY OF WORK 01010-2 DISTRICT j. Replace two (2) existing DC Secheron Breakers UR26-82St installed and operating in the dc Switchgear at Wickliffe Substation with Secheron Breakers UR-40.
F. The contractor shall modify, re-program and test the existing RTU to accommodate the additional status and control points as required per contract drawing.
G. Replace smoke deduction system.
1.03 REMOVAL OF TRACTION POWER EQUIPMENT
A. Work required under this section includes providing all labor, material, apparatus and services necessary to disconnect traction power equipment and telecommunication items which are affected by this replacement work.
B. Visit the Project Site and thoroughly investigate Existing Conditions prior to submitting Bid. Carefully evaluate all Electrical Work which will be required to provide removal of existing traction power equipment, dc feeder cables and associated control and SCADA circuits. All these removals shall be coordinated with utility companies. No additional charges will be allowed for failure to include all labor and material that is required for these removals and relocations.
C. Prior to disconnecting and removal of any traction power equipment, the Contractor shall verify that the District has disconnected the 34.5kV incoming power to the traction power transformer and 1500 volt dc outgoing feeders to the catenaries and the negative return cables to the negative bus.
1.04 SITE EXAMINATION
A. Prior to mobilization at any site, the Contractor shall photograph and video record on DVD format, the existing condition of all areas that are to be occupied, worked on, restored or affected in any way by the project. Include conditions of adjacent structures and site improvements, as well as finished surfaces that may be misconstrued as damaged caused by construction or demolition operations. Submit reports, video DVDs and photographs of existing conditions to the Engineer prior to mobilization. The same is to occur after the work is completed.
B. The Contractor shall notify the District at least forty-eight (48) hours in advance prior to videotaping and taking photographs to afford the District the opportunity to accompany the Contractor while performing this work.
C. The Contractor shall be responsible and shall repair or replace any portions of the building, structures and site damaged by his acts, whether negligent or otherwise and shall leave the site in as good condition as existed prior to commencement of the contract work.
SUMMARY OF WORK 01010-3 DISTRICT
D. Certain District’s power, signal and communication cables will remain in continuous operation. The Contractor shall be responsible for ascertaining where the existing cables interfere with construction and either shall temporarily relocate these cables or adjust the installation process to avoid them.
E. Where applicable, furnish, install and maintain temporary access locations for access to the work site.
1.05 ACCESS REQUIREMENTS
A. Access to the project site is restricted. The site can be viewed during a walk through, the date and time for which the Contractor will be advised of, or by arrangement with the District. The Contractor should visit the site at that time to inspect the premises and get acquainted with the site and scope of the work and the conditions under which the work will be performed.
B. The Contractor shall be thoroughly familiarized with respect to conditions, dimensions, clearances, limitations, the need for peculiarities of construction, access to the site, and other factors which may affect the outcome of the work covered by the Contract.
C. By submitting a proposal, the Contractor agrees that the Contract Documents and the site have been carefully examined, and that from the Contractor’s own investigation, the Contractor has been satisfied as to the nature and location of the Work, the general and local conditions and matters which may in any way affect the Work or its performance. This shall include all physical conditions, site characteristics, means of access and egress to and from the site and any other factors which may influence the cost of the work. The Contractor shall inspect the project site, and as a result of such examination and investigation, imply that the Contractor fully understands the intent and purpose of the documents and conditions for bidding. .
1.06 DOCUMENTS FURNISHED A. The District will provide to the awarded Contractor, the following without charge Contract Drawings and Specifications: Three (3) sets; and one (1) CD.
B. Additional requested copies of will be furnished at cost.
1.07 REGULATORY REQUIREMENTS
A. It is the Contractor's responsibility to apply, expedite, obtain all required building
SUMMARY OF WORK 01010-4 DISTRICT and other permits, licenses, bonds and pays all fees required by all governing agencies and as required to perform the work of this project. Unless noted otherwise, the District or its consultant will supply the sealed or certified architectural and engineering drawings required to obtain the permit.
B. The Contractor for this project must meet and comply with all applicable requirements, codes, rules, orders, regulations, and ordinances of the State of Indiana and/or other applicable governing authorities.
C. The Contractor must comply with the State of Indiana Construction and Demolition Recycling Ordinance if applicable for this project. The Contractor shall be responsible for completing the city’s recycling compliance forms to provide documentation of compliance and shall be responsible for any fines levied for non-compliance.
D. The time required to obtain the permits after the Notice to Proceed must be included in the Contractor's schedule. All costs incurred by the Contractor to apply for, expedite and pay for the permits and any other fees or licenses must be included in the Contractor's price. No extras will be allowed for any permits, fees, licenses, or bonds required by any governmental agency applicable to this project.
E. Submit two (2) copies of the permits to the District prior to starting the work.
1. Furnish and install a weatherproof, glass enclosed, outdoor bulletin board and mount same near construction office (or on exterior wall of construction office), for the purpose of posting all valid permits.
2. Permits shall remain posted in exterior "visible" location during the entire construction period.
F. The Contractor shall immediately notify the District of requirements in the contract documents which do not strictly comply with the applicable laws, ordinances, and rules governing the work, before proceeding with that part of the work. Failure of the Contractor to do so shall be understood as an agreement on the part of the Contractor to guarantee compliance with the requirements for work covered by this Contract.
1.08 GENERAL REQUIREMENTS
A. The Contractor shall provide reasonable access to the site and shall not prohibit nor interfere with lawfully conducted inspections and site visits by properly identified representatives of the District or regulatory agencies.
B. The Contractor shall protect the District’s property and adjacent properties from damage and debris. The Contractor shall take all necessary precautions for the safety of the public and all employees at or near the work.
C Precautions shall be taken to avoid adverse environmental conditions during the work. The creation of air borne dust and debris shall be minimized.
SUMMARY OF WORK 01010-5 DISTRICT
D Clean-up shall be done routinely at the end of each work day. It is the General Contractor’s responsibility to make sure each trade cleans up after their work and that each work zone is cleaned daily. Remove and dispose of removed materials off of site legally and according to all local regulations . E. Remove snow and ice from the work zones as required.
1.09 CONTRACTOR VERIFICATION OF PREMISES AND WORK
A. Field Conditions require that the Contractor examine the site of work and adjacent premises including various means of site access; storage of materials and equipment, staging, delivery means and paths; installing and operating the necessary construction equipment; and any other difficulties that may be encountered in the execution of the work.
B. It is required that the Contractor is thoroughly familiar with the work of this nature, and has experience with similar projects. Due to nature of work to be performed, the Contract Drawings are not completely detailed and are schematic in nature and show general routing of conduit, duct lines, cable racks and trays. They do not show details and interferences which may require special attention during the construction.
C. The Contractor shall examine all Contract Drawings and identify the areas requiring special attention during construction for cutting, patching, cleaning, disconnecting, reconnecting, or relocating existing electrical facilities.
D. Confirm the accuracy of on-site grade and elevations, dimensions and locations prior to beginning the work. Verify existing conditions and dimensions. Verify and confirm the location, use and condition of all above and below ground utilities in the general project limits. Report to the District any discrepancies or conditions discovered in the field that may adversely affect the Work. Errors because of failure to verify such information shall be properly rectified without additional cost to the District.
E, Verify measurements for finished work at the site; do not scale drawings.
1.10 CONTRACTOR’S REQUIREMENTS
A. Personnel: Furnish the services of a competent superintendent at the construction site during all working hours. All labor employed will be subject to the approval of the District.
B. Contractor shall furnish mobilization and temporary work required to complete this Contract. This will include all temporary work required to maintain construction operation, all requisite lights, structures, fences, barricades, walkways, signage and other safeguards for the protection of the work and safety of personnel and premises.
SUMMARY OF WORK 01010-6 DISTRICT C. Provide all temporary heat required for the prevention of damage to work and materials by freezing, as found necessary to carry on construction operations, or for any reason as directed by the District.
D. The Contractor shall be held responsible for any damage to the structures, building elements, site elements, pavements, landscaping or other property, and for any injury inflicted to the public or other personnel due to negligence of the Contractor’s workers or other personnel.
1.11 CONTRACTOR USE OF THE PREMISES
A. The District must maintain operations at all times. The Contractor shall accommodate those operations and avoid interferences. The Contractor shall provide and maintain safe access through and around the construction site as necessary.
B Limit use of the premises for construction activities to the areas within contract limits or as indicated; do not disturb adjacent areas. Coordinate operations, access to the site, staging area, locations for storage and disposal or new and removed materials, and use of premises with the District.
C. If the District deems any of the work or operations of the Contractor disruptive to the District's operations, the District shall order the Contractor to immediately suspend work until reasonable remedial measures are taken satisfactory to the District.
D. The District's review of any of the Contractor's procedures, methods, temporary structures, tools or equipment does not relieve the Contractor of responsibility for the safety, maintenance, and repairs of any temporary structure or work, or for the safety, construction, and maintenance of the work, or from any liability whatsoever on account of any procedure or method employed, or due to any failure or movement of any temporary structure, tools or equipment furnished.
E. The Contractor shall at all times observe all rules, safety regulations and other requirements of the District.
1. Deliveries, loading and unloading operations shall minimize interference with the District’s operations and be coordinated with the District. Schedule deliveries to minimize space and time requirements for the storage of materials and equipment on site. Coordinate with the District for the location to store materials, debris and equipment.
2. Provide and maintain temporary access locations and temporary modifications to permit construction access to work sites. The Contractor shall submit temporary access locations and all proposed modifications to the District for approval.
3. Keep driveways and entrances serving the premises clear and available to the District at all times. Do not use those areas for parking or storage of
SUMMARY OF WORK 01010-7 DISTRICT materials.
F. The Contractor must not interfere with, block, or in any way encumber, fully or partially, any sidewalk, street, public right-of-way or access to private property without proper permits, approvals or permission from the governmental agency having jurisdiction or private entity having ownership; and make every effort to keep such closures to a minimum. Proof of authorization and copies of required permits shall be submitted to the District. Provide all required traffic control, signs, barricades, protection, warning lights, etc. meeting local requirements. Contractor must keep all public ways and adjacent properties clean.
1. Provide barriers as required to protect the District’s personnel and vehicles during the Work and allow for the District’s operations without interruption. Direct personnel and vehicular traffic away from work area.
2. Do not fully block entrances, exits, streets, drives or other access with materials, parking, or other construction activity. The design and placement of all proposed temporary protection shall be approved by the District.
G. The Contractor shall always provide clear access to all hydrants, water valves, gas valves, manholes, and other essential appurtenances.
H Protect newly installed work from damage until completion.
I. Protect all landscaping, paving, walks, utilities, and existing structures and site elements to remain from damage by construction operations. Perform any required repairs to the District’s satisfaction and at no cost to the District.
1.12 STORAGE OF MATERIALS
A. The Contractor shall not store or dispose of any material on the District’s property or structure at any time unless approved by the District.
B. The Contractor shall obtain and pay for the use of all storage areas required for its execution of the Contract. If it becomes necessary in the opinion of the District to move such materials which are temporarily at a location within project limits, Contractor shall move such materials to other locations as directed by the District at no additional cost to the District.
C. The Contractor assumes full responsibility for protection and security of all materials and equipment stored on the site. The Contractor shall secure all Contractor owned or Contractor used equipment on the project site during hours of work or non-work to prevent theft, vandalism, and the unauthorized use of the equipment for any purpose.
1.13 WORK AREA CLEANING
A. Follow city ordinances regarding the regulation and maintenance of construction sites.
SUMMARY OF WORK 01010-8 DISTRICT
B. Provide dumpsters for trash collection within the fenced construction site. Do not allow trash or debris to migrate outside the construction limits. Clean up and remove trash and debris after every work shift.
C. Keep the construction site, the surrounding areas, and access roads clean. Wash off trucks before leaving the construction site. Sweep and keep clean roadways on a daily basis or more often if required. Keep landscaped areas clean and without damage. Control dust with misting and covering of construction materials and trucks leaving the site. Minimize noise. Avoid toxic fumes.
PART 2 PRODUCTS
NOT APPLICABLE
PART 3 EXECUTION
NOT APPLICABLE
END OF SECTION
SUMMARY OF WORK 01010-9 DISTRICT
SECTION 01011
DRAWING LIST For MADISON SUBSTATION
Following is a list of Contract Drawings attached to and made part of this Specification.
SHEET DOCUMENT NUMBER DRAWING TITLE REVISION
1 2077-5914-COVER COVER SHEET 2 2077-5914-INDEX INDEX SHEET 3 2077-5914-E1D SINGLE LINE DIAGRAM 4 2077-5914-E1 SINGLE LINE DIAGRAM 5 2077-5914-E2 PROTECTION SCHEME 6 2077-5914-E3 RECTIFIER THREE PHASE SCHEMATIC 7 2077-5914-E4 RECTIFIER DIODE MONITORING SCHEMATIC 8 2077-5914-E5 RECTIFIER AUXILIARIES 9 2077-5914-E6 RECTIFIER START-UP AND ANNUNCIATOR CIRCUIT 10 2077-5914-E7 DC CATHODE BREAKER -72 11 2077-5914-E8 DC WEST FEEDER BREAKER - 172-1 12 2077-5914-E9 DC EAST FEEDER BREAKER 172-2 13 2077-5914-E10D AC REMOTE RELAY PANEL SCHEMATIC & CONNECTION DIAG. 14 2077-5914-E10 AC REMOTE RELAY PANEL SCHEMATIC & CONNECTION DIAG. 15 2077-5914-E11D ELECTRICAL EQUIPMENT LAYOUT 16 2077-5914-E11 ELECTRICAL EQUIPMENT LAYOUT 17 2077-5914-E12D DC FEEDER CABLES AND BUS, PLAN AND SECTIONS 18 2077-5914-E12 DC FEEDER CABLES AND BUS, PLAN AND SECTIONS 19 2077-5914-E13D OUTDOOR INSTALLATION AND GROUNDING 20 2077-5914-E13 OUTDOOR INSTALLATION AND GROUNDING 21 2077-5914-E14D OPERATING FLOOR CONDUIT LAYOUT 22 2077-5914-E14 OPERATING FLOOR CONDUIT LAYOUT 23 2077-5914-E15D DC CABLE GETAWAYS 24 2077-5914-E15 DC CABLE GETAWAYS 25 2077-5914-E16D CABLE SCHEDULE 26 2077-5914-E16 CABLE SCHEDULE 27 2077-5914-E17D INTERCONNECTION DIAGRAM 28 2077-5914-E17 INTERCONNECTION DIAGRAM 29 2077-5914-E18D SUPERVISORY INTERCONNECTION DIAGRAM 30 2077-5914-E18 SUPERVISORY INTERCONNECTION DIAGRAM 31 2077-5914-E19D DC FEEDER CABLES AND TRAY PLAN, SECTIONS AND DETAILS 32 2077-5914-E19 DC FEEDER CABLES AND TRAY PLAN, SECTIONS AND DETAILS 33 2077-5914-S1 OPERATING FLOOR AND YARD PLAN 34 2077-5914-S2D EQUIPMENT FOUNDATIONS AND FLOOR ALTERATION
DRAWING LIST 01011-1 DISTRICT
SECTION 01011
DRAWING LIST
Following is a list of Reference Drawings attached to this Specification. These drawings show the plan, layout and wiring of the existing equipment and shall be utilized by the Contractor for guidelines,coordination and design purposes.. SHEET DOCUMENT NUMBER DRAWING TITLE REVISION
1 900-4-A1 ARCHITECTURAL OPREATING FLOOR PLAN & ELEVATIONS 2 900-4-A2 ARCHITECTURAL ALTERATION DETAILS 3 900-4-C1 PLOT PLAN 4 900-4-E2 AUXILIARY EQUIPMENT SINGLE LINES 5 900-4-E6 OUTDOOR INSTALLATION AND GROUNDING 6 900-4-E7 LIGHTING 7 900-4-E11 MISCELLANEOUS SCHEMATICS AND WIRING DIAGRAMS 8 900-4-E12 SUPERVISORY INTERCONNECTION DIAGRAMS 9 D-101 231 957 FP TRANSFORMER OUTLINE DIMENSIONS 10 637Z0B00707 OUTLINE 2 MW RECTIFIER EQUIPMENT 11 3631-D502 ELEVATION 1500V DC SUBSTATION 12 3631-D520 SCHEMATIC DIAGRAM 172 FEEDER BREAKER 13 3631-D521 SCHEMATIC DIAGRAM 72 CATHODE BREAKER 14 3631- D523 SCHEMATIC DIAGRAM DC SWITCHGEAR AUXILIARY 15 ESK 900-15 BILL OF MATERIAL 16 ESK-900-17 34.5 KV SWITCHYARD ARRANGEMENT 17 SS05914 MADISON SCADA - COVER PAGE 18 SS05914.01 MADISON SCADA - INDEX SHEET 19 SS05914.02 MADISON SCADA - LOCATION PLAN 20 SS05914.03 MADISON SCADA - SCADA INDICATIONS HLC 1 21 SS05914.04 MADISON SCADA - SCADA INDICATIONS HLC 2 22 SS05914.05 MADISON SCADA - SCADA CONTROLS HLC PANEL #1 23 SS05914.06 MADISON SCADA - SCADA CONTROLS HLC PANEL #2 24 SS05914.07 MADISON SCADA - FUTURE SCADA I/O 25 SS05914.08 MADISON SCADA - HLC LAYOUT 26 SS05914.09 MADISON SCADA - COMMUNICATION INTERFACE & HLC CKTS. 27 SS05914.10 MADISON SCADA - I/O FUNCTIONS 28 SS05914.11 MADISON SCADA - CODE DATA AND I/O ASSIGNMENTS 29 SS05914.12 MADISON SCADA - TERMINAL DESIGNATIONS G4, G5 & G6 30 SS05914.13 MADISON SCADA - POWER DISTRBUTION & LINE CIRCUITS 31 SS05914.14 MADISON SCADA - RACK 1 DETAILS 32 SS05914.15 MADISON SCADA - RACK 2 DETAILS 33 SS05914.16 MADISON SCADA - SHELF PROFILE JMUX EQUIPMENT
DRAWING LIST 010011-2 DISTRICT
SECTION 01027
SCHEDULE OF VALUES
PART 1 - GENERAL
1.01 DESCRIPTION
A. The work of this Section covers preparing and submitting a Schedule of Values for the work performed under this Contract, and, if the Schedule is affected by change orders, of preparing and submitting updated copies of the Schedule.
1.02 RELATED SECTIONS
A. Section 01012 - Work Sequence and Constraints
B. Section 01310 - Progress Schedule and Reports
C. Section 01700 - Project Closeout
1.03 SUBMITTALS
A. Refer to Section 01300, Submittals, for submittal procedure.
B. Identify items in the Schedule of Values with the Specification Section numbers, Specification Section title, and Bid Item number. Identify by a distinct item the cost of removal and disposal of all existing disconnected cables from trays and conduits.
C. Upon request by NICTD, support values given with data which will substantiate the correctness of the values.
D. Schedules will be used only as a basis for Contractor’s Application for Payment and for Progress Payment. Tasks in the Schedule of Values will closely reflect line items in the Contractor’s Baseline CMP Progress Schedule.
E. If review by NICTD indicates that changes to the schedules are required, revise and resubmit schedules in the same manner as the original schedules were prepared and submitted.
SCHEDULE OF VALUES 01027-1 DISTRICT
PART 2 - PRODUCTS
Not Used.
PART 3 - EXECUTION
3.01 GENERAL
A. Submit a balanced Schedule of Values. The total value of the activities shall equal the Contract amount. Overhead and profit shall be prorated into the amounts indicated for the activities. Activity values shall be rounded to the nearest dollar.
B. If, in the opinion of NICTD, the Schedule of Values is unbalanced, the Contractor will be required to present documentation substantiating the cost allocations of those activities believed to be unbalanced.
C. The schedule of values shall be submitted to NICTD for review prior to processing of any Contractor progress payments.
D. The schedule of values shall be updated to incorporate change orders prior to payment against change order work.
E. Requests for advance payment against material and equipment invoices, must be identified against the applicable activity number in the schedule of values.
F. In the event that the Contractor's scheduling software does not include a Schedule of Values and an Earned Value report function, then the Schedule of Values shall be formatted utilizing MS Excel latest version. A copy of the electronic file shall be made available to NICTD with the Approved Schedule of Values format, entitled Form 01027A - Earned Value Report.
END OF SECTION
SCHEDULE OF VALUES 01027-2 DISTRICT
SECTION 01300
SUBMITTALS
PART 1 - GENERAL
1.01 DESCRIPTION
A. This Section of the Specifications covers all submittals including shop drawing submission and concurrence requirements, and further complements the requirements of the Construction Contract. The Contractor shall make submittals required by the Contract Documents, and revise and resubmit as necessary to establish compliance with the specified requirements.
B. Submittals that are not required may be reviewed at the discretion of NICTD.
C. Contractors may require subcontractors to provide drawings, installation diagrams, and similar information to help coordinate the work, but such data shall remain between the Contractors and the subcontractors and will not be reviewed by NICTD unless it is required by other pertinent Sections of the Specifications. If required, it must be reviewed and approved by the Contractor prior to forwarding to NICTD.
1.02 RELATED WORK
A. Section 01010 - Summary of Work.
B. Section 01700 – Project Closeout.
1.03 QUALITY ASSURANCE
A. Coordination of Submittals:
1. Prior to each submittal, carefully review and coordinate all aspects of each item being submitted. Shop drawings of systems containing closely related items and components must be submitted as a single submission showing the interrelationship of the components required for that system. The Contractor, by affixing his signature to each submittal, certifies that all necessary coordination has been performed.
SUBMITTALS 01300-1 DISTRICT
2. The Contractor shall verify prior to submission that each shop drawing is well prepared and that the submittal conforms in all respects with the specified requirements. The drawings shall provide complete information regarding proper fabrication and installation.
3. The Contractor shall sign each submittal and affix a stamp with specific written indication that the Contractor has satisfied all responsibilities under the Contract Documents with respect to review of the submission.
4. Shop drawings shall be tailored to the specific project need including coordination of various trades, and should include material descriptions, quantities, dimensions, design criteria and similar data to enable NICTD to review the information as required. The shop drawings must show clear and complete information for the fabrication and installation of materials.
5. Orient the plan(s) on the shop drawing(s) in the same manner as the plans on the Contract Drawings.
6. Shop drawings with reproduction(s) of the Contract Drawings will not be accepted.
7. Structural fabrication and erection drawings shall be prepared, checked, signed and sealed by a Professional Engineer licensed in the State of Indiana with proven qualifications and similar experience.
8. Unless the Contract Documents indicate specific steel connections, the Contractor shall design and provide sufficient details to accomplish the work for NICTD’s review and comment.
B. Responsibility:
The Contractor is solely responsible and accountable for:
1. Means, methods, techniques, sequences, procedures, and construction including fabrication, assembly, installation/erection, safety precautions and programs incidental to any submittal reviewed and approved by NICTD.
2. Accuracy of all submittals, shop drawings and final installation drawings. As built drawings shall fully integrate existing (pre- construction) drawings.
SUBMITTALS 01300-2 DISTRICT
1.04 SUBSTITUTIONS
A. "Or Equals" Substitutions:
1. Equals Considered - Whenever a material or article required is specified or shown on the plans by using the name of the proprietary product or of a particular manufacturer or vendor, any material or article which will, in the opinion of NICTD's Project Manager, perform adequately the duties imposed by the general design will be considered equal and satisfactory provided material or article so proposed is of equal substance and function in NICTD's opinion. It shall not be purchased or installed without NICTD's prior written approval.
2. "Or Equal" requests will be considered only when substantiated by the Contractor's submittal of data documenting the "or equal" nature of material or article.
B. Substitutions for Unavailability
1. Substitutions may be considered when a product becomes unavailable through no fault of the Contractor. The Contractor shall document each request with complete data substantiating compliance of proposed substitution with Contract Documents, or there is a clear benefit to NICTD, including cost. A request constitutes a representation that the Contractor:
a. Has investigated proposed product and determined that it meets or exceeds the quality level of the specified product.
b. Shall provide the same warranty for the substitution as for the specified product.
c. Shall coordinate installation and make changes to other work that may be required for the work to be complete with no additional cost to NICTD.
2. The Contractor shall waive claims for additional costs and/or time extension that may subsequently become apparent.
1.05 SUBMITTALS
A. NICTD’s action on submittals will be indicated by one of the following comments:
NO EXCEPTIONS TAKEN
SUBMITTALS 01300-3 DISTRICT
PROCEED AS NOTED; REVISE AND RESUBMIT FOR RECORD
DO NOT PROCEED; REVISE AND RESUBMIT
REJECTED
NOT APPLICABLE
B. After checking and verifying all field measurements and, after complying with the applicable procedures of the Contract, Contractor shall submit shop drawings, catalog cuts, samples and substitution(s) for NICTD review and comment.
C. Submittals will be reviewed by NICTD and/or its design consultant and/or Construction Manager.
D. Submittals not in compliance with the Contract will be returned to the Contractor for revision. Any loss of time and additional costs associated with resubmittal(s) will be the Contractor's responsibility.
E. Each submission and or re-submission shall give specific written notice on the transmittal of each variation that the shop drawings or samples may have from the requirements of the Contract Documents and, in addition, shall cause a specific notation to be made by the Contractor on each shop drawing submitted for review and approval of each such variation.
F. Each resubmission shall clearly identify and make specific notation(s) on each shop drawing concerning the:
1. Changes that are made as a result of NICTD’s comments on the previous submittal(s).
2. Changes that the Contractor does not make as a result of a previous NICTD comment shall be explained and justified by the Contractor.
3. Changes that are made by the Contractor, but not as a result of a NICTD comment on the previous submittal(s). The Contractor shall provide a detailed explanation and justification for such changes.
G. Submittals that are marked by NICTD "Proceed as Noted" are for the purpose of expediting procurement, fabrication, and installation of the intended work.
SUBMITTALS 01300-4 DISTRICT
H. Payment for completed work that is related to "Proceed as Noted" submittal will not be made until the corrected and final resubmittal is accepted by NICTD.
PART 2 – PRODUCTS
2.01 SHOP (FABRICATION/INSTALLATION) DRAWINGS:
A. General:
1. The Contractor's Drawings shall show the general arrangement and such details as are necessary to provide a comprehensive description and depiction of the work to be performed.
2. As indicated below, prepare such working and shop drawings as are necessary to adequately perform the work and document the installation for NICTD's future maintenance and operations.
3. Prepare all work and shop drawings accurately to a scale sufficiently large to show all pertinent aspects of the item and its method of connection to the work. If requested by the Contractor, a typical title block will be provided by NICTD as a template for Shop Drawing production at the start of the Project.
4. Accurately and distinctly indicate the following:
a. All working and erection dimensions.
b. Arrangements and sectional views.
c. Necessary details, including complete information for making connections between existing facilities and work under this Contract.
d. Kinds of materials and finishes.
e. Parts lists and descriptions thereof.
f. On drawings for mechanical and electrical equipment, present where applicable, such data as dimensions, weight and performance characteristics. Show conformance with the performance characteristics and other data incorporated in the Contract Drawing and Specifications.
SUBMITTALS 01300-5 DISTRICT
5. Furnish detail drawings for temporary work and methods of construction proposed for use. Take responsibility for such drawings and for the safe and successful construction of the work.
B. Shop and Working Drawings:
1. Definition - Shop Drawing:
Shop Drawings consist of design, fabrication, erection, and installation drawings, schedule drawings, manufacturer's scale drawings, wiring and control diagrams, cuts of entire catalogs, pamphlets, descriptive literature and performance and test data. Test plans for all systems and subsystems shall also be submitted as a shop drawing.
2. Definition - Working (or Design) Drawing:
a. Working Drawings consist of plans for temporary work and for such other work as may be required for construction but which does not become an integral part of the completed project. They should be accompanied by calculations or other sufficient information to completely explain the structure or system described and its intended manner of use and be signed and sealed by a Professional Engineer registered in the State of Indiana.
b. Coordinate drawings for work on utility facilities, streets and other facilities which are constructed for owners other than NICTD so that the information required by these owners is included on the Working Drawings for their facilities.
3. Submit three (3) legible prints of all complete and detailed Shop and Working Drawings to NICTD for review. One marked-up copy will be returned to the Contractor.
C. Distribution of submitted Shop and Working Drawings shall be as designated by NICTD. Review comments will be shown on the copy returned to the Contractor. The Contractor shall make and distribute all additional copies required for his purpose.
2.02 CERTIFICATES OF COMPLIANCE:
A. Submit to NICTD all Certificates of Compliance for material approval prior to installation of materials as follows:
SUBMITTALS 01300-6 DISTRICT
1. Certify that all materials used in the work comply with all specified provisions. Certification shall not be construed as relieving the Contractor from furnishing satisfactory materials if, by the Contractor or by NICTD, the material is found to not meet specified requirements.
2. Show on each certification the name and location of the work, name and address of Contractor, quantity and date or dates of shipment or delivery to which the certificate applies, and name of the manufacturing or fabricating company. Certification shall be in the form of letter or company-standard form containing all required data. Certificates shall be signed by an officer of the manufacturing or fabricating company and shall bear the Contractor's approval stamp.
3. In addition to the above information, all laboratory test reports submitted with Certificates of Compliance shall show the date or dates of testing, the specified requirements for which testing was performed, the results of the test or tests, and shall be signed by the technician performing the tests.
2.03 MANUFACTURER'S LITERATURE:
A. General: Where contents of submitted literature from manufacturers includes data not pertinent to the submittal, clearly indicate which portion of the contents is being submitted for review.
B. Number of Copies Required: Submit seven (7) copies to NICTD.
2.04 SAMPLES:
A. NICTD may request samples of selected hardware and assemblies if the contractor is proposing a substitution.
B. Number of Samples Required: Unless otherwise specified, submit two (2) samples to NICTD. NICTD will retain both samples.
C. Pre-pay all shipping charges on samples.
D. Label each sample indicating:
1. Name of Project and Contract Number.
2. Name of Contractor and Subcontractor.
3. Material or equipment represented.
SUBMITTALS 01300-7 DISTRICT
4. Source.
5. Name of producer and brand (if any).
6. Specification Section, article and paragraphs.
E. Certain samples may be tested by NICTD as specified. Samples determined by NICTD to be in general conformance with the design concept, and that are destroyed in testing may be retained by NICTD. Materials and equipment incorporated into the work shall match conformed samples. Samples not destroyed in testing and not in conformance will be returned, at the Contractor's expense, if so requested at time of submission.
2.05 COLORS AND PATTERNS
A. Unless the precise color and pattern is specifically called out in the Contract Documents, and whenever a choice of color or pattern is available in the specified products, the Contractor shall submit accurate color and pattern charts to NICTD for selection.
PART 3 - EXECUTION
3.01 IDENTIFICATION OF SUBMITTALS:
A. General: Consecutively number all submittals. Accompany each submittal with a letter of transmittal containing all pertinent information required for identification and checking of submittals.
B. At the Contractor’s option, they may establish an internet site/connection for sending/receiving submittals and correspondence.
C. Transmittal Form: At the Preconstruction Meeting, the Contractor shall submit his proposed transmittal form to NICTD for review and approval.
D. Each submittal shall include as a minimum the following information:
1. Submittal number. 2. Specification Section and Reference Paragraph. 3. Project Name. 4. Date. 5. Name and address of Engineer. 6. Name and address of Contractor.
SUBMITTALS 01300-8 DISTRICT
7. Name and address of Subcontractor. 8. Name and address of Supplier. 9. Name of Manufacturer. 10. Drawing number and detail references, as appropriate. 11. Type of Submittal. 12. Name, State Registration No. and Seal of Professional Engineer certifying the computations on original design work.
E. Resubmittals: When material is resubmitted for any reason, the resubmittal shall carry the same submittal number as the original submittal except an appendage "A", "B", "C", etc. shall be added to indicate that the material is a first, second, third, etc., submission. For example, submission 177 would indicate an original submission; 177A, a second submission; and 177B, etc.
F. Submittal Log: Maintain an accurate computerized submittal log for the duration of the Contract, showing current status of all submittals. Make the submittal log available for NICTD’s review upon request. Log(s) should be kept on software acceptable to NICTD’s Project Manager.
3.02 GROUPING OF SUBMITTALS:
A. Grouping of Submittals: Unless otherwise specified, make all submittals in groups containing all associated items to ensure that information is available for checking each item when it is received.
B. Partial and or poorly prepared submittals shall be rejected as not complying with the provisions of the Contract Documents and the Contractor shall be strictly liable for all delays so occasioned.
C. Submittal Organization: All shop drawings, catalog cuts; certificates of compliance and manufacturer's literature shall be grouped together, categorized in a logical sequence and submitted within three-ring binders. In the front of the binder an updated submittal log shall be provided showing the current status of all project submissions.
3.03 TIMING OF SUBMITTALS:
A. Make all submittals in accordance with the approved Submittal Schedule and far enough in advance of scheduled dates for installation to provide all time required for reviews, for securing necessary approvals, for possible revisions and resubmittals, and for placing orders and securing delivery.
SUBMITTALS 01300-9 DISTRICT
B. NICTD's Review Time: The Contractor will allow at least twenty-one (21) calendar days for review by NICTD following his receipt of the submittal. NICTD will stamp all submittals "Received", and the date so stamped shall be the official receipt date. This review time will be increased for the submittal(s) that are so extensive that twenty-one (21) days of turn around period is unreasonable as determined by NICTD. This determination shall be binding on the Contractor.
C. Delays: Delays caused by tardiness in receipt of submittals will not be an acceptable basis for extension of the Contract Completion Date. Continued submission of material and repetitious submittals which clearly fail to meet the requirements of the Contract Documents which may cause delays in the completion of the Contract and any such delays shall be the sole responsibility of the Contractor.
3.04 NICTD’s REVIEW:
A. Review and processing by NICTD shall not relieve the Contractor from responsibility for errors that may exist in the submitted data.
B. Revisions:
1. The Contractor shall make required revisions as noted on initial submittal.
2. If the Contractor considers any required revision to be a change, it shall so notify NICTD as provided for in the Construction Contract.
3. The review of the shop drawings waives the original contract requirements of the Contract Documents only if the Contractor clearly states and highlights the proposed deviation in a prominent fashion on the shop drawing itself, and only as specially stated in writing by NICTD, that the Contract Documents are waived.
END OF SECTION
SUBMITTALS 01300-10 DISTRICT SECTION 01310
PROGRESS SCHEDULE AND REPORTS
PART 1 - GENERAL
1.01 DESCRIPTION
A. This Section specifies requirements and procedures for the Contractor in preparing construction schedules. The purpose of the construction schedule shall be to ensure adequate planning and executing of the work by the Contractor, to establish the standard against which satisfactory completion of the project will be judged, to assist NICTD in monitoring progress and to facilitate assessment of the impact of construction changes on the construction schedule. The Baseline Progress Schedule tasks will closely reflect the Schedule of Values and will be used in the review and approval of progress payments.
1.02 SUBMITTALS
A. Refer to Section 01300, Submittals, for submittal procedures.
B. Furnish as a minimum:
1. Schedules:
a. Preliminary construction schedule with narrative: Submit for review at the pre-construction conference. Include mobilization material and equipment procurement, construction work, and training. Clearly indicate major milestones and the time(s) for completion which are required to be met under the terms of the Contract. Include a Critical Path Schedule, and Schedule of Values.
b. Construction Schedule: Critical path construction bar chart, schedule of values and cash flow projection shall be submitted within 60 days of Notice to Proceed and at least 21 days prior to the first progress payment request.
2. Monthly progress reports:
a. Submit narrative reports of work accomplished in support of each monthly progress payment request.
PROGRESS SCHEDULE AND REPORTS 01310-1 DISTRICT b. A revised Critical Path Schedule shall be submitted monthly with the progress payment request.
c Participate in a monthly review of the construction schedule. Revisions deemed necessary shall be submitted within 10 calendar days of each monthly review.
3. Submittal schedule: Identify all required submittals and projected submittal dates.
PART 2 - PRODUCTS
2.01 CONSTRUCTION SCHEDULES .
A. Schedules shall be computerized and shall be submitted both in hard copy and in electronic format. Information submitted on disks shall be fully compatible with “Primavera – P6 version 16” scheduling software.
B. The construction bar chart based on the construction schedule shall be time scaled.
C. Activities: Show on construction bar charts at their early start/finish time period.
D. In preparing the schedule of values, break up the work into construction activities such that the duration of each activity shall not exceed 30 working days and construction activity values not to exceed $100,000 unless approved by NICTD. Non-construction activities (submittals, fabrication, etc.) may have durations in excess of 30 working days.
E Submittal and procurement activities shall include preparation and submittal of shop drawings, product data, samples, fabrication, delivery, as-built drawings and O&M manuals.
F. Dates imposed on the schedule by the Contractor shall not be binding on NICTD.
G. Failure of the Contractor to include any element of work required for the performance of this Contract shall not excuse the Contractor from completing the work as described in the Contract Documents.
PROGRESS SCHEDULE AND REPORTS 01310-2 DISTRICT H. Provide a list of the holidays and non-work days applicable to the schedule.
I. Include in the construction schedule owner operator training, O&M manuals and milestone dates as specified in other sections of the Contract Documents.
J. The critical path shall be clearly shown.
K. Network diagrams and construction bar charts shall be prepared on 11-inch x 17-inch Sheets.
L. Bar Charts will be banded by major activity as agreed with NICTD.
2.02 SCHEDULE OF VALUES
A. Submit a balanced schedule of values. The total value of the activities shall equal the Contract amount. Overhead and profit shall be prorated to the activities. Activity values shall be rounded to the nearest dollar.
B. Refer to Section 01027, “Schedule Of Values”.
2.03 MONTHLY REPORTS
A. Include construction bar chart, schedule of values, cash flow projection and narrative summary.
B. The narrative summary: Briefly describe the progress of the project. Describe how the project is progressing towards its completion. Identify milestones completed, major equipment deliveries and problems arising during the month. Project the work anticipated during the coming month, including major deliveries and submittals.
2.04 WEEKLY PROGRESS REPORT
A. Include a 2 week look-ahead schedule showing what work the Contractor anticipates working on. This work will include all work by NICTD and any other agencies such as NIPSCO .
PROGRESS SCHEDULE AND REPORTS 01310-3 DISTRICT 2.05 CASH FLOW REPORT
A. Include a forecast, by month, based on the current schedule, of cash requirements to complete the Contract
PART 3 - EXECUTION
3.01 SCHEDULE REVISIONS
A. The Contractor’s request for Contract Schedule revisions shall be based on the latest updated schedule, and shall be accompanied by a narrative description and justification for the change. Updates or minor adjustments approved by NICTD at monthly progress review meetings are not considered as revisions in this context.
B. The Contractor shall submit the proposed revisions in similar format to monthly schedule updates.
C. The Contract Schedule may be revised, subject to the approval of NICTD, when one or more of the following occur:
1. When a Change Order affects the Contract completion date or sequence of work items.
2. When the Contractor elects to change the schedule logic, sequence or duration of activities potentially affecting the critical path.
3. When NICTD directs a change that affects the Contract completion and/or interim Milestone date(s) specified in Section 01012, “Work Sequence and Constraints”.
3.02 CONTRACT TIME ADJUSTMENTS
A. If the Contractor requests an extension of time for completion of any milestone or Contract completion date in respect to a delay event, the determination by NICTD of the schedule impact of the event will be based upon analysis of the update and revision of the schedule, current at the time of the event, and upon all data relevant to the delay. Such approved data and extension of time shall be incorporated in the next monthly update of the schedule after the determination is made. Similar principles shall be applied to any event, including NICTD concessions or changes, potentially reducing the time for completion of any milestone or contract completion date.
PROGRESS SCHEDULE AND REPORTS 01310-4 DISTRICT B. The Contractor acknowledges and agrees that delays in activities which, according to the schedule delay impact analysis, are not critical to any milestone date or the Contract completion date (i.e., in activities containing float), will not be the basis for any extension of time.
3.03 AS-BUILT SCHEDULE
A. The contractor shall maintain, continuously update and submit monthly, with the schedule update in time-scaled network plot format, an “as-built” Contract Schedule showing actual start and finish dates for all activities and milestones. On completion of all contract work, the contractor shall submit the “Final” As-Built schedule.
END OF SECTION
PROGRESS SCHEDULE AND REPORTS 01310-5 DISTRICT
SECTION 01700
PROJECT CLOSEOUT
PART 1 – GENERAL
1.01 DESCRIPTION
A. This Section specifies the requirements for closing out the project in addition to those other requirements specified in the Construction Contract.
B. Project Closeout is the term used to describe the collective project requirements that are to be fulfilled near the Completion Date, in preparation for Final Acceptance and occupancy of the work by NICTD, as well as final payment to the Contractor and the normal termination of the Contract.
C. Substantial Completion is part of Project Closeout and is defined in the Construction Contract . The specifics of Substantial Completion will be mutually agreed upon by contracting parties.
D. There may be a single or multiple Substantial Completions depending upon circumstances.
1.02 RELATED WORK
A. Requirements as specified in the Construction Contract
B. Specific requirements for individual units of work are included in the appropriate sections of these specifications.
C. Section 01027 – Schedule of Values
1.03 PREREQUISITES TO SUBSTANTIAL COMPLETION
A. General:
1. Substantial Completion is a Contractor initiated activity that, if the contracting parties agree, will result in issuing a Certificate of Completion from NICTD to the Contractor.
2. The Contractor shall initiate the process by requesting, in writing, for final inspection of the work. The Contractor shall attach to this request the following:
a. The progress payment showing either 100% completion for the portion of the work claimed as substantially complete, and/or a
PROJECT CLOSEOUT 01700-1 DISTRICT
listing of incomplete items, the value of the incomplete items, and the reasons for the items being incomplete.
b. Submit written certification to NICTD that the Project, or designated portion, is substantially complete.
c. Submit list of items to be completed or corrected and material delivery dates of major items, as applicable.
d. Submit a statement showing an accounting of changes to the Contract Sum.
e. Advise NICTD of pending insurance changeover requirements.
f. Submit three copies of all specific warranties for materials and equipment, workmanship/maintenance bonds, maintenance agreements, final certifications and similar documents. The effective time limits of all guarantees and warranties shall commence on the date of Final Acceptance.
g. Obtain and submit releases enabling NICTD's full unrestricted use of the work and access to services and utilities.
h. Deliver excess tools; spare parts, extra stock of material and similar physical items to NICTD.
i. Discontinue or change over and remove temporary facilities and services from the project site, along with construction tools and facilities, mock-ups, and similar elements.
j. Complete final cleaning requirements, including touch-up painting and otherwise repair and restore marred finishes.
k. All contract record documents, maintenance manuals, warranties, and bonds shall be submitted as defined in the Agreement.
B. Inspection Procedures:
1. Within 5 days upon compliance of item 1.03.A above, NICTD will either proceed with the inspection or advise Contractor of pre- requisites not fulfilled.
2. Following the inspection, NICTD will either prepare Certificate of Completion, or advise the Contractor of specific elements of work that must be complete prior to the issuance of the Certificate.
3. Repeat inspections within 30 days after request will be made to assure that work has been substantially completed.
PROJECT CLOSEOUT 01700-2 DISTRICT
4. The results of the inspection by NICTD will constitute the "Punch List" for Final Acceptance. The "punchlist" will be returned to the Contractor with the Certificate of Completion.
1.04 PRE-REQUISITES TO FINAL ACCEPTANCE AND PAYMENT
A. General: Submit the following, signed, sealed and notarized, before requesting NICTD's final inspection for Certification of Final Acceptance and Final Payment, as required by Contract. List known exceptions, if any, in the request.
1. Final payment request with final releases and supporting documentation not previously submitted and accepted. Include certificates of insurance for products and completed operations where required.
2. Updated final statement, accounting for final additional changes to the Contract Sum.
3. Certified copy of NICTD's final punch-list of itemized work to be completed or otherwise resolved for acceptance and has been endorsed and dated by NICTD.
4. Final meter readings for utilities, a measured record of stored fuel, and similar data either of the date of substantial completion, or else when NICTD took possession of and responsibility for corresponding elements of the work;
5. Consent of surety to final payment. Affidavit of payments of Debts and Claims. Affidavit of Release of Liens. General release by Trade Contractor of Owner, Guarantee against Defects, any warranties and Maintenance Bonds. Any special documentation such as Engineer Permits or Certification of Occupancy.
6. Evidence of final, continuing insurance coverage complying with insurance requirements.
7. Record drawings (as-builts), final project photographs, damage or settlement survey, and similar final record information. Both hardcopy and AutoCadtm electronic data file record drawings shall be furnished.
8. Written certification that Contract Documents have been reviewed.
9. Specific guarantees for material and equipment.
10. All certificates obtained in connection with the work.
11. Field books and stakeout data.
12. Final certificate of labor wages.
PROJECT CLOSEOUT 01700-3 DISTRICT
13. Statement of Patent Rights (if applicable);
14. Maintenance manuals (if applicable);
15. Quality control records and test results.
B. Re-inspection Procedure: NICTD will re-inspect the work upon receipt of the Contractor's notice that the work, including punch-list items resulting from earlier inspections, has been completed, except for those times whose completion has been delayed because of circumstances that are acceptable to NICTD.
1. Upon completion of re-inspection, NICTD will either prepare a certificate of final acceptance and process final payment, or will advise the Contractor of work that is incomplete or of obligations that have not been fulfilled, but are required for final acceptance.
2. If necessary, the re-inspection procedure will be repeated.
1.05 REIMBURSEMENT OF NICTD COSTS
A. The Contractor shall be responsible for all costs incurred by NICTD if the inspections related to substantial completion and Final Acceptance are extended more than once for each level of completion.
PART 2 - PRODUCTS
Not Used
PART 3 - EXECUTION
Not Used
END OF SECTION
PROJECT CLOSEOUT 01700-4 DISTRICT
SECTION 16010
GENERAL PROVISIONS ELECTRICAL
PART - 1 GENERAL
1.1. SUMMARY
A. This Section details general provisions for electrical work necessary to support the sections, in Division 16 specifying the categories of traction power substation equipment, building facilities and electrical work. The work under this section includes detail design and furnishing all labor, materials, tools, equipment and incidentals necessary to provide, install and test the electrical work specified in Division 16, ELECTRICAL.
B. This Section specifies general provisions that are applicable to all Sections of Division 16 related to traction power. Additional general provisions applicable only to individual Sections are specified under each such Section.
C. The Contract Drawings and Specifications for the replacement of traction power substation work furnished with this Specification are to be considered as supplementing each other. Work specified but not shown, or not specified, shall be performed or furnished as mentioned in Specifications and /or Drawings.
D. The Contract Drawings show the general arrangement required for the replacement of traction power equipment, and other associated traction power items. The Contractor shall follow these Contract Drawings as closely as possible. Should conditions necessitate any rearrangement, the Contractor shall prepare and submit drawings showing the changes to the District for approval before proceeding with the work.
E. Due to the small scale of the Contract Drawings, it is not possible to show all the offsets and detail every point at which exigencies of construction may require special attention. Any additional fittings, conduits or specialties and other appurtenances due to field conditions shall be furnished and installed by this Contractor at no extra cost to the District.
1.2 APPLICABLE STANDARDS, CODES, AND REGULATIONS
A. All equipment, material and work furnished and/or installed under this Specification for the replacement of traction power Substation work, shall conform to all Federal, State or Municipal laws or ordinances, and if any work shown or specified conflicts with such laws or ordinances, this Contractor shall make such changes as are necessary to meet said requirements. GENERAL PROVISIONS ELECTRICAL 16010-1 DISTRICT
B. The cost of such changes shall be borne by the Contractor and shall be Included in the Contractor’s original bid. Where any standards shown on the Contract Drawings or specified herein exceed the minimum standards set by law, the Contractor shall adhere to the higher standard.
C. All work shall comply with the latest edition of the applicable standards and codes of the organizations listed below:
1. IEEE – Institute of Electrical and Electronic Engineers 2. AISI – American Iron and Steel Institute 3. ASME – American Society of Mechanical Engineers 4. ASTM – American Society for Testing Materials 5. AWS – American Welding Society 6. IES – Illuminating Engineering Society 7. IPS – Iron Pipe Size 8. ICEA – Insulated Cable Engineers Association 9. NEMA – National Electrical Manufacturers Association 10. ANSI – American National Standard Institute 11. CFR – Code of Federal Regulations 12. FTA – Federal Transportation Administration 13. NEC – National Electrical Code 14. NESC – National Electrical Safety Code 15. NBFU – National Board of Fire Underwriters 16. NFPA – National Fire Protection Association 17. UL – Underwriters’ Laboratories, Inc 18. OSHA – Occupational Safety & Health Administration
D. In addition to the National Codes, the Contractor shall comply with all local codes and standards insofar as they apply to the equipment and installation.
E Failure to mention any governing codes in this Specification does not relieve the Contractor from adhering to all codes applicable to the work.
F. Electrical equipment and material(s) furnished by this Contractor shall bear the UL label wherever standards have been established by that agency.
G. The Contractor shall study the Contract Drawings and Specifications prior to submitting his Proposal, and if local code or labor conditions require work in addition to that specified or shown, the Contractor shall state in his bid the items involved and the additional amounts required for such items.
H. After entering into a Contract, the Contractor agrees that all such items are included in his bid and will be no cause for additional charges to the District.
GENERAL PROVISIONS ELECTRICAL 16010-2 DISTRICT
I. At the completion of the work, the Contractor shall obtain and turn over to the District a Certificate of Inspection indicating approval and acceptance of the work by the appropriate inspection District.
PART - 2 PRODUCTS
NOT APPLICABLE
PART - 3 EXECUTION
NOT APPLICABLE
END OF SECTION
GENERAL PROVISIONS ELECTRICAL 16010-3 DISTRICT
SECTION 16011
BASIC ELECTRICAL MATERIALS AND METHODS
PART - 1 GENERAL
1.1. SUMMARY
A. This Section specifies all raceways and boxes as well as appurtenances thereto required under Division 16, related to traction power substation work, as indicated on the Contractor Drawings and as specified herein these specifications.
1.2 SUBMITTALS
A. All materials shall be new and the best of their respective kinds. The use of other than "prime" grades will not be accepted.
B. The Contractor shall specify products of manufacturers for consideration. Submittals shall be made to the District for approval. Submit all data necessary for products offered for approval.
PART - 2 PRODUCTS
2.1. RACEWAYS
A. Conduit and fittings
1. Metal and Fittings:
a. Material: 1) All conduits shall be thin walled, galvanized steel EMT conduits except the conduits for 34.5kV service which shall be galvanized rigid metal conduit (GRC). GRC Conduits shall be hot-dipped galvanized steel with uniform chromate coating for added protection inside and outside. Threads, galvanized after cutting, shall be ¾ inch taper National Pipe Thread. GRC Conduits shall comply with the latest revisions of the following specifications and standards: Federal Specification WWC-581 ANSI, C80.1 UL 6 and 1242. EMT Conduits shall comply with the latest revisions of the following Standards: NEMA Standard FB-1, UL Standard 514B and Federal Specification A-A-50553 2) Each full length of conduit shall bear the UL label. 3) Fittings for metal conduit shall be galvanized malleable iron or steel, and shall be UL listed.
BASIC ELECTRICAL MATERIALS AND METHODS 16011-1 DISTRICT
B. Fiberglass Reinforced Epoxy Conduit (RTRC)
1. The Contractor shall submit certifications of compliance and/or samples of the conduit to be installed. No alternatives to the Specification will be allowed. 2. Fiberglass reinforced epoxy conduit shall be lightweight, fire and ultraviolet ray resistant, and suitable for overhead installation and concrete encasement construction. End bells, couplings, deflection couplings, adapters, bends, sweeps and other fittings shall be furnished as required. Conduit and fitting shall be UL listed, and shall be durably labeled. Fiberglass reinforced epoxy conduit shall meet the following specifications:
a. Conduit shall be fiberglass-reinforced epoxy, composed of glass filaments encapsulated in an epoxy matrix size as shown on contract documents. All conduits shall be filament-wound, and shall have pigment dispersed homogeneously throughout the epoxy glass matrix for ultraviolet protection. Conduit installed in encased in concrete or exposed shall be low smoke type. Each conduit length shall have an integral wound-in expanded coupling. b. Average wall thickness shall be .070 inches. c. Conduit and fittings in the 2 inch through 6 inch sizes, inclusive, shall have inside diameters equal to the trade size. d. Conduit shall be suitable for continuous operation from -40 degrees C to +110 degrees C without significant change in mechanical properties. e. Conduit shall have a burning point in excess of 130 degrees C (+ 124 degrees C for above ground installation) and combustion shall cease when the heat source is removed. When tested in accordance with ASTM D635, conduit shall not outgas chlorine. Other toxic gases shall not outgas in excess of .0015 cubic feet per square foot of material. f. Conductor shall not adhere to conduit or fittings in fault conditions. g. Conduit shall have the following minimum physical properties:
1) Tensile strength, longitudinal: 11,000 psi, when tested per ASTM D2105. 2) Compressive strength, axial: 12,000 psi, when tested per ASTM D695. 3) Ultimate elongation: 2 percent when tested per ASTM D2105. 4) Modulus of elasticity in tension: 1,250,000 psi for below ground and 1,300,000 psi for above ground when tested per ASTM D2105 -. 5) Modulus of elasticity in bending: 2,280,000 psi for above ground and 2,500,000 psi for below ground when tested per ASTM D2105. 6) Thermal conductivity: 0.828 BTU/Hr./Sq.Ft./Degrees F/Inch per ASTM D335. 7) Coefficient of linear thermal expansion: 1.37 x 10 -5 Inch/Inch/Degrees F, when tested per ASTM D 696. 8) Specific gravity 1.94, when tested per ASTM D 792 9) Temperature range: Minus 40 Degrees C to plus 110 Degrees C for below ground and minus 40 Degrees C to plus 124 Degrees C for above ground. 10) Dielectric Strength: 500 volts/mil, when tested per ASTM D 149-94.
BASIC ELECTRICAL MATERIALS AND METHODS 16011-2 DISTRICT
11) Dissipation factor: 0.5 percent average at room temperature, when tested per ASTM D150. 12) Water absorption: less than 0.175 percent (14 days at room temperature) when tested per ASTM D570-95.
h. The conduit shall be thoroughly cured and shall be free of any foreign material. It shall be straight and shall have a circular bore with the inner surface smooth and free from dents, obstructions, or any other defects which would cause damage to cables. The bores shall pass freely a mandrel 36 inches in length and 1/4 of an inch less in diameter than the nominal diameter of the conduit. i. The conduit shall have passed UL flammability tests UL 1684 - for above and below ground and UL 94 for below ground only. All conduit elbows, bends, sweeps, deflection fittings, expansion fittings, and miscellaneous fittings shall conform to NEMA TC and shall be UL listed. j. Each 10-foot length of conduit, sizes 2 inch through 6 inch, shall be provided with an integral end bell or factory-installed double end bell, containing a urethane seal. The other end of each 10-foot length shall be provided with a scribe mark, indicating the proper distance to which the conduits must be mated to ensure a secure (100-pound pull out), water-tight (15 psi) connection. 20-foot lengths will only be used where permitted by District k. No threads or adhesives shall be required to assure water-tight joints for in ground and concrete encased installations. l. Each length and each fitting shall be listed by the Underwriters' Laboratories, or the Canadian Standards Association, and shall be provided with an appropriate label affixed thereto. m. Contractor shall submit for approval, shop drawings and descriptive literature for all conduit, fittings, spacers, support devices, anchors, and hangers.
C. Flexible Conduit
1. Flexible conduit connections, approximately 18 inches in length, shall be made to all motors and other devices where rigid connection is not practical or advisable. 2. Flexible conduit shall be liquid-tight, consisting of flexible steel construction covered with an extruded jacket of neoprene or PVC. Conduit shall be American Flexible Conduit Company, Anaconda Metal hose Div., Electric-Flex Company or approved equal. Bare "BX" type flexible conduit will not be acceptable. 3. Fittings for liquid tight flexible metal conduit shall be UL listed and approved for grounding. 4. Flexible conduit above 1-1/4 inch trade size shall have grounding conductor run within the flex. Conductor must be sized on the basis of the rating of the overcurrent protective device for the circuit run within the flex, all in accordance witch NEC, US and any local governing codes. 5. All flexible conduits shall have a grounding conductor run inside the conduit, code sized for all circuits indicated.
BASIC ELECTRICAL MATERIALS AND METHODS 16011-3 DISTRICT
D. Inserts and Sleeves
1. Conduit Sleeves:
a. Wall Sleeves: All exterior and interior wall sleeves shall be of fiberglass reinforced epoxy conduit. All exterior sleeves shall be made watertight, using watertight sealing bushings. b. Floor Sleeves: Conduits passing through floors shall be sleeved with fiberglass reinforced epoxy conduit and shall be sealed with neoprene rope and caulk. Sleeves shall extend 1 inch above finished floor surface.
2.2 WIRES AND CABLES . A. Cable (600 volt and below)
1. Conductors, insulation and jacket materials shall be in accordance with applicable ICEA and ASTM Standards, and shall conform to the following specifications:
a. Multi-Conductor Cable: Multi-Conductor Cables for control and miscellaneous power shall be stranded copper conductor, #12 AWG minimum size, XHHW, VW-1 flame retardant moisture resistant 600 Volt, cross linked synthetic polymer insulation, rated 90C dry, 75C wet, flame and moisture resistant fillers, vulcanized chlorosulphonated polyethylene jacket (Hypalon). b. Single-Conductor Wire: Single-Conductor Wire for miscellaneous control and power shall be copper conductor, #12 AWG minimum size, stranded conductor, XHHW, VW-1 flame retardant moisture resistant 600 Volt, cross linked synthetic polymer insulation, rate 90C dry, 75C wet. Wire shall be suitable for conduit or duct installation, wet or dry locations.
c. Color Coding: . 1) All multi-conductor control cables shall be color coded in accordance with ICEA standards S-66-524, NEMA WC-7 Table K-2.
d. Wire and Cable Take-Offs:
1) It will be the Contractor's responsibility to furnish and install wire and cable where needed. The Contractor will be responsible for making cable take-offs for ordering sufficient wire and cable for the project requirement. The Contractor shall fill-in the column “As Installed” indicating cable lengths installed in the cable schedule included with the Contract Documents.
e Cable Manufacturer's Data:
BASIC ELECTRICAL MATERIALS AND METHODS 16011-4 DISTRICT
1) Data to be supplied by the Contractor for each type of size of wire and cable furnished shall include:
a) Number of conductors, materials, stranding b) Voltage rating of insulation c) Temperature rating of insulation d) Insulation material and thickness e) Jacket material and thickness f) Overall diameter g) Weight, lbs/1000' h) Manufacturer's test report.
2.3 BOXES
A. Terminal Boxes
1. Where necessary for conductor terminations, the Contractor shall furnish and install NEMA 12 type enclosure with continuous hinged covers for indoor installations and NEMA IV for outdoors. 2. All terminal boxes shall be made up from No. 14 gauge galvanized steel. Boxes shall be finished with gray primer inside and outside over phosphatized surfaces 3. Each box shall be provided with a removable No. 12 or No. 14 gauge galvanized steel panel mounted on collar studs (panels having 400 square inches of surface or more shall be No. 12 gauge). Panel shall be given one prime coat over phosphatized surface and be finished with one coat of white enamel. 4. Terminal blocks shall be suitable for the size of wire, voltage and current rating of the conductor being terminated. Blocks shall include standard terminals, mounting rails, barriers, covers, end stop insulating section and clamp, ground clamps and markers. The terminal strip used shall include a minimum of 10 percent spare terminals.
B Pull Boxes
1. Pull boxes shall be furnished and installed to facilitate conductor installation. Pull box construction details shall comply with the same specifications as for junction box construction. 2. In general, conduit runs of more than 100 feet, or with more than three right angle bends, shall have a pull box installed at a convenient intermediate location. 3. All pull box installations by the Contractor are subject to the approval of the Engineer and must be noted on the "as built" drawings. 4. Boxes shall be supported independently of conduits entering them. Brackets, rod hangers, mounting channels or other Engineer-approved supporting methods shall be used. 5. Pull boxes shall be provided with suitable barriers where required. Vertical offset pull boxes shall contain cable supports at turns to prevent cables from resting on corners.
BASIC ELECTRICAL MATERIALS AND METHODS 16011-5 DISTRICT
2.4 WIRE CONNECTIONS AND CONNECTING DEVICES
A. Cable and Wire Tags
1. Each cable shall be tagged at both ends and in each pull box or junction box where terminations are made or where the cable passes through. Each conductor of each cable shall be tagged at all terminations with its circuit or wire number.
2. Cable tags, furnished and installed by the Contractor, shall be as described for the locations listed below:
a. Nylon Cable Tags: Nylon cable tags, 3/4 inch x 2 inch, hand marked with indelible ink characters 1/4 inch high and covered by surface film protection shall be attached to cables with nylon ties where cables are indoors or protected by equipment or enclosures. b. Wire Markers: Each conductor of multi-conductor control cable or each individual single conductor wire, at the point of termination, shall be identified by plastic-coated or colored plastic, slip-on type wire markers with factory printed numbers or letters. The factory printed numbers or letters shall not be affected by cleaning solvent. Wire marker designations shall conform to designations on wiring diagrams or to designations on control terminal block marking strips.
B. Terminal Lugs and Splicing
1. Terminal Lugs:
a. The Contractor shall furnish and install solderless lugs or studs for power, control and miscellaneous cables. Bolting hardware for all lugs shall be silicon-bronze. The Contractor furnished lugs shall be of the pressure- indented type for power and grounding cables and the crimp type for control and miscellaneous cables. Note that all lugs for control cables shall be insulated ferrule, ring-tongue type (open or fork-tongue are not permitted). b. All cable lugs shall be of the compression indent type requiring the use of a special tool. c. Cable lugs shall be as listed by Underwriters Laboratories Inc. or meet UL 486 heating and pullout tests for compression-indent type. d. Branch circuit conductor lugs for cable sizes #10 AWG and smaller, shall be ring type only with insulated barrel. e. Branch or feeder circuit conductor lugs for cable sizes #8 to #2 AWG shall be single-hole type. f. Branch or feeder circuit conductor lugs for cable sizes #2 AWG and larger shall be two-hole type. Bolt hole spacing shall conform to NEMA standards. g. All enclosures shall be sized to accommodate the specified connectors so that conductors are bent to radii larger than that recommended by the cable manufacturer.
BASIC ELECTRICAL MATERIALS AND METHODS 16011-6 DISTRICT
2. Cable Splicing and Termination:
a. Joints in branch circuit wiring shall be made mechanically and electrically secure with solderless connectors as listed by Underwriter's Laboratories Inc., UL 48 or UL 486.
b. Terminal blocks, for control circuit interconnections external to equipment, shall be furnished and installed by this Contractor. These terminal blocks shall be heavy duty, barrier type, 600 Volt rating, #10-32 washer head screw terminals with marking strip.
2.5 NAMEPLATES
A. Each major component of equipment shall have, as a minimum, the manufacturer’s name, address, and catalog number, model, style or type on a nameplate securely attached to the item in an area easily accessible to normal visual demands by maintenance and service personnel. Nameplates for electrical apparatus shall conform to the referenced standards and as specified elsewhere in this Specification.
B. Each switchgear assembly, circuit breaker and auxiliary unit, transformer, rectifier, terminal box, and all panel mounted and individually mounted equipment and devices shall be provided with nameplates for proper identification. Panel mounted devices shall be identified in the rear with designations indicated on manufacturer’s connection diagrams. Internally mounted devices shall be similarly identified.
C. Nameplates identifying major equipment shall have lettering two inches high, minimum, unless otherwise specified. Two nameplates shall be provided, one on front, the second on the rear of the equipment.
D. Nameplates identifying dc circuit breaker and auxiliary units shall have lettering one inch high, minimum, unless otherwise specified. Inscription shall include circuit breaker number and service. One nameplate shall be provided on front, the second on the rear of each unit.
E. Nameplates for panelboards, terminal boxes and similar equipment shall have lettering ¾ inch high, minimum, unless otherwise specified.
F. Nameplates for panel mounted relays, meters, control and instrument switches, fuses and auxiliary devices and individually-mounted circuit breakers, disconnect switches, etc., shall have ¼ inch, minimum, lettering, unless otherwise specified. For protective and auxiliary relays, the nameplate inscription shall include device number and function. Nameplates for fuses shall note the type and rating of fuse, polarity and identify the circuit.
G. All nameplates shall be laminated plastic with dull white surface and black core unless otherwise specified. Letters shall be engraved through outer layer to expose
BASIC ELECTRICAL MATERIALS AND METHODS 16011-7 DISTRICT
black core. All exposed edges shall be beveled. Nameplates shall be fastened with machine screws. Use of self-tapping screws or adhesives will not be permitted.
H. The legends of all nameplates shall be submitted to the Engineer for approval.
PART - 3 EXECUTION
3.1. INSTALLATION OF CONDUIT AND FITTINGS
A. Conduit runs shall be no smaller than 3/4 inch trade size.
B. Conduit shall be run in straight lines parallel with or at right angles to building walls, partitions, floors and ceilings. When the location of a conduit is not shown on the Contract Drawing, or the location indicated thereon interferes with other work in place or subsequently to be placed, the Contractor shall work out a satisfactory location free from interferences and, subject to the Engineer's approval, shall proceed on the basis of the selected location.
C. In all cases, conduits and fittings shall be located so as to be accessible for maintenance, to permit removal or repairs to equipment to which conduit is attached and so as not to obstruct or inconvenience personnel in performance of maintenance duties.
D. When installing metallic conduit, all conduit shall be taper threaded. Use of running threads will not be permitted, including field cut threads. Each conduit shall be threaded to its full thread length in the conduit coupling or conduit fitting hub to ensure good metallic contact for the ground return path. All conduit ends must be cut square and reamed clean of burrs.
E. Before conduit joints are made, the threads shall be cleaned and then coated with anti-seize, electrically conductive compound.
F. Secure all conduits to outlet boxes, junction boxes or cabinets by placing locknuts on outside of box, and locknuts and bushings on inside of box. Conduit terminations 1-1/4 inch and larger shall be equipped with insulating bushings.
G. Conduits and fittings shall be kept clean and dry during installation. Conduit sleeves shall be used where conduits pass through walls, partitions, floors, ceilings and foundations to prevent shear conditions.
H. Conduit hangers and fasteners shall be made of malleable iron (galvanized or cadmium-plated) appropriate in design and dimensions for the particular applications. Metallic conduits, surface mounted on walls and/or ceilings, shall be supported by means of one-hole clamps and clamp backs. Conduits shall be clamped on steel work, where required, with approved clamps.
BASIC ELECTRICAL MATERIALS AND METHODS 16011-8 DISTRICT
I. All conduits penetrating building exterior walls, roofs, or membranes shall be provided with a watertight fitting, pitch pocket, flange, or membrane clamping ring to provide a watertight construction.
J. Avoid using bends and offsets wherever possible. Field bends shall be made so as to avoid changing the internal diameter of conduit and so as not to damage its protective coating either outside or inside. Field bends shall be free from kinks, indentations, or flat surfaces and shall be made with approved conduit bending machines or devices. Individual bends shall not exceed 90 degrees and no more than 270 degrees total bend shall be allowed in any one conduit run, except where a pull box is used.
K. Radius of curvature to the inside edge of field bends shall be a minimum of eight-times the trade size of conduit.
L. The Contract Drawings show the approximate routing of the Conduits. Exact routing and termination locations shall be determined by the Contractor in the field, subject to final approval by the Engineer.
M. Empty conduits shall be plugged at both ends prior to cable installation.
N. All conduit elbows, offsets and bends shall be uniform and symmetrical. Installation and workmanship shall be of the best quality and skill to provide a firm mechanical assembly.
O. Conduits shall be continuous from outlet to outlet and from outlet to cabinets and junction/pull/terminal boxes with entry secure in such manner that each system shall be electrically continuous. Entry connections shall be made with two locknuts and an insulated conduit bushing or an insulated grounding bushing as required. The locknuts shall electrically connect the conduit to the cabinet or box. Exterior conduit connections to the cabinets or boxes shall be made by using insulated watertight, threaded hubs as manufactured by the Myers Electric Products, Inc. ("Scru-tite" Type), Thomas & Betts Company ("Bullet" Series 401) or OZ/Gedney (type 4Q).
P. Conduit systems shall be completed before conductors are drawn-in. Conduits shall be firmly fastened within 3 feet of each outlet box, junction box, cabinet, offset or bend, and shall be supported at the intervals listed in paragraph Q below:
Q. Maximum acceptable support spacing for rigid conduit, in feet, shall be in accordance with the following table:
Conduit size Wall Ceiling Vertical
¾ inches 5 7 8 1 inch and larger 6 8 10
R. Channel type metal framing systems to support conduit and/or cable systems shall be based on a channel 1-5/8 inches square, No. 12 gauge steel, mill galvanized
BASIC ELECTRICAL MATERIALS AND METHODS 16011-9 DISTRICT
conforming to ASTM Specification A-525 and shall be furnished complete with all associated or required mounting hardware.
S. Expansion joints shall be provided wherever construction joints occur in the concrete slabs. Conduit runs shall be adjusted so that expansion joints are at right angles to the slab joints.
3.2 INSTALLATION OF REINFORCED EPOXY CONDUIT
A. Conduit and fittings shall be run in straight lines parallel with or at right angles to building walls, partitions, floors and ceilings. When the location of a conduit is not given on the Contract Drawings or the location indicated thereon interferes with other work in place, the Contractor shall work out a satisfactory location free from interferences and, subject to the Engineer's approval, shall proceed on the basis of the selected location.
1. In all cases, conduits and fittings shall be located so as to be accessible for maintenance, to permit removal or repairs to equipment in which conduit is attached and so as not to obstruct or inconvenience personnel in performance of operation and maintenance duties.
B. Conduits and fittings shall be kept clean and dry during installation.
C. When installing fiberglass reinforced epoxy conduit overhead, conduit fittings shall be of the same manufacturer.
D. All conduit elbows, offsets and bends shall be uniform and symmetrical. Installations and workmanship shall be of the best quality and skill to provide a firm mechanical assembly.
E. Conduit routes shown on the Contract Drawings are approximate. Exact routing and termination locations shall be determined by the Contractor in the field subject to final approval by the Engineer.
3.3 INSTALLATION OF WIRE AND CABLE
A. Unless otherwise noted, all wire and cable runs external to equipment assemblies shall be installed in conduits.
B. The Contractor shall obtain and observe recommendations of the manufacturer as to installation, care and handling of the various cables. Minimum bending radius shall not be less than that allowed by the ICEA Standards.
C. No splices will be permitted in any power or control cable runs. Cables must be continuous from termination to termination. No splices or joints will be permitted in lighting feeders or branches except at outlets or accessible junction boxes. Joints in
BASIC ELECTRICAL MATERIALS AND METHODS 16011-10 DISTRICT
branch circuit wiring for conductors not larger than #10 AWG shall be made mechanically and electrically secure using screw-on connectors.
D. Any spare conductors shall be labeled as such and be left neatly coiled, with the ends taped and extending from the cable a minimum of 36 inches.
E. The Contractor's cable pulling shall be in accordance with accepted modern practices so as to prevent damage to the cable. Before pulling cables, a round test mandrel shall be pulled through the duct which is to be occupied, in order to be sure that it is cleared of all obstructions. The test mandrel shall be of a size especially designed for the duct being tested. The mandrel shall be of the rigid type not less than 12 inches in length and shall have tool-steel cutting ends to remove obstructions. Cable pulling tensions, speed, lubricants and other pertinent factors in connection with pulling and handling shall be in accordance with the cable manufacturer's recommendations, or as approved or directed by the District. A cable protector shall be fitted in the end of the duct during pulling operation in order to prevent injury to the cable. The cable shall be fed into the duct through a flexible metal pull-in guide. Where more than a single cable is being pulled in, all cable shall be pulled directly into the duct from the coil or reels on which they are received.
F. Cables shall not be pulled off and laid on the ground prior to installation. Cable grips shall be designed for the purpose and shall not cut or otherwise damage the cable. No cable shall be pulled with ends open. A rubber tape seal shall be maintained at all times. The cable shall be continuously inspected during installation and any cuts, abrasions, or otherwise injured portions shall be brought to the attention of the District and repaired or removed as directed.
G. Conductors shall not be drawn into conduit until the conduit is free of moisture. In drawing wires into conduit, sufficient slack or lead shall be allowed to permit the connections to devices without splices.
3.4 FILLING OF OPENINGS
A. Where conduit and raceway pass through fire-rated walls, ceilings or floor, provide seals to prevent passage of fire and fume and to maintain integrity of fire-rated structure.
B. Close unused openings or spaces in floors, walls and ceilings. Plug or cap unused conduit and sleeves.
3.5 IDENTIFICATION
A. At end of each run, use brass with stamped markings to establish identification of conduit, raceway and ducts.
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B. Test metallic conduit and boxes for electrical continuity. Conduct tests in presence of District.
END OF SECTION
BASIC ELECTRICAL MATERIALS AND METHODS 16011-12 DISTRICT
SECTION 16125
TRACTION POWER CABLES
PART 1: GENERAL
1.1 SUMMARY
A. This section specifies the requirements for providing 750, 1,500 and 2000 kcmil traction power cables, which are used in the traction power distribution circuits of Northern Indiana Commuter Transportation District’s Commuter Railroad (District).
B. Provide new, ethylene propylene rubber (EPR) insulated, thermoset, low smoke, non-halogen cross-linked polyolefin jacketed cables which shall be rated for 5,000 volts, or higher, for use on the DC distribution system. The cable shall have excellent heat and moisture resisting characteristics and be rated for 90ºC normal operation in wet/dry locations, 130ºC for emergency and 250ºC for short circuit operation. The cable shall have special fire resistant characteristics. The cable insulation and jacket shall be halogen free. The cable shall be listed and approved by UL where applicable.
C. Procure the cables only from well known experienced manufacturers engaged in regular commercial production of the specified cables. The manufacturer shall have not less than ten (10) years of practical and successful commercial field experience with the EPR insulation and low smoke, non-halogen, cross-linked polyolefin jackets. The manufacturer shall furnish complete technical information to demonstrate that the insulation and jacket meet the requirements of this specification for the type and size of cable involved. Failure to supply satisfactory evidence of this experience shall be sufficient cause for rejection of the manufacture.
1.2 STANDARDS
A. The construction and testing of the cables shall conform to the latest editions of the following applicable standards:
1. ASTM Standard B 8-14 Specification for Concentric Lay Stranded Copper Conductors 2. ASTM Standard D 470-13 Test Methods for Cross Linked Insulations and Jackets for Wire and Cable. 3. ASTM Standard D 471-12a Test Methods of Rubber Property – Effect of Liquids 4. ASTM Standard D 573-04 (2015) Test Method of Rubber – Deterioration in Air 5. ASTM Standard D 2240-05 (2010) Test Method for Rubber Property – Durometer Hardness TRACTION POWER CABLES 16125-1
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6. ASTM Standard D 2802-14 Specification for Ozone-Resistant Ethylene- Alkene Polymer Insulation for Wire and Cable 7. ASTM Standard D 2863-13 Test Method for Measuring the Minimum Oxygen Concentration for Candle Like Combustion of Plastics 8. ASTM Standard E 662-15 Test Method for Specific Optical Density Smoke Generated by Solid Materials 9. ICEA S-68-516/NEMA WC 8 Standard for Ethylene Propylene Insulated Wire and Cable 10. ANSI / NEMA WC 70-2009, ICEA S-95-658-2009 Standard for Non- Shielded Power Cables Rated 2000 Volts or less for the Distribution of Electrical Energy 11. IEEE Standard 383 12. MIL C-24643 13. Naval Engineering Standard - 711 14. Naval Engineering Standard – 713 15. National Fire Protection Association 70-2014 Edition 16. Underwriter Laboratories 1072
B. Where standards are at variance with each other or with other parts of this specification, the most stringent requirements, as determined by an Engineer from the District, shall apply.
1.3 SUBMITTALS
A. Submit shop drawings showing the cable construction details and cable ratings. Also include:
1. Test data from previous tests 2. Suggested cable pulling compound and storage/handling requirements 3. Maximum allowable pulling tension 4. Maximum allowable sidewall pressure 5. Minimum bending radius 6. Size of cable 7. Quantity of cable in feet 8. Cutting lengths in feet 9. Reel size
B. Submit certified test reports for all specified technical data that illustrates the manufacturer’s ability to successfully manufacture the cable. Include a detailed list identifying previous users, date cable was supplied, and name and telephone number of references. If the Contractor is unable to provide this information upon request, the manufacture may be rejected.
C. The Contractor shall supply a signed statement that the cable insulation and jacket proposed has been tested for, and complies with the requirements of this specification. The Contractor shall furnish a certified copy of the result of these tests.
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D. Submit the trade name of the insulation and jacket which is proposed to be furnished on this Contract.
E. Cable identification shall be printed on jacket at 3 feet intervals with manufacturer's name, year of manufacture, conductor size, voltage, insulation and jacket type.
F. The Contractor shall furnish complete technical information to ensure that the insulation and jacket are compatible for the type and size of cable involved. The Contractor shall quote the insulation and jacket thickness as specified. The Contractor shall have had not less than seven (7) years of practical and successful commercial field experience with the EPR insulation and low smoke, non-halogen, cross linked polyolefin jacket. Failure to be able to supply satisfactory evidence of this experience shall be the cause for rejection of his/her proposal.
PART 2: PRODUCTS
2.1 INTENDED USE AND STRANDING
A. Cables covered in this section are intended for use in dc traction service operated on a 1500 Volt DC nominal system subjected to additional voltages as may occur on the account of switching and operation of trains and rectifier equipment. Cables shall be suitable for installation in wet or dry locations, in exposed or underground/encased conduits, trays, cable racks, direct buried or exposed.
B. Cable Conductor - The conductor shall be uncoated soft-drawn annealed copper conductor, 98.16% (min.) conductivity at 25 degrees Celsius, Class B stranded compressed concentric round per ASTM B 8. The conductor shall conform to all requirements called for in ICEA S-96-659 for Ethylene Propylene Rubber-Insulated Wire and Cable for Transmission and Distribution of Electrical Energy and in ASTM B-8.
C. Conductor stranding and insulation thickness shall be in accordance with Table 1 of this specification and shall be in conjunction with the size of the cable as called for in the Contract Documents.
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2.2 INSULATION
A. The cable insulation shall be ethylene propylene rubber (EPR) insulation rated at 90 degrees Celsius wet or dry for normal operation. The insulation shall be rated for 130°C emergency overload temperature and 250°C short circuit temperature.
B. The insulation shall comply with ASTM D: 2802-1998 “Ozone-Resistant Ethylene Alkene Rubber Insulation for Wire and Cable”. However, relative to Para 5.3.2 of ASTM D 2802, the insulation resistance shall be not less than 100% (not 60%) of that required for the primary insulation based of the thickness of that insulation even if a non-conducting separator is used.
C. The EPR insulation shall conform to the physical and electrical requirements, including moisture and voltage tests, as called for in Tables 1 and 2 of this specification.
D. All test samples shall pass all moisture and voltage tests called for in this specification.
E. The insulation shall strip easily and cleanly from the conductor. An opaque polyester tape is optional and, if used, shall be applied between the conductor and EPR insulation to facilitate ability to strip.
F. The insulation thickness and AC test voltage shall be in accordance with Table 1 of this specification.
G. The insulation shall be circular in cross-section and concentric to the conductor. The minimum thickness at any point shall not be less than 90% of the specified thickness called for in Table 1 of this specification.
2.3 JACKET (SHEATH)
A. Directly over the EPR insulation, provide an extruded layer of flame retardant, thermoset, low smoke, and non-halogen cross-linked polyolefin jacket (sheath). The jacket compound shall have been listed by Underwriters Laboratories (UL) for use with cable rated for 90o C operation (except 1,500 kcmil). The jacket (sheath) shall be black in color.
B. The jacket thickness shall be in accordance with Table 1 of this specification and shall be in conjunction with the size of the cable as called for in the Contract Documents. The jacket thickness shall be circular in cross-section, concentric to the conductor. The minimum thickness at any point shall be not less than 90% of the specified thickness listed in Table 1 of this specification
C. The jacket shall conform to the physical and electrical requirements, including moisture and voltage tests, as called for in Tables 1 and 3 of this specification TRACTION POWER CABLES 16125-4
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. 2.4 SPLICES
A. The contract does not involve substantial lengths of cables. Use single continuous runs of cables. Splices are not allowed.
PART 3: EXECUTION
3.1 TESTS AND INSPECTIONS
A. The Contractor shall perform tests on the insulation, jacket and completed cables in accordance with applicable standards as listed in this specification. Where standards are at variance with each other or with other portions of this specification, or the cable insulation and/or jacket thickness preclude obtaining samples of sufficient size for testing, special arrangements shall be made with the Engineer from the District. All tests shall be conducted on the cable called for in this specification.
B. The Contractor shall submit, prior to shipment, preliminary certified test reports for review by the Engineer. All preliminary certified tests shall be performed with the cable on the shipping reels. The preliminary certified test report shall include the conductor DC resistance, insulation resistance, and physical dimensions of the insulation and jacket (i.e.: minimum, maximum and average thicknesses for each reel). Each preliminary certified test report shall include cable footage identification and reel number.
C. All tests identified in Tables 1, 2, and 3 shall be performed .Included in these tests shall be a 70,000 BTU per hour flame test in accordance with IEEE 383 for sizes of cable ordered.
D. NICTD reserves the right to witness all tests. The Engineer representing the District shall have free entry to the manufacturer’s facilities at all times while work on the contract for the District is being performed and to all parts of the manufacturer’s works which concern the manufacture of the cable. The Contractor shall afford the Engineer, without charge, all reasonable facilities to satisfy the Engineer that the cable is being furnished in accordance with this specification. The District reserves the right to reject all material, after delivery to the District, which does not conform to this specification.
E. Prior to the shipment of any cable, the Contractor shall furnish to the District three certified copies of the final certified test results which include the itemized tests required by this section, using procedures as called for by the respective ASTM specifications and any other tests in this section. The Contractor shall furnish dimensional cross sections of each size of cable with the certified test results. The certified test reports shall also include the identification number of each shipping reel and the footage on each reel.
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F. The Contractor has the responsibility to ensure that all cables supplied will meet this specification. Cable not in accordance with this specification will be rejected.
G. If the Contractor’s final certified tests results demonstrate compliance with this specification and are approved by the Engineer acting as a representative for the District, the Contractor will be so notified to ship the cable. The Contractor shall not ship cable without approval.
H. The Contractor shall provide the Engineer at least a twenty-one working day notice prior to any scheduled testing.
3.2 TEST RESULTS AND DATA REQUIRED
A. The following data shall be included in the certified test reports:
1. Type of cable, insulation and jacket (sheath); cable size, conductor stranding and specification number. 2. A statement indicating the cable complies with this specification. 3. Conductor resistance per 1,000 feet. 4. Test results for EPR Insulation per Tables 1 and 2 of this specification. 5. Test results for cross-linked Polyolefin Jacket per Tables 1 and 3 of this specification.
3.3 PACKAGING
A. Cable shall be shipped on non-returnable reels. The length of cable on each reel will be provided by the Contractor.
B. Prior to shipment, cable reels shall be wrapped with cardboard or other approved wrapping complete with an overlay of 2 inches by 4 inches of wood lagging.
C. Cables shall be supplied with the ends capped and sealed with heat shrinkable caps to exclude moisture.
D. Each reel or coil shall carry suitable tags showing name of consignee, address, reel identity, order number, name of manufacturer, and type of cable, size, weight and length.
TRACTION POWER CABLES 16125-6
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3.4 DELIVERY
A. All transportation charges, including the transit insurance, to the delivery location shall be paid by the Contractor and shall be included in the Contract price.
B. Handling or re-handling of material, at the Contractor’s manufacturing and storage locations, prior to delivery shall be considered incidental to the Contract.
3.5 INSTALLATION
A. General
1. Install dc traction power cables as shown on the Contract Drawings.
B. Cleaning Ducts
1. Use a flexible rodding device and pass it through each conduit to check for continuity and cleanliness. 2. After rodding, pull a mandrel, which should not be less than ¼” smaller than the inside diameter of the conduit, preceded by a wire brush tied to the same string, through the conduit, once in each direction. If any difficulty is encountered in passage of the duct rodding device or mandrel, a series of wire brushes shall be drawn through the conduit, once in each direction, using a trailing line. Continue with the wire bushes until the final brush is 1/8”diameter less than the inside diameter of the conduit. If the correct size cannot be passed through on the initial pull, the operation must be repeated until accomplished. 3. When the conduit is partially or fully obstructed with mud, dirt, or gravel, the duct must be flushed clean with water using flushing nozzle which should be pushed into the conduit and applied until the duct is clear. After cleaning, follow the procedure outlined above for the rodding and wire brushing. 4. After all obstructions have been removed and the conduits wire brushed clean, pull a nylon cord of suitable strength into each cleaned conduit and attach to the nearest pulling eye with a six foot length left at each end. Immediately upon completion of installation of the nylon cord, both ends of the conduit shall be plugged to prevent entry of foreign matter before the cables are pulled.
TRACTION POWER CABLES 16125-7
DISTRICT
C. Installation and Protection of Cable
1. Strip cable reels of all nails on outside edges of reel heads before pulling of cable. Conveniently locate reels for feeding cable into the duct or conduit without excessive bending or possible injury to cable by abrasion on concrete or sides of duct. Jack reels by at least 6 inches to clear ground level before pulling of cable. 2. Attach pulling ropes to cables with ball bearing swivels to prevent twisting of cable during pulling. 3. Pull cables only after conduits have been cleaned, rodded, mandrelled, and are free of all obstructions. Pull cables after authorization is received from District. Pull only one cable into each duct or conduit. 4. Cable-ends shall be sealed per manufacturer’s recommendations before pulling into ducts. The ends of cables when cut shall not be left with the insulation exposed to moisture. Protect cables until proper termination or lug is installed. 5. Use the installation method recommended by the cable manufacturer utilizing an approved cable grip. 6. Pull cable into ducts/conduits under moderate tension. Manufacturer’s recommended maximum pulling tensions shall not be exceeded. 7. Any lubricant used shall not have a deleterious effect on the conductor insulation or jacket. Use cable pulling compounds which are recommended by the cable manufacturer. Do not use petroleum jelly. 8. Use sufficient personnel between the reel and the duct entrance during pulling operation to inspect, control, and direct passage of cable. Ream duct/conduit mouth where applicable and equip with a fair lead to prevent chafing of the cable. 9. Minimum bending radii as measured to inside surface of the cables shall not be less than those recommended by the manufacture, or not less than eight times the outside diameter of the cable, whichever is the larger. 10. Do not allow cable to chafe on the ground, concrete or sharp surface during pulling. Provide timbers and flexible cable pulling tubes to guide and protect the cable, where necessary. 11. Install duct shields to protect cable at the duct mouth. Use split nylon tube or equal. 12. Label all cables, as required by District, with printed numbers on cable tags at all terminal points and duct entrances. 13. Install cables with freedom of horizontal movement to accommodate expansion and contraction of the cables in the ducts. 14. Do not work on energized cables. 15. No fireproofing tape is required.
TRACTION POWER CABLES 16125-8
DISTRICT
16. Inform District about any field conditions encountered which are not covered or differ substantially from those shown or specified in the contract documents. Perform the work in question in accordance with District’s instructions.
3.6 TESTING
A. Upon completion of the installation of each cable, test the cable insulation as recommended by the manufacturer or as directed by District.
B. If no specific test is recommended, test the cable by megger. The insulation resistance should not be less than 3,000 megohm divided by the cable length in feet.
C. Do not energize the cables until approved by District.
Note: Following are the Tables 1, 2 and 3.
Table 1 – Conductor Stranding, Insulation and Jacket Thickness.
Insulation Jacket Size Number of Insulation AC Thickness Thickness (KCMIL) Strands Test Voltage (V) (Mils) (Mils) 750 61 155 26000 125
*1500 91 155 26,000 125
*2000 127 155 26,000 125
TRACTION POWER CABLES 16125-9
DISTRICT
Table 2 – Ethylene Propylene Rubber (EPR) Insulation
Additional Requirement/Test Applicable Standard Requirement Requirement Operating Temperature, Normal 90°C Dry or Wet Unaged Tensile Strength ASTM D470 1,200 psi, minimum Unaged Elongation at Rupture ASTM D470 250%, min. Hot Creep Test (ICEA T-28-562) Condition at 150o +/-2 Elongation ASTM D470 50%, maximum Celsius Set 5%, maximum Tensile Strength after 121o C, 168 75% of the unaged ASTM D470 hours Air Oven Test value, min. 75% of the unaged Elongation after Air Oven Test ASTM D470 value, minimum Perform tests in water tank on selected completed reels of AC Voltage Test ICEA S-96-659, Table 4-2 13kV, 5 minutes cable after 6 hours of immersion and while still immersed Perform tests in water tank on selected completed reels of DC (Triple AC) Voltage Test ICEA S-96-659, Table 4-2 35kV cable after 6 hours of immersion and while still immersed - Perform tests in water tank on selected 30,000 MΩ/1,000 ft completed reels of Insulation Resistance ICEA S-96-659, Table 4-5 cable after 6 hours of immersion and while still immersed K Constant for Insulation ICEA S-68-516, Table 3.1 Resistance Power Factor after 24 Hours at ICEA S-68-516 3.5% Room Temperature Ozone Resistance test 3 hours ASTM D 470 Pass ICEA S-68-516, Method Immersed in 75°C±1°C Moisture Absorption Test EM 60 Water Dielectric constant after 1 day ICEA S-68-516, Method 4.5 Note: immersion EM 60 75°C requirement, Increase in capacitance 1 to ICEA S-68-516, Method 3.5% test shall be performed 14 days EM 60 on #14 AWG wire using Increase in capacitance 7 to ICEA S-68-516, Method insulation originating 2.0% 14 days EM 60 from the same batch ICEA S-68-516, Method compound Stability factor, after 14 days 1.0, maximum EM 60 Mixture Moisture Absorption (Gravimetric 15 mg/sq. inch, ASTM D740 168 hours at 82°C Method) maximum
TRACTION POWER CABLES 16125-10
DISTRICT
Table 3 – Low Smoke, Non-Halogenated Jacket
Applicable Requirement/Test Requirement Additional Requirement Standard Unaged tensile strength ASTM D470 1,700 psi, min. Unaged Elongation at rupture ASTM D470 150%, min. After air oven test (168 hours at 121°C) (i) 75% of the unaged ASTM D573 value, min. (i) tensile strength (ii) 60% of the (ii) elongation unaged value, min. After air oven test (168 hours at 150°C) (i) 60% of the ASTM D573 unaged value, min. (i) tensile strength (ii) 60% of the (ii) elongation unaged value, min. After oil immersion (18 hours at 121°C) (i) 60% of the ASTM D471 unaged value, min. Use Oil No. 1 (i) tensile strength (ii) 60% of the (ii) elongation unaged value, min. Moisture absorption, gravimetric 20 mg/in. sq., method ASTM D470 maximum 168 hours at 70°C (Test to be performed on Durometer Shore A, hold for 1 completed piece of 750, ASTM D2240 90±3 sec. 1500 and 2000 Kcmil cables) Limiting oxygen index ASTM D2863 35%, minimum Smoke density test on materials used in the manufacture of cables Uncorrected/Corrected specific optical density during first 4 minutes of test - Flaming Mode 50/45, max. - Non-Flaming Mode 50/45, max. Uncorrected/Corrected specific optical density value Prepare material in 100 ASTM E662 obtained during 20 minutes mil thick slabs of test - Flaming Mode 200/190, max.
- Non-Flaming Mode 300/290, max. Ozone Resistance Test, 24 ASTM 470 Pass hours at 150 PPM Material shall be prepared in slab of 100 Smoke Index NES-711 20, max. Mils thick, plus or minus 5 Mils
TRACTION POWER CABLES 16125-11
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Table 3 – Low Smoke, Non-Halogenated Jacket (continued)
Applicable Additional Requirement/Test Requirement Standard Requirement Hydrochloric detector tube, with measuring range 0.5 to 25 PPM, Acid Gas Equivalent MIL C-24643 0.1 ppm/mg, max. similar to National Draeger Tube Part #CH29501 Toxicity Index NES 713 1.5 Cold Bend- 24 hours, 8 times 35 lbs./in., ICEA S-68-516 cable diameter (at -25°C) minimum Fluid Immersion Tests
Hydraulic Fluid (24 hours Use Hydraulic Fluid
immersion at 49°C) MIL-H-17672
MIL-DTL-915/1F 50% of the original Tensile strength value, min. 50% of the original Elongation value, min. Diesel Fuel (24 hours immersion
at 49°C) 50% of the original Tensile strength value, min. 50% of the original Elongation value, min. Lubricating Oil (24 hours
immersion at 99°C) 50% of the original Tensile strength value, min. 50% of the original Elongation value, min. 24 hour immersion at Salt Water (10% by weight) 20°C 90% of the original Tensile strength min. 90% of the original, Elongation min. 24 hour immersion at Methanol ASTM D471 25°C 50% of the original, Tensile min.
50% of the original, Elongation min. Gasoline (24 hour immersion at 24 hour immersion at
25°C) 25°C 50% of the original Tensile strength value, min. 50% of the original Elongation value, min.
END OF SECTION
TRACTION POWER CABLES 16125-12
DISTRICT
SECTION 16126
TRACTION POWER CABLE LUGS
PART - 1 GENERAL
1.1. SUMMARY
A. The Contractor shall furnish and install cable termination lugs for all traction power and control cables as noted herein.
B. The Contractor shall prepare traction power cable for termination using the cable manufacturer’s recommenced method.
C. Contact surfaces at traction power terminations shall be clean and bright and free of oxide, and shall be coated with oxide inhibitor when bolted connections are made.
PART - 2 PRODUCTS
2.1 TRACTION POWER CABLE LUGS
A. Cable lugs used for termination of traction power cables shall be either solder type or bolted compression type as described herein:
B. Solder Lugs:
1. Solder type, straight terminal lugs shall be installed at cable connections to hand operated knife switches. 2. Where lugs are bolted together, as in potheads, the hardware shall be 3/4 inch brass bolts and nuts as shown on the drawings. Solder shall conform to ASTM Designation B32 Solder Metal, Alloy Grade 50A, 50 percent tin, 50 percent lead. Soldering shall be non-corrosive.
C. Soldering Procedure:
1. Cable to Straight Lug in Upright Position:
a. The Contractor shall cut and skin cable insulation to proper length (approximately 1/8 inch copper exposed beyond lug). b. The Contractor shall clean cable and lug (inside) with fine wire brush or abrasive pad. c. The Contractor shall apply non-acid flux (paste) liberally to cable and lug (inside). d. The Contractor shall put lug on cable (lug has a pre-drilled 1/4 inch diameter hole in top of barrel). e. The Contractor shall tape lug and cable at connection with friction tape.
TRACTION POWER CABLE LUGS 16126-1 DISTRICT
f. The Contractor shall heat lug in center until it is hot enough to take solder in molten form at contact. g. The Contractor shall feed string solder (50:50 ratio of tin and lead), into hole at top of barrel while constantly heating lug until it starts to overflow. Cold solder joints are not acceptable. h. The Contractor shall remove heat from lug and continue feeding solder until molten solder stops flowing to eliminate air pockets. i. The Contractor shall let assembly air-cool. j. The Contractor shall wait until after assembly has cooled down, remove friction tape to see if solder flowed into the bottom of the lug. If not, repeat steps e thru h. k. The Contractor shall clean assembly with wire brush or abrasive pad. (Make sure lug machine surfaces are clean of excess solder.) l. The Contractor shall install heat-shrinkable tube (5 inch approx.) at joint.
D. Bolted Compression Lugs:
1. Bolted compression terminal lugs shall be installed for traction power cable connection to bus bars. Lugs shall be bronze with NEMA standard tongue drilling complete with silicon-bronze bolts and brass self-locking nuts. 2. Lug tongue surfaces, both sides, shall be machined smooth for good electrical contract. 3. The Contractor shall furnish silicon bronze bolts, washers, and brass self- locking nuts for tongue bolting the lugs to bus bars as shown on the drawings. Length of bolts to be determined in field. 4. Contact surfaces shall be cleaned of oxide and made bright metal before assembly.
E. Control Cables:
1. Control cable/wire termination lugs shall be solder-less pressure indented (crimp) type. Lugs shall be insulated eye or ring-tongue type (open or fork tongue type are not permitted). Termination lugs shall be as manufactured by T&B Corp. (STA-KON type), Burndy (small hydrant type), or approved equal. 2. The Contractor shall prepare control cable/wire for termination using cable manufacturers and termination lug manufacturers recommended procedures. 3. Any spare conductors shall be left neatly coiled with the ends taped. Spare conductors shall be minimum of 36 inches from cable end.
PART - 3 EXECUTION
NOT USED
END OF SECTION
TRACTION POWER CABLE LUGS 16126-2 DISTRICT
SECTION 16127
CABLE TAGS
PART - 1 GENERAL
1.1. DESCRIPTION
A. All traction power and control cables installed by the Contractor shall be tagged. Cable tags furnished and installed by the Contractor, shall be either “brass” or “nylon” tags as described by locations listed herein.
PART - 2 PRODUCTS
2.1. BRASS CABLE TAGS
A. Brass cable tags shall be 2 inch x 3 inch x 1/4 inch for 1 line or 2 lines designation of information.
2.2. NYLON CABLE TAGS
A. Nylon cable tags, 3/4 inch x 2 inch hand marked with indelible ink characters 1/4 inch high and covered by surface film protection.
PART - 3 EXECUTION
3.1. BRASS CABLE TAGS
A. Brass cable tags, 2 inch x 3 inch x 1/4 inch, die-stamped with 1/2 inch high characters shall be attached to cables with 14 AWG solid copper tie wires. This type cable tag shall be used in the substation, at the duct line entrances and above the cubicle enclosures. Also in manholes, at the entrance and exit duct openings, at the top of conduit risers, or similar locations where cables will be accessible for inspection and maintenance.
3.2. NYLON CABLE TAGS
A. These tags shall be attached to cables with nylon tie straps. This type cable tags shall be used in switch enclosures, negative return bus enclosures, substation, and all other similar locations where cables are protected by enclosures
END OF SECTION
CABLE TAGS 16127-1 DISTRICT
SECTION 16601
GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT
PART - 1 GENERAL
1.1. SUMMARY
A. This section sets forth the conditions and technical requirements for the replacement of traction power equipment at Madison Substation.
B. Replacement of traction power equipment shall include removing the existing traction power equipment and designing, manufacturing, testing, delivering, installing and commissioning the following:
1. One (1) self-cooled, dry type, outdoor rectifier transformer.
2. One (1) natural convection air cooled 3000 kW, 1500 volt dc rectifier.
3. One (1) 1500 volt dc switchgear line-up.
4. One (1) set of anode bus duct.
5. DC feeder cables and control cables associated with traction power equipment.
6. Station Control Cabinet
1.2. RELATED DOCUMENTS
A. Drawings and general provisions of Contract, including General and Special Conditions and Division 1 Specification Sections apply to this section.
1.3. DESIGN AND PERFORMANCE DATA
A. General:
1. The rectifier transformer, anode bus duct, rectifier and dc switchgear line-up specified herein and shown in single line diagram of the Contract Drawings, shall function as a complete coordinated package for normally unattended operation of the District's system. All components shall be sized and selected for safe, reliable operation. All material and equipment furnished shall be of the highest quality material, design and workmanship.
2. The substation building has been designed in such a manner as to permit easy removal of the existing traction power equipment and installation of the new
GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT 16601-1 DISTRICT
equipment as indicated on the Contract Drawings. It also sets forth certain limiting area dimensions which shall be maintained for District usage exclusively and minimum clearance as required for District safe operation.
3. It is imperative that the new equipment shall be installed in the same orientation and location exactly from where the existing equipment is removed.
4. All substation equipment shall be shipped in the largest assemblies which can be brought in through the equipment door and passage as shown on the drawings. Equipment dimensions shall be such that any piece can be removed from the building through this same door or passage in the future without dismantling other equipment. Final arrangement of equipment and manner of assembly and disassembly will be subject to the approval of the District. .
B. Service Conditions:
1. The rectifier transformer, anode bus duct, rectifier and dc switchgear line-up herein serve as supply for the District’s Commuter Railroad in parallel with the existing traction power equipment installed at other locations. Individual rectifier load can be expected to vary from a 15 second peak near 450 percent full load current rating during peak periods to a 30 minute near zero current during off-peak periods. High voltage spikes of either polarity from train operations may be transmitted to these substations through the interconnected- systems.
2. The three phase 34.5 kV ac power to the rectifier transformer is supplied from the NIPSCO oil circuit breaker located in the NIPSCO switchyard, remote from the substation. A 34.5 kV underground line from the NIPSCO switchyard provides connection to the rectifier transformer via disconnect switches mounted outdoor on a switch structure, approximately 10 feet from the centerline of the transformer. The auxiliary transformer for the substation has also been mounted on the switch structure.
3. While it is not expected that this installation will present any harmonic, electromagnetic, radiofrequency or telephone interference problems, should such problems arise in the rectification equipment, Contractor shall give immediate and full engineering assistance to the District in determining proper corrective measures including, preparation of the Specifications for additional equipment required, if any.
4. The noise level at any and all points, three feet from any and all of the equipment in the building covered by this Specification with any and all equipment energized for normal service, but with rectifier unloaded, shall not exceed the following values:
GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT 16601-2 DISTRICT
Octave Band
a. 20-75 Hz 80 dB(A) b. 75-150 Hz 75 dB(A) c. 150-300 Hz 75 dB(A) d. 300-600 Hz 72 dB(A) e. 600-1200 Hz 68 dB(A) f. 1200-2400 Hz 65 dB(A) g. 2400-4800 Hz 55 dB(A) h. 4800-10000 Hz 45 dB(A)
C. Proposed Control and Supervision:
1. The protection, control, measurement and automation of the entire traction power equipment of the substation consisting of rectifier transformer, rectifier, and DC switchgear shall be integrated in a single unit through a microprocessor based system, similar to Siemens Sitras Pro DC Protective Unit integrated with Programmable Logic Controller, Profinet I O protocol and interface through Fiber Optic cables or approved equal products.
2. The Siemens Sitras Pro or approved equal products shall consist but not be limited to the following Sitras Pro or approved equal modules:
a. Sitras Pro CU: The Central Unit contains 32-bit microprocessor system, shall supply power to other modules and perform protection and control of the traction power system b. Sitras Pro HMI – Human Machine Interface shall be externally accessible, mounted on the door of the cubicles and shall have ergonomic design, individual LEDs for display functional assignment or device information, monochrome graphical display. large keyboard for convenient handling, five individually functional keys with separate keys to execute important functions c. Sitras Pro BA – DC Buffer Amplifier shall be used for measuring the current and voltages of .the traction power equipment. Digital output shall be transmitted to central uni via fiber optic cable and analog output shall be connected to display voltage and current.. d. Sitras Pro SW – PC User Software
3. A centrally controlled Sitras Pro or approved equal unit for the control and status of rectifier transformer, rectifier and DC switchgear shall be installed in a standalone Station Control Cabinet (SCC). .
4. The digital relays replacing the electromechanical relays located in the AC Relay Panel for the protection of 34.5 kV incoming line as well as the control of Utility’s (NIPSCO) OCB shall also be mounted in the SCC.
5. The rectification equipment specified herein will normally be in continuous
GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT 16601-3 DISTRICT
service. However, they shall be provided with control and supervision features such as to safeguard the various equipment and to permit both local and/or supervisory control
6. The Schematic diagrams included in the contract drawings shall be used as a guide to the basic operation of control and protection scheme of the rectifier and dc cathode and feeder breakers. These functional schemes shall be integrated into the Siemens Sitras Pro or approved equal product unit.
7. Not all devices referred to are to be supplied under this specification nor are all devices to be furnished herein listed. These devices have been included in the discussion hereinafter so that the Contractor can have a better understanding of the integration of the equipment supplied with the overall control and supervision scheme. The actual equipment to be supplied under this Specification is listed herein. For purposes of this discussion, the following device numbers shall be used hereafter. .
DEVICE NO. FUNCTION
1 Local control switch (START-STOP PULL TO LOCKOUT). 3 Checking of interlocking relay 4 Master control relay. 4X Auxiliary master control relay 8 DC control power breaker or switch 26D1, 26SD1 Delta and Wye Positive rectifier bank overtemperature, device -First step 26D1A, 26SD1A Delta and Wye Negative rectifier bank overtemperature, device -First step 26D, 26SD Delta and Wye Positive rectifier bank overtemperature, device- Second step 26DA, 26SDA Delta and Wye Negative rectifier bank overtemperature, device-Second step 26X Auxiliary to 26D and 26DA 26SX Auxiliary to 26SD and 26SDA 27 Undervoltage relay, device 27 27B Battery failure relay 27BC Battery charger failure relay 30 Rectifier annunciator 32 Reverse current trip device 32P Polarizing coil for dc reverse current trip 33 Substation door alarm 33B Breaker truck position switch 33R Rectifier compartment door position switch 33T Rectifier transformer equipment door position switch
GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT 16601-4 DISTRICT
37 Undercurrent or Underpower Relay 37B Battery low voltage alarm 43 Rectifier permissive control switch (REMOTE- LOCAL) 48 Incomplete Sequence 48TDC Incomplete Sequence time delay closing relay 49T Trans. winding over temp. device, first step 49TH Trans. winding over temp. device, second step 50/51 Rectifier AC Breaker (OCB) .overcurrent relay Inst & time delay 52 Rectifier AC Breaker (OCB) 62T Time delay start relay 64C Rectifier hot structure relay 64X Rectifier ground structure relay 69 Breaker permissive control switch 72 Rectifier dc breaker 74 Trouble alarm relay 83 AC transfer switch 86 Lockout relay 86X Conditional lockout relay 89N Rectifier negative disconnect switch 95X Surge protection monitoring relay. 95Y Diode fuse alarm loss of one diode 99Y Rectifier surge diverter failure alarm 129 Contactor for load measuring resistor 130 Station alarm annunciator 150Y DC overcurrent relay, rate of rise device 164X DC switchgear ground relay, hot structure 164MX DC switchgear ground relay, grounded structure 169 Permissive control switch (REMOTE-LOCAL) 172 DC feeder breaker. 172Y DC feeder breaker auxiliary relay 172Z DC feeder breaker auxiliary relay 174 Station trouble alarm relay 176 Direct acting series trip device 182 Solid state dc reclosing relay 182X Load measuring device auxiliary relay 183 Voltage measuring relay 186X Conditional lock-out 201 Supervisory close relay 201D Feeder breaker Emergency 201X Feeder master relay indication relay 237 SCADA loss of dc 243 Supervisory control switch 269 Permissive control indication relay 283 SCADA loss of ac
GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT 16601-5 DISTRICT
286 Supervisory lockout relay 294 Supervisory trip relay 751A Microprocessor relay for comprehensive overcurrent protection. Phase negative- sequence, residual ground, and neutral overcurrent protection in a package. The standard relay configuration of 3 outputs and 2 inputs including an option to provide an additional card with three digital inputs, four digital outputs and with one analog output of a 4-20 milliamp signal. SEL 751A EC Emergency close relay FD Fire detecting relay LMR Load measuring resistor
8. Starting of rectifier shall be accomplished by energizing 4X. This shall be accomplished locally by operation of master control switch device 1 or remotely by supervisory control through operation of 201. The following shall prevent energization of 4X:
a. Loss of control voltage b. Energization of 86 or de-energization of 86X c. Remote lockout through operation of 286 d. Local operation of master control switch device 1 to the Pull to Lock position.
9. Operation of 43 to the local position shall prevent energization of 4X except through operation of master control switch device 1.
10. Shut-down of rectifier shall be accomplished by de-energizing 4X. This shall be accomplished locally by the operation of master control switch device 1, automatically by the operation of 4 or loss of control voltage and remotely by supervisory control through operation of 286 or 294. The rectifier shall be shut-down by the operation of any of these devices regardless of the position of 43.
11 Energization of 4X shall cause 48 and 62T to time and closure of rectifier transformer breaker (Device 52). Closure of rectifier dc breaker, (Device 72) shall follow closure of rectifier transformer breaker (Device 52) after device 62T drops out.Failure of 72 to close and remain closed within a normal length of time shall cause device 48 to operate, which shall result in a lockout. Operation of 43 to LOCAL position will prevent operation of device 48 as described above. DE-energization of 4X shall cause opening of 52, 72 and shut-down of that rectifier unit.
GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT 16601-6 DISTRICT
12 The following safety devices shall operate 86 and cause shut-down of the rectifier until 86 is hand reset. This type shut-down is termed LOCKOUT. (Loss of ac control power shall not cause operation of any of these devices):
a. Rectifier breaker reverse current, device 32. b. Fire detected relay, device FD c. Rectifier breaker Inst. & over current, device 50/51 and 51A d. DC switchgear master trip relay, device 86S e. DC switchgear structure hot., device 164X f. Diode fuse loss of 2 diodes device, 95X g. Rectifier hot structure, device 64C h. Rectifier door open, device 33R i. Incomplete sequence, device 48TDC j. Rectifier negative switch open, device 89N k. Supervisory lockout ,device 286
13. The following safety devices shall de-energize 86X relay and cause the shutdown of the rectifier until the condition is corrected. This type shutdown is termed CONDITIONAL LOCKOUT.
a. Rectifier second step diode heat sink temperature, delta connected positive and negative, devices 26D and 26DA through a time delay relay 26X. b. Rectifier second step diode heat sink temperature, wye connected positive and negative, devices 26SD and 26SDA through a time delay relay 26SX. c. Transformer second step high winding temperature device 49TH.
14. The following safety devices shall activate the device 74 and cause a TROUBLE ALARM, until the condition is corrected.
a. Battery charger low voltage, device 27B b. DC switchgear grounded, device 164MX c. Rectifier first step diode heat sink temperature, delta connected, positive and negative, devices 26D1 and 26D1A. d. Rectifier first step diode heat sink temperature, wye connected, positive and negative, devices 26SD1 and 26SD1A. e. Transformer winding 1st step, devices 49T. f. Loss of one diode fuse, device 95Y g. Rectifier enclosure grounded (Device 64X). h. Rectifier surge diverter failure (Device 99Y).
15. Local supervision shall be provided to indicate operation of all safety devices in the Station Control Cabinet through Siemens Sitra Pro CU or approved equal product. Audible alarm for annunciator shall be operable only when 43 is in LOCAL position.
16. Supervisory control shall be provided to permit remote control and monitoring of the following items. The Contractor shall furnish and connect the necessary
GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT 16601-7 DISTRICT
contacts to supervisory terminal boards. The contractor shall revise supervisory hardware and software to accommodate the additional remote control and monitoring points a. Start and shut-down of the rectifier (Devices 201 and 294 for control and 4X for monitoring). b. Lockout shut-down of the rectifier (Device 286 for control and 4 for monitoring). c. West Feeder Close and Trip d. East Feeder Close and Trip e. Cathode Breaker Close and Trip f. Rectifier Trip and Lockout
17 The supervisory shall be provided to permit remote monitoring of the following items. The Contractor shall furnish and connect the necessary indicating contacts to supervisory terminal boards. The contractor shall revise supervisory hardware and software to accommodate the additional monitoring points
a. West Feeder Trip / Close b. East Feeder Trip / Close c. Cathode Breaker Trip / Close d. Rectifier ON / OFF e. Rectifier Lockout f. Hot Structure Trip Rectifier g. West Feeder Local / Remote h. East feeder Local / Remote i. Cathode Breaker Local / Remote j. West Feeder Closing Function k. East Feeder Closing Function l. AC Power ON / OFF m. Section Tie Open / Close n. Track 2 West On Station o. Track 2 East On Station p. Track 1 West On Station q. Track 1 East On Station r. Building Entry s. Fire t. Maintenance u. West Section v. East Section
D. Protective Device Coordination:
1. The Contractor shall furnish protective devices in the traction power rectifier equipment as listed elsewhere in this part of Specification, or as may be required, to provide reliable coordinated protection for the system. All such devices shall be adjustable and shall be factory calibrated to provide the following general protective scheme.
GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT 16601-8 DISTRICT
2. Using protective devices for the NIPSCO 34.5 kV OCB.
a. Pick-up of instantaneous element on short time relay to trip rectifier ac breaker (OCB) for 34.5 kV ac circuit and rectifier transformer faults. (Device 751A). b. Pick-up of short time relays to trip rectifier ac breaker (OCB) for rectifier transformer secondary and/or 1500V dc feeder breakers for faults on dc feeders. It shall also provide coordination with the reverse current trip on the dc breaker of any one other rectifier operating in parallel (see Section 16605). (Device 751A) c. Relay pick-up time shall not be less than 7 cycles. (Device 751A). d. Approximately 15 seconds pickup of long time relays to trip rectifier ac breaker at 450 percent rectifier full load current (Device 751A). e. Approximately 60 seconds pickup of long time relays to trip rectifier ac breaker at 300 percent rectifier full load current (Device 751A). f. Two hours of long time relays to trip rectifier ac breaker (OCB) at 160 percent rectifier full load current. (Device 751A).
3. Using Sitras Pro CU or approved equal product on dc switchgear:
a. Pick-up of reverse current device to trip rectifier dc breaker for the rectifier Internal faults (Device 32). Coordination of protective devices shall prevent tripping of OCB on any rectifier operating in parallel for this condition (see Section 16605).
b. Pick-up of adjustable polarized discrimination and instantaneous trip devices to trip dc feeder breakers for dc feeder faults. The discriminating trip device shall have operating characteristics and adjustable ranges such as to trip for remote short circuits on the catenaries and discriminate against tripping for inrush on starting of trains insofar as possible. The instantaneous trip devices shall have operating characteristics such that ac breaker tripping shall not occur on dc feeder faults (Devices 150 and 176).
1) Load measuring and automatic re-closing features on dc feeder breakers will cause automatic re-closure as soon as the condition that caused tripping is corrected.
c. The functions described above for tripping the cathode breaker on reverse current, and feeder breakers on rate of rise and permissive for closing the feeder breakers on load measuring shall be accomplished the Sitras Pro CU or approved equal product located in the corresponding DC switchgear cubicles.
4. Using temperature devices on rectifier transformer:
a. Conditional lockout of rectifier following 150 percent of rectifier full load
GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT 16601-9 DISTRICT
current for approximately 2 hours (Device 49TH).
5. Using Sitras Pro CU or approved equal product on rectifier:
a. Individual current limiting fuse in series with each parallel silicon rectifier element to blow for element failure. Provide indicating lamps and diode fuse monitor as may be required to indicate failure of either element or fuse. b. Pick-up of thermal switches on heat sinks to trip associated ac and dc circuit breakers on heat sink high temperature due to any combination of excessive ambient temperature, reduced heat sink efficiency or excessive base load and load current including short circuits, that would result in failure of rectifier elements and/or fuses before other protective devices on ac and dc switchgear could operate (Device 26D).
E. Relays and Devices:
1. The Siemens Sitras Pro CU with integrated programmable logic controller or approved equal product used in the control and supervision of the supplied equipment shall have proved successful in similar application over at least a 5 year period of use.
2. All control and instrument switches shall be rotary type provided with properly designated black escutcheon plates, clearly marked with white letters to show operating position. Breaker control switches shall be spring return. Instrument switches shall have an "OFF" position. Handles shall be solid colored plastic, or approved equal. Selection of operating handles shall be as follows:
a. Breaker Control Pistol grip, black b. Permissive Control Oval, black c. Instrument Knurled round, black d. Pistol grip control switches shall be G.E. type SBM, Electro switch or approved equal.
3. All control and auxiliary relays shall be suitable for use in switchgear equipment as defined in the latest issue of ANSI C37.90. Operating coils for direct current relays shall be suitable for continuous operation between 90 volts and 145 volts dc and alternating current relays between 85 percent and 110 percent of nominal rating.
4. All indicating lights shall be LED high output and shall operate with sufficient intensity between 90-145 volts dc. LED shall be visible under 50 fc operating floor lighting and shall not suffer premature failure from battery float or equalize voltage. LED samples of all colors used shall be furnished to District for evaluation and approval, prior to installation on the equipment.
5. All indicating instruments shall be semi-flush mounted and shall have metal scales with black figures on a white background. They shall be approximately
GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT 16601-10 DISTRICT
4-1/4 inch in size, have taut band suspension, and be of 250-degree scale design.
6. All fuses and disconnect switches for ac and dc control circuits shall be manufactured in the United States and shall be located in such a position that they are easily and safely accessible. In dc switchgear cubicles, all 1500 volt fuses shall be mounted in enclosed fuse blocks and installed in the rear compartments. Minimum current interrupting capability shall be 15,000 amperes at 2000 volt dc, with an L/R ratio of 0.05 sec. Minimum voltage rating shall be 600 volt dc for 125 volt circuits and below. All control and monitoring circuits connected to 1500 volt dc system shall be rated 2000 volt dc.
7. All devices such as fuses, meters, relays, switches and lamps shall be suitably identified by plastic tags with black letter on white background and device symbol, and in case of fuses, rating and circuit feed. Identify polarities of fuses and switches. The tags shall be mounted under device with machine screws. Use of self -tapping screws, rivets or adhesives will not be permitted.
8. Each circuit and panel-mounted device shall have a suitable processed plastic nameplate with black letters on white background for proper identification. Nameplate shall be of 1/16 inch thickness and type for specific use and shall be smooth with 0.003 inch Melamine covering as manufactured by Duralith Corp., or approved equal. Each circuit nomenclature will be specified later. Lettering shall be 1/4 inch in height where possible. The nameplates shall be mounted with machine screws. Use of self tapping screws, rivets or adhesives will not be permitted.
9. Mounting holes for outdoor nameplates shall be fitted with a resilient grommet under a non-corrosive eyelet to prevent cracking of the enamel during the mounting application. All outdoor nameplates shall have full color coverage and shall be guaranteed for ten years, with outside usage, against fading and defects such as blisters, peeling, cracks, chipping, pin holes and discoloration.
10. Approved tags, identifying dc feeder breaker sections, rectifier dc breaker, rectifier transformer and rectifier shall be provided. Front and back tags for dc breaker sections, rectifier dc breaker and rectifier shall be 14 inches by 6 inches by 1/8 inch, 3 layers plastic with sunlight yellow surface color on both sides and black center core (black lettering). Front and back tags for rectifier transformer shall be 17½ inches by 3½ inches by 1/8 inch, 3 layers plastic with cardinal red surface color on both sides and white center-core (white lettering). The tags shall be mounted with machine screws. Use of self tapping screws, rivets or adhesives will not be permitted.
11. Adjustable lugs on tubular resistors of 1.125 inches diameters shall be Ohmite Manufacturing Co., double-thumb screw adjustable lug, Catalog No. 2160, or approved equal. Adjustable lugs on tubular resistors of 0.438; 0.563; 0.750;
GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT 16601-11 DISTRICT
1.500; 1.625 and 2.500 diameters shall be Ohmite silver contact, bake-lite knob type Catalog Nos. 2163, 2165, 2167, 2183, 2187 and 2191 respectively, or approved equal. Adjustable lugs of .313 diameter shall be Ohmite silver contact screw driver type catalog No. 2161, or approved equal.
12. All sections shall include Marathon terminal blocks series 1500 in addition to the GE EB-5 and Weidmueller type SAK.
13. All sections shall include that the pistol grip control switches shall be GE type SBM, Electro Switch, or approved equal.
F. Miscellaneous:
1. Bolted joints of current carrying members shall be provided with proper spring tension devices to maintain proper joint pressure under load (heat) cycles. For copper to copper joints use Everdure hardware or approved equal, for aluminum to aluminum joints use Belleville washers or approved equal.
2. Copper to aluminum bolted joint shall not be allowed.
3. Cable and control wires shall be copper, and shall meet the requirements of the National Electrical Code.
4. Each wire shall be clearly identified using white plastic slip-on markers with etched black lettering. The marker diameter shall be consistent with the wire diameter to insure a snug fit, but yet able to be rotated for identification.
5. Device layouts shall provide visibility of and safe, easy access to all terminal blocks, fuses, switches relays, and other devices and their associated wiring without reaching into blind spots and/or physically climbing into the enclosure. All devices such as fuses, switches, terminal blocks, etc. shall be mounted within 18 inches of the face of the cubicle accessible for operation and maintenance. All 2000 volt fuses and disconnects shall be mounted in rear cubicles. Any device layout which is judged not to be safely maintainable will be rejected.
6. Serviceability under NAFP70E rules shall be taken into consideration for equipment layout with the intent of minimizing arc blast exposure and protective clothing requirements. Furthermore, all equipment shall have appropriate arc blast warning labels attached.
7. Transducers shall be fused separately.
8. Equipment enclosures shall be fabricated to provide sturdiness, durability and neat appearance. Structures shall provide adequate rigidity to prevent warping, bonding and vibration of panels and doors. Where required, heavier gauge metal and/or extra stiffeners shall be used to insure that doors, panels and
GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT 16601-12 DISTRICT
appurtenant mountings do not bend or rattle when being accessed for maintenance or, in case of breaker cubicles, when breakers are opened or tripped.
9. Equipment dimensions on drawings will be shown in metrics and with inches in brackets.
10. Wiring terminals shall be ring style compression type.
1.4. RECTIFICATION EQUIPMENT DRAWINGS AND DESIGN CONFERENCE
A. Bidder shall submit with the proposal a statement that the equipment to be furnished will not exceed the dimensions shown on the Contract drawings.
B. Schematic and wiring diagrams shall be prepared utilizing ANSI-IEEE standard device symbols and nomenclature as defined and listed in ANSI Standard C37.2 except where specified otherwise herein. Terminals and terminal block studs shall be clearly marked on all equipment and the markings shall agree with the drawings. All components on the drawings shall be marked to indicate size and rating.
C. All diagrams, drawings and instruction material shall be prepared utilizing the latest issue AutoCAD in English language and U.S. Standard system of weights and measures. All drawings and reproducible tracings shall be 22inches x 34 inches overall. The equipment layout drawing shall be drawn to 1/4 inch = 1 foot-0 inch scale. A bar chart (graphic scale) shall be provided on all equipment layout drawings. All drawings when reduced to 11inches x17inches size shall be clearly legible. D. All as-in-service (AIS) drawings, diagrams and instruction material shall be provided to NICTD in original AutoCAD dwg format. Text documents shall be provided in Microsoft Word.
E. The equipment manufacturer shall start detail design and drafting work for all equipment immediately upon Award of the Contract and shall process design work to completion without delay and without regard to normal manufacturing schedule, to permit timely rectification equipment installation.
F. Within thirty (30) days after Award of the Contract, there shall be a design conference at the equipment manufacturer's facility, which shall be attended by District’s personnel and their authorized agents.
G. During the Design Conference the Contractor shall provide the following:
1. Certified-outlined dimensions and weights of all major items of equipment, namely:
a) Rectifier Transformer b) Anode Bus, indoor and outdoor/indoor
GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT 16601-13 DISTRICT
c) Rectifier d) DC Switchgear Line-up e) Station Control Cabinet
2. A list of any and all items the contractor proposes to substitute for items listed in the Specification. Each proposed item of substitution must be supported by the following information:
a) Device name, catalog number, and device number as shown on the Contract Drawings. b) Technical and descriptive literature of device. c) Schematic diagram of device down to component level. d) Reason for substitution.
3. Outline of all tests to be performed in his factory or in factory of his supplier.
4. Name of testing laboratory which will perform the tests that cannot be conducted in the Contractor's or the Contractor's Supplier's factories.
5. Request for extension of any test report which cannot be submitted within thirty (30) days after the day the test is performed.
6. A list of all problems or conditions which require clarification.
7. The Contractor shall submit six (6) copies for the District’s approval, the detail minutes of the design conference including all the documents that were submitted by the Contractor during the design conference.
H. Design Conference Cost:
1. Any transportation (air-economy plus-coach class, and any other necessary) and first class lodging required by the District personnel, their authorized agents, or their authorized consultants, which are necessary to accomplish the satisfactory inspection of this Contract shall be included in the bid price. It is anticipated that one trip for 5 persons and lodging for 4 days and 3 nights will be required for conference.
I. Shop Drawings:
1. Submit six (6) copies of each of the following reduced drawings, 11x17 in size to District’s for review after award of the Contract as scheduled hereinafter. The District review will be general and will in no way relieve the Contractor from fulfilling all of his obligations and/or guarantees. All equipment outlines, plans and section drawings shall be drawn to scale.
2. Within sixty (60) days after Award of the Contract:
GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT 16601-14 DISTRICT
a. Certified outline drawings indicating overall dimensions, aisle space requirements, location of control and protective devices on panels, and reference tables to furnished. b. Certified floor plans showing dimensions necessary for installing equipment, equipment base details, and entrance available for main and control cables. c. Certified section views of each non-identical unit showing bus and equipment locations and location of outgoing power and control terminals. Drawings must be in sufficient detail to illustrate accessibility for maintenance and for adjustments while energized. d. Single line diagram showing all main connections and protective devices, and the location of all current, potential and auxiliary devices, with the devices energized by them. e. Schematic diagram of transformer, rectifier and dc circuit breaker controls and alarms - these shall include schematic and dc elementary diagrams of all circuits. f. Internal connection diagram of devices (as may be shown separately). g. External wiring diagrams for all the equipment furnished for all the traction power substation work. h. In order to give a concise review, the District may require additional information than what the Contractor may have included in his/her design submittal. Therefore, a supplement to this submittal may be required. However, the Contractor will continue forward with whatever review responses the District provided. The submittal shall be delivered to the District within ten (10) calendar days of receipt by the Contractor. i. Time vs. current curves for all dc breakers.
3. Within thirty (30) days after return of schematic diagrams marked "Approved:, "Approved as Noted-Work to Proceed", and "Revised and Resubmit" the Contractor shall resubmit the revised drawings, including:
a. Connection diagrams of each non-identical unit showing the following:
1) Internal wiring. 2) Terminal Block Arrangement Drawings. Drawings shall show physical location with dimensions, sufficiently detailed for and accurate layout for external cable connections. b. Interconnection wiring diagrams showing the external connections between each piece of equipment furnished for the traction power substation work. Interconnection wiring diagrams shall show the terminal blocks of each individual unit and interconnection of each piece of equipment. The interconnection diagrams shall also show the wire cable and terminal numbers where each wire has been terminated. c. All control wiring must be shown connected to the terminal blocks and the conductors shall be grouped in accordance with the cable tabulation. d. If the wiring is color coded, the coding shall be shown on the external wiring. If the wiring is numbered, the numbers shall be shown.
GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT 16601-15 DISTRICT
e. Wiring diagrams that use a table or a spread sheet shall be rejected. f. Equipment nameplate data. g. Instrument transformer ratio, phase angle and excitation characteristic curves.
4. Protective Device Coordination Curves.
a. The Contractor shall be responsible for the relay coordination study. Coordination curves shall be submitted electronically within 120 days after award of contract, showing relay and direct acting trip device coordination for all equipment furnished hereunder.
b. Coordination curves shall include plot of rectifier design capability and shall clearly indicate actual margin of coordination (from breaker trip to design capability) at each of 150 percent, 300 percent and 450 percent full load current and short circuit, taking into account derating due to current imbalance and loss of one leg in each phase. c. Final coordination will be subject to the Engineer's approval.
J. After final review, and prior to the construction, of all drawings in the latest issue of AutoCAD format diagrams, material lists, recommended support parts shall be issued for the construction.\\
K. Test Costs.
1. Prior to shipping of equipment, numerous factory tests will be required as covered in Section 16608 and 16609 of this Specification. 2. Any transportation (air- economy plus-coach class, and any other necessary) and first class lodgings required by the District personnel, their authorized agents or their authorized consultants which are necessary for witnessing the factory tests and to accomplish the satisfactory inspection of this contact shall be included in the bid price. Following is the anticipated number of personnel and length of lodging needed for the tests:
Test Number of Lodging Personnel Days
In line test 5 5 Transformer 5 5 Rectifier 5 3 DC Switchgear 5 5 Diode 5 5
3. If additional trips are required due to problems developed because of the negligence of the Contractor, the cost of those trips including the labor shall also be borne by the Contractor.
GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT 16601-16 DISTRICT
1.5. EXPERIENCE
A. The Bidder shall submit sufficient evidence that he has a minimum of 5 years current experience in the successful manufacture of silicon rectifier conversion equipment for commuter railroad substation systems and equal experience as prime equipment Contractor for commuter railroad conversion substation systems, or the Bidder shall demonstrate, to the satisfaction of the Engineer, that he has equivalent experience or knowledge.
B. The Bidder shall submit sufficient evidence that the manufacturers of the subcontracted major equipments have a minimum of 5 years current experience in successful manufacture of the generic type of equipment proposed.
C. The Bidder shall submit sufficient evidence that the equipment of the subcontracted manufacturers, by generic type, have been used successfully by the Bidder for commuter railroad conversion substation systems for at least 5 years, or that this equipment is presently being used successfully in traction power substations.
D. Evidence submitted shall include a list of users name, telephone number and length of time in service.
E. The right is reserved to reject bids when, in the opinion of the District, insufficient evidence is submitted to establish the experience requirements of this specification.
END OF SECTION
GENERAL REQUIREMENTS FOR TRACTION POWER EQUIPMENT 16601-17 DISTRICT SECTION 16602
RECTIFIER TRANSFORMER
PART 1 - GENERAL
1.1. SUMMARY
A. This section covers details requirements for designing, manufacturing, testing, delivering, installing and commissioning the Rectifier Transformer for Madison Substation.
B. The rectifier transformers shall be silicon vacuum pressure encapsulated (VPE), ventilated, self-cooled, dry type for outdoor use. The transformer will be supplied from a three phase 34.5 kV service from the oil circuit breaker remotely located in the NIPSCO switchyard.
C. Contract plans show the location of the existing transformer which is to be replaced under this Contract .The new transformer shall be installed in the same location on the existing transformer pad.
1.2. TECHNICAL REQUIREMENTS
A. The rectifier transformer shall be designed to meet the requirements of NEMA RI 9 for extra heavy duty traction service and shall be designed such as to fully coordinate with and operate in conjunction with the rectifier specified under Section 16603. The transformer shall have electrical and mechanical characteristics and general design features as follows:
B. Electrical Characteristics:
1. KVA Rating:
a. Rating commensurate with rectifiers, detailed under Section 16603. b. Average winding temperature rise by resistance at a 40 degrees Celsius ambient shall not exceed 80 degrees Celsius after a 2 hour, 162 percent RMS load following continuous 100 percent load stabilized thermal conditions. c. Average winding temperature rise by resistance at a 40 degrees Celsius ambient shall not exceed 85 degrees Celsius after temperature stabilizes at 150 percent full load current. d. Maximum winding hot-spot temperature rise shall not exceed 180 degrees Celsius in an ambient corrected to 40 degrees Celsius after
RECTIFIER TRANSFORMER 16602-1 DISTRICT running at 300 percent full load current for 36 minutes following stable thermal conditions at 100 percent full load current. e. Winding insulation shall be Class H for a total temperature of 220°C or better. 2. Windings:
a. All windings and connections shall be delta or wye connected copper. b. High voltage winding shall be for 3-phase, 60 Hz, 34,500 volt ac nominal delta connected, suitably for use with on effectively grounded system. Winding insulation shall be 34.5kV, rated for basic impulse level of 200 kV minimum. c. Transformer shall have two 3-phase low voltage copper windings: one delta, the second wye connected, arranged in accordance with IEEE Circuit NO. 31, as defined in IEEE Standard 1653.2 (2009) to provide twelve-phase, multiple delta –wye, double-way supply to the rectifier. Voltage and related characteristics shall commensurate with rectifiers detailed under Section 16603. d. All current carrying conductors and connections shall be insulated.
3. Taps:
a. The rectifier transformer shall be provided with no-load, full capacity 3 plus 2 1/2 percent and 2 minus 2 1/2 percent high voltage windings taps, complete with necessary manual tap changer mechanism. The rectifier transformer tap voltage ratings shall be:
37,089 Volts 34,500 Volts 36,226 Volts 33,637 Volts 35,363 Volts 32774 Volts
b. The no-load taps shall be brought to an externally operated manually taps changer for operation only when the transformer is de-energized. The taps shall be accessible through removable panels on the transformer enclosure.
c. No-Load Losses
1). No-load losses for 3,000 kW transformer at rated voltage shall not exceed 6,500 watts.
d. Impedance and Insulation Voltage Class:
1). Impedance shall be as low as possible consistent with good design. Exact value shall be determined by the guaranteed no load losses and by the requirements for output voltage.
RECTIFIER TRANSFORMER 16602-2 DISTRICT 2). High Voltage insulation class shall be 38 kV with BIL of 200 kV or more. Low voltage insulation class shall be 3 kV with BIL of 45 kV or more.
e. Bushings:
1) Porcelain bushings shall be provided for all power terminals. 2) High voltage bushings along with the lightning arresters shall be water tight cover mounted on the top of the transformer for connection to the existing disconnect switches mounted on a remote switch structure. 3) Contractor shall provide for each bushing and lightning arrester a heavy duty bolted type NEMA 4-hole terminal lug suitable for connection to 4/0 AWG ACSR wire or 4/0 AWG Aluminum wire. 4) The terminals H1, H2 and H3 shall be clearly marked.
f. Lightning Arresters:
1) Lightning arresters shall be station class rated at 30kV.
g. L.V. Enclosure:
1). The low voltage bushing shall be either cover or side wall mounted enclosed by a water tight flanged throat or an air filled terminal chamber. The enclosure shall be arranged for direct connection to the anode bus ducts furnished by the Contractor in accordance with Section 16605. The joint shall be flanged, gasketed and water tight and provided with means of easy separation of bus duct from the transformer. The method of connection shall be approved by the Engineer. Bolted readily removable links shall be provided for connecting the bus to the transformer terminals. 2). The terminals R1, R2, R3, R4, R5 and R6 shall be clearly marked and indelibly written on the transformer.
h. Noise Level:
1). Noise level shall not exceed 65 decibels (A) at no load with excitation on the transformer when measured in accordance with conditions outlined in NEMA Standard TRI-9.04 and in accordance with OSHA Vol. 37, No. 202, Pt. II, Section 1910.95.
C. Mechanical Characteristics: 1. The transformers shall be so designed that all connections, tap changing devices, meters, relays and probes are easily accessible for inspection and maintenance. All devices such as fuses, switches, terminal blocks, etc. shall be mounted within 18 inches of the face of the cubicle.
RECTIFIER TRANSFORMER 16602-3 DISTRICT 2. The enclosure shall be rodent proof and shall be substantial enough to prevent physical damage to the transformer coils. 3. Outdoor enclosures shall be corrosion resistant and protect the transformer coils, connections, and ancillary equipment from wind driven rain and snow. The enclosure shall be provided with thermostatic controlled space heaters. 4. The enclosure shall be provided with an interlock system such that the transformer will not be energized when any portion of the enclosure is open. This interlock system shall be of the type that is not affected by vibration, wind or other occurrences which would cause false operations. The security of the enclosure shall be monitored by a light on the front of the enclosure. 5. The enclosure shall be constructed of panels which are hinged so that panel may be opened in a horizontal direction. Each panel shall have a three-point latching mechanism operated by a pad lockable handle. 6. Vacuum Pressure Encapsulated VPE construction: a. The completed coil winding (HV and LV) shall be dried at atmospheric pressure in an oven through which hot air is continuously circulated. After the coil is preheated and dried, it shall be vacuum impregnated in silicone resin. The resin shall be cured on the coil following an established temperature vs. time baking cycle in a hot air circulating oven. After the resin is cured on the coil, a second coating of silicone varnish shall be applied to the impregnated coil and cured as above. The silicone resin shall completely encapsulate the coils and thus sealing against moisture, dirt, and other extraneous contaminates. b. The transformer core shall be constructed of high grade non-aging silicon steel laminations with high magnetic permeability and low hysteresis and eddy current losses. Magnetic flux densities shall be kept well below the saturation point. The core shall be a step lap mitered design and clamped together with heavy steel members. All cores clamping and bolting is insulated with high temperature insulation. 7. There shall be no rigid mechanical connections tying the low voltage (LV) and high voltage (HV) coils together. The HV and LV coils shall be supported and spaced apart by epoxy bottom support blocks, epoxy space blocks and shock absorbing top epoxy blocks to facilitate thermal expansion and contraction of the coils. 8. The VPE coils shall be suitable for operation in an ambient temperature range of -50 degrees Celsius to +50 degrees Celsius without degradation or cracking of the insulation system. 9. The VPE coils must not absorb moisture and shall be suitable for operation at 50 degrees C ambient temperature at 100 percent humidity. The transformers must be suitable for prolonged storage in 100 percent
RECTIFIER TRANSFORMER 16602-4 DISTRICT humidity and be capable of immediately being switched on a full voltage and load without pre-drying. !0 The VPE coils shall be fabricated in a facility with at least 5 years’ experience in the manufacture of transformer coils for the use on Rapid Transit Systems. The manufacturer of the coils shall also submit factory certified tests showing that prototype coils, rated 500 KVA (minimum) have been subjected to temperature shock tests whereby the coils have undergone temperature changes of 100 degrees Celsius (minimum) in a 5 minute (maximum) time period either by heating a cold transformer or cooling a hot transformer - followed by a 200 KV BIL test. Following this test, the transformers shall have been examined for cracking by both visual testing and corona discharge testing. In the absence of such certified test, the Contractor shall arrange for factory witness testing of this type of shock testing. No VPE coil transformer design will be accepted without such certified or witness tests 11. Windings: a. The transformer coils should be of round concentric construction. The windings shall be wound without joints to provide minimum voltage stress on insulation. b. Low voltage coils wound with continuous copper strip or of a helical construction. High voltage coils shall be of barrel wound or of continuous disc construction. No splices will be allowed. Insulation system shall be based upon the voltage rating, temperature rating and the compatibility of the insulation with epoxy resin. This includes all appurtenant materials such as ties, mounting pads, etc. 12 Core-Construction: a. The core shall be grain-oriented, non-aging silicone steel stacked in the step or cruciform method to best accommodate a round coil. 13. Core and Coil Assembly: a. The individual coils shall be assembled on the core so that an even compression on the coils is maintained through the warming/cooling cycles. 14. The entire assembly shall be braced or bolted adequately to prevent displacement and distortion under all normal conditions of handling and operation under short-circuit conditions. Locking provision shall be made for all inside bolted members or connections. Serial number shall be stamped on core or core clamp in a conspicuous place. 15. Tap changer shall be arranged for one person using simple hand tools. All energized parts shall be adequately insulated. The tap arrangement shall be designed to prevent incorrect tap connections. Actual arrangement requires approval of the NICTD.
RECTIFIER TRANSFORMER 16602-5 DISTRICT 16. Base: a. The transformer shall be mounted on skids of the I-beam, sled-runner type, or approved equal. Base members shall be suitable for skidding in any direction on rails or rollers. Jack pads and crane lifting lugs shall be provided. The base drawings shall clearly indicate the type of jack pads, their outline dimensions and their location from the longitudinal and transverse axes of the transformer, and also the dimensions and location of the base members so as to facilitate design of the concrete foundation. 17. Two (2) stainless steel transformer grounding pads shall be provided. 18. All exposed metal work shall be thoroughly cleaned, treated against rust and corrosion, and primed with zinc chromate. The transformer shall be finished with two coats of ANSI-61 Light Gray color by powder coat painting process. One pint of touch-up paint shall be furnished with the transformer. D. Protective and Maintenance Devices: 1. The rectifier transformer shall be provided with the following protective and maintenance devices: a. Two-step winding temperature indicator with contacts which open on rising temperature for transformer alarm indication and tripping. A thermocouple shall be installed in the low voltage center winding. b. Door interlocks as specified. c. Secondary and control wiring shall be ICEA Standard Type SIS, No. 12 AWG or larger, insulated for 600 volt ac service and shall be factory-wired to screw type terminal blocks for bottom connection to external conductors. Terminal blocks shall be General Electric Company, Type EB-5, Marathon Series 1500, or approved equal. Secondary and control wiring shall be in rigid conduit, galvanized inside and outside, except for short flexible connections to devices which will be Sealtite flexible conduit, or approved equal. d. Push to test indicating blue light shall be installed on the transformer enclosure to mounted doors condition. Blue light "on" where any one transformer enclosures door is open. A nameplate shall be installed above the blue light. e. Nameplates showing winding connections, voltages, ratings, impedance, serial number, and other information as may be required, in accordance with latest edition of ANSI C 57.12.00. f. Warning signs as required by NFPA-70E, Article 420 at the appropriate location.
PART 2 EXECUTION
RECTIFIER TRANSFORMER 16602-6 DISTRICT 2.1 INSTALLATION
A. See Section 16607 for the rectifier transformer installation requirements.
2.2 TESTING
A. See Section 16608 and 16609 for the rectifier transformer testing requirements.
END OF SECTION
RECTIFIER TRANSFORMER 16602-7 DISTRICT
SECTION 16603
1500 VOLT DC SILICON RECTIFIER
PART - 1 GENERAL
1.1. SUMMARY
A. This section covers the requirements for designing, manufacturing, testing, delivering, installing and commissioning 1500 volt dc silicon rectifier assembly at Madison Substation.
B. The rectifier shall be indoor, metal enclosed, natural convection cooled, and using building air for cooling under ambient condition for 12 phase multiple double way rectification.
C. The rectifier will be supplied directly from the rectifier transformer covered in Section -16602 and will serve as the source of supply for the dc switchgear covered in Section-16604. Rectifier circuits shall be in accordance with IEEE Circuit 31 as defined in IEEE Standard 1653.2 to receive a twelve phase , multiple delta-wye, double way supply from the rectifier transformer.
D. Contract plans show the location of the existing rectifier which is to be replaced under this Contract .The new rectifier shall be installed in the same location.
1.2. TECHNICAL REQUIREMENTS
A. The rectifier, using outside air under ambient conditions, shall be designed for parallel, non-attended operation as set forth in Section 16601 and shall function as an integrated unit with the rectifier transformer and the dc switchgear.
B. The complete rectification package (including rectifier transformer, rectifier and anode bus) shall have a continuous full load output rating of 3000 kW at 1500 volt dc at a maximum ambient-room temperature for 40 degrees Celsius (104°F). After constant temperature rise is reached following continuous full load, it shall be capable of operating guaranteed overload equal to base overload of 150 percent full load current for 2 hours and superimposed cycle overload consisting of 5 periods of 300 percent full load current for 1 minute, followed by 1 period of 450 percent full load current for 15 seconds, spaced throughout the 2 hour period as follows:
1500 VOLT DC SILICON RECTIFIER 16603-1 DISTRICT C.
TIME IN MINUTES E. The complete rectifier package (including rectifier, transformer and anode bus) shall have a full overall efficiency of not less than 97.5 percent, a displacement power factor above 90 percent lagging. The voltage regulation characteristic based on the minimum short circuit supply in MVA and X/R ratio of the ac incoming supply from NIPSCO, shall be such as to provide output voltage within the limits set forth below when ac system voltage at no load corresponds to transformer tap voltage. These limits shall be met on all transformer taps. All dc values shall be based on use of averaging type meters.
Output Current Output Voltage-DC
0.5 percent Full Load 1585 to1560 100 percent Full Load 1510 to1485 150 percent Full Load 1475 to1445 300 percent Full Load 1365 to1335 450 percent Full Load 1250 to1220
D. The complete rectifier package (including rectifier transformer, rectifier and anode bus and dc switchgear) shall be capable of withstanding a bolted short circuit on the rectifier output terminals without damage to any component, including protective fuses and rectifier elements immediately following the 2 hour overload period specified in Subparagraph 1.2B above.
E. The rectifier shall be designed so that damage to the rectifier elements and fuses is prevented by current-time overload relays. Thermal devices on heat-sinks shall take rectifier out of service and prevent rectifier operation under any combination of excessive ambient temperature; reduced heat sink efficiency and/or excessive base load such that the rectifier elements and fuses are no longer afforded complete protection by the current time overload relays. Each thermal device shall be mounted and wired to the terminal blocks to permit easy removal.
F. The manufacturer shall provide a sufficient number of diodes per phase, polarity to fulfill all the requirements of this specification but in no case shall the number of diodes provided per phase polarity be less than the number "D" determined by the following calculations:
1500 VOLT DC SILICON RECTIFIER 16603-2 DISTRICT Let D = Minimum quantity of diodes per phase leg.
Let C= Published diode peak surge current rating in amperes (maximum peak value of rated non-recurrent one cycle sinusoidal current on a 60 Hz basis). Must conform with ANSI/EIA Standards for Silicon Rectifier Diodes, ANSI / EIA- 282A-1989.
Let X/R = Overall reactance-to-resistance ratio, including alternating current supply system, transformer, bus duct, and rectifier.
Let K = 2.12 for X/R = 15
Let Es = Rectifier transformer low voltage winding voltage, line-to-line, at no load
Let Iss = Average dc sustained short circuit current with rectifier output terminals bolted, with NIPSCO supply system at 34.5 kV, and
1.35(Es) Z R2 X 2 And Iss = 3Z
C 1 0.74(Iss) 2 K ThenD 1 C 1 0.0074(Iss) 2 K
Curve Attached (See the following page)
1500 VOLT DC SILICON RECTIFIER 16603-3 DISTRICT
TRANSIENT RMS FACTOR K AS RELATED TO THE SYSTEM X/R RATIO
2.4
2.2
2.0
1.8
1.6 K 1.4
1.2
1.0 0 2 4 6 8 10 12 14 16 18 20 X/R
1500 VOLT DC SILICON RECTIFIER 16603-4 DISTRICT G. Rectifier assembly shall include interchangeable diodes, fuses, and interconnecting links throughout the rectifier section to permit interchangeability without affecting current balance compliance.
H. The diodes shall be easily accessible. The silicon diodes shall be press pack (hockey puck) type. Each diode shall be hermetically sealed. The diodes shall be mounted in between two heat sinks held by diode clamps. These shall be easily removable and replaced by unbolting the diode clamps
I. The rectifier assembly shall include one section containing the devices required for control and supervision as set forth herein or shown on Contract Drawings. The rectifier shall be controlled and supervised from Station Control Cabinet (SCC) through Sitras Pro CU or approved equal product. The control, status, and supervisory signals shall be transmitted to the cathode breaker in dc switchgear and to the SCC by means of fiber optic cables. Normal control equipment and circuits shall be physically accessible, and so connected as to permit convenient testing and/or maintenance of relays and control circuitry. All devices such as fuses, switches, terminal blocks etc. shall be mounted within 18 inches of the front of the cubicle.
J. The rectifier assembly shall be freestanding, metal enclosed with hinged doors having rubber gasketed transparent safety glass panes, on the rectifier section and hinged doors on the auxiliary and/or control sections. Provisions shall be made to prevent energizing the rectifier while any door on rectifier section is open. Full height doors shall be securely fastened in the closed position with a minimum of three latches and easily opened without the use of tools. The rectifiers shall have jacking and lifting pads. All doors shall have edge stripping and be lockable with a padlock.
K. The 2000 kcmil solderless removable type terminal lugs shall be provided for each of 2 outgoing positive cables, and each of 2 outgoing negative cables. The solderless type lugs shall be Penn Union type V V L or approved equal. The cable supports shall be provided so that cables within the rectifier cubicle are self supporting. The positive and negative power circuit entrances shall be from the top.
L. The rectifier assembly shall be arranged for bolted connection to anode buses furnished under Section 16605 of this Specification. Sturdy supports shall be provided inside the rectifier assembly so that the anode bus is self- supporting. Rectifier internal bus shall be copper with all bolted contact surfaces silver plated or aluminum with all joints welded. The contact surfaces at cable take-offs and anode bus connections shall be silver plated.
M. The secondary control and supervisory control wiring shall be ICEA Standard Type SIS No. 12 AWG or larger stranded switchboard wire, insulated for 2000 volt dc service, or similar to BOSTRAIL AAR S501 car wire, 2kV, extra flexible, XLPO insulation, soft annealed copper stranded conductor, as manufactured by DRAKA USA. Cables shall be factory wired
1500 VOLT DC SILICON RECTIFIER 16603-5 DISTRICT to screw-typed terminal blocks for connection to external conductors. The terminal blocks shall be General Electric Company Type EB-5, Weidemuller type SAK, Marathon Series 1500 or approved equal.
N. All metal work shall be thoroughly cleaned, treated against rust and corrosion, bonderized, and finished with 2 coats of ANSI-61 light gray color by powder coat painting process. 1 quart of matching touch-up paint shall be furnished with each assembly.
O. The floor area under the rectifier shall have a 1/4 inch thick NEMA grade GPO-3 polyester resin, fiberglass reinforcing insulating sheet and an insulated matting all around the rectifier floor area to insulate the rectifier enclosure from the building.
1.3. DETAIL EQUIPMENT:
The equipment to be furnished shall be for use in the coordinated system shown on the Contract Drawings and shall be in accordance with the following:
A. One (1) 1500 volt dc indoor, self-cooled metal enclosed silicon rectifier unit shall be incorporated into one continuous enclosure and mounted on the insulated sheet anchored by means of insulated bolts and made up of components including but not limited to the following:
1. One (1) set of current limiting fuses in the connections to each silicon diode which will protect all remaining diodes in the event of any diode failure, complete with one (1) diode fuse monitor. Fuse monitoring system shall consist of target type fuses which are clearly visible in illuminated enclosure with internal lights and panel switch. Opening of one fuse in each phase polarity shall not reduce capacity from the listed in Paragraph 1.2B of this Section nor adversely affect ability to withstand short circuit.
2. Each individual silicon diode shall be mounted on adequate air-cooled heat sink for maximum heat dissipation. Twenty four (24) circuit- opening- on rising temperature, bimetallic thermal devices shall be furnished and mounted on diode heat sinks and shall be wired to the PLC as follows:
a. Three (3) thermal devices shall be connected to provide rectifier positive first step high temperature alarm for delta connected winding. b. Three (3) thermal devices shall be connected to provide rectifier positive first step high temperature alarm for wye connected winding. c. Three (3) thermal devices shall be connected to provide rectifier negative first step high temperature alarm for delta connected winding. d. Three (3) thermal devices shall be connected to provide rectifier negative first step high temperature alarm for wye connected winding.
1500 VOLT DC SILICON RECTIFIER 16603-6 DISTRICT e. Three (3) thermal devices shall be connected to provide rectifier positive second step high temperature trip for delta connected winding. f. Three (3) thermal devices shall be connected to provide rectifier positive second step high temperature trip for wye connected winding g. Three (3) thermal devices shall be connected to provide rectifier negative second step high temperature trip for delta connected winding. h. Three (3) thermal devices shall be connected to provide rectifier negative second step high temperature trip for wye connected winding.
3. Reactors of sufficient size, or other equivalent means, shall be provided to maintain current balance between diodes in each phase polarity and hold individual diode currents within guaranteed capability under all load conditions up to and including 450 percent full load current with one fuse per phase polarity open. Unless they are completely interchangeable, the reactors or other devices shall be keyed or otherwise mechanically matched to insure that they are always inserted in the proper location. With any diode fuse open at any and all rated loads, the current in any other diode in the same phase polarity shall not exceed its pro rata share by an amount greater than 20 percent. The pro rata share is defined as the total rated phase polarity current divided by the number of paralleled diodes in that phase polarity. The use of matched diodes will not be acceptable for this purpose. The diodes shall have a minimum repetitive peak inverse rating of 5400 volt. Each individual silicon diode shall be hermetically sealed and mounted on adequate air cooled heat sink for maximum heat dissipation. The diode shall be as manufactured by IXYS.
4. The surge protective devices shall limit the repetitive reverse voltage surges, induced during lightning, faults and switching or by operation of trains across the diode to within 75 percent of the peak reverse voltage (PRV) rating of the diodes. Two sets of surge protectors shall be provided; one set each for ac and dc portion of the rectifier. The surge protectors rating shall be based on the calculated short circuit current of the system. The signal for failure of surge protector resulting in a blown fuse shall be wired to the PLC.
5. Each rectifier shall be able to withstand a transient surge voltage of 3000 volt crest and 1.5 X 40 microsecond full wave shape of either polarity applied to all rectifier terminals, including cathode terminal while operating at rated current and full rated temperature without operation of surge protective devices and shall be protected against surge voltages of at least 7500 volt crest. Surge diverter micro switches shall be wired to the PLC to indicate the failure to surge diverter devices.
1500 VOLT DC SILICON RECTIFIER 16603-7 DISTRICT 6. One (1) set of the interlock switches (Device 33) designed to de-energize the rectifier when the rectifier access door(s) are opened exposing "Live" parts. The interlock contacts shall be wired to the PLC to trip device 86 in the SCC .The switches shall be of the type which would keep the door open in the by-pass position without tripping device 86. This procedure is to be accomplished by turning the rectifier off first, then placing the switch in by-pass position, and after the rectifier door is opened; the rectifier should be able to be energized without tripping. The by-pass position will only be used during maintenance testing.
7. One (1) manual negative lead disconnecting switch, single pole, 2000 volt dc, 3000 ampere complete with a key interlock to prevent its operation in either direction unless the cathode breaker is open and to prevent the closing of the cathode breaker unless the negative switch is closed . The switch shall be operable by an insulated handle and mounted inside the rectifier enclosure. The switch shall be Eaton’s Pringle bolted switch. or approved equal, (Device 89N).
8. One (1) auxiliary control compartment isolated from primary portion of the rectifier by suitable barrier, including:
a. One (1) PLC , similar to Siemens SIMATIC S7-1200, Compact CPU b. One (1) single phase primary switched , ac to dc power supply similar to Phoenix Contact, Model Quint – PS 100 c. One (1) media converter similar to Siemens SCALANCE for transmitting fiber optical signals to the cathode breaker and to the SCC through fiber optic cables
9. One (1) set ground detection equipment, including adjustable relays, associated devices and semi-conductor rectifier type auxiliary dc power supply to furnish continuous supervision of insulation of rectifier enclosure from station ground, railway negative, and rectifier components. The positive potential 75 volt on the rectifier enclosure shall cause lockout and de-energization of the rectifier (Device 64C). Loss of insulation to ground or railway negative shall cause alarm (Device 64X). Ground detection equipment must function without damage on structure potential up to 2000 volt above ground potential. The alarm voltage and sensitivity shall be adjustable.
10. One (1) set of dc voltmeter 0-2000 volt dc scale
1.4.1 DESIGN CALCULATIONS
A. The Contractor shall submit at design conference complete design calculations, which shall include, but not be limited to, the following:
1500 VOLT DC SILICON RECTIFIER 16603-8 DISTRICT
1. Voltage Regulation Curve.
2. Power Factor - Load Curve.
3. Efficiency - Load Curve.
4. Harmonic Amplitude - Load Curve for 5th, 7th, 11th and 13th harmonics.
5. Commutation Reactance for X/R.
6. Momentary Peak and Sustained Short. Circuit Current.
PART-2 EXECUTION
2.1 INSTALLATION
A. See Section 16607 for the silicon rectifier replacement requirements.
2.2 TESTING
A. See Section 16608 and 16609 for the silicon rectifier testing requirements.
END OF SECTION
1500 VOLT DC SILICON RECTIFIER 16603-9 DISTRICT
SECTION 16604
1500 VOLT DC SWITCHGEAR
PART-1 GENERAL
1.1. SUMMARY
A. This section covers the requirements for designing, manufacturing, testing, delivering and commissioning indoor metal clad draw-out type 1500 volt dc switchgear at Madison Substation.
B. The switchgear will be supplied directly from one (1) 3000 kW rectifier and will serve as the supply for two (2) 1500 volt dc traction feeders as outlined hereinafter.
C. Contract plans show the location of the existing dc switchgear which is to be replaced under this Contract .The new dc switchgear shall be installed in the same location.
1.2. TECHNICAL REQUIREMENTS
A. The circuit breakers shall be 1500 volt dc, single pole, air break, draw-out type without negative disconnecting device and shall be of semi-high or high speed classification. The circuit breaker shall either be capable of withstanding a fault on the 1500 volt dc bus until ac relays switch off the rectifier, ac switchgear, or tripping a device which will protect the circuit breaker from damage under bus fault conditions. The operating mechanism shall be suitable for operation from the 130V volt dc supply and shall be electrically and mechanically trip free. The register type operations counter shall be mounted on the removable element.
B. The breaker tripping devices shall be furnished as required to provide reliable coordinated protection for the system. They shall have operating characteristic and adjustable ranges such as to trip for faults as outlined in Section 16601. Range of trip settings shall be as specified in detail Specifications and calibration scales shall be calibrated covering full range of adjustable setting with breaker in cubicle.
1. Circuit breakers shall be provided with an under-voltage trip device which is magnetically held by flux produced by control power current which mechanically trips the circuit breaker upon reduction of control power voltage to 70 volt dc.
1500 VOLT DC SWITCHGEAR 16604-1 DISTRICT 2. The mechanically latched dc circuit breakers which require control power for any part of an instantaneous over-current or reverse current trip arrangement shall be provided with a second over-current (reverse current) trip arrangement. The redundant instantaneous over-current (reverse current) trip arrangements shall independently sense magnitude of circuit breaker current and may each utilize control power for their tripping arrangement but they shall have their own separate electrical component and they shall not share any common electrical components with the first overcurrent and reverse current arrangement. One of the two tripping arrangements may utilize the under voltage trip device to effect circuit breaker tripping. The discriminating trip equipment will not be acceptable as the second tripping arrangement specified above. However, the discriminating trip equipment may utilize a current sensor and trip coil in common with either of the required redundant instantaneous over-current (reverse current) trip arrangements and may utilize the under-voltage trip device to effect circuit breaker tripping. The discriminating trip device will have a separate counter. Each of the redundant instantaneous over-current (reverse current) trip arrangement shall provide the overall coordination as outlined in Section 16601.
a. If a high speed trip box is furnished with the breaker, the coil and sensor monitoring circuits shall be furnished with the high speed trip box. High speed trip devices shall not utilize high voltage capacitors to store energy. These circuits must be approved by the District.
b. For the dc feeder circuit breakers the required second over-current tripping arrangement may be a solid state trip device, a current magnitude sensing non-polarized relay which shunt trips or under-voltage trips the circuit breaker, or other arrangement in conformance to these Specifications which is approved by the Engineer.
1). Tripping for the redundant over-current arrangement shall be adjustable in the range of 100 percent and 400 percent of the rating of the direct acting instantaneous series trip device specified for the feeder circuit breakers. Long time delay over-current tripping arrangement shall also be provided for dc feeder breakers, adjustable between 50 percent and 100 percent of feeder breaker rating and time delay adjustable range up to 3 minutes. 2). Time vs. Amps curves shall be supplied.
c. For the rectifier dc circuit breakers, the second reverse current tripping arrangement (required, unless it can be established that the reverse current trip is fail safe) may be a polarized solid state device, a current sensing polarized relay which shunt trips or under voltage trips the circuit breaker, or other arrangement in conformance to these Specifications which is approved by the District..
1500 VOLT DC SWITCHGEAR 16604-2 DISTRICT
3. The circuit breakers which are magnetically latched shall be latched by flux produced from control power and tripped by interaction between this flux and flux produced by circuit breaker primary current.
a. For the feeder dc circuit breakers, the magnitude of latch flux shall be such that at least 30,000 amperes of primary current are required to cause tripping shift of flux. The circuit breaker tripping arrangement shall not be responsive to rate of rise of primary current. The control power current for the magnetic latch shall not exceed 500 milliamperes. The dc feeder circuit breakers shall be provided with a second tripping arrangement which is easily adjustable to cause tripping between the limits of 100 percent and 400 percent of the rating of direct acting instantaneous series trip device specified for the breaker.. This second tripping arrangement may be a solid state trip device which electrically trips the circuit breaker, a current magnitude sensing non-polarized relay which shunt trips the circuit breaker, or other arrangement in conformance to these Specifications which is approved by the District.. The rate of rise discrimination equipment will not be acceptable as the second tripping arrangement specified above but may utilize a common trip coil. Long time delay overload trip devices shall be adjustable between 50 and 100 percent of breaker rating and must have time delay adjustable range up to 3 minutes. Time vs. current curves shall be supplied.
b. For the rectifier dc circuit breaker, the magnitude of latch flux shall be at least 200 percent of the minimum value required for successful closing of the circuit breaker without primary current. The circuit breaker tripping arrangement may be responsive to rate of rise of reverse current by use of inductive shunts or other means. The control power current for the magnetic latch shall not exceed 500 milliamperes
C. All dc circuit breakers shall have peak current, momentary current, short time current and short circuit current ratings required for operation in a substation with the number of rectifiers, of the size and type herein specified in operation. The specified short circuits are those applied to the load terminals of dc feeder circuit breaker and to the load terminals of the rectifiers.
1. The dc circuit breakers which limit peak value of short circuit current shall have short circuit current rating equal to or greater than the maximum available prospective peak short circuit current and maximum available rate of rise of short circuit current under the short circuit conditions specified. The short circuit rating of the circuit breaker with delayed tripping shall not be less than 100,000 amperes.
1500 VOLT DC SWITCHGEAR 16604-3 DISTRICT 2. The dc circuit breakers which do not limit peak value of short circuit current shall have short circuit current rating equal to or greater than the maximum available short circuit current during short circuit interruption under the short circuit conditions specified.
3. The dc rectifier circuit breakers shall have momentary current rating which is equal to or greater than the maximum available peak circuit breaker current with a short circuit at the load terminals of the circuit breaker.
4. The dc rectifier circuit breakers shall have short time current ability which is equal to or greater than the maximum RMS value of available circuit breaker current during a period of 250 milliseconds following application of short circuit to the load terminals of the circuit breaker. The short time current ability is defined as the designated limit of available RMS current which the circuit breaker can carry for a period of 250 milliseconds, without impairing the circuit breaker's ability to carry rated current without thermal runaway.
5. The dc feeder circuit breakers which do not limit the offset peak of short circuit current with fastest acting tripping arrangement provided shall have momentary current rating no less than the maximum peak value of maximum available short circuit current. The momentary current rating is defined as the peak value of current which the closed circuit breaker can withstand without impairing the circuit breaker's ability to meet its continuous current rating.
6. The dc feeder circuit breakers which limit peak value of short circuit current with fastest acting tripping arrangement provided shall have a momentary current rating no less than 125,000 amperes.
7. All dc circuit breakers shall be rated to successfully dissipate the maximum value of energy stored in system inductance during circuit breaker arcing under the short circuit conditions up to 9 miles distance and greater than 60msec. circuit time constant.
D. The circuit breaker close and trip circuit leads shall be wired through a plug-in type disconnect device mounted on the removable element arranged to isolate normal local and remote control, including the dc source, from the breaker mechanism and permit local breaker operation from a plug-in type control station while in normal operation and when removed from the cubicle. Breaker shall be arranged to trip automatically upon operation of any of its normal protective devices while under control of the plug-in type control station when the breaker is in the normal operate position in the cubicle. The plug-in control station shall be separately fused from the dc control bus.
1500 VOLT DC SWITCHGEAR 16604-4 DISTRICT E. The circuit breakers shall be controlled by an integrated Siemens Sitras Pro DC Protective Unit and Controller or approved equal product. In both local and remote control modes all operational close and trip operations shall be issued through the SITRAS system.
F. A local / Remote selector switch shall be provided to operate local and remote modes.
G. The cathode breaker can be closed locally only in the test position by the local control switch. When the breaker is in the connected position and the selector switch in the remote position , it can be closed locally through control switch or through HMI and remotely either by the master switch in the Station Control Cabinet or through the supervisory only after the closing of the 34.5 kV OCB.
H. The feeder breakers can be closed locally in the test position by the local control switch. When the breaker in the connected position and the selector switch in the remote position, it can be closed locally through HMI or control switch and remotely through HMI at SCC or through the supervisory subsequent to the load measuring operation.
I. The LED indicating lights shall be provided for breaker open position, breaker closed position, breaker trip by fault, selector switch in local position and selector switch in remote position.
J. The normal control equipment and circuits, whether mounted on the compartment door or other portion of the stationary unit structure, must be physically accessible and so connected as to permit testing and/or maintenance of relays and control circuitry in de-energized condition while the circuit breaker is in the normal operate position and under the control of the plug-in type control station.
K. A DC test cabinet shall be provided to test the breakers. The test cabinet shall have a momentary contact control switch with spring return to normal for opening and closing the breaker in test position with red and green indicating lights with a plug in control unit An extension cord minimum of twenty five feet long with receptacle at each end for connection to plug in unit at the breaker and the dc test cabinet shall be provided. The wiring of the receptacle shall be individually insulated using insulating sleeves at pins to prevent shorts
L. All combination fuse disconnects shall be fully enclosed and mounted in the rear cubicles. The fuses shall be installed in enclosed fuse blocks and shall be draw-out or removable type.
M. Hinged doors shall be provided at front and rear of each circuit breaker unit, suitable for mounting Sitras Pro Human Machine Interface (HMI), meters, switches and indicating lights. Doors shall be formed of sheet steel and
1500 VOLT DC SWITCHGEAR 16604-5 DISTRICT shall be properly reinforced against distortions by suitable flanges and stiffening members. Hinges shall be heavy duty of a type approved by the Engineer. Full height doors shall be securely fastened in the closed position with a minimum of three latches and easily opened without the use of tools. For doors less than the full height of the equipment, a minimum of two latches will be acceptable. Doors shall be provided with 2 stop positions, 90 degrees and 110 degrees to hold them securely in the open position. With the front door of any compartment in the 90 degree open position it shall not prevent the adjacent compartment door from being opened and its breaker completely removed from its housing. Door handles shall be lockable with a key.
N. Current shunts, Sitras Pro DC buffer amplifier, Sitras Pro Central unit and other such equipment shall be accessible for testing and maintenance with the bus energized. The buffer amplifier shall be separately fused and mounted in rear cubicles.
O. Positive-acting mechanical and electrical interlocking system shall be provided so that a breaker in the closed position cannot be disconnected from or connected to the bus. The switchgear shall have the capability of racking the breakers into the connected position with door closed. Breaker must be arranged so personnel are guarded from contact with energized parts while racking the circuit breaker into or out of the connect position. Structurally reliable automatic shutters shall be provided to prevent accidental personnel contact with current-carrying parts when the removable element is in the test, disconnect, or completely withdrawn position. An engraved plastic laminated tag with white background and 1 inch high red lettering labeled "DANGER-DO NOT OPEN" as well as a warning sign as required by NFPA-70E shall be installed above each shutter. The secondary disconnect, test and wiring within the cubicle shall be accessible from the front of the cubicle.
1. A centering device may be required for the racking handle, if the handle has difficulty in engaging the racking mechanism.
P. Positive acting mechanical and electrical interlocking system shall be provided so that with a breaker in the connected position, the breaker cannot be closed with the door open and the door cannot be opened with the circuit breaker closed.
Q. Bus shall be copper, rated 4,000 ampere capacity, and shall be supported and braced to withstand short circuit stresses at least as great as those for which the breakers are designed. The contact surfaces of bolted joints in the bus and main connections shall be silver-plated.
R. The floor area for installation of the dc switchgear has been extended 3 feet past switchgear and 6 feet in front of the switchgear and has been prepared from plastic resin cement, Amazite, 3/8 inch thick, to insulate switchgear
1500 VOLT DC SWITCHGEAR 16604-6 DISTRICT structure from building structure. The switchgear shall be secured to the insulated epoxy floor with approved insulated anchors. The Contractor shall make provisions and supply suitable materials for insulation of the individual switchgear cubicles from each other, and from the rectifiers.
S. The switchgear shall be arranged for top and bottom entrance of all incoming power circuits on the feeder breakers. All control circuits shall also enter from the top of switchgear. Two (2) 2000 kcmil solderless removable type terminal lugs (Penn Union type VVL, or approved equal) shall be provided for each feeder circuit and two (2) 2000 kcmil solderless removable type terminal lugs for the rectifier breaker circuit. Provisions shall be made to permit a individual quick disconnection and isolation of cables from load studs in stationary unit during emergencies by providing a removable bus bar between the stationary load stud and cable lug. This requires access to the connections through an easily opened hinged panel and sturdy support of the cable close to the connection point. The cable supports shall be provided so that all cables within each cubicle are self-supporting.
T. One (1) 125 volt dc control bus shall be provided integral with the assembly. Supply shall be factory wired to the suitable screw type terminal block for top connection to #6 AWG cable.
U. A single conductor, 2kV #6 AWG insulated cable shall be provided integral with the assembly. It shall be used as the dc insulated negative bus.
V. Circuit breaker control circuit in each cubicle shall be separately fused from the dc control bus. Fuse holders shall be ultra safe type similar to Ferraz Shawmut fuse holder, where energized parts are not exposed until fuse is disconnected from the circuit. Fuses shall be rated 2000 volt dc. Switches rated 2000 volt dc shall also be provided to disconnect each breaker control circuit. In addition, each circuit breaker close circuit shall be protected by a secondary set of fuses to prevent opening of main fuses (and loss of trip ability) on close-circuit faults. Fuse sizes shall be of appropriate current rating with 20,000 ampere dc (minimum) interrupting rating. All necessary fuses shall be furnished with the equipment.
W. All interconnecting cables between the cubicles carrying control voltage shall be installed in a closed and sealed cable trough in order to isolate a cubicle while it is being worked on, and still allow the power to pass through to the adjacent cubicles.
X. The secondary and control wiring in each unit including that on removable element shall be ICEA Standard Type GRY SIS, No. 12 AWG or larger standard switchboard wire, insulated for 2000 volt dc service or similar to BOSTRAIL AAR S-501 car wire, 2kV, extra flexible, XLPO insulation, soft annealed copper stranded conductor, as manufactured by DRAKA USA.
1500 VOLT DC SWITCHGEAR 16604-7 DISTRICT Y. Circuits requiring external connections shall be factory-wired to screw-type terminal blocks for connections to field wiring. Terminal blocks shall be General Electric Company, type EB-5, (Weidermueller Type SAK, Marathon Series 1500) or approved equal. All wiring terminations to be Ring Style compression type, and shall be accessible from the front of the cubicle.
Z. All metal work shall be thoroughly cleaned, treated against rust and corrosion, primed, bonderized and finished with 2 coats of ANSI-61 light gray color by powder coat painting process. 1 quart of matching touch-up paint shall be furnished.
1.3. DETAIL EQUIPMENT
A. The equipment to be furnished shall be 18” wide for each breaker cubicle and arranged as shown on the Contract Drawings and shall be in accordance with the following:.
B. The rectifier breaker position shall include but not limited to:
1. One (1) metal enclosed stationary unit with 1500 volt dc bus.
2. One (1), air circuit breaker, high speed, draw out single pole, 1500 volt dc, 4000 amp direct acting reverse current trip , direct acting under voltage trip, reverse current auxiliary switch 32X, shunt trip coil rated 125 volt dc. 125 volt dc control; control switch, device 72 CS: local remote permissive switch, device 69; green and red breaker status lights and Kirk key interlock with 11 or 12 stage auxiliary switch. The instantaneous reverse current trip device, set at minimum value consistent with overall coordination. The breaker shall be similar SECHERON UR series or approved equal.
3. One (1) 6000 ampere, 50 millivolt shunt.
4. One (1) dc Buffer Amplifier, voltage divider to transmit current and voltage values output to Sitras PRO central unit via fiber optic cable and analog output for connection to voltmeter and ammeter, Similar to Sitras PRO BA or approved equal. The buffer amplifier shall be fused separately located as close as possible to the shunt.
5. One DC ammeter, 4-1/2” square, connected through a shunt, rated 0-10 volt input, 0-8,000 amp full scale value, switchboard type
6. One DC voltmeter 4-1/2” square, connected through a shunt rated 0-10 volt input, 0-2000 volt full scale value, switchboard type
1500 VOLT DC SWITCHGEAR 16604-8 DISTRICT 7. One (1) removable element position switch with required interchangeable stages.
8. One (1) permissive control switch (REMOTE-LOCAL), REMOTE position at 12 o'clock, LOCAL position clock-wise (Device 69).
9. One (1) control switch, with red and green indicating lamps (Close Right-Trip Left).
10. One (1) reverse current trip (Device 32).
11. One (1) second reverse current trip.
12. One (1) set hot structure/ground detection equipment, to provide continuous supervision of switchgear enclosure from the ground rail negative and live switchgear components. The relay shall give an alarm through an output contact when the switchgear enclosure gets grounded through a breach in insulation. The ground relay shall trip the lockout relay through an output contact when a leakage or fault occurs between the bus and the enclosure (hot). The set points for ground structure and hot structure trip shall be adjustable. Test buttons for both ground structure annunciation and hot structure trip shall be provided on the front panel. The structural ground relay shall be rated for 125 volt dc, Device 64.
13. One (1) Sitras PRO central unit S24-240 volt dc, 110-240 volt ac with PROFIBUS DP/PROFINET IO communication option, control option, integrated programmable logic controller, and fiber optic cable. or approved equal.
14. One (1) Sitras PRO Human Machine Interface (HMI) including interface fiber optic cable or approved equal.
C. Each of the two dc automatic re-closing feeder position shall include, but not limited to:
1. One (1) metal enclosed stationary unit with 1500 volt dc bus.
2. One (1), air circuit breaker, draw out single pole, 1500 volt dc, 4000 amp direct acting overcurrent device rated 4000A-16000A. Long time delay over-current tripping arrangement shall also be provided, adjustable between 50 to 200% of feeder breaker rating, under voltage trip, shunt trip coil rated 125 volt dc, close solenoid rated 125 volt dc, closing control rated 125 volt dc, with a 12 stage auxiliary switch, connector for remote circuit operation; control switch, device 72 CS: local remote permissive switch, device 69; green and red breaker status lights The breaker shall be similar SECHERON UR series or approved equal
1500 VOLT DC SWITCHGEAR 16604-9 DISTRICT 3. One (1) 4000 ampere, 50 millivolt shunt.
4. One (1) dc Buffer Amplifier, voltage divider to transmit current and voltage values output to Sitras PRO central unit via fiber optic cable and analog output for connection to voltmeter and ammeter, Similar Sitra PRO BA or approved equal
5. .The buffer amplifier shall be fused separately located as close as possible to the shunt.
6. One bi directional DC ammeter, 4-1/2” square, through a shunt rated -10 0-10 volt input,8000- 0-8,000 amp full scale value, switchboard type
7. One DC voltmeter 4-1/2” square, through a shunt rated 0-10 volt input, 0- 2000 volt full scale value, switchboard type
8. One (1) removable element position switch with required interchangeable stages.
9. One (1) permissive control switch (REMOTE-LOCAL), REMOTE position at 12 o'clock, LOCAL position clock-wise (Device 69).
10. One (1) control switch, with red and green indicating lamps (Close Right-Trip Left).
11. One (1) Sitras PRO central unit S24-240 volt dc, 110-240 volt ac with PROFIBUS DP/PROFINET IO communication option, control option, integrated programmable logic controller, and fiber optic cable. Or approved equal.
12. One (1) Sitras PRO Human Machine Interface (HMI) including interface fiber optic cable or approved equal.
1.4. QUANTITY OF EQUIPMENT REQUIRED
A. Each of the items listed below shall be furnished and delivered at the substation site in quantity and type as listed hereinafter. Each type of equipment shall be equipped as detailed in Paragraph 1.3 of this section. The switchgear line-up shall include the switchgear positions of the types listed below and shall be incorporated into one continuous enclosure made up of compartments as required and shown on the Drawings:
1. Madison Substation:
a. Item 1. One (1) - 4,000 ampere rectifier breaker positions.
1500 VOLT DC SWITCHGEAR 16604-10 DISTRICT b. Item 2. Two (2) - 4,000 ampere automatic reclosing feeder breaker positions.
c. Item 3. One (1) - Spare 4,000 ampere air circuit breaker removable element. The breaker element shall not be incorporated into the dc switchgear lineup but shall be furnished loose.
d. Item 4. One (1) - Set of accessories.
B. Certification of ratings
1. The Manufacturer must furnish certified evidence of prior tests that the proposed switchgear meets these specifications. In the absence of such test data, the DISTRICT reserves the right to require a factory test demonstration of said equipment.
PART-2 EXECUTION
2.1 INSTALLATION
A. See Section 16607 for the dc switchgear replacement requirements.
2.2 TESTING
A. See Section 16608 for the dc switchgear testing requirements.
END OF SECTION
1500 VOLT DC SWITCHGEAR 16604-11 DISTRICT
SECTION 16605
ANODE BUS DUCT
PART 1 GENERAL.
1.1 SUMMARY
A. AC anode bus duct shall be furnished and installed for connecting the rectifier transformer with the rectifier. Contract Plans indicate the existing arrangement of the cable bus ducts which are to be replaced under this Contract. The new bus ducts shall follow the same route. At the Design Conference, Contractor shall bring to Engineers' attention for any deviations he plans to make from the arrangement shown.
B. A single bus duct assembly containing the conductors from both of the three phase secondary windings of the transformer shall be provided.
1.2 TECHNICAL REQUIREMENTS
A. Metal Enclosure
1. The metal enclosed anode bus duct shall be water tight, non- ventilated for outdoor portion and ventilated for indoor potion. The enclosure shall be fabricated from corrosion resistant high strength aluminum. Removable covers shall be provided to allow access to bolted bus connections and insulators for cleaning and inspection. Removable covers shall be secured with bolts to the frame. The outdoor covers shall be lipped at both ends.
2. All metalwork shall be carefully finished to remove sharp edges and burrs. All surfaces shall be thoroughly cleaned and treated with rust inhibiting phosphatized coating prior to painting, then finished with two coats of semi-gloss ANSI-60 light gray color by powder coating process.
B. Copper Bus Bars
1. Bus bars shall be of high conductivity rectangular copper with round edges finished to required size by cold rolling or drawing. Bus bars shall have uniform shape and dimensions, free from defects in material and workmanship. Bus bars shall be
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individually insulated, properly supported and braced to each other and to the enclosure with approved, high quality, high strength, non-tracking insulators to withstand short circuit stresses to be encountered in use. All bus taps and connections shall be tightly bolted. Contact surfaces of bolted joints shall be factory silver plated.
2. Bus bars shall be rated for current and voltages specified for individual applications. They shall be designed for continuous operation at the rated load conditions.
3. The temperature rise of bus bars at the hottest spot for the specified duty shall not exceed 65 degrees C over an ambient of 40 degrees C, thus limiting the maximum operating temperature of bus conductor to 105 degrees C.
C. Lengths and Fittings
1. The bus duct containing two phases, shall be supplied complete with connection flanges, taps, elbows, insulated housing sections, offsets, splicing plates, terminal connectors, and associated accessories. Bus duct assemblies shall be furnished in accordance with the arrangement, dimensions and details depicted on final, Engineer's approved shop drawings.
2. The Contractor shall field measure the length, bends and the routing of the existing anode bus duct in order to adhere to same routing for the new bus duct. The shipping sections shall be pre- assembled in the factory so that minimum installation is required at the site. It is the responsibility of the Contractor to furnish the equipment as specified here so that it can be installed as a system without any modifications or requiring additional materials and labor at site, except to carry out the manufacturer's installation instructions.
D. Hardware and Supports
1. All hardware required making the field connections between sections and terminations to the equipment shall be furnished in sufficient quantity.
2. Suitable support of bus enclosure shall be provided as may be required to ensure rigid structure and workman like installation of the system. Support of the bus duct shall be designed and coordinated with the manufacturer of the rectifier transformer and
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silicon rectifier so there is no need for any external additional supports connected to any portion of the substation building.
E. Expansion Joints
1. Expansion joints shall be provided by the Contractor wherever required for proper operation of the equipment.
F Induced Heating
1. Bus ducts are intended for operation at high value of currents. The design of bus ducts shall be such as to minimize the induced magnetic heating and induced circulating currents in the metallic enclosure of the bus duct, adjacent enclosures and supporting structures.
G. Insulated Sections
1. Insulated sections of bus duct housing shall be provided to isolate rectifier enclosure from bus duct enclosures unit. The material and detailed design of insulated sections are subject to Engineer's approval.
H. 1500 Volt AC Anode Bus Ducts
1. The 1500 volt ac anode bus ducts shall meet all the applicable requirements of ANSI C37.20 and meet the following additional requirements:
a. Rated maximum voltage: 1585 volt, maximum 1500 volts, nominal
b. Rated impulse level 45 kV BIL (1.5x40 microseconds)
2. Buses shall be rated to carry continuously the current of the rectifier transformer and rectifier operated at 160 percent of rated full load. The temperature of the bus bars shall not exceed maximum limit of 105 degrees C under these loading conditions. The bus duct assembly shall be compatible in design and construction with the provisions made at the transformer and rectifier and shall operate as an integral unit when assembled.
3. The outdoor section of the bus duct shall be provided with thermostatically controlled space heaters suitable for operation on 120 volt, single phase, ac supply. Space heater terminals shall be brought to the same terminal block where connections are
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made to the transformer terminal box heaters. No separate AC supply shall be provided for the outdoors bus duct heaters.
4. A weatherproof opening shall be provided at the rectifier transformer end of the bus duct for access to bus duct-to- transformer connections.
5. Weatherproof wall seals shall be provided both inside and outside of duct for each run through substation wall. Seal shall be of noncombustible material and shall prevent smoke and water from entering the building. The frame of the bus duct shall be coordinated with the existing wall opening.
6. Connection sections for termination of the bus enclosure at rectifier shall be of the insulated type using fiberglass or Micarta boxed portion in vertical section providing minimum six inch clearance between bus metal enclosure and nearest metal on rectifiers. Alternate arrangement is insulated section in horizontal providing three feet clearance between bus metal enclosure and nearest metal connection to rectifier.
7. Knee braces or other suitable support of bus enclosure shall be provided as may be required to ensure rigid structure and workmanlike installation of the system.
8. The bus ducts, because of the inherent characteristics of the circuit, remain at a dc potential relative to the bus enclosure while energized. Construction of the bus duct and the materials used shall be proper for this type of service.
9. At both transformer and rectifier ends, flexible bus terminations shall be provided. The termination details shall be fully coordinated with the rectifier transformer and the rectifier.
10. A ground pad shall be provided on the bus enclosure for connection to the station ground
1.3 QUANTITY OF EQUIPMENT REQUIRED
A. One (1) set of ac anode bus duct assembly containing two (2) 3- phases,1500 volt ac anode buses for connection between transformer secondary and rectifier input terminals, complete with equipment flange at the transformer, insulated section and equipment flange at the
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rectifier, connectors and associated fittings, etc, to provide a complete installation.
PART-2 EXECUTION
2.1 INSTALLATION
A. See Section 16607 for the anode bus duct replacement requirements.
2.2 TESTING
A. See Section 16608 and 16609 for the anode bus duct testing requirements
END OF SECTION
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SECTION 16606
STATION CONTROL CABINET
PART 1 GENERAL.
1.1 SUMMARY
A. This section specifies the requirements of furnishing and installing a standalone freestanding Station Control Cabinet which will house the protection, control, measurement and automation of the entire traction power equipment integrated into a single unit through microprocessor based system, similar to Siemens Sitras Pro DC Protective Unit integrated with Programmable Logic Controller, Profinet I O Protocol and interface with fiber optic cables or approved equal products
B. The Station Control Cabinet shall be installed in the same location where AC Relay panel is now located.
1.2 MECHANICAL REQUIREMENTS
A. Metal Enclosure
1. The metal enclosed Station Control Cabinet shall consist of rigid self-supporting, floor mounted, standard welded and bolted type structural steel, 11 gauge enclosure. The added rigidity shall be provided using steel members’ gussets in all corners of the structure.
2. Hinged doors shall be provided at front and rear of the cabinet, suitable for mounting Sitras Pro Human Machine Interface (HMI), Siitras Pro Central Unit (PLC), meters, switches and indicating lights. Doors shall be formed of sheet steel and shall be properly reinforced against distortions by suitable flanges and stiffening members. Hinges shall be heavy duty of a type approved by the Engineer. Full height doors shall be securely fastened in the closed position with a minimum of three latches and easily opened without the use of tools. For+ doors less than the full height of the equipment, a minimum of two latches will be acceptable. Doors shall be provided with 2 stop positions, 90 degrees and 110 degrees to hold them securely in the open position. Door handles shall be lockable with a key.
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3. All metalwork shall be carefully finished to remove sharp edges and burrs. All surfaces shall be thoroughly cleaned and treated with rust inhibiting phosphatized coating prior to painting, then finished with two coats of semi-gloss ANSI-60 light gray color by powder coating process.
1.2 TECHNICAL REQUIREMENTS
A. Sitras Pro Central Unit shall have the following characteristics:
1. A 32 bit ‘Microprocessor system
2. Fully digitized measurement processing and control for operating the dc breakers and rectifier based on the operational procedure described herein and shown on the contract drawings.
3. Provide complete electrical isolation and noise immunity of the internal circuitry from the measuring, control and supply circuits.
4. Communication shall be provided through either RS 485, Ethernet or fiber optic cables with protocols of profibus or profinet IO
5. The following protection shall be provided.
a. Instantaneous and time overcurrent b. Over and under voltage. c. Line voltage monitoring. d. Circuit breaker failure. e. Impedance. f. Rate of rise. g. Thermal overload.
B. Operator control and monitoring system shall be provided through:
1. Sitras Pro HMI with the following characteristics:
a, Monochrome graphical interface. b. Ergonomic design c. Large key pad. d. Functional keys and LEDs for functional assignment and text label
2. Sitras Pro SW with the following features:
a. Context menus
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b. Drop down lists c. Display of limits of values. d. Recovery function e. Print function
3. Manual switches and indicating lights
1.3 DETAIL EQUIPMENT;
A. Following devices shall be provided but not limited to.
1. One (1) Central Processing Unit, with 2 interface Ethernet Profinet, with 2 port switch and memory cards, similar to Siemens CPU 315-2, Simatics S7-300 PN/DP, or approved equal, Device PLC.
2. Two (2) Signal Digital Input modules, 24 volts dc, each with 32 optically isolated inputs, similar to Siemens, SM 321, Simatics S7-300, or approved equal, Devices P1 and P2
3. One (1) Signal Digital output module, 24 volts dc, with 32 optically isolated outputs, similar to Siemens SM 322, Simatics S7-300, or approved equal, Device P3
4. Two (2) Digital relay output modules, 24 volts dc, each with 16 optically isolated outputs, similar to Siemens SM 322, Simatics S7-300, or approved equal, Devices P4 and P5
5. One (1) Ethernet switch with 6 optical connections with RJ45 port, similar to Siemens SCALANCE X240-2, or approved equal, Device MC1
6. One (1) digital voltage monitoring relay, with adjustable input range 1— 275 volts AC, with time delay 0.1 to 20 seconds with 2 contacts, similar to Siemens 3UG4 or approved equal, device AGA.
7. One (1) Human Machine Interface, 12” wide screen, with touch operation for control and monitoring, keypad, monochrome graphical screen, LEDs and functional keys, similar to Siemens Simatic TP 1200 or approved equal, Device HMI
8. One (1) microprocessor relay overcurrent protection for 34.5 kV OCB. Phase, negative sequence, residual ground and neutral overcurrent protection in a package with a standard relay configuration of 3 outputs and 2 inputs, including an option to provide an additional card with three digital inputs and four digital outputs and one analog output of a range of
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4-20 milliamp signal for an input to the ac ammeter, similar to Schweitzer SEL 751A or approved equal, device SEL -751A.
9. One (1) master control switch for the startup circuit of the rectifier, spring return to normal, trip-close- lockout operation, pistol grip handle, similar to Electroswitch2458 or approved equal, device CS.
10. One (1) manual reset lockout relay to trip rectifier under subnormal conditions listed in Section 16601, 24 volt dc with 8NO and 8NC contacts, similar to Electroswitch Series 24 or approved equal, device 86.
11. One (1) conditional self-reset lockout relay to trip rectifier under abnormal resettable conditions listed in Section 16601, 24 volt dc with six convertible output contacts similar to GE HFA relay or approved equal, device 86X.
12. Monitoring of alarm conditions listed in Section 16601
13. One (1) indicating ammeter input 4-20 milliamp signal, 0-150 ampere AC analog scale.
14. One (1) AC ammeter switch. 3 phase with “OFF” position, make before break contacts round knurled handle similar to Electroswitch 2410C or approved equal.
15. One (1) AC indicating voltmeter, 125 volt ac input, 300:1 PT ratio, 0-45 kilovolts AC analog scale.
16. One (1) AC voltmeter switch, 3 phase, phase to phase , round knurled handle, similar to Electroswitch 2404 or approved equal
17. Three (3) Test switches for connecting CT, PT circuits and output contacts of relay SEL 751A.
18. Miscellaneous devices such as power supply, terminal blocks and auxiliary relays etc. as required.
PART-2 EXECUTION
2.1 INSTALLATION
A. See Section 16607 for the station control cabinet installation requirements.
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2.2 TESTING
A. See Section 16608 for the station control cabinet testing requirements.
END OF SECTION
STATION CONTROL CABINET 16606-5
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SECTION 16607
TRACTION POWER EQUIPMENT REMOVAL AND INSTALLATION
PART - 1 GENERAL
1.1. SUMMARY
A. This section covers the requirements for replacement of traction power equipment at the location shown on Contract Plans.
B. The Contractor should note that the replacement work involves working in close proximity with the energized and operating equipment. Therefore, the Contractor shall use utmost safety measure in performing the work.
C. The Contractor shall take every precaution in disconnecting, removing and disposing as well as in handling, setting, aligning and assembling the equipment to avoid distortion of frame. The Contractor shall thoroughly familiarize himself, with the manufacturer's instructions before attempting to handle, install and operate the equipment. Contractor shall ensure that all personnel working with the equipment fully understands the operation of the various components to avoid misoperation, damage to equipment and possible personal injury.
D The Contractor shall make all equipment assembly connections between shipping units, including all bolted connections to mechanically assemble the units and installation of all splice plates, connecting bases and throats.
E. Basic routing of conduits and cables for control and auxiliary circuits for interconnecting equipment and devices are shown on Contract Plans. However, Contractor shall determine the specific application of these cables to satisfy all control, indication, supervisory and auxiliary functions specified. Installation of cables shall be in accordance with the Engineer's approved cable schedule and the Contract Drawings.
2.1. REPLACEMENT WORK
A. Removal of Existing Traction Power Equipment,
1. Prior to dismantling and removal of transformer, rectifier, anode bus, dc switchgear, and ac relay panel, the Contractor shall verify that the District has disconnected and locked out the 34.5 kV incoming power to the transformer. Removal of power to the transformer will be accomplished by opening and locking out the oil circuit breaker and its disconnect switches in the NIPSCO switch yard as well as 34.5 kV disconnect switch adjacent to the transformer in the NICTD yard. The contractor shall also make sure that CTs of the OCB
TRACTION POWER EQUIPMENT REMOVAL AND INSTALLATION 16607-1 DISTRICT
connected to the relays are jumpered to the ground. The control power associated with the existing mechanical relays shall also be disconnected.
2. The contractor shall open the 1500 volt disconnect switches for the feeder cables mounted on inside and outside of the substation wall.
3. Disconnect negative return cables from the negative bus connected to the impedance bonds. After removing the terminal lugs tape the ends of these cables and leave in place for reconnection.
4. The Contractor shall make sure that 1500 volt dc, all controls, SCADA and auxiliary power to these equipment are disconnected.
5. After the traction power equipment is completely de-energized, auxiliary power, controls and SCADA wiring disconnected, the Contractor shall take field measurements and observe the method and type of terminations of the following:
a 34.5 kV cable termination at both ends.
b. Anode bus duct termination at the transformer and the rectifier.
c. 1500 volt dc positive and negative cables at the rectifier, dc switchgear and at the negative bus.
6 These measurements and observations will be needed for the Contractor to provide right type and size of throat, flanges and bushings, terminators similar to the ones used in the existing equipment.
7 Disconnect and dispose 34.5 kV cables from the disconnect switches to the transformer and all control, auxiliary power and SCADA cables connected to the transformer. All indoor and outdoor power and control cables shall be removed and disposed of.
8. Disconnect the anode bus duct- at both ends.
9. Drain and dispose the oil of the transformer.
10. Disconnect and dispose 5kV positive cables from the rectifier to the dc switchgear and 5kV negative cables from the rectifier to the negative bus as well as all external control and auxiliary power wiring connected to the rectifier.
11. Disconnect and dispose 5kV dc feeder cables from the dc switchgear cubicles to the indoor feeder disconnect switches as well as all external control and auxiliary power wiring connected to the dc switchgear
TRACTION POWER EQUIPMENT REMOVAL AND INSTALLATION 16607-2 DISTRICT
12. Disconnect and dispose control cable numbers 32,33,34 and 85 connected to the ac relay panel.
13. Disconnect but do not dispose cables 35, 36, 37 and 38 connected to the ac relay panel. The other ends of these cables are terminated at NIPSCO terminal cabinet. Tape the ends of these cables and leave in place for connection to the Station Control Cabinet which will be installed at the same location where ac relay panel is located.
14. After dismantling, the contractor shall deliver to NICTD in Michigan City or dispose as directed by District the following traction power equipment.
a. Transformer.
b. Rectifier.
c. Anode bus duct.
d, DC switchgear.
e. AC Relay Panel
2.2. INSTALLATION OF TRACTION POWER EQUIPMENT.
A. Rectifier Transformer
1. Prior to installation of the new dry type transformer on existing transformer pad, the existing yard stone and the soil around the transformer pad area shall be removed and replaced. The transformer pad shall be thoroughly clean to remove the oil spill and stains. The transformer pad shall be modified, if needed, to accommodate the installation of the new transformer.
2. Connect # 4 ACSR bare wires between high voltage insulators and lightning arresters of the transformer and the terminal pads of the 34.5 kV disconnect switch.
3. Low voltage terminals of the transformer shall be connected to the anode bus duct.
4. For grounding the transformer, the Contractor shall install two ground cables, connect these ground cables to the existing ground grid and
TRACTION POWER EQUIPMENT REMOVAL AND INSTALLATION 16607-3 DISTRICT
stub them at the transformer foundations. The Contractor shall then connect the stubbed cables to the transformer ground pads.
5. The Contractor shall furnish and install new auxiliary power and control cables in existing conduits, ducts and/or trays necessary for the operation of the transformer as shown in the drawings and as described in the specifications.
B. Rectifiers and Accessories
1. Prior to installation of the rectifier, the existing three feet wide insulating mat around the side and rear of the rectifier position shall be carefully removed. The insulating floor under the rectifier shall be scraped, and removed. The floor area shall be thoroughly scrubbed, leveled and cleaned.
2. A new ¼ inch thick track resistant, flame retardant, NEMA grade GPO- 3 polyester resin, fiberglass reinforcing insulating red color sheet shall be installed under the floor area of the rectifier. The sheet shall extend 3 inches all around beyond the floor area of the rectifier. The insulating sheet shall be Polyply L-50 as manufactured by Polyply Composite Inc or approved equal. The insulating sheet shall be installed as per manufacturer’s recommendations.
3. After the rectifier is fully assembled and completely installed in accordance with Engineer's approved manufacturer's drawings, the floor area, three feet around the side and rear of the rectifier shall be covered with a layer rubber insulating matting to insulate the rectifier enclosure from the building.
4. The insulating matting shall comply with the latest revision of ASTM standard D178-77 and shall be as follows:
a. Type II, Made of high grade rubber compounds of material or synthetic origin.
b. Class 2, 40 kV dc proof test voltage. 17 kV ac proof test voltage
c. Thickness: 1/4 inch with corrugated surface design.
d. Color Black
5. The matting shall be permanently marked at no more than 3 foot intervals with the name of the manufacturer, ASTM D178 type and class. The matting shall be supplied in sufficient lengths to allow 6 inch
TRACTION POWER EQUIPMENT REMOVAL AND INSTALLATION 16607-4 DISTRICT
overlap at the edges. Rubber insulating matting shall be manufactured by W.H.Salisbury and Company or approved equal.
6. After completion of the installation of the matting, the rectifier enclosure shall be completely insulated from the building structure.
7. Rectifier units shall be connected to the rectifier transformer via ac anode bus duct and to the rectifier dc main circuit breaker in the dc switchgear through the external cables. Rectifier negative terminals shall be connected to the negative bus in the rectifier, by means of cables.
8. The Contractor shall terminate the negative return cables from the rectifier to the station negative bus.
9. Replace in kind four (4) existing 750 kcmil negative return cables from the station negative bus to the impedance bonds and terminate these at both ends with new 750 kcmil solderless removable terminal lugs..
10. The Contractor shall furnish and install new control cables in existing conduits, ducts and/or trays necessary for the operation of the rectifier as shown in the drawings and as described in the specifications
C. DC Switchgear
1. DC switchgear shall be fully assembled and completely installed in accordance with Engineer's approved manufacturer's drawings at location shown on Contract Plans. All dc switchgear units shall be insulated from each other by means of minimum of 1/4" thick insulated material.
2. The Amazite insulated floor under and around the switchgear shall not be scraped or removed. Care shall be taken that the insulated floor area is not scraped or otherwise damaged during installation. Insulated anchors shall be furnished and installed in the floor slab in accordance with manufacturer's instructions. After completion of the installation the dc switchgear structure shall be completely insulated from the building structure.
3. The switchgear units shall be assembled in such a manner as to ensure proper leveling and alignment between the various shipping groups and for proper placement of all the conduits that are required for the equipment interconnection. Contractor shall make all necessary electrical connections between the units of the assembly, including the joints in the 1500 volt positive bus.
TRACTION POWER EQUIPMENT REMOVAL AND INSTALLATION 16607-5 DISTRICT
4. The rectifier main circuit breaker unit shall be connected to the rectifier by means of 2-1/c 2000 kcmil, 5 kV cables as shown on the Contract Drawings. The cables shall be terminated with 2000 kcmil solderless removable type terminal lugs.
5. Each feeder breaker unit shall be connected to the indoor disconnect switch by means of 2-1/c-2000 kcmil, 5 kV cables The cables shall be terminated with 2000 kcmil solderless removable type terminal lugs at the breaker end and with NEMA-4 hole pad at the disconnect switch end.
6. After completion of the installation, the Contractor shall ensure that all doors operate freely and the breaker removable elements can be moved into and removed from the housings without encountering the change of elevation from within the housing to the floor. Contractor shall correct all misalignments to the satisfaction of the Engineer.
7. The Contractor shall furnish and install new control cables in existing conduits, ducts and/or trays necessary for the operation of the dc switchgear as shown in the drawings and as described in the specifications.
D. Anode Bus Duct
1. The anode bus duct interconnecting rectifier transformer to the rectifier assemblies shall be fully assembled and completely installed in accordance with Engineer's approved manufacturer's drawings and as shown on Contract Drawings.
2. The Contractor shall be responsible to verify equipment lineup to assure perfect fit of the interconnecting equipment. This applies to the anode bus wall opening, bus connections to the transformer and the rectifier, and the height of the transformer concrete pad. The existing wall opening may need to be widened or reduced depending upon the size of the anode bus.
3. Bus duct shall be provided with suitable mounting hangers supported from the ceiling, or as directed by the Engineer. Contractor shall furnish and install all trapezes, brackets, rods, clamps, suspension fittings and miscellaneous steel to provide a complete, firm and rigid support system for the bus ducts under all operating conditions and during short circuits. Supports shall be designed and installed in a manner to minimize induced circulating currents and induced magnetic heating.
4. All ferrous elements of the support system shall be hot dipped galvanized. Hanger supporting ungrounded portions of anode buses
TRACTION POWER EQUIPMENT REMOVAL AND INSTALLATION 16607-6 DISTRICT
shall be provided with approved insulators to insulate the bus enclosures from the building structure.
5. Bus ducts shall be assembled in such manner as to insure proper alignment between the shipping sections and the equipment they connect. After alignment and leveling, the bus enclosure shall be bolted to the equipment and then the enclosure splice plates shall be attached and securely fastened.
6. Insulated bus enclosure section shall be installed in the rectifier anode bus runs to isolate the rectifier enclosure from its transformer.
7. Before connections are made, all contact surfaces shall be wiped clean (sandpaper or abrasive tools shall not be used) and covered with a thin coat of approved grease. Joints in bus conductors shall be made using splice plates on each side of the conductor. Connections to equipment terminals shall be made with flexible connectors as specified. All joints shall be made with a minimum of four 1/2 inch by 13 high tensile strength silicon bronze bolts and nuts. All nuts shall be provided with approved locking devices. All bolts shall be tightened to the torque of 4 foot-pounds, or as directed by the Engineer, using an accurate torque wrench.
8. After completion, all joints shall be covered by die-molded, flame retardant polyvinyl chloride boots, or approved equal, providing full voltage insulation for the joint. These boots shall be easily removable for inspection of the joint without destruction of the boot.
E Station Control Cabinet
1. The station control cabinet shall be installed at the same location where the AC relay panel is located.
2. Control wiring for control and test switches, protective relaying, analog metering and current transformer secondary shall be 600 volt, stranded copper, SIS. Current transformer wiring shall be No.10 AWG. The control wiring shall not be smaller than No 12 AWG
3. Each control wire at the point of termination shall be identified by its wire number. The wire numbers shall be identified by printed numbers or letters and shall be installed in plastic coated or colored plastic sleeve, slip-on type wire markers. Printed numbers or letters shall not be affected by cleaning solvent. Wire marker designations shall conform to designations of the wiring
TRACTION POWER EQUIPMENT REMOVAL AND INSTALLATION 16607-7 DISTRICT
4. All control wiring shall be terminated in insulated sleeves with solder less crimp type lugs. The lugs shall be insulated ferrule, ring- tongue type. Open or fork-tongue type terminal lugs shall not be permitted. All lugs shall be compression indent type requiring the use of a special tool . 5. All power and control wiring for external connections shall be terminated at single layered heavy duty terminal blocks similar to Marathon series 1500, GE EB-5 or approved equal. Multilayered terminal blocks for external connections shall not be accepted.
6. Re-terminate cables 35, 36, 37 and 38 left in place with new terminal lugs. Furnish and install all new auxiliary power and control cables necessary for the operation of station control cabinet as shown on the drawings and as described in the specification
G. External Cable Connections:
1. Furnish and install all external interconnecting power, control and auxiliary power cables for the transformer, rectifier, dc switchgear, station control cabinet and ac and dc panels and for miscellaneous circuits as required for installation and commissioning of traction power equipment.
END OF SECTION
TRACTION POWER EQUIPMENT REMOVAL AND INSTALLATION 16607-8 DISTRICT
SECTION 16608
TRACTION POWER EQUIPMENT TESTING
PART 1 - GENERAL
1.1. SUMMARY
A. This section covers the requirements for factory and field testing of the traction power equipment described in Sections 16602 thru 16606.
B. All traction power equipment furnished and installed under this contract shall be subject to the test program described herein. Testing shall include tests at a manufacturer's facility and in the field.
C. The Contractor shall formulate overall test program of the equipment which shall include but not be limited to the tests specified in this Section to ensure equipment compliance with the relevant standards, this Specification and satisfactory and reliable performance in intended operation.
D. The contractor shall furnish a step by step procedure for NICTD’s approval for testing of all the protective relays furnished under this contract.
1.2. FACTORY TESTS
A. Tests at the factory shall include but not be limited to:
1. Manufacturer's standard tests. 2. Tests as per currently applicable NEMA, IEEE, and ANSI Standards. 3. Operational tests to ensure satisfactory performance of the traction power equipment.
1.3. FIELD TEST
A. Tests in the field shall include but not be limited to:
1. Manufacturer's standard tests 2. Test as per currently applicable NEMA, and ANSI Standards. 3. Operational tests to ensure satisfactory performance of the traction power equipment. 4. IEEE standard 1653 for DC traction power system field testing and acceptance criteria for systems up to 1500 volt dc.
TRACTION POWER EQUIPMENT TESTING 16608-1 DISTRICT
1.4. TEST REPORTS
A. The Contractor shall submit certified copies of test reports for all the tests conducted at the factory and in field for Engineer's approval. Test reports shall be submitted to the Engineer within seven days after completion of tests. Test reports shall contain the characteristics curves, etc. where required for interpretation of results.
1.5. CONDITIONS FOR TESTS
A. General Conditions
Prior to testing of any equipment specified in this Section, all of the following conditions shall be fulfilled by the Contractor:
1. All shop drawings of the equipment to be tested have been approved by District. 2. The Contractor shall submit a step by step test procedure including pass- fail criteria to District four weeks in advance of the commencement of the test. District reserves the right to add, delete and make necessary changes in the test procedure. The Contractor shall arrange to conduct all tests per District approved procedure. 3. A minimum of four weeks advance notification shall be given to District on the scheduled date of tests to enable them to witness the same. 4. Testing shall not commence without an approved test procedure.
B. Witnessing Tests
1. District personnel and/or their authorized agents will witness complete testing of all equipment unless a waiver is granted, in which case certified test reports of equipment for which waiver was granted, shall be submitted for review to obtain clearance for packing and shipping. Waiver of witnessing tests on equipment shall not be construed as a waiver for all remaining equipment either of the same type or different type.
C. Responsibility
1. The Contractor shall assume full responsibility during the factory and field testing of all equipment and installation provided by him. Should there be any loss or damage to such equipment, materials or the building as result of these tests, the Contractor shall be fully responsible for replacing the damaged equipment and repairing the building. Replacement of damaged equipment shall include all costs, including but not limited to, transportation of, testing and installation of replacement equipment.
TRACTION POWER EQUIPMENT TESTING 16608-2 DISTRICT
D. Rejection and Retesting
1. Failure of equipment to successfully pass the tests or to meet ratings shall be sufficient grounds for rejection of equipment.
2. Any equipment rejected shall be retested in presence of the Engineer after rectification. If the modifications or changes are such as to affect any of the drawings, diagrams or any other documents submitted and accepted by the Engineer, revised drawings or diagrams shall be submitted, showing proposed changes and Engineer's approval obtained before changes or modifications are made on the equipment. Modifications or changes which do not warrant revision of any drawing shall be furnished to the Engineer along with notice of retesting.
3. If it is not possible to rectify rejected equipment, new equipment shall be manufactured and the requirements of the drawings and design calculations of the original unit shall be applicable for the new unit.
E. Cost of Rectification or New Unit
1. The entire cost of rectification or new unit shall be borne by the Contractor including retesting and cost of witnessing retesting.
PART - 2 DETAIL REQUIREMENTS FOR FACTORY TESTS
2.1. Factory Test
A. General
1. If facilities for conducting any of the tests listed below are not available to the Contractor, these tests shall be conducted elsewhere by him or by an independent agency as approved by the Engineer. Contractor shall, however, clearly indicate in his proposal, the name of the facilities where he intends to conduct those tests.
B. Rectifier Transformer
1. Following tests listed in IEEE Standard C57.12.91 shall be conducted at the manufacturing facility on the rectifier transformer to be furnished in this Contract:
a. Cold resistance measurement test on all windings on the rated voltage connections and at all taps per C57.12.91.
TRACTION POWER EQUIPMENT TESTING 16608-3 DISTRICT
Pass/Fail Criteria.
[ 3(Rmax-Rmin) ] X 100 ≤ 5% R1+R2+R3
b. Polarity and phase relation test at rated voltage connection. Pass/Fail Criteria per C57.12.91.
c. Ratio test on the rated voltage connection and at all taps, per C57.12.91. Pass/Fail Criteria: All taps tolerance within 0.5%.
d. No load loss and excitation current test at 90%, 100% and 110% rated tap voltage per C57.12.91. Pass/Fail Criteria 4.5kW.
e. Load loss and impedance voltage test at 90%, 100% and 110% rated tap voltage. Pass/Fail Criteria per C57.12.91.
f. Dielectric test:
1) Insulation resistance test per C57.12.91. Pass/Fail Criteria: All windings ≥ 1000 Mohm, Core ≥ 100 Mohm . 2) Insulation power factor test: Pass/Fail Criteria per C57.12.91.
3) Applied voltage (H1-Pot) test per C57.12.91. Pass/Fail Criteria: No change in measuring current
4) Induced voltage level test (To be performed after impulse test) per C57.12.91. Pass/Fail Criteria: No abrupt current change.
g. Impulse test consisting of reduced, 2 chopped and full wave applied to high and low voltage winding per C57.12.91. Pass/Fail Criteria: per C57.12.91.
h. Partial discharge test. Corona inception and extinction levels on all primary terminals. Pass/Fail Criteria: Corona inception shall not occur at less than 125 percent above the highest voltage connection (maximum winding). Extinction must be at least 15 percent above the highest voltage connection.
TRACTION POWER EQUIPMENT TESTING 16608-4 DISTRICT
2. Following tests shall be conducted at the manufacturer's facility on the transformer. Tests shall be performed on the primary unit:
a. Temperature rise test to determine that the temperature rise of the windings are within the permissible limit after delivering full load continuously and fulfilling the rectifier-transformer duty cycle. For the purpose of this test, readings will be considered to have stabilized when the rate of temperature rise is less than two degree Celsius during a consecutive 3 hour period. The test shall be performed per Standard C57.12.91 in the following sequence:
1) Step 1:
a) Temperature stabilized at 100% continuous load at lowest voltage and highest current tap. This temperature will be used as a base line for the remaining temperature rise test.
b) Record data at shut down.
2) Step 2:
a) Re-stabilize the temperature at 100% continuous load.
b) Apply 300% full load current for 36 minutes.
c) Record data at shut down.
d) Pass/Fail Criteria: Hot spot temperature shall not exceed 120 degrees Celsius in an ambient corrected to 40 degrees Celsius.
3) Step 3:
a) Re-stabilize the temperature at 100% continuous load
b) Apply 162% full load current for 2 hours.
c) Record data at shut down.
d) Pass/Fail Criteria: The temperature rise shall not exceed 60 degrees Celsius in an ambient corrected to 40 degree Celsius.
4) Step 4:
a) Re-stabilize the temperature at 150% continuous load.
b) Record data at shut down.
TRACTION POWER EQUIPMENT TESTING 16608-5 DISTRICT
c) Pass/Fail Criteria: The temperature rise shall not exceed 65 degrees Celsius in an ambient corrected to 40 degrees Celsius. 5) Step 5:
a) Following step 4, apply 1200% full load current for 12 seconds. b) Pass/Fail Criteria: No physical or electrical damage should occur.
b) Audible sound level test in accordance with IEEE Standard C57.12.91, The transformer shall be connected for and energized at rated voltage and frequency at no load. Pass/Fail Criteria less than 65 dB(A).
C. Interphase Transformer
1. Following tests listed in IEEE STD 1653.2 shall be conducted at the manufacturing facility on the interphase transformer furnished under this Contract:
a. Resistance measurement per IEEE STD 1653.2, Section 11.2.1.
b. Reactance, excitation, current and core Loss measurement per IEEE STD 1653.2, Section 11.2.1.
c. Insulation resistance measurement between winding and core per IEEE STD 1653.2, Section 11.2.1.
d. Applied Voltage or high pot test at the test voltage level of the rectifier. per IEEE STD 1653.2, Section 11.2.1.
D. Rectifier
2. Following tests listed in IEEE STD 1653.2 shall be conducted at the manufacturing facility on the rectifier furnished under this Contract
a. Dielectric voltage test per IEEE STD 1653.2, Section 11.3.1 Pass/Fail Criteria: No momentary flashover to ground, no external flashover to ground, no excessive noise and no excessive leakage current.
b. Rated voltage test. The test to be performed with 110% of rated input voltage applied for 5 minutes per IEEE STD 1653.2, Section 11.3.5.
TRACTION POWER EQUIPMENT TESTING 16608-6 DISTRICT
Pass/Fail Criteria: Recorded vac values between R1, R2 and R3 match expected value of the ac voltage.
c. Rate current test per IEEE STD 1653.2, Section 11.3.7. Pass/Fail Criteria: The rectifier conducts 110% of its rated current without any incident. The temperature should be the same as recommended for regular service.
d. Power factor test per IEEE STD 1653.2, . e. Current balance test at 150 percent full load current. With 150 percent full load applied and temperatures stabilized measure temperature of ambient air-in and air-out, temperature of each of 4 selected diodes and their associated heat sinks (use same positions on each unit) and current in each diode.
1) Increase current by 7 percent waveform and conduction angle adjustment factor to compensate for loading by short circuit. Pass/Fail Criteria: Maximum current unbalance between parallel connected individual diodes in a leg and between legs shall not exceed + 10%.
f. The following certified test or manufacturer's certified test data for the diode (per device) units of the rectifier shall be furnished to the Engineer:
1) Average forward current rating, per ANSI 282A.
2) Peak forward current rating.
3) Maximum surge current rating.
4) Forward voltage drop.
5) Threshold voltage.
6) Differential resistance.
7) Crest working voltage.
8) Working peak reverse voltage rating, per ANSI 282A.
9) AC RMS voltage rating.
10) DC voltage blocking rating, per ANSI 282A.
TRACTION POWER EQUIPMENT TESTING 16608-7 DISTRICT
11) Repetitive peak reverse voltage rating, per ANSI 282A (PRV rating).
12) Non-repetitive peak reverse voltage rating, per ANSI 282A.
13) Initial reverse voltage.
14) Forward power loss.
15) Reverse power loss.
16) Temperature derating.
17) Positive non-conducting period.
18) Surge forward current rating per ANSI 282A.
19) Operating temperature rating, per ANSI 282A.
20) Thermal fatigue rating, per ANSI 282A
E. DC Switchgear
1. Following test listed in ANSI C37.14 as "Design Tests" shall be conducted on one representative dc circuit breaker of each rating
a. Dielectric withstand test
b. Continuous current test
c. Short-circuit current interrupting test: The short-circuit test value shall be as calculated for the Substation with the equivalent of two 3000kW rectifiers feeding the dc bus. Primary ac system available fault capacity shall be taken as 500 MVA at 34.5 kV and X/R Ratio 15. The fault shall be between the load side terminals of the feeder breaker and the nearest negative bus of the substation. The dc power source shall preferably be from the silicon rectifier. Engineer's approval shall be obtained prior to testing if other sources of supply are to be used. Previous test certifications are not acceptable.
d. Endurance test
1) Electrical endurance test.
2) Mechanical endurance test
TRACTION POWER EQUIPMENT TESTING 16608-8 DISTRICT
2 .Following tests listed in ANSI C37.14 as "Production Tests" shall be conducted at the manufacturer's facility on each and every dc circuit breaker.
a. Calibration tests on the individual direct acting trip device prior to final assembly
b. Control and secondary wiring check test
c. Dielectric withstand test
d. Mechanical operation test
e. Calibration test 1) Direct acting trip devices
2) Undervoltage trip device
f. Manufacturer's standard tests not included in the above tests
3. Following tests listed in ANSI C37.20 as "Design Tests" shall be conducted on the dc switchgear assembly.
a Dielectric tests
b. Rate continuous current tests.
c. Momentary current tests
d. Mechanical operational tests.
e. Sequence tests
f. Flame-retardant tests.
g. Electrical operation and control wiring test
1) Control wiring insulation test.
2) Polarity test
3) Complete functional and operational tests for closing and tripping schemes for cathode and feeder breakers per contract and manufacturer shop drawings utilizing control switches and HMI.
TRACTION POWER EQUIPMENT TESTING 16608-9 DISTRICT
F. Anode Bus
1. Following tests shall be conducted at the manufacturer's facility specified under "Design Tests" in ANSI C37.20 for the metal-enclosed anode bus.
a. Dielectric tests 1) Power frequency withstand
2) Impulse withstand
b. Temperature rise tests
c. Momentary tests
2. In addition, temperature rise test the following additional test shall be performed on the anode bus.
a. Measure temperature rise of conductors in 40 degrees Celsius ambient at continuous 150 percent rated load, load to be applied until all readings have stabilized. This test may be performed concurrent with the in-line tests specified for rectifier package tests, provided the readings have stabilized during the two hour application of 150 percent load. For the purposes of this test, readings will be considered to have stabilized when the rate of temperature rise is less than two degree Celsius during a consecutive 3 hour period.
3. Insulation and Moisture Test (Outdoor Bus Duct only).
a. One complete bus duct shall be mounted as it would be in normal service. Install spray nozzle to permit thorough wetting of all interior parts.
b. Apply 2200V, 60 Hertz bar to bar and each bar to enclosure for one minute.
c. Measure insulation resistance bar to bar and each bar to enclosure.
d. Spray all internal parts until thoroughly wetted for 2 hours.
e. Apply 2200V, 60 Hertz for 1 minute.
f. Measure insulation resistance as in step (c) above.
TRACTION POWER EQUIPMENT TESTING 16608-10 DISTRICT
4. Power Frequency withstand test shall be conducted at the manufacturer's facility on each and every shipping length as specified under "Production Test" in ANSI C37.20 for metal-enclosed buses.
G. Station Control Cabinet
1. Complete functional and operational tests for control, protection, measurement of rectifier transformer, rectifier, cathode and feeder breakers per contract and manufacturer’s shop drawings..
PART - 3 DETAIL REQUIREMENTS FOR FIELD TESTS
3.1. Field Test
A. General
1. Contractor shall perform the following field tests on all equipment specified in this Section after installation of the equipment, and all 34.5kV cable installation is complete. Field tests are to be performed to supplement the factory tests and to ensure proper operation of equipment and proper calibration and coordination of protective devices. Contractor shall furnish and set up all special equipment required for the tests, including relay tests set, switches, properly calibrated indicating instruments, timing devices, shorting devices, loading devices and other associated appurtenances as may be required.
2. The work includes furnishing labor, material, test instruments and services necessary to perform required testing and checking of electrical equipment installation.
3. All tests shall be successfully completed to show that the installation meets the specification requirements and that the equipment and devices operate as intended, before final acceptance by the District.
4. Tests and checkouts shall be conducted in accordance with the Engineer's approved test procedure specified herein and in National Electrical Code, and applicable Standards and Specifications' of ANSI, NEMA, etc.
5. Contractor shall provide properly qualified personnel who shall be responsible for supervising, coordinating, and performing all the electrical field testing and checking work and who shall maintain a written record of
TRACTION POWER EQUIPMENT TESTING 16608-11 DISTRICT
tests conducted. Testing and checkouts shall be performed in the presence of the Engineer.
6. Contractor shall furnish four copies of all tests results to the Engineer. Result sheets shall include date of test, personnel involved, items tested, type of tests and test data. 7. Any equipment or material damaged due to improper test procedure or test apparatus handling shall be replaced or restored to original condition by Contractor at his expense. 8. Safety devices including but not limited to rubber gloves and blankets, screens and barriers, danger signs, padlocks, etc., shall be used to protect and warn all personnel in the vicinity of the tests.
9. All test instruments used shall have a certified calibration sticker showing last date of calibration and expiration date
.
B. Field Test Requirements
1. Contractor shall formulate a complete Field Test procedure for all equipment to be furnished and installed under this Contract. Test procedure shall be comprehensive and shall include the required tests as specified in relevant standards of ANSI, NEMA and IEEE, supplementing the Factory Test Procedure.
2. The Contractor shall submit the test procedure to the Engineer for review and approval well in advance to the commencement of field tests. Engineer reserves the right to add, delete or make necessary changes in the test procedure. The Contractor shall arrange to conduct all the field tests as per the Engineer's approved procedure. Since the Contractor is responsible for the performance and installation of the equipment furnished under this Section, he shall, therefore, prior to testing, verify that the installation is proper and in accordance with all applicable installation instructions specified herein.
C. The following field test shall be performed:
1. Perform continuity and dielectric test to prove this correctness of circuitry.
2. Each and every dc circuit breaker shall be thoroughly inspected and certified by the Contractor's Engineer.
3. Check relay and trip devices settings and coordination.
TRACTION POWER EQUIPMENT TESTING 16608-12 DISTRICT
4. Perform functional and operations tests of all equipment and of all devices and circuits.
5. Calibration test also shall be performed on:
a. Item 1- 1500V dc, 4000A rectifier breaker position
b. Item 2 -Two (2) 1500V dc, 4000A automatic reclosing feeder breaker positions
TRACTION POWER EQUIPMENT TESTING 16608-13 DISTRICT
TRANSFORMER TESTS
TEST DESCRIPTION STANDARD PASS/FAIL ROU DESIGN NOTES CRITERIA TINE Commutating Reactance IEEE C57.18.10 XXXXX Resistance of all windings at all IEEE C57.12.91 XXXXX taps Resistance of all windings at all IEEE C57.12.91 Imbalance < or = XXX taps Section 5.4 5.0% XX Polarity and phase relation at IEEE C57.12.91 Per IEEE C57.12.91 XXX XXXXX nominal voltage tap Section 6.3 XX Turns Ratio of all windings at all IEEE C57.12.91 Per IEEE C 57.12.91 XXX XXXXX taps Section 7.3 Tolerance +/- 0.5% all XX taps No load loss and excitation IEEE C57.12.91 4.5 kW XXX XXXXX current @ 90%, 100% and 110% Section 8.2 XX of nominal tap voltage Impedance voltage of all windings IEEE C57.12.91 Per IEEE XXXXX at all taps C 57.12.01.9.2 Load loss of all windings at all IEEE C57.12.91 Per IEEE XXXXX taps Section 9.3 C 57.12.01.9.3 Load loss of all windings at IEEE C57.12.91 Per IEEE XXX nominal voltage tap and tap C 57.12.01.9.3 XX extremes Impedance voltage of all windings IEEE C57.12.91 Per IEEE XXX at nominal voltage tap and tap C 57.12.01.9.2 XX extremes Insulation Resistance; IEEE 57.12.91.10.9 Windings > XXX XXXXX H.V.-L.V. & earth ground 1000Mohm XX L.V.-H.V. & earth ground Core – Earth ground Core > 100Mohm
Insulation Power Factor C57.12.91.10.8 Per IEEE C57.12.91.10.8
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TRANSFORMER TESTS (continued)
TEST DESCRIPTION STANDARD PASS/FAIL ROUTINE DESIGN NOTES CRITERIA Applied voltage IEEE No change in XXXXX XXXXX C57.12.91.10.3 measured current Induced Voltage (Performed after IEEE C57.12.91.10.4 XXXXX XXXXX LV winding at 2X rated voltage impulse test) C57.12.91.10.4 IEEE C57.98
Temperature Rise at 100% at IEEE C57.12.91 No specified XXXXX Used as a baseline for the remaining lowest voltage, highest current Spec 16602 value temperature rise tests tap Temperature Rise at 150% at IEEE C57.12.91 85 degrees XXXXX Corrected to 40 deg. C ambient lowest voltage, highest current Spec 16602 Celsius tap Temperature Rise at 162% at IEEE C57.12.91 80 degrees XXXXX Corrected to 40 deg. C ambient lowest voltage, highest current Spec 16602 Celsius tap Temperature Rise at 300% at IEEE C57.12.91 Hot spot < 145 XXXXX Corrected to 40 deg. C ambient lowest voltage, highest current Spec 16602 deg. C tap 1200% short circuit withstand at Spec 16602 No Damage XXXXX highest voltage, lowest current tap Impulse (H.V. winding), Reduced, IEEE C57.12.91.0 IEEE C57.98.2.5 XXXXX XXXXX 200 kV BIL chopped and full wave. Minimum IEEE C57.12.01 IEEE C57.98.2.8 winding, highest tap. IEEE C57.98 Impulse (L.V. winding), Reduced, IEEE C57.12.91 IEEE C57.98.2.5 XXXXX XXXXX 45 kV BIL chopped and full wave IEEE C57.98 IEEE C57.98.2.8 Partial Discharge (Corona IEEE C57.12.91 PD <10 pC XXXXX XXXX Inception/Extinction) Audible Noise IEEE C57.12.91 < 65 d.b.a. XXXXX
TRACTION POWER EQUIPMENT TESTING 16608-15 DISTRICT
RECTIFIER TESTS
TEST DESCRIPTION STANDARD PASS/FAIL ROUTINE DESIGN NOTES CRITERIA Dielectric strength IEEE 1653.2 No flashover XXXXX XXXXX Section 11.3.1 Rated Voltage IEEE 1653.2 No failure XXXXX XXXXX Section 11.3.5 Rated Current IEEE 1653.2 Diode junction XXXXX XXXXX Section 11.3.7 temperature shall not to exceed maximum rating Efficiency IEEE 1653.2 Per Specification XXXXX Section 8.1 Section 16603 Voltage Regulation (At 0.5%, IEEE 1653.2 Per Specification XXXXX 25%, 50%, 75%, 100%, 150%, Section 8.2 Section 16603 300% and 450% load 100% Current Balance (N diodes) IEEE 1653.2. +/- 20% Max per XXXXX Section 8.4 section; +/- 10% between sections 150% Current Balance (N diodes) IEEE 1653.2 +/- 20% Max per XXXXX XXXXX Section 8.4 section; +/- 10% between sections Power Factor IEEE 1653.2, IEEE XXXXX Section 8.3 1653.2.8.3 Harmonic Amplitude IEEE 519 THD < 5% XXXXX Individual < 3% Commutation Reactance IEEE 1653.2 Per IEEE 1632.2 XXXXX Constant Annex B Annex B
150% Diode Temperature Spec 16603 Diode junction XXXXX temperature shall not to exceed maximum rating
END OF SECTION
TRACTION POWER EQUIPMENT TESTING 16608-16 DISTRICT
SECTION 16609
IN-LINE TEST ON RECTIFICATION EQUIPMENT AND SURGE AND DESTRUCTIVE TEST ON DIODES
PART 1 - GENERAL
1.1. SUMMARY
A. This section covers the requirements for in-line test on rectification equipment and surge destructive test on diodes.
B. All the applicable requirements of Part-1 "General" of Section 16610 shall apply to this Section.
PART 2 - DETAIL REQUIREMENTS FOR IN-LINE TEST
2.1. IN-LINE TEST
A. General
1. If facilities for conducting the in-line tests are not available to the manufacturer, these tests shall be conducted elsewhere by him or by an independent agency as approved by the Engineer. Contractor shall, however, clearly indicate in his proposal the name of the facility, where he intends to conduct these tests.
B. Rectifier surge voltage and short-circuit tests
1. The rectifier package, consisting of transformer, rectifier and interconnecting anode bus assembled in line shall be subjected to the following tests to ensure compliance with specification requirements. Test set-up shall include primary supply system having minimum 150MVA capacity, switchgear having operating characteristics equivalent to specified, protective devices having operating characteristics equivalent to actual devices and which have been adjusted to provide pick-up values and operating times conforming to those proposed for final installation, as well as shunt, properly calibrated meters, shorting devices, loading devices and other associated appurtenances as may be required.
a. Open circuit test to insure ability to withstand transient surge voltages in steps as follows:
1) Energize transformer and rectifier at rated voltage with no load by closing ac supply breaker
In-Line Test On Rectification Equipment And Surge And Destructive Test On Diodes 16609-1 DISTRICT
2) De-energize transformer and rectifier by tripping ac supply breaker.
3) Record voltage waveforms and amplitudes at transformer and rectifier output terminals and at critical points in surge protection network during close and trip operation.
4) Repeat test a minimum of ten times to insure maximum transient.
5) Maximum crest of transient surge impressed on rectifier shall not exceed 75 percent of the voltage withstand of the diodes in a phase leg.
b. Short circuit test to determine short circuit current in steps as follows:
1) Energize transformer and rectifier at rated voltage with no load.
2) Short rectifier output terminals with shorting device.
3) Clear short (bolted fault) by tripping the ac supply breaker through equivalent ac switchgear protective devices.
4) Record current waveform and amplitude at rectifier output terminals during shorting operation.
5) Calculate theoretical values of peak and sustained short circuit currents for rated voltage fault on a 500 MVA system having X/R ratio of 15. Calculate theoretical transformer over-voltage and test supply system X/R ratio required to obtain a minimum of these values on actual test set-up.
6) Repeat short circuit test with transformer energized at theoretical over-voltage and the X/R ratio of the test supply system adjusted to the value calculated in 5 above. Continue to adjust voltage until calculated peak and sustained values of current are realized. .
C. Rectifier Current Balance and Load Test
1. The rectifier package, including transformer, rectifier and interconnecting anode bus assembled in line and subjected to the following tests to insure compliance with the Specification requirements. Test setup shall include necessary supply and loading systems including switchgear and protective devices, ventilation system with temperature controlled at 104 degrees Fahrenheit, shunts, thermocouples, properly calibrated meters, and associated appurtenances as may be required. 125 volt dc control power shall be provided to the control circuits of the rectifier in order to keep
In-Line Test On Rectification Equipment And Surge And Destructive Test On Diodes 16609-2 DISTRICT
thermal devices energized during the test. Reduced voltage-reduced capacity supply system will be acceptable for certain portions of these test providing currents specified are increased by 7 percent waveform and conduction angle adjustment factor to compensate for loading by short circuit. Individual silicon diode junction temperatures shall not exceed design values established, in Contractor's load and short circuit calculations as determined from actual case temperature using junction versus case temperature data.
a. Current balance test to insure compliance with the requirement for current balance between diodes sharing current of same polarity in steps as follows:
1) Attach six thermocouples, 1 per leg and apply 100 percent full load current and measure all diode currents in each phase polarity. After stabilization of temperature, repeat test for 150 percent (N diodes).
2) Remove 1 diode fuse in each phase polarity to create maximum diode current unbalance; then apply 150 percent full load current and measure remaining diode currents in each phase polarity, after stabilization of temperature.
b. Efficiency measurement test. The test shall be performed on the rectifier at 25 percent load, 50 percent load, 75 percent load, 100 percent load, 150 percent load rated load. Efficiency shall be determined by calculation based on measured losses on 100% rated load, for rated voltage, current and frequency.
c. Voltage regulation test shall be performed at 0.5 percent load, 25 percent load, 50 percent load, 75 percent load, 100 percent load, 150 percent load, 300 percent load and 450 percent load.
d. Harmonic amplitude test.
e. Load current test to insure compliance with rectifier current rating (thermal capability) and ability of rectifier to withstand short circuit under load in steps as follows:
1) With 1 diode fuse removed in each phase polarity as in test above, apply 100 percent full load current until constant diode temperature is reached. Measure and record current and temperature of 2 diodes, which had maximum current.
2) Apply 150 percent full load current for two (2) hours immediately after completion of the 100 percent full load current test above.
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3) Superimpose 5 one-minute overloads of 300 percent full load current followed by one, 15 second overload of 450 percent full load current spaced equally throughout the 2 hour period. (Current values specified shall continue for the full interval of each superimposed overload.)
4) Apply short circuit current, obtained in the short circuit test (2.1.B.1.b.6) for the operating time of the short time relays plus ac breaker opening time in cycles immediately after completion the test (2.1.B.1.b.3) above. A time interval of 1 second is allowed between the 450 percent overload and the application of short circuit.
5) Record load current, ambient air temperature, supply air temperature, discharge air temperature, transformer winding hot spot temperature and diode case temperature of diode having maximum current unbalance as determined in the current balance test (2.1.C.1.a.2) at sufficiently close time intervals to provide accurate current - time - temperature relationship.
6) Monitor rectifier commutation with Astromed Dash 8 recorder during- test loadings set forth in test (2.1.C.1.b.3) above to insure normal operation. If possible, trace rectifier input voltage wave forms.
7) Failure of equipment to withstand tests or to meet ratings shall be sufficient grounds for rejection of equipment.
D. Commutation Reactance
Determine the commutation reactance and resistance of the rectifier package (transformer, rectifier and anode bus) using any one of the following three
propositions so that the equipment voltage regulation may be calculated (ED =
EDO - ETH - EX - ER = average dc voltage) under load to insure compliance with output voltage characteristics set forth in this Specification. For definitions applicable to the following see Paragraph 2.1.D.4.
1. Proposition I:
a. Transformer, bus duct, and rectifier connected in-line.
1) Ambient of entire package adjusted and maintained at 40 degrees C. 2) With rectifier dc output terminals shorted, adjust and maintain transformer primary current while at 34,500 volt tap at 100 percent
In-Line Test On Rectification Equipment And Surge And Destructive Test On Diodes 16609-4 DISTRICT
IP at 60 Hz until the hottest spot winding temperature stabilizes (not more than 2 degrees C rise in a consecutive 3 hour period).
3) Measure input watts "P", ac amperes "IP", ac volts “V”, dc amperes
"Id" and the voltage across the shorting strap "Vd."
4) Determine X for Package as follows:
2 2 3VI P 2 E ohms X sec P s 2 3I p E p phase
5) Determine R for Package as follows:
2 P I V 2E E ohms R d d TH s 2 3I P E p phase
Proposition II:
a. Transformer at 34,500 volt ac taps set up for certified heat run.
1) Measure primary and secondary resistances at any ambient. Note
ambient temperature (T1).
2) With transformer secondary open circuited, energize primary of transformer at rated voltage and frequency until individual winding temperature stabilizes. Measure average winding temperature by resistance method. Determine temperature rise Te.
3) With transformer secondary short circuited, circulate rated full load current in primary until transformer winding temperature rises do not change more than 2° C during a consecutive 3-hour period.
4) Measure input watts "P", ac amperes "Ip", and ac volts 'V.'
5) Shut down and quickly measure dc resistance of primary and secondary windings. Record elapsed time between instant of shut-down and each resistance measurement. All reading must be completed within 4 minutes of shut-down. Otherwise the temperature test should be resumed until temperature is normal again, after which the remaining readings will be taken.
In-Line Test On Rectification Equipment And Surge And Destructive Test On Diodes 16609-5 DISTRICT
6) Determine temperature rise of copper winding and correct R for 40 degrees Celsius ambient.
Let R1 = resistance (step a) at copper temperature t1.
R2 = resistance at 100 percent Ip continuous and test ambient.
t2 = copper temperature at 100 percent Ip continuous and test ambient.
R3 = resistance at 100 percent Ip continuous and 40 degrees Celsius ambient. t = copper temperature at 100 percent I continuous, normal 3 p excitation on the core and 40 degrees Celsius ambient.
t3 t3 40 TEST AMBIENT TC TC
1.25 0.8 T T T 1 e C C T c
Where, as defined in NEMA TR-27, page 29, part -5.
Te = individual stabilized winding temperature rises measured immediately following the run with normal excitation on the core.
Tc = individual stabilized winding temperature rises measured immediately following full load current flowing in one (1) winding with the other winding short circuited.
R 2 t2 234.5 t1 234.5 R1
234.5 t3 R3 R1 234.5 t1
7) Determine X from volt-amperes and watts measured in step 5 as follows:
2 2 3VI P 2 E ohms x P s 2 3I p E p phase
In-Line Test On Rectification Equipment And Surge And Destructive Test On Diodes 16609-6 DISTRICT
2 8) Calculate Ip R2 loss. 2 9) Subtract Ip R2 from watts measured in (step 5) to get stray losses
at copper winding temperature t2. 2 10) Calculate Ip R3 losses.
11) Stray losses at t3 =.
234.5 t2 STRAY LOSSES AT t2 234.5 t3
2 12) Total watts loss for purpose of determining effective R will be Ip
R3 + stray losses at t3.
2 TOTAL E ohms R 400 C AMBIENT s 2 3I p E p phase
b. Bus duct and rectifier connected in line.
1) Rectifier inlet air maintained at 40 degrees Celsius.
2) With rectifier dc output terminals short circuited, adjust
rectifier output current to 107 percent Id. Note temperatures and measure bus duct input watts "P", ac
amperes “Is”, ac volts “V”, dc amperes "Id", and
voltage across shorting strap "Vd".
3) Calculate rectifier R as follows:
P I d Vd 2ETH R 2 3I s
In-Line Test On Rectification Equipment And Surge And Destructive Test On Diodes 16609-7 DISTRICT
4) Calculate X of bus duct and rectifier combined using measured values volt-ampere and input Watts (step b.2 above). 5) The X and R of package are respectively the sum of X and R of transformer, bus duct and rectifier.
3. Proposition III:
a. Transformer as in Proposition II.
b. Bus duct alone.
1) With bus duct at ambient temperature between 15 degrees Celsius and 40 degrees Celsius adjust bus duct current for 100 percent, with its output shorted. Measure input watts, ac amperes, ac volts and note ambient temperature. 2) Determine X of bus duct using measured values of volt amperes and input watts (step b.1 above). 3) Determine R of bus duct using measured input watts.
c. Rectifier alone
1) With inlet air maintained at 40 degrees Celsius and rectifier dc output terminals shorted adjust rectifier output current to 107
percent “Id".
2) Measure input watts "P", ac amperes ''Is", ac volts "V'', dc
amperes " Id", and voltage across shorting strap "Vd". 3) Calculate rectifier R as follows:
P I d Vd 2ETH R 2 3I s
4) Determine X using measured values of volt-amperes and input watts (step C.2 above).
In-Line Test On Rectification Equipment And Surge And Destructive Test On Diodes 16609-8 DISTRICT
d. The X and R of package are respectively the sum of X and R of transformer bus duct, and rectifier.
4. Definitions:
a. Where EDO = 1.35ES b. Where Es = no load RMS voltage of transformer secondary measured line to line at transformer secondary terminals with transformer on rated tap and voltage Ep applied to primary terminals.
c. Where Eth = voltage axis intercept of line drawn through two points on instantaneous forward voltage versus instantaneous forward current curve of the diode. The points chosen shall be 25 percent and 100 percent rated diode current with junction temperature at 50 degrees C.
3X I Where E c d x
d. Where Xc - Total ohms reactance of rectifier transformer plus interconnecting bus duct on a transformer secondary line to neutral base with transformer on rated tap. See Proposition I, II and III for determination.
e. Where Id = Total current (average value) through load connected to rectifier.
f. Where Ip = Line current (RMS) to transformer primary terminals on rated tap.
g. Where Ep = Rated line-to-line RMS voltage of transformer primary at rated tap.
Where ER 21d Rc
h. Where Rc = Total ohms resistance of rectifier transformer plus rectifier plus interconnecting bus duct on a transformer secondary line to neutral base with transformer on rated tap.
i. Where VD = Voltage drop across rectifier dc output terminals shorting strap.
j. Where Is = Current in bus duct. (RMS)
In-Line Test On Rectification Equipment And Surge And Destructive Test On Diodes 16609-9 DISTRICT
PART 3 - DETAIL REQUIREMENTS FOR SURGE AND DESTRUCTIVE TEST ON DIODES
3.1. SURGE AND DESTRUCTIVE TEST ON DIODES
A. General
1. Prior to diode testing, the Contractor shall demonstrate that the test equipment to be used is capable of providing 10,000 amperes (minimum) over the rated forward surge current; that the test equipment is capable of providing sufficient power to destroy the diode, should the diode's limits be exceeded; and that the equipment can safely detect diode failure. 2. Three (3) sets of 10% or no less than five (5) diodes that have been subject to all in-line tests called for in this section of the Specification will be selected by District. These diodes will be removed from their heat tank assemblies for the test.
B. Surge Test On Diodes
1. The surge test shall be conducted as follows:
a. Out of the group of three (3) sets, one (1) set of five (5) diodes would be surge tested per NEMA-EIA Standard as follows:
1) One hundred applications of forward current equal to the non- repetitive surge forward current rating under the following conditions:
a) The rectifier diode is operating at its rated working peak reverse voltage, forward current and case temperature prior to surge.
b) The rectifier diode is required to support its rated working peak reverse voltage during the surge and, following the surge, it must support the rated forward current specified in paragraph 3.a of NEMA-EIA-RS282 and non repetitive leak reverse voltage for one-half cycle and then working peak reverse voltage.
c) Successive surges may not be applicable until the rectifier diode has returned to the operating conditions specified in paragraph 3.a of NEMA-EIA-RS282.
d) The one-half-cycle (1/120 of a second) surge forward current consists of a single-phase half-wave 60 Hertz sinusoidal pulse. The peak surge forward current consists of the peak of the half-
In-Line Test On Rectification Equipment And Surge And Destructive Test On Diodes 16609-10 DISTRICT
wave pulse current flowing through the rectifier diode during the surge period. This is required JEDEC registration data. e) The surge current four times greater than one cycle consists of a series of half-wave pulses for a specified period of time. f) Each diode failure will require complete retest of same amount additional diodes as initial test, selected by the District.
b. An acceptable diode failure is defined as a failure resulting from the failure of hydraulics on the diode test press, and electrical power surge resulting from some in-plant anomaly outside of this testing, or an electrical power surge resulting from the Utility supply system. Human error or negligence toward the test procedure or Mil. Spec. defined failures will not be an acceptable cause for a diode failure.
C. Destructive Test On Diodes
1. The destructive test on diodes shall be conducted as follows:
a. Repeat the surge test described above except the forward surge current application is increased by 3,000 amperes.
b. The surviving diodes shall be tested to destruction by increasing forward surge current applicable in 3,000 amperes increments applied as in step above, noting number surviving for each 3,000 ampere test series.
c. The Contractor shall supply and install at no extra charge to the Authority fifteen (15) identical replacements diodes in rectifier from which subject diodes were removed.
In-Line Test On Rectification Equipment And Surge And Destructive Test On Diodes 16609-11 DISTRICT
IN-LINE TESTS
TEST DESCRIPTION STANDARD PASS/FAIL ROUTINE DESIGN NOTES CRITERIA Commutating Reactance and Section 16609 XXXXX Proposition I, II or III Resistance 100% Current Balance (N diodes) IEEE 1653.2 +/- 10% Max XXXXX @ 40 deg C ambient unbalance and diode junction temp < max value 150% Current Balance (N diodes) IEEE 1653.2 +/- 10% Max XXXXX @ 40 deg C ambient Section 16609 unbalance and diode junction temp < max value 100% Current Balance (N-1 IEEE 1653.2 +/- 20% Max XXXXX @ 40 deg C ambient diodes) Section 16609 unbalance and diode junction temp < max value 150% Current Balance (N-1 ANSI C34.2 +/- 20% Max XXXXX @ 40 deg C ambient diodes) Section 16609 unbalance and diode junction temp < max value Efficiency Section 16609 > 97.5% XXXXX @ 40 deg C ambient Displacement Power Factor Section 16609 >90% lagging XXXXX @ 40 deg C ambient Voltage Regulation Section 16609 Per DISTRICT XXXXX @ 40 deg C ambient 16603 100% Rated Full Load Current Section 16609 No specified value XXXXX @ 40 deg C ambient Temperature Rise Used as a baseline for determining stability 150% Temperature Rise Section 16609 No specified Value XXXXX @ 40 deg C ambient RI-9 Overload Test Section 16609 No electrical XXXXX @ 40 deg C ambient failures and no temperatures above max allowable values Short Circuit Test Section 16609 No physical XXXXX Immediately following RI-9 test damage, electrical failures, or fuse openings
IN-LINE TEST ON RECTIFICATION EQUIPMENT AND SURGE AND DESTRUCTIVE TEST ON DIODES 16609-12 DISTRICT
IN-LINE TESTS (Continued).
TEST DESCRIPTION STANDARD PASS/FAIL ROUTINE DESIGN NOTES CRITERIA Harmonic Analysis XXXXX Transient Voltage Surge Test < 75% of diode XXXXX withstand rating
END OF SECTION
IN-LINE TEST ON RECTIFICATION EQUIPMENT AND SURGE AND DESTRUCTIVE TEST ON DIODES 16609-13 DISTRICT
SECTION 16610
SERVICE ENGINEER
PART - 1 GENERAL
1.1. SUMMARY
A. This section covers the requirements for furnishing a qualified English- speaking factory trained service engineer to ensure the details of field work are properly carried out and the testing is performed in accordance with the various manufacturer requirements and approved testing procedures.
1.2. DETAIL REQUIREMENTS
A. The Contractor shall promptly furnish a service engineer when requested by the District for installation, inspection, testing, and adjustment of the equipment described herein, to insure satisfactory performance, and to instruct a reasonable number of the District employees in the proper use and care of equipment. The costs of the service engineer including salary, transportation and other expenses shall be included in the Contract Price.
B. It is understood by the Contractor that the District has obligations to place the equipment herein in safe, reliable commercial operation on a specific date. Due to this obligation, the District will determine and schedule the order and time that individual equipment is readied for service. Without regard to his normal scheduling procedures, the Contractor shall provide, within seventy two (72) hours after notification by the District, a qualified field service engineer to commence and continue to conclusion of any work, which is required to be ready for safe commercial operation.
C. The cost of the service engineer included in the contract price shall include, but is not limited to the following work by the service engineer:
1. During the installation after the delivery of equipment herein, the service engineer shall spend a minimum of two (2) full days per week at the job site, continued until satisfactory completion of field test. Variations from this schedule and requirements will not be permitted except with the consent of the District, or for reasons which the District deems are beyond the control of the Contractor.
2. Promptly expedite delivery of material supplied herein required for installation, including the exchange of incorrect material supplied.
SERVICE ENGINEER 16610-1 DISTRICT
3. Promptly identify and make corrections to defects in material, workmanship, or manufacturer of equipment supplied.
4. Promptly identify and make corrections to equipment and material supplied to meet requirements of this Specification.
5. Promptly supply supplementary installation instructions when, in the opinion of the District the installations instructions supplied are incomplete, ambiguous, or otherwise inadequate.
6. Test, calibrate, and adjust equipment to insure proper operation of equipment as required by the Contractor and this Specification.
7. Insure the manufacturer's written installation instructions are followed and notify the District immediately when methods of installation are not satisfactory to the Contractor.
8. Test and inspect equipment and certify that equipment is properly installed and ready for service prior to being placed in service.
9. Arrange for and participate in field tests.
10. Instruct the District employees in the proper use, care and adjustment of the equipment.
END OF SECTION
SERVICE ENGINEER 16610-2 DISTRICT
SECTION 16612
TRACTION POWER SUPPORT
PART - 1 GENERAL
1.1. SUMMARY
A. This section covers the requirements for furnishing the support for operating and maintenance of the traction power equipment specified in Section 16602 thru 16606.
B. The Contractor shall furnish a reasonable number of parts such as to insure adequate supply for installation and testing of the various components of equipment furnished and installed under this Contract for traction power substation work. These parts shall include but not be limited to power fuses, control and instrument fuses and installation hardware such as bolts, nuts, and other special devices. Such parts shall be delivered at the time with the equipment to which it applies.
C. The Contractor shall furnish all necessary installation and maintenance tools such as wrenches, threading devices, etc., for all fittings which do not conform to U.S. Screw, Bolt and Pipe Standards.
1.2. REQUIREMENTS
A. The Contractor shall furnish at the time of delivery of equipment the following items of rectification equipment to reduce down-time on the system due to unit failure. Each item shall be clearly identified and marked for delivery.
1. Twenty four (24) sets of each type of diode, diode fuse and diode commutating capacitor used in the rectifier. 2. Two (2) surge arrester assemblies of each type used. 3. For each rating of breaker supplied, furnish two (2) complete sets of main contacts, arcing contacts and arc chute assemblies. 4. For each rating of breaker supplied, furnish two (2) of each type of electromotive devices integral to the breaker used for closing and tripping, two (2) control switches of each type, two (2) solid state reclosing systems including but not limited to, closing coils, closing motors, spring charging motors, trip coils or holding coils, two (2) electronic tripping devices and test sets. 5. For each rating of breaker supplied, furnish two (2) complete sets of main current carrying disconnect assemblies, two (2) complete sets of auxiliary control disconnect assemblies, and two (2) sets of auxiliary contacts. 6. One (1) diode fuse monitor. 7. One (1)) winding over temperature, 49 device. .
TRACTION POWER SUPPORT 16612-1 DISTRICT
8. One (1) set of primary and two (2) sets of secondary rectifier power transformer bushings and/or standoff insulators. 9. One (1) manual reset lockout relay. 10. One (1) spring return, pistol grip control switch. 11. One maintained contact two position selector switch with pistol grip handle. 12. One (1) HMI, touch panel with 12 “display screen including interface cable. 13. One (1) PLC, central processing unit. 14. Two (2) optically isolated digital inputs. 15. Two (2) optically isolated digital outputs. 16. Two (2) Ethernet switches. 17. Fiber optic cables. 18. One (1) software programmer. 19. Two (2) sets of power supply units. 20. For each color of indicating light supplied, furnish four (4) sets of lights. 21. For each type of fuses supplied for traction power equipment, furnish minimum of 10 percent but not less than four (4). 22. One (1) programmable and diagnostic test set to test. 23. Six (6) sets of maintenance manuals in 3-hole hard cover binders and one (1) CD in pdf format. 24. The Contractor shall also furnish at the time of delivery a detailed list of recommended support parts and/or devices. The prices shall be furnished with this list along with names of suppliers and catalog numbers for such parts if they are not originally manufactured by this Contractor. 25. The Contractor shall also provide a three (3) day, 24 hour course to 10 NICTD personnel in Michigan City, on circuit theory operation, maintenance, and trouble shooting procedures. Complete instruction manuals (including schematics and wiring diagrams showing all internal solid state components) shall be provided for all personnel at least 1 week in advance of the course. The intent and general approach of the training shall be as follows:
a. The intent of the training program shall be to provide NICTD personnel with adequate classroom and practical training necessary to operate and maintain the Traction Power Substation. b. This training program shall consist of both Classroom and Practical (Field) Training. It shall be broken down into Traction Power Elements arranged in a sequential fashion from the incoming line to output of the catenary system. The training program shall also encompass maintenance procedures, problem setups and troubleshooting exercises. Maintenance sequence and frequency shall also be presented. Standardized training methods, acceptable to the industry shall be applied. c. Sequence of Learning Objectives:
1) Sequence of learning objectives shall be to provide a safe overview followed by general electrical technical knowledge, print reading, symbols and abbreviations. Once general knowledge has been developed with the students, the course shall be site specific
TRACTION POWER SUPPORT 16612-2 DISTRICT
concentrating on single line diagrams, theory of operations, and control schematics. 2) Upon completion of the classroom theory sessions the training course shall concentrate on details of each specific piece of equipment and its function for the following: dc switchgear, rectifier/transformer, rectifier, meters, relays and control devices. 3) Once the technical aspect of the Traction Power Substation has been established and understood, the course shall depart training by hands on applications, testing, troubleshooting and maintenance. These elements of the training course shall be conducted in the field.
d. The training schedule for the date and time will be coordinated with the NICTD. The District will supply the facility for the training, both classroom and at the site of the Traction Power Substation.
END OF SECTION
TRACTION POWER SUPPORT 16612-3 DISTRICT
SECTION 16613
MODIFICATION, TESTING, & REPROGRAMMING
OF
SCADA RTU
PART 1 – GENERAL
1.1 SUMMARY
A. SCOPE
1. This section covers the requirements for modification, testing and reprogramming of existing SCADA RTU.
B. RELATED DOCUMENTS
1. Madison Substation SCADA drawings SS05914, Sheets 1 thru 16 have been included as reference drawings in the contract bid documents. These drawings shall be utilized for modifying the Madison SCADA system.
PART 2 – PRODUCT .
2.1 GENERAL
A. The existing RTU is GE Transportation System HLC.
B. The Supervisory Control Office System is integrated into NICTD’s dispatching system which is a Wabtec TMDStm , Train Management Dispatching System.
C. Existing inputs to SCADA are shown on sheets 3 and 4. Control outputs from SCADA are indicated on sheets 5 and 6. Future control outputs and indication inputs are depicted on sheets 7 of NICTD drawing SS05914.
MODIFICATION, TESTING, & REPROGRAMMING OF SCADA RTU 16613-1 DISTRICT
PART 3 – EXECUTION
3.1 INSTALLATION
A. CONTROL WIRING
1. All external wiring interfacing with the RTU cabinet shall terminate on easily accessible interposing terminal blocks within the RTU cabinet. Terminal block shall be TRW Cinch Jones Series 141 dual barrier style or approved equal. All wiring shall be stranded and of suitable gauge and insulation to meet the intended use. Extra flexible stranded control wires shall be used for wiring between hinged and stationary portions of panels.
2. Input and output wiring shall be kept physically separate where possible. AC and low voltage dc wiring shall be kept physically separate where possible.
3. All wiring shall be secured into harnesses. All wiring including harnesses shall be routed in such a manner as to not obstruct the installation or removal of RTU components, and shall be secured to the cabinet where appropriate for neatness and to reduce strain on components
B. RTU CAPACITY AND EXPANSION
1. Since more input/output points may be required in the future, modularity is extremely important. Initially, only those panels, input/output and point cards that are needed to fulfill the required point counts as shown on the drawings shall be installed. However, space and any necessary pre-wiring shall be provided such that additional points can be added by plugging in additional circuit boards/relay panels and installing additional pre- constructed plug-in cables. All spare wiring capacity shall be tested to verify that it is correct
C. PROGRAMMING
1. Contractor will reuse assigned controls and indications where functionality is identical.
MODIFICATION, TESTING, & REPROGRAMMING OF SCADA RTU 16613-2 DISTRICT
2. Contractor shall revise GE HLC software as necessary to implement new and revised controls and indication.
3. Contractor shall provide Definition Document describing control and indication changes to be made to RailComm DOC in support of traction power rehabilitation project.
4. Contractor shall coordinate with NICTD and RailComm who shall revise and reprogram RailComm DOC software as necessary.
3.2 FIELD TESTING
A. GENRAL
1. All wiring modified herein shall be given tests consisting of individual operating tests and dielectric tests in accordance with applicable Institute of Electrical and Electronic Engineers Standards. RTUs will undergo complete functional tests. All points shall be given complete control and indication tests. Tests shall be run simulating the line conditions existing between the master and the remote unit.
2. All tests shall be witnessed by the Authority's representatives. .
3. The testing shall exercise every conceivable function of the SCADA system and shall include, but not be limited to, the following:
a. Demonstration that all peripheral hardware and software are operational. b. Simulation of alarms including multiple simultaneous status changes. Simulated or actual inputs shall be provided to the RTU. c. Demonstration of the control operation of each control output with proper lights or other indications to confirm the control operations. d. Demonstration of the performance of the RTUs, including: 1) Proper cabling 2) Proper card counts 3) Accuracy 4) Proper operation of all input and output functions 5) Proper link-up with data base.
MODIFICATION, TESTING, & REPROGRAMMING OF SCADA RTU 16613-3 DISTRICT
e. Simulation of RTU noise and transient conditions, verifying that erroneous indications and operations do not occur, and no damage to equipment results f. Creation and handling of all possible error and device failure conditions.
4. Discrepancies found during the test shall be documented and maintained in a record file. The subsequent correction shall be described and proper operation be verified by representatives of the Authority and the Contractor.
5. The discrepancies noted shall be corrected and retested. The Authority may request that other modules that may be impacted by the correction be retested also.
END OF SECTION
MODIFICATION, TESTING, & REPROGRAMMING OF SCADA RTU 16613-4