appendix a digester gas generation projections rfp 10-11-45.pdfsampling and analyses be performed in...

APPENDIX A

DIGESTER GAS GENERATION PROJECTIONS

APPENDIX - A City of Visalia WCP - Digester Gas Generation Projections

NOTES: 1 WCP upgrade project is expected to be completed by 2013. 2 All components of RPGS, except power generation system with heat recovery, shall be designed for the DG flow rate corresponding to 18 mgd of wastewater flow rate.

Year Wastewater Flow (mgd)

Digester Gas Flow (scfm)

2011 13.13 173 2012 13.46 177 20131 13.80 181 2014 14.14 186 2015 14.50 190 2016 14.86 195 2017 15.23 200 2018 15.61 205 2019 16.00 210 2020 16.40 215 2021 16.81 220 2022 17.23 226 2023 17.66 231 20242 18.10 237 2025 18.56 243 2026 19.02 249 2027 19.50 255 2028 19.98 261 2029 20.48 268 2030 20.99 274 2031 21.52 281 2032 22.06 288

APPENDIX B

DIGESTER GAS ANALYSIS RESULTS

8645 154th Avenue NE Redmond, WA 98052 Phone (425) 497-8111 Fax (425) 881-3378

COVER PAGE

Project Name: Visalia WCP

Report Type: Biogas Analytical Summary with Recommendations

Report Date: April 30, 2010

ESC Project Number: ESC21004

Project Address: City of Visalia WCP 7579 Ave. 288 Visalia, CA 93277

Site Contact: Jeff Misenhimer, Wastewater Superintendent Phone: 559-713-4176 [email protected]

Sampling Date: 04/21/2010

Sampling Locations: Raw Digester Gas (triplicate)

Sample Analysis Date: 04/22/2010 and 04/23/2010

Contracted by:

Vamsi Seeta PE, LEED AP PARSONS Water & Infrastructure, Inc. 100 W Walnut St, Pasadena, CA 91124 Office: (626) 440 2997 Fax: (626) 440 6337 [email protected]

Alternate Contacts (Safety Related)

Jennifer Hernandez (626) 440 2323 [email protected] Paul Skager [email protected]

Purchase Order No: 260449-00001

SECTION NO. 1.0 PAGE NO. 1.02

Anaerobic Digester Gas ESC DOCUMENT NO.: ESC21004-01.0-002

Revisions

NO. BY APP DATE DESCRIPTION

1 JVW ADG 04-30-10 Biogas Analytical Summary with Recommendations

CLIENT: Parsons

P.O. NO.: 260449-00001

ESC REF. ESC21004

SITE: VISALIA WCP

Introduction Parsons Engineering in Pasadena, CA is conducting a feasibility study to determine the best approach for the production of electrical power from the municipal anaerobic digester gas (MADG) at Visalia, CA. Detailed gas analyses are required to determine the quality of the digester gas and the potential treatment needed to produce a fuel meeting the specifications of either a fuel cell or microturbines. It is anticipated that with the appropriate gas quality and volume, a target of 1 MW of power can be achieved. On April 21, 2010, ESC sampled the anaerobic digester gas at the Visalia WCP using 400 cc Silanite-lined steel canisters. Parsons Engineering issued a Purchase Order to ESC Corporation requesting that the sampling and analyses be performed in triplicate. Analyses performed were the ASATM D1945 for major (or ”permanent”) gas constituents, ASTM D5504 for hydrogen sulfide and other sulfur-containing species, and the EPA Method TO-15 with additional standards to determine the complete VOC contaminant profile, including the siloxanes and organosilicons. The complete analytical report for the April 21, 2010 samples is included at the back of this report. Conclusion The Visalia WCP digester gas contains a fairly typical distribution of permanent gases, with an apparent methane content of 63.77% (HHV of 646 BTU/ft3). Total sulfur species is around 233 ppmv which is predominantly hydrogen sulfide. The VOCs are typical and average 11.4 ppmv. There are three siloxane species totaling around 3 ppmv. No halogenated species were detected. A standard 3-stage biogas treatment system (H2S removal, moisture removal, and siloxane removal) will be required to purify the Visalia WCP anaerobic digester gas to meet microturbine influent gas quality. For fuel cells, a 4-stage biogas treatment system will be required, with the final stage being required to reduce the total sulfur species to below 30 ppbV. It is recommended that a regenerable VOC/Siloxane removal system such as ESC’s CompHeet® Process be used to assure complete siloxane removal. The CompHeet® Process also provides additional insurance against increases in VOC concentration, and complete halogen removal should these appear in the anaerobic digester gas in the future.



Revisions



CLIENT: Parsons

P.O. NO.: 260449-00001

ESC REF. ESC21004

SITE: VISALIA WCP

Data Summary

Gas Constituents 04/21/2010

Raw Sample #1

04/21/2010 Raw Sample

#2


#3 Typical Range

Methane (% by Volume) 63.9 64.0 63.4 58 to 73 Carbon Dioxide (% by Volume) 34.9 34.9 35.6 35 to 41 Nitrogen (% by Volume) 1.0 0.9 0.8 0.5 to 2.5 Oxygen (% by Volume) 0.2 0.2 0.2 0.1 to 1.5 Total BTU per ft3 HHV 647 648 642 580 to 730 Total BTU per ft3 LHV 582 583 578 500 to 665 Total specific gravity (relative to air) 0.898 0.896 0.902 0.89 to 0.96 Silicon in Fuel, µg Si / ft3 632.0 490.4 576.9 150 to 1,500 Silicon in Fuel, µg Si / BTU 0.959 0.744 0.875 0.10 to 1.80


#1


#2


#3 Typical Range

Siloxanes and Organosilicons

ppbv ppbv ppbv ppbv

Trimethylsilanol N.D. N.D. N.D. < 100 to 250

Pentamethyldisiloxane N.D. N.D. N.D. < 100

Hexamethyldisiloxane (MM) N.D. N.D. N.D. < 100 to 500

Octamethyltrisiloxane (MDM) N.D. N.D. N.D. < 100 to 500

Decamethyltetrasiloxane (MD2M) N.D. N.D. N.D. < 100 to 250

Hexamethylcyclotrisiloxane (D3) 186 608 251 250 to 1,000

Octamethyltcyclotetrasiloxane (D4) 1080 983 2,660 250 to 2,500

Decamethylcyclopentasiloxane (D5) 1,540 804 N.D. 500 to 5,000

Dodecamethylcyclohexasilxane (D6) N.D. N.D. N.D. <100 to 500

Other N.D. N.D. N.D. <100 to 250

Total Siloxanes and Organosilicons 2,806 2,395 2,911 2,500 to 7,500 N.D. = not detected (“Unidentified siloxane in analyses is assumed to be D5)



Revisions



CLIENT: Parsons

P.O. NO.: 260449-00001

ESC REF. ESC21004

SITE: VISALIA WCP

Data Summary

04/21/2010 Raw Sample #1

04/21/2010 Raw Sample #2

04/21/2010 Raw Sample #3 Typical Range*

Sulfur Species ppbv ppbv ppbv ppbv

Hydrogen Sulfide* 226,582 225,517 246,218 250,000 to 3,000,000 Carbon Disulfide (from TO-15) 221 --- --- 0 to 2,500 n-Propyl Mercaptan 181 248 240 Total Sulfur Species 226,983 225,764 246,458 250,000 to 3,000,000

*Without ferric chloride addition.


#1


#2


#3 Typical Range

VOCs

ppbv ppbv ppbv ppbv EPA Method TO-15 Compounds 2,360 1,912 2,102 5,000 to 15,000 C6+ Compounds From TO-15 1,059 958 902 2,500 to 10,000 Tentatively Identified Compounds (TICs) 8,841 8,261 8,808 2,500 to 25,000 Total VOCs from TO-15 and TICs 11,201 10,173 10,910 5,000 to 30,000 Total VOCs including siloxanes 14,007 12,568 13,821 5,000 to 35,000

(TIC = “Tentatively Identified Compound”)



Revisions



CLIENT: Parsons

P.O. NO.: 260449-00001

ESC REF. ESC21004

SITE: VISALIA WCP

Data Interpretation The complete analytical results appear at the end of the report. The siloxanes are fairly typical for digester gas, in the middle of the typical concentration range. Organosilicons and siloxanes comprise about 20% of the total VOCs identified. The siloxane concentration in this gas is expected to cause significant damage to power generation or other combustion equipment. The hydrogen sulfide level is too high to use this gas without treatment to protect the siloxane removal system. A catalytic iron sponge system is the most economical approach to remove the hydrogen sulfide for power generation equipment. Siloxanes D3, D4 and D5 account for 100% of the organosilicons detected and 100% of the potential silicon dioxide that would be generated by combustion of untreated gas. For this type of gas, our standard SIL-X™ three-stage system design should be adequate for all types of power generating equipment except for fuel cells. The organosilicon content of the Visalia WCP digester gas is fairly typical based on identifiable siloxanes compared to other municipal digester gas in Canada and the United States. Where the siloxanes are well over 300 ppbv total, removal of the organosilicon content is necessary to protect the ultimate combustion equipment from operational problems and potential failure. At the measured levels of siloxanes and organosilicons, a treatment system for their removal is required. Combustion of this digester gas untreated will produce approximately 209 lb. at 165 SCFM and 343 lb. at 288 SCFM of silicon dioxide per year. This silicon dioxide can build up a deposit to levels where critical equipment components can fail. Discussion Although ferric chloride addition to the digesters is practiced at the Visalia WCP, the hydrogen sulfide levels in the digester biogas are fairly high. If it is possible to dose more ferric chloride, the hydrogen sulfide levels could be lower, and thus the media life in the scavenger-type removal system would be longer. It is not possible, however, to totally eliminate the scavenger type system by ferric chloride dosing. A standard anaerobic digester gas treatment train consists of a water knockout followed by hydrogen sulfide removal, then moisture removal, siloxane and VOC removal and final particulate filtration. ESC proposes to supply a complete integrated 3-stage SIL-X™ treatment system or 4-stage SIL-X™ treatment system. For fuel cells, a 4-stage CompHeet™® treatment system is recommended. The integrated 3-stage SIL-X™ treatment system includes pressure boosting, moisture removal, and gas re-heating to approximately 25 degrees F above the dew point. Moisture removal is necessary to protect the SIL-X™ media from fouling. A properly designed moisture removal system is a packaged treatment system comprised of a gas chiller (gas to liquid), a condensed water removal trap, and gas reheat or “economizer.”



Revisions



CLIENT: Parsons

P.O. NO.: 260449-00001

ESC REF. ESC21004

SITE: VISALIA WCP

Summary Damage to power generation equipment by anaerobic digester gas can be from inorganics contained in the water vapor, the hydrogen sulfide, the siloxanes, or a combination of two or all three. Siloxanes are most often responsible for nearly all of the damage to combustion equipment. Several siloxanes species were detected at a moderately high total level in this gas and would be expected to inflict significant damage to power generation equipment. At the minimum, a non-regenerable siloxane removal system should significantly reduce or eliminate the damage caused by these siloxanes. It should be recognized that analyses performed at the same time provide only a snapshot of the digester gas at the time of sampling. While digester gas does not normally change much, there is no guarantee of consistent siloxane or VOC levels in the gas and spikes of high levels of either can shorten the media life and increase the cost of operation. A separate proposal will be provided detailing the preliminary capital and O&M costs based on the present gas analyses. This is not a firm proposal, which will be provided upon an agreed scope of work for the project.

APPENDIX C

WELL WATER QUALITY TEST REPORTS

APPENDIX D

RPGS NET PRESENT VALUE WORKSHEET

Number Technical Data for RPGS Fuel Cell Energy Fuel Cell Energy Ingersoll Rand CapstoneFuel Cell (DFC 1500) Fuel Cell (DFC 300) Microturbine (MT250) Microturbine (CR200)

1 Number of Units proposed for year 20132 Gross Capacity of each unit, kW3 Total Capacity of all units, kW4 Guaranteed Parasitic Loads (including DG booster blowers and fuel conditioning system), kW5 Effective Total Capacity, kW (deducting parasitic loads) (Item 3 - Item 4)6 Guaranteed Electrical Efficiency @100% load, %7 Guaranteed Heat Input Rate, BTU/kWh8 Power generation from available DG, kW9 Net Power Output (less parasitic loads), kW (Item 8 - Item 4)10 Guaranteed Annual Availability for Equipment, Hours/year11 Net Power Generated from DG, kWh/year (Item 9 x Item 10)12 Guaranteed Thermal Efficiency, %13 Recoverable Waste Heat total, MMBTUs/hr

Capital Cost14 Capital Cost, $15 Capital Cost of Renewable Power Generation, $/kW (Item 14/Item 3)16 SCE Incentive (SGIP), $/kW17 SCE Incentives for first MW or part thereof (SGIP), $18 SCE Incentives for second MW or part thereof (SGIP) - if applicable - Only for fuel cells alternative19 Other Incentives, $20 Total Incentives (Item 17 + Item 18 + Item 19)

Operating Cost21 Five Year Maintenance Service Program Description 22 Lump sum for five year O&M Contract including gas conditioning system, $23 Major Overhaul for all units (beyond first five years), $ - Only for microturbines alternative24 Fuel cell stack replacement for all units (beyond first five years), $ - only for fuel cells alternative

APPENDIX - DCity of Visalia - WCP Upgrades Project

RPGS - Net Present Value Worksheet

APPENDIX E

GUARANTEED OPERATING AND PERFORMANCE CONDITIONS

City of Visalia - WCP Upgrades Project RPGS Pre-selection 1

APPENDIX E

Guaranteed Operating and Performance Conditions for RPGS (To be filled-in by the EQUIPMENT SUPPLIER and the values are considered as Guaranteed Values to be used for

bid evaluation) No. Capacity or Performance Item Bidder’s Response A DG BOOSTER BLOWERS

1 Number (duty, standby) 2 Type of blower 3 Capacity of each unit, scfm 4 Pressure rating of each unit, psig 5 Motor rating, HP 6 Cooling system

B DG Purification System

Guaranteed availability of the DG Purification System, hours/year

Hydrogen Sulfide Removal System 1 Number of vessels (duty, standby) 2 Size of each vessel (diameter x height) 3 Material of construction for vessels 4 Type of media used 5 Quantity of media per vessel, lb 6 H2S removal capacity of media, lb H2S/lb media 7 Is media regenerable on-site? 8 Guaranteed maximum pressure drop across each unit, psig 9 Guaranteed life of media between change-

outs/regenerations, days

10 Design inlet concentration of H2S 11 Guaranteed outlet concentration of H2S Refrigeration / Chiller System (If applicable) 1 Number of heat exchangers 2 Type of heat exchangers, gas to gas etc. 3 Design pressure due point for the gas, 0F 4 Guaranteed power consumption of the system, HP 5 Temperature of the gas leaving the system, 0F Siloxane Removal System 1 Number of vessels (duty, standby) 2 Size of each vessel (diameter x height) 3 Material of construction for vessels 4 Type of media used 5 Quantity of media per vessel, lb 6 Is media regenerable on-site? 7 Guaranteed maximum pressure drop across each unit, psig 8 Guaranteed life of media between change-

outs/regenerations, days

9 Design inlet concentration of siloxane species 10 Guaranteed outlet concentration of siloxanes


No. Capacity or Performance Item Bidder’s Response C Power Generation System

1 Guaranteed availability of the Power Generation System, hours/year

2 Guaranteed annual degradation in electrical efficiency, % of full rated capacity on day 1 (only for fuel cells alternative)

3 Guaranteed time interval between minor and major over hauls, hrs (only for microturbines alternative)

4 Guaranteed time interval between stack replacement, hrs (only for fuel cells alternative)

5 Number of units 6 Rated capacity of each unit, kW 7 Guaranteed availability for each unit, hours/year 8 Required DG gas flow per unit at guaranteed power output,

scfm

9 Guaranteed power output per unit at full load, kW 10 Guaranteed heat input per unit electricity generated at full

load, Btu/kWh

11 Maximum turn down (%) and corresponding electrical efficiency (%) on DG

12 Minimum fuel pressure required at the gas train for each unit, psig

13 Guaranteed total parasitic loads to power generation, HP 14 Maximum H2S level allowed in the fuel gas, ppm 15 Maximum siloxane level allowed in fuel gas, ppbv 16 Guaranteed electrical efficiency at the following loads on

DG, minimum %

17 At full 100% rated load 18 At 75% of full rated load 19 At 50% of full rated load 20 Guaranteed maximum NOx emissions on DG, ppmvd and

lb/MWh

21 Guaranteed maximum CO emissions on DG, ppmvd and lb/MWh

22 Guaranteed maximum VOC emissions on DG, ppmvd and lb/MWh

Heat Recovery System 1 Number of units (duty, standby) 2 Rated heat capacity of each unit, MMBtu/hr 3 Type of heat exchanger used 4 Exhaust gas flow rate of the power generation system, scfm 5 Exhaust temperature of the power generation system, 0F 6 Guaranteed thermal efficiency of the proposed system, %

of heat input

7 Guaranteed recoverable heat from exhaust, MMBtu/hr 8 9 Hot water loop flow rate, gpm 10 Hot water loop inlet temperature (HWR), oF 11 Hot water loop outlet temperature (HWS), oF 12 Guaranteed pressure drop through heat recovery system, psi


No. Capacity or Performance Item Bidder’s Response

Power Generator (if applicable) 1 Generator type 2 Generator rating and pitch 3 Generator efficiency at 100% load with 1.0 PF, % 4 Generator voltage, volts 5 Generator insulation class 6 Generator power factor

APPENDIX F

LIST OF NAMED EQUIPMENT / MATERIAL SUPPLIERS

APPENDIX F

LIST OF NAMED EQUIPMENT/MATERIAL SUPPLIERS

The EQUIPMENT SUPPLIER shall indicate below, which Supplier he intends to use to furnish each item of equipment or material listed on this form. The listing of more than one supplier for each equipment/material to be furnished with the words “and/or” will not be permitted. Failure to comply with this requirement may render the proposal non-responsive and may cause its rejection.

No Equipment/Material Name of Supplier Model

1 DG Booster Blowers

2 Hydrogen Sulfide Removal System

3 Refrigeration /Chiller System (if applicable)

4 Siloxane Removal System

5 Power Generation System

6 Heat Recovery System

7 Power Inverters

8 Programmable Logic Controllers (PLCs)

9 Step-up Transformers

10 Variable Frequency Drives (VFDs)

NOTE : The EQUIPMENT SUPPLIER shall note that, where applicable, the selection of equipment/material suppliers shall comply with all pertinent requirements of SGIP, as referenced throughout this RFP document.

Signed Bidder

Company

APPENDIX G

GENERAL REQUIREMENTS (DIV 01)

City of Visalia – WCP Upgrades RPGS Pre-selection 01300 – 1 December 2010 Equipment Supplier Submittals

SECTION 01300 – EQUIPMENT SUPPLIER SUBMITTALS

PART 1 – GENERAL

1.01 WORK INCLUDED

A. Wherever submittals are required hereunder, all such submittals by the EQUIPMENT SUPPLIER shall be submitted to the CITY/ENGINEER, unless specifically stated.

B. Within 15 calendar days after the Notice of Selection from the CITY/ENGINEER, the EQUIPMENT SUPPLIER shall submit the following items to the CITY/ENGINEER for review:

1. A preliminary schedule of Shop Drawings, Samples, and proposed Substitutes ("Or-Approved Equal") submittals.

1.02 SHOP DRAWINGS

A. The EQUIPMENT SUPPLIER shall furnish during the design phase to the CITY/ENGINEER for review, eight (8) copies, plus one reproducible copy and one electronic copy (PDF format), of each shop drawing submittal. The term "Shop Drawings" as used herein shall be understood to include shop drawings, fabrication, and installation drawings, erection drawings, list, graphs, catalog sheets, data sheets, and similar items. Whenever the EQUIPMENT SUPPLIER is required to submit design calculations as part of a submittal, such calculations shall bear the signature and seal of an engineer registered in the appropriate branch and in the state of California, unless otherwise directed.

B. Verify that the material or equipment described in each submittal conforms to all requirements of the Contract Documents. Where the detailed specifications require specific submittal data, submit all data at the same time. The submittals are to be accompanied by the transmittal form attached at the end of this Section. The CITY/ENGINEER may return for resubmittal any information not accompanied by the specified transmittal form, properly completed.

C. Except as may otherwise be indicated herein, the CITY/ENGINEER will return prints of each submittal to the EQUIPMENT SUPPLIER with its comments noted thereon, within 30 calendar days following their receipt by the CITY/ENGINEER. It is considered reasonable that the EQUIPMENT SUPPLIER shall make a complete and acceptable submittal to the CITY/ENGINEER by the second submission of a submittal item. The CITY/ENGINEER reserves the right to withhold moneys due to the EQUIPMENT SUPPLIER to cover additional costs ($140/hr) of the ENGINEER’S review beyond the second submittal. The ENGINEER’S maximum review period for each submittal, including all resubmittals, will be 30 days per submittal.

D. If three (3) copies of a submittal are returned to the EQUIPMENT SUPPLIER marked "NO EXCEPTIONS TAKEN," formal revision and resubmission of said submittal will not be required.


E. If three (3) copies of a submittal are returned to the EQUIPMENT SUPPLIER marked "MAKE CORRECTIONS NOTED," formal revision and resubmission of said submittal will not be required.

F. If a submittal is returned to the EQUIPMENT SUPPLIER marked "AMEND-RESUBMIT," the EQUIPMENT SUPPLIER shall revise said submittal and shall resubmit the required number of copies of said revised submittal to the CITY/ENGINEER.

G. If a submittal is returned to the EQUIPMENT SUPPLIER marked "REJECTED-RESUBMIT," the EQUIPMENT SUPPLIER shall revise said submittal and shall resubmit the required number of copies of said revised submittal to the CITY/ENGINEER.

H. Fabrication of an item shall be commenced only after the CITY/ENGINEER has reviewed the pertinent submittals and returned copies to the EQUIPMENT SUPPLIER marked either "NO EXCEPTIONS TAKEN" or “MAKE CORRECTIONS NOTED". Corrections indicated on submittals shall be considered as changes necessary to meet the requirements of the Contract Documents and shall not be taken as the basis for changes to the contract requirements.

I. All EQUIPMENT SUPPLIER shop drawings submittals shall be carefully reviewed by an authorized representative of the EQUIPMENT SUPPLIER, prior to submission to the CITY/ENGINEER. Each submittal shall be dated, signed, and certified by the EQUIPMENT SUPPLIER as being correct and in strict conformance with the Contract Documents. In the case of shop drawings, each sheet shall be so dated, signed, and certified. No consideration for review by the ENGINEER of any EQUIPMENT SUPPLIER submittals will be made for any items which have not been so certified by the EQUIPMENT SUPPLIER. All non-certified submittals will be returned to the EQUIPMENT SUPPLIER without action taken by the CITY/ENGINEER, and any delays caused thereby shall be the total responsibility of the EQUIPMENT SUPPLIER.

1.03 EFFECT OF ACCEPTANCE OF EQUIPMENT SUPPLIER INFORMATION

A. Acceptance by the ENGINEER of any drawings, method of work, or any information regarding materials or equipment the EQUIPMENT SUPPLIER proposes to provide shall not relieve the EQUIPMENT SUPPLIER of his responsibility for any errors therein and shall not be regarded as an assumption of risk or liability by the CONTRACTOR, ENGINEER, or CITY, or by any officer or employees thereof, and the EQUIPMENT SUPPLIER shall have no claim under the contract on account of the failure or partial failure or inefficiency of any plan or method of work or material or equipment so accepted. Such acceptance shall be considered to mean merely that the CONTRACTOR, ENGINEER, or CITY has no objection to the EQUIPMENT SUPPLIER using, upon his own full responsibility, the plan or method of work proposed, or providing the materials or equipment proposed.

B. Approval of shop drawings by the ENGINEER is only for general conformance with the design concept of the project and general compliance with the information given in the Contract Documents. Any action shown is subject to the requirements of the plans and specifications. The EQUIPMENT SUPPLIER is responsible for dimensions which shall be confirmed and correlated at the job site, fabrication process and techniques of


construction, coordination of his work with that of all other trades and the satisfactory performance of his work.

1.04 DEVIATIONS FROM CONTRACT DOCUMENTS

A. If the EQUIPMENT SUPPLIER proposes to provide material or equipment which does not conform to all of the Contract Documents, the transmittal form accompanying the submittal copies shall indicate under "comments" the deviations.

1.05 PRODUCT DATA AND SAMPLES

A. Where required in the specifications, test specimens or samples of materials, appliances and fittings to be used or offered for use in connection with the work shall be submitted at the EQUIPMENT SUPPLIER'S expense, with information as to their sources, with all freight charges prepaid, and in such quantities and sizes as may be required for proper examination and tests to establish the quality or equality thereof, as applicable.

B. All samples and test specimens are to be submitted in ample time to enable the ENGINEER to make any tests or examinations necessary, without delay to the work. The EQUIPMENT SUPPLIER will be held responsible for any loss of time due to the neglect or failure to deliver the required samples to the ENGINEER as specified.

C. Samples may also to be taken during the course of the work, as required by the ENGINEER.

D. Laboratory tests and examinations that the CITY and/or ENGINEER elects to make will be made at no cost to the EQUIPMENT SUPPLIER, except that if a sample of any material or equipment proposed for use by the EQUIPMENT SUPPLIER fails to meet the Specifications, the cost of testing subsequent samples will be borne by the EQUIPMENT SUPPLIER.

E. All tests required by the specifications to be performed by an independent laboratory are to be made, and the samples therefore furnished shall be at the sole expense of the EQUIPMENT SUPPLIER.

F. Material used in the work is to conform with the submitted samples and test certificates as approved by the ENGINEER.

1.06 EQUIPMENT SUPPLIER'S SCHEDULES

A. Within 14 calendar days after the Commencement Date in the Notice to Proceed, the EQUIPMENT SUPPLIER shall furnish the CITY and the CONTRACTOR a schedule showing the dates that manufacturing and assembly is to start and shipment is to commence. This schedule shall be developed and followed to ensure the timely delivery of the equipment. The schedule shall be subject to the CONTRACTOR'S review and EQUIPMENT SUPPLIER resubmittal of the schedule shall be as required by the CONTRACTOR.

B. Notwithstanding anything to the contrary herein or elsewhere in the RFP, EQUIPMENT SUPPLIER shall not proceed with fabrication of any equipment until the


CONTRACTOR and the CITY approve the equipment delivery schedule in writing, at which time EQUIPMENT SUPPLIER’S delivery schedule shall begin.

1.07 OPERATION AND TECHNICAL MANUALS

A. The EQUIPMENT SUPPLIER shall submit technical operation and maintenance information for each item of mechanical and electrical equipment and instrumentation in an organized manner in the Operation and Technical Manuals. It shall be written so that it can be used and understood by the CITY'S operation and maintenance staff. The Operation and Technical Manual information shall also be submitted in electronic format using compact discs (CD), with each part of manual included as an individual pdf file. All individual equipment sheets shall be submitted on CD as individual pdf files.

B. The Operation and Technical Manuals shall be subdivided by "Part." "Parts" shall conform to the following (as applicable):

1. Part 1 - Equipment Summary: A summary table shall indicate the equipment name, equipment number, and process area in which the equipment is installed.

2. Part 2 - Operational Procedures: Manufacturer-recommended procedures on the following shall be included in Part 2:

a. Installation

b. Adjustment

c. Startup

d. Location of controls, special tools, equipment required, or related instrumentation needed for operation

e. Operation procedures

f. Load changes Calibration Shutdown

g. Troubleshooting, Disassembly, Reassembly

h. Realignment

i. Testing to determine performance efficiency

j. Tabulation of proper settings for all pressure relief valves, low and high pressure switches, and other protection devices

k. List of all electrical relay settings including alarm and contact settings

3. Part 3 - Preventive Maintenance Procedures: Preventive maintenance procedures shall include all manufacturer-recommended procedures to be performed on a periodic basis, both by removing and replacing the equipment or component, and by leaving the equipment in place.

a. Schedules: Recommended frequency of preventive maintenance procedures shall be included. Lubrication schedules, including lubricant SAE grade, type, and temperature ranges, shall be covered.


4. Part 4 - Parts List: A complete parts list shall be furnished, including a generic description and manufacturer's identification number for each part. Addresses and telephone numbers of the nearest equipment supplier and parts warehouse shall be included.

a. Drawings: Cross-sectional or exploded view drawings shall accompany the part list.

5. Part 5 - Wiring Diagrams: Part 5 shall include complete internal and connection wiring diagrams for electrical equipment items.

6. Part 6 - Shop Drawings: This part shall include approved shop or fabrication drawings, complete with dimensions.

7. Part 7 - Safety: This part describes the safety precautions to be taken when operating and maintaining the equipment or working near it.

8. Part 8 - Documentation: All equipment warranties, affidavits, and certifications required by the Technical Specifications shall be placed in this part.

9. Part 9 - Spare Parts: This part shall contain spare parts information for all mechanical, electrical, and instrumentation equipment. The spare parts list shall include the current list price of each spare part. The spare parts list shall be limited to those spare parts which each manufacturer recommends be maintained by the CITY in inventory at the plant site. Each manufacturer or equipment supplier shall indicate the name, address, and telephone number of its nearest outlet of spare parts to facilitate the CITY in ordering. The EQUIPMENT SUPPLIER shall cross-reference all spare parts lists to the equipment numbers designated in the Contract Documents.

C. The EQUIPMENT SUPPLIER shall submit to the ENGINEER three (3) identical Operation and Technical Manuals a minimum of 90 calendar days prior to the scheduled startup of the EQUIPMENT.

D. The ENGINEER will review the Operation and Technical Manuals within 30 days following their receipt by the ENGINEER. The EQUIPMENT SUPPLIER shall then make any corrections and changes noted and compile all the corrected Operation and Technical Manuals for final submittal to the ENGINEER.

– END OF SECTION –


STANDARD SUBMITTAL FORM

Date: ____________________________ _______________________________

_________________________________ SUBMITTAL NO. ____________________

FROM: ___________________________ TO:_______________________________

(To be completed afterward)

This is: (Check one) EQUIPMENT SUPPLIER: An Original Submittal A 2nd Submittal

A Submittal Previous Submittal Nos. No. of Submittal Copies

SPECIFICATION OR SUBJECT OF SUBMITTAL EQUIPMENT DESIGNATION DRAWING REFERENCE

We have verified that this submittal contains all applicable material and information required for evaluation against the project Specifications. Furthermore, we submit these items, which comply with the Drawings and Specifications (check one):

With no exceptions

Except for the following deviations

NO.

DEVIATIONS

EQUIPMENT SUPPLIER'S Authorized Representative

City of Visalia – WCP Upgrades RPGS Pre-Selection 01600 – 1 December 2010 Products, Materials, Equipment, and Substitutions

SECTION 01600 – PRODUCTS, MATERIALS, EQUIPMENT, AND SUBSTITUTIONS

PART 1 – GENERAL

1.01 DEFINITIONS

A. The word "Products," as used herein is defined to include purchased items for incorporation into the WORK. The word "Materials," is defined as products which must be substantially cut, shaped, worked, mixed, finished, refined, or otherwise fabricated, processed, installed, or applied to form units of work. The word "Equipment" is defined as products with operational parts, regardless of whether motorized or manually operated and particularly including products with service connections (wiring, piping, and other like items). Definitions in this paragraph are not intended to negate the meaning of other terms used in the Request for Proposal, including "specialties," "systems," "structure," "finishes," "accessories," "furnishings," special construction," and similar terms, which are self-explanatory and have recognized meanings in the construction industry.

B. Neither "Products" nor "Materials" nor "Equipment" includes machinery and equipment used for preparation, fabrication, conveying and erection of the WORK.

1.02 QUALITY ASSURANCE

A. Source Limitations: To the greatest extent possible for each unit of WORK, the EQUIPMENT SUPPLIER shall provide products, materials, and equipment of a singular generic kind from a single source.

B. Compatibility of Options: Where more than one choice is available as options for EQUIPMENT SUPPLIER’S selection of a product, material, or equipment, the EQUIPMENT SUPPLIER shall select an option which is compatible with other products, materials, or equipment. Compatibility is a basic general requirement of product, material and equipment selections.

C. All products, materials and equipment incorporated in the WORK shall be new, undamaged, of current manufacture and in strict compliance with the specifications except as otherwise approved by the CITY/ENGINEER.

1.03 PRODUCT DELIVERY

A. The EQUIPMENT SUPPLIER shall deliver the WORK in accordance with manufacturer's written recommendations and by methods and means which will prevent damage, deterioration, and loss including theft.

1.04 TRANSPORTATION AND HANDLING

A. Products shall be transported by methods to avoid damage and shall be delivered in undamaged condition in manufacturer's unopened containers and packaging.


1.05 MAINTENANCE OF STORAGE

A. For mechanical and electrical equipment, the EQUIPMENT SUPPLIER shall provide a copy of the manufacturer's service instructions with each item and the exterior of the package shall contain notice that instructions are included.

1.06 PROPOSED SUBSTITUTIONS OR “OR-EQUAL” ITEMS

A. Whenever materials or equipment are indicated in the Request for Proposal documents by using the name of a proprietary item or the name of a particular Supplier, the naming of the item is intended to establish the type, function, and quality required. If the name is followed by the words "or equal" indicating that a substitution is permitted, materials or equipment of other suppliers may be accepted if sufficient information is submitted by the EQUIPMENT SUPPLIER to allow the ENGINEER to determine that the material or equipment proposed is equivalent or equal to that named, subject to the following requirements:

1. The burden of proof as to the type, function, and quality of any such substitution product, material or equipment shall be upon the EQUIPMENT SUPPLIER.

2. The ENGINEER will be the sole judge as to the type, function, and quality of any such substitution and the ENGINEER’S decision shall be final.

3. The ENGINEER may require the EQUIPMENT SUPPLIER to furnish additional data about the proposed substitution.

4. The CITY may require the EQUIPMENT SUPPLIER to furnish a special performance guarantee or other surety with respect to any substitution.

5. Acceptance by the ENGINEER of a substitution item proposed by the EQUIPMENT SUPPLIER shall not relieve the EQUIPMENT SUPPLIER of the responsibility for full compliance with the Request for Proposal and for adequacy of the substitution.

B. The procedure for review by the ENGINEER will include the following:

1. If the EQUIPMENT SUPPLIER wishes to provide a substitution item, the EQUIPMENT SUPPLIER shall make written application to the ENGINEER on the "Substitution Request Form”. The Substitution Request Form is attached to the end of this specification. The "Substitution Request Form(s)," along with all required documentation to establish “equivalence” by the ENGINEER, shall be submitted together with the EQUIPMENT SUPPLIER’S proposal.

2. Wherever a proposed substitution item has not been submitted within the above time frame, or wherever the submission of a proposed substitution material or equipment has been judged to be unacceptable by the ENGINEER, the EQUIPMENT SUPPLIER shall provide the material or equipment indicated in the RFP at no additional cost to the CITY and without adjustment to the EQUIPMENT SUPPLIER’S delivery schedule.


3. The EQUIPMENT SUPPLIER shall certify that the proposed substitution will perform adequately the functions and achieve the results called for by the general design, and be similar and of equal substance to that indicated, and be suited to the same use as that specified.

4. The ENGINEER will evaluate each proposed substitution within a reasonable period of time.

5. As applicable, no shop drawing submittals shall be made for a substitution item nor shall any substitution item be ordered, installed, or utilized without the ENGINEER’S prior written acceptance of the EQUIPMENT SUPPLIER’S "Substitution Request Form."

6. The ENGINEER will record the time required by the ENGINEER in evaluating substitutions proposed by the EQUIPMENT SUPPLIER.

C. The EQUIPMENT SUPPLIER’S application using the "Substitution Request Forms" shall contain the following statements and information which shall be considered by the ENGINEER in evaluating the proposed substitution:

1. The evaluation and acceptance of the proposed substitution will not prejudice the EQUIPMENT SUPPLIER’S achievement of commissioning and start-up on time.

2. Whether or not incorporation or use of the substitution in connection with the WORK is subject to payment of any license fee or royalty.

3. All variations of the proposed substitution from the items originally specified will be identified.

4. Available maintenance, repair, and replacement service will be indicated. The manufacturer shall have a local service agency (within 150 miles of the site) which maintains properly trained personnel and adequate spare parts and is able to respond and complete repairs within 24 hours.

D. Without any increase in cost to the CITY, the EQUIPMENT SUPPLIER shall be responsible for and pay all costs in connection with proposed substitutions and of inspections and testing of equipment or materials submitted for review prior to the CONTRACTOR'S purchase thereof for incorporation in the WORK, whether or not the ENGINEER accepts the proposed substitution or proposed equipment or material. The EQUIPMENT SUPPLIER shall reimburse the CITY for the charges of the ENGINEER for evaluating each proposed substitution.


City of Visalia – WCP Upgrades RPGS Pre-Selection 01600 – 4 December 2010 Substitution Request Form

SUBSTITUTION REQUEST FORM TO: (ENGINEER)

Parsons Water & Infrastructure Inc. 100 W. Walnut Street

Pasadena, CA 91124

PLEASE CHECK THE APPROPRIATE BOXES BELOW:

□ Substitution Request Along with Proposal. □ Product or System Substitution □ Design Change Substitution

[The EQUIPMENT SUPPLIER shall assign a number in the format shown below]

SUBSTITUTION REQUEST # SR-XX WE HEREBY SUBMIT FOR YOUR CONSIDERATION THE FOLLOWING PRODUCT OR METHOD AS SUBSTITUTION FOR THE SPECIFIED OR DRAWING ITEM FOR THIS PROJECT: PROJECT: City of Visalia – Water Conservation Plant Upgrade_______________________ SPECIFIED ITEM: ______________________________________________________________________ _____________ _______ _______ ________________________________ Specification Section # Page # Paragraph # Description PROPOSED SUBSTITUTION: ______________________________________________________________________ Attached data includes product description, specifications, drawings, photographs, performance and test data adequate for evaluation of the request; applicable portions of the data are clearly identified. Attached data also includes a description of changes to the RFP Documents which the proposed substitution will require for proper installation and subsequent operation. The undersigned claimant agrees/certifies: (Modifications by the claimant to the following list is cause for automatic rejection without further review) 1. The proposed substitution does not affect dimensions shown on drawings or code requirements indicated. 2. The undersigned claimant will compensate the Engineer as specified in Section 1600-1.06D of the RFP

Documents, at a rate of $175.00 per hour, payable by check or money order to “Parsons Water and Infrastructure” if evaluation of the substituted item requires excessive time to complete due to inadequate design/performance information provided by the manufacturer.

3. Maintenance and service parts will be locally available for the proposed substitution. 4. Information is attached for a minimum of three projects where the substitution has been used locally within a

100 mile distance of this project, including names, addresses and telephone numbers of OWNERS who have accepted this product into their projects.

5. All direct and indirect cost data resulting from the substitution is attached, with explanations including a discussion on quality of proposed substitution and cost differential.

6. The undersigned claimant shall bear any subsequent changes in cost of carrying out the WORK that result from the substitution, whether or not apparent at the time of approval of the substituted item.

City of Visalia – WCP Upgrades RPGS Pre-Selection 01600 – 5 December 2010 Substitution Request Form

Fill in blanks below: A. What affect does the substitution have on other trades? ___________________________________________________________________________________________________ B. What are the differences between proposed substitution and specified item? ___________________________________________________________________________________________________ C. Manufacturer's guarantees of the proposed and specified items are: ________ Same ________ Different (explain on attachment) D. Cost difference between proposed substitution and specified item. Is there a cost savings to CITY? ___________________________________________________________________________________________________ The undersigned Claimant(s) declares under penalty of perjury per the California Government Code Section 12650, et seq., that the claim of function, appearance and quality are equivalent or superior to the specified item, and further know and understand that submission for certification of a false claim may lead to fines, imprisonment and /or other severe legal consequences.

BELOW IS FOR USE BY SUBMITTED BY CLAIMANT: DESIGN CONSULTANT ONLY

Signature ________________________________ Reviewed By________________________________

Firm ____________________________________

Firm________________________________________

Date ____________________________________

Date________________________________________

Remarks_________________________________ _________________________________________ _________________________________________

Remarks_____________________________________ ____________________________________________ ____________________________________________

Note: The Substitution Request Form may be completed electronically or typed, however a “wet” signature shall be affixed to the original submission with required fees and information.

APPENDIX H

MECHANICAL SPECIFICATIONS (DIV 11)

City of Visalia – WCP Upgrades RPGS Pre-Selection 11000 – 1 December 2010 Equipment General Provisions

SECTION 11000 – EQUIPMENT GENERAL PROVISIONS

PART 1 – GENERAL

1.01 WORK INCLUDED

A. The provisions of this section apply to all sections of Division 11 and Section 6 of this Request for Proposal (RFP), unless specifically revised therein.

B. Furnish each piece of equipment complete with its base, drives, shafting, couplings, controls, guards, and other appurtenances which are specified or are required for proper and safe operation. Anchor bolts will be provided by CONTRACTOR. The CONTRACTOR will be responsible for installation of the equipment specified in the RFP and Division 11.

C. Furnish any special tools or equipment required for proper operation maintenance, testing, or adjusting.

1.02 REFERENCE STANDARDS

A. Equipment shall be in accordance with the following standards, as applicable and as indicated in each equipment specification:

ANSI B1 6.1 Cast Iron Pipe Flanges and Flanged Fittings, Class 25, 125, 150

ANSI B1 6.5 Pipe Flanges and Ranged Fittings, Steel, Nickel Alloy and other Special Alloys

ANSI B46.1 Surface Texture

ANSI S12.6 Method for the Measurement of the Real-Ear Attenuation of Hearing Protectors

ASME B1.20.1 General Purpose Pipe Threads (Inch)

ASME B31.1 Power Piping

ASME B31.3 Process Piping

AWWA C206 Field Welding of Steel Water Pipe

AWWA C207 Steel Pipe Flanges for Waterworks Service - Sizes 4 inch Through 144 inch (100 mm through 3,600 mm)

AWWA D1 00 Welded Steel Tanks for Water Storage ASTM A 48 Gray Iron Castings

ASTM A 108 1.04 Steel Bars, Carbon, Cold-Finished, Standard Quality


1.03 SUBMITTALS

A. Submittals shall be made in accordance with Section 01300 - EQUIPMENT SUPPLIER SUBMITTALS and the specific equipment specifications sections.

B. Shop Drawings: Furnish complete drawings and technical information for equipment, piping, valves, and controls. Where indicated or required by the ENGINEER, Shop Drawings shall include clear, concise calculations showing equipment anchorage forces and the capacities of the anchorage elements proposed by the EQUIPMENT SUPPLIER.

C. Spare Parts List: The EQUIPMENT SUPPLIER shall obtain from the manufacturer and submit at the same time as Shop Drawings a list of suggested spare parts for each piece of equipment. EQUIPMENT SUPPLIER shall also furnish the name, address, and telephone number of the nearest distributor for each piece of equipment.

1.04 ADAPTATION OF EQUIPMENT

A. Furnish equipment readily adaptable for installation and operation. Equipment furnished shall be compatible with all other equipment furnished under the Contract.

B. Assume full responsibility for all modifications of mechanical and electrical controls, equipment, wiring, piping, as required to accomplish function intended by the RFP and within the EQUIPMENT SUPPLIER'S agreed upon Scope of Work.


A. Guarantees: Unless otherwise excepted herein, the EQUIPMENT SUPPLIER shall guarantee all equipment and installation required. Guarantees shall cover the following:

1. Faulty or inadequate design.

2. Improper assembly.

3. Leakage, breakage, or other failure.

4. Defective workmanship or materials.

B. Inspection, Start-up and Field Adjustment: The EQUIPMENT SUPPLIER shall demonstrate that all equipment meets the specified performance requirements. EQUIPMENT SUPPLIER shall provide the services of an experienced, competent, and authorized service representative of the manufacturer of each item of major equipment who shall visit the site of Work to perform the following tasks:

1. Assist the CONTRACTOR in the installation of the equipment.

2. To inspect, check, adjust if necessary and approve the equipment installation.

3. To start-up and field-test the equipment for proper operation, efficiency, and capacity.


4. To perform necessary field adjustments during the test period until the equipment installation and operation are satisfactory to the ENGINEER.

5. To instruct the CITY'S personnel in the operation and maintenance of the equipment. Instruction shall include step-by-step trouble shooting procedures with all necessary test equipment.

C. Quality and Tolerances: Tolerances and clearances shall be as shown on the Shop Drawings and shall be closely adhered to.

D. Machine Finish: The type of finish shall be the most suitable for the application and shall be shown in micro-inches in accordance with ANSI B46.1

E. Manufacturer's Experience: Equipment manufacturer shall have a record of at least five (5) years of successful, trouble free manufacturing and operation in similar applications and size equal or larger than the equipment in this contract.

PART 2 – PRODUCTS

2.01 VIBRATION LIMITATIONS

A. Vibration frequencies shall be 1.5 mils peak to maximum amplitude. Where specified, measurements shall be obtained while the installed equipment is operating within the specified speed range.

B. Positive Displacement Machines: Unless otherwise specified, positive displacement machines of the rotary, reciprocating and controlled volume types shall operate without any lateral or torsional vibration characteristics that may accelerate wear of the equipment. The EQUIPMENT SUPPLIER shall provide manufacturer's certification that the manufacturer has inspected the machine under operating conditions and found it to comply with the requirements of this paragraph.

2.02 CRITICAL SPEED REQUIREMENTS

A. Unless otherwise specified, rotating mechanical equipment shall not exhibit critical speeds within the specified range of operating speeds and impeller blade pass frequencies. Critical speeds for equipment with rigid rotor systems shall be at least 20 percent greater than maximum operating speed and maximum impeller blade pass frequency, whichever is greater. Critical speeds for equipment with flexible shaft-rotor systems shall be at least 15 percent below minimum operating speed and 20 percent above maximum operating speed and blade pass frequency.

B. Vibration Isolators: Air compressors, blowers, engines, inline fans shall be provided with restrained spring-type vibration isolators or pads per manufacturer's written recommendations. Vibration isolations shall be provided with seismic restraint.

2.03 DRIVE TRAINS AND SERVICE FACTORS

A. Drive Trains and Service Factors: Service factors shall be applied in the selection or design of mechanical power transmission components. All components of drive train assemblies between the prime mover and the driven equipment shall be designed and rated to deliver the maximum peak or starting torque, speed, and horsepower. All of


the applicable service factors shall be considered, such as mechanical (type of prime mover), load class, start frequency, ventilation, ambient temperature, and fan factors. Drive train components include couplings, shafts, gears, and gear drives, drive chains, sprockets, and V-belt drives. Unless otherwise indicated, the following load classification shall apply in determining service factors:

Type of Equipment Load Classification

Centrifugal Fans Uniform

Pumps Uniform

Centrifugal or Rotary Uniform

Reciprocating Moderate Shock

B. Mechanical Service Factors:

Mechanical Service Factors

Uniform 1.25

Moderate Shock 1.50

Heavy Shock 2.0

C. For thermal rating adjustments such as start frequency, ambient temperature, and hourly duty cycle factor, ventilation factor, and fan factor, refer to gear manufacturer sizing information.

D. For electric motor service factors, see Section 16460 – Electric Motors.

E. Where load classifications are not indicated, service factors based on AGMA 514.02 shall be used for standard load classification and for flexible couplings.

2.04 SHAFTING

A. Shafting shall be continuous between bearings and shall be sized to transmit the power required. Keyways shall be accurately cut in line. Shafting shall not be turned down at the ends to accommodate bearings or sprockets whose bore is less than the diameter of the shaft. Shafts shall rotate in the end bearings and shall be turned and polished, straight, and true.

B. Design Criteria: All shafts shall be designed to carry the steady state and transient loads suitable for unlimited number of load applications, in accordance with ASME B1 06.1 M - Design of Transmission Shafting. Where shafts are subjected to fatigue stresses, such as frequent start and stop cycles, the mean stress shall be determined by using the modified Goodman Diagram. The maximum torsional stress shall not exceed the endurance limit of the shaft after application of the factor of safety of 2 in the endurance limit and the stress concentration factor of the fillets in the shaft and keyway. Stress concentration factor shall be in accordance with ASME Standard B1 7.1 - Keys and KeySeats.


C. Materials: Shafting materials shall be appropriate for the type of service and torque transmitted. Environmental elements such as corrosive gases, moisture, and fluids shall be taken into consideration. Materials shall be as indicated unless furnished as part of an equipment assembly.

1. Low carbon cold-rolled steel shafting shall conform to ASTM A 108, Grade 1018.

2. Medium carbon cold-rolled shafting shall conform to ASTM A 108, Grade 1045.

3. Other grades of carbon steel alloys shall be suitable for service and load.

4. Corrosion-resistant shafting shall be stainless steel or Monel, whichever is most suitable for the intended service.

D. Differential Settlement: Where differential settlement between the driver and the driven equipment may occur, a shaft of sufficient length with sets of universal type couplings shall be provided.

2.05 BEARINGS

A. Bearings shall conform to the standards of the Anti-Friction Bearing Manufacturers Association, Inc. (AFBMA).

B. To assure satisfactory bearing application, fitting practice, mounting, lubrication, sealing, static rating, housing strength, and lubrication shall be considered in bearing selection.

C. All re-lubricatable type bearings shall be equipped with a hydraulic grease fitting in an accessible location and shall have sufficient grease capacity in the bearing chamber.

D. All lubricated-for-life bearings shall be factory-lubricated with the manufacturer's recommended grease to insure maximum bearing life and best performance.

E. Anti-Friction Type Bearing Life: Except where otherwise indicated, bearings shall have a minimum L-10 life expectancy of 10 years or 20,000 hours, whichever occurs first. Where so indicated, bearings shall have a minimum rated L-10 life expectancy corresponding to the type of service, as follows:

Type of service Design Life, years L-10 Design Life, hours

(Whichever comes first)

8-hour shift 10 20,000

16-hour shift 10 40,000

Continuous 10 60,000

F. Bearing housings shall be of cast iron or steel and bearing mounting arrangement shall be as indicated or as recommended in the published standards of the manufacturer. Split-type housings may be used to facilitate installation, inspection, and disassembly.


G. Sleeve Type Bearings: Sleeve-type bearings shall have a steel, cast iron or ductile iron housing and Babbitt or bronze liner. Bearing housing shall be bolted and doweled to the lower casing half. These housings shall be provided with cast iron caps bolted in place and the bearing end caps shall be bored to receive the bearing shells. Sleeve bearings shall be designed on the basis of the maximum allowable load permitted by the bearing manufacturer. If the sleeve bearing is connected to an equipment shaft with a coupling, the coupling transmitted thrust will be assumed to be the maximum motor or equipment thrust. Lubricant, lubrication system, and cooling system shall be as recommended by the bearing manufacturer.

H. Plate Thrust Bearings: Thrust bearings shall be the Kingsbury Type, designed and manufactured to maintain the shaft in the fixed axial position without undue heating or the necessity of adjustment or attention. Bearings shall be oil lubricated to suit the manufacturer's standard method of lubrication for the specific bearing. If bearing cooling is required, manufacturer shall provide necessary piping, filters, and valves.

2.06 MOTORS

A. All motors shall comply with requirements listed in Section 16460 – Electrical Motors. All variable frequency drive (VFD) controlled motors shall be inverter duty motor and shall comply with NEMA MG-1 Design “B” requirements and Section 16483 - Variable Frequency Controllers.

2.07 PAINTING

A. Prime all steel and iron surfaces using V.O.C. Compliant recoatable universal epoxy mastic (Tnemec Series 66 Hi-Build Epoxoline), 3 to 4 mils dry film, or approved equal. Surface preparation shall be in accordance with SSPC SP-6 commercial Blast Cleaning.

B. Apply two coats of primer to equipment surfaces which will be inaccessible after assembly.

C. Shop finish electric motors, speed reducers, starters and other self-contained components with low sheen chemical resistant Aliphatic Poly Urethane Enamel, 3 to 4 mils dry film, or approved equal. Finish must be minimum 58% solids by volume V.O.C. compliant. Tnemec Series 73 Endurashield III or approved equal.

D. Apply rust preventive compound to all machined, polished and nonferrous surfaces which are not to be painted.

E. For equipment furnished with a finish coat, provide at least one quart of finish coat material with equipment for field touchup.

2.08 EQUIPMENT BASES

A. Steel Bases: Structural steel bases shall be rectangular in shape for all equipment other than 1 centrifugal refrigeration machines and pump bases, which may be “T” or “L” 1 shaped where shown. Pump bases for split base pump shall include supports for suction and discharge base ells. All perimeter members shall be beams with a minimum depth equal to 1/1 0th of the longest dimension of the base. Beam depth


need not exceed 14 inches provided that the deflection and misalignment is kept within acceptable limits as determined by the manufacturer. Grout holes shall be provided for the bases of all equipment where vibration isolation is not specified. Where vibration isolation is required, height saving brackets shall be employed in all mounting locations to provide a base clearance of 1 inch.

B. Cast Iron Bases: Cast iron bases located within a building do not require galvanizing. All fasteners requiring connections to the base shall be terminated by nuts welded to the bottom side of the base and plugged with cork, plastic plugs, or grease, or acorn nuts. In no case shall the fasteners terminate only into the metal base.

2.09 FASTENERS

A. Unless otherwise specified, fasteners shall be provided by CONTRACTOR.

B. Corrosive Service: All bolts, nuts, and washers in the locations listed below shall be stainless steel as indicated below:

1. All buried locations

2. All submerged locations.

3. All locations subject to seasonal or occasional flooding.

4. Inside hydraulic structures below the top of the structure.

5. Inside buried vaults, manholes, and structures which do not drain through a gravity sewer or to a sump with a pump.

6. All chemical handling areas.

7. Inside trenches, containment walls, and curbed areas.

8. Locations designated by the ENGINEER to be provided with stainless steel bolts.

C. Unless otherwise indicated, stainless steel bolts, anchor bolts, nuts, and washers shall be Type 316 stainless steel, Class 2, conforming to ASTM A 193 for bolts and to ASTM A 194 for nuts. All threads on stainless steel bolts, to meet government specifications MIL-A-907E.

1. Antiseize lubricant shall be classified as acceptable for potable water use by the NSF. Antiseize lubricant shall be “PURE WHITE” by Anti-Seize Technology, Franklin Park, IL, 60131, AS-470 by Dixon Ticonderoga Company, Lakehurst, NJ, 08733, or approved equal.

D. For equipment with an operating weight greater than 1000 pounds (250 pounds in the case of vibration isolated equipment having seismic restraints), the EQUIPMENT SUPPLIER shall provide detailed calculations which demonstrate that the anchor bolting will not fail in shear or in tension. Calculations shall be signed by a civil or structural engineer registered in state of California and include the following steps as a minimum:

1. Determination of the operating weight and centroid of the equipment, if not already completed.


2. Determination of the shear and overturning forces at each anchorage due to a force equal to 0.3 times the operating weight of the equipment being applied at the centroid in each direction along the three principal orthogonal axes (use the values obtained in the dynamic analysis in the case of seismically restrained vibration isolated equipment).

3. Determination of the shear and tension forces which must be developed by the anchor bolts at each support to resist the forces calculated in step 2.

4. Selection of anchor bolting patterns to be provided based on the maximum shear and tension forces calculated in step 3.

E. Before delivery of any anchor bolts, the EQUIPMENT SUPPLIER shall provide certificates which attest to their material compliance with these specifications.

F. Anchor bolt holes in equipment support frames shall not exceed the bolt diameters by more than 25 percent, up to a limiting maximum oversizing of 1/4 inch. Minimum anchor bolt diameter shall be 1/2 inch. Anchor bolts shall be furnished with leveling nuts, the faces of which shall be tightened against flat surfaces as shown to not less than 10 percent of the bolt's safe tensile stress.

G. Tapered washers shall be provided where mating surface is not square with the nut.

H. Expansion anchors and wedge anchors shall not be permitted. Expansion shields set in holes drilled in the concrete after the concrete is placed will not be permitted in substitution for anchor bolts except where otherwise specified. Upset threads shall not be acceptable.

2.10 LUBRICATION

A. Provide lubrication systems that automatically operate with equipment and do not require attention during start-up or shutdown and that do not waste lubricants.

2.11 SPARE PARTS

A. Spare parts, where specified, shall be provided in clearly labeled boxes. Labels shall display "Visalia Water Conservation Plant," the major piece of equipment to which the part belongs, the part name, and the manufacturer's part number.

2.12 NAMEPLATES

A. Equipment nameplates of ANSI TYPE 316 stainless steel shall be engraved or stamped and fastened to the equipment in an accessible location with No. 4 or larger oval head stainless steel screws or drive pins. Nameplates shall contain the manufacturer's name, model, serial number, size, characteristics, and appropriate data describing the machine performance ratings.


PART 3 – EXECUTION

3.01 PROTECTION

A. Box, crate, or otherwise completely enclose and protect all equipment during shipment, handling, and off-site storage. Responsibility for storage on the job site will be assigned to the CONTRACTOR.

B. Protect equipment from exposure to elements and keep all items thoroughly dry at all times.

C. Protect all primed surfaces against impact, abrasion, discoloration and other damage.

D. Protect electrical equipment, controls and insulation against moisture, freezing, or water damage.

3.02 INSTALLATION

A. Equipment shall be installed in accordance with the manufacturers written recommendations.

1. The CONTRACTOR shall select or recommend the size and type of coupling required to suit each specific application; installation shall be per equipment manufacturer's printed recommendations.

2. All insulating connections shall be installed in accordance with the manufacturer's printed instructions.

B. Alignment: Equipment shall be field tested to verify proper alignment.

3.03 SERVICES OF MANUFACTURER

A. Inspection, Startup, and Field Adjustment: Where required by individual sections, an authorized, experienced, and competent service representative of the manufacturer shall visit the Site for the number of days indicated in those sections to witness or perform the following and to certify in writing that the equipment and controls have been properly installed, aligned, lubricated, adjusted, and readied for operation.

1. Supervision of equipment installation

1. Inspection, checking, and adjusting the equipment and approving its installation

2. Startup and field testing for proper operation, efficiency, and capacity

3. Performing field adjustments during the test period to ensure that the equipment installation and operation comply with requirements

4. Performance acceptance testing

B. Instruction of the CITY's Personnel: Where required by the individual equipment sections, an authorized training representative of the manufacturer shall visit the Site for the number of days indicated in those sections to instruct the CITY's personnel in the operation and maintenance of the equipment, including step-by-step


troubleshooting with necessary test equipment. Instruction shall be specific to the models of equipment provided.

1. The representative shall have at least 2 years experience in training. A resume of the representative shall be submitted.

2. Training shall be scheduled 3 weeks in advance of the scheduled session.

3. Proposed training material and a detailed outline of each lesson shall be submitted for review. Review comments from the ENGINEER shall be incorporated into the material.

4. The training materials shall remain with the trainees after the session.

5. The CITY may videotape the training for later use by the CITY's personnel.

C. Vibration Monitoring: For the equipment types listed in Paragraph 2.01, the EQUIPMENT SUPPLIER shall arrange for at least two site visits by the manufacturer's specialist during testing of the equipment covered by torsional and vibration analysis submittals to measure the amount of vibration and prepare written recommendations for keeping the vibration within acceptance limits. If vibration readings exceed the specified or the applicable referenced standard vibration limits for the type of equipment, the EQUIPMENT SUPPLIER shall make necessary corrections for the equipment to meet the acceptance criteria.

3.04 PACKAGED EQUIPMENT

A. When any system is furnished as pre-packaged equipment, the installing CONTRACTOR shall coordinate all necessary space and structural requirements, clearances, utility connections, signals, and outputs with subcontractors to avoid later change orders.

B. If the packaged system has any additional features (as safety interlocks, etc.) other than required by the RFP, the EQUIPMENT SUPPLIER shall coordinate such features with the ENGINEER and provide all material and labor necessary for a complete installation as required by the manufacturer.

3.05 FIELD TESTS

A. Where indicated by the individual equipment sections, equipment shall be field tested after installation to demonstrate satisfactory operation without excessive noise, vibration, or no overheating of bearings or motor.

B. The following field testing shall be conducted:

1. Start equipment, check, and operate the equipment over its entire operating range. Vibration level shall be within the amplitude limits as indicated or as recommended by the reference applicable Standards.

2. Obtain concurrent readings of motor voltage, amperage, capacity, vibration, and bearing temperatures.


C. The ENGINEER shall witness field testing. The EQUIPMENT SUPPLIER shall notify the ENGINEER of the test schedule ten days in advance.

D. In the event that any equipment fails to meet the test requirements, the equipment shall be modified and resettled until it satisfies the requirement.


City of Visalia – WCP Upgrades RPGS Pre-Selection 11000 – 1 December 2010 Blowers and Compresors, General

SECTION 11370 – BLOWERS AND COMPRESSORS, GENERAL

PART 1 – GENERAL

1.01 WORK INCLUDED

A. Provide blowers and appurtenances, complete and operable, in accordance with the RFP.

B. The provisions of this Section shall apply to all blowers, except where otherwise indicated.

C. The EQUIPMENT SUPPLIER shall assign to a single manufacturer full responsibility for the furnishing and functional operation of the blower, including drives, drive motors, and accessories. The designated single Manufacturer, however, need not manufacture more than one part of the unit(s) (blower, or motor and drive), but shall coordinate the design, assembly, testing, and erection of the unit(s).

1.02 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. COMMERCIAL STANDARDS:

ANSI B1 6.1 Cast Iron Pipe Flanges and Flanged Fittings, Class 25, 125,250, and BOO

ANSI B1 6.5 Pipe Flanges and Flanged Fittings, Steel Nickel Alloy and Other Special Alloys

ANSI/ASME PTC 9 Performance Test Code - Displacement Compressors, Vacuum Pumps and Blowers

ANSI/ASME PTC 10 Performance Test Code - Compressors and Exhausters

ANSI/ASME B31.1 Power Piping

ANSI/ASME B31.3 Process Piping

ANSI/IEEE 112 Test Procedure for Polyphase Induction Motors and Generators

ASTM A 48 Gray Iron Castings

1.03 SUBMITTALS

D. Furnish submittals in accordance with Section 01300 – EQUIPMENT SUPPLIER SUBMITTALS.

E. Shop Drawings shall include the following information:

1. Equipment name, identification number and specification number.

2. Performance curve and data.


3. The EQUIPMENT SUPPLIER shall require the manufacturer to indicate points on the blower performance curves, and the limits recommended for stable operation between which the blowers may be operated without surge and vibration. The stable operating range shall be as wide as possible based on actual tests, performed at the factory in accordance with the ANSI/ ASME PTC 9 and 10 test codes.

4. Equipment detailed description and specification,

5. Electrical data including control and wiring diagrams.

6. Assembly and installation drawings including shaft size, seal, coupling, anchor bolt plan, part nomenclature, material list, outline dimensions and shipping weights.

7. Equipment drive and motor in accordance with Section 16460 - Electric Motors.

F. Operation and Technical Manuals: Prior to start-up, furnish complete Operation and Technical Manuals in accordance with Section 01300 – EQUIPMENT SUPPLIER SUBMITTALS. Printed instructions relating to proper maintenance, including lubrication, and parts lists indicating the various parts by name, number, and diagram where necessary, shall be furnished in duplicate with each unit or set of identical units in each station. A recommended spare parts list shall be included. Instructions for field procedures for erection, adjustments, inspection, and testing shall be provided prior to installation of each piece of equipment.

1.04 NOISE CONTROL REQUIREMENTS

G. Unless otherwise specified, the maximum permissible noise level for a complete piece of mechanical equipment located within or outside a structure shall not exceed 80 dBA at 3 feet per ISO R495. A complete piece of equipment includes the driver and driven equipment plus any intermediate couplings, gears and auxiliaries.

H. Maximum permissible noise (sound pressure) levels are in decibels as read on the "A" weighing network of a standard sound level meter (dBA); all measurements are made in relation to a reference pressure of 0.0002 microbar. Measurements of emitted noise levels shall be made on a sound level meter meeting at least the Type II requirements as set forth in the latest revision of ANSI S 1.4 Specification for General Purpose Sound Level Meters. The sound level meter shall be set on the "A" scale and to slow response. Unless changed in the specific section relating to a particular piece of equipment, the point of measurement of sound level shall be made at the specified distance from any major surface along the entire perimeter and at midheight of the piece of equipment or at the specified distance from an outer major surface encompassing the sound source including inlets or outlets.

I. Where specified in the individual equipment specification section, the EQUIPMENT SUPPLIER shall furnish for each piece of equipment, prior to shipment to the job site, a certified factory noise test report on the actual equipment to be provided or an unconditional guarantee that the equipment, when operating under design conditions, will not produce noise exceeding the permissible levels specified.

8. Noise levels in excess of that specified shall be cause for rejection of the equipment. Standard noise data is not acceptable.


9. Noise measurements shall be accomplished preferably at the factory; in any event, these measurements shall be accomplished prior to shipment of any equipment to the job site. The measurements shall take place in a reverberant or semireverberant condition, with equipment sitting on a hard reflective surface. Alternative permitted conditions are those which duplicate the circumstances under which the equipment will operate at this project. Tests shall be made at full load where applicable. The manufacturer shall certify the maximum noise levels emanating from the equipment, its operating conditions, the environment in which tested, a list of the acoustical instrument used, and the points at which the measurements were made. The description shall be sufficiently detailed to permit the test to be repeated, and it shall include a sketch of the item being measured which shows the points of measurement and the point of maximum encountered noise level on the measurement line.

10. Certified test results shall be submitted to the ENGINEER prior to shipment.

11. Final acceptance of any equipment is dependent upon satisfactory noise level performance after installation.

1.05 HEAT LOAD REQUIREMENTS

J. Blowers and their related equipment shall not discharge any heat to the surroundings inside the blower room, unless as required per section 1.05.B

K. In locations where heating is required during winter time to maintain minimum indoor temperature, blower manufacturer shall provide equipment and controls needed to divert the heat rejected from the blowers to the room as needed. Controls shall be compatible with room HVAC controls.

L. Blower manufacturer must provide detailed information on the heat rejection process, including heat rejection loads.


M. Equipment Testing: The EQUIPMENT SUPPLIER shall be responsible for the coordination of the following tests of each blower, compressor, and vacuum pump, drive, and motor:

12. Tests shall be performed in accordance with the ANSI/ASME PTC 9 and 10 Performance Test Codes. Tests shall be performed on the actual assembled unit from surge condition to 25 percent above the required design capacity. Prototype model tests will be acceptable.

13. Factory Tests of Blowers and Compressors: All blowers, compressors, and motors of sizes 10 to 125 hp (inclusive) shall be factory-tested in accordance with the above requirements. Seven sets of certified test data shall be submitted to the ENGINEER.

14. Factory Tests of Motors: Motors of size 10 hp and larger shall be assembled, tested, and certified at the factory and the working clearances checked to insure that all parts are property fitted. The tests shall be in accordance with ANSI/IEEE 112 standards, including heat run and efficiency tests. All computations shall be recorded and seven certified and dated copies of the test results shall be furnished to the ENGINEER.


15. Factory Witnessed Tests: Blowers and compressors, with motors 150 hp and larger, shall be factory-tested as complete, assembled units, as indicated above, and witnessed by the ENGINEER. The EQUIPMENT SUPPLIER shall give the ENGINEER a minimum of 30 days notification prior to the test. All costs for CITY and ENGINEER representative expenses shall be borne by the EQUIPMENT SUPPLIER and included in the proposal price. Such costs shall include all travel and subsistence for two (2) people for up to three (3) days but shall exclude salaries. Test results in triplicate shall be submitted to the ENGINEER and no equipment shall be shipped until the test data have been approved by the ENGINEER.

16. Acceptance: In the event of failure of any blower or compressor to meet any of the above requirements or efficiencies, the EQUIPMENT SUPPLIER shall make all necessary modifications, repairs, or replacements to conform to the requirements of the RFP and the equipment shall be retested at no additional compensation, until found satisfactory.

N. Warranty: After completion, the EQUIPMENT SUPPLIER shall furnish to the CITY the manufacturer's written guarantees, that the equipment will operate with the published efficiencies, heads, and flow ranges and meet these specifications.

1.07 MANUFACTURER'S SERVICE REPRESENTATIVE

O. Erection and Startup Assistance: Service and instruction assistance by the manufacturers service representative for each blower unit 10 hp and larger shall be provided by the EQUIPMENT SUPPLIER during the following periods.

P. Instruction of CITY's Personnel: The EQUIPMENT SUPPLIER shall provide for the services of a factory service representative for at least two (2) days to instruct the CITY's personnel in the operation and maintenance of the equipment.

PART 2 – PRODUCTS

2.01 GENERAL

Q. Wherever it is required that a single designated manufacturer shall be responsible for the compatible and successful operation of the various components of any equipment, it shall be understood to mean that the EQUIPMENT SUPPLIER shall provide only such equipment as the manufacturer will certify is compatible with its equipment and with the further understanding that this in no way constitutes a waiver of any requirements.

R. All manufactured items provided under this Section shall be new, current models, and the products of reputable companies specializing in the manufacture of such products, with previous experience in such manufacture. The EQUIPMENT SUPPLIER shall furnish the names of not less than five (5) successful installations of its equipment of comparable nature to that offered under this Request for Proposal.

S. Where two (2) or more units of the same type and/or size of equipment are required, such units shall be from the same manufacturer.


2.02 MATERIALS

T. Materials employed in the blower, compressor, and vacuum pump equipment shall be suitable for the intended application; material not indicated shall be high-grade, standard commercial quality, free from any defects and imperfections that might affect the serviceability of the product for the purpose for which it is intended, and shall conform to the following requirements:

17. Cast iron casings shall be of close-grained gray cast iron, conforming to ASTM A 48, or approved equal.

18. Stainless steel shafts shall be of Type 400, Series. Miscellaneous stainless steel parts shall be Type 316.

19. Anchor bolts, nuts, and washers shall be hot-dip galvanized unless otherwise indicated in individual equipment specifications.

2.03 APPURTENANCES

U. Nameplates: Each blower and motor shall be equipped with ANSI TYPE 316 stainless steel nameplate indicating rated head and capacity, impeller size, speed, and manufacturers name, serial, and model number. Nameplates for electric motors shall be in accordance with Section 16460 - Electric Motors.

V. Gauges: Blowers shall be equipped with pressure gauges, installed in the discharge lines. Pressure gauges shall be located in a representative location, where not subject to shock or vibrations, in order to achieve true and accurate readings. Pressure gauges shall conform to Section 13320 - Field Mounted Instruments.

W. Controls shall be in accordance with Section 13100 – Instrumentation and Control.

X. Electric Motors: Electric motors shall comply with the requirements of Section 16460.

Y. Flanges: Suction and discharge flanges shall conform to ANSI B16.1 or B16.5 dimensions.

Z. Lubrication: Blowers and motors shall be oil- or-grease-lubricated per individual specifications.

2.04 TOOLS AND SPARE PARTS

AA. Tools: Special tools necessary for maintenance and repair of the equipment and one pressure grease gun for each type of grease required for blowers motors shall be furnished as a part of the WORK hereunder; such tools shall be suitably stored in metal tool boxes, and identified with the equipment number by means of stainless steel or solid plastic name tags attached to the box.

BB. Spare Parts: The EQUIPMENT SUPPLIER shall furnish spare parts subject to wear, such as seals, packing, gaskets, nuts, bolts, washers, wear rings, etc., as well as a set of spare bearings, and one year's supply of filter elements. Furnish parts suitably packaged and labeled in a box as described above for tools.



3.01 INSTALLATION (BY CONTRACTOR)

CC. General: Blowers shall be installed in accordance with the Shop Drawings and as indicated. General installation requirements shall be as indicated in Section 11000 – Equipment General Provisions.

DD. Alignment: Equipment shall be field tested by CONTRACTOR to verify proper alignment and operation as specified, and freedom from binding, scraping, excessive noise, overheating, vibration, shaft runout, or other defects. Drive shafts shall be measured just prior to assembly to ensure correct alignment without forcing. Equipment shall be secure in position and neat in appearance.

EE. Piping and Mounting: Piping shall be provided with sufficient expansion joints, guides, and anchors and be supported so as to preclude the possibility of exerting undue forces and moments on the equipment flanges. Suitable flexible connectors shall be provided to isolate the equipment from the piping system. Each unit shall be mounted on a flat and level concrete pad capable of supporting the dead weight of the unit, by means of restrained vibration isolators or resilient pads of suitable design.

FF. Lubricants: The installation work shall include furnishing the necessary oil and grease for initial operation and for one year's operation.

3.02 TESTS

GG. Field Tests: Units shall be field tested after installation, in accordance with the RFP, to demonstrate satisfactory operation, without causing excessive noise, vibration, and overheating of the bearings. The field testing shall be performed by the EQUIPMENT SUPPLIER in the presence of a factory-trained, experienced field representative of the manufacturer, who shall supervise the following tasks and shall certify in writing that the equipment and controls have been properly installed, aligned, lubricated, adjusted, and readied for operation:

20. Start-up, check, and operate the equipment over the entire speed range vibration shall be within acceptable limits.

21. Equipment performance shall be documented by obtaining concurrent readings, showing motor voltage, amperage, and discharge head. Each power lead to the motor shall be checked for proper current balance.

22. Bearing temperatures shall be determined by a contact-type thermometer running time of at least 20 minutes shall be maintained for this test.

23. Electrical and instrumentation testing shall conform to other applicable Sections of the Specifications.

24. The field testing will be witnessed by the CITY or its representative. In the event any of the equipment fails to meet the above test requirements, it shall be modified and retested in accordance with the requirements of this Section. The EQUIPMENT SUPPLIER shall then certify in writing that the equipment has been satisfactorily tested, and that final adjustments thereto have been made. Certification shall include


date of final acceptance test, as well as a listing of all persons present during tests, and resulting test data. The costs of all work by factory-trained representatives shall be borne by the EQUIPMENT SUPPLIER. The CITY will pay for power costs. When available, the CITY'S operating personnel will provide assistance in the field testing.


City of Visalia – WCP Upgrades RPGS Pre-selection 11409 - 1 December 2010 Digester Gas Booster Blowers

SECTION 11409 – DIGESTER GAS BOOSTER BLOWERS

PART 1 – GENERAL

1.1 WORK OF THIS SECTION

A. The WORK of this Section includes providing equipment, services and spares for digester gas booster blowers, pre-wired, pre-piped, complete with drives, motors, capacity control features, instrumentation and controls and accessories each on a common skid, externally mounted gas cooling system, PLCs and control panels in accordance to the requirements of this contract.

B. The WORK includes design, assembly, factory testing, supervision for field testing, start-up assistance, training and Operation and Maintenance Manuals.

1.2 LOCATION

A. The digester gas booster blowers to be furnished under this section will be located to the west of existing digesters 5,6 and 7 and in close proximity to digester gas membrane gas holder.

1.3 REFERENCE SPECIFICATIONS, CODES AND STANDARDS

A. The design, and manufacture of this equipment shall meet or exceed the applicable provisions and recommendations of the following codes and standards.

1. AGMA, American Gear Manufacturer Association

2. ASME, American Society of Mechanical Engineers

3. ASTM, American Society of Testing Materials

4. ANSI, American National Standards Institute

5. IEEE, Institute of Electrical and Electronic Engineers

6. NEC, National Electric Code

7. NFPA, National Fire Protection Association

8. OSHA, Occupational Safety and Health Act

9. ISA, Instrument Society of America

10. NEMA, National Electric Manufacturers Association

B. Except as otherwise indicated, the current editions of the following apply to the WORK of this Section:

1. ANSI/ASME PTC 9 Performance Test Code - Displacement Compressors, Vacuum Pumps and Blowers

2. ANSI/ASME PTC 10 Performance Test Code - Compressors and Exhausters

3. ANSI/IEEE 112 Test Procedure for Polyphase Induction Motors and Generators


4. ANSI/IEEE 115 Test Procedure for Synchronous Machines

1.3 SHOP DRAWINGS AND DOCUMENT SUBMITTAL

A. The following shall be submitted in compliance with this Section:

1. P&ID of the system to identify the scope of supply, equipment interfaces and skid unit limits.

2. General description of digester gas booster blower with physical and performance data, curves, and the limits recommended for stable operation without surge and vibration. The stable operating range shall be as wide as possible based on actual tests performed at the factory in accordance with the ANSI/ASME PTC 9.

3. Plot plan of the system proposed, showing accessibility and space requirements of the various equipment and skids, piping layout and required connections to the external utilities.

4. Mechanical drawing of blower assembly showing blower base dimensions, anchoring, overall weight, and weight of largest components requiring removal for maintenance, and clearances required around unit for maintenance and access.

5. Process Duty/ Mechanical Equipment Specification Data Sheets (cooling system, water to water heat exchangers, strainers, valves, expansion tanks, instrumentation and controls integrated with the blower unit controls etc. to show that the units meet the specified requirements.

6. List of components and catalog cut fully describing all items:

a. Mechanical and structural components

b. Instruments

c. Programmable Logic Controller (PLC)

d. Operator Interface / Machine Monitors

e. Electrical Components

7. System functional description with a written description of the control system(s) covering normal operation, start-up, alarms, interlocks and emergency shutdowns and sufficient information to allow system checkout and maintenance activities.

8. Electrical Connection and Internal Wiring Connection Diagram including terminals, terminal strips/ blocks as identified and shown on actual equipment

9. Electrical equipment data and rating.

10. Control Solenoid and Terminal Enclosure Layout including program definition, panel layout, power supply, grounding and shielding information.

11. Obtaining and transmitting all sub-vendor warranties to the OWNER in addition to the system warranty.


12. Certification that the designated single manufacturer accepts responsibility for coordination of design, assembly, testing and installation.

13. Structural calculations for anchoring system performed and signed by a civil engineer registered in the State of California.

1.4 OWNER'S MANUAL

A. The following shall be submitted in compliance with this Section:

1. Manufacturer's installation and startup procedures.

2. Manufacturer's maintenance procedures and maintenance summary forms.

3. Trouble shooting guides for system and all equipment furnished.

4. Certified mechanical equipment and instrument data.

5. Complete part lists with manufacturer model and part numbers.

6. List of special tools, diagrams and drawings required for operating and maintenance of the system.

7. List of spare parts recommended by the manufacturer.

8. Copy of test results and certification by CONTRACTOR and manufacturer that products comply with the indicated requirements.

1.5 WARRANTY AND GUARANTEE

A Digester gas booster blower capacity and power consumption at specified guarantee points under normal operating conditions as specified in this Specification. The power guarantee must contain a minimum of three "off-design" guarantee points to fully evaluate blower operation over the range of all ambient conditions and machine capacity.

B. Ratings on all auxiliary equipment, pumps, heat exchangers and valves.

C. Mechanical equipment components shall be warranted free of manufacturing defects for a period of minimum 1 year from Substantial Completion or as specified otherwise in the RFP.

1.6 POWER GUARANTEE

A. The EQUIPMENT SUPPLIER shall submit guaranteed wire to air kW values. The wire to air kW shall include all losses associated with the blower unit at all specified operating points. The EQUIPMENT SUPPLIER shall provide wire to air kW values by completing Table 1 below, and also include a specific curve for each point at site conditions. The completed table will be considered the basis of the Power Guarantee specific to DG booster blowers and all related requirements as specified herein. The guaranteed wire to air KW value at the specified operating points shall be guaranteed per flow rates calculated using test standards specified herein with +0 tolerance. The guaranteed wire to air KW’s of the blower unit shall not exceed the following

(2)


Power Guarantee – Table 1 Design Point

Capacity %

Flow/ Blower, SCFM (1)

Pressure, psia Inlet Temp, DegF

Rel Hum, %

Guaranteed Wire to Air Power Per Blower, KW

Evaluation Factor

Factored Power Draw, KW

Atm. Discharge 1 100 (2) 14.53 (2) 110 85 (2) 0.20 (2) 2 75 (2) 14.53 (2) 110 85 (2) 0.35 (2) 3 60 (2) 14.53 (2) 110 85 (2) 0.30 (2) 4 50 (2) 14.53 (2) 110 85 (2) 0.15 (2)

(1) SCFM measured at 14.7 PSIA, 68°F, 36% Relative Humidity (2) To be Stated by the EQUIPMENT SUPPLIER

B. The EQUIPMENT SUPPLIER shall reaffirm stated guarantee wire to air kW values for

the blower unit in the final submittal and associated shop drawings. The guaranteed wire to air kW values must match what is presented in the preliminary submittal. Failure to meet this requirement will result in immediate rejection.

1.7 CONTRACT PRICE ADJUSTMENT

A. Even after repeated testing after making all necessary adjustments and reworking on the air blowers, should the factory tests show that the actual wire to air KW is more than the guaranteed wire to air KW, the Contract Price Value shall be adjusted as follows:

Adjusted contract price = A minus B. A = Contract price B = $20,630* times C C = Sum of positive evaluated wire to air KW values * Based on the 20 year present worth of 1 kW continuous draw @ $0.13/kWh escalated at 4% per year and discounted at 5% per year. "C" shall be calculated as follows:

Operating (1)

Point Evaluation

Factor Actual Wire to Air KW

Minus Guaranteed Wire to Air KW

Evaluated (2) KW

1 0.20 [________] [________] 2 0.35 [________] [________] 3 0.30 [________] [________] 4 0.15 [________] [________] "C" (sum of above) (1) These operating points shall be the operating points as specified in the Power Guarantee section of these Specifications. (2) Evaluated KW = evaluation factor times (actual wire to air KW minus guaranteed wire to air KW). Only the positive evaluated KW values will be considered in calculating “C.”


PART 2 – PRODUCTS

2.1 GENERAL

A. Self-contained, rotary sliding-vane, water jacketed, positive displacement digester gas booster blowers with drives, motors, integrated closed-loop cooling system and all accessories as required for reliable and efficient operation on digester gas service. See Appendix B for recent digester gas analysis reports.

B. The digester gas booster blowers shall be designed according to the following performance requirements

Performance Requirements

Flow (SCFM)

:

To be determined by EQUIPMENT SUPPLIER

Inlet Pressure (inches of W.C.) 4 – 12

Inlet Temperature (o 95 F)

Discharge Temperature (o

125 F)

Motor Rating (HP) To be determined by EQUIPMENT SUPPLIER

Max Speed (RPM) To be determined by EQUIPMENT SUPPLIER

Outlet Pressure* (PSIG) To be determined by EQUIPMENT SUPPLIER

C. The digester gas booster blower equipment shall be designed for a continuous outdoor operation with ambient temperature ranging from + 25 deg. F to +115 deg. F at elevation of 300 ft above sea level.

D. The digester gas booster blower shall be designed for a turndown of 100% to 55%. The turndown shall be achieved through a VFD. acceptable methods are: inlet flow control vanes or bypass with a flow control valve. The EQUIPMENT SUPPLIER shall include proposed flow turndown system that is complete with the skid and its performance is guaranteed.

E. The digester gas booster blower construction shall be of ANSI/ASME Type 316 stainless steel for all parts in contact with digester gas, anodized aluminum impellers and Inconel electrical connection for maximum corrosion-resistance. The booster blowers shall be of a leak-tight construction body with gas-tight shaft seals, completely hermetic design with zero leakage to the environment.

2.2 EQUIPMENT DESIGN

A. The digester gas booster blower shall be manufacturer's standard proven stationary construction and design, suitable for continuous boosting of the digester gas. All items specified in this section shall be furnished to provide a sole source of responsibility and all equipment and accessories furnished shall be designed for digester gas service.

B. The digester gas booster blower package shall include, as a minimum, the following:


1. Structural steel sub-base frame of adequate size to support the blower/ motor drive assembly, lubricating system and accessories.

2. Inlet filter/separator for moisture and particle removal from the incoming stream of digester gas.

3. Water cooled heat exchanger with separator and automatic condensate drain, cooling water solenoid valve for automatic shut-off cooling water when blower is idle, complete with strainer, and backpressure sustaining valve and isolating ball valves. Coolers shall be designed per ASME Section VIII with a code stamp. Cooler and separator shall be of 316 SS construction. Each cooling system shall be sized to provide the cooling loads varying for each blower from 55% load in winter to 100% at peak summer.

4. Suction isolation valve, which closes suction side when blower does not load or on loss of power. The valve shall close by spring force and shall open with gas at about 8.5 inches of water column as measured on the suction side.

5. All lube oil piping, cooling water piping, and all piping transmitting wet gases to and from the blowers shall be of 316 SS. All interface piping shall terminate at the edge of the skid with a blind flange.

6. Each blower shall be provided with induction motor in TEFC enclosure designed in accordance with current NEMA, ANSI and IEEE standards. The motor HP shall be equal to, or in excess of, minimum normal load that will be imposed at any point in the operating range of the design conditions specified. Each motor shall have a 1.15 service factor with class "F" insulation. Each motor shall be premium balanced for reduced vibration and supplied with lifting lug and space heaters.

7. Motor starter shall be solid state reduced voltage with bypass contactors, NEMA 4X, enclosure for outdoor, unclassified location.

8. Motor terminal box shall be oversized to provide adequate space for connections and shall be constructed of cast iron or fabricated steel. The motor leads shall be permanently marked in agreement with the connection diagram.

9. Blowers and motors shall be equipped with stainless steel nameplates indicating rated head and capacity, impeller size, speed, and manufacturer's name, serial, and model number.

10. Automatic condensate traps, quantity as required for each unit with a manual back-up traps, strainers and isolating ball valves.

C. Duplex Coalescing Filter

1. Provide duplex coalescing filters, one duty and one standby with reusable elements capable of removing aerosols and solids particles 0.03 micron and larger. Filters shall remove at least 99.99% of liquid oil, water, and solids particles. Provide an automatic drain and automatic switchover with pneumatic valves to alternate when pressure drop reaches preset point.

2. Filter housing pressure rating shall be at least 25 psi higher that the discharge pressure rating of the blowers. Maximum pressure drop though the filer shall not


exceed 3 psi at rated flow. Provide a manual bypass of the duplex coalescing filters with isolation valve as shown on the drawings.

2.3 CONTROLS

A. All electrical wiring for blower skid and within 10 ft from gas piping shall be designed for Class 1, Division 1 and Group D Electrical Area Classification. All electrical wiring and control panel located outside the 10-ft classified envelope shall be designed for outdoor, unclassified area classification. The control circuit shall include a control transformer for 120 VAC and a power-on light.

B. Process and Instrumentation

1. Control Panel Requirements: Each control panel supplied shall be a free standing control panel, NEMA 12 enclosure, with a Programmable Logic Controller (PLC) and a Human Machine Interface (HMI). The system shall be designed and tested by the EQUIPMENT SUPPLIER for control and monitoring of the associated equipment and instrumentation. The PLC control panel will be located adjacent to the RPGS. The PLC control panel and field instruments furnished shall conform to the requirements of Division 13 specifications in Appendix I.

2. PLC Requirements

a. The PLC shall control the process, via electrically operated devices such as relays, motors, power contactors, solenoid valves, etc., on the basis of a stored digital program of instructions and various input process variables and discrete contacts, which provide process condition feedback, and externally selectable manual switches. PROFIBUS interface shall be provided for the Variable Frequency Drives (VFDs) and motorized valves for communication with the system PLC. The PLC shall be Allen-Bradley ControlLogix. The programming method shall be ladder logic via a PC programming terminal. All programming, monitoring, searching, and editing shall be accomplished using latest version of RSLogix 5000 Enterprise edition or latest programming software.

b. The HMI shall be Allen-Bradley PanelView Plus 12.5” TFT Touch display terminal with multiple color screens to display operating variables, valve positions, and other relevant data. Operating screens shall have a touch sensitive screen to select the operating sequence of the pumps, blowers, make adjustments of set points and select auto or manual control of pumps, blowers and valves. The operation shall be programmed to be user-friendly by providing sufficient prompting that an operator can intuitively follow through the commands to operate the system. Programming shall be accomplished using the latest version of FactoryTalk View Machine Edition or latest programming software.

c. Data communication between the RPGS PLC and PLCs provided with other process equipment in the plant expansion shall be via Ethernet/IP. The EQUIPMENT SUPPLIER shall coordinate with the CONTRACTOR in configuring the communications between the PLC and the plant wide SCADA system.

d. The EQUIPMENT SUPPLIER shall be responsible for the PLC Program logic and HMI graphic development and configuration. The PLC panel shall be supplied with an Uninterruptible Power Supply (UPS) with 7 minutes minimum


battery back-up to assure that the HMI display and communication with the SCADA system remain operational after a power failure.

e. The EQUIPMENT SUPPLIER shall provide a hardcopy and software copy of the PLC program logic, HMI graphic development and database configuration on a CD-ROM.

f. The EQUIPMENT SUPPLIER shall provide a list of recommended data points for integration with the plant wide SCADA system and shall provide field support to the SCADA system integrator during system startup and testing.

g. The EQUIPMENT SUPPLIER shall provide one (1) on duty and one (1) standby on the shelf PLC processor. The standby processor shall be fully programmed and ready for direct swap.

C. A PLC message screen with digital readout shall be provided for the following blower system:

1. Cooling water temperature at the outlet of cooling system.

2. Compressed gas temperature at blower inlet.

3. Compressed gas temperature at blower outlet.

4. Pressure gauges for oil pressure, suction pressure and final pressure.

5. Bypass system/ inlet vane system flow control as applicable.

6. Operation of the cooling water solenoid valves and suction isolation valves with pneumatic operators equipped with position switches. The duty unit shall have inlet isolation valve open while the standby unit shall be isolated. In case of the duty unit failure, the suction isolation valve shall be closed by the local PLC. The standby unit suction isolation valve shall then open by it’s local PLC after it receives the start command from the plant PLC.

D. One common fault light with dry contact for remote alarms shall be provided for the blower system. Each fault shall be able to read on the PLC message board and alarm shall be provided for:

1. Low oil pressure.

2. High oil temperature.

3. Low suction pressure.

4. High motor temperature.

5. High cooling water outlet temperature.

6. Motor failure with indicating light.

E. Wire skid mounted electrical components and terminate interface connections on terminal strips in junction boxes and/or electrical enclosures mounted at the edge of the skid. No splice shall be permitted in any wire or cable, and no more than two wires per terminal shall be used. A minimum 10% of spare terminals shall be provided. Conduit entry shall be at the bottom of each box.


F. Install solenoid valves on the water cooling lines and oil lubrication lines. Solenoid valve electrical ratings and their enclosures shall be compatible with the motor voltage and area classification. The WORK includes conduit wiring installation from control panel to solenoid valves.

2.4 TOOLS AND SPARE PARTS

Provide special tools necessary for maintenance and repair; such tools shall be stored in tool boxes, and identified with the equipment number by means of stainless steel or solid brass name tags. Include lubricants for initial operation and for one year's operation.

Spare parts shall be tagged by project equipment number and identified as to part number, equipment manufacturer, and subassembly component. Spare parts subject to deterioration such as ferrous metal items and electrical components shall be properly protected by lubricants or desiccants and encapsulated in hermetically sealed plastic wrapping. Spare parts with individual weights less than 50 pounds and dimensions less than 2 feet wide, 18 inches high, or 3 feet in length shall be stored in a wooden box with a hinged wooden cover and locking hasp. Hinges shall be strap type. The box shall be painted and identified with stenciled lettering stating the name of the equipment, equipment numbers, and the words "spare parts." A list of the spare parts in the box shall be taped to the underside of the cover.


3.1 GENERAL

A. Unless otherwise indicated, execution of the WORK, including but not necessarily limited to fabrication, equipment protection, installation, field testing, protective coatings, lubricants and cleaning, shall comply with this Section.

3.2 FACTORY TESTING

A. The WORK includes equipment testing as follows:

1. General: Tests shall be performed in accordance with the ANSI/ASME PTC 9 and 10 Performance Test Codes. Tests shall be performed on the actual assembled unit from surge condition to 25 percent above the indicated design capacity. Prototype model tests will not be acceptable. All tests performed in the factory shall be certified by the manufacturer and submitted by the CONTRACTOR for approval, prior to shipment.

2. Factory Tests: Blower and motor shall be assembled, tested, and certified at the factory and the clearances shall be verified to ensure that parts fit properly. The tests shall be conducted in accordance with ANSI/IEEE 112 and ANSI/IEEE 115 standards, including heat run and efficiency tests. Mount each unit on a concrete pad using resilient vibration pads of adequate load ratings.

3.3 INSTALLATION

A. Digester gas booster blowers will be installed by the CONTRACTOR in accordance with the EQUIPMENT SUPPLIER’s installation instructions and approved shop drawings.

– END OF SECTION 11409 –

APPENDIX I

INSTRUMENTATION & CONTROL SPECIFICATIONS (DIV 13)

Visalia Water Conservation Plant Upgrades December 2010 RPGS Pre-selection 13100-1 Instrumentation and Control

SECTION 13100 – INSTRUMENTATION AND CONTROL

PART 1 – GENERAL

1.01 WORK INCLUDED

A. It is the intent of these specifications to have the EQUIPMENT SUPPLIER be singularly responsible for selecting, configuring, and verifying correct operation of compatible hardware and software to provide a functional PLC-based Control System (PLC-CS) and to provide future support of the provided Programmable Logic Controller (PLC) hardware and software. To preserve this focused responsibility, the EQUIPMENT SUPPLIER shall be the integrator of all hardware and all database, data acquisition, control, display, and other software associated with the system. Additionally, the EQUIPMENT SUPPLIER shall be responsible for the application programming of the PLC and Human Machine Interface (HMI).

B. The EQUIPMENT SUPPLER shall be responsible for the following, as a minimum, as it pertains to the system.

1. Procurement of all hardware and software required to conform to these specifications.

2. Design and submit PLC-CS hardware, software, and spare parts submittals.

3. Design and submit PLC-CS factory and on-site training requirements.

4. Perform all required PLC-CS tests, adjustments, and calibrations.

5. Furnish qualified labor to supervise PLC-CS installation and to perform start-up activities.

6. Furnish qualified certified instructors to provide PLC-CS instruction and training.

7. Furnish all required PLC-CS tools, test equipment, spare parts, supplies, Operation and Technical Manuals, reproducible record drawings, and program listings as specified herein.

8. PLC application programming and HMI display programming.


NEMA ICS 1 General Standards for Industrial Control and Systems.

NEMA ICS 3 Industrial Systems.

NEMA ICS 6 Enclosures for Industrial Controls and Systems.

NFPA 70 National Electrical Code.


1.03 SUBMITTALS

A. Submit under provisions of Section 01300 – EQUIPMENT SUPPLIER SUBMITTALS

B. Shop Drawings: The EQUIPMENT SUPPLIER shall coordinate the work specified so that a complete instrumentation and control system for the System will be provided and will be supported by accurate shop and record drawings. Interface between instruments, motor starters, control valves, variable speed drives, chemical analyzers, flow meters, existing instruments, and chemical feeders shall be shown in the shop drawing submittal.

C. A complete index shall appear in the front of each submittal volume. A separate technical brochure or bulletin shall be included with each instrument data sheet. The data sheets shall be indexed in the submittal by instrument type. If an instrument type is used in multiple locations, all similar devices may be listed by tag number on one data sheet and one brochure or bulletin may cover all identical uses of that instrument. This submittal shall include:

1. Loop Drawings: These diagrams shall show and identify each component of each loop or system using legend and symbols from ANSI/ISA S5.4, extending the format of ANSI/ISA S5.1 as used on the project drawings. Each system or loop diagram shall be drawn on a separate drawing sheet. PLC input/output (I/O) wiring schematics arranged in a PLC module-per-page basis is acceptable in replacement of the instrument loop diagrams.

2. Data Sheets: A data sheet shall be submitted for each supplied component, together with a technical product brochure or bulletin. As a minimum, the data sheets shall show:

a. Component functional description used herein and on the drawings;

b. Manufacturer's model number or other product designation;

c. Project tag number used herein and on the drawings;

d. Project system or loop of which the component is a part;

e. Project location or assembly at which the component is to be installed

f. Input and output characteristics;

g. Scale range and units (if any) and multiplier (if any);

h. Requirements for electric supply (if any);

i. Requirements for air supply (if any);


j. Materials of component parts to be in contact with, or otherwise exposed to, process media;

k. Special requirements or features;

l. List of special tools required for calibration or repair (if any).

3. Schematic and Wiring Diagrams: Complete details on the circuit interrelationship of all devices within and outside each control panel shall be submitted first, using schematic control diagrams. Subsequent to return of this first submittal by the ENGINEER, piping and wiring diagrams shall be prepared and submitted for review by the ENGINEER; the diagrams shall consist of component layout drawings to scale, showing numbered terminals on components together with the unique number of the wire to be connected to each terminal. Piping and wiring diagrams shall show terminal assignments from all primary measurement devices, such as flow meters, and to all final control devices, such as samplers, pumps, valves and chemical feeders. The EQUIPMENT SUPPLIER shall furnish all necessary EQUIPMENT SUPPLIER’S shop drawings to facilitate inclusion of this information by the System Integrator. Schematic and wiring diagram criteria shall be followed as established in NEMA Standards Publication No. ICS-1970, "Industrial Controls and Systems".

4. Assembly and Construction Drawings: These Drawings shall be submitted for each control panel and for other special enclosed assemblies for field installation. These drawings shall be to scale and include dimensions, identification of all components, surface preparation and finish data, nameplates, and the like. These drawings shall include enough details, to define exactly the style and overall appearance of the assembly; a finish treatment sample shall be included.

5. Installation Details: Installation, mounting, and anchoring details for all components and assemblies shall be submitted and shall include conduit connection or entry details. In addition to anchoring details for control panels, seismic calculations shall be submitted in accordance with the requirements and criteria described in Section 11 000 - Equipment General Provisions.

6. Bill of Material: Bills of material shall include all items within an enclosure and shall include manufacturers name and model number for these components.

D. Operation and Technical Manuals: Operation and Technical Manuals shall be supplied for the CITY and the ENGINEER, in accordance with Section 01300 – EQUIPMENT SUPPLIER SUBMITTALS. Operation and Technical Manuals shall include, but not be limited to:

1. Bound copies of operating and programming instructions.

2. Troubleshooting, adjustments, and preventative maintenance procedures and materials.


1.05 INSTALLATION AND SYSTEM TESTS

A. An installation test description shall be submitted in accordance with the requirements of Part 3.02.

B. System Tests procedures shall be submitted in accordance with the requirements of Part 3.02.

1.06 QUALIFICATIONS

A. Manufacturer: Company specializing in manufacturing the Products specified in this section with minimum 5 years experience.

B. The EQUIPMENT SUPPLIER shall guarantee all non-CITY-furnished equipment and installation of all equipment, as specified herein, for a period of one year following the date of completion of the work as specified under the General Conditions of these specifications. Warranty services shall be performed within 3 calendar days after notification by the CITY.

1.07 MAINTENANCE SERVICE

A. Furnish manufacturer's service and maintenance of programmable controllers for one year from Date of Substantial Completion.

PART 2 – PRODUCTS

2.01 GENERAL

A. Code and Regulatory Compliance: PLC-CS WORK shall conform to or exceed the applicable requirements of the National Electrical Code.

B. Current Technology: Meters, instruments, and other components shall be the most recent field-proven models marketed by their manufacturers at the time of submittal of the Shop Drawings unless otherwise required to match existing equipment.

C. Hardware Commonality: Instruments which utilize a common measurement principle (for example, d/p cells, pressure transmitters, level transmitters that monitor hydrostatic head) shall be furnished by a single manufacturer. Panel mounted instruments shall have matching style and general appearance.

D. Instruments performing similar functions shall be of the same type, model, or class, and shall be from a single manufacturer.

E. Password Protection: No proprietary passwords shall be allowed. Password protection of any PLC component or programming software shall be limited to only those


specified or requested by the CITY. All passwords shall be provided to the CITY upon completion of the project with no exceptions.

F. Loop Accuracy: The accuracy of each instrumentation system or loop shall be determined as a probable maximum error; this shall be the square root of the sum of the squares of certified accuracies of the designated components in each system, expressed as a percentage of the actual span or value of the measured variable. Each individual instrument shall have a minimum accuracy of plus and minus 0.5 percent of full scale and a minimum repeatability of plus and minus 0.25 percent of full scale unless otherwise indicated. Instruments that do not conform to or improve upon these criteria are not acceptable.

G. Instrument and Loop Power: Power requirements and input/output connections for all components shall be verified. Power for transmitted signals shall, in general, originate in and be supplied by the control panel devices. The use of “2-wire” transmitters is preferred, and use of 4-wire transmitters shall be minimized. Individual loop or redundant power supplies shall be provided as required by the manufacturer's instrument load characteristics to ensure sufficient power to each loop component. Power supplies shall be mounted within PLC panels or in the field at the point of application.

H. Loop Isolators and Converters: Signal isolators shall be provided as required to ensure adjacent component impedance match where feedback paths may be generated, or to maintain loop integrity during the removal of a loop component. Dropping precision wire wound resistors shall be installed at all field side terminations in the control panels to ensure loop integrity. Signal conditioners and converters shall be provided where required to resolve any signal level incompatibilities or provide required functions.

I. Environmental Suitability: Indoor and outdoor control panels and instrument enclosures shall be suitable for operation in the ambient conditions associated with the locations designated in the RFP. Taking into account the temperature rise in the enclosure, heating, cooling, and dehumidifying devices shall be provided in order to maintain all instrumentation devices 20 percent within the minimums and maximums of their rated environmental operating ranges. For example, if the most critical instrumentation device in the enclosure is the HMI with operating temperature limits between 32 and 131 degrees F, devices shall be provided to maintain the internal enclosure temperature between 39 and 105 degrees F. The EQUIPMENT SUPPLIER shall provide power wiring for these devices. Enclosures suitable for the environment shall be furnished. All instrumentation in hazardous areas shall be suitable for use in the particular hazardous or classified location in which it is to be installed.

J. Unless indicated otherwise, control panels shall be housed in NEMA rated enclosures in accordance with Section 16050 – General Electrical Provisions. The panels shall be


either free-standing, pedestal-mounted or equipment skid-mounted, as indicated. Internal control components shall be mounted on an internal back-panel.

K. Signal Levels: Analog measurements and control signals shall be as indicated herein, and unless otherwise indicated, shall vary in direct linear proportion to the measured variable. Electrical signals outside control panels shall be 4-20 mA DC except as indicated. Signals within enclosures may be 1-5 VDC. Electric signals shall be electrically or optically isolated from other signals. Pneumatic signals shall be 3 to 15 psig with 3 psig equal to 0 percent and 15 psig equal to 100 percent.

L. Alternative Equipment and Methods: Equipment or methods requiring redesign of any project details are not acceptable without prior written approval of the ENGINEER. Any proposal for approval of alternative equipment or methods shall include evidence of improved performance, operational advantage, and maintenance enhancement over the equipment or method indicated, or shall include evidence that an indicated component is not available.

2.02 OPERATING CONDITIONS

A. The PLC-Control System shall be designed and constructed for satisfactory operation and long, low maintenance service under the following conditions:

Environment A public wastewater treatment facility Temperature Range 40 through 110 degrees F Thermal Shock 1 degree F per minute, max Relative Humidity 5 through 95 percent, non-condensing

2.03 FIELD MOUNTED INSTRUMENTS

A. All field instruments which will be mounted in wet, hazardous, or corrosive areas or in areas subject to splashing shall utilize hermetically sealed switch contacts. Instruments which require external solid state electronic calibrators for calibration such as the Rosemount smart transmitter line shall be supplied with one electronic calibrator for the project.

B. All field instruments mounted outdoors shall have separate sun shields installed over the top, East, South, and West sides. Instruments which are not rated for the ambient air temperature listed in Section 16050 - General Electrical Provisions, shall be installed in an outer enclosure with sun shields.

C. Nameplates: A nameplate shall be supplied for identification of all field-mounted instruments and final control elements, including flow meters and their transmitters, chemical analyzers, and flow control valves. These nameplates shall identify the instrument, valve, analyzer, or meter, descriptively, as to function and system, and by


tag number. These nameplates shall be fabricated from black-face, white-center, laminated engraving plastic. The nameplate shall be permanently attached to the instrument using stainless steel screws or 16 gauge stainless steel wire. Adhesive mounting of nameplates is not acceptable

2.04 SPARE PARTS

The EQUIPMENT SUPPLIER shall furnish a list of recommended spare parts for field instruments, PLC components and miscellaneous panel components (for example, power supplies, fuses, etc.) with unit prices for the CITY to select from. The total price of selected spare parts by the CITY will not exceed US$10,000 and shall be included in the EQUIPMENT SUPPLIER’s proposal price. All special tools and spare parts shall be submitted before start-up commences, suitably wrapped and identified.

2.05 FACTORY TESTING

A. The EQUIPMENT SUPPLIER shall arrange for the Manufacturers of the equipment and fabricators of panels and cabinets supplied under this Section to allow the ENGINEER and CITY to inspect and witness the testing of the equipment at the site of fabrication. Costs for CITY/ENGINEER inspection, including travel and subsistence for two (2) people for up to three (3) days in the place of manufacture, excluding salaries, shall be borne by the EQUIPMENT SUPPLIER and included in his/her proposed price. Equipment shall include the cabinets, special control systems, instrumentation, and other pertinent systems and devices.

B. Submit a Factory Test Plan describing step by step the inputs and expected outputs of the logic to be demonstrated for the ENGINEER review and approval prior to the test. A minimum of ten working days notification shall be provided to the ENGINEER prior to testing.

C. No shipments shall be made without the ENGINEER's approval.


3.01 DELIVERY

A. Deliver products to site under provisions of Division 1.

3.02 TESTING

A. Analog Loop Tests: The EQUIPMENT SUPPLIER shall provide all necessary labor, tools, and equipment to field test, inspect and adjust each instrument installed under this contract to its specified performance requirement in accordance with manufacturer's specifications and instructions. Any instrument furnished by the EQUIPMENT SUPPLIER which fails to meet any contract requirement, or any published manufacturer performance specification for functional and operational


parameters not specified in the contract, shall be repaired or replaced, at the discretion of the ENGINEER at no cost to the CITY. The EQUIPMENT SUPPLIER shall bear all costs and provide all personnel, equipment and materials necessary to implement all installation tests and inspection activities specified herein.

1. At least 15 days before the anticipated initiation of installation testing, the EQUIPMENT SUPPLIER shall submit to the ENGINEER a detailed description of the installation tests to be conducted to demonstrate the correct installation of the Instrumentation and control system. Representative examples of test forms shall be included.

2. Elements such as controllers, electronic function modules, etc., shall be tested and exercised by the EQUIPMENT SUPPLIER to demonstrate correct operation, first individually and then collectively as functional analog networks. Each hardwired analog control network shall be tested to verify proper performance within specified accuracy tolerances. Specified accuracy tolerances for each analog network are defined as the root-mean-square-summation of individual component accuracy requirements. Individual component accuracy requirements shall be as specified by contract requirements or by published manufacturer accuracy specifications, whenever contract accuracy requirements are not specified.

3. Each analog network shall be tested by applying simulated analog and/or discrete inputs to the first element(s) of an analog network (i.e., applying simulated analog and/or discrete signals to element(s) of the network; e.g., controllers, alarms, indicators, valve operators, etc.). For networks which incorporate analog elements, simulated sensor inputs corresponding to 25, 50, 75, and 100 percent of span shall be applied, and the resulting element outputs read to verify compliance to calculated root-mean-square-summation accuracy tolerance requirements. Continuously variable analog inputs shall be applied to verify the proper operation and setting of discreet devices (i.e., alarms, etc.). Provisional settings shall be made on controllers, alarms, etc., during analog loop tests. All analog loop test data shall be recorded on test forms, which include calculated root-mean-square-summation system accuracy tolerance requirements for each output.

4. When installation tests have been successfully completed for all individual instruments and all separate analog control networks, a certified copy of all test forms, with test data entered, shall be furnished to the ENGINEER together with a clear and unequivocal statement that all instrumentation has been successfully calibrated, inspected, and tested.

B. System Testing: System testing shall comply with the requirements specified herein. System testing shall commence after acceptance of all wire, calibration, and loop tests, and all inspections have been conducted and shall demonstrate that the instrumentation and control system complies with all contract requirements. System testing shall demonstrate proper operation of all process systems provided under this contract with


process equipment operating over full operating ranges under actual operating conditions.

1. All system testing and test activities shall follow detailed test procedures, check lists, etc., previously developed and submitted by the EQUIPMENT SUPPLIER which have been reviewed and accepted by the ENGINEER. All test data shall be acquired using equipment as specified and recorded on test forms, previously reviewed by the ENGINEER, which include calculated tolerance limits for each step. Completion of all system testing activities shall be documented by a certified report, including all test forms with test data entered, delivered to the ENGINEER with a clear and unequivocal statement that all system testing requirements have been satisfied.

2. The proper operation of all final control elements, control panels, and instrumentation furnished under this contract shall be verified by tests conducted in accordance with the requirements specified herein. Where feasible, system testing activities shall include the use of water to establish service conditions that simulate, to the greatest extent possible, normal final control element operating conditions in terms of applied process loads, operating ranges and environmental conditions. Final control elements, control panels, and ancillary equipment shall be tested under start-up and steady-state operating conditions to verify that proper and stable control is achieved using motor control center and local field mounted control circuits. All hardwired and software control circuit interlocks and alarms shall be operational. The control of final control elements and ancillary equipment shall be tested using both manual and automatic (where provided) control circuits. The stable steady-state operation of final control elements running under the control of field mounted automatic analog controllers or software based controllers shall be assured by adjusting the controllers, as required, to eliminate oscillatory final control element operation. The transient stability of final control elements operating under the control of field mounted, or software based automatic analog controllers shall be verified by applying control signal disturbances, monitoring the amplitude and decay rate of control parameter oscillations (if any) and making necessary controller adjustments, as required, to eliminate excessive oscillatory amplitudes and decay rates.

3. All electronic control stations incorporating proportional, integral and/or derivative control circuits shall be optimally tuned, experimentally, by applying control signal disturbances and adjusting the gain, reset and/or rate setting(s) as required to achieve a proper response. Measured final control element variable position/speed setpoint settings shall be compared to measured final control element position/speed values at 10, 50, and 90 percent of span and the results checked against specified accuracy tolerances. Specified accuracy tolerances are defined as the root mean-square-summation of individual component accuracy requirements. Individual component accuracy requirements shall be as specified in the contract or as specified by published manufacturer accuracy specifications whenever contract accuracy requirements are not specified.


4. The EQUIPMENT SUPPLIER shall submit an instrumentation and control system completion report which shall state that all contract requirements have been met and which shall include a listing of all instrumentation and control system maintenance/repair activities conducted during the system testing. Prior to the start of the plant operational test, acceptance of the system testing must be provided in writing by the ENGINEER. Final acceptance of the control system shall be upon plant completion as stated in the general conditions.

3.03 TRAINING

A. The EQUIPMENT SUPPLIER shall train the CITY’s personnel on the operation and maintenance of the PLC-CS. The training shall be performed by an instructor certified by the Equipment Supplier with a minimum of 3 years experience. The proposed instructor’s resume shall be submitted for the CITY’s review and approval. The training session shall be scheduled a minimum of 3 weeks in advance, and the course outline shall be submitted at this time for the CITY’s review and comments.

B. The training class shall be a minimum of 8 hours duration and shall include operation and maintenance procedures, trouble shooting, set point changes, etc.

C. Within 10 days after the completion of the training session, the EQUIPMENT SUPPLIER shall submit the following:

1. A list of CITY personnel that attended the session. 2. An evaluation of the CITY personnel via written testing or equivalent evaluation. 3. A copy of the training material used during the lesson with all notes, diagrams,

and comments.

3.04 START-UP

A. Plant Operational Testing: The EQUIPMENT SUPPLIER shall provide start-up support to include electrical personnel and any instrument manufacturers’ representatives as required during the testing period to produce a fully operational system. This support shall be provided at no additional cost to the CITY. The plant operational test shall be conducted in accordance with the requirements of Section 01202 – EQUIPMENT SUPPLIER’S Field Services

3.05 FIELD QUALITY CONTROL

A. Perform operational testing on control systems to verify proper operation and field wiring connections.


Visalia Water Conservation Plant Upgrades December 2010 RPGS Pre-selection 13320-1 Field Mounted Instruments

SECTION 13320 – FIELD MOUNTED INSTRUMENTS

PART 1 – GENERAL

1.01WORK OF THIS SECTION

A. This Section specifies field mounted process instrumentation, auxiliary equipment and supplies directly related to the installation and operation of these instruments, to perform the required functions in conjunction with information and equipment specified in other Sections of Division 13.


This specification is only applicable to the instruments in the EQUIPMENT SUPPLIER’S scope.

A. Manufacturer. In addition to requirements of Section 13100, instrumentation and control equipment furnished shall be manufactured by a firm regularly and currently engaged in the design and manufacture of similar equipment. All equipment furnished shall be new and of current design.

B. Maintainability. All instruments shall be designed for ease of maintenance and repair, and access to critical parts shall not require a major disassembly. Internal field adjustments where permitted or required herein shall be easily accessible upon removal of a panel or cover.

C. Materials and Installation shall comply with the requirements of the current editions of referenced instrumentation and electrical codes and standards, and the codes and standards referred to shall be used for establishing the minimum quality of the materials and equipment supplied and installed. All equipment of the same type shall be product of the same manufacturer.

PART 2 – PRODUCTS

2.01 LEVEL TRANSMITTERS AND SWITCHES

A. Ultrasonic Level Transmitters and Switches

1. General. The level sensor shall measure continuous level and discrete level points in a liquid material application. The ultrasonic primary element shall be an electronically excited device. The output signal from the remote amplifier unit shall be 4-20 milliampere (mA) and two independently adjustable contacts to reflect the presence (or absence) of level. The output contacts shall be single-pole, double-throw (SPDT), rated at 120 VAC, 2 ampere pilot duty.

2. Specific Requirements. The type of process medium, temperature range, measuring pressure range, level measurement range, and other requirements shall be as required


by the application. Unless otherwise specified the accuracy shall be plus or minus 0.25 percent of full range.

3. Construction. The transducer of the ultrasonic type level transmitter shall be resistant to steam and corrosive chemicals. The enclosure of transmitter shall be hermetically sealed. It shall be totally enclosed with temperature compensation and shall be suitable for accurate level measurement in the presence of vapor and gases over the liquid level. The level transmitter shall be microprocessor based for input power of 120 VAC and with output of 4-20 mA. It shall be programmable for different operating parameters, including, but not limited to range, span, units of measurement, selection of reading from tank bottom up or from sensor face down. Echo loss and sensor fault detection and remote transmission shall also be provided. Integral display of level measurement, span and signal strength shall be provided. The transmitter shall be suitable for wall, rack or panel mounting as required by the application. The deadband of switches shall be individually adjustable.

4. Manufacturer. The ultrasonic type level transmitter shall be as manufactured by Siemens, Model HydroRanger 200 (transmitter) and XPS-15 (transducer). No Substitution.

B. Tilt Liquid level Switch

1. The level switch shall be micro switch encapsulated type in a polypropylene casing.

2. The cable shall be sheathed with a PVC compound from switch to junction box terminals without splices.

3. Switch contacts shall be SPDT contacts rated at 4 amperes at 250 VAC and at 1/2 hp.

4. Capsule shall be suspended in sump and field adjusted for low level, high level and high-high level alarms as required.

5. Manufacturer. The tilt level switch shall FLYGT, Model ENM-10. No Substitution.

C. Submersible Level Transmitter

1. The level sensor shall measure the reservoir water level utilizing a bottom diaphragm that measures head pressure as an indication of level.

2. Diaphragm, isolation rings and coating material will be selected to handle the process fluid requirements.

3. Upper assembly housing shall include signal conditioning, protective electronics, terminal blocks and the expansion bag of the sealed breathing system. The upper assembly shall be powered by a 24 VDC power supply located in a PLC panel on a 2-wire 4-20 mA configuration.


4. Connecting cable between the upper and lower assemblies will have a 1/2 - inch polyurethane jacket, a 3-conductor shielded AWG #16 cable, and an integral flexible breather tube that is part of the sealed breathing system.

5. Manufacturer shall be Siemens, System A1000i. No Substitution.

D. Radar Level Transmitters

1. General. The level sensor shall measure continuous level and discrete level points in a liquid material application. The radar primary element shall be an electronically excited device. The output signal from the remote amplifier unit shall be 4-20 mA and two independently adjustable contacts to reflect the presence (or absence) of level. The output contacts shall be SPDT, rated at 120-VAC, 2-Amperes.

2. Specific Requirements. The type of process medium, temperature range, measuring pressure range, level measurement range, and other requirements shall be as required by the application. Unless otherwise specified the accuracy shall be plus or minus 0.25 percent of full range.

3. Construction. The transducer of the radar type level transmitter shall be corrosion and penetration resistant to a full range of chemicals and gases. The enclosure of the transmitter shall be NEMA 4 and suitable for use in areas specified. It shall be totally enclosed with powerful sonic pulses and temperature compensation and shall be suitable for accurate level measurement in the presence of vapor and gases over the liquid level. The level transmitter shall be microprocessor based for input power of 120 VAC and with output of 4-20 mA. It shall be programmable for different operating parameters, including, but not limited to range, span, units of measurement, selection of reading from tank bottom up or from sensor face down, etc. Echo loss and sensor fault detection and remote transmission shall also be provided. Integral display of level measurement, span and signal strength shall be provided. The transmitter shall be suitable for wall, rack or panel mounting as required by the application. The dead band of switches shall be individually adjustable.

4. Manufacturer. The radar type level transmitter shall be as manufactured by Endress & Hauser, Model FMR 231. No Substitution.

2.02 PRESSURE SWITCHES AND GAUGES

A. Pressure Switches

1. Pressure switches shall be diaphragm actuated; single set point adjustment pressure switches with two (2) SPDT contacts rated for a minimum of 5 amperes, continuous, at 120 Vac. The adjustable set point range shall be such that the indicated set point falls between 15 and 100 percent of the nominal range. The deadband shall be a maximum of +/- 4 percent of the maximum allowable pressure range. The switch enclosure shall be rated NEMA 4X in an unclassified area or NEMA 7/9 in classified area, unless otherwise specified. Unless otherwise indicated, each unit shall be


automatic reset type. The diaphragm shall be Buna-N, and the lower housing shall be Type 316 SS with a 1/2-inch bottom sensing connection, unless otherwise indicated.

2. Pressure switches shall be Ashcroft B Series type 400 (unclassified area) or type 700 (classified area). No Substitution.

B. Pressure Diaphragm Seals

1. Diaphragm seals shall consist of bottom housing, lower ring, diaphragm capsule, fill screw, threaded connection, and a top housing. The diaphragm seal shall attach to the inlet connection of a pressure instrument to isolate its measuring element from the process fluid. The space between the diaphragm and the instrument pressure element shall be completely filled with a suitable liquid. Displacement of the liquid fill in the pressure element through the movement of the diaphragm shall transmit process pressure changes directly to a gauge, transmitter, switch or any other pressure instrument. The diaphragm seal shall have a removable bottom housing to permit the servicing of the diaphragm capsule without the need to refill. All surfaces exposed to process fluids shall be Type 316 stainless steel or other compatible material suitable for the process connection.

2. Pressure diaphragm seals shall be Ashcroft Series 201. No Substitution. The model number may vary with process compatibility.

C. Iso-Ring Diaphragm Seals

1. The isolation ring seal shall consist of a ring assembly that fits between standard pipe flanges, like many butterfly valves. It has a flexible inner cylinder, behind which is the fill fluid. The process liquid exerts pressure on the cylinder, which transmits the pressure to the measuring instrument, through the fill fluid.

2. Iso-ring diaphragm seals shall be used in applications where considerable fouling or clogging can occur due to the process liquid characteristics.

3. Manufacturer shall be Ashcroft Series 80. No Substitution.

D. Pressure and Vacuum Gages

1. Pressure and Vacuum Gages. Pressure and vacuum gages shall, unless otherwise specified, conform to the following requirements. Gages shall be of the stem mounting type unless a panel mounted type is required.

2. Construction. Gages shall be liquid filled and be of the Bourdon tube or bellows type with 270 degrees pointer travel. Dials shall be white with black numerals. Accuracy shall be 0.5 percent and dial size shall be 4-1/2 inches unless otherwise indicated. Panel mounted gages shall have round bezels for flush mounting and rear connection; others shall have a stem mounting bottom connection. Connections shall be male 1/4-inch NPT with square wrench flats. Wetted parts shall be Type 316 stainless steel or


as indicated otherwise; and shall be the manufacturer's best quality standard. When required, the gage shall be supplied with a silicone oil filled stainless steel diaphragm seal or shall be equipped with pulsation dampeners. Cases shall be black phenolic or anodized aluminum.

3. Manufacturer. The gages shall be a product of Ashcroft, Type 1279 or 1188. No Substitution.

2.03 MAGNETIC FLOW METERS

A. General. Magnetic meters shall use the principal of electromagnetic induction to produce a DC current proportional to the rate of liquid flow. Coil excitation shall be DC. The coils shall generate a magnetic field, which in turn induces a voltage in the flowing liquid, which is sensed by a pair of electrodes in contact with the liquid.

1. The coils shall be protected from contact with the liquid and the electrodes shall be made of Hastelloy. When specified, the meters shall be housed to be splash and drip-proof and shall withstand submersion up to 12 feet for a period of 48 hours. They shall otherwise be housed in a dust and weatherproof case. The metering tube shall be suitably lined to withstand abrasion of the fluid.

2. The meters shall be designed to operate from a 120 VAC, 60 Hz, single-phase power supply and a 10 percent variation in power line voltage shall not affect the meter output accuracy in excess of 0.2 percent of full scale.

3. Each magnetic flow meter system shall have an accuracy within 1 percent of rate over the application operating range indicated in the Schedule. Meters shall have a repeatability of 0.1 percent of full scale.

4. Each magnetic flow meter shall be equipped with a signal converter transmitter to transmit an isolated analog 4 – 20 mA dc signal. When specified, a frequency and/or a scaled pulse rate to drive totalizing counters shall also be provided for local indication only. The pulse rate shall be scaled to provide one pulse per unit of measurement. Span adjustment shall provide for outputting full-scale analog and pulse signals for 30 percent of maximum flow. Signal shall be linear with flow within the accuracy specified above. The converter shall be pedestal or wall mounted as specified in the data sheet. The meters shall have automatic zero correction. Inter-connection between meters and signal converters shall be by cable furnished by the manufacturer. The converter shall be provided with two adjustable flow switches of the change over type (form C contacts).

B. Construction. The magnetic flow meters shall be of the short-form type with a laying length approximately 1-1/2 times the diameter for line sizes 3 inches and larger. Meters shall be designed with end connections as shown in the data sheet. Field coils shall be either completely encapsulated in the meter lining material or the meter tube shall be of Type 304SS with a suitable liner. A suitable protective shield shall be provided, where


indicated in the data sheet, at each end of the liner to withstand the scouring velocities of the process fluid at the maximum flow rates.

C. Grounding. Provide a grounding circuit for each magnetic meter. Provide grounding rings, grounding electrodes or protective shields to serve as a liquid ground, when the meter is installed in a nonconductive line or when indicated in the data sheet.

D. Manufacturer. Meter and signal converters shall be ABB MagMaster series. No Substitution.

2.04 VENTURI METERS

A. General

1. Basic Design: The meter differential pressure shall indicate flow change as a modified Venturi tube without use of devices which employ entire or partial pilot effects, or which amplify differential, or which introduce noise. The tube coefficient of discharge shall be constant for all water flow Reynolds numbers over a 10:1 range. Maximum head loss at maximum flow shall not exceed 9 percent of differential pressure output. Minimum discharge coefficient shall be 0.97. The accuracy shall be plus and minus 1 percent of actual rate of flow corresponding to the differential produced over the ranges indicated. The total overall error of each flow measurement loop, including flow tube, transmitting, receiving, and totalizing equipment shall not exceed 2 percent of actual rates of flow over the indicated flow ranges.

2. Compatibility: Similar flow metering equipment shall be obtained from a single manufacturer.

3. Characteristics of Flow Tubes: Meter shall be of the pressure differential-producing type utilizing static pressures sensed at the inlet and at the throat, without the use of devices which amplify differential through change in flow at the cross-sections where inlet and throat static pressure is sensed.

4. Tube Design: The inlet section with high pressure tap shall be a cylindrical section of the same diameter as the pipe. The throat section with low pressure tap shall be a cylindrical liner with a length equal to half its diameter. The metering element shall be free of debris-collecting cavities or annular chambers and shall have single pressure connections at the inlet and at the throat. Pressure taps shall be perpendicular to the axis of the meter and shall be straight-through-port easy to clean.

B. Basic Materials

1. Flanged Body Type: The Venturi body shall be of carbon steel, with a Type 316 stainless steel throat. The tubes shall have flanged ends to match ANSI 150 lb. piping.


2. A stainless steel nameplate shall be provided and attached to the completed venturi pipe section.

C. Manufacturer: Lambda Square Model FT-10 Low Head Loss Venturi. No Substitution.

2.05 ROTAMETERS

A. General

1. The meters shall be suitable for the service and chemicals conveyed, at process temperatures.

2. All meters shall be rated for a minimum working pressure of 150 psi.

3. Contractor shall verify that all material selected is suitable for the corrosive fluid application.

B. Basic Materials

1. Threaded (NPT) Meters shall be specified for Chemical Solutions. All threaded rotameters for chemical solutions and other service, where shown, shall be calibrated in gallons per hour, pounds per 24 hours (for chlorine gas), or cubic feet per minute for other gases and air. Flow accuracy shall be plus or minus 2 percent. The scales shall be suitable for the capacity ranges specified. Where indicated, the flow meter shall have an integral 2-wire transmitter with a 4-20 mA dc output signal linear to the measured flow rate.

2. Manufacturer: Brooks 1110. No Substitution.

2.06 VANE FLOW SWITCHES

A. Vane Type Flow switch shall be magnetically actuated to trip on high flow conditions. The lower housing shall be constructed from brass, and shall be leak proof, holding the flow vane and magnet that sense the flow, and actuate the switch mechanism located in the electrical, upper housing. Vane material shall be stainless steel, upper housing shall be constructed from brass. Enclosure shall be NEMA 4X. Contacts shall be SPDT, with a rating of 125 VAC at 5 amperes.

B. Manufacturer: Dwyer, Flotect Model V6. No Substitution.

2.07 THERMAL FLOW SWITCHES

A. Thermal Type Flow switch shall be the insertion type and shall be provided with temperature compensation to ensure the accuracy of the flow switch set point. All wetted materials shall be Type 316L SS or better. The switch enclosure shall be Nema 4X, suitable for the electrical area classification it is located in. Contacts shall be 2 SPDT, with a rating of 115 VAC at 6 amperes.


B. Manufacturer: Fluid Components Intl. Model FLT93B. No Substitution.

2.08 ELECTRONIC DIFFERENTIAL PRESSURE (AND FLOW RATE) TRANSMITTERS

A. Electronic differential pressure transmitters shall consist of a capsule assembly, bottom works, vent plug, drain plug, cover flange, process connector and connection, amplifier unit, integral indicator, terminal box with cover, block and bleed valves, and conduit connections. Pressure applied to the transmitter shall be transmitted by a sealed fill fluid to both sides of a sensing diaphragm. The sensing diaphragm and the sensor body shall function as the moving and fixed electrodes of a differential capacitor respectively. As the applied pressure causes the diaphragm to move, the capacitance of the cell shall change. The amplifier unit shall convert the change in capacitance to a 4-20 mA DC signal, two-wire type, with an allowable loop load of no less than 600 ohms. Static pressure rating shall be a minimum of 500 psig. The maximum overrange pressure limit shall be a minimum of 150 percent of the minimum range. Span shall be adjustable over a minimum of 5:1 range: External adjustments shall include zero and span. Damping shall be provided as an internal adjustment. All equipment shall be suitable for an ambient operating range of minus 40 to plus 175 degrees F. All wetted parts shall be constructed of Type 316 SS. All block and bleed valves shall be constructed of Type 316 SS. The integral indicator shall be calibrated in engineering units. The differential pressure transmitter shall be housed in a NEMA 4X watertight enclosure and shall be suitable for use in a Class 1 Division 1 hazardous area. Power supply shall be 24 Vdc. Accuracy, including linearity and repeatability, shall be a plus or minus 0.075 percent of span.

B. Electronic differential pressure transmitters shall be Rosemount Model 3051CD. No Substitution.

2.09 ELECTRONIC GAUGE PRESSURE TRANSMITTERS

A. Electronic gauge pressure transmitters shall consist of a capsule assembly, bottom works, vent plug, drain plug, cover flange, process connector and connection, amplifier unit, integral indicator, terminal box with cover, block and bleed valves, and conduit connections. Pressure applied to the transmitter shall be transmitted by a sealed fill fluid to both sides of a sensing diaphragm. The sensing diaphragm and the sensor body shall function as the moving and fixed electrodes of a differential capacitor respectively. As the applied pressure causes the diaphragm to move, the capacitance of the cell shall change. The amplifier unit shall convert the change in capacitance to a 4-20 mA DC signal, two-wire type, with an allowable loop load of no less than 600 ohms. Static pressure rating shall be a minimum of 500 psig. The maximum overrange pressure limit shall be a minimum of 150 percent of the minimum range. Span shall be adjustable over a minimum of 5:1 range: External adjustments shall include zero and span. Damping shall be provided as an internal adjustment. All equipment shall be suitable for an ambient operating range of minus 40 to plus 175 degrees F. All wetted parts shall be constructed of Type 316 SS. All block and bleed valves shall be


constructed of Type 316 SS. The integral indicator shall be calibrated in engineering units. The gauge pressure transmitter shall be housed in a NEMA 4X watertight enclosure and shall be suitable for use in a Class 1 Division 1 hazardous area. Power supply shall be 24V DC. Accuracy, including linearity and repeatability, shall be a plus or minus 0.075 percent of span.

B. Electronic gauge pressure transmitters shall be Rosemount Model 3051L (Level) or 3051T (Non-Level). No Substitution.

2.10 TEMPERATURE MEASURING SYSTEMS

A. Insertion type RTDs shall be 100 ohms nominal at 0 degree C, tip-sensitive, three-wire platinum in 0.25-inch and moisture proof accessory seal. Time constant in agitated water shall not exceed 6.0 seconds. RTD shall comply with IEC-751. Accuracy shall be plus or minus 0.5 degree C or plus or minus 0.5 percent of reading, whichever is smaller. Three-wire lead configuration for ambient temperature compensation shall be provided as a minimum. Where indicated with thermowells, RTDs shall be provided with appropriate NPT dimension and Type 316 SS thermowell and insertion length as specified in the data sheet, spring-loading device, extensions, unioncoupler and explosion-proof aluminum connection head. Union shall extend out beyond pipe lagging.

B. The RTD type temperature transmitter shall be a resistance sensing unit. The transmitter shall be a two wire device with continuously adjustable span, zero and damping adjustments, integral indicator scaled in engineering units, solid-state circuitry, and 4-20 mA output proportional to temperature. Accuracy shall be plus or minus 0.5 percent of span. The materials of construction shall be injected low copper aluminum with a Type 316 SS NEMA 4X housing and suitable for use in Class 1, Division 1 hazardous location.

C. The temperature transmitter shall be Rosemount Model 3144P. No Substitution.

2.11 PROCESS ANALYZER MEASURING SYSTEMS

A. General

1. Power Input: Analyzers shall be the fully isolated 2-wire type, unless the type is not available, in which case the analyzer shall be the fully isolated four wire type with power supply of 120 volts plus and minus 10 percent, 60 Hz plus and minus 5 percent.

2. Signal Output: Outputs shall be current regulated 4-20 mA DC, capable of driving 0 to 600 ohms.

3. Ambient Conditions: Analyzers shall be suitable for continuous automatic on-line analysis of the indicated parameter under the conditions indicated.


4. Equipment shall operate satisfactorily in ambient temperatures between 40 and 110 degrees F or shall be provided with isothermal enclosures so that accuracies will not exceed 1 percent of span.

5. Process fluid temperatures will typically range between 65 and 80 degrees F but in occasional cases can be as low as 40

6. Sample Flow: Samples shall not pass through housings containing electronics unless indicated otherwise. Some analyzers may require submersible sample pump.

and as high as 110 degrees F unless indicated otherwise.

7. Local Indication: Each analyzer shall be provided with local indication scaled in process units.

8. Calibration: Each analyzer shall be fitted with calibration connections at the analyzer.

9. Single manufacturer: All electrodes, fittings, and transmitters on analyzers measuring the same parameter shall be products of a single manufacturer.

B. Oxidation-Reduction Potential Measuring System

1. Each Oxidation-Reduction Potential (ORP) analyzer system shall consist of an indicating analyzer/transmitter, ORP sensor with mounting hardware.

2. ORP analyzer/transmitter shall continuously measure and indicate the oxidation-reduction potential of the solution in the process tank or stream. The analyzer shall produce an isolated 4-20 mA dc output signal proportional to a range of -2000 to +2000 mV. Three (3) SPDT alarm relays shall be provided for remote status information.

3. The ORP measurement shall be of Differential Electrode Method which uses two ORP electrodes to compare the process signal to a reference. Sensor shall be submerged in the aeration tank and is cleaned using a soft cloth by wiping the end of the sensor off approximately once per month. Accuracy shall be +/-20 mV.

4. ORP analyzer/transmitter shall have local indication. The display shall be graphic dot matrix LCD with backlighting. It shall be mounted in a NEMA Type 4X enclosure. The unit shall be suitable for either surface or panel mounting. The analyzer/transmitter shall be provided with a sunshade resistant to ultraviolet light and corrosive environments.

5. The sensor shall be provided with a pole mounting kit, allowing for a minimum of 10-inch separation from the wall, with a minimum insertion depth of 18 inches into the process. Provide pivoting pole mounting kit for the sensor mounting from the Hach Company.

6. The sensor assembly shall be convertible style with protector constructed of chemically-resistant Ryton, and the reference junction is coaxial porous Teflon.


Mounting brackets shall be provided to hold the sensor in the water. The brackets shall be designed to permit easy withdrawal and inspection of the sensor.

7. Each unit shall operate on a 120 VAC, 60 Hz power source.

8. The Oxidation-Reduction Potential Measuring System shall be Hach Model SC100 with a Hach pHD type ORP sensor. No Substitution.

C. Turbidity Measuring System

1. Turbidimeter shall measure turbidity in the range of 0.001-100 NTU and be a continuous-reading, on-line nephelometric instrument meeting all design and performance criteria specified by USEPA method 180.1.

2. The unit shall be provided with an infrared light source as required by ISO 7027 with a minimum lamp life of 10 years. The light shall generate a beam of light which will pass through the sample. One detector arranged at a 90° angle to the sample shall measure the light.

3. The unit shall include a circulation fan to maintain a dry environment to eliminate interferences from transient moisture. Bubble rejection shall be included to eliminate air in the sample without influencing response time.

4. The measuring chamber shall consist of a rotational flow through assembly with replaceable glass cuvette.

5. The unit shall have all electronics, operator controls and measurement cell mounted in a single NEMA 4X housing. It shall have an integral LCD display for turbidity levels and measurement for guidance in setup, calibration and troubleshooting.

6. An isolated 4-20 mA DC output and 2 configurable SPDT alarm relays shall be available for interfacing with any control system. It automatically accepts an input of 120 VAC, 60 Hz.

7. The turbidity measuring system shall be Hach model 1720E with SC100 controller. No Substitution.

2.12 EXHIBIT

A. Exhibit A – Visalia WCP Instrumentation List


Visalia Water Conservation Plant Upgrades December 2010 RPGS Pre-selection 13320-A Field Mounted Instruments

Section 13320 – Exhibit ‘A’

Visalia WCP Instrumentation List (EQUIPMENT SUPPLIER SHALL NOTE THAT NOT ALL INSTRUMENTS ARE APPLICABLE TO RPGS PROJECT)

Instrument Manufacture / Model

Ultrasonic Level Transmitter Siemens / Hydroranger 200 (transmitter) and And Switch XPS-15 (transducer) Tilt Liquid Level Switch Flygt / ENM-10 Submersible Level Transmitter Siemens / A1000i Radar Level Transmitter Endress + Hauser / FMR 231 Pressure Switch Ashcroft / B Series Type 400 (unclassified area)

Or Type 700 (classified area) Pressure Diaphragm Seal Ashcroft / Series 201 Iso-Ring Diaphragm Seal Ashcroft / Series 80 Pressure and Vacuum Gage Ashcroft / Type 1279 or 1188 (low pressure) Magnetic Flow Meter (Liquid Flow) ABB / MagMaster Venturi Meter (Gas Flow) Lambda Square / FT-10 Low Head Loss Rotameter Brooks / 1110 Open Channel Flow Meter Marsh McBirney / Flo-Station (transmitter) and Flo-Dar Sensor (transducer) Vane Flow Switch Dwyer Instruments / Flotect V6 Thermal Flow Switch Fluid Components Intl. / FLT93B Electronic Differential Pressure Rosemount / 3051CD (and Flow Rate) Transmitter Electronic Gauge Pressure Transmitter Rosemount / 3051L (level) or 3051T (non-level) Temperature Transmitter Rosemount / 3144P Dissolved Oxygen Measuring Hach / SC100 controller and LDO sensor System Oxidation-Reduction Potential Hach / SC100 controller and pHD type ORP sensor Measuring System Total Residual Chlorine Measuring System Wallace & Tiernan / Micro/2000 Residual Analyzer Turbidity Measuring System Wallace & Tiernan / TMS561 Gas Sensors MSA / UltimaX

Visalia Water Conservation Plant Upgrades December 2010 RPGS Pre-selection 13510-1 PLC Based Control System Hardware

SECTION 13510 – PLC-BASED CONTROL SYSTEM HARDWARE

PART 1 – GENERAL

1.01 WORK INCLUDED

A. The EQUIPMENT SUPPLIER, shall provide a PLC-based Control System (PLC-CS) complete and operable, in accordance with the RFP.

1.02 SUBMITTALS

A. Shop Drawings: PLC-CS submittals shall be in accordance with the applicable requirements of Section 13100 – Instrumentation and Control.

B. Submittals: The PLC hardware submittal shall be a single submittal which includes at least the following:

1. A complete set of PLC I/O wiring diagrams, PLC panel wiring diagrams and assembly drawings.

2. UPS and battery load calculations to show that the backup capacity and time meet the specified requirements.

3. Data sheets shall be included for each PLC-CS component together with a technical product brochure or bulletin. These data sheets shall show the component name as used within the RFP, the manufacturer's model number or other identifying product designation, the project tag number, the project system of which it is a part, the input and output characteristics, the requirements for electric power, the ambient operating condition requirements, and details on materials of construction.

4. Complete and detailed bills of materials: A bill of material list, including quantity, description, manufacturer, and part number, shall be submitted for each component of the PLC system. Bills of material shall include all items within an enclosure.

5. Calibration, adjustment, and test details for all PLC components.

C. Operation and Technical Manuals: General requirements for Operation and Technical Manuals are as described in Section 01300 – EQUIPMENT SUPPLIER SUBMITTALS. The following items shall also be included in the PLC manual:

1. A documented PLC program listing including the I/O list and housing configuration for each PLC, a memory usage report for each PLC, and a register layout list for each PLC.

2. Operation and Technical Manuals for all hardware furnished under this Section.


A. The CONTRACTOR / EQUIPMENT SUPPLIER shall arrange for visits by, and services of, technical field representatives of the manufacturer for installation certification, system testing, training, and start-up. These services shall be part of the WORK and provided at no additional cost to the CITY.


B. Warranty Requirements: Special warranty requirements shall be in accordance with the applicable requirements of Section 13100– Instrumentation and Control

1. Equipment, software, and materials which do not achieve design requirements after installation shall be replaced or modified by the EQUIPMENT SUPPLIER to attain compliance. The cost for doing so shall be the EQUIPMENT SUPPLIER’S responsibility. Following replacement or modification, the EQUIPMENT SUPPLIER shall retest the system and perform any additional procedures needed to place the complete system in satisfactory operation and attain design compliance approval from the ENGINEER.

2. The EQUIPMENT SUPPLIER warrants the materials and workmanship used for the PLCs equipment and materials and further guarantees the materials and workmanship used for any equipment and materials produced and furnished hereunder as a part of the Work to be as required and agreed upon, free from injurious defects, and in all respects satisfactory for the service required.

3. The EQUIPMENT SUPPLIER warrants/guarantees the satisfactory performance of the equipment and materials under operating conditions for a period of two years after the date of final acceptance. In the event that tests and inspections disclose latent defects or failure to meet the specified requirements, the EQUIPMENT SUPPLIER shall proceed at once to correct or repair any such defects or non-conformance. The delivery of new equipment or parts as may be necessary for conformity to the requirements shall be made at no additional cost to the CITY. In case of any required repairs or other corrective or remedial work covered under warranty, the goods repaired, corrected, or replaced under the provisions of this warranty shall be subject to the same warranty provisions for the remainder of the original warranty period or for a minimum period of twelve months from the date of repair or replacement, whichever is longer. If the CITY performs repair, the EQUIPMENT SUPPLIER shall reimburse the CITY for all costs incurred in the removal of the defective material and installation of the replacement.

PART 2 – PRODUCTS

2.01 GENERAL

A. All materials and all PLC-CS equipment furnished under this Contract shall be new, free from defects, of first quality, and produced by manufacturers regularly engaged in the manufacture of these products.

B. Hardware Commonality: Where there is more than one item of similar equipment being furnished all such similar equipment shall be the product of a single manufacturer.

2.02 PROGRAMMABLE LOGIC CONTROLLER (PLC)

A. Manufacturers: The PLC shall be Allen-Bradley ControlLogix 1756-L6 series.

B. Each PLC shall be of solid-state design. All CPU operating logic shall be contained on plug-in modules for quick replacement. Chassis wired logic is not acceptable. The controller shall be capable of operating in a hostile industrial environment and designed to provide high reliability specifically in this process application. The internal wiring of


the controller is to be fixed, with the logic functions it must perform in a given application to be programmed into its memory. The controller shall be supplied with the CPU, input/output scanner, inputs, outputs, memory, power supply, communication modules including but not limited to Ethernet/IP and Profibus, and all power and interface cables necessary to function as a complete and operable PLC system. The PLC shall be furnished with an onboard RS-232 communication port.

C. Design: Each PLC shall have all of the facilities required to implement the control schemes and database indicated. PLC shall have the following functions and features:

1. Modular, field expandable design allowing the system to be tailored to this process control application. The capability shall exist to allow for expansion of the system by the addition of hardware and/or user software.

2. The processor plus input and output circuitry shall be of a modular design with interchangeability provided for all similar modules. Modules are defined herein as devices which plug into a chassis and are keyed to allow installation in only one direction. The design must prohibit upside down insertion of the modules as well as safeguard against the insertion of a module into the wrong slot.

3. The PLC shall have downward compatibility whereby all new module designs can be interchanged with all similar modules in an effort to reduce obsolescence.

4. All PLC hardware shall be suitable for an ambient temperature range of 0 to 60 degrees C (32 to 140 degrees F), with an ambient temperature rating for storage of -40 to +85 degrees C (-40 to +185 degrees F), and shall function continuously in the relative humidity range of 5 to 95 percent with no condensation. The PLC system shall be designed and tested to operate in the high electrical noise environment of a wastewater treatment plant.

5. The PLC shall provide a means for mounting the chassis in a standard cabinet.

6. It shall be possible to communicate with remote I/O racks or other PLC’s via fiber optic cable by inserting fiber optic modems.

D. Central Processors (CPU): Each CPU shall contain all the relays, timers, counters, number storage registers, shift registers, sequencer, arithmetic capability, and comparators necessary to perform the indicated control functions.

It shall be capable of interfacing sufficient discrete inputs, analog inputs, discrete outputs, and analog outputs to meet requirements. Specifically, the PLC shall have the following features and capabilities:

1. All PLC's shall be provided to support and implement closed loop floating and PID control which is directly integrated into the PLC's control program.

2. The CPU shall be a self-contained unit, and shall provide control program execution and support remote or local programming. This device shall also supply I/O scanning and inter-processor and peripheral communication functions.


3. The CPU within the system shall perform internal diagnostic checking and give visual indication to the user by illuminating a "green" indicator when no fault is detected and a "red" indicator when a fault is detected.

4. The main chassis front panel shall include two-color indicators showing the following status information:

a. Program or Run mode of the controller

b. The fault status of the controller

c. Input and output status

d. RS-232 activity

e. Battery status

5. Non-volatile memory shall store the operating system information to protect against loss in the case of power loss or system shut-down. Only at the time of a hardware change shall this configuration status be altered or reentered.

E. Program Creation and Storage (Memory)

1. The program storage medium shall be of a static RAM type.

2. The PLC system shall have a user memory size of 4MB minimum.

3. Memory capacity shall be configurable to allow for the most efficient match to the intended application. It shall be possible to upgrade to a processor with a larger memory size simply by saving a program, replacing the processor, and downloading the program to the new system without having to make any program changes.

4. Memory shall contain battery back-up capable of retaining all stored program data through a continuous power outage for 4 months under worst case conditions. The capability shall exist to remove all batteries from the system without removing system power. A low battery condition must be detectable in ladder logic, but shall not automatically generate a major fault.

5. Each PLC unit shall be supplied with sufficient memory to implement the indicated control functions plus a 40 percent reserve capacity. This reserve capacity shall be totally free from any system use.

F. Programming Techniques

1. The programming format shall be IEC 61131-6 compliant Ladder Logic.

2. The capability shall exist to change a contact from normally open to normally closed, add instructions, change addresses, etc. It shall not be necessary to delete and reprogram the entire rung.

3. It shall be possible to insert relay ladder diagram rungs anywhere in the program, even between existing rungs, insofar as there is sufficient memory to accommodate these additions.


4. The PLC shall have the capability to remove an entire logic rung into an edit buffer where individual parameters may be easily altered.

5. A single program command or instruction shall suffice to delete an individual ladder diagram rung from memory. It shall not be necessary to delete the rung contact by contact.

6. It shall be necessary to issue a two-part command in order to delete all relay ladder rungs from memory. This will provide a safeguard wherein the operator must verify their intentions before erasing the entire program.

7. A clock/calendar feature shall be included within the CPU. Access to the time and date shall be from the programming terminal, user program, or message generation.

8. Latch functions shall be internal and programmable.

9. The system shall have the capability to address software timers and software counters in any combination and quantity up to the limit of available memory. All management of these instructions into memory shall be handled by the CPU. Instructions shall permit programming timers in the "ON" or "OFF" delay modes. Timer programming shall also include the capability to interrupt timing without resetting the timers. Counters shall be programmable using up-increment and down-increment. The PLC shall have support for integer and floating point signed math functions consisting of addition, subtraction, multiplication, division, and square root.

10. The system shall have the capability to enter rung comments above ladder logic rungs. These comments may be entered at the same time the ladder logic is entered.

11. The system shall have the capability to enter address comments and symbols. These entities may be entered at the same time the ladder logic is entered.

12. The capability shall exist for adding, removing, or modifying ladder logic rungs during program execution. When changes to ladder logic are made or new logic rungs are added, it shall be possible to test the edits of such rungs before removal of the prior logic rung is executed.

13. It shall be possible to manually set (force) either on or off all hardwired input or output points from the programming terminal. Removal of these forced I/O points shall be either individually or totally through selected keystrokes. The programming terminal shall be able to display forced I/O points.

14. The ability to program control logic via symbols from the global database of the PLC shall exist.

15. An instruction shall be supported to incorporate closed loop control systems. The "proportional", "integral", and "derivative" elements shall be accessible to the user in order to tune a closed loop system. This instruction must fully support floating point math.

16. The CPU shall support indexed and indirect addressing of inputs and outputs, along with all data table words (integer, binary, floating point, timers, and counters) for the software instruction set.


G. PLC Power Supply: The PLC shall operate in compliance with an electrical service of 120 VAC. The power supply shall be mounted in the PLC housing and be sized to power all modules mounted in that housing and an "average module load" for any empty housing slots plus 25 percent above that total. Power supply shall be by the same manufacturer as the PLC and shall be of the same product line. A single main power supply shall have the capability of supplying power to the CPU and local input/output modules. Auxiliary power supplies shall provide power to remotely located racks.

1. The power supply shall automatically shut down the PLC system whenever its output current is detected as exceeding 125 percent of its rated current. The power supply shall monitor the incoming AC line voltage for proper levels. When the power supply is wired to utilize 120/240 VAC power, the system shall function properly within the range of 85 to 265 VAC.

2. Design features of the PLC power supply shall include diagnostic indicators mounted in a position to be easily viewed by the user.

3. At the time of power-up, the power supply shall inhibit operation of the processor and I/O modules until the AC voltages are within specifications.

4. The power supply shall offer fuse protection.

H. PLC Input/Output (I/O) Modules: All I/O housings and modules shall be suitable for hostile industrial environments as described above. All I/O modules shall be isolated and conform to Institute of Electrical and Electronics Engineers (IEEE) Surge Withstand Standards and NEMA Noise Immunity Standards. The I/Os shall be 4-20 mA DC for all analog inputs and outputs and shall be 120 VAC for discrete inputs and dry relay contacts for safe discrete outputs. Modules shall be removable without having to disconnect wiring from the module's terminals by means of a swing-arm or plug-in wiring connector. Each PLC I/O location shall contain the I/O modules required to provide all of the I/O points contained in the I/O Lists. As a minimum, each PLC I/O location shall contain an installed spare capacity of 20 percent. During normal operation, a malfunction in any remote input/output channel shall affect the operation of only that channel and not the operation of the CPU or any other channel. Any remote input/output channel shall be field selectable to shut down the CPU upon failure of that channel. Upon remote channel shutdown the CPU shall see all inputs on the malfunctioning channel as they were when the shutdown occurred and all outputs shall de-energize on that channel. Circuit components for both remote input and output shall be mounted on plug-in modules and keyed to prevent module insertion into the wrong slot Isolation shall be used between all internal logic and external power circuits.

1. Discrete Input Modules: Defined as contact closure inputs from devices external to the programmable controller module. The modules shall have LED's to indicate status of each discrete input. Input signal level shall be 120 VAC. Input modules shall have 16 points each. Discrete Input Modules shall be Allen-Bradley 1756-IA16.

2. Discrete Output Modules: Defined as contact closure outputs for ON/OFF operation of devices external to the programmable controller module. The output modules shall be optically isolated from inductively generated, normal mode and low energy, common mode transients to 1500 volts peak. All output modules shall have LED's to


indicate status of each output point. Output contact rating shall be 2.0 A minimum, 24 VDC. Discrete output contacts shall be provided with interposing relays located in the PLC panel. Output modules shall have 16 points each. Discrete Output Modules shall be Allen-Bradley 1756-OB16I.

3. Analog Input Modules: Defined as 4-20 mA DC signals, where an analog digital conversion is performed with 16-bit precision and the digital result is entered into the processor. The analog to digital conversion shall be updated with each scan of the processor. Input modules shall be source or sink to handle 2-wire or 4-wire transmitters respectively. Analog input modules shall have 8 input channels. Analog Input Modules shall be Allen-Bradley 1756-IF16.

4. Analog Output Modules Defined as 4-20 mA DC output signals where each output circuit performs a digital to analog conversion minimum of 16-bit precision with each scan of the processor. The EQUIPMENT SUPPLIER shall provide current loop isolators as required to break ground loops. Analog Output Modules shall have 6 individually isolated current outputs. Analog Output Modules shall be Allen-Bradley 1756-OF6CI.

5. A Profibus Master DPV1 interface module shall be provided for interface with the VFDs and motorized control valves. The Profibus module shall be ProSoft Technology Profibus DPV1 Master model MV156-PDPMV1.

6. An Ethernet/IP communication module shall be provided for communication with other plant PLCs, remote I/O and local peripheral devices. The Ethernet/IP module shall be Allen-Bradley 1756-EN2T.

2.03 PLC ENCLOSURES

A. Each PLC and its corresponding I/O modules, power supply module(s), communication interface device(s), and peripheral equipment. All I/O wiring from the field to the I/O modules shall be terminated on terminal blocks in the enclosure. The PLC panel enclosure shall house the UPS, 24 VDC power supplies and interposing relays. Provide segregation between 120 VAC and 24 VDC components.

B. All panel front mounted instruments, switches, indicating lights, etc. shall be identified by suitable nameplates, fastened with a permanent but dissolvable adhesive or by screws. For NEMA 12 panels, nameplates shall be black lamicoid with minimum 1/4-inch high white letters for major area titles, 3/16-inch for component titles, and 5/32-inch for sub-titles. For NEMA 4X panels, nameplates shall be Type 316L SS with minimum 1/4-inch high engraved letters for major area titles, 3/16-inch for component titles, and 5/32-inch for sub-titles.

C. PLC enclosures shall be provided in accordance with Section 16050 - General Electrical Provisions.

D. Doors with concealed hinges and flush three-point vault type key-locking latches shall be provided. These latches shall be in addition to any required screw clamps. Keys in duplicate shall be provided for each panel door and each instrument, which has a separate lock.


2.04 UNINTERRUPTIBLE POWER SUPPLY (UPS)

A. Provide and install UPS to power all PLC hardware furnished under this Specification.

B. The Uninterruptible Power Supply (UPS) shall receive a 120 VAC, 60 HZ power input, and generate a 120 VAC, 60 HZ output signal which is protected from incoming spikes, sags, noise, brownouts, and power outages.

1. The UPS shall incorporate a battery pack, a battery charger, an inverter, and a microprocessor based controller to provide continuous, on-line, computer grade uninterruptible power. Output voltage regulation shall be +3 percent with less than 5 percent total harmonic distortion. UPS efficiency shall be at least 85 percent. The UPS shall be rated for operating temperatures from 32 degrees F to 104 degrees F and relative humidity from 0 to 95 percent non-condensing.

2. Each UPS shall maintain power to all of its connected loads for a minimum of 7 minutes full load. The equipment submittal shall include sizing calculations which support the model and size selected. The UPS shall be supplied with a low output voltage cutoff to prevent damage to loads when the battery power is exhausted.

3. A bypass switch shall be provided to manually bypass the UPS for maintenance purposes. During bypass operation, the load shall be directly connected to the primary power source.

4. Provide seismic strapping for the UPS.

5. The UPS shall be EATON Powerware PW9130 series.

2.05 HUMAN MACHINE INTERFACE (HMI)

A. The HMI unit shall be an industrial-hardened graphics display touchscreen terminal. The touch screen terminal shall be 12.5” diagonal or as indicated otherwise. It shall be TFT color graphic display flush mounted on the control panel door. The screen shall be scratch-resistant and suitable for indoor installation. It shall be NEMA 4X or as indicated otherwise and suitable for operating temperature range of 32 to 131 degrees F. The application memory shall be 64 MB RAM/64 MB Flash minimum. The HMI shall be Allen-Bradley PanelView Plus 12.5” TFT Touch terminal. Communication between the HMI and PLC shall be through Ethernet.

2.06 PANEL COMPONENTS

A. The main disconnecting mean (fused switch or circuit breaker) shall be provided and shall have a door-mounted handle interlocked with the door, and shall be provided with manual defeater unless otherwise specified or shown.

B. Pushbuttons, selector switches, and pilot lights shall be of the heavy-duty, oil-tight type. Miniature style devices are not acceptable. Devices shall be as manufactured by G.E, Square D, Allen-Bradley or equal.

1. Pilot lights shall be full voltage LED cluster style.

2. Provide hazardous location type pilot devices in classified locations.


C. Relays shall be 3 PDT with 10 amp contacts, plug-in type utilizing rectangular blades and provided with sockets for screw-type termination and hold-down clips. Relays shall be as manufactured by Square D, Potter Brumfield, Allen-Bradley or equal.

D. Time delay relays shall be combination “on delay” and “off delay” (selectable) with adjustable timing ranges. Provide socket with screw terminal connections and retaining strap.

E. Ethernet switches shall be industrial type manufactured by Phoenix Contact.

F. PLC Panel Power Supplies: PLC panels shall be provided with redundant 24 VDC power supplies which are configured in a fault-tolerant manner to prevent interruption of service upon failure and interruption of service necessitated by the replacement of a power supply. Power supplies shall have an excess rated capacity of 40 percent. The failure of a power supply shall be annunciated at the control panel HMI and repeated to the SCADA System. Power supplies shall be Phoenix Contact Quint series.

G. One grounded 120 VAC, 60 Hz single phase power receptacle shall be provided in the PLC panel.

2.07 PANEL WIRING

A. Control wires shall be #14 AWG minimum, machine tool grade type MTW, UL approved and rated for 90 degrees C at dry location.

B. Instrumentation Signal Cables shall be single twisted pair or multi twisted pairs of stranded, copper cables with 600 volt, 15 mil polyvinyl chloride insulation with 4 MIL nylon jacket over each conductor, overall aluminum-mylar tape shield, overall tinned copper drain wire and 45 mil minimum polyvinyl chloride jacket overall, 90 degrees C dry / 75 degrees C wet rating. Twisted pair cables that are required to be shielded, shall have aluminum-mylar tape shields and tinned copper drain wires over individual twisted pairs of cable. Single twisted pair cables shall be #16 AWG minimum. Cables shall be Okonite "Okoseal-N-type P-OS, type TC", Dekoron type TC or equal.

C. Each control or power panel shall be provided with identified terminal strips for the connection of all external conductors. Terminal blocks shall be screw terminal, heavy duty, rated at 20 amperes minimum, 600 volt AC. The EQUIPMENT SUPPLIER shall provide sufficient terminal blocks to connect 25 percent additional conductors in the future. Termination points shall be identified in accordance with accepted shop drawings.

D. All internal wiring shall be factory-installed and shall be contained in plastic raceways or troughs having removable covers. Wiring to door-mounted devices shall be extra flexible and anchored to doors using wire anchors cemented in place. Exposed terminals of door-mounted devices shall be guarded to prevent accidental personnel contact with energized terminals.


2.08 SOFTWARE

A. The PLC programming software shall be RSLogix 5000 Enterprise series Professional edition latest version. HMI programming software shall be FactoryTalk View Machine Edition latest version.

2.09 SPARE PARTS

A. PLC system spare parts shall be furnished in accordance with Section 13100 – Instrumentation and Control

2.10 EXHIBIT

A. Exhibit A – Visalia WCP PLC Panel Components List


3.01 STORAGE AND HANDLING

A. All equipment and materials delivered to the Site shall be stored in a location which shall not interfere with the operations of the CITY's personnel or interfere with construction. Storage and handling shall be performed in a manner which shall afford maximum protection to the equipment and materials. It is the CONTRACTOR's responsibility to assure proper handling and on-site storage.

3.02 INSTALLATION

A. The CONTRACTOR shall utilize personnel to accomplish, or supervise the physical installation of all elements, components, accessories, or assemblies which it provides. The CONTRACTOR shall employ installers who are skilled and experienced in the installation and connection of all elements, components, accessories, and assemblies it provides.

3.03 CALIBRATION, TESTING, AND INSTALLATION

A. Calibration: All analog inputs and outputs of the PLC shall have their calibration checked at a minimum of 4 points to verify consistency with the balance of the analog loop. This calibration check shall be done in conjunction with the analog loop tests in Section 13100. Workstation displays and PLC registers shall both be verified for correctness.

B. Testing: After the PLC installation has been certified and the analog points have been calibrated, the PLC shall be tested to verify that all discrete inputs and outputs of both the PLC system and the workstation system are correct. All points shall be checked “end to end”. For example, valve status inputs shall be checked by stroking the valve and a pump start output shall be checked by using it to start the pump. Simulated testing shall be allowed only when no practical alternative exists. Workstation displays shall be verified for correctness at the same time. An I/O checklist shall be used to record test results and a copy provided to the ENGINEER upon completion.

3.04 LADDER LOGIC DOCOUMENTATION


A. The EQUIPMENT SUPPLIER shall annotate the PLC ladder logic by providing a descriptive label for all relays and function blocks and functional description of each rung. The EQUIPMENT SUPPLIER shall hand over to the CITY the PLC ladder logic program and all related documentation in electronic format at the end of the warranty period.


Visalia Water Conservation Plant Upgrades December 2010 RPGS Pre-selection 13510-A PLC Based Control System Hardware

Section 13510 – Exhibit ‘A’

Visalia WCP PLC Panel Components List

Component Manufacturer and Model/Part#

Lean Managed Ethernet Switch Phoenix Contact / 2832658 (2 FO and 4 RJ45 ports) Standard Ethernet Switch Phoenix Contact / 2891929 (8 RJ45 ports) Fiber Optic Patch Panel Wall-Mounted Connector Housing: Corning / WCP-02P Connector Panel: Corning / CCH-CP12-91

Panel-Mounted Patch Panel: 3M / Model No. 8423 See Dwg I-03 for details

24VDC Power Supply Phoenix Contact / Quint Series Uninterruptible Power Supply Eaton Powerware / PW9130 Control Relays, Circuit Breakers, Phoenix Contact and Terminal Blocks

APPENDIX J

ELECTRICAL SPECIFICATIONS (DIV 16)

City of Visalia – WCP Upgrades RPGS Pre-selection 16050 - 1 December 2010 General Electrical Provisions

SECTION 16050 – GENERAL ELECTRICAL PROVISIONS

PART 1 – GENERAL

1.01 WORK INCLUDED

The WORK included under this specification consist of furnishing all equipment, materials, start-up services, specialty tools, and other equipment necessary for the electrical and control equipment fabrication, delivery, and testing as specified herein.

A. The intent of the electrical specifications is to provide enough information to the manufacturer to illustrate the electrical equipment standards and requirements for which the power and control system are to be fabricated. All field installation (except the required manufacturer's checking, start-up, and testing) will be done by others.


A. All equipment, materials, and methods of design and manufacture are to comply with the National Electrical Code, the basic Electrical Regulations of the State where the equipment is to be installed, the Occupational Safety and Health Act (OSHA), and the requirements of all other applicable codes. Codes and standards of the following organizations may be referred to in this section and shall be considered as the minimum acceptable. A reference herein to any portion of the standard or code is not to be considered as negating any other portion of the standard or code.

ANSI American National Standards Institute, Inc.

IEEE Institute of Electrical & Electronic Engineers

ASTM American Society for Testing & Materials

UL Underwriters Laboratories, Inc.

NEMA National Electric Manufacturers Association

IPECA Insulated Power and Cable Engineers Institute

NEC National Electric Code

ISA Instrument Society of America

B. All electrical equipment shall be listed by and shall bear the label of Underwriters' Laboratories, Inc. (UL) or an independent testing laboratory acceptable to the local code enforcement agency having jurisdiction.

B. Where these specifications require a higher degree of workmanship or quality of material than the above codes and standards imply, then these specifications will prevail.


1.03 EQUIPMENT SUPPLIER SUBMITTALS

A. Make all submittals in accordance with Section 01300 – EQUIPMENT SUPPLIER SUBMITTALS.

B. Within 15 days after the contract award, submit material lists for this section of the work. Lists will include manufacturer and brand name of each class of material.

C. Submit complete shop drawings for review prior to manufacture or assembly of the equipment.

1. Drawings will show:

a. Elevations Layout and Construction details

b. Bill of Material Nameplates Temperature limitations Voltage requirement, phase, and current, as applicable Grounding requirements (if applicable) Catalog cut sheets or brochures for mass produced, non-custom manufactured material.

C. Package drive diagrams are to be of the elementary type and show terminal identifications and associated field connections for each drive.

D. Provide Operation and Technical Manuals in accordance with Section 01300 – EQUIPMENT SUPPLIER SUBMITTALS.


A. All equipment furnished under this section will be guaranteed for a minimum period of one (1) year from date of accepted installation against defective materials, design, and workmanship in accordance with the provisions of the General Conditions.

B. Tests

1. The EQUIPMENT SUPPLIER shall be responsible for all factory tests required by specifications in Division 16 and by the ENGINEER or other authorities having jurisdiction. The EQUIPMENT SUPPLIER shall furnish necessary testing equipment and replacement parts resulting from damaged/failed equipment from testing.

2. Where test reports are indicated, proof of design tests reports for mass-produced equipment shall be submitted with the Shop Drawings, and factory performance test reports for custom-manufactured equipment shall be submitted and be approved prior to shipment. Test reports shall be submitted for review prior to Submittal completion.

3. Equipment or material that fails a test shall be removed and replaced. All tests which do not pass shall be repeated after identifying and correcting the problems. Any


corrections to equipment or materials that are furnished with a factory warranty shall be corrected per the recommendations of the manufacturer and in a manner which does not violate the terms of the warranty.

1.05 AREA DESIGNATIONS

A. Electrical equipment and components location shall comply with requirements listed in the table below:

Area

NEMA ENCLOSURE CLASSIFICATION

1 3R 4 4X 7 9 12 Notes

Below grade vaults, manholes, etc.

X

Outdoors, non-hazardous, non corrosive locations

X UL listed for outdoor & wet locations

Outdoors, non-hazardous, corrosive locations

X UL listed for outdoor & wet locations

Outdoors, hazardous, non-corrosive locations

X UL listed for outdoor & wet locations, or add rain Shields

Outdoors, hazardous & corrosive locations

X UL listed for outdoor & wet locations, and epoxy coated

Building Interior, non-hazardous, non corrosive locations

X

Building Interior, non-hazardous, corrosive locations

X

Building Interior, hazardous, non corrosive locations

Class 1, Div 1/2 as required by applicable codes.

Building Interior, hazardous & corrosive locations

Class 1, Div 1/2 as required by applicable codes. Only non-corroding materials allowed or epoxy coating required.

A. Electrical WORK not included in the table above shall be NEMA 4X, unless applicable

code requires otherwise.


B. Installation in hazardous locations shall conform strictly to the requirements of the Class, Group and Division indicated or required by applicable codes.

PART 2 – PRODUCTS

2.01 GENERAL

A. All equipment and material is to be new, free from defects, of current manufacture, and listed by Underwriters Laboratories, Inc., (UL) where UL requirements apply. All materials are to be products of reputable and experienced manufacturers. Similar items in the project are to be of the same manufacturer. Use only equipment and materials of industrial quality and durability, and capable of long, reliable, trouble free service.

2.02 MOUNTING HARDWARE

A. Miscellaneous Hardware

All nuts and bolts shall be stainless steel.

Anchors for attaching equipment to metal skids shall be stainless steel.

2.03 ELECTRICAL IDENTIFICATION

A. Nameplates: Nameplates shall be fabricated from white-letter, black face laminated plastic engraving stock, Formica Type ES-1, or equal. Each shall be fastened securely, using fasteners of brass, cadmium plated steel, or stainless steel, screwed into inserts or tapped holes as required. Engraved characters shall be block style with no characters small than 1/8-inch top to bottom.

B. Conductor and Equipment Identification: Conductor and equipment identification devices shall be either imprinted plastic-coated cloth marking devices such as manufactured by Brady, Thomas & Betts, or equal, or shall be heat-shrink plastic tubing, imprinted split-sleeve markers cemented in place, or equal.

2.04 SIGNAGE AND MARKINGS

A. Provide danger, caution, and warning signs and equipment identification markings in accordance with applicable federal and state OSHA and NEC requirements.

2.05 TERMINAL BLOCKS

B. Terminal Blocks where required shall be screw terminal, heavy duty, rated at 20 amperes minimum, 600 volt AC. Terminals shall be provided with integral marking strips which shall be permanently identified with the connecting wire numbers as shown on the drawings. Each terminal block shall be uniquely identified.



3.01 INSTALLATION

A. Documents: The EQUIPMENT SUPPLIER shall provide detailed installation drawing depicting necessary wiring, interlocks, etc. for use by a subsequent installation CONTRACTOR.

3.02 EQUIPMENT IDENTIFICATION

A. Equipment and devices shall be identified as follows:

1. Nameplates shall be provided for pumps and motors, control and instruments. In addition to nameplates, control devices shall be equipped with standard collar-type legend plates.

2. Control devices within enclosures shall be identified as indicated. Identification shall be similar to the subparagraph above.

3. Equipment names and tag numbers, which indicate on the Drawings, shall be utilized on nameplates.

4. Terminal point on terminal blocks shall be labeled by identifiers attached to the terminal strip. Identifiers shall be pre-printed by the terminal manufacturer custom printed markers, hand lettered markers shall be acceptable.


City of Visalia – WCP Upgrades RPGS Pre-selection 16100 - 1 December 2010 Basic Electrical Materials and Methods

SECTION 16100 – BASIC ELECTRICAL MATERIALS AND METHODS

PART 1 - GENERAL

1.01 DESCRIPTION

Requirements specified in theis RFP and Section 16050 form a part of this section. This Section outlines the requirements for the basic electrical materials and methods for the electrical work, and forms a part of all other Sections of Division 16 unless otherwise specified.

1.02 SUBMITTALS

Submit for the CITY's approval material lists, shop drawings, factory test reports and technical data to the extent required in this Section and Section 16050.

1.03 WIRING

Wiring for furnished equipment shall include the following:

A. Wiring for Furnished Equipment. The wiring diagram from components to a skid mounted terminal box (if any) shall be provided.

PART 2 - PRODUCTS

2.01 GENERAL

Provide basic materials and all wiring installations as indicated, specified and required.

2.02 METAL CONDUITS (IF APPLICABLE)

A. Metal conduits shall be steel, hot-dipped galvanized (including threads) and equipped with couplings and thread protector caps. The surfaces and threads shall be corrosion-resistant coated. Conduits shall be in ten foot lengths and manufactured in accordance with U.L. 6 by Triangle, Pittsburgh, V.A.W., and Wheatland, Allied or equal. Conduits shall be a minimum size of 3/4 inch.

A. PVC Coated Conduit shall have a polyvinyl chloride coating bonded to the outer surface of rigid steel conduit and couplings. The plastic coating for all PVC coated conduit shall have an average thickness of 0.040 inches. The bonding of the PVC coating to the conduit shall be stronger than the tensile strength of the PVC coating. The polyvinyl chloride coating shall be bonded to the galvanized surface of rigid steel conduit by Youngstown, Kor-Kap, Occidental Coating, Robroy or equal.

2.03 FLEXIBLE CONDUIT (IF APPLICABLE)

A. Liquid-tight Flexible Conduit shall have an interlocked, flexible, galvanized steel core, permanently bonded UV resistant exterior gray polyvinyl chloride jacket and shall be UL listed.

B. Conduits, l-l/4 inch and smaller shall have an internal copper bonding conductor wound spirally in the space between each convolution.


C. Manufacturers of liquid-tight flexible conduit shall be Anaconda (by Anamet, Inc.), Type UA, Electri-Flex Type LA, Universal or equal.

D. All above ground, outside conduits shall be PVC coated conduits.

2.04 CAST METAL BOXES AND FITTINGS (IF APPLICABLE)

Cast boxes and fittings shall be finished as specified in Section 16050. The outlet bodies, boxes, fittings, covers and supports shall be cast iron alloy with threaded hubs. The materials shall be manufactured by Crouse-Hinds, Appleton, Pyle-National, Efcor or equal.

A. Covers and Gaskets shall be provided for all conduit outlet bodies, boxes and fittings. The covers shall be cast iron alloy and equipped with neoprene gaskets. Explosion-proof boxes shall have externally threaded surface covers.

B. Seal Fittings shall be Crouse-Hinds Type EYS or equal. Ceramic or other non-asbestos fiber materials and sealing compound, UL listed to match the fitting, shall be provided for completing the seal.

C. PVC Coated Fittings shall have the same polyvinyl chloride coating that is on the conduit to which they shall be connected. The PVC coating shall have an average thickness of 0.040 inches and the bonding shall be stronger than the tensile strength of the PVC coating. The PVC coating shall be bonded to the surfaces of cast outlet bodies, boxes, fittings, supports, etc. by Occidental Coating, Kor-Kap, Robroy, Youngstown, or equal.

D. Plastic Fittings shall be solvent weld type and shall be compatible with the conduit to which they shall be connected.

E. Expansion/Deflection Fittings shall consist of cast metal conduit hubs securely attached to a flexible outer neoprene jacket. A flexible copper grounding strap shall be provided inside the fitting and connected to the two hubs. The linear expansion or contraction shall be a movement up to 3/4 inch. The linear misalignment shall be a movement up to 3/4 inch. The angular misalignment shall be a movement up to 30 degrees. The expansion/deflection fittings shall provide flexible and watertight conduit joints.

F. Thread Lubricant shall inhibit corrosion and maintain grounding continuity, and shall be Crouse-Hinds STL, Thomas and Betts "Koper-Shield" or UL listed equal.

g. Couplings and Elbows. For rigid steel conduits, the couplings and elbows shall be steel, hot dipped galvanized, threaded and one-piece. For plastic conduits, couplings and elbows shall have plain ends for tight weld fits, which form watertight joints. For joining plastic and rigid steel conduit systems, couplings shall have a plain end and a threaded end.

2.05 STEEL BOXES AND FITTINGS (IF APPLICABLE)

A. Pull Boxes. Boxes 24 inches square and smaller shall have gasketed screw type covers. Larger boxes shall have bi-parting gasketed hinged doors with latch mechanisms,


handles and cylinder locks complete. Provide two keys for each lock. Pull boxes shall be painted as specified in Section 16050. The pull boxes shall be Hoffman, Boss, Circle A-W or equal.

B. Outlet Boxes and Fittings for connections to concealed steel electrical metallic tubing (EMT) shall be galvanized, pressed steel, one piece, knock-out type. Box extensions, plaster rings and covers shall fit. See Article 3.03. of this Section for required sizes. Outlet boxes and fittings shall be Appleton, Bowers, Steel City or equal.

2.06 WATER AND GAS SEAL FITTINGS (IF APPLICABLE)

A. Water and gas seal fittings shall consist of a thick, synthetic rubber, sealing ring secured between two metal plates by socket head screws. When the conduit water and gas seal fitting is in place and the screws are tightened, the synthetic rubber shall become compressed between the metal plates and be forced against the conduit inside wall and also against the conductor insulation to form a watertight seal inside the conduit. The synthetic rubber shall resist aging, ozone, sunlight, water, chemicals and extreme temperature variations. The water and gas seal fittings shall be O-Z/Gedney Type CSB or equal.

B. Water and gas wall and floor seals shall consist of a synthetic rubber sealing ring between two pressure rings or a series of synthetic rubber links between pressure plates held together with corrosion resistant bolts, nuts and washers. When the bolts are tightened, the synthetic rubber expands to provide a watertight seal between the outer surface of the entering conduit, and the inner surface of the wall or floor penetration. The synthetic rubber shall resist aging, ozone, sunlight, water, chemicals and extreme temperature variations. The seals shall be Thunderline "Link-Seal", O-Z/Gedney Type CSM, and FSK, WSK or equal.

2.07 CONDUIT FITTINGS

Conduit fittings shall be hot dipped galvanized steel and cast iron as required.

A. Liquid-tight Conduit Fittings shall be Types LT, ST, CT as manufactured by Crouse-Hinds, Appleton, Pyle-National or equal. Fittings 1-1/2 inch and larger shall have provision for a separate equipment ground conductor.

B. Unions shall be type UNY or UNF. Running threads are not acceptable. Unions shall be Appleton, Crouse-Hinds, Pyle-National or equal.

C. Bushing reducers shall be Appleton, Thomas and Betts, Efcor or equal.

D. Conduit Enlargers shall be Appleton, Thomas and Betts, Efcor or equal.

E. Locknuts shall have notches all around for tightening with a screwdriver. Locknuts shall be Appleton, O-Z, Thomas and Betts or equal.

F. Metallic Insulated Bushings shall have ground terminals and smooth and well rounded surfaces to protect the conductor insulation. The conduit threads shall be deep, clean


and easily attached to the conduits. The bushings shall be O-Z, Efcor, Thomas and Betts or equal.

G. Plugs shall be the recessed type and Appleton, Crouse-Hinds or equal.

H. Interchangeable Hubs shall have an insulated throat, sealing ring and vibration-proof nut. Machined serrations on hub and nut shall bite into the metal enclosure assuring an equipment ground. The hubs shall be Myers "Scru-Tite", Efcor "Space-Saver" or equal.

I. Conduit seals shall be Crouse-Hinds type EYSX expanded fill sealing fitting or equal.

2.08 CONDUCTORS AND CABLES (IF APPLICABLE)

Conductors and cables shall be new, single conductor, copper, not smaller than #12 AWG (except control wires when installed inside conduit which may be #14 AWG) unless otherwise indicated, and as shown on the drawings. Control wires at panel and cabinet can be #16, machine tool grade type MTW, UL approved and rated for 90 degree C at dry location. All multi-conductor cables shall be approved for cable tray installation.

A. Conductors 250 kcmil and larger shall be stranded, 600 volts, flame retardant, ethylene propylene rubber insulation, UL labeled, Type RHW, without outer covering. Insulation other than ethylene propylene rubber shall not be used. Conductors shall be Rome FR-EPR, Okonite-FMR, Houston Wire and Cable FREP or equal.

B. Conductors smaller than 250 kcmil shall be stranded (except #10 and #12 for lighting and receptacle circuits which shall be solid), 600 volt and Type THWN or THHN. Conductors shall be Rome, Carol Cable, Techbestos, Triangle, Atlas, Northern or equal. Sizes #10 and smaller shall have colored insulation where indicated.

C. Ground and Neutral Conductors.

1. Insulated ground and neutral conductors shall be the same type as the phase conductors, except for circuits above 600 volts which shall be Type THWN.

2. Bare ground conductors shall be copper, soft drawn, annealed, concentric lay, stranded conforming to ASTM Specifications B3 and B8.

D. Fixture Wires shall be rated 90o centigrade, #16 AWG stranded, thermoplastic insulated with an outer jacket. The wire shall be Type TFFN and manufactured by Brand-Rex, Carol Cable or equal.

E. Instrumentation Signal Cables shall be single twisted pair or multi twisted pairs of stranded, copper cables with 600 volt, 15 mil polyvinyl chloride insulation with 4 MIL nylon jacket over each conductor, overall aluminum-mylar tape shield, overall tinned copper drain wire and 45 mil minimum polyvinyl chloride jacket overall, 90° centigrade dry/75° centigrade wet rating. Twisted pair cables that are required to be shielded, shall have aluminum-mylar tape shields and tinned copper drain wires over individual twisted pairs of cable. Single twisted pair cables shall be #16 AWG


minimum. Cables shall be Okonite "Okoseal-N-type P-OS, type TC", Dekoron type TC or equal.

F. Wire Lubricant shall be Burndy "Slikon", Holub "Hi- Green", Ideal "Yellow 77" or equal.

G. Identifications on the conductors and cables shall be continuous and include the type, voltage, size and name of the manufacturer.

2.09 WIRE CONNECTORS (IF APPLICABLE)

Connectors shall be provided for splices and terminal connections of all conductors and cables. The connector shall fit the conductor to which it shall be connected, and the assembly shall have joint contact surfaces not less than 50 percent.

A. Compression Connectors shall be copper lugs for terminal connections, and two-way copper sleeves and taps for splice connections. A crimping tool shall be provided to make tight and neat compression connections. The connectors and crimping tool shall be Anderson-Square D, Thomas and Betts, Buchanan or equal.

B. Tapered Spring Connectors shall have live springs attached to inner steel housings and enclosed with plastic insulators, and shall be Buchanan B-Cap, 3-M, Scotchlok Type Y, R, G, B, Ideal Wire-Nut or equal.

C. Connectors in all manholes, handholes and flush with grade pull boxes shall be watertight. Connector splice kits for the wire range size for which they apply shall be 3M Type DB-6 and DBR-6, Buchanan B-cap Twist and Seal, or equal.

D. Electrical Tape shall be plastic, 0.007 inches thick, and resistant to abrasion, alkalies, acids, corrosion, moisture, low and high temperatures. The tape shall be Scotch No. 33 Plus, Plymouth Premium Black No. 4453 or equal.

E. Wire Markers. The individual conductor wire markers shall be adhesive and manufactured by Thomas and Betts, Brady, Scotch 3M or equal. The wire marker to identify groups of conductors shall be nylon cable tie markers as manufactured by Thomas and Betts, Panduit or equal. The marker pads on the cable tie markers shall be large enough to show the motor or device numbers using minimum 3/16 inch high numbers and letters. Manufacturer shall provide permanent marking pens.

2.10 PANELBOARDS (IF APPLICABLE)

Panelboards shall be factory assembled, metal enclosed, dead front and equipped with bus, time switches, contactors, terminals and thermal-magnetic molded case circuit breakers as shown on the drawings.

A. Circuit Breakers shall be molded case, quick-make, quick-break, single and multipole, bolted type, and arranged as shown on the drawings. Each circuit breaker shall have clear indications for "ON", "OFF" and "TRIP" positions. The minimum interrupting capacity shall be 14,000 symmetrical amperes at 240 volts (65,000 symmetrical amperes at 480 volts). As indicated, provide devices to lock the branch circuit breaker


in the "ON" and "OFF" positions. Ground fault protection, 5 milliampere sensitivity, shall be provided for the indicated branch circuits, which shall be an integral part of the regular branch breaker. A circuit breaker with integral ground fault circuit interruption shall require no more panelboard branch circuit space than the regular circuit breaker. Branch circuits that have exterior convenience outlets, toilet convenience outlets, laboratory convenience outlets and as indicated shall be equipped with ground fault protection.

B. Copper Bus shall be provided for panelboard. Bus shall be provided for the complete length of the panelboard branch circuit area including circuits indicated as spaces. Bus bars shall be drilled and tapped for the indicated spaces for installation of future circuit breakers.

C. Single Phase Panelboard, three wires, shall be bussed so that any two adjacent single-pole breakers shall be connected to opposite polarities. A single handle two-pole circuit breaker can be installed in any location, and in place of two adjacent single pole breakers.

D. Three Phase Panelboard, four wires, shall be bussed so that any three adjacent single-pole breakers shall be connected to different phases. A single handle two-pole breaker or three-pole breaker can be installed in any location, and in the same space of two or three adjacent single pole breakers.

E. Terminals and connectors shall be provided for all feeder, branch, neutral and ground conductors shown on the drawings.

F. Circuit Numbers shall start at the top of the panelboard. Odd numbers shall be assigned in sequence on the left side, and even numbers shall be in sequence on the right side of the panelboard.

G. The Cabinet shall enclose the bus and breaker assembly, and shall be steel fabricated and coated with corrosion-resistant finish as specified in Section 16050. The front of the panelboard shall include a trim, hinged door, flush cylinder lock with catch. The lock shall be furnished with two keys, and all locks shall be keyed alike. Fronts shall not be removable when the door is in the locked position.

H. Time Switches shall be provided as indicated and specified in Section 16900.

I. Contactors shall be provided as indicated and specified in Section 16900.

J. Metal Circuit Directory frame and card with clear plastic covering shall be provided on the inside of the door. The directory card shall provide a space at least 1/4-inch high and 3 inches long for each branch circuit. The card shall be completely typed to identify each connected circuit, spare and space.

K. Manufacturers for three phase, 480Y/277 volt panelboard shall be Square D Type NHEB, Cutler-Hammer POW-R-LINE 2, General Electric Type AE or equal. The


single phase 120/240 volt and three phase 208Y/120 volt panelboard shall be Square D Type NQOD, Cutler-Hammer POW-R-LINE 1, General Electric Type AQ or equal.

2.11 SUPPORTS

A. Channels shall be steel, cold rolled and PVC coated. One side of the channel shall have a continuous slot. On both sides of the slot, the edges turn inward and form a guide for the spring nuts. The fittings shall be fabricated from steel and attached to the channel with bolts and spring nuts. The channel, fittings and hardware shall be hot-dipped galvanized, and then PVC coated and manufactured by Unistrut, Power-Strut, Kindorf or equal.

B. One-Hole Clamps shall be malleable iron, galvanized for steel conduits and equipped with clamp-backs. The clamps shall be Efcor, Thomas and Betts, Appleton or equal.

C. Beam Clamps shall be malleable iron, galvanized, right angle and parallel types. The clamps shall be manufactured by Efcor, Thomas and Betts, Appleton or equal.

D. Spacers, provided to support underground conduits in concrete encasements, shall be plastic. The spacers shall be Carlon, Johns-Manville, Underground Products or equal.

E. Steel Anchors shall be sleeve and stud types for securing equipment to concrete foundations, floors and walls. The anchors shall be Phillips "Red Head", Diamond or equal.

F. Toggle Bolts shall be steel, spring wing type for securing equipment to hollow walls and ceilings. Toggle bolts shall be Phillips "Red-Head", Diamond or equal.

G. Stanchions shall be structural steel as shown on the drawings, shop fabricated, coated with a rust inhibiting primer per requirements of "Painting and Protective Coatings" Section of the Specifications.

H. Conduit Hangers shall be heavy gauge formed steel, galvanized and then PVC coated and equipped with carriage bolts, 1/4-inch rods and nuts. The hangers shall be Efcor, Kindorf, Appleton or equal.

I. U-Bolts shall be heavy gauge steel, galvanized and equipped with two hexagon steel nuts. The U-bolts shall be Efcor, Kindorf or equal.

J. Fixture Hangers shall be cast iron alloy, cushion type, equipped with cover, screw terminal blocks, and permits the pendant to swing 20 degrees from perpendicular in any direction. Hangers shall be Crouse-Hinds Type ALT, Appleton Type ALT, Pyle-National Type A-2152M or equal.

K. Guardrail clamps, guardrail and conduit in a location should be of the same metal. Where dissimilar metals shall be joined together, the clamps shall be PVC coated and attached with stainless steel hardware.


L. Hardware for corrosive areas shall be 316 stainless steel.

2.12 NAMEPLATES

A. The Nameplates shall be engraved, laminated black plastic with minimum 1/4 inch high letters showing through from the white core, NEMA ES-1, 3-ply (Black-White-Black), 1/16-inch thick, beveled and satin finished. Nameplate inscriptions shall include the identifications for the equipment and loads and shall identify the controls on control equipment as shown on the Drawings. Nameplates shall be provided on receptacle plates with 1/8 inch high letters.

2.13 TAGS

Tags shall be 1/16 inch thick stainless steel and shall have embossed (raised) lettering. Lettering shall be a minimum of 3/8 inch high. Provide a 1/8 inch hole at each end for mounting or wire attachment. All corners shall be rounded and edges ground smooth.


3.01 GENERAL

Provide the wiring installations and equipment installations, including connections and interconnections as indicated, specified and required in a neat and workmanlike manner. Assure proper fits for all equipment and materials in the spaces shown on the drawings.

3.02 RACEWAYS

Provide all conduit installations, including the outlet bodies, boxes, gaskets, covers, fittings and supports to complete the raceway systems as shown on the drawings and as required. Conduits shall be a minimum size of 3/4 inch. All exposed conduits shall be PVC coated. Install ground conductors in all conduits. This paragraph applies if electrical equipment and components mounted on skids are pre-wired in the factory to a common pull-box or marshalling box.

A. No run of conduit, between device, equipment, box or fitting and another device, equipment, box or fitting, shall contain more than the equivalent of three 90 degree bends (270 degrees total), including offset bends located immediately at the device, equipment, box or fitting.

B. Couplings and Elbows shall be of the same type as the conduit to which they shall be connected, except where rigid steel bends and risers are connected to non-metallic conduits where conduits rise above grade.

C. Flexible Conduits. Flexible conduits shall be liquid-tight with fittings for short tight connections (30 inches maximum) to equipment, except in Class 1, Division 1 areas. A separate ground conductor shall be installed in flexible conduit that does not have the internal copper bonding conductor included by the manufacturer.

D. Threads. All steel conduit threads shall be coated with a conductive, corrosion resisting lubricant, and the connections shall be made watertight. The lubricant shall maintain the grounding continuity.


E. Conduit Connections. Where conduits are connected to couplings, fittings, boxes, etc., a minimum of 5 threads shall be engaged so that the system is rigid and sturdy. Also, the tapered portion of the threads shall be sufficiently engaged to provide electrical continuity. The use of lock-nuts, or other gimmicks with threaded fittings to add rigidity, is not acceptable. Unions shall be provided, as required, for conduit connections to threaded outlet bodies, boxes and equipment, and for connecting two steel conduits together. Conduit enlargers shall be provided for connecting two conduits of different sizes together.

F. Water and gas seal fittings shall be provided on all conduits that enter or leave corrosive areas. The seal fitting shall prevent corrosive gases from passing from a corrosive area to a non-corrosive area through the conduit system. Ceramic or other non-asbestos fiber material and sealing compound shall be placed in the fitting to complete the seal.

G. Water and gas seal fittings shall be installed on the ends of exterior conduits that terminate at indoor equipment. The fittings shall provide a water and gas tight seal between the wires and cables and the inside of the conduit.

H. Water seal fittings shall be installed to completely water seal the areas around conduits that pass through concrete floors and outside walls, unless concrete is placed after conduit is installed.

I. Tool Marks. Conduits and fittings that have tool marks shall be smoothed and finished with paint that matches the original finish.

3.03 BOXES AND FITTINGS

Conduit outlet bodies, boxes, fittings, gaskets, covers and supports for lighting outlets, lighting switches, receptacles, control stations, alarm, switch and thermostat outlets, etc. in exposed conduit installations, shall be installed as indicated, specified and required, and shall be of sufficient size to provide free space for all conductors that shall be enclosed.

A. Cast Iron. Cast iron outlet bodies, boxes, gasketed covers and fittings shall be connected to expose galvanized rigid steel conduits.

B. PVC Coated. Outlet bodies, boxes, gasketed covers and fittings shall be PVC coated and connected to PVC coated steel conduits.

C. Sheet Steel. Sheet steel boxes shall be of sufficient size to accommodate the connected conduits and enclosed conductors and provided with close-fit holes for steel conduit connections. Weatherproof boxes shall be provided with interchangeable conduit hubs for steel conduit connections as indicated.

D. Interchangeable Hubs. The hubs shall be installed in steel enclosures for rigid steel conduit connections. Cut a close fitting hole in the sheet steel enclosure and place the interchangeable hub in the opening. Connect the hub on the conduit and make a tight connection to the enclosure.


3.04 CONDUCTORS, CABLES, CONNECTIONS AND WIRE MARKERS

Install all the conductors, cables and connections for the wiring as indicated, specified and required. Recommended pulling tensions shall not be exceeded. Provide separate neutral conductors as required. Ground conductors shall be insulated wire unless noted otherwise on the Drawings.

A. Conductors. Conductors shall be completely installed and connected. Apply wire lubricant to ease the pulling of conductors in conduits. Splice and terminal connections shall be made tight with spring and compression connectors. The connectors shall be crimped with a tool that provides uniform and tight connections. Connectors shall be sized as outlined in paragraph on Wire Connectors in this Section. Include all the required wiring interconnections. When routing conductors and cables through pull boxes, the longest (not shortest) route from entrance to exit shall be used.

B. Connections.

1. Low Voltage Connectors. Connectors for conductors No. 8 AWG and larger shall be compression type. Use the provided crimping tool to make tight and neat compression connections. Connectors for conductors No. 10 AWG and smaller shall be tapered spring type.

2. Conductor and cable splices shall be located only in pull-boxes, junction boxes, handholes and manholes.

C. Insulate. All connections shall be insulated as required with tight wraps of plastic tape.

D. Furnished Equipment. Provide wiring installations as shown on the drawings, and specified in other Sections of the Specifications for furnished equipment.

3.05 SUPPORTS

Install the required structural channels, brackets, stanchions, U-bolts, clamps, anchors, hangers, fittings and other hardware to securely attach and support all the equipment, materials and conduits, as indicated, specified and required. Supports shall be PVC coated in corrosive areas.

A. Painting. Brackets, stanchions and other unfinished steel supports shall be painted per requirements of Section 09900 (NOT APPLICABLE).

3.06 NAMEPLATES

Nameplates shall be provided as indicated to identify equipment, and the positions and circuits within the equipment. Also, individually enclosed equipment shall be provided nameplates as indicated. Plastic nameplates shall be positioned and lined-up to provide a neat appearance, and shall be attached to the cleaned metal surfaces of enclosures with stainless steel screws.

A. Plastic Nameplates. Nameplates shall be provided on primary interrupters, switchgears, substations, switchboards, service equipment, motor controllers, motor control centers, panelboards, and individually enclosed circuit breakers, disconnect switches, magnetic starters, manual starters, relays and control stations unless otherwise indicated. Provide lighting switch nameplates as indicated on the drawings.


B. Nameplates shall be attached to the object, or adjacent to the object, with self taping screws. Adhesive materials shall not be used for attachment. Objects such as explosion proof enclosures, that would have their UL listing nullified by drilling for mounting screws shall have their nameplate mounted on an adjacent wall or plate provided by the Constructor.

3.07 CHECKING, ADJUSTING AND TESTING

Provide the required labor and equipment, and all checking, adjusting and testing in the factory.

a. Check. All wire terminals shall be checked to assure tight connections.

B. Tests.

1. Tests shall be per Section 16960.

2. For items not included in Section 16960, tests shall be performed per NETA and IEEE standards, to detect wrong connections, short circuits, continuity and ground. Tests shall be made with a hand crank test instrument (megger) on all transformer windings, motor windings and all cables and conductors.

NOTE: WARNING. Do not make insulation tests on any conductors either signal or power that are connected to semi-conductor type equipment. Disconnect the conductors from the equipment before insulation testing; severe damage may result from megger-type instruments. Power feeders and branch conductors shall be tested phase to phase and phase to ground. Phase to ground tests on shielded cable shall mean "conductor to shield". After insulation resistance tests have been performed, high voltage and medium voltage shielded cables shall be "hi-Pot" tested in accordance with the current ICEA Standards and the manufacturer's recommendation. Voltage shall be applied and removed in a slow, even manner, and the conductors shall be grounded for at least one minute after the voltage is removed to insure that no charge remains. Test voltage and application time for the various cables and conductors shall be submitted to the CITY. Correct any defects in the wiring systems.

C. Equipment Tests. Perform equipment tests as indicated and directed at the factory.

D. Test Data. Test data for equipment shall be submitted to the CITY.


City of Visalia – WCP Upgrades RPGS Pre-selection 16381 - 1 December 2010 Induction Motors

SECTION 16150 – INDUCTION MOTORS

PART 1 – GENERAL

1.01 DESCRIPTION

Requirements specified in Conditions of the Contract, Section 16050 and Section 16100 form a part of this Section. This Section outlines the electrical requirements for squirrel-cage induction motors.

1.02 SUBMITTALS

Submit for the CITY's approval shop drawings, factory test reports, manufacturers' certified reports and technical data for motors supplied with driven equipment to the extent required in this Section, Section 16050 and the Specification Sections for mechanical equipment.

A. Shop Drawings. In addition to information to be included in the shop drawings as specified in Section 16050, shop drawings shall include the following:

1. Motor locked rotor and full load currents.

2. Power factors and efficiencies at full load, three quarters load and half load.

3. Motor housing material, winding material, NEMA Design letter, NEMA Code Letter, ambient temperatures and maximum elevations in which motor is designed to operate continuously, service factor, NEMA insulation Class, temperature rise, type of enclosure, voltage, bearing life and dynamic balance; all of which shall comply to the requirements of the specifications.

4. Nameplate data.

5. Dimensions and weights of motors.

6. Motor construction details.

7. Speed torque/current at 100 percent volts.

8. Wiring diagrams, internal and typical external connections.

9. Letter or standard motor manufacturer’s literature confirming that motor (or motors) are designed for use with adjustable frequency drives/SCR drives.

10. Time-current damage curves, plotted on full size log-log paper for motors 100 horsepower and larger.

B. Current Data. Submit eight copies to the CITY of field recorded current data. The data shall indicate the full load current for each motor and current rating for the overload relay in each motor starter and controller.


PART 2 – PRODUCTS

2.01 GENERAL

Motors shall be supplied by the manufacturer of the driven equipment as specified in this section, and specifically outlined in the driven equipment specifications. The Motors shall be completely fabricated, assembled, checked and tested at the factory in accordance with NEMA MG-1. The induction motors shall be Baldor, General Electric, Toshiba, Reliance, Siemens, and U.S. Electrical Motors.

A. Motor Ratings.

1. Torque and slip characteristics shall be as recommended by the manufacturer of the driven equipment and as specified. Motor manufacturer shall confirm motor capability to the specifications.

2. Motors shall have a continuous rating and shall operate continuously and satisfactorily in ambient temperatures from minus 10 degrees Celsius to plus 40 degrees Celsius at a maximum elevation of 3,300 feet without exceeding nameplate horsepower rating.

3. The motors shall have high power factor and the minimum power factor shall be 80 percent at full load.

4. Motors shall be designed for high efficiency. Motors with the following minimum efficiencies, at full load, shall be provided:

a. 84 percent minimum efficiency shall be provided for motors through 5 horsepower.

b. 87.5 percent minimum efficiency shall be provided for motors 7-1/2 through 15 horsepower.

c. 91 percent minimum efficiency shall be provided for motors 20 through 40 horsepower.

d. 93 percent minimum efficiency shall be provided for motors 50 through 125 horsepower.

e. 95.4 percent minimum efficiency shall be provided for motors 150 to 400 horsepower.

5. The motors shall be sized so that the maximum BHP of the load does not exceed 90 percent of the full load nameplate horsepower of the motor unless otherwise indicated in the driven equipment specifications.

6. The motor must be able to accelerate the driven machine from zero to top speed at 90 percent of rated voltage without overheating.

7. The maximum locked rotor KVA/HP code letter for motors smaller than 15 HP shall not exceed the requirements for NEMA Design B motors. The maximum locked rotor KVA/HP code letter shall be Code G for motors 15 HP through 250


HP unless otherwise indicated. The maximum locked rotor KVA/HP code letter shall be Code F for motors 300 horsepower and larger unless otherwise indicated.

8. All motors shall be insulated and braced for full voltage across the line starting regardless of the starting method used.

9. Motors 1/2 HP and larger shall be NEMA MG1-1.16 Design B and shall have NEMA MG1-1.66 Class F insulation, minimum.

10. The temperature rise by resistance above the temperature of the cooling medium, for each of the various parts of the motor shall not exceed the values of the NEMA MG1-1.66 Class B insulation system as indicated in NEMA MG 1-12.43.

11. All motors shall have a 1.15 service factor at the specified maximum ambient temperature

12. Motors 1/2 HP and larger shall be 460 volts, 3 phase, 60 Hertz unless otherwise indicated.

13. Motors smaller than 1/2 HP shall be 115/230 volts, 1 phase, 60 Hertz unless otherwise indicated.

14. Motors for variable speed application equipped with adjustable frequency drive controller shall be of the inverter duty type with winding temperature switches for alarm and shutdown application. The permeate pump and air scour blower motors shall be inverter duty type with winding temperature switches for alarm/shutdown applications.

B. Motor Construction.

1. Enclosures for induction motors shall be approved for the installations and as indicated. The enclosure types shall be one of the following as outlined in the driven equipment specifications unless otherwise indicated.

a. Weather Protected 1.

b. Totally-enclosed fan cooled.

2. Housing, end brackets and all outside components shall be cast iron.

3. A condensate drain hole shall be provided on all non explosion- proof enclosed motors. The drain hole shall be provided in each end bracket on horizontal motors. A single drain hole shall be provided in the lower bracket of vertical motors.

4. The motors shall be equipped with terminal boxes for all conduit and wire connections as required.

a. The terminal boxes shall be properly sized, diagonally split, cast iron, and rotatable in 90-degree steps. Provide a gasket between the box and motor frame and between the box and the cover. Terminal boxes shall be attached to


the motor frame with grade 5 zinc plated and chromated steel bolts or cap screws. All terminal boxes shall have threaded holes for conduit entrance.

5. The castings shall be coated with a red-oxide zinc-chromate primer, and finished with a corrosion resistant epoxy coating. All fabricated steel enclosures shall be coated on all inside and outside surfaces except shafts and register fits.

6. Provide stainless steel nameplates of ample size with clear numerals and letters.

a. Nameplates shall indicate the manufacturer, serial number, model number, type, horsepower, phase, hertz, volts, design, full load amperes, locked rotor code letter, service factor, speed, insulation class, temperature rating, information required by NEMA MG 1-10.39, NEMA MG 1-10.40 and other essential data.

b. Nameplate data shall be in the English language and units.

c. Nameplates shall be secured to the motor frame with corrosion resisting pins in accessible locations.

7. Ground lugs shall be provided in all main motor terminal boxes for grounding.

8. All motors shall have copper windings.

9. Antifriction bearings shall be grease lubricated except for vertical high thrust motors which may require oil lubrication.

a. at one year B-10 bearing life.

b. Pre-

c. lubricated, double shield bearings are acceptable only on single phase and 56 frame motors Grease lubricated bearings shall include accessible fittings for in-service, periodic relubrication.

d. Oil lubricated bearings shall be a reservoir type with a sump for settling foreign matter, accessible and exterior fill and drain plugs and a visual oil level indicator with maximum and minimum indicator levels.

e. Horizontal, direct connected motor bearings shall be designed for 1 year minimum B-10 bearing life at NEMA minimum V-belt criteria for the rating.

f. Horizontal, V-belt connected motor bearings shall be designed for 3 year minimum B-10 bearing life for the application V-belt drive or 1 year minimum B-10 bearing life at NEMA minimum V-belt criteria whichever is more restrictive.

g. Vertical motor bearings shall be designed for 2-year minimum B-10 bearing life at design operating thrust. At maximum operating thrust, B-10 life shall not be less than one year. Transient (shut-off) thrust shall not exceed 30% of the static deformation limit. Motor shall be designed for 30% momentary upthrust capacity except 3,600 RPM units, which must have 30% continuous


upthrust capacity. Any system, which exceeds 30% upthrust must be designed for continuous upthrust.

10. The dynamic balance of motors built in frame size 143 and larger shall be 0.001 inches total amplitude or peak- to- peak displacement.

11. Accessories shall include the following:

a. Space heater shall be provided for all outdoor motors and motors installed in confined and damp location. The space heater shall be 120 volt, 1 phase, and adequately sized to raise the temperature inside the motor to a minimum of 6 degrees Fahrenheit above ambient and provide temperature switches on the windings for alarm and shutdown functions.

b. For motors 200 HP and larger provide temperature sensors in stator windings of pump motor. Six (6) RTD type temperature sensors shall be provided.

c. For motors 200 HP and larger provide temperature sensors in pump motor’s bearings. Two (2) RTD type temperature sensors shall be provided.

12. Motors shall have a guaranteed maximum noise level in accordance with NEMA MG1-12.49 for integral horsepower motors and NEMA MG1-20.50 for large motors, except where more restrictive requirements are outlined in other Sections of the Specifications.


3.01 GENERAL

Provide all the equipment installations and wiring installations, including connections as indicated, specified and required. Assure proper fits for all equipment and materials in the spaces as shown on the Drawings.

A. Motors.

1. Provide power, control, alarm, and grounding installations for all motors as indicated and required.

2. Check the connections and provide correct rotation for all motors.

3. Record the full load current to each motor, and the overload relay rating in each motor starter for the certified data submittal.

4. Provide the wiring for heaters in the motor frames and the required controls to deenergize the heater when the motor operates.

5. Provide the required wiring for all control equipment that shall be furnished and installed by other Sections of the Specifications.

6. Install the motor control stations as shown on the Drawings.


7. Field damaged factory finish on equipment shall be touched-up with paint that is equal in quality and color to the original factory finish.

3.02 FACTORY TESTS

A. All Motors shall be given a standard commercial test as defined by NEMA MG 1-12.51 and IEEE 112 a and b.

B. Conduct megger test and record reading of all motor windings just prior to connecting the motor to its feeder to determine if accumulation of moisture has occurred in the motor during storage. The reading shall be documented, submitted to the ENGINEER for review, and included in the final Operation and Technical Manuals.

C. Noise Tests shall be determined by measurement in accordance with the latest revision of IEEE-85, Test Procedure for Air Borne Noise Measurements and Rotating Electrical Machinery. The motor shall be operating during test on rubber at no load with rated voltage and frequency.

D. Vibration Tests shall be per NEMA MG 1-12.07 for small and medium motors and MG 1-20.54 for large motors, except 3,600 RPM motors greater than 250 horsepower and motors with sleeve bearings shall be tested at full nameplate horsepower load and temperature.

E. All Testing, other than locked rotor conditions shall be at full voltage +5 percent.

3.03 FIELD CHECKS

A. Motor Installations shall be complete and correct.

B. Operation Tests shall be performed to observe that motors start, run and stop satisfactorily under design load.


City of Visalia – WCP Upgrades RPGS – Pre-selection 16325 - 1 December 2010 Step-up Secondary Substation Transformers

SECTION 16325 – STEP-UP SECONDARY SUBSTATION TRANSFORMERS

PART 1 – GENERAL

1.1 THE REQUIREMENT

A. This specification covers the design, fabrication, testing, delivery, and installation of the step-up pad- mounted transformers specified herein. The EQUIPMENT SUPPLIER shall provide the pad-mounted transformers complete and operable, in accordance with the Contract Documents.

B. All components, testing and services specified or required for a complete system shall be included. The EQUIPMENT SUPPLIER shall bear the responsibility that the equipment has been designed and fabricated in accordance with all codes, standards and governmental regulations applicable and performs under the conditions and to the standards specified herein.

C. The information included in this specification and drawings is intended to describe the general design, performance, interface characteristics and construction features of the equipment. The accuracy of the EQUIPMENT SUPPLIER furnished data and information, and the compatibility of such information with the overall performance of the equipment shall be the sole responsibility of the EQUIPMENT SUPPLIER.

D. The CONTRACTOR shall furnish all tools, equipment, materials, and shall perform all labor as required for installing, and testing of all pad-transformers, including accessories as indicated on the drawings and specifications herein.

E. The requirements of Section 16050 – General Electrical Provisions, apply to the WORK of this Section.

1.2 REFERENCE, CODES AND STANDARDS

A. Reference Codes.

1. All work specified herein shall conform to or exceed the applicable requirements of the National Electrical Code (NEC.); provided, that where a local codes or ordinances is in conflict with NEC., the said local codes or ordinances shall take precedence. For additional requirements, see paragraph “Reference Standards“, Section 16050 – General Electrical Provisions.

2. Applicable Publications:

NEMA National Electrical Manufacturers Association

NFPA National Fire Protection Associations

UL Underwriters’ Laboratories, Inc.

IEEE Institute of Electrical and Electronic Engineers Associations

ANSI American National Standards Institute


1.3 CONTRACTOR SUBMITTALS

A. The CONTRACTOR shall submit shop drawings of all transformers and components in accordance with the requirements of Section 01300 – EQUIPMENT SUPPLIER Submittal, Section 16050 – General Electrical Provisions, and the additional requirements specified below:

B. The following information shall be submitted;

1. Front view elevation, floor plan and total weight

2. Insulating oil quantity and weight

3. Nameplate diagram

4. Component list and product data sheets.

5. Conduit entry/exit locations

6. Primary and secondary voltage, taps and current, KVA and wiring diagrams, and transformer windings damage curves.

7. Basic Impulse level

8. Impedance

9. Insulation class and temperature rise

10. Sound level

11. Cable terminal sizes.

12. Certified production test reports

13. Seismic certification and equipment anchorage details to meet the seismic requirements of the 2007 California Building Code (CBC) and applicable Sections of ASCE Standard 7-05 by using the following minimum values in design: Seismic Component Importance Factor for Anchorage of Mechanical and Electrical Equipment, I: 1.25.

1.4 WARRANTY AND QUALITY ASSURANCE

A. General

The transformers and all components shall be designed, manufactured and tested in accordance with the requirements of NEMA and ANSI.

B. Warranty

The system warranty shall be not less than two year after the initial commissioning of the equipment and shall include all costs for repair, parts, labor, and travel and living expenses.

C. Storage

The Transformers shall be stored in a clean, dry space. Factory wrapping shall be maintained, or a heavy plastic cover shall be provided to protect units from dirt, water,


construction debris, and traffic. Storage space shall be heated, or space heaters shall be energized.

1.5 FACTORY TESTS

A. All components shall be tested in accordance with the applicable ANSI, IEEE, and NEMA Standards. Production and conformance tests shall be made on the transformers in accordance with the requirements of ANSI, NEMA Standards.

B. Certified completed test reports shall be furnished listing all required tests, instrument calibration dates and the results of each test for the transformers. Each test report shall clearly state that the equipment tested and supplied is in conformance with all applicable Codes and Standards. Test reports shall include records of all test failures, repairs, reworks, or corrective actions, and re-tests.

1.6 ENVIRONMENTAL CONDITIONS

A. The transformers shall be designed for continuous service in the environmental conditions specified in Section 16050 - Electrical Work, General.

1.7 OPERATION AND MAINTENANCE.

A. The CONTRACTOR shall submit operation and maintenance manual. The data sheets shall be supplemented by written texts and shall include the following:

1. Operation procedures.

2. Maintenance procedures.

PART 2 – PRODUCT

2.1 RATING

A. The ratings of the transformer shall be as follows or as shown on the drawings:

kVA Rating: As shown, OA, 55º/65º Temperature Rise.

Impedance: NEMAI Standard (+ 7-1/2% Tolerance).

High-voltage: 12 KV, Delta-connection

High-voltage Taps: 2 - + 2-1/2% full capacity

Low-voltage: 480Y/277V, Wye-connection

HV & LV BIL: NEMA Standard

2.2 CONSTRUCTION

A. The transformer(s) shall be compartmental-type, self-cooled and tamper-resistant for mounting on a pad. The unit shall restrict the entry of water (other than flood water) into the compartments so as not to impair its operation. There shall be no exposed screws, bolts or other fastening devices which are externally removable.

B. The unit shall be filled with Envrotemp FR 3 fluid by Cooper Power Systems and shall be in accordance with the latest edition of the NEC.


C. The transformer shall carry its continuous current rating with average winding temperature rise by resistance that shall not exceed 55 degrees C, based on average ambient of 30 degrees C over 24 hours with a maximum of 40 degrees C. The insulation system shall allow an additional 12% kVA output at 65 degrees C average winding temperature rise by resistance, on a continuous basis, without any decrease in normal transformer life.

D. The transformer shall be designed to meet the sound level standards for liquid transformers as defined in NEMA and ANSI.

E. High-voltage and low-voltage windings shall be copper.

F. Each radiator assembly shall be individually welded and receive a quality control pressurized check for leaks. The entire tank assembly shall receive a similar leak test before tanking. A final six-hour leak test shall be performed.

G. The transformer(s) shall consist of a transformer tank and full-height, bolt-on high- and low-voltage cable terminating compartments located side-by-side separated by a rigid metal barrier. Each compartment shall have separate doors, designed to provide access to the high-voltage compartment only after the low-voltage has been opened. .The low-voltage door shall have a handle-operated, three-point latching mechanism designed to be secured with a single padlock. Both high and low-voltage doors shall be incorporated into the low-voltage door latching mechanism. Both high and low-voltage doors shall be equipped with lift-off type stainless steel hinges and door stops to secure them in the open position.

H. The high voltage terminations and equipment shall be dead-front and shall conform to ANSI C57.12.26.

I. Compartment sills, doors and covers shall be removable to facilitate cable pulling and installation. The high-voltage door shall be on the left with the low-voltage door on the right. Compartments shall be designed for cable entry from below and shall be sized to the minimum dimensions of ANSI C57.12.26.

J. Transformer(s) shall be supplied with a welded main tank cover and be of a sealed-tank construction designed to withstand a pressure of 7 psig without permanent distortion. The tank cover shall be domed to shed water and be supplied with a tamper-resistant access handhole sized to allow access to internal bushing and switch connections. Transformers filled with Envirotemp FR 3 fluid shall be manufactured to withstand 12 psig without rupture. The transformer shall remain effectively sealed for a top-oil temperature of -5 degrees C to 105 degrees C. When necessary to meet the temperature rise rating specified above, flat cooling panels of the common header type shall be provided.

K. When high-voltage taps are specified, full-capacity taps shall be provided with a tap changing mechanism designed for de-energized operation. The tap changer operator shall be located within one of the compartments.

L. The coil windings shall be of the two winding type, designed to reduce losses and manufactured with the conductor material as specified above. The windings shall incorporate a secondary sheet conductor for 600V class secondary to maximize short-circuit strength. For higher-voltage class secondary, strap conductor shall be utilized. All


insulating materials shall be rated for 65 degrees C rise, 80 degrees C hot-spot operation.

M. The core material shall be high-grade, grain-oriented, non-aging silicon core steel with high magnetic permeability, low hysteresis and eddy current losses. Magnetic flux densities are to be kept well below saturation to allow for a minimum of 10 percent over voltage excitation. The cores shall be properly annealed to reduce stresses induced during the manufacturing processes and reduce core losses.

N. The core frame shall be designed to provide maximum support of the core and coil assembly. The core frame shall be welded or bolted to ensure maximum short-circuit strength.

O. The core and coil assembly shall be designed and manufactured to meet the short-circuit requirements of ANSI C57.12.90. The core and coil assembly shall be baked in an oven prior to tanking to "set" the epoxy coating on the Kraft paper and remove moisture from the insulation prior to vacuum filling.

P. Transformer shall be vacuum-filled with the appropriate fluid as indicated above. The process shall be of sufficient vacuum and duration to insure that the core and coil assembly is free of moisture prior to filling the tank.

2.3 FINISH

A. Transformer units shall include suitable outdoor or indoor paint finish. Each transformer shall be painted utilizing an initial phosphatizing cleaning treatment, followed by manufacturer's standard paint process baked on to a total of three (3) to five (5) mils average thickness.

B. The finish color shall be ANSI 61 unless otherwise specifically indicated.

2.4 ACCESSORIES

A. Transformer features and accessories shall include:

1. Dial-type thermometer with alarm contact

2. Liquid level gauge with alarm contact

3. Pressure-vacuum gauge with alarm contact

4. One (1) inch drain valve with sample valve

5. Automatic pressure relief device.

6. Non-PCB label

7. One (1) inch upper fill/filter press connection

8. Additional accessories as shown on the drawings; such as rapid pressure rise relay, winding temperature relay, etc.

2.5 HIGH VOLTATGE SWITCHING

A. Where a radial feed operation is shown on the drawings, provide a two-position, oil-immersed, gang-operated, rotary, load-break switch. The switch mechanism shall be


spring loaded and the operation shall be independent of operator speed. The switch rating shall be 600 ampere continuous and load interrupting, 10,000 ampere make and latch, and 10,000 ampere symmetrical for 10 cycle and 2 seconds.

B. Where a loop-feed operation (sectionalizing switch) is shown on the drawings, provide a four-position, oil-immersed, gang-operated, rotary, load-break switch. The switch mechanism shall be spring-loaded and the operation shall be independent of operator speed. The switch rating shall be 600 ampere continuous and load break, and momentary 10,000 ampere symmetrical for 10 seconds.

2.6 PRIMARY FUSING

A. Where shown on the drawings, provide the following fuses

1. Provide drawout load break current-limiting fuses.

2.7 PRIMARY CONNECTIONS

A. Transformer primary connections shall be live front bushings with NEMA spades or eyebolt terminals suitable for cable sizes shown on the drawings


3.1 FACTORY TESTING

A. The following standard factory tests shall be performed on the equipment provided under this section. All tests shall be in accordance with the latest applicable ANSI and NEMA standards.

1. Resistance measurements of all windings on the rated voltage connection of each unit and at the tap extremes of one unit only of a given rating on this project

2. Ratio tests on the rated voltage connection and on all tap connections.

3. Polarity and phase-relation tests on the rated voltage connections

4. No-load loss at rated voltage on the rated voltage connection

5. Exciting current at rated voltage on the rated voltage connection

6. Impedance and load loss at rated current on the rated voltage connection of each unit and on the tap extremes of one unit only of a given rating on this project

7. Applied potential test

8. Induced potential tests

3.2 INSTALLATION (BY CONTRACTOR)

A. The CONTRACTOR shall install all equipment per the manufacturer's recommendations and the contract drawings.


A. Provide the services of a qualified factory-trained manufacturer's representative to assist the CONTRACTOR in installation and start-up of the equipment specified under this section for a period of 3 working days. The manufacturer's representative shall provide


technical direction and assistance to the CONTRACTOR in general assembly of the equipment, connections and adjustments, and testing of the assembly and components contained herein.

B. The Conractor shall provide three (3) copies of the manufacturer's field start-up report.

3.4 FIELD TESTING

A. Measure primary and secondary voltages for proper tap settings.

B. Megger primary and secondary windings

C. Liquid transformers -- Test oil for dielectric strength

3.5 FIELD ADJUSTMENTS

A. Adjust taps to deliver appropriate secondary voltage


City of Visalia – WCP Upgrades RPGS Pre-selection 16355 - 1 December 2010 COGEN 480 VAC Paralleling Switchgear

SECTION 16355 – COGEN 480 VAC PARALLELING SWITCHGEAR

PART 1 – GENERAL


A. This specification covers the design, materials, equipment, labor, fabrication, testing, delivery and installation of the COGEN 480 VAC Paralleling Switchgear specified herein. The EQUIPMENT SUPPLIER shall provide the Switchgear, if required depending on the type of power generation equipment proposed, complete and operable, in accordance with the Contract Documents.

B. The system shall be designed to provide a fully automatic operation with provisions for manual control for parallel operation of the generation system with the SCE grid.

C. The system shall be designed, manufactured, tested and warranted by the EQUIPMENT SUPPLIER.

D. All components, testing and services specified or required for a complete system shall be included. The EQUIPMENT SUPPLIER shall bear the responsibility that the equipment has been designed, fabricated and tested in accordance with all codes, standards and governmental regulations applicable and performs under the conditions and to the standards specified herein.

E. The information included in this specification and drawings is intended to describe the general design, performance, interface characteristics and construction features of the equipment. The accuracy of the EQUIPMENT SUPPLIER furnished data and information and compatibility of such information with the overall performance of the equipment and systems shall be the sole responsibility of the EQUIPMENT SUPPLIER.

1.2 APPLICABLE CODES AND STANDARDS

A. All work specified herein shall conform to or exceed the applicable requirements of the following standards and publications, and all governmental and local codes or ordinances. Where the requirements of local codes are in conflict with the other requirements, the local codes shall take precedence.

B. Standards and Publications.

1. ANSI/NFPA 70 National Electrical Code

2. NFPA 110 Standard for Emergency and Standby Power Systems.

3. ANSI American National Standards Institute.

4. UL Underwriters’ Laboratories, Inc.

5. NEMA National Electrical Manufacturers’ Association

6. IEEE Institute of Electrical and Electronic Engineers’ Association

7. UL 486A Wire Connectors and Wiring Lugs for Use with Copper Conductors


8. UL 1066 Low-Voltage AC and DC Power Circuit Breakers Used in Enclosures

9. UL 1558 Listed and labeled switchgear

10. ANSI C12.1 Electricity Metering

11. ANSI/IEEE C37.16 Low-voltage Power Circuit Breaker and AC Power Circuit Breaker Protectors – Preferred ratings, Related Requirements and Application Recommendations

12. ANSI/IEEE C37.17 Trip Devices for AC and General Purpose DC Low-Voltage Power Circuit Breaker

13. ANSI C37.20.1 Metal-Enclosed Low-voltage Power Circuit Breaker Switchgear

14. ANSI C37.90 Standards for Relays and Relay Systems associated with Electrical Power Apparatus.

15. ANSI/IEEE C39.1 Requirements for Electrical Analog Indicating Instruments

16. ANSI C57.13 Standard Requirements for Instrument Transformers

17. NEMA SG 3 Low-Voltage Power Circuit Breakers

18. NEMA SG 5 Power Switchgear Assemblies

19. NEMA 250 Enclosures for Electrical Equipment (1000 volts, maximum)

20. NEMA EI 21.1 Instrument Transformers for Revenue Metering 110 KV BIL and less

21. NEMA PB 2.2 Application Guide for Ground Fault Protective Devices for Equipment

22. INETA ATS Acceptance Testing Specifications for Electrical Power Distribution Equipment and Systems (International Electrical Testing Association)

C. The requirements of Federal, State and Local Codes and Regulations, NFPA, UL, ANSI, IEEE, NEMA and INETA Standards applicable to this equipment.

D. All equipment, devices, etc specified in this section, where applicable, shall bear the appropriate label of Underwriters Laboratories’ Inc. The manufacturer shall provide UL listing documentation prior to procurement.

1.3 ENVIRONMENTAL CONDITIONS

A. The Switchgear shall be designed for continuous service in the environmental conditions specified herein.

1. Ambient indoor temperature: 0 to 40 degree C (32 to 104 degree F)

2. Ambient outdoor temperature: -7 to 50 degree C (20 to 122 degree F)

3. Humidity: 0 to 95 % non-condensing (relative)


4. Elevation: Less than 3,300 feet

5. UBC Seismic Zone: 2007 California Building Code (CBC) and applicable Sections of ASCE Standard 7-05

6. Wind speed: 100 mph

1.4 CONTRACTOR SUBMITTALS

A. Shop Drawings

1. The CONTRACTOR shall submit seven (7) copies of shop drawings for the Switchgears, and components in accordance with the requirements of the Section 01300 – EQUIPMENT SUPPLIER Submittals, and section 16050 – Electrical General Provisions.

2. Complete narrative description of the proposed system operating sequence

3. Outline drawings of proposed equipment in plan, sections and elevation view with all devices, including all overall dimensions, weights, shipping splits, and mounting details of the completely assembled equipment.

4. Installation details including anchoring and installation clearances. The seismic calculation shall be submitted.

5. One-line and three-line diagrams showing all components, devices and equipment and their wiring.

6. Schematic diagrams of control and alarm circuits. Schematic diagrams shall identify all devices and parts.

7. Complete point-to-point wiring diagrams showing connection of component devices supplied inside the switchgear.

8. Font elevation, sides and sections showing all devices mounted on the panels

9. Nameplate schedule.

10. Actual device and terminal locations and interconnection diagrams with all wire numbers assigned. The external device connection and terminal numbers shall also be shown.

11. Proposed protection relay scheme and all protection relay information with characteristic curves and brochures, connection diagrams, and ancillaries related to the system protection.

12. All major metering and monitoring.

13. Schematic diagrams showing control, interlocks and alarm circuits with the external device connections with the dotted lines.

14. Conduit entry areas and spaces for the conduits shown on the drawings.

15. Short-circuit and temperature rating of bus, and interrupting and withstand rating of circuit breakers.


B. Parts List and Data Sheets:

1. Complete bill of material with data sheets on all major components (circuit breakers, relays, instrument transformers, meters, controllers, etc).

2. Data sheets of all major components.

3. Nameplate and switch escutcheon plate schedule.

4. Test procedures for final shop and field testing of the Switchgear assembly.

C. Operation and Maintenance Manual:

1. The EQUIPMENT SUPPLIER shall submit seven (7) copies of the operation and maintenance manuals within 30 days after the shipment for the Engineer’s review.

2. The Operation and Maintenance Manual shall include the following:

a. Receiving, inspection, storage, and handling information.

b. “As Built” drawings.

c. Complete installation and maintenance instructions for equipment components.

d. Part identification for replaceable parts and assembles.

e. Complete “AS Built” wiring diagrams of equipment showing connections of component devices, relays and equipment.

f. All major components of the system such as circuit breakers, synchronizers, master and power generation system control sections, control panels, PLC and their communication capabilities, etc.

D. Operation and Maintenance Manual shall also include the following data:

1. A complete description of the system operating sequences.

2. Operating Procedures:

a. Start-up routine, paralleling and normal operating instructions.

b. Control, stopping, shutdown and emergency instructions.

c. Special operating instructions.

3. Maintenance Procedures:

a. Routine maintenance.

b. Adjustment and checking.

c. Original manufacturer's parts list, illustrations, assembly drawings and all diagrams for maintenance.



A. All materials and components utilized in the manufacture of the equipment shall be new, of the latest available version, and shall be delivered with no prior service except as required for the factory tests.

B. All materials shall be tested and inspected in accordance with Section 16050 – Electrical General Provisions and Section 16960 - Electrical Equipment Testing, and the following requirements.

C. Prior to shipment of the equipment, the factory production tests on complete Switchgear assembly shall be performed in accordance with ANSI C37.20 Section 5.3. Seven (7) copies of certified Factory Test Reports conducted on the Switchgear assembly shall be submitted. Test results shall indicate that the equipment meets the standards specified before shipment can be made.

1.6. Factory Tests

A. The following production tests shall be performed prior to the shipment.

1. Ringing out all AC and DC circuits.

2. Checking operation and calibration of all metering devices using secondary current or voltage injection.

3. Simulation of operation to ensure that all protection and control circuits function correctly.

1.7 WARRANTY

A. The system warranty shall be no less than 2 years after initial startup and shall include all costs for repair, parts, travel, living expenses, and labor. Any failure to comply with the Contract Documents or any defects within two (2) year period shall be corrected immediately at no cost the CITY.

1.8 SPARE PARTS

A. Published recommended spare parts list

B. Furnish spare parts included in the above recommended spare parts lists.

1.9 MANUFACTURER

A. The Switchgear shall be by GE Energy Commander Paralleling Switchgear, Russelectric Inc. Paralleling Switchgear, Automatic Switch Co. 4000 Series Digital Generator Paralleling Switchgear, Kohler Power System PD-300 Series Paralleling Switchgear, or equal. Any variances not specifically highlighted in the proposal shall be considered non-responsive. Cost incurred to modify the building or interfacing equipment which is affected as a result of an alternate shall be the responsibility of the CONTRACTOR.

PART 2 – PRODUCTS

2.1 GENERAL

A. The Paralleling Switchgear shall be metal-clad low-voltage switchgear, and shall consist of a Master Control Section, COGEN system Main Circuit Breaker Section, Net Metering


Section, Power Generation System Control Sections with Generator Circuit Breaker, Distribution Feeder Circuit Breaker Sections, other auxiliary sections or compartments, bus work, relays, instruments and instrument transformers. Included also is the NEMA 3R, 600 VAC, 4000 A, 3 wire, ground bus that will connect the step-up COGEN transformer with the COGEN 480 VAC paralleling switchgear main circuit breaker. (Approximate length is 25 feet)

B. Switchgear assembly shall be designed to operate on 480 VAC, 3-phase, 3-wire, 60 Hz, low resistance grounded system.

C. The Switchgear assembly short-circuit withstand and interrupting ratings shall correspond with the highest rated circuit breaker ratings unless otherwise indicated or shown on the drawing.

D. The Switchgear shall provide a complete automatic and manual synchronization and parallel operation of the generating system with the utility company power system.

E. The switchgear system shall be provided with the protection for the unintended islanded operation.

F. There shall be a master control section for control of the synchronization with utility, import and export load (KW VAR), bumpless system loading and unloading, power generation system units, and distribution circuit breaker. The system control shall be redundant PLC-based and the PLC (Master PLC) shall have a communication capability with power generation system control PLC and remote Plant PLC.

G. There shall be a Net Metering section.

H. There shall be a separate section for each power generation system unit control. The control shall be PLC based for automatic and manual control of generator, bumpless load/unload control, metering and protective relaying. The PLC shall have a communication capability with Master control PLC in Master Control Section.

I. Additional sections shall be provided for distribution feeder circuit breakers, numbers and sizes as shown. Circuit breakers shall be of the same type as the generator circuit breakers.

J. The Switchgear assembly, equipment or devices used shall bear the UL label, where applicable, and shall meet the requirements of the referenced standards.

2.2 CONSTRUCTION

A. The Switchgear assembly shall be a metal-clad structure with draw-out circuit breakers, and shall consist of individual vertical sections, housing various combinations of circuit breaker, auxiliaries, protection relays, control devices for operation and control, protection, paralleling of generator sets with the utility, and bolted to form a rigid metal-clad switchgear assembly. Metal side sheets shall provide grounded barriers between adjacent structures and solid removable metal barriers shall isolate the major primary sections of each circuit. Hinged panel sections shall access all of the sub-panel mounted control equipment. End sections shall be designed to permit future additions without disturbing the initial installation.

B. The Switchgear shall be constructed of formed sections of smooth, rolled sheet steel, bolted together and reinforced where necessary with structural steel members. Doors


and interior panels shall be constructed of 12-gage (minimum) formed sheet steel. Hinges shall be the concealed type and shall allow the doors to swing through not less than 105 degrees from the closed position. Each door shall be furnished with a locking latch with keys removable in both the locked and unlocked position. All locks shall be keyed alike. Vents or louvers shall be provided, where required, to give adequate ventilation. Hinged padlockable rear doors shall be provided unless otherwise indicated.

C. All steel work shall be thoroughly cleaned after all welding is completed. The cleaning process shall be followed immediately with a rust-resisting priming coat.

D. Steel channel anchoring sills shall be furnished with the Switchgear assembly.

E. Provisions shall be made for top and bottom cable entry for the conduits and bus duct as shown on the Contract Drawings.

F. The stationary contacts shall be silver-plated and recessed within insulating tubes. A steel shutter shall automatically cover the stationary primary disconnecting contacts when the breaker is in disconnected position or out of the cell. Provide rails to allow withdrawal of each circuit breaker for inspection and maintenance without the use of a separate lifting device.

G. The Switchgear shall be constructed so that all buses, bus supports and connections shall withstand stresses that would be produced by currents equal to the momentary rating of the circuit breakers. The bus shall have provisions for future extension. All bus joints shall be plated, bolted and insulated with easily installed boots. The bus shall be braced to withstand fault currents equal to the close and latch rating of the circuit breakers. The temperature rise of the bus and connections shall be in accordance with ANSI standards.

H. Hinged front and rear cubicle doors shall be provided with locking type handles.

I. The removable power circuit breaker compartment shall be equipped with disconnecting contacts, rails and interlocks for draw-out application. It shall have four positions, CONNECTED, TEST, DISCONNECTED, and REMOVED.

2.3 BUS

A. The main bus shall be high conductivity tin-plated copper and shall be rated as shown on the drawings.

B. The continuous and momentary current rating of busses shall be as required by ANSI standards C37.20. The bus bracing shall correspond with the highest rated circuit breaker momentary rating unless otherwise shown on the drawings.

C. The bus shall be supported by heavy-duty high dielectric strength, flame-retardant, non-hygroscopic insulating materials.

D. All busses and joints shall have an insulation of flame-retardant and non-hygroscopic type. Where possible, all busses and connections shall be insulated at the factory. For other connections and connectors not insulated at the factory, a phenolic insulation of a flame-retardant and non-hygroscopic type shall be furnished by the manufacturer for installation at the site.


E. The phase sequence of the assembled three-phase busses and primary conductors shall be A, B, C, counting from front to back, top to bottom, or left to right, as viewed from the circuit breaker operating mechanism side in accordance with ANSI C37.20.

F. All joints shall be silver plated with at least 2 bolts per joint.

G. A copper ground bus shall be provided and shall be extended throughout the entire lineup with connection to each breaker grounding contact and each cable compartment ground terminal. Station ground connection points shall be located in each end section.

H. Surge arresters of metal oxide in combination with capacitor shall be provided where indicated on the drawings.

2.4 POWER CIRCUIT BREAKERS

A. Horizontal draw-out type. Equipped with a stored-energy spring mechanism for quick-make, quick-break, and trip free operation. Design the stored-energy mechanism so that the closing speed is independent of both control voltage and operator. Provide three-pole, single throw, 600 volt, 60 hertz breakers with a continuous current and trip ratings as shown on the drawings and three independent arc quenchers, closing mechanism, mechanical trip device , inter-pole barriers and positive indicator. Provide breakers of like frame sizes that are completely interchangeable.

B. Design guide support rails for racking out or removing breakers as an integral part of the cubicle and not an auxiliary device requiring manual insertion and removal. Provide a heavy duty rail latch to positively prevent breaker from rolling off the guide rail. Provide a breaker racking mechanism of the positive engagement, lead screw type.

C. Design breaker to prevent removal from, or insertion into the cubicle with the closing springs fully charged. Do not allow the breakers to be removed between the CONNECTED-TEST-DISCONNECTED positions unless the breaker is in open position.

D. Provide dead-front construction with a steel barrier between the operator and live parts during racking operations. Provide capability to padlock in at least the DISCONNECTED position such that breaker cannot be closed or moved to any other position.

E. Effectively ground breakers to enclosure prior to being inserted into the TEST and CONNECTED positions. In the TEST position, separate the primary breaker disconnects contacts by a safe distance from the line and load contacts. Provide contacts which are self-aligning and positively and securely engaged in the CONNECTED position. Provide silver-to-silver contacts which are accessible for inspection. Construct all current carrying parts of the breaker of 98 percent conductivity copper with silver plated joints.

F. Provide secondary disconnecting contacts of rugged self-aligning, constant pressure, silver plated construction for control circuit connections to the movable element. Fully engage secondary contacts when the circuit breaker is in the TEST and CONNECTED positions. Harness all control wiring together, protected from physical damage and kept away from moving parts.

G. Provide breakers that meet applicable ANSI and NEMA operational requirements under no load and full load conditions. Provide solid-state type breaker protective trip devices.


H. The circuit breakers shall be electrically operated by the following control voltage provided by the EQUIPMENT SUPPLIER. The circuit breakers control voltage shall be as follows:

1. A 24 VDC Control Power System (DCCPS) for switchgear controls, relays, and breaker tripping shall be furnished and shall consist of a battery charger and storage batteries. The operation shall be completely automatic with the charger maintaining the batteries fully charged under all conditions. All circuit breaker closing and charging shall be 120 VAC coming from a control transformer for each generator, a control transformer on the line side of the main COGEN circuit breaker and from a control transformer connected on the switchgear bus for the auxiliary load circuit breaker.

2. Storage batteries shall be installed on a free standing, multi-tiered seismic rated, battery rack.

3. The storage batteries shall be a sealed non-gassing, maintenance free lead-acid or nickel-cadmium type.

4. The battery racks and battery charger shall be mounted inside an additional switchgear section added to the switchgear lineup unless otherwise required.

5. The DC Control Power System shall be designed for 24 volt DC for switchgear service and ampere-hour capacity to deliver the enough power for operation of Switchgear. The batteries shall be sized to handle the continuous and instantaneous load. The instantaneous load shall be calculated to trip all circuit breakers simultaneously. The Battery ampere-hour capacity calculation shall be submitted as a shop drawing.

6. The battery charger shall be a “trickle charger” and shall be provided with the following requirements”

a. Ampere rating shall be sufficient to satisfy the following requirements:

(1) Self discharge loss of the batteries.

(2) Continuous load of the Switchgear, etc.

(3) Equalization charge or high-rate output requirements.

b. The battery charger shall be provided with the following alarm output contacts for remote indication.

(1) AC power fails.

(2) DC low voltage.

2.5 CABLE COMPARTMENT AND CONDUIT ENTRY

A. Conduit entries for each section connecting the generators and feeding the auxiliary loads shall be both bottom and top entries and shall be provided with ample spaces for the conduits and cables shown on the Contract Documents. The main circuit breaker section shall be connected to a copper bus duct tied to the secondary side of the Step-up Secondary Substation Transformer. (Refer to Specification Section 16325)


B. Power cable compartment shall have ample spaces for connecting power cables with factory-fabricated terminal lugs, zero-sequence current transformers, surge arresters and other items indicated on the drawings or specified.

C. Control and signal conduit entries shall have ample spaces to accommodate conduits and cables shown on the Contract Documents. The maximum size of conduits shall be 2 inches.

2.6 PROTECTION RELAYS

A. The EQUIPMENT SUPPLIER shall furnish and install the quantity, type, and rating of protection relays specified or as indicated on the drawings as a general guide. Additional relays shall be installed if required to make the system protection complete.

B. It shall be the responsibility of the EQUIPMENT SUPPLIER to complete the detail design of the complete protection relaying system in accordance with the functional requirement specified and as shown on the one-line diagrams.

C. Relays shall be of semi-flush mounted, draw-out unit with a companion case. The case shall have a front door with a large window, for visual access to the front panel with the door closed.

D. All protection relays shall be provided with test switches and automatic current transformer shorting devices upon withdrawal of the relay, and shall be mounted on the front door operating face of the equipment. Auxiliary relays shall be surface mounted at easily accessible locations in each cubicle. The relay shall include the hand reset trip indicator.

E. The relays shall be true RMS sensing solid-state microprocessor-based multi-function types that operate from the secondary output of current and voltage transformers.

F. All applicable functions and features of the relays specified and furnished shall be programmed or activated even if they are not specifically indicated in the specifications or on the drawings.

G. The relay shall be field configurable to provide the complete protection.

H. The relay shall have a built-in alphanumeric display of set points, fault trip values, and all measured variables.

I. The self-test alarm output contact shall be wired for the remote alarm indication.

J. At least one set of programming device each relay group or equipment shall be furnished.

K. The relay shall have the following features:

1. Integral manual testing capability of the functions.

2. Continuous self-testing of internal circuitry

3. Unit failure alarm contacts for remote indication.

4. Programmable set-points for device curve selection.

5. Programmable inputs, such as current and voltage transformer secondary outputs.


6. Programmable outputs for remote indication or control of other devices.

L. The relay Alarm / or Trip contacts shall not change state if power is lost or an under-voltage occurs. These contacts shall change state only upon detection of Alarm or Fault.

M. The relay shall have communication capability. The relay shall be capable of the following over the communication network:

1. Ability to display and transmit all information contained in the relay.

2. Ability to close and open the associated breaker from remote location over the communication network.

N. All instrument transformers required for the protective relaying shall be provided.

O. Feeder Management Relay:

1. The Feeder Management Relay (FMR) shall meet the requirements specified in Paragraph 2.6. A through N. The relay shall be 3-phase multi-function type. The FMR shall be provided with the following protection functions as a minimum. Some of the major functions are indicated below:

a. Undervoltage (device # 27-1, 27-2).

b. Overvoltage (device # 59-1, 59-2).

c. Directional power (device # 32)

d. Negative sequence voltage (device # 47).

e. Phase instantaneous and time overcurrent (device # 50/51)

f. Zero sequence ground-fault overcurrent (device # 50G/51G), or

g. VT fuse-loss detection and blocking (Device # 60 FL)

h. Directional inverse and definite time phase overcurrent (device # 67P).

i. Ground directional overcurrent (device # 67N).

J. Under frequency (device 81U)

k. Over frequency (device # 81O

l. Lockout Relay (86)

2. The relay shall be provided with the following metering functions as a minimum:

a. Actual V, A, Hz, W, Wh, Var, Varh, VA & P.F.

b. Running and maximum demand of A, MW, Mvar, MVA

c. Percent of load –to-trip.

d. KWH pulse output


3. The relay shall provide the following monitoring functions as a minimum:

a. Breaker status: Open, Close, Fail, & Trip Counter

b. Voltage Transformer Failure

4. The relay shall provide at least 5 auxiliary programmable output relays which any event can be programmed at field.

5. The relay shall have a capability to communicate with and transmit and receive any signals to and from remote devices such as PC, PLC or SCADA systems specified in the Specification Division 13 – Instrumentation.

6. The FMR shall be GE SR 750, Schweitzer 351 series, or equal, with additional relays to meet the basic functions described above.

P. Station Bus Differential Protection Relay (Device # 87B).

1. The Bus Differential Protection Relay shall meet the requirements specified in Paragraph 2.6. A through N. The relay shall be 3-phase type unless the single-phase type is required. The Bus Differential Protection Relay shall be provided with the following protection functions as a minimum. Some of the major functions are indicated below:

a. Restrained and instantaneous differential protection.

b. Phase, Neutral, Ground instantaneous on time overcurrent protection

c. Lockout relay (device # 86)

d. The Bus Differential Relay (device # 87B) shall be Basler BE!-87B, or equal.

Q. The Generator Protection Relay (GPR)

1. The GPR shall meet the requirements specified in Paragraph 2.6. A through N. The relay shall be 3-phase type. The GPR shall be provided with the following protection functions as a minimum. Some of the major functions are indicated below:

a. Instantaneous and time overcurrent (device # 50/51)

b. Voltage restraint phase overcurrent (device # 51V).

c. Instantaneous and time neutral overcurrent (device # 50N/51N).

d. Instantaneous and time zero sequence ground overcurrent (device # 50G/51G).

e. Phase balance current (device # 46).

f. Reverse power (device # 32).

g. Under/Over frequency (device # 81 O/U).

h. Under/Over voltage (device # 27/59).

i. Phase differential (device 87G).

j. Ground differential (device # 87GN).


k. Negative sequence voltage (device # 47).

l. Over excitation (device # 24).

m. Loss of excitation (device # 40).

n. Over speed (device # 12).

o. Stator RTD (device # 49).

p. Bearing RTD (device # 38).

q. Lockout relay (device # 86).

r. Inadvertent energizing (device # 50/27).

s. Generator breaker failure (device # 50BF).

t. VT fuse-loss detection and blocking (device # 60FL).

2. The GPR relay shall be GE SR 489, Basler BE1-GPS 100 with BE1-87G, Beckwith M3425A or equal, and if required, additional relays shall be provided to meet the above basic functions described.

R. Feeder Protection Relay

1. The Feeder Protection Relay (FPR) shall meet the requirements specified in Paragraph 2.6. A through N. The relay shall be 3-phase type. The FPR shall be provided with the following protection functions as a minimum. Some of the major functions are indicated below:

a. Phase and neutral instantaneous over-current (device # 50/50N)

b. Phase and neutral time over-current (device 51/51N)

c. Zero sequence ground overcurrent (device # 50G/51G)

d. Lockout relay (device # 86).

2. The relay shall be provided with the following metering functions as a minimum:

a. Actual Amp.

b. Percent of load –to-trip.

3. The relay shall be GE Multilin: SR 735/737, Basle: BE1-851, or equal.

2.7 FUSES:

A. Voltage transformer primary and secondary circuits to meters, instruments, and DC control circuits shall be fused. Secondary circuits to protection relays, voltage regulators, circuit breaker trip circuits, and equipment of similar importance shall be fused using fuses having special delay curves.

B. Fuses shall be mounted in draw-out carriage or pull-out type fuse holders so that the fused circuits may be easily isolated.


2.8 INDICATING INSTRUMENTS:

A. All indicating instruments such as frequency meter, voltmeter, ammeter, wattmeter, KWH meter, etc., shall be of the flush-mounted, back connected, direct reading, switchboard type. They shall be 4-1/2 inches square, 250-degree scale, and one percent accuracy class.

B. Each instrument shall have a zero adjusting device so that the zero position of the pointer can be adjusted without removing the cover. Instrument scales shall be white with black markings. Scale markings shall be appropriate for the function.

2.9 INSTRUMENT TRANSFORMER

A. Final selection of required number, turn ratio, burden and accuracy class of the voltage and current transformers for metering and relaying shall be the responsibility of the equipment manufacturer.

B. Voltage Transformers (VT).

1. Voltage transformers shall be draw-out type, equipped with current-limiting fuses and shall have an accuracy as required by each Switchgear unit and shall conform to ANSI C57.13.

2. V.T. shall be dry type, and shall be mounted on a draw-out type frame. In the disconnected position, the primary and secondary circuits shall be automatically disconnected, and primary fuses grounded.

3. The voltage class shall not be less than that of the Switchgear in which they are installed. The BIL of the V.T. shall be the same as that of the Switchgear.

4. The V.T. accuracy class and burden shall be rated as required for the functions and shall have voltage ratings as shown on the drawings.

5. Voltage transformers shall be provided with primary and secondary fuses with disconnecting means.

C. CURRENT TRANSFORMERS (CT).

1. The current transformers shall have ratios, and relay and metering accuracy as required for the each Switchgear and the circuit breaker.

2. C. T. shall be multi-ratio, rated to withstand the specified operational, short-circuit, and voltage impulse conditions, and shall conform to ANSI C 57.13.

3. The voltage class shall be not less than that of the Switchgear in which they are installed. The C. T. shall be either of the wound, window, or bar type and shall have five (5) ampere secondary. Window type current transformers for ground sensors shall have adequate opening for power cables of the size indicated on the drawings.

4. The metering and relaying accuracy class of C. T. shall be per ANSI C 57.13.

5. All current transformers shall have five amperes secondary and shall be wired to short-circuiting type terminals or test blocks located in the secondary termination compartment.


6. When secondary windings of current transformers are required to be grounded, they shall be grounded at one point only at the terminal boards or test blocks, which shall be readily accessible and clearly identified.

2.10 WIRING

A. The instrument, control, and protection wiring, including all electrical interlocks and inter-compartment wiring shall be installed and completely connected to provide for proper operation and control of the Switchgear assembly.

B. All instrument, control and relay wiring except wiring that crosses hinged joints, shall be stranded, tinned, single-conductor copper wires. Current transformer secondary wiring shall be not smaller than No. 12 AWG. Other stranded wires shall not be smaller than No. 14 AWG. Wires that cross hinged joints, such as between hinged instrument panels and terminal blocks in Switchgear housing, shall be flexible hinged-type wire with service loops. Type SIS, XLP insulated wires, or equal, shall be used. All wires shall be rated for 90 degree C conductor temperature. All unused contacts on relays and auxiliary switches shall be connected to terminal blocks. All wiring shall be capable of passing the ICEA flame Resisting Test, ICEA Publication No. S-19-81.

C. Exposed wiring shall be kept to a minimum. Wiring duct systems shall be installed to minimize exposed wiring and to provide for easy access for inspection and modification.

D. The terminal blocks for all external control connections shall be 600-volt type, having minimum rating of 20 amperes with marker strips identifying all internal and external wiring. The terminal blocks shall have at least 20 percent spare connections after completion of wiring. Lugs shall be provided in the incoming line section for connection of main grounding conductor. Additional lugs for connection of other grounding conductors shall be provided as required.

E. Adequate space shall be provided in each compartment for the termination of power and control cables shown on the drawings.

F. Provisions shall be made for the entrance of cables or bus ducts both from bottom and top.

G. Secondary cable termination shall be located in a separate compartment, shielded from all primary connections and accessible with the primary circuit energized.

H. Cable entrances and cable supports shall be located in a manner that will result in minimum of bending of the cables. Cable bends shall have a radius of not less than that recommended by the cable manufacturer.

I. Terminals for metering, protection, indication, control and secondary winding shall be of the stud type (with ring type lugs) suitable for termination of conductors up to No. 8 AWG. Terminals shall have insulated ferrules.

J. Terminal blocks shall have a rating 600 volts and shall be of the molded plastic type having screw-type terminals for No. 10 machine screws. A minimum of 20 percent spare terminals shall be provided and distributed among the terminal blocks.

K. Identification of wiring shall be provided using manufacturer’s standard identification system Identification shall be protected by the application of clear heat shrink protective sleeves. The proposed wire identification system shall be included in the submittals.


Individual wire identification for each wire shall be included in the wiring and schematic diagrams submitted. All wires shall be labeled at both ends and at any point in between where wires may terminate.

L. The CONTRACTOR shall furnish all cable lugs and terminals for termination of the power cables.

2.11 CONTROL AND INSTRUMENT SWITCHES

A. All control and instrument switches shall be of the rotary switchboard type with handles on the front and the operating contact mechanisms on the rear of the panels. Contacts of all control and instrument switches shall be of phosphor-bronze and shall operate with a wiping action. The switches shall have a continuous rating of 30 amperes at 600 volts, ac.

B. Each control and instrument switch shall be provided with an escutcheon plate clearly marked to show each operating position. The switch identifications shall be engraved on the escutcheon plates or on separate nameplates.

2.12 NAMEPLATES:

A. Nameplates shall be furnished for all instruments, relays, control switches, pushbuttons, indicating lights, circuit breakers, etc. In the case of instruments, instrument switches and control switches where the function is indicated on the dial plate or on the switch escutcheon plate no nameplate is required, except where there are two or more similar devices performing similar functions on the same panel, in which case, nameplates shall be furnished to identify the circuits.

B. Nameplates shall be made of black and white laminated phenolic or similar material with black letters engraved through the white finish top lamination. The lettering shall be of a size and design such that it will be legible from reasonable angles of observation.

C. Nameplates shall be mounted using an extruded holder secured with corrosion resistant self-tapping screws to prevent warping. The use of adhesive type mounting is not acceptable.

2.13 GROUNDING RESISTOR

A. Where shown on the drawings, neutral grounding resistors shall be provided for the generators.

B. The grounding resistor(s) shall be as follows:

Current rating as shown on drawing

Line to ground voltage rating 277 VAC

Time rating Continuous

Temperature rise, Short-time: 760 degree C

C. The resistor units shall be edge-wound type constructed of stainless steel. Each resistor element shall be individually supported at each end by ceramic insulators and shall be designed to permit thermal expansion.


D. The frame assembly of resistor units shall be constructed of corrosion-resistant hot-dipped galvanized angles. All members shall be assembled using outdoor hardware and be of sufficient strength to withstand severe mechanical stress.

E. The grounding resistors shall be provided with a screened safety enclosures. It shall be suitable for indoor or outdoor pad mounting. Where requited, furnish stand for floor mounting.

F. Provide current transformers where shown on the drawings (alternate location of CT – generator terminal box)

2.14 SYSTEM AND DEVICES DESCRIPTION

A. Master Control Section:

The master control section shall be furnished with the following basic components, logics and any additional equipment or devices necessary to provide for a complete and dependable system.

1. One master control system with a redundant hot-standby Programmable Logic Controllers (Master PLC) for control and monitoring of the system and communication with HMI, respective Generator PLC and the remote Plant PLC. The programming shall be the responsibility of the EQUIPMENT SUPPLIER.

2. One Master Synchronizer and Load Control system (Woodward MSLC or equal), capable of digital communication with generator Digital Synchronizer and Load Control system (Woodward DSLC or equal), for control of the system synchronizing, var/power factor control, automatic system loading and unloading for bumpless load transfer to and from the utility, power export and import of the system based on the system operation modes specified in Para. 2.15.

3. The system shall be provided with capabilities to synchronize to the utility power system through the main circuit breaker of the Incoming Main Switchgear (SWGR-M) and also synchronize to the SWGR–M bus through the Generator Bus Main Circuit Breaker.

4. The system will receive remote utility three (3) phase voltage signals from the incoming switchgear voltage transformers and 4-20 ma analog signals from three (3) phase load kw and knar transducers for import and export load control.

5. Load Shedding Control: shall be provided monitoring the system operation as follow

a. Programmable three (3) stage Load-Shedding control capability shall be provided for future use.

6. Resynchronization with utility shall be accomplished upon utility power restoration. The resynchronization shall be done automatically or manually depending on the selector switch position.

7. One System Manual-Off-Auto Switch.

8. One System Operation Mode Selector Switch

9. One synchronizing mode selector switch (Run-permissive-Check-off switch).


10. Selector switch for synchronizing at the Inter-tie Circuit Breaker at Incoming Main Switchgear or at the COGEN system Main Circuit Breaker.

11. One sync check switch

12. One red mushroom emergency lockout switch.

13. Incoming line voltmeter with selector switch

14. One Station bus voltmeter with selector switch.

15. One Station ammeter with selector switch.

16. One Station Kilowatt meter with analog output

17. One Station KW hour meter with pulse output.

18. One KVA meter with analog output.

19. One Station Kvar meter with analog output.

20. One Station power factor meter with analog output

21. One Station frequency meter with analog output

22. One swing-out manual synchronizing panel mounted on the master control cubicle door with the following metering:

a. One station bus and one utility voltmeter.

b. One station bus and one utility frequency meters.

c. One synchroscope.

d. One sync-check relay (device # 25).

e. Two synchronizing lamps.

23. Necessary indicating lights, switches and pushbuttons.

24. A Human-Machine-Interface (HMI) shall be provided, communicate with Master PLC and provide visual and audio alarms, and monitoring of system parameters. The HMI shall indicate current alarms, status, monitored values and their histories. Following is a list of alarms, status and monitoring functions. All alarm, status and monitored values shall also be transmitted to remote PLC by a via communication link. The HMI manufacturer shall be as specified in the Instrument section.

FUNCTION MODE

M-O-A switch not in Auto status Sync mode switch not in Run status Critical control voltage failure alarm Start signal received status System frequency value monitoring Under frequency alarm


FUNCTION MODE

Under frequency shutdown Over frequency alarm Over frequency shutdown System Voltage value monitoring Under voltage alarm Under voltage shutdown Over voltage alarm Over voltage shutdown System KW value monitoring System KVA value monitoring System KVAR value monitoring System KWH monitoring Bus differential tripped shutdown Utility tie C.B closed status Utility tie C.B open status Power Generation System running status Power Generation System stopped status PLC fail shutdown Control power fail shutdown Main PLC in control status Backup PLC standby status Process control voltage fail shutdown Circuit breaker control DC voltage low alarm Station power AC voltage fail alarm Any other common facilities Alarm or shutdown

B. Main Circuit Breaker Section

1. The Main Circuit Breaker Section shall be furnished with the following basic components, and any additional equipment necessary to provide a complete dependable system.

a. One main circuit breaker meeting requirement specified in Paragraph 2.4

b. Circuit breaker control switch.

c. Incoming line voltage transformers.

d. Station Bus voltage transformers.

e. Current transformers required for protection relaying, metering, etc.

f. Current transformers for station bus differential relaying.

g. Zero-sequence current transformer for ground-fault protection.


h. Feeder Management Relay (FMR) specified in Para. 2.6.O

i. Bus Differential relay

j. Other items shown on the drawings.

C. Net Metering Section

A Net metering section meeting the requirements of SCE shall be furnished, with the following basic components, and any additional equipment necessary to provide a dependable system:

1. Provision for mounting voltage and current transformers, furnished by the utility.

2. Net Meter furnished by the utility.

3. The utility metering (Net Metering) section shall be approved by the utility.

D. Generator Circuit Breaker Compartment:

The generator circuit breaker compartment shall be provided with the following basic components, devices and any additional equipment necessary to provide for a complete and dependable system:

a. One generator circuit breaker meeting the requirements specified in Paragraph 2.4

b. One generator circuit breaker control switch.

c. Sets of current transformers for relaying and metering.

d. One sets of current transformer for differential relaying. One set mounted in the circuit breaker compartment and one set mounted in the generator terminal box.

e. One set of cross-current compensation current transformer (when voltage regulator is located at the field, locate CCCT in the generator terminal box)

f. One zero sequence ground fault current transformer for ground fault relaying.

g. Generator Protection Relay (GPR) specified in Para. 2.6.Q.

h. Other items shown on the drawings or required to make the system complete.

E. Distribution Feeder Circuit Breaker Section:

The Distribution feeder circuit breaker section shall be provided with the following basic components, and any additional equipment necessary to provide for a complete and dependable system:

1. Feeder circuit breaker meeting the requirements specified in Paragraph 2.4

2. Current transformers for protection relaying, metering, etc.

3. Current transformers for station bus differential relaying.

4. Zero-sequence ground fault current transformer for relaying.


5. Circuit breaker control switch with indicating lights.

6. Feeder Protection Relay (FPR) specified in Para. 2.6.Q.

F. Generator Control Logic Power Supply.

Generator control power shall be 24V DC and shall be derived from the engine starting batteries. The control logic shall be powered through a suitable means that permits continuity of power until the last battery is no longer available. The controls shall be powered from any battery or combination of batteries and prevent feedback to a failing battery. The transition of control logic power from any battery combination to any other battery combination shall be accomplished without disruption in the power flow.

A single DC-to-DC converter shall provide a constant 24 VDC power to all generators and Master PLC’s during starting and cranking of all power generation system sets simultaneously.

2.15 SYSTEM OPERATION

A. System Operation Modes

The switchgear shall have the provisions for the following modes of system operation. The modes of the system operation shall be as described below and the each mode shall be initiated either locally or remotely via a communication link to the Plant Control System. The mode initiation can be by operator or programmed schedule,

1. Mode 1 – Process Follower Operation

The system operates based on the process following mode and feeds the plant load. The shortage is imported from the utility.

2. Mode 2 – Base Load Operation

The system operates based on the full capacity and feed the load connected and the shortage imported from the utility.

B. Description of Switch Function

1. Manual-Off-Auto Switch in Master Control Section

a. In the Manual mode, the system operates manually controlling each generator for synchronizing, loading, power factor and var, etc.

b. In the Off mode, the system is shutdown.

c. In the Auto mode, the system operates automatically in conjunction with Synchronizing Mode Switches in Mater Control Section and corresponding Generator Control Sections.

2. Operation Mode Selector Switch in Master Control Section

a. The selection of mode will determine what operation mode the system will be running.

3. Run-Permissive-Check-Off Switch (synchronizing mode switch) in Master Control Section.


a. In the Run position, the Station will operate automatically and provides normal automatic phase-lock operation control over station voltage, frequency or phase, and will automatically synchronize to the utility.

b. In the Permissive position, the Station will operate with no control over Station bus frequency or phase, but provides a Sync check relay contact closure when the parameters are within the preset limits. In this position with the Sync Check switch in On position, the Station shall be controlled manually bringing the Station parameters to the preset limits to be synchronized. The Station can be synchronized to the utility by automatically closing the utility circuit breaker, when the Station system parameters are within preset limits.

c. In the Check position, The Station will operate providing normal automatic phase-lock control over Station bus frequency, and phase, but with no synchronizing relay contact closure when sync conditions are met. To synchronize, the utility circuit breaker should be manually closed when the Station system parameters are within preset limits.

d. In the Off position, the Station shall be shutdown going through normal cool down cycle. Whenever the selector switch is placed in Off position while the power generation system is operating, the generator circuit breaker will trip, but the system will continue to operate until the expiration of the cool down time delay setting

4. Emergency Lockout Switch in Master Control Section.

In the Emergency Lockout position, the Station shall be locked out. Whenever the selector switch is placed in Emergency Lockout position, the circuit breaker shall immediately trip and shutdown the power generation system immediately without going through cool down cycle.

5. Run-Permissive-Check-Off Switch (synchronizing mode switch) in power generation system Control Section.

a. In the Run position, the generator will operate automatically and provides normal automatic phase-lock operation control over generator voltage, frequency or phase, and will automatically synchronize to the Station bus.

b. In the Permissive position, the power generation system will operate with no control over generator voltage, frequency or phase, but provides a Sync check relay contact closure when the parameters are within the preset limits. In this position with the Sync Check switch in On position, the generator shall be controlled manually bringing the generator parameters to the preset limits to be synchronized. The generator can be synchronized to the Station bus by automatically closing the generator circuit breaker, when the generator system parameters are within preset limits.

c. In the Check position, the generator will operate providing normal automatic phase-lock control over generator voltage, frequency, and phase, but with no synchronizing relay contact closure when sync conditions are met. The generator can be synchronized to the Station bus by manually closing the generator circuit breaker, when the generator system parameters are within preset limits.


d. In the Off position, the generator shall be shutdown going through normal cool down cycle. Whenever the selector switch is placed in Off position while the power generation system is operating, the generator circuit breaker will trip, but the power generation system will continue to operate until the expiration of the cool down tIme delay setting.

6. Emergency Lockout Switch in the Power Generation System Control Section.

a. In the Lockout position, the power generation system shall be locked out. Whenever the selector switch is placed in Lockout position, the circuit breaker shall immediately trip and shutdown the power generation system immediately without going through cool down cycle.

7. Sync Switch in Power Generation System Control Section:

a. In Off position, the generator will operate automatically in conjunction with the Run position of the Synchronizing Mode Selector Switch in the Power Generation System Control Section and the generator shall be automatically synchronized to the Station bus.

b. In the On position, the synchronizing panel will be connected to the Station bus and generator systems for manual synchronization. The Manual synchronization could be accomplished with the Synchronizing Mode Selector Switch in either Check or Permissive position.

2.16 ENCLOSURE

A. Construction and Finish.

1. The enclosure shall be designed and constructed for use under seismic load conditions per the seismic requirements of the 2007 California Building Code (CBC) and applicable Sections of ASCE Standard 7-05 by using the following minimum values in design: Seismic Component Importance Factor for Anchorage of Mechanical and Electrical Equipment, I: 1.25.

2. The enclosure shall meet the requirements of the ANSI, ASTM, NFPA, NEC, NEMA and UL.

3. All electrical equipment and devices shown or specified shall be installed at the factory.

4. The enclosure shall be provided with the low wattage space heaters in each section of the line up. The heaters shall have a main switch and shall be controlled with thermostats with manual thermostat bypass switches.

5. The finish color shall be ANSI 61.

6. Enclosure shall be provided with a sign “ DANGER - HIGH VOLTAGE “ at the front and rear.

B. The enclosure shall be Indoor NEMA Type 1.


2.17 TOOLS, SPARE PARTS AND ACCESSORIES

A. Special tools, such as wrenches, or spanners, or any other devices which are required for installation and maintenance of the mechanism, contacts, interrupters, or other parts shall be furnished.

B. The following accessories shall be furnished:

1. Set of special tools for installation, operation, or maintenance of the equipment.

2. Breaker manual charging lever.

3. Breaker test jumper for electrically operating the breaker while out of its compartment.

4. Breaker test cabinet for testing electrically operated breaker outside the housing.

5. Breaker portable lifting device and transfer truck for moving the circuit breaker into and out of the breaker housing.

6. Other necessary devices for breaker removal and transportation.


3.1 COORDINATION

A. EQUIPMENT SUPPLIER shall be responsible for providing the coordinating interconnect diagrams showing the electrical connections between all related equipment specified in this specification.

B. The EQUIPMENT SUPPLIER shall supply the CONTRACTOR with any required power generation system interface hardware, electronic governor, and voltage regulator system components. Along with this equipment, the EQUIPMENT SUPPLIER shall furnish detailed drawings outlining proper interconnection and physical mounting data. The equipment shall be mounted and wired by the CONTRACTOR.

C. The EQUIPMENT SUPPLIER shall verify the completion of all startup commissioning and site testing of the Switchgear. The EQUIPMENT SUPPLIER shall also assist the CONTRACTOR as necessary in performance of the site startup and testing of the power generation system.

3.2 FACTORY TESTING

A. At the factory, the EQUIPMENT SUPPLIER shall perform tests on the Switchgear and generator controls as required verifying the proper operation of the each components and demonstrating full compliance with the requirements of the specification. The factory reports shall be submitted.

B. The equipment shall be completely assembled, wired adjusted, and tested at the factory. Rigid inspection before and after the assembly shall assure the correctness of design and workmanship. After the assembly, each Switchgear assembly shall be tested for operation under simulated conditions.

C. After the visual inspection, the following operational tests shall be performed:

1. Check the circuit breaker operation and interlocks.


2. Check stored energy mechanism of each breaker by tripping, closing, and tripping each breaker after removal of control power.

3. High pot test.

4. Test all protection relay/devices by simulation tests.

3.3 INSTALLATION

A. The Switchgear shall be installed following the procedures set forth by the manufacturer. The manufacturer shall assist the Electrical Contractor as required in interpreting the installation instructions

B. Following the installation, the EQUIPMENT SUPPLIER shall inspect and verify correct installation of the Switchgear, including all individual components.

3.4 FIELD SERVICE STARTUP AND TRAINING REQUIREMENTS

A. The EQUIPMENT SUPPLIER shall provide the services of a field service engineer for a pre-installation coordination meeting with the engine generator supplier and electrical Contractor to coordinate the installation and interconnection of the Switchgear system and generators.

B. EQUIPMENT SUPPLIER shall provide a field engineer for an initial visit to checkout the installation of the Switchgear to allow the energization of the utility main service breaker if required.

C. The EQUIPMENT SUPPLIER shall provide a field engineer for post installation startup and testing assistance, prior to the system turnover and initial instruction and training for the facility’s operating personnel. This trip shall include all service required to checkout the Switchgear system and demonstrate the complete operation for final acceptance by the CITY. The manufacturer’s representative shall certify in writing that the equipment has been installed, adjusted and tested in accordance with the manufacturer’s recommendation.

D. At the time of startup of the system equipment, the EQUIPMENT SUPPLIER shall furnish two (2) preliminary set of installation, operating and maintenance manuals. This manual shall include any and all changes that have occurred during the equipment startup. The amended manuals shall serve as reference tool until the final sets of O & M manuals are supplied.

E. Training sessions of the CITY’s personnel in all aspect of Switchgear operation and maintenance, including step-by-step trouble shooting procedures with necessary test equipment shall be provided for up to ten CITY’s representatives for minimum five (5) working days at the jobsite location determined by the CITY. The training shall be given after Switchgear is in place and in full operation.

F. The instruction shall include recommended field test procedures as defined in the standards. A schedule listing the frequency prescribed for performing the field tests shall be provided.

G. The proposal shall include the cost for all services described above.


City of Visalia – WCP Upgrades RPGS Pre-selection 16483 - 1 December 2010 Variable Frequency Drive Controllers

SECTION 16483 – VARIABLE FREQUENCY DRIVE CONTROLLERS

PART 1 – GENERAL

1.01 WORK INCLUDED

A. This Section includes solid-state, Pulse Width Modulation (PWM), VFDs for speed control of three-phase, induction motors. VFDs are to be integral to motor control centers when applicable. All VFD Controllers shall be equipped with Profibus System Accessory Interface module and Communication Module with input points.

1.02 SUBMITTALS

A. Product Data: For each type of VFD, provide dimensions; mounting arrangements; location for conduit entries; shipping and operating weights; and manufacturer's technical data on features, performance, electrical ratings, characteristics, and finishes.

B. The following shall be included in the Proposal package:

1. Description of equipment and tests included in Proposal to meet the indicated power quality requirements.

2. Nearest factory authorized service center meeting all requirement of 1.3A.

3. Qualification and name of engineering and technical persons responsible for support and warranty of this project.

C. The following shall be included in the submittal package and be approved by the ENGINEER prior to any construction of the VFD system:

1. Include dimensioned plans, elevations, sections, and details, including required clearances and service space around equipment. Show tabulations of installed devices, equipment features, and ratings. Include the following:

a. Each installed unit's type and details.

b. Nameplate legends.

c. Short-circuit current ratings of integrated unit.

d. UL listing for series rating of overcurrent protective devices in combination controllers.

e. Features, characteristics, ratings, and factory settings of each motor controller (VFD).

2. Wiring Diagrams: Power, signal, and control wiring for VFD. Provide schematic wiring diagram for each type of VFD.

3. Detailed description of the filter equipment and sample graphs and data to meet IEEE 519-1992.


4. Carrier frequency information.

D. Qualification Data: For testing agency and manufacturer.

E. Field Test Reports: Written reports specified in Part 1.12 below.

F. Manufacturer's field service report.

G. Operation and Maintenance Data: For VFDs, all installed devices, and components to include in emergency, operation, and maintenance manuals. In addition to items specified in other sections, include the following:

1. Routine maintenance requirements for VFDs and all installed components.

2. Manufacturer's written instructions for testing and adjusting overcurrent protective devices.


A. Manufacturer Qualifications: Maintain, preferably in Visalia, CA, a service center capable of providing training, parts, and 24 hour emergency maintenance and repairs.

B. Source Limitations: Obtain VFDs of a single type through one source from a single manufacturer.

C. The system shall be pre-integrated with the necessary harmonic mitigation equipment.

D. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.

E. Comply with NFPA 70, IEEE 519-1992, ANSI C37, and ANSI C57.

PART 2 – PRODUCTS

2.01 COORDINATION

A. Match features of VFDs, installed units, and accessory devices with pilot devices and control circuits to which they connect.

B. Match features, accessories, and functions of each VFD and each installed unit with ratings and characteristics of supply circuit, motor, required control sequence, and duty cycle of motor and load. See Divisions 11 and 13 sections for information on motor control requirements.

2.02 VARIABLE FREQUENCY CONTROLLERS

A. Description: NEMA ICS 2, IGBT, PWM, VFD; listed and labeled as a complete unit and arranged to provide variable speed of a NEMA MG 1, Design B, 3-phase, induction motor by adjusting output voltage and frequency.


B. All VFD control keypad, pushbuttons, switches and pilot lights shall be mounted on the face of the control panel for easy access.

C. Design and Rating: Match load type such as fans, blowers, and pumps; and type of connection used between motor and load such as direct or through a power-transmission connection.

D. Output Rating: 3-phase; 6 to 120 Hz, with horsepower constant throughout speed range.

E. Unit Operating Requirements:

1. Input ac voltage tolerance of 480 V, plus or minus 10 percent.

2. Input frequency tolerance of 60 Hz, plus or minus 6 percent.

3. Output Rating: 3-phase; 6 to 66 Hz, with amperage equal or greater to motor nameplate amperage including altitude derating.

4. Minimum Inverter Efficiency: 96 percent at 60 Hz, full load.

5. Minimum Displacement Primary-Side Power Factor: 96 percent lagging.

6. Overload Capability: 1.1 times the base load current for 60 seconds; 2.0 times the base load current for 3 seconds.

7. Starting Torque: Default to be 50% with adjustment to 120%.

8. Speed Regulation: Plus or minus 1 percent.

9. Isolated control interface to allow controller to follow control signal over an 10:1 speed range.

F. Internal Adjustability Capabilities:

1. Minimum Speed: 5 to 25 percent of maximum rpm.

2. Maximum Speed: 80 to 100 percent of maximum rpm.

3. Acceleration: Adjustable from.01 to 3600 seconds.

4. Deceleration: Adjustable from.01 to 3600 seconds.

5. Current Limit: 50 to 110 percent of maximum rating.

G. Self-Protection and Reliability Features:

1. Input transient protection by means of surge suppressors.

2. Snubber networks to protect against malfunction due to system voltage transients.

3. Under- and overvoltage trips; inverter overtemperature, overload, and overcurrent trips.


4. Filtering to prevent noise interference with other electronic equipment.

5. Motor Overload Relay: Adjustable.

6. Notch filter to prevent operation of the controller-motor-load combination at a natural frequency of the combination.

7. Instantaneous line-to-line and line-to-ground overcurrent trips.

8. Loss-of-phase protection.

9. Reverse-phase protection.

10. Short-circuit protection.

11. Motor overtemperature fault.

H. Automatic Reset and Restart: To attempt three restarts after controller fault or on return of power after an interruption and before shutting down for manual reset or fault correction. Bi-directional auto speed search shall be capable of starting into rotating loads spinning in either direction and returning motor to set speed in proper direction, without damage to controller, motor, or load.

I. Power-Interruption Protection: To prevent motor from re-energizing after a power interruption until motor has stopped. VFD to automatically re-start motor after outage.

J. Carrier Frequency Adjustment: Provide ability to manually adjust drive carrier frequency. VFDs 100HP and less shall provide carrier frequency adjustment capability from 1 to 10 kHz. VFDs over 100HP shall include carrier frequency adjustment information recommended by the manufacturer.

K, Torque Boost: Automatically vary starting and continuous torque to at least 1.5 times the minimum torque to insure high-starting torque and increased torque at slow speeds.

A. Motor Temperature Compensation at Slow Speeds: Adjustable current fallback based on output frequency for temperature protection of self-cooled fan-ventilated motors at slow speeds.

B. Provide line and load side filtering to minimize total harmonic distortion.

C. Status Lights: Door-mounted LED indicators shall indicate the following conditions:

1. Power on.

2. Run.

3. Overvoltage.

4. Line fault.

5. Overcurrent.


External fault.

D. Panel-Mounted Operator Station: Start-stop and auto-manual selector switches with manual speed control potentiometer and elapsed time meter.

E. Indicating Devices: Meters or digital readout devices and selector switch, mounted flush in controller door and connected to indicate the following controller parameters:

1. Output frequency (Hz).

2. Motor speed (rpm).

3. Motor status (running, stop, and fault).

4. Motor current (amperes).

5. Motor torque (percent).

6. Fault or alarming status (code).

7. PID feedback signal (percent).

8. DC-link voltage (VDC).

9. Set-point frequency (Hz).

10. Motor output voltage (V).

F. Control Signal Interface: Provide VFD with the following:

1. Electric Input Signal Interface: A minimum of 2 analog inputs (0 to 10 V or 0/4-20 mA) and 6 programmable digital inputs.

2. Pneumatic Input Signal Interface: 3 to 15 psig (20 to 104 kPa).

3. Remote Signal Inputs: Capability to accept any of the following speed-setting input signals from the BMS or other control systems:

a. 0 to 10-V dc.

b. 0-20 or 4-20 ma.

c. Potentiometer using up/down digital inputs.

d. Fixed frequencies using digital inputs.

e. RS485.

f. Keypad display for local hand operation.

4. Output Signal Interface:

a. Provide analog output signals (0/4-20 mA), which can be programmed for the following:


b. Output frequency (Hz).

c. Output current (load).

d. DC-link voltage (VDC).

e. Motor torque (percent).

f. Motor speed (rpm).

g. Set-point frequency (Hz).

5. Remote Indication Interface: Provide dry circuit relay outputs (120-V ac, 1 A) for remote indication of the following:

a. Motor running.

b. Set-point speed reached.

c. Fault and warning indication (overtemperature or overcurrent).

d. PID high or low speed limits reached.

6. Communication link: Profibus

G. Provide bypass switch and contactor to allow manual bypass of the drive and across-the-line starting.

H. Integral Disconnecting Means: Provide Heating, Air Conditioning & Refrigeration (HACR) rated breaker as indicated on drawings.

2.03 ACCESSORIES

A. Devices shall be factory installed in motor control center.

B. Push-Button Stations, Pilot Lights, and Selector Switches: NEMA ICS 2, heavy-duty type.

C. Stop and Lockout Push-Button Station: Momentary-break, push-button station with a factory-applied hasp arranged so padlock can be used to lock push button in depressed position with control circuit open.

D. Control Relays: Auxiliary and adjustable time-delay relays.

E. Standard Displays:

1. Output frequency (Hz).

2. Set-point frequency (Hz).

3. Motor current (amperes).

4. DC-link voltage (VDC).


5. Motor torque (percent).

6. Motor speed (rpm).

7. Motor output voltage (V).

F. Historical Logging Information and Displays:

1. Real-time clock with current time and date.

2. Running log of total power versus time.

3. Total run time.

4. Fault log, maintaining last four faults with time and date stamp for each.

G. Current-Sensing, Phase-Failure Relays for Bypass Controller: Solid-state sensing circuit with isolated output contacts for hard-wired connection; arranged to operate on phase failure, phase reversal, current unbalance of from 30 to 40 per-cent, or loss of supply voltage; with adjustable response delay.

H. Harmonic Mitigation: Complying with IEEE Standard 519-1992 shall be a requirement of this project. Harmonic filters, 18 pulse converter configurations, phase multiplication devices, or any other components required to mitigate harmonic voltage and current to IEEE Std. 519-1992 shall be an integral part of the VFD system. Designs which are not pre-integrated and factory wired as part of the UL label will not be acceptable.

1. Designs which cause voltage rise at the VFD terminals must document coordination with the total system variation to prevent nuisance tripping.

2. Designs which do not provide both true and displacement, measured at the VFD terminals, of at least 95% or better at full load are not accept-able. Designs that allow leading power factor at minimum loads are not acceptable.

I. Relevant data for VFD EQUIPMENT SUPPLIER calculations to meet IEEE Std. 519-1992 requirements are as follows:

1. The point of common coupling (PCC) shall be defined per IEEE Std. 519- 1992.

2. The calculated load current (IL) shall be the total combined full load current of each ASD system supplied as part of this project or the total combined amperage of loads designated as “non-linear”.

3. The short circuit current (ISC) available at the PCC is estimated at 65,000 amps.

2.04 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, provide products by one of the following:

1. ABB Power Distribution, Inc.; ABB Control, Inc. Subsidiary.


2. Or approved equal

B. Contractor job site integration of reactors, harmonic filters, power components, etc. will not be acceptable. Start-up, harmonic testing and warranty support services must be supplied by the above or other ENGINEER pre-qualified vendor/manufacturer.


3.01 EXAMINATION

A. Examine areas, surfaces, and substrates to receive VFDs for compliance with requirements, installation tolerances, and other conditions affecting performance.

B. Proceed with installation only after unsatisfactory conditions have been corrected.

3.02 APPLICATIONS

A. Select features of each VFD to coordinate with ratings and characteristics of supply circuit and motor; required control sequence; and duty cycle of motor, drive, and load.

B. Select rating of controllers to suit motor controlled. The VFD vender shall certify that the supplied equipment is properly matched to the loads being fed.

C. The drive shall be capable of operating in compliance with IEEE 519-1992, with point of common coupling (PCC) as defined by the standard. Drive manufacturer shall provide harmonic calculations and on-site post installation harmonic testing with certified reports prior to final acceptance of installation. See 1.1 2.A.3.

3.03 IDENTIFICATION

A. Operating Instructions: Frame printed operating instructions for VFDs, including control sequences and emergency procedures. Fabricate frame of finished metal, and cover instructions with clear acrylic plastic. Mount on front of VFD units.

3.04 CONNECTIONS

A. Tighten electrical connectors and terminals according to manufacturer's published torque-tightening values. If manufacturer's torque values are not indicated, use those specified in UL 486A and UL 486B.


A. Prepare for acceptance tests as follows:

1. Test insulation resistance for each VFD element, bus, component, connecting supply, feeder, and control circuit.

2. Test continuity of each circuit.

3. All tests necessary to prove compliance with IEEE Standard 519-1992.


B. Testing: Perform the following field quality-control testing:

1. Perform each electrical test and visual and mechanical inspection stated in NETA ATS, Sections 7.5, 7.6, and 7.16. Certify compliance with test parameters.

2. Correct malfunctioning units on-site, where possible, and retest to demonstrate compliance; otherwise, replace with new units and retest.

C. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect field-assembled components and equipment installation, including pretesting and adjusting VFDs.

D. Test Reports: Prepare a written report to record the following:

1. Test procedures used.

2. Test results that comply with requirements.

3. Test results that do not comply with requirements and corrective action taken to achieve compliance with requirements.

3.06 STARTUP SERVICE

A. Delete first paragraph below if factory-authorized service representative is not required.

B. Engage a factory-authorized service representative to perform startup service.

C. Verify that electrical wiring installation complies with manufacturer's submittal and installation requirements in Division 16 Sections.

D. Complete installation and startup checks according to manufacturer's written instructions.

3.07 ADJUSTING

A. Set field-adjustable switches.

3.08 CLEANING

A. Clean VFDs internally, on completion of installation, according to manufacturer's written instructions. Vacuum dirt and debris; do not use compressed air to assist in cleaning.

3.09 DEMONSTRATION

A. Engage a factory-authorized service representative to train CITY's maintenance personnel to adjust, operate, and maintain VFDs.


City of Visalia – WCP Upgrades RPGS Pre-selection 16485-1 Unit Control Panels December 2010

SECTION 16485 - UNIT CONTROL PANELS

PART 1 - GENERAL


A. The Vendor shall provide complete unit control panels (UCP) as shown and as specified herein or in other Sections of the Specification. The UCP shall be designed to provide the sequence of operation specified in Section 13300 - Process Control and Instrumentation Systems, P&ID drawings, and relevant mechanical sections

1.02 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS

A. UCP shall comply with the requirements of NEC, NEMA, and UL.

B. UCP shall meet the requirements of UL 508A.

C. All work specified herein shall conform to the requirement of Section 16050 – General Electrical Provisions and Section 16100 – Basic Electrical Materials and Methods.

1.03 SUBMITTALS

A. The Vendor shall submit shop drawings in accordance with the requirements specified in Sections 01300 – Equipment Supplier Submittals, and 16050 – General Electrical Provisions.

B. Ladder diagrams and written descriptions explaining system operation shall be provided with shop drawings.

C. When microprocessor based solid-state control unique to the specific control systems are provided, written description of the operation of the systems with supplemental ladder diagrams or brochures shall be submitted.

D. Provide catalog cuts of all control equipment including enclosures, overcurrent devices, relays, pilot devices, terminations, and wire troughs.


PART 2 - PRODUCTS

2.01 GENERAL

A. The Vendor shall provide the UCP that satisfy the functional requirements specified in the relevant mechanical equipment, and Instrumentation & Control specification sections and as shown on the Electrical Elementary Schematics. Each UCP shall be fabricated with UL labeled components. UCP not specifically specified as being provided in other Sections of the Specification shall be furnished and installed under this Section. All UCP shall be wired under this Section.

B. The controls shall be 120 volt maximum. Where the electrical power supply is 240 volt single phase, or 480 volt, 3-phase, as shown on the electrical drawings, the panels shall be provided with a fused control power transformer. Control conductors shall be provided in accordance with the requirements specified in Section 16050 and 16120.

C. Each UCP shall be provided with identified terminal strips for the connection of all external conductors. The Vendor shall provide sufficient terminal blocks to connect 25 percent additional conductors in the future. Termination points shall be identified in accordance with accepted shop drawings. The UCP shall be the source of power for all interconnected devices and items. All equipment associated with the UCP shall be ready for service after connection of conductors to equipment, controls, and stations.

D. All internal wiring shall be factory-installed and shall be contained in plastic raceways or troughs having removable covers. Wiring to door-mounted devices shall be extra flexible and anchored to doors using wire anchors cemented in place. Exposed terminals of door-mounted devices shall be guarded to prevent accidental personnel contact with energized terminals.

E. Enclosures shall meet the requirements of AREA CLASSIFICATON and ENCLOSURES specified in Section 16050 – Electrical Work, General.

F. Main disconnecting mean (circuit breaker rated 65 KAIC unless otherwise shown on the drawings) shall be provided and shall have a door-mounted handle interlocked with the door, and shall be provided with manual defeater unless otherwise specified or shown.

G. The UCP manufacturer shall provide short-circuit and overload protection for the system and equipment connected and controlled by the panel, unless otherwise shown on the drawings or specified elsewhere.

H. Identification of panel-mounted devices, conductors, and electrical components shall meet the requirements specified in Section 16050.

I. All panel-mounted devices shall be mounted a minimum of 3 feet above finished floor elevation.


2.02 PANEL COMPONENTS

A. Pushbuttons, selector switches, and pilot lights shall be of the heavy-duty, oil-tight type. Miniature style devices are not acceptable. Devices shall be as manufactured by G.E, Square D, Allen-Bradley or equal.

1. Lens colors shall be red for "run," or “ closed “; green for "stopped “, “ open “, and amber for alarm or shutdown.

2. Pilot lights shall be full voltage LED cluster style.

3. Provide hazardous location type pilot devices in classified locations.

A. Relays shall be 3 PDT with 10 amp contacts, plug-in type utilizing rectangular blades and provided with sockets for screw-type termination and hold-down clips. Relays shall be as manufactured by Square D, Potter Brumfield, Allen-Bradley or equal.

B. Elapsed time meters shall be non-re-settable type read to a maximum of 99999.9 hours and shall be as manufactured by G.E., or equal.

C. Combination magnetic starters shall meet the following requirements:

1. Minimum size of starter shall be NEMA-1. IEC or dual NEMA / IEC rated type are not acceptable.

2. Starter shall be combination starters with magnetic only instantaneous trip circuit breakers such as G.E., "Mag-Break," or equal.

3. Control power transformer shall be provided, with primary and secondary fuses, 120 VAC maximum control voltage.

D. Terminal strips shall be provided for all panels and shall be of the flanged fork or ring lug type suitable for No. 12 A.W.G. stranded wire minimum. Provide 25 percent spare terminals in each panel.

E. Current-to-current converter/isolators shall be 4-20 mA input, 4-20 mA output for operation from 120 volt AC power, and shall be by Moore, A.G.M., or equal.

F. Process alarm relays (current trip relay) shall have a 4-20 mA input and two (2) independent SPST contact outputs as manufactured by A.G.M., Moore, or equal. Power input shall be 120 VAC.

G. Digital indicators shall have 4-20 mA input and shall display the signal in process units. 0-100% as a displayed signal shall only be acceptable to indicate speed. Indicators shall be as manufactured by Newport, Red Lion, or equal for operation from 120 VAC. Provide splash-proof covers in NEMA 4X panels, and viewing windows in NEMA 7 panels.

H. Single and Multi-Loop Controllers shall have the following features:

1. Analog and digital inputs and outputs as specified, or shown on the P & ID.

2. PID control algorithms.


3. Graphic display indicating input, setpoints and all alarms.

4. Operate on 120 VAC. Face shall be approximately 3"W x 6"H.

5. Unit shall be provided completely programmed and ready for use. Include a portable programming device.

6. Provide window kit for the UCP enclosure over all controllers.

I. Manual loading stations shall have 4-20 mA outputs and 4-20 mA inputs for remote or auto control. Switching from local and remote or from manual to auto shall be by means of controls on the face of the unit or by isolated contact closure as shown on the elementary schematics. Provide window kit for the enclosure over all manual loading stations.

J. Time delay relays shall be combination “on delay” and “off delay” (selectable) with adjustable timing ranges. Provide socket with screw terminal connections and retaining strap.

K. Reset Timers: Reset timers shall be synchronous motor driven with a solenoid operated clutch. Timer shall be on-delay for semi-flush panel-mounting. The timers shall be rated 120-volt, 60 Hz, with 10-amp rated contacts, and with time range as shown.

L. Any relays, devices and switches, etc, located in Hazardous Areas and connected to the panels shall be explosion proof type or intrinsically relay or barrier shall be installed in the unit control panel.

M. Programmable logic controller(s) (PLC’s) may be supplied with panel, in lieu of relays, provided the programmable logic controllers match the PLCs furnished under Section 13300 - Process Control and Instrumentation Systems.

2.03 FACTORY TESTING

A. Each UCP shall be factory assembled, and tested for sequence of operation prior to jobsite delivery. Depending on the complexity of the UCP, the Client has the options to witness a scheduled factory testing of said UCP. The Vendor shall notify the Client 2 weeks in advance of any scheduled factory testing.

2.04 SPARE PARTS

A. Provide a minimum of 10% spare lamps (minimum 2) and one spare lens for each color pilot lamp in each panel.


PART 3 - EXECUTION

3.01 INSTALLATION

A. UCP shall be installed in accordance with the requirements specified in Section 16050 and in accordance with the Manufacturer's recommendations.

B. UCP shall be protected at the jobsite from loss, damage, and the effects of weather. Stations shall be stored in an indoor, dry location. Heating shall be provided in areas subject to corrosion, and humidity.

C. Panel interiors, and exteriors shall be cleaned, and coatings shall be touched up to match original finish upon completion of the work.

D. Conduit, conductors, and terminations shall be installed in accordance with the requirements specified in relevant section of this specification.

3.02 FIELD TESTING

A. Each UCP shall be tested again for functional operation in the field after the connection of external conductors, and prior to equipment startup.

- END OF SECTION 16485 -

SECTION 16553 – POWER INVERTERS

PART 1 GENERAL

1.01 SUMMARY

A. Section Includes:

1. Manufacturing, design, and installation requirements for:

a. Grid-connected power inverters.

b. Inverter equipment pads.

c. Inverter sunshade structures.

B. Related Sections:

1. Contract Documents are a single integrated document, and as such all Divisions and Sections apply. It is the responsibility of the SUPPLIER and its Sub-Suppliers to review all sections to ensure a complete and coordinated project.

1.02 REFERENCES

A. Furnish and install power inverters, inverter equipment pads, and inverter sunshade structures in accordance with the applicable sections of the current version of the following documents. Where a conflict exists between the following documents and statements made herein, the statements herein shall take precedence.

1. IEEE-1547: Standard for Interconnecting Distributed Resources with Electric Power Systems.

2. ASME.

3. National Electric Code (NFPA-720).

4. OSHA.

5. International Building Code (IBC) and California Building Code (CBC).

1.03 DEFINITIONS

A. Definitions of terms and other considerations as set forth in the:

1. National Electric Code (NEC).

2. Institute of Electrical and Electronic Engineers (IEEE).

3. American National Standards Institute (ANSI).

4. Underwriters Laboratories (UL).

5. National Electrical Manufacturers Association (NEMA).

6. American Society of Testing and Materials (ASTM).

7. American Society of Mechanical Engineers (ASME).

B. MPPT: Maximum Power Point Tracking.

1.04 SYSTEM DESCRIPTION

A. Provide all power inverters required to convert all DC power produced by the RPGS furnished under this contract to AC power.

B. Provide a concrete equipment pad for every power inverter provided under this Contract:

1. Where multiple power inverters are installed in the same location a single, common equipment pad may be furnished and installed.

C. Provide a sunshade structure for every power inverter provided under this contract:

1. Where multiple power inverters are installed in the same location a single, common sunshade structure may be furnished and installed.

1.05 SUBMITTALS

A. Furnish complete submittals in accordance with Sections 01120 and 16050.

B. Product data:

1. Manufacturer of the inverter.

2. Manufacturer of all major components of the inverter.

3. Dimensions:

a. Height.

b. Width.

c. Depth.

4. Weight.

5. Nameplate schedule.

6. Electrical characteristics including but not limited to:

a. AC power output.

b. AC voltage output.

c. Nominal output current per phase.

d. Maximum fault current per phase.

e. Nominal DC current.

f. California Energy Commission rated efficiency.

g. Nominal Maximum Power Point DC voltage range.

h. AC voltage range setpoints.

7. Catalog cut sheets for major components.

8. List of recommended spare parts, including price list and contact information for the nearest supplier for all listed spare parts.

C. Design Drawings and Calculations:

1. Complete plan and elevation drawings and calculations showing all dimensions, reinforcement requirements, welding connections and details for all equipment pads and sunshade structures. Drawings and calculations shall be stamped by a Professional Engineer registered in the State where the equipment will be installed.

D. Shop Drawings:

1. Complete plan and elevation drawings showing:

a. All dimensions.

b. Panel, sub-panel, and component layout.

c. Conduit connections.

d. Required clearance around equipment.

2. Complete schematic, wiring and interconnection diagrams showing connections to both internal and external devices:

a. Include terminal numbers and wire numbers on all wiring diagrams.

3. Complete single-line and three-line diagrams including, but not limited to, disconnects, fuses, control devices, fuel cell stacks, interconnection wiring and other equipment comprising the complete RPGS.

a. Clearly indicated on the Drawings the electrical ratings associated with all components

4. Complete plan and elevation drawings showing all dimensions, reinforcement requirements, welding connections and details for all equipment pads and sunshade structures.

E. Installation Instructions:

1. Furnish manufacturer’s instructions for storage, handling, protection, examination, and preparation of inverters, equipment pads, and sunshade structures.

2. Furnish written instructions describing the complete installation and/or assembly of inverters, equipment pads, and sunshade structures including moving and setting into place.

3. Furnish anchorage instructions and requirements for the inverters and sunshade structures, stamped by a Professional Engineer registered in the State where the equipment will be installed and in accordance with:

a. Section 01612 - Seismic Design Criteria.

b. Section 01614 - Wind Design Criteria.

4. Furnish torque specifications for all wiring connections and terminations.

F. Test Reports.

G. Manufacturer’s Field Reports:

1. Furnish written verification from the inverter manufacturer that all inverters have been installed in accordance with the manufacturer’s requirements.

2. Furnish a report listing the settings of all adjustable parameters after start-up of the complete RPGS.

H. Operation and maintenance data:

1. Furnish operation and maintenance manual in accordance with Section 01782.

1.06 DELIVERY, STORAGE, AND HANDLING

A. As specified in Section 16050.

1.07 PROJECT/SITE CONDITIONS

A. Provide inverters, equipment pads, and sunshade structures suitable for permanent installation and continuous operation in the project site conditions as specified in Sections 01612, 01614, and 16050.

1.08 WARRANTY

A. For a period of ten (10) years after final acceptance of the project, the manufacturer shall warrant its products against any defects in workmanship, materials, or performance. The manufacturer shall promptly, within ten (10) days of notification by the OWNER of a defect, perform services to correct said defect by repair or replacement of equipment or parts as may be necessary to obtain compliance to the design and performance requirements of the contract documents. Following repair or replacement, manufacturer shall retest the RPGS and perform such additional testing to place the complete system in satisfactory operation and obtain compliance acceptance from the OWNER.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Power Inverters.

1. Xantrex Technology, Inc.

2. SatCon Power Systems Canada Ltd.

3. Or equal.

B. All power inverters provided under this Contract shall be manufactured by a manufacturer approved by California Energy Commission (CEC).

C. All power inverters provided under this Contract shall comply with the requirements specified in the latest version of the SGIP Handbook.

D. All power inverters provided under this Contract shall be of the same manufacturer.

2.02 MATERIALS

A. Reinforced Concrete:

1. Shall have minimum 4000 psi compressive strength (28 days) meeting the requirements of the International Building Code (IBC).

2.03 EQUIPMENT

A. Power inverters:

1. Provide maximum power point tracking type inverters that operate at the voltage that will result in maximum power production from the RPGS at all times.

2. Inverters must be eligible for use in the California Energy Commission’s California Solar Initiative Program.

a. List of eligible inverters is available online at http://www.consumerenergycenter.org/cgi-bin/eligible_inverters.cgi

3. Input voltage:

a. Nominal MPPT DC voltage range: 330 to 600 VDC.

b. Maximum open circuit voltage: 600 VDC.

c. Output voltage: 480 VAC plus or minus 10 percent.

d. Output connection: 3-phase, grounded wye.

e. Output frequency range: 59.5 - 60.5 Hz.

f. Output power factor: 1.0.

g. Output Total Harmonic Voltage Distortion: less than 3 percent.

h. Peak efficiency range: 95 - 97 percent.

4. Minimum output AC power rating: 225 kWac.

5. Provide inverters with a communications port for remote monitoring of the following inverter parameters:

a. Instantaneous DC input voltage.

b. Instantaneous DC input current.

B. Provide power inverters suitable for:

1. Interconnection with the SCE electrical grid via net metering

2. Permanent installation.

3. Unattended, automatic, continuous, and stable operation over the range of voltages, currents, and power levels for the size and type of power generation system used.

2.04 COMPONENTS

A. Monitoring and control:

1. Furnish inverters with a communications port for remote monitoring of the following inverter parameters:

a. Instantaneous DC input voltage.

b. Instantaneous DC input current.

c. Instantaneous AC output voltage.

d. Instantaneous AC output current.

e. Operational status.

f. Summary alarm.

g. Individual alarms.

2. Furnish one of the following inverter communications network protocols, no equals or substitutes will be considered:

a. Ethernet.

B. DC Disconnect:

1. Furnish a DC disconnect with:

a. Ground fault protection.

b. Short-circuit protection.

c. Overload protection.

2. Furnish DC disconnect with a lockable, NEMA 4X stainless steel enclosure suitable for installation in the project site conditions as specified in Section 16050.

3. If the SUPPLIER’s design calls for the inverter to be installed more than 25 feet away from the RPGS that it is connected to, or if there is not a clear line of sight between the inverter and the RPGS, furnish two separate DC disconnects; one located next to the RPGS and one located next to the inverter.

4. Provide a flange mounted disconnect at the inverter, if located as part of the inverter assembly.

C. AC Disconnect:

1. Furnish an AC circuit breaker disconnecting means with:

a. Ground fault protection.

b. Short-circuit protection.

c. Overload protection.

2. Provide AC circuit breaker disconnect with a lockable, NEMA 4X stainless steel enclosure suitable for installation in the project site conditions as specified in Section 16050.

3. Provide an AC circuit breaker disconnect within or directly adjacent to the inverter enclosure.

a. Externally operable if installed within the inverter enclosure.

b. flange mounted at the inverter, if located as part of the inverter assembly.

D. Provide all electrical components, including overcurrent protection, disconnects, surge suppression devices, conduit, wiring and terminals that have UL or equivalent listing and have appropriate voltage, current, and temperature ratings for the intended application.

E. Wiring:

1. Provide wiring rated for operation at 600 volts, 90 degrees Celsius, and in wet locations.

2. All current carrying conductors must be enclosed in conduit.

a. With the exception of grounding conductors, the use of any exposed conductors or cabling is not acceptable.

3. All terminations must use listed box terminal or compression type connections.

a. Twist on wire splices, crimped, soldered or taped connections are not acceptable.

4. The AC output neutral shall be electrically isolated from the inverter chassis.

5. Provide an equipment ground terminal for bonding to the inverter chassis.

F. Conduit:

1. Galvanized Rigid Conduit.

2. Liquid Tight Flexible Metallic Conduit:

a. Continuous length shall not exceed 18 inches.

G. Overcurrent Protection Devices:

1. Size the trip ratings no greater that the derated ampacity of the conductors protected by the device.

2.05 ACCESSORIES

A. Inverter Enclosure:

1. Lockable.

2. Stainless steel, NEMA 4X or 3R with no openings.

3. Integral temperature and humidity controls as required:

a. Provide a split cooling system such that air within the enclosure is cooled and self-contained and not mixed with air external to the enclosure.

b. The temperature inside the enclosure shall not exceed 10 degrees Fahrenheit below the lowest maximum temperature rating of any device inside the enclosure.

c. The temperature inside the enclosure shall not fall below 10 degrees Fahrenheit above the highest minimum temperature rating of any device inside the enclosure.

4. Provisions for hoisting, jacking, and forklift handling.

5. Suitable for installation in the project site conditions as specified in Section 16050.

2.06 ANCILLARY EQUIPMENT

A. Provide inverter equipment pads:

1. Suitable for the project site conditions as specified in Sections 01612, 01614, and 16050.

2, With a minimum height above grade of 8 inches.

3. Extending six inches beyond the outer edges of equipment located on the pad.

4. In accordance with inverter manufacturer anchoring and installation instructions.

5. With provisions for conduit entry into the bottom of inverter enclosure:

a. Number, size, and location of conduit entries shall be coordinated with the specific inverter manufacturer.

B. Provide inverter sunshade structures:

1. Suitable for the project site conditions as specified in Sections 01612, 01614, and 16050.

2. Designed to minimize the amount of direct sunlight received by the inverter enclosure(s).

3. Designed to cover all enclosures associated with the power inverters.

4. Designed to comply with inverter manufacturer clearance and access requirements.

5. Extending to the edges of the structural pad.

2.07 FABRICATION

A. Inverters.

1. Fabricate inverters using replaceable subassemblies:

a. Plug-in printed circuit board assemblies.

b. Interchangeable assemblies and like components.

2.08 SOURCE QUALITY CONTROL

A. Provide all materials and components comprising the inverter, equipment pad, and sunshade structure that are new, of current manufacture, high grade and free from all defects and that have not been in prior service except as required for factory testing.

PART 3 EXECUTION

3.01 INSTALLATION

A. Installation of all equipment and materials shall be in accordance with:

1. Manufacturer’s recommendations.

2. Requirements for suitable installation in the project site conditions as specified in Sections 01612, 01614, and 16050.

3. All applicable building codes.


A. Furnish the services of an Inverter Manufacturer factory technician for startup assistance and training.

B. Inverter Manufacturer factory technician to be present at the site for a five 8 hour days to furnish the following services.

1. Inspection, startup, field adjustment:

a. Supervise the following and submit written certification that the equipment and controls have been properly installed, aligned, adjusted, and readied for operation:

1) Installation of the equipment.

2) Inspection, checking, and adjusting of the equipment.

3) Startup and field testing for proper operation.

4) Performing field adjustments to ensure that the equipment installation and operation comply with the requirements of the Contract Documents.

2. Field testing:

a. Perform all testing, checkout, and startup of the inverter equipment.

C. Under no circumstances is the inverter, or any of its components, to be energized without authorization from the Inverter Manufacturer's factory technician.

3.03 DEMONSTRATION

A. After installation is complete, demonstrate the operation of all inverters to the ENGINEER’S and OWNER’S satisfaction.

B. Training:

1. Furnish classroom level instruction on the operation and maintenance of the inverter for the OWNER’S operation and maintenance staff.

a. Operator’s training session detailing the complete operations and control of the Inverter 1) Two separate 4-hour sessions. 2) Scheduled on different days so that all operations staff may attend either session.

b. Maintenance training session detailing the complete maintenance and troubleshooting of the Inverter. 1) One 8-hour session. 2) Scheduled with the Owner so that the maximum number of maintenance staff can attend.

c. Instruction shall occur at the OWNER’s facility and shall utilize the actual inverters installed at the site.

END OF SECTION

City of Visalia – WCP Upgrades RPGS Pre-selection 16960-1 Electrical Equipment Testing December 2010

SECTION 16960 – ELECTRICAL EQUIPMENT TESTING

PART 1 – GENERAL

1.01 DESCRIPTION

Requirements of this RFP, Division 1, and Section 16100 form a part of this Section.

A. Work Included in This Section.

a. Testing of all electrical equipment and components.

1.02 REFERENCES

The inspections and tests shall be in accordance with the following applicable codes and standards except as provided otherwise herein.

A. National Electrical Code - NEC (NFPA 70).

B. National Electrical Manufacturer’s Association - NEMA.

C. American Society for Testing and Materials - ASTM.

D. Institute of Electrical and Electronic Engineers - IEEE.

E. National Electrical Testing Association - NETA.

F. American National Standards Institute - ANSI.

G. State and Local Codes and Ordinances.

H. Insulated Cable Engineers Association - ICEA.

I. OSHA Part 1910; Subpart S, 1910.308.

J. National Fire Protection Association - NFPA.

1.03 SUBMITTALS

A. Prior to the Start of Work

1. Written test procedures by the manufacturer. The CITY shall be provided a copy of the test procedures.

2. Manufacturer’s Test and Report Forms.

B. Upon completion of testing provide formal Test Report to include the following:

1. Summary of test.

2. Description of equipment tested.


3. Description of test.

4. Test results.

a. The following is a list of reports and forms that the manufacturer shall use in reporting the results:

1. Instrument Calibration Test and Data Sheet (2 sheets).

2. Insulation/Megger Resistance Test Report.

3. Polarity Index Test Results (for 200 hp or larger motor).

5. Conclusions and recommendations.

6. Appendix, including appropriate completed test forms.

7. List of test equipment used and calibration date.

1.04 SYSTEM DESCRIPTION

A. The inspections and tests shall utilize the following references.

1. Manufacturer’s instruction manuals applicable to each particular apparatus.

2. Drawings submitted by manufacturers and vendors.

B. All instruments used to evaluate electrical performance shall meet Specifications for Test Instruments (refer to Part 2 of this Specification).

C. Electrical performance tests shall include the following:

1. 600 volt feeder cables.

2. Induction motors.

D. The EQUIPMENT SUPPLIER shall notify the CITY when equipment becomes available for electrical tests. Work shall be coordinated to expedite project scheduling.

E. The EQUIPMENT SUPPLIER shall notify the CITY prior to commencement of any testing.

F. Set points shall be noted on all calibration stickers.

G. Any system material or workmanship, which is found defective on the basis of electrical tests shall be replaced and retested at no additional cost to the CITY.

H. The manufacturer shall maintain a written record of all tests and upon completion of the project, assemble and certify a final test report.


PART 2 – PRODUCTS

2.01 TEST INSTRUMENT TRACEABILITY

A. The manufacturer shall have a calibration program, which maintains applicable test instrumentation within rated accuracy.

B. The accuracy shall be traceable to the National Institute for Standards and Technology in an unbroken chain.

C. Instruments shall be calibrated in accordance with the following frequency schedule:

a. Laboratory instruments - 12 months.

b. Leased specialty equipment - 12 months. (Where accuracy is guaranteed in writing by the lessor.)

D. Dated calibration labels shall be visible on all test equipment.

E. Records must be kept up to date which show date and results of all instruments calibrated or tested.

F. An up-to-date instrument calibration instruction and procedure will be maintained for each test instrument.


3.01 SAFETY AND PRECAUTIONS

A. Safety practices shall include, but are not limited to, the following requirements:

1. Occupational Safety and Health Act - OSHA.

2. Accident Prevention Manual for Industrial Operations, Seventh Edition, National Safety Council, Chapter 4.

3. Applicable State and local safety operating procedures.

4. NETA Safety/Accident Prevention Program.

5. National Fire Protection Association - NFPA 70 (NEC).

6. National Fire Protection Association - National Electrical Safety Code.


3.02 TABLES

Table 16960.1 – Insulation Resistance Test Voltage

Maximum Voltage Rating of Equipment

Minimum Test Voltage, DC

Minimum Insulation Resistance in Mega-ohms

250 500 25 600 1,000 100

5,000 2,500 1,000 8,000 2,500 2,000 15,000 2,500 5,000

Values of insulation resistance less than manufacturer’s minimum or kV + 1 in megohms should be investigated. Overpotential tests should not proceed until insulation resistance levels are raised to said minimum.

Table 16960.2 – Insulation Resistance Conversion Factors for Conversion of Test Temperature to 20°C

Temperature Transformer °C °F Oil Dry 0 32 .25 .40 5 41 .36 .45 10 50 .50 .50 15 59 .75 .75 20 68 1.00 1.00 25 77 1.40 1.30 30 86 1.98 1.60 35 95 2.80 2.05 40 104 3.95 2.50 45 113 5.60 3.25 50 122 7.85 4.00 55 131 11.20 5.20 60 140 15.85 6.40 65 149 22.40 8.70 70 158 31.75 10.00 75 167 44.70 13.00 80 176 63.50 16.00


APPENDIX K

REFERENCE DRAWINGS