NC0047384_Application (ATC) Specs_20200108

August 2017
WATER RECLAMATION FACILITY
BNR UPGRADE PROJECT
City of Greensboro
North Carolina
Water Resources Department
Package 4
BID DOCUMENTS
Contract Number- 2016-002A
31221-009-CV02.cdr
GREENSBORO

31221-009\00003: 9-26-17 00003-1 WRF BNR UPGRADE PROJECT
ATC MODIFICATION - BLOWER TZ OSBORNE PACKAGE 4

T.Z. Osborne Water Reclamation Facility
Package 4: Biological Nutrient Removal

SECTION 00003

TABLE OF CONTENTS

TECHNICAL SPECIFICATIONS

PACKAGE NO. 4 – BLOWER REPLACEMENT

Division

Section

Title

11 EQUIPMENT GENERAL PROVISION
11184 Integral-Gear Single-Stage Centrifugal Blowers

15 MECHANICAL
15100 Valve Operators and Electric Valve Actuators

16 ELECTRICAL
16121 Medium Voltage Cable
16305 Medium Voltage Motor Control Centers – RVSS Starter

17 CONTROL AND INFORMATION SYSTEMS
17060 Signal Coordination Requirements
17190 Uninterruptible Power Systems

31221-009\11183: 11-06-18 11183-1 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
SECTION 11184

INTEGRAL-GEAR SINGLE-STAGE CENTRIFUGAL BLOWERS

PART 1 -- GENERAL

1.01 THE REQUIREMENT

A. The Supplier shall furnish one electric motor driven, integral-gear single-stage centrifugal
blower unit including electric motor, steel base, discharge expansion joint, discharge cone,
discharge valve, check valve, inlet filters/silencers, blow-off valve, blow-off check valve,
valve actuators, control panels and all necessary auxiliary equipment and accessories.
Integral-gear single-stage centrifugal blowers shall be Howden Roots-Turblex Model
KA66-SV-GL400.

B. All equipment specified in this section shall be designed and furnished by the blower
manufacturer, who shall be responsible for the suitability and compatibility of all included
equipment.

1.02 SUBMITTALS

A. The Supplier shall submit seven copies of Shop Drawings, Operation and Maintenance
Instructions and other information for the blower systems, and all equipment specified
herein within 14 weeks after a purchase order is issued.

B. Shop Drawings shall include complete erection, installation, and adjustment instructions
and recommendations, electrical characteristics, connection diagrams and schematics
identifying all items requiring electrical control and power. Installation instructions shall be
complete including unloading, check-out following shipment, storage, handling, assembly,
and anchorage, and start-up instructions.

C. Shop Drawings shall include weights of all system components and total weight of the
operating blowers.

D. The performance characteristic curves for the blower shall be submitted with the shop
drawings. Performance curves shall be developed in terms of standard conditions of 14.7
psia, 68°F, and 36% relative humidity, as well as the design criteria specified in Paragraph
2.02, and the curves shall show standard horsepower draw over the range of SCFM flow
rates for various pressure conditions. Additional operational data for the blower shall be
submitted including recommended temperature and vibration alarm settings and
operational limits.

E. A complete description of the protective coating system to be used for all components,
prior to shipment and after installation shall be submitted with the shop drawings.

F. A minimum of seven copies of certified test reports including all details of apparatus,
procedure, and results and all required calculations shall be submitted for each shop test
conducted. Reports for shop tests shall be approved by the Engineer prior to shipment.

31221-009\11183: 11-06-18 11183-2 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
G. The Supplier shall submit a performance guarantee and two year warranty in accordance
with Paragraph 1.04.

1.03 SERVICES OF MANUFACTURER'S REPRESENTATIVE

A. The Supplier shall furnish experienced start-up/service personnel to inspect the final
installation and supervise the field start-up tests of the equipment. The services shall be
provided for a minimum of two (2), eight-hour (8-hour) days for each blower. If there are
difficulties in operation of the equipment due to the Manufacturer's fabrication or
Contractor’s installation, additional service shall be provided at no extra cost to the Owner.

1. Provide, as a minimum, the following field services:

a. Verify proper connection of piping and installation of accessories

b. Verify alignment of the motor, blower, and coupling

c. Check leveling of blower base

d. Confirm proper wiring of all instruments and field wired items

e. Run motor uncoupled for up to one-half (1/2) hour to verify motor operation
and check magnetic center for proper marking/location

2. A minimum four (4) hour field run test shall demonstrate that, under all conditions
of operation, each unit:

a. Has not been damaged by transportation or installation

b. Has been properly installed

c. Has no mechanical defects

d. Has fully functional instrumentation, properly calibrated and set

e. Will start, run, and stop in the prescribed manner

f. Will run through the entire range of specified pressure and flow

g. Has the proper shutdown sequence of standard stop, soft stop, and
emergency stop

h. Is free of overheating of any parts

i. Is free of objectionable vibration and noise

j. Is free of overloading of any parts

k. Demonstrates the simultaneous and continuous efficiency optimization by
altering the inlet guide vane position based on inlet temperature, differential
pressure, and capacity

31221-009\11183: 11-06-18 11183-3 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4

3. Field demonstration testing shall be conducted after the installation of all
equipment has been completed and the equipment has operated for a sufficient
period to make all desirable corrections and adjustments.

B. A factory representative shall be provided to instruct representatives of the Owner on
proper operation and maintenance, including start-up and shut-down procedures, proper
lubrication practices, and troubleshooting of all equipment.

1.04 QUALITY ASSURANCE

A. The Supplier shall warrant the integral-gear single-stage centrifugal blowers, motors,
control panels, valves, and accessories for materials and workmanship for a period of two
(2) years after start-up A 24-month warranty shall begin upon successful completion of
startup and certification for full scale operation by the Supplier. Warranty shall be
submitted with the Shop Drawings. The Supplier shall pay all labor and material costs to
replace defective or unsatisfactory equipment during the warranty period at no cost to the
Owner.

B. The materials covered by the Specifications shall be standard equipment of proven
reliability. The equipment furnished shall be designed, constructed, and installed in
accordance with the best practices and methods.

C. All materials shall be new and both workmanship and materials shall be of the very best
quality, entirely suitable for the service to which the units are to be subjected and shall
conform to all applicable sections of these specifications. All parts of duplicate machines
shall be interchangeable without modification. The construction of the blowers shall be
such that the blowers will not be damaged during continuous operation and will not have
undue vibration above the blower's surge limit. The design and construction of the blowers
shall not cause any unbalanced floor loadings.

D. Equipment and appurtenances shall be designed in conformance with ASTM, ASME,
AIEE, and NEMA standards.

1.05 COORDINATION OF DELIVERIES AND RESPONSIBILITY FOR STORAGE

A. The Contractor shall be responsible for scheduling and coordinating deliveries of blowers
with the manufacturer to minimize the time that blowers are on-site and not installed in the
existing Blower Building per Section 01520. Contractor shall be required to place blowers
onto their pads within 24 hours after arrival of the blowers at the site. Contractor shall
coordinate deliveries directly with the Supplier according to Contractor’s construction
schedule such that blowers are shipped from Springfield, MO when production and testing
are completed and no storage of blowers in Springfield, MO is required. Failure of the
Contractor to properly coordinate or maintain schedule for delivery of the blowers will
require storage of the blowers at Howden Roots shop in Springfield, MO at no additional
cost to the Owner. Costs for storage beyond 30 days past the date that blowers are ready
to be shipped are not included in Howden-Roots quotation in the Proposal section. The
Contractor shall be responsible for any additional cost incurred for storage of blowers at
Howden Roots shop in Springfield, MO as follows:

31221-009\11183: 11-06-18 11183-4 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
Number of Blowers Stored $/Month Storage Charge
1 600

PART 2 -- PRODUCTS

2.01 GENERAL

A. The aeration blowers shall be single-stage, centrifugal type with integral gear box. The
blowers shall be driven at the gearbox input shaft by direct coupled electric motors with
flexible couplings and guards as specified herein.

2.02 PERFORMANCE REQUIREMENTS

A. The proposed blowers shall satisfy the conditions of service and requirements listed
below. Standard cubic feet per minute (SCFM) is defined as the delivered airflow rate at
the blower discharge in terms of standard conditions (68°F, 14.7 psia and 36% relative
humidity). The blowers shall be capable of delivering the specified design flow rate per
blower (in SCFM) at the specified discharge pressure at the minimum inlet pressure,
design maximum air temperature and relative humidity at the design maximum
temperature as specified for the blower primary design point below. The design air
temperatures and inlet pressure listed shall be at the inlet to the blower. Motor horsepower
shall not exceed the maximum rated motor horsepower specified. The blowers shall be
capable of turndown to the minimum flow rate specified below throughout the ambient
temperature range specified.
B.

Ambient Conditions
Site Elevation, ft 750
Ambient Barometric Pressure, psia 14.31
Ambient Temperature Range, °F 0 - 104
Ambient Relative Humidity Range, % 0 - 100
Design Inlet Conditions
Minimum Inlet Pressure, psia 14.01
Design Maximum Air Temperature, °F 93
Relative Humidity at Design Max. Temperature, % 42
Capacity Requirements
Number of Blowers 1
Mass Flow Rate/Blower, SCFM 33,200
Volumetric Flow Rate/Blower at Design Inlet, ICFM 37,000
Discharge Pressure, psig 10.52
Discharge Pressure (absolute), psia 24.83
Minimum Flow Rate/Blower, SCFM 15,000
Minimum Surge Pressure, psig 11.02

31221-009\11183: 11-06-18 11183-5 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
Motor Requirements
Voltage, V 4160
Enclosure Type WPII
Maximum Rated Power, horsepower 2,000

B. Surge is defined herein as the airflow rate at which the blower exhibits the first indication
of pressure pulsations or flow reversal. The blowers shall not surge when airflows are at
or above the minimum flow rate per blower and the discharge pressure is below the
minimum surge pressure specified above for the ambient temperature and humidity
ranges provided when throttled using a combination of discharge diffuser and inlet guide
vanes.

2.03 BLOWER MOTORS

A. The blower manufacturer shall be responsible for furnishing new electric motors for the
blowers. The manufacturer shall be responsible for the proper selection, testing,
installation, and operation of the motors and for coordinating the motors with the
compressor equipment. Motors shall be premium efficiency motors.

B. Motor shall be horizontal squirrel cage induction motor in WP II enclosure designed in
accordance with the latest ANSI, NEMA, and IEEE standards. Motor shall be 2,000
horsepower, 4160 volts, 3 phase, 60 Hz. Motor shall be designed and manufactured for
continuous duty for operation under the following conditions:

1. Altitude below 3300 ft.

2. Ambient temperature ranging from 0°F to 104°F.

3. Voltage variations of plus or minus 10 percent.

4. Frequency variation of plus or minus 5 percent.

5. Combined voltage and frequency variation of plus or minus 10 percent with
frequency variation not exceeding plus or minus 5 percent.

C. The motor shall provide a service factor of 1.15. Motor speed shall not exceed 3,600 rpm.

D. Motor torque characteristics shall be at least 20 percent greater than the maximum full
load torque requirements over the full range of operating conditions from start-up to full
load. Motor shall be suitable for accelerating the blower to full speed using a reduced
voltage, autotransformer or solid-state type starter (starters by others) with inrush limited
to acceptable levels.

E. Motor enclosure shall be WP II. Motor shall be designed for quiet operation. Motor sound
pressure shall not exceed 85 db at 3 feet from the motor in unloaded condition.

F. Motor shall provide premium efficiencies and power factors throughout the operating
range. The power factors specified shall be achieved without the use of power factor

31221-009\11183: 11-06-18 11183-6 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
correction capacitors. Motor shall provide minimum efficiencies and power factors as
follows:

Percent Full Load
Minimum Efficiency
Percent
Minimum Power
Factor Percent
100 95.7 88.0
75 96.0 87.0
50 95.7 83.3

Efficiencies and power factors for each motor shall be verified by shop testing as specified.

G. Motor insulation shall be Class F or H insulation; however, temperature rise shall be limited
to that of Class B insulation. Manufacturer's premium grade insulation shall be used.

H. The stator shall be assembled from high grade electrical sheet steel laminations
adequately secured together. Stator windings and end turn connections shall be fully
braced to withstand all mechanical, electrical, and thermal stresses. The shaft shall be
made of high grade machine steel or steel forging and of size and design adequate to
withstand the load stresses. The rotor shall be fabricated of one piece die-cast aluminum
or copper/copper alloy adequately fastened together and to the shaft.

I. Bearings shall be oil lubricated sleeve bearings with oil level sight glass. Split bearing
housings shall be used such that bearings can be inspected or replaced without disturbing
alignment. Oil shall be distributed uniformly over the bearing and shaft journal regardless
of direction of rotation. Motor shall be supplied with constant level oilers to maintain oil
level in the bearing housing. Oil level switches shall be furnished with the motor for alarm
and shutdown to prevent potential damage from insufficient oil.

J. Each motor shall be provided with an oversized terminal box with space for connections
and shall be constructed of cast iron or fabricated steel, neoprene gasketed and bolted.
The motor leads shall be permanently marked in agreement with the connection diagram.
Motor terminal box shall include lightning arrestors, surge capacitors, and differential
current transformers that shall be factory-mounted and prewired. Current transformer
leads shall be prewired to terminal strips mounted in a separate low voltage terminal
compartment. Arrestors and capacitors shall be rated in accordance with IEEE Std. 141-
1993-6.7.3.9.2. The three stator phase leads shall be provided with 2-hole pad connectors
for the incoming cables.

K. Motor shall be designed and manufactured for operation in the direction required for the
blowers. The phase sequence shall be marked permanently and plainly inside the stator
lead junction box or on the outside of the motor.

L. Motor shall be provided with six platinum resistance temperature detectors embedded in
the stator winding. RTDs shall be 100 ohm, platinum, 3 wire type having a stability of
better than 0.2 percent of maximum exposed temperature for one year of service, or 0.25
degrees Celsius, whichever is greater. Two detectors per phase are required and shall
be placed at locations determined to give close approximation of the hottest spot
temperatures.

31221-009\11183: 11-06-18 11183-7 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
M. Motors shall be supplied with space heaters for 120V operation.

N. Motor bearings shall be provided with vibration detectors and RTD's mounted in 316
stainless steel thermowells or mounted in such a way that removal and/or replacement is
possible without complete motor disassembly. RTD's and vibration monitoring equipment
shall be as specified below.

2.04 BASE

A. A welded steel fabricated base shall be provided for mounting each new blower, gear box,
electric motor, lubricating system, cooling system and accessories. The base shall be
fabricated A36 steel in a rigid box section shape with drip lip, lifting eyelets, and sufficient
rigidity to permit lifting with a 4-point lift with all equipment mounted. The box section shall
be properly ribbed for stiffness and present large bearing areas for carrying the load on
the foundation. The base shall contain the oil reservoir. Machined pads shall be provided
as required to properly level the base. The base shall be rigid to prevent deflection during
start-up and normal operation that would affect alignment. Spring mount vibration isolation
pads shall be provided between the concrete pad and the base of the blower unit.

2.05 BLOWER AND INTEGRAL GEARBOX CASING

A. Blower casing shall be made of ductile iron ASTM A536, 60-40-18 or close grained cast
iron ASTM A278, Class 30, have a maximum continuous duty design temperature of
400°F, and a design pressure of 50 psig. Air inlet shall be axial through an annular inlet.
The discharge flange shall be faced and drilled to ANSI B16.1, Class 125 pound. A
threaded port shall be provided at the lowest point of the casing for drainage. The blower
casing shall be provided with lifting lugs capable of supporting the blower/gearbox.

B. The gear drive housing shall be of close-grained cast iron ASTM A48, Class 30B or close
grained cast iron ASTM A278, Class 30, vertically or horizontally split, sufficiently rigid to
maintain the shaft positions under maximum loads. Two inspection ports, with bolt-on
covers, shall be provided in the upper portion of the gearbox housing. The ports shall
allow access to the gearbox internals for the purpose of inspection. Adjustment of the
vibration proximity probes on the high-speed shaft shall be possible from the outside of
the gearbox.

C. Gearbox configuration shall incorporate a single helical gear set in an over/under
configuration. The overhung impeller and fast-shaft shall operate between the first and
second critical speeds.

D. The blower and gear housing assemblies shall be machined to close tolerances for
bearing fit, gear alignment, air, and oil tightness.

E. The gearbox shall be of ample size and rated to transmit the maximum torque and
horsepower input requirements to the blower under all operating conditions and
continuous duty.

F. All exposed machined surfaces shall be coated with grease prior to shipment.

31221-009\11183: 11-06-18 11183-8 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
2.06 IMPELLERS

A. The impellers shall be radial flow type with open and backward leaning blades. Impellers
shall be milled or fabricated from forged hiduminimum aluminum alloy (ASTM B247
AA2618). The impeller shall be attached to the shaft by shrinkfit and locknut arrangement.
The impeller shall be statically and dynamically balanced.

2.07 VARIABLE VANES

A. The purpose of the inlet guide vane and variable discharge diffuser vanes shall be to
facilitate turndown of each blower from 100% to 45% of capacity, while maximizing
efficiency over the entire turndown range.

B. An adjustable inlet guide vane assembly shall be provided to pre-rotate incoming air and
maximize efficiency. Inlet guide vanes shall be made in an aerodynamic, streamlined
design in cross-section and located in radial fashion around the annular inlet. Inlet guide
vane position shall be controlled through the PLC in the blower control panel.

C. The inlet guide vanes shall modulate simultaneously with the diffuser vanes to
continuously optimize efficiency.

D. Variable discharge diffuser vanes shall be provided for capacity control. Vanes shall be
aerodynamically shaped for maximizing efficiency.

E. The inlet guide vane and the variable diffuser assemblies shall be mounted integrally with
each blower, multi-leaf and pivoted, and located in cast iron housings. All vanes shall be
mounted in permanently lubricated sleeve bearings. Operating linkages for inlet guide
vanes and variable diffusers shall be housed within the blower.

F. Each variable vane assembly shall include a blower mounted electric actuator and position
indication on the blower control panel.

G. The position of each set of vanes, from fully open to fully closed, shall be transmitted to
the blower control panel via an analog signal. The inlet guide vane and the diffuser vane
position shall be indicated on the display on the blower control panel.

2.08 SHAFTS, GEARS, AND SEALS

A. The blower gear shafts shall be machined from heat-treated, forged steel and suitably
ground. Any responsive lateral critical speed of the rotating assembly shall be at least
fifteen (15) percent from the normal operating speed. Any torsional resonances of the
package shall be at least ten (10) percent from the normal operating speed. All rotating
elements shall be dynamically balanced and conform to "Design and Selection of
Components for Enclosed Gear Drives" (AGMA 6001-C88).

B. The speed-increasing, helical, parallel shaft type gears shall be made of case-hardened
alloy steel forgings with the gear teeth precision ground. All gears shall be manufactured
in accordance with the American Gear Manufacturers Association "Standard Specification
for Measurement of Sound on Enclosed Helical, Herringbone, and Spiral Bevel Gear
Drives" (AGMA 6025-C90) to a minimum AGMA quality number no less than twelve (12),

31221-009\11183: 11-06-18 11183-9 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
as specified in AGMA 2000/A88. Service factor used to size the gearbox shall be a
minimum of 1.5 based on full load horsepower rating of the motor.

C. The shaft seals shall be of a non-contact, multi-point, labyrinth type and operated dry. A
vented space between air and oil seals shall be provided. Any leakage shall be minimized
by having small clearances between female and male parts. The female part shall be
made of aluminum or bronze to avoid damage to the shaft in the event of a seal rub.
Numerous slinger rings (diameter changes) on the shaft shall be provided in the sealing
area to ensure oil is centrifugally slung off the shaft.

2.09 BEARINGS

A. Hydrodynamic, oil pressure lubricated bearings shall be required with sufficient oil film
thickness under all operating conditions. All bearings shall be of bronze construction.

B. Drive shaft radial bearings shall be cylindrical, journal type. Drive shaft thrust bearings
shall be multiple segment designed for thrust in both directions.

C. Pinion shaft radial bearings shall be multi-segment and babbitted, designed to suppress
hydrodynamic instabilities and provide sufficient dampening to limit rotor vibrations. Pinion
shaft thrust bearings shall be multiple segment, tapered land type and designed for thrust
in both directions.

D. Rolling element (i.e. ball bearings) shall not be used for any bearing in the gearbox.

2.10 OIL LUBRICATION SYSTEM

A. A complete lube oil system shall be provided with each blower, installed integrally with the
blower base and arranged to permit ease of accessibility for operation, maintenance,
inspection, and cleaning.

B. One main motor or gearbox shaft-driven primary oil pump and one electric motor-driven
oil pump (as pre-lube and post-lube) shall be provided, each capable of full capacity and
pressure to supply lubrication for the air blower/gearbox when operating and during
start/stop. The electric motor-driven oil pump shall operate at start/stop of the blower and,
at low oil pressure, be activated by the control system located in the blower control panel.
The motor shall be minimum 3 Hp, 480 VAC, 3 phase, 60 Hz, TEFC, high efficiency and
have adequate power to pump oil at the minimum oil temperature of 50°F.

C. The oil reservoir shall be integral to the blower base with the reservoir interior de-scaled
and rust-proofed by the application of a permanent coating of the Manufacturer's standard.
Reservoirs shall be baffled to minimize air entrainment, to isolate foam, and shall be
equipped with a suitably sized vent and breather filter, and have a minimum working
capacity of three (3) minute retention time based on normal flow. The reservoir shall have
a minimum 28 square inch clean-out with a blind flange or gasketed cover plate and 1½
inch NPT valve drain at the lower/side of the reservoir.

D. The oil filter shall be of the full flow, replaceable cartridge, duplex type with integral transfer
valve, and capable of removing particles over ten (10) microns with a clean oil filter
element pressure drop not exceeding five (5) psi at design temperature and flow. A visual
gauge shall indicate when a filter is dirty and requires changing.

31221-009\11183: 11-06-18 11183-10 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4

E. Oil-to-air heat exchangers shall be provided for each blower and mounted on the blower
base. Oil-to-air heat exchanges shall be rated for a design pressure of 250 psig and
design temperature of 250 degrees Fahrenheit. The system shall provide fully automatic
operation to maintain a constant oil supply temperature of 120°F.

F. Oil heating shall be provided by use of the auxiliary oil pump to maintain oil temperature
above 50°F. An RTD shall be provided for measurement and indication of oil temperature.
The blower shall not start unless the oil is above 50°F. Low oil temperature warning
indication shall be provided on the display on the blower control panel.

2.11 COUPLING

A. A flexible, steel, double-disc, dry type spacer coupling shall be furnished to connect the
blower and motor. Couplings requiring grease lubrication shall not be allowed. Coupling
and spacer shall be balanced to AGMA, Class 8, or better, and sized with a minimum
service factor of 1.5. Coupling construction shall be such that either shaft of the unit may
be removed without disturbing adjustment of the other. An OSHA approved steel guard
shall be provided and installed over the coupling and painted Safety Yellow.

B. A complete torsional critical speed analysis shall be conducted by the Supplier to ensure
that the blower, motor, and coupling are properly designed. Include data in the submittal
to confirm that there are no torsional critical speeds within the operating range of the unit.

2.12 PRESSURE GAUGES

A. Inlet and discharge pressure gauges shall be installed by the Contractor on the suction
and discharge of each blower.

B. The inlet vacuum gauge shall be a 316 stainless steel bellows gauge with a range of 0-30
inches of mercury/0-15 psi. Scale shall be a 270° arc. Dial size shall be 4-1/2 inches with
black phenolic case. Gauge tap shall be 1/4 inch minimum.

C. The discharge pressure gauge shall be a 316 stainless steel bourdon type with a range of
0-15 psi. Scale shall be a 270° arc scale with figure interval every 1 psi and minor
graduations every 0.1 psi. Dial size shall be 4 1/2 inches with black phenolic case. Gauge
tap shall be 1/4 inch minimum.

D. Gauges shall have an accuracy of plus or minus 1 percent. All gauges shall be by the
same manufacturer.

2.13 BLOWER CONTROL PANELS

A. The Supplier shall furnish remote mount NEMA 12 blower control panels (BCPs) for the
new blowers. Each blower control panel shall include a touch screen operator interface
on the front of the panel, a programmable logic controller (PLC), and network
communication hardware to interface with the existing in-plant PLC systems.

B. The PLC control system and I/O subsystem shall all be products of GE Fanuc PAC
systems RX3i. The PLC in the Blower Control Panel shall be designated as PLC–
BLOWER 2. The PLC shall utilize TCP/IP Ethernet communication protocol. All PLC

31221-009\11183: 11-06-18 11183-11 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
inputs/outputs shall be provided in accordance with Section 17060 – Signal Coordination
Requirements.

C. The Blower Control Panels shall each include a UPS to provide uninterruptible power to
the PLCs. The UPS shall conform to all requirements of Section 17190 – Uninterruptible
Power Systems.

D. PLC–BLOWER 2 shall be connected to the in-plant Ethernet control system network. All
data available at PLC–BLOWER 12shall be available in the Plant SCADA system.

E. Each blower control panel shall contain controls for blower motor normal starting and
stopping sequences, surge and overload detection and protection, emergency shutdown
control and sequencing, alarm systems, inlet guide vanes, variable diffuser vanes,
discharge valve, bypass valve, and the oil lubrication system operation as a minimum.

F. Each blower control panel shall operate from a single 480 VAC, 3 phase supply and shall
contain a main power disconnect which interlocks the enclosure door. Starters for variable
vane operators, oil pumps and oil-to-air heat exchangers shall be furnished and installed
by the blower manufacturer in the blower control panel. Power supply for the blow-off
valve and discharge isolation valve operators shall be provided by the blower
manufacturer in the blower control panel. Low voltage variable power signals entering the
blower control panel shall be isolated.

G. All branch circuit protection shall be in accordance with NEC codes, as well as protection
for the instrumentation power, the (120/60/1) duplex GFCI protected receptacle, Operator
Interface, and the PLC.

H. The PLC shall start and shut down the blower in a permissive sequence, receive input,
monitor and control operating variables. The PLC shall also contain a program for
continuous optimization of blower efficiency with respect to changes in operating
conditions.

I. Lightning arrestors and surge suppressors shall be provided for 120V control power.

J. Surge suppressors shall be provided for "noise" protection and to remove transient peaks
across all inductive loads.

K. Signal isolators, PLC rack-mounted RTD input modules, vibration transmitters, and other
controls shall be supplied, as required, for complete system control.

L. Identify each end of each wire by a unique wire number printed on a heat shrunk sleeve
marker.

M. Provide an Operator Interface with a touch screen active matrix TFT color graphic 12"
LCD display that incorporates all controls, alarms and meters in easy to interpret color
screens. Operator Interface shall be GE FANUC QuickPanel View Series.

N. The operator interface screens shall provide start-stop and operational mode interface,
alarm status, help messages, and diagnostics. The following operator interface screens
shall be provided, generally as described, and incorporating state-of-the-art upgrades

31221-009\11183: 11-06-18 11183-12 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
available at the time of engineering design and submittal for the Engineer's review. As a
minimum, provide the following:

1. Local Control Panel Menu - The master screen lists all operating screens as touch-
sensitive screen points, for selection.

2. Main Blower Operations - Touch-sensitive screen points for blower start, blower
stop, increase or decrease capacity, local or remote selection. This screen shall
display a bar chart or dial indicator of blower capacity (in percent) and numerical
horsepower or amperage draw. A 1 x 3 inch message center shall display
appropriate messages, including a troubleshooting guide, upon alarm.

3. Service Functions Display – When in service mode, touching an identified screen
point shall display on-off (open-close) screen points to operate the items listed
below. A normal or service/test screen point shall also be displayed to change
operation status.

· Normal/Service mode selection and status
· Inlet guide vanes – current position, scale, open, close
· Discharge guide vanes – current position, scale, open, close
· Inlet/discharge guide vanes recalibration
· Discharge valve – current position, open limit (adjustable), open, close
· Blow-off valve – current position, close limit (adjustable), open, close
· Blow-off valve start-up settings – setpoint, delay
· Auxiliary oil pump – start/stop
· Oil cooler fan – start/stop
· Oil cooler water (if oil-water cooling specified) - start/stop

4. Blower Transmitter Display – Shall display all blower components, their current
value, units of measurement, alarm settings and trip settings including but not
limited to:

· Inlet guide vanes
· Variable diffuser vanes
· Inlet air temperature
· Discharge air temperature
· Differential pressure
· Oil reservoir temperature (high and low alarm and trip settings)
· Oil pressure
· Blower bearing temperatures
· Blower shaft and gearbox vibration
· Discharge valve position
· Blow-off valve position
· Blower shaft speed

5. Motor Transmitter Display – Shall display all motor components, their current
value, units of measurement, alarm settings and trip settings including but not
limited to:

31221-009\11183: 11-06-18 11183-13 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
· Amperage
· Motor bearing temperatures
· Motor winding temperatures
· Motor shaft vibration
· Motor bearing vibration
· Motor horsepower draw (from the MCC)

6. Alarm/Trip Display – A flashing warning lamp icon shall be indicated on the display
upon detection of an alarm or trip. Pressing the icon shall display the alarm/trip
display. The alarm/trip display shall provide a description of the individual alarms
or trips detected along with the date and time the alarm or trip occurred. The
screen shall display a troubleshooting list to use as a guide to correct the alarm.
The operator shall acknowledge the alarm once corrected by pressing an
“acknowledge” button. All cleared alarm and trip messages (including date and
time) shall continue to be accessible through a legacy alarm screen to monitor
alarm trends and facilitate diagnosis/corrective actions. An alarm horn silence
button shall also be provided.

7. Configuration Display – Shall allow selection and display of the following:

· Test mode button
· Powerup default – Normal or service modes
· Powerup default – local or remote control mode

8. Transmitter Scaling Set-Up - Lists calibration range of all analog signals.
Password access shall be required to change any value.

O. Additional selector switches, pushbuttons, and indicators shall include:

1. Service/Normal/Test - Located on the Operator Interface. This touch sensitive
screen point allows permissive start of the blower components only in the Service
Mode. When in Test Mode, this diverts MCC start signal to test logic that simulates
motor start to facilitate testing of the system without starting the drive motor.

2. Emergency stop mushroom button on panel door

3. Separate, non-resettable hour meter. Location to be coordinated with client during
the submittal phase to provide hour meter near existing hour meters for the three
existing blowers.

P. Monitor and indication of all analog signals shall be displayed on the Operator Interface,
including, but not limited to:

1. Motor horsepower

2. Variable diffuser vane position

3. Inlet guide vane position

4. Temperature signals

31221-009\11183: 11-06-18 11183-14 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4

5. Pressure signals

6. Vibration signals

7. RTD bearing/winding temperatures

Q. The surge detection system shall sense unbalanced/surge conditions by use of inlet
pressure, inlet temperature and/or motor horsepower. Detection of surge conditions shall
trip the blower off-line. Adjustable time delays shall be incorporated to prevent nuisance
shutdowns.

R. Motor overload protection software shall be provided to control the maximum vane setting
on the blower, so that motor current does not exceed a pre-set level. Motor overload
protection shall be provided such that if motor current exceeds 105% of full load amps the
blower shall be shutdown through the PLC in the Blower Control Panel.

S. The output air flow in scfm shall be displayed on the Operator Interface. The calculation
of this flow may utilize dynamic field inputs of differential pressure across the blower, inlet
temperature, and shaft power derived from motor wire power or current, in conjunction
with performance test stand data. The multi variant algorithm based on test stand data
and the defined inputs of air temperature, pressure, and motor power draw may be used
to determine flow throughout the operating range of the compressor.

T. The high inlet air temperature (recirculation) alarm and the zero speed switch shall be
active when there is no main motor feedback present at the blower control panel from the
MCC (i.e. blower is "off" and not running). The purpose of these sensors is to detect
reverse air flow through the compressor and reverse rotation of the impeller.

U. All electrical work associated with the blower panels, instruments, and controls provided
by the blower system manufacturer shall be in accordance with the National Electric Code.
Switches and pushbuttons shall be heavy duty, oil-tight, NEMA 4 type. The completed
panel shall receive a UL label. Each blower control panel shall be provided with a power
disconnect switch. Provide separate 24 volt power supplies as required.

V. Control panel shall be painted at the factory. The exterior of the panel shall receive the
premium factory paint system with color as directed by the Engineer. The interior of the
panel shall receive one coat of white enamel paint.

W. The control panel shall be completely pre-wired and tested at the factory by the blower
system manufacturer.

X. A red mushroom emergency stop pushbutton shall be provided on the panel door.

Y. Terminal blocks shall be 600 volt, 30 amp, barrier type screw terminals with 10% on each
block as spares. Each terminal shall be identified. Power and control wiring shall use
separate block from analog signal wiring. Analog signal wiring shall be shielded.

Z. An as-built diagram of the completed panel shall be encased in plastic inside the panel.

31221-009\11183: 11-06-18 11183-15 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
AA. Engraved plastic nameplates shall be mounted on the inside of each blower panel to
identify the various devices, instruments, etc. Nameplates shall have white letters on a
black background.

AB. Alarms shall not be annunciated under normal start-up and shut-down conditions.

2.14 REQUIREMENTS FOR INTERFACE WITH THE PLANT’S SCADA SYSTEM

A. The Contractor shall provide coordination required for communication of information
between the blower control panels and the existing Plant SCADA system. The blower
manufacturer will make available in separate contiguous registers the required digital and
analog information to the Plant SCADA system through network communication. The
blower manufacturer shall submit copies of the graphic displays for approval. The
Contractor shall coordinate with the control system subcontractor under Division 17 to
develop the graphic displays in the SCADA display format protocol. The Plant SCADA
system shall provide the following for information from the blower control panels (by the
control system subcontractor under Division 17):

1. Log all monitored points for trend analysis

2. View realtime trends

3. View historical information

4. Display graphs and charts

5. Date/time history of alarms including surge

2.15 BLOWER INSTRUMENTATION

A. The Contractor shall furnish and install new conduit and wiring from junction boxes on the
blower skid to the blower control panel (BCP) and from field-mounted instruments to the
BCP as described below. Skid mounted instruments shall be installed in the factory and
shall be factory-terminated in junction boxes (one digital and one analog) on the blower
skid and connected by the Contractor to the BCP. Contractor shall provide taps, isolation
valves, tubing, and pipe stanchions required for pressure gauge and other new devices
for installation as specified. A summary of devices for each blower and installation work
required by the Contractor is as follows:

31221-009\11183: 11-06-18 11183-16 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
Device(s) per Blower Installation Work by Contractor
Surge Control Sensors (1) Furnish and install wire and conduit from the
junction box to the BCP.

Inlet/Discharge Pressure Gauges (2) Install gauges for reading at floor level.
Contractor shall provide pipe stanchions for
gauge mounting as required and tubing
between taps and gauges. Gauges shall be
supplied by the blower manufacturer.

Discharge Air Temperature RTD’s (1) Install RTD supplied by blower manufacturer.
Provide conduit and wire and connect to BCP.

Motor Windings and Motor and Blower
Bearing RTDs (10)
Furnish and install wire and conduit from the
junction box to the BCP.

Motor and Blower Vibration Monitors (8) Furnish and install wire and conduit from the
junction box to the BCP.

Motor/ Blower Shaft Keyphaser (1) Furnish and install wire and conduit from the
junction box to the BCP.

Inlet Air Temperature Transmitter (1) Furnish and install conduit and wire from the
junction box to the BCP.

Operators for Inlet Guide Vanes
and Variable Diffuser Vanes (2)
Furnish and install conduit and wire from the
junction boxes to the BCP.

31221-009\11183: 11-06-18 11183-17 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
Device(s) per Blower Installation Work by Contractor
Electric Operators for Blow-Off
Valves and Discharge Valves (2)
Install electric valve operators at locations
indicated on the Drawings. Provide conduit
and wire and connect signals to BCP. Provide
conduit and wire for 480 volt power supply and
install interconnecting wiring between blower
control panels and valve operators. Valves
and valve operators shall be supplied by the
blower manufacturer.

Motor Protector Unit
(1)
Install motor protector unit in motor starter
under Division 16. Provide conduit and wire
and connect signals to BCP including power
draw, motor run status, and electrical
malfunction alarm.

Oil Lube Pressure Gauge (1) None required. (Installed at factory by blower
manufacturer.)

Oil Lube Temperature Gauge
(1)
None required. (Installed at factory by blower
manufacturer.)

Oil Temperature Transmitter
(1)
Furnish and install conduit and wire from the
junction box to the BCP.

Oil Filter Differential Pressure
Indicator (1)
None required. (Installed at factory by blower
manufacturer.)

Oil Filter Differential Pressure
Switch (1)
Furnish and install conduit and wire from the
junction box to the BCP.

Zero Speed Switch (1) Furnish and install conduit and wire from the
junction box to the BCP.

Low Oil Level in Reservoir (1) Furnish and install conduit and wire from the
junction box to the BCP.

Inlet/Discharge Differential
Pressure Transmitter (1)
Contractor shall install ¼-inch tubing between
the transmitter and the discharge cone and
shall furnish and install conduit and wire from
the junction box to the BCP.

Air Filter Differential Pressure
(2)
Furnish and install conduit and wire from the
differential pressure switch/gauges to the
BCP.

Low Oil Pressure Switches (2) Furnish and install conduit and wire from the
junction box to the BCP.

31221-009\11183: 11-06-18 11183-18 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
B. The RTD monitor system shall include 100 ohm platinum RTD's embedded in the motor
windings (two per phase; one active, one spare) and in each bearing of both the motor
and blower/gearbox. The system shall monitor and display actual winding and bearing
temperature at the blower control panel. When the windings or bearings reach the
selected temperature, an indicator illuminates until reset and the unit shuts down. The
PLC shall receive and the Operator Interface shall graphically display the RTD signals.
The Supplier shall provide the necessary hardware for direct communication between
RTD's, PLC, and Operator Interface.

C. A shaft vibration monitoring system shall be furnished for each blower and motor. The
system shall include:

1. Blower gearbox pinion shaft X-Y configuration shaft vibration detectors

2. Blower gearbox pinion shaft (Z) thrust bearing (axial) position/vibration detectors

3. Blower gearbox casing mounted velometer

4. A Keyphasor sensor on the shaft between the motor and blower

5. X-Y configuration vibration detectors at each bearing of the motor, four (4) probes
total per motor

The PLC in the blower control panel shall receive, and the Operator Interface shall
graphically display, the vibration probe signals. The Operator Interface shall include an
adjustable alarm feature on the rising vibration levels that first alarms and is followed by
unit shutdown. The alarm/shutdown shall be displayed until reset. Provide necessary
hardware for direct communication between vibration probes, PLC, and Operator
Interface.

2.16 BLOWER START-UP AND SHUTDOWN SEQUENCE CONTROL PROGRAMS

A. The Blower start-up and shutdown sequence control programs shall be provided by the
blower manufacturer in each blower control panel as follows:

1. A blower may be called to start or stop by the following:

a. Manually at the blower control panels through the touch screen operator
interface panel.
b. Manually through the Plant SCADA System. (remote-manual)
c. Automatically through the Plant SCADA System.

2. When a blower is called to start, a "blower #__ start-up sequence initiated"
message shall be provided on the blower control panel operator interface and on
the SCADA system display. All messages to be displayed on the blower control
operator interfaces shall be provided to the SCADA system through the
communication network. Status of delay timers showing countdown time shall be
displayed during a start-up and shutdown sequence.

31221-009\11183: 11-06-18 11183-19 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
3. Automatic control of the dissolved oxygen control valves and variable diffuser
vanes by the SCADA system shall be discontinued by the SCADA system until
completion of the start-up sequence.

4. A "blower #___ start-up sequence in progress" message shall be provided on the
blower control panel operator interface and on the SCADA system display and
shall remain on the screen in flashing mode until the start-up sequence is
completed.

5. The SCADA system or the operator through the touch screen operator interface at
the blower control panel shall provide a command to the blower control panel to
start its respective blower. The PLC shall confirm that alarm conditions are cleared
and the blower is available for starting. In the case of a blower failure or if a blower
is locked out by a PLC-based "permissive", the SCADA system shall try to start
the next available blower according to the control program in the SCADA system.
Indication of the next blower to be started and the next blower to be shut down
through the strategy shall be provided on the SCADA system graphic displays.

6. The oil pre-lubrication system (auxiliary oil pump) shall energize and run for a field
adjustable minimum, initially set at 2 minutes, pre-lubrication time. “Pre-lube in
progress” message shall be provided on the blower control panel operator
interface and on the SCADA system display.

7. Failure to establish sufficient oil pressure (15 psig) within one minute shall
generate a "blower # ___start-up sequence/low-low oil pressure failure" alarm
through the PLC, shall terminate the start-up sequence, and shall provide alarm
indication on the blower control panel operator interface and on the SCADA system
display.

8. The PLC shall move inlet guide and discharge diffuser vanes on the blower to be
started to their "Start-up” position. The SCADA system will provide a command to
blowers already operating to move variable diffuser vanes (or inlet throttling valves
for the existing multistage blowers) to their “start-up” position. The PLC will use
continuous 4-20 ma position feedback information from the operators to monitor
position for start-up. The PLC shall confirm that the discharge valve of the blower
to be started is fully closed and shall move the blow-off valve for the blower to be
started to the fully open position. Indication that the PLC is "positioning valves"
shall be provided on the blower control panel operator interface and on the SCADA
system display. Failure of any of the valves to move to their required positions
within the time required shall initiate a "start-up sequence/valve failure" alarm
through the PLC, shall terminate the start-up sequence, and shall provide alarm
indication on the blower control panel operator interface and on the SCADA system
display.

9. At the end of the 2-minute pre-lubrication cycle, the blower PLC gives a Start/Stop
(dry contact) signal to the MCC (Motor Control Center) to energize the drive motor.
The PLC shall receive a feedback signal from the starter confirming that the main
drive motor starter has been energized. If the start verification is not received in
30 seconds, the start sequence is terminated on a “No Motor Feedback Alarm
(Sequence Failure)”. After the motor feedback signal is received, the discharge
valve shall start opening and a 5-minute blow-off valve "guardian" timer shall start.

31221-009\11183: 11-06-18 11183-20 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
The oil pressure at the mechanical oil pump must be established (higher than 29
psig) within 20 seconds after the motor feedback is received. If the oil pressure
setpoint is not achieved in 20 seconds, the start sequence is terminated on a “Low
Oil Pressure Alarm” (Sequence Failure). If the oil pressure setpoint is achieved
in 20 seconds, the auxiliary oil pump shall run for another 10 seconds before going
off-line. After the auxiliary oil pump has gone off-line, the inlet guide vanes shall
move to the maximum position. When the inlet guide vanes are at their maximum
position, and the discharge valve is opened, the blow-off valve shall begin to close.
If the blow-off valve is not closed when the 5-minute blow-off “guardian” timer
expires, the start sequence is terminated on a “Start Taking Too Long Alarm”
(Sequence Failure). After the blow-off valve is closed, the inlet guide vanes shall
be positioned by the blower PLC. When the inlet guide vanes are stabilized, the
variable diffuser vanes are ready for operational control; and the start sequence is
finished. A "blower #___ start-up sequence completed" message shall be provided
on the blower control panel operator interface and on the SCADA system display.
The SCADA system shall restore automatic control of the dissolved oxygen,
control valves, and blower variable diffuser vanes.

10. After a start-up sequence is initiated and the blower blow-off (bypass) valve begins
closing where applicable, the PLC shall monitor pressure in the discharge header
(obtained via network from the SCADA system) and shall control the position of
the blow-off (bypass) valve for the single stage blower to be started such that
pressure in the discharge header does not exceed 11 psig. Programming shall be
provided in the PLC for (1) opening the blow-off valve for the blower during the
start-up sequence when discharge header pressure exceeds an adjustable
setpoint (initial setting 11 psig) after an adjustable time delay (initial setting = 10
seconds) after the blower is called to start; and (2) closing the blow-off valve as
long as discharge pressure is less than 11 psig. Blow-off valve shall be fully closed
under normal operating conditions. This blow-off (bypass) valve control program
shall be capable of being enabled or disabled. All pressure and time setpoints
shall be adjustable.

11. When a blower is called to stop either through the SCADA system or the local
touch screen operator interface, a "blower #___ shutdown sequence initiated"
message shall be provided on the blower control panel operator interface and on
the SCADA system display.

12. After the command is received from the SCADA system to shut down the blower
(or a blower shutdown is initiated manually through the touch screen) the PLC shall
close the variable diffusers to their minimum position, start a 120-second stop
timer, open the blow-off valve to its fully opened position, and shall close the
discharge valve to the fully closed position. When the discharge valve is fully
closed (or the 120 second timer expired), the start/run signal will drop to the MCC
to stop the drive motor. After the motor feedback signal is lost, the auxiliary oil
pump shall start the 5-minute post-lube cycle, and the inlet guide vanes shall move
to their minimum position. Five minutes after the motor feedback signal is lost, the
auxiliary oil pump shall stop. The stop sequence is finished. A "Blower No. ____
stopped" message shall be provided on the blower control panel operator interface
and on the SCADA system display.

31221-009\11183: 11-06-18 11183-21 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
13. Upon completion of blower shut-down, the PLC shall satisfy the stand-by
conditions.

14. Emergency stop capability shall be provided through the local blower control panel,
at the skid mounted digital junction box, at the motor starter and through the
SCADA system through a single-click function. Emergency stop shall de-energize
all equipment on the blower base and cannot be reset or reactivated until
maintained emergency stop has been released to restart the blower after an
emergency stop.

15. The blower control panel shall include protective shutdown interlocks to protect the
blower from abnormal operating conditions. A “soft” stop shall be provided through
the PLC if initiated by any of the following:

a. High Oil Temperature
b. High Inlet Air Temperature
c. High Compressor Bearing Temperature
d. High Motor Bearing Temperature
e. High Motor Winding Temperature
f. High Motor Amps
g. Surge
h. Impending Surge

“Soft” stop shall consist of opening the blow-off valve to its full open position and
de-energizing the main drive motor 8 seconds after the alarm condition occurs.
Normal post-lube and other normal stop functions shall follow.

16. An “emergency” stop shall be provided trough the PLC initiated by any of the
following:

a. Low Oil Pressure
b. No Run Status Contact Feedback from Starter During Starting
c. Loss of Run Status Contact Feedback from Starter
d. Star Sequence Failure
e. Stop Sequence Failure
f. High Compressor Casing Vibration
g. High Compressor Shaft Vibration
h. High Motor Bearing Vibration
i. Pushing Emergency Stop Pushbutton
j. PLC Failure

An “Emergency” stop shall consist of opening the blow-off valve to its full open
position and de-energizing the main drive immediately. Normal post-lube and
other normal stop functions shall follow.

17. The PLC shall move the discharge valve to the fully closed position after the blower
is shut down for any reason.

31221-009\11183: 11-06-18 11183-22 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4

2.17 BLOWER MACHINE MONITORING PROGRAMS

A. The blower monitoring programs shall be provided by the blower manufacturer in each
blower control panel as follows:

1. Monitoring and protection of the blowers from abnormal operating conditions shall
be provided through the PLC.

2. Horsepower inputs to each PLC shall be from the respective blower starter.

3. Provide monitoring of all analog inputs. PLC shall shut down the blower if inputs
are not within the acceptable range. Hold-out circuitry shall be provided in the PLC
programming to prevent shut-down on alarm condition while the blower is being
started. All analog inputs to the PLC shall be re-transmitted to the Plant SCADA
system via Ethernet communication.

B. The following is a listing of the analog inputs to the PLC at each blower control panel.
Analog inputs shall be monitored/displayed at the PLC and monitored/logged/displayed
through the Plant SCADA system. Eight spare analog inputs shall be provided on each
PLC.

1. Motor Drive End Bearing Temperature

2. Motor Non-Drive End Bearing Temperature

3. Blower Low Speed Drive End Bearing Temperature

4. Blower Low Speed Non-Drive End Bearing Temperature

5. Blower High Speed Drive End Bearing Temperature

6. Blower High Speed Non-Drive End Bearing Temperature

7. Blower High Speed Thrust Bearing Temperature

8. Inlet Air Temperature

9. Discharge Air Temperature

10. Oil Reservoir Temperature

11. Motor Drive End Bearing Vibration (2)

12. Motor Non-Drive End Bearing Vibration (2)

13. Blower Gearbox Vibration

14. Blower High Speed Shaft Vibration (3)

15. Blower/Motor Shaft Keyphasor

31221-009\11183: 11-06-18 11183-23 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4

16. Blower Power Draw (from the MCC)

17. Inlet Guide Valve Position

18. Variable Diffuser Vane Position

19. Blower Blow-off Valve Position

20. Discharge Isolation Valve Position

21. Motor Windings Temperature (3)

22. Motor Amperage

23. Inlet/Discharge Differential Pressure Transmitter

24. Blower Gearbox Rotation Speed Monitor

C. The PLC shall include programming to report the order in which alarm conditions are
received, such that operators can determine the alarm that caused blower shut-down.

D. Discrete inputs to each PLC shall include:

1. Blower motor run status

2. Electrical malfunction alarm

3. Low oil pressure switch

4. Low/low oil pressure switch

5. Low oil level switch

6. Auxiliary oil pump run status

7. Auxiliary oil pump fail

8. Blow-off valve operator remote/local indication

9. Oil cooler fan run status

10. Oil filter differential pressure switch

11. Zero speed switch

12. Inlet air filter 1st Stage differential pressure switch

13. Inlet air filter 2nd Stage differential pressure switch

14. LCP Emergency Stop Push/Pull

31221-009\11183: 11-06-18 11183-24 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4

15. Blow-off Valve Open Limit Switch

16. Blow-off Valve Close Limit Switch

17. Discharge Valve operator remote/local indication

18. Discharge Valve Open Limit Switch

19. Discharge Valve Close Limit Switch

20. Surge Detection Switch

21. UPS Alarm

22. UPS on Battery

E. Discrete outputs from the PLC shall include:

1. Aux Oil pump start/stop

2. Main motor run (hour meter)

3. Main motor start/stop

4. Open discharge valve

5. Close discharge valve

6. Blow-off valve open

7. Blow-off valve close

8. Inlet guide vane open

9. Inlet guide vane close

10. Variable diffuser vane open

11. Variable diffuser vane close

12. Oil cooling fan start/stop

13. Alarm horn

14. Alarm Beacon

2.18 CHECK VALVES

A. The Supplier shall provide each blower and blow-off line with a wafer type discharge check
valve of the dual, flat-plate type with center hinge, spring closure, steel or cast iron body,

31221-009\11183: 11-06-18 11183-25 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
Viton-B seal and aluminum-bronze plates, Inkonel 600 springs, and rated for temperatures
up to 300°F. The check valves shall be installed by the Contractor as shown on the
Drawings. The Contractor shall perform any piping modifications necessary to incorporate
the check valve provided by the blower equipment Supplier at no cost to the Owner.
Check valves shall be installed in the horizontal position.

2.19 DISCHARGE ISOLATION AND BLOW-OFF (BYPASS) VALVES

A. The Supplier shall provide electrically operated butterfly valves for the blow-off line and
discharge line of each blower. The butterfly valves shall be installed by the Contractor as
shown on the Drawings. The Contractor shall perform any piping modifications necessary
to incorporate the valves provided by the blower equipment Supplier at no cost to the
Owner.

B. All valves shall have flanged end connections, Ductile Iron ASTM A536, Grade 65-45-12
or 316 SST seat ring, 304 SST ASTM A276 shafts and packing and seals suitable for
temperature as high as 300°F.

C. Motor actuators shall be provided for discharge isolation and blow-off valves and shall
meet the requirements of specification Section 15100. Motor actuators for the discharge
isolation valves shall be open-close service. Motor actuators for the blow-off valves shall
provide for modulating operation. Cycle time from full open to full closed shall be
approximately 60 seconds. 4-20 ma position feedback signals shall be provided for each
actuator. Contractor shall wire 4-20 ma position signals to the PLC.

2.20 EXPANSION COUPLINGS

A. The blower manufacturer shall provide an expansion coupling on the inlet and discharge
piping of each blower.

B. Expansion couplings shall be FMI Expansion Joints as manufactured by Flexible Metal,
Inc., Tucker Georgia; Safe Flex as manufactured by Mid Atlantic Technical Services,
Annapolis, Maryland, or Max-Joint Style 1101 EPDM Expansion Joint by General Rubber.

C. Expansion coupling shall be suitable for a pressure of 25 psig and a temperature of 300°F.
Expansion couplings shall be short metal bellows type made of stainless steel.

2.21 DISCHARGE CONE/SILENCER

A. Provide a discharge cone/silencer (Evasè stack) for each blower to increase the blower
outlet size to the larger diameter air discharge piping as shown on the Drawings.
Maximum sidewall angle increase shall be 7° per side (14° total). Minimum 10-gauge
carbon steel shall be used. Instrument connections shall be provided on the cone/silencer.

2.22 INLET FILTER SILENCER

A. Each new blower shall be provided with an inlet filter/silencer designed for maximum air
flow at absolute minimum pressure drop. Walls of the silencer shall consist of sandwiched
galvanized steel outer skin and an acoustical sound deadening material of one (1) inch
sound insulation containing an inert barrier, on the inside of the housing. The inert barrier
on the walls shall have a thin aluminum foil on its exterior, affixed to the barrier with an

31221-009\11183: 11-06-18 11183-26 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
industrial adhesive. The silencer housing structural frame shall be hot-dipped galvanized.
Legs shall be adjustable for vertical positioning and leveling.

B. The integral inlet silencer shall consist of a set of lamella, mounted internally in the
filter/silencer between the filter elements and the blower inlet, suitably wrapped with sound
deadening material. Lamella construction shall be such that there is no direct line of sight
(direct flow) through the lamella, and the lamella so configured such that the line of air flow
shall make at least four turns, for maximum attenuation. An air tight seal shall be provided
between the filter frame and silencer.

C. The filter elements shall be rectangular, replaceable elements mounted on a flat, vertical
track of aluminum construction, and removable through galvanized steel doors located on
each side of the galvanized steel housing. A two-stage filter panel system shall be
supplied. The coarse pre-filter shall have a minimum ASHRAE 52.2 MERV value of 8.
The final filter element shall have a minimum ASHRAE 52.2 MERV value of 13. The
filter/silencer shall provide a capacity of 37,000 cfm while limiting velocity to 500 feet per
minute (fpm).

D. Maximum clean filter pressure drop of the inlet filter/silencer with the elements installed
shall be 2.5 in. w.c. (0.09 psig). Maximum pressure drop with dirty inlet filters shall be 4.2
inch w.c. (0.15 psig).

PART 3 -- EXECUTION

3.01 INSTALLATION

A. All equipment specified herein shall be installed in accordance with the manufacturer's
instructions and checked by the manufacturers' representative, in conformity with the
applicable sections of this specification. After installation, the equipment shall be aligned
and adjusted as required for proper operation.

B. Contractor shall not install new control panels until environmental conditioning equipment
is operational in the new control room. Contractor shall maintain dust-free conditions in
areas where new instruments and panels are installed.

3.02 SHOP TESTS

A. Shop running and performance tests for the blower shall be made by the manufacturer,
and certified curves and reports shall be submitted for approval prior to shipment.

B. Each blower shall be tested in accordance with the ASME Power Test Code for Centrifugal
Compressors and Exhausters, PTC-10-1974 (reaffirmed 1986) edition. Tests may be
conducted using the job motor or a factory test motor. In either case, a calibrated torque
meter shall measure the gearbox/compressor shaft input horsepower as per Paragraph
4.35 of the Code to verify shaft power draw measurements. The test shall include
determination of the surge point and verification of the guarantee points. Shaft power
consumption shall include one operating oil pump. Compressor net delivered flow rate
and discharge pressure shall be guaranteed with no negative tolerance. There shall be
no other tolerances or measuring uncertainties used in reporting test results (i.e., the tests
shall be reported with ±zero percent tolerance).

31221-009\11183: 11-06-18 11183-27 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4
1. The capacity of the blower shall be defined as per Paragraph 4.26 of the ASME
PTC-10 Power Test Code. Specifically, capacity is defined as, "the net rate of flow
compressed and delivered, expressed in terms of cubic feet per minute at the
prevailing inlet temperature and pressure. It shall be measured in a suitable
manner to exclude effectively all external leakage losses from sources such as
shaft seals." That is, air flow shall be measured on the discharge side of the
compressor at zero percent tolerance.

2. All test equipment shall be calibrated and certified by an independent test agency
no more than twelve (12) months prior to the test date. Certificates shall show the
stability of calibration over a period of at least one year per ISO 9001, Paragraph
4.1.1.

3. Velocity vibration versus frequency levels shall be recorded within 10-1,000 and
10-10,000 Hz frequency range.

C. Upon completion of assembly, each blower, motor, and oil lubrication skid shall be
functionally tested with the blower control panel connected to all skidded instruments,
electric valves, and appurtenances. Witnessing of functional testing for the blowers shall
be at Owner’s option with all travel costs paid by the Owner. The oil lubrication system
shall be run and tested for leaks. All start/stop sequences and all safety and alarm
systems shall be tested, simulating start of the blower motor and shall be demonstrated
to the Owner/Engineer. The functional test may be witnessed by up to two (2)
representatives of the Owner and one (1) representative of the Engineer.

D. Witness testing of ASME PTC-10 tests for the blowers shall be at Owner’s option with all
travel expenses paid by the Owner. If more than one trip is required to complete the
witnessed shop testing, then all subsequent travel expenses for the Owner and/or
Engineer to complete the shop tests shall be paid by the Supplier.

E. The Supplier shall prepare and submit test results, performance curves, and all
calculations with a statement certifying that shop tests were successfully conducted in
accordance with the test requirements and that all specified performance conditions were
demonstrated for each blower system. Certified performance curves based on the results
of the shop performance test shall be developed in terms of standard conditions of 14.7
psia, 68°F, and 36% relative humidity, as well as the design criteria specified in Paragraph
2.02, at the actual blower speed for each point. SCFM shall be plotted against pressure
at both standard and design conditions, and the curve shall show standard horsepower
draw over the range of SCFM flow rates.

F. Each motor shall be shop tested prior to delivery to the Supplier. Each motor shall be
subjected to a complete test per IEEE and NEMA consisting of a full load heat run, percent
slip, running light current, locked rotor current, breakdown torque (calculated), starting
torque, winding resistance, high potential, efficiencies and power factors at 100%, 75%,
50% of full load, bearing inspection and vibration testing per NEMA. In case of failure of
any motor to meet test requirements, the manufacturer shall make such alterations as are
necessary and the tests shall be repeated at no additional cost until the equipment is
satisfactory. The motor manufacturer shall prepare and submit test results with a
statement certifying that shop performance and quality assurance tests were successfully
conducted in accordance with test requirements. Seven copies of certified test reports
shall be submitted prior to shipment to the Supplier.

31221-009\11183: 11-06-18 11183-28 WRF BNR UPGRADE PROJECT
T.Z.OSBORNE PACKAGE 4

3.03 PAINTING

A. The blower, motor, base, and all skid mounted items shall be painted. Paint shall be
furnished by the blower manufacturer. Submit type, application data, specification and
color charts with the submittal drawings. All surface preparation, shop painting, field
repairs, and field painting shall conform to specifications and approved paint system.

3.04 EQUIPMENT IDENTIFICATION

A. The equipment shall be provided with a substantial stainless steel nameplate, securely
fastened in a conspicuous place and clearly inscribed with the manufacturer's name, year
of manufacture, serial number, and principal rating data.

3.05 MAINTENANCE AND REPAIR OF ANCILLARY EQUIPMENT

A. The manufacturer shall contract with a local service representative for maintenance and
repair of ancillary equipment including, but not limited to, check valves, isolation valves,
butterfly valves, actuators, expansion couplings, and pressure/temperature gauges.
Manufacturer shall submit a list of equipment that is acceptable to be repaired by a local
service representative with the submittal.

- END OF SECTION -

31221-009\15100: 11-06-18 15100-1 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4

SECTION 15100

VALVE OPERATORS AND ELECTRIC VALVE ACTUATORS

PART 1 - GENERAL

1.01 THE REQUIREMENT

A. Equipment shall be provided in accordance with the requirements of Section 11000 –
Equipment General Provisions and Section 15000 – Basic Mechanical Requirements.

B. Reference Section 15390 – Schedules for additional information on valves and
operators/actuators.

C. The electric valve actuators shall meet the signal requirements described in Section
17060 – Signal Coordination Requirements, Section 17920 – Control System
Input/Output Schedule, and Section 17950 – Functional Control Descriptions.

D. Valve operators and electric valve actuators shall be designed to unseat, open or close,
and seat the valve under the most adverse operating condition to which the valves will be
subjected.

E. Operator mounting arrangements shall be as indicated on the Drawings or as directed by
the manufacturer and/or Engineer. There shall be no mounting restrictions on the
electric valve actuator.

F. The valve operators and electric actuators shall be the full and undivided responsibility of
the valve manufacturer in order to ensure complete coordination of the components and
to provide unit responsibility.

1.02 SUBMITTALS

A. The following items shall be submitted with the Shop Drawings in accordance with, or in
addition to the submittal requirements specified in Section 01300, Submittals; and
Section 11000, Equipment General Provisions:

1. Certification that the force required to operate all valves is as specified herein.

1.03 WARRANTY AND GUARANTEE
A. Warranty and Guarantee shall be as specified in Section 11000 with the exception that
the warranty period shall be for two (2) years.

31221-009\15100: 11-06-18 15100-2 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4

PART 2 -- PRODUCTS

2.01 GENERAL

A. Electric actuators shall be provided where specified in the Valve Schedule in Section
15390 – Schedules.

B. Manual operators shall be provided on all valves which do not receive electric actuators.
Manual operator type shall be as specified herein and as shown on the Drawings.

C. Quarter turn valves 8” and greater in size shall have geared operators. Gate valves 14”
and greater in size shall have geared operators.

D. Operators/actuators shall be furnished with conservatively sized extension bonnets,
extension stems, or torque tubes, and all required appurtenances required for a complete
installation. Operators furnished with extension bonnets shall include stainless steel
extension stems, or stainless steel torque tubes.

2.02 MANUAL OPERATORS

A. Unless otherwise specified or shown on the Drawings, manual operator type shall be as
follows:

1. Buried valves shall be equipped with nut operators, extended stems, and valve
boxes. Where the depth of the operating nut is more than 4 feet below finish
grade, a valve operator extension shall be provided to bring the operating nut to
within 18-24 inches of the surface.

2. Exposed valves in water service pipes up to 6-inches shall be lever operated
(except gate valves).

3. All exposed valves in process air piping shall be lever operated unless a
chainwheel is required for access.

4. Exposed valves 8-inches and larger in water service pipes shall be handwheel
operated.

5. Exposed gate valves shall be handwheel operated.

6. Valves with centerline of operator located more than 6-feet above the floor or
platform from which it is to be operated shall have a chainwheel operator unless
otherwise indicated on the Drawings.

B. Manual operators shall be rigidly attached to the valve body unless otherwise specified or
shown on the Drawings.

C. All operators shall turn counter-clockwise to open and shall have the open direction
clearly and permanently marked.

31221-009\15100: 11-06-18 15100-3 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4

D. Valve operators shall be designed so that the force required to operate the handwheel,
lever, or chain (including breakaway torque requirements) does not exceed 80 pounds
applied at the extremity of handwheel or chainwheel operator. Design pressures for
sizing of valve operators shall be the piping test pressure for the piping in which the valve
is to be installed as shown in the Piping Schedule in Section 15390 – Schedules.

E. Handwheels for valves operators shall not be less than 12 inches in diameter. The
maximum diameter of any handwheel shall not exceed 24”.

F. Nut operators shall have standard 2-inch square AWWA operating nuts designed in
accordance with AWWA C504-94.

G. Geared manual operators shall be of the worm gear, traveling nut or scotch yolk type
except manual operators for butterfly valves 18-inch in diameter or larger which shall be
worm gear, unless otherwise indicated in the individual valve specification. Gear
operators shall be of the worm gear or bevel gear type. Gear box designs incorporating
end of travel stops in the housing shall be equipped with AWWA input stops. Each
gearbox shall require a minimum of 10 turns for 90 degree rotation or full valve stem
travel and shall be equipped with a mechanical valve position indicator.

H. Manual operators on below grade (and vault installed) valves shall be permanently
lubricated and watertight under an external water pressure of 10 psi.

2.03 ELECTRIC VALVE ACTUATORS

A. Electric Actuators shall be open/close service or modulating service as specified in the
Valve Schedule in Section 15390 – Schedules.

1. Open/Close (non-modulating) valve actuators shall be IQ series as manufactured
by Rotork, SA/SQ series as manufactured by AUMA, or equal.

2. Modulating valve actuators shall be Type IQM as manufactured by Rotork, Type
SAR/SQR as manufactured by AUMA, or equal.

B. Performance Requirements

1. The actuators shall be designed for indoor and outdoor service and shall be
capable of mounting in any position.

2. Torque capacity of the actuators shall be sufficient to operate the valves with the
maximum pressure differential, as indicated in the Valve Schedule in Section
15390, with a safety factor of 1.5. Actuators in modulating service will be
selected such that the required dynamic valve torque is no more than 60% of the
electric actuator’s maximum rated breakaway of torque.

3. Operating time for full limits of travel shall be not more than 2 seconds per inch
diameter of the valve, +/- 50 percent through 20 inches; +/- 30 percent for valves
24 inches and larger. Operating time shall not be less than 60 seconds for all
modulating valves.

31221-009\15100: 11-06-18 15100-4 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4

4. Actuators shall be capable of operating in ambient temperatures ranging from 0
degrees F – 160 degrees F.

5. For open/close (non-modulating) actuators, the gearing, motor and contactor
shall be capable of 60 starts per hour without overheating.

6. For modulating actuators, the gearing, motor and contactor shall be capable of
1200 starts per hour without overheating.

C. The actuators shall include, in one integral housing, individual compartments for the
motor, gearing, wiring terminals, and control circuits. The terminal compartment shall be
separated from the inner electrical components of the actuator by means of a watertight
seal. The inner seal shall protect the motor and all other internal electrical elements of
the actuator from entrance of moisture and dust when the terminal cover is removed.
Double cartridge shaft seals shall be provided on the hand wheel and output shafts for
weatherproof protection. All external fasteners shall be stainless steel. Compartments
shall be provided with moisture and dust-proof rigid cast covers meeting NEMA 6,
certified to submergence in 6 ft of water for 30 minutes. Actuators located in classified
areas shall be suitable for use in Class 1, Division 1, Group D environments.

D. All gearing shall be hardened alloy steel or bronze and shall be rated at twice the output
torque of the operator and shall be designed to withstand the stall torque of the motor
without failure. Output drive gearing shall consist of a worm shaft and worm gear pinion
operating in an oil bath. The worm gear pinion shall be alloy bronze. Worm gear drive
shall be self-locking to prevent creeping of the valve disc in an intermediate position.
Heavy-duty grease shall protect gearing and sealed ball bearings of the main shaft for
five years without changing. Motor reduction gearing shall be spur or planetary gearing
and shall allow for field repair and change in gear ratio. For quarter turn applications,
overtravel of the operator shall be prevented by internal mechanical stops cast into the
actuator.

E. A mechanical dial or digital position indicator shall be furnished to continuously indicate
the position of the valve at and between the fully open and fully closed positions. The
indicator shall be driven by gearing driven off of the main worm gear pinion and shall
operate when the actuator is in either the electrical mode or manual mode and with or
without main power.

F. A handwheel shall be permanently attached for manual operation. A gear assembly shall
be provided between the handwheel and the worm shaft if required to reduce the force
necessary to operate the handwheel to less than 40 pounds. A positive declutch
mechanism, or pushbutton, shall engage the handwheel when required. When the
actuator is set in the declutched position for handwheel operation, it shall return
automatically to electric operation when actuator motor is energized. The handwheel
shall not rotate during electric operation nor shall a fused motor prevent handwheel
operation.

G. The drive motor shall be specifically designed for actuator service and shall be
characterized by high starting torque and low inertia. Motors shall be 460 volts, three
phase, 60 Hz AC reversible squirrel cage induction type motors and shall be specifically
designed for modulating service where indicated on the Valve Schedule in Section

31221-009\15100: 11-06-18 15100-5 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4

15390. Motors shall be totally enclosed, non-ventilated, with NEMA Class F insulation
minimum (Class H for modulating actuators) and a maximum continuous temperature
rating of 120 degree C (rise plus ambient). A 120 VAC space heater shall be provided in
the motor compartment. The electric motor shall have a time rating of at least 15
minutes at 104°F (40°C) or twice the valve stroking time, whichever is longer, at an
average load of at least 33% of maximum valve torque. Motor bearings shall be
permanently lubricated by premium lubricant. The motor shall have plug and socket
electrical connection to facilitate easy removal and replacement. The actuator shall
include a device to ensure that the motor runs with the correct rotation for the required
direction of valve travel with either phase sequence of the three-phase power supply
connected to the actuator. The motor shall include single phase protection. A suitable
thermal protection device shall be incorporated in the motor or motor starter circuits,
connected to a tripping device. Fast acting fuses shall be provided to protect solid state
components. The motor shall be capable of starting against the rated load in either the
open or close direction when voltage to the motor terminals is plus or minus ten (10)
percent of nameplate rating.

1. Open/Close actuators shall be furnished with electro-mechanical reversing
starters.

2. Modulating actuators shall be furnished with solid state reversing starters utilizing
thyristors.

H. Leads from the motor shall be brought to the control circuit (limit switch) compartment
without external piping or conduit box. An adequately sized space heater shall be
installed in the control circuit compartment to aid in the prevention of damage resulting in
from condensation. The following items shall be located in the control circuit
compartment.

1. Torque limit switches shall be provided to de-energize the motor control circuit in
the event of a stall when attempting to unseat a jammed valve and when torque is
exceeded during valve travel. Each actuator shall have an open direction torque
switch and a close direction torque switch. The torque switches shall be
mechanically operated and able to be set in torque units. Torque switches shall
be calibrated prior to the actuator’s assembly to the valve.

2. Travel limit switches shall be provided to de-energize the motor control circuit
when the actuator reaches the limits of travel in the open and close directions.
The limit switch drive shall be of the counter gear type and “in step’” with the
actuator output drive at all times in either the electrical or manual mode of
operation. A minimum of six (6) contacts, three (3) normally open and three (3)
normally closed, shall be supplied at each end of valve travel. Four (4) additional
contacts shall be provided to report end of travel or any desired position between
ends of travel.

I. Modulating actuators shall have a position feedback potentiometer mounted directly to
the valve actuator gearing inside the gearing compartment. The potentiometer shall
provide a 4-20 mA signal corresponding to valve position. Modulating valve actuators
shall be designed to respond to either a 4-20mADC analog signal or a digital pulse signal
as specified herein or as required to coordinate with the requirements of Division 17.

31221-009\15100: 11-06-18 15100-6 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4

1. Modulating valve actuators designed to respond to a 4-20mADC signal shall be
provided with a valve positioner which shall position the valve proportional to an
externally generated 4-20mADC signal. The valve positioning control circuitry
shall position the valve by comparing the command signal with the present valve
position as indicated by the feedback potentiometer. The positioner shall be field
adjustable to fail to the “open,” “closed,” or “last” position on loss of 4-20 mADC
command signal.

2. Modulating valve actuators designed to respond to “pulse” open/close signals
shall operate the valve during the time the open or close pulse signal is high.
Modulating actuators designed to respond to “pulse” open/close signals shall
have the latching circuitry described above for open/close actuators disabled.

J. The electrical terminals shall be housed in a double sealed terminal compartment
isolated from the rest of the actuator components. The actuators shall be designed to
operate from a single 480VAC, 3-phase source. The actuators shall be furnished with
fuses inside of the terminal compartment. A quantity of two – ¾ inch NPT conduit entries
shall be furnished.

K. Actuators shall contain wiring and terminals for the following control functions. All dry
contacts shall be rated for 5A at 250VAC.

1. Open, Close, and Stop commands from external dry contacts (utilizing internal
24VDC power supply) and/or from an external signal of 12V to 120V. The inputs
for the open, close, stop signals shall be field selectable to be respond to either
maintained or momentary remote signals. In momentary mode, the actuator shall
have internal latching circuitry that causes the operator to drive the valve to its
limit of travel upon receipt of the momentary contact signal unless a stop signal is
received.

2. Emergency override input from a normally closed or normally open contact. The
actuator shall either open or close (field selectable) upon receiving the
emergency override input.

3. Remote Local-Off-Remote selector switch, Open/Close pushbuttons, and
Open/Closed pilot lights for a remote manual control station (see below). The
remote Local-Off-Remote selector switch and Open/Close pushbuttons shall be a
dry contact input to the actuator control circuitry. The Open/Closed pilot lights
shall be powered from the valve actuator control power.

4. Four (4) unpowered contacts shall be provided which can be selected to indicate
valve “Opened” and “Closed” position, “Remote” status of the actuator, and fail
status of the actuator. The fail status contacts shall activate upon motor
overtemperature and actuator overtorque as a minimum.

5. Terminals for 4-20mADC position command and 4-20mADC position feedback as
described above for modulating actuators.

31221-009\15100: 11-06-18 15100-7 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4

L. Local Controls

1. Actuators shall be furnished with a Local-Off-Remote selector switch; Open-
Stop-Close pushbuttons or selector switch for local control; a red lamp indicating
closed and a green lamp indicating open. The L-O-R switch shall be padlockable
in any of the three positions.

a. When the LOR is in the “Local” position, open/close control shall be by the
open-stop-close pushbuttons or switches on the actuator. The stop
pushbutton or switch shall stop the actuator travel. Unless specified
elsewhere, the pushbutton or switch for an open/close service actuator
shall be maintained in the open or close position until selected otherwise.
Likewise, the pushbutton or switch for a modulating service actuator shall
be spring loaded so as not to maintain that output when an open or close
selection is made.

b. When the LOR is in the “Off” position, the actuator shall not operate.

c. When the LOR is in the “Remote” position, the actuator shall be controlled
by remote inputs from the PLC or from the remote manual controls station.

2. The local controls shall be arranged so that the direction of travel can be reversed
without the necessity of stopping the actuator.

M. Remote Manual Control Station

1. Where indicated in the Valve Schedule in Section 15390 – Schedules, manual
actuator controls shall be furnished in a separate NEMA 4X stainless steel
enclosure (NEMA 7 if located in a classified area). Remote manual control
stations shall include a Hand–Off-Auto selector switch; Open-Stop-Close
pushbuttons or selector switch; a red lamp indicating closed and a green lamp
indicating open.

a. When the HOA is in the “Hand” position, open/close control shall be by
the open-stop-close pushbuttons or switch on the remote manual control
station. The stop push button or switch shall stop actuator travel. Unless
specified elsewhere, the pushbutton or switch for an open/close service
actuator shall be maintained in the open or close position until selected
otherwise. Likewise, the pushbutton or switch for a modulating service
actuator shall be spring loaded so as not to maintain that output when an
open or close selection is made.

b. When the HOA is in the “Off” position, the actuator shall not operate.

c. When the HOA is in the “Auto” position, the actuator shall be controlled by
remote inputs to the valve actuator from the PLC.

d. Selector switches shall be 30.5 mm, heavy-duty, oil tight NEMA 4X
corrosion resistant with legend plates as specified in Section 16902.

31221-009\15100: 11-06-18 15100-8 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4

2.04 ELECTRIC OPERATORS FOR PVC/CPVC VALVES

A. Automatic electric operators shall be provided for PVC/CPVC valves where specified
and/or as shown on the Drawings. Operators shall operate on 120 volt AC, single phase,
60 hertz power and be equipped with solid state electronic internal controls. Motors shall
be brushless, capacitor-run, reversing type, suitable for high duty cycle applications and
shall be specifically designed for open/close service. Motors shall be provided with
integral thermal overload protection with auto-reset. Operator gears and shafts shall be
constructed of heat treated high-alloy steel. Operator output shaft shall be electro-less
nickel plated. Operator gear trains shall be permanently lubricated. The gear train shall
withstand operator stall torque. Operator enclosures shall be NEMA 4. Operators shall
be provided with internally wired, thermostatically controlled enclosure heaters to
maintain an enclosure temperature of at least 40 degrees F. Operators shall be provided
with positive visual position indication markings permanently affixed to the operator body
and final output shaft. Operator drive output shall be provided with a declutchable
manual override. A manual lever shall be provided for manual valve positioning.
Operators shall be failsafe, utilizing a mechanical spring with a clutch mechanism to
uncouple the motor during spring return operation, allowing the spring to relax and either
open or close the valve. Selection of either fail-opened or fail-closed shall be made by
selection of field wiring terminals.

B. Independently adjustable cam-operated position limit switches shall be provided with dry
contacts for remote fully opened and fully closed valve position indication. Operators
shall respond to external dry contact open/close controls. The actuator shall have
internal latching circuitry that causes the operator to drive the valve to its limit of travel
upon receipt of the momentary contact open or close signal unless a stop signal is
received. The all actuator control circuitry, including latching circuitry, shall be internal to
the valve actuator. Valve control circuits and components mounted in a separate
enclosure external to the valve actuator assembly will not be permitted. Connections for
external remote controls shall be powered from an internal 24VDC or 120VAC power
supply. Limit switches shall be rated for 15 amps at 120 VAC. Valve remote status shall
also be provided as specified in Section 17950. The Contractor shall coordinate operator
controls with the functional requirements specified in Section 17950 – Functional Control
Descriptions.

2.06 SPARE PARTS

A. Spare parts which are identical and interchangeable with the original parts shall be
furnished in clearly identifiable and labeled containers. The Contractor shall provide the
following spare parts in accordance with Section 11000, Equipment General Provisions:

1. Manufacturer recommended spare parts for 5 years of operation.
2. One set of spare fuses for each type of electric actuator supplied.
3. Two spare power supply units suitable for use with electric open/close actuators.
4. Two spare interface boards suitable for use with electric open/close actuators.

31221-009\15100: 11-06-18 15100-9 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4

PART 3 -- EXECUTION

3.01 MANUFACTURER’S FIELD SERVICES

A. The services of a qualified manufacturer's technical representative shall be provided in
accordance with Section 11000, Equipment General Provisions and shall include the
following site visits for electric actuators:

Service Number of Trips Number of Days/Trip
Installation and Testing 1 1
Startup and Training 1 1
Services after Startup 1 1

3.02 INSTALLATION

A. All valve actuators shall be installed in accordance with the manufacturer's published
recommendations and the applicable specification sections for valves, and motor
controls.

B. Valve actuators shall be factory coated in accordance with the manufacturer’s standard
paint system.

3.03 SHOP TESTING

A. Shop testing shall be in accordance with Section 11000, Equipment General Provisions
and with the following additional requirements:

1. Conduct a complete functional check of each unit. Correct any deficiencies found
in shop testing prior to shipment.

2. Submit written certification that:

a. Shop tests for the electrical system and all controls were successfully
conducted;

b. Electrical system and all controls provide the functions specified and
required for proper operation of the valve operator system.

3. Each actuator shall be performance tested and individual test certificates shall be
supplied free of charge. The test equipment shall simulate each typical valve load
and the following parameters should be recorded:

a. Current at maximum torque setting

b. Torque at maximum torque setting

c. Flash Test Voltage

d. Actuator Output Speed or Operating Time

31221-009\15100: 11-06-18 15100-10 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4

e. In addition, the test certificate should record details of specification, such
as gear ratios for both manual and automatic drive, closing direction, and
wiring diagram code number.

f. Verification of actuator torque rating with valve.

3.04 FIELD TESTS

A. Field testing shall be in accordance with Section 11000, Equipment General Provisions
and with the following additional requirements:

1. Valve actuators shall be field-tested together with the associated valves.

2. Test all valves at the operating pressures at which the particular line will be used.

3. Test all valves for control operation as directed.

4. Field testing shall include optimization of opening and closing times of the valves.
Valve opening and closing times shall be adjusted based on process
requirements to optimize operation of the valves. Final valve opening and closing
times as determined by field tests shall be approved by the Engineer prior to final
acceptance of the system.

B. Preliminary Field Tests

1. General: Preliminary field tests shall be conducted prior to start-up and shall
include a functional check of the entire valve operator system and all system
components.

2. Scope: Preliminary field tests shall demonstrate that the valve operator system
performs according to specifications and that all equipment, valves, controls,
alarms, interlocks, etc., function properly.

3. Based on results of preliminary field tests, the Contractor shall make any
adjustments required to settings, etc., to achieve the required valve closing time
and operation, as specified or otherwise directed.

C. Final Field Tests

1. Final field tests shall be conducted in accordance with the latest revision of
AWWA C500.

2. Final field tests shall be conducted simultaneously with the start-up and field
testing of the pumps.

3. Final field tests shall be conducted for the full range of operating modes and
conditions specified and as directed by the Engineer. Each of the valves shall be
tested at minimum, maximum, and normal head/flow conditions, and under all
specified conditions of opening and closing.

31221-009\15100: 11-06-18 15100-11 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4

4. Certification of Equipment Compliance: After the final field tests are completed
and passed, submit affidavit according to Section 11000.

- END OF SECTION -

31221-009\16121: 03-04-19 16121-1 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
SECTION 16121

MEDIUM VOLTAGE CABLE

PART 1 -- GENERAL

1.01 THE REQUIREMENT
A. The Contractor shall furnish, install, connect, test, and place in satisfactory operating
condition, ready for service, all medium voltage cables indicated on the Drawings, as
specified herein, or required for proper operation of the installation. The work of connecting
cables to equipment and devices shall be considered a part of this Section. All
appurtenances required for the installation of medium voltage cable systems shall be
furnished and installed by the Contractor.
B. The scope of this Section does not include internal wiring factory installed by medium
voltage electrical equipment manufacturers.
C. The manufacturer(s) shall furnish a twenty-five (25) year product warranty on all supplied
medium voltage cables and a ten (10) year warranty on splices and terminations.
D. All Contractor personnel installing medium voltage splices or terminations shall be trained
as specified in Part 3, Execution, of this Specification.
E. Reference Section 16000 – Basic Electrical Requirements.
1.02 CODES AND STANDARDS
A. Medium voltage cables and appurtenances shall be designed, manufactured, and/or listed
to the following standards as applicable:
1. Underwriters Laboratories (UL)
a. UL 486A-486B – Standard for Safety Wire Connectors
b. UL 1072 – Standard for Medium-Voltage Power Cables
c. UL 1685 – Standard for Vertical-Tray Fire-Propagation and Smoke-
Release Test for Electrical and Optical-Fiber Cables
2. American National Standards Institute (ANSI)
a. ANSI C119.1 - Electric Connectors - Sealed Insulated Underground
Connector Systems Rated 600 Volts
b. ANSI WC 53 – Standard Test Methods for Extruded Dielectric Power,
Control, Instrumentation, and Portable Cables for Test
3. American Society for Testing and Materials (ASTM)
a. ASTM B3 – Standard Specification for Soft or Annealed Copper Wire 1030185BR

31221-009\16121: 03-04-19 16121-2 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
b. ASTM B8 – Standard Specification for Concentric-Lay-Stranded Copper
Conductors, Hard, Medium-Hard, or Soft
c. ASTM B496 – Standard Specification for Compact Round Concentric-Lay-
Stranded Copper Conductors
d. ASTM D149 – Standard Test Method for Dielectric Breakdown Voltage and
Dielectric Strength of Solid Electrical Insulating Materials at Commercial
Power Frequencies
e. ASTM D150 – Standard Test Methods for AC Loss Characteristics and
Permittivity (Dielectric Constant) of Solid Electrical Insulation
f. ASTM D412 – Standard Test Methods for Vulcanized Rubber and
Thermoplastic Elastomers-Tension
g. ASTM D2303 – Standard Test Methods for Liquid-Contaminant, Inclined-
Plane Tracking and Erosion of Insulating Materials
h. ASTM D2754 – Standard Specification for High-Temperature Glass Cloth
Pressure-Sensitive Electrical Insulating Tape
4. National Electrical Manufacturers Association
a. NEMA WC 53 – Standard Test Methods for Extruded Dielectric Power,
Control, Instrumentation, and Portable Cables for Test
b. NEMA WC 74 - 5-46 kV Shielded Power Cable for Use in the Transmission
and Distribution of Electric Energy
5. Insulated Cable Engineers Association (ICEA)
a. ICEA T-27-581 – Standard Test Methods for Extruded Dielectric Power,
Control, Instrumentation, and Portable Cables for Test
b. ICEA S-93-639 - 5-46 kV Shielded Power Cable for Use in the
Transmission and Distribution of Electric Energy
c. ICEA S-97-682 – Standard for Utility Shielded Power Cables Rated 5
Through 46 kV
6. Institute of Electrical and Electronics Engineers (IEEE)
a. IEEE 48 – Standard for Test Procedures and Requirements for Alternating-
Current Cable Terminations Used on Shielded Cables Having Laminated
Insulation Rated 2.5 kV through 765 kV or Extruded Insulation Rated 2.5
kV through 500 kV
b. IEEE 386 – Standard for Separable Insulated Connector Systems for
Power Distribution Systems above 600 V
c. IEEE 404 – Standard for Extruded and Laminated Dielectric Shielded
Cable Joints Rated 2.5 kV to 500 kV
d. IEEE 1202 – Standard for Flame Testing of Cables
7. Association of Edison Illuminating Companies (AEIC)

31221-009\16121: 03-04-19 16121-3 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
a. AEIC CS8 – Specification for Extruded Dielectric Shielded Power Cables
Rated 5 Through 46 kV
1.03 SUBMITTALS
A. In accordance with the procedures and requirements set forth in the General Conditions
and Section 01300 – Submittals, the Contractor shall obtain from the cable manufacturer
and submit the following:
1. Shop Drawings
2. Reports of Certified Shop and Field Tests
3. Wiring Identification Methods
4. Manufacturer’s Warranty Statements
5. Certificates of training for termination and splice installers
B. Each submittal shall be identified by the applicable specification section.
1.04 SHOP DRAWINGS
A. Each submittal shall be complete in all respects, incorporating all information and data
listed herein and all additional information required for evaluation of the proposed
materials’ compliance with the Contract Documents.
B. Partial, incomplete, or illegible Submittals will be returned to the Contractor without review
for resubmittal.
C. Shop drawings shall include but not be limited to:
1. A Compliance, Deviations, and Exceptions (CD&E) letter. If the shop drawings are
submitted without this CD&E letter, the submittal will be rejected. The letter shall
include all comments, deviations and exceptions taken to the Drawings and
Specifications by the Contractor AND Equipment Manufacturer/Supplier. This
letter shall include a copy of this specification section. In the left margin beside
each and every paragraph/item, a letter "C", "D", or "E" shall be typed or written in.
The letter "C" shall be for full compliance with the requirement. The letter "D" shall
be for a deviation from the requirement. The letter "E" shall be for taking exception
to a requirement. Any requirements with the letter "D" or "E" beside them shall be
provided with a full typewritten explanation of the deviation/exception. Handwritten
explanation of the deviations/exceptions is not acceptable. The CD&E letter shall
also address deviations, and exceptions taken to each Drawing related to this
Specification Section.
2. Product data sheets.
3. Cable pulling calculations.
4. Cable identification methods and materials.

31221-009\16121: 03-04-19 16121-4 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
5. Medium voltage splicing and termination product data sheets.
6. The cable manufacturer’s recommended maximum test voltage and time duration
values for field acceptance testing.
D. The shop drawing information shall be complete and organized in such a way that the
Engineer can determine if the requirements of these specifications are being met. Copies
of technical bulletins, technical data sheets from "soft-cover" catalogs, and similar
information which is "highlighted" or somehow identifies the specific equipment items the
Contractor intends to provide are acceptable and shall be submitted.
1.05 IDENTIFICATION
A. Each cable shall be identified as specified in Part 3, Execution, of this Specification.
1.06 CABLE PULLING CALCULATIONS
A. The Contractor shall submit cable pulling calculations for approval at least 5 working days
prior to making each cable pull. These calculations, to be performed by a currently
registered professional engineer in the state in which the project is located, shall define
pulling tension and sidewall loading (sidewall bearing pressure values) for all medium
voltage cable installations.

PART 2 -- PRODUCTS

2.01 MANUFACTURERS
A. The cables to be furnished and installed for this project shall be the product of
manufacturers who have been in the business of manufacturing medium voltage cables
for a minimum of ten (10) years. Cables shall be designed, constructed, and installed in
accordance with the best practices of the trade, and shall operate satisfactorily when
installed as specified herein and indicated on the Drawings. Only one (1) manufacturer for
each cable type shall be permitted.
B. The cable manufacturer shall be ISO 9000 registered.
2.02 SHIELDED POWER CABLE (ALL VOLTAGE CLASSES)
A. Except where specified otherwise herein, the requirements of this Article shall apply to all
voltage classes of medium voltage shielded power cable (5kV/8kV, 15kV, 25kV, and
35kV).
B. The cable to be furnished and installed for medium voltage circuits shall be shielded power
cable, UL Listed as NEC Type MV-105. The voltage class of the cable for each circuit shall
be as indicated on the Drawings, or if not shown, as approved by the Engineer. In no case
shall the voltage rating of the shielded power cable be less than the voltage rating of the
circuit being supplied by the cable.
C. The conductor shall be annealed bare copper per ASTM B3, Class B compact or
compressed stranded per ASTM B8 or B-496, with an extruded thermoset semiconducting

31221-009\16121: 03-04-19 16121-5 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
EPR conductor shield/screen (i.e. strand shield/screen). The conductor screen shall meet
or exceed the electrical and physical requirements of ICEA S-93-639 (NEMA WC74) and
S-97-682, AEIC CS8, and UL 1072.
D. The insulation shall be an ethylene-propylene rubber (EPR) based thermosetting
compound which meets or exceeds the electrical and physical requirements of ICEA S-
93-639 (NEMA WC74) and S-97-682, AEIC CS8, and UL 1072. Insulation level shall be
133% for the respective voltage class, and as specified elsewhere herein.
E. A thermoset extruded semiconducting insulation screen shall be extruded directly over the
insulation and shall be easily strippable without the use of a release agent. The insulation
screen shall meet or exceed the electrical and physical requirements of ICEA S-93-639
(NEMA WC74) and S-97-682, AEIC CS8, and UL 1072. The insulation thickness and
voltage rating shall be as specified herein.
F. The semiconducting conductor shield/screen, insulation, and semiconducting insulation
screen shall be simultaneously extruded utilizing an enclosed, true triple extrusion process
to prevent contamination of the conductor shield/screen, insulation, and insulation shield.
G. The metallic insulation shield shall be a 5 mil bare copper tape helically applied over the
insulation with a nominal 25% percent overlap. Cables using corrugated shield/drain wires
are not acceptable.
H. The cable jacket shall be flame-retardant, moisture, abrasion, and sunlight-resistant PVC
which meets or exceeds the electrical and physical requirements of ICEA S-93-639
(NEMA WC74) and S-97-682, and UL 1072. Sizes #1/0 AWG and larger shall be shall be
listed and marked “Sunlight- Resistant FOR CT USE” in accordance with the NEC.
I. The shielded power cable shall be Okoguard-Okoseal as manufactured by the Okonite
Company, Uniblend XLF PVC High Speed as manufactured by General Cable, SIMpull
CT1 ET as manufactured by Southwire Company equivalent, or equal.
2.03 5KV/8KV SHIELDED POWER CABLE
A. The insulation for 5kV/8kV shielded power cables shall be 115 mils, rated 5kV-133%
insulation level or 8kV-100% insulation level.
2.04 15KV SHIELDED POWER CABLE
A. The insulation for 15kV shielded power cables shall be 220 mils, rated 15kV-133%
insulation level.
2.05 25KV SHIELDED POWER CABLE
A. The insulation for 25kV shielded power cables shall be 320 mils, rated 25kV-133%
insulation level. Insulation that is 345 mils, rated 25kV-133% insulation level or 35kV-100%
insulation level is also acceptable.
2.06 35KV SHIELDED POWER CABLE

31221-009\16121: 03-04-19 16121-6 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
A. The insulation for 35kV shielded power cables shall be 420 mils, rated 35kV-133%
insulation level.
2.07 5-35KV SHIELDED POWER CABLE TERMINATIONS
A. Shielded power cable termination kits shall be factory engineered for the application. The
insulator material for the termination shall be suitable for outdoor applications and made
from UV-stable, non-tracking (per ASTM D2303) materials. Sealant materials to help
prevent moisture ingress and contamination shall also be included. All terminations shall
meet or exceed all rating requirements for IEEE 48 Class 1 terminations. These
terminations shall meet the test sequence requirements prescribed by IEEE 48, including
130°C load cycling and 130°C impulse withstand.
B. In “Heavy” or “Extremely Heavy” environments, as classified by IEEE-48, terminations
shall consist of a heat shrinkable outer insulating tubing coated internally with a stress
control material or a heat shrinkable outer insulating tubing and a separate heat shrinkable
stress control tubing. Heat-activated sealant materials to help prevent moisture ingress
and contamination shall also be included. These terminations shall meet the test sequence
requirements prescribed by IEEE 48, including 140°C load cycling and 140°C impulse
withstand.
C. Terminations for outdoor exposed locations shall be provided with insulating skirts.
Terminations for indoor locations, or within weather-protected outdoor equipment shall not
be required to have insulating skirts, so long as the termination length does not require
the termination to be partially installed into the associated conduit. Insulating skirts shall
be provided where termination would otherwise be partially installed into the associated
conduit.
D. The terminations shall be manufactured by The 3M Company, Tyco Electronics
(Raychem), or equal.
2.08 5-35KV SHIELDED POWER CABLE SPLICES
A. Power cable splices shall be factory-engineered kits that rebuild the primary cable
insulation, shielding and grounding systems, and outer jacket equivalent to that of the
original cable. When assembled on the cable, the splice shall be capable of passing the
electrical test requirements of IEEE 404, and the water immersion tests of ANSI C119.1.
Splices shall be suitable for direct-burial, manhole, cable tray, and UV exposed areas.
Pre-molded splices are not acceptable. Taped splices are not acceptable.
B. The splices shall provide a positive moisture seal provided by heat activated or pressure
activated sealant.
C. The splices shall accommodate a range of cable sizes and be completely independent of
cable manufacturer’s tolerances. Splices shall be capable of being properly installed on
out-of-round cables per relevant ICEA and AEIC standards.
D. Splices for armored cables shall provide a means of reinstating the armor over the span
of the installed splices.

31221-009\16121: 03-04-19 16121-7 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
E. Heat shrinkable splices shall meet the 140°C load cycling and 140°C impulse withstand
requirements of IEEE 404.
F. Heat shrinkable splices shall be of a uniform-cross-section heat shrinkable polymeric
construction. Internal moisture seals shall inhibit migration of moisture from other sections
of the cable where jacket damage may have occurred.
G. Single component cold shrinkable splices shall be molded from silicone rubber and have
integrated stress relief cones and a faraday cage. It is preferred to have integrated on a
single spiral holdout: the splice body, metallic shield, and re-jacketing sleeve. The
integrated metallic shield shall be a flexible copper sock capable of carrying the neutral
current with ampacity greater than or equal to 1/0AWG copper. The re-jacketing sleeve
shall be extruded from EPDM rubber. The re-jacketing sleeve shall provide a tight
interference fit with the cable jacket and supplied sealing mastic in order to assure an
environmental seal per IEEE 404.
H. In “Heavy” or “Extremely Heavy” environments as classified by IEEE 48, heat shrinkable
splices are required.
I. The splice manufacturer shall provide a test report demonstrating compliance with the
above requirements.
J. Modular splicing kits, utilizing separable connectors which bolt together, may only be used
if specifically approved, in writing, by the Engineer. Modular splicing kits shall be rated for
5-25kV, 600A, and shall meet or exceed the requirements of IEEE 386.
K. The splices shall be manufactured by The 3M Company, Tyco Electronics (Raychem), or
equal.
2.09 CABLE PULLING LUBRICANTS
A. Cable pulling lubricants shall be non-hardening type and approved for use on the type of
cable installed. Lubricant shall be Cable Gel by Greenlee, Poly-Gel by Gardner Bender,
or equal.

PART 3 -- EXECUTION

3.01 GENERAL
A. The cables shall be installed as specified herein and indicated on the Drawings.
B. The cables shall be terminated in accordance with the cable and/or termination product
manufacturer's instructions for the particular type of cable.
C. Splices shall not be allowed in any medium voltage cables. If splices are required, the
Contractor shall obtain approval in writing from the Engineer prior to splicing. Splicing
material shall be as specified herein and as accepted by the Engineer.
D. Cable Sizes

31221-009\16121: 03-04-19 16121-8 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
1. The sizes of cable shall be as indicated on the Drawings, or if not shown, as
approved by the Engineer.
E. Cable Identification
1. Identify 25kV/35kV Class cables by the use of four (4) strips of identification tape.
Identify 15kV Class cables by the use of three (3) strips of identification tape.
Identify 5kV/8kV Class cables by the use of the two (2) strips of identification tape
2. All cables shall be identified at each point of termination. This includes but is not
limited to identification at the source, load, and in any intermediate junction boxes
where a termination is made. The Contractor shall meet with the Owner and
Engineer to come to an agreement regarding a cable identification system prior to
installation of any cables. Cable numbers, where applicable, shall not be
duplicated.
3. Cable identification in manholes, pull boxes, vaults, and other accessible
components in the raceway system where the cables are continuous shall be
accomplished by means of a tag installed around the bundled group of conductors.
Identification shall utilize a FROM-TO system. Each group of conductors shall
consist of all of the individual conductors in a single conduit or duct. The tag shall
have text that identifies the bundle in accordance with the ‘FROM’ and ‘TO’ column
for that particular conduit number in the conduit and wire schedule. Minimum text
size shall be 10 point. The tag shall be affixed to the cable bundle by the use of
nylon wire ties, and shall be made of polyethylene as manufactured by Brady,
Seton equivalent, Panduit equivalent, or equal.
F. Cable Arc and Fireproofing
1. All medium voltage cables installed in manholes, pull boxes, vaults, and other
accessible components in the raceway system shall be arc and fireproofed utilizing
one of the following tape systems:
2. Plymouth Rubber Group
a. 53 PLYARC Arc and Fireproofing Tape
i. 3 inches wide with a thickness of 30 mils.
ii. Tape shall be wrapped around cable in one half-lapped layer.
b. 77 PLYGLAS Glass Cloth Tape
i. 7 mils thickness.
ii. Tape shall be utilized to secure the 53 PLYARC.
iii. Tape shall be in accordance with ASTM D-2754.

31221-009\16121: 03-04-19 16121-9 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
3. The 3M Company
a. Scotch 77 Fire and Electric Arc Proofing Tape
i. 1.5 inches or 3 inches wide, depending upon cable diameter and in
accordance with the manufacturer’s installation instructions, with a
thickness of 30 mils.
ii. Tape shall be wrapped around cable in one half-lapped layer.
b. Scotch 69 Glass Cloth Tape
i. 7 mils thickness.
ii. Tape shall be utilized to secure the Scotch 77.
iii. Tape shall be in accordance with ASTM D-2754.
4. Each individual cable shall be individually arc and fireproofed 6” into the duct.
Multiple cables within a single wrap of fireproofing tape shall not be permitted.
G. Training of Cable
1. The Contractor shall furnish all labor and material required to train cables around
cable vaults within buildings, and in manholes in the outdoor underground duct
system. Sufficient length of cable shall be provided in each manhole and vault so
that the cable can be trained and racked in an approved manner. In training or
racking, the radius of bend of any cable shall be not less than the manufacturer's
recommendation. All manhole cables shall be arc and fire-proofed. The training
shall be done in such a manner as to minimize chaffing. Reference Section 16118
– Underground Electrical.
H. Connections at Equipment
1. Connections at equipment shall be made in accordance with the best practices of
the trade, and the cable and/or termination product manufacturer's instructions for
the particular type of cable.
I. Pulling Temperature
1. Cable shall not be flexed or pulled when the temperature of the jacket is such that
damage will occur due to low temperature embrittlement. When cable will be pulled
with an ambient temperature of 40°F or less within a three (3) day period prior to
pulling, the cable reels shall be stored three (3) days prior to pulling in a protected
storage area with an ambient temperature of 55°F or more. Cable pulling shall be
completed during the work day for which the cable is removed from the protected
storage. Any remaining cable reels shall be returned to storage at the completion
of the workday.
3.02 MEDIUM VOLTAGE CABLE INSTALLATION
A. Medium voltage cable shall be installed so that no damage occurs to the insulation or
outer jacket. Cable shall not be bent or twisted such that the tape shield is pulled apart.
The tape shield shall be twisted and grounded at each termination.

31221-009\16121: 03-04-19 16121-10 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
B. Terminations shall be made with stress control kits in freestanding equipment and
loadbreak elbows in pad mounted equipment. Terminations shall meet or exceed the
ratings of the cable and the interrupting capacity of the connected equipment.
Terminations shall be as specified in Part 2, Products, of this Specification.
C. All splices and terminations shall be in compliance with the cable and splice/termination
manufacturer's recommendations. These recommendations shall be submitted to the
Engineer for review one (1) week prior to making any splices or terminations.
D. Installers shall be trained by the factory supplying medium voltage terminations and
splices in the proper installation of the products. Installers shall be able to produce
evidence of such training within the past three (3) years. This evidence shall be submitted
to the Engineer for review one (1) week prior to making any splices or terminations.
3.03 MATERIAL STORAGE AND HANDLING
A. The Contractor shall inspect the cable and reels upon receipt for visible or hidden damage.
Reels should not be shipped on their side, and should be shipped with a protective cover
over the cable on the reel. Reels turned over onto their side are subject to damage. Reels
shall not be rolled-off the truck or lifted by forks on the drum. Reels shall be lifted by a
chain connected to a spreader bar through the arbor hole. Reel ends shall be covered by
a heat-shrinkable end cap upon shipment, and again each time a cable end has been cut
from the reel. The Contractor shall note any damage that has been identified on the bill of
lading and take photos of the damage at the time of delivery. Any damage shall be
reported to the engineer, project management, and cable distributor, and such report(s)
shall include the photos of the damage.
B. Cable reels shall be stored in areas away from high traffic (where it may be subject to
damage).
3.04 TESTING
A. All testing shall be performed in accordance with the requirements of the General
Conditions and Division 1. The following tests are required:
1. Shop Tests
a. Cables shall be tested in accordance with the applicable ICEA Standards.
Cables shall be physically and electrically tested in accordance with the
manufacturer’s standards.
b. Cable shall be tested at the factory in accordance with AEIC CS8 (latest
revision) except that the cable shall be corona free when tested at 200 VAC
per mil and 363 VDC per mil. Corona test results to be available on an X-Y
plot. Tests shall be as described by ICEA S-93-639 (NEMA WC74), Section
6 or ICEA T-27-581 (NEMA WC53).
2. Field Tests
a. Field testing shall be performed in accordance with NETA Acceptance
Testing Specifications (ATS), latest edition.

31221-009\16121: 03-04-19 16121-11 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
b. After installation, all medium voltage cables shall be tested for insulation
levels and continuity in accordance with NETA test documents and the
cable manufacturer’s recommendations. Insulation resistance between
conductors of the same circuit and between conductor and ground shall be
tested. Testing for insulation levels shall be as follows:
i. Cable shall be given a conductor continuity check and a high
voltage DC field acceptance test after installation. The DC test
voltage shall be in accordance with AEIC CS8, however shall not
exceed the cable manufacturer’s recommended maximum test
voltage and time duration.
B. Medium voltage cables shall be tested before being connected to equipment.
C. If tests reveal defects or deficiencies, the Contractor shall make the necessary repairs or
shall replace the cable as directed by the Engineer, without additional cost to the Owner.
All conductors of a multi-phase circuit shall be replaced if one conductor fails the required
testing. If part of a multi-set (parallel conductors per phase) circuit fails testing, only the
set containing failure shall be replaced.
D. All tests shall be made by and at the expense of the Contractor who shall supply all testing
equipment. Test reports shall be submitted to the Engineer.

- END OF SECTION -

31221-009\16305: 03-04-19 16305-1 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
SECTION 16305

MEDIUM VOLTAGE MOTOR CONTROL CENTERS – RVSS STARTER

PART 1 -- GENERAL

1.01 THE REQUIREMENT

A. The Contractor shall provide the services of the equipment manufacturer’s field services
group to modify the existing medium voltage motor control center (MCC-1). The Contractor
shall furnish, install, test, and place in satisfactory operating condition new medium voltage
motor control equipment (new sections added to the existing medium voltage motor
control center) as specified herein and indicated on the Drawings. The Contractor shall
also provide demolition of the existing RVAT starter, turning over the starter to the Owner
after being removed from service.

B. The medium voltage motor controllers shall be of the roll-out design with vacuum
contactors.

C. The medium voltage motor control center line-up additions and/or modifications shall
include medium voltage motor controllers, protective relays, control devices, and all
accessories as specified herein and indicated on the Drawings to result in a complete
equipment assembly.

D. The Contractor shall obtain the motor control centers from a single manufacturer who shall
also manufacture the structure and major equipment components. Subcontracting of
wiring is not acceptable.

E. The medium voltage motor controllers shall be assembled using NEMA rated components.
Components designed and built to International Electrotechnical Commission (IEC)
standards are not recognized. Equipment designed, manufactured and labeled in
compliance with IEC standards is not acceptable.

F. Motor control circuits shall be wired in accordance with the requirements specified herein
or indicated on the Drawings.

1.02 CODES AND STANDARDS

A. The medium voltage motor controllers shall be designed, manufactured, assembled, and
tested in accordance with the following standards:

1. ANSI/NEMA ICS-3-Part 2

2. UL 347

3. EEMAC E14-1.

1.03 TESTING
092612BR

31221-009\16305: 03-04-19 16305-2 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
A. All tests shall be performed in accordance with the requirements of the General Conditions
and Division 1. The following tests are required:

1. Witnessed Shop Tests

a. The motor control centers specified in this Section shall be witness shop
tested and inspected in accordance with the equipment manufacturer's
standard procedures. The testing and inspection procedures shall
demonstrate that the equipment tested conforms to the requirements
specified and shall be approved by the Engineer. At least 10 days’ notice
shall be given the Engineer prior to such tests and inspection dates.

2. Certified Shop Tests and Reports

a. Submit description of proposed testing methods, procedures, and
apparatus.

b. Submit certified copies of all test reports.

c. As a minimum, the entire motor control center addition shall go through a
quality inspection before shipment. This inspection shall include, but is not
limited to, the following:

i. Physical inspection of the structure and the electrical conductors
including bussing, general wiring, and motor controller sections.

ii. General electrical tests including power circuit phasing, control
circuit wiring, instrument transformers, meters, protective relaying,
and device electrical operation.

iii. AC dielectric tests of the power circuits and control circuits.

iv. Markings/labels, including instructional type, Underwriters
Laboratory (U.L.), and inspector's stamps.

d. The following standard factory tests shall be performed on the equipment
provided under this Section. All tests shall be in accordance with the latest
version of ANSI and NEMA standards.

i. Wiring check.

ii. Sequence of control circuits.

iii. Dielectric Test (Hi Pot) per NEMA ICS 3 Part 2 at 2000 volts plus
2.25 times nominal voltage, for 60 seconds, phase-to-phase and
phase-to-ground.

iv. Style/part no. check of components.

31221-009\16305: 03-04-19 16305-3 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
e. The manufacturer shall use integral quality control checks throughout the
manufacturing process to maintain the correctness of the motor control
center.
3. Field Tests

a. Field tests shall be performed in accordance with requirements specified in
the General Conditions, Division 1, and Section 16000, Basic Electrical
Requirements.

1.04 SUBMITTALS

A. In accordance with the procedures and requirements set forth in the General Conditions
and Section 01300, Submittals, the Contractor shall obtain from the equipment
manufacturer and submit the following:

1. Shop Drawings

2. Operation and Maintenance Manuals

3. Spare Parts List

4. Special Tools List

5. Proposed Testing Methods and Reports of Certified Shop Tests.

6. Manufacturer's representative's certification.

B. Each submittal shall be identified by the applicable specification section.

1.05 SHOP DRAWINGS

A. Each submittal shall be complete in all respects, incorporating all information and data
listed herein and all additional information required for evaluation of the proposed
equipment's compliance with the Contract Documents.

B. Partial, incomplete, or illegible submissions will be returned to the Contractor without
review for resubmittal. The letter and performance affidavit described above must be
included in the first submittal.

C. Shop drawings for each motor control center assembly shall include but not be limited to:

1. A Compliance, Deviations, and Exceptions (CD&E) letter. If the shop drawings are
submitted without this CD&E letter, the submittal will be rejected. The letter shall
include all comments, deviations and exceptions taken to the Drawings and
Specifications by the Contractor AND Equipment Manufacturer/Supplier. This
letter shall include a copy of this specification section. In the left margin beside
each and every paragraph/item, a letter "C", "D", or "E" shall be typed or written in.
The letter "C" shall be for full compliance with the requirement. The letter "D" shall
be for a deviation from the requirement. The letter "E" shall be for taking exception
to a requirement. Any requirements with the letter "D" or "E" beside them shall be
provided with a full typewritten explanation of the deviation/exception. Handwritten

31221-009\16305: 03-04-19 16305-4 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
explanation of the deviations/exceptions is not acceptable. The CD&E letter shall
also address deviations, and exceptions taken to each Drawing related to this
Specification Section.

2. Product data sheets.

3. Complete assembly, layout, installation, and foundation drawings with clearly
marked dimensions.

4. Weights of all major component parts, assembled weight of units and approximate
total shipping weight.

5. Example equipment nameplate data sheet.

6. Plan, front and side view drawings, including overall dimensions of each motor
control center. Identify shipping splits and show conduit entry/exit locations
indicated on the drawings.

7. Custom internal schematic and point-to-point wiring diagrams of each motor
controller. Standard wiring diagrams that are not custom created by the
manufacturer for the motor controllers for this project are not acceptable. One
wiring diagram which is typical for an equipment group (e.g. Blowers) is not
acceptable. Each wiring diagram shall include wire identification and terminal
numbers. Indicate all devices regardless of their physical location on the diagrams.
Identify on each respective wiring diagram the specific equipment name consistent
with those indicated on the Drawings.

8. External connection diagram showing the wiring to the external controls and
devices associated with the motor control center.

9. Complete one-line diagram for each motor control center showing isolating switch,
fuses, vacuum contactor, instrument transformers, meters, protective relays, motor
protection module, timers, control devices, and other equipment comprising the
complete assembly. Clearly indicate electrical ratings of all devices. Ratings
include contactor size and type, fuse rating, transformer ratings, motor
horsepower, speed, full load current, and similar information.

10. Bill of material for each section comprising the motor control center assembly.

11. Nameplate schedule for each section.

12. Manufacturer's installation instructions.

13. Manufacturer's standard warranty.

14. Cable terminal sizes.

D. The shop drawing information shall be complete and organized in such a way that the
Engineer can determine if the requirements of these specifications are being met. Copies
of technical bulletins, technical data sheets from "soft-cover" catalogs, and similar

31221-009\16305: 03-04-19 16305-5 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
information which is "highlighted" or somehow identifies the specific equipment items the
Contractor intends to provide are acceptable and shall be submitted.

1.06 OPERATION AND MAINTENANCE MANUALS

A. The Contractor shall submit operation and maintenance manuals in accordance with the
procedures and requirements set forth in the General Conditions and Division 1. The
manuals shall include:

1. Instruction books, descriptive bulletins, technical bulletins, application data
booklets, and other applicable instructional information.

2. Recommended spare parts list.

3. Final as-built construction drawings included in the shop drawings incorporating all
changes made in the manufacturing process.

1.07 TOOLS, SUPPLIES, AND SPARE PARTS

A. The medium voltage motor control centers and accessories shall be furnished with all
special tools necessary to disassemble, service, repair, and adjust the equipment and all
spare parts as recommended by the equipment manufacturer.

The Contractor shall furnish the following minimum spare parts for each motor control
center assembly:

No.
Required
Description
1 set Fuses of each size provided
1 Control power transformer for each size used
2 Lamps and lenses for indicating lights, each
color

B. The spare parts shall be packed in containers suitable for long term storage, bearing labels
clearly designating the contents and the pieces of equipment for which they are intended.

C. Spare parts shall be delivered at the same time as the equipment to which they pertain.
The Contractor shall properly store and safeguard such spare parts until completion of the
Work, at which time they shall be delivered to the Owner.

D. Spare parts lists, included with the shop drawing submittal shall indicate specific sizes,
quantities, and part numbers of the items to be furnished. Terms such as "1 lot of packing
material" are not acceptable.

E. Parts shall be completely identified with a numerical system to facilitate parts inventory
control and stocking. Each part shall be properly identified by a separate number. Those
parts which are identical for more than one size, shall have the same parts number.

1.08 SERVICES OF MANUFACTURER'S REPRESENTATIVE

31221-009\16305: 03-04-19 16305-6 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4

A. The Contractor shall provide the services of a qualified, factory-trained, manufacturer's
technical representative who shall adequately supervise the installation and testing of
equipment furnished under this Contract and instruct the Contractor's personnel and the
Owner's operating personnel in its maintenance and operation as outlined in Division 1
and Section 11000, Equipment - General Provisions. The services of the manufacturer's
representative shall be provided for a period of not less than six (6) days as follows:

1. One trip of three (3) working days during installation of the equipment.

2. One trip of two (2) working days after acceptance of the equipment to perform
startup services. Startup shall be closely coordinated with the Electrical Contractor,
Blower Manufacturer, and Motor Protection Relay programmer to ensure all parties
are at startup at the same period of time.

3. One trip of one (1) working day during the warranty period.

B. Any additional time required to achieve successful installation and operation shall be at
the expense of the Contractor. The manufacturer's representative shall sign in and out at
the office of the Engineer's Field Representative on each day he is at the project.

1.09 IDENTIFICATION

A. Each motor control center shall be identified with the identification number indicated on
the Drawings (e.g. Blower No.2 RVSS). A nameplate shall be securely affixed in a
conspicuous place on each motor control center section. Nameplates shall be as specified
in Section 16195, Electrical - Identification.

1.10 TRAINING

A. The Contractor shall provide training for Owner personnel. Training shall be conducted by
the manufacturer's factory-trained representative(s) who shall instruct Owner personnel in
operation and maintenance of all equipment provided under this Section. Training shall be
in accordance with the requirements of Section 11000, Equipment - General Provisions.

1.11 CONSTRUCTION SEQUENCING

A. The Contractor shall reference Section 01520, Maintenance of Utility Operations During
Construction, of these Specifications for construction sequencing information during the
construction period.

PART 2 -- PRODUCTS

2.01 MANUFACTURERS

A. The equipment covered by these specifications is intended to be standard equipment of
proven performance as manufactured by reputable concerns. Equipment shall be
designed, constructed, and installed in accordance with the best practices of the trade,
and shall operate satisfactorily when installed as shown on the Drawings.

31221-009\16305: 03-04-19 16305-7 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
B. It is the intent of these specifications that the medium voltage motor control centers be
produced by a single manufacturer who shall be responsible for matching all components
and providing equipment which functions together as a system.

C. The medium voltage motor control center sections shall be Eaton Ampgard as
manufactured by Eaton Corporation to match the existing lineup, no substitutions shall be
permitted.

2.02 MEDIUM VOLTAGE MOTOR CONTROL CENTERS

A. General

1. These specifications define requirements for medium voltage vacuum motor
starters of the sizes, types, and ratings as specified herein and indicated on the
Drawings.

2. All starters shall be designed and tested to meet the latest applicable NEMA and
ANSI standards. The starters shall be fused type, NEMA Class E2, as defined by
NEMA Industrial Control Standard ICS2-324.

3. All starters shall be equipped with current limiting power fuses.

4. The starters shall be designed to accommodate motors of the size and type as
shown on the Drawings and as provided in the Appendix. Unless otherwise noted,
the type of starting shall be across the line with a minimum 400A (open) /360A
(enclosed) contactor. Where reduced voltage starters are required, they shall
provide closed transition starting from reduced to full voltage.

B. Ratings

1. Additional starters added to the exiting medium voltage MCC lineup shall match
the rating of the existing assembly. Refer to the Contract Drawings for model and
serial numbers of the existing lineup.

C. Construction

1. The medium voltage motor control center shall be of the two-high cabinet design
with a vacuum contactor and bolted field wiring terminations. Enclosures shall be
NEMA 1A (gasketed) unless otherwise noted, made of 12 gauge steel, painted as
specified herein.

2. Isolating switch and contactor assemblies, including current limiting fuses, shall be
of the component-to-component design without any interconnecting cables or
flexible shunts. They shall be easily removed from the front of the enclosure. Line
and load cable terminations shall be completely accessible from the front.

3. The non-load break isolating switch shall be an externally operated, manual, three-
pole type such that in the open position it isolates the starter from the line leaving
no exposed high voltage. Integral mechanical interlocks shall prevent entry into the
high voltage areas while the starter is energized and shall block accidental opening
or closing of the isolating switch when the door is open or contactor is closed. The

31221-009\16305: 03-04-19 16305-8 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
isolating switch handle shall have provisions for three padlocks in the "OFF"
position.

4. Current limiting power fuses shall be of the self-protecting type with visible fuse
condition indicators, and with special time/current characteristics for motor service
allowing proper coordination with the contactor and overload relay for maximum
motor protection. This coordination shall be such that under a low fault condition
the interrupting rating and drop-out time of the contactor shall be properly
coordinated with all possible fuse sizes to eliminate contactor racing. The power
fuses shall be vertically mounted permitting easy inspection and replacement
without starter disassembly. Fuses shall be coordinated with the starting and
acceleration time requirements of their respective connected motors.

D. Vacuum Contactors

1. The vacuum contactors shall be of the roll-out design with single-break, high
pressure type main contacts with weld-resistant alloy contact faces. The vacuum
contactor contact wear shall be easily checked with the use of a feeler gauge
included with each contactor.

2. The vacuum contactors shall have the following ratings:

Description Specification
Interrupting Rating
400 MVA at 4.6kV
NEMA Fused (E2)
Maximum Insulation Voltage 7.2kV
Maximum Interrupting Current
(Three Operations) 8.5kA
Rated Current (Open) 400A
Chop Current 0.3A Avg.
Short Time Current
30 Sec.
1 Sec.
8.7 MS (0.5 cycle)
2.4kA
6.0kA
63kA Peak
Mechanical Life 2.5 Million Operations
Electrical Life 300,000 Operations at Rated Current
Impulse Withstand 60kV
(1.2 x 50 microseconds)

E. Reduced Voltage Solid-State Starters

1. The reduced voltage solid-state controller shall be Eaton type MV4S, no
substitutions. The starter shall be UL and CSA listed. The SCR-based power
section shall consist of back-to-back SCRs and shall be rated for a minimum peak
inverse voltage rating as shown in the ratings section. Units using triacs or
SCR/diode combinations shall not be acceptable. Resistor/capacitor snubber

31221-009\16305: 03-04-19 16305-9 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
networks shall be used to prevent false firing of SCRs due to dv/dt effects.

2. The fully-rated run bypass contactor shall energize when the motor reaches 90%
of full speed. The solid-state power stack assembly shall be mounted on a roll-out
truck for ease of maintenance. The full-voltage starting feature of the RVSS shall
be programmatically disabled at the factory to ensure the motor will only be start
and ran using the SCRs.

3. Reduced voltage solid-state controllers shall include protection and ramp features
programmable via the integrated keypad or a laptop computer including:

a. Dual ramp adjustments with current limit to 600% FLA, acceleration time of
1 to 120 seconds
b. Kick start, 0.1 to 2.0 seconds at 10% to 100% voltage
c. Selectable ramp profiles to match any application
d. Pump deceleration, 1 to 60 seconds with begin and end torque adjustments

4. Reduced voltage solid-state controllers shall include a fiber-optically isolated low
voltage compartment.

5. The reduced voltage solid-state starters shall have the following ratings:

Description Specification

Horsepower HP as shown on the drawings
Power Ratings 600% FLA for 30 Sec. 125% Continuous
PIV Ratings 5000 Vac: 14000 V
Starting Torque 5 to 85%
Ramp Time 0 to 180 Seconds
Maximum Voltage Rating 5000 Vac
BIL Rating 60 KV
Rated Short Circuit Amperes 50 kA rms Sym.
SCR Voltage Drop or 3.5 V without bypass/<1 V with bypass
Voltage Drop “L” to “T”
Overall Efficiency 99.7% without bypass/99.94% with bypass
Transient Protection DV/DT Circuits/Phase

F. Bus

1. When starters are grouped together in a line-up, the horizontal main bus shall be
located in its own separate, 12-inch high enclosure and isolated from the starters.
To allow for ease of maintenance or extension of line-ups without disassembling
starters, the main bus shall be front, top and side accessible. The main horizontal
bus compartment may also be located within the standard 90-inch high enclosure.

2. Starters shall be connected by an insulated vertical bus.

3. All bus bars shall be tin-plated copper. Bus shall be rated for 1200A continuous
current.

31221-009\16305: 03-04-19 16305-10 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
4. Each section shall be furnished complete with a suitably sized (1/4 x 2 inch,
minimum) uninsulated ground bus.

5. The new motor controller(s) shall be bussed to the existing line-up using insulated
tin-plated copper bus. This includes the main bus and the uninsulated ground bus.

G. Low Voltage Control

1. The low voltage control shall be isolated and barriered from the high voltage area
and provided on a panel with a separate low voltage access door.

2. A built-in test circuit shall be included to permit checking of the starter control and
pilot circuit with the high voltage de-energized and isolated and the contactor in its
normal position or in its draw-out inspection position. In the test mode, the control
circuit shall be capable of being energized through a polarized plug connector from
an external 115 VAC supply.

H. Programmable Motor Protection Relay

1. Each medium voltage motor protection relay shall be provided with a
microprocessor based, motor protection relay in each individual starter to protect,
monitor, and control the motor.

2. The motor protection relay shall be capable of monitoring electrical current; receive
commands from remote sources either by contact closures or digital data; give
commands (e.g. fail, trip, etc.) to the motor controller and other devices under its
control; and communicate by alphanumeric display with the operator and by digital
signals with other equipment.

3. True rms current shall be constantly monitored, separated into positive and
negative sequence components to determine the heating effects caused by both,
and processed to provide maximum motor utilization.

The motor protection relay shall be mounted on the low voltage compartment door.
Current transformers shall be provided as indicated on the Drawings and as
required.

4. Specific data entry to suit the actual motor application shall be accomplished by
means of an operator panel. Entered data shall be stored in "non-volatile" memory
so as not to require battery back-up.

5. A digital display of monitoring functions including, but not limited to, the following
shall be provided:

a. Line current in each phase in rms amperes

b. Running time (cumulative in hours)

c. Remaining starts

d. Motor starts exceeded

31221-009\16305: 03-04-19 16305-11 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4

e. Alarm status

6. The following protection and control functions including, but not limited to, the
following shall be provided:

a. Motor running time overcurrent (thermal overload): Device 49/51

b. Locked rotor: Device 49S/51.

c. Phase instantaneous and inverse-time overcurrent: Device 50P/51P

d. Ground (zero-sequence) instantaneous and inverse-time overcurrent:
Device 50G/51G (50X/51X and 50R/51R)

e. Jam and stall: Device 50J

f. Phase unbalance negative sequence overcurrent: Device 46

g. Underload trip with start and run time delays: Device 37

h. Starts per hour: Device 66

i. Lockout: Device 86

j. Breaker failure: Device 50BF

k. Motor Differential Protection: Device 87

7. Motor protection relays shall include RS-232 and RS-485 ports for Modbus-RTU
communications, and shall be furnished with an RJ-45 Ethernet port for Modbus-
TCP communication to the plant control system.

8. Motor protection relays shall be provided with the analog output option to
provide a 4-20mA power signal to the Blower Control Panel. Relay shall be
configured to calculate HP using voltage and current inputs, and transmit
the calculated HP.

8. Motor protection relays shall be model EMR-5000 as manufactured by Eaton
Corporation, no substitutions.

I. Reduced Voltage Solid-State Controllers

1. Each squirrel-cage motor, reduced voltage solid-state controller shall include, but
not be limited to, the following equipment:

High Voltage Section

3 Isolated vertical line connectors

1 Three-pole isolating switch

31221-009\16305: 03-04-19 16305-12 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4

3 Current limiting power fuses

1 Roll-out three-pole main vacuum contactor

1 Reduced voltage solid-state starter assembly

1 Control power transformer, size as required (2kVA, minimum)

2 Control power transformer primary current limiting fuses

1 Control power transformer secondary fuse

1 Control circuit disconnect plug

1 Run test circuit

3 Spare electrical interlocks

3 Ring (window) type current transformers for the programmable motor
protection relay

1 Current transformer for zero-sequence ground fault protection

3 Load terminals

1 Operating and maintenance instructions manual mounted on door

Low Voltage Section

1 Motor protection system as specified above

Lot Control relays and adjustable timing relays as required. Timing relays shall
be as specified in Section 16902.

1 Set of control circuit terminal blocks

1 Solid-state reduced-voltage control assembly

J. Wiring and Terminations

1. Low voltage wiring shall have tag identification at each end and shall be neatly
bundled. Medium voltage wiring must be properly braced and sized for the
maximum horsepower rating of the contactor. The use of twine or string for the
harnessing of cables shall not be permitted. Any taping of power connection points
is prohibited.

2. Wire markers shall be a molded plastic "clip-sleeve" type.

3. All control wire shall be UL/CSA approved.

31221-009\16305: 03-04-19 16305-13 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
4. Standard control wire shall be No. 14 AWG, stranded, tin-plated, red, dual-rated
Type XLPE (3173) 125 degree C, SIS 90 degree C.

5. Current transformer circuits shall utilize No. 12 AWG (minimum) wire with the same
characteristics as above. Number 10 AWG or larger wire shall be used to decrease
circuit resistance as required.

6. Provide shorting blocks for all current transformers.

7. Provide "plug-in" terminal blocks rated 600V, 50A with "clamping collar".
"Clamping-collar" type terminals shall be used to terminate control wiring.

8. Current transformer circuits shall be provided with ring-type terminals where
applicable.

K. Enclosures

1. Provide NEMA 1A (gasketed) enclosures for indoor applications where shown on
the Drawings. Enclosures shall be provided with space heaters and thermostats.
Control power shall be obtained from an internal control power transformer.

2. Enclosures for the medium voltage starters shall meet NEMA ICS-6 standards.
Enclosure shall be completely front accessible, allowing for free-standing, against
a wall, or back-to-back mounting.

3. Provide a dedicated incoming line enclosure section to accommodate the number
and size of incoming cables for bottom entry.

4. Provide structures for line and match connection. Provide blank structures to
complete bus tie-in as required.

5. Structures shall be welded steel frame, formed steel doors and side sheets, flat
steel top and rear covers.

6. Standard hardware shall be Grade 5, plated zinc-dichromate.

L. Finish

1. The finish for internal and external parts shall consist of a coat of ANSI 61 (gray)
thermosetting, polyester powder paint applied electrostatically to pre-cleaned
phosphatized steel and aluminum surfaces.

M. Warning Signs

1. Warning signs shall be of red and white laminated phenolic materials engraved
through red exterior lamination to white center with approximately 1/2 high letters.

2. Sign shall read "WARNING-HIGH VOLTAGE-KEEP OUT" in compliance with
NEC 110-34(c). All new and existing motor control center sections shall have a
warning sign installed in the appropriate location.

31221-009\16305: 03-04-19 16305-14 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
N. Accessories

1. Provide a motor protection relay communication cable and any required software
with licenses for access to the programming of the new motor protection relay.
Provide instructions on communication settings required.

2. A fuse puller shall be provided for each new and modified motor controller.

PART 3 -- EXECUTION

3.01 INSTALLATION

A. The medium voltage motor control centers shall be furnished and installed as shown on
the Drawings and in accordance with the manufacturer's installation instructions. One (1)
copy of these instructions shall be included with the equipment at time of shipment. The
equipment shall be suitably protected with space heaters connected until accepted by the
Owner.

B. The Contractor shall check all bolted connections to assure that they are in accordance
with the manufacturer's recommended torque requirements.

3.02 PAINTING

A. Prior to final completion of the work, all metal surfaces of the equipment shall be cleaned
thoroughly, and all scratches and abrasions shall be retouched with the same coating as
used for factory finishing coats.

3.03 FIELD ADJUSTMENTS

A. The protective relays shall be properly configured and the appropriate settings shall be
installed in the field by a qualified representative of the manufacturer, in conjunction with
the input from the Blower Manufacturer. The settings to be installed shall be specific to
blower applications and shall be submitted to the Engineer for review/comment, prior to
programming.

3.04 MANUFACTURER'S CERTIFICATION

A. A qualified factory-trained manufacturer's representative shall certify in writing that the
equipment has been installed, adjusted, and tested in accordance with the manufacturer's
recommendations.

- END OF SECTION -
31221-009\17060: 06-16-17 17060-1 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
SECTION 17060
SIGNAL COORDINATION REQUIREMENTS
PART 1 -- GENERAL
1.01 THE REQUIREMENT
A. The Contractor shall conform to the signal coordination requirements specified herein.
B. The Contractor shall be responsible for coordinating signal types and transmission
requirements between the various parties providing equipment under this Contract. This
shall include, but not be limited to, distribution of appropriate shop drawings among the
equipment suppliers, the electrical subcontractor and the HVAC subcontractor.
C. Analog signals shall be signals for transmitting process variables, etc. from instruments
and to and from panels, equipment PLC's and Control System PLC's.
D. Discrete signals shall consist of contact closures or powered signals for transmitting
status/alarm information and control commands between starters, panels, equipment
PLC's, the Control System, etc.
1.02 ANALOG SIGNAL TRANSMISSION
A. Signal transmission between electric or electronic instruments, controllers, and all
equipment and control devices shall be individually isolated, linear 4-20 milliamperes and
shall operate at 24 volts D.C.
B. Signal output from all transmitters and controllers shall be current regulated and shall not
be affected by changes in load resistance within the unit's rating.
C. All cable shields shall be grounded at one end only, at the control panel, with terminals
bonded to the panel ground bus.
D. Analog signal isolation and/or conversion shall be provided where necessary to interface
with instrumentation, equipment controls, panels, and appurtenances.
E. Non-standard transmission systems such as pulse duration, pulse rate, and voltage
regulated shall not be permitted except where specifically noted in the Contract
Documents. Where transmitters with nonstandard outputs do occur, their outputs shall be
converted to an isolated, linear, 4-20 milliampere signal.
F. The Contractor shall provide 24 V power supplies for analog signals and instruments
where applicable and as required inside panels, controls, etc.
G. Where two-wire instruments transmit directly to the Control and Information System, the
Contractor shall provide power supplies at the PLC-equipped control panels for those
instruments.
31221-009\17060: 06-16-17 17060-2 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4
H. Where four-wire instruments with on-board loop power supplies transmit directly to the
Control and Information System, the Contractor shall provide necessary signal isolators or
shall otherwise isolate the input from the Control and Information System loop power
supply. Similar provisions shall be made when a third element such as a recorder,
indicator, or single loop controller with integral loop power supply is included in the loop.
1.03 DISCRETE INPUTS
A. All discrete inputs to equipment and Control and Information System PLC's, from field
devices, starters, panels, etc., shall be unpowered (dry) contacts in the field device or
equipment, powered from the PLC's, unless specified otherwise.
B. Sensing power (wetting voltage) supplied by the PLC shall be 24 VDC.
1.04 DISCRETE OUTPUTS
A. All discrete outputs from local control panels and Control and Information System PLC's
to field devices, starters, panels, etc., shall be 24 VDC powered (sourced) from PLC's.
B. PLC powered discrete outputs shall energize 24 VDC pilot relay coils in the field devices,
starters, panels, etc. which in turn open or close contacts in the associated control circuit.
The 24 VDC relay coil, contacts, and associated control circuitry shall be furnished
integral with the field device, starter, panel, etc. by the supplier and Contractor furnishing
the field device, starter, or panel.
C. Where required or specified herein, discrete outputs from equipment and Control and
Information System PLC's to field devices, starters, panels, motor operated valves, etc.,
shall be dry contact or relay outputs.
PART 2 -- PRODUCTS
2.01 PILOT RELAYS
A. Pilot relays shall be supplied with the following:
1. 24 VDC coils.
2. At a minimum, DPDT contacts rated at 5 A, 120 VAC or 28 VDC.
3. Socket of different configuration from 120 VAC relays.
4. Clips for attachment to sockets.
5. Indicator lights that glow when the relay coil is powered.
B. Pilot relays shall be as manufactured by Square D, Allen Bradley, Potter & Brumfield, or
equal.
PART 3 -- EXECUTION
(NOT USED)
- END OF SECTION -

31221-009\17190: 11-06-18 17190-1 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4

SECTION 17190

UNINTERRUPTIBLE POWER SYSTEMS

PART 1 -- GENERAL

1.01 THE REQUIREMENT

A. The Contractor shall furnish, test, install and place in satisfactory operation all uninterruptible
power systems, with all spare parts, accessories, and appurtenances as herein specified
and as shown on the Drawings.

B. One UPS shall be provided for each operator workstation and its peripherals (i.e. printer,
network equipment, radio, etc.) provided under this Contract.

C. One UPS shall be provided for each programmable logic controller (PLC) or remote
telemetry unit (RTU) and its appurtenant equipment provided under this Contract. However,
courtesy receptacles in PLC and RTU cabinets shall not be powered by the UPS.

D. UPS’s shall be mounted in or near enclosures containing digital hardware, unless otherwise
specified or shown on the Drawings, as follows:

1. UPS’s for operator’s consoles shall be mounted within the consoles.

2. UPS’s for control panels containing PLCs shall be mounted either within the cabinet
or in an adjacent cabinet of suitable environmental rating.

3. UPS’s for RTUs shall be mounted within the RTU cabinet.

4. Where the UPS is mounted within a dedicated enclosure, that enclosure shall be
properly sized for heat dissipation and all other applicable requirements as specified
in Section 17500 and its subordinate Sections.

5. Where the UPS is mounted within the PLC or RTU cabinet, it shall not interfere with
access to other equipment or wiring within the panel (i.e., it shall not be necessary to
move or remove the UPS to remove or service other panel-mounted equipment).
For floor-mounted PLC cabinets with bottom wiring access (including those cabinets
with legs), the UPS shall be placed on a dedicated shelf within the cabinet.

1.02 RELATED WORK SPECIFIED ELSEWHERE

A. Section 17000 – Control and Information System Scope and General Requirements

B. Section 17120 – Programmable Logic Controllers

1.03 SUBMITTALS

A. The Contractor shall submit UPS sizing calculations for all UPS’s furnished under this
Contract in accordance with Section 17030 - Control and Information System Submittals.

31221-009\17190: 11-06-18 17190-2 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4

PART 2 -- EQUIPMENT

2.01 UNINTERRUPTIBLE POWER SYSTEMS

A. Each UPS shall consist of a freestanding UPS module and battery modules as required to
meet backup run time requirements.

B. UPS's shall be true on-line type. Each UPS shall be sized to match the maximum power
requirements of the associated digital equipment, control panel power supplies and
accessories. Under normal operation, the AC power shall be converted to DC. The DC
power from the battery charger shall supply an inverter and maintain the battery module at
full charge. The AC output from the inverter shall be fed to the associated digital equipment
power supply unit and/or other equipment power supplies as appropriate. Upon loss of the
AC supply, the inverter shall continue to supply normal power to the device, drawing DC
from the batteries.

C. An automatic bypass switch shall be provided on UPS's of greater than 2 kVA capacity. The
transfer switch shall be of the solid state, make-before-break type and shall automatically
transfer load from the inverter to the AC line in the event of an inverter malfunction. The
total transfer time shall be 5 milliseconds or less. The transfer switch shall be provided with
a manual override.

D. A manually operated maintenance bypass switch shall be provided for each UPS installation
to allow hardware to be powered while the UPS is removed for maintenance. The bypass
switch shall be the make-before-break type to ensure continuous power to the associated
PLC.

E. Loss of AC power shall be monitored on the line side of the UPS and reported via normally
closed (fail safe) unpowered contacts to the associated PLC/RTU.

F. Each UPS shall meet the following requirements:

1. Input voltage shall be 117 VAC, single phase, 60 Hz.

2. Voltage regulation shall be +/-5 percent for line and load changes.

3. The output frequency shall be phase-locked to the input AC line on AC operation
and shall be 60 hertz +/-0.5 percent when on battery operation.

4. The batteries shall be of the sealed, lead acid or lead calcium gelled electrolyte type,
or VRLA absorbed glass mat (AGM) type. The battery modules shall have a
minimum full load backup time of 30 minutes for PLC-based control panels, and 45
minutes for remote telemetry units.

5. A status monitoring and control panel shall be provided and shall include the
following:

a. Status indicating lights for both normal and abnormal conditions.

31221-009\17190: 11-06-18 17190-3 WRF BNR UPGRADE PROJECT
TZ OSBORNE PACKAGE 4

b. Individual alarm contacts that shall close upon loss of the AC line, low battery
level or operation of the static transfer switch. Contacts shall be wired to the
closest discrete input subsystem. Alternatively, an RS-232 or USB port shall
provide UPS status to an operator workstation. All required interface
software and hardware shall be provided.

c. Circuit breaker for the AC input.

6. Sound absorbing enclosure.

7. EMI/RF noise filtering.

8. Surge protection shall be provided on the AC input circuit, which shall have a UL
TVSS clamping voltage rating of 400 V with a <5 ns response time.

G. UPS systems shall be Model GXT2 as manufactured by Liebert, equivalent by Powerware,
MGE UPS Systems, GE Digital Energy, or equal.

PART 3 -- EXECUTION

3.01 REQUIREMENTS

A. Refer to Section 17000, Part 3 of the Specifications.

- END OF SECTION -