nku thermal power plant - northern kentucky universitynkuconstruct.nku.edu/central plant cooling...

Department for Facilities ManagementFrankfort KentuckyNew Power Plant forNorthern Kentucky University

NKU Thermal Power PlantCooling Tower Fan Control

The thermal plant’s cooling tower is equipped with 48 fan drives, each powered by a 7.5 HP inverter duty motor. The tower is divided into eight cells, each cell equipped with six fans.

The fans are operated from motor control center #3. A total of 48 - FVNR starters, each operating at 480-volts, 3-phase, consist of a circuit breaker, motor contactor, overload block and HOA selector. Each starter also has a 100-VA control transformer. In the “hand” position, the fan runs subject to an overload block’s auxiliary contact. In the “auto” position, the fan is additionally subject to an external permissive contact located on an interposing relay in a relay cabinet adjacent to MCC#3. All 48 IP relays are individually controlled from the plant’s DCS control system.

The present control scheme operates all or partial groups of six fans per cell at full speed. Abandonment of this scheme in favor of reduced motor speed operation controlled by VFD drives will reduce operating cost.

The motors are rated at 1.15 service factor and may be found operating within the service factor range. Full load current draw is 11-amperes or at 1.15 surcharge – 12.65-amperes. To accommodate these loads, the VFD starter project adds two 250-HP rated drives upstream of MCC#3. The MCC’s main bus will be reopened at a shipping split resulting in two equal sized MCC units. Each MCC will be fed from a dedicated VFD. This places one-half of the fans, or three cells, twenty-four fans, on each of the MCC’s. Each group of fans will be driven by a dedicated VFD. An analog (4-20ma or 0-10 vdc) control cable will be extended from the VFD starter to the DCS control location to achieve speed control via control programming.

Since the main bus of MCC#3 will see variable voltage, the existing individual control transformers will not function properly. The starters will be re-fed from a constant 480-volt source to provide a constant 120-vac control source. The incoming feeder to one VFD drive will be tapped at 480-volts.

It is important that when a VFD drive is operating under load, that all of the load is not suddenly dropped, possibly causing damage to the VFD’s due to over-voltage. Therefore, during a shutdown operation, the VFD must be ramped down to zero speed and then shut down. To avoid shutdown damage, the existing starters scheme offers two control options; 1) an operation of any overload energizes an “OL Tripped” light in either the “manual” or “auto” mode. Presence of a 120-vac voltage at the pilot light terminal may be detected to inform the DCS to execute a safe VFD shutdown. 2) Each motor starter has a spare motor normally-open contactor “M” contact. The 24 available contacts per VFD may be wired in series, or parallel, or

Fosdick & Hilmer, Inc. December 02, 2004

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some other combination and extended to either the DCS or directly to the VFD’s to execute a safe VFD shutdown.

The adopted control option is the wiring of the spare motor normally-open contactor “M” contacts in parallel. The resulting parallel contact group is connected to the VFD drive as a “run permissive’. Therefore, while running, only one operating motor is required to hold the VFD in operating status. When the contactor of the single operating drive opens, the VFD must change the operating frequency to zero and reduce voltage to zero as quickly as possible.

For restart, a minimum of one drive contactor must be closed to permit the drive to apply voltage and increase frequency.

The operating intent is always to operate substantially all twenty-four motors simultaneously. If a cooling tower cell is taken out of service, the fans for that cell shall be manually turned off at MCC 3 by turning the affected motor starters to the off position.

The changes to the TAC America system shall be to eliminate the temperature control of condenser water by turning cooling tower fans on or off and replace the temperature control by a 0 to 10 volt output signal run to both of the VFDs. The temperature control loop will be the same as before with only the output signal being changed.


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SECTION 16111

CONDUIT

PART 1 - GENERAL

1.1 SECTION INCLUDES

A. Metal conduit.

B. Flexible metal conduit.

C. Liquidtight flexible metal conduit.

D. Electrical metallic tubing.

E. Nonmetallic conduit.

F. Fittings and conduit bodies.

1.2 RELATED SECTIONS

A. Section 16130 - Boxes.

B. Section 16190 - Supporting Devices.

1.3 REFERENCES

A. ANSI C80.1 - Rigid Steel Conduit, Zinc Coated.

B. ANSI C80.3 - Electrical Metallic Tubing, Zinc Coated.

C. ANSI/NEMA FB 1 - Fittings, Cast Metal Boxes, and Conduit Bodies for Conduit and Cable Assemblies.

D. ANSI/NFPA 70 - National Electrical Code.

E. NECA "Standard of Installation".

F. NEMA TC 3 - PVC Fittings for Use with Rigid PVC Conduit and Tubing.


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1.4 DESIGN REQUIREMENTS

A. Conduit Size: ANSI/NFPA 70.

B. Minimum Size: unless otherwise specified or noted

1.5 PROJECT CONDITIONS

A. Verify that field measurements are as shown on Drawings.

B. Verify routing and termination locations of conduit prior to rough-in.

C. Conduit routing is shown on Drawings in approximate locations unless dimensioned. Route as required to complete wiring system.

PART 2 - PRODUCTS

2.1 CONDUIT REQUIREMENTS

A. Underground Installations:

1. More than Five Feet from Foundation Wall: Use Schedule 40 nonmetallic conduit - unless specified otherwise.

2. Within Five Feet from Foundation Wall: Use galvanized rigid steel conduit.3. Under Slab on Grade: Use Schedule 40 nonmetallic conduit with rigid steel

elbows up through slab.4. Minimum Size: 1 1/4 inch.

B. Installations in concrete or masonry walls: Use rigid steel conduit.

C. Outdoor Locations, Above Grade: Use rigid steel conduit.

D. Wet and Damp Locations: Use rigid steel conduit.

E. Dry Locations:

1. Concealed: Use electrical metallic tubing.2. Exposed: Use electrical metallic tubing.

F. Feeders over 600 volts: Use rigid steel conduit.

G. Connections to motors, transformers and other equipment subject to vibration: Use Liquidtight flexible metal conduit.


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2.2 METAL CONDUIT

A. Rigid Steel Conduit: ANSI C80.1.

B. Fittings and Conduit Bodies: ANSI/NEMA FB 1; material to match conduit.

2.3 FLEXIBLE METAL CONDUIT

A. Description: Interlocked steel construction.

B. Fittings: ANSI/NEMA FB 1.

2.4 LIQUIDTIGHT FLEXIBLE METAL CONDUIT

A. Description: Interlocked steel construction with PVC jacket.

B. Fittings: ANSI/NEMA FB 1.

2.5 ELECTRICAL METALLIC TUBING (EMT)

A. Description: ANSI C80.3; galvanized tubing.

B. Fittings and Conduit Bodies: ANSI/NEMA FB 1; steel or malleable iron compression type only.

2.6 NONMETALLIC CONDUIT

A. Description: NEMA TC 2; Schedule 40 PVC.

B. Fittings and Conduit Bodies: NEMA TC 3.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install conduit in accordance with NECA "Standard of Installation" and manufacturers instructions.

B. Conduit shall not block access to equipment.

C. Arrange supports to prevent misalignment during wiring installation.

D. Support conduit using coated steel or malleable iron straps, lay-in adjustable hangers, clevis hangers, and split hangers.


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E. Group related conduits; support using conduit rack. Construct rack using steel channel; provide space on each for 25 percent additional conduits.

F. Fasten conduit supports to building structure and surfaces under provisions of Section 16190.

G. Do not support conduit with wire or perforated pipe straps. Remove wire used for temporary supports.

H. Do not attach conduit to ceiling support wires.

I. Arrange conduit to maintain headroom and present neat appearance.

J. Route exposed conduit parallel and perpendicular to walls.

K. Route conduit installed above accessible ceilings parallel and perpendicular to walls.

L. Route conduit under slab from point-to-point.

M. Maintain adequate clearance between conduit and piping.

N. Maintain 12 inch clearance between conduit and surfaces with temperatures exceeding 104 degrees F (40 degrees C).

O. Cut conduit square using saw or pipecutter; de-burr cut ends.

P. Bring conduit to shoulder of fittings; fasten securely.

Q. Join nonmetallic conduit using cement as recommended by manufacturer. Wipe nonmetallic conduit dry and clean before joining. Apply full even coat of cement to entire area inserted in fitting. Allow joint to cure for 20 minutes, minimum.

R. Where conduits enter boxes or cabinets, install double locknuts and insulated metallic bushings. Use "Liqua-Tite" insulated fittings to terminate all flexible conduit.

S. Install no more than equivalent of three 90-degree bends between boxes. Use conduit bodies to make sharp changes in direction, as around beams. Conduit bends shall be of long radius and shall be made using benders approved by the conduit manufacturer for the purpose. Bends shall not cause kinking, cross sectional deformation or reduction of inside diameter.


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T. Contractor shall install pull boxes where required to meet NEC requirements for maximum number of bends in a conduit run.

U. Avoid moisture traps; provide junction box with drain fitting at low points in conduit system.

V. Provide suitable fittings to accommodate expansion and deflection where conduit crosses seismic, control and expansion joints. Maintain ground continuity across fittings.

W. Provide suitable pull string in each empty conduit except sleeves and nipples.

X. Use suitable caps to protect installed conduit against entrance of dirt and moisture until wires are pulled.

Y. Ground and bond conduit under provisions of Section 16170.

Z. Identify conduit under provisions of Section 16195.

3.2 INTERFACE WITH OTHER PRODUCTS

A. Install conduit to preserve fire resistance rating of partitions and other elements.

END OF SECTION


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SECTION 16123

BUILDING WIRE AND CABLE

PART 1 - GENERAL


A. Building wire and cable.

B. Wiring connectors and connections.


A. Section 16111 - Conduit.

B. Section 16130 - Boxes.

C. Section 16195 - Identification.

1.3 REFERENCES

A. ANSI/NFPA 70 1999 - National Electrical Code.


A. Wire and cable routing shown on Drawings is approximate unless dimensioned. Route wire and cable as required to meet Project Conditions.

B. Where wire and cable routing is not shown, and destination only is indicated, determine exact routing and lengths required.

1.5 COORDINATION

A. Determine and maintain required separation between cable and other work.

B. Install cable routing to avoid interference with other work.

PART 2 - PRODUCTS

2.1 BUILDING WIRE AND CABLE

A. Low Voltage (600 V and Below) Wire And Cable


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1. Description: Single conductor insulated wire.

2. Conductor: Stranded copper.

3. Insulation Voltage Rating: 600 volts.

4. Insulation: ANSI/NFPA 70, Type THHN/THWN or XHHW.

5. All wire and cable shall be UL listed.

6. Acceptable manufacturers: Service Wire, ENCORE Wire, Circle Wire, ALCAN Cable, BICC/General, ROME.

7. For auxiliary systems such as fire alarm, audio/visual, etc., use cable specified under the appropriate heading or cable recommended by system manufacturer.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Verify that installed wiring will be protected from weather.

B. Verify that work, the performance of which could damage wire, has been completed.

3.2 PREPARATION

A. Completely and thoroughly swab raceway before installing wire.

3.3 WIRING METHODS

A. Dry Interior Locations: Use building wire, Type THHN/THWN or XHHW insulation, in raceway.

B. Wet or Damp Interior Locations: Use only building wire, Type XHHW-2 insulation, in raceway.

C. Exterior Locations: Use only building wire, Type XHHW-2 insulation, in raceway.

D. Underground Installations: Use only building wire, Type XHHW-2 insulation, in raceway.


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3.4 INSTALLATION

A. Install products in accordance with manufacturers instructions.

B. Use conductor not smaller than 12 AWG for power and lighting circuits unless otherwise noted on drawings.

C. Use conductor not smaller than 14 AWG for control circuits unless otherwise noted on drawings.

D. All wires of any one circuit shall be run in the same conduit. No more than three current carrying conductors (exclusive of grounds and common neutrals) shall be run in the same conduit, unless otherwise noted.

E. Whenever possible, unless otherwise noted, utilize common neutrals to minimize number of wires in lighting and receptacle circuits. This will result in three wires for two circuits in single phase systems and four wires for three circuits in three phase four wire systems. Common neutrals for two or more 20 ampere circuits shall be no. 10 AWG minimum wire size.

F. Use 10 AWG conductors for 20 ampere, 120 volt branch circuits longer than 100 feet.

G. Use 10 AWG conductors for 20 ampere, 277 volt branch circuits longer than 200 feet.

H. Pull all conductors into raceway at same time.

I. Use suitable wire pulling lubricant for building wire 4 AWG and larger. Use only PolyWater DynaBlue (e.g. 5 gal drum p/n D-640) pulling lubricant on all cable pulls. The use of Yellow 77, and other similar pulling lubes, is not acceptable.

J. Neatly train and lace wiring inside boxes, equipment, and panelboards.

K. Clean conductor surfaces before installing lugs and connectors. ALL Medium Voltage Termination kits to be installed by PROPERLY TRAINED PERSONNEL ONLY. A Properly trained person is further defined by those having been trained by Raychem or a Raychem Factory-Trained Technician / Representative. Validation of this training must be documented or supportable, if requested, by a letter from the technician / representative. Persons able to provide proof of having more than ten (10) years experience specifically in the application of Raychem medium & high voltage cable termination kits may also be considered as being qualified. In any event, the cable cleaning kits are to be PolyWater p/n NFT-369/S.


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L. Make splices, taps, and terminations to carry full ampacity of conductors with no perceptible temperature rise.

M. Use only long barrel compression lugs installed with a minimum of two crimps per termination for copper conductor splices and taps, 8 AWG and larger. CRIMPING IS TO BE PERFORMED USING PROPER TOOLS - SUCH AS A DIE-LESS HY-PRESS. For low-voltage (<600 Volt) circuits, re-insulate all uninsulated conductors and connectors with electrical tape to 150 percent of insulation rating of conductor or provide U.L. approved heat shrink tubing insulating system, Raychem WCSM or approved equal. NOTE: There are no applications in this installation which would require splicing of medium voltage cables.

N. Use insulated spring wire connectors with plastic caps for copper conductor splices and taps, 10 AWG and smaller. Fixed spring connectors and self-stripping tap connectors shall not be used.

3.5 INTERFACE WITH OTHER PRODUCTS

A. Identify wire and cable as per provisions of Section 16195.

B. Identify each conductor with its circuit number or other designation indicated on Drawings.

3.6 FIELD QUALITY CONTROL

A. Inspect wire for physical damage and proper connection.

B. Measure tightness of bolted connections and compare torque measurements with manufacturer's recommended values.

C. Verify continuity of each feeder and branch circuit conductor. Perform high-resistance test (Megger) on all primary motor load and distribution panel circuits in accordance with NETA Recommended Acceptance Testing Specifications.

D. Properly torque and perform low-resistance readings (Ductor) readings on all cable to

conductor, cable to bus, or bus to bus splice plate connections. ALL torqued and tested connection points shall be identified by a mark (black Magic Marker) extending from the conducting surface, across the lug (if applicable), across the flat washer - lock washer and head of the bolt. If a connection is inspected and found not to have been marked - re-torquing and re-testing will be required. No exceptions.

E. All medium voltage cables shall be installed utilizing a tugger having a ft-lb gauge to ensure that at no time during the pull does cable tension exceed manufacturers recommended levels.


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F. All medium voltage cable are to be Go - No-Go tested utilizing a 5 KV DC high-resistance test set (Megger) after pulling and prior to termination kit application. After termination kit application, the completed installation shall be tested in accordance with NETA Recommended Acceptance Testing Specifications utilizing a suitable NIST traceably DC Overpotential Test Set (DC Hi-Pot). Appropriate test reports shall be generated in accordance with testing specifications and will include such information as temperature, humidity, etc.. Final acceptance shall be by engineer approval.

END OF SECTION


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SECTION 16130

BOXES

PART 1 - GENERAL


A. Wall and ceiling outlet boxes.

B. Pull and junction boxes.


A. Section 16160 - Cabinets and Enclosures.

1.3 REFERENCES

A. ANSI/NEMA FB 1 - Fittings and Supports for Conduit and Cable Assemblies.

B. ANSI/NEMA OS 1 - Sheet-steel Outlet Boxes, Device Boxes, Covers, and Box Supports.

C. ANSI/NFPA 70 2002 - National Electrical Code.

D. NEMA 250 - Enclosures for Electrical Equipment (1000 Volts Maximum).

1.4 PROJECT RECORD DOCUMENTS

A. Submit as per provisions of Section 16010.

B. Accurately record actual locations and mounting heights of outlet, pull, and junction boxes.


A. Verify locations of outlets prior to rough-in.

PART 2 - PRODUCTS

2.1 OUTLET BOXES

A. Sheet Metal Outlet Boxes: ANSI/NEMA OS 1, galvanized steel.


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1. Luminaire and Equipment Supporting Boxes: Rated for weight of equipment supported; include inch (13 mm) male fixture studs where required.

B. Cast Boxes: NEMA FB 1, Type FD, cast ferally. Provide gasketed cover by box manufacturer. Provide threaded hubs.

2.2 PULL AND JUNCTION BOXES

A. Sheet Metal Boxes: NEMA OS 1, galvanized steel.

B. Surface-Mounted Cast Metal Box: NEMA 250, Type 4; flat-flanged, surface-mounted junction box.

1. Material: Galvanized cast iron.2. Cover: Furnish with ground flange, neoprene gasket, and stainless steel

cover screws.

C. In-Ground Cast Metal Box: NEMA 250, Type 6, outside flanged, recessed cover box for flush mounting.

1. Material: Galvanized cast iron.2. Cover: Nonskid cover with neoprene gasket and stainless steel cover

screws.3. Cover Legend: ELECTRIC.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install electrical boxes as shown on drawings, and as required for splices, taps, wire pulling, equipment connections and compliance with regulatory requirements.

B. Install electrical boxes to maintain headroom and to present neat mechanical appearance.

C. Install pull boxes and junction boxes above accessible ceilings and in unfinished areas only.

D. Inaccessible Ceiling Areas: Install outlet and junction boxes no more than 6 inches (150 mm) from ceiling access panel or from removable recessed luminarie.

E. Install boxes to preserve fire resistance rating of partitions and other elements, using materials and methods approved by Architect and/or owner.


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F. Outlets adjacent to one another in any room or corridor shall be in horizontal or vertical alignment, unless otherwise shown.

G. Use flush mounting outlet boxes in finished areas.

H. Do not install flush mounting boxes back-to-back in walls; provide minimum 6 inch (150 mm) separation. Provide minimum 24 inches (600 mm) separation in acoustic rated walls.

I. Secure flush mounting box to interior wall and partition studs. Accurately position to allow for surface finish thickness.

J. Use stamped steel bridges to fasten flush mounting outlet box between studs.

K. Install flush mounting box without damaging wall insulation or reducing its effectiveness.

L. Use adjustable steel channel fasteners for hung ceiling outlet box.

M. Do not fasten boxes to ceiling support wires.

N. Support boxes independently of conduit.

O. Use gang box where more than one device is mounted together. Do not use sectional box.

P. Use gang box with plaster ring for single device outlets.

Q. Use cast outlet box in exterior locations and wet locations.

R. Large Pull Boxes: Boxes larger than 100 cubic inches (1 600 cubic centimeters) in volume or 12 inches (300 mm) in any dimension.

1. Interior Dry Locations: Use hinged enclosure under provisions of Section 16160.

2. Other Locations: Use surface-mounted cast metal box.

S. Determine the exact location of ceiling lighting fixtures from the architectural reflected ceiling plans.

T. Where fixtures occur in acoustic tile ceilings, they shall be centered in tile, take the place of tile, or be centered at intersection of four tiles, as indicated on the drawings.


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U. Drilling & punching holes in boxes: NOTE! ALL DRILLING AND PUNCHING OF HOLES IN ANY ENCLOSURES FOR ANY REASON SHALL INCLUDE DUE-DILIGENCE EFFORT TO ENSURE METAL FLAKES, SHAVINGS, KNOCK-OUTS, ETC. DO NOT FALL DOWN INTO SWITCHGEAR, INACCESSIBLE LOCATIONS AND OTHER POTENTIALLY HAZARDOUS AREAS.

3.2 ADJUSTING

A. Adjust flush-mounting outlets to make front flush with finished wall material.

B. Install knockout closure in unused box opening.

END OF SECTION


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SECTION 16170

GROUNDING AND BONDING

PART 1 - GENERAL


A. Grounding electrode conductors.

B. Equipment grounding conductors.

C. Bonding.

1.2 REFERENCES

A. ANSI/NFPA 70 - 2002 - National Electrical Code.

1.3 GROUNDING ELECTRODE SYSTEM

A. Metal underground water pipe.

B. Driven ground rods.

C. Building steel.

1.4 PERFORMANCE REQUIREMENTS

A. Grounding System Resistance: 5 ohms (or less).

PART 2 - PRODUCTS

2.1 MECHANICAL CONNECTORS

A. Material: Bronze

2.2 EXOTHERMIC CONNECTIONS

A. Manufacturers:

1. Cadweld2. Approved Equal


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2.3 WIRE

A. Material: Stranded copper.

B. Grounding Electrode Conductor: 7-Strand 4/0 AWG (minimum) - unless noted otherwise.

C. Equipment grounding conductor: Sized per NEC table 250-66 and table 250-122.

2.4 GROUND RODS

A. Minimum 5/8" Copper-clad ground rods in 8' (or 10') lengths.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install products in accordance with manufacturer's instructions and as indicated on drawings.

B. Provide bonding to meet Regulatory Requirements.

C. Equipment Grounding Conductor: Provide separate, insulated conductor within each feeder and branch circuit raceway. Terminate each end on suitable lug, bus, or bushing. Bond ground wires to all junction boxes, to ground busses of all equipment provided with same, to motor frames, and non-current carrying metal parts of all other equipment to which electrical connections are made.

D. Bond all conduit using ground bushings or other approved means.

E. In each electric closet or grouping of panels, bond all panelboard ground busses together using a green insulated copper conductor of no. 6AWG minimum size.

F. Connect all steel conduits and ground bars in bus ducts entering switchgear assemblies to switchgear ground bus. Connection must meet or exceed ampacity of switchgear ground bus.

3.2 FIELD QUALITY CONTROL

Mechanical Testing & Inspections:A. Inspect the quality of all CAD-Weld. These inspections include conductor-to-

conductor and conductor-to-steel connections. Welds are to be inspected for general integrity, holes, burned-conductors, unusual discoloration, uneven welding and insufficient weld material.


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B. Inspect the overall condition of the conductor, noting broken strands, crimps, etc.

C. Torque all bolted connections. If torque values are unavailable, notify the Engineer. The bolted connections shall also include fence and gate jumpers, cable tray jumpers, etc.

3.3 Electrical Testing & Inspections:

A. Ground grids shall be tested using the three-point fall-of-potential method or the point-to-point method, depending on site conditions.

B. All tests are to be performed using equipment specifically designed for analyzing ground-grids. All equipment must be calibrated and NIST traceable.

C. Trend test results against previous values, notify the owner immediately of any abnormalities or out-of-tolerance values.

D. Where the 3 point method is not applicable, utilize a point-to-point method of testing referencing a common point as shall be illustrated, graphically, on the test report. In any event, minimum relative point-to-point testing shall yield values below 5 Ohms. These tests MUST be performed during desirable weather conditions - not following or during such events as heavy-rainfall, which may affect results.

E. Provide all test results in the O&M Manual information.

END OF SECTION


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SECTION 16190

SUPPORTING DEVICES

PART 1 - GENERAL


A. Conduit and equipment supports.

B. Anchors and fasteners.

1.2 REFERENCES

A. NECA - National Electrical Contractors Association.

B. ANSI/NFPA 70 2002 - National Electrical Code.

PART 2 PRODUCTS

2.1 PRODUCT REQUIREMENTS

A. Materials and Finishes: Provide adequate corrosion resistance. Adequate corrosion resistance is further described by one of the following: Stainless Steel Construction, Aluminum Construction, Post-Construction Hot-Dipped Galvanize, Epoxy-Based Powder Coating, composite material construction (i.e. Bronze), post-construction plating, etc... Simple primer / acrylic-enamel painting is ONLY acceptable where equipment is NOT located in high-humidity (or otherwise corrosive) environments.

B. Provide materials, sizes, and types of anchors, fasteners and supports to carry the loads of equipment and conduit. Consider weight of wire in conduit when selecting products.

C. Anchors and Fasteners:

1. Concrete Structural Elements: Use expansion anchors.2. Steel Structural Elements: Use beam clamps.3. Concrete Surfaces: Use self-drilling anchors and expansion anchors.4. Solid Masonry Walls: Use expansion anchors.

PART 3 EXECUTION

3.1 INSTALLATION


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A. Install products in accordance with manufacturer's instructions.

B. Provide anchors, fasteners, and supports in accordance with NECA "Standard of Installation".

C. Do not fasten supports to pipes, ducts, mechanical equipment, and conduit.

D. Do not use spring steel clips and clamps.

E. Obtain permission from Construction Manager before using powder-actuated anchors.

F. Do not drill or cut structural members.

G. Install surface-mounted cabinets and panelboards with minimum of four anchors.

H. In wet and damp locations use steel channel (Unistrut) supports to stand cabinets and panelboards one inch off wall and a minimum of 2" off floor.

END OF SECTION


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SECTION 16195

ELECTRICAL IDENTIFICATION AND PHASE ROTATION

PART 1 - GENERAL


A. Nameplates and labels.

B. Wire and cable markers.

C. Conduit markers.

1.2 REFERENCES

A. ANSI/NFPA 70 2002 - National Electrical Code.

PART 2 - PRODUCTS

2.1 NAMEPLATES AND LABELS

A. Nameplates: Engraved two-layer laminated plastic, black letters on white background for normal system and white letters on red background for emergency system. Edges shall be beveled.

B. Locations:

1. Each electrical distribution, control and equipment enclosure.

C. Letter Size:

1. Use 3/16" letters for identifying individual equipment and loads.2. Use 1/4" letters for identifying grouped equipment and loads.3. Use 1/2" letters for identifying substations and medium voltage equipment.


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Department for Facilities ManagementFrankfort KentuckyNew Power Plant forNorthern Kentucky UniversityPNKU0395

2.2 WIRE MARKERS

A. Description: Tape, Raychem Shrink-on or slip-on type wire markers.

B. Locations: Each conductor at panelboard gutters, pull boxes, outlet and junction boxes and each load connection.

C. Legend:

1. Power and Lighting Circuits: Branch circuit or feeder number indicated on drawings.

2.3 CONDUIT IDENTIFICATION

A. Location: Furnish color coding using spray paint for each conduit longer than 6 feet and all junction boxes.

B. Color:

1. Normal Power System: White2. Emergency Power System: Black3. Fire Alarm: Red4. Computer/Data: Green5. Telephone: Green6. CCTV/MATV: Blue

C. Phase Rotation:

Phase rotation shall be identified at each respective cable termination location utilizing industry-accepted colors for low and medium voltage circuits (i.e. Red/White/Blue). In addition, phase rotation on new equipment shall be A-B-C front-to-back, left-to-right, top-to-bottom as seen FACING THE EQUIPMENT/CABINET.

PART 3 - EXECUTION

3.1 PREPARATION

A. Degrease and clean surfaces to receive nameplates.

3.2 APPLICATION

A. Install nameplate parallel to equipment lines.

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B. Secure nameplate to equipment front using stainless steel self-tapping sheet metal screws and adhesive. Use of adhesive only will not be acceptable.

C. Paint colored band with operating voltages on each conduit longer than 6 feet (Decals are acceptable).

D. Paint bands 5 feet on center (Decals are acceptable).

E. Refer to Section 16121 for required identification of medium voltage cables, boxes, and exposed conduits.

END OF SECTION



SECTION 16483

VARIABLE SPEED AC DRIVE CONTROLLERS

PART 1 - GENERAL

1.1 Provide variable speed AC drive controller(s) equipped with bypass contactors, unit mounted circuit breaker disconnect and harmonic suppression as shown on the drawings. The controllers are herein identified as VFDs.

1.2 The VFD manufacturer shall furnish, field test, adjust and certify each installed VFD for satisfactory operation according to the specific application.

1.3 RELATED SECTIONS RELATED SECTIONS

A. Section 16190 - Supporting Devices.

B. Section 16195 - Electrical Identification: Engraved Plastic Laminate Nameplates.

1.4 SCOPE OF WORK

A. Provide all labor, materials, equipment and incidentals required, to completely install, place into operation and field test the VFD unit(s).

B. The electrical contractor shall provide the VFDs per this specification. VFD voltage and horsepower shall be per the drawings. All drives shall be of the same manufacturer and type.

C. Each VFD shall operate a group of from one to twenty-four 7.5 HP cooling tower fans at a common drive frequency.

D. The VFD shall be a space vector Pulse-Width Modulated (PWM) design. Modulation methods which incorporate "gear-changing" techniques are not acceptable.

1.5 QUALITY ASSURANCE

A. The entire VFD system shall be factory assembled and system tested by the VFD manufacturer.

B. Codes: Provide equipment in full accordance with current applicable rules, regulations, and standards of:

1. 2002 National Electric Code (NEC).2. Underwriters Laboratories (UL). 3. American National Standards Institute(ANSI).4. National Electrical Manufacturers Association (NEMA).5. Institute of Electrical and Electronics Engineers (IEEE).



C. The complete drive system shall be UL listed.

1.6 SUBMITTALS

A. Submittals shall conform in all respects to Section 16010.

B. Submittals shall be custom prepared by the VFD manufacturer for this specific application.

C. Submittal information shall include, but not be limited to:

Equipment dimensions, including stub-up locations, shipping splits and shipping weights.

Catalog cuts indicating major components.Spare parts listWarrantyHarmonic Distortion Analysis

1.7 Warranty

A. All VFD drive equipment furnished under this section shall be warranted for parts and labor by the equipment manufacturer for a period of one (2) years after completion of startup.

B. All site installation shall be warranted for parts and labor by the contractor for a period of one (1) year after completion of startup.

PART 2 - PRODUCTS

2.1 MATERIAL AND EQUIPMENT

A. Any modifications to a standard product required to meet this specification shall be performed by the VFD manufacturer only. Distributor or system integrator changes to the VFD manufacturer's product are specifically disallowed.

B. The VFD system shall consist of a circuit breaker, electronic overloads, drive power electronic assembly, line reactor, build-in PI controller, H-O-A switch with manual speed capability and a 4-20 ma or 0-10 VDC control interface.

C. Each drive shall also be provided with a manual bypass option including a circuit breaker, drive input fuses and motor overloads.

D. Each drive shall also be provided with a dv/dt output filter option in a separate cabinet for field installation near the VFD drive. The filter shall be rated for the full VFD drive current value.



E. The drive shall be thermally rated for continuous operation to 40 degrees C with full current without compromise by temperature variations within any 24-hour period.

F. Drive enclosure shall be NEMA 1 rated.

G. All components listed, including power factor correction/harmonic filters and transformers shall be integral to the VFD lineup, factory wired and tested as a complete system.

H. VFD(s) shall meet all requirements of IEEE 519-1992 for each individual and total harmonic voltage and current. The maximum allowable total harmonic current demand distortion limits for each VFD operating at full load and speed shall not exceed 5% as calculated and measured at the VFD input terminals.

I. The 'VFD' system shall maintain a 0.95 (lagging) minimum true power factor across its entire range of operation.

J. Acceptable Manufacturers:

1. ABB ACH550 series2. Cutler-HammerSquare DSiemensEquivalents to item (1).

K. Any drive type submitted other than ABB ACH550 series must receive the engineers written pre-bid approval and shall include documentation confirming that all aspects of this specification are met.

2.2 VARIABLE FREQUENCY DRIVES

A. The drive shall have an integral programmable controller featuring several options of HVAC system control regulation.

1. Pre-configured HVAC control application macros.2. User configurable control application macros.

B. The drive shall provide an alpha-numeric display to display fault information in non-coded plain language text.

C. A fault logging function shall retain for display seven or more diagnostic values for display with time and date stamped references.

D. Two PID loops shall be provided for analog input and output.

E. Thirteen or more digital input/output points shall be provided.



F. Communications protocols shall include commonly used fieldbus systems including N2, FLN and Modbus. Provision for other systems shall consist of space within the drive enclosure for communications modules.

2.3 COOLING TOWER FAN DRIVE APPLICATION

A. The thermal plant’s cooling tower is equipped with 48 fan drives, eachpowered by a 7.5 HP inverter duty motor rated at 115% service

factor. The tower is divided into eight sections or cells, each cell equipped with six fans.

B. All fans are operated from motor control center #3. A total of 48 - FVNR starters, each operating at 480-volts, 3-phase, each consisting of a circuit breaker, motor contactor, overload block and HOA selector. Each starter also has a 100-VA control transformer that will be replaced with a common 120-volt source upstream of the VFD. In the “hand” position, the fan runs subject to an overload block’s auxiliary contact. In the “auto” position, the fan is additionally subject to an external permissive contact that will be permanently disabled.

C. The new VFD drive consists of two 250-HP rated drives installed upstream of MCC#3. The MCC’s main bus will be reopened at a shipping split resulting in two equal sized MCC units. Each MCC will be fed from a dedicated VFD. This places one-half of the fans, or three cells, twenty-four fans, on each of the MCC’s. An analog (4-20ma or 0-10 vdc) control cable will be extended from the VFD starter to the DCS control location to achieve speed control via control programming by others. The operating intent is always to operate substantially all twenty-four motors simultaneously.

D. Control wiring is required such that when a VFD drive is operating under load, and the motor contactors suddenly open, possible damage to the drive due to over-voltage is avoided. The adopted control option is the wiring of the spare normally-open motor contactor “M” contacts in parallel. The resulting parallel contact group is connected to the VFD drive as a “run permissive’. While running, only one operating motor is required to hold the VFD in operating status. When the contactor of the single operating drive opens, the VFD must change the operating frequency to zero and reduce voltage to zero as quickly as possible. For restart, a minimum of one drive contactor must be closed to permit the drive to apply voltage and increase frequency.

Part 3 - EXECUTION



3.1 Factory Testing

The VFD manufacturer shall provide as a minimum, all products subject to 100% testing and final inspection.

3.2 Startup and Training

VFD manufacturer shall provide the services of a factory technician for startup assistance and training.

3.3 Spare Parts

A. The following spare parts shall be furnished:

1. Three of each type of fuse rated 460V or less.2. Two of each type of converter power semiconductor.3. Two of each type of inverter power semiconductor.4. Five of each type of panel lamp.5. One of each type of type control printed circuit board and gate

firing boards.6. One keypad assembly.

3.4 The contractor shall verify that the location is ready to receive work and the dimensions are as indicated.

3.5 The contractor shall install VFD equipment as per manufacturer recommendations and/or instructions.

END OF SECTION


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