retrofitting existing controls & breakers · existing equipment is brought up to the latest...

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REV0.0 12/01/2016 1| Page Retrofitting Existing Controls & Breakers Introduction When considering whether to maintain & upgrade existing equipment opposed to replacing older aging existing equipment, facilities must take into account the capital cost, along with potential disruption to the mission critical processes and workflow during the course of replacing equipment that can be a massive undertaking to extend the life of a system. Russelectric has a Retrofit solution than can provide a fraction of the downtime to complete than replacement, is a less expensive alternative, maintains the ability to improve reliability as new equipment would, upgrades technology to current standards and increases serviceability of equipment. Retrofitting the Utility Control and/or Generator paralleling control switchgear: There are many specific items/devices that are no longer available and do not have direct replacement parts. Older devices and technology may not have modifications available to be completed on an itemized basis and the majority have become unserviceable and the reliability can be concerning to mission critical facilities. This leads to the recommendation that the control sections and breakers be upgrade in their entirety rather than replace the entire switchgear where the framework, bus work are mechanically still in good condition. This process will modernize and upgrade the existing controls to the latest technologies and allow for increased reliability and serviceability. In the end, the existing buildings power system is not modified, the equipment remains intact as is and the interior and door controls of the existing equipment is brought up to the latest control standards and would restore reliability, serviceability for the controls and provides all the benefits to new switchgear. Overview of Retrofit Process To summarize the retrofit of the controls; new controls are designed, Built and Tested at Russelectric. The retrofit control panels utilizing our current standard devices, including PLC’s & Operator interface panels. All devices would be prewired on electrical plates, mounted and wired on temporary open frame cubicles for testing and shipping (The panels are removed at the site and installed in place of the existing), with everything tested in the factory just like a new switchboard. We then ship the out the open frame cubicles individually to the site along with our temporary control panel setup which we would use to keep the site with automatic backup power and operational while we remove the existing controls and install the new. The site would experience a few transfers in the beginning and multiple transfers during final testing but for the duration of the work, the facility will have automatic operation & emergency backup with our temp controls. This process has been completed at many mission critical facilities in the US and the process has been refined to suit the requirements of each site as required.

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Page 1: Retrofitting Existing Controls & Breakers · existing equipment is brought up to the latest control standards and would restore reliability, serviceability for the controls and provides

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RetrofittingExistingControls&Breakers

IntroductionWhen considering whether to maintain & upgrade existing equipment opposed to replacing older aging 

existing equipment, facilities must take into account the capital cost, along with potential disruption to the 

mission critical processes and workflow during the course of replacing equipment that can be a massive 

undertaking to extend the life of a system.  Russelectric has a Retrofit solution than can provide a fraction of 

the downtime to complete than replacement, is a less expensive alternative, maintains the ability to improve 

reliability as new equipment would, upgrades technology to current standards and increases serviceability of 

equipment.   

Retrofitting the Utility Control and/or Generator paralleling control switchgear:  There are many specific items/devices that are no longer available and do not have direct replacement parts.  Older devices and technology may not have modifications available to be completed on an itemized basis and the majority have become unserviceable and the reliability can be concerning to mission critical facilities. This leads to the recommendation that the control sections and breakers be upgrade in their entirety rather than replace the entire switchgear where the framework, bus work are mechanically still in good condition.  This process will modernize and upgrade the existing controls to the latest technologies and allow for increased reliability and serviceability.   In the end, the existing buildings power system is not modified, the equipment remains intact as is and the interior and door controls of the existing equipment is brought up to the latest control standards and would restore reliability, serviceability for the controls and provides all the benefits to new switchgear.     

OverviewofRetrofitProcessTo summarize the retrofit of the controls; new controls are designed, Built and Tested at Russelectric.  The retrofit control panels utilizing our current standard devices, including PLC’s & Operator interface panels.  All devices would be prewired on electrical plates, mounted and wired on temporary open frame cubicles for testing and shipping (The panels are removed at the site and installed in place of the existing), with everything tested in the factory just like a new switchboard.  We then ship the out the open frame cubicles individually to the site along with our temporary control panel setup which we would use to keep the site with automatic backup power and operational while we remove the existing controls and install the new.  The site would experience a few transfers in the beginning and multiple transfers during final testing but for the duration of the work, the facility will have automatic operation & emergency backup with our temp controls.    This process has been completed at many mission critical facilities in the US and the process has been refined to suit the requirements of each site as required.     

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AftermarketSolutions

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BenefitsofaControlsRetrofitThe benefits of a retrofit opposed to replacement are: 

Russelectric can keep the system operational during the upgrade process and allow for automatic operations with the minimum number of generators at all times to that of half of the system generators. 

Improved operational efficiency and performance. 

Increased time to completion when compared to complete replacement. 

Reduced or eliminating the downtime or disruption to critical load. 

System is updated with the most advanced Russelectric controls 

New control panels and doors are prewired and tested at the factory to streamline installation 

Lower cost than replacing equipment 

Available custom SCADA allows control of plant operations remotely 

Reduced cost from replacement of equipment. o No cost to replace power cables. o Minimal to no cost for control interconnect replacements. o No additional building space required to install. o Eliminates the cost of downtime and shutdown costs. 

Optional simulators facilitate operator training and scenario evaluation from the comfort and safety of an office environment 

Renew the equipment life expectancy.  

Reduces MRO costs 

Increased Operator and user awareness with extensive event history collection with no history recording limitations.   

The latest technology which supports optional remote monitoring.  

BenefitsofBreakerRetrofits Increased reliability and safety 

Improve overcurrent selectivity  

Updating circuit breakers allows the use of new option and accessories such as arc reduction modes and Zone Selective Interlocking (ZSI) 

Eliminate concerns about the availability of new parts to repair circuit breakers 

Trip unit accuracy and repeatability with new circuit breakers 

Power metering, monitoring and communication 

Less maintenance and overhaul, which is expensive and time consuming 

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EquipmentEnhancementSolutions

TempPanelControlsforRetrofittingExistingSystemsUseThe temporary controls panel built by Russelectric as shown in the picture below, allows for the opportunity 

to control existing switchgear in a temporary fashion while controls are being replaced.  This temp panel acts 

as a master control cubicle and transfer control cubicle(s) and uses the existing generator control cubicles to 

control the paralleling operations in an automatic mode of operation.   

The temporary controls are setup to accommodate Paralleling control systems with 5 or less generators with 

or without a gen bus tie, (can be expanded up to 8 generators), (8) load controls priorities for ATS or Breakers, 

(2) Transfer pairs with a load bus tie (H system).   

TypicalRetrofitOverviewTo summarize the retrofit of the 

controls; new controls are 

designed, manufactured and fully 

tested at Russelectric just as a new 

system would be produced.  The 

retrofit control panels utilize 

Russelectric latest standard 

devices, including PLC’s & operator 

interface touch panels.  All devices 

would prewired on electrical panels 

designed to be mounted in the 

sites existing switchgear.  These 

panels would be mounted and 

wired on temporary open frame 

cubicles for testing and shipping 

(the panels are removed at the site 

and installed into the existing 

cubicles).  With everything tested in the factory just like a new switchboard, Russelectric then ships the 

cubicles to the site along with the temporary control panel setup which is used to keep the site with automatic 

backup power and operational while the removal of the existing controls and the new controls are installed.  

The site would experience a few transfers at the commencement and multiple transfer during final testing 

after the retrofit is complete.  For the duration of the work, the system will have automatic operation & 

emergency backup power with Russelectric temp controls. 

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EquipmentEnhancementSolutions

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FunctionsThe temporary panel consists of three separate panels EXPS, TPF (front) and TPR (rear). All of the temporary 

panels have premade harnesses for the inter‐panel connections. The panels also has premade harness’s that 

connect to the switchboard it will be controlling. There are Wago XCOM connectors on the temp panel side 

and lugs on the switchboard side for connection. The temporary panel has the functions listed below. 

1. Best Battery Circuit: In the EXPS panel there is a Sola‐HD Power supply with an interconnect terminal 

strip to a remote 120VAC source. The front of the EXPS panel has IDEC annunciation that indicates the  

120VAC input and 24VDC output of the Sola‐HD Power Supply is energized. In the TPR panel there are 

separate 15A ABB breakers and Crydom diodes for each engine battery input. The outputs of the 

diodes connect to the Sola Power supply to make up the 24vdc best battery circuit.  

 

2. Manual Breaker Closure: On the front of the TPR panel is a synchroscope, sync selector switch and 

breaker control switch that allows an operator to close up to 4 generator breakers. A Crompton sync 

check relay and Wago MCK kit are installed in the temporary panel to provide for safe closure of the 

generator breakers.  

 

3.  Automatic Dead Bus Closure: There are PLC outputs in the TPR panel that energize relays for the dead 

bus closure of up to 4 generator breakers. Premade wiring harnesses are connected to dry contacts of 

the dead bus relays.  

 

4. Automatic Sync Enable Outputs: There are PLC outputs in the TPR panel that energize relays to enable 

the existing automatic synchronizers in the switchboard being modified.  

 

5. Engine Start Outputs: There are PLC outputs in the TPR panel that energize relays to automatically 

start up to 4 engines during a power failure or load test  

 

6. Engine Status Inputs: The engine status inputs listed below are in the TPR panel for four engines. 

a. Engine at rate voltage/frequency (G‐Relay) 

b. Generator Breaker Closed Input 

c. Engine Locked Out Input 

d. Spare Generator Alarm/Status Input 

 

7. ATS Engine Start Inputs: There are PLC engine start inputs in the TPR panel for up to 8 ATS’s 

 

8. ATS/ Distribution Breaker Load Control: PLC outputs in the TPR energize relays for 8 load control 

priorities. Premade harnesses are connected to dry contacts on the load control relays.  

 

9. Load Control Annunciation: Small Dialco Lights are mounted on the front of the TPR panel to indicate 

the status of the load control outputs. The Block Transfer lights are red. The load shed lights are green.  

 

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EquipmentEnhancementSolutions

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10. Generator Breaker Annunciation: A  2 by  4 IDEC light box is mounted on the front of the TPR panel to 

display the closed status of the generator breakers and if the engine is at rated voltage and frequency 

 

11. Utility “H” System Control: There are PLC inputs and outputs in the  TPR panel to monitor and control 

two utility main breaker, two generator main breakers and two load bus tie breakerds. Control of these 

breakers would be in open transition mode of operation. The inputs listed below are being monitored 

for the Utility “H” system control.  

 

a. Main Breaker Open and Withdrawn Status: 

b. Generator Main Breaker Open and Withdrawn Status 

c. Load Bus Tie Breaker Closed and Withdrawn Status 

d. Utility Main Voltage Available Input 

e. Generator Main Voltage Available Input 

 

12. Generator Bus Tie Status: There are PLC inputs and outputs in the  TPR panel to monitor and control 

two generator bus tie breakers. The generator bus tie breaker open and withdrawn status is being 

monitored. 

 

13. Operator Control Switches: The operator control switches listed below are included on the front of the 

TPF panel  

a. Master Control Selector Switch – Manual/Auto 

b. No Load Test Switch – Off/Test 

c. Retransfer Selector Switch – Manual/Automatic 

d. Retransfer Initiate Pushbutton 

e. Alarm/Transfer Failure Reset Pushbutton 

f. Alarm Horn Silence Pushbutton 

g. Spare Two Position Key Switch 

h. Spare Pushbutton.  

 

14. Alarm Horn and Annunciation: An alarm horn and 2 by 7 IDEC is included on the front of the TPF panel 

to indicate a control voltage failure and other alarms/status’s  in the temporary panel. 

 

 

 

 

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Equipment Enhancement

Services

Page 7: Retrofitting Existing Controls & Breakers · existing equipment is brought up to the latest control standards and would restore reliability, serviceability for the controls and provides

Enhance Performance, Extend Life, Increase Capabilities

Operator Interface and Communications Upgrades

Preventive Maintenance

ATS Control Upgrades

Upgrade existing critical power equipment to increase reliability, operational control, and ease of maintenance. It is a more cost-effective alternative to replacing equipment.

• Improve performance and enhance capabilities

• Bring your systems up to the latest technology

• Extend the life of your mission critical equipment

• Reduce maintenance and increase serviceability

• Performed by Russelectric Field Engineers

• All work backed by Russelectric warranty

• A fraction of the time and cost of replacing equipment with minimal downtime

Upgrade to the latest operator interface technology and communications equipment to dramatically enhance system monitoring capabilities.

• Provide detailed information on current system status through a dynamic one-line graphical interface

• Provide complete, detailed alarm and event history for faster response to problems

• Facilitate optional TJC (The Joint Commission) reporting

• Allow optional remote access to systems

Start with a Russelectric audit of your critical power system.

• Assess overall equipment condition

• Identify areas of risk including equipment and maintenance

• Identify opportunities for performance, safety, and / or communications upgrades

• Recommend upgrades and options to enhance system capabilities

• Suggest maintenance best practices

• Detail all concerns and recommendations

Replace automatic transfer switch / bypass isolation switch control systems in one day during a scheduled shutdown.

• Improve switch operating accuracy and functionality

• Update control, monitoring, and communication protocols

• Eliminate concerns about the availability of legacy components

Older switchgear (left) upgraded with new PLC controls and communications (right)

Russelectric Field Service Engineers provide preventive maintenance services and upgrades.

Operator Interface Panel (OIP) with dynamic one-line graphical interface enhances system monitoring capabilities.

RPTCS ATS Control

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Programmable Logic Controller (PLC) Upgrades

Many existing systems utilize legacy or approaching end-of-life PLC architecture. Upgrade your control system to the newest technology with minimal program changes.

• New technology improves performance and accommodates advanced communications

• Eliminate replacement part availability concerns

• Improve functionality of existing equipment

• Most upgrades can be completed without interruption of critical loads or operational changes

• Drop-in replacements available

Breaker Upgrade Solutions

Replace obsolete / unsupported vintage power breakers and accessories with new OEM-supplied replacements adapted for form, fit, and function.

• Improve overcurrent selectivity

• Updating circuit breakers allows the use of new options and accessories such as arc reduction modes and Zone Selective Interlocking (ZSI)

• Eliminate concerns about the availability of new parts to repair circuit breakers

• Upgrades available for various circuit breaker manufacturers

System Controls Retrofits

A system retrofit involves replacement of all existing controls — while keeping the system operational.

• Update with the most advanced Russelectric controls

• Temporary control package for use during upgrades reduces / eliminates downtime

• New control panels and doors are prewired and tested at the factory to streamline installation

• Lower cost than replacing equipment

• New controls and OIP permit remote real-time monitoring from smart devices

• Available custom SCADA allows control of plant operations remotely

• Optional simulators facilitate operator training and scenario evaluation from the comfort and safety of an office environment

PLC upgrades add capabilities and enhance system operation.

Circuit breaker upgrades extend switchgear life.

A complete controls retrofit can add improved functionality and years of life to an older system.

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Equipment Enhancement Solutions vs. Replacing with New Equipment

Relative Project Cost and Timetable Comparison

Upgrade Cost Time to Complete (weeks)

PreventiveMaintenance $ 3 - 6

ATS Control Upgrades $$ 6 -8

Operator Interface and PLC Upgrades $$$ 10 -20

Controls Retrofits and /or Breaker Upgrades $$$$ 16 -24

Replace with New Equipment* $$$$$$$ 40 -60

* Based on typical project involving the purchase and installation of new equipment.

Russelectric Inc South Shore Park

Hingham, MA 02043© 2016 Russelectric

800 225-5250 russelectric.com sales @ russelectric.comEES1 8/16 Printed in USA

PR

Field Service Locations

Markets Served

• Data Centers• Healthcare • Telecom• Banking• Insurance• Utilities• Airport• Municipalities• Higher Education• Water / Wastewater• Cogeneration• Alternative Energy

Products & Services

• Power Control Systems• Custom SCADA • Simulators• Automatic Transfer Switches• Bypass / Isolation Switches• DTWG Web Server Communications• Start-Up Commissioning• Equipment Enhancement Solutions

• Customer Focused• Complete In-House

Manufacturing Solutions • Custom Order Engineering• R&D and Product Design• Equipment Field Services

and Engineering • National Coverage with

Field Service Engineers• Emergency Response

Teams Available 7 / 24 / 365

Key Capabilities

Manufacturing / Field Service

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Aftermarket & Field Engineering

Date SITE NAME Address City, State Re: JOB NAME Russelectric Shop Order Number: xxxxx Russelectric Aftermarket Number: xxxxx To Whom It May Concern: The following is to provide a method of procedure and information pertaining to the modifications for the Russelectric Generator Paralleling Switchgear. The means of this modification is to provide the generator paralleling switchgear with new updated controls retrofit of the existing switchgear. The Russelectric Paralleling Switchgear modifications will be to remove the existing controls for the master and generator control cubicles and provide new PLC controls and logic to the switchgear. The intended modifications will be completed is such a way to make every effort to ensure that at all times throughout the modifications (2) emergency generators are available and can be manually or automatically closed to the generator main bus. During these modifications, a temporary panel will be used to provide automatic emergency power generation control and load controls of the existing generators and ATS’s. Prior to the commencement of the modifications it is recommended that the hospital complete the following:

1.) Have a testing company complete a study to determine the load of each ATS connected to the switchgear.

2.) Ensure that CAT/Cummins can be onsite for testing of the switchgear. 3.) Determine commissioning details and protective relay settings.

4.) Have a testing company tentatively scheduled to be onsite at the time of the modifications

to complete maintenance and testing to the generator breakers, distribution breakers and all testing of new protective relays.

5.) Customer to provide a list of ATS’s with priorities and Expected kW of each ATS load,

priorities will be limited to 1, 2 and 3 for the modifications.

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Aftermarket&FieldEngineering

R E V 1 . 3 2 | P a g e

Method of Procedure The following provides a method of procedure for the intended modifications: Pre modification:

Step 1.0.0: Unpack and inventory all panels and components. Step 2.0.0: Review and tag all existing wiring that is needed for connection to the temporary panel and wiring from all ATS’s

Commencement of Modifications:

Step 3.0.0: Install wiring needed for temporary panel to generators 2, 3 and 4. Install all ATS engine start, load shed and block transfer wiring for the temporary panel. Install an alarm to alarm if any engine start from any ATS is present.

Step 3.1.0: Testing: Prior to completing any work, complete a full building load test. This will ensure the functionality of the temporary panel controls.

Step 4.0.0: Lift existing wiring from the master control cubicle to the generator 2, 3 & 4 control cubicles (Lift wires on generator cubicle end) that are associated with the control of the temp panel.

Step 4.1.0: Testing: Complete a full building load test of all ATS’s with Generator No. 1 locked out. Ensure that all ATS transfer and the load controls of the temporary panel work as they should.

Note: At this point automatic control of the generators will be controlled by the temporary panel. Generator No. 1 will be locked out and unavailable.

Step 5.0.0: Begin the removal of the existing panels, doors, wiring and controls from the master control cubicle and Generator No. 1 cubicle.

Step 5.1.0: Testing: Complete a No load test to ensure generator operations. Step 6.0.0: Upon completing the removal of the panels and the load test, begin the installation of the new panels, doors and wiring for the master control cubicle and Generator No. 1 cubicles.

Step 6.0.1: Install temporary wiring for generator No. 1 breaker position to the temporary panel.

Step 6.1.0: Complete testing for the master control cubicle and portions of the Generator No. 1 control cubicle include dead bus.

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Aftermarket&FieldEngineering

R E V 1 . 3 3 | P a g e

Note for STEPS 5.0.0 – 7.0.0: Keep Generator No. 1 breaker racked out when engines 2, 3 & 4 are in Auto.

Note: While a Russelectric Engineer is onsite, the temporary panel may be disabled while the testing of the master control cubicle and the generator No. 1 cubicle. In the event of an outage the master cubicle will be placed in manual and the temporary panel will be enabled.

Step 7.0.0: Remove all wiring associated with the temporary panel for Generator No. 2.

Note: While the generator control cubicle No. 2 is upgraded the site will only have 1 generators available for automatic operations. Generator No. 1 can be added manually.

Step 8.0.0: Begin the removal of the existing panels, doors, wiring and controls from the Generator No. 2 cubicle. Step 8.1.0: Upon completing the removal of Generator No. 2 controls, panels and doors, begin the installation of the new panels, doors and wiring Generator No. 2 cubicle. Step 9.0.0: Complete testing and commissioning for the portions of the Generator No. 2 control cubicle. Step 9.1.0: Complete the remaining testing for the master control cubicle and the Generator No. 1 & 2 control cubicles, including load controls for the ATS’s.

Step 9.1.1: Testing: With the temporary panel disabled and the new master controls enabled complete a load test of a priority two ATS. Upon completion, complete a load test of a priority one ATS. Complete a full building load test by adding ATS one by one to ensure all correct engine start, load shed, block transfer, ATS position contacts are correct.

Note: All automatic controls will now be governed by the new master control cubicle and will relay on automatic operation of generators No. 1 & 2. Generator Controls 4 will be able to be added manually. Step 10.0.0: Remove all associated wiring for Generator Control Cubicles No. 3 and 4. Step 10.1.0: Begin the removal of the existing panels, doors, wiring and controls from the Generator No. 3 cubicle. Step 10.2.0: Upon completing the removal of Generator No. 3 controls, panels and doors, begin the installation of the new panels, doors and wiring Generator No. 3 cubicle. Step 11.0.0: Complete testing for Generator No. 3 controls with the new master control cubicle, including all automatic and manual operations

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Step 11.0.1: Testing: Complete a full building load test and ensure that all ATS transfer. With Normal power available, complete load shed testing for the return to normal.

Note: Full automatic control of generators No. 1-3 is available and is governed by the new master controls.

Step 12.0.0: Begin the removal of the existing panels, doors, wiring and controls from the Generator No. 4 cubicle. Step 12.1.0: Upon completing the removal of Generator No. 4 controls, panels and doors, begin the installation of the new panels, doors and wiring Generator No. 4 cubicle. Step 13.0.0: Complete testing for Generator No. 4 controls with the new master control cubicle, including all automatic and manual operations Step 13.1.0: Program the new controls with new priorities provided from the customer.

Step 13.1.1: Testing: Complete a full building load test(s) to ensure that all ATS transfer when the correct engines come online and all load shed controls work correctly.

Note: Full automatic control of generators No. 1-4 is available and is governed by the new master controls. Step 14.0.0: Complete any remaining testing for alarms and non-critical functions. Install the remote touch panel and ensure operation.

Step 15.0.0: Complete commissioning for the entire system.

Summary Notes: The above times are estimates and may be longer in duration than expected. No-load testing will need to be completed at unannounced times. Also the length of any load test or no load test cannot be predetermined. If any further questions arise please feel free to contact me at any time by phone or email to discuss these modifications/events in more detail.

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Aftermarket & Field Engineering

Date Customer Address City, State JOB NAME Russelectric Shop Order Number: Russelectric Aftermarket Number: Russelectric Emergency Contact: FS Personnel

Phone (cell): Site Info: Site Contacts: Name: Phone (office): Phone (Cell) Schedule & Method of Procedure for Modifications to Retrofit Switchgear

Date: Day 1

Label all interconnect wires in all cubicles.

Connect and powerup the temp panel and verify it is powered up and all devices are working as they should be.

Verify current programs loaded in the temp panel controls and load project specific

programs if necessary.

Verify that the harnesses are disconnected on the temp panel side, to prevent the system from interfering with the existing operation.

Install wiring needed for temporary panel to Generator 1

Install wiring needed for temporary panel to Generator 2

Install wiring needed for temporary panel to Generator 3

Install wiring needed for temporary panel to Generator 4

Install all ATS engine start, load shed and block transfer wiring for the temporary panel.

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If the system has individual transfer pairs, H system or requires breaker controls, Install

breaker control harness.

Testing Complete a No load test on the existing system. This will ensure the functionality

for the system.

Lift existing wiring from the master control cubicle to the Generator 1.

Lift existing wiring from the master control cubicle to the Generator 2.

Lift existing wiring from the master control cubicle to the Generator 3.

Lift existing wiring from the master control cubicle to the Generator 4.

Lift wires on generator cubicle and master cubicle end that are run between cubicle 3 and 4 and 4 and master.

Connect the harnesses to the temp panel controls.

Testing:

Complete a startup/checkout of the temp controls and verify all safety’s.

Complete a full building load test of all ATS’s with Generator No. 1 locked out, Generator No.2 & 3 in automatic and controlled by the temp panel. Ensure that all ATS transfer and the load controls of the temporary panel work as they should.

Note: At this point automatic control of the generators will be controlled by the temporary panel. Generator No. 1 will be locked out and unavailable.

Date: Day 2

Begin the removal of the existing panels, doors, wiring and controls from the Master Control Cubicle.

Begin the removal of the existing panels, doors, wiring and controls from the Generator 1

Cubicle.

Testing (End of Day before leaving): Complete a No Load test to ensure the operation of the temp panel.

Date: Day 3 & 4

Begin the installation of the new panels, doors and wiring for the Master Control cubicle

Begin the installation of the new panels, doors and wiring for the Generator No. 1 cubicle

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Install temporary wiring for Generator No. 1 breaker position to the temporary panel.

Testing:

Complete testing for the master control cubicle and portions of the Generator No. 1 control cubicle include dead bus.

Note: Keep Generator No. 1 breaker racked out when engines 2, 3 & 4 are in Auto. Testing (End of Day before leaving):

Complete a No Load test of the temp panel to ensure the operation of the temp panel with generators 2, 3 and 4.

Note: While a Russelectric Engineer is onsite, the temporary panel may be disabled while the testing of the master control cubicle and the generator No. 1 cubicle. In the event of an outage the master cubicle will be placed in manual and the temporary panel will be enabled.

Date: Day 5 (24 Hour Coverage)

Remove all wiring associated with the temporary panel for Generator No. 2

Begin the installation of the new panels, doors and wiring Generator No. 2 cubicle.

Note: Keep Generator No. 1 breaker racked out when engines 3 & 4 are in Auto, Keep master control cubicle manual-auto switch in manual.

Note: While the generator control cubicle No. 2 is upgraded the site will only have 2 generator available for automatic operations. Generator No. 1 can be added manually. Testing (End of Day before leaving):

Complete a No Load test to ensure the operation of the temp panel Date: Day 6 & 7 (24 Hour Coverage)

Complete testing and commissioning for the portions of the Generator No. 2 control cubicle.

Complete the remaining testing for the master control cubicle and the Generator No. 1 & 2

control cubicles,

Move load control wiring to the ATS’s onto the master cubicle.

Complete load controls testing for the ATS’s.

Testing:

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Complete the remaining testing for the master control cubicle and the Generator No. 1 & 2 control cubicles,

Complete load controls testing for the ATS’s.

With the temporary panel disabled and the new master controls enabled complete a

load test of a priority two ATS.

With the temporary panel disabled and the new master controls enabled, complete a load test of a priority one ATS.

With the temporary panel disabled and the new master controls enabled, complete

a full building load test by adding ALL ATS one by one to ensure all correct engine start, load shed, block transfer, ATS position contacts are correct.

Note: All automatic controls will now be governed by the new master control cubicle and will relay on automatic operation of generators No. 1 & 2. Date: Day 7

Begin the removal of the existing panels, doors, wiring and controls from the Generator No. 3 cubicle.

Begin installation of the new panels, doors and wiring for the Generator No. 3 cubicle.

Testing (End of Day before leaving):

Complete a No Load test to ensure the operation of the Master control cubicle

Note: Keep Generator No. 4 breaker racked out when engines 1 & 2 are in Auto, Keep master control cubicle manual-auto switch in manual .

Date: Day 8

Complete the installation of the new panels, doors and wiring Generator No. 3 cubicle.

Testing: Complete testing for Generator No. 3 controls with the new master control cubicle,

including all automatic and manual operations

Step 11.0.1: Testing: Complete a full building load test and ensure that all ATS transfer. With Normal power available, complete load shed testing for the return to normal.

Note: Full automatic control of Generators No. 1-3 are available and is governed by the new master controls.

Date: Day 9 (Only if system has more than 3 generators in the system)

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Begin the removal of the existing panels, doors, wiring and controls from the Generator No.

4 cubicle.

Begin installation of the new panels, doors and wiring for the Generator No. 4 cubicle.

Testing (End of Day before leaving): Complete a No Load test to ensure the operation of the Master control cubicle

Date: Day 10 (Only if system has more then 3 generators in the system)

Complete the installation of the new panels, doors and wiring Generator No. 4 cubicle.

Testing: Complete testing for Generator No. 4 controls with the new master control cubicle,

including all automatic and manual operations

Step 11.0.1: Testing: Complete a full building load test and ensure that all ATS transfer. With Normal power available, complete load shed testing for the return to normal.

Note: Full automatic control of Generators No. 1-4 are available and is governed by the new master controls.

Date: Day 11

Complete any remaining testing for alarms and non-critical functions.

Optoional but recommended: Customer to rent a load bank and bring in for use by CAT & Russelectric to setup the existing load sharing modules for complete operation.

Complete Load bank testing.

Date: Day 12

Complete commissioning for the entire system.

Testing: Complete commissioning for the entire system.

Date: Day 13

Training for Staff