SCHOOLFIELD 69/12 KV SUBSTATION SUBSTATION PACKAGER

SCHOOLFIELD 69/12 KV SUBSTATION

SUBSTATION PACKAGERSPECIFICATION

Danville, Virginia

UCS TECHNICAL SPECIFICATION NO.16845-SD0301.00

PREPARED FOR:

Danville Utilities1040 Monument StreetDanville, Virginia 24541

Specification Developed by:

UC SYNERGETIC, LLC123 N. WHITE STREETFORT MILL, SC 29715

UC Synergetic, LLC123 N. White StreetFort Mill, SC 29715

Date: 03/01/2017 Page: UCS Job No.:Revision: B 2 of 36 16845Client: Danville UtilitiesProject: Schoolfield SubstationSpecification No.: 16845.SD0301.00

Specification Title: Substation Packager Specification

VERIFICATION OF SPECIFICATIONProject Owner Danville Utilities

Specification Title Substation Packager Specification

Specification No. 16845.SD0101.00

Revision No. B Revision Date: 03/01/2017

In accord with established procedures, the quality of this specification has been assured.Signatures below certify that the above specification was originated, reviewed, andapproved as noted.

Prepared By: Jeffrey D Giles, P.E. Date: 01/23/2017

Checked By: Robert Srednicki, P.E. Date: 02/17/2017

Reviewed by Responsible Discipline:

Mechanical Engineering: N/A Date:

Electrical Engineering: Jeffrey D Giles, P.E. Date: 02/17/2017

Civil/Structural Engineering: Date:

Approved By: Robert Srednicki, P.E. Date: 02/17/2017

Revision Log:

A. Issued for Review 2.

B. Issued for Bid 3.

0. 4.

1. 5.




Table of ContentsSubject Location

FRONT MATTERCover SheetVerification of SpecificationTable of Contents

1000 SCOPE1001 Purpose 6

1002 Definitions 6

1003 Description of Project 6

1004 Buyer Contact Information 6

1005 Exclusions from Specification 7

1006 Seller Responsibilities 7

1006.1 MATERIALS AND EQUIPMENT 71006.2 TECHNICAL SUPPORT SERVICES 81006.3 DRAWINGS AND TECHNICAL INFORMATION 9

1006.3.1 Definitions 91006.3.2 Approval Documents 91006.3.3 Final Documents 111006.3.4 Record Documents 111006.3.5 Information Contents and Formats 11

1007 Key Dates for Sellers 12

2000 SPECIFICATIONS2001 Station Design Criteria 13

2002 Structures 15




2002.1 MATERIALS 15

2002.2 FABRICATION1017

2002.3 GALVANIZING 192002.4 INSPECTION AND TESTING 202002.5 PACKAGING AND SHIPPING 20

2003 Insulators 21

2004 Buses and Jumpers 22

2004.1 GENERAL 222004.2 RIGID BUS 222004.3 FLEXIBLE CONDUCTORS 232004.4 APPROVED MANUFACTURERS 23

2005 Gang-Operated Disconnect Switches 23

2006 Hookstick-Operated Disconnect Switches 29

2007 Surge Arresters 31

2008 Fuses and Fuse Cutouts 33

2009 Station Lighting 34

2010 Station Grounding 34

3000 INSTRUCTIONS TO BIDDERS3001 GENERAL INSTRUCTIONS 353002 SPECIFIC INSTRUCTIONS 353003 COMMERCIAL TERMS AND CONDITIONS 36




ATTACHMENTS

The following reference project drawings are attached:

Cover Sheet & Drawing Index CV01Power Single Line Diagram PSL01General Arrangement GA01Elevations & Sections EL01Elevations & Sections EL02Elevations & Sections EL03Elevations & Sections EL04Elevations & Sections EL05




1000 SCOPE

1001 PurposeThe purpose of this specification is to describe a planned upgrade to theSchoolfield 69/12 kV substation in sufficient detail to enable Bidders to submitproposals for the complete substation package as described herein.

1002 DefinitionsFor the purpose of this specification, the following definitions apply:

Site: Schoolfield Substation, Danville, VirginiaOwner: City of DanvilleBuyer: Danville UtilitiesProject Manager: Primary Buyer contact for both Bidders and Sellers.Bidder: Any party responding to Buyer's solicitation for proposals.Seller: Party to whom order or any part thereof is awarded.Seller's Engineer: Primary Seller Contact.

1003 Description of ProjectThe Buyer plans to upgrade an existing substation in the south west section ofits service territory. The substation is an existing loop through 69kV main bus,feeding two (2) new 69/12 kV power transformers. The 69/12 kV transformerswill feed two (2) 2000a 12kV main breakers and 8 new 12kV vacuum circuitbreakers. The 12kV breakers will be broken up into 2-12kV main/transfer bussections tied together with a 12kV 2000a bus tie breaker. The 12kV feederexits will be underground. Buyer is responsible for project design,engineering, procurement and construction.NOTE: The intent is to provide all low voltage switches, breakers andinsulation at the 25kV level and spaced for 25kV clearances, operating at12kV.

1004 Buyer Contact Information

Bidders and Sellers shall direct all correspondence, inquiries, questions, bids,proposals, drawings, instruction manuals and other information and materialpertaining to this proposal or award of purchase order to the Project Manager:




Mr. Craig SibleyElectric Substation SuperintendentDanville UtilitiesDivision of Power and Light1040 Monument StreetDanville, Virginia 24541Telephone: 434.799.5277e-mail: [email protected]

1005 Exclusions from Specification

This specification pertains to materials and equipment only. The followingitems will be provided by other parties and are thus specifically excluded fromthe scope of this Specification and from Seller's responsibilities pertainingthereto:

Construction labor; Standard tools and construction equipment; 25 kV circuit breakers; 69 KV circuit breakers; Station service transformer; Instrument transformers; Foundation materials other than anchor bolts; Ground grid materials which will be located below ground; Cable, pull boxes, terminal boxes and conduit; Controls, control house, relays, panels, control circuits, and associated

cabling; Switchyard fence, fire alarm/suppression systems, and; Power transformers with arresters Metering equipment.

1006 Seller Responsibilities1006.1 MATERIALS AND EQUIPMENT

With the exception of the items specifically excluded in Section 1005 –Exclusions from Specification, Seller shall furnish all materials, equipment andsupplies required to construct a complete substation as described anddepicted on Buyer's drawings, this specification including, not necessarily




limited to the following, which are further described in Section 2000 -Specifications.

Substation structures; Lighting fixtures, poles and brackets; Gang-operated disconnect switches; Hookstick-operated switches; Surge arresters (lines and feeders); Fuse cutouts and links; Insulators; Connectors, fittings and hardware; Conductor for rigid bus and flexible connections; Ground wires and fittings which are located above ground; Expendables, such as oxide inhibitors, etc., and; Required special tools and recommended spare parts.

1006.2 TECHNICAL SUPPORT SERVICES

Prompt Responses to Buyer's Inquiries - Seller shall provide Buyer with thename and contact information of Seller's Engineer. Seller's Engineer shall beavailable for consultation by telephone, e-mail and fax throughout the durationof the project. Seller responsiveness being essential to completion of theproject on schedule and within budget, Buyer inquiries shall receive promptattention by Seller's Engineer. In general, turnover time for responding toBuyer inquiries shall not exceed 24 hours.

Field Service Engineer - Seller shall be responsible for furnishing theservices of a qualified Field Service Engineer to advise, familiarize and assistBuyer with the installation, assembly, testing and commissioning of structuresand equipment furnished. Such Field Service Engineer shall be available toBuyer via telephone, beginning at a date to be specified by Buyer.

Quality Control and Quality Assurance - Seller shall conduct appropriatetests and quality assurance measures for each item provided and shall, atleast three weeks in advance, provide Buyer with a schedule for such testing.Buyer reserves the right to witness any or all such testing and to conductadditional quality assurance tests and measures at his discretion. Test reportsshall be submitted to Buyer's Project Manager.




Materials Status Reports - Following the receipt of approval drawings anddocuments from Buyer, Seller's Engineer shall file reports with each shipmentof materials, but certainly no less frequently than weekly, such reports toinclude the quantities and dates of materials shipped, quantities of materialsnot yet shipped, and best estimates of shipping dates for those materials yetto be shipped. These reports shall employ a format approved by Buyer.

1006.3 DRAWINGS AND TECHNICAL INFORMATION

1006.3.1 DefinitionsThe following information is required from the Seller only. The followingdefinitions apply.

Approval Documents - Drawings, bills of materials, equipment outlines andspecifications, instruction manuals and other pertinent information which aresubmitted to Buyer for review, comment and approval.

Final Documents - Drawings, bills of materials, equipment outlines andspecifications, instruction manuals and other pertinent information which havebeen approved by Buyer.

Record Documents - Drawings, bills of materials, equipment outlines andspecifications, instruction manuals and other pertinent information whichrepresent the equipment as shipped and the project as built.

1006.3.2 Approval DocumentsSubmittals - Seller shall submit for Buyer's review and approval drawings,bills of materials, equipment outlines, instruction manuals and other pertinentinformation. Submittals may be electronic, in pdf or Acad .dwg format, viaemail or an established ftp site to be announced later. Approval informationshall include but shall not be limited to the following items:

Steel erection and detail drawings (shop drawings);

Anchor bolt plan, including anchor bolt sizes, locations, and dimensions;

Electrical arrangement drawings, including bus and connection details; andrigid bus conductor cutting schedule;

Drawings and information detailing packaging for shipping, storagerequirements.

Miscellaneous Safety Data Sheets as prescribed by OSHA regulations;




Bills of materials, manufacturer’s outline drawings, specification sheets,descriptive information and instruction manuals for materials andequipment to be furnished;

Structural design calculations, including foundation reaction loads.Reaction loads shall be broken down by load components andcombinations. Both magnitude and direction shall be provided for allfoundation loads;

Descriptive information on minor and major maintenance of equipment tobe furnished;

Information describing installation and commissioning procedures;

Maximum vertical, horizontal, longitudinal, and torsional loading for busconnection terminals;

Copy of design tests showing compliance with the provided specificationsand applicable standards;

Information describing production tests applied to each device;

List of recommended spare parts and prices, and;

Detailed schedule for delivery of Approval Drawings and delivery ofmaterials on site. Material shipping status-tracking reports shall also besubmitted until all Seller-supplied material is delivered to site.

The scheduled due dates for delivery of approval drawings are given inSection 1007 - Key Dates for Sellers.

Approval - Buyer will review Approval Documents, mark them as necessaryfor correction or revision, and return one (1) marked set to Seller. Seller shallmake Buyer's specified revisions and corrections. Documents which do notmeet Buyer’s approval will be resubmitted for further revision as necessaryuntil Buyer’s specifications are met.

Communication - Buyer's Project Manager, or his designate, and Seller'sEngineer, or his designate, shall communicate as needed prior to Seller'ssubmitting Final Documents to ensure that Buyer's intent, instruction, anddirection and Seller's recommendations are fully understood and the FinalDocuments to be submitted reflect agreement Buyer's needs.




1006.3.3 Final Documents

Drawings which meet Buyer’s approval shall be returned to Seller markedeither APPROVED or APPROVED EXCEPT AS NOTED. Seller shall supplysubstation package based on Final Documents.

1006.3.4 Record Documents

Within four (4) weeks following final shipment of equipment and materials,Seller shall submit Record Documents to Buyer, which shall consist of all as-built drawings, bills of materials, equipment outlines and nameplatereproductions (including serial numbers), instruction manuals, and otherpertinent final information which have been corrected to represent the finalstate of the project in accord with Buyer's direction. Record Documents shallbe sealed and signed by a Professional Engineer.

1006.3.5 Information Contents and Formats

Formats - Approval drawings may be submitted in electronic form, in pdf orAcad .dwg format, via email or an established ftp site to be announced later.Other information may be submitted in electronic Excel spreadsheets, or in.pdf format. All Submittals shall be legible copies of manufacturers' catalog cutsheets with items being furnished clearly identified. Document sizes shall besufficient to make all information clearly legible. Additional copies of RecordDocuments, as defined in Sections 1006.3.1 and 1006.3.4, shall be provided.

Drawing Numbers - All drawings shall be numbered with Buyer's numberingsystem used on Buyer's drawings. Communication between Buyer and Sellerwill reference these numbers. Seller may further identify drawings with hisown numbering system elsewhere on the drawing if so desired, provided thatBuyer's number is the more prominently visible.

Coordination of Information - Materials and structure identification numbersused on the bill of materials shall be also appear on the drawings, equipmentoutlines, catalog sheets and other relevant documents in order to coordinatethe documents and facilitate engineering review and construction.

Structural Steel Drawings - Approval Drawings, Final Drawings and RecordDrawings (erection drawings and shop drawings) for structural steel shallcontain all dimensions, component identifying marks and other necessaryinformation in sufficient detail to facilitate rapid, ready and economical




fabrication, identification of individual components at the Site, and erection ofall structures

Electrical Drawings - Approval Drawings, Final Drawings and RecordDrawings for substation and equipment shall contain all dimensions,component identifying marks and other necessary information in sufficientdetail to facilitate rapid, ready and economical erection, identification ofindividual components at the Site, mounting, and connection of equipment.Drawings shall also include any special instructions or information required forinstallation.

Bill of Materials - Bill of Materials shall contain sufficiently detaileddescriptions of equipment to facilitate identification of components andequipment.

Equipment information - Seller shall clearly identify all relevant items onequipment outlines, catalog cut sheets and other information, and mark eachcomponent with the same identifying number as those used in the Bill ofMaterials and on the drawings in order to facilitate rapid identification ofcomponents, connectors and hardware at the Site and on the drawings.

1007 Key Dates for Sellers

Seller shall schedule deliveries of the required information, materials andservices to ensure adherence to the following project schedule and key dates:

Event or Requirement Description Due Date

Award of Contract

Submit Structural Steel Calculations and FoundationReaction Loads to Buyer

Submit Approval Drawings to BuyerDelivery of Final Drawings, Bills of Materials andOther Required InformationDelivery of All Anchor Bolts

Delivery of All Structures, Equipment and MaterialsDelivery of Record Information

End of Section 1000




2000 SPECIFICATIONS

2001 Station Design Criteria

General - Design and design loading of substation structures, conductors andequipment shall conform to the latest revisions of the following standards andguidelines:

ANSI/IEEE 605, Guide for Design of Substation Rigid Bus Structures; ANSI C2, National Electric Safety Code (NESC); ASCE 113, Substation Structure Design Guide, and; IEEE 693, Recommended Practices for Seismic Design of Substations.

Site Geophysical Data - Station design shall take into account the following SiteGeophysical Data unless otherwise specified.

CRITERION DATUMGeodetic Coordinates (Lat. X Lon.) 36°33'54.20"N, 79°26'21.55"WElevation above MSL 582 feetMean Annual Precipitation 45 inches (Avg. Snowfall = 10 inches)Temperature Range -4ºF (-20ºC) to 104ºF (40ºC)Average Relative Humidity 69 percentIsokeraunic Activity Level 50 thunderstorm-days/yearNESC Ice & Wind Loading District Heavy – 1/2” Ice, 4 psf wind at 0°FSeismic Requirements

Site Class: DFa 1.6Fv 2.4SDs 0.164gSD1 0.119g




Electrical Design Criteria - Installation will be a three-phase medium voltageelectrical substation designed and built to the following electrical criteria.

CRITERION SPECIFICATIONFrequency 60 HzNominal Operating Voltage 12.47 kV 69 kVBasic Impulse Level 150 kV 350 kVMaximum Continuous Current 2,000 amps rmsShort Circuit Current 25,000 amps rms symmetrical

NOTE: The intent is to provide all low voltage switches, breakers andinsulation at the 25kV level and spaced for 25kV clearances, operating at12kV.

Mechanical and Structural Design Criteria - Design loading methodology forstation structures and equipment shall be the ASCE 113 – Substation StructureDesign Guide, unless otherwise specified herein.

Wind loads shall be applied from the direction which results in maximumstructural stresses. Ice loading of structures, conductors and equipment shallassume weight associated with a glazed ice density of 57 lbs/ft2.

The following structural and mechanical design criteria shall be employed.

Criterion ValueNESC Wind Loading District HeavyExtreme Wind Speed 90 mphNESC Ice Loading District HeavyExtreme Ice Coating Radial Thickness 0.75 inchesExposure Category CImportance Factor 1.15




Structure Deflection Criteria - Structure allowable deflections shall meet thelatest revision of the ASCE 113 – Substation Structure Design Guide, exceptwhere the operational requirements of affected equipment indicate morerestrictive criteria. In general, limits of structural member and rigid bus deflectionwill be:

Horizontal and Vertical Deflection Limits = L / 200

where L = Span length in feet for horizontal members and height in feet abovebaseplate for vertical members.

Loading Design Cases - Design of station structures shall consider separatelyeach of the loading cases described below.

Case 1: NESC Heavy District Loading Case

Case 2: Extreme Wind Condition Loading Case

Case 3: Heavy Ice Loading Case

Case 4: NESC Heavy District Wind Loading + Heavy District Ice Case

Case 5: Seismic Load Case

Case 6: Deflection Load Case (No ice, wind or overload factor)

Case 7: Short Circuit Load Case

Case 8: Wind Load + Short Circuit Load

Case 9: Seismic Load + Short Circuit Load

Case 10: Wind Load + Ice Load + Short Circuit Load

2002 Structures

2002.1 MATERIALS

General - Unless otherwise specified, structures shall be designed andfabricated as prescribed in the latest revisions of the following standards andguidelines:

AISC Steel Construction Manual;

ASTM A36, Structural Steel;




ASTM A123, Zinc (Hot-Dip Galvanized) Coatings on Iron and SteelProducts;

ASTM A143, Safeguarding Against Embrittlement of Hot-Dip GalvanizedStructural Steel and Procedure for Detecting Embrittlement;

ASTM A153 Zinc Coating (Hot-Dip) on Iron and Steel Hardware;

ASTM A 325, Steel Zinc Coated Structural Bolts;

ASTM E376, Measuring Coating Thickness by Magnetic Field or EddyCurrent (Electromagnetic) Test Methods;

ASTM A384, Safeguarding Against Warpage and Distortion During Hot-Dip Galvanizing of Steel Assemblies;

ASTM A385, Providing High-Quality Zinc Coatings (Hot-Dip);

ASTM A436, Hardened Steel Washers;

ASTM A563, Carbon and Alloy Steel Nuts;

ASTM A780, Repair of Damaged Hot-Dip Galvanized Coatings, and;

AWS D1.1 Structural Welding Code.

Substation Structures - Substation structures shall be constructed of eitherstandard rolled steel shapes, of tapered tubular steel sections or of standardtubular steel. The choice shall be based on economics and on Buyer'spreference.

Bolts - Bolts shall have hexagonal heads and shall conform to ASTM A325.Bolt threads shall be excluded from the shear plane.

Nuts - Nuts shall be hexagonal and shall conform to ASTM A563-DH orA563-2H.

Washers - Washers, flat or beveled as may be appropriate, shall be providedat all connections and shall conform to ASTM A436. Malleable iron washerswill not be acceptable.

Anchor Bolts - Anchor bolts for all structural columns shall be designed withsufficient length and anchoring capacity to develop the full strength of the boltswhen embedded in 3,000 psi test concrete, and shall conform to ASTM A354.




The top 12-inches of anchor bolts shall be galvanized as prescribed in ASTMA153. Each anchor bolt shall be furnished with two nuts for leveling andplumbing structures. Nuts shall conform with ASTM A563.

2002.2 FABRICATION

General - Steel structures shall be fabricated to AISC specifications and inaccord with Buyer's requirements.

Deformation - Structures and structural members shall be straight, true andaccurate. Members or pieces which are seriously deformed or distorted willbe rejected by Buyer. Minor deformations or distortions may be corrected withthe permission of the Buyer using methods which Buyer approves. In no caseshall items be heated to correct distortions.

Equipment Mounting Provisions - Structures shall provide for appropriatemounting or attachment of electrical equipment, bus, conduit, connectors orother associated apparatus or equipment without requiring field-drilled holes.

Cutting Tools - Shears, punches, dies, drill bits and other cutting tools usedin fabrication shall be clean and sharp to prevent burrs or other defects alongcut edges.

Cuts - Cutting or shearing of steel shall be done to gage and in a manner thatresults in clean-cut edges and no variation in length beyond that noted in theshop drawings. All bevel cutting shall be true and accurate and shall be madeprior to galvanizing.

Holes - Dimensions for connection or mounting bolt holes shall be 1/16 inchlarger than the diameters of the corresponding bolts unless otherwisespecified. Dimensions for holes for anchor bolts shall be 3/8 inch larger thanthe diameter of the corresponding anchor bolts unless otherwise specified.Punching and drilling shall be to gage and shall be true and accurate.Plugging or welding holes punched or drilled in an incorrect location shall notadversely affect the integrity of the member or structure.

Bends - Any required bending of members shall be reasonably true, accurateand sharp. Holes which are located within four inches of bends shall not bemade until after bends have been made.

Bolted Connections - All connections to be made after galvanizing shall bebolted connections. Center-to-center dimensions of end holes of a membershall not vary by more than 1/16 inch. The use of drift pins to correct




misalignments of holes shall be permitted provided that they do not damagethe protective coating of the steel surface. Fabricator shall provide torquerequirements for bolted connections.

Welded Connections - All connections to be made prior to galvanizing shallbe welded connections unless otherwise specified. Welded connections shallcomply with AISC specifications and welder operator and welding procedurequalifications shall conform to AWS D1.1.

Weld Information on Shop Drawings - Weld details on fabricator's shopdrawings shall include identification of weld and method to be used for makingthe welds as prescribed in AWS D1.1.

Weld Materials - Weld filler materials shall be compatible with the substratesto which they will be applied as defined by AWS specifications. Welding rod,flux and other consumable welding materials shall be stored as prescribed inAWS D1.1.

Preparation and Welding Process - Pieces to be connected by welding shallbe carefully fitted, assembled and aligned. Surface to be welded and surfacewithin 1/2 inch of proposed weld edge shall be thoroughly cleaned of rust, dirt,oil, grease, water and other contaminants before making the weld.Connections shall be made by full-penetration welds in continuous seams.Welding shall be controlled to minimize shrinkage, warp or other distortion orstress.

Weld Defects - Completed welds shall be carefully inspected for voids, pitting,cratering, cracks, slag inclusions and undercuts which exceed the permitteddefects prescribed in AWS D1.1. Any such defects shall be removed asprescribed in AWS D1.1, and then rewelded. Completed welds shall bechipped and ground as required to make the surfaces smooth and free of slagprior to galvanizing.

Structure Grounding Provisions - Each structure shall be provided with atwo-hole grounding pad near the ground level on each column or leg.

Erection Marks - All structural members shall be identified with erectionmarks which correspond to the shop detail drawings, erection drawings andbill of materials. Erection marks shall consist of stamped 3/4-inch high x 1/16-inch deep minimum letters and/or numerals, and shall be locatedconspicuously near the ends of the members being marked to facilitateidentification of members in the field. Members over 14 feet in length shall bemarked at both ends. Identical members shall bear identical erection marks.Erection marks shall be stamped into members prior to galvanizing.




2002.3 Galvanizing

General - All steel shall be hot-dip galvanized after fabrication in accord withASTM A123 for structural steel and ASTM A153 for steel hardware. Minimumgalvanized coating thickness, as measured by magnetic field or eddy currenttest methods prescribed by ASTM A376, latest revision, shall be:

Average of: Structural Steel Bolting HardwareAll Specimens Tested 4.7 mils (2.82 oz/ft2) 2.8 mils (1.68 oz/ft2)Individual Specimen 4.2 mils (2.52 oz/ft2) 2.5 mils (1.50 oz/ft2)

Both exterior and interior of rolled shapes or tubular steel structures, membersand components, including all welds, shall be completely coated in a single-dip process unless a double-dip process. Double dip galvanizing will not beacceptable.

Excess Zinc - Heavy coating runs, encrustation, lumps or protrusions ofexcess zinc will not be acceptable.

Deformation - Fabricator shall safeguard against warping or distortingstructures, members and components during the galvanizing process asprescribed in ASTM A384, latest revision. Minor distortions may be corrected,provided that such corrections do not require heating the steel.

Tapped Holes - All tapped holes or nuts welded to members or structureassemblies shall be re-tapped with the properly oversized tap aftergalvanizing. Bolts and nuts shall be assembled after galvanizing to ensurethat friction provides finger-fit tightness. Wrench tightness or spinning fit arenot acceptable.

Final Cleaning - All materials shall be thoroughly cleaned after galvanizing toremove traces of flux, flux inclusions, pre-flux salts, acid dross and other suchmaterials. The presence of wet storage stain (white rust) shall be cause forrejection of the material by the Buyer.

Shipping Damage - Seller shall be responsible for repair of any damage tocoating system which occurs during fabrication, handling and shipping untilstructures are delivered to the Site. Repairs shall comply with ASTM A780,latest revision.




2002.4 INSPECTION AND TESTING

Fabricator shall inspect, measure and test structures, members, componentsand materials to verify that they conform to this specification and all applicablestandards. Certified copies of mill test reports showing the physical andchemical properties of the materials used in fabrication, and Manufacturer'sCertificate of Inspection for Zinc (Hot-Dip Galvanized) Coatings on StructuralSteel shall be provided to the Buyer.

Buyer shall have right to inspect manufacturer's shop or the work in process atany time prior to or during the fabrication.

2002.5 PACKAGING AND SHIPPING

Complete Packages - All steel structures shall be furnished as a completepackaged lot, including assembly drawings (with each member or partindexed), details, bill of materials, assembly hardware (bolts, nuts, flatwashers and lock washers), base plates, and all other items required to erectat the Site the completed structures described in this specification.

Package Size and Content - Structural steel shipping packages shall be aslarge as is practical. Only complete structures shall be shipped; completestructures, including required hardware, shall be packaged and shippedtogether. Hardware (bolts, nuts, washers, lock washers) shall be packaged incloth bags, with different hardware segregated and like hardware baggedtogether. Each bag shall be clearly and indelibly marked with its contents.

Package Identification - Identity of each package shall be clearly andindelibly marked, and Seller shall provide Buyer with package lists whichmatch package identifications prior to shipment.

Protection from Damage - Components shall be prepared for shipping in amanner which will ensure that no damage occurs during transit, and shall beshipped in an open top or flatbed truck to facilitate unloading at the site.

Advance Notification of Delivery - Seller shall provide Buyer with 48-hourminimum advance notice of delivery of packages, including descriptions ofmaterials included in the packages. Where construction schedules may beadversely affected by this provision, it may be waived with the Buyer consent.




2003 Insulators

Materials for Station Post Insulators - Station post insulators shall beconstructed of commercial grade wet-process porcelain with uniformconsistency free of voids or other defects which may adversely affect electricalor mechanical performance. Surface shall be smooth and relatively free ofimperfections. The entire surface which will be exposed after assembly shallbe glazed. Metal parts shall be constructed of commercial grade malleableiron, ductile iron or steel and shall be hot-dip galvanized after fabrication inaccord with ASTM A123.

Materials for Strain/Suspension Insulators -The suspension insulatorsoperating at 69 kV shall be polymer type and have the following minimumelectrical and mechanical characteristics, in addition to those required byelectrical or structural design calculations:

Positive Impulse Flashover 390 kV

Wet Withstand (10 Sec.) 145 kV

Leakage Distance Inches 72 Inches

Specified Mechanical Load 25,000 Pounds

Routine Test Load 12,500 Pounds

Ratings and Characteristics – Station and bus insulators shall be highstrength (ANSI TR-227 for 12kV, ANSI TR-278 for 69kV) station post design,and shall meet or exceed the latest revision of the ANSI C29.1 and C29.9 andthe following minimum design characteristics.

CHARACTERISTIC RATINGDielectric Material PorcelainImpulse Withstand (kV) 150 (for 12kV)




350 (for 69kV )Critical Impulse Flashover-Pos. (kV) 170 (for 12kV)

390 (for 69kV )Wet Withstand (kV) 60 (for 12kV )

145 (for 69kV )Leakage Distance (inches) 24 (for 12kV )

72 (for 69kV )Maximum RIV at 1 MHz (μV) 100 (for 12kV )

200 (for 69kV )Cantilever Strength (lbs.) 4,000 (for 12kV )

3,000 (for 69kV )Tensile Strength (lbs.) 20,000 (for 12kV )

25,000 (for 69kV )Torsional Strength (inch-lbs.) 16,000 (for 12kV )

40,000 (for 69kV )Compression Strength (lbs.) 20,000 (for 12kV )

60,000 (for 69kV )

NOTE: The intent is to provide all low voltage switches, breakers andinsulation at the 25kV level and spaced for 25kV clearances, operating at12kV.

Color - Dielectric surfaces shall be ANSI 70 Sky Gray.

Spares - Quantities shall include 5 percent spare quantities (rounded up to thenext whole number) to allow for damaged units.

Approved Manufacturers - Approved manufacturers for insulators: Hubbell,Lapp, NGK Locke, Newell.

2004 Buses and Jumpers

2004.1 GENERAL

Phase-to-phase and phase-to-ground minimum clearances shall conform tothe latest revision of the ANSI C37.30.1. Minimum clearances betweenenergized overhead conductors and ground shall conform to RUS Bulletin1724E-300 for personnel safety or as shown on Buyer's drawings.

2004.2 RIGID BUS

Conductors - Rigid bus conductor shall be seamless aluminum pipe, alloy6063.T6, and shall conform to ASTM B-345, latest revision, with base currentrating of 30°C rise over 40°C ambient with full sun exposure and 2-ft/sec crosswind. For 3” dia. pipe, a single, continuous length of 266.8 kcmil ACSR




(Partridge) cable shall be inserted into each horizontal section of bus over itsentire length to suppress aeolian vibration. Seller shall provide tube cuttingschedule as a part of the drawings. Tubing shall be perforated with 3/8 -inchdiameter holes spaced at 36-inch intervals on the undersides to permit drainageand prevent accumulation of water.

Fittings and Connectors – Factory fittings shall be welded. Field fittings shall beof the welded type. Bus shall be fixed at one end with an expansion fitting at theother end to allow for thermal expansion. Quantities of each type of fitting andits associated hardware (bolts, nuts, flat washers, lock washers) shall include5 percent spare quantities (rounded up to the next whole number).

2004.3 FLEXIBLE CONDUCTORS

Conductors - Flexible conductors shall be 1,272 kcmil AAC (Narcissus), 500kcmil AAC (Hyacinth), 4/0 kcmil AAC (Oxlip), and #2 kcmil AAC (Iris) as shownon the drawings accompanying this Specification.

Fittings and Connectors - Fittings and connectors for flexible conductors shallbe of the compression type.

2004.4 APPROVED MANUFACTURERS

Approved manufacturers of fittings and connectors for both rigid and flexible busand lines: Anderson (Hubbell), Dossert (AFL), Burndy, Homac (T&B), Sefcor.

2005 Gang Operated Disconnect SwitchesGeneral - Switch shall meet or exceed the requirements prescribed in thelatest revisions of all applicable standards, including ANSI/IEEE C37-30, 32,34, 34a and 37, NEMA, ASME, AISC and AWS.

69 kV Switch Ratings – 69kV Switches shall be vertical break, three-pole-single-throw, gang-operated, air-break disconnect switch, capable of beingmounted in a horizontal or vertical orientation, and shall meet the followingminimum ratings.




69 KV SWITCH DATA (VERTICAL BREAK)

Quantity 2

Nominal Operating Voltage 69 kV

Operation Type Manual Gang Operated

Motor Control Voltage 125 VDC

Basic Impulse Level 350 kV

Continuous Current Capacity 1,200A

Momentary Current Capacity 61,000 Amps

25 kV Switch Ratings –25kV Switches for the main bus and transfer bus shallbe V-configuration, three-pole-single-throw, gang-operated, center side-break,air-break disconnect switch, capable of being mounted in a horizontal orvertical orientation.

25kV Switches for the tie bus shall be V-configuration, three-pole-single-throw,gang-operated, vertical break, air-break disconnect switch, capable of beingmounted in a horizontal or vertical orientation.

25kV Switches for the feeder bays shall be V-configuration, hook-stickoperated, center side-break, air-break disconnect switch, capable of beingmounted in a horizontal or vertical orientation

All 25kV switches shall meet the following minimum ratings.




25 KV MAIN BUS SWITCH DATA (CENTER SIDE BREAK – WITH ARCING HORNS)

Quantity 2


Operation Type Manual (Gang Operated)




25 KV BUS TIE SWITCH DATA (VERTICAL BREAK)

Quantity 2









25 KV TRANSFER BUS SWITCH DATA (CENTER SIDE BREAK – WITH ARCINGHORNS)

Quantity 8






Operator - Switch shall be manually operated, and capable of operating underice loading conditions prescribed in the latest revision of ANSI/IEEE C36.34.

Arcing Horns – All 69kV Switches shall be equipped with arcing horns. The2,000-amp main bus and 1,200-amp transfer bus 25kV Switches shall beequipped with arcing horns

Insulators - Provide 25kV switches with porcelain type TR-227 insulators ANSI70 Skytone gray. Provide 69kV switches with porcelain type TR-278 ANSI 70Skytone gray. Insulators to be mounted on switch and shipped as a completeunit. Insulator alignment and leveling devices, which shall be excluded fromthe current carrying paths of the switches, shall be provided. Bolt circles forleveling bolts which are in contact with insulator caps shall be identical tothose for mounting bolts.

Ferrous Components - Ferrous parts shall be hot dip galvanized afterfabrication as prescribed in ASTM A153. All switch and mechanism partsshall be of materials which are resistant to damage by ultraviolet light.

Temperature Rise - Temperature rise of current carrying components over40°C ambient shall not exceed 53°C, except switch terminals which shall notexceed 43°C.




Blade Material - Switch blades shall be constructed of electrical alloyaluminum.

Contacts - All contacts shall be surfaced with a ten (10) mil minimumthickness of silver, silver alloy or suitable equivalent on both surfaces, brazedon exposed contacts, and either brazed or electroplated on sealed contacts.Rivets, beads or screws are not acceptable as contacts.

Contact Pressure Adjustment - Uniform contact pressure shall bemaintained under all operating conditions, and shall not change as a resulthigh momentary or continuous current. Springs and spring washers used formaintaining contact pressure shall be located outside the current carrying pathto prevent overheating and annealing. Material for contact pressure springs orspring washers shall be 300-series non-magnetic stainless steel or equivalent.Contact adjusting bolts shall be of 3/8-inch minimum diameter.Hinge-End Contacts - The current path must be maintained and unbroken atthe hinge end of the switch throughout the complete open-and-close cycle ofoperation. Hinge-end contacts must be readily visible to facilitate inspection.

Connections - Copper-to-aluminum connections shall be made with silver,silver alloy or suitable equivalent.

Terminal Pads - Switch shall be furnished with 4-hole NEMA standardhorizontally-oriented flat terminal pad, machine-finished on the top surface,which will accommodate connectors without mechanical interference.Underside surface of pad shall be smooth in order to accommodate flatwashers on each bolt.

Base - Switch shall be furnished complete with galvanized steel base ofsufficient rigidity to provide for smooth operation, and suitable for mounting onsteel structures with 4’–0” pole-to-pole spacing for 12 & 25 kV, 7’-0” pole-to-pole spacing for 69 kV. Adjustable stops shall be provided on the bases.Mounting of the switch on the structures shall not require field-drilled holes inthe base.

Operating Linkages - Switch shall be furnished with all operating piping,inter-phase piping, and fittings, which shall be interchangeable from left toright with minimal effort and expense. All piping shall be of steel construction,cut to proper lengths by the switch manufacturer, and hot-dip galvanized afterfabrication. Minimum inter-phase piping diameter shall be 1-inch IPS. Inter-phase piping shall have threaded clevis-type connections to allow tightening oradjusting with a single wrench. Threaded connections shall be protected fromrust.




Bearings - Bearings shall be maintenance free and sufficiently sealed toprevent entry of dust and moisture, and shall be located outside the currentcarrying path. Bearings shall be heavy duty, of the double-row stainless steelball bearing type, with case-hardened races, and shall contain no plastic orother synthetic components. Outboard bearings shall be interchangeable fromleft to right.

Fittings - Fittings shall be of the clevis and U-bolt type. Metal piercing setscrew type fittings shall not be acceptable.

Blade Control - The operating mechanism shall maintain positive control ofthe blade in both the fully open and fully closed positions and at all points inbetween.

Operating Mechanism - Operating mechanism shall be of the swing-handletype.

Switch Operator - Switch operator shall be equipped with adjustable stops forboth open and closed positions with security linkage for locking with a 5/16-inchshort-shackle padlock only in the open or the closed position, but at no point inbetween. Switch position shall not be altered or affected by de-coupling theoperator. Operator and operating mechanism shall be mounted 3’-0” abovethe bottom of the steel base plate. Operating handle shall be equipped with aflexible braid-type jumper connecting it to the structure ground.

Position Indicators - Permanent OPEN and CLOSED position indicatorsshall be mounted on the vertical drive pipe. Peel-off stickers shall not beacceptable.

Component Marking - Switch components and hardware shall be tagged withremovable, weatherproof markings which clearly identify each item.

Hardware - All steel hardware (bolts, nuts, and washers) needed for assemblyof the switch shall be hot dip galvanized and where required shall be coatedwith appropriate compound prior to installation. Only hex head bolts and hexnuts shall be used. Hardware (bolts, nuts, washers, lock washers) shall bepackaged in cloth bags, with different hardware segregated and like hardwarebagged together. Each bag shall be clearly and indelibly marked with itscontents.

Nameplate - A metal nameplate shall be secured to the side of each switchbase and operator, parallel to the switch blade when closed, and visible fromthe ground. The nameplate shall include the following information:




Manufacturer's name and address; Switch type; Model or catalog number;Rated continuous and maximum voltages and currents and BIL, and; Serialnumber.

Approved Manufacturers - Approved manufacturers for disconnect switches:Usco, Memco, Pascor, Southern States, Turner, Cleveland/Price.

2006 Hookstick-Operated Disconnect Switches

General – Switch shall meet or exceed the requirements prescribed in thelatest revisions of all applicable standards, including ANSI/IEEE C37-30, 32,34, 34a and 37, NEMA, ASME, AISC and AWS.

Ratings - Switch shall be single-pole-single-throw, vertical-break, air-breakdisconnect switch suitable for mounting in a vertical orientation, and shall meetthe following minimum ratings:

25 KV FEEDER BAY SWITCH DATA (HOOKSTICH OPERATED)

Quantity 16


Operation Type Manual (Hook-Stick Operated)




Insulators – Provide 25kV switches with porcelain type TR-227 insulators,ANSI 70 Skytone gray. Switches shall be furnished complete with all insulatorsmounted.

Ferrous Components - Ferrous parts shall be hot dip galvanized afterfabrication as prescribed in ASTM A153. All switch and mechanism partsshall be of materials which are resistant to damage by ultraviolet light.




Temperature Rise - Temperature rise of current carrying components over40°C ambient shall not exceed 53°C, except switch terminals which shall notexceed 43°C.

Blade - Switch blade shall be constructed of electrical copper. Each bladeshall be trussed to provide sufficient rigidity to withstand a 50-lb. lateral forceat the ring in the open position and still operate satisfactorily to close and latchwithout transfer of metal on the contacts. Documentation of the test of thiscapability shall be provided.

Blade Latch - Switch shall be equipped with a positive blade latch and largeoval operating ring (minimum 2-1/8" inside diameter) of rugged constructionfor easy engagement. Each switch shall have a cam out leverage exceeding4 to 1 ratio.

Blade stops - Switch shall be equipped with 90-degree blade stops. Stopsshall be of sufficient strength, to resist damage during normal operations.

Blade Guides – Switch shall be equipped with blade guides to ensure positivealignment when blade is closed.

Contacts - All contacts shall be surfaced with a ten (10) mil minimumthickness of silver, silver alloy or suitable equivalent on both surfaces, brazedon exposed contacts, and either brazed or electroplated on sealed contacts.Rivets, beads or screws are not acceptable as contacts.

Contact Pressure Adjustment - Uniform contact pressure shall bemaintained under all operating conditions, and shall not change as a resulthigh momentary or continuous current. Springs and spring washers used formaintaining contact pressure shall be located outside the current carrying pathto prevent overheating and annealing. Material for contact pressure springs orspring washers shall be 300-series non-magnetic stainless steel or equivalent.Contact adjusting bolts shall be of 3/8-inch minimum diameter.

Hinge-End Contacts - The current path must be maintained and unbroken atthe hinge end of the switch throughout the complete open-and-close cycle ofoperation. Hinge-end contacts must be readily visible to facilitate inspection.

Connections - Copper-to-aluminum connections shall be made with silver,silver alloy or suitable equivalent.

Terminal Pads - Switches shall be furnished with 4-hole NEMA standardhorizontally-oriented flat terminal pad, machine-finished on the top surface,which will accommodate connectors without mechanical interference.




Underside surface of pad shall be smooth in order to accommodate flatwashers on each bolt.

Base - Switch shall be furnished complete with galvanized steel channel baseof sufficient rigidity to allow the switch to operate successfully when a 50-lb.lateral force is applied to the ring of the opened switch. Mounting of theswitches on the structures shall not require field-drilled holes in the base.

Hardware - All steel hardware (bolts, nuts, and washers) needed for assemblyof the switch shall be hot dip galvanized and where required shall be coatedwith appropriate compound prior to installation. Only hex head bolts and hexnuts shall be used. Hardware (bolts, nuts, washers, lock washers) shall bepackaged in cloth bags, with different hardware segregated and like hardwarebagged together. Each bag shall be clearly and indelibly marked with itscontents.

Nameplate - A metal nameplate shall be secured to the side of each switchbase and operator, parallel to the switch blade when closed, and visible fromthe ground. The nameplate shall include the following information:Manufacturer's name and address; Switch type; Model or catalog number;Rated continuous and maximum voltages and currents and BIL, and; Serialnumber.

Approved Manufacturers - Approved manufacturers for hookstick-operateddisconnect switches: Hubbell, Memco, Pascor, Southern States, Turner,Cleveland/Price.

2007 Surge Arresters

General - Surge arrester shall be station class, shunt-gap, metal oxide varistortype surge arresters for application on grounded system, suitable for mountingin a vertical upright, or an inverted, upside down orientation.

Characteristics and Ratings - Surge arrester shall meet or exceed therequirements prescribed in the latest revisions of all applicable standards,including ANSI/IEEE C62.11 and C62.22, NEMA, ASME, AISC and AWS.,with characteristics and ratings meeting or exceeding those specified in thefollowing table.




CHARACTERISTIC VOLTAGE RATINGMaximum Continuous Operating Voltage 12 kV 8.4 kVBasic Impulse Level Rating 110 kVMaximum Front of Wave Impulse Crest 27.8 kVMaximum Crest Switching Surge Sparkover 19.8 kVMaximum Crest at 10,000 amps (8 - 20 μsec wave) 25.3 kV

Maximum Continuous Operating Voltage 69 kV 48 kVBasic Impulse Level Rating 350 kVMaximum Front of Wave Impulse Crest 163.5 kVMaximum Crest Switching Surge Sparkover 116.4 kVMaximum Crest at 10,000 amps (8 - 20 μsec wave) 148.6 kV

Materials – 69 kV Arrester housing shall be constructed of ultraviolet-resistantdielectric polymer material with uniform consistency free of voids or otherdefects which may adversely affect electrical or mechanical performance.Surface shall be smooth and relatively free of imperfections. Arrester cap andbase shall be constructed of aluminum or aluminum alloy. - Internalcomponents shall be protected from atmospheric contamination by a weather-tight seal.

12 kV Arrester housing shall be constructed of ultraviolet-resistantdielectric polymer material with uniform consistency free of voids or otherdefects which may adversely affect electrical or mechanical performance.Surface shall be smooth and relatively free of imperfections. Arrester cap andbase shall be constructed of aluminum or aluminum alloy. - Internalcomponents shall be protected from atmospheric contamination by a weather-tight seal.


Mounting Hardware – 69 kV Arresters shall be equipped with a mountingbase, 10 inch diameter bolt pattern, for 3 – 1/2 inch bolts, equally spaced at120 degree separation. The arrester shall be suitable for upright or horizontalmounting. 12 kV & 25kV Arresters shall be equipped with a mounting base, 10inch diameter bolt pattern, for 3 – 1/2 inch bolts, equally spaced at 120 degreeseparation. The arrester shall be suitable for vertical, horizontal or underhungmounting.




Connections - Arrester shall be equipped with 4 hole NEMA pad topconnector and 1-hole bottom connector, suitable for terminating No. 4/0 AWGstranded copper wire.

Approved Manufacturers - Approved manufacturers for surge arresters:Ohio Brass, ABB, GE, Cooper Power Systems, and S&C.

2008 Fuses and Fuse CutoutsGeneral – Fuse cutout shall be station class, slant body, hookstick-operated,tube-type, porcelain fuse cutout for application on grounded system, riser-poleconfiguration, and shall be mounted in a vertical upright orientation.

Characteristics and Ratings - Cutout shall meet or exceed the requirementsprescribed in the latest revisions of all applicable standards, includingANSI/IEEE C62.11 and C62.22, NEMA, ASME, AISC and AWS., withcharacteristics and ratings meeting or exceeding those specified in thefollowing table.

CHARACTERISTIC RATINGOperating Voltage 12.47 kVBasic Impulse Level Rating 110 kVContinuous Current Capacity 100 ampsSymmetrical Interrupting Capacity 9,300 ampsAsymmetrical Interrupting Capacity 14,000 ampsLeakage Distance 15 inches

Materials – Cutout body shall be constructed of ultraviolet-resistant dielectricpolymer material or commercial grade wet-process porcelain with uniformconsistency free of voids or other defects which may adversely affect electricalor mechanical performance. Surface shall be smooth and relatively free ofimperfections. For porcelain housing, entire surface which will be exposedafter assembly will be glazed. Mounting bracket and hardware shall beconstructed of galvanized steel or aluminum.


Latch – Cutout shall have positive lever-operated latch to prevent openingdue to vibration or other non-operating causes.




Fuse Tube – Cutout shall be equipped with small bore, double venting fusetube with spring-loaded flipper.

Connections – Cutout shall be equipped with connector for No. 2 AWGcopper conductor at top and bottom.

2009 Lighting

Seller shall provide light fixtures and lamps to be mounted on structures asshown on the included general arrangement and elevation drawings. Thefixture mounting arms shall be mounted to the structures 30 feet above thebottom of the structure base plate, and 20 feet above top of concrete for thosemounted on the transformer firewall.

Light fixtures shall be LED luminaries equivalent to those described in thefollowing table.

Light Description Luminaire LampStructure Lighting GE Evolve

EALP010L2AN730NDS1 Gray330 Watt

Light fixture shall be 120 volts AC.Seller shall provide Universal Mounting arm assemblies with knuckle slipfitterfor 2.3 in – 3.0 in OD tenon with leads.

2010 Grounding

Capacity - Above-ground grounding shall be 4/0 AWG copper.

Connectors – Grounding connectors shall be suitable for connection to No.4/0 AWG copper pigtail from below-ground ground bus.

End of Section 2000




3000 INSTRUCTIONS TO BIDDERS

3001 General Instructions

Bid Requirements - Bidder shall submit a fixed price bid for the materialsincluded in this specification. Individual materials or components shall bedescribed in sufficient detail to permit Buyer to evaluate their suitability, andshall be itemized as to components and prices.

Bidder's Responsibilities - It is the Bidder's responsibility to submit a bid forfurnishing all the materials, equipment, supplies and expendables required fora complete substation package, excluding only those items which are listed inSection 1005, Exclusion from Specification. Seller's charges to Buyer shallnot exceed those disclosed in its bid unless agreed to in advance by Buyer.

Bid Evaluation by Buyer - In general, work will be awarded to biddersubmitting best proposal in the judgment of the Buyer, such decision to bebased on price, quality and suitability of materials proposed, quality of theproposal, Bidder's experience, reputation and qualifications, and other factors.Buyer reserves the right to disqualify any Bidder, to reject any and allproposals received, to withdraw request for proposal and to disregard anyirregularities in proposals.

3002 Specific Instructions

Qualifying Information - Bidders shall be required to furnish the followinginformation with proposals: Name address and contact information for company Ownership of company and names of principals Statement of qualification to perform the proposed work List and descriptions of similar projects successfully completed Names and statements of qualifications of personnel to be assigned

Technical Information - Bidders shall submit the following technicalinformation in support of their proposals:

Conceptual drawings for each structure proposed, including estimatedweights and estimated foundation reaction loads;

Detailed material list, including basic descriptions, ratings, specifications,manufacturers' names and model numbers, and other pertinentinformation for all devices proposed,




Proposed schedule for completing the work proposed, including but notlimited to a schedule for submitting approval drawings and information,shipment of anchor bolts, steel structures and all other components andequipment proposed;

Descriptions of project schedule management and quality control systemsand measures which will be used in fulfillment of the project requirements;

Description of additional services related to the project.

Exceptions - Bidders shall furnish detailed descriptions of exceptions to thisspecification along with explanations of the reason for the exceptions.

3003 Commercial Terms and Conditions

See accompanying City of Danville requirements.

End of Section 3000

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End of Specification