Electrical Lab Equipment Upgrade

The objective of this procurement is for the purchase and installation of components to replace
the existing out-of-date substation behind the Mine Simulation Lab located at the National Mine
Health and Safety Academy, and to purchase and install components to upgrade the power center
in the electrical lab. This upgrade is needed to provide students with the most updated equipment
for training. 

The following are the REQUIREMENTS: 
The following products and tasks are required under this Contract:

750 kVA -1000 kVA COMPLETE MINE POWER SYSTEM
The underground coal mine power center is to be rebuilt with all components listed below and
Fully Functional at Completion.

HIGH VOLTAGE INPUT SECTION
 1 Input Coupler, 15kV, 600A. (PLM High Voltage Couplers)
 1 Feedthrough Coupler, 15kV, 600A. (PLM High Voltage Couplers)
 1 Palm E-Stop pushbutton
 6 Top Cover Interlock Switches
 12 Side Cover Interlock Switches
 1 Visible Disconnect Switch, 600A, 5kV. Grounded in the open position, Lockable Handle, With Viewing window for switch position
 3 H.V. Fuses, 3/7.2kV, Properly Sized
 3 Lightning Arrestors, Properly Sized

MAIN TRANSFORMER
 1 Primary kVA / Voltage 750-1000kVA @ 4160V Delta or Equivalent Transformer
 1 Secondary #1 kVA / Voltage 350kVA @ 995Y/575 Volts or Equivalent Transformer
 1 Secondary #2 kVA / Voltage 400kVA @ 480Y/277 Volts or Equivalent Transformer
 Install counter flashing
 Impedance 5% to 7% Z

 Phase: Three
 Frequency: 60 Hz

CONTROL TRANSFORMER
 1 Primary kVA / Voltage Single Phase 480/240/120 volts or Equivalent Transformer

MISCELLANOUS
 1 995 Volt Secondary Neutral Ground Resistor / 575 L-N, 15 Amp, Ground Resistor or Equivalent.
 1 Back-Up Ground Fault Monitor for 995 Volt Circuit
 1 480 Volt Secondary Neutral Ground Resistor / 277 L-N, 15 Amp, Ground Resistor or Equivalent.
 1 Back-Up Ground Fault Monitor for 480 Volt Circuit
 1 Zigzag XFMR to derive the neutral for the Delta Connected Secondary XFMR
 1 Current induced Test Circuit for all circuits without the use of HV, transfer-switch and 120 VAC 20-amp input plug

OUTPUT CIRCUITS
 1 E2L 400A 1000V Circuit Breaker with trip range of 500-2500 With MCI 25593 with Ground Monitor and TJB Receptacle and Plug Install one ply of Optimax mineral in Weather King adhesive (4’ x 4’) 1 completed panel including all devices 1 E2L 400A 600V Circuit Breaker with a trip range of 500-2500 With MCI 25593 With MCI 25593 Ground Monitor and No.64 Receptacle and Plug 1 completed panel including all devices
 1 E2L 400A 600V Circuit Breaker with a trip range of 500-2500 With MCI 25593 Ground Monitor and Joy X8345 Receptacle and Plug 1 completed panel including all devices
 1 E2K 225A 600V Circuit Breaker with a trip range of 200-1500 With GM8000 Wireless Monitor and Ground Relay Figure with No.67 Receptacle and Plug 1 completed panel included all devices
 1 E2K 225A 480V Circuit Breaker with a trip range of 200-1500 With 25593 Wired/Impedance Monitor and Ground Relay Figure with No.67 Receptacle and Plug 1 Complete panel including all devices
 1 Unit to be Shipped Factory Assembled
 (3) Electrical Drawings (complete set of at least 1 in digital format)

ADDITIONAL REQUIREMENTS
 All control wirings shall be 600-volt type SIS stranded copper conductor and shall not be smaller than #14 AWG. Control wiring shall be run in vented plastic wire-ways, where possible. No wiring will be spliced. All copper buss work and brace to withstand short
circuit stresses.
 All high voltage cables will be an adequate type and supported with fiberglass supports and hangers. No high voltage cables are allowed to come in contact with other high voltage cables or ground. A 3” separation is maintained between insulated cables and a 3” clearance phase to ground.
 Wiring labeled according to wiring diagrams and schematics and correspond with appropriate termination point.
 Terminal blocks to be marked and located adjacent to proper termination point.
 Warning and hazard labels to indicate voltage levels present.
 Labels for operating devices.
 Circuit breaker and fuse tags to indicate capacity and circuits protected.
 Existing Equipment in good working conditions recommended to be used such as
Enclosure, Circuit Breakers, Ground Monitors, Test Circuit, ground resistor
 Existing Power Center needs to be sized to fit existing glass lids that are installed on existing power center located in electrical – lab
 Onsite visit highly recommended as this is a site-specific request.
 Finish Paint Required

15 kV SUBSTATION SIMULATOR
The substation simulator is to be rebuilt with components listed below in workman-like manner
and Test Circuits Fully Functional at Completion. Unit Will Only Be Provided with Low Voltage
Control Power Not to Exceed 240 volts.

MAJOR COMPONENTS
 1 High Voltage, 600 Amp Vacuum Circuit Breaker or Equivalent
 1 Strain Clamp In/Out or Equivalent
 1 Visible Disconnect, 15kV, 600 A or Equivalent
 1 Neutral Ground Resistor, 12.47 kVL-L, 7200L-N, 15A or Equivalent
 3 300 5 Phase Current Transformers Properly Sized for Relays
 1 Potential Transformer (PT) with voltage relay for back up ground default
 Lightning arrestors for primary and secondary

TEST CIRCUITS
 1 Switch for Relay Selection
 4 General Electric Electro-mechanical relays or equivalent
 1 Schweitzer – SEL751A Relay or equivalent
 1 Schweitzer – SEL501 Relay or equivalent
 1 General Electric- 735 Multilin Relay or equivalent
 4 Westinghouse CO Relay or equivalent

MISCELLANOUS
 1 Breaker Control & Indication Circuit
 1 Capacitor Trip Circuit
 1 High Voltage Ground Monitor MCI 24286 or equivalent
 3 sets Electrical Drawings (three complete sets, at least one in digital format)
 Isolated Ground Field at least 25 Feet from the substation must be installed to measure 25 NEC requirements
 All Test Circuits to be Selectable
 Guy Wires repaired/installed as needed
 Existing Equipment in good working condition recommended to be used such as Ground resistor, Mechanical Relays, etc.
 If the existing concrete pad is not sufficiently sized for the Enclosure footprint a new pad is required