Download Static Frequency Converters Contractor Questionnaire

SECTION 16262 - APPENDIX C
SFC CONTRACTOR QUESTIONNAIRE
PART 1 - GENERAL
1.01
RELATED SECTIONS
A.
Section 16262 – Static Frequency Converter
B.
Section 16262A – SFC Technical Fill-In Data Sheets
C.
Section 16262B – SFC Document Submittal Schedule
PART 2 - PRODUCTS
2.01
TECHNICAL FILL-IN DATA SHEETS
The SFC Contractor shall complete the following questionnaire and submit to SEPTA with the
Request for Proposal Bid Documents.
Note that the numbering of the questions follows those presented in the 15% Scope Definition
Report. Some questions have been deleted, some revised, and a few new questions have been
added.
Wayne Junction SFC
Rehabilitation Project
16262C-1
60% Design Submittal
November 29, 2016
No.
1.
1.a
1.b
1.c
Question
Converter system - existing equipment
Are you able to rehabilitate the existing cycloconverter
power block equipment? This would involve refurbishing
all thyristor-controlled power equipment to restore the
system to like-new performance, with an expected lifetime
of no less than forty years. Please describe how equipment
would be refurbished.
Are you able to rehabilitate the existing control room
equipment? This would involve refurbishing all control
room equipment, including converter computers, load
sharing equipment, and converter protection relays, to
restore the system to like-new performance, with an
expected lifetime of no less than forty years. Please
describe how equipment would be refurbished.
If proposing new SFC power-block equipment (the latest
technology), are you able to use the existing SFC input and
output power transformers? If technically compatible,
would you be able to refurbish in order to achieve an
expected lifetime of no less than forty years?
2.
2.a
Converter system - new equipment
Are you able to provide a new SFC system that will be
technically and functionally compatible with SEPTA's
existing 60 Hz-to-25 Hz power supply system? In other
words, can you provide a replacement converter system that
will meet SEPTA's requirements?
2.b
What type of converter system do you propose, e.g., dc-link,
cycloconverter?
Wayne Junction SFC
Rehabilitation Project
Response
16262C-2
90% Design Submittal
April 29, 2017
No.
2.c
Question
What type of power electronics is used in your converter
system, e.g., IGBT, IGCT?
2.d
Is there inherent redundancy with your design? For
example, if one module fails, will the converter keep
functioning and supply real and reactive power to the 25 Hz
system?
3.
3.a.1
Converter system operation
The existing cycloconverters are rated as follows:
Each can supply 15 MVA continuously, then supply an
overload of 18 MVA for 1 hour, 24 MVA for 6 minutes, 30
MVA for 30 seconds, and 4000 A for 2 seconds at 12 kV,
followed by 15 MVA for 1 hour before next overload cycle.
3.d
3.e
Response
Please confirm your equipment will meet these ratings:
15 MVA continuous power
18 MVA for 1 hour
24 MVA for 6 minutes
30 MVA for 30 seconds
4000 A for 2 seconds at 12 kV
followed by 15 MVA for 1 hour before next overload cycle
Input power factor: ≥0.95 lagging
Output power factor: ≥0.7 lagging
Are your proposed converters a standard design or do you
propose to modify your standard design (either increase
ratings or decrease ratings) in order to meet the SFC
continuous and overload power requirements?
What are the benefits of your proposed technology over the
other available vendor equipment on the market today?
Wayne Junction SFC
Rehabilitation Project
16262C-3
90% Design Submittal
April 29, 2017
No.
3.f
Question
Please provide electrical single-line and schematic drawings
for the proposed system to assist with bid evaluation.
3.g
Please provide an estimated value and duration of shortcircuit current that each converter will supply during a fault
on the 60 Hz system or a fault on the 25 Hz system.
Assume that the short-circuit is on the supply side of the 60
Hz circuit breaker or the load side of the 25 Hz circuit
breaker. As a minimum, the 12 kV, 25 Hz side shall supply
4000 A for 2 seconds.
With the converter step-down transformers supplied from a
13.2 kV, 60 Hz, three-phase system, what is the minimum
and maximum required short-circuit current, voltage
regulation, voltage transients, and voltage harmonics
permissible from the utility or railway system in order for
your SFC system to operate correctly?
3.h
3.i
The present Wayne Junction SFC station transmits power
from 60 Hz to 25 Hz only. Can your converter system
operate with power flowing in either direction? Can the
converter supply power from SEPTA's 25 Hz system to
PECO's 60 Hz system?
3.j
Are there any special requirements for your proposed
converters to operate in parallel with SEPTA's existing three
15 MVA cycloconverters on the same 24/12 kV, 25 Hz,
single-phase bus?
Wayne Junction SFC
Rehabilitation Project
Response
16262C-4
90% Design Submittal
April 29, 2017
No.
3.k
3.l
3.m
Question
Response
Describe how the new SFC units will share real and reactive
power load with the existing cycloconverters. In order to
share real and reactive power equally, will the new converter
equipment need to interface with the existing loading
sharing equipment at Wayne Junction? Note that the
existing load sharing equipment was designed for the
addition of a fourth unit. Please address whether you will
need to perform a field test to determine the existing SFCs'
droop curves (real power vs. load angle, reactive power vs.
bus voltage).
Are there any issues with operating new SFC technology in
parallel with existing cycloconverters? For example, the
existing cycloconverters have filters on both 60 Hz and 25
Hz sides. Will this impact the design or operation of new
SFCs, considering that the existing filters will most likely be
removed if four new SFCs are provided?
Describe the startup and shutdown operating sequence and
instructions for your equipment. For example, are there any
special synchronizing requirements or procedures required
for your equipment? How are the 60 Hz and 25 Hz circuit
breakers controlled?
3.n
What are the operating modes of the converters, e.g., startup
(black start), power operation, reactive power operation?
3.o
Can the converters operate during a momentary loss of 60
Hz utility power? What is the time of the longest allowable
momentary loss of 230 kV, 60 Hz supply voltage that the
converters can withstand before they need to be
automatically separated from the 60 Hz system?
Wayne Junction SFC
Rehabilitation Project
16262C-5
90% Design Submittal
April 29, 2017
No.
3.p
Question
Can the converters operate during a continuous loss of 13.2
kV, 60 Hz, 3-phase utility power to function as a source of
reactive power to SEPTA's 25 Hz system, given that 480 V
auxiliary power is still available?
3.q
What are the no-load losses and full-load losses of each (15
MVA) converter unit operating separately? What are the
no-load losses and full-load losses of all four converter units
operating together? Please provide a graph of losses as a
function of loading from 0% load to 100% load. The losses
shall be for a single converter unit between the 13.2 kV
terminals of the input transformer to the 24/12 kV terminals
of the output transformer or reactor. Losses shall include all
auxiliary power system components.
What are the harmonic currents expected from the converter
system during normal operation? During full-load
operation, what are the typical values of the fundamental
and harmonic currents? Provide the values for current in
amperes for the fundamental and each harmonic.
How is harmonic current control designed into your system?
For example, are the input and output transformers specially
designed to reduce harmonics or sound? Are filters required
to reduce harmonics?
3.r
3.s
3.t
Are there any special electromagnetic interference
mitigation requirements? For example, do the converters
require a Faraday cage or special screens around the
converter buildings?
3.u
What are the noise levels associated with the converter in
full power production?
Wayne Junction SFC
Rehabilitation Project
Response
16262C-6
90% Design Submittal
April 29, 2017
No.
3.v
4.
4.a
4.b
4.c
Question
What is the highest normal operating voltage of the SFC
power block? If you are using open-rack equipment with
exposed energized parts, this will determine clearance space
around equipment per NFPA 70, The National Electrical
Code. Please note that this project plans on requiring that
the room housing the SFC power block is automatically deenergized as soon as a door is opened to the room - no
person will be allowed to work on or near energized SFC
equipment.
Layout, Dimensions, and Weights
Based on the site dimensions provided on RFP drawings,
will your proposed converter system equipment fit within
the available areas, e.g., filter yards, input and output
transformer areas, SFC rooms, control room, roof? What
are the major components that will be placed in these areas?
What are the minimum clearances required to bring your
SFC equipment into the SFC rooms? Are the doorways and
corridors wide enough to bring your new equipment into the
building? Are doorway heights sufficient? Are SFC room
heights sufficient?
What are the minimum clearances required around the
completed SFC equipment after installation?
4.d
Describe the typical building requirements for your
complete converter system, e.g., control room, converter
room, pump and water conditioning, air cooling and
ventilation, fire protection.
4.e
Can any of the equipment be designed for multi-story
construction so that physical layout space can be reduced?
For example, can the heat exchangers be placed on the SFC
building roof?
Wayne Junction SFC
Rehabilitation Project
Response
16262C-7
90% Design Submittal
April 29, 2017
No.
4.f
4.i
Question
Please provide typical layout drawings with dimensions and
labeled components. Provide the overall converter system
dimensions, i.e., area required for input transformers, filters,
converters, cooling system, output transformers, and
reactors. Note that equipment must fit within the designated
areas on RFP drawings.
Provide the 60 Hz input transformers dimensions and
weights, including tank, radiators, and conservator.
Provide the 60 Hz filter and/or reactor dimensions and
weights.
Provide the SFC power block dimensions and weights.
4.j
Provide the dc filter dimensions and weights.
4.k
Provide the cooling equipment dimensions and weights.
4.l
Provide the 25 Hz output transformers dimensions and
weights, including tank, radiators, and conservator.
Provide the 25 Hz filter and/or reactor dimensions and
weights.
What are the foundation requirements of your equipment?
4.g
4.h
4.m
4.m
4.o
5.
5.a
Response
The existing SFC thyristor equipment is enclosed in metal
panels within the SFC rooms. Personnel are able to walk
into the SFC rooms while the equipment is in operation. To
access SFC #1 room, personnel walk from the control
building corridor, through SFC #2 room, and into SFC #1
room without shutting down equipment. Will your proposed
SFC equipment be enclosed in metal cubicles? Note that
access to SFC power block equipment rooms will be
prohibited when equipment is energized.
60 Hz input transformers
What type of input transformers are required, i.e., number
transformer tanks per converter, number of windings per
tank, connection type, grounding?
Wayne Junction SFC
Rehabilitation Project
16262C-8
90% Design Submittal
April 29, 2017
No.
5.b
5.c
5.d
5.e
6.
6.a
6.b
7.
7.a
7.b
8.
8.a
8.b
9.
9.a
9.b
9.c
Question
What type of transformer cooling is provided, i.e., fans, oil,
water?
How many gallons of oil per tank, radiators, and
conservator?
Does your design use "charging transformers"? These are
typically energized prior to energizing the main transformers
in order to charge the converter capacitors or power
transformer magnetizing circuits, reducing the inrush current
when starting the system.
What type of transformer insulating oil is being offered?
60 Hz filters
Are 60 Hz harmonic filters required?
Response
How is filtering accomplished? Are there separate filters?
Are they always in operation?
DC filters
Are DC harmonic filters required?
How is filtering accomplished? Are there separate filters?
Are they always in operation?
25 Hz filters
Are 25 Hz harmonic filters required?
How is filtering accomplished? Are there separate filters?
Are they always in operation?
25 Hz output transformer and/or reactors
What type of output transformer is required, i.e., number
tanks per converter, number of windings per tank,
connection type, grounding?
What type of transformer cooling is provided, i.e., fans, oil,
water?
How many gallons of oil per tank, radiator, and conservator?
Wayne Junction SFC
Rehabilitation Project
16262C-9
90% Design Submittal
April 29, 2017
No.
9.d
9.e
10.
10.a
10.b
11.
11.a
11.b
Question
The converters are required to supply power to a 24/12 kV,
25 Hz, single-phase traction power substation. If no step-up
transformers are required, will the new converters require
any type of reactors?
What type of transformer insulating oil is being offered?
Response
Circuit Breakers
Are there any special circuit breaker requirements for the
13.2 kV, 60 Hz, 3-phase side of the converters? The
existing circuit breakers used for each SFC are Siemens type
GM1-1000-3000-77 vacuum interrupters rated 15 kV, 3000
A. There is a spare circuit breaker of the same model that
could be used for SFC #4.
Are there any special circuit breaker requirements for the
24/12 kV, 25 Hz, 1-phase side of the converters?
Auxiliary Power System
The station has 480 V, 60 Hz, 3-phase power available for
supporting the SFC auxiliary systems. What type of
auxiliary power system is required to supply the converter
system during shutdown, startup, and normal power
operation?
What is the required capacity of the ac auxiliary power
system for each converter unit, including all auxiliary
supporting equipment?
Wayne Junction SFC
Rehabilitation Project
16262C-10
90% Design Submittal
April 29, 2017
No.
11.c
Question
What is the required capacity of the dc auxiliary power
system, including charger size and battery amp-hour
capacity?
11.d
What is the longest allowable momentary loss of the 480 V,
60 Hz auxiliary power distribution system that the converter
system can withstand before it stops supplying power to the
25 Hz railway system?
The Project plans on supplying two independent 480 V, 60
Hz, 3-phase power feeders directly to the SFC power
distribution equipment for each SFC unit (a total of eight
power feeders for all four SFCs). It is assumed that each
SFC power distribution panel will have a transfer switch
between the two supplied 480 V power feeders. It is also
assumed that each SFC power distribution system has a drytype transformer to step voltage down to 208Y/120 V ac, or
any other voltage required to operate the SFC system.
Please confirm the assumptions and describe your local SFC
power distribution system.
The Project plans on supplying the roof mounted airconditioning system for each SFC room from the SFC
power distribution system located in the SFC room, which is
fed from the two independent 480 V power feeders. This
allows each SFC room to operate independently, including
local power distribution to auxiliary equipment. Please
confirm this method is acceptable.
Protection
What type of converter protection systems are required?
11.e
11.f
12.
12.a
12.b
12.c
Response
For internal faults, how does the converter trip the 60 Hz
system input circuit?
For internal faults, how does the converter trip the 25 Hz
system output circuit?
Wayne Junction SFC
Rehabilitation Project
16262C-11
90% Design Submittal
April 29, 2017
No.
12.d*
13.
13.a
Question
Where will the 60 Hz and 25 Hz transformer protection
relays be located, e.g., within your proposed converter
control building?
Environmental Cooling, Heating, and Air Handling
What type of cooling system is required for converter
operation?
Response
13.b
What type of heating and cooling systems are required for
the buildings?
13.c
How many pumps are required to operate the converter
cooling system?
13.d
Are there pollution limitations or filtration requirements?
13.e
What are the environmental conditions required for the
converter system components?
13.f
Is there redundancy in the cooling, heating, and air handling
equipment for the converters?
13.g
Does the cooling system have a remote tank for cooling
liquid level monitoring and filling?
13.h
Are there any check valves or monitoring on the cooling
system to stop the flow of coolant should there be a coolant
rupture?
How are the cooling tubes connected to the system, e.g.,
quick-connect, bolted?
13.i
13.j
How much heat is given off of a SFC unit during full-load
operation?
13.k
At what temperature and humidity must the SFC room be
maintained during full-load operation and when the SFC is
shut down?
Wayne Junction SFC
Rehabilitation Project
16262C-12
90% Design Submittal
April 29, 2017
No.
13.l
Question
Is a moisture or humidity control system required?
14.
14.a
14.b
Communications and Controls
What type of computer operating system do the converters
use?
What type of computer communication protocols are used?
14.c
Are the communication system languages proprietary?
14.d
How is the converter system operated? Can it be operated
locally and/or remotely?
Manufacturing
Describe how you can comply with "Buy America"
requirements per United States Code Title 49 (49 U.S.C.),
Section 24405(a)(1), i.e., how you will use steel, iron, and
manufactured goods for this project that are produced in the
United States.
Provide the manufacturer names and locations where the
major components will be made.
15.
15.a
15.b
Response
16.
16.a
Testing and Commissioning
How will the system be tested and commissioned? The
Wayne Junction station must be kept operational at all times
with a minimum of two SFCs in-service.
16.b
If components of the system need to be separated or
specially built to accommodate the limited space
requirements at the Wayne Junction site, how will this affect
the commissioning of the system?
Shipping
17.
Wayne Junction SFC
Rehabilitation Project
16262C-13
90% Design Submittal
April 29, 2017
No.
17.a
Question
What is the largest item to be shipped to the site? What are
the dimensions and weight of this item?
17.b
How are components shipped? Describe the contents of
typical shipping sections, e.g., transformer tanks, radiators,
conservator, converter power block, cooling system
components, filters, etc.
Will the converter power blocks be pre-assembled, tested,
and installed in a final containment prior to shipping to the
site, or will the power blocks be assembled, installed, and
tested inside the SFC rooms after arriving at site?
Assembly
Who will be required to assemble the equipment at the
Wayne Junction site? Will the assembly of equipment
require special supervision by the SFC manufacturer?
Is special training required to assemble the equipment?
17.c
18.
18.a
18.b
18.c
19.b
What is the estimated division of labor while assembling the
converter system at the Wayne Junction site, e.g., 20% by
the SFC vendor and 80% by others?
Maintenance and Support
What is the normal maintenance schedule for your provided
equipment?
Where are the converter maintenance facilities located?
19.c
Where is "customer support" located?
19.d
Where are replacement parts built?
19.e
Are the maintenance and support personnel part of the same
company that designed and installed the equipment?
Training
Is special training required to maintain your equipment?
19.
19.a
20.
20.a
Wayne Junction SFC
Rehabilitation Project
Response
16262C-14
90% Design Submittal
April 29, 2017
No.
20.b
21.
21.a
21.d
Question
What type of training program is recommended?
Parts
Are any proprietary parts requiring SEPTA to buy
replacement parts from only one vendor?
Are the parts for proposed converter system used by your
company in any other industry? For example, are any parts
of the converter power block used in the wind generation
industry or motor drive industry? Can any parts of the
converter system be directly replaced by parts used in these
other industries? Please provide specific examples where
your converter parts are currently being used, such as the
name of the product line and number of these products being
used.
SEPTA is concerned that converter system parts may
become obsolete within 20 years. Specific parts of concern
are the control cards or power electronic devices. In your
proposal, you confirmed that the parts used by your
proposed converter system are also used by your company
in any other industries. Please provide specific examples
where your converter parts are currently being used, such as
the name of the product line and number of these products
being used.
Can the parts supplied by your converter system be supplied
by several vendors or are they exclusive?
What are the life spans of the components?
21.e
What is the designed life span of the power delivery system?
21.f
What is the designed life span of the cooling system?
21.g
What is the design life of the converter control system?
21.h
How many major parts are in the system? Describe how
they are grouped or preassembled.
21.b
21.b.1*
21.c
Wayne Junction SFC
Rehabilitation Project
Response
16262C-15
90% Design Submittal
April 29, 2017
No.
21.i
Question
What parts of the converters are considered modular?
21.j
Are there any hazardous materials associated with your
proposed system? If so, please provide references to
material safety data sheet (MSDS) information.
Reliability
What are the mean-time-between-failure (MTBF) indices for
the major components of the converter system? Please
provide a system availability calculation to evaluate the
statistical performance of the system over a long period of
observation in terms of the mean time between failure
(MTBF) for components and the system.
What are the failure rates?
22.
22.a
22.b
22.c
22.d
22.e
23.
23.a
Response
What are the repair times for various failure modes of your
equipment?
What is the availability of parts?
How many years have the parts supplied with your system
been in service in the industry?
Experience and References
How many similar sized facilities does your company have
in operation?
23.b
What is the commissioning date of the last supplied similar
facility? Where is it located?
23.c
Please provide references for your equipment installed in
similar conditions. References shall include client name,
installation date, installation location, type of system,
system ratings, contact information, and cost.
Wayne Junction SFC
Rehabilitation Project
16262C-16
90% Design Submittal
April 29, 2017
No.
23.d
Question
Please provide a summary of any known failures of
operating converter systems supplied by your company.
Provide a brief summary of the failure and how your
company responded to the failure. For example, if your
converter technology was known to recently experience
high-voltage transients when an output fault was cleared,
how was this deficiency corrected?
23.e
Have you installed and tested a similar type of facility to
Wayne Junction? For example, has your company installed
new SFC units in parallel to existing older SFC units at the
same substation? If so, how were the units made to share
real and reactive power load?
24.
24.a
Cost Proposal
Provide your cost based on supply of: 60 Hz filters and/or
reactors as required; 60 Hz input transformers; the SFC
power block equipment; associated cooling and control
equipment; 25 Hz output transformers; 25 Hz filters and/or
reactors as required; protective relays and instrument
transformers; all interconnection wiring and bus work;
design engineering associated with the supply of the SFCs
and related equipment; factory testing; delivery; installation
support; and commissioning.
25.
25.a
Schedule
Please provide the schedule for the design, production,
factory testing, shipping to the Wayne Junction site,
assembly at the site, site testing and commissioning,
training, and turnover for SEPTA operation.
Wayne Junction SFC
Rehabilitation Project
Response
16262C-17
90% Design Submittal
April 29, 2017
No.
26.
26.a
Question
Construction Phasing
There are three existing SFC units with one new unit to be
added at Wayne Junction. Two SFC units are to remain inservice, with on in stand-by, at all times during the
replacement of the three existing units and addition of the
new unit. The Project is planning on building the new SFC
#4 building first, then replacing SFC #3, SFC #1, and SFC
#2, in that order. The sequence is based on a planned
method of removing equipment from each room. Each unit
must be commissioned at the completion of each unit's
installation. Please provide your suggested construction
phasing sequence, including demolition, installation, and
commissioning requirements.
26.a.1
Based on your site walkdown, do you have any suggestions
for construction phasing, demolition,
installation, or commissioning?
26.c
The Project is planning that SFC rooms will be accessed by
constructing a wall between the existing outside doorways
and the SFC power block equipment. The SFCs will be
accessed through double-doors from the new corridor. This
will keep the SFC power block equipment free of debris.
SFC power distribution equipment, controls, and pump skids
would be located in this corridor area, outside of the SFC
power block room. Please provide your assessment of this
proposed installation arrangement.
Response
END OF SECTION
Wayne Junction SFC
Rehabilitation Project
16262C-18
90% Design Submittal
April 29, 2017