Digital Governor/ Unit Control Turbine Controls REVISION TABLE Rei 0 1 Date 11/30/2015 1/6/2016 Purpose Bidding Bidding ~JW Prepared Bo6 Lilly w;. Bob Lilly Reviewed -B\U^M^ Bill Yates ^\J^^l^^ Bill Yates Approved Mike Noth ^.^w. '-/^!fy.,...,-.^^^".^^.-. --^^ "\ "o -:;,-'* J?'<..>'.'.' - -y '.i^ t>n- v!sky " ''<. -i^ /' \. ~^ '\ Vi ' '\ </ "^^^-f/:'."$».,\ T -Xy^' ;?' Page 2 of 47
TABLE OF CONTENTS 1 DIGITAL GOVERNOR / UNIT CONTROLLER...4 2 TYPE AND GENERAL DESCRIPTION...4 3 CODES AND STANDARDS...5 4 PERFORMANCE CHARACTERISTICS...6 5 OPERATING MODES...7 6 OPERATING SEQUENCES...9 7 TURBINE CONTROL CABINENT (TCC)...11 8 SPEED SENSING...17 9 EXTERNAL DEVICES...17 10 REMOTE INTERFACE...18 11 GOVERNOR PUMPING UNIT (GPU)...19 12 HYDRAULIC INTERFACE...20 13 ACCUMULATOR SYSTEM...21 14 SPARE PARTS...21 15 STANDARD FACTORY TESTS...22 16 DRAWING SUBMITTALS...25 17 PLC PROGRAMMING...29 18 DATA TO BE FURNISHED BY LCRA...29 19 EXISTING CONDITIONS...30 APPENDIX A...31 APPENDIX B TYPICAL TCC ARRANGEMENT...45 Page 3 of 48
1 DIGITAL GOVERNOR / UNIT CONTROLLER 1.1 The Contractor shall design and manufacture or procure, new components associated with the Digital Governor / Unit Controller Equipment as specified herein. All measurements taken shall be made with instruments capable of measuring to the nearest 0.001 inch without interpolation, unless otherwise stated or approved. Instruments shall have been calibrated within 90 days before measurements being taken, unless otherwise approved, and certification of calibration and calibration data shall be on file for review at the Contractor's facilities. 1.2 This document defines a digital processor based speed governing system and unit controls for the Mansfield Unit 3. All equipment necessary to provide a complete and functional system is included in the scope of this specification. Optional hardware and functions are also described, any or all of which may be added. Selection of operating modes, meters, etc. may be modified as necessary. 1.3 The Contractor shall startup and commission the unit controller and governor. 1.4 The Contractor shall submit recommendations for repair and/or refurbishing of equipment associated with the governor and receive written approval prior to commencing with said repair or refurbishment. 2 TYPE AND GENERAL DESCRIPTION 2.1 The control system for the hydraulic turbine shall be of the electro-hydraulic type in which the fundamental speed governing functions including speed sensing, development of the governing control signal, its modification with stabilizing terms, and speed droop are all developed by a digital processor. Other standard operational modes such as power control with frequency influence and synchronous condenser operation shall be affected in a similar fashion so that stable operation is maintained. All unit control shall be performed by the control system. 2.2 The link between the controller and the hydraulic actuator shall be an electrical gate position signal derived by the processor and transmitted to an electronically controlled valve arrangement that initiates wicket gate movement. Electronic gate position feedback shall be used to ensure that actual wicket gate position corresponds to the position defined by the control signal, and to minimize maintenance. 2.3 The controller shall consist of the following elements: Page 4 of 48
2.3.1 Control cabinet, containing the digital processor and its associated equipment, Human Machine Interface (HMI) Security Box mounted on door, speed switch, control relays, valve driver cards, power supplies, Potential Transformer (PT) sensing module terminal strips, wiring and other hardware, generally as described in Section 7 2.3.2 The existing Permanent Magnet Generator (PMG) is to be removed and modified by the Contractor as described in Section 8 2.3.3 External devices such as gate position feedback transducers, and power supplies, which provide control signals and power to the governor, generally as described in Section 9 2.3.4 The existing Governor pumping unit will be modified/refurbished. 2.3.5 The main distributing valve shall be retained. 2.3.6 The existing mechanical controller assembly and control column shall be replaced with an electronic pilot assembly generally as described in Section 9. 2.3.7 The existing pressure tank shall be retained. 2.3.8 Remote Interface - with LCRA Master and Local Control Station as described in Section 10 2.3.9 The arrangement of the controller elements shall be sufficiently modular to allow optimum placement in the powerhouse. For example, the control cabinet can be located on the powerhouse generator floor, with the Governor Pumping Unit and actuator assembly installed in proximity to the turbine. 3 CODES AND STANDARDS 3.1 Unless otherwise specified, the control system shall conform to the most recent revision of the codes and standards listed below. 3.1.1 In the event of conflicts between standards, LCRA will determine the applicable standard. 3.1.2 IEEE Std. 125-2007, Recommended Practice for Preparation of Equipment Specifications for Speed-Governing of Hydraulic Turbines Intended to Drive Electric Generators. 3.1.3 ASME Power Test Code No. 29, Speed Governing Systems for Hydraulic Turbine-Generator Units. Page 5 of 48
3.1.4 IEC No. 308, International Code for Testing of Speed Governing Systems for Hydraulic Turbines. 3.1.5 ANSI/IEEE C37.2-2008, Electrical Power System Device Function Numbers. 3.1.6 ANSI/IEEE C37.90.1-2002, Relays-Surge Withstand Capability (SWC) Test. 3.1.7 ANSI/ASME, Division 1 Section 8, Boiler and Pressure Vessel Code (Unfired Pressure Vessels). 3.1.8 ANSI/SAE J514-2012, Hydraulic Tube Fittings 3.1.9 Joint Industry Council H-1-1973. 3.1.10 Any applicable OHSA lockout/tagout standards 3.1.11 LCRA Operations Support Electronic Engineering Document Management Standard: Standard No: 04 v01- Appendix A 4 PERFORMANCE CHARACTERISTICS 4.1 The following definitions shall apply to the performance characteristics of the Digital Governor / Unit Controller 4.1.1 Deadband - Deadband is the total percentage change of speed which can occur before detection and implementation of the change by the governor. The speed deadband at rated speed shall not exceed +0.02%. 4.1.2 Deadtime - The deadtime is defined as the time elapsed between a speed excursion and the initial movement of the servomotor in reaction to the excursion. For a step speed change of more than 1% of the rated speed of the turbine, the deadtime of the governor shall not be more than 0.2 seconds. 4.1.3 Capacity - The rated capacity of the governor, which is the combined capacity of the servomotors of the turbine, shall be sufficient to operate the turbine gates through a full opening stroke in 3.0 seconds at a minimum supply oil pressure of <300 PSI. A full stroke is defined as twice the time taken by the wicket gates to open from 25% to 75%. This part of the governor is not being changed, servos and valves shall remain intact. 4.1.4 Ambient Temperature - The governor shall be capable of continuous operation at a maximum ambient temperature of 50 degrees C. The normal range of operation will be 30 degrees F to 104 degrees F. Page 6 of 48
5 OPERATING MODES 5.1 The controller shall be capable of controlling the turbine in the following modes of operation. 5.1.1 Speed Control - The following modes shall be included: 5.1.1.1 Speed Control - Speed control governing shall be used to maintain synchronous speed and aid system stability. Three sets of constants shall be available: 5.1.1.1.1 Network - These constants shall be used when operating in parallel or on a large network. The damping time shall be set to obtain a fast step response to network frequency deviations. 5.1.1.1.2 Isolated - These constants shall be used when operating isolated or on a small network. The damping time constant shall be set to a higher value than for network operation to assure system stability. All other operating modes shall be ineffective when in the isolated mode. 5.1.1.1.3 No Load These constants shall be used when operating the unit at synchronous speed with breaker open. Page 7 of 48
5.1.2 Gate Position Control - The controller shall be capable of maintaining a gate position based on a gate position setpoint adjusted on the control cabinet or by remote input. 5.1.3 Power With Frequency Influence - This mode of operation shall develop a governor error signal based on the power setpoint, real power feedback and rotor speed signal. By contrast with speed regulation, this mode shall permit selection of a power set point. No permanent droop value shall be displayed since it is not appropriate in this mode. 5.1.3.1 The "power with frequency influence" mode shall be the default mode. This mode of operation shall only be in effect while the machine's speed remains within an adjustable speed band. If the machine's speed falls out of the speed band, then the governor logic shall change its operating mode to speed control and remain in this mode until a command for mode change is initiated. 5.1.3.2 When operating in the "power with frequency influence" mode, if the main circuit breaker opens, without a stop command, the "governor" mode shall convert to the isolated speed control, and upon re-closing of the main circuit breaker, the power with frequency influence mode shall again be effective. 5.1.4 Automatic Generation Control (AGC) - When in AGC, the power setpoint will be via remote setpoint request. 5.1.5 KVA Limit - A maximum generator KVA limit shall be available when operating in power or gate position control. The KVA limit setpoint shall be programmed during start-up to a value determined by the customer. Normally, the limit is set to maximum rated generator capacity to prevent generator damage during unattended, automatic operation. The power limit setpoint shall take priority over the Voltage setpoint. The controller shall also be capable of maintaining the Voltage value in this mode. 5.1.6 Synchronous Condenser - The controller shall be capable of operating the generator as a synchronous condenser. While starting as a condenser, the unit shall proceed through the normal start sequence, and when the breaker closes, the gates shall close. Voltage control shall be possible in this mode. While running as condenser, the unit shall automatically switch to power control mode upon a low frequency condition, or after a change to any other mode. 5.1.7 Automatic Mode Transfer - The following mode transfers shall take place automatically when required by operating conditions. Page 8 of 48
5.1.7.1 Upon closure of the unit circuit breaker, the governor shall automatically switch from speed control to power control with frequency influence. Also, regardless of type of automatic operating mode, speed control shall become effective immediately after the unit circuit breaker opens. 5.1.7.2 During network operation in speed control, gate position control, power control with frequency influence, a changeover to speed control isolated mode shall be made automatically to re-establish rated speed, if the turbine speed falls below or exceeds a programmable speed band. 5.1.8 Bumpless Transfer - All mode changes initiated either automatically or manually shall result in a bumpless transfer. If a change is made from power control or speed control to gate position control, the gate position setpoint shall start at the last gate position required by the previous operating mode. It shall then be possible to manipulate gate position from that setpoint. When a change is made from any mode to power control, the gate position setpoint shall automatically ramp to 100% and the gates shall follow that setpoint until the gate position required by power control is less than the gate position setpoint, at which time power control shall become effective. When changing between modes, gate position shall be ramped up or down as required by the new operating mode. 6 OPERATING SEQUENCES 6.1 The controller will be equipped with preprogrammed automatic routines to start and stop the turbine under several conditions. 6.2 START SEQUENCES - Two types of start sequences will be provided as described below. 6.2.1 Automatic start - Upon receiving a start signal, the controller will proceed with the start sequence, and begin to verify the pre-start conditions. The pre-start conditions include the status of lockout and non-lockout relays, circuit breaker status, and the integrity of the system control power. In the event a pre-start is not met, the start sequence must be initiated again. After the pre-start conditions are met, the controller will initiate the start of the auxiliary systems. The system then checks the post-start conditions. These conditions, which include all flow, pressure and level permissives, must be satisfied within an adjustable period to prevent an incomplete start sequence alarm. When the conditions are met, the shutdown solenoid will be energized, enabling the gates to move to the start position. At this point, the controller, will control the wicket gates through two start openings Page 9 of 48
greater than the no-load position, before settling at speed-no-load, with rapid acceleration to minimize wear on the turbine/generator bearings due to slow acceleration. The change to the different gate start positions will be made at particular programmable percentages of speed. The turbine start gate positions will be programmable. Voltage and phase matching will be accomplished with equipment provided by others. When the generator circuit breaker closes, the selected control mode is engaged. 6.2.2 Automatic Synchronization - The controller shall be equipped with provisions for automatic synchronization. The automatic synchronization will be accomplished using customer specified synchronizer in conjunction with a Beckwith synchronization check relay. The synchronizer shall be equipped with provisions for black starting/dead bus operation. The Operator interface terminal and unit controller program shall include provisions for dead bus starting. 6.2.3 Manual Start Sequence - The manual sequence will be similar to the automatic except that after the shutdown solenoid is energized, all auxiliaries must be operated manually from the HMI. All protection is maintained in this mode. The gate opening will be controlled by using the gate setpoint adjust switch. When the generator circuit breaker closes, gate position control is engaged. As a subset of this mode, all outputs controlled by the governor shall be manually selectable and operable. 6.3 SHUTDOWN SEQUENCES - The controller will include programmed stop routines for normal, emergency and partial shutdown conditions. These sequences are described herein. 6.3.1 Normal Shutdown Sequence - Upon receiving a stop signal, the system will begin to ramp the wicket gates closed at the normal operating rate to the speed-no-load position. The controller will open the main circuit breaker when speed-no-load position is achieved, and the shutdown solenoids will be de-energized to fully close the gates. The brakes will be energized at 25% speed. When the unit comes to rest, the auxiliaries will be stopped. After the controller completes the stop sequence, and the unit is at rest, the controller will begin creep detection. In case of creep, the water and lube oil pumps and brakes will be energized, and an alarm sounded. 6.3.2 Emergency Shutdown - An emergency shutdown is an event that requires the unit to be immediately separated from the network, and prevented from restarting. These faults are typically from the generator lockout relay (86) and the emergency stop input. The controller will be arranged so that on receipt of an emergency input, the generator breaker trips, and the shutdown solenoid is de-energized, closing the wicket gates at their fastest Page 10 of 48
rate. A restart is allowed when the fault is cleared and the lockout relay reset. 6.3.3 Mechanical Shutdown - A mechanical shutdown is an event that requires the unit to be shutdown in a controlled fashion, and prevented from restarting. These faults are typically from the level and pressure devices. The controller will be arranged so that on receipt of a mechanical shutdown input, the shutdown solenoid is de-energized, closing the wicket gates at their fastest rate. When the breaker is opened, the controller will perform a normal shutdown sequence. A restart is allowed when the fault is cleared. 6.3.4 Partial Shutdown - Partial shutdown is provided when the generator breaker opens without a fault or shutdown input. Upon receiving a partial shutdown input, the controller will control the turbine gates to maintain rated speed, and operate in isolated mode. It will be possible to restart the unit, without a complete stop, after an adjustable time limit is exceeded. 6.3.5 Droop Test Sequence The Programmable Logic Controller (PLC) will be provided with software to perform an online droop test 6.4 Panel View / Local / Remote - A three position software switch will be available to select the operating sequence and the origin of control signals. The highest active level of control determines the proper distribution of the control signal. Lower levels of control cannot supersede commands from above. 7 TURBINE CONTROL CABINENT (TCC) 7.1 General - The control cabinet shall be self contained, free standing and of NEMA 12 construction and contain the digital processor, HMI security box, speed detection electronic equipment, control relays, analog outputs, electronic valve driver cards, power supplies, terminal strips, and wiring as further described below. 7.2 Enclosure - The enclosure shall be fabricated from cold rolled finished steel with a lockable hinged door. The enclosure will be similar to the Austin VTC size of 90x48x52 with three (3) equipment mounting panels. Two access doors shall be provided. Each access door shall have a continuous hinge to form a permanent, rigid construction. Multi-point latches shall be used to insure a good, tight fit and alignment when closed. All latches shall be operated, through a linkage mechanism, by one conveniently located handle. No center post shall be used in the cabinet construction. 7.2.1 The top and/or bottom of the enclosure (to be finalized during detailed design) shall have removable gasket plates to permit location of conduits, cable slots, or pull boxes for incoming cables as desired. The enclosure, Page 11 of 48
door and panels shall be cleaned per phosphated TT C-490 Type II prior to receiving a standard primer finish. 7.2.2 Two final coats of Sherwin Williams polane B polyurethane enamel paint shall be applied. The finish coat color shall be ANSI 61 light grey for both exterior and interior of the enclosure. The mounting panels shall be white. In addition, a quart container of exterior paint final coat shall be supplied for touch-up. 7.2.3 One conveniently located 120 VAC utility duplex outlet shall be provided in each cabinet for programming and testing devices. One single phase, 120 VAC cabinet heater with thermostat shall be supplied for maintaining internal cabinet temperature. An external 120 VAC power circuit for the interior light, receptacle, and heater shall be required from plant station service. 7.3 Control Hardware - A solid state digital processor and input/output (I/O) modules shall be rack mounted inside a 16 slot chassis. The digital processor shall be an AB 1756-L6 or L7. The data highway address shall be specified by LCRA. The IP address will be defined by LCRA. 7.3.1 The system shall be designed to permit revisions to be made to the operational sequences and governor parameters. Revisions to the program shall be possible from both local and remote locations with the appropriate program interface equipment using Allen Bradley RSLOGIX 5000(L6) or Studio 5000(L7) program software. Page 12 of 48
7.3.2 The I/O modules shall be independently removable and shall have individual wiring arms for ease of maintenance. All modules shall be connected to the processor via printed circuit cards located on the mounting chassis. I/O modules shall be supplied to interface with the following type and quantity of signals: Type Discrete Inputs Discrete Outputs Analog Inputs Analog Outputs Thermocouple High Speed Ctr VREG-RIO Signal Quantity- Module Type 24 VDC Nom 2-1756-IB32 24 VDC Nom. 1-1756-OB32 4-20 ma 1-1756-IF8 4-20 ma 1-1756-IF4XOF2F E type 1-1756-IT6I 2-CFM 1-1734-ENT 2-1734-IB8 2-1734-IE2C 2-1734-OW4 Page 13 of 48
7.4 A 16 Port Switch shall be supplied. 7.5 A Power Monitor shall be supplied. 7.6 A syncscope with isolation switch shall be supplied. 7.7 An autosync module shall be supplied. 7.8 A dual port MODBUS interface module shall be supplied. 7.9 Sync Check Relay - A Beckwith M-0390 sync check relay shall be supplied to back up the synchronizer and prevent inadvertent breaker closure. 7.10 Test Switches - All Potential and Current Circuits connected to the synchronizer shall be provided with test switches for isolating the device from the CT and PT circuits. 7.11 Thermocouple - A type E thermocouple shall be furnished and mounted in the governor cubicle. 7.12 All I/O modules and the processor module shall have LED type indicating lights for trouble shooting purposes. 7.13 The I/O chassis shall be securely mounted in the rear of the control cabinet. It shall have space for the digital processor and I/0 module power supply, and shall have 16 slots for I/O module placement. All I/0 slots shall be keyed to prevent insertion of modules in the improper slot location. 7.14 HMI - The TCC will be equipped with an HMI Security Box for a portable maintenance device to display current operating data, allow adjustment of setpoints, control and display system alarms, and other important parameters. 7.15 Pushbuttons, Selector Switches and Setpoint Adjust Switches - The control cabinet shall be equipped with an Emergency Stop pushbutton with shroud located on the front door. All pushbuttons, selector switches, and setpoint adjust switches shall be Allen-Bradley 800 series or equal. 7.16 Speed Switch - The control cabinet shall be equipped with an electronic speed switch with four independent switches. The input to the speed switch shall be pulses generated by the speed sensing elements. The actuation points of the switches shall be programmable over the full range of turbine speed. 7.16.1 The switches shall be utilized as follows 7.16.1.1 n <= 25%: Switch shall close on decreasing speed for use in the brake circuit. 7.16.1.2 n >= 120% : This switch shall close on increasing speed for overspeed. 7.16.1.3 n < 1% : Speed Switch Assembly failure input to PLC Page 14 of 48
7.16.1.4 Spare 7.16.1.5 The speed switch shall have a 4-20 ma output and be a device external to the digital processor to provide independent contact outputs, as detailed above. 7.17 Control Relays - Control relays shall have a minimum of two sets of contacts, rated as required for the interfacing control circuit. Relay coils shall be suitable for operation in 24 VDC control circuits. Control relays shall be Deltrol 66 series or Allen Bradley 700CF as required where multiple contacts are required, or equal with contact ratings of 5A at 24 VDC or 10 A at 120 VAC. One relay shall be provided for each discrete output required for circuits exterior to the control cabinet and shall include a breaker close relay as controlled by the synchronizer for synchronization. 7.18 Electronic Valve Driver - An individual rack mountable electronic valve driver card shall be supplied in the control cabinet. The card shall compare the governor position command signal with the actual servomotor position and amplify the error signal in proportion to the deviation. The output signal of the valve driver card will include dither of adjustable frequency and amplitude to improve the response output of the proportional valve. The proportional valve converts the electrical output signal of the governor to a hydraulic output. The valve driver card shall be comparable to the Voith Siemens VCA3 card. 7.19 Power Supplies - The control cabinet shall contain one Lambda LRS-56-24 130 VDC to 24 VDC power supplies, for DC control circuitry power, Kepco or Equal. 7.20 Terminal Blocks - High density type terminal blocks shall be provided for connection of external wiring. The blocks shall be 600 V, 45 amp, screw type capable of accepting standard copper wire sizes AWG No. 8 through No. 18. Terminal blocks shall be Allen Bradley 1492-W10 or equal. Ten percent spare terminal points shall be provided. 7.20.1 Terminal blocks shall be color coded as follows: 7.20.1.1 Blue 125VDC Yellow PLC discrete inputs 7.20.1.2 Red 120VAC Orange PLC discrete outputs 7.20.1.3 Gray 24 VDC Yellow/Green Grounds Page 15 of 48
7.21 Power Supply Connections - All incoming power supply feeders to the cabinet shall be protected by fuses. The Contractor shall determine the appropriate fuse size. 7.22 Wire - All control and other auxiliary wiring shall be SIS type, stranded copper conductor with flame retardant insulation, except analog signals and I/O module wiring. 7.22.1 Wiring shall be sized per the following table: Function Wire Size (Awg) C u r r e n t T r a n s f o r m e r 1 0 Potential Transformer 12 C o n t r o l W i r i n g 1 4 Analog Signals (shielded) 16 I/O Module Wiring Arms 18 22 Page 16 of 48
7.22.2 Current transformer wiring terminations shall be made with self-insulated crimp-on type ring tongue lugs. 7.22.3 Internal wiring shall be identified with a wire number on each end of each wire by a plastic sleeve or similar permanent marker. Control wire bundles shall be formed without sharp bends and shall be adequately supported. 7.22.4 All digital processor spare I/O points shall be terminated on the field interconnect terminals to facilitate field additions. 8 SPEED SENSING 8.1 Turbine Speed - A new speed signal generator shall be furnished. Turbine speed sensing equipment shall consist of a refurbished toothed disc and pulse initiating proximity pick-ups designed with new brackets to mount in the existing bolt holes of the PMG housing. The existing PMG assemblies main mercury overspeed switch, auxiliary mercury overspeed switches, gear box mechanism, and the rotor will be removed. The existing bearings and bushing will be replaced. 8.1.1 Three Airpax type 30 proximity pick-ups and mounting brackets shall be provided and utilized. Two shall be dedicated to speed control circuits. The other shall be used for speed measuring points and speed indication. The speed pickups will be primarily used for creep detection, speed reference during startup and as backup for the PT sensing module. 8.1.2 PT Sensing Module A new PT sensing module will be installed in the TCC. The primary function of this module is to monitor speed during excitation of the unit, synchronization, and online speed regulation. 9 EXTERNAL DEVICES 9.1 The following devices located external to the control cabinet shall be furnished. 9.1.1 Input Power - The system shall be designed to accept 120 VAC from the Station vital AC inverter. 9.1.2 Gate Position - A Gemco Patriot linear position transducer of the magnetostrictive type with 4-20 ma output shall be furnished for wicket gate position feedback. Zero and span adjustments shall be programmed for calibration purposes. All necessary mounting brackets (supplied in Section 5.2), hardware, and linkages to translate gate ring movement into linear movement of the transducer shall be provided by the Contractor. Page 17 of 48
9.1.3 Distributing Valve Spool Position-The main spool of the existing distributing valve shall be equipped with a linear position transducer to provide main spool position feedback to the valve driver card for improved response. 9.1.4 Pilot Valve conversion adapter and interface hardware - The existing pilot piston assembly shall be modified by removing the existing adapter and control mechanism. A new adapter shall be provided to connect the open and close pressure lines from the hydraulic interface equipment (proportional valve) to the existing pilot piston. 9.1.5 Turbine Guide Bearing Lube Oil Motors and Pumps The existing lube motors and pumps shall be replaced by a new AC and DC lube oil motors and pumps. Roper pumps are preferred. 9.1.6 Air Brake Panel The existing air brake system shall be retained and refurbished. 10 REMOTE INTERFACE 10.1 The governor shall interface with the Master Control Station (MCS) and Local Control Station (LCS) using the processor Ethernet communication port. The system will be sized to contain the following number of inputs and outputs. 10.1.1 LCRA Unit RIO (Control Room Location) 10.1.1.1 1 (one) 1756-ENBT 10.1.1.2 2 (two) 1756-IB16 10.1.1.3 1 (one) 1756-OX8I 10.1.1.4 2 (two) 1756-IF16 10.1.2 LCRA TEMP-RIO (Generator Floor-Generator Housing Location) 10.1.2.1 1 (one) 1756-ENBT 10.1.2.2 2 (two) 1756-IR6I 10.1.2.3 2 (two) 1756-IT6I 10.1.3 TPIT-RIO (Generator Turbine Pit Location) 10.1.3.1 1 (one) 1734-AENT 10.1.3.2 2 (two) 1734-IB8 10.1.3.3 1 (one) 1734-OW4 10.1.3.4 1 (one) 1734-IE2C 10.1.4 GPU-RIO (Governor Pump Cabinet) 10.1.4.1 1 (one) 1734-AENT 10.1.4.2 2 (two) 1734-IB8 Page 18 of 48
10.1.4.3 1 (one) 1734-OB8 10.1.4.4 2 (two) 1734-IE2C 10.1.4.5 1 (one) 1734-IT2I 10.1.5 A full I/0 list will be developed by the LCRA & the Contractor design team. Any increases in I/0 which require an additional PLC rack card to be added will be considered a change in scope. 11 GOVERNOR PUMPING UNIT (GPU) 11.1 The governor pumping unit (GPU) consists of the pump/motor sets, oil reservoir, and accessories completely prewired to the controls in the GPU terminal. The GPU was furnished as an integral assembly. The GPU utilizes Rexroth components available from the 3 day delivery catalog where feasible. 11.2 The oil reservoir is located on the turbine floor of the powerhouse. The reservoir is sized to receive 110% of the total volume of active oil in the system. The active oil includes: 11.2.1 Turbine servomotor oil volume 11.2.2 Pressure tank oil volume (minimum two strokes allowed) 11.2.3 Pipe oil volume 11.3 In addition to the active oil volume, additional oil capacity can be added, as necessary, to provide adequate pump intake submergence, and to prevent overheating or foaming of the oil. 11.4 The existing governor pumping system shall be refurbished and retained. 11.5 Pump Operation: 11.5.1 The pumps can be started or stopped by pressure and level from the main processor or manually from the GPU control enclosure. All control devices for pump operation shall be as listed in this section. Logic for the pump controls is programmed into the unit controller processor. 11.5.2 The pump can cycle according to pressure, level and/or oil temperature. The pump oil delivery shall be controlled by a solenoid operated unloader valve located at the pump discharge. On low system oil pressure, the unloader valve can be activated to deliver oil under pressure to the system. When de-activated, the unloader valve returns oil at zero pressure to the reservoir. The pumps can start and stop while unloaded. Page 19 of 48
11.6 Motors/ gear pump The motors and gear pump shall be refurbished by a shop certified to repair Woodward equipment. The motors shall be dipped, baked, bearings replaced and tested. The gear pump shall be inspected for damage and wear. The pump gear to side plate shall be machined to reestablish proper clearances. All bearings associated with the pump shall be replaced. 11.7 Motor Starters - The existing motor starters shall be retained.. 11.8 Pump Unloader/Relief Valves - The pump discharge line utilizes a solenoid operated unloader relief valve. The relief valve shall be replaced with a like kind valve. The valve shall be sized for full pump discharge with minimal pressure drop to avoid overheating the oil while unloading. Unloading shall occur in a controlled manner to prevent slamming of the pump check valve and objectionable hammering in the piping. The pump controls includes provisions for manually unloading using a pushbutton (hand/off/automatic switch with pump load pushbutton) located on the pump control panel. 11.9 Check Valve - The existing pump discharge check valve shall be resurfaced and reutilized. 11.10 Black Start The governor pumping unit shall be equipped by LCRA with provisions to start the pumping unit with backup AC power. 12 HYDRAULIC INTERFACE 12.1 General The existing main distributing valve shall be retained and modified to accept position control signals from a new hydraulic interface. The Contractor shall provide technical assistance to LCRA during the removal of obsolete components and re-installation of the replacement components. 12.1.1 The hydraulic interface assembly consists of the following: 12.1.1.1 Adapter manifold at the pilot piston to connect the open and close pressure ports to the existing pilot piston actuator 12.1.1.2 Miscellaneous pilot oil piping and fittings, supplied by LCRA 12.1.1.3 Pressure switch for reporting a trip condition. 12.1.1.4 Two pilot operated 2-way isolation cartridge valves for shutdown control. 12.1.1.5 Cartridge type shutdown solenoid for emergency shutdown mounted in the manifold block. 12.1.1.6 Proportional Valve 12.1.1.7 Pilot oil duplex filter with clogged filter alarm contact. 12.1.1.8 Auxiliary valve blanking plate to be installed in place of the auxiliary pilot valve. Mounting brackets for hydraulic manifold block. 12.1.1.9 Three Stauff test ports. Page 20 of 48
13 ACCUMULATOR SYSTEM 13.1 The existing pressure tank shall be retained. 14 SPARE PARTS 14.1 The following spare parts shall be furnished. 14.1.1 Control Cabinet Quantity Description Page 21 of 48
14.1.1.1 5 Control relays 14.1.1.2 10 Fuses of each rating used 14.1.1.3 10 Varistors of each type and rating used 14.1.1.4 10 Diodes of each type and rating used 14.1.1.5 1 Pushbutton of each type 14.1.1.6 1 Power supply for the Processor 14.1.1.7 1 Power supply for the TCC cabinet 14.1.1.8 1 Buffer Amplifier 14.1.1.9 1 32 Point Digital Input Module 14.1.1.10 1 32 Point Digital Output Module 14.1.1.11 1 Analog Input Module 14.1.1.12 1 Analog Output Module 14.1.1.13 1 Valve Driver Card 14.1.1.14 1 PT Sensing Module 14.1.2 External Devices and Speed Sensing Elements Quantity Description 14.1.2.1 1 Inductive speed pick-up 14.1.2.2 1 Valve position feedback transducer 14.1.2.3 1 Gate position feedback transducer 14.1.3 Governor Pumping Unit and Actuator Quantity Description 14.1.3.1 Case Pilot oil pressure filters 14.1.3.2 1 Shutdown solenoid 14.1.3.3 1 Proportional Valve 15 STANDARD FACTORY TESTS 15.1 Governor Equipment Functional Tests 15.1.1 General - Individual factory tests shall be performed on the following governor equipment in accordance to the Contractor s Factory Test Procedure. 15.1.2 Control Cabinet 15.1.2.1 Mechanical Tests 15.1.2.1.1 Control cabinet structural integrity Page 22 of 48
15.1.2.1.2 Equipment supplied per bill of material 15.1.2.1.3 Cabinet dimensions 15.1.2.1.4 Overall appearance 15.1.2.1.5 Paint 15.1.2.1.6 Proper location of all devices 15.1.2.1.7 Devices securely mounted 15.1.2.1.8 Nameplates correct and securely mounted 15.1.2.2 Electrical Tests 15.1.2.2.1 Point to point wiring 15.1.2.2.2 Wiring proper gauge 15.1.2.2.3 Cable shield properly installed 15.1.2.2.4 Wire markers installed 15.1.2.3 Functional Tests 15.1.2.3.1 Proper interface between the digital processor and control cabinet devices 15.1.2.3.2 Polarity test on all metering devices and relay circuits 15.1.2.3.3 Proper operation of all switches and lights 15.1.3 Hydraulic Interface 15.1.3.1 Mechanical Tests 15.1.3.1.1 Overall appearance 15.1.3.1.2 Piping 15.1.3.1.3 Bill of Material 15.1.3.1.4 Connections 15.1.3.2 Electrical Tests 15.1.3.2.1 Wiring Proper Gauge 15.1.3.2.2 Point to point wiring 15.1.3.2.3 Wiring markers installed 15.1.3.3 Functional Tests 15.1.3.3.1 Operation with simulated control input Page 23 of 48
15.2 Governor Performance Tests 15.2.1 General - The following field tests shall be performed to demonstrate governor performance in accordance with the Contractor s Commissioning document. For testing purposes, machine speed, which is the governor input signal, shall be simulated using a function generator and shall be recorded as a function of DC voltage. Tests shall be performed with the control cabinet and actuator assembly. Substitute servomotors shall be used; a substitute governor pumping unit may be used. 15.2.2 Permanent Speed Droop - The permanent speed droop test shall demonstrate governor linearity, accuracy, and speed setpoint adjustment range. The test shall be performed at speed setpoints of 90, 100, and 110 percent with permanent speed droop set at four percent. At each speed setpoint, the governor input shall initially be set to achieve 90 percent effective servomotor stroke. The governor input shall be increased in four approximately equal increments to achieve a final servomotor position of ten percent of effective stroke. The permanent speed droop shall be demonstrated by recording the governor input and servomotor position on a multi-channel recorder 15.2.3 Deadband - The deadband test shall verify governor insensitivity which is defined as half of the deadband. Beginning at rated speed, progressively smaller step changes in frequency of 0.05, 0.02, 0.01 and 0.005 percent, in alternating direction, shall be input to the governor. The deadband shall be verified if a frequency change of 0.01 percent results in a servomotor position change. The governor permanent speed droop shall be four percent for this test. Deadband shall be demonstrated by recording the governor input signal and the servomotor position on a multi-channel recorder. 15.2.4 Deadtime - The deadtime test shall determine the time response between a speed change and a change in servomotor position. A change in speed of two percent shall be used for this test. The deadtime shall be measured by plotting the governor input signal and the servomotor position on a multichannel recorder. 15.2.5 Stability - The stability test shall verify that the governor output is stable for a stable input. A start will be initiated, and the gate servomotor brought to speed no load, and 100% speed will be simulated. With the governor in isolated mode, the governor output will be plotted versus time. The stability of the speed input signal will be validated using a frequency counter. Page 24 of 48
16 DRAWING SUBMITTALS 16.1 All drawings submitted shall conform to APPENDIX A, ELECTRONIC ENGINEERING DOCUMENT MANAGEMENT STANDARD unless otherwise noted herein. 16.2 The following drawings shall be submitted within days noted below from receipt of contract, or as noted elsewhere in this specification. 16.2.1 Schedule of Vendor Supplied Equipment 60 Days 16.2.2 Turbine Control Cabinet - Due September 1st 2016 1. General arrangement and equipment outline including the foundation and assembly drawings defining the following: Overall dimensions of each assembly delivered 60 Days Page 25 of 48
Location of shipping splits if applicable. Layout and space requirement for all equipment for installation and maintenance. The weight of each major equipment item. Lifting and handling procedures for each major equipment item. Clearance requirements. Cable/conduit entry areas. Anchoring details 2 Electrical schematics 60 Days 3 Governor system block diagram 60 Days 4 Bill of Material - All components use in the governor assembly shall be listed with manufacturer and model number. 60 Days 5 System hydraulic schematic 60 Days 6 Terminal Block Layout Diagrams on Schematics. (suitable to prepare interconnection drawings) 7 Hydraulic system internal connection diagrams with piping line sizes, port connection details. 8 Instruction Manuals - The instruction manuals shall include installation, start-up, testing, operation, and maintenance information. 100 Days 100 Days Shipment 16.2.3 Governor Pumping Unit and Actuator 1 General arrangement and equipment outline including the assembly drawings defining the following: 60 Days Page 26 of 48
Overall dimensions of each assembly delivered and location of shipping splits if applicable. Layout and space requirement for all equipment for installation and maintenance. The weight of each major equipment item. Lifting and handling procedures for each major equipment item. Clearance requirements. Cable/conduit entry areas. Anchoring details. 2 System internal connection diagrams with piping line 120 Days 3 sizes. Wiring Diagrams 120 Days 4 Terminal Arrangement Diagrams 120 Days 5 Bill of Material. 90 Days Page 27 of 48
The LCRA Official Record of this document is a PDF SECURED document. If you are viewing a non-secured PDF file or a hard copy, you are not viewing the LCRA Official Record 6 Equipment arrangement diagrams showing the physical or relative location of all devices including port connections 60 Days 7 Power requirements for solenoid valves. 90 Days 8 Weight of equipment and load distribution. 60 Days 9 System hydraulic schematic 60 Days 10 Instruction Manual - The instruction manuals shall include: Shipment Installation,start-up, testing, operation, and maintenance information. 11 Commissioning Procedures 30 Days after Shipment Page 28 of 48
17 PLC PROGRAMMING 17.1 General-PLC programming shall include the following: 17.1.1 Unit control and governor control. 17.1.2 All discrete and analog data shall be provided for remote communications in separate data files. 17.1.3 All speed governor algorithms and program shall be furnished. 17.1.4 Excel spreadsheets shall be provided for both the main program and operator interface terminal programs 17.1.5 Logic for automatic synchronization and display of electrical parameters. 17.1.6 Reserved data files and program files for use by LCRA 18 FURNISHED BY LCRA 18.1 The LCRA will be responsible for installation of Contractor supplied components and cabling, etc. according to Contractor s supplied installation drawings. 18.2 The LCRA will be responsible for furnishing the following data and information to assist the suppler as required to determine the interface requirements (I/O) for the unit controller/speed governor for Mansfield Unit 3 including but not limited to the following: 18.2.1 With Task Order: 18.2.1.1 LCRA Equipment Designations for discrete inputs and outputs 18.2.1.2 Analog Input signal type designations and scales 18.2.1.3 Existing Wicket Gate Servomotor timing will remain unchanged. Page 29 of 48
18.2.2 With Drawing Approval: 18.2.2.1 LCRA SCADA Tag Identification 18.2.2.2 LCRA required Unit Pre-Start Conditions 18.2.2.3 LCRA required Unit Post-Start Conditions 19 EXISTING CONDITIONS 19.1 The Mansfield turbines were manufactured by Baldwin Lima Hamilton. The turbine runners were upgraded by Allis Chalmers in 1984. 19.2 The unit is presently controlled by a mechanical cabinet actuator with dual push-pull servomotors acting on the turbine gate ring. 19.3 The existing servomotor data is as follows: 19.3.1 Normal Servomotor Stroke (inches) 15.625 19.3.2 Allowance for Spring in Vanes (inches) 0.375 19.3.3 Total Servomotor Stroke (inches) 16 19.3.4 Servomotor Rod Diameter (inches) 5 19.3.5 Servomotor Bore (inches) 18.875 19.3.6 Governor Timing (seconds) Design 3 19.3.7 Governor Timing Based on Field Testing (Seconds) 19.3.7.1 72% to 7.3% 3.48 19.3.7.2 7.3% to 0% 3.08 19.3.8 Design Pressure (psig) 300 19.3.9 Normal Operating Pressure (psig) 250-270 19.4 The servomotor is designed to provide a stepped closure law accomplished by a cushion designed into the servomotor END OF SECTION Operations Support Page 30 of 48
AA APPENDIX A ELECTRONIC ENGINEERING DOCUMENT MANAGEMENT STANDARD Operations Support Electronic Engineering Document Management Standard Approvedby: Standard No: 04 v01 Electronic Engineering Document and Drawing Requirements for A/E Firm Date: 4/5/2013 Page 31 of 48
1. Purpose The purpose of this Standard is to provide the minimum requirements for Architectural and Engineering (NE) design firms that produce or modify Engineering Documents or Drawings for Lower Colorado River Authority (LCRA) Operations Support (OS). 2. Scope The scope of this Standard applies to Engineering Documents, Drawings or GIS maps that may be either produced or modified by an NE design company for OS. 3. Acronyms and Definitions Acronyms A/E DCC EDMS GIS LCRA OS PDF PE QA/QC R&A Architectural and Engineering Document Control Coordinator Electronic Document Management System Geographic Information System Lower Colorado River Authority Operations Support Portable Document Format Professional Engineer Quality Assurance and Quality Control Records and Archives Definitions Architectural/Engineering A company that provides engineering services as defined by Page 32 of 48
(NE) Firm Convenience Copy Document Control Coordinator (DCC) Drafting Platform the Texas Engineering Practice Act 1001.003, Practice of Engineering. An electronic Engineering Document or Drawing in AutoCAD, Hybrid, TIF, or PDF available for review or modification. The file is a copy of the For Record document or drawing and reflects the most current layout or equipment installation. The OS individual responsible for managing Engineering Documents and Drawings for each facility. AutoCAD 2012 is the approved software for producing and modifying LCRA Engineering Drawings. Electronic Document Management System (EDMS) The enterprise-wide electronic content management system used both for storage of OS Convenience Copies and Working Files and for Archiving of For Record Engineering Documents and Drawings. Engineering Engineering Documents or Drawings The practice of engineering work which, in accordance with the Texas Engineering Practice Act 1001.003. Practice of Engineering means the performance of or an offer or attempt to perform any public or private service or creative work, the adequate performance of which requires engineering education, training, and experience in applying special knowledge or judgment of the mathematical, physical, or engineering sciences to that service or creative work. Documents or drawings that require Engineering to create or revise. Engineering Services The Engineering and Project Management Services department within OS that has the responsibility for ensuring engineering requirements of these standards for OS are met. Page 33 of 48
For Record Operations Support Electronic Engineering Document Management Standard Standard No: 04 v01 Electronic Engineering Document and Drawing Requirements for A/E Firms For Reference For Revision Hybrid Drawing Non-Exempt Engineering Documents Portable Document Format (PDF) Professional Engineer (PE) Records and Archives (R&A) Any Engineering Documents and Drawings commonly referred to as conformance documents, documents of record, or "As Built" drawings. The For Record revision of a document is the final issuance of a document. Typically it is the Official Record that is transferred to R&A. For Record drawings are typically issued after construction is complete and the drawings issued during construction have been verified as being correct by field verification and/or engineering verification. The drawing shall be modified, as required, to depict actual conditions and be sealed by a PE. The status of Engineering Documents or Drawings issued for information purposes only. These documents or drawings may be used for design input only. They are not to be revised. The Check Out Status of Engineering Drawing that will be revised for a project. An electronic Engineering Drawing that consists of two separate files (dwg/tif) that are linked together. Engineering Documents prepared by an A/E firm registered in the State of Texas. The electronic format required by R&A for Archiving Engineering Documents other than For Record Engineering Drawings. An individual that holds a valid PE license issued by the State of Texas. A central point within LCRA for the protection and storage of permanent records including electronic media formats in accordance with State and local government codes. Page 34 of 48
Redrawn Standards Superseded By Tagged Image File Format (TIF) Vendor Drawing Voided Drawing Working File An Engineering Drawing may be redrawn in cases were revising the original drawing is impractical. Redrawn Engineering Drawings will be assigned the next Number Revision. The OS Electronic Engineering Document Standards. The designation of a For Record Engineering Drawing that is being replaced by a new For Record Engineering Drawing with the appropriate Number Revision. The electronic format required by R&A for Archiving Official Record Engineering Drawings. A document or drawing provided by a manufacturer of a particular piece of equipment. An Engineering Drawing that has been taken out of service and is never to be used again. The most current Engineering Documents or Drawings checked out from the EDMS, whether issued For Record, for construction, or for Number Revision. 4. General Engineering Document and Drawing Requirements for A/E Firms a. NE firms shall comply with all requirements in this Standard. Exceptions to this Standard must be documented contractually. b. All Working Files and/or new Engineering Documents or Drawings shall be posted to a secure Internet web space in Portable Document Format (PDF) and made available to Engineering Services and LCRA's project team for review during design and through completion of construction. c. NE firms shall furnish all final Engineering Documents and Drawings in the approved electronic format as defined by this Standard. d. All Non-Exempt Engineering Document or Drawing revisions issued for bid, for construction, or For Record shall be sealed by a Professional Engineer (PE). Page 35 of 48
e. All Non-Exempt Engineering Drawings that reflect "as built" conditions shall be sealed by a PE and the revision block shall reflect that the Engineering Drawing has been issued For Record. Modified drawings should include revision clouds and deltas per Section 13. f. The NE firm shall submit the original hard copy For Record drawing, signed and sealed, and two electronic files. One electronic file shall be in the approved OS Drafting Platform format and the other shall be a TIF. i. The TIF shall be a scanned image of the original drawing that has been sealed, signed, and dated by a PE. ii. The Drafting Platform file shall display a disclaimer that identifies the PE name, PE license number, revision number, and date sealed. Example: "This drawing is a working copy of the Official Record which is archived. The Official Record of this drawing is signed and sealed by the following licensed engineer. John Doe, P.E., TX xxxxx For Revision x Only Date xxxx/xx/xx" g. The NE firm shall submit additional hard copies of the For Record drawings for internal distribution if required by contract. h. The NE firm shall submit a complete list of all For Record Engineering Documents and Drawings that will be provided to OS. The list shall be submitted in accordance with Section 10 of this Standard. i. The NE firm shall submit all other required Vendor Documents and Engineering Documents as PDFs, or as the most current OS-approved version of Microsoft Office documents if applicable, along with the contract specified number of hard copies. j. All final electronic Vendor Documents and Engineering Documents and Drawings shall be submitted to the authorized Document Control Coordinator (DCC) on DVD or CD along with a document list in accordance with Section 10 of this Standard. k. A/E firms shall follow established Engineering Document or Drawing size and numbering systems at each OS facility. New facilities shall follow the requirements of Section 5 of this Standard. Page 36 of 48
5. OS Engineering Standard Drawing Preparation Requirements The following table defines the standard NE drawing sizes and their letter designations that shall be used on all Engineering Drawings within OS. Letter Designation Sheet Width (inches) Sheet Length (inches) Margin (inches) Orientation A 8 1 / 2 11 3/8 Portrait B 11 17 3/8 Landscape C 18 24 1/2 Landscape D 24 36 1/2 Landscape E* 34 or 36 44 or 48 1/2 Landscape *Note: E size drawings may be either size (34x44 or 36x48) listed depending on the size of the existing drawing being modified. New drawings at existing facilities shall follow the existing size format. 6. Multi-Sheet Drawing Requirements a. Multi-sheet drawings are permitted in all sizes. b. All sheets of multi-sheet drawings shall be the same size. c. The first sheet of a multi-sheet drawing shall always contain the complete title block, list of material, revision block, and general notes. d. Existing OS facility sheet number sequencing and formats shall be used and assigned by the DCC. If a sheet numbering system does not exist, first sheets shall include the total number of sheets (e.g., "SHEET 1 OF X"). Numbering of continuation sheets shall state the specific sheet number (e.g., "SHEET 2 OF X", "SHEET 3 OF X"). 7. Title and Revision Block Requirements a. Title blocks and revision blocks shall be present on all electronic Engineering Drawings. b. A/E firms shall use title block formats provided by the DCC for use on all Non- Exempt Engineering Drawings. c. If Title blocks and revision blocks are not provided by the DCC, they shall conform at a minimum to the following. Page 37 of 48
The LCRA Official Record of this document is a PDF SECURED document. If you are viewing a non-secured PDF file or a hard copy, you are not viewing the LCRA Official Record i. Border A bold line weight border shall be located 1/2 or 3/8 inch from the edge of the paper (see Section 5). ii. Reference Grid (excluding size A) Grid divisions of equal spacing shall be present. iii. Spacing shall equally divide the bordered region, not the paper. iv. Divisions shall be lined in the margins outside the border both on the bottom and right sides of the document. v. Division labels shall be numbered (1-8) on the bottom and lettered (A- H) on the right. Quad A-1 shall be in the lower right hand corner. vi. Numbers and letters shall be centered in the columns and rows. vii. Engineering Seal All Non-Exempt Engineering Drawings, both hard copy and electronic, shall clearly display a stamp by a PE. Preferably the seal shall be located 1 inch from bottom drawing area border and 1 inch from right drawing area border. 8. File Type and Drawing Name Requirements a. Engineering Drawings and associated revisions shall be produced using the current OS Drafting Platform. No other drafting software is permitted b. OS Working Files may not always be provided to the A/E firm in the OS Drafting Platform format. They may be provided as Hybrid Drawings or TIFs. c. The Working File shall be submitted to the DCC in the current OS Drafting Platform format. d. The For Record Engineering Drawing file and Working File names shall match the drawing number and contain at least 8 characters plus the extension. e. For Record (TIF) files and Working Files (DWG/Hybrid/1-1F) shall have the same file name (e.g., 12345678.dwg/12345678.tif). 9. Drafting Platform Requirements a. Only AutoCAD ROMANS or TXT fonts shall be used. No proprietary fonts are permitted. b. All capital lettering shall be used. c. No fonts smaller than 1/8 th inch shall be used on D size drawings. No fonts smaller than 1/16 th inch shall be used on smaller sized drawings (A- C). d. Only AutoCAD line types shall be used. No proprietary line types are permitted. e. Consistent line type with 0.010 plot thickness shall be used. Page 38 of 48
f. Line thickness shall not be defined by color. g. Color may only be used on Working Files and Convenience Copies when it adds clarity and serves a purpose. When work is complete and the drawing is transitioned to For Record on the EDMS, the Convenience Copy shall be in pure black and white (monochrome) unless the color continues to serve a purpose. All For Record Engineering Documents and Drawings (electronic/hard copy) shall be provided in monochrome. h. Color conventions shall conform to existing Engineering Drawings. If conventions do not exist, use of color shall be agreed upon prior to use by the OS PE. i. Engineering Drawings shall be saved with view set to "Zoom Extents" to display the entire drawing. All unused entities and blocks shall be purged. J. All new Engineering Drawings shall have consistent size as referenced in Section 5 of this Standard. k. All revised Engineering Drawing sizes shall be consistent with the original Engineering Drawings. 10. Engineering Documentation and Drawing List Requirements All Engineering Documentation and Drawing lists shall be in the current LCRA-approved Microsoft Excel (.xls) format and shall include the following. Filename Title OS Drawing Number Revision Vendor Number Project Number Vendor Name Notations Voided and Superseded By drawings shall be noted. 11. Engineering Document and Drawing Numbering System Requirements Page 39 of 48
a. NE firms shall follow the established/existing Engineering Document and Drawing numbering systems at each OS facility. b. If an established numbering system does not exist, the NE firm shall submit a document to Engineering Services that outlines the proposed Engineering Document and/or Drawing numbering system for approval prior to design. 12. New and Existing OS Engineering Drawing Requirements a. Working Files checked out For Revision shall only be provided by the DCC in the Drafting Platform format, Hybrid Drawing format, or TIF. b. Convenience Copies shall be sent to the NE firm in the Standard Drafting Platform format, Hybrid format, TIF, or PDF For Reference only. c. Engineering Drawings may not be produced from For Reference documents. d. The OS Facility DCC will furnish drawing numbers for each type of drawing for use by the NE firm. e. The NE firm shall request and receive all new Engineering Drawing numbers from the DCC prior to issuing to LCRA for construction or issuing to vendors for bid. f. OS Engineering Drawing numbers and associated file names shall not be changed, reassigned, or added without OS approval. g. Revisions made to existing OS Engineering Drawings shall match the size and format of the Working File provided by the DCC. h. NE firms shall remove all previous seals, clouds, and deltas before revising an Engineering Drawing. i. New equipment, valves, pipeline designations, etc. added as a result of work shall follow the same naming convention currently used at the OS facility. J. If any OS Engineering Drawings were Voided or Superseded By, it shall be noted on the drawing list and the drawing. Voided and Superseded By drawings shall go to the next revision and shall be signed and sealed by a PE. 13. Engineering Drawing Modification Requirements a. All modifications to Engineering Drawings in the field shall follow an established design change process to assure engineering approval (signed and sealed by a PE) of changes made to a Working File of an Engineering Drawing. b. When a Working File of an Engineering Drawing cannot be modified electronically, it shall be Redrawn. Page 40 of 48
c. Engineering Drawings may not be simultaneously checked out of EDMS to multiple entities For Revision. d. If a requested Engineering Drawing is already checked out of the EDMS For Revision, a Convenience Copy shall be provided For Reference only along with contact information of the PE that has the Engineering Drawing currently checked out For Revision. e. A Working File that has been issued for bid or construction shall be available For Reference only as a PDF when requested by a OS PE. All changes made by an NE firm to existing Engineering Documents or Drawings shall be documented. f. Any change to a Working File of an Engineering Drawing shall be identified by using revision clouds and deltas, and the drawing revision number shall be incremented. g. Following construction or installation of new equipment, a copy of marked up Engineering Drawings shall be sent to the OS PE for review. h. After a revision to a Working File has been made and verified by a PE that the Engineering Drawing reflects "as built" conditions, the hard copy Engineering Drawing and associated Working Files shall be issued For Record and submitted to the OS DCC in accordance with the requirements in Section 4 of this Standard. 14. GIS Mapping Specifications Lower Colorado River Authority (LCRA) projects and activities generate both spatial and tabular data sets for use in GIS. These data sets will be incorporated into various databases and made available to a wide range of users. In order for this to occur effectively, certain standards and product specifications must be followed. This document provides general standards for spatial data collection and submission to the LCRA. A. All data collected or submitted shall be geo-referenced and provided in the standard projection noted below. Projection Texas State Plane Coordinate System Datum North American Datum Spheroid GRS 1980 Page 41 of 48
Zone Texas Central Zone 5376 Units Feet GIS Map file format used by ESRI mapping software, such as ArcMap; saved in a compound format that includes the map description, layout, and embedded objects saved in the map. Mandatory files for an.mxd:.shp shape format; the feature geometry itself.shx shape index format; a positional index of the feature geometry to allow seeking forwards and backwards quickly.dbf attribute format; columnar attributes for each shape, in dbase IV format.prj projection format; the coordinate system and projection information, a plain text file describing the projection using wellknown text format.sbn and.sbx a spatial index of the features.shp and.xml geospatial metadata in.xml format, such as 'ISO 19115 or other schemas B. To enable LCRA to directly import the CAD drawings into GIS, the following procedures must also be followed: Begin and end polyline/linestrings at logical locations; do not add artificial breaks. For example, a linestring representing a water pipe should begin/end at a fitting, tee, valve, hydrant, and reducer. A linestring representing a pipe should not be arbitrarily broken at locations other than those listed above. Linestring break points should be developed for each necessary CAD drawing layer. C. GIS Data Transfer Media Complete and verified data will be delivered via DVD or Portable Hard drive (preferred) and/or by software compressed (zipped) file. All digital and hardcopy information that is part of the project must be delivered, including GIS data, reports, metadata, photos, and other supporting materials. D. GIS Metadata Page 42 of 48
All LCRA GIS (and non-spatial) data sets should contain metadata describing the content, condition, source, accuracy and precision, use limitations, and other characteristics of the data. All metadata should be maintained using the Content Standards for Digital Geospatial Metadata as developed by the Federal Geographic Data Committee (FGDC), and anyone who creates or submits data should be responsible for that metadata. All required fields of the LCRA metadata table must be populated. 14. Quality Assurance and Quality Control (QA/QC) Requirements a. An NE firm shall develop a specific QA/QC plan that references or incorporates the requirements of this Standard. b. The QA/QC plan shall contain documented procedures which ensure that all hard copy and electronic Engineering Documents and Drawings submitted to OS conform to the requirements of this Standard.. c. At a minimum, the documented procedures shall include the following. i. The control of Engineering Documents and Drawings ii. Conformance to this Standard iii. Corrective and preventative actions d. The QA/QC plan shall be implemented during design, procurement, construction/installation, and project close out. e. The PE who seals a For Record Engineering Document or Drawing shall have performed all tests and inspections necessary to substantiate the accuracy and conformance to For Record conditions. f. The NE firm shall make reasonable accommodations to allow OS to verify the performance of the QA/QC plan during the course of the work, on request. End of Standard Page 43 of 48
The LCRA Official Record of this document is a PDF SECURED document. If you are viewing a non-secured PDF file or a hard copy, you are not viewing the LCRA Official Record Page 44 of 48
GES Project Number APPENDIX B TYPICAL TCC ARRANGEMENT Page 45 of 48
GES Project Number Page 46 of 48
GES Project Number Page 47 of 48
GES Project Number Page 48 of 48