Engineering Specifications Mansfield Unit 3 - LCRA 10031... · Engineering Specifications Mansfield...

Engineering Specifications Mansfield Unit 3Project Number: 3523327

Digital Governor/ Unit Control Turbine ControlsRehabilitation Project

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REVISION TABLE

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Date

11/30/2015

1/6/2016

Purpose

Bidding

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This information is intended only for the person(s) to whom it is addressed and may contain confidentialand/or privileged material. Any review, retransmission, dissemination, or other use of or taking of anyaction in reliance upon this information by persons other than those intended is prohibited.

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Engineering Specifications Mansfield Unit 3

Digital Governor / Unit Control Turbine ControlsRehabilitation Project

Project Number: 3523327

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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




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1 DIGITAL GOVERNOR / UNIT CONTROLLER

1.1 The Contractor shall design and manufacture or procure, new componentsassociated with the Digital Governor / Unit Controller Equipment as specifiedherein. All measurements taken shall be made with instruments capable ofmeasuring to the nearest 0.001 inch without interpolation, unless otherwisestated or approved. Instruments shall have been calibrated within 90 days beforemeasurements being taken, unless otherwise approved, and certification ofcalibration and calibration data shall be on file for review at the Contractor'sfacilities.

1.2 This document defines a digital processor based speed governing system andunit controls for the Mansfield Unit 3. All equipment necessary to provide acomplete and functional system is included in the scope of this specification.Optional hardware and functions are also described, any or all of which may beadded. Selection of operating modes, meters, etc. may be modified asnecessary.

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 ofequipment associated with the governor and receive written approval prior tocommencing 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 typein which the fundamental speed governing functions including speed sensing,development of the governing control signal, its modification with stabilizingterms, and speed droop are all developed by a digital processor. Other standardoperational modes such as power control with frequency influence andsynchronous condenser operation shall be affected in a similar fashion so thatstable operation is maintained. All unit control shall be performed by the controlsystem.

2.2 The link between the controller and the hydraulic actuator shall be an electricalgate position signal derived by the processor and transmitted to an electronicallycontrolled valve arrangement that initiates wicket gate movement. Electronicgate position feedback shall be used to ensure that actual wicket gate positioncorresponds to the position defined by the control signal, and to minimizemaintenance.

2.3 The controller shall consist of the following elements:




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2.3.1 Control cabinet, containing the digital processor and its associatedequipment, Human Machine Interface (HMI) Security Box mounted on door,speed switch, control relays, valve driver cards, power supplies, PotentialTransformer (PT) sensing module terminal strips, wiring and otherhardware, generally as described in Section 7

2.3.2 The existing Permanent Magnet Generator (PMG) is to be removed andmodified by the Contractor as described in Section 8

2.3.3 External devices such as gate position feedback transducers, and powersupplies, 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 bereplaced with an electronic pilot assembly generally as described in Section9.

2.3.7 The existing pressure tank shall be retained.

2.3.8 Remote Interface - with LCRA Master and Local Control Station asdescribed in Section 10

2.3.9 The arrangement of the controller elements shall be sufficiently modular toallow optimum placement in the powerhouse. For example, the controlcabinet can be located on the powerhouse generator floor, with theGovernor Pumping Unit and actuator assembly installed in proximity to theturbine.

3 CODES AND STANDARDS

3.1 Unless otherwise specified, the control system shall conform to the most recentrevision of the codes and standards listed below.

3.1.1 In the event of conflicts between standards, LCRA will determine theapplicable standard.

3.1.2 IEEE Std. 125-2007, Recommended Practice for Preparation of EquipmentSpecifications for Speed-Governing of Hydraulic Turbines Intended to DriveElectric Generators.

3.1.3 ASME Power Test Code No. 29, Speed Governing Systems for HydraulicTurbine-Generator Units.




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3.1.4 IEC No. 308, International Code for Testing of Speed Governing Systemsfor Hydraulic Turbines.

3.1.5 ANSI/IEEE C37.2-2008, Electrical Power System Device FunctionNumbers.

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 ManagementStandard: Standard No: 04 v01- Appendix A

4 PERFORMANCE CHARACTERISTICS

4.1 The following definitions shall apply to the performance characteristics of theDigital Governor / Unit Controller

4.1.1 Deadband - Deadband is the total percentage change of speed which canoccur 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 speedexcursion and the initial movement of the servomotor in reaction to theexcursion. For a step speed change of more than 1% of the rated speed ofthe turbine, the deadtime of the governor shall not be more than 0.2seconds.

4.1.3 Capacity - The rated capacity of the governor, which is the combinedcapacity of the servomotors of the turbine, shall be sufficient to operate theturbine gates through a full opening stroke in 3.0 seconds at a minimumsupply oil pressure of <300 PSI. A full stroke is defined as twice the timetaken by the wicket gates to open from 25% to 75%. This part of thegovernor is not being changed, servos and valves shall remain intact.

4.1.4 Ambient Temperature - The governor shall be capable of continuousoperation at a maximum ambient temperature of 50 degrees C. The normalrange of operation will be 30 degrees F to 104 degrees F.




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5 OPERATING MODES

5.1 The controller shall be capable of controlling the turbine in the following modes ofoperation.

5.1.1 Speed Control - The following modes shall be included:

5.1.1.1 Speed Control - Speed control governing shall be used to maintainsynchronous speed and aid system stability. Three sets of constantsshall be available:

5.1.1.1.1 Network - These constants shall be used when operating inparallel or on a large network. The damping time shall be set toobtain a fast step response to network frequency deviations.

5.1.1.1.2 Isolated - These constants shall be used when operatingisolated or on a small network. The damping time constant shallbe set to a higher value than for network operation to assuresystem stability. All other operating modes shall be ineffectivewhen in the isolated mode.

5.1.1.1.3 No Load – These constants shall be used when operating theunit at synchronous speed with breaker open.




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5.1.2 Gate Position Control - The controller shall be capable of maintaining agate position based on a gate position setpoint adjusted on the controlcabinet or by remote input.

5.1.3 Power With Frequency Influence - This mode of operation shall develop agovernor error signal based on the power setpoint, real power feedbackand rotor speed signal. By contrast with speed regulation, this mode shallpermit selection of a power set point. No permanent droop value shall bedisplayed since it is not appropriate in this mode.

5.1.3.1 The "power with frequency influence" mode shall be the defaultmode. This mode of operation shall only be in effect while themachine's speed remains within an adjustable speed band. If themachine's speed falls out of the speed band, then the governor logicshall change its operating mode to speed control and remain in thismode until a command for mode change is initiated.

5.1.3.2 When operating in the "power with frequency influence" mode, if themain circuit breaker opens, without a stop command, the "governor"mode shall convert to the isolated speed control, and upon re-closingof the main circuit breaker, the power with frequency influence modeshall again be effective.

5.1.4 Automatic Generation Control (AGC) - When in AGC, the power setpointwill be via remote setpoint request.

5.1.5 KVA Limit - A maximum generator KVA limit shall be available whenoperating in power or gate position control. The KVA limit setpoint shall beprogrammed during start-up to a value determined by the customer.Normally, the limit is set to maximum rated generator capacity to preventgenerator damage during unattended, automatic operation. The power limitsetpoint shall take priority over the Voltage setpoint. The controller shallalso be capable of maintaining the Voltage value in this mode.

5.1.6 Synchronous Condenser - The controller shall be capable of operatingthe generator as a synchronous condenser. While starting as acondenser, the unit shall proceed through the normal start sequence, andwhen the breaker closes, the gates shall close. Voltage control shall bepossible in this mode. While running as condenser, the unit shallautomatically 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 placeautomatically when required by operating conditions.




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5.1.7.1 Upon closure of the unit circuit breaker, the governor shallautomatically switch from speed control to power control withfrequency influence. Also, regardless of type of automatic operatingmode, speed control shall become effective immediately after the unitcircuit breaker opens.

5.1.7.2 During network operation in speed control, gate position control,power control with frequency influence, a changeover to speed controlisolated mode shall be made automatically to re-establish ratedspeed, if the turbine speed falls below or exceeds a programmablespeed band.

5.1.8 Bumpless Transfer - All mode changes initiated either automatically ormanually shall result in a bumpless transfer. If a change is made frompower control or speed control to gate position control, the gate positionsetpoint shall start at the last gate position required by the previousoperating mode. It shall then be possible to manipulate gate position fromthat setpoint. When a change is made from any mode to power control, thegate position setpoint shall automatically ramp to 100% and the gates shallfollow that setpoint until the gate position required by power control is lessthan the gate position setpoint, at which time power control shall becomeeffective. When changing between modes, gate position shall be rampedup or down as required by the new operating mode.

6 OPERATING SEQUENCES

6.1 The controller will be equipped with preprogrammed automatic routines to startand stop the turbine under several conditions.

6.2 START SEQUENCES - Two types of start sequences will be provided asdescribed below.

6.2.1 Automatic start - Upon receiving a start signal, the controller will proceedwith the start sequence, and begin to verify the pre-start conditions. Thepre-start conditions include the status of lockout and non-lockout relays,circuit breaker status, and the integrity of the system control power. In theevent 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 ofthe 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 startsequence alarm. When the conditions are met, the shutdown solenoid willbe energized, enabling the gates to move to the start position. At this point,the controller, will control the wicket gates through two start openings




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greater than the no-load position, before settling at speed-no-load, withrapid acceleration to minimize wear on the turbine/generator bearings dueto slow acceleration. The change to the different gate start positions will bemade at particular programmable percentages of speed. The turbine startgate positions will be programmable. Voltage and phase matching will beaccomplished with equipment provided by others. When the generatorcircuit breaker closes, the selected control mode is engaged.

6.2.2 Automatic Synchronization - The controller shall be equipped withprovisions for automatic synchronization. The automatic synchronizationwill be accomplished using customer specified synchronizer in conjunctionwith a Beckwith synchronization check relay. The synchronizer shall beequipped with provisions for black starting/dead bus operation. TheOperator interface terminal and unit controller program shall includeprovisions for dead bus starting.

6.2.3 Manual Start Sequence - The manual sequence will be similar to theautomatic except that after the shutdown solenoid is energized, allauxiliaries must be operated manually from the HMI . All protection ismaintained in this mode. The gate opening will be controlled by using thegate setpoint adjust switch. When the generator circuit breaker closes, gateposition control is engaged. As a subset of this mode, all outputs controlledby the governor shall be manually selectable and operable.

6.3 SHUTDOWN SEQUENCES - The controller will include programmed stoproutines for normal, emergency and partial shutdown conditions. Thesesequences are described herein.

6.3.1 Normal Shutdown Sequence - Upon receiving a stop signal, the system willbegin to ramp the wicket gates closed at the normal operating rate to thespeed-no-load position. The controller will open the main circuit breakerwhen speed-no-load position is achieved, and the shutdown solenoids willbe de-energized to fully close the gates. The brakes will be energized at25% 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, thecontroller will begin creep detection. In case of creep, the water and lube oilpumps and brakes will be energized, and an alarm sounded.

6.3.2 Emergency Shutdown - An emergency shutdown is an event that requiresthe unit to be immediately separated from the network, and prevented fromrestarting. These faults are typically from the generator lockout relay (86)and the emergency stop input. The controller will be arranged so that onreceipt of an emergency input, the generator breaker trips, and theshutdown solenoid is de-energized, closing the wicket gates at their fastest




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rate. A restart is allowed when the fault is cleared and the lockout relayreset.

6.3.3 Mechanical Shutdown - A mechanical shutdown is an event that requiresthe unit to be shutdown in a controlled fashion, and prevented fromrestarting. These faults are typically from the level and pressure devices.The controller will be arranged so that on receipt of a mechanical shutdowninput, the shutdown solenoid is de-energized, closing the wicket gates attheir fastest rate. When the breaker is opened, the controller will perform anormal shutdown sequence. A restart is allowed when the fault is cleared.

6.3.4 Partial Shutdown - Partial shutdown is provided when the generator breakeropens without a fault or shutdown input. Upon receiving a partial shutdowninput, 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 acomplete stop, after an adjustable time limit is exceeded.

6.3.5 Droop Test Sequence — The Programmable Logic Controller (PLC) will beprovided with software to perform an online droop test

6.4 Panel View / Local / Remote - A three position software switch will be available toselect the operating sequence and the origin of control signals. The highestactive 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 NEMA12 construction and contain the digital processor, HMI security box, speeddetection electronic equipment, control relays, analog outputs, electronic valvedriver cards, power supplies, terminal strips, and wiring as further describedbelow.

7.2 Enclosure - The enclosure shall be fabricated from cold rolled finished steel witha lockable hinged door. The enclosure will be similar to the Austin VTC size of90x48x52 with three (3) equipment mounting panels. Two access doors shall beprovided. 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 andalignment when closed. All latches shall be operated, through a linkagemechanism, by one conveniently located handle. No center post shall be used inthe cabinet construction.

7.2.1 The top and/or bottom of the enclosure (to be finalized during detaileddesign) shall have removable gasket plates to permit location of conduits,cable slots, or pull boxes for incoming cables as desired. The enclosure,




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door and panels shall be cleaned per phosphated TT C-490 Type II prior toreceiving a standard primer finish.

7.2.2 Two final coats of Sherwin Williams polane B polyurethane enamel paintshall be applied. The finish coat color shall be ANSI 61 light grey for bothexterior and interior of the enclosure. The mounting panels shall be white.In addition, a quart container of exterior paint final coat shall be supplied fortouch-up.

7.2.3 One conveniently located 120 VAC utility duplex outlet shall be provided ineach cabinet for programming and testing devices. One single phase, 120VAC cabinet heater with thermostat shall be supplied for maintaininginternal cabinet temperature. An external 120 VAC power circuit for theinterior light, receptacle, and heater shall be required from plant stationservice.

7.3 Control Hardware - A solid state digital processor and input/output (I/O) modulesshall be rack mounted inside a 16 slot chassis. The digital processor shall be anAB 1756-L6 or L7. The data highway address shall be specified by LCRA. The IPaddress will be defined by LCRA.

7.3.1 The system shall be designed to permit revisions to be made to theoperational sequences and governor parameters. Revisions to the programshall be possible from both local and remote locations with the appropriateprogram interface equipment using Allen Bradley RSLOGIX 5000(L6) orStudio 5000(L7) program software.




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7.3.2 The I/O modules shall be independently removable and shall haveindividual wiring arms for ease of maintenance. All modules shall beconnected to the processor via printed circuit cards located on the mountingchassis. I/O modules shall be supplied to interface with the following typeand quantity of signals:

TypeDiscrete InputsDiscrete OutputsAnalog InputsAnalog OutputsThermocoupleHigh Speed CtrVREG-RIO

Signal Quantity- Module Type24 VDC Nom 2-1756-IB3224 VDC Nom. 1-1756-OB324-20 ma 1-1756-IF84-20 ma 1-1756-IF4XOF2FE type 1-1756-IT6I

2-CFM1-1734-ENT2-1734-IB82-1734-IE2C2-1734-OW4




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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 toback up the synchronizer and prevent inadvertent breaker closure.

7.10 Test Switches - All Potential and Current Circuits connected to the synchronizershall be provided with test switches for isolating the device from the CT and PTcircuits.

7.11 Thermocouple - A type E thermocouple shall be furnished and mounted in thegovernor cubicle.

7.12 All I/O modules and the processor module shall have LED type indicating lightsfor trouble shooting purposes.

7.13 The I/O chassis shall be securely mounted in the rear of the control cabinet. Itshall have space for the digital processor and I/0 module power supply, and shallhave 16 slots for I/O module placement. All I/0 slots shall be keyed to preventinsertion of modules in the improper slot location.

7.14 HMI - The TCC will be equipped with an HMI Security Box for a portablemaintenance device to display current operating data, allow adjustment ofsetpoints, control and display system alarms, and other important parameters.

7.15 Pushbuttons, Selector Switches and Setpoint Adjust Switches - The controlcabinet shall be equipped with an Emergency Stop pushbutton with shroudlocated on the front door. All pushbuttons, selector switches, and setpoint adjustswitches shall be Allen-Bradley 800 series or equal.

7.16 Speed Switch - The control cabinet shall be equipped with an electronic speedswitch with four independent switches. The input to the speed switch shall bepulses generated by the speed sensing elements. The actuation points of theswitches 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 brakecircuit.

7.16.1.2 n >= 120% : This switch shall close on increasing speed foroverspeed.

7.16.1.3 n < 1% : Speed Switch Assembly failure input to PLC




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7.16.1.4 Spare7.16.1.5 The speed switch shall have a 4-20 ma output and be a device

external to the digital processor to provide independent contactoutputs, 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 suitablefor operation in 24 VDC control circuits. Control relays shall be Deltrol 66 seriesor Allen Bradley 700CF as required where multiple contacts are required, orequal with contact ratings of 5A at 24 VDC or 10 A at 120 VAC. One relay shallbe provided for each discrete output required for circuits exterior to the controlcabinet and shall include a breaker close relay as controlled by the synchronizerfor synchronization.

7.18 Electronic Valve Driver - An individual rack mountable electronic valve drivercard shall be supplied in the control cabinet. The card shall compare thegovernor position command signal with the actual servomotor position andamplify the error signal in proportion to the deviation. The output signal of thevalve driver card will include dither of adjustable frequency and amplitude toimprove the response output of the proportional valve. The proportional valveconverts the electrical output signal of the governor to a hydraulic output. Thevalve 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 130VDC 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 forconnection of external wiring. The blocks shall be 600 V, 45 amp, screw typecapable of accepting standard copper wire sizes AWG No. 8 through No. 18.Terminal blocks shall be Allen Bradley 1492-W10 or equal. Ten percent spareterminal points shall be provided.

7.20.1 Terminal blocks shall be color coded as follows:

7.20.1.1 Blue 125VDC Yellow PLC discrete inputs7.20.1.2 Red 120VAC Orange PLC discrete outputs7.20.1.3 Gray 24 VDC Yellow/Green Grounds




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7.21 Power Supply Connections - All incoming power supply feeders to the cabinetshall be protected by fuses. The Contractor shall determine the appropriate fusesize.

7.22 Wire - All control and other auxiliary wiring shall be SIS type, stranded copperconductor with flame retardant insulation, except analog signals and I/O modulewiring.

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 0Po ten t ia l T rans fo rmer 12C o n t r o l W i r i n g 1 4Analog Signals (shielded) 16I/O Module Wiring Arms 18 — 22




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7.22.2 Current transformer wiring terminations shall be made with self-insulatedcrimp-on type ring tongue lugs.

7.22.3 Internal wiring shall be identified with a wire number on each end of eachwire by a plastic sleeve or similar permanent marker. Control wire bundlesshall 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 fieldinterconnect terminals to facilitate field additions.

8 SPEED SENSING

8.1 Turbine Speed - A new speed signal generator shall be furnished. Turbine speedsensing equipment shall consist of a refurbished toothed disc and pulse initiatingproximity pick-ups designed with new brackets to mount in the existing bolt holesof the PMG housing. The existing PMG assemblies main mercury overspeedswitch, auxiliary mercury overspeed switches, gear box mechanism, and therotor 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 beprovided and utilized. Two shall be dedicated to speed control circuits. Theother shall be used for speed measuring points and speed indication. Thespeed pickups will be primarily used for creep detection, speed referenceduring startup and as backup for the PT sensing module.

8.1.2 PT Sensing Module — A new PT sensing module will be installed in theTCC. The primary function of this module is to monitor speed duringexcitation 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 theStation vital AC inverter.

9.1.2 Gate Position - A Gemco Patriot linear position transducer of themagnetostrictive type with 4-20 ma output shall be furnished for wicket gateposition feedback. Zero and span adjustments shall be programmed forcalibration purposes. All necessary mounting brackets (supplied in Section5.2), hardware, and linkages to translate gate ring movement into linearmovement of the transducer shall be provided by the Contractor.




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9.1.3 Distributing Valve Spool Position-The main spool of the existing distributingvalve shall be equipped with a linear position transducer to provide mainspool position feedback to the valve driver card for improved response.

9.1.4 Pilot Valve conversion adapter and interface hardware - The existing pilotpiston assembly shall be modified by removing the existing adapter andcontrol mechanism. A new adapter shall be provided to connect the openand 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 lubemotors and pumps shall be replaced by a new AC and DC lube oil motorsand pumps. Roper pumps are preferred.

9.1.6 Air Brake Panel — The existing air brake system shall be retained andrefurbished.

10 REMOTE INTERFACE

10.1 The governor shall interface with the Master Control Station (MCS) and LocalControl Station (LCS) using the processor Ethernet communication port. Thesystem 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-ENBT10.1.1.2 2 (two) 1756-IB1610.1.1.3 1 (one) 1756-OX8I10.1.1.4 2 (two) 1756-IF16

10.1.2 LCRA TEMP-RIO (Generator Floor-Generator Housing Location)

10.1.2.1 1 (one) 1756-ENBT10.1.2.2 2 (two) 1756-IR6I10.1.2.3 2 (two) 1756-IT6I

10.1.3 TPIT-RIO (Generator Turbine Pit Location)

10.1.3.1 1 (one) 1734-AENT10.1.3.2 2 (two) 1734-IB810.1.3.3 1 (one) 1734-OW410.1.3.4 1 (one) 1734-IE2C

10.1.4 GPU-RIO (Governor Pump Cabinet)

10.1.4.1 1 (one) 1734-AENT10.1.4.2 2 (two) 1734-IB8




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10.1.4.3 1 (one) 1734-OB810.1.4.4 2 (two) 1734-IE2C10.1.4.5 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 addedwill 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. TheGPU was furnished as an integral assembly. The GPU utilizes Rexrothcomponents available from the 3 day delivery catalog where feasible.

11.2 The oil reservoir is located on the turbine floor of the powerhouse. The reservoiris sized to receive 110% of the total volume of active oil in the system. Theactive 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, asnecessary, to provide adequate pump intake submergence, and to preventoverheating 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 mainprocessor or manually from the GPU control enclosure. All control devicesfor pump operation shall be as listed in this section. Logic for the pumpcontrols 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 unloadervalve located at the pump discharge. On low system oil pressure, theunloader valve can be activated to deliver oil under pressure to the system.When de-activated, the unloader valve returns oil at zero pressure to thereservoir. The pumps can start and stop while unloaded.




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11.6 Motors/ gear pump – The motors and gear pump shall be refurbished by a shopcertified to repair Woodward equipment. The motors shall be dipped, baked,bearings replaced and tested. The gear pump shall be inspected for damageand wear. The pump gear to side plate shall be machined to reestablish properclearances. 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 solenoidoperated unloader relief valve. The relief valve shall be replaced with a like kindvalve. The valve shall be sized for full pump discharge with minimal pressuredrop to avoid overheating the oil while unloading. Unloading shall occur in acontrolled manner to prevent slamming of the pump check valve andobjectionable hammering in the piping. The pump controls includes provisions formanually unloading using a pushbutton (hand/off/automatic switch with pumpload pushbutton) located on the pump control panel.

11.9 Check Valve - The existing pump discharge check valve shall be resurfaced andreutilized.

11.10 Black Start — The governor pumping unit shall be equipped by LCRA withprovisions 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 toaccept position control signals from a new hydraulic interface. The Contractorshall provide technical assistance to LCRA during the removal of obsoletecomponents 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 closepressure ports to the existing pilot piston actuator

12.1.1.2 Miscellaneous pilot oil piping and fittings, supplied by LCRA12.1.1.3 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 Valve12.1.1.7 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.




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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




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14.1.1.1 5 Control relays14.1.1.2 10 Fuses of each rating used14.1.1.3 10 Varistors of each type and rating used14.1.1.4 10 Diodes of each type and rating used14.1.1.5 1 Pushbutton of each type14.1.1.6 1 Power supply for the Processor14.1.1.7 1 Power supply for the TCC cabinet14.1.1.8 1 Buffer Amplifier14.1.1.9 1 32 Point Digital Input Module14.1.1.10 1 32 Point Digital Output Module14.1.1.11 1 Analog Input Module14.1.1.12 1 Analog Output Module14.1.1.13 1 Valve Driver Card14.1.1.14 1 PT Sensing Module

14.1.2 External Devices and Speed Sensing Elements


14.1.2.1 1 Inductive speed pick-up14.1.2.2 1 Valve position feedback transducer14.1.2.3 1 Gate position feedback transducer

14.1.3 Governor Pumping Unit and Actuator


14.1.3.1 Case Pilot oil pressure filters14.1.3.2 1 Shutdown solenoid14.1.3.3 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 followinggovernor equipment in accordance to the Contractor’s Factory TestProcedure.

15.1.2 Control Cabinet

15.1.2.1 Mechanical Tests

15.1.2.1.1 Control cabinet structural integrity




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15.1.2.1.2 Equipment supplied per bill of material15.1.2.1.3 Cabinet dimensions15.1.2.1.4 Overall appearance15.1.2.1.5 Paint15.1.2.1.6 Proper location of all devices15.1.2.1.7 Devices securely mounted15.1.2.1.8 Nameplates correct and securely mounted

15.1.2.2 Electrical Tests

15.1.2.2.1 Point to point wiring15.1.2.2.2 Wiring proper gauge15.1.2.2.3 Cable shield properly installed15.1.2.2.4 Wire markers installed

15.1.2.3 Functional Tests

15.1.2.3.1 Proper interface between the digital processor and controlcabinet devices

15.1.2.3.2 Polarity test on all metering devices and relay circuits15.1.2.3.3 Proper operation of all switches and lights

15.1.3 Hydraulic Interface

15.1.3.1 Mechanical Tests

15.1.3.1.1 Overall appearance15.1.3.1.2 Piping15.1.3.1.3 Bill of Material15.1.3.1.4 Connections

15.1.3.2 Electrical Tests

15.1.3.2.1 Wiring Proper Gauge15.1.3.2.2 Point to point wiring15.1.3.2.3 Wiring markers installed

15.1.3.3 Functional Tests

15.1.3.3.1 Operation with simulated control input




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15.2 Governor Performance Tests

15.2.1 General - The following field tests shall be performed to demonstrategovernor performance in accordance with the Contractor’s Commissioningdocument. For testing purposes, machine speed, which is the governorinput signal, shall be simulated using a function generator and shall berecorded as a function of DC voltage. Tests shall be performed with thecontrol cabinet and actuator assembly. Substitute servomotors shall beused; a substitute governor pumping unit may be used.

15.2.2 Permanent Speed Droop - The permanent speed droop test shalldemonstrate governor linearity, accuracy, and speed setpoint adjustmentrange. The test shall be performed at speed setpoints of 90, 100, and 110percent with permanent speed droop set at four percent. At each speedsetpoint, the governor input shall initially be set to achieve 90 percenteffective servomotor stroke. The governor input shall be increased in fourapproximately equal increments to achieve a final servomotor position often percent of effective stroke. The permanent speed droop shall bedemonstrated by recording the governor input and servomotor position on amulti-channel recorder

15.2.3 Deadband - The deadband test shall verify governor insensitivity which isdefined as half of the deadband. Beginning at rated speed, progressivelysmaller step changes in frequency of 0.05, 0.02, 0.01 and 0.005 percent, inalternating direction, shall be input to the governor. The deadband shall beverified if a frequency change of 0.01 percent results in a servomotorposition change. The governor permanent speed droop shall be fourpercent for this test. Deadband shall be demonstrated by recording thegovernor input signal and the servomotor position on a multi-channelrecorder.

15.2.4 Deadtime - The deadtime test shall determine the time response between aspeed change and a change in servomotor position. A change in speed oftwo percent shall be used for this test. The deadtime shall be measured byplotting the governor input signal and the servomotor position on a multi-channel recorder.

15.2.5 Stability - The stability test shall verify that the governor output is stable fora stable input. A start will be initiated, and the gate servomotor brought tospeed no load, and 100% speed will be simulated. With the governor inisolated mode, the governor output will be plotted versus time. The stabilityof the speed input signal will be validated using a frequency counter.




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16 DRAWING SUBMITTALS

16.1 All drawings submitted shall conform to APPENDIX A, ELECTRONICENGINEERING DOCUMENT MANAGEMENT STANDARD unless otherwisenoted herein.

16.2 The following drawings shall be submitted within days noted below from receiptof 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 outlineincluding the foundation and assembly drawingsdefining the following: Overall dimensions of each assembly delivered

60Days




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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 governorassembly shall be listed with manufacturer and modelnumber.

60 Days

5 System hydraulic schematic 60 Days

6 Terminal Block Layout Diagrams on Schematics.(suitable to prepare interconnection drawings)

100 Days

7 Hydraulic system internal connection diagrams withpiping line sizes, port connection details.

100 Days

8 Instruction Manuals - The instruction manuals shallinclude installation, start-up, testing, operation, andmaintenance information.

Shipment

16.2.3 Governor Pumping Unit and Actuator

1General arrangement and equipment outlineincluding the assembly drawings defining thefollowing:

60 Days




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Overall dimensions of each assembly deliveredand location of shipping splits if applicable.

Layout and space requirement for all equipmentfor installation and maintenance.

The weight of each major equipment item.

Lifting and handling procedures for each majorequipment item.

Clearance requirements.

Cable/conduit entry areas. Anchoring details.

2 System internal connection diagrams with piping linesizes.

120 Days

3 Wiring Diagrams 120 Days

4 Terminal Arrangement Diagrams 120 Days

5 Bill of Material. 90 Days

The LCRA Official Record of this document is a PDF SECUREDdocument. If you are viewing a non-secured PDF file or a hard copy,you are not viewing the LCRA Official Record

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6Equipment arrangement diagrams showing thephysical or relative location of all devices includingport 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

10Instruction Manual - The instruction manuals shallinclude:Installation,start-up, testing, operation, andmaintenance information.

Shipment

11 Commissioning Procedures 30 Days afterShipment




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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 communicationsin 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 andoperator 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 componentsand cabling, etc. according to Contractor’s supplied installation drawings.

18.2 The LCRA will be responsible for furnishing the following data and informationto assist the suppler as required to determine the interface requirements (I/O)for the unit controller/speed governor for Mansfield Unit 3 including but notlimited to the following:

18.2.1 With Task Order:

18.2.1.1 LCRA Equipment Designations for discrete inputs and outputs18.2.1.2 Analog Input signal type designations and scales18.2.1.3 Existing Wicket Gate Servomotor timing will remain unchanged.




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18.2.2 With Drawing Approval:

18.2.2.1 LCRA SCADA Tag Identification18.2.2.2 LCRA required Unit Pre-Start Conditions18.2.2.3 LCRA required Unit Post-Start Conditions

19 EXISTING CONDITIONS

19.1 The Mansfield turbines were manufactured by Baldwin Lima Hamilton . Theturbine runners were upgraded by Allis Chalmers in 1984.

19.2 The unit is presently controlled by a mechanical cabinet actuator with dualpush-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% 3.4819.3.7.2 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 bya cushion designed into the servomotor

END OF SECTION Operations Support




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Approvedby:

AA

APPENDIX A – ELECTRONIC ENGINEERING DOCUMENT MANAGEMENTSTANDARD

Operations Support

Electronic Engineering Document Management Standard

Standard No: 04 v01

Electronic Engineering Document and Drawing Requirements for A/E FirmDate: 4/5/2013




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1. Purpose

The purpose of this Standard is to provide the minimum requirements forArchitectural and Engineering (NE) design firms that produce or modifyEngineering 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 GISmaps that may be either produced or modified by an NE design company for OS.

3. Acronyms and Definitions

Acronyms

A/E Architectural and Engineering

DCC Document Control Coordinator

EDMS Electronic Document Management System

GIS Geographic Information System

LCRA Lower Colorado River Authority

OS Operations Support

PDF Portable Document Format

PE Professional Engineer

QA/QC Quality Assurance and Quality Control

R&A Records and Archives

Definitions

Architectural/Engineering A company that provides engineering services as defined by




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(NE) Firm the Texas Engineering Practice Act § 1001.003, Practice ofEngineering.

Convenience Copy

Document ControlCoordinator (DCC)

Drafting Platform

Electronic DocumentManagement System(EDMS)

Engineering

Engineering Documentsor Drawings

An electronic Engineering Document or Drawing inAutoCAD®, Hybrid, TIF, or PDF available for review ormodification. The file is a copy of the For Record documentor drawing and reflects the most current layout or equipmentinstallation.

The OS individual responsible for managing EngineeringDocuments and Drawings for each facility.

AutoCAD 2012 is the approved software for producing andmodifying LCRA Engineering Drawings.

The enterprise-wide electronic content management systemused both for storage of OS Convenience Copies andWorking Files and for Archiving of For Record EngineeringDocuments and Drawings.

The practice of engineering work which, in accordance withthe Texas Engineering Practice Act § 1001.003. Practice ofEngineering means the performance of or an offer or attemptto perform any public or private service or creative work, theadequate performance of which requires engineeringeducation, training, and experience in applying specialknowledge or judgment of the mathematical, physical, orengineering sciences to that service or creative work.

Documents or drawings that require Engineering to create orrevise.

Engineering Services The Engineering and Project Management Servicesdepartment within OS that has the responsibility for ensuringengineering requirements of these standards for OS are met.




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For Record

For Reference

For Revision

Hybrid Drawing

Non-Exempt EngineeringDocuments

Portable DocumentFormat (PDF)

Professional Engineer(PE)

Records and Archives(R&A)

Operations SupportElectronic Engineering Document Management Standard

StandardNo:04 v01ElectronicEngineeringDocumentandDrawingRequirementsforA/EFirms

Any Engineering Documents and Drawings commonlyreferred to as conformance documents, documents ofrecord, or "As Built" drawings. The For Record revision of adocument is the final issuance of a document. Typically it isthe Official Record that is transferred to R&A. For Recorddrawings are typically issued after construction is completeand the drawings issued during construction have beenverified as being correct by field verification and/orengineering verification. The drawing shall be modified, asrequired, to depict actual conditions and be sealed by a PE.

The status of Engineering Documents or Drawings issuedfor information purposes only. These documents or drawingsmay be used for design input only. They are not to berevised.

The Check Out Status of Engineering Drawing that will berevised for a project.

An electronic Engineering Drawing that consists of twoseparate files (dwg/tif) that are linked together.

Engineering Documents prepared by an A/E firm registeredin the State of Texas.

The electronic format required by R&A for ArchivingEngineering Documents other than For Record EngineeringDrawings.

An individual that holds a valid PE license issued by theState of Texas.

A central point within LCRA for the protection and storageof permanent records including electronic media formats inaccordance with State and local government codes.




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Redrawn An Engineering Drawing may be redrawn in cases wererevising the original drawing is impractical. RedrawnEngineering Drawings will be assigned the next NumberRevision.

Standards The OS Electronic Engineering Document Standards.

Superseded By The designation of a For Record Engineering Drawing that isbeing replaced by a new For Record EngineeringDrawing with the appropriate Number Revision.

Tagged Image File The electronic format required by R&A for Archiving OfficialFormat (TIF) Record Engineering Drawings.

Vendor Drawing

Voided Drawing

Working File

A document or drawing provided by a manufacturer of aparticular piece of equipment.

An Engineering Drawing that has been taken out ofservice and is never to be used again.

The most current Engineering Documents or Drawingschecked out from the EDMS, whether issued For Record,for construction, or for Number Revision.

4. General Engineering Document and Drawing Requirements for A/EFirms

a. NE firms shall comply with all requirements in this Standard. Exceptionsto this Standard must be documented contractually.

b. All Working Files and/or new Engineering Documents or Drawings shall beposted to a secure Internet web space in Portable Document Format (PDF) andmade available to Engineering Services and LCRA's project team for reviewduring design and through completion of construction.

c. NE firms shall furnish all final Engineering Documents and Drawings in theapproved electronic format as defined by this Standard.

d. All Non-Exempt Engineering Document or Drawing revisions issued for bid, forconstruction, or For Record shall be sealed by a Professional Engineer (PE).




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e. All Non-Exempt Engineering Drawings that reflect "as built" conditions shall besealed by a PE and the revision block shall reflect that the Engineering Drawinghas been issued For Record. Modified drawings should include revision cloudsand deltas per Section 13.

f. The NE firm shall submit the original hard copy For Record drawing, signed andsealed, and two electronic files. One electronic file shall be in the approved OSDrafting Platform format and the other shall be a TIF.

i. The TIF shall be a scanned image of the original drawing that has beensealed, signed, and dated by a PE.

ii. The Drafting Platform file shall display a disclaimer that identifies thePE name, PE license number, revision number, and date sealed.

Example:

"This drawing is a working copy of the Official Record which isarchived. The Official Record of this drawing is signed and sealed bythe 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 forinternal distribution if required by contract.

h. The NE firm shall submit a complete list of all For Record EngineeringDocuments and Drawings that will be provided to OS. The list shall besubmitted in accordance with Section 10 of this Standard.

i. The NE firm shall submit all other required Vendor Documents and EngineeringDocuments as PDFs, or as the most current OS-approved version of MicrosoftOffice documents if applicable, along with the contract specified number of hardcopies.

j. All final electronic Vendor Documents and Engineering Documents andDrawings shall be submitted to the authorized Document Control Coordinator(DCC) on DVD or CD along with a document list in accordance with Section 10of this Standard.

k. A/E firms shall follow established Engineering Document or Drawing size andnumbering systems at each OS facility. New facilities shall follow therequirements of Section 5 of this Standard.




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5. OS Engineering Standard Drawing Preparation Requirements

The following table defines the standard NE drawing sizes and their letterdesignations that shall be used on all Engineering Drawings within OS.

LetterDesignation

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 theexisting drawing being modified. New drawings at existing facilities shall follow the existingsize 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 titleblock, list of material, revision block, and general notes.

d. Existing OS facility sheet number sequencing and formats shall be used andassigned by the DCC. If a sheet numbering system does not exist, first sheetsshall include the total number of sheets (e.g., "SHEET 1 OF X"). Numbering ofcontinuation 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 EngineeringDrawings.

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 shallconform at a minimum to the following.


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i. Border — A bold line weight border shall be located 1/2 or 3/8 inchfrom the edge of the paper (see Section 5).

ii. Reference Grid (excluding size A) — Grid divisions of equal spacingshall 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 onthe 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, bothhard copy and electronic, shall clearly display a stamp by a PE.Preferably the seal shall be located 1 inch from bottom drawing areaborder and 1 inch from right drawing area border.

8. File Type and Drawing Name Requirements

a. Engineering Drawings and associated revisions shall be produced usingthe 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 OSDrafting Platform format. They may be provided as Hybrid Drawings or TIFs.

c. The Working File shall be submitted to the DCC in the current OSDrafting Platform format.

d. The For Record Engineering Drawing file and Working File names shallmatch the drawing number and contain at least 8 characters plus theextension.

e. For Record (TIF) files and Working Files (DWG/Hybrid/1-1F) shall have thesame file name (e.g., 12345678.dwg/12345678.tif).

9. Drafting Platform Requirements

a. Only AutoCAD ROMANS or TXT fonts shall be used. No proprietary fontsare permitted.

b. All capital lettering shall be used.

c. No fonts smaller than 1/8th inch shall be used on D size drawings. Nofonts smaller than 1/16th 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.




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f. Line thickness shall not be defined by color.

g. Color may only be used on Working Files and Convenience Copies when itadds clarity and serves a purpose. When work is complete and the drawing istransitioned to For Record on the EDMS, the Convenience Copy shall be inpure black and white (monochrome) unless the color continues to serve apurpose. All For Record Engineering Documents and Drawings(electronic/hard copy) shall be provided in monochrome.

h. Color conventions shall conform to existing Engineering Drawings. Ifconventions do not exist, use of color shall be agreed upon prior to use bythe OS PE.

i. Engineering Drawings shall be saved with view set to "Zoom Extents" todisplay the entire drawing. All unused entities and blocks shall be purged.

J. All new Engineering Drawings shall have consistent size as referencedin Section 5 of this Standard.

k. All revised Engineering Drawing sizes shall be consistent with theoriginal Engineering Drawings.

10. Engineering Documentation and Drawing List Requirements

All Engineering Documentation and Drawing lists shall be in the currentLCRA-approved Microsoft Excel (.xls) format and shall include thefollowing.

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 NumberingSystem Requirements




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a. NE firms shall follow the established/existing Engineering Documentand Drawing numbering systems at each OS facility.

b. If an established numbering system does not exist, the NE firm shall submita document to Engineering Services that outlines the proposedEngineering Document and/or Drawing numbering system for approvalprior to design.

12. New and Existing OS Engineering Drawing Requirements

a. Working Files checked out For Revision shall only be provided by the DCC inthe Drafting Platform format, Hybrid Drawing format, or TIF.

b. Convenience Copies shall be sent to the NE firm in the Standard DraftingPlatform 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 foruse by the NE firm.

e. The NE firm shall request and receive all new Engineering Drawing numbersfrom the DCC prior to issuing to LCRA for construction or issuing to vendors forbid.

f. OS Engineering Drawing numbers and associated file names shall not bechanged, reassigned, or added without OS approval.

g. Revisions made to existing OS Engineering Drawings shall match the size andformat of the Working File provided by the DCC.

h. NE firms shall remove all previous seals, clouds, and deltas before revising anEngineering Drawing.

i. New equipment, valves, pipeline designations, etc. added as a result of workshall follow the same naming convention currently used at the OS facility.

J. If any OS Engineering Drawings were Voided or Superseded By, it shall benoted on the drawing list and the drawing. Voided and Superseded By drawingsshall 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 establisheddesign 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 modifiedelectronically, it shall be Redrawn.




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c. Engineering Drawings may not be simultaneously checked out of EDMS tomultiple entities For Revision.

d. If a requested Engineering Drawing is already checked out of the EDMS ForRevision, a Convenience Copy shall be provided For Reference only along withcontact information of the PE that has the Engineering Drawing currentlychecked out For Revision.

e. A Working File that has been issued for bid or construction shall be available ForReference only as a PDF when requested by a OS PE. All changes madeby an NE firm to existing Engineering Documents or Drawings shallbe documented.

f. Any change to a Working File of an Engineering Drawing shall be identifiedby using revision clouds and deltas, and the drawing revision number shallbe incremented.

g. Following construction or installation of new equipment, a copy of markedup 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 thatthe Engineering Drawing reflects "as built" conditions, the hard copyEngineering Drawing and associated Working Files shall be issued ForRecord and submitted to the OS DCC in accordance with the requirementsin Section 4 of this Standard.

14. GIS Mapping SpecificationsLower Colorado River Authority (LCRA) projects and activities generate bothspatial and tabular data sets for use in GIS. These data sets will beincorporated into various databases and made available to a wide range ofusers. In order for this to occur effectively, certain standards and productspecifications must be followed. This document provides general standardsfor spatial data collection and submission to the LCRA.

A. All data collected or submitted shall be geo-referenced and provided inthe standard projection noted below.

• Projection Texas State Plane CoordinateSystem

• Datum North American Datum

• Spheroid GRS 1980




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• Zone Texas Central Zone 5376

• Units FeetGIS 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 well-known 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




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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 orincorporates the requirements of this Standard.

b. The QA/QC plan shall contain documented procedures which ensure thatall hard copy and electronic Engineering Documents and Drawingssubmitted 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 shallhave performed all tests and inspections necessary to substantiate theaccuracy and conformance to For Record conditions.

f. The NE firm shall make reasonable accommodations to allow OS to verifythe performance of the QA/QC plan during the course of the work, onrequest.

End of Standard


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APPENDIX B – TYPICAL TCC ARRANGEMENT




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