University Corporation for Atmospheric Research National Science Foundation Funds Request 1. (NSF USE ONLY) 2. FACILITY NAME & LOCATION 3. PROJECT NAME 4. UCAR TRACKING NUM. NCAR Mesa Lab 15KV FEEDER REPLACEMENT NSF07ML001 5. INVESTMENT CATEGORY 6. DATE SUBMITTED New Program Expansion Replace Obsolete Energy Savings Cost Improvement Environmental Other (explanation) 01/31/2007 MM/DD/YYYY 7. TECHNICAL LEAD TELEPHONE 8. UCAR POINT OF CONTACT TELEPHONE 9. (REV. NUM.) & DATE 10. * UCAR PRIORITY 11. David Patterson (303) 4978507 Jeff Reaves (303) 4978890 (2) 08/17/2007 9 ITEM COST ESTIMATES 12. U/M 10. * UCAR PRIORITY: 25 = CRITICAL 1 = LESS IMPORTANT 13. QUANTITY 14. UNIT COST 15. COST ($000) Planning & Design Costs in 2007 dollars: Amount requested for 2007. $89 Construction Costs $981 Allowances: Rocky Soil Conditions & Asbestos Abatement Construction & Allowance Costs in 2008 dollars: Construction & Allowances, Adjusted for Inflation (5%) (+1 Yr) 2009 (+2 Yr) 2010 (+3 Yr) 2011 (+4 Yr) 2012 (+5 Yr) 2013 $114 $1,095 $1,150 $1,208 $1,268 $1,332 $1,398 16. DESCRIPTION OF PROPOSED CONSTRUCTION Proposed construction consists of the following: Install a new underground conduit ductbank from the Xcel Energy demarcation point to the Mesa Lab (~1 mile). Install one (1) new 15kV feeder cable in the new ductbank. Demolish one (1) old 15kV feeder cable in the old ductbank. Abandon the old ductbank in place. Replace pole mounted 15kV switches with ground mounted 15kV metalclad switchgear. 17. CURRENT SITUATION The Mesa Lab facility is electrically served by two 15kV feeder lines from Xcel Energy. One feeder, in a conduit ductbank, is 45 years old and the other, direct buried, is 25 years old. Both are past their predicted lifetimes and either or both could fail at any time. If one feeder were to fail, the Mesa would be able to operate on the second, though the second could also fail. It is estimated that a planned replacement of even one feeder could take up to 10 months. If both feeders should fail together, the Mesa Lab could potentially be out of power for several months while at least one new feeder is installed. Pole Mounted Switches: The existing pole mounted switches are hanging from decayed wooden structures. It is feared that if someone were to operate the pole cutout devices the entire crossarms, switches, and 15kV lines could potentially fall on the operator. In the past, Contractors have refused to perform repairs due to the possibility of creating further damage to poles and cables. Consultants recommend replacing the pole mounted equipment with safer ground mounted switching equipment. 18. IMPACT IF NOT PROVIDED There are no immediate impacts the feeders are operational today. Though, if a feeder did fail it would take many months to replace. In those months the second could fail during construction. If both feeders fail, the Mesa would have to be closed until power is restored. Page 1
University Corporation for Atmospheric Research National Science Foundation Funds Request 1. (NSF USE ONLY) 2. FACILITY NAME & LOCATION 3. PROJECT NAME 4. UCAR TRACKING NUM. NCAR Mesa Lab 19. ALTERNATIVE SOLUTIONS CONSIDERED 15KV FEEDER REPLACEMENT NSF07ML001 Install new direct buried 15kV feeders rather than install a new ductbank. Reason for rejecting: Rocky soil and shifting soil conditions could damage direct bury cables and direct bury cables have a shorter life expectanncy than cables in conduit. In the longterm, a new ductbank/conduit system will make future feeder replacements cheaper than direct burying cables each time a new one is needed. We also considered trying to "rout out" and reline the old ductbank conduits. Reason for rejecting: It is not a common technology for electrical conduits to be relined plus the existing Orangeburg type conduits contain asbestos. Grinding or routing out asbestos containing conduits would be cost prohibitive. 20. DELIVERABLES AT END OF PROJECT 1. One new underground ductbank with 4 conduits; 1 for the new 15kV feeder, 2 for 15kV spares, and 1 for fiber optic cable in order to monitor both the pump house and new ground mounted switchgear. 2. One set of ground mounted 15kV outdoor switchgear at the Xcel demarcation point to be connected to one existing Xcel Energy 15kV line. Another spare switch will be installed for a future connection to the 2 nd Xcel Energy 15kV line. 3. One new 15kV copper feeder conductor from the Xcel demarcation point (new ground mounted switchgear) to the Mesa Lab main switchgear; completely installed, terminated and tested. 4. Removal of 1 pole and pole switches. The 2 nd pole will remain in place until the 2 nd (direct buried) 15kV feeder is replaced. 21. ADDITIONAL The 2 nd 15kV (direct buried) feeder will not be replaced on this project. Either a planned replacement will occur when funds become available or it will be allowed to fail and then replaced. Either option is acceptable once the new feeder is installed. During this project, the intent is not to disturb the 2 nd feeder in any way, so as not to initiate premature failure. Page 2
PROJECT DETAI 1. PROJECT NAME 2. UCAR TRACKING NUM. REPLACE OBSOLETE 15KV POWER FEEDS NSF07ML001 BACKGROUND Electrical power to the Mesa Lab is delivered from Xcel Energy via two 13,200 volt electrical lines (also referred to as 15kV lines). The two electrical feeds begin at the same substation which Xcel calls their NCAR Substation. It is located east southeast of the Mesa Lab at the bottom of the hill near the residential areas. A combination of underground and overhead lines, owned by Xcel Energy, bring power through the residential areas to the east and around to an area north of Mesa Lab, at the bottom of a deep ravine, we refer to as the Pump House area. At this location is where Xcel Energy s responsibility for power feeder care ends and NCAR s begins. As a side note, the Xcel Energy feeders serve NCAR, the NOAA Campus to the north, the NIST campus to the north, and a large section of residential areas to the east. Much of the lines through residential areas are above ground with large trees very near the lines. Several residents do not allow trimming of their trees thus several outages each year can be attributed to wind and snow loads forcing trees against the main power lines feeding the Mesa Lab. At the Xcel Energy demarcation point, NCAR owns two poles and their associated switching equipment. Figure 1 illustrates typically how each appears in relation to the Xcel demarcation point, though the older original pole is not shown in this photo. The original older pole, equipment and cables were installed in 1965 when the building was built (~42 years old). The original work included a concrete ductbank from near the pole up to the Mesa through a series of manholes. Later, when the supercomputing computer room was built, around 1985, the second directburied feeder was installed to the right of the existing ductbank (~22 years old). The spare conduits in the old ductbank were unusable. The existing switching poles are rotted and there is concern that pulling on the pole mounted cutouts may cause the entire crossarm structure to fall. Contractors have been requested to repair the pole equipment but all have advised against it, citing that any work on the equipment could permanently damage the feeder cables and equipment, thus leaving the Mesa with a useless feeder. Both 15kV feeder cables to the Mesa Lab are well past their predicted lives. There is concern that one, or both, electrical feeders could fail anytime in the near future. Work to replace them will likely take several months. Figure 1 Xcel/ NCAR Poles PROPOSED SOLUTION The proposed solutions put forth by UCAR Engineering are conceptual and primarily based on experience and what is known today. The final design solution could be different in concept, cost and schedule. 1. Install a new ductbank over the old ductbank. It will save cost by installing new ductbanks and cables in the same area as the originals. Any digging outside this predug zone will likely result in problems digging through granite rock. (See Figure 2 15kV Route) The old ductbank cannot be used. The ductbank sleeves are Orangeburg conduits and have swelled shut. Orangeburg conduits are asbestos containing material so trying to drill through or rout out the old conduits would be expensive and hazardous. The old ductbank may be deep enough to place a new one directly on top thereby using the existing manholes. The old ductbank would be sealed and abandoned. This scenario can be performed with both feeders hot. During construction the oldest feeder, also the one being built upon, would be turnedoff for safety. The building would continue to operate on the other feeder. Each evening the feeder would be reenergized to provide redundant feeds to the building. The entire new feeder can be installed with only a brief outage for final terminations on each end. Page 3
PROJECT DETAI 1. PROJECT NAME 2. UCAR TRACKING NUM. REPLACE OBSOLETE 15KV POWER FEEDS NSF07ML001 If it is not possible to build over the existing duct bank, then significant work would be required to install the feeders directly adjacent to the old ductbank, again trying to avoid excavating new granite filled ground. The new ductbank would contain extra conduits; one for the 2 nd feeder replacement which would occur once the direct bury cable fails. A second spare would be installed for a future wire pull and if one of the other two were damaged and unusable. An additional small conduit would also be installed for fiber optic cable to the new switchgear and pump house for monitoring system connections. Figure 2 15kV Route 2. The poles and associated equipment at the Xcel demarcation point would be converted from pole mounted equipment to ground mounted switching equipment, for safety and ease of use. The new ground mounted gear configuration would be for two 15kV feeds from Xcel Energy out to two feeds to the Mesa Lab. Additionally, there would be a feed/switch to the pump house. The pump house should be able to get its power from either main feeder. A manual switch would allow the enduser to select either 15kV feeder. In the past, we have lost the one 15kV feeder feeding the pump house for long periods of time. There was concern that a) the water tank would run dry and thus the Mesa Lab would not have fire suppression, and b) the pump house would freeze and break the supply lines to the water tank, again leaving the Mesa without water. Without water the Mesa Lab would have to be closed. 3. While work is being done on the old manholes (used for the new ductbank) it is proposed we add gravity drains to each manhole. Currently, manholes fill with ever present ground water. Water has a tendency to degrade power lines. In the past, sump pumps were placed in the manholes and would keep them dry. Since then the sump pumps have failed and the manholes are continuously filled. While the manholes are being excavated, a simple core drill and drain pipe could be installed to allow any water accumulation to be drained downhill (to the east side of the access road). A better, simpler solution. 4. Possible Risks: The existing 15kV ductbank lies next to the access road. Just to the right of this 15kV ductbank is a fiber optic and communications ductbank. Just to the right of that is the direct buried 15kV power line. Damage could occur to one or all of these systems during construction. PREDECESSORS/ SUCCESSORS The ductbank work should occur before any repaving of the Mesa Lab access road. Installing the new 15kV ductbank is likely to damage the existing road edge. Another fund request to the NSF is, Replace the Pump House Switchgear. The pump house connects to the 15kV feeder pole that is to be replaced on this package. This means the old wire from the 15kV service point to the pump house would have to be replaced. While the pump house is down, the main transformer and pump house gear could easily be replaced. The new transformer and gear would be safer than the old equipment. At a minimum, this project and the replace obsolete pump house gear project should be designed together so the final systems can work as an integrated unit. Page 4
PROJECT DETAI 1. PROJECT NAME 2. UCAR TRACKING NUM. REPLACE OBSOLETE 15KV POWER FEEDS NSF07ML001 COST ESTIMATE DETAIL (see attached) Estimate Assumptions: It is assumed an Electrical Contractor will self perform all work and no subcontractors will be used. The UCAR Staff will be required to review designs and to project manage the installation. Markups are included for their support. The old Orangeburg conduits are asbestos containing materials. An allowance is shown in case the old ductbank has to be disturbed and the old conduits removed. An allowance is shown for rocky soil conditions in case excavation must be done away from the existing ductbank routes. The surrounding soils are full of solid granite and boulders. Planning and Design costs include money for a) potholing the depth of the existing ductbank, and b) survey work. Potholing is required to see if a new ductbank can be constructed directly over the old ductbank and still meet code requirements for minimum depth of coverage over the new ductbank. PROJECT SCHEDULE (see attached) Schedule Assumptions & Details: The existing feeders are operational at the time of construction; not an emergency. Engineering drawings and estimates are completed one year prior to construction. The Contractor will procure the longlead switchgear and materials after winning the project bid. The 15kV Power Feed project and the Replace Pump House Gear and Transformer project are interrelated and design should be coordinated. Therefore, the pump house design will occur the same time as design for this work. Construction of the pump house electrical can either occur the same time as this project or separately. The schedule shown includes the pump house construction. A separate, standalone schedule is shown for the pump house should it be constructed separately. Underground work is scheduled to occur in spring or summer. A milestone is shown for underground work complete and the paving of the access road can begin, at this milestone date or later. Page 5
Job Title: Replace Obsolete 15kV Power Feeds Conceptual Design/ Study PPS Project No.: NSF07ML001 08/17/07 Estimate Summary Contractor Install Material Labor Equip Total Markups to Roll Markup Amt For Totals for Description Qty Unit $ $ $ $ % of Subtotal Into Base Items Each Base Item New Totals NSF Sheet Electrical Demolition $10,189 $80,547 $6,944 $97,680 17% $61,300 $158,980 $159 Pad Mounted Switches $160,378 $16,869 $2,464 $179,711 31% $112,780 $292,491 $292 Feeder Ductbank and Cables $152,855 $95,884 $47,984 $296,722 52% $186,213 $482,935 $483 Subtotal $323,422 $193,300 $57,391 $574,113 100% $360,294 $934,406 $934 Subcontractor Material Markup 10% $32,342 $32,342 $32,342 ubcontractor Labor Overhead and Profit 56% $108,248 $108,248 $108,248 Subcontractor Equipment Markup 10% $5,739 $5,739 $5,739 Price w/ Subcontractor Markups $355,764 $301,548 $63,130 $720,442 General Contractor Markup on Sub 0% $0 $0 $0 $0 $0 Bond 2.5% $8,894 $7,539 $1,578 $18,011 $18,011 Permit 0.0% $0 $0 $0 $0 $0 Price w/ Contractor Markups $364,658 $309,087 $64,708 $738,453 UCAR Overhead (on 1st $25K per year) 50.9% $12,725 $12,725 Contractor w/ UCAR OH $751,178 A/E design fees 12% $88,614 $88,614 $89 UCAR Overhead (on 1st $25K per year) 50.9% $12,725 $12,725 AE Fees w/ UCAR OH $101,339 Traffic services 0 ls $0 $0 $0 Doc Furniture relocation fees ea $1,200 $0 $0 NETS plates/services 0 ea $1,500 $0 $0 Maintenance Support ls $0 $0 $0 $0 $0 Price w/ UCAR Costs $852,517 Budget Contingency 20% $170,503 $170,503 Allowance for Asbestos Mitigation $25,000 $25,000 $25 Allowance for Rocky Soil Conditions $84,000 $84,000 $84 Estimated Construction Project Cost $1,132,021 $360,294 $1,132,021 $1,132 Sum of Markups Check Total NSF Total Inflation Rate 5.0% Design Construct Allowance Total Original 2007 Values + Inflation Replace (1) 15kV Feeder and Pole Mounted Switches 2007 $89 $934 $109 $1,132 Values highlighted in green and bold outline are used on NSF Request form 2008 +1 yr $981 $114 $1,095 2009 +2 yr $1,030 $120 $1,150 2010 +3 yr $1,082 $126 $1,208 2011 +4 yr $1,136 $132 $1,268 2012 +5 yr $1,193 $139 $1,332 2013 +6 yr $1,252 $146 $1,398 2014 +7 yr $1,315 $153 $1,468 2015 +8 yr $1,381 $161 $1,542 2016 +9 yr $1,450 $169 $1,619 2017 +10 yr $1,522 $178 $1,700 Page 1 8/17/2007 NSF07ML001 COSTEST 15kV Feeder Replacement.xls
May September January May September January May Se ID Task Name Duration Start 5/6 6/24 8/12 9/30 11/18 1/6 2/24 4/13 6/1 7/20 9/7 10/26 12/14 2/1 3/22 5/10 6/28 8/16 1 15kV Feeder Replacement 472 days Fri 9/28/07 2 Design Funds Received from NSF 0 days Fri 9/28/07 3 A/E Bids/ Award 6 wks Fri 9/28/07 4 A/E Design 2 mons Fri 11/9/07 5 Construction Funds Received from NSF 0 days Tue 9/30/08 6 Construction Bids/ Award 2.5 mons Tue 9/30/08 7 Procure longlead materials 5 mons Tue 1/6/09 8 Underground ductbank 2 mons Tue 3/31/09 9 Access road paving can begin 0 days Mon 5/25/09 10 Ground mounted 15kV primary switches 1 mon Tue 5/12/09 11 15kV cable install & test 3 wks Tue 6/9/09 12 Energize 0 days Mon 6/29/09 13 O&M Manuals/ Closeout 3 wks Tue 6/30/09 14 15 Pump House Gear & Xfmr 105 days Tue 2/3/09 16 Procure longlead materials 3 mons Tue 2/3/09 17 Replace pump house gear & xfmr 4 wks Tue 6/2/09 9/28 9/30 5/25 6/29 Title: Replace Obsolete 15kV Power Feeders Project: NSF07ML001 Date: Fri 8/17/07 Task Split Progress Milestone Summary Project Summary External Tasks External Milestone Deadline Page 1