National Science Foundation
University Corporation for
Atmospheric Research
FACILITY NAME & LOCATION
3.
NCAR – Mesa Lab
Boulder, Colorado
5.
PROJECT NAME
4.
UCAR TRACKING NUM.
15KV FEEDER REPLACEMENT
NSF07-ML001
INVESTMENT CATEGORY
6.
New Program
Cost Improvement
7.
(NSF USE ONLY)
Funds Request
Boulder, Colorado
2.
1.
TECHNICAL LEAD
Expansion
Environmental
TELEPHONE
David Patterson
(303) 497-8507
8.
Replace Obsolete
Other (explanation)
UCAR POINT OF CONTACT
01/31/2007
MM/DD/YYYY
TELEPHONE
Jeff Reaves
DATE SUBMITTED
Energy Savings
(303) 497-8890
9.
(REV. NUM.) & DATE
10. * UCAR PRIORITY
(2) 08/17/2007
9
10. * UCAR PRIORITY: 25 = CRITICAL 1 = LESS IMPORTANT
COST ESTIMATES
11.
ITEM
12.
U/M
13.
QUANTITY
14.
15.
UNIT COST
COST ($000)
$89
Amount requested for 2007.
-
LS
-
Construction Costs
LS
-
-
$981
Allowances: Rocky Soil Conditions & Asbestos Abatement
LS
-
-
LS
-
-
$114
_______
$1,095
-
-
-
$1,150
$1,208
$1,268
$1,332
$1,398
Planning & Design Costs in 2007 dollars:
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
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 metal-clad 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 cut-out 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
National Science Foundation
University Corporation for
Atmospheric Research
FACILITY NAME & LOCATION
NCAR – Mesa Lab
Boulder, Colorado
(NSF USE ONLY)
4.
UCAR TRACKING NUM.
Funds Request
Boulder, Colorado
2.
1.
3.
PROJECT NAME
15KV FEEDER REPLACEMENT
NSF07-ML001
19. ALTERNATIVE SOLUTIONS CONSIDERED
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 long-term, 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 re-line the old ductbank conduits. Reason for rejecting: It is not a common
technology for electrical conduits to be re-lined 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 2nd 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 2nd pole will remain in place until the 2nd (direct buried) 15kV feeder is
replaced.
21. ADDITIONAL
The 2nd 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 2nd feeder in any way, so as not to initiate premature failure.
Page 2
1.
PROJECT DETAILS
PROJECT NAME
2.
REPLACE OBSOLETE 15KV POWER FEEDS
UCAR TRACKING NUM.
NSF07-ML001
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.
Figure 1 - Xcel/ NCAR Poles
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 direct-buried 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 cut-outs may cause the entire cross-arm 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.
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 pre-dug 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 turned-off for safety. The building would continue to operate on the other feeder. Each evening the
feeder would be re-energized 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
1.
PROJECT DETAILS
PROJECT NAME
2.
REPLACE OBSOLETE 15KV POWER FEEDS
UCAR TRACKING NUM.
NSF07-ML001
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 2nd 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 end-user 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
1.
PROJECT DETAILS
PROJECT NAME
REPLACE OBSOLETE 15KV POWER FEEDS
2.
UCAR TRACKING NUM.
NSF07-ML001
COST ESTIMATE DETAIL - (see attached)
Estimate Assumptions:
• It is assumed an Electrical Contractor will self perform all work and no sub-contractors 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 long-lead 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, stand-alone 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
PPS Project No.: NSF07-ML001
Estimate Summary - Contractor Install
Description
Qty
Electrical Demolition
Unit
Pad Mounted Switches
Feeder Ductbank and Cables
Subtotal
Subcontractor Material Markup
ubcontractor Labor Overhead and Profit
Subcontractor Equipment Markup
Price w/ Subcontractor Markups
10%
56%
10%
General Contractor Markup on Sub
Bond
Permit
Price w/ Contractor Markups
0%
2.5%
0.0%
Conceptual Design/ Study
08/17/07
Material
$
$10,189
Labor
$
$80,547
Equip
$
$6,944
Total
$
$97,680
% of Subtotal
$160,378 $16,869
$152,855 $95,884
$323,422 $193,300
$2,464
$47,984
$57,391
$179,711
$296,722
$574,113
$5,739
$63,130
$32,342
$108,248
$5,739
$355,764 $301,548
$32,342
$108,248
$5,739
$720,442
$0
$0
$8,894
$7,539
$0
$0
$364,658 $309,087
$0
$1,578
$0
$64,708
$0
$18,011
$0
$738,453
$0
$18,011
$0
$12,725
$751,178
$12,725
$32,342
$108,248
UCAR Overhead (on 1st $25K per year) 50.9%
Contractor w/ UCAR OH
A/E design fees
Markups to Roll
Markup Amt For
Into Base Items
Each Base Item
New Totals
NSF Sheet
17%
$61,300
$158,980
$159
31%
52%
100%
$112,780
$186,213
$360,294
$292,491
$482,935
$934,406
$292
$483
$934
$88,614
$89
$25,000
$84,000
$25
$84
12%
$88,614
UCAR Overhead (on 1st $25K per year) 50.9%
AE Fees w/ UCAR OH
$12,725
$101,339
$12,725
$0
$0
$0
$0
$852,517
$0
$0
$0
$0
$170,503
$170,503
Traffic services
Doc Furniture relocation fees
NETS plates/services
Maintenance Support
Price w/ UCAR Costs
Budget Contingency
0
ls
ea
0 ea
ls
$0
$0
$1,200
$1,500
$0
$0
20%
Allowance for Asbestos Mitigation
Allowance for Rocky Soil Conditions
$25,000
$84,000
Estimated Construction Project Cost
$1,132,021
Inflation Rate
Original 2007 Values + Inflation
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
Page 1
Totals for
$360,294
$1,132,021
$1,132
Sum of Markups
Check Total
NSF Total
5.0%
Design Construct Allowance
Total
Replace (1) 15kV Feeder and Pole Mounted Switches
$89
+1 yr
+2 yr
+3 yr
+4 yr
+5 yr
+6 yr
+7 yr
+8 yr
+9 yr
+10 yr
$934
$981
$1,030
$1,082
$1,136
$1,193
$1,252
$1,315
$1,381
$1,450
$1,522
$109
$114
$120
$126
$132
$139
$146
$153
$161
$169
$178
8/17/2007
$1,132
$1,095
$1,150
$1,208
$1,268
$1,332
$1,398
$1,468
$1,542
$1,619
$1,700
Values highlighted in green and bold outline are used on NSF Request form
NSF07-ML001 COSTEST - 15kV Feeder Replacement.xls
ID
1
Task Name
15kV Feeder Replacement
Duration
472 days
Start
Fri 9/28/07
0 days
Fri 9/28/07
6 wks
Fri 9/28/07
2
Design Funds Received from NSF
3
A/E Bids/ Award
4
A/E Design
5
Construction Funds Received from NSF
6
Construction Bids/ Award
7
Procure long-lead materials
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
105 days
Tue 2/3/09
3 mons
Tue 2/3/09
4 wks
Tue 6/2/09
2 mons
Fri 11/9/07
0 days
Tue 9/30/08
2.5 mons
Tue 9/30/08
5 mons
Tue 1/6/09
May
5/6
September
January
May
6/24 8/12 9/30 11/18 1/6 2/24 4/13 6/1
7/20
September
January
9/7 10/26 12/14 2/1
9/28
9/30
5/25
6/29
14
15
Pump House Gear & Xfmr
16
Procure long-lead materials
17
Replace pump house gear & xfmr
Title: Replace Obsolete 15kV Power Feeders
Project: NSF07-ML001
Date: Fri 8/17/07
May
Se
3/22 5/10 6/28 8/16
Task
Milestone
External Tasks
Split
Summary
External Milestone
Progress
Project Summary
Deadline
Page 1