Cynergy Electric

Scope Of Work

Cynergy was awarded an $11,184,628 contract to provide 480 volt switchgear, bus-duct, network protectors and transformer replacements at the Rayburn House Office Building for the Architect of the Capitol in four below ground electrical vaults. The project was completed in March of 2013. The nature of the building’s occupants required a high level of security. All vehicles and contents were subject to clearance, inspection and identification procedures conducted by the United States Capitol Police. All personnel were subject to a security background investigation. The project required all outages to be performed during work hours that would not interfere with the building occupants. There were complex rigging requirements to deliver the new transformers to below ground vaults and to deliver switchgear to second floor electrical rooms. The existing transformers were considered hazardous because they had traces of PCB which requires a high level of knowledge and skill for proper handling. Complex crane plans were developed and approved prior to any work. All work to install the bus-duct had to be performed on the weekends because it was installed in an active parking garage.

Principle features of the project in each (4 total) electrical vault were as follows;

• Replace 4000 amp 480 volt switchgear including draw-out breakers
• Replace 4-1000KVA 13.8KV-480 volt Silicone filled network type transformers
• Dispose of existing transformers as per EPA requirements for PCB contamination
• Replace 4-1600 amp 480 volt network protectors and disconnect switches
• Relocate and connect 15,000 volt primary feeders to the four network transformers
• Replace a 800 amp switchboard with a new 1200 amp 480 volt switchboard in the garage
• Replace 930 feet of 1350 amp aluminum bus with 1200 amp copper bus in the East and West garage
• Replace 4 runs of 2000 amp 480 volt bus between the network disconnects and switchgear
• Install a new 800 amp 480 volt panelboard and relocate various feeders
• Provide architectural and structural demolition and modifications including concrete pads, floors, walls and door hardware replacements
• Provide new HVAC and ventilation equipment for the switchgear room and transformer vault
• Provide upgrades and modifications to the existing building management systems (BMS)
• Provide asbestos floor abatement for the demolition of vinyl tile mastic
• Paint the transformer vault floor with clear epoxy
• Provide mechanical demolition and modifications, including piping, ventilation equipment, ductwork, controls, wiring and accessories for the equipment

Phased outages were required for the installation of the new switchgear and transformer equipment. An existing block wall had to be removed to accommodate the new switchgear location. The new switchgear was installed in a different location and phased outages were required to transfer loads from the old switchgear to the new. The switchgear had to be delivered to the site in sections on a weekend and rigged through a second floor window into the switchgear vault and assembled. The existing PCB contaminated transformers were removed from the building during after hours to minimize the exposure to personnel. An industrial hygienist was on site monitoring asbestos and PCB remediation activities. The switchgear and transformers were connected to the customer’s monitoring system.

New 2000 amp bus-duct was installed between each network transformer disconnect and the new switchgear. New 1200 amp bus-duct was installed from the new switchgear to the garage switchboard.

Miscellaneous installation items included; fire alarm system, lighting, control circuits and low voltage circuits to the HVAC equipment and fans, etc. A new temperature control system was provided for the HVAC equipment (BMS).

Commissioning and field testing was a large component in the project. Third party testing was provided for all medium voltage equipment, bus duct and cables. Factory field services were provided for the hands on training, classroom training and operation and maintenance manuals were provided for all operational systems.