7. SECTION 22 REHABILITATION OF TURBINE PIT PIPING AND PIPING SUPPORT.pdf

USIBWC Amistad Reservoir and Dam Turbine Pit Pipeline and Supports Corrosion Mitigation

Val Verde County, Texas

July 2020 USIBWC Solicitation

Rehabilitation of Turbine Pit Piping and Pipe Supports 22.05.10-Page 1

SECTION 22.05.10

REHABILITATION OF TURBINE PIT PIPING AND PIPE SUPPORTS

PART 1 - GENERAL

1.1 SECTION INCLUDES

Part 1 - General

1.1 Section Includes

1.2 Related Requirements

1.3 Reference Standards

1.4 Submittals

1.5 Measurement and Payment

1.6 General

1.7 General Work Procedure

1.8 Quality Control

1.9 Welding Qualifications

1.10 Material Delivery, Storage, and Protection

1.11 Cleanup

1.12 Warranty

Part 2 - Products

2.1 Piping Materials

2.2 Pipe Support Materials

2.3 Insulation Materials

2.4 Bolts and gaskets

2.5 Miscellaneous Piping Items

2.6 Source Quality Control

Part 3 - Execution

3.1 Piping Workmanship

3.2 Pipe Supports

3.3 Painting and coating

3.4 Field Quality Control

3.5 Cleaning, Adjustment, and Sterilization

3.6 Protection of Piping

--End of Section--

1.2 RELATED REQUIREMENTS

A. Section 09.90.00-Painting and Coating

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B. Section 09.97.13-Galvanizing

C. MWH now part of Stantec Report, “Amistad Powerhouse Final Inspection Report.”

D. Drawing Nos. M001 through M011

1.3 REFERENCE STANDARDS

A. Commercial Standards

1. AISC 325 D, “Steel Construction Manual, Fourteenth Edition, Allowable Stress Design;” (2011)

2. ANSI A 117.1, “Accessible and Usable Buildings and Facilities;” (2009)

3. ANSI Z535.1 “Safety Color Code” (2006, R2011)

4. ANSI/ASME A13.1, “Scheme for the Identification of Piping Systems” (2007)

5. ASME B1.1, "Unified Inch Screw Threads (UN and UNR Thread Form);" (2003, R2008)

6. ASME B1.20.1, “Pipe Threads, General Purpose (Inch);” (2013)

7. ASME B16.5, "Steel Pipe Flanges and Flanged Fittings (NPS ½ through NPS 24

Metric/Inch Standard);" (2013)

8. ASME B16.9, "Factory-Made Wrought Buttwelding Fittings;" (2012)

9. ASME B16.11, “Forged Steel Fittings, Socket-Welding and Threaded;” (2011)

10. ASME B16.18, "Cast Copper Alloy Solder-Joint Pressure Fittings;" (2012)

11. ASME B16.20, "Metallic Gaskets for Pipe Flanges – Ring Joint, Spiral-Wound and

Jacketed;" (2012)

12. ASME B16.21, "Nonmetallic Flat Gaskets for Pipe Flanges;" (2011)

13. ASME B16.22, "Wrought Copper and Copper Alloy Solder Joint Pressure Fittings;"

(2013)

14. ASME B16.24, "Case Copper Alloy Pipe Flanges and Flanged Fittings Classes 150, 300, 400, 600, 1500 and 2500;" (2016)

15. ASME B31.1, "Power Piping;" (2016)

16. ASME B36.19M “Stainless Steel Pipe.” (2004, R2005)

17. ASME PBVC Section IX. (2015)

18. ASTM A 53/A 53M-12, "Standard Specification for Pipe, Steel, Black and Hot-

Dipped, Zinc-Coated, Welded and Seamless;" (2012)

19. ASTM A 106/A 106M-12, "Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service;" (2012)

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20. ASTM A 126-04, “Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings;” (2004, R2014)

21. ASTM A 139/A 139M-16, "Standard Specification for Electric-Fusion (Arc)-Welded Steel Pipe (NPS in 4 in. and Over);" (2016)

22. ASTM A 148/A 148M-15A, “Standard Specification for Steel Castings, High- Strength, for Structural Purposes;” (2015)

23. ASTM A 167, "Standard Specification for Stainless and Heat-Resisting Chromium- Nickel Steel Sheet and Strip;" (1999, R2009)

24. ASTM A 182/A 128M-16A, "Standard Specification for Forged or Rolled Alloy and Stainless-Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High- Temperature Service;" (2016)

25. ASTM A 193/A 193M, "Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature or High-Pressure Service and Other Special Purpose Applications;" (2016)

26. ASTM A 194/A 194M-16A, "Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure and High-Temperature Service, or Both;" (2016)

27. ASTM A 216/A 216M, "Standard Specification for Steel Castings, Carbon, Suitable for Fusion Welding, for High-Temperature Service;" (2016)

28. ASTM A 276/A 276M-16A, "Standard Specification for Stainless Steel Bars and Shapes;" (2016)

29. ASTM A 307, "Standard Specification for Carbon Steel Bolts and Studs, 60,000 PSI Tensile Strength;" (2014)

30. ASTM A 312/A 312M-16A, “Standard Specification for Seamless, Welded and Heavily Cold Worked Austenitic Stainless Steel Pipe;” (2016)

31. ASTM A 351/A 351M, "Standard Specification for Castings, Austenitic;" (2016)

32. ASTM A 376/A 376M, Type 304L and 316L “Seamless Austenitic Steel Pipe for

High-Temperature Service.” (2014)

33. ASTM A 403/A 403M, “Standard Specification for Wrought Austenitic Stainless

Steel Piping Fittings,” (2016)

34. ASTM A 572/A 572M, “Standard Specification for High-Strength Low-Alloy

Columbium-Vanadium Structural Steel;” (2015)

35. ASTM A 582/A 582M-12E1, "Standard Specification for Free-Machining Stainless and Steel Bars;" (2012)

36. ASTM A743/A 743M-13AE1, "Standard Specification for Castings, Iron-Chromium, Iron-Chromium-Nickel and Corrosion-Resistant for General Application;" (2013)

37. ASTM A 744/A 744 M, "Standard Specification for Castings, Iron-Chromium-Nickel

Corrosion-Resistant for Severe Service;" (2013)

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38. ASTM B 21/B 21M, "Standard Specification for Naval Brass Rod, Bar, and Shapes;"

(2014)

39. ASTM B 32, “Standard Specification for Solder Metal;” (2008, R2014)

40. ASTM B 42-15A, “Specification for Seamless Copper Pipe, Standard Sizes.” (2015)

41. ASTM B 43, "Standard Specification for Seamless Red Brass Pipe, Standard Sizes;"

(2015)

42. ASTM B 62, "Standard Specification for Composition Bronze or Ounce Metal

Castings;" (2015)

43. ASTM B 88, "Standard Specification for Seamless Copper Water Tube;" (2016)

44. ASTM B 828, “Standard Practice for Making Capillary Joints by Soldering of Copper and Copper Alloy Tube and Fittings;” (2016)

45. ASTM D2240, “Standard Test Method for Rubber Property-Durometer Hardness;”

(2015)

46. ASTM D412, “Standard Test Methods for Vulcanized Rubber and Thermoplastic

Elastomers-Tension;” (2016)

47. ASTM D 6439, “Standard Guide for Cleaning, Flushing, and Purification of Steam, Gas, and Hydroelectric Turbine Lubrication Systems;” (2011)

48. AWS D1.1/D1.1M, "Structural Welding Code-Steel;"(2015)

49. AWWA C207, “Standard for Steel Pipe Flanges for Waterworks Service – sizes 4 in.

through 144 in.” (2013)

50. AWWA C208, “Standard for Dimensions for Fabricated Steel Water Pipe Fittings.”

(2012)

51. IBC, “International Plumbing Code;” (2015)

52. MSS SP-6, "Standard Finishes for Contact Faces of Pipe Flanges and Connecting-

End Flanges of Valves and Fittings;" (2012)

53. MSS SP-55, "Quality Standard for Steel Castings for Valves, Flanges and Fittings and Other Piping Components - Visual Method for Evaluation of Surface Irregularities;" (2011)

54. SSPC-SP 1, "Solvent Cleaning;" (2016)

55. SSPC-SP 5, “White Metal Blast Cleaning;” (2007)

56. SSPC-SP 10, “Near White Blast Cleaning.” (2007)

1.4 SUBMITTALS

A. Submittals shall be transmitted by the Contractor in accordance with the requirements of the PWS. The Contractor shall be responsible for certifying that all submittals are in compliance with the Contract requirements.

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B. Submittals shall include the following information and be submitted at least 30 days prior to the execution of Work on site:

1. Contractor shall submit complete shop drawings and certificates, shop and field test procedures, installation instructions, operating and maintenance instructions, parts lists, and warranty information of all piping and piping supports.

2. Contractor shall submit as part of the shop drawings a statement from the pipe fabricator certifying that all pipes will be fabricated subject to a recognized Quality Control Program. An outline of the program shall be submitted for review prior to the fabrication of any pipe.

3. Copies of all shop inspection records and certified copies of all test reports, including complete test data, shall also be submitted.

4. The Contractor shall submit statement of the origin, composition and manufacture of materials to show that all materials meet the Buy American Act.

1.5 MEASUREMENT AND PAYMENT

The work performed by the Contractor under this Section shall not be paid for directly, but shall be included in the various Bid Items under this Contract.

1.6 GENERAL

In accordance with the Specifications contained in this Section and as shown on the Drawings, or as directed, the Contractor shall perform the Work described below. The scope described below represents the work for a single turbine unit, but this scope shall be applied to both Units 1 and 2 turbines.

A. General Requirements:

1. All mechanical work shall conform to the applicable requirements of the AISC Manual, ASME B31.1, and the IBC International Plumbing Code. The type of piping material used in the various piping systems throughout the Project shall be as shown on the Drawings. The use or incorporation of materials containing asbestos or lead is prohibited.

B. Turbine Pit Piping Corrosion Scope of Work: The Work for the turbine pit piping shall consist of cleaning corrosive product and removing all paint from the exterior surface of the piping, surface preparation and repainting of the exterior surface of the piping.

1. The existing 3” and 4” depression piping (steel) inside the turbine pit only shall be cleaned from rust and all paint on the exterior surfaces shall be removed (total length of 3” pipe in each turbine pit is approximately 21 feet). The base layer red primer that is to be removed contains lead. See Section 09.90.00.

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2. The exterior surface of the 3” and 4” depression piping shall be prepared for painting and repainted. See Section 09.90.00.

3. All copper piping located inside the turbine pit below the turbine pit walkway at El.

885.67 shall be cleaned from rust and all paint on the exterior surfaces shall be removed. The base layer red primer that is to be removed contains lead. See Section

09.90.00 for details of lead paint abatement. The copper piping includes:

a. Existing 2” copper piping for runner seal cooling water supply, total length of copper pipe in each turbine pit is approximately 82 feet.

b. Existing 1½” copper piping for bearing cooling water discharge, total length of copper pipe in each turbine pit is approximately 82 feet.

c. Existing 1½” copper piping for bearing cooling water supply, total length of copper pipe in each turbine pit is approximately 82 feet.

d. Existing 1½” copper piping for packing box sealing water supply, total length of copper pipe in each turbine pit is approximately 82 feet.

e. Existing 1“copper piping for runner seal cooling water supply, total length of copper pipe in each turbine pit is approximately 82 feet.

f. Existing 1½” copper piping for bearing lubricating oil supply, total length of copper pipe in each turbine pit is approximately 98 feet.

g. Existing 1½” copper piping for bearing lubricating oil return, total length of copper pipe in each turbine pit is approximately 98 feet.

4. The exterior surface of the 1½” and 2” copper piping shall be prepared for painting and repainted. See Section 09.90.00 for painting specifications.

5. Limited corrosion mitigation work is required for gate servomotor piping, instrumentation piping, grease piping and gage tubing located inside each turbine pit as indicated on the drawings.

C. Turbine Pit Piping Support Corrosion Scope of Work: The Work for the turbine pit pipe supports shall consist of removing all existing turbine pit pipe supports and procuring, installing, and electrically isolating new steel pipe supports for all existing turbine pit pipe supports below the turbine pit walkway. The pipe supports included in this section consist only of those located below the turbine pit walkway for the piping lines as indicated on the drawings.

1. As a minimum, five (5) pipe supports for 3” steel depression line in each turbine pit shall be replaced as shown on the Drawings.

2. As a minimum, eighteen (18) pipe supports for 1½’ and 2” copper lines in each turbine pit shall be replaced as shown on the Drawings.

3. All existing pipe supports above turbine walkway will not require replacement supports and shall be cleaned and provided with touchup painting.

D. Turbine Pit Piping Flushing Scope of Work: All copper piping located in turbine pit shall be flushed clean. Flushing shall be done before new stainless steel flow meters are

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22.05.10-Page 7 installed in water lines to allow collection of sediments accumulated in the lines upstream of the flow meters into special collection pans provided by the Contractor for flushing.

E. Turbine Pit Piping Section Replacement: Four copper piping sections in each turbine pit shall be replaced with a new stainless steel piping. The Contractor shall re-install existing stainless steel orifice plates between the new stainless steel orifice flanges as shown on the drawings after flushing of the lines is completed.

1. Piping and flow meter orifice flanges size is 1½”. See drawing number M-003 for details.

F. Acceptable Suppliers: The Suppliers shall be in the business of supplying similar equipment for no less than 15 years and shall have at least 5 working installations for not less than 10 years. The supplier shall be subject to the confirmation of compliance of the COR. Documentation verifying the above shall be submitted with the supply bid.

G. Coordination: It shall be the responsibility of the selected supplier to coordinate the design, fabrication, cleaning and repainting of the piping, pipe supports and accessories to match the existing piping layout and dimensions. To this effort, the Supplier is required to visit the Amistad Dam site for an inspection of the exiting piping installation in each turbine pit.

H. Equipment Description: For equipment description, see Subsection 2.

1.7 GENERAL WORK PROCEDURE

A. The following general work procedure shall work in conjunction with the detailed means and methods submitted for review and compliance confirmation by the Contractor (see Subsection 1.4.B):

1. The following items shall be performed by the Government prior to handing equipment over to the Contractor (See Section 01.11.00):

a. The units shall be dewatered;

b. The turbine pits shall be drained;

c. The turbine pit pipelines shall be drained;

d. Proper lock-outs/tag-outs shall be made;

2. The following items shall be performed by the Contractor, in addition to the detailed means and methods submitted for review and compliance confirmation:

a. The Contractor shall follow all applicable safety standards, including but not limited to those related to PPE, and work, ventilation and air circulation in a confined space.

b. The scope of Work associated with this Section shall be coordinated and scheduled appropriately with the scope of Work associated with Section 09.90.00.

c. Turbine pit piping surfaces shall be stripped of their paint and corrosion, prepared, and repainted, as specified in this Section and in Section 09.90.00.

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d. Turbine pit pipe supports shall be replaced, electrically isolated and painted, as specified in this Section.

e. Turbine pit piping shall be flushed, as specified in this Section.

f. Flow meter piping sections shall be replaced and commissioned prior to turning the equipment back over to the Government, as specified in this Section.

1.8 QUALITY CONTROL

A. Inspection: All pipe shall be required to pass visual inspection and Non Destructive Examination (NDE). During the manufacture of the pipe, Contractor shall make all inspections necessary to confirm compliance with the Specifications.

B. Tests: Except where otherwise indicated, all materials used in the manufacture of the pipe shall be tested in accordance with the applicable specifications and standards. Welds shall be tested as indicated. Perform all tests at no additional cost to the Government.

C. Welding Requirements: All welding procedures used to fabricate pipe shall be prequalified under the provisions of ANSI/AWS D1.1. Welding procedures shall be required for, but not necessarily limited to, longitudinal and girth or spiral welds for pipe cylinders, spigot and bell ring attachments, reinforcing plates and ring flange welds, and plates for lug connections.

D. Welder Qualifications: All welding shall be done by skilled welders, welding operators, and tackers who have had adequate experience in the methods and materials to be used.

Welders shall be qualified under the provisions of ANSI/AWS D1.1 by an independent local, compliance confirmed testing agency not more than 6 months prior to commencing Work on the pipeline. Machines and electrodes similar to those used in the Work shall be used in qualification tests. Furnish all material and bear the expense of qualifying welders at no increased cost to the Government.

1.9 WELDING QUALIFICATIONS

All welders and welding operators assigned to the work shall have passed a qualification test conforming to the AWS "Standard Qualification Procedure" for structural welders and ASME B31.1 for piping welders. If at any time, in the opinion of COR, the work of any operator appears questionable, such operator shall be requalified. All test plates and all welding electrodes required for making the qualification tests shall be furnished in accordance with the requirements of the applicable ASME Codes.

1.10 MATERIAL DELIVERY, STORAGE, AND PROTECTION

All piping materials, fittings, valves, and accessories shall be delivered in a clean and undamaged condition and stored off the ground, to provide protection against oxidation caused by ground contact. All defective or damaged materials shall be replaced with new materials.

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1.11 CLEANUP

After completion of the Work, all remaining pipe cuttings, joining and wrapping materials, and other scattered debris, shall be removed from the site. The entire piping system shall be handed over in a clean and functional condition.

1.12 WARRANTY

The warranty on all equipment described in this Section shall be as specified in the General Conditions.

PART 2 - PRODUCTS

2.1 PIPING MATERIALS

A. General: Piping materials used in the various piping systems shall be as shown on the

Drawings and shall conform to the requirements specified hereinafter.

B. Pipe flanges and flanged fittings shall conform to ASME B16.5.

C. Seamless and welded austenitic stainless steel pipe shall conform to any standard listed herein: ASTM A 312/A 312M, Type 316L.

D. Wrought austenitic stainless steel piping fittings shall conform to any standard listed herein: ASTM A 403/A 403M, Type 316L.

E. Forged stainless steel fittings, butt weld, socket-weld and threaded shall conform to ASTM A 182/A 182M, Type 316 for threaded, Type 316L for socket-welded.

F. Soft annealed stainless steel tubing shall conform to any standard listed herein: ASTM A

269 or ASTM A 213, Grade TP316.

G. Pipe flanges shall conform to AWWA C207, Class B, ASTM A516, grade 70, ASTM

A105, ASTM B21/B21M, ASTM B32, ASTM B42, ASTM B43, ASTM B62, ASTM

B88, or ASTM B828.

2.2 PIPE SUPPORT MATERIALS

A. General: The Contractor shall be responsible for fabrication and installation of all pipe supports. Pipe supports shall be similar to the existing supports and shall be subject to the COR’s compliance confirmation. All interior piping supports inside each turbine pit shall accommodate existing piping locations and shall reuse existing anchoring provisions to the maximum extent possible. Existing concrete inserts for hanging and support of the existing pipe shall be cleaned from rust under this Specification. All materials not galvanized shall be prime painted before installation and finish painted after installation as per Section 09.90.00. All support components shall be designed, fabricated, and installed in general conformance with Sections 120 and 121 of ASME B31.1.

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B. Materials: Supports at or above elevation 880’ shall be steel hot-dip galvanized after fabrication and shall be compatible to be installed and mounted to the existing wall pipe support inserts. Supports below elevation 880’ shall be steel epoxy coated after installation and shall be compatible to be installed and mounted to the existing wall pipe support inserts.

2.3 INSULATION MATERIALS

A. At each location where a pipe passes through a pipe support, the full circumference of the pipe shall be wrapped with 1/8” neoprene sheet. The neoprene gasket shall be 1/8” thick, black with a typical hardness value of 60, minimum tensile strength of 820 psi, per ASTM D2240 and ASTM D412.

B. Insulating unions shall be provided at all points where pipes of dissimilar metals are connected. Unions used between dissimilar metals shall be capable of separating metals in a manner which will prevent the passage of more than 1% of the galvanic current which would exist with metal-to-metal contact. Union connectors shall be of the same material as the piping to which attached. Pressure and temperature rating shall be no lower than those of the piping system in which installed. Unions shall be provided with molded bushing insulation and Buna-N gaskets. The Buna-N gaskets shall be commercial grade, durometor (shore A) hardness value of 60, minimum tensile strength of 1000 psi, per ASTM D2240 and ASTM D412.

C. Flange insulating kit for an exposed flange mating to an embedded flange shall have dielectric strength of 400 VPM and consist of one type E full faced, neoprene faced phenolic gasket, and one integral Mylar sleeve with attached washer, and one stainless steel washer per bolt, suitable for use with ANSI and/or AWWA flange joints as applicable.

2.4 BOLTS AND GASKETS

A. All bolts and nuts shall be of similar material to the material of the flange, pipe support brackets, and pit liner welded support plates, unless otherwise noted in the Contract Documents. An insulating material as specified in this Section shall be provided to isolate the dissimilar materials.

B. Stainless steel bolts, all pressures, shall be threaded full length, conforming to ASTM A

193, Grade B8, Class 2; hexagonal nuts shall conform to ASTM A 194/A 194M, Grade 8, threaded in accordance with ASME B1.1, Class 2A external threads and Class 2B internal threads. Gaskets shall be of commercial grade black neoprene material, 60 Durometer, and shall conform to the requirements of ASME B16.21.

C. Galvanized and epoxy coated bolts, studs, nuts and screws shall conform to ASME standard thread forms and dimensions.

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2.5 MISCELLANEOUS PIPING ITEMS

A. Orifice Plates shall be paddle type, for installation between Class 150 flanges, pipe sizes and orifice sizes as shown on the Drawings, Type 304 stainless steel.

B. Pipe line stickers shall comply with ANSI/ASME A13.1 2007 “Scheme for the

Identification of Piping Systems” and be installed as required at the same exact location where existing pipe line stickers were located. Pipe markers shall conform to ANSI Z535.1 “Safety Color Code” and shall have the same color as the existing pipe line stickers.

2.6 SOURCE QUALITY CONTROL

A. Each item of the equipment shall be shop assembled and tested to verify that all parts function properly and that no interference occurs in the moving parts. Any error in alignment or fit-up discovered during assembly shall be corrected. All shop test procedures shall be compliance confirmed by COR prior to testing.

B. Written verification shall be provided that all piping materials furnished comply with the specified materials.

C. Size and dimensions of all replaced piping supports shall be the same as the existing pipe supports.

D. New steel supports shall be hot-dip galvanized after fabrication.

E. The qualification welding procedures, of welders, and of welding operators shall conform to standards at least equal to Section IX of the ASME “Boiler and Pressure Vessel Code”.

The Contractor shall provide copies of the weld procedures and weld procedure qualification tests along with copies of the qualification test results to the COR. The welders and welding operators shall be qualified in the position and progression to be used. Certificates of welders’ qualifications shall be maintained by the Contractor and furnished to the COR upon request. Contractor shall replace any welder or welding operator deemed unacceptable by the COR.

PART 3 - EXECUTION

3.1 PIPING WORKMANSHIP

A. General: All permanent exposed piping, including pipe and fittings, valves, hangers, insulation, expansion joints, anchors and guides where required, and special supports not otherwise specifically provided for in these specifications but necessary to complete the various systems shall be installed. The work shall conform to the requirements of the standards listed in Subsection 1.3; to the applicable local codes; and to the requirements and codes specified herein. Pipe shall be cut accurately to dimensions established at the

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Site and shall be worked into place without springing or forcing. Where location is not exactly shown by detailed dimensions, pipe shall be installed as closely as possible to walls, ceilings, columns, etc., so as to occupy the minimum of space. Piping shall be run parallel with the lines of the structure, unless otherwise distinctly shown or noted on the Drawings. Proper allowance shall be made for expansion and contraction of pipe, whether or not such provision is shown on the Drawings. The Contractor shall route all piping as shown on the drawings to the maximum extent possible.

B. Flanged and Welded Pipe: Flanged joints shall be made up with undamaged gaskets, and all bolts shall be torqued as required. Welded joints shall be fabricated in accordance with the applicable sections of ASME B31.1. Intersections and changes in direction shall be made with welded fittings unless bends or mitered joints are specifically shown on the Drawings.

C. Coordination With Other Work: All piping work shall be coordinated with other work inside the turbine pit so that all items may be installed in the most direct and workmanlike manner and so that interference between existing piping, ducts, equipment, cable trays, lighting, and architectural and structural features will be avoided.

3.2 PIPE SUPPORTS

A. The type of pipe supports necessary for properly securing all piping shall be as required for proper fastening. At each location where the pipe passes through a pipe support, the full circumference of the pipe shall be wrapped with 1/8” neoprene sheet. This applies to all support types. The spacing of the pipe supports shall be identical to the current spacing of supports as the new pipe supports will be replacing the current supports. The locations of the pipe supports for each unit are shown on the Drawings.

3.3 PAINTING AND COATING

Painting and coating of the existing and new piping, and all pipe supports in each turbine pit shall be in accordance with Section 09.90.00.

3.4 FIELD QUALITY CONTROL

A. General: Details of methods of testing the various piping systems are given hereinafter.

In general, all new piping sections installed within the existing piping shall be hydrostatically tested at 150% of design working pressure after flushing operations are completed, unless otherwise specified herein, and compliance confirmed before acceptance. Sections which have been found satisfactory need not be retested after completion of the entire system unless so directed. Should the tests indicate leakage or any other defect, acceptable repairs or replacement shall be made. Air tests shall take into account changes in temperature and atmospheric pressure during the test. Before any tests are undertaken, the COR shall be notified so that such tests may be witnessed by them or their authorized representative. A minimum of two weeks’ notice in advance of any tests shall be given. All field test procedures shall be compliance confirmed by the

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COR prior to testing. All tests shall be conducted in such manner that gauges, pressure switches, or other appurtenances will not be damaged. All equipment and test piping required to make complete tests shall be furnished. Tests for all piping shall conform to ASME B31.1. All pressure gauges shall be calibrated within 30 days of the test, or as directed by the COR. All field test procedures shall be compliance confirmed by the COR prior to testing. A record of all pressure gauges and their associated calibration reports shall be maintained. The record and reports shall be made immediately available to the COR.

B. Raw Water, Service Water, Depression, and Miscellaneous Water Piping: This piping shall be subjected to a hydrostatic test for a period of not less than one hour at 225 psi, and shall indicate no loss of pressure for the duration of the test. During the test, each joint shall be examined carefully for evidence of leakage. Flanged joints and soldered joints shall be drawn up securely; if leakage continues, the gasket shall be replaced.

Defective welds causing leakage shall be removed and rewelded and epoxy lining shall be repaired. All welded joints shall be visually inspected on the external surface for cracks, lack of fusion, undercut, and weld reinforcement. Cracks, lack of fusion, undercut greater than 1/32 in., and weld reinforcement greater than 3/16 in. will not be acceptable. The field test procedure may require magnetic particle, liquid penetrant or ultrasonic inspection of any welded joint which is suspected of being unsound.

Inspection acceptance criteria for magnetic particle, liquid penetrant or ultrasonic inspection will be provided by the Government if conditions other than those above are questioned.

C. Defective Work: If inspections or tests show defects, such defective work or material shall be replaced and inspected, and tests repeated. All repairs to piping shall be made with new material. No caulking of screwed joints or holes will be accepted.

3.5 CLEANING, ADJUSTMENT, AND STERILIZATION

A. At the completion of the work, all parts of the installation shall be thoroughly cleaned.

All existing equipment, pipe, valves, and fittings shall be cleaned of grease, welding metal, metal cuttings, and sludge which may have accumulated during the system rehabilitation work. Each unit of the water distribution system shall be sterilized with chlorine before acceptance for domestic operation. The amount of chlorine applied shall be such as to provide a dosage of not less than 50 ppm nor greater than 100 ppm. The chlorinating material shall be introduced into the distribution system in a manner compliance confirmed by the COR. After a contact period of not less than 8 hr, the system shall be flushed with clean water until the residual chlorine content is not greater than 0.2 ppm. All valves in the lines being sterilized shall be opened and closed several times during the contact period. A bacteriological examination shall be made and if it shows that contamination still persists in the system, the procedure shall be repeated.

Special care shall be exercised to remove all metal particles from the piping system to prevent damage to valves and other operating mechanisms. The Contractor shall coordinate all sterilization and testing of the water system to meet state and Federal

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22.05.10-Page 14 standards. Any additional materials, work, or testing required shall be performed at no additional cost to the Government.

3.6 PROTECTION OF PIPING

A. Care shall be taken to keep all pipe and fittings clean during the progress of the work. Should any pipe become either partially or wholly clogged before final acceptance of the work, it shall be cleaned in a manner satisfactory to COR, or replaced. To prevent clogging of drains and embedded pipes during the construction work, open ends of pipe shall be protected by cast iron plugs or other suitable closures. Such closures shall be removed only when additional piping is added to the system and shall be immediately reinstalled at the end of the newly installed piping. Removal of closures on completed systems shall be done only when compliance confirmed by the COR. Such compliance confirmation will be given only after danger of contamination of systems caused by construction operations is past.

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