16332-24-001

SOW NO. 16332-24-01

29 February 2024

NOT SENSITIVE

IRA-7303

STATEMENT OF WORK

TO

SUSTAIN 161kV TRANSFORMERS

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TN 37389-9998

DRAFT

ANZY169008

TABLE OF CONTENTS

1. SCOPE

2. APPLICABLE DOCUMENTS

2.1 Government Documents

2.2 Non-Government Documents

3. REQUIREMENTS

3.1 General

3.2 Survey

3.3 Internal Inspection

3.4 Baseline Testing

3.5 Oil Processing

3.6 Transformer Control Cabinet

3.7 Cooling System Refurbish Service

3.8 Tap Changer

3.9 Auxiliary Equipment

3.10 Painting

3.11 Process and Test Oil

3.12 Verification and Testing

3.13 Spare Parts

3.14 Warranty

3.15 Submittals

Appendix A CSI Specification Sections Appendix B Oil Test Reports - Example PWT3 Appendix C Appendix D Appendix E Appendix F

Transformer Control Cabinet Transformer Oil Testing and Processing Reference Drawings - Example PWT3 Nameplate Data - Example PWT3

Appendix G Photographs - Example PWT3 Appendix H AEDC SHE Standards (Attached Separately)

NOT SENSITIVE- IRA-7303

Table of Contents-1

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1. SCOPE

1.1. General: The scope of work is to refurbish, rewind, repair, design, supply, and/ or install of the existing 161kV Transformers in multiple locations in the following 161kV substations: Main, PWT, PES, VKF, ETF 1, ETF 2, ETF A, ASTF Airside, and ASTF Exhaust. All work shall be done at Arnold Air Force Base, Tennessee, unless approved by Government. Scope to include, but may not limited to the following:

Transformer Name High Level Requirements Additional Requirements

ETF-C A2 New bushings, gaskets, controls, paint, fans, pumps, oil processed

As Needed

ETF-C A3 New bushings, gaskets, controls, paint, fans, pumps, oil processed, rebuild tap changer

As Needed

ETF-C A4

New bushings, gaskets, controls, paint, fans, pumps, oil processed

As Needed

ETF-C AA

New bushings, gaskets, controls, paint, oil processed

As Needed

ETF-C E1

New bushings, gaskets, controls, paint, fans, pumps, oil processed

As Needed

ETF-C E2

New bushings, gaskets, controls, paint, fans, pumps, oil processed

As Needed

ETF-C E3

New bushings, gaskets, controls, paint, fans, pumps, oil processed

As Needed

ETF-C E4

New bushings, gaskets, controls, paint, fans, pumps, oil processed

As Needed

ETF-C E5

New bushings, gaskets, controls, paint, fans, pumps, oil processed

As Needed

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ETF-C E6 New bushings, gaskets, controls, paint, fans, pumps, oil processed, rebuild tap changer

As Needed

ETF-C EA

New bushings, gaskets, controls, paint, oil processed

As Needed

PWT1 Remove pig mat and process oil, internal inspection

As Needed

PWT2 Gaskets, Process Oil and fix oil leaks

As Needed

PWT3

New bushings, gaskets, controls, paint, fans, pumps, oil processed

As Needed

ETF2 Gaskets, pumps, coolers, process oil, internal inspection

As Needed

CF1

Gaskets, Paint, Controls, Bushings, Oil processing, fans, LTC, LA's HVB 944 Bay LA’s and

As Needed

CF2

Gaskets, Paint, Controls, Bushings, Oil processing, fans, LTC, LA's HVB 964 Bay LA’s and

As Needed ETF5 Paint, coolers, controls, LA, oil processed Yard LA’s and

As Needed

ETF7

Gaskets, paint, fans, controls, bushings, LA, oil processed

Yard LA’s and As Needed

VKF2

Gaskets, paint, fans, controls, bushings, oil processed Yard LA’s and

As Needed PWT5 Gaskets, spot paint, controls, oil processed As Needed

PES6

Gaskets, paint, fans, controls, bushings, LA, oil processed

Yard LA’s and As Needed

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Potential New Transformers:

PES 5

ETF 5

ETF-C A3

ETF-C E6

ETF 7

ETF 2

PWT 3

PWT 2

ETF 6

2. APPLICABLE DOCUMENTS

2.1. Government Documents:

2.1.1. AEDC Environmental Policy:

https://media.defense.gov/2022/Nov/29/2003122404/-1/-

1/1/ARNOLD_AFB_ENVIRONMENTAL_COMMITMENT_STATEMENT_15JUL

22.PDF

2.1.2. AEDC Safety, Health, and Environmental (SHE) Standards latest version, provided in Appendix H.

A. A6 with Supplement User and Subcontractor Safety (Mandatory Documents/Submittals), B. A9 Hazard Communication.

C. A10 Job Safety Analysis.

D. B1 Master Work Permit.

DRAFT

https://media.defense.gov/2022/Nov/29/2003122404/-1/-1/1/ARNOLD_AFB_ENVIRONMENTAL_COMMITMENT_STATEMENT_15JUL22.PDF https://media.defense.gov/2022/Nov/29/2003122404/-1/-1/1/ARNOLD_AFB_ENVIRONMENTAL_COMMITMENT_STATEMENT_15JUL22.PDF https://media.defense.gov/2022/Nov/29/2003122404/-1/-1/1/ARNOLD_AFB_ENVIRONMENTAL_COMMITMENT_STATEMENT_15JUL22.PDF

ANZY169008 NOT SENSITIVE - IRA-7303 Page-4

E. B2 Lockout/Tagout (LOTO).

F. B3 Control of Hazardous Areas Using Safety Signs, Tags, and Barricades.

G. B4 High Voltage Electrical Work.

H. B5 Confined Spaces.

I. B6 Low Voltage Electrical Systems and Related Work Practices.

J. C2 Contaminated Equipment.

K. D5 Hoisting Devices.

L. D6 Aerial Work Platforms.

M. D8 Portable Power Tools.

N. D9 Fixed and Portable Ladders.

O. D10 Scaffolding.

P. E7 Asbestos.

Q. E11 Oil Pollution Prevention and POL Storage Tank Management.

R. E17 Oil and Hazardous Substance Spill Response.

S. E18 Hazardous Material Management Program.

T. E19 Lead and Heavy Metals.

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U. F2 Personal Protective Equipment.

V. F5 Hazardous Noise and Hearing Conservation (NRR Method for Estimating the Adequacy of Hearing Protector Attenuation).

W. F6 Fall Protection.

2.1.3. Code of Federal Regulations:

A. 29 CFR 1910.134 Respiratory Protection.

B. 29 CFR 1910.1200 Hazard Communication.

C. 29 CFR 1926.55 Gases, Vapors, Fumes, Ducts, and Mists.

D. 29 CFR 1926.57 Ventilation.

E. 29 CFR 1926.59 Hazard Communication.

F. 29 CFR 1926.62 Lead Standard.

G. 29 CFR 1926.1101 Asbestos.

H. 29 CFR 1926.1407 Power Line Safety (up to 350 kV)- Assembly and Disassembly.

I. 29 CFR 1926.1408 Power line safety (up to 350 kV)- Equipment Operations.

J. 40 CFR 61 National Emission Standards for Hazardous Air Pollutants (NESHAP).

K. 40 CFR 82 Subpart F Protection of Stratospheric Ozone, Recycling and Emissions Reduction.

L. 40 CFR 82.161 Technician Certification.

M. 40 CFR 112 Oil Pollution Prevention.

N. 40 CFR 260 Hazardous Waste Management Systems: General.

O. 40 CFR 261 Identification and Listing of Hazardous Waste.

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P. 40 CFR 262 Standards Applicable to Generators of Hazardous Waste.

Q. 40 CFR 279 Standard for the Management of Used Oil Authority.

R. 40 CFR 370 EPA Hazardous Chemical Reporting and Community Right to Know Requirement.

S. 49 CFR 172 Department of Transportation (DOT) Regulations for Use of Hazardous Materials

Tables and for Communication.

T. 49 CFR 178 DOT Specifications for Packaging.

2.1.4. Environmental Protection Agency:

A. EPA SW-846 Proposed Sampling and Analytical Methodologies for Additions to Test Methods for Evaluating Solid Waste:

Physical/Chemical Methods, 2021.

2.1.5. Public Law:

A. PL 101-637 The Asbestos School Hazard Abatement Reauthorization Act (ASHARA), 1990.

2.1.6. Tennessee Department of Environment and Conservation Standard:

A. Chapter 1200-01-20 Asbestos Accreditation Requirements, 2009.

B. Chapter 1200-3-11-02 Hazardous Air Contaminants, Asbestos, 2018.

2.1.7. Specifications: The following CSI Specification sections are included in Appendix A as AEDC specific requirements and are listed as follows:

A. Appendix A.1 – 01 10 00 – Job Conditions at AEDC.

B. Appendix A.2 – 01 33 00 – Submittal Procedure.

C. Appendix A.3 – 01 74 19 – Construction Waste Management and Disposal.

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D. Appendix A.4 – 02 08 00 – Asbestos Removal.

E. Appendix A.5 – 02 08 50 – Lead and Heavy Metal Removal

F. Appendix A.6 – 09 90 00 – Painting and Coating.

2.1.8. Drawings:

A. Reference Drawings – Appendix E.

B. Nameplate Data – Appendix F.

C. Photographs – Appendix G.

2.2. Non-Government Documents:

2.2.1 American Society of Safety Professionals:

A. ASSP Z9.2-18 Fundamentals Governing the Design and Operation of Local Exhaust Ventilation Systems.

2.2.2 American Society of Mechanical Engineers:

A. ASME A13.1-23 Scheme for the Identification of Piping Systems.

B. ASME B16.5-20 Pipe Flange and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard.

2.2.3 ASTM International:

A. ASTM D877-19 Standard Test Method for Dielectric Breakdown Voltage of Insulating Liquids Using Dish Electrodes.

B. ASTM D923-23 StandardPractices for Sampling Electrical Insulating Liquids.

A. ASTM D924-23 Standard Test Method for Dissipation Factor (or Power Factor) and Relative

Permittivity (Dielectric Constant) of Electrical Insulating Liquids.

B. ASTM D971-20B. ASTM D971-20 Standard Test Method for Interfacial Tension of Oil

Test Method for Interfacial Tension of Oil Against Water by the Ring Method.

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C. ASTM D974-22 Standard Test Method for Acid and Base Number by Color-Indicator Titration.

D. ASTM D1275-24 Standard Test Method for Corrosive Sulfur in Electrical Insulating Oils.

E. ASTM D1298-23 Standard Test Method for Density, Relative Density (Specific Gravity), or API Gravity of Crude Petroleum and Liquid Petroleum Product by Hydrometer Method-API Designation.

F. ASTM D1500-17 Standard Test Method for ASTM Color of Petroleum Products (ASTM Color Scale).

G. ASTM D1524-22 Standard Test Method for Visual Examination of Used Electrical Insulating Oils of Petroleum Origin in the Field.

H. ASTM D1533-20 Standard Test Method for Water in Insulating Liquids by Coulometric Karl Fischer Titration.

I. ASTM D1816-19 Standard Test Method for Dielectric Breakdown Voltage of Insulating Oils of Petroleum Origin Using VDE Electrodes.

J. ASTM D2668-13 Standard Test Method for 2,6- DitertiaryButyl Paracresol and 2,6- Ditertiary-Butyl Phenol in Electrical Insulating Oil by Infrared Absorption.

K. ASTM D2945-09 Standard Test Method for Gas Content of Insulating Oils.

L. ASTM D3487-17 Standard Specification for Mineral Insulating Oil Used in Electrical Apparatus.

M. ASTM D7151-23 Standard Test Method for Determination of Elements in Insulating Oil.

2.2.4 Institute of Electrical and Electronic Engineers:

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A. IEEE C57.19.00-23 General Requirements and Test Procedure for Outdoor Power Apparatus Bushings.

B. IEEE C57.19.01-17 Performance Characteristics and Dimensions for Outdoor Apparatus Bushings.

C. IEEE C57.93-19 Guide for Installation and Maintenance of Liquid-Immersed Power Transformers

D. IEEE C57.106-15 Guide for Acceptance and Maintenance of Insulating Oil in Equipment.

E. IEEE 4-13 Standard Techniques for High-Voltage Testing.

F. IEEE 315-93 Graphic Symbols for Electrical and Electronics Diagrams.

2.2.5 International Electrotechnical Commission:

A. IEC 60068-2-1-07 Environmental Testing – Cold.

B. IEC 60068-2-2-07 Environmental Testing – Dry Heat.

2.2.6 National Electrical Manufacturers Association:

A. NEMA 250-20 Enclosures for Electrical Equipment (1000 Volts Maximum).

B. NEMA ICS 1-22 Industrial Control and Systems: General Requirements.

2.2.7 National Electrical Testing Association:

A. NETA MTS-23 Maintenance Testing Specifications.

2.2.8 The Society for Protective Coatings:

A. SSPC Guide 6-21 Guide for Containing Surface Preparation Debris Generated During Paint Removal Operations.

B. SSPC PA 1-16 Shop, Field, and Maintenance Painting of Steel.

C. SSPC PA 2-22 Measurement of Dry Coating Thickness with Magnetic Gages.

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D. SSPC SP1-16 Solvent Cleaning.

E. SSPC SP2-18 Hand Tool Cleaning.

F. SSPC SP3-18 Power Tool Cleaning.

G. SSPC SP6-07 Commercial Blast Cleaning.

H. SSPC SP12-02 Surface Preparation and Clean of Metals by Waterjetting Prior to Recoating.

2.2.9 Underwriters Laboratories, Inc.(UL):

A. UL 50-20 Enclosures for Electrical Equipment.

B. UL 467-22 Grounding and Bonding Equipment.

C. UL 586-22 High-Efficiency, Particulate, Air Filter Units.

3. REQUIREMENTS

3.1. General:

3.1.1. The Contractor shall provide all labor, materials, and equipment required for disconnecting and reconnecting of all primary 161kV high voltage conductors and secondary medium voltage conductors required for the on-site field survey, bushing replacement, and transformer refurbish service. Contractor shall have capability to rewind transformer as necessary.

3.1.2. Provide a single point of contact or project manager to serve as on-site field service support for supervision of bus duct replacement, repair and refurbishment, transformer reconditioning, oil processing, startup, and commissioning of the refurbished transformer. Provide a Field Application Engineer, environmental coordinator, and safety professional.

3.1.3. Provide a list of personnel assigned to this project with telephone numbers and email addresses. Identify the team design lead and respective design discipline of each member of the team.

3.1.4. Perform all work in accordance with Appendix A.1, Job Conditions at AEDC.

3.1.5. All meetings shall be conducted, as necessary, as agreed to by the Government.

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3.1.6. A Microsoft Team’s meeting between the Contractor and the Government Representative shall be held at least weekly for technical discussions and updates.

3.1.7. Contractor shall submit final construction drawings and final as-built drawings to the Government for approval.

3.1.8. Final design documentation (drawings) shall become the sole property of the Government.

3.1.9. The Contractor shall field verify existing site conditions.

3.1.10. Schedule and outages:

A. Submit plan to initially test the transformer within 3 days of notice to proceed. The Government expectation for initial electrical testing is defined in this SOW. The test plan shall comply with this SOW or deviations shall be approved by the Contracting Officer.

B. Submit a design plan and schedule within 10 days of notice to proceed.

C. Contractor shall submit request for outages 30 days in advance. The Government will provide outages for additional equipment upon request.

This includes but is not limited to the following services:

1. All work or repairs that require a crane to lift equipment or personnel.

Submit critical lift plan for review with request for outage in accordance with AEDC SHE Standard D5.

2. All work required in the 161kV substation control room.

3.1.11. Safety:

A. All work shall comply with AEDC SHE Standards A6 with supplement, A9, A10, B1, B2, B3, B4, B5, B6, C2, D5, D6, D8, D9, D10, E7, E11 E17, E18, E19, F2, F5, and F6. Contractor shall determine if additional SHE Standards are required. Submit a Safety Plan in accordance with AEDC SHE Standard A6 prior to beginning onsite work be performed in accordance with AEDC SHE Standards.

B. All work stoppages due to unsafe conditions will be at the Contractor’s expense and will not be grounds for outage extension.

C. All work or repairs that require a crane to lift equipment or personnel shall comply with the provisions of 29 CFR 1926.1407 and 1408, which states

ANZY169008 Page-12 that cranes may be used within a minimum clearance of 15-feet from energized 161kV and shall comply with the requirements of a critical lift.

D. Work inside transformer tanks is considered to be a confined space and shall be in accordance with AEDC SHE Standard B5. Submit confined space procedure within 3 days of notice to proceed. Comply with the confined space procedure whenever personnel are inside the tank.

E. Prepare Job Safety Analysis per AEDC SHE Standard A10.

3.1.12. Do not order materials or start refurbishment work until receiving approval of the final submitted design plan, schedule, and drawings unless otherwise approved by the Government Representative.

3.1.13. Provide new components and devices, complete, with all necessary materials for installation. Provide materials, components, parts, and equipment to be incorporated into the work, which are manufactured in accordance with recognized and accepted standards such as IEEE, ASTM, and NEMA or similar.

Where possible, use materials, components, parts, and equipment which have been tested and listed by an independent agency such as UL. All components, parts and equipment shall be designed for operation 24 hours per day, seven days per week for 25 years. Reject damaged and inferior materials, components, parts, and equipment. All materials used shall be new and unused. The Government reserves the right to inspect all material for discrepancies, damage, and inferiority once the material arrives on-site.

3.1.14. Allow a minimum of 14 calendar days for the Government to review submissions made by the contractor.

3.1.15. Reference drawings of the facilities are attached to the SOW in Appendix E. The contractor shall be responsible for verifying the accuracy of Government-furnished drawings.

3.1.16. Disconnect the transformer as required, including high voltage connections, auxiliary power, medium voltage power, control cables and wires, relay wiring, and conduits.

3.1.17. Upon completion of vacuum filling, re-connect the transformer, including high voltage connections, medium voltage connections, auxiliary power, control cables and wires, relay wiring, and conduits.

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3.1.18. For all repairs, perform using factory trained and qualified filed engineer and technician. Submit certification for qualifications to perform repairs. Repair shall include but not limited to:

A. Necessary internal repairs.

B. Necessary external repairs.

3.2. Survey:

3.2.1. The Contractor shall perform a detailed on-site field survey to review the current condition of the transformer(s) and verify the accuracy of the bushing data in Appendix E and F and all reference drawings in Appendix E as required to refurbish the transformer and replace wiring as per the specifications. As part of the on-site field survey, inspect and review existing wiring installation, document exact detail of the field wiring and hardware connected to the transformer control panels. During the on-site field survey, the Contractor shall verify the information on Appendix E and F and complete internal inspections required to gather dimensional data for the replacement high voltage, neutral, and low voltage bushings.

3.2.2. Provide tanker, pumping equipment, oil processing and filter equipment, and oil spill contingency to drain oil to prepare for initial inspection per Appendix D.

Submit certification cleanliness of actual tanker to be used prior to pumping oil.

3.2.3. Provide dry air supply to maintain positive pressure during the oil removal process. Provide dry air throughout the internal inspection phase.

3.3. Internal Inspection:

3.3.1. Perform internal inspection using factory trained and qualified field engineer and technician. Submit certification for qualifications to perform inspection.

3.3.2. The internal inspection shall include but not be limited to the following: A.

Leads and lead structure(s).

B. De-energized tap changer contacts and operating mechanism.

C. Current Transformers (CT)s and associated mountings and wiring.

D. Tightness and integrity of all the coils.

E. Transformer core.

F. All low voltage bushings.

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G. Internal tank structure.

3.3.3. Document inspection and findings with photographs taken with Government provided camera.

3.3.4. Discuss findings with Government within 4 hours of completing the inspection.

3.3.5. Submit preliminary written report with detailed findings and anomalies observed within 24 hours of completion of inspection.

3.3.6. Submit recommendations for revisions to initial test plan within 3 days of completion of the internal inspection.

3.3.7. Perform an engineering evaluation to determine the need to replace the original tap changer with a new unit with appropriate ratings to meet or exceed the original equipment specifications. Submit evaluation with recommendation. Do not perform additional work unless approved by Government.

3.3.8. Test oil in accordance with Appendix D. Submit written results within three days of drawing the sample.

3.3.9. Perform electrical test of the transformer in accordance with the requirements in this SOW. Discuss findings with Government within 24 hours of completing the testing. Submit written electrical results with recommendations for all repairs outside the scope of this statement of work within three days of completion of the tests.

3.3.10. Evaluate and replace the control cables if approved by the Government.

3.4. Baseline Testing:

3.4.1. Perform baseline electrical testing on the transformer in accordance with NETA MTS prior to starting the repair. Where the manufacturer’s requirements are more stringent than the standard NETA requirements, the manufacturer’s requirements shall prevail. Submit a detailed report of the test results as part of the consolidated transformer test report. Inform the Government Representative following completion of testing of all test values that fall outside the recommended range. The electrical testing shall include but not be limited to the following tests:

A. External visual inspection of all transformer devices and general conditions.

Note any nitrogen piping that appears to have been recently replaced and in good condition.

B. Insulation power factor.

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C. Insulation resistance.

D. DC winding resistance on all tap positions for all windings.

E. Winding excitation on all tap positions, verify proper test pattern.

F. Transformer turns ratio on all tap positions for all windings.

G. Leakage reactance.

H. Each current transformer ratio and polarity.

I. Sweep frequency response analysis.

3.4.2. Submit preliminary design drawings for repairs within 90-days of notice to proceed.

Design review documentation shall include Contractors’, manufacturers or fabricators’ drawings and shall be submitted to the Contracting Officer.

3.4.3. Within 25-days of conclusion of the on-site field survey submit final shop drawings detailing demolition and refurbishment work, wiring diagrams, and schematics in accordance with IEEE 315, using drawings in Appendix E as a basis. Drawings shall include wiring diagrams, schematic diagrams, one-line and three-line diagrams, mounting details, outline, and complete dimensional information. The drawings shall also include all bushings, gauges, mechanical relief device, control cabinet power, controls, auxiliary, and alarm components. Provide drawings meeting the following requirements:

A. All drawings shall clearly indicate the location and arrangement of all materials and equipment.

B. All drawing submittals shall include three electronic copies on CD-ROM in AutoCAD 2020 format or later format and three legible and reproducible paper copies. Drawings shall be completely legible when the printed size is 11 by 17 inches.

C. Provide a project title block for all drawings provided. The title block shall include the drawing number and description for each drawing sheet.

D. Provide detailed schematic wiring and fabrication shop drawings for the custom designed transformer control cabinet enclosures (Refer to Appendix C for detailed requirements), the transformer temperature cooling system remote operator control panels and the nitrogen regulator enclosure which accurately and completely describe the control circuits, all wire designations, terminal points and labels, control devices and device contact points shown and labeled with proper ANSI device numbers.

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E. Provide detailed wiring and connection diagram for all components that will be wired to terminals in the transformer control panel. This includes detailed transformer component wiring connections and wiring connections in the transformer control panel. Drawings shall include but not be limited to:

1. Conduit installation drawings or specifications for connection of transformer components to the transformer control panel.

2. Detailed installation drawings and specifications for mounting the transformer control cabinets.

3. Detailed operational specifications of transformer components to be wired. For example, a high temperature switch the detail shall indicate “OPERATES ON TEMPERATURE RISE AT 100

DEGREES-F”.

4. Detailed installation drawings and specifications for mounting the remote operator control panel.

5. Detailed conduit and wiring installation drawings and specifications for connection of the transformer control cabinets, the remote control panels, and the nitrogen regulator enclosures. All wiring and installation drawings shall include cable identification labels.

6. Detailed fabrication drawings for the oil winding temperature indicator brackets.

7. Detailed fabrication drawings for the oil flow indicator brackets.

8. Detailed wiring and installation drawings required to replace the field wiring detailed in this SOW.

3.4.4. Provide detailed bill of materials (BOM) drawing sheet(s) listing each specific part with brand name, part number, quantity, detailed description, and reference drawing for sheet(s) where part is shown. This drawing shall have part numbers that can be referenced on a drawing sheet(s) with a part number symbol (number). The detailed BOM for hardware shall include the manufactures documented Mean Time Between Failure (MTBF), and Mean Time to Repair (MTTR) information for all components and assemblies.

3.4.5. Provide detailed three-phase wiring schematic for the replacement transformer cooling system controls.

3.4.6. Provide a detailed logic flow diagram for the transformer cooling system controls.

The logic flow diagram shall be the basis for the logic programming of the Intelligent Electronic Device (IED) detailed in Appendix C.

3.4.7. Provide a drawing sheet for the replacement diagrammatic nameplate detailed within this SOW.

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3.4.8. Provide a drawing sheet for the replacement high voltage bushings, the low voltage neutral bushings, and the low voltage phase bushings.

3.5. Oil Processing:

3.5.1. Provide tanker, pumping equipment, oil processing and filter equipment, and oil spill contingency to drain oil for necessary on-site repairs per the procedures in Appendix D. Submit certification of cleanliness of actual tanker to be used prior to pumping oil if using tanker different than previous.

3.5.2. Provide dry air supply to maintain positive pressure during the oil removal process. Adjust oil flow rate to maintain a slight positive pressure on the tank at all times. Provide dry air throughout the on-site repair phase.

3.5.3. Provide new Type II oil for all oil filled cable compartments, tap changers, and flushing oil. New oil shall meet the requirements listed in ASTM D3487. Submit a certified test report to the Contracting Officer on the characteristics of the new oil prior to off-loading to verify that the oil meets the specifications. Provide tanker, pumping equipment, oil processing and filter equipment, and oil spill contingency in accordance with the procedures in Appendix D. Government storage is within one mile of the job location where the oil can be stored. If that storage method is chosen, deliver the oil to the Government storage vessel.

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3.6. Transformer Control Cabinet:

3.6.1. Design, fabricate and provide a new transformer control cabinet with enclosures and the transformer insulation oil cooling system motor controls in accordance with Appendix C. Exceptions include transformers: ETF #2, PWT #1. PWT #2 that have already had the control cabinet replaced.

3.6.2. Within 10-days following fabrication the Contractor shall provide inspection and testing of the transformer control cabinet enclosures and transformer temperature cooling system remote operator control panels. At least 14 days before scheduled inspection and testing submit plans and details for on-site preshipment factory testing and inspection. The purpose of this inspection is to verify that the design and fabrication of the cabinets meets all requirements. The Contractor submitted plans shall include but not be limited to a detailed agenda for functional testing and documentation review and list the proposed date and site of testing. Government reserves the right to witness testing.

3.6.3. Provide power inverter suitable to operate the entire load of the control cabinet controls. Normal source shall be 120VAC with capability to switch to 125VDC station battery upon loss of 120VAC. For example, the existing power inverters are Majorpower and Majorsine. Notify the Government of the required circuit ampacity with the initial design submittal. The Government will provide the location for the new circuit. Provide all new components include 2pole knife switch, fuses, wire, and install the new circuit as required. Work shall be performed by the contractor to install the power inverter and all necessary components.

3.7. Cooling System Refurbish Service:

3.7.1. Remove and refurbish transformer insulating oil cooling system assembly.

3.7.2. Cooling Fans: Disassemble and replace fans, fan motors, fan guards, fan brackets, and all fan wiring. Replacement bolts, mounting brackets, and all hardware shall be fabricated from non-corrosive material or plated to prevent corrosion. Relinquish the existing undamaged fan assemblies to the Government.

3.7.3. Steam clean to remove oil, dirt, and grime from radiators.

3.7.4. Perform an engineering evaluation on the need to replace the oil pumps and submit evaluation with recommendation.

3.7.5. Replace drain valves suitable for draining oil from the cooler pumps as required.

Valves shall be for use with insulating oil and shall be capable of holding hot oil without leaking. Valves shall have National Pipe Threads. Provide plugs for valves.

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3.7.6. Clean all surfaces and sand as needed. Radiators shall be flow coated and receive 2 coats of epoxy primer and 1 coat of final coating in accordance with Appendix A.6.

3.7.7. Test all the cooling fans and pumps individually and all together. Perform an engineering evaluation on the recommended settings for forced oil initiation, forced air initiation, and alarm settings for the oil and winding temperature gauges. Verify that the fans and pumps turn on per each of the recommended settings via each gauge. Verify that the SCADA alarms are initiated for each recommended temperature level. Submit a certified test report on all testing after the testing is complete as part of final transformer test reports.

3.7.8. Replace existing insulating oil cooling system flow indicators. Remove the existing oil cooling system flow indicators and install new oil flow indicators. Each device shall include the following features and options:

A. One set of normally open and normally closed form C alarm contacts with interrupting rating of 0.5-amps non-inductive suitable for use on 125VDC. The Contractor shall install wiring connections from the alarm contacts to a terminal block for the IED in the transformer control panel. B. NEMA 4X housing to protect wiring connections.

3.8. Tap Changer:

3.8.1. Rebuild each load tap changer (LTC).

A. Provide and erect scaffolding as required.

B. Perform visual inspection of LTC and note all abnormalities.

C. Drain and excess oil from LTC.

D. Replace door gasket.

E. Wipe down the LTC active part with clean rags.

F. Check bypass contacts.

G. Check selector contacts.

H. Replace contacts, all replaceable components, and broken components.

I. Perform timing measurements (used to determine excessive backlash in drive train).

J. Full motor drive inspection.

NOT SENSITIVE - IRA-7303 ANZY169008 Page-20

K. Perform a sequence check on the LTC.

L. Perform an operational check in the manual and electrical modes.

M. Provide new oil and fill LTC compartment thru filter press.

N. Perform check for leaks.

O. Provide a separate written report of inspection results and work.

P. Replace tap changer controllers with new modern controllers. Provide one spare controller of each model installed. Provide one complete set of spare parts that includes all replaceable components for each LTC.

3.8.2. If rebuild isn’t possible, recommend replacement with the initial bid.

3.9. Auxiliary Equipment:

3.9.1. Replace the existing nameplate with a new stainless-steel nameplate permanently etched in black ink that shows all the new information, including weights, connections, gallons of oil, impedance, etc. The new nameplate, as a minimum, will have the same information as the original. Discuss with Government Representative on each transformer to determine if nameplate replacement is necessary.

3.9.2. Evaluate C-air and C-exhaust transformer’s neutral current transformers if the neutral current transformer looks like it has been recently replaced, inform the Government representative so a decision can be made about replacement. If the units are not replaced, turn the new replacement units over to the Government. Otherwise, replace the two existing neutral current transformers.

Neutral current transformers shall be outdoor type rated 15kV, 110kV BIL, 60 Hertz, 50/100 primary amp rating to 5-amp secondary ratio, for example our existing neutral current transformers are ABB type KOR-11, Style 7524A13G05 . Verify the existing ratio before disconnecting then connect new current transformers secondary wiring for the proper ratio.

3.9.3. Provide a dial-type liquid temperature indicating thermometer with its sensing element located in the path of the hottest oil. Locate the thermometer on the transformer tank approximately five feet above the base of the transformer.

Provide thermometer dials with a range of 0 to 120 degrees C and three adjustable circuit-closing alarm contacts suitable for use with an ungrounded 125-volt dc circuit and with a resettable drag hand to capture the hottest temperature experienced. Analog 4-20 mA output proportional to temperature.

Install wiring connections from the temperature indicating device analog outputs to a terminal block in the control cabinet then connect to the SEL-2414. Program the SEL-2414 to accept the analog input and display the oil temperature. In

ANZY169008 Page-21 addition to the liquid temperature indicator, provide RTD sensors to detect top oil temperature and ambient temperature and connect the sensors to the SEL-2414.

Program the SEL-2414 to accept the RTD inputs.

3.9.4. Replace the transformer main tank oil level indicator. The indicators shall be a magnetic-type oil gage equipped with low-level alarm contacts, NEMA form C with an interrupting rating of 0.5 amps (minimum) non-inductive suitable for use on 125VDC. The Contractor shall install wiring from the alarm contacts to a terminal block in the transformer control panel. The Contractor shall include details for the oil level indicator on the detailed BOM included in the design drawings. The oil level indication device shall include:

A. 6-inch dial face with lever (radial) or heavy-duty gear driven arm float arm, marked to show 25 degrees Celsius oil level and the minimum and maximum oil levels.

B. NEMA 4X housing to protect electronics.

C. Analog 4-20 mA output proportional to level. Install wiring connections from the temperature indicating device analog outputs to a terminal block in the control cabinet then connect to the SEL-2414. Program the

SEL2414.

3.9.5. Replace the sudden-pressure relay mounted to detect a sudden rise in oil pressure in the tank. Provide a relay with at least one set of normally open and one set of normally closed contacts suitable for use on a 125VDC ungrounded circuit. The sudden-pressure relay shall be connected to the transformer oil space through a valve approved by the Government. The sudden-pressure relay shall be wired to a seal-in relay provided by the Contractor that shall be installed in the transformer control cabinet. Provide a seal-in relay with not less than one set of normally open and one set of normally closed alarm contacts and one set of normally open trip contacts with surge protection suitable for use on 125VDC.

The seal-in relay contacts shall be rated to make 20-amps, carry 10-amps, and break 0.5-amps (minimum) resistive. Include details for the replacement sudden pressure relay, seal-in relay and the connection valve hardware on the detailed BOM included in the design drawings.

3.9.6. Replace the mechanical pressure relief device (MRD). Design the MRD to be self-sealing to protect the tank against an explosion due to arcing within the tank.

Design the MRD to permit vacuum filling of the tank and to minimize oil discharge and to exclude air and water after it opens and shall be equipped with a visible flag to indicate operation. Equip the MRD with not less than one set of normally open and one set of normally closed alarm contacts with interrupting rating of 0.5 amps (minimum) non-inductive suitable for use on 125VDC. Install wiring connections from the pressure relief device to a terminal block in the control

ANZY169008 Page-22 cabinet. Include details for the replacement device on the detailed BOM included in the design drawings.

3.9.7. Replace all winding temperature indication equipment devices. Include details for the replacement winding temperature indicator on the detailed bill of materials (BOM) included in the design drawings. All replacement winding temperature indicating equipment shall be mounted on a custom mounting bracket located directly above or beside the transformer control cabinet enclosure. The mounting height of winding temperature indicators shall be 84-inches maximum (unless approved by the Government). The mounting brackets shall be designed, fabricated and provided by the Contractor. The fabricated mounting brackets shall be painted in accordance with Appendix A.6. The winding temperature indication equipment device shall include:

A. 6-inch thermometer dials with a range of 0-160 degrees Celsius with a resettable drag hand to capture the hottest temperature experienced.

B. Four field adjustable switches with visible settings.

C. One set of normally open and normally closed form C alarm contacts with interrupting rating of 0.5-amps non-inductive suitable for use on 125VDC.

The Contractor shall install wiring connections from the temperature indicating device alarm contacts to a terminal block in the transformer control cabinet.

D. Analog 4-20mA output proportional to temperature. The Contractor shall install wiring connections from the temperature indicating device analog outputs to a terminal block in the transformer control cabinet.

E. E. NEMA 4X housing to protect electronics.

3.9.8. Replace the oil temperature indication equipment device. The Contractor shall include details for the replacement oil temperature indicator on the detailed BOM included in the design drawings. The replacement winding temperature indicating equipment shall be mounted on the custom mounting bracket located directly above or beside the transformer control cabinet enclosure. The mounting height of oil temperature indicators shall be 84-inches maximum (unless approved by the Government). The oil temperature indication equipment device shall include:

A. 6-inch thermometer dials with a range of 0-120 degrees Celsius with a resettable drag hand to capture the hottest temperature experienced.

B. Three field adjustable switches with visible settings.

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C. One set of normally open and normally closed form C alarm contacts with interrupting rating of 0.5-amps non-inductive suitable for use on 125VDC.

The Contractor shall install wiring connections from the temperature indicating device alarm contacts to a terminal block in the control cabinet.

D. Analog 4-20mA output proportional to temperature. The Contractor shall install wiring connections from the temperature indicating device analog outputs to a terminal block in the control cabinet.

E. NEMA 4X housing to protect electronics.

3.9.9. Replace all existing external conduit and wiring between all transformer protective devices and components and between the transformer protective devices and components and the transformer control cabinet (unless approved by the Government). Use rigid galvanized conduit and/or liquid-tight metallic flexible conduit for all replacement conduit. All connections to transformer protective devices and components with type NPT thread connections shall be made with liquid-tight metallic conduit and stainless-steel connectors. All wiring for transformer protective devices with NPT conduit connections shall be installed in conduit, unless approved by the Government. All other transformer protective devices shall be connected with outdoor rated type cable and connectors with water-tight seal and fabricated with corrosion resistant materials. All conduit connections to the transformer control panel enclosure shall be made with liquid-tight flexible metallic conduit and PVC coated connectors. All conduit bodies used for pulling conductors or connection conduits shall be cast-iron construction and painted in accordance with Appendix A.6.

3.9.10. Replace all gaskets for all oil-to-air openings and valves on outside of the transformer and all gaskets for oil-to-air transformer secondary bushing connections that are leaking; do not replace gaskets that show no evidence of leaking.

3.9.11. Nitrile rubber shall be used for all gasket joints having a recessed gasket grove.

Include details for each replacement gasket on the detailed BOM included in the design drawings.

3.9.12. Replace the following gaskets:

A. High voltage phase bushings.

B. Low voltage neutral bushings.

C. Manholes and hand-holes.

D. Pass through for current transformer wiring.

E. Pass through for temperature sensing elements.

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F. Plug on stiffener on Northwest corner of main tank.

G. Drain plugs on both oil pumps.

H. Replace seals and repack leaking gate and globe valves.

I. All gauges replaced by this contract.

J. Low voltage cable housing and bushings.

3.9.13. Many of the existing fasteners for hardware noted above to be re-gasketed are rusted or damaged. Replace all fasteners including bolts, nuts and washers for all hardware to be re-gasketed. All replacement fasteners shall be exact replacement or full equivalent to existing fastener hardware. All replacement fastener hardware shall be fabricated from corrosion resistant material or plated with corrosion resistant material. The details for all replacement fasteners shall be included on the BOM drawing sheets.

3.9.14. Provide station class lightning arrestors mounted to the top of the transformer tank within three feet or as close as possible to the high-voltage terminals as determined to be required for each transformer between the Contractor and Government representative. The lightning arrestors shall have a Maximum Continuous Operating Voltage (MCOV) rating of 106kV and for nominal system voltage of 161kV. Existing lightning arrestors are ABB type Style Q144SC115C.

3.9.15. Replace the existing lightning arresters in the following substations below.

Provide new mounting beams or modify the existing mounting as needed for proper height. Provide proper high voltage, ground connections, and mounting hardware. The lightning arrestors shall have a Maximum Continuous Operating Voltage (MCOV) rating of 106kV and for nominal system voltage of 161kV.

Existing lightning arrestors are ABB type Style Q144SC115C.

A. ETF 1 Substation - one set of lightning arresters.

B. ETF 2 Substation– one set of lightning arresters.

C. ETF 7 Substation - one set of lightning arresters.

D. ETF- C Exhaust Substation– three sets of lightning arresters.

E. Main Substation – Bay 944 - one set of lightning arresters.

F. Main Substation – Bay 964 – one set of lighting arresters.

G. PES Substation – one set of lighting arresters.

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H. VKF Substation - one set of lighting arresters.

3.9.16. Provide all hardware, materials, and labor to replace the high voltage phase bushings, the low voltage neutral bushings, and the low voltage phase bushings if determined to need replacement by the Contractor. Discuss findings with Government Representative before proceeding with decision for bushing replacement. Provide suitable termination to match existing connections. The new bushings shall meet or exceed all electrical requirements of the existing bushings listed in Appendix E and F. The Basic Insulation Levels (BIL) for replacement bushings shall be 750kV BIL for the 161kV bushings and 110kV BIL for the low voltage and neutral bushings. The electrical requirements of the new bushings shall be designed in accordance with IEEE C57.19.00 and IEEE C57.19.01 for application on power transformers. The Contractor shall include details for each replacement bushings on the detailed BOM included in the design drawings. The bushings shall be integrated with the CTs. The replacement specifications shall include but not be limited to:

A. Provide suitable termination to match existing connections for all bushings.

B. Subject bushings to power factor, partial discharge, C1 and C2 capacitance factory tests in accordance with IEEE C57.19.01. C. Subject bushings to hot collar test.

D. The new bushings shall be an exact mechanical fit as determined by the critical dimensions of the original bushings. Exception: standard bushings with mechanical dimensions for mounting flange connections less than the existing bushings may be used provided a factory designed and provided adapter plated is used to retrofit the new replacement bushing. The mechanical dimensions of the new bushings shall be in accordance with IEEE C57.19.01 except where this will preclude matching critical dimensions of the original bushing. Critical dimensions include:

1. Dimensions above the bushing flange.

2. Dimensions below the bushing flange.

3. Bushing flange to transformer interface.

4. Flange dimensions.

5. Top connector fit.

6. Bottom connector fit.

7. Minimum oil level.

8. Clearance in transformer opening.

ANZY169008 Page-26

E. Drain the oil from all oil filled bushings that are to be replaced. Test each oil-filled bushing for printed circuit board (pcb) concentration prior to draining. Submit copies of pcb results with bushing common description and serial number. Handle and dispose of oil in accordance with 40 CFR

279. Transport old bushings after pcb results have been deemed acceptable to Government designated salvage yard.

F. If existing bushings have recently been replaced, salvage the existing undamaged bushings, and provide to the Government. Place the bushing into the shipping containers provided with the new bushings.

3.9.17. Install fiber optic cable from the transformer control cabinet enclosure to the existing Supervisory Control and Data Acquisition (SCADA) System panel located in the 161kV substation control room. Each cable shall only be terminated in the transformer control panel at the fiber optic patch panel. The opposite end of the cable installed to the existing SCADA system panel shall be cut (with 240inches of spare length) and stored in the existing SCADA system panel and not be terminated. The cable for each transformer shall be uniquely labeled on each end with an oil resistant label, yellow with 0.25-inch black lettering, including a designation for each specific transformer refurbished for this contract.

Example: “TRANSFORMER A FUTURE SCADA SYSTEM RTU CABLE”. The cable end not terminated and installed to the existing SCADA system panel shall be covered with insulated cold shrink tubing to prevent damage and contamination. Each fiber cable shall be tight buffer cable with 6 single-mode fibers, indoor/outdoor color orange outer jacket, UL-listed type OFNR, riser rated and UV water and fungus resistant.

3.9.18. Evaluate the existing nitrogen cabinet, piping, and valves in place. Replace all damaged nitrogen piping and valves. Replace nitrogen piping with new stainless-steel piping and fittings in accordance with ASME B16.5. Replace the nitrogen gauge with new gauge that matches or exceeds the existing gauge features and replace the alarm wiring. All piping noted as being in good condition shall be left in place. Leak check the system after the installation is complete. If the existing nitrogen cabinet is determined to have been replaced recently, inform Government representative so a decision can be made about replacement.

3.10. Painting:

3.10.1. After completion of all repair work and component replacement the transformer shall be painted in accordance with Appendix A.6.

3.11. Process and Test Oil:

3.11.1. Fill transformer and process oil per Appendix D in preparation of final baseline electrical testing.

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3.11.2. Test oil per Appendix D. Submit written results within three days of drawing the sample.

3.12. Verification and Testing:

3.12.1. Perform final (baseline) electrical testing as per NETA MTS and IEEE 4 after the refurbishment of the transformer. Where the manufacturer’s requirements are more stringent than the standard NETA requirements, the manufacturer’s requirements shall prevail. The Contractor shall inform the Government Representative following completion of testing of all test values that fall outside the recommended range. All testing shall be performed by technicians certified by the National Electrical Testing Association (NETA) or National Institute for Certification in Engineering Technologies (NICET). All testing shall be accomplished using calibrated test equipment, which have recorded accuracy traceable to the National Institute of Standards Technologies (NIST). The Contractor shall provide a detailed report of the test results. Clean the new bushings prior to testing. The electrical testing shall include:

A. External visual inspection of all transformer devices and general conditions.

B. Insulation power factor.

C. Insulation resistance.

D. DC winding resistance on the present tap position for all windings. Test on all tap positions if tap changer was repaired or replaced.

E. Winding excitation on the present tap position, verify proper test pattern.

Test on all tap positions if tap changer was repaired or replaced.

F. Transformer turns ratio on present tap position for all windings. Test on all tap positions if tap changer was repaired or replaced. G. High voltage bushing power factor and capacitance.

H. Neutral bushing hot collar.

I. Low voltage bushing hot collar.

J. Leakage reactance.

K. Control wiring insulation resistance.

L. Applied potential test of control wiring and auxiliary circuits for one minute.

M. Sweep frequency response analysis for new baseline.

ANZY169008 Page-28

N. Oil testing for the concentration of Furanic compounds for new baseline.

O. Test the transformer tank for leaks when filled with oil at a test pressure of 5 pounds per square inch and maintain the test pressure for at least four hours with no leaks.