Attachment_2_Delivery_Order_1_SOW_KA3A_and_KA5A_Transformer_Material.pdf

U.S. Department of the Interior SPECIFICATIONS

Bureau of Reclamation

Lower Colorado Dams Office

Boulder City, Nevada January 2023

Acquire Material and Services to Rehabilitate Two (2) Generator Step-Up Transformers at Hoover Dam

Boulder Canyon Project, Arizona, Nevada

Dated: December 5, 2023

This page intentionally left blank.

FOREWORD

The transformers are physically located on the downstream ramp of Hoover Dam.

Hoover Dam is approximately 8 miles northeast of Boulder City, Nevada and 32 miles from Las

Vegas, in Clark County, Nevada.

The transformers are located on the Arizona side of the power plant.

The transformers are three phase transformers manufactured by ABB (Asea Brown

Boveri). The transformers have a nameplate rating of 135MVA and hold 11,710 gallons of oil each. The transformer is class FOW (Forced Oil and Water). The transformer designations are

KA3A and KA5A. Serial numbers are:

KA3A: 6311-786

KA5A: 6311-789

Hoover is seeking a contractor to supply materials to replace aging and failing components on both GSU (generator step-up) transformers. Additionally, we are seeking a company to handle oil removal, transformer dry-out (if necessary), oil processing and addition of oxygen inhibitor to the oil. Details of what is required for oil processing and dry-out will be described later in this document.

Company supplying materials is asked to contact Hitachi Energy to confirm parts supplied under this contract will fit the listed transformers.

Contents

1. GENERAL

1.1 Abbreviations

1.2 Transformer Details

1.3 Requirements

1.4 Period of Performance

1.5 Schedule

1.6 Government furnished Equipment, Utilities and Facilities

1.7 Liquidated Damages

1.8 Security / Clearances

1.9 Safety

1.10 Hazardous Materials

1.11 Protection of Existing Installations and Structures

1.12 Final Acceptance of Work

1.13 Special Work Permit

1.14 Access to the Construction Work Area

1.15 Government Submittal Review

1.16 Drawings

1.17 Shipping and Labeling of Boxes

2. TECHNICAL REQUIREMENTS

2.1 Specifications

2.2 Testing

2.3 Instrumentation, Controls, and ancillary devices

2.3.1 Low Voltage Winding Temperature Gauge

2.3.2 High Voltage Winding Temperature Gauge

2.3.3 Oil Temperature Gauge

2.3.4 Buchholz Relay

2.3.5 Sudden Pressure Relay

2.3.6 Oil Flow Indicators

2.3.7 Fault Monitor / DGA

2.3.8 Oil Level Indicator

2.3.9 Winding Temperature Transmitters

2.3.10 Hot Spot Detector Equipment

2.3.11 Current Transformer Connection Blocks

2.4 Tank Oil Valves

2.5 Oil Motors and Pumps

2.6 Heat Exchangers

2.7 Conservator

2.7.1 Air System

2.7.2 Dehydrating Breather

2.8 Gasket Material

2.9 Flexible Metallic Conduit

2.10 Oil Processing

2.11 Inspection

2.12 Hardware

2.13 Paint/Coatings

2.14 Piping and Fittings

2.15 Technical Manuals

2.16 Technical Support

2.17 Reference Drawings and Documents

3. SUBMITTALS

4. ASEA BROWN-BOVERI Operation and Maintenance Manual

1. GENERAL

1.1 Abbreviations

A. The following is a list of abbreviations used through-out this document with definitions.

USBR: United States Bureau of Reclamation

MVA: Mega Volt Ampere kV: kilovolt

OSHA: Occupational Safety and Health Administration

CO: Contracting Officer

COR: Contracting Officer’s Representative

Hz: Hertz

BIL: Basic Impulse Level

RSHS: Reclamation Safety and Health Standards

IEEE: Institute of Electrical and Electronics Engineers

FOW: Forced Oil and Water

MR: Multi-Ratio

DGA: Dissolved Gas Analysis

GSU: Generator Step-Up ppm: parts per million

SPDT: Single Pole Double Throw

DPDT: Double Pole Double Throw

UV: Ultraviolet

1.2 Transformer Details

The contractor shall provide materials and oil services for (2) 135 MVA Three Phase transformers at Hoover Dam.

1.3 Requirements

Hoover personnel will perform the installation of components purchased under this contract. A contractor is needed to remove oil from the transformer and hold in a suitable container for processing and refilling transformers.

Instrumentation:

Contractor to supply thermo wells for devices listed under instrumentation with wells designed for use with respective gauges.

Supply three (3) X Winding Resistive Temperature Devices (RTD) for KA3A

Supply Dial type capillary thermometers for X windings temperature for KA3A

Supply three (3) X Winding Resistive Temperature Devices (RTD) for KA5A

Supply Dial type capillary thermometers for X windings temperature for KA5A

Supply three (3) H Winding Resistive Temperature Devices (RTD) for KA3A

Supply Dial type capillary thermometers for H windings temperature for KA3A

Supply three (3) H Winding Resistive Temperature Devices (RTD) for KA5A

Supply Dial type capillary thermometers for H windings temperature for KA5A

Supply two (2) Capillary Style Oil Temperature Gauges for KA3A and KA5A

Supply Oil Temperature RTD’s for KA3A and KA5A

Supply Oil Level Gauge for KA3A

Supply Oil Level Gauge for KA5A

Controls and ancillary devices:

Supply Buchholz Relay for transformer KA3A

Supply Buchholz Relay for transformer KA5A

Supply Gate Valves quantity four (4)– between Conservator and Buchholz Relay and between Buchholz Relay and transformer tank.

Pressure Relief Device:

Supply Pressure Relief Device for transformer KA3A

Supply Pressure Relief Device for transformer KA5A

DGA Monitor:

Supply DGA monitor for transformer KA3A

Supply Globe Valve for DGA Monitor on transformers KA3A

Tank:

Supply two (2) Gate Valves Oil Suction for Oil Pumps on KA3A

Supply two (2) Gate Valves Oil Return from Heat Exchangers on KA3A

Supply two (2) Gate Valves Oil Suction for Oil Pumps on KA5A

Supply two (2) Gate Valves Oil Return from Heat Exchangers on KA5A

Oil Pumps, motors, and valves:

Supply two (2) Oil Flow Indicators with bases for KA3A

Supply two (2) Gate Valves Oil Inlet #1 on KA3A

Supply two (2) Oil circulating pumps and motors on KA3A

Supply two (2) Oil Flow Indicators with bases for KA5A

Supply two (2) Gate Valves Oil Inlet #2 on KA5A

Supply two (2) Oil circulating pumps and motors for KA5A

Heat Exchangers:

Supply two (2) Heat Exchangers for KA3A

Supply two (2) Gate Valves Oil Inlet on KA3A

Supply two (2) Gate Valves Oil Outlet on KA3A

Supply two (2) Gate Valves Water Inlet on KA3A

Supply two (2) Gate Valves Water Outlet on KA3A

Supply two (2) Heat Exchangers for KA5A

Supply two (2) Gate Valves Oil Inlet on KA5A

Supply two (2) Gate Valves Oil Outlet on KA5A

Supply two (2) Gate Valves Water Inlet on KA5A

Supply two (2) Gate Valves Water Outlet on KA5A

Conservator

Air System

Supply Conservator Air Cells for KA3A and KA5A

Oil Processing

Process and Re-use Oil on two transformers (requirements for oil processing can be found under “Oil Processing section of this document)

Current Transformer Connection Blocks

Contractor to supply necessary amount of current transformer blocks to replace existing on each transformer and provide one (1) spare for each type/style. These are the blocks that provide the oil seal near the bushings.

1.4 Period of Performance

A. The overall period of performance is 360 calendar days. Outage season at Hoover Dam occurs between October 1 and May 30. The individual outages for the two transformers will be in this timeframe.

1.5 Schedule

A. Daily Work Hours. The work shall be done during normal work hours (6:30 a.m. to

5:00 p.m., Nevada time)– Monday thru Friday.

B. Holiday, Overtime, Night work or Weekend work may be available and requires approval from the Contracting Officer’s Representative 72 hours prior.

C. Project Schedule - The contractor shall submit schedules for work on both transformers. This schedule can be one document provided it shows the start and end dates for work on these transformers. A new schedule shall be submitted to the Contracting Officer’s Representative monthly to show when parts are ordered, and every two weeks once on-site work starts. The schedule shall be viewable and created using Microsoft Project.

D. KA3A – Outage

1. Overall schedule including parts and equipment acquisition.

2. Testing and commissioning.

E. KA5A – Outage

1. Overall schedule including parts and equipment acquisition

2. Testing and commissioning.

See section 3 for submittal schedules.

1.6 Government Furnished Equipment, Utilities and Facilities

A. Available Electrical

1. 480VAC, 3Φ is available for use at the contractor’s discretion. If used, the contractor is responsible for connections and power distribution in the work area.

2. 110VAC, single phase is also available for limited amperage use

B. Roadway access

1. Due to hairpin turns, access via lower portal road is limited to utility trucks and shorter flatbed delivery trucks.

2. The cable way crane will be used for equipment and material that cannot be delivered by truck to the job site. Contractor shall make necessary arrangements to use the cradle used with the cable way crane. USBR employees will make determination if equipment can be lowered via the cable way crane. This is dependent on how the load is stabilized. The contractor shall provide all necessary strapping to hold load during transit.

1.7 Liquidated Damages

Liquidated damages will be incurred at $1,000.00 per day starting at the eleventh day after notice is given to contractor to return to site to begin vacuum filling and oil processing of removed transformer oil. Notice shall be given by Contracting Officer or Contracting Officer’s

Representative on Contracting Officer’s behalf.

1.8 Security / Clearances

A. For all on site work, all contractor personnel working on site shall be subject to passing background investigations and be cleared prior to commencement of work. It shall be the contractor’s responsibility to incur costs for the credentialing process.

B. The contractor will be required to furnish a list of all employees (prime and subcontractors) who have passed background investigations and will be working at the site(s).

C. The following identifies the requirements:

1. CONTRACTOR EMPLOYEE SECURITY REQUIREMENTS. Operations at

Hoover Dam, and their power-plants, require continuous and effective security measures. In accordance with Homeland Security Presidential Directive-12, all on-site Contractor personnel shall have a Government-issued Personal Identity Verification credential before being allowed access to work at the site.

2. The cost of initiating the credentialing process, submitting the requisite forms, obtaining fingerprints, travel to a Credentialing Center for card enrollment and activation, and security interviews shall be borne by the Contractor.

3. The cost of suitability and PIV related background investigations will be borne by the Government.

4. For each employee who will be working at Hoover Dam the Contractor shall complete the highlighted portion of the Request for Initiation of Contractor Background

Investigation form and all Declaration for Federal Employment Forms (OF-306) and Fair Credit

Authorization Forms. Failure to complete the forms timely may cause delays in processing background investigations.

5. Promptly mail (do not e-mail or fax) the completed forms to:

Andy Trader (LCD-23203)

Hoover Dam

PO Box 60400

Boulder City, NV 89006-0400

6. Following the submittal of the above investigation package for each employee, the employee will receive an invitation to provide additional information required for their background investigation through the on-line e-QIP process. The background investigation will be conducted by the Office of Personnel Management, with the results furnished to the

Reclamation Office of Security, Safety, and Law Enforcement for final determination of the employee’s suitability to be assigned to a Reclamation facility.

7. Once a favorable determination has been made, Contractor personnel shall be invited to visit the Reclamation Credentialing Center at:

Lower Colorado Regional Security Office

200 Date Street

Boulder City, NV 89005

(702) 293-8008

8. Contractor personnel may have the option of visiting a more convenient location to complete the enrollment process.

9. The Contractor shall be responsible for ensuring that its employees comply with all required investigation interviews and established security rules and regulations.

10. Contract personnel shall not be permitted to enter established or designated restricted areas unless so authorized by the Government. Entry shall be in accordance with and subject to the security regulations established in the area. It shall be the Contractor’s responsibility to ensure that its personnel do not enter these areas unless authorized.

11. The Personal Identity Verification Card must be obtained from, and returned to, the Hoover Dam Police Department at the completion of on-site work.

1.9 Safety

A. The Contractor shall comply with all federal, state, and local laws and standards as well as the current version of the Bureau of Reclamation manual Reclamation Safety and Health

Standards (RSHS).

B. The Contractor may also download or view the electronic version of the RSHS manual at no charge from the Bureau of Reclamation web site at:

C. For the onsite work, the contractor shall perform and submit a Job Hazard Analysis to:

1. Identify safety hazards

2. Determine methods to mitigate and eliminate those hazards.

3. All onsite personnel shall read, understand, and sign the Job Hazard Analysis.

D. The contractor shall ensure all areas are cleaned and maintained in neat and orderly manner.

E. Each morning, the job foreman shall conduct an on-the-job or toolbox safety meeting and all employees under their supervision must attend.

F. The contractor shall report accidents, injuries, or illnesses in accordance with

Reclamation Safety and Health Standards, Section 3.5.

G. The contractor must remove employees who refuse or repeatedly fail to comply with safe work practices and standards, or supervisors who fail to enforce compliance.

H. Some Existing Hazards to be aware of:

1. Electrical hazard - Work is in the vicinity of 230 kilovolt lines that will be energized. Proper distances must be maintained around live circuits. Please refer to OSHA

Section 1910.269 for minimum approach distances to energized circuits.

2. Fall hazard while working on top of transformer.

3. Fall hazard while working on transformer deck. The transformers are located on a shelf next to the roadway. The elevation of the shelf above the roadway is approximately 4 feet. Care must be taken when working in the area.

4. Trip Hazard – on road next to transformer ramp. Rails are embedded in the concrete, and care must be taken when walking on this road.

5. In the case of a fire alarm, drill or actual fire, all contractor personnel working at Hoover will report to the transformer ramp near the Nevada roll-up door and provide a head count to the Government Contracting Representative (the inspector). Personnel will not return to work until the LCDO Safety, or authorized management official has sounded the “all clear” air horn.

1.10 Hazardous Materials

A. The Contractor shall be responsible for chemicals, grout, sealant, or other pollutants that are released into the air, drainage system of the dam, or into the river. The contractor shall ensure precautions are taken at the work site to contain potential hazardous material release into the Colorado River. Contractor shall store flammable liquids in a flammable locker supplied by the contractor.

B. Waste material shall be removed and properly disposed of in approved and legal manners.

C. Costs of disposal of the bushings, gaskets, non-used hardware, and any additional material shall be included with the bid amount. Old bushings shall be disposed according to government regulations. Any transformer oil that is not re-used shall be disposed according to current environmental regulations. All costs of disposal of bushings and oil shall be paid by contractor. These costs shall be included in the total bid price.

D. The contractor is responsible for proper and legal disposal of all waste materials, oils, and solvents according to hazardous waste disposal regulations.

E. Contractor shall manage disposal of all removed equipment and shall arrange to have all parts disposed of according to environmental regulations. Contractor is prohibited from disposing of removed material in trash containers managed by Hoover.

F. Contractor shall have oil absorbent pads on-site to handle small oil spills. Contractor is responsible for disposing of oil-soaked material in accordance with environmental regulations.

Disposal of oil-soaked material using dumpsters and trash containers at Hoover is prohibited.

G. Contractor is required to submit a Hazardous Material Control Plan prior to starting work due to the hazards involved with handling transformer oil. The Hazardous Material

Control Plan must be approved by the government before this work may take place.

Approximately four weeks will be needed by the government to review the plan. Work performed shall comply with the Resource Conservation and Recovery Act. The plan shall address items listed below.

H. The contractor shall submit an oil spill plan and reporting procedures.

I. The contractor shall maintain onsite the technical data sheet and SDS sheet for material used on site.

J. All diverted waste should be tracked using FORM E: Waste Diversion Table and submitted to the COR.

K. The contractor shall remove all unused material, tools, debris.

L. Contractor shall submit a list including quantities of all chemicals brought to the work site. This list shall be approved prior to start of work.

M. Contractor shall complete a waste manifest for all chemicals removed from the facility. This shall account for chemicals used during work and any chemicals that were not used. The government shall receive a copy of this manifest at the time the chemicals are shipped from the job site.

1.11 Protection of Existing Installations and Structures

A. The contractor shall safeguard the existing facilities and equipment from any harm resulting from their operations by using enclosures, drop cloths, coverings, etc. Any materials necessary to provide protection of existing facilities and equipment will be furnished by the contractor, remains the property of the contractor, and upon completion of the work, will be removed from the facility area by the contractor.

B. The contractor shall repair, at the contractor’s expense, any damage to property caused by the contractor’s action or by failure of the contractor to adequately protect the property. If the contractor fails to make such repairs in a timely manner, the Government may elect to repair the damage and to charge the contractor the cost of repair.

C. Any damage to historical property must be restored to original condition within a time frame as coordinated with the contracting officer or contracting officer’s representative not to exceed one year. The contractor shall repair, at the contractor’s expense, any damage to existing installations due to the contractor’s failure to provide proper protection. The Government may exercise the option to repair any such damage and charge the contractor for the cost at the discretion of the Contracting Officer.

1.12 Final Acceptance of Work

A. An inspection will be conducted by the Government at the completion of all work.

When the work has been completed, inspected, and accepted, final payment for the work will be authorized.

B. Clean up shall be inspected by Government and completed to the Governments satisfaction before final payment is made.

1.13 Special Work Permit

A. The contractor will be required to sign and abide by the instructions in a special work permit spelling out the allowed Dam and powerhouse areas for the contractor.

B. This special work permit will also identify any unusual hazards that might exist in the construction areas. The special work permit will also include any clearances required for safe completion of work.

1.14 Access to the Construction Work Area

A. The Contractor shall coordinate and plan for access to the installation area with the

Government.

B. The Contractor shall not block traffic with parked vehicles, equipment, and/or materials. Additional area for the Contractor’s use shall be provided at an area near the warehouse.

C. The Contractor shall place identification labels, with the Contractor’s name, on the windshield of their vehicles parked at any location on the Hoover Dam site. This shall not be required if the Contractor’s name is prominently displayed at some other location on the vehicle.

1.15 Government Submittal Review

A. The government will have the opportunity to review all submittals and provide feedback. The government will be allowed 16 calendar days to review and provide feedback on a submittal. If a submittal is found deficient, the government will send notice to the contracting companies representative stating the deficiency and will suggest a solution to remedy the deficiency. If the contractor does not act to correct the deficiency, the contract may be delayed until a solution is agreed to. If a submittal is deemed deficient, the government will have another 16 days to review the modified submittal. A submittal found deficient will require correction or modification before it will be considered approved.

B. Approval of each submittal does not waive any requirements of the contract.

The contractor must meet the terms of the contract regardless of submittal approval unless the contracting officer orders a change to the contract requirements in writing.

1.16 Drawings

A. Provide detail drawings of all materials supplied. The drawings shall be approved by the manufacturer for distribution and shall include dimensions, thread sizes, and list necessary material needed to secure to the transformer.

1.17 Shipping and Labeling of Boxes

A. All crates shipped to Hoover Dam shall be visibly labeled reading “KA3A and KA5A

Transformer Parts and Materials” for identification upon receipt at the warehouse.

B. Crates sent to the warehouse shall be shipped on flat bed trucks to allow easy offloading with a fork truck. Crates shipped in closed container trucks will be rejected.

2.0 Technical Requirements

2.1 Specifications

A. Contractor shall review and use the following standards for the planning, installation and commissioning of all parts and labor associated with this work. The standards are:

IEEE C57.12.00 – General Requirements for Liquid Immersed Distribution, Power and

Regulating Transformers

IEEE C57.12.10 – Requirements for Liquid Immersed Power Transformers

IEEE C57.12.80 – Terminology for Power and Distribution Transformers

IEEE 64-1969 – Guide for Acceptance and Maintenance of Insulating Oil in Equipment

IEEE Std 637 – IEEE Guide for the Reclamation of Insulating Oil and Criteria for Its Use

IEEE Std 1276 – IEEE Guide for the Application of High-Temperature Insulation Materials in

Liquid-Immersed Power Transformers

IEEE Std 1538 – IEEE Guide for Determination of Maximum Winding Temperature Rise in

Liquid-Filled Transformers

IEEE Std C57.12.10 Cor 1 – IEEE Standard Requirements for Liquid Immersed Power

Transformers

IEEE Std C57.12.10 Cor 2 – IEEE Standard Requirements for Liquid-Immersed Power

IEEE Std C57.12.70 – IEEE Standard Terminal Markings and Connections for Distribution and

Power Transformers

IEEE Std C57.12.90 – IEEE Standard Test Code for Liquid-Immersed Distribution, Power and

Regulating Transformers

IEEE Std 57.13 – IEEE Standard Requirements for Instrument Transformers

IEEE Std C57.13.1 – IEEE Guide for Field Testing of Relaying Current Transformers

IEEE Std C57.19.01 – IEEE Standard Performance Characteristics and Dimensions for Outdoor

Apparatus Bushings

IEEE Std C57.19.100 – IEEE Guide for Application of Power Apparatus Bushings

IEEE Std C57.91 – IEEE Guide for Loading Mineral Oil Immersed Transformers

IEEE Std C57.93 – IEEE Guide for Installation and Maintenance of Liquid-Immersed Power

ANSI/IEEE 57.94 – IEEE Recommended Practice for Installation, Application, Operation and

Maintenance of Dry-Type General Purpose Distribution and Power Transformers

IEEE Std C57.96 – IEEE Guide for Loading Dry-Type Distribution and Power Transformers

IEEE Std C57.98 – IEEE Guide for Transformer Impulse Tests

IEEE Std C57.100 – IEEE Standard Test Procedure for Thermal Evaluation of Liquid-Immersed

Distribution and Power Transformers

IEEE Std C57.104 – IEEE Guide for Interpretation of Gases Generated in Oil-Immersed

Distribution and Power Transformers

IEEE Std C57.105 – IEEE Guide for Application of Transformer Connections in Three-Phase

Distribution Systems

IEEE Std C57.106 – IEEE Guide for Acceptance and Maintenance of Insulating Oil in

Equipment

IEEE Std C57.109 – IEEE Guide for Liquid-Immersed Through Fault Current Duration

ASME B16 – Valves, Flanges, Fittings and Gaskets

ASTM D3487 – Standard Specification for Mineral Insulating Oil Used in Electrical Apparatus

2.2 Acceptance Testing

A. Contractor shall perform DGA tests on transformer oil prior to removal and after processing to verify oxygen inhibitor meets the required levels. This will also serve as baseline and after processing information to show oil processing efforts are effective and meet the requirements listed under the oil processing section of this document.

2.3 Instrumentation, Controls and Ancillary Devices

2.3.1 Low Voltage Winding Temperature Gauge

A. Supply total quantity two (2): Replacement temperature gauge shall be manufactured by Qualitrol, AKM Series with four (4) normally open contacts per gauge. The temperature range for this gauge is 0 to 160 degrees Celsius. The replacement gauge shall have the same number and type of contacts and shall have the same temperature scale. This gauge shall read

“Low Voltage Winding Temperature”. The casing of the gauge shall be ANSI 70 light gray.

The low voltage winding temperature electrical contacts shall be wired into the existing wiring located on the transformer. These devices shall be rated IP56 or higher and be rated for outdoor use. The dial gauge with contacts shall be housed in a metal casing to meet the IP56 requirement. This gauge shall have a resettable indicator for highest temperature obtained. This temperature gauge shall be a capillary type thermometer. Gauge shall work with already installed current transformer installed on transformer.

2.3.2 High Voltage Winding Temperature Gauge

A. Supply total quantity two (2): Replacement temperature gauges shall be manufactured by Qualitrol, AKM Series with four (4) normally open contacts per gauge. The temperature range for these gauges is 0 to 160 degrees Celsius. The replacement gauges shall have the same number and type of contacts and shall have the same temperature scale. This gauge shall read

“High Voltage Winding Temperature”. The casing of the gauge shall be ANSI 70 light gray.

The high voltage winding temperature electrical contacts shall be wired into the existing wiring located on the transformer. These devices shall be rated IP56 or higher and shall be rated for outdoor use. The dial gauge with contacts shall be housed in a metal casing to meet the IP56 requirement. This gauge shall have a resettable indicator for highest temperature obtained. This temperature gauge shall be a capillary type thermometer.

2.3.3 Oil Temperature Gauge

A. Supply quantity of two (2): Replacement temperature gauges shall be manufactured by Qualitrol 104 series with 1 normally open contact. The replacement temperature gauge shall be rated IP56 or higher and shall be rated for outdoor use. The temperature gauge shall come equipped with a minimum of 1 normally open contact. The gauge shall read from 0 to 120 degrees Celsius and shall be marked “Liquid Temperature”. The casing of the gauge shall be

ANSI 70 light gray. The oil temperature gauge electrical contacts shall be wired into the existing wiring located on the transformer. The casing for the dial shall be metal to meet the IP56 requirement. This gauge shall have a resettable indicator for highest temperature obtained. This temperature gauge shall be a capillary type thermometer.

2.3.4 Buchholz Relay (Gas Relay)

A. Supply total quantity two (2): The existing gas relay is manufactured by EGEM. The replacement gas relay shall have one normally open contact for alarm and one normally open contact for tripping. The new device will have the same mechanical mounting configuration.

The new device shall be wired into the existing detection circuit on the transformer. This device shall be rated for outdoor use. Gaskets shall be supplied for use on both sides of oil piping to this device. Existing relay is VEB BF50/10-2.

B. Supply total quantity four valves (4) for use on both sides of Buchholz relay. USBR is looking to isolate both sides of Buchholz relay. The new valve shall be made of the same material as the existing.

2.3.5 Pressure Relief Device

A. Supply total quantity two (2): Replacement pressure relief devices shall be manufactured by Qualitrol type XPRD. Contractor shall supply a new pressure relief device that mates with the existing opening of the transformer. The new pressure relief device shall have a minimum of one (1) normally open latching contact that closes when the pressure rises. The new sudden pressure relief device shall have a flag showing when the device activates. This device shall be rated for outdoor use. Contractor shall supply Qualitrol pvc piping option KIT-046 with this device. Government will install this device and the kit when received.

2.3.6 Oil Flow Indicators

A. Supply total quantity four (4): Replacement oil flow indicators shall be made by

Qualitrol type 092. The new flow indicators shall be labeled “Oil Flow Indicator”. It shall also have the following labels “Pump On” and “Pump Off” with the correct indication represented by a dial. The oil flow indicators shall be rated IP56 or higher and shall be rated for outdoor use.

The case shall be constructed of die cast aluminum with an ASA #70 thermosetting powder coat finish. The indicator shall have a UV stabilized polycarbonate lens securely fastened in place with stainless steel bezel ring and hardware. The casing shall be metal to meet the IP56 rating.

These indicators shall have one double pole double throw (DPDT) switch per indicator.

2.3.7 Fault Monitor / Dissolved Gas Analyzer

A. Supply total quantity two (2): Dissolved Gas Analyzers. The new gas monitors shall have the ability to detect the following gases: Hydrogen

(H2), Oxygen (O2), Methane (CH4), Carbon Monoxide (CO), Carbon

Dioxide (CO2), Ethylene (C2H4), Ethane (C2H6), Acetylene (C2H2) and

Nitrogen (N2). This device shall be rated IP65 or higher. These devices shall be rated for outdoor use. A remote screen shall be located near the main control box on the transformer that shows the amount of each of these gases. The screen shall be ultraviolet resistant and shall show each gas for a minimum of five seconds and no more than ten seconds before scrolling to the next gas percentage. A keypad shall be included allowing an operator to scroll through the screen display at their convenience. The screen and keypad shall be located approximately 4-5 feet above the concrete pad for the transformer to allow easy viewing for personnel. The fault monitors shall have the ability to measure moisture in oil. The monitor shall have a 7-inch color LCD screen. The monitor shall have a two-enclosure design. The monitors shall use photo-acoustic spectroscopy

(PAS) for gas measurement. The frequency of gas measurement shall be adjustable from once per hour to once every week and shall come with a rapid mode to obtain a sample in 30 minutes. The monitors shall have an

IP56 compliant enclosure.

B. The DGA monitors shall include a push to test light for lamps on the outside panel and all panels shall have handles made of UV resistant material. Plastics do not survive due to the amount of sunlight.

C. Each DGA monitor shall come with a sun shield to protect the device for sunlight. The cost of the sun shield shall be included in the DGA price.

D. Commissioning of the DGA monitors shall be included with the supply.

Commissioning shall be performed by manufacturer.

E. The DGA monitors shall come with four (4) sections of stainless steel hose to connect the transformer tank to the monitor. Each section of stainless steel hose shall be 25 feet in length and shall be flexible to allow bends in connecting to monitor.

F. The monitor shall come with a stainless steel mounting stand.

G. The monitors shall not require a ‘make-up’ gas to perform measurements.

2.3.8 Oil Level Indicator

A. Supply two (2) new oil level indicators with compatible float arms. Each level indicator will have a single pole double throw (SPDT) contact/contacts. The contacts shall be rated for operation of 24 to 220 volts either alternating current or direct current. The maximum switching current will be 2 amps. The oil level gauges shall have a 6-inch dial face with a UV resistant polycarbonate lens. The level indicators shall have a die cast aluminum housing with a thermosetting powder coat finish. The oil level indicators shall be magnetically coupled. The casing for the indicators shall be metal and shall meet IP56 requirements.

2.3.9 Winding Temperature Transmitters

A. Contractor to supply six (6) winding temperature transmitters with a 100-ohm platinum transmitter RTD’s. The transmitter shall utilize the existing current transformer for temperature compensation. The transmitter shall also come with a terminal box with the output of the transmitter wired to existing terminal blocks in the transformer control cabinet.

2.3.10 Hot Spot Detector Equipment

A. Equipment needed to duplicate hot spot detection shall be provided with RTD’s and temperature gauges and shall be included in temperature/thermometer pricing.

2.3.11 Current Transformer Connection Blocks

A. Contractor to supply current transformer blocks used to route current transformer wires outside of transformer tank. The blocks shall have the same number of terminals as blocks already installed on transformer.

B. The blocks shall be made of material able to withstand vacuum placed on transformer for oil filling and prevent oil leakage while in service.

2.4 Tank Oil Valves

A. All valves supplied shall have ASTM and ANSI ratings. The valves sizes shall match what is listed below for sizing and shall mate with supplied heat exchangers and transformer connections.

B. Supply the following valves on both transformers:

1. One (1) 4-inch drain valve located at the bottom of the transformer on KA3A and one (1) 4-inch drain valve located at the bottom of the transformer for KA5A.

2. Two (2) 4-inch oil supply valves for oil cooling for KA3A and two (2) 4-inch oil supply valves for oil cooling for KA5A.

3. Two (2) 4-inch oil return valves located at top of tank for KA3A and two (2) 4-inch oil return valves located at top of tank for KA5A.

4. One (1) 4-inch fill valve located on top of transformer for KA3A and one (1) 4-inch fill valve located on top of transformer KA5A.

5. Two (2) 4-inch gate valves for oil-water cooler inlet #1 and #2 for KA3A and two

(2) 4-inch gate valves for oil-water cooler inlet # 1 and #2 for KA5A.

6. Two (2) 4-inch gate valves for oil-water cooler outlet #1 and #2 for KA3A and two (2) 4-inch gate valves for oil-water cooler outlet #1 and #2 for KA5A.

7. One (1) conservator shut off valve located near buchholz relay for KA3A, and one (1) conservator shut off valve located near buchholz relay for KA5A.

8. One (1) isolating valve for DGA monitor for KA3A and one (1) isolating valve for DGA monitor for KA5A.

9. Two (2) valves on oil cooler supply lines for KA3A and two (2) valves on oil cooler supply lines for KA5A. Sizes unknown.

10. Two (2) valves on oil return lines for KA3A and two (2) valves on oil return lines for KA5A. Sizes unknown.

11. Two (2) Oil Pump Supply isolation valves for KA3A and two (2) oil pump supply isolation valves for KA5A.

12. Two (2) Oil Pump Return isolation valves for KA3A and two (2) oil pump return

13. Two (2) Water Inlet isolation valves for KA3A and two (2) water inlet isolation valves for KA5A.

14. Two (2) Water Outlet isolation valves for KA3A and two (2) water outlet

15. One (1) pressure gauge isolation valve for KA3A and one (1) pressure gauge isolation valve for KA5A.

D. All supplied valves shall be made of the same material as the existing valves and shall be ready for use when shipped.

E. All valves shall be painted the same color as the exterior finish of the transformer.

F. Contractor to submit data sheets for all valves listed above.

G. All valves shall have a position indicator located on the stem of the valve to show open or closed position.

2.5 Oil Pumps and Motors

A. Contractor to supply four (4) oil pumps with motors to be used on these transformers.

Existing oil pumps are 460VAC three phase. New motors with pumps shall be the same voltage.

Model number of existing pump motors is VMO LF350-002C made by ASEA.

B. New oil pumps will have connections identical to the existing pumps.

C. Contractor to supply data sheets on oil pumps and motors for approval prior to ordering.

2.6 Heat Exchangers

A. Transformers KA3A and KA5A

1. Shell

a. Maximum allowable working pressure: 50 psi

b. Test Pressure: 75 psi

c. Maximum allowable working temperature: 200 degrees Fahrenheit

d. Plate Thickness: .375 inches

2. Channel

a. Maximum allowable working pressure: 75 psi

b. Test Pressure: 115 psi

c. Maximum allowable working temperature: 100 degrees Fahrenheit

B. Hoover is expecting the same type of heat exchangers manufactured by Keeprite

Unifin to minimize modifications required to the existing piping.

C. Instruction booklets shall be provided with each heat exchanger. The heat exchangers shall be delivered to the Hoover warehouse with shipping costs paid by the contractor.

2.7 Conservators

2.7.1 Air System

A. Conservator Bladder - Contractor shall supply a new bladder inside the conservator tank. Information for this bladder is limited. Contractor is responsible for contacting a supplier to determine the correct size and material for this bladder. A suggested supplier is PRONAL.

2.7.2 Dehydrating Breather

A. Contractor to supply new dehydrating breathers for both transformers. The breather shall be suitable for use with this style transformer and have the following characteristics:

1) Casing of breathers shall be made from stainless steel or aluminum.

2) Breather shall have an oil trap.

3) Exterior of breather shall match the color of the transformer tank.

4) The new dehydrating breather shall have four compartments that each hold 1kg of desiccant (silica gel). New silica gel shall be provided for each compartment. The silica gel shall be dark blue in color when absent of moisture and shall change to pink-pale when introduced to moisture.

5) The dehydrating breather shall be able to remove moisture from

70% relative humidity air at 30 degrees Celsius at a volume of 1.9 cubic meters per kilogram.

6) The new silica gel shall be able to absorb 75 gr/kg at complete discoloration.

7) The new silica gel shall be reusable. Instructions for drying out the silica gel shall be included in submitted instruction manuals to the government.

8) The breather shall have four (4) compartments with desiccant and an oil trap. This is what is currently in operation.

2.8 Gasket Material

A. Contractor to supply sheets of gasket material in 3/16 inch and ¼ inch thickness. The material shall be cork neoprene and contractor shall provide 160 square feet of each thickness. Contractor to supply 42” wide rolls of material for both thicknesses.

B. Contractor to supply sheets of Garlock in 3/16 inch thickness. Total amount of

Garlock shall be 128 square feet.

2.9 Flexible Metallic Conduit (Seal-Tite)

A. Contractor to supply 100 feet of ½ inch diameter flexible metallic conduit. The flexible metallic conduit shall be grey.

B. Contractor to supply 100 feet of ¾ inch diameter flexible metallic conduit. The flexible

C. Contractor to supply 100 feet of 1 inch diameter flexible metallic conduit. The flexible

D. Contractor to supply 100 feet of 1-1/2 inch diameter flexible metallic conduit. The flexible metallic conduit shall be grey.

E. Contractor to supply 100 feet of 2 inch diameter flexible metallic conduit. The flexible

F. Contractor to supply 100 feet of 2-1/2 inch diameter flexible metallic conduit. The flexible metallic conduit shall be grey.

2.10 Oil Processing

A. The removed oil will be stored in a clean container supplied by the contractor.

B. Contractor to supply oil processor, oil holding tank/tanks, engine generator to power oil processor, a crane is necessary and all tools and fittings necessary to perform the required work.

C. After the bushings are installed, conservator replaced and the covers are installed, the transformer oil shall be processed with a Purivac or similar model of oil purifier to remove moisture, contaminants, and dissolved gases. The process shall be applied for three times the volume of transformer oil.

D. Dissolved gas analysis shall be performed on the transformer oil to verify gases and contaminants are removed from the oil. The cost for this test shall be included in the bid price and paid for by the contractor performing this work. Dissolved gas analysis shall show that no additional contaminants or moisture have been introduced into the oil.

Contractor is required to meet the dissolved gas metrics listed in Part N.

E. Gasket material needed for this work shall be supplied by the group performing the work. Work will include preparing all surfaces for connections and torquing all connections to manufacturers recommended values.

F. All gasket surfaces shall be clean and free of debris before applying new gasket material. Care shall be taken when prepping these areas to prevent any particles and/or contaminants from falling in the transformer.

G. All hardware used shall be suitable for use with the type of bushings being installed.

New hardware shall be supplied by contractor performing work.

H. All covers removed to access the bushings shall be installed prior to completion of the work, and prior to transformer testing.

I. Contractor to place vacuum on transformer prior to filling with oil. Contractor shall follow manufacturer and industry guidelines. Refer to ABB manuals for details on vacuum filling transformers.

J. Contractor shall be responsible for bringing the oil level to the correct level indicated by the level indicator on the transformer. The cost of the oil to bring the transformer to the correct level shall be included in the bid price. Contractor shall also add oxygen inhibitor to the transformer oil to bring the inhibitor level to 0.3% by total weight. The tolerance for the inhibitor concentration shall be +/- .02%. The cost of the oxygen inhibitor shall be included in the bid price.

K. Contractor shall have equipment with capacities to store the amounts of oil in each transformer. Precautions must be in place to prevent oil from being spilled on the ground and introduced to the Colorado River. The contractor shall have oil containment in place under the take holding transformer oil, under the oil processor (purifier) and shall have oil containment under the transformer while work is being performed. If an oil spill occurs, the Contracting Officer

Representative (COR) / Contracting Officer Technical Representative (COTR) shall be notified immediately.

L. Oil that is removed from the transformer will be filtered prior to being pumped back in the transformer. The contractor is responsible to fill the transformer to the amount required for normal operation. This is indicated by the level reading at the 25-degree Celsius line located on the oil level gauge. The cost of the oil shall be included in the bid price. This includes oil necessary if the transformer is already low and/or to account for oil lost while work is being performed.

M. Once oil processing is started, it shall continue without interruption.

N. A dissolved gas test will be performed to determine if the processed oil meets the following specifications:

Gases:

H2 5ppm or less

CH4 5ppm or less

C2H2 0ppm

CO 20ppm or less

CO2 300ppm or less

O2 4,000ppm or less

Physical Properties

Water Less than 10ppm

Dielectric Strength 38kV minimum ASTM D-1816

Interfacial Tension 36 dynes/cm minimum

Acid Number 0.3 mg KOH/gm maximum

O2 Inhibitor 0.3% by oil weight minimum +/- .02%

O. The contractor is responsible for meeting the criteria for both gases in oil and the physical properties of the oil after oil processing. The contractor may use any lab it feels necessary to obtain a DGA of the oil after the processing takes place. The government may send a sample to a lab of their choice to confirm the results of the DGA test.

P. Additional oil necessary to bring oil level to fill line shall be Shell Diala S2 ZX-A.

Contractor is responsible for level of inhibitor in transformer oil at the end of processing.

2.11 Inspection

A. Contractor and COR shall inspect the work area after oil processing takes place. This will ensure area is clean after use and no spills are observed. Any spills shall be cleaned at the contractor’s expense. All material used to clean the work area shall be disposed at the contractor’s expense.

2.12 Hardware

A. Contractor shall include hardware necessary to attach supplied parts to transformer. Bolts and washers shall be stainless. Nuts shall be grade 2H.

Hardware shall be adequate length and thickness to meet torque requirements for installation of supplied items in this document.

2.13 Paint/Coatings

A. Contractor shall supply 15 gallons of Sherwin Williams Pro Industrial Procryl Primer paint. Series B66-W00310.

B. Contractor shall supply 15 gallons of Sherwin Wiliams Polane 8910 Polyurethane

Enamel. Color and gloss shall meet ANSI 61 semi-gloss.

C. Contractor shall supply data sheets for both the primer and exterior coating for review and approval. Contractor shall also supply safety data sheets (SDS) sheets for both items including necessary curing agents.

D. Contractor shall submit paint swatches with SDS sheets to confirm color and finish for the primer and exterior coating. The swatches shall be approved before the paint is ordered.

2.14 Piping and Fittings

A. Contractor to provide 60 linear feet of seamless schedule 40 pipe domestic.

B. Contractor to provide twelve (12) class 150 raised face 4 inch slip on flanges domestic.

C. Contractor to provide four (4) schedule 40 4-inch tees.

D. Contractor to provide six (6) class 150 high performance butterfly valves, 4-inch raised face, non-raising stem.

E. Contractor to provide one (1) 180 degree schedule 40 4-inch.

F. Contractor to provide six (6) schedule 40 long radius elbows.

G. Contractor to provide six (6) metric class 150 slip on full face.

H. Contractor to provide three-hundred (300) 5/8-11 x 3-1/2 PTFE coated studs.

I. Contractor to provide six-hundred (600) 5/8-11 PTFE coated heavy hex nuts.

J. Contractor to provide thirty (30) class 150 4-inch ring gaskets.

K. Contractor to submit data sheets for material listed in this section for approval.

2.15 Technical Manuals

A. Data sheets on materials supplied will serve as technical manuals listed in this section. Government is responsible for binding and reproducing the supplied documents/data sheets.

2.16 Technical Support

A. Contractor shall be available to provide technical support for all material provided under this contract. This shall also serve for questions relating to vacuum filling and oil processing. Contractor will only be liable to answer questions relating to material they provided.

2.17 Reference Drawings and Documents (See Solicitation/Contract Attachment 2)

1. ABB Operation and Maintenance manual

2. Hoover Drawing 45-D-9325: Arrangement of overhead lines and circuits from Hoover

2.18 Optional Material

A. Government is seeking pricing and availability on the following material.

These items are in addition to the items and quantities listed in the corresponding sections.

Description: Section

Reference:

Quantity: Unit Price: Extended

Price:

Low Voltage

Winding

Temperature Gauge

2.3.1

High Voltage

Winding

Temperature Gauge

2.3.2

Oil Temperature

Gauge

2.3.3

Buchholz Relay (Gas

Relay)

2.3.4

Pressure Relief

Device

2.3.5

Oil Flow Indicators

(Switches)

2.3.6

Fault Monitor

(Dissolved Gas

Analyzer)

2.3.7

Oil Level Indicator 2.3.8

Winding

Temperature

Transmitters

2.3.9

Hot Spot Detector

Equipment

2.3.10

Current Transformer

Connection Blocks

2.3.11

4-inch drain valve 2.4.B.1

4-inch oil supply valves

2.4.B.2

4-inch oil return valves

2.4.B.3

4-inch oil fill valve 2.4.B.4

4-inch gate valve cooling water inlet

2.4.B.5

4-inch gate valve cooling water outlet

2.4.B.6

Conservator isolation valve

2.4.B.7

DGA isolation valve 2.4.B.8

Heat exchanger oil inlet isolation valves

2.4.B.9

Heat exchanger oil outlet isolation valves

2.4.B.10

Oil pump inlet isolation valves

2.4.B.11

Oil pump outlet isolation valves

2.4.B.12

Heat exchanger water inlet isolation valves

2.4.B.13

Heat exchanger water outlet isolation valves

2.4.B.14

Pressure gauge isolation valve

2.4.B.15

Oil Pump with motor 2.5

Heat exchanger 2.6

Conservator Bladder 2.7.1.A

Dehydrating Breather

(one complete assembly)

2.7.2.A

Cork Neoprene

Gasket Material

2.8

Garlock Gasket

Material

2.8

Flexible Metallic

Conduit (Seal-Tite) ½ inch diameter

2.9 A

Flexible Metallic

Conduit (Seal-Tite) ¾ inch diameter

2.9 B

Flexible Metallic

Conduit (Seal-Tite) 1 inch diameter

2.9 C

Flexible Metallic

Conduit (Seal-Tite)

1-1/2 inch diameter

2.9 D

Flexible Metallic

Conduit (Seal-Tite) 2 inch diameter

2.9 E

Flexible Metallic

Conduit (Seal-Tite)

2-1/2 inch diameter

2.9 F

Seamless Schedule

40 pipe domestic

2.14

Class 150 raised face

4 inch slip on flanges domestic

2.14

Schedule 40 4-inch tees

2.14

Class 150 high performance butterfly valves, 4-inch raised face, non-raising stem

2.14

180 degree schedule

40 4-inch

2.14

Schedule 40 long radius elbows

2.14

Metric class 150 slip on full face

2.14

Class 150 4-inch ring gaskets

2.14

SECTION 3 – SUBMITTALS

Table 1A – List of Submittals

*Submittal types: A – Approval, I - Information ** CO indicates Contracting Officer. COR indicates Contracting Officer’s Representative. Denver TSC indicates Technical Service Center

RSN

Clause or Section Title

Submittals required Due date or delivery time Type

Respon-sible code

No. of sets to be sent to: **

CO COR

001 52.204-7, 52.232-33

System for Award Management updated annually and 14 days prior to first payment

CO

002 52.228-15 Performance and Payment Bonds/Alternate Payment Protections

Within 10 days after award and prior to issuance of Notice to Proceed (NTP) and commencement of onsite work.

A CO 2 0

003 52.228-5 & 1452.228-70

(1) Insurance certificate

(2) Current certification for each subcontractor.

(1)…