Draft Specification - 48 20 00_DRAFT.pdf

SECTION 48 20 00

TRANSFORMER SHIPMENT, HAULING AND SITE ASSEMBLY

PART 1 GENERAL

1.1 GENERAL INFORMATION

This Section, in conjunction with Sections 48 19 23.50, 01 10 10 and 01 57 20, covers the Contractor's responsibilities for shipment of the 87,0 00 kVA transformers for delivery f.o.b. destination Detroit Dam, hauling, off-loading and placement, site assembly, gas-filling, field testing, and provision of Erecting Engineer services.

1.2 DESCRIPTION OF WORK

Deliver the transformers to the Detroit Dam per the required delivery schedule as included in Clause 52.211-8, "TIME OF DELIVERY". The Contractor shall be responsible for the site work identified within this Section, including:

a. After delivery of the transformers to the Detroit Dam, perform on-truck inspections and testing (as required), off-loading of transformers onto the existing transformer piers on the tailrace deck

b. Reassemble transformer in its final operating location.

c. Process and gas-fill the assembled transformer.

d. Perform all final tests to ensure suitability for operation.

e. Provide manufacturer's Erecting Engineer services for witnessing all site movement and work performed, as required in paragraph, "ERECTING ENGINEER SERVICES".

f. Provide the services of a Commissioning Agent for the witnessing all work performed during the pre-operational testing, operational testing, and commissioning activities for each transformer when placing back into service, as required in Section 26 08 01.

1.3 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASTM INTERNATIONAL (ASTM)

ASTM B 3 (2012) Soft or Annealed Copper Wire

ASTM B 8 (2011) Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, or Soft

ASTM D 923 (2007) Standard Practice for Sampling

Electrical Insulating Liquids

ASTM D 1933 (2003; R 2008) Nitrogen Gas as an Electrical Insulating Material

ASTM D 3283 (1998; R 2012) Air as an Electrical Insulating Material

ASTM D6871 (2003; R 2008) Standard Specification for Natural (Vegetable Oil) Ester Fluids Used in Electrical Apparatus

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C57.12.00 (2010) General Requirements for Liquid-Immersed Distribution, Power, and Regulating Transformers

IEEE C57.12.90 (2010) Test Code for Liquid-Immersed Distribution, Power, and Regulating Transformers

IEEE C57.13 (2008) Requirements for Instrument Transformers

IEEE C57.93 (2007) Guide for Installation and Maintenance of Liquid-Immersed Power Transformers

IEEE C57.106 (2006) Guide for Acceptance and Maintenance of Insulating Oil in Equipment

IEEE C57.152 (2013) Guide for Diagnostic Field Testing of Fluid-Filled Power Transformers, Regulators, and Reactors

UNDERWRITERS LABORATORIES (UL)

UL 1581 (2001; Rev thru Jan 2013) Reference Standard for Electrical Wires, Cables, and Flexible Cords

1.4 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES.

SD-01 Preconstruction Submittals

1. Transformer Movement Plan; G, AO

A transformer movement plan detailing movement of the transformers from the railhead (if shipped by rail), to the operating location shall be submitted for approval not later than 60 calendar days prior to delivery of the first transformer (see paragraph

"TRANSFORMER MOVEMENT PLAN").

2. Transformer Site Assembly Procedure; G, HDC

A transformer site assembly procedure and schedule detailing the reassembly of each transformer, vacuum gas-filling, final field testing, and durations shall be submitted for approval not later than 60 calendar days prior to delivery of the first transformer (see paragraph "Transformer Site Assembly Procedure").

3. Field Supervisor Experience; G, HDC

The qualifications for the field supervisor experience shall be submitted a minimum of 60 calendar days prior to the performance of sitework, if the proposed field supervisor is different than that included with the proposal documents. (see paragraph "Field Supervisor Experience").

4. Erecting Engineer's Qualifications; G, HDC

The manufacturer's Erecting Engineer's qualifications shall be submitted not later than 60 days prior to delivery of the first transformer (see paragraph "Erecting Engineer's Qualifications").

SD-05 Design Data

Dry Air; G, HDC

Descriptive data for dry air shall be submitted for approval no later than 90 calendar days prior to shipment shipment of the first transformer, to demonstrate fully that all items will conform to the requirements and intent of the specifications.

SD-06 Test Reports

1. Delivery Transformer Gas Test Report; G, HDC

A transformer gas field test report, showing that the transformer gas meets the requirements of Section 48 19 23.50 (paragraph, "SF6 Gas") prior to filling of each transformer, shall be submitted for approval not later than 7 working days following taking of the gas sample (see paragraph "Transformer Gas for Processing").

2. Transformer Field Test Report; G, HDC

A transformer field test report shall be submitted for approval not later than 7 calendar days following completion of the field tests for each transformer (see paragraph "Electrical Tests").

SD-07 Certificates

Shipping Notices; G, AO

A list of articles shipped with descriptive data shall be submitted within 7 days of each shipment (see paragraph "Packaging and Marking for Shipment").

SD-08 Manufacturer's Instructions

Training Outline; G, AO

A training outline covering the material to be used for performance of the on-site training session, including a schedule, shall be submitted not later than 10 calendar days prior to completion of the transformer field tests for the first transformer (see paragraph "CONTRACTOR-FURNISHED TRAINING OF

GOVERNMENT PERSONNEL").

SD-09 Manufacturer's Field Reports

1. Field Supervisor daily report; G, AO

The field supervisor shall provide a copy of the daily report to the COR at the end of every working day. (see paragraph "FIELD

SUPERVISOR EXPERIENCE AND RESPONSIBILITIES").

2. Impact Recorder Summary Report; G, AO

The impact recorder summary report, including a copy of the impact recorder log, shall be submitted for approval within 24 hours after delivery of each transformer (see paragraph "Site Delivery Inspection Procedure and Schedule")

3. Site Delivery Inspection Report; G, AO

The site delivery inspection report shall be submitted for approval within 48 hours following completion of the site delivery inspection for each transformer (see paragraph "Site Delivery Inspection Report")

Tools and parts control checklist; G, AO

A copy of the tools and parts control checklist shall be provided to the COR at the end of every working shift, for each transformer. (see paragraph "Tools and Parts Control").

1.5 POINT OF CONTACT FOR SITE ACCESS

[NAME]

Detroit Dam Powerplant

Near Detroit, OR 97342 Phone: , ext. [xxxx]

1.6 FIELD SUPERVISOR EXPERIENCE AND RESPONSIBILITIES

1.6.1 Field Supervisor Experience

The field supervisor shall have been engaged in the field (site) movement, reassembly, oil-filling and testing of similar power transformers as specified herein. Qualifying experience shall have been performed at a minimum of five projects within the previous ten years. A verifying contact, name and phone number shall be provided for three such facilities. The field supervisor experience shall be submitted for approval, which shall include a listing of projects performed, scope of the work, and a contact name and phone number.

1.6.2 Responsibilities

One full-time employee of the Contractor shall be available at the worksite anytime other Contractor or subcontractor personnel are working on the site, to supervise and direct the work specified herein. This field supervisor shall be fluent in the spoken and written English language. The supervisor shall be present at the Detroit Dam during all site work including transformer site movement, reassembly, oil-filling and testing, and shall be responsible for following OSHA safe clearance procedures and the Government's Safe Clearance procedures. The supervisor shall keep all as-built drawings current and provide copies upon completion of the work.

The field supervisor shall be responsible for the performance, oversight and correctness of all site work identified in these specifications, including the following:

a. Comply with all safety, health and reporting requirements of these specifications, including power plant Safe Clearance procedures, accident prevention, environmental protection, activity hazard analysis, fall protection, and confined space entry.

b. Preparation of all required submittals and documentation.

c. Securing an inventory of all materials entering the transformer to ensure no unintended foreign objects remain in the tank.

1.6.3 Daily Reports

The field supervisor shall maintain a Field Supervisor daily report, and provide a copy to the COR at the end of every working day. The daily report shall include the following activities, at a minimum:

a. Weather conditions

b. References to Activity Hazard Analysis

c. Inspection activities

d. Detailed description of work performed

e. Photographs

f. Tests performed with results

g. Tools and parts control daily checklist

h. Problems noted

1.7 ERECTING ENGINEER SERVICES

1.7.1 General

The Contractor shall give personal attention to the faithful execution and completion of this work and shall provide a transformer manufacturer’s erecting engineer on the site of the work continually during the progress of transformer delivery, movement, assembly, oil-filling and testing. The erecting engineer shall be fluent in the spoken and written English language. The erecting engineer’s qualifications and identification shall be provided, as identified below.

1.7.2 Erecting Engineer's Qualifications

The erecting engineer shall be a permanent employee of the transformer manufacturing facility, or a factory certified representative thereof, and shall have been engaged in the witnessing of field (site) assembly and installation of similar power transformers, as specified herein, for a minimum of five years, and shall have performed this work at a minimum of five projects. A verifying contact, name and phone number, shall be provided for three such facilities, and the Erecting Engineer’s Qualifications shall be submitted for approval. The Erecting Engineer shall have the authority to make decisions on behalf of the transformer manufacturer.

1.7.3 Responsibilities

The transformer manufacturer's erecting engineer shall be responsible for the transformers, and for the oversight and correctness of instructions given during their reassembly. The erecting engineer shall be responsible for performance of the following work, for each transformer:

a. Witness and guide off-loading and loading of the transformers at the rail siding (if shipped by rail), and off-loading the transport truck of one transformer in the powerhouse assemly bay and one transformer in the designated storage area at the Detroit Dam.

b. Witness and guide the reassembly of the first transformer in the powerhouse assembly bay.

c. Witness or guide the movement of the first transformer to its final operating location.

d. Witness, guide, or perform the oil-filling processes of the first transformer in its final operating location.

e. Witness, guide or perform all transformer inspections and tests.

f. Witness and guide loading, movement, and off-loading of the second transformer from the designated storage area to the powerhouse assembly bay.

g. Witness and guide the reassembly of the second transformer in the powerhouse reassembly bay.

h. Witness or guide the movement of the second transformer to its final operating location.

i. Witness, guide, or perform the oil-filling processes of the second transformer in the final operating location.

j. Witness, guide or perform all transformer inspections and tests.

k. After completion of all transformer site work, conduct training for

Government personnel, per the requirements of paragraph

"CONTRACTOR-FURNISHED TRAINING OF GOVERNMENT PERSONNEL".

1.7.4 Specialized Equipment Installation Services

The on-line dissolved gas and moisture content monitor shall be installed during the transformer site reassembly process utilizing turnkey installation services by the specific equipment manufacturer.

1.7.5 Reporting

The Erecting Engineer shall keep a record of all data taken during site assembly and installation, and shall provide this information to the Field Supervisor for inclusion in the daily reports. The Erecting Engineer's records shall include inspection activities, instructions provided, test results, recommendations and observations.

PART 2 PRODUCTS

2.1 DRY-AIR

2.1.1 Dry-Air in Cylinders

Dry-air provided in cylinders, if used, shall be in accordance with ASTM D 3283, Type I. As identified in the referenced standard, the composition and properties of the dry-air shall be as follows:

a. Oxygen, volume: 19.5% to 23.5%

b. Carbon monoxide, max. volume: 0.0020%

c. Carbon dioxide, max. volume: 0.10%

d. Nitrogen: predominantly balance

e. Dew point, max.: -58 Degrees Celsius

2.1.2 Air Compressor Dryer

Dry-air supplied by an oil-less compressor shall include the following, as a minimum:

a. Desiccant system on the output of the compressor designed for removal of dirt, water, oil and uncondensed moisture from compressed air lines.

b. Maintain a maximum -40 degrees Fahrenheit dew point, while achieving a 0% compressed air humidity.

c. Coalescer that removes oil and sub-micron particles down to 0.01 microns.

d. Filter that provides removal of water and contaminants down to 5 microns.

e. Provides a filtration capacity up to 30 CFM @ 175 psi.

f. Replaceable or regenerative desiccant system which provides indication of silica gel saturation.

PART 3 EXECUTION

3.1 PROTECTION OF MATERIAL AND WORK

At all times prior to delivery and during the assembly and testing process, all materials, supplies, and equipment of every description including property which may be Government-owned and all work performed shall be protected and preserved. If, as determined, material, equipment, supplies, and work performed are not adequately protected, such property may be protected by the Government and the cost thereof may be charged to the Contractor or deducted from any payment due. All machinery, materials, and articles in a complete or incomplete state for which progress payment has been made prior to delivery shall be adequately protected from loss and from corrosion and all other forms of damage. The Contractor shall also be responsible for and make good any damages due through their fault or negligence occurring during assembly and testing of the equipment at the powerhouse.

3.2 TRANSFORMER SHIPMENT PREPARATION

3.2.1 General

It is the Contractor's responsibility to supply units of shipping dimensions and weight that allow for transport from the point of manufacture to the power plant. If beams are required to distribute loading during shipment, their weight and height shall be taken into consideration when determining shipping dimensions and weight, and the beams shall be provided as part of the contract. Any internal blocking or bracing that is to be removed from the transformers at their destination shall be colored bright yellow, and specifically addressed in the Transformer Site Assembly Procedure. Any material to be returned to the vendor after transformer shipment shall be returned at the Contractor's expense, and shall bear identification of material ownership and shipping address. Materials not so marked will be disposed of at the Government's discretion.

3.2.2 Packaging and Marking for Shipment

a. All material and articles shall be prepared and loaded for shipment in such manner as to protect them from damage in transit, and any and all damage shall be made good until the equipment is delivered to the Government at the specified delivery point. At a minimum, the transformers shall be prepared for shipment as follows:

(1) All bushings left installed on the transformers during shipment shall be protected by covers constructed of either wood or metal, securely fastened.

(2) All valves located within 48 inches of the base of the transformer tank shall be protected by covers constructed of either wood or metal, and securely fastened.

b. Where necessary, heavy parts shall be mounted on skids or shall be crated, and any articles or materials that might otherwise be lost shall be boxed or wired in bundles and plainly marked for identification. All parts exceeding two hundred (200) pounds of gross weight shall be prepared for shipment so that slings for handling by the crane may be readily attached while the parts are on the car or transport truck. Boxed parts, where it is unsafe to attach slings to the box, shall be packed with slings attached to the part, the slings to project through the box or crate so that attachment to the hoisting equipment can be readily made.

c. No material or equipment shall be shipped until after it has been inspected and accepted for shipment by the Government, or unless inspection of the equipment has been waived in writing. The Government shall be notified at least 15 days in advance as to the expected shipment dates of the equipment.

d. All accessories and spare parts shall be packed separately in containers plainly marked, ACCESSORIES ONLY, or SPARE PARTS ONLY. A packing list, listing the contents of each container, shall be placed in a moisture-proof envelope and securely fastened to the outside of the container. The packing list shall provide the following information for each spare part or accessory in the container:

(1) Manufacturer

(2) Contract number

(3) Identification, including the manufacturer's drawing number reference

e. Each spare part or accessory shall be identified so that it can be easily matched against its entry on the packing list.

f. All crates containing equipment that should be stored indoors shall be marked "STORE INDOORS" in 2-inch high lettering. For items that are required to be shipped and stored in a particular arrangement such as bushings, shall be marked with "THIS SIDE UP" or similar in 2-inch high lettering.

g. As soon as each shipment is made shipping notices shall be submitted on which shall be shown, in addition to the usual data, a description of the article furnished, the item number of the contract schedule to which the article applies, the shipping weight of each item, the number of pieces, the total weight, and, if shipped by railroad, the car number.

3.3 SHIPPING

3.3.1 Preparation for Shipment

The transformers shall be delivered without oil. Each tank shall be purged, filled with dry air (dew point of -50 degrees-C maximum), and plumbed with a bottle and regulator set to at least 2.5 psi. The regulator assembly shall include gauges to show tank pressure and bottle pressure. A shipping marker shall be attached near the gas connection showing the regulator setting, bottle pressure, and date the tank was sealed. Prior to shipment, the tank shipping pressure shall be maintained for a minimum of

24 hours, and it shall be verified that there is no appreciable reduction in bottle pressure. At time of shipment, a dew point test shall be performed on the gas in each transformer. The dew point temperature and the test method used shall be shown on the shipping marker. If shipped by rail, the transformers shall be shipped on rail cars equipped with hydraulic draft gear and hydraulic snubbing devices.

3.3.2 Impact Recorders

Each transformer shall be shipped with a 3-axis analog impact recorder.

For transportation within North America, a digital impact recorder with GPS satellite tracking, such as the Lat-Lon "RoadRider" monitoring and tracking system shall also be affixed. The impact recorders shall be mounted on a plate that is part and parcel to the transformer, and covered with a shield. The impact recorders shall be inspected before removal for tight securement, in position as loaded, protective cover intact, seals in position, and whether the area the device is secured to is intact, loose, or deformed. Any exceptions to the shipment observed shall be brought to the attention of the COR. The digital impact recorder shall be calibrated to record and transmit impact data greater than 1.0g, and shall also provide timed reports every 12 hours. The impact recorder "real-time" data shall be Internet viewable, and the Contracting Officer shall be provided with the "login" and "password" for site access prior to shipment.

Mounting provisions for the impact recorder shall be removed after delivery of the transformers.

3.3.3 Shipment

After completion of factory testing and the transformers have been released for shipment by the COR, each transformer and ancillary equipment shall be prepared for shipment and transported from the Contractor's manufacturing facility to the power plant. There is no rail access or rail siding near the powerhouse location. If transported by rail, the Contractor shall be responsible for all off-loading and movement operations for each transformer from the railcar, to the powerhouse, and to the final operating locations.

3.3.4 Hauling

The dimensions and weight of the largest piece as shipped by the Contractor shall not exceed that allowed for truck transport and for movement to the Detroit Dam. In the event the shipping dimensions or weight of the largest piece exceed those allowed for truck transport or at the project, the unit shall be designed such that its weight and dimension can be safely reduced in the field to that allowed for transport. Any limitations affecting transportation shall not become the basis for claims or damages, or for extension of time for completion of work.

3.4 TRANSFORMER MOVEMENT PLAN

The Contractor shall be responsible for the transport and movement of each transformer to the power plant. Government approval of the movement plan does not constitute approval by railroad or transportation authorities. A transformer movement plan shall be submitted for approval, and shall include the following as a minimum:

a. The method and means of lifting and off-loading the transformers from the railcar (if shipped by rail) and onto a transport truck.

b. Drawings or detailed maps showing the intended route to be taken by the the transporter to the power plant.

c. Wheel, axle, outrigger, and track loads of the transport truck, as applicable, and their locations along the route. Axle loading and road loading limitations shall be coordinated with the applicable state and county Departments of Transportation.

d. The Powerhouse parking area, as noted on drawings X-XXX and X-XXX, shall be utilized for temporary storage one one transformer prior to scheduled reassembly. Include loading calculations and description of the temporary cribbing proposed for storage.

d. Analysis of transformer off-loading into the powerhouse assembly bay, as shown on drawing X-XXX and directed by the COR, using the jack and skid method, including loading and layout calculations for temporary cribbing used during movement and for supporting the transformers for reassembly.

e. Analysis of transformer movement from the temporary cribbing in powerhouse assembly bay to the existing embedded rails using the jack and skid method, including loading and layout calculations for any temporary cribbing used during movement.

f. Method and means of movement from the powerhouse assembly bay embedded rail system to the final operating locations using the existing, embedded pulling eyes.

3.5 SITE DELIVERY INSPECTIONS

3.5.1 Site Delivery Inspection Procedure and Schedule

A transformer site delivery inspection procedure and schedule shall be submitted, and shall contain a step-by-step activity listing and a schedule that defines critical path activities and activity dependencies. Included in the procedure shall be the persons on each shift responsible for superintendence and safe clearance. Activities that are hazardous, affect plant operation, or require participation by Government personnel, shall be included in the plan. An Impact Recorder Summary Report shall be submitted within 24 hours after delivery of each transformer.

3.5.2 Sample Site Delivery Inspection Procedure

The following outline is based on the expected site delivery inspection and shipping procedure, and is intended to show the scope of the required work. The actual step-by-step procedure submitted shall be applicable to the transformer actually furnished, may differ from the following procedure, and shall list methods of repair and/or retesting if unacceptable results of the inspections are obtained.

a. If shipped by rail, perform an on car external inspection of each transformer and associated equipment for rail shipping damage, including signs of movement on the rail car, and loose or damaged tie rods.

b. Check the tank gas pressure by use of a pressure gauge. Tank pressure shall be positive.

c. Perform a dew point check, per the requirements of IEEE C57.93, paragraph 4.3. Moisture content, in terms of temperature, pressure and dew point should be essentially the same as when the unit was shipped.

Comparisons shall be made, and if the transformer insulation is determined to be wet, the manufacturer shall be contacted with respect to field dry-out procedures.

d. Inspect the impact recorder charts in the presence of the COR for any indication of excessive impacts during shipment. If damage due to shipment is suspected, a core insulation test shall be performed. If the transformer fails the core insulation test, recommendations for repair shall be included in the site delivery inspection report.

e. The Contractor will be responsible for acceptance of all delivered materials and equipment, the condition, and completeness as compared to the manufacturer's shipping packing list.

f. Perform an SFRA test on each transformer in its shipping configuration, as specified in Section 48 19 23.50, paragraph "Sweep Frequency Response Analysis Tests", and paragraph "FIELD TESTS", below, and compare to the factory SFRA tests as performed with the transformer in its shipping configuration. Wavetrace comparisons are expected to match closely, with little differences between matched scans.

Wavetrace comparisons that do not match closely shall be explained to the satisfaction of the COR, and may be grounds for transformer rejection, requiring an internal inspection of the transformer by the Contractor to determine the cause of the deviations, or requiring the transformer to be sent back to the manufacturing facility for repair at no expense to the Government.

g. If shipping damage is suspected, perform an on car internal inspection of the suspect transformer to check for internal damage such as loose coils, broken lead supports, dislodged end insulation, frayed lead insulation, core grounds, or loose nuts or bolts. A temporary cover shall be erected over the transformer, and the manhole covers shall be cleaned before the tank is opened. Prior to performing the internal inspection, the tank shall be purged with dry air until analysis of the gas in the transformer indicates at least 19.5 percent oxygen. The duration the inside of the tank is exposed to the atmosphere shall be recorded, and kept to a minimum. Reseal the transformer after the internal inspection has been completed, and repressurize the transformer to 2.5 psi with dry air. Positive pressure shall be maintained during transportation of the transformer to the project, off loading, and until such time that the tank is breached during assembly. An additional dew point check shall be performed 24 hours after reseal of the transformer.

h. All inspections listed in (a) through (g), above, shall be repeated after the transformer has been trucked from the railhead to the power plant, if applicable.

3.5.3 Site Delivery Inspection Report

After completion of the transformer site delivery inspections, the Contractor shall submit a site delivery inspection report for each transformer, based upon the approved procedural outline. The site delivery inspection report shall include, but not necessarily be limited to, the following:

a. Gas analysis, dew point and pressure.

b. Visual inspection log.

c. Core insulation test results (if required).

d. Sweep Frequency Response Analysis test results.

e. Proposed method of repair of any damage incurred during shipment.

f. Procedure for diagnosis and correction in the event of loss of positive gas pressure during shipment.

3.6 TRANSFORMER DRY-OUT

It is not anticipated that it will be necessary to dry-out the transformers; however, if gas pressure has been lost during shipment or shipping damage is suspected, this dry-out may be necessary. The insulation shall be field dried using Method 2, high vacuum drying, as described in Paragraph 4.9.2 of IEEE C57.93. If it becomes necessary to dry-out any part of the transformer, the Contractor shall perform all such operations as required at no additional cost to the Government.

3.7 TRANSFORMER CLEANING

Prior to movement to the powerhouse assembly bay, each transformer shall be thoroughly steam cleaned if determined to be dirty by the C.O.R. as a result of the transformer shipment process. This cleaning process may be performed on the transport truck, and shall be performed at a location approved by the C.O.R. Care shall be taken during steam cleaning to avoid the ingress of moisture into any electrical cabinets.

3.8 SITE MOVEMENT AND ASSEMBLY

3.8.1 Transformer Movement and Site Placement

Each transformer shall be off-loaded from the heavy haul truck and onto temporary cribbing using the jack and skid method. One transformer shall be off-loaded to the temporary storage location outlined on drawing X-XXX.

The other transformer shall be directly off-loaded to the transformer reassembly location in the powerhouse assembly bay outlined on drawing X-XXX.

After reassembly of the transformer in the assembly bay is completed, it shall be moved from the temporary cribbing to the embedded rails via the jack and skid method. Following the reassembled transformer's placement in the final operating location, the transformer stored in the transformer temporary storage location in the plaza may be hauled into the assembly bay and offload in the same manner as the first transformer. After placement on the embedded rails, each transformer shall be moved to its permanent operating location utilizing the existing rail system and pulling eyes, as the location is made available by the separate installations contractor.

The Contractor is responsible for providing come-alongs, hoists, and any other equipment necessary to move the transformers along the rail system.

Care shall be taken during placement of any cribbing so as to prevent damage to the existing facilities. Any hydraulic oil leaks from jacks or hydraulic rams shall be cleaned. Damage to powerhouse facilities by cribbing or movement shall be repaired by the Contractor to the satisfaction of the COR.

3.8.2 Transformer Site Assembly Procedure

After off-loading each transformer onto temporary cribbing in the powerhouse assembly bay, the Contractor shall be responsible for their complete reassembly. Operational verification of all transformer ancillary equipment, oil-filling, and performance of the final field tests as required in paragraph "FIELD TESTS" will be performed after movement to the final operating location. A transformer site assembly procedure shall be submitted for approval, which shall include a step-by-step activity listing and a proposed time line for each specific task. Any activities that are hazardous, affect plant operation, or require participation by Government personnel, shall be included. Provide a transformer reassembly procedure, including applicable references to the manufacturer's literature. As a minimum, the assembly procedure shall include:

3.8.2.1 Site Assembly Performed in the Powerhouse

The powerhouse overhead bridge crane will be made available to the Contractor for use in assembling the transformers, as needed. The bridge crane will be operated by Detroit personnel. The Contractor shall coordinate bridge crane support needs in advance with the COR and Powerhouse Superintendent. The following work may be completed in the powerhouse assembly bay:

a. All bolted connections (including factory bolted connections) shall be torqued to the manufacturer's recommendations, and indicated with a permanent marker that the torquing process was performed.

b. Perform an internal inspection of the transformer during the assembly process, by visual inspection through the manhole and bushing covers, for evidence of shifting components during transportation, condition of high-voltage lead insulation for evidence of abrasion, and verification that no tools or hardware were inadvertently left inside the tank after the manufacturing process. Any discovered anomalies shall immediately be brought to the attention of the COR. Photos of the inside of the transformer shall be taken during this inspection process, and included in the field test report.

c. Remove any interior shipping braces, and install and connect the bushings, cooling groups, radiators and ancillary equipment. All gasketed connections disassembled for installation of components removed for shipping purposes shall have new gaskets installed. All gasketed grooves shall be thoroughly cleaned prior to installation of the new gasket, and a lubricant shall be applied to the gasket during installation, such as Dow Corning Molykote 111, or approved equal.

During installation, the gasket shall be inspected to assure no damage exists, and that the gasket is properly sized to provide approximately 25% compression for filling of the groove when installed, and not oversized causing the gasket to be compressed out of the groove and pinched between the metal.

d. Pressure test the assembled transformers.

e. Assemble the fall protection system railing and wire rope on one transformer, and verify that the wire rope railing can be tensioned per the requirements of Section 48 19 23.50, paragraph "Personal Fall Protection System". Any modifications to the wire rope tensioning system as required to allow proper tensioning shall meet the requirements of the contract specifications, the approved manufacturer's design, and shall be at the contractor's expense. After the correct fitment has been performed, remove the fall protection system components, clean the components if made dirty during fitment, and place into the storage container.

f. Coordinate the services of the factory representative to install the _____ as required in paragraph "______".

3.8.2.2 Site Assembly Performed in the Final Operating Location

The following work shall be completed on the powerhouse tailrace deck with the transformer in its final operating location:

a. Perform vacuum treatment and hot oil-fill each transformer under vacuum to the normal operating level per the requirements of paragraph "TRANSFORMER OIL-FILLING AND PROCESSING". A listing of all equipment to be used during the filling process shall be provided.

b. Test the CT ratio and polarity in accordance with IEEE C57.13, (paragraphs 6.1.4 and 6.4). Verify that all the shorting screws on the bushing current transformer terminal blocks within the control cabinet are installed, and the current transformers are shorted to ground.

c. Perform inspections and verify the correct operation of all the transformer ancillary equipment and devices after reassembly, oil-filling, and processing.

d. Verify the tightness of all valve stem packing glands.

e. Assemble the fall protection system railing and wire rope on one transformer, and verify that the wire rope railing can be tensioned per the requirements of Section 48 19 23.50, paragraph "Personal Fall Protection System". Any modifications to the wire rope tensioning system as required to allow proper tensioning shall meet the requirements of the contract specifications, the approved manufacturer's design, and shall be at the contractor's expense. After the correct fitment has been performed, remove the fall protection system components, clean the components if made dirty during fitment, and place into the storage container.

f. Completely clean each transformer after completion of the reassembly process, including the insulator sheds on the bushings, and perform touch-up painting.

3.9 REQUIREMENTS FOR PERFORMANCE OF WORK WITHIN THE TRANSFORMER TANK

3.9.1 General

The following additional requirements shall be met by the Contractor when working within the transformer tank:

a. Prior to the removal of any tank man-hole covers, the top of the transformer shall be thoroughly cleaned and vacuumed to minimize the possibility of contaminants entering the tank.

b. The temperature and relative humidity around the transformer shall be monitored during the performance of work. The transformer tank shall not be opened if the measured relative humidity is greater than 60%, or if there are signs of external condensation on the tank surfaces.

c. Any time the transformer tank internals are exposed to the atmosphere, the tank shall be continuously purged with dry air utilizing a dry-air compressor delivering moisture-free air at a maximum dew point of -40 degrees Fahrenheit. The dry-air shall be introduced at the lower filter valve.

d. Purge the tank with dry air until analysis of the gas in the transformer indicates at least 19.5 percent oxygen, prior to entry by contractor personnel.

e. All personnel entering the transformer tank shall wear 'Tyvek' suits, or equivalent, and a logbook shall be maintained of all items entering and leaving the transformer tank to assure nothing has inadvertently been left inside (See paragraph "Tools and Parts Control and Accountability").

f. All openings to the transformer tank shall be covered whenever possible to prevent any falling objects from entering the tank.

g. At the end of each working day, the tank shall be re-sealed and pressurized with 2.5 psi of dry-air using a dry-air cylinder.

3.9.2 Tools and Parts Control and Accountability

3.9.2.1 Purpose

A tool and parts control and accountability program is necessary to ensure that foreign objects are not left within the transformer tank during internal inspections and transformer reassembly work. The Contractor shall be responsible for overall control of tools, parts and personnel entering the transformer tank.

3.9.2.2 Tools and Parts Control

Personnel shall remove all personal items prior to entering the transformer tank. All tools and parts taken into the transformer tank, or which are used within the transformer tank, and any personal items which must remain with the Contractor personnel when working within the tank, shall be logged onto a tools and parts control checklist. At the end of each shift, and prior to resealing of the transformer tank, all tools and parts shall be accounted for and identified on the checklist, and the interior of the transformer tank inspected for any loose tools or parts. To maintain control of the tools entering the transformer tank, all personal transportable tools will be checked out of a controlled space, such as a tool bin, and checked back during each shift. The Contractor Quality Control manager shall be responsible during each shift to assure that inventoried tools for each craftsperson are accounted and signed for, and logged on the Tools and Parts Control Checklist. To control parts entering the transformer tank, the Quality Control manager shall inventory and issue the parts during each shift. At the end of each shift, a count will be made of the installed parts to ensure that the quantity checked out matches what was installed. A copy of the Tools and Parts Control Checklist shall be turned in to the Contracting Officer's Representative at the end of each shift for work being performed within the transformer tank,or when the transformer tank is open. Any discrepancies in tools or parts shall be brought to the attention of the Contracting Officer's Representative.

3.11 TRANSFORMER GAS-FILLING AND PROCESSING

The Contractor shall be responsible for the provision of all oil handling and high-vacuum processing equipment for filling of each transformer tank.

Transformer oil-filling and processing shall be performed per the requirements of IEEE C57.93, paragraph 4.8, or the manufacturer's recommendations, whichever is more stringent. The transformer oil-filling and processing procedure shall be included in the transformer site assembly procedure. No Government provided power source will be available to the Contractor for this equipment.

3.11.1 Tank Pressure Test

Prior to performing the tank pressure test, the contractor shall verify that all bolted connections have been torque-checked, and tight. After each transformer has been fully assembled, but prior to oil-filling, the transformer shall undergo pressure testing at a gauge pressure of 4 psi for 12 hours. The gauge used for monitoring tank pressure shall have a pressure range of no greater than 10 psi. The tank shall hold pressure during the test duration without leakage, and any leaks detected resolved prior to proceeding to vacuum treatment.

3.11.2 Vacuum Treatment

After each transformer has been fully assembled, but prior to oil-filling, the transformer shall undergo vacuum treatment. During the vacuum treatment process, the contractor shall ensure that all devices which are not suitable for vacuum have been valved off. A vacuum leak test shall be performed, and the leakage rate calculated. During the vacuum leakage tests, the maximum allowable pressure rise in microns shall not exceed the rise as calculated in IEEE C57.93, para. 4.8.3.2. If necessary, corrective action shall be taken by the contractor to determine the source of the vacuum leak, and any necessary connections shall be tightened. After an acceptable leak rate has been achieved, transformer vacuum shall be held for per the manufacturer's recommendations, but shall be a minimum of 24 hours. During this period, hot oil may be introduced to aid in heating the windings for moisture removal, then drained to allow for moisture removal using vacuum.

3.11.3 Transformer Oil for Processing

A copy of the transformer oil certification tests shall be provided by the transformer oil supplier to the COR prior to filling of the transformers.

An oil sample shall be taken from each tanker truck upon arrival to the site, and sent out for testing. The tests shall comply with the requirements of Section 48 19 23.50 (paragraph "Chemical, Physical and Electrical Characteristics") and a Delivery Transformer Oil Test Report shall be submitted for approval. Any nonconformance with the required oil characteristics shall be remedied during the field processing, at no cost to the Government, by a process submitted for approval. The Contractor shall provide any temporary oil storage facilities required for handling and processing the transformer oil.

3.10.4 Vacuum Filling

After vacuum treatment, the oil shall be handled from the tanker trucks to the transformers via a high-vacuum purifier. Each complete transformer shall be vacuum-filled with hot oil, at a temperature between 60 - 65 degrees Celsius. A minimum of two full volume passes of hot oil shall be circulated after the vacuum filling process to aid in moisture removal.

The transformer shall be filled in a continuous operation to the correct oil level based upon the oil temperature, per the manufacturer's recommendations as included in the Operations and Maintenance Instructions. After the completion of vacuum filling, the nitrogen blanket system oil preservation system shall be established per the manufacturer's recommendations.

3.11 TOUCH-UP PAINTING

Any abrasions to the transformer paint shall be thoroughly cleaned, and the damaged areas shall be given one coat of primer and one finish coat of paint. All finished surfaces to receive primer on which the factory coating has deteriorated or been damaged shall be cleaned by means of solvents, degreasers, light sanding with 240 grit aluminum oxide paper or cloth moistened with Kerosene, or other approved means which removes all grease, paint markings, dirt, rust, and other foreign substances.

Appropriate measures shall be taken to protect adjacent surfaces and equipment from overspray or paint splatter. The use of wet or dry cloths or paper shall be as approved by the COR on an individual basis. Primer paint and finish coats shall be as specified in Section 48 19 23.50, (paragraph "FACTORY CLEANING AND PAINTING").

3.12 FIELD TESTS

3.12.1 Device Functional Tests

After reassembly of each transformer, all devices and wiring connections removed for shipment shall be functionally tested to verify proper operation.

3.12.2 Electrical Tests

After each transformer has been filled with oil, the bushings installed, and assembly of the transformer is complete, but prior to the performance of any external connections by the separate installations contractor, the Contractor shall perform electrical tests in accordance with the applicable requirements of IEEE C57.152 and the approved Transformer Site Assembly Procedure. A copy of each transformer factory acceptance test report shall be present during performance of the field tests, and test result comparisons shall be made to verify acceptable transformer condition after reassembly and oil-filling. Any deviations between the factory and field test results shall be brought to the attention of the COR for determination of acceptance. The Contractor shall submit certified copies of the Transformer Field Test Report for approval. The witnessing representatives of the Contractor and the COR shall sign reports of all witnessed tests.

The following electrical tests shall be performed on the transformer prior to final acceptance by the Government:

a. Transformer Turns Ratio test (TTR) on each tap (IEEE C57.152, para.

7.2.10)

b. Excitation Current (IEEE C57.152, para. 7.2.11)

c. Winding insulation resistance of each winding to ground and between windings (IEEE C57.152, para. 7.2.13)

d. Polarization Index (IEEE C57.152, para. 7.2.13.4)

e. Power Factor test of each transformer winding (IEEE C57.152, para.

7.2.14)

f. Power Factor Test of each transformer bushing (IEEE C57.152, para.

7.3.3)

g. Core insulation resistance (IEEE C57.152, para. 7.2.6.2)

h. Leakage Reactance Measurement Tests (IEEE C57.152, para. 7.2.12).

Leakage reactance measurement tests shall be performed between the high-voltage winding and the low-voltage winding, using the same model test equipment and methods as used in the manufacturing facility. The leakage reactance test results shall not deviate more than 0.5 percentage points as compared to the factory test reports. Deviations in excess of 0.5 percentage points shall be explained to the satisfaction of the COR, and may be grounds for requiring an internal inspection of the transformer by the Contractor, at no expense to the Government, to determine the cause.

i. Sweep Frequency Response Analysis Test. A sweep frequency response analysis (SFRA) test shall be performed, using the same equipment and methods as used during the transformer factory acceptance testing. The proposed SFRA test equipment, setup, and test procedure shall be included in the field test procedures submittal. The SFRA test results shall be compared with the factory acceptance test "baseline" results, to determine the integrity of the core and winding structure after shipment from the manufacturing facility. The SFRA data obtained during the factory acceptance testing shall be loaded into the test equipment software to facilitate wavetrace comparisons. Wavetrace comparisons are expected to match closely, with little differences between matched scans. Wavetrace comparisons that do not match closely shall be explained to the satisfaction of the COR, and may be grounds for transformer rejection, requiring an internal inspection of the transformer by the Contractor to determine the cause of the deviations, or requiring the transformer to be sent back to the manufacturing facility for repair at no expense to the Government. Electronic files of the SFRA results in the test equipment's standard database format shall be submitted on a CD with the transformer field test report.

3.12.3 Oil Tests

After transformer oil filling and processing has been completed, samples of the insulating oil shall be taken from each transformer and sent to two independent laboratories for analysis. Oil samples shall be taken from the transformers per the requirements of ASTM D 923. Identity of samples and results of analyses shall be included in the final transformer field test report. The following analyses shall be performed, as a minimum:

a. Dissolved gases

b. Water

c. Neutralization number

d. Interfacial tension

e. PCB-in-oil

f. Dissipation factor

g. Dielectric breakdown voltage

h. Furans

i. Dissolved metals

j. Sediment and soluble sludge

k. Oxidation stability

l. Oxidation inhibitor

m. Viscosity

n. Specific gravity

o. Color

p. Flash point

q. Corrosive sulfur

3.13.4 Oil Test Requirements

After processing, the oil shall meet all of the requirements as indicated in ASTM D6871.

3.14 CONTRACTOR-FURNISHED TRAINING OF GOVERNMENT PERSONNEL

3.14.1 Training General Requirements

Within one week after the performance of the transformer field tests have been completed for the first transformer, conduct a course at Detroit Dam in the theory, operation, and maintenance of the power transformers.

Coordinate the actual date in which the training is to be performed with the COR. The course shall be of 8 hours minimum duration for approximately 10 Government personnel. Record video of the training session and provide a DVD of the training session for future use by the Government. Course requirements include, but are not limited to:

a. Theory of operation of the transformer control circuits

b. Use of the electronic…