KN6A and KN8A Transformer Rehabilitation Specification - Draft_1.pdf

U.S. Department of the Interior SPECIFICATIONS Bureau of Reclamation Lower Colorado Dams Office Boulder City, Nevada April, 2020

Hoover Dam Powerplant Rehabilitate Two (2) 100 MVA Single Phase transformers at Hoover Dam

Boulder Canyon Project, Arizona, Nevada

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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.

Contents

1. GENERAL

1.1 Transformer Details

1.2 Requirements

1.3 Period of Performance

1.4 Schedule

1.5 Government furnished Equipment, Utilities and Facilities

1.6 Liquidated Damages

1.7 Security / Clearances

1.8 Safety

1.9 Hazardous Materials

1.10 Protection of Existing Installations and Structures

1.11 Final Acceptance of Work

1.12 Special Work Permit

1.13 Access to the Construction Work Area

Contents Continued

2. TECHNICAL REQUIREMENTS

2.1 Specifications

2.2 Testing

2.3 Bushings

2.4 Instrumentation, Controls, and ancillary devices

2.4.1 Dial type thermometer

2.4.2 Oil Level Gauge

2.4.2 Oil temperature sensor and dial type thermometer

2.4.3 Buchholz Relay

2.4.4 Sudden Pressure Relay

2.4.5 Pressure Relief Device

2.4.6 Oil Flow Indicators

2.4.7 Fault Monitor / DGA

2.4.8 Oil Level Indicator

2.4.9 Rupture Bladder Indicator

2.4.10 Hot Spot Detectors

2.5 Tank Oil Valves

2.6 Oil Motors and Pumps

2.7 Heat Exchangers

2.8 Conservator

2.8.1 Air System

2.8.2 Oil

2.9 Tank Penetration and additional Gasket Replacement

2.10 Conduit and Wiring Replacement

2.11 Buss - Feed Thru insulators

2.12 Transformer Tank Cleaning

2.13 Oil Processing

2.14 Inspection

2.15 Reference Drawings

3. SUBMITTALS

4. ILLUSTRATION

1. GENERAL

1.1 Transformer Details

The contractor shall provide the personnel, equipment, and materials to rehabilitate two (2) 100 MVA Single Phase transformers (KN6A and KN8A) at Hoover Dam.

KN6A and KN8A are generator-step-up transformers with 16.5kV low side and 230 kV high side.

1.2 Requirements

Contractor is required to supply all material necessary to perform the following work on both transformers KN6A-A and KN8A-A:

Bushings

1. Replace H1 Bushing

2. 2 H1 Current Transformers

3. 1 H1 Current Transformer for winding Temp simulation

4. Replace X1 and X2 bushings

5. 2 X1/X2 Current Transformers

6. 1 X1/X2 Current Transformer for winding temp simulation

7. Replace H2 Bushing

Instrumentation

1. Replace X Winding Hot Spot Detector Detector

2. Dial type thermometer for X windings temperature

3. Replace H Winding Hot Spot Detector Detector

4. Dial type thermometer for H windings temperature

5. Replace Oil Temperature Gauge and Probe

6. Dial type thermometer for oil temperature

7. Item 41,42,46,47 in SMIT Part List

Controls and ancillary devices

1. Buchholz Replace Gate Valves – between Conservator and Buchholz Relay Replace Buchholz Relays; Replace Gate Valves on Both Sides of Buchholz Relays Replace Gate Valves – between Buchholz Relay and tank

Pressure Relief Device

1. Replace Pressure Relief Devices

DGA Monitor

1. Replace Fault Monitors with DGA monitors;

2. Replace Globe Valve for Fault (Hydrogen) Monitors

Tank

1. Replace Gate Valve Oil Outlet Tank #1

2. Replace Gate Valve Oil Inlet Tank #1

3. Replace Gate Valve Oil Inlet Tank #2

Oil Pumps, motors, and valves

1. Replace Pump #1 Oil Flow Indicators

2. Replace Gate Valves Oil Inlet #1

3. Replace Oil circulating pump #1 and motor #1

4. Replace Pump #2 Oil Flow Indicators

5. Replace Gate Valves Oil Inlet #2

6. Replace Oil circulating pump #2 and motor #2

Heat Exchangers

1. Replace Heat Exchanger #1

2. Replace Gate Valve Oil Outlet

3. Replace Gate Valve Water Inlet

4. Replace Gate Valve Water Outlet

5. Replace Heat Exchanger #2

6. Replace Gate Valve Oil Outlet

7. Replace Gate Valve Water Inlet

8. Replace Gate Valve Water Outlet

Conservator

1. Air System Replace Conservator Bladder

Replace Air Vent Replace Alarm relay “rupture bladder” Replace Globe Valve – Top of Conservator Replace Dehydrating Breather Process and Re-use Oil Replace Gate Valve - Filling conservator Replace Globe Valve – Filling pipe Replace Oil Level Gauge

Tank Penetrations and Gaskets – Replace the following gaskets

1. Top HV Bushing HV Manhole for connection HV Manhole for CTs HV Oil Return Near top of HV Bushing penetration

LV Bushing – X1 LV Bushing – X2 LV Manhole for connection for CT LV Side Hatch Cover 1 LV Side Hatch Cover 2 LV Oil Return

Pressure Relief Device - @ 1100 Oil Pipe to Conservator @ 0300

HO Bushing @0500 Oil Pipe to cross pipes @ 0600 Blind Flanged Opening @0600

2. Side Top

1. Fault Monitor @ 0100

2. Oil Return @0300

3. HO Bushing Manhole @0500

4. Capped Valve @0700 Upper Filter Valve

Bottom

1. Tap Changer @0100

2. Manhole @0100

3. Capped Valve @0100 Lower Filter Valve with sampling device

4. Oil Inlet@0200

5. Oil Inlet@0400

Electrical Line to be replaced

1. Conservator Oil Level Gauge Line

2. Conservator Bladder Rupture Alarm Relay

3. Buchholtz Relay

4. Oil flow indicator 1

5. Oil Flow indicator 2

6. Power to Pump 1

7. Power to Pump 2

8. HV CT 3 total

9. LV CT 3 total

10. HV Temp

11. LV Temp

12. Oil Temp

*** Trace out the line that you want replaced and provide a drawing

Buss - Feed-Thru Insulators Replace Feed-Thru Insulators at Transformer Base

Process Oil

Drawings

1.3 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.

B. KN6A (A-Phase) - The contractor shall have 30 calendar days to do all the field work on KN6A. During the outage season for this transformer, a hazardous energy clearance will be placed. The timeline begins after the clearance is set and the transformer is available for the contractor to sign onto the clearance. When the contractor releases the clearance, the transformer shall ready to be put back into service.

C. KN8A (A-Phase) - The contractor shall have 30 calendar days to do all the field work on KN8A. During the outage season for this transformer, a hazardous energy clearance will be placed. The timeline begins after the clearance is set and the transformer is available for the contractor to sign onto the clearance. When the contractor releases the clearance, the transformer shall ready to be put back into service.

1.4 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.

Holiday, Overtime, Night work or Weekend work may be available and requires approval from the Contracting Officer 48 hours prior.

B. 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 both transformers.

C. KN6A – Outage

1. Overall schedule including parts and equipment acquisition

2. Field work installation schedule during outage for the transformer

D. KN8A – Outage

1. Overall schedule including parts and equipment acquisition

2. Field work installation schedule during outage for the transformer

E. See section 3 for submittal schedules.

1.5 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.

1.6 Liquidated Damages

A. Liquidated damages will be incurred at $1,000.00 per day past the end of the period of performance.

1.7 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.

1. 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).

2. The following identifies the requirements:

A. CONTRACTOR EMPLOYEE SECURITY REQUIREMENTS

1) 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:

5) 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.

6) 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

7) 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.

8) 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

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

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

11) 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.

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

1.8 Safety

A. The Contractor shall comply with all federal, state and local laws and standards as well as the Bureau of Reclamation manual Reclamation Safety and Health Standards (RSHS), 2014 Edition.

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:

http://www.usbr.gov/ssle/safety/RSHS/rshs.html

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.

http://www.usbr.gov/ssle/safety/RSHS/rshs.html

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 3.7.

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.

I. In the case of a fire alarm, drill or actual fire, all contractor personnel working at Hoover will report to the Arizona ramp adjacent to Unit A3 transformer and provide a head count to the Government Contracting Representative (the inspector). Personnel will not return to work until the Bureau of Reclamation’s Safety Officer has sounded the “all clear” air horn.

1.9 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.

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 cop of this manifest at the time the chemicals are shipped from the job site.

1.10 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.

1.11 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.

1.12 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. 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.

1.13 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.

2.0 Technical Requirement

2.1 Specifications

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

ASME B16 – Valves, Flanges, Fittings and Gaskets

2.2 Testing - Before and After

A. Contractor shall perform power factor tests on the bushings before and after installation, along with tests of the transformer to verify the transformer can be put back in service after work is completed.

B. Transformer tests shall include but not be limited to power factor, winding insulation resistance, core megger testing, exciting current tests, bushing power factor testing and dissolved gas analysis. Tests shall be done before the start of work by the contractor and after work is complete by the contractor.

The results of these tests may be compared with previous test data obtained by BOR personnel at Hoover and the comparison may determine whether the transformer can/should be put back in service.

C. Copies of the test results will be supplied to the COR when completed. The copies shall be printed hard copies.

2.3 Bushings

A. The bushings being replaced will be supplied by the contractor.

B. Contractor will proceed to install the new bushings with gaskets and hardware and connect them to the transformer.

C. Contractor to supply crane with operator, oil processor, oil holding tank/tanks, oil containment and all tools necessary to perform the required work.

D. H1 Bushing

1. The high side bushings designated H1 shall be replaced with new bushings manufactured by ABB. These bushings do not require a higher temperature rating. The new bushings shall have porcelain insulation and shall be gray. The bushings shall be rated for operating voltages at or above 230kV and shall meet IEEE standards. Each bushing shall have a power factor test tap. These bushings shall be rated for outdoor use and shall be weather resistant. These bushings are used in an oil filled transformer.

E. X1 and X2 Bushings

1. Bushings shall be replaced with new bushings manufactured by ABB. The voltage rating for this style of bushing shall be 25kV. The low side bushings shall be constructed with 125 degrees Celsius insulation and shall be made of porcelain. This is a high temperature feature available from ABB. The porcelain shall be gray. These bushings will meet IEEE standards. These bushings shall be rated for outdoor use and shall be weather resistant. These bushings are used in an oil filled transformer.

F. H2 Bushing

1. Neutral bushing shall be replaced with a new bushing manufactured by ABB and shall be made of porcelain. This bushing does not require a higher temperature rated insulation. The porcelain shall be gray. These bushings shall meet IEEE standards. Each bushing shall have a test tap. These bushings shall be rated for outdoor use and shall be weather resistant. These bushings are used in an oil filled transformer.

2.4 Instrumentation, Controls and Ancillary Devices

2.4.1 Low Voltage Winding Temperature Gauge

1. The existing hot spot temperature gauge is manufactured by Qualitrol, 104

Series with four (4) normally open contacts. 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 IP65 or higher and be rated for outdoor use.

2.4.2 High Voltage Winding Temperature Gauge

1. The existing hot spot temperature gauge is manufactured by Qualitrol, 104

Series with four (4) normally open contacts. 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 “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 IP65 or higher and shall be rated for outdoor use.

2.4.3 Oil Temperature Gauge

1. The existing oil temperature gauge is manufactured by Qualitrol 104 series with 1 normally open contact. The replacement temperature gauge shall be rated IP65 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.

2.4.4 Buchholz Relay

1. The existing buchholz relays are manufactured by EGEM type 9 (BF

80/10). This device has one normally open contact that closes when excessive gas is detected. The new device will have the same mechanical mounting configuration and the same style contact. The new device shall be wired into the existing detection circuit on the transformer. This device shall be rated for outdoor use.

2. The two (2) three inch gate valves on both sides of the buchholz relay shall be replaced with new gate valves. The two new valves shall be in inches (metric is not acceptable). The new valves shall be made of the same material as the existing. This will include gaskets used around the valves and buchholz relay. The gaskets shall be the same type as the ones removed.

2.4.5 Sudden Pressure Relay

1. The existing pressure relief devices are manufactured by Qualitrol type

208-002-04 + SWT 612-1. 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 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.

2.4.6 Oil Flow Indicators

1. The existing oil flow indicators are made by Qualitrol type FLA 644-2 +

CAS 664-2. 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 IP65 or higher and shall be rated for outdoor use.

2.4.7 Fault Monitor / Dissolved Gas Analyzer

1. Fault monitors ( Hydran 201R Gas Monitors) are presently installed on the transformers. The outputs of the gas monitors have been disabled due to nuisance tripping. There is also an isolation valve in front of both gas monitors. The contractor will replace the isolation valve in front of the gas monitors with a similar style globe valve and install new gas monitors.

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.

2. Contractor to replace the 2 inch globe valve used to isolate the fault monitor. The new valve shall be the same type and material as already installed on the transformers.

2.4.8 Oil Level Indicator

1. The existing oil level indicator is made by Qualitrol model 042-001-CS

5394. A new oil level indicator will be installed and will have one normally open contact that will close with a decrease in oil level. The contact shall be rated for operation of 24 to 220 volts either alternating current or direct current. The maximum switching current will be 2 amps.

2.4.9 Rupture Bladder Indicator

1. The rupture bladder indicator shall be replaced with a similar style that can be installed without allowing air to enter. Contractor shall be responsible for finding a suitable replacement.

2.4.10 Hot Spot Detectors

1. Contractor to replace hot spot detectors named 49TRH (H1-winding) and 49 TRX (X1 winding) with 100 ohm platinum detectors. These detectors will be used with existing current transformers. The H1 current transformer has a ratio of 800:4 with a 15VA rating. The X1 current transformer has a ratio of 6000:4 with a 15VA rating.

2.5 Tank Oil Valves

A. All valves supplied shall have ASTM and ANSI ratings. The valves shall be standard sizing and thread. Metric valves are not permitted. The valves sizes shall match what is listed below for sizing and shall mate with supplied heat exchangers and transformer connections.

1. One 3 inch gate valve with gaskets for the Buchholz relay on the conservator side of the relay. SMIT Item No. 61

2. One 3 inch gate valve with gaskets for the Buchholz relay on the tank side of the relay. SMIT Item No. 62

3. One 2 inch globe valve with gaskets on top of the conservator. SMIT Item No. 64

4. One 1 inch gate valve with gaskets and an adapter to 1 inch NPT filling valve for the conservator. SMIT Item No. 65

5. One 1 inch globe valve with gaskets in the filling pipe for the conservator.

SMIT Item No. 67

6. One 1 inch utility valve with gaskets located on the top cover of the transformer. SMIT Item No. 96

7. One 2 inch globe valve with correct adapter for new fault (dissolved gas) monitor. SMIT Item No. 97

8. One 2 inch upper filter valve with gaskets. SMIT Item No. 100

9. One 2 inch lower filter valve with gaskets and oil sampling port. SMIT

Item No. 101

10. Two (2) five inch gate valves with gaskets for oil inlet to tank. SMIT Item No. 130

11. One 4 inch gate valve with gaskets for oil outlet to tank. SMIT Item No.

12. One 2-1/2 inch gate valve with gaskets before pump number 1. SMIT Item No. 211

13. One 2-1/2 inch gate valve with gaskets before pump number 2. SMIT

Item No. 212

14. One 2-1/2 inch gate valve with gaskets after heat exchanger number 1.

SMIT Item No. 221

15. One 2-1/2 inch gate valve with gaskets after heat exchanger number 2.

SMIT Item No. 222

16. One 2 inch gate valve for the water inlet on heat exchanger number 1.

SMIT Item No. 241

17. One 2 inch gate valve for the water inlet on heat exchanger number 2.

SMIT Item No. 242

18. One 2 inch gate valve for the water outlet on heat exchanger number 1.

SMIT Item No. 251

19. One 2 inch gate valve for the water outlet on heat exchanger number 2.

SMIT Item No. 252

B. All valves shall be replaced with new valves made of the same material and shall be mounted in a configuration that would not impede the operation or maintenance of a device in the same area.

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

D. Contractor to submit data sheets for all valves listed in Item A above.

2.6 Oil Pumps and Motors

A. Oil pump motors are 460 Volt AC, 60 Hz and shall be replaced with the same voltage and frequency motors and the same horsepower. The existing pump motors are rated 1.8kW and draw 2.9 amps at 460 volts AC. The existing oil pumps have 2 ½ inch connections at the inlet and outlet. They are manufactured by Renzmann & Grunewald type: 25/160/65 UD90.

B. New oil pumps will have 2 ½ inch connections identical to the existing pumps.

C. Contractor to install new motor starters for the oil pump motors. The new starters shall come equipped with the necessary contact and overloads to operate with the existing equipment on the transformer and equipment in the control cabinet. Any additional modifications necessary to operate new pump motors shall be performed by the contractor.

D. Contractor to supply data sheets on oil pumps and motors for approval prior to arrival to job site.

2.7 Heat Exchangers

A. Heat exchangers are manufactured by Bloksma, type N220-2Z-L=1300

B. The heat exchanger shall have a capacity of 136kW.

C. Heat exchangers shall be double tube with the outer side made of deoxidized high phosphorous copper, not tinned according to ASTM B111 Alloy 122.

D. The inner side of the tube shall be 90-10 copper-nickel according to

ASTM B111 Alloy 706.

E. Each heat exchanger shall have 26 tubes.

F. Oil connections shall be 2-1/2”.

G. Water connections shall be 2 inch.

H. Total width of new heat exchanger shall not exceed 68 inches.

I. New heat exchangers shall mount identically to existing heat exchangers and shall be made to match newly installed oil and water valves listed in items F and G under section 2.7. Contractor shall supply any adapters and piping necessary to mate the new heat exchangers with the new valves.

J. New heat exchangers shall be provided with detection to indicate leaking tubes.

K. The shell and baffles of the new heat exchangers shall be steel.

L. The outside of the heat exchangers shall be painted ANSI 70 light gray and intended for outdoor use.

M. The transformer shall be able to carry a load of 70% with one cooler out of service.

N. The gate valves at the water inlet and outlet of each heat exchanger shall be replaced with 2 inch gate valves made of the same material. The gaskets for these valves shall be replaced with the same style as already installed. The total quantity of these valves is 4 per transformer, for a total quantity of 8 needed for these two transformers. The valve operator shall be located where it can be accessed without obstruction.

O. The 2 ½ inch gate valves on the inlet and outlet side of the heat exchangers for the oil inlet and outlet shall be replaced with gate valves made of the same material and the size of the heat exchanger inlet and outlet ports. Contractor shall supply any necessary piping, fittings and adapters to make a complete installation. A complete installation means the heat exchangers are ready for use and are free from both oil and water leaks once the work is finished. The valve operator shall be located where it can be accessed without obstruction.

P. Contractor to submit data sheets on supplied heat exchangers for approval prior to arriving at job site.

2.8 Conservator

A. Air System

1. Conservator Bladder - Contractor shall install a new bladder inside the conservator tank. Information on the conservator bladder is shown on SMIT drawing 210-17104. The existing bladder is made by PRONAL.

The bladder is nitrile. The supplied bladder shall be constructed to operate in the temperature range of -50 degrees Fahrenheit to 248 degrees

Fahrenheit. A suitable material would be Temp – Shield 30 ( 30.0 oz per square yard of material).

2. Contractor shall follow industry guidelines and SMIT installation guidelines for the replacement of the bladder. Any fittings that require replacement shall be supplied by the contractor. The fittings shall be of suitable material for the application and exact replacements according to SMIT information.

3. All piping for the air vent at the top of the conservator bladder shall be replaced with new piping with the same size opening and same material.

4. All piping to the dehydrating breather shall be replaced with new piping with the same size opening and same material.

5. A new globe valve shall be installed on top of the conservator. The new globe valve shall be similar style and material to existing. The new globe valve shall be installed on the dehydrating breather line.

6. A new air vent shall be installed on top of the conservator. The new vent shall be identical to the existing.

B. Cleaning of Conservator Tank

1. Contractor shall clean the inside of the conservator tank. This will include the removal of any sludge, foreign material and anything that would disturb the normal operation of the transformer and conservator.

Any and all materials used to clean the conservator tank shall be disposed of according to regulatory requirements.

2.9 Tank Penetrations and Additional Gasket Replacement

A. Bushing gasket material will be supplied by group performing the work.

Nitrile (Buna-N) gasket material and VITON are acceptable materials. All gaskets that are disturbed when removing the conservator tank shall be replaced with new gaskets of buna-n or viton material or as recommended by the manufacturer.

B. Tank Oil Valves – The following valves shall be replaced on the transformer in addition to other valves stated in this document:

b. Gate Valve Oil Outlet Tank #1

c. Gate Valve Oil Inlet Tank #1

d. Gate Valve Oil Inlet Tank #2

These valves shall be replaced with valves of the same size and material as existing.

C. Contractor shall replace all gaskets on both transformers. The acceptable gasket materials to be used are nitrile (buna-n) and VITON. These gaskets are to be replaced on the transformer:

TOP:

1. HV Bushing

2. HV Manhole for connection

3. HV Manhole for CTs

4. HV Oil Return Near top of HV Bushing penetration

5. LV Bushing – X1

6. LV Bushing – X2

7. LV Manhole for connection for CT

8. LV Side Hatch Cover 1

9. LV Side Hatch Cover 2

10. LV Oil Return

11. Pressure Relief Device - @ 1100

12. Oil Pipe to Conservator @ 0300

13. HO Bushing @0500

14. Oil Pipe to cross pipes @ 0600

15. Blind Flanged Opening @0600

SIDE: (TOP)

1. Fault Monitor @ 0100

2. Oil Return @0300

3. HO Bushing Manhole @0500

4. Capped Valve @0700

5. Upper Filter Valve

BOTTOM:

1. Tap Changer @0100

2. Manhole @0100

3. Capped Valve @0100

4. Lower Filter Valve with sampling device

5. Oil Inlet@0200

6. Oil Inlet@0400

D. All covers removed for gasket replacement shall be torqued down in a pattern to prevent leaking of oil from the transformer. Guidance is available in FIST publication 3-30 Transformer Maintenance available at:

https://www.usbr.gov/power/data/fist_pub.html

2.10 Conduit and Wire Replacement

A. Contractor shall replace all exposed wiring and flexible metallic conduit (seal-tite). This is required due to the effect of the sun on the exposed wiring and flexible metallic conduit. All flexible metallic conduit shall be water-tight. This requires an external PVC jacket. Any fittings that are found damaged shall be replaced. Contractor is responsible for adjusting lengths of the water-tight flexible metallic conduit to connect with newly installed gauges. All exposed cabling shall be sun-light and weather resistant.

B. Contractor to replace wiring between wired device and transformer local control cabinet. The local control cabinet is the split box that gathers all https://www.usbr.gov/power/data/fist_pub.html wiring from transformer devices before being fed into the plant. This wiring will include hot spot detectors, temperature and level gauges, current transformers, sudden pressure and buchholz relays, oil pumps and oil flow meters. Contractor shall replace all wiring with same type and size unless a new device requires a larger gauge wire where contractor shall supply. The cost of the wire shall be included in the total bid price.

C. A drawing will be provided showing field wiring between the main control cabinet and field devices.

2.11 Iso-Phase Bus and Feed-Thru Insulators

A. Each transformer has two sections of iso-phase bus work that travel through the base at each transformer. The bushings that penetrate the floor at the base of the transformer are showing signs of aging. The bushings are ceramic with a semi-conductive coating on the interior of the bushing. The semi-conductive coating is degrading and these bushings will be replaced as part of this work. Details on the bushings will be included in the attached documentation.

2.12 Transformer Tank Cleaning

A. With oil removed from the transformer and necessary precautions taken prior to anyone entering the transformer tank, contractor shall remove any sludge and/or contamination that has accumulated inside the transformer. Care shall be taken to leave the core and coils of the transformer as found. The cleaning is primarily intended to remove contamination that has settled at the bottom of the transformer. Contractor is responsible for taking the contamination off site and disposing of according to appropriate environmental and regulatory guidelines.

2.13 Oil Processing

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

B. Contractor to supply crane with operator, oil processor, oil holding tank/tanks and all tools 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. KN6A-A and KN8A-A transformer each hold approximately 7200 gallons of oil. This equates to processing three times this amount i.e. 21,600 gallons for each transformer. The process shall be done in accordance with manufacturers guidelines for the type of oil purification system used.

D. Dissolved gas analysis shall be performed on the transformer oil to verify gases and contaminants are removed from the oil as a result of the process.

Dissolved gas analysis shall show that no additional contaminants or moisture have been introduced into the oil as a result of the bushing replacement.

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 torqueing 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 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.

J. The transformer nameplate states the transformer holds 7200 gallons of oil. Contractor shall have equipment to store this amount of oil.

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 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.

K. 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. 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.

2.14 Inspection

A. Contractor shall perform a visual inspection of the interior of the transformer noting areas of concern. This will include inspection of stand-off insulators for the core of the transformer and inspection of the windings. Contractor shall inspect leads of the transformer and make note of any damage whether through normal use and wear or by other work performed inside the transformer. The contractor shall supply fall protection and a means of retrieval of all persons entering the transformer.

Contractor shall also perform gas monitoring of the inside of the transformer prior to and when a person is inside.

B. The government inspector shall be notified one day in advance before anyone enters the transformer. All material necessary to remove a person from the transformer shall be supplied by the contractor. The contractor shall also follow their own policies, USBR policies and appropriate OSHA policies related to confined space entry.

C. Contractor shall provide a bound report documenting the condition of the transformer at the time of the inspection and provide any recommendations to operate the transformer as intended. Contractor shall also provide the report in Adobe pdf format to the government.

D. Contractor shall inspect the load tap changers on these transformers. The contractor shall provide a description and report on the as found condition and provide recommendations on future use. If the load tap changer is unusable, the contractor shall notify the government and wait for guidance on how to handle. The load tap changers are never exercised. They may be found unusable during inspection. The government will provide guidance on how they want to proceed in addressing load tap changer concerns.

2.15 Reference Drawings and Documents

SMIT-NYMEGEN

Serial Number: 219801 – KN6A-A Serial Number: 219802 – KN8A-A

Hoover Drawing 45-D-9325: Arrangement of overhead lines and circuits from Hoover SMIT Drawing 3961C896 – High Side Bushing Detail SMIT Drawing 3944C678 – Low Side Bushing Detail SMIT Drawing 394B357 – Neutral Bushing Detail SMIT Drawing 210-17104 – Conservator Outline Showing Bladder SMIT Drawing 410-56474 – Low Side Bushing Connection Drawing SMIT Instruction Manual

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) Within 7 calendar days after award of contract. Updated certificates are to be submitted prior to expiration of policies as evidenced on the insurance certificate.

(2) At least 3 days before entry of subcontractor’s personnel on the Government installation.

A CO 1 0

004 52.222-26 Information required by Executive Order11246 (SF- 100)

Within 30 days after contract award.

I CO 1 0

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

005 Safety and Health 1452.223-81

Safety program, site specific

Submitted and accepted before commencing onsite work. See section 3 of

RSHS

A COR 0 1

006 Safety and Health

(1452.223- 81)

Monthly accident summary report

Completed monthly while on site and submitted within the first 5 days of the following month.

I COR 1 1

** CO indicates Contracting Officer. COR indicates Contracting Officer’s Representative.

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

007 52.236-15 Work Plan and Construction Schedule

Within 20 days after Notice to Proceed is given. Updated Schedules are to be provided weekly or as otherwise directed by the COR.

A COR 1 1

008 1452.237-80, C.2.6, and

C.2.7

(1)List of all contractor and subcontractor employees

(2) Information for Government PIV Card

20 days after Notice to Proceed is given.

A COR 1 1

009 52.222-11 (1) List of Subcontracts

(2) Standard Form

Within 10 days after award.

I CO 1 1

010 52.236-13 Accident Prevention Plan

20 days prior to on-site work.

A COR 1 2

011 1.9 of Statement of Work and 52.223-3A1

(1) Original List of Hazardous Materials (LHM) and

Safety Data Sheets

(SDS)

(2) Updates to LHM and SDS

(1) After award and prior to delivery of each hazardous material

(2) Prior to delivery

I COR 0 2

012 1.8 of Statement of Work

Job Hazard Analysis

(JHA)

Submitted and accepted before commencing on site work.

A COR 0 2

013 1.9 of Statement of Work

Waste production and disposal records

Within 7 days of waste disposal

I COR 0 2

014 1.9 of Statement of Work

Hazardous waste manifest

Within 7 days of hazardous waste disposal.

I COR 0 2

015 Environmental site assessment

To be submitted within 15 days following the site inspection.

I COR 0 2

016 1.9 of Statement of Works

Spill Containment and Clean Up Plan

25 days after Notice to Proceed is given

** CO indicates Contracting Officer. COR indicates Contracting Officer’s Representative

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

017 Material List Within 30 days after Notice to Proceed and prior to start of on-site work.

A COR 0 2

018 2.8 of Statement of Work

New Conservator Bladder Drawing Showing Material

25 days after Notice to Proceed is given.

A COR 1 1

019 2.3 of Statement of Work

Low Side Bushing (X1 & X2) Drawing

20 days after Notice to Proceed is given.

A COR 1 1

020 2.3 of Statement of Work

Neutral Bushing (H0) Drawing

20 days after Notice to Proceed is given.

A COR 1 1

021 2.3 of Statement of Work

High Side Bushing (H1) Drawing

20 days after Notice to Proceed is given

A COR 1 1

022 2.5 of Statement of Work

Supplied Valve List with Data Sheets for Each Replacement Valve

20 days after Notice to Proceed is given

A COR 1 1

023 2.6 of Statement of Work

Oil Pumps and Motors Data Sheets

30 days after Notice to Proceed is given

A COR 1 1

024 2.7 of Statement of Work

Replacement Heat Exchanger Data Sheet

30 days after Notice to Proceed is given

025 2.4 of Statement of Work

Buchholz and Sudden Pressure Relay Data Sheets

25 days after Notice to Proceed is given

A COR 1 1

026 2.4 of Statement of Work

Oil Level Gauge Data Sheet

25 days after Notice to Proceed is given

A COR 1 1

027 2.4 of Statement of Work

Oil Temperature Gauge Data Sheet

25 days after Notice to Proceed is given

A COR 1 1

028 2.4 of Statement of Work

High and Low Voltage Winding Temperature Gauges (Hot Spot Detectors) Data Sheets

25 days after Notice to Proceed is given

A COR 1 1

029 2.11 of Statement of Work

Feed Thru Bushing Drawing and Detail

25 days after Notice to Proceed is given

A COR 1 1

029 2.2 of Statement of Work

Acceptance Testing After completion of the work and prior to final payment. Test results will be interpreted by USBR personnel to determine quality of work

I COR 1 1

030 1452-204-70 Release of Claims (DI-137) against the United States.

After completion of the work and prior to final payment.

I CO 0 1