FINAL_SPEC-LPH-EQUIPMENT-Borden_11_Feb_2016_.doc

SPECIFICATION FOR:

OIL FILTRATION SYSTEM

Left Power House- Grand Coulee Dam

2-10-2016

1.0 SCOPE:

This specification defines the design, testing and performance requirements for a self-contained lubrication oil filtration system to be used in the Left Power House (LPH) at Grand Coulee Dam in north central Washington. The oil filtration system will be used to remove particulates and accumulated free, emulsified, and dissolved moisture from hydro-electric generating unit lubrication oil. Indication from the oil purification system should accurately measure the parameters required herein, including but not limited to, residual moisture and ISO particulate levels.

2.0 GENERAL REQUIREMENTS:

2.1 UNIT CONFIGURATION

The oil filtration unit shall be an integrated and self-contained unit that filters incoming turbine lubrication oil to remove larger particulates prior to a heater section that warms the oil for greater efficiency in a vacuum-assisted oil dispersion section optimized for the removal of moisture followed by a final particulate filtration section that reduces the particulates to the required level or below. The moisture removal section shall be further optimized with an air-cooled moisture condenser in addition to a subsequent moisture reservoir that allows for controlled moisture disposal.

2.2 TURBINE OIL TO BE PROCESSED

This oil filtration unit shall be specifically designed and optimized to filter Mobil DTE Heavy Medium turbine oil. No other oil besides this turbine oil shall be used in this oil filtration system during fabrication, assembly and testing, other than fluids called for by the individual components to perform their functions.

2.3 UNIT CONTROL

This oil filtration unit shall be designed with control oversite by an on-board control system that allows unattended operation, as well as real time unit parameter and oil condition monitoring.

2.4 HUMAN FACTORS

The oil filtration unit shall be designed to maximize the ease of use, maintenance, and potential repair. Careful human factors design shall be integrated into this design at all levels, and care shall be taken to minimize unit design features that could potentially injure workers.

3.0 SYSTEM REQUIREMENTS

3.1 PERFORMANCE

3.1.1 The oil filtration unit shall remove free, emulsified, and dissolved water to a level less than 20 parts per million (ppm).

3.1.2 The oil particulate cleanliness output of the oil filtration unit shall not exceed ISO 16/14/11 per ISO 4406:1999.

3.1.3 The oil filtration unit shall have a process flow rate of no less than 30 GPM at 60F using the lubrication oil specified. The unit shall maintain this flow performance while subjected to a negative suction head of 29 inch Hg at 30 cubic feet per minute (CFM).

3.1.4 The oil filtration unit shall include a vacuum pump to process the oil being filtered that has a flow rate of no less than 30 CFM at 29 inches Hg and an end vacuum of 0.5 Torr minimum.

3.1.5 The oil filtration unit discharge filter shall have a Beta 3(c) (3 micron) particulate removal performance of no less than 1000 per ISO 16889.

3.2 CONSTRUCTION

3.2.1 A minimum of two constant volume, positive displacement process oil pumps producing a minimum of 30 GPM at 60F using Mobil DTE Heavy Medium oil are required.

3.2.1.1 The pumps shall have integral pressure relief valves.

3.2.2 The oil filtration unit shall have inlet and outlet flow indicators, as well as a unit output flow meter that incorporates a flow totalizer readout.

3.2.3 The unit vacuum pump shall be a rotary vane type vacuum pump design.

3.2.3.1 The vacuum pump shall include its own self-contained lubrication system with spin-on oil filter, oil level sight glass, wire mesh inlet screen, filter discharge pressure gauge, integral discharge filters, and a reverse-flow check valve.

3.2.4 The unit shall utilize a stainless steel vacuum chamber with permanent media-packed dispersal elements.

3.2.5 The unit shall include an air-cooled condenser and condensate holding reservoir working in conjunction with the vacuum system to remove the moisture. The reservoir stores the moisture/condensate until proper disposal can be performed

3.2.5.1 The reservoir shall be stainless steel for corrosion prevention.

3.2.5.2 The reservoir shall have an automatic condensate drain valve.

3.2.6 The oil filtration unit shall incorporate clear observation windows on both the vacuum chamber and the condensate reservoir for monitoring during operation.

3.2.7 The unit shall have a flow diversion valve to regulate the filtration flow rate.

3.2.8 The unit shall have an inlet particulate filter with a unit isolation valve directly upstream from the inlet filter, and a discharge particulate filter with a unit isolation valve directly downstream of it.

3.2.8.1 An oil sample port with shutoff shall be located between the inlet unit isolation valve and the inlet particulate filter.

3.2.8.2 An oil sample port with shutoff shall be located between the discharge particulate filter and the unit discharge isolation valve.

3.2.9 Filter media and dispersion elements shall be optimized for the turbine oil specified herein.

3.2.10 The unit shall include an inlet filter assembly with synthetic glass filter media with no more than a 6 micron absolute rating.

3.2.11 The unit shall include an outlet filter assembly with synthetic glass filter media with no more than a 3 micron absolute rating.

3.2.12 The unit shall have internal bypass valves to prevent over-pressurization of the filters.

3.2.13 Process heaters to warm the oil prior to vacuum moisture processing and final oil filtration shall be incorporated into the design.

3.2.13.1 The primary heater capacity shall be a minimum of 64 kilowatts total. Multiple smaller wattage heater elements shall be utilized together to allow for the heaters to only come on when they are needed to maintain the required temperature and not overheat the oil.

3.2.13.2 There shall also be an auxiliary 16 kilowatt heater.

3.2.13.3 The heating elements shall not degrade the oil by overheating the oil, and there shall not be any direct contact between the oil being processed and the heating elements themselves.

3.2.14 Envelope

The oil filtration unit shall not exceed 52 inches wide. The height shall not exceed 79 inches. The length shall not exceed 70 inches.

3.2.14.1 Any additional components that are not within the dimensional constraints of this paragraph may be allowed, but floor area required shall be minimized, and government approval for this deviation is required.

3.2.14.1.1 If a second unit is considered necessary, the second unit outside dimensions shall not exceed the size envelope stated herein.

3.2.15 The unit shall be transportable by fork lift. Fork lift guides for lifting and moving the unit shall be an integral part of the base design with the guides positioned so when the unit is to be carried, the fork lift travel is along the long length dimension centerline and the unit width does not exceed the maximum width stated herein.

3.2.16 The unit shall be equipped with heavy duty casters to facilitate moving the unit around.

3.2.17 The entire oil filtration unit weight shall not exceed 2600 pounds without prior government approval.

3.2.18 Unit Interface

3.2.18.1 The unit shall be configured so that the oil inlet fittings and the oil discharge fittings are located on a long side of the oil filtration unit away from the unit control panel which would ideally be located on the opposite long side, unless otherwise approved by the government.

3.2.18.2 The unit inlet and discharge fittings shall be located for easy attachment to LPH tank fittings. The LPH tank fittings are located in what will be the back the oil filtration unit (side opposite the control panel) and at a centerline of 52 inches vertically off the concrete floor. The oil filtration unit need not hard mount to these fittings, but interconnection length shall be minimized and interconnection and piping simplicity shall be optimized to the extent possible.

3.2.19 Any duplex filter system utilized shall include a single lever for transferring flow for one filter housing to the other without interrupting flow.

3.2.20 The oil filtration unit shall be constructed so that a drip pan is under all components and equipment. A means to drain this pan shall be included in the design.

3.2.21 The oil filtration unit shall be constructed of stainless steel where moisture could reduce the reliability and life of the system.

3.2.22 As a minimum, those components that are not constructed of stainless steel shall be primed and painted with a two-part industrial epoxy paint. Stainless parts may be painted if the paint does not interfere with the functionality of the component.

3.2.23 Galvanic corrosion potential between dissimilar materials shall be minimized and mitigated in the design.

3.2.24 If hoses are utilized in the oil filtration unit fabrication, they shall suffer no degradation from exposure to the intended fluids nor to ozone.

3.2.25 Environment

3.2.25.1 The unit shall be designed for indoor operation in an oil storage room that is typically in a range of 60F to 70F.

3.2.25.2 The unit will be installed in an area that has an elevation of 951 feet above sea level.

3.3 ELECTRICAL

3.3.1 The oil filtration unit shall use 480 Volt, 3 Phase, 60Hz power.

3.3.2 The unit shall not draw more than 200 amperes in any mode.

3.3.3 The unit shall have a separate red master emergency shutdown switch in an easily accessible location that de-energizes all components at one time without damaging any system component.

3.3.4 The electrical controls and enclosure shall be NEMA 4 rated and UL approved (CUL 508 Stamped).

3.3.5 All electrical wiring and components shall be protected by on-board circuit breakers. Fuses, if used, shall only be used on control transformer and phase protection circuits.

3.3.6 All electric motors used shall be a Totally Enclosed Fan-Cooled (TEFC) motor design.

3.3.7 The inline process flow heaters shall be a low watt density design and the system shall have the following features:

3.3.7.1 A temperature controller with LED temperature and set point display controls.

3.3.7.2 The control system shall allow activation of heaters in increments to maintain the oil temperature to within 1 degree F.

3.3.7.3 There shall be an additional auxiliary heating element on an independent circuit for heavy moisture removal.

3.3.7.4 A high temperature circuit shall be provided and designed to shut down the heaters in the event of a component failure.

3.3.8 The unit shall incorporate a foam control system for operational efficiency.

3.4 INSTRUMENTATION

3.4.1 A Programmable Logic Controller (PLC) shall control all functions of the oil filtration system and allow the system to be started in automatic mode by operating a single Start button.

3.4.2 The control PLC shall be pre-programmed with a normal shutdown sequence that initiates a safe shutdown of the entire system, with continued oil flow without energized heaters, to enable a non-detrimental cool down of the oil.

3.4.3 The system vacuum pump shall operate for a minimum of 15 minutes after normal shutdown to facilitate complete drying of vacuum pump lube system.

3.4.4 The control system shall allow for manual and separate operation of each oil pump and the vacuum pump.

3.4.5 The system shall have a flow switch that does not allow activation of the heating system without proper flow.

3.4.6 Control Panel alarms shall include, but are not limited to, the following:

a. High Level Oil

b. High Level Condensate

c. High Temperature

d. Low Oil Flow

e. High Foam

f. Dirty Filter condition for inlet filter

g. Dirty Filter condition for outlet filter

3.4.7 System Display Readouts

The following shall be included in the system display readouts as a minimum:

a. An ISO format particulate meter.

b. A moisture percent saturation meter.

c. Machine operation hour meter.

d. Direct reading differential pressure gages for each filter.

e. ‘Dirty Filter’ indicator for each filter.

f. Temperature and set point display for the process heater system controller.

g. Early warning for Low, Medium and High contamination levels.

3.4.8 The oil filtration unit shall automatically empty the condensate reservoir when the condensate holding reservoir is full, unless otherwise commanded. There shall be control modes for automatic reservoir emptying, shutting the entire system down when the reservoir is full, or a complete manual mode for controlling the condensate reservoir drain valve.

3.4.9 The unit drip pan shall have a level switch that shuts the system down if liquid is detected in the drip pan.

3.4.10 The oil filtration unit shall have visual and audio alarms as necessary, and the alarm system shall have an automatic and manual method of operations that includes a warning level.

4.0 TEST REQUIREMENTS

4.1 FACTORY TESTING

The oil filtration unit shall be thoroughly tested prior to shipment to verify compliance with all the requirements of this specification.

4.2 ON-SITE INSPECTION

Prior to on-site acceptance testing, the system shall be inspected for compliance with the specification requirements as detailed herein. The inspection shall be conducted by the government representative assigned, along with others the government representative may designate. They have the right to reject defective materials, workmanship, or anything that does not meet the requirements of this specification. Any discrepancy shall be addressed in writing prior to on-site acceptance testing, unless otherwise approved by the government.

4.3 ON-SITE ACCEPTANCE TESTING

Acceptance testing shall be conducted in the presence of the government’s representatives after installation in the LPH by government workers. A demonstration and functional test of the oil filtration system and all of its specification-required features is required prior to on-site acceptance and contract approval.

5.0 OTHER REQUIREMENTS

5.1 TRAINING REQUIREMENTS

5.1.1 Prior to final contract acceptance, the contractor shall provide an operator and maintenance training class to LPH personnel that will be using the oil purification system. This training class shall have up to fifteen (15) students. Training shall be conducted at the Left Power House at Grand Coulee Dam where the system is to be installed at the convenience of the government. The training class shall include the following as a minimum:

5.1.1.1 A demonstration of all the features and components included in the system.

5.1.1.2 Normal system and control panel operation, troubleshooting, maintenance, emergency and/or safety procedures.

5.1.2 The Contractor’s worker(s) performing the system demonstration and training are required to obtain government security badges after a background screening by government security forces. No worker will be allowed on site without being able to fulfill the government security requirements and obtain a security badge. Background screening shall be accomplished prior to this training class.

5.1.3 The Contractor’s worker(s) shall adhere to all Grand Coulee Power Office (GCPO) Safety Requirements, as well as the requirements of the Bureau of Reclamation ‘Reclamation Safety and Health Standards’ (RSHS) while demonstrating the system and/or conducting the training class.

5.1.4 Any chemicals used at any time during the training or system demonstration other than the specified turbine oil shall be approved by the GCPO Safety Office prior to use.

5.2 WARRANTY REQUIREMENTS

The oil purification system as a whole shall have a warranty with the following terms and conditions as a minimum:

5.2.1 The warranty for the system shall be for a minimum period of one (1) year from the date of final system acceptance by the government.

5.2.2 Contractor shall warrant the entire system delivered to be free from defects in material, labor, design, and to be in compliance with contract specifications.

5.2.3 Warranty work on any component of the system is the sole responsibility of the Contractor, and shall be accomplished in a timely manner at the convenience of the government.

5.3 TECHNICAL SUBMITTALS

5.3.1 The contractor shall provide all technical submittals required for approval by the government no later than the system delivery, unless otherwise approved by the government or noted herein. Government procurement will forward a copy of these technical submittals to the Left Power House for review and approval.

5.3.2 The technical documentation to be submitted to the government to satisfy contractual requirements shall include, but is not limited to, the following:

5.3.2.1 System “as-built” drawings, schematics, manuals, and inspection forms.

5.3.2.2 Two (2) Operator’s Manuals and two (2) Maintenance/Parts Manuals.

5.3.2.3 Flow and exploded view diagrams of the complete system, including pumps, valves, filters, chambers, tanks, etc., including any diagrams to further explain the system maintenance and operation.

5.3.2.4 A comprehensive list of all system components which are supplied in accordance with these specifications. The list shall include the manufacturer, part number, and any other pertinent details to facilitate future maintenance.

5.3.2.5 System warranty shall be provided.

5.3.2.6 Individual component warranty(s) shall also be delivered.

5.3.2.7 Digital version of the above documentation on CD/DVD Disc.

5.3.3 This contract shall not be considered ‘substantially complete’ until the unit and the submittals per this paragraph are delivered as a minimum.

5.4 SPECIFICATION DEVIATION

5.4.1 Deviation from the approved specification requirements after contract award may be considered, but requires government review to determine if they are deemed equal or superior to the specification requirements prior to approval and implementation of the deviation.

5.4.1.1 Deviations from the specification shall be explained fully on separate sheet(s) and submitted to the government for review and potential approval.

5.4.1.2 The government reserves the right to request additional information, technical data, demonstrations, or samples considered equal by the Contractor.

5.5 PRE-SHIPMENT CLEANING

The supplier shall thoroughly clean and inspect the filtration unit removing all foreign material prior to shipment.

5.6 PREPARATION FOR SHIPPING

The oil filtration unit shall be prepared and protected for shipment in such a way that no damage, no internal contamination, and no corrosion can occur during shipment and storage. The entire unit shall be wrapped in plastic film for shipment as a minimum. All fluid connections shall be plugged or capped to prevent contamination in transit and these plugs or caps shall be of a design where they cannot be left in place when permanently installed.

5.7 PROPOSAL REQUIREMENTS

The Proposer is cautioned to be thorough and complete with their proposal package. Proposal submittals will be utilized in evaluating compliance with the specification requirements with pre-build meeting held at Grand Coulee Left Powerhouse after solicitation acceptance.

5.7.1 The Proposer shall submit the following design information and drawings for government review and approval as part of their bid proposal:

5.7.1.1 System description, including drawings clearly showing all the features of the oil purification system.

5.7.1.2 System flow diagram and a description of the component parts.

5.7.1.3 Detailed description of the system operation with information outlining the system maintenance procedures required.

5.7.1.4 A proposed schedule to deliver the completed oil filtration unit.

5.7.2 The Proposer shall provide a document that addresses each and every requirement in this government specification, and it shall be cross referenced to the specification paragraph numbers herein. Failure to do so may be considered grounds for rejection of the proposal.

5.7.3 Specification requirements shall be strictly adhered to. Deviations from the specification requirements shall be fully documented in the Proposer’s bid proposal package for review and consideration by the government.

5.7.3.1 Deviations shall be listed by specification page and paragraph attached to the proposal. The government reserves the right to request additional information, technical data, demonstrations, or samples on deviations considered equal by the Proposer.

5.7.3.2 If there are no deviations to the government specification submitted with the proposal, the Proposer warrants that the design and equipment shall meet all government specification requirements.

5.7.4 The Proposer shall include shipping in their quotation for this oil filtration unit to the Grand Coulee, WA site.

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