Draft_Specifications.pdf

The Dalls Thrust Bearing Oil Cooler Supply TDATBOC16

SECTION 05 50 03.00 26

METALWORK, FABRICATION, MACHINE WORK, AND MISCELLANEOUS PROVISIONS

PART 1 GENERAL

1.1 GENERAL INFORMATION

This section covers general painting and workmanship requirements, applicable to the fabrication, installation, and inspection of various items of metalwork and machine work and items made from contract or reference drawings. These requirements are in addition to those contained in the specification sections covering the specific items of work or as shown.

1.2 REFERENCES

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

ASME INTERNATIONAL (ASME)

ASME B4.1 (1967; R 2009) Preferred Limits and Fits for Cylindrical Parts

ASME B46.1 (2009) Surface Texture, Surface Roughness, Waviness and Lay

ASTM INTERNATIONAL (ASTM)

ASTM A123/A123M (2013) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A193/A193M (2012a) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A194/A194M (2013) Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

ASTM A36/A36M (2012) Standard Specification for Carbon Structural Steel

ASTM F436 (2011) Hardened Steel Washers

1.3 SUBMITTALS

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

submittals having an "I" designation are for information only.

Designation following the "G" or "I" 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:

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DRAFT

SD-01 Preconstruction Submittals

Inspection Agency Qualifications ; G, HDC

SD-06 Test Reports

Inspection and Test Reports ; G, HDC

1.4 INSPECTIONS AND TESTS

Perform inspections and tests in accordance with this section to demonstrate that the fabrication and machine work are in conformity and in addition to the applicable inspection requirements elsewhere specified.

Prepare a detailed plan as part of the Contractor's Quality Control (CQC) (per SECTION: 01 45 04.00 28 ). Record all measurements, and other details that indicate the plans and specifications are met. Perform these tests and inspections at the Contractor's expense, certify, and make available for review. For inspections and tests, conform to the requirements of the particular sections of these specifications and plans for the respective items of work unless otherwise specified or authorized.

Submit the Inspection Agency Qualifications at least 30 calendar days prior to the scheduled date of their use. The Government will notify the Contractor which inspections and tests shall be conducted in the presence of and witnessed by the Government Quality Assurance Representative (GQAR). Notify the Government of the dates of the inspections and tests as required.

Submit Inspection and Test Reports within 7 calendar days after completing the inspection or test. At a minimum, include the following in the inspection and test reports: Date of test/inspection, personnel present, name of person and company performing test/inspection, equipment used, dimensions or data taken/recorded, and any abnormalities found.

PART 2 PRODUCTS

2.1 MISCELLANEOUS METALS AND STANDARD METAL ARTICLES

For miscellaneous metal materials and standard metal articles, conform to the respective specifications and other designated requirements. Use sizes as specified or shown on shop drawings. Where material requirements are not specified, furnish materials suitable for the intended use and are subject to Government approval.

2.1.1 Structural Steel

For steel, use ASTM A36/A36M unless otherwise specified or approved.

2.1.2 Bolts, Nuts, and Washers (General Purpose)

Unless otherwise specified, provide fasteners for piping systems that meet the following requirements/standards:

Bolts and Studs: ASTM A193/A193M , Grade B7

Hex Nuts: ASTM A194/A194M , Grade 2H

Flat Washers: ASTM F436

SECTION 05 50 03.00 26 Page 2

Provide bolts, studs, nuts, and washers that are galvanized in accordance with ASTM A123/A123M .

2.1.3 Bolts, Nuts, and Washers (Corrosion Resistant)

When fasteners are in contact with stainless steel, provide fasteners for piping systems that meet the following requirements:

Bolts and Studs: ASTM A193/A193M , Grade B8

Hex Nuts: ASTM A194/A194M , Grade 8

Flat Washers: UNS S30400

2.2 FABRICATED METAL ITEMS

For metals, equipment, and miscellaneous material, conform to the requirements referred to in these specifications and when not specifically covered, furnish metals and materials of standard quality. Use materials with the classification and grades approved by the Contracting Officer (CO). Products other than those specified may be accepted when it is proved that they are equal in strength, durability, usefulness, and convenience for the purpose intended. In case the Contractor desires to use stock material not manufactured specifically for the work covered by these specifications, submit evidence that such material conforms to the requirements of the specifications. Assure metals are free from scale, corrosion, and/or objectionable defects.

PART 3 EXECUTION

3.1 FABRICATION

3.1.1 General

Assure material is straight before being laid out or worked. If straightening is necessary, use methods that will not impair the metal.

Sharp kinks or bends will be cause for rejection of the material. Material with welds will not be accepted except where welding is definitely specified, indicated on the drawings, or otherwise approved. Make bends by dies, press brakes, or bending rolls normally used in this type of fabrication. Accurately cut and neatly finish all portions of the work.

Make corners square and true unless otherwise shown.

3.1.2 Dimensional Tolerances for Structural Work

Measure dimensions by an approved calibrated steel tape of approximately the same temperature as the material being measured at the time of measurement. Assure the overall dimensions of an assembled unit are within the tolerances shown or as specified in the particular section of these specifications for the item of work. Where tolerances are not specified in other sections of these specifications or shown, an allowable variation of 1/32 inch is permissible in the overall length of component members with both ends milled. For component members without milled ends, do not deviate from the dimensions shown by more than 1/16 inch.

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3.2 MACHINE WORK

3.2.1 General

a. For tolerances, allowances, and gages for metal fits between plain, non-threaded, cylindrical parts, conform to ASME B4.1 for the class of fit shown or to the dimensions shown. Where fits are not shown, use good industrial practice for the intended application and obtain approval prior to the beginning of work. Use tolerances for machine-finished surfaces designated by non-decimal dimensions within 1/64-inch unless otherwise specified:

(1) One decimal place (X.X).........0.3

(2) Two decimal places (X.XX).........0.020

(3) Three decimal places (X.XXX).........0.001

b. Allow sufficient excess material stock on surfaces requiring machining to ensure true surfaces of solid material while maintaining the specified minimum or finished plate thickness. Use true and exact finished contact or bearing surfaces to secure full contact. Finish all surfaces in accordance with the contract drawings to ensure proper operation when assembled. Accurately machine parts and assure all like parts are interchangeable. Accurately locate all drilled bolt holes to ensure interchangeability.

3.2.2 Finished Surfaces

Make surface finishes as indicated or specified in accordance with ASME B46.1 . Values of required roughness heights are arithmetical average deviations expressed in micro inches. These values are maximum. Lesser degrees are satisfactory unless otherwise indicated. Determine compliance with surface requirements by electronic profilometer, sense of feel and visual inspection of the work compared to roughness comparison specimens in accordance with the provisions of ASME B46.1 . Use consistent values of roughness width and waviness height with the general type of finish specified by roughness height. Where the finish is not indicated or specified, use the most suitable for the particular surface, provide the class of fit required, and indicate on the shop drawings by a symbol that conforms to ASME B46.1 when machine finishing is provided. Flaws such as scratches, ridges, holes, peaks, cracks, or checks that will make the part unsuitable for the intended use will be cause for rejection.

3.2.3 Unfinished Surfaces

Lay out all work to secure proper matching of adjoining unfinished surfaces unless otherwise directed. Where there is a discrepancy between adjoining unfinished surfaces, grind them smooth or machine to secure proper alignment. Make unfinished surfaces true to the lines and dimensions shown and grind them free of all projections and rough spots.

Fill in depressions or holes not affecting the strength or usefulness of the parts using an approved method.

3.2.4 Pin Holes

Bore pin holes in accordance with the dimensions and tolerances shown or noted.

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3.3 SHOP INSPECTION

Inspect each unit prior to assembly to determine the correctness of the fabrication and machining of the component parts. Do not exceed the tolerances shown. Closely check each unit inspected to ensure that dimensions and tolerances are met. Keep an inspection record for review by the GQAR for each item inspected.

3.4 PROTECTION OF MACHINED SURFACES

Thoroughly clean machined surfaces of foreign matter. Oil unassembled pins and bolts and wrap with moisture resistant paper or protect by other approved means.

3.5 BOLTED CONNECTIONS

3.5.1 General

For bolts, nuts, and washers, use the type specified or indicated on the drawings. Equip all nuts with washers. Use beveled washers where bearing faces have a slope of more than 1:20 with respect to a plane normal to the bolt axis.

3.5.2 Bolt Holes

3.5.2.1 Regular Bolts

Drill holes for regular bolts or subdrill and ream. Accurately locate holes and make holes smooth, perpendicular to the member, cylindrical and not more than 1/16-inch larger than the diameter of the bolt, unless shown otherwise.

3.6 SET SCREWS

Use set screws of the socket type, with sockets of the hexagonal or multi-splined shape. Do not use set screws for transmitting torsion.

Install set screws using Loctite.

3.7 SPECIAL NON-DESTRUCTIVE TESTING

When doubt exist as to the soundness of any part, such part may be subjected to any form of non-destructive testing determined by the GQAR.

This may include ultrasonic, magnaflux, dye penetrant, x-ray, gamma ray, or any other test that will thoroughly investigate the part in question.

The cost of such investigation will be borne by the Government only if the part is found not to be defective. Repair or replacement of defective parts and all retesting is at Contractor's expense. This is in addition to the non-destructive testing required by the CQC Plan.

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SECTION 05 50 03.00 26 Page 5

SECTION 40 05 13.96 26

WELDING

PART 1 GENERAL

1.1 SUMMARY OF WORK

This section covers the qualification, procedures, and general requirements for shop welding of all pressurized portions of the coolers

1.2 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.

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ANSI/ASNT CP-189 (2011) ASNT Standard for Qualification and Certification of Nondestructive Testing Personnel (ANSI/ASNT CP-105-2006)

AMERICAN WELDING SOCIETY (AWS)

AWS A2.4 (2012) Standard Symbols for Welding, Brazing and Nondestructive Examination

AWS A3.0M/A3.0 (2010) Standard Welding Terms and Definitions

AWS QC1 (2007) Standard for AWS Certification of Welding Inspectors

ASME INTERNATIONAL (ASME)

ASME B31.1 (2012; INT 2-6, 8-10, 13, 15, 17-25, 27-31

and 42-46) Power Piping

ASME BPVC SEC II-C (2010) BPVC Section II-Materials Part C-Specifications for Welding Rods Electrodes and Filler Metals

ASME BPVC SEC IX (2010) BPVC Section IX-Welding and Brazing Qualifications

ASME BPVC SEC V (2010) BPVC Section V-Nondestructive Examination

1.3 SUBMITTALS

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

submittals having an "I" designation are for information only.

Designation following the "G" or "I" designation identifies the office that will review the submittal for the Government. Submit in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES:

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SD-01 Preconstruction Submittals

Welding Procedure Specifications ; G C,HDC

Procedure Qualification Test Records ; G C,HDC

Written Practice Manual ; G C,HDC

Welding Repair Plan ; G, C, HDC

SD-03 Product Data

Electrode and Filler Metal ; G C,HDC

SD-06 Test Reports

NDE Testing Reports ; G C,HDC

SD-07 Certificates

Welder Certification ; G C,HDC

Certified Welding Inspectors ; G C,HDC

NDE Personnel ; G C,HDC

1.4 DEFINITIONS AND SYMBOLS

Definitions must be in accordance with AWS A3.0M/A3.0 . Symbols must be in accordance with AWS A2.4 .

1.5 PERFORMANCE REQUIREMENTS

Quality of all joint preparation, welding, and examination is the Contractor's responsibility. Clearly identify and record all materials used in the welding operations. The inspection and testing defined in this specification are minimum requirements. Additional inspection and testing shall be the responsibility of the Contractor when it is deemed necessary to achieve the quality required.

1.6 QUALIFICATIONS

1.6.1 Welding Procedure Specifications

Record in detail and qualify the Welding Procedure Specifications for every proposed welding procedure. Prepare a Welding Procedure Specification for each type of weld joint configuration being used.

Qualification for each welding procedure must conform to the requirements of ASME BPVC SEC IX and to this specification. Describe the type of backing rings or consumable inserts, if used, as well as the removal process.

Submit copies of the welding procedure specifications and procedure qualification test records for each type of welding required. The Welding Procedure Specifications must describe all essential, nonessential, and when required, supplementary essential variables in accordance with

ASME BPVC SEC IX .

Submit product data sheets for the electrode and filler metal to be used

SECTION 40 05 13.96 26 Page 2 with each welding procedure specification at the same time as the applicable welding procedure specification. Approval of any procedure does not relieve the Contractor of the sole responsibility for producing acceptable welds. Identify welding procedures individually and reference them on the shop drawings.

1.6.1.1 Previously Qualified Welders and Procedures

Welding procedures, welders, and welding operators previously qualified by test may be accepted for the work without requalification, provided that all of the following conditions are fulfilled:

a. Copies of the welding procedures, the procedure qualification test records, and the welder and welding operator performance qualification test records are submitted and approved.

b. Testing was performed by an approved testing laboratory or technical consultant or by the Contractor's approved quality assurance organization.

c. The welding procedures, welders, and welding operators were qualified in accordance with ASME BPVC SEC IX and base materials, filler materials, electrodes, equipment, and processes conformed to the applicable requirements of ASME B31.1 and this specification.

d. The requirements of paragraph "Renewal of Qualification" below are met and records showing name of employer and period of employment using the process for which qualified are submitted as evidence of conformance.

1.6.2 Welder and Welding Operator Performance

Each welder and welding operator assigned to work must be qualified in accordance with ASME B31.1 .

Before assigning welders or welding operators to the work, submit welder certification that each individual is performance-qualified as specified.

The certification must state the type of welding and positions for which each is qualified, the code and procedure under which each is qualified, date qualified, and the firm and individual certifying the qualification tests.

1.6.2.1 Identification

Identify each particular weld with the personal number, letter, or symbol assigned to each welder or welding operator. Submit written records that indicate the location of welds made by each welder or welding operator.

Each welder or welding operator must apply the personal mark adjacent to the welds using a rubber stamp or felt-tipped marker with permanent, weatherproof ink or other methods approved by the Contracting Officer that do not deform the metal. For seam welds, place identification marks adjacent to the welds at 3 foot intervals. Identification by die stamps or electric etchers will not be allowed.

1.6.2.2 Renewal of Qualification

Requalification of a welder or welding operator is required under any of the following conditions:

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a. When a welder or welding operator has not used the specific welding process for a period of 3 months; the period may be extended to 6 months if the welder or welding operator has been employed on some other welding process.

b. When a welder or welding operator has not welded with any process during a period of 3 months, all the personal qualifications will be considered expired, including any extended by virtue of a., above.

c. There is specific reason to question the person's ability to make welds that will meet the requirements of the specifications.

d. The welder or welding operator was qualified by an employer, other than those firms performing work under this contract, and a qualification test has not been taken within the preceding 12 months.

e. Renewal of qualification for a specific welding process under conditions a., b., and d., above, needs to be made on only a single test joint or pipe of any thickness, position, or material to reestablish the welder's or welding operator's qualification for any thickness, position, or material covered under previous qualification.

1.6.3 Inspection and NDE Personnel Qualifications

All inspection and NDE personnel must be qualified in accordance with the following requirements. Submit all inspection and NDE personnel certifications.

1.6.3.1 Certified Welding Inspectors

Welding inspectors must be Certified Welding Inspectors (CWI). Each welding inspector must hold a current CWI certification and be qualified in accordance with AWS QC1. All weld inspectors must have a minimum of five years experience in weld inspection.

1.6.3.2 NDE Personnel

a. Each NDE inspector must be certified to ANSI/ASNT CP-189 Level II.

An ASNT Level III may conduct tests if that person provides documentation of having passed a Level II practical examination within the last three (3) years.

b. Submit certification record, along with visual examination record, for each NDE method used.

c. Contractor and Testing Agency must submit a written practice manual as developed in accordance with ANSI/ASNT CP-189 .

1.7 DELIVERY, STORAGE, AND HANDLING

1.7.1 Material Control

Store materials in a controlled access and clean, dry area that is weathertight and is maintained at a temperature recommended by the manufacturer. Store materials so that they are not in direct contact with the floor, and are stored on wooden pallets or cribbing.

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1.7.2 Damaged Materials

Materials which are damaged shall be discarded. Covered electrodes which are oil or water-soaked, dirty, or on which the flux has separated from the wire shall be discarded.

1.7.3 Welding Materials

1.7.3.1 Welding Materials, General

Deliver all filler metals, electrodes, fluxes, and other welding materials to the site in the manufacturers' original packages and store them in a dry space until used. Packages must be properly labeled and designed to give maximum protection from moisture and to ensure safe handling.

1.7.3.2 Low-Hydrogen Steel Electrodes

Store low-hydrogen steel electrodes in their sealed shipping container.

If the seal is damaged during shipment or storage, and the damage is not immediately detected, discard the affected electrodes or rebake them in accordance with the manufacturer's instructions prior to issuance. If a container is damaged in storage and the damage is witnessed, immediately place the electrodes from that container in a storage oven. Set the storage oven temperature as recommended by the manufacturer or the welding material specification.

1.7.3.3 Partially Used Electrodes

When a container of covered electrodes is opened and only a portion of the content is issued, within 1/2 hour, place the the remaining portion in a storage oven.

PART 2 PRODUCTS

2.1 MATERIALS

Provide welding materials which comply with ASME BPVC SEC II-C . Use welding equipment, electrodes, welding wire, and fluxes that are capable of producing satisfactory welds when used by a qualified welder or welding operator using qualified welding procedures.

PART 3 EXECUTION

3.1 WELDING OPERATIONS

Perform welding in accordance with qualified procedures using qualified welders and welding operators. Submit detailed procedures which define methods of compliance to contract drawings and specifications; Inspection and material procurement records; System and material testing and certification records; Written records and drawings indicating location of welds made by each welder or welding operator.

Do not weld when the quality of the completed weld could be impaired by the prevailing working or weather conditions.

3.1.1 Base Metal Preparation

Oxy-fuel cutting of austenitic stainless steel or nonferrous materials is not allowed.

SECTION 40 05 13.96 26 Page 5

3.1.2 Weld Joint Fit-Up

Use bars, jacks, clamps or other mechanical fixtures to fit, align and retain parts in the correct position during welding operations. Use of temporary attachments that are welded to the parts are not allowed except when it is impractical to use mechanical fixtures. Make temporary attachments from the same material as the base metal. Completely remove any temporary attachments by grinding or thermal cutting. If thermal cutting is used, cut the attachment no less than 1/4 inch from the member. Remove the balance by grinding. After the temporary attachment has been removed, visually examine the area.

3.1.3 Preheat and Interpass Temperatures

Use preheat temperatures that meet the requirements of the welding procedure and governing welding codes. The maximum interpass temperatures must not exceed 300 degrees F for austenitic stainless steels, nickel alloys, and copper alloys; and 500 degrees F for carbon steels. Use preheat techniques that ensure that the full thickness of the weld joint preparation and/or adjacent base material, at least 3 inches in all directions, is at the specified temperature.

Preheating by induction or resistance methods is preferred. When flame heating is used, only use a neutral flame. Do not use oxy-fuel heating on austenitic stainless steel or nickel-alloy materials; however, air-fuel heating is acceptable if controlled to ensure that the surface temperature does not exceed 150 degrees F.

Check interpass temperature on the surface of the component within 1 inch of the weld groove and at the starting location of the next weld pass, and for a distance of 6 inches ahead of the weld, but not on the area to be welded.

3.1.4 Production Welding Instructions

Perform welding in accordance with the following requirements:

a. Do not weld when the ambient temperature is lower than 0 degree F .

b. Welding is not permitted on surfaces that are wet or covered with ice, when snow or rain is falling on the surfaces to be welded, or during periods of high winds, unless the welders and the work are properly protected.

c. Gases for purging and shielding must be welding grade and have a dew point of minus 40 degrees F or lower.

d. Back purges are required for austenitic stainless steels and nonferrous alloys welded from one side. Set up the back purge such that the flow of gas from the inlet to the outlet orifice passes across the area to be welded. Use a purging gas that has an oxygen content that is no less than 2 percent, prior to welding.

e. Maintain the purge on groove welds for at least three layers or 3/16 inch .

f. Make removable purge dams from expandable or flexible materials such as Plexiglas or plywood. If wood is used, it must be kiln-dried

SECTION 40 05 13.96 26 Page 6 quality. Make non-removable purge dams, and purge dam adhesives, from water soluble materials. Do not make purge dams from polyvinyl alcohol.

g. Do not perform any welding process which requires the use of external gas shielding in a draft or wind, unless the weld area is protected by a shelter. Make shelters such that the wind velocity in the vicinity of the weld is a maximum of 5 miles per hour (440 feet per minute).

h. Welding of low-alloy and hardenable high-alloy steels may be interrupted provided a minimum of at least 3/8 inch thickness of weld deposit or 25 percent of the weld groove is filled, whichever is greater, and the preheat temperature is maintained during the time that welding is interrupted. If the temperature falls below the minimum preheat temperature before all welding has been completed on a joint, or, where required, before post weld heat treatment, a liquid penetrant or magnetic particle examination must be performed to ensure sound deposited metal before reheating. Welding of other materials may be interrupted without restriction provided a visual inspection is performed before welding is resumed.

i. Taper the ends of tack welds that are to be incorporated in the final by grinding or welding technique. Remove tack welds that are cracked or defective. Retack the groove prior to welding. Temporary tack welds shall be removed, the surface ground smooth, and visually inspected. For low-alloy and hardenable high-alloy steels, inspect the area using magnetic particle examination.

j. Do not grind finished welds any more than is required to perform effective NDE, including any inservice examination, and to provide weld reinforcement within the requirements of ASME B31.1 . If the surface of the weld requires grinding, avoid reducing the weld or base material below the minimum required thickness. Minimum weld external reinforcement must be flush between external surfaces.

3.1.5 Postweld Heat Treatment

a. Perform postweld heat treatment in accordance with ASME B31.1 .

Use thermocouples that are in contact with the weldment to measure temperatures for local postweld heat treatment.

b. Perform postweld heat treatment of low-alloy steels immediately upon completion of welding and prior to the temperature of the weld falling below the preheat temperature. Postweld heat treatment may be postponed after the completion of the weld, if, immediately after the weld is completed, it is maintained at a minimum temperature of 300 degrees F or the preheat temperature, whichever is greater, for 2 hours per inch of weld thickness.

c. For low-alloy steels, use cooling rates such that temper embrittlement is avoided.

3.2 EXAMINATIONS, INSPECTIONS, AND TESTS

3.2.1 General

Inspect all welding to ensure that the welds conform to the requirements of ASME BPVC SEC V, ASME B31.1 , and additional requirements as specified

SECTION 40 05 13.96 26 Page 7 in this Section.

3.2.2 Inspection

Prior to any welding, a certified weld inspector (CWI) must visually inspect and document the preparation of material for welding at each weld or joint in order to assure compliance with ASME BPVC SEC V and ASME B31.1 .

Only approved CWIs may perform weld inspection.

The CWI must be present at all times during welding operations and perform VT inspection on all completed welds throughout the welding process to assure compliance with ASME BPVC SEC V and ASME B31.1 . Perform VT on 100 percent of all welds. All welds must be free of oxide, flux, scale, paint spatter, or other foreign matter before inspection.

3.2.3 Visual Inspection Procedures

Visually inspect weld joints as follows:

a. Before welding - For compliance with requirements for joint preparation, placement of backing rings or consumable inserts, alignment and fit-up, and cleanliness.

b. During welding - For cracks and conformance to the qualified welding procedure.

c. After welding - For cracks, contour and finish, bead reinforcement, undercutting, overlap, and size of fillet welds.

3.2.4 Non-Destructive Examination (NDE)

Perform non-destructive examination of completed welds as specified in the following paragraphs. Only approved NDE personnel may perform and evaluate the examinations. All non-destructive examination must comply with the requirements of ASME BPVC SEC V and ASME B31.1 . Use the acceptance standards in ASME B31.1 to determine the acceptability of inspected welds.

3.2.5 Extent of NDE

a. Inspect 10 percent of complete joint penetration welds that are sized 5/16 inches and larger by ultrasonic testing.

b. Inspect 25 percent of fillet welds by magnetic particle testing or liquid penetrant testing.

Any weld that does not meet the acceptance criteria will not count as meeting the above inspection requirements. Rejection of any portion of a weld inspected on less than a 100 percent basis, by a method other than visual, will be 100 percent inspected by the method used in finding the defect. This inspection will not count towards meeting the above quality requirements. Submit NDE Testing Reports in an organized binder with a separate tab for each component. In the reports, include at a minimum, location of examined welds, method of examination used, examination procedures, personnel performing examination, and examination results (number and location of defects, if any).

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3.3 CORRECTIONS AND REPAIRS

Remove and repair defects as specified in ASME B31.1 , unless otherwise specified. Prepare and submit a Welding Repair Plan 14 calendar days prior to performing the welding repair, unless otherwise approved in writing.Repair defects that are discovered between weld passes before additional weld material is deposited. Contractor to provide all costs of repairs and retesting, except for repair of members cut to remove test coupons that were found to contain acceptable welds.

Wherever a defect is removed, and repair by welding is not required, blend the affected area into the surrounding surface eliminating sharp notches, crevices, or corners.

After defect removal is complete and before rewelding, examine the area by the same test method which first revealed the defect to ensure that the defect has been eliminated. After rewelding, reexamine the repaired area using the same test method originally used for that area. Any indication of a defect will be regarded as a defect unless reevaluation by NDE or by surface conditioning shows that no disqualifying defects are present. The use of any foreign material to mask, fill in, seal, or disguise welding defects will not be permitted.

3.4 GOVERNMENT QUALITY ASSURANCE

3.4.1 General

All welds are subject to inspection by the Government. The Government reserves the right to require the Contractor to conduct non-destructive examination of any weld by any of the methods listed in this specification. The Government may require that coupons be cut from any location in any joint. For rejected welds found by the Government Quality Assurance Program, inspect the full length of the weld at Contractor's expense using the NDT method that found the first defect in the weld.

3.4.2 Test Coupons

The Government reserves the right to require the Contractor to remove coupons from completed work when doubt as to soundness cannot be resolved by non-destructive inspection. Samples will be tested and evaluated by any means deemed appropriate by the Government. Should tests of any two coupons cut from the work of any welder show non-conformance with ASME B31.1 , it will be considered evidence of negligence or incompetence, and such welder removed from the work. When coupons are removed from any part of a structure, repair the members cut with joints which conform to the applicable welding code in accordance with paragraph Repairs.

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SECTION 42 13 19.00 26

THRUST BEARING OIL COOLERS

PART 1 GENERAL

1.1 SUMMARY OF WORK

This section specifies the requirements for supply of new thrust bearing oil coolers cooler assemblies, including spares, for Main Units 15 thru 22 and both Station Service Units.

1.2 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 A182/A182M (2014) Standard Specification for Forged or Rolled Alloy-Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service

ASTM A240/A240M (2014) Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A312/A312M (2014) Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes

ASTM A36/A36M (2012) Standard Specification for Carbon Structural Steel

ASTM A403/A403M (2013a) Standard Specification for Wrought Austenitic Stainless Steel Piping Fittings

ASTM B111/B111M (2011) Standard Specification for Copper and Copper-Alloy Seamless Condenser Tubes and Ferrule Stock

ASTM B152/B152M (2013) Standard Specification for Copper Sheet, Strip, Plate, and Rolled Bar

ASTM B171/B171M (2012) Standard Specification for Copper-Alloy Plate and Sheet for Pressure Vessels, Condensers and Heat Exchangers

ASTM F2329 (2013) Zinc Coating, Hot-Dip, Requirements for Application to Carbon and Alloy Steel Bolts, Screws, Washers, Nuts, and Special Threaded Fasteners

SECTION 42 13 19.00 26 Page 1

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2010; Errata 2011) Structural Welding Code - Steel

ASME INTERNATIONAL (ASME)

ASME B16.11 (2011) Forged Fittings, Socket-Welding and Threaded

ASME B16.15 (2013) Cast Copper Alloy Threaded Fittings Classes 125 and 250

ASME B16.18 (2012) Cast Copper Alloy Solder Joint Pressure Fittings

ASME B16.22 (2013) Standard for Wrought Copper and Copper Alloy Solder Joint Pressure Fittings

ASME B16.29 (2012) Wrought Copper and Wrought Copper Alloy Solder Joint Drainage Fittings - DWV

ASME B16.5 (2013) Pipe Flanges and Flanged Fittings:

NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME B16.9 (2012) Standard for Factory-Made Wrought Steel Buttwelding Fittings

1.3 SUBMITTALS

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

submittals having an "I" designation are for information only.

Designation following the "G" or "I" designation identifies the office that will review the submittal for the Government. Submit in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Shop Pressure Test Plan ; G, HDC

Material Test Reports ; G, HDC

SD-02 Shop Drawings

Oil Cooler Shop Drawings ; G, HDC

SD-03 Product Data

Oil Cooler Descriptive Literature and Specifications ; G, HDC

SD-06 Test Reports

Shop Pressure Test Report ; G, HDC

SD-07 Certificates

Finned Tube Supplier ; G, HDC

SECTION 42 13 19.00 26 Page 2

1.4 QUALITY ASSURANCE

1.4.1 Verification of Dimensions

Become familiar with details of the work and advise the Contracting Officer of any discrepancy before performing any work. The new coolers are interfacing with existing equipment and must fit in the existing site conditions without modification to the existing equipment.

1.4.2 Finned Tube Supplier Qualifications

The supplier of the finned tubes must have been in the business of producing finned tubes as specified herein for at least 2 years prior to bid opening. During that time, the finned tube supplier must have produced finned tubing for similar types of coolers for hydroelectric generating units that are specified in this section.

Submit the qualifications and resume of the Finned Tube Supplier . The submittal must include examples and references for coolers that have been successfully installed.

1.4.3 Product Data

Submit complete, Oil Cooler Descriptive Literature and Specifications for each manufactured product used in the coolers. The literature shall include original, legible, manufacturer's cut sheets and data sheets that clearly indicate physical construction, operation, mechanical and structural characteristics, and associated hardware, as applicable. For data sheets with extraneous data, clearly indicate which data applies by crossing out other models, or circling or highlighting the correct options. Product data shall clearly show conformance with these Specifications, including, but not limited to: product manufacturers' declarations of conformance to applicable technical standards. Submit product data concurrent with the shop drawings.

1.4.4 Shop Drawings

Prepare and submit Oil Cooler Shop Drawings for the new cooler assemblies. Show the complete fabrication, assembly, and installation details of the coolers. Show detail views, with appropriate tolerances and material callouts for all fabricated parts. Show all welding details, including cross reference to all weld procedures. Include a bill of materials or parts list on the drawings.

1.4.5 Material Test Reports

For each item or batch of materials used to fabricate the coolers, submit material test reports (MTR). The reports must show full compliance with all applicable standards. Reports must clearly show country of origin for the material

PART 2 PRODUCTS

2.1 GENERAL

2.1.1 Materials

Materials and equipment must conform to the requirements of these specifications. When materials and equipment are specified to be replaced

SECTION 42 13 19.00 26 Page 3 in kind, at minimum they must be of equal design as existing equipment being replaced, unless specified otherwise.

In cases where material is not covered by one of the listed specification groups, furnish the highest commercial grade of material or product available.

2.1.2 Standard Products

Provide materials and equipment that are the standard products of manufacturers regularly engaged in the manufacture of such products.

Items of equipment provided must essentially duplicate equipment that has been in satisfactory use at least 2 years prior to bid opening.

2.1.3 Dissimilar Metals

Electrically isolate all dissimilar metals from one another, including bolts, nuts and washers. The isolation must prevent electrical current flow between adjacent parts. The material of the isolation means must be suited for the service and atmosphere it is placed in. Clearly show on the shop drawings how dissimilar metals are isolated.

2.2 BOLTS, NUTS, AND WASHERS

Provide bolts, nuts, and washers per SECTION: 05 50 03.00 26 METALWORK, FABRICATION, MACHINE WORK, and MISCELLANEOUS PROVISIONS.

Unless specified otherwise, bolts, nuts and washers that are in contact with, or joining stainless steel parts must be made from stainless steel.

Carbon steel bolts, nuts and washers must be hot-dip galvanized in accordance with ASTM F2329.

2.3 NAMEPLATES

Provide a nameplate for each cooler that is permanently affixed to the cooler. Make the nameplates from corrosion resistant material. Emboss or engrave the letters on to the nameplates. Coatings or vinyl letters or logos are not allowed on the name plates. Locate nameplates on the side of the cooler at an elevation that is midway between the top and bottom of the cooler. Nameplates must contain the following information, at a minimum:

a. Manufacturer name, address, and phone number;

b. Serial Number;

c. Model Number;

d. Manufacture date;

e. Maximum allowable working pressure, at temperature;

f. Weight, empty;

g. Weight, full of water;

Include a sample of the nameplate on the cooler shop drawings.

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2.4 MAIN UNIT THRUST BEARING OIL COOLERS

2.4.1 Main Unit Coolers General

The main unit 15 thru 22 thrust bearing oil coolers consist of two semi-circular sections. The coolers are curved tube type with water boxes on either end. Each cooler half is constructed of a frame supporting an array of finned tubes with a supply/discharge manifold at one end and a return header on the other end. Supply new coolers that are identical to the existing coolers except where modified by these specifications. The new coolers must be dimensionally interchangeable with the existing coolers. Reference drawings show some of the details for the existing coolers and the piping. One existing cooler will be made available to the Contractor for the purpose of reverse engineering. The specifics regarding the availability of the cooler for reverse engineering is located in PARAGRAPH: Cooler Availability for Reverse Engineering.

2.4.2 Existing Conditions

The general shape and dimensions of the existing coolers is shown in the reference drawings. The following additional information is known about the existing finned tubing. Note dimensions listed are approximate and must be verified by the Contractor during the reverse engineering process:

Tube outer diameter: 1 inch

Fin Height: 1/2 inch

Fin Pitch: 9 fins/inch

2.4.3 Finned Tubing

Make fins from copper (UNS C10XXX series) that meets the requirements of ASTM B152/B152M . Make the water tubes from copper that meets the requirements of ASTM B111/B111M , UNS C70600. Use tube with a wall thickness no less than 0.065 inches.

Spriral tension wrap the fins onto the water tube. Coat the finned tube assembly with lead free solder. Mechanically expand the tube ends into the tube sheets.

2.4.4 Water Boxes

Make water boxes from stainless steel that meets the requirements of

ASTM A240/A240M , UNS 30400.

2.4.5 Cooling Water Piping and Connections

Provide cooling water piping and connections in accordance with the following:

a. Use seamless, stainless steel, pipe that meets the requirements of

ASTM A312/A312M

b. Use stainless steel socket weld or butt weld flanges that meet the requirements of ASTM A182/A182M and dimensions in accordance with ASME B16.5 or ASME B16.11 , Class 150.

SECTION 42 13 19.00 26 Page 5

c. Use stainless steel, butt-welding fittings that meet the requirements of ASTM A403/A403M and ASME B16.9 .

d. Use schedule 40 pipe and fittings.

There are minor dimensional difference between units for the flanges where the cooler piping connects to the greater cooling water system. To accomodate these minor dimensional differences, modify the cooling water from the existing design in the following manner:

a. Stub the pipe horizontally out from the cooler and weld on a flange.

b. Provide 6 inches of additional horizontal and vertical length on the remaining pipe sections.

c. Provide the required quantity of flanges and gaskests to complete the remaining joints.

2.4.6 Tube Sheets

Make tube sheets from naval brass that meets the requirements of

ASTM B171/B171M , UNS C46400.

2.4.7 Cooler Frame

Make the cooler frame from carbon steel that meets the requirements of

ASTM A36/A36M.

2.4.8 Gaskets and O-Rings

Make all rubber gaskets out of Buna-N or Viton materials.

2.5 STATION SERVICE UNIT THRUST BEARING OIL COOLERS

2.5.1 Station Service Unit Coolers General

The station service unit thrust bearing oil coolers consist of two sections of coiled tubes. Supply new cooler assemblies in accordance with this Section and the Contract Drawings.

2.5.2 Cooler Tubing

Fabricate the coolers using 90/10 copper/nickel tubing that meets the requirements of ASTM B111/B111M , UNS C70600. Fabricate coolers in a manner to minimize the number of joints in the coil. Joints or splices are only acceptable when more tubing is needed than what is commercially available as raw material (i.e. 60 feet of tubing is required, but tubing only comes in 30 feet lengths, in this specific example it would be acceptable to have one splice/joint). Bends must be made in a manner that doesnt distort or change the inner diameter of the tube.

2.5.3 Tubing Fittings

Provide fittings made from copper and that meet the requirements of ASME B16.15 , ASME B16.18 , ASME B16.22 , and/or ASME B16.29

2.5.4 Cooler Frame

Fabricate the cooler frames from steel that meets the requirements of

SECTION 42 13 19.00 26 Page 6

ASTM A36/A36M

PART 3 EXECUTION

3.1 QUANTITY AND SPARE COOLERS

Supply nine main unit cooler assemblies and 3 station service unit assemblies. One assembly of each type is designated as a spare and will be placed into long-term storage. The spare assemblies have extra packaging requirements that are listed below.

3.2 COOLER AVAILABILITY FOR REVERSE ENGINEERING

One of the existing main unit cooler assemblies will be made available for the purpose of reverse engineering of the existing coolers and developing the shop drawings . The cooler will be available for a period of 8 weeks.

The cooler must be returned to the Government in the same condition as it was received by the Contractor. The Contractor is responsible for any damage that occurs to the cooler. The Government will remove the cooler and place it in a location that is coordinated in advance with the Contractor. It is the Contractor's responsibility to package the cooler for shipping and arrange all shipping to from The Dalles Lock and Dam.

3.3 FABRICATION

Fabricate the thrust bearing oil coolers to the quantity and materials specified in this section. Fabricate one set of main unit coolers and one set of station service coolers . Pressure test them and ship to site so that that they can be installed. Pause fabrication on the remainder of the coolers until the initial set is tested on-site. Fabricate the remainder of the coolers after the initial set has been accepted.

3.3.1 Welding

Perform welding of all pressurized components on the cooler assemblies per SECTION 40 05 13.96 26 WELDING, PIPING. Perform all other welding in accordance with AWS D1.1/D1.1M

3.3.2 Metal Work

Unless noted otherwise, perform metal work and machining in accordance with the requirements of Section 05 50 03.00 26 , METALWORK FABRICATION, MACHINE WORK, AND MISCELLANEOUS PROVISIONS.

3.4 SHOP ASSEMBLY

Fully assemble the new thrust bearing oil cooler assemblies at the fabricator's shop before shipping. Ship coolers fully assembled. Repair any damage, such as bent fins, before shipping the coolers.

3.5 CLEANLINESS

All external surfaces of the coolers must be cleaned to remove any oil, grease, dust, debris, or any other foreign material that could contaminate the thrust bearing cooling oil. Do not use solvents when performing cleaning operations. The Government will verify cleanliness prior to acceptance. Any coolers that do not meet the cleanliness requirements will not be accepted until they are cleaned.

SECTION 42 13 19.00 26 Page 7

3.6 PROTECTION OF COOLERS

Handle coolers to prevent damages including, but not limited to, dents and scratches. Tightly cover openings on cooler flanges with caps or plugs during shipping to prevent entry of foreign material. Protect coolers against dirt, water, and chemical or mechanical damage. The Government will inspect the coolers prior to acceptance and will not accept the coolers until any damage has been repaired, at no additional cost to the Government.

3.7 SHIPPING

Package the coolers for long term storage. Ensure all openings are securely plugged. Package the coolers in wooden crates that are capable of being stacked upon one another , up to 3 crates high . Label crates with contract number, contract title, current date, contents of the crate , proper orientation of the crate, and safe stacking height .

3.8 SHOP PRESSURE TEST

Pressure test each cooler section before shipping the coolers to the job site. The Government will witness the test. Except for the initial set, group the tests such that a minimum of 4 cooler sets are tested at one time. Notify the Government a minimum of 45 days prior to the starting of the test. Provide all equipment, materials, and personnel required to complete the pressure tests. During the test, orient and support the coolers in the same manner that they will be installed in. Verify correct operation of all vents and drains before performing the test.

The test must be a static pressure test, using water as the test medium.

Use a test pressure of 75 psi. Use a test period of a minimum of one hour. The criteria for a successful test is: zero drop in pressure and zero leaks. Any drop in pressure or leak from the cooler will result in a failed test. If a leak is discovered during testing, repair the leak and re-perform the test in full.

3.8.1 Shop Pressure Test Plan

Submit a Shop Pressure Test Plan a minimum of 30 days before the planned start date of the test. The test plan must include the following elements at a minimum:

a. Date and planned location test will take place;

b. Name and contact information for Contractor point of contact that will be conducting the test;

c. Make, model, serial number, and up-to-date calibration certificates for each instrument to be used in the test;

d. Drawings or sketches that show the support fixtures and how the coolers will be connected to the pressure supply;

e. A detailed, step-by-step, repeatable testing procedure;

f. A blank copy of the form that certifies a successfully completed test.

SECTION 42 13 19.00 26 Page 8

3.8.2 Shop Pressure Test Report

Submit a Shop Pressure Test Report no later than 7 days after the successful completion of a test. The report must include the following elements at a minimum:

a. Date and location test took place;

b. Names of Contractor personnel involved with testing

c. Summary of test parameters and tests performed

d. Certification of successful test completion for each cooler tested;

e. If a leak was discovered during the test, note which cooler the leak occurred on, the specific location of the leak and the measures taken to fix it.

3.9 OPERATION AND MAINTENANCE (O&M) DATA

In addition to the standard requirements for operation and maintenance data submittals, include the…