Fort Randall Oil Accessories Scope of Work.pdf

Scope of Services for Fort Randall Transformer Accessories

High Pressure Relief Table of Contents

1. Scope

1.1 Scope of Contract Requirements

2. Applicable Regulation

3. Submittals

4. General Requirements

4.1 Outage

4.2 Government Provided Utilities

4.3 Field Supervisor Experience

4.4 Contractor Responsibilities

4.5 Clean-Up or Work Area

4.6 Spill Prevention Plan

5. Technical

5.1 Inspection

5.2 Materials

5.3 Testing

5.4 Transformer Reassembly

6. Manuals and Data

7. Warranties

8. Appendix – Pertinent Information

8.1 Appendix – Transformer Data

8.2 Appendix – Photos

8.3 Appendix – For Information Only Drawings/Manuals

1. Scope This project is to replace and install Pressure Relief Devices, Sudden Pressure Relays, and Winding Temperature Devices on a total of 16 transformers. The Contractor shall provide all of the devices, modify the transformers as necessary, install the equipment, and test for proper operation. Project shall be complete August 1, 2011(See allowable outages below).

1.1 Scope of Contract Requirements

1. Before purchasing the contractor shall inspect and determine that all the pressure relief, sudden pressure relays and temperature devices being supplied are compatible with the transformers and will perform the intended functions.

2. Contractor shall replace and install all protective devices. The oil shall not be lowered below the transformer core and a positive nitrogen pressure shall be maintained on tank.

3. Replace with new gaskets and seals on all devices installed and if necessary on all covers removed.

4. The contractor will be responsible for all disassembly and reassembly of the transformers and shall provide the equipment necessary to perform all tasks. The transformer shall be reassembled. If during process of performing the work the oil is contaminated or the positive pressures is lost the contract will be required to perform the necessary on site filtering with the contractor supplying all equipment for filtering and transformer oil at cost to the contractor.

5. Upon reassembly contractor shall clean all the external surfaces of the transformers that were dirty by the replaced devices or dirty during the work. Solvents used for cleans shall be submitted for approval and shall be environmentally friendly.

6. Final oil tests shall be performed showing that the oil is equal to preconstruction levels.

2. Applicable Regulation The latest sections, editions and addenda of the following Government regulations, codes, policy statements, industry standards and recommended practices form a part of this specification. Nothing in these specifications is to be construed as permitting work not conforming to these requirements. The Contractor shall be responsible for determining the extent to which these regulations effect any operations resulting from this solicitation and to comply therewith.

a. EPA - Environmental Protection Agency Regulations for the Control and disposal of PCB Contaminant Waste

b. EPA Policy Statement on residual PCB's in processed liquids and solids

c. OSHA - Occupational Safety and Health Administration regulations

d. RCRA - Resources Conservation and Recovery Act (Primarily 40 CFR 268)

e. TSCA - Toxic Substances and Control Act (Primarily 40 CFR 761)

f. DOT - Department of Transportation Regulations for the Transportation of Toxic Wastes

g. CERCLA-Comprehensive Environmental Response, Compensation, and Liability Act of 1980 (SUPERFUND)

h. CWA - Clean Water Act of 1972

i. Safe Drinking Water Act of 1974

j. All other applicable Federal, State, Country and City codes, laws, standards and regulations.

3. Submittals

3.1.1 Documentation of the qualifications of the Services Supervisor.

3.1.2 A plan for Spill Prevention and Spill Countermeasures, including clean-up procedures.

3.1.3 Required Submittals

Prior to the supply of equipment/materials the Contractor shall be required to submit to the Contracting Officer for approval: schematics, drawings, descriptive literature and data as identified below.

SD-01 Pre Site Work Submittals Certificates of Insurance - To indemnify against long-term liabilities and catastrophic occurrences.

Work Plan – Detailing the process, step and methods for performing the work Outage Requests Schedule Quality and Safety Control Plan Permits Hazardous Energy plan Spill prevention plan

SD-02 Instructions;

Submit installation plan Submit plan for gasket installation

SD-03 Product Data Materials;

Submit data sheets on materials that will be installed according to this scope of work. ie gaskets, relays, temperature meters

SD-06 Test Reports

Final Tests;

Submit Final Oil Test Results

3.1.4 Submittal Form.

The attached submittal form (ENG Form 4025) shall be used for transmitting the submittal.

This form may be reproduced by the Contractor and shall be properly executed by filling out all the heading blank spaces and identifying each time submitted. Special care should be exercised to ensure proper listing of the specification paragraph and/or sheet number of the contract drawings pertinent to the date submitted for each item. The Contractor shall provide copies for each submittal to the location stated below.

3.1.4.1 Meaning of Approvals

Action Codes will be as indicated on the back of ENG Form 4025. The Contracting Officer will mark an Action Code on each submitted ENG Form 4025 prior to returning a copy to the Contractor. The approval of a submittal by the Contracting Officer shall not be construed as a complete check, but will indicate only that the general method of prosecution and detailing is satisfactory. Approval will not release the Contractor of the responsibility for any error that may exist, as the Contractor is responsible for satisfactory prosecution and detailing of all work.

3.1.4.2 When Not Approved

The Contractor shall make all corrections required by the Contracting Officer and promptly furnish a corrected submittal in the form and number of copies as specified in the initial submittal.

3.1.4.3 Submittal Delivery

The Contractor shall provide a completed copy of ENG Form 4025 with 3 copies of each submitted item to the Contracting officer at the Fort Randall Project.

U.S. Army Corps of Engineers Fort Randall Project Post Office Box 199 Pickstown, SD 57367-0199

Two copies off all submittal shall be submitted to the following address:

Attn: Lucas Kirkpatrick (OD-SM) U.S. Army Corps of Engineers 1616 Capitol Ave Omaha, NE 68102

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4. General Requirements

4.1 Outage

Work shall be completed with mutually agreeable dates coordinated between the Government and the Contractor. Permissible dates are September through November of 2010 and March through May of 2011. The contractor shall efficiently execute work to minimize the outage period. All work will be done sequentially requiring no more then two mobilizations and if possible concurrent with the government’s scheduled outages. Only one transformer bank shall be under an outage at a time, concurrent outages will not be allowed. The contractor will be required to work under the Government’s “Control of Hazardous Energy” clearance program. Contractor personnel are required to sign into the appropriate clearances. The government will install grounds on the High Voltage side and the Low Voltage side. The contractor shall provide and install all other personal protective grounds and enter grounds points into the clearance for the purpose of tracking.

4.2 Government Provided Utilities

The government will make 120volt and 480volt electrical service available to the contractor. The contractor shall provide all extension cords, ladders, cranes and any other tools and materials needed to perform the contract.

4.3 Field Supervisor Experience

All related work, including transformer inspection and oil processing shall be under the direct supervision of a qualified field services supervisor. Qualifications shall include:

A minimum of 3 years' experience supervising power work.

The satisfactory completion of formalized training on regulations and procedures for oil processing including spill prevention/clean-up, safety precautions, and testing and handling of mineral oil products including PCB items.

The satisfactory completion of formalized training in the safety procedures pertaining to high voltage electrical equipment and confined space entry.

4.4 Contractor Responsibilities

The Contractor shall conduct a pre-job safety meeting. The Contractor shall take all necessary precautions to protect all employees and the general public from exposure to solids, liquids, vapors, and mists. Prior to commencing any work activities, barricades, roping, and "Danger-Keep Out" signs shall be put in place which clearly identify the work areas and equipment transport corridors and guard against unauthorized entry into the work area.

Prior to commencing any operations involving the transformer, temporary oil containment shall be constructed around the transformer and processing equipment. Sorbents shall be placed within the work area in amounts adequate to absorb 50 gals of the volume of transformer oil.

4.5 Clean-Up or Work Area

After completion of work, all equipment used shall be decontaminated in accordance with applicable EPA regulations and properly secured. All rinsate shall be disposed of in accordance with federal, state, and local environmental regulations.

All concrete (or other surfaces) which have come in contact with contaminated fluids in the course of the work shall be thoroughly scrubbed using a combination of sorbents, absorbents, solvents, and cleansers.

All soils which have been contaminated as a result of work-related activities shall be removed and replaced with "clean" soil at the Contractor's expense.

4.6 Spill Prevention Plan

Prior to commencement of work, the contractor shall submit and receive approval for a Spill Prevention Control & Countermeasure (SPCC) plan. The plan shall be developed in accordance with 40 CFR 112 and at a minimum include the following:

The emergency spill response plan encompassing all steps the contractor will take in the event of a spill or other emergency.

Safety procedures covering all phases of operations including, but not limited to, handling, loading, transporting, securing loads, and first aid procedures.

5. Technical Contractor shall follow requirements of this scope of services and all applicable ASTM and IEEE standards. Note See IEEE standard

5.1 Inspection

Before mobilization the contractor shall ensure that equipment being provide is adequate for the transformers on which they are being installed.

5.2 Materials

Contractor shall install the required devices on all transformers expect where noted. Some of the transformers currently have outdated devices that will be replaced under this specification. The rest of the transformers do not currently have the devices and may need to be physically modified in order for the new device be installed. The contractor shall be responsible for performing all required modifications. Where applicable the contractor shall reuse ports and wells for device installation.

5.2.1 Pressure Relief Devices:

Contractor shall provide 1 pressure relief device per transformer for a total of 16. Pressure Relief Device shall be Qualitrol XPRD or approved equal to replace existing pressure relief diaphragm to protect for overpressure of oil filled transformers. Features shall include high flow rate (greater than 10,000 SCFM) for quick relief of overpressure, integrated directional shield. Outlet shall be connected to a contractor supplied and installed aluminum piping with compression couplings and protective end screen routed to within 18" of switchyard surface. A minimum of three pipe supports in addition to the connection to the pressure relief device shall be provided. Direction and pipe route to be approved by government.

Routing and method of shall connect to the outlet to maximize flow rate and control hot oil and gas discharge. Contractor shall use corrosion resistant stainless steel directional shield, hardware, operating valve, and discharge piping.

Additionally Contractor to determine correct:

• Operating pressure

• Indicator style

• Switches

• Electrical connection style

5.2.2 Sudden Pressure Relays:

Contractor shall provide 1 pressure relief device per transformer for a total of 16. Devices to be Qualitrol 900 Series or 910 Series where applicable (or approved equal) and shall provide a transformer trip for sudden pressure rise condition. This alarm shall be wired to parallel existing trip devices. Device shall be mount horizontally or vertically with flange or thread mounting as dictated by unit requirements.

Additionally Contractor shall provide:

• Seal in relay for latching alarm or trip signal

(Qualitrol 909 or approved equal per transformer)

• 1 Field test kit (Qualitrol KIT-013 or approved equal)

• Flange or thread mounting as unit requires

5.2.3 Winding Temperature Devices:

Contractor shall provide 1 winding temperature device per single phase transformer and 3 devices per 3phase transformer for a total of 18. Devices to be Qualitrol 104/TR6000 or approved equal and shall provide temperature indication with integrated control and alarm functions. System shall utilize Bourdon tube based capillary measurement with resettable maximum pointer. Minimum of four user adjustable switches (contacts) shall be provided for control and alarms. The display head shall have a 6 inch (150mm) dial face with an angular dial span of 90° and fine measurement adjustment. The display head shall be placed and angled for easy viewing. The display will also have a built in spring loaded pointer for switch field testing.

Additionally Contractor shall determine and supply:

• Temperature ranges applicable for oil (liquid) or winding (winding simulation requires heated well or QUALITROL Thermal plate)

• Electrical connection type, connector cable type and wire colors

• SCADA output (0-1mA or 4-20mA) with integrated power supply

5.2.4 Oil Temperature Devices:

Total of 9 Oil Temperature devices to be installed (2-Qualitrol 165s and 7-TR6000s). All temperature devices shall be placed for easy viewing. Transformer Banks B, C, D have had all but 2 oil temperature gauges replaced. Contractor shall install and replace the remaining two gauges; one on bank B and 1 on bank C. Contractor shall install meters identical to the new ones installed on banks B, and C. The new meter is a type Qualitrol 165.

On transformers in banks A, E, and F a total of 7 remote mounted device similar to a Qualitrol 104/TR6000 or approved equal and shall be installed which provide temperature indication with integrated control and alarm functions. System shall utilize Bourdon tube based capillary measurement with resettable maximum pointer. Minimum of four user adjustable switches (contacts) shall be provided for control and alarms. The display head shall have a 6 inch (150mm) dial face with an angular dial span of 90° and fine measurement adjustment. The display head shall be placed and angled for easy viewing.

The display will also have a built in spring loaded pointer for switch field testing.

Additionally Contractor shall determine and supply:

• Temperature ranges applicable for oil (liquid) or winding (winding simulation requires heated well or QUALITROL Thermal plate)

• Electrical connection type, connector cable type and wire colors

• SCADA output (0-1mA or 4-20mA) with integrated power supply

5.2.5 Liquid Level Gauge Assembly:

Contractor shall provide 1 oil level gauage case assembly per transformer for a total of 16.

Devices to be Qualitrol 032/045 as applicable (or approved equal). Device provides continuous indication of the liquid level inside of a transformer’s main tank or consevetor tank where applicable.

Additionally Contractor shall determine and supply:

• Gear or lever type (this is not being replaced)

• Electrical connection type, connector cable type and wire colors

5.2.6 Gaskets

The gaskets shall be made of a resilient material that will not deteriorate under the action of hot oil, are suitable for their environment and will remain oil tight. Gasket materials must be durable and reusable with a durometer rating of 65 to 80. The Contractor shall provide a submittal for all gasket materials supplied. Nitrile and cork-neoprene gaskets are acceptable. Ordinary cork or neoprene is not approved.

Contractor shall provide a plan describing the gasket installation process. Gaskets shall be installed on all open covers in addition to all seals required for protective device installation.

5.3 Testing

Contractor shall perform the following test on the oil after the work is complete. The contractor may either compare the final tests to latest sample taken by the Corps or they may perform initial tests whose results must then be submitted before start of onsite work.

Final oil samples may be taken up to two weeks after completion of work if the contractor wishes the transformers to be energized before taking oil samples.

Physical Tests

Interfacial tension – ASTM D971-99a

ASTM D2285-99

Electrical Tests Dielectric breakdown voltage – ASTM D877-00

Chemical Tests

Gas content – ASTM D3612-02 Water in insulation liquids – ASTM D1533-00

5.4 Transformer Reassembly

1. Contractor shall remove cover ports as necessary.

2. During installation process a positive pressure shall be held with the nitrogen.

3. Upon completion of the installation, with positive pressure maintained, transformers shall then be sealed.

If Contractor exposes the winding or contaminates the oil the IEEE C57.3 shall be followed where necessary for returning the transformer to service.

6. Manuals and Data Contractor shall supply all manuals, drawings and spare parts listings associated with the provided equipment. Additionally, all changes made to the equipment (ie, the new devices being installed, conductors installed or devices replace etc) shall be document and supplied to the government.

7. Warranties Contractor shall provide standard industry warranty for all equipment installed. This will cover at minimum one year of service. It will include all equipment, costs and work associated with replacement of defective part.

8. Appendix – Pertinent Information The government will not be held responsible for errors in photos, test data, drawings or in site conditions which vary from the information provided in this appendix. It is the contractor’s responsibility to field check and field verify all equipment, conditions and tests.

The contractor shall perform all work required in the above Scope of Services.

8.1 Appendix – Transformer Data

Transformer Bank A Three Single Phase Transformers Manufacturer: Moloney Electric Co.

Year of Manufacture: 1953 Type: Nitrogen Blanketed

Phase: Single Cycles: 60 Voltage: 115/13.2 kV Rating: 32,500 KVA (OA/FA) Oil Quantity: 4,650 gal per transformer

Transformer Bank B, C, D Single Phase Transformers (9 transformers total) Manufacturer: Westinghouse Electric Corporation.

Year of Manufacture: 1950??

Type: Nitrogen Blanketed Phase: Single Cycles: 60 Voltage: 230/13.2 kV Rating: 32,500 KVA (OA/FA) Oil Quantity: 4,325 gal per transformer

Autotransformer Bank E Three Single Phase Transformers Manufacturer: General Electric Year of Manufacture: ??

Type: Nitrogen Blanketed Phase: Single Cycles: 60 Voltage: 230 GRY/ 132.8 -115 GRY/66.4-13.8 kV Rating: 35,556 KVA (OA/FA) Oil Quantity: 6,600 gal per transformer

Autotransformer Bank F Three Phase TRAFO-UNION Transformer Year of Manufacture: 1984 Type: Conservator Tank Phase: 3 Cycles: 60 Voltage: 230 -115 Rating: 107,000 KVA (OA) Oil Quantity: 9,680 gal

8.2 Appendix – Photos

Moloney Transformer – Single Phase XFMRs on Bank A

Westinghouse Transformer – Single Phase XFMR on Banks B, C, D

GE Transformers – Single Phase Transformers on Bank E

Trafo Union Transformer – Three Phase XFMR Bank F

8.3 Appendix – For Information Only Drawings/Manuals

The following drawings are provided as For Information Only Drawings. They do not indicate the work to be performed. The government will not be held responsible for errors in drawings or in site conditions which vary from the information provided in this appendix.

It is the contractor’s responsibility to field check and field verify all equipment.