Amd_0004_Specs.pdf

Fort Peck GSU & SS Transformer Supply FTPTS15

Section 48 20 00 Page 1

Changes:

SECTION 26 08 01, TRANSFORMER COMMISSIONING

Paragraph 1.1: Clarification that transformer commissioning requirements are after the transformers are installed by the separate installations contractor.

SECTION 48 20 00, TRANSFORMER SHIPMENT, HAULING AND SITE ASSEMBLY

Paragraph 1.2: Changed this paragraph to clarify that the transformers are being placed into storage, and the responsibilities of the Erecting

Engineer and Commissioning Agent.

Paragraph 1.7.3: Changed this paragraph to clarify the responsibilities of the Erecting Engineer.

Part 2: Added paragraphs 2.1 and 2.2 detailing the requirements for oil containment berms and cribbing to be provided for transformer storage.

Paragraph 3.8: Changed the paragraph to clarify that the transformers are being placed into storage.

Paragraph 3.8.2: Added the requirement to ground the bushing terminals to the tank ground pad for transformer storage.

Paragraph 3.13.1: Changed the paragraph to require the training to be performed after the first transformer has been installed and commissioning has been performed.

SECTION 26 08 01

TRANSFORMER COMMISSIONING

PART 1 GENERAL

1.1 COMMISSIONING PROGRAM DESCRIPTION

After each transformer has been fully reassembled, oil-filled and tested, per the requirements of Section 48 20 00, site movement from the storage location to the permanent operating location and interconnections to the power plant, along with other associated site-work, will be performed by a separate installations contractor. Upon completion of the installations, each transformer will be commissioned for placement back into service by the separate installations contractor and the Government. A designated

Commissioning Agent (CA) shall be provided under this contract for support during the overall commissioning activities for each transformer, as required herein. The CA shall develop a commissioning program, coordinate

Contractor commissioning activities, and act as the point of contact during the commissioning process. The commissioning program shall include pre-operational testing, monitoring during the start-up and energization period, and operational testing and monitoring during the load test period. The

Contractor shall furnish all material, labor and travel required to accomplish and complete the commissioning requirements, as specified herein.

1.2 COMMISSIONING PHASES

All testing, inspections, and procedures for each of the commissioning phases shall be completed, documented, submitted, and approved by the

Government prior to proceeding to the next commissioning phase. The

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Section 48 20 00 Page 2

Contractor's quality control (CQC) system manger and CA are responsible for certifying that each phase in the commissioning program is completed and receives Government approval, prior to starting work on the next phase of the program.

1.2.1 Pre-operational Test Phase

During the pre-operational test phase, the Contractor shall have the responsibility for verifying proper operation of all transformer equipment after each transformer has been interconnected to the power plant by the separate installations contractor, and shall provide support to the

Government during any required pre-operational testing of power plant interfaces. During the coordination meeting, the Government will communicate the necessary Contractor support for the Government's pre-operational testing activities.

1.2.2 Operational Test Phase

The Government will be responsible for the overall coordination of operational testing, and will operate the controls of the equipment under mutual agreement with the separate installations contractor and the

Contractor's CA. The Contractor shall provide support to the Government during the operational test phase by taking equipment readings, observing equipment operation, verifying settings, making any necessary adjustments, and troubleshooting. The operational testing will begin after the completion of the pre-operational testing and Government approval of the pre-operational inspection and test reports. During the operational test phase, the consequences of a failure are heightened, and therefore the primary goal of commissioning is to assure adequate planning has been completed to protect Government equipment, systems and personnel.

1.3 COMMISSIONING PROGRAM REQUIREMENTS

The Contractor shall develop an overall Contractor's Commissioning Program that contains the following information:

a. Pre-operational inspections to ensure that the transformer reassembly is in accordance with the requirements of the contract specification, and that all deficiency items noted during the reassembly process have been resolved.

b. Pre-operational test plan, to include the activities of the CA, the electronic temperature monitor manufacturer's representative, and the on-line dissolved gas monitor manufacturer's representative.

c. Operational test plan, to include the recommended energization period prior to loading, the recommended staged levels of transformer loading, including durations at each stage, and the monitoring requirements.

1.4 CONTRACTOR'S COMMISSIONING AGENT

1.4.1 Commissioning Agent Qualifications

The Contractor's Commissioning Agent shall have a minimum of five (5) years construction experience regularly engaged in planning and testing of

Section 48 20 00 Page 3 electrical equipment of comparable type and complexity. The qualifications shall be submitted in resume format and submitted for approval.

1.4.2 Responsibilities

The responsibilities of the Contractor's Commissioning Agent shall include, but not be limited to:

a. Development of a Commissioning Program, including but not limited to: preparation of inspection and test plans, scheduling, and execution of the commissioning activities including activities of all involved subcontractors. The scope of this work is further detailed in

Part 3. Commissioning activities associated with interconnection wiring to the powerhouse and other Government systems not part of this supply contract are the responsibility of a separate installations contractor.

b. Participation in coordination meetings necessary to discuss and schedule Commissioning activities.

c. Oversee the commissioning activities of each transformer.

d. During operational testing where the Government has lead responsibility, participate in testing coordination meetings to help resolve operational issues between the installed equipment and the overall Government system.

1.5 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.

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

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

1.6 SUBMITTALS

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

submittals not having a "G" designation are for information only or as otherwise designated. When used, a designation following the "G" designation identifies the office that will review the submittal for the

Government. The following shall be submitted in accordance with Section 01

33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Contractor's Commissioning Program; G, HDC

Commissioning Agent Qualifications; G, HDC

SD-11 Closeout Submittals

Commissioning Reports; G, HDC

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Section 48 20 00 Page 4

PART 2 PRODUCTS - NOT USED

PART 3 EXECUTION

3.1 PRE-OPERATIONAL TESTS

3.1.1 Transformer Control, Annunciation, and Power Circuits

Following completion of the transformer installation activities by the separate installations contractor, the Contractor shall request from the COR to have the transformer control, annunciation, and cooler power energized for the purposes of the performance of pre-operational testing. Pre-operational tests shall be performed utilizing the transformer schematic diagrams, and initiating the circuit being tested at the device source rather than by jumpering contacts, to the maximum extent possible. The following tests shall be performed by the Contractor during the pre-operational test phase, at a minimum (as applicable):

a. Functional testing of all 120 VAC and 125 VDC control circuits.

b. Functional testing of all 125 VDC annunciation circuits.

c. Functional testing of all 240 VAC cooling circuits, including verification of proper cooling fan phasing.

d. Functional testing of the on-line dissolved gas-in-oil monitor.

e. Functional testing of the electronic temperature monitor.

3.1.2 Electronic Temperature Monitor (ETM)

The ETM shall be fully programmed and functional during the performance of the pre-operational tests. A Commissioning Engineer shall be present during performance of the tests, who is an employee of the ETM manufacturer, for commissioning activities, to include the following at a minimum:

a. Verify all settings are correctly entered into the software.

b. Verify correct operation of the cooling groups by simulating winding temperature rise at the winding temperature RTD inputs.

c. Verify the correct settings and operation of all winding and oil temperature alarms and trips.

d. During operation of the cooling fans, the ETM shall be setup for monitoring and recording the cooling group inrush and normal operating currents, and for establishing the recommended operational current hysteresis for the alarming of cooling group trouble.

3.1.3 Dissolved Gas-In-Oil Monitor

The dissolved gas-in-oil monitor shall be fully programmed and functional during the performance of the pre-operational tests. A Commissioning

Engineer shall be present during performance of the tests, who is an

Section 48 20 00 Page 5 employee of the gas-in-oil monitor manufacturer, for commissioning activities, to include the following at a minimum:

a. Verify all oil lines have been properly bled, and there are no leaks.

b. Verify there are no leaks for the consumable gas connections, and proper pressure adjustments have been made.

c. Verify equipment calibration by comparing the software gas-in-oil analsyis to the PPM values listed on the calibration cylinder.

d. Verify all initial settings have been entered for the gas caution and alarm levels.

e. Verify correct processing of dissolved gas-in-oil measurements, and the ability to communicate this information with the provided software as installed on a Government laptop.

3.1.4 Tests Performed by Others During Pre-operational Testing

During performance of the pre-operational tests, the separate installations contractor and the Government will perform concurrent testing of the transformer control and annunciation interfaces to the power plant equipment. The Contractor pre-operational testing shall be coordinated with this other testing through the COR.

3.2 OPERATIONAL TESTS

The Government will perform the following during the operational test phase for the transformers, per the requirements of IEEE C57.93, paragraph 4.12.

The Contractor shall perform the inspections and record all data during the performance of the operational tests, and perform any necessary adjustments to the transformer equipment. Commissioning reports shall be submitted for each transformer.

3.2.1 Initial Transformer Energization

After all previous tests and checks have been performed and approved, the transformers may be energized at no-load. The transformers will be held at the no-load energized condition for a minimum of 12 hours prior to applying load. During this period, the following inspections shall be made, with recordings as required made hourly:

a. Check for excessive audible noise or vibrations.

b. Inspect for oil leaks, and monitor the oil level indicator.

c. Monitor and record oil temperature until stabilized.

d. Monitor and record winding temperatures until stabilized.

e. Monitor and record the ambient temperature.

f. Observe and record the dissolved gas-in-oil levels.

Section 48 20 00 Page 6

g. Operate and verify the performance of each cooling group via manual override.

h. Take an oil sample from each transformer at the end of the energization period, prior to loading.

3.2.2 Loading - Phase 1

During the Phase 1 loading of the operational tests, the transformers should be loaded to approximately 50 percent of the base nameplate rating, and held at this level until the winding and oil temperatures stabilize. During this period, only the 'lead' cooling group should be in operation. Monitor and record hourly the oil, winding, ambient temperatures and dissolved gas-in-oil levels.

3.2.3 Loading - Phase 2

Final transformer loading should be at full nameplate rating. After 24 hours of operation at full nameplate, the Contractor shall perform all inspections (with the exception of verifying the operation of each cooling group via manual override), and obtain oil samples for testing as indicated in paragraph 3.2.1, "Initial Transformer Energization". All final settings to the electronic temperature monitor shall be recorded, and included in the

Operations and Maintenance Manual.

-- End of Section --

SECTION 48 20 00

TRANSFORMER SHIPMENT, HAULING AND SITE ASSEMBLY

PART 1 GENERAL

1.1 GENERAL INFORMATION

This Section, in conjunction with Sections 48 19 23.01, 48 19 23.02, 48 19

23.04, 01 10 10 and 01 57 20, covers the Contractor's responsibilities for shipment of the 60,000/80,000 kVA Generator Step-Up (GSU) transformer, 3,000 kVA station service transformers, and the 25,000/33,333 kVA GSU transformer

(if the Government exercises the option), for delivery f.o.b. destination

Fort Peck power plant, hauling, off-loading and placement, site assembly, oil-filling, field testing, and provision of Erecting Engineer services.

1.2 DESCRIPTION OF WORK

All site work for removal of the existing transformers, modifications to the switchyards for acceptance of the new transformers, movement of the new transformers from the storage location to the new operating locations (as described below), and interconnection of the new transformers to the power plant will be performed by a separate installations contractor. The transformers shall be delivered to the Fort Peck power plant per the required delivery schedule as included in Clause 52.211-8, "TIME OF

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Section 48 20 00 Page 7

DELIVERY", and the Contractor shall be responsible for the following site site work identified within this Section for each transformer:

a. Perform on-car inspections and testing for each transformer(as required).

b. Perform cleaning of each transformer.

c. Provide an oil containment berm and cribbing for each transformer at the designated storage locations.

d. Haul the 60,000/80,000 kVA GSU transformer, one 3,000 kVA station service transformer and the optional 25,000/33,333 kVA transformer, including all accessory crates, into switchyard No. 1 and off-load each transformer onto the cribbing and oil containment berms at the designated storage locations. The accessory crates shall be placed in a location within the switchyard as designated by the COR.

e. Haul one 3,000 kVA station service transformer and accessory crates into switchyard No. 2 and off-load the tranformer onto the cribbing and oil containment berm at the designated storage location. The accessory crates shall be placed in a location within the switchyard as designated by the COR.

f. After each transformer has been placed in its storage location, perform transformer reassembly, oil-filling, and all required field tests.

g. Provide manufacturer's Erecting Engineer services for witnessing all site movement of the transformers to their storage locations, and site reassembly, oil-filling and testing work performed, as required in paragraph, "ERECTING ENGINEER SERVICES".

h. The transformers will be stored in these locations until such time that their permanent operating locations are made available by the separate installations contractor. As each transformer permanent operating location is made available, the separate installations contractor will move the transformers and place them on their mounting pads. Provide a manufacturer's Erecting Engieer to the supervise the movement of each transformer from the storage location to the permanent operating location by the separate installations contractor. A transformer movement plan as prepared by the separate installations contractor will be made available for review and acceptance by the transformer manufacturer's Erecting Engineer.

i. Provide Commissioning Agent services after each transformer has been installed in its permanent operating location, as required in

SECTION 26 08 01.

1.3 REFERENCES

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

ASTM INTERNATIONAL (ASTM)

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Section 48 20 00 Page 8

ASTM D 923 (2007) Standard Practice for Sampling

Electrical Insulating Liquids

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

Insulating Material

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

Insulating Material

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C57.12.00 (2010) General Requirements for Liquid-

Immersed Distribution, Power, and Regulating

Transformers

IEEE C57.12.90 (2010) Test Code for Liquid-Immersed

Distribution, Power, and Regulating

IEEE C57.13 (2008) Requirements for Instrument

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

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

IEEE C57.152 (2013) Guide for Diagnostic Field Testing of

Fluid-Filled Power Transformers, Regulators, and Reactors

1.4 SUBMITTALS

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

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

SD-01 Preconstruction Submittals

1. Transformer Movement Plan; G, AO

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

"TRANSFORMER MOVEMENT PLAN").

2. Transformer Site Assembly Procedure; G, HDC

A transformer site assembly procedure and schedule detailing the reassembly of each transformer, heated oil-filling, final field testing, and durations shall be submitted for approval not later than 60 calendar days prior to delivery of the first transformer

(see paragraph "Transformer Site Assembly Procedure").

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Section 48 20 00 Page 9

3. Field Supervisor Experience; G, HDC

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

Supervisor Experience").

4. Erecting Engineer's Qualifications; G, HDC

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

SD-05 Design Data

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

1. Dry Air; G, HDC

2. Oil Containment Berms; G, HDC

3. Hardwood Timber Mats; G, HDC

SD-06 Test Reports

1. Delivery Transformer Oil Test Report; G, HDC

A transformer oil field test report, showing that the transformer oil meets the requirements of Sections 48 19 23.01, 48 19 23.02 and

48 19 23.04 (paragraph, "Chemical, Physical and Electrical

Characteristics") prior to filling of each transformer, shall be submitted for approval not later than 7 working days following taking of the oil samples (see paragraph "Transformer Oil for

Processing").

2. Transformer Field Test Report; G, HDC

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

SD-07 Certificates

Shipping Notices; G, AO

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

Marking for Shipment").

SD-08 Manufacturer's Instructions

Training Outline; G, AO

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Section 48 20 00 Page 10

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

TRAINING OF GOVERNMENT PERSONNEL").

SD-09 Manufacturer's Field Reports

1. Field Supervisor daily report; G, AO

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

SUPERVISOR EXPERIENCE AND RESPONSIBILITIES").

2. Impact Recorder Summary Report; G, AO

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

Inspection Procedure and Schedule")

3. Site Delivery Inspection Report; G, AO

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

Inspection Report")

Tools and parts control checklist; G, AO

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

1.5 POINT OF CONTACT FOR SITE ACCESS

Point of contact for coordinating site access is as follows:

Dale Pugh

Fort Peck Power Plant

22 Lower Yellowstone Rd.

Fort Peck, MT 59223

Phone: (406) 526-3431

1.6 FIELD SUPERVISOR EXPERIENCE AND RESPONSIBILITIES

1.6.1 Field Supervisor Experience

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

The field supervisor experience shall be submitted for approval, which shall include a listing of projects performed, scope of the work, and a contact name and phone number.

Section 48 20 00 Page 11

1.6.2 Responsibilities

One full-time employee of the Contractor shall be available at the worksite anytime other Contractor or subcontractor personnel are working on the site, to supervise and direct the work specified herein. This field supervisor shall be fluent in the spoken and written English language. The supervisor shall be present at the Fort Peck power plant during all site work including transformer site movement, reassembly, oil-filling and testing, and shall be responsible for following OSHA safe clearance procedures and the

Government's Safe Clearance procedures. The supervisor shall keep all as-built drawings current and provide copies upon completion of the work. The field supervisor shall be responsible for the performance, oversight and correctness of all site work identified in these specifications, including the following:

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

b. Preparation of all required submittals and documentation.

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

1.6.3 Daily Reports

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

a. Weather conditions

b. References to Activity Hazard Analysis

c. Inspection activities

d. Detailed description of work performed

e. Photographs

f. Tests performed with results

g. Tools and parts control daily checklist

h. Problems noted

1.7 ERECTING ENGINEER SERVICES

1.7.1 General

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

Section 48 20 00 Page 12 language. The erecting engineer’s qualifications and identification shall be provided, as identified below.

1.7.2 Erecting Engineer's Qualifications

The erecting engineer shall be a permanent employee of the transformer manufacturing facility, or a factory certified representative thereof, and shall have been engaged in the witnessing of field (site) assembly and installation of similar power transformers, as specified herein, for a minimum of five years, and shall have performed this work on a minimum of 20 transformers. A verifying contact, name and phone number, shall be provided for three such facilities, and the Erecting Engineer’s Qualifications shall be submitted for approval. The Erecting Engineer shall have the authority to make decisions on behalf of the transformer manufacturer.

1.7.3 Responsibilities

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

a. Witness and guide off-loading and loading of each transformer at the rail siding (if shipped by rail), and off-loading from the transport truck at the Fort Peck power plant.

b. Witness the movement of each transformer to its storage location onto the cribbing and oil-containment berm.

c. Witness and guide the reassembly of each transformer, including the oil filling process.

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

Witness the future movement of each transformer from the storage location to its permanent operating location by a separate installations contractor.

e. After completion of all transformer site installation work by a separate installations contractor, conduct training for Government personnel, per the requirements of paragraph "CONTRACTOR-FURNISHED

TRAINING OF GOVERNMENT PERSONNEL".

1.7.4 Specialized Equipment Installation Services

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

1.7.5 Reporting

The Erecting Engineer shall keep a record of all data taken during site assembly and installation, and shall provide this information to the Field

Supervisor for inclusion in the daily reports. The Erecting Engineer's records shall include inspection activities, instructions provided, test results, recommendations and observations.

Section 48 20 00 Page 13

PART 2 PRODUCTS

2.1 DRY-AIR

2.1.1 Dry-Air in Cylinders

Dry-air provided in cylinders shall be in accordance with ASTM D 3283, Type

I. As identified in the referenced standard, the composition and properties of the dry-air shall be as follows:

a. Oxygen, volume: 19.5% to 23.5%

b. Carbon monoxide, max. volume: 0.0020%

c. Carbon dioxide, max. volume: 0.10%

d. Nitrogen: predominantly balance

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

2.1.2 Air Compressor Dryer

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

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

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

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

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

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

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

2.2 OIL CONTAINMENT BERMS

A one-piece oil containment berm shall be provided for the storage of each transformer, sized so that the overall volume within the containment berm minus the volume of the cribbing is greater than the volume of the transformer oil. The berms shall be manufactured from a reinforced geomembrane of a minimum 30 mil thickness, chemically resistant to transformer oil, with supported collapsible walls. The containment berms shall include provisions for the manual draining of standing water using a suitable valve. A ground mat pad shall be provided with each containment berm to help protect the berm from punctures due to ground irregularities or protrustions. The oil containment berms used under the transformers shall remain with the transformers during the full storage duration.

Section 48 20 00 Page 14

2.3 HARDWOOD TIMBER MATS

Hardwood timber mats shall be provided for the placement of each transformer within the oil containment berms. Each timber mat shall be made from 12-inch square oak timbers, secured together with steel rods. The timber mats shall be sized dimensionally at least 24-inches longer and wider than the base of the transformer tank.

PART 3 EXECUTION

3.1 PROTECTION OF MATERIAL AND WORK

At all times prior to delivery and during the assembly and testing process, all materials, supplies, and equipment of every description including property which may be Government-owned and all work performed shall be protected and preserved. If, as determined, material, equipment, supplies, and work performed are not adequately protected, such property may be protected by the Government and the cost thereof may be charged to the

Contractor or deducted from any payment due. All machinery, materials, and articles in a complete or incomplete state for which progress payment has been made prior to delivery shall be adequately protected from loss and from corrosion and all other forms of damage. The Contractor shall also be responsible for and make good any damages due through their fault or negligence occurring during assembly and testing of the equipment at the power plant.

3.2 TRANSFORMER SHIPMENT PREPARATION

3.2.1 General

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

3.2.2 Packaging and Marking for Shipment

a. All material and articles shall be prepared and loaded for shipment in such manner as to protect them from damage in transit, and any and all damage shall be made good until the equipment is delivered to the

Government at the specified delivery point. At a minimum, the transformer shall be prepared for shipment as follows:

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

Section 48 20 00 Page 15

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

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

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

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

1. Manufacturer

2. Contract number

3. Identification, including the manufacturer's drawing number reference

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

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

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

3.3 SHIPPING

3.3.1 Preparation for Shipment

Each transformer shall be delivered without oil. The tank shall be purged, filled with dry air (dew point of -50 degrees-C maximum), and plumbed with a

Section 48 20 00 Page 16 bottle and regulator set to at least 2.5 psi. The regulator assembly shall include gauges to show tank pressure and bottle pressure. A shipping marker shall be attached near the gas connection showing the regulator setting, bottle pressure, and date the tank was sealed. Prior to shipment, the tank shipping pressure shall be maintained for a minimum of 24 hours, and it shall be verified that there is no appreciable reduction in bottle pressure.

At time of shipment, a dew point test shall be performed on the gas in the transformer. The dew point temperature and the test method used shall be shown on the shipping marker. If shipped by rail, the transformer shall be shipped on rail cars equipped with hydraulic draft gear and hydraulic snubbing devices.

3.3.2 Impact Recorders

Each transformer shall be shipped with a 3-axis analog impact recorder. For transportation within North America, a digital impact recorder with GPS satellite tracking, such as the Lat-Lon "RoadRider" monitoring and tracking system shall also be affixed. The impact recorders shall be mounted on a plate that is part and parcel to the transformer, and covered with a shield.

The impact recorders shall be inspected before removal for tight securement, in position as loaded, protective cover intact, seals in position, and whether the area the device is secured to is intact, loose, or deformed.

Any exceptions to the shipment observed shall be brought to the attention of the COR. The digital impact recorder shall be calibrated to record and transmit impact data greater than 1.0g, and shall also provide timed reports every 12 hours. The impact recorder "real-time" data shall be Internet viewable, and the Contracting Officer shall be provided with the "login" and

"password" for site access prior to shipment. Mounting provisions for the impact recorder shall be removed after delivery of each transformer.

3.3.3 Shipment

After completion of factory testing and the transformers have been released for shipment by the COR, the transformers and ancillary equipment shall be prepared for shipment and transported from the Contractor's manufacturing facility to the power plant. If transported by rail, the Contractor shall be responsible for off-loading the transformer at the rail siding on to truck transport for delivery to the power plant.

3.3.4 Hauling

The dimensions and weight (without oil) of the largest piece as shipped by the Contractor shall not exceed that allowed for truck transport and for movement to the Fort Peck power plant. In the event the shipping dimensions or weight of the largest piece exceed those allowed for truck transport or at the project, the unit shall be manufactured such that its weight and dimension can be safely reduced in the field to that allowed for transport.

Any limitations affecting transportation shall not become the basis for claims or damages, or for extension of time for completion of work.

3.4 TRANSFORMER MOVEMENT PLAN

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

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

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

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

d. The method and means of transformer off-loading and handling at the power plant switchyards, including equipment, loading plans for equipment, and intended route while on Government property at the power plant.

3.5 SITE DELIVERY INSPECTIONS

3.5.1 Site Delivery Inspection Procedure and Schedule

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

3.5.2 Sample Site Delivery Inspection Procedure

The following outline is based on the expected site delivery inspection and shipping procedure, and is intended to show the scope of the required work.

The actual step-by-step procedure submitted shall be applicable to the transformers actually furnished, may differ from the following procedure, and shall list methods of repair and/or retesting if unacceptable results of the inspections are obtained.

a. If shipped by rail, perform an on car external inspection of the transformer and associated equipment for rail shipping damage, including signs of movement on the rail car, and loose or damaged tie rods. Photographs of any noted rail shipping damage shall be taken, and included in the Site Delivery Inspection Report.

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

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

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

d. Inspect the impact recorder charts in the presence of the COR for any indication of excessive impacts during shipment. If damage due to

Section 48 20 00 Page 18 shipment is suspected, a core insulation test shall be performed. If the transformer fails the core insulation test, recommendations for repair shall be included in the site delivery inspection report.

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

f. Perform an SFRA test of the transformer in its shipping configuration, as specified in Sections 48 19 23.01, 48 19 23.02 and 48

19 23.04, paragraph "Sweep Frequency Response Analysis Tests", and paragraph "FIELD TESTS", below, and compare to the factory SFRA tests as performed with the transformer in its shipping configuration.

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

g. If shipping damage is suspected due to rail shipment, an on car internal inspection of the suspect transformer may be performed to check for internal damage such as loose coils, broken lead supports, dislodged end insulation, frayed lead insulation, core grounds, or loose nuts or bolts. During this internal inspection, the requirements of paragraph, "REQUIREMENTS FOR PERFORMANCE OF WORK WITHIN THE

TRANSFORMER TANK" shall be followed. Reseal the transformer after the internal inspection has been completed, and repressurize the transformer to 2.5 psi with dry nitrogen or dry air. Positive pressure shall be maintained during transportation of the transformer to the project, off loading, and until such time that the tank is breached during assembly. An additional dew point check shall be performed 24 hours after reseal of the transformer.

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

3.5.3 Site Delivery Inspection Report

After completion of the transformer site delivery inspections, the

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

a. Gas analysis, dew point and pressure.

b. Visual inspection log.

c. Core insulation test results (if required).

d. Sweep Frequency Response Analysis test results.

e. Photos of any shipping damage, with a description.

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

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

3.6 TRANSFORMER DRY-OUT

It is not anticipated that it will be necessary to dry-out the transformers;

however, if gas pressure has been lost during shipment or shipping damage is suspected, this dry-out may be necessary. The insulation shall be field dried using Method 2, high vacuum drying, as described in Paragraph 4.9.2 of

IEEE C57.93. If it becomes necessary to dry-out any part of the transformers, the Contractor shall perform all such operations as required at no additional cost to the Government.

3.7 TRANSFORMER CLEANING

Prior to movement of each transformer to its storage location at the power plant, the transformers shall be thoroughly steam cleaned if determined necessary by the C.O.R. This cleaning process may be performed on the transport truck, and shall be performed at a location approved by the C.O.R.

Care shall be taken during steam cleaning to avoid the ingress of moisture into any electrical cabinets.

3.8 SITE MOVEMENT AND ASSEMBLY

3.8.1 Transformer Movement and Site Placement

a. Provide a one-piece oil containment berm and hardwood timber mats for each transformer. Prior to placement of the containment berm ground mat pads, the ground surface shall be swept free of debris to reduce the possibility of punctures to the berm material.

b. Haul the 60,000/80,000 kVA GSU transformer, one 3,000 kVA station service transformer and the optional 25,000/33,333 kVA transformer, including all accessory crates, into switchyard No. 1 and off-load each transformer onto the cribbing and oil containment berms at the designated storage locations. The accessory crates shall be placed in a location within the switchyard as designated by the COR.

c. Haul one 3,000 kVA station service transformer and accessory crates into switchyard No. 2 and off-load the tranformer onto the cribbing and oil containment berm at the designated storage location. The accessory crates shall be placed in a location within the switchyard as designated by the COR.

d. After each transformer has been placed in its storage location, perform transformer reassembly, oil-filling, and all required field tests.

e. Provide manufacturer's Erecting Engineer services for witnessing all site movement of the transformers to their storage locations, and site reassembly, oil-filling and testing work performed, as required in paragraph, "ERECTING ENGINEER SERVICES".

f. The transformers will be stored in these locations until such time that their permanent operating locations are made available by the

Section 48 20 00 Page 20 separate installations contractor. As each transformer permanent operating location is made available, the separate installations contractor will move the transformers and place them on their mounting pads. Provide a manufacturer's Erecting Engieer to the supervise the movement of each transformer from the storage location to the permanent operating location by the separate installations contractor. A transformer movement plan as prepared by the separate installations contractor will be made available for review and acceptance by the transformer manufacturer's Erecting Engineer.

3.8.2 Transformer Site Assembly Procedure

After off-loading and placement of each transformer at its storage location, the Contractor shall be responsible for its complete reassembly, perform an operational verification of all transformer components, oil-filling and performance of the final field tests as required in paragraph "FIELD TESTS".

A transformer site assembly procedure shall be submitted for approval, which shall include a step-by-step activity listing and a proposed time line for each specific task. Any activities that are hazardous, affect plant operation, or require participation by Government personnel, shall be included. As a minimum, the assembly procedure shall include:

a. Provide a transformer reassembly procedure, including applicable references to the manufacturer's literature. All bolted connections shall be torqued to the manufacturer's recommendations, and indicated with a permanent marker that the torquing process was performed.

b. Perform an internal inspection of the transformer during the assembly process, by visual inspection through the manhole and bushing covers, for evidence of shifting components during transportation, condition of high-voltage lead insulation for evidence of abrasion, and verification that no tools or hardware were inadvertently left inside the tank after the manufacturing process.