Amend_0003_Section_48_13_13.20_26.pdf

Dworshak & McNary Lubrication Oil System Flushing W912EF-17-R-0018 Amend-0003

SECTION TABLE OF CONTENTS

DIVISION 48 - ELECTRICAL POWER GENERATION

SECTION 48 13 13.20 26

FLUSHING AND CLEANING OF LUBRICATING OIL SYSTEMS

PART 1 GENERAL

1.1 SCOPE OF WORK

1.2 REFERENCES

1.3 SUBMITTALS

1.4 FLUSHING CONTRACTOR QUALIFICATIONS

1.5 OIL TEST INDEPENDENT LABORATORY QUALIFICATIONS

PART 2 PRODUCTS - NOT USED

PART 3 EXECUTION

3.1 GENERAL

3.2 SITE VISIT AND FLUSHING SURVEY

3.3 HIGH-VELOCITY FLUSHING

3.3.1 General

3.3.2 Flushing Oil

3.3.3 Flushing Locations

3.3.4 Flushing Procedure

3.3.5 Flushing Startup Requirements

3.4 HIGH-VELOCITY FLUSHING TESTING AND REPORTING

3.4.1 Temperature and Flow Records

3.4.2 Cleanliness Measurements

3.4.3 Flushing Oil Samples

3.5 TANK CLEANING

3.6 CLEANING AND DISPOSAL

3.6.1 Remaining Fluids

3.6.2 Disposal of Materials

3.6.3 Work-Site Equipment Removal

3.7 SPILL PREVENTION PLAN FOR OIL FLUSHING

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SECTION 48 13 13.02 26

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SECTION 48 13 13.20 26

FLUSHING AND CLEANING OF LUBRICATING OIL SYSTEMS

PART 1 GENERAL

1.1 SCOPE OF WORK

Contractor must provide all expertise, equipment, and labor to provide all work specified in this section. All work must be performed in accordance with ASTM D6439, unless otherwise specified herein. Unless explicitly stated otherwise, each paragraph in these specifications applies to both Powerhouses which are part of this scope, which are Dworshak and McNary.

The Contractor's scope of work under this specification section includes but is not limited to:

a. For both powerhouses, provide suitable flushing oil and perform high-velocity hot-oil turbulent flushing of the oil lubrication system, including at a minimum, the main supply and drain headers, and the supply and drain branches going from the headers to each main unit's governor sump. Do not use a pneumatic vibrator on the piping during flushing.

b. For both powerhouses, clean oil storage tanks ranging in size from 2000-gallon volume to 15,000-gallon volume. Refer to environmental specifications for relevant requirements.

1.2 REFERENCES

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

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM D6439 (2011) Standard Guide for Cleaning, Flushing, and Purification of Steam, Gas, and Hydroelectric Turbine and Lubrication Systems

ASTM D7155 (2011) Standard Practice for Evaluating Compatibility of Mixtures of Turbine Lubricating Oils

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 11171 (2010) Hydraulic Fluid Power - Calibration of Automatic Particle Counters for Liquids

ISO 4406 (1999) Hydraulic Fluid Power - Fluids - Method for Coding the Level of Contamination by Solid Particles

ISO/IEC 17025 (1999) General Requirements for the Competence of Testing and Calibration Laboratories

SECTION 48 13 13.02 26

U.S. Army Corps of Engineers (USACE)

EM 385-1-1 Safety and Health Requirements Manual

U.S. National Archives and Records Administration (NARA)

29 CFR 1910 Occupational Safety and Health Standards

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

Site Visit Report and Flushing Survey at Dworshak; G, HDC, NWW-OD Submit no later than 45 calendar days after award.

Site Visit Report and Flushing Survey at McNary; G, HDC, NWW-OD Submit no later than 45 calendar days after award.

Flushing Oil; G, HDC Submit no later than 45 calendar days after award.

Flushing Procedures at Dworshak; G, HDC, NWW-OD Submit no later than 90 calendar days after award.

Flushing Procedures at McNary; G, HDC, NWW-OD Submit no later than 90 calendar days after award.

Spill Prevention Plan For Oil Flushing at Dworshak; G, ECC, NWW-OD Submit no later than 90 calendar days after award.

Spill Prevention Plan For Oil Flushing at McNary; G, ECC, NWW-OD Submit no later than 90 calendar days after award.

SD-06 Test Reports

Oil Removal Report; I, ECC, NWW-OD Submit a maximum of 5 days following the transfer of high-velocity flushing oil to a truck.

Final Flushing Test Report for Dworshak; G, HDC, NWW-OD Submit a maximum of 5 working days following test.

Final Flushing Test Report for McNary; G, HDC, NWW-OD Submit a maximum of 5 working days following test.

SD-07 Certificates

Flushing Contractor Qualifications; G, HDC

Calibration Certificate for High-Velocity Flushing; G, HDC Calibration certificate of particle counter, a minimum of 15 calendar days prior to performing oil flushing. This may be submitted as part of the Procedure and Sequence of Work, if preferred.

OIL TEST INDEPENDENT LABORATORY QUALIFICATIONS; G, HDC

1.4 FLUSHING CONTRACTOR QUALIFICATIONS

Certify that flushing contractor has performed a minimum of 5 jobs including high-velocity hot-oil flushing of piping systems at least 100 feet in length and a minimum of 1.5 inches nominal pipe diameter.

Contractor must have had experience using flushing equipment with sufficient flowrates to reach a minimum Reynolds number of 4000, and achieving a cleanliness level of 15/13/10 or better.

1.5 OIL TEST INDEPENDENT LABORATORY QUALIFICATIONS

Submit for approval the qualifications of the proposed oil testing laboratory, within 60 days of Notice of Award. The laboratory must be independent of the Contractor. The laboratory must be ISO/IEC 17025 certified, must have a minimum of 5 years of experience performing the ASTM D7155 compatibility testing and chemical and physical characteristics testing required in these specifications, and must specialize in oil analysis for hydroelectric power generation. One example of a qualifying laboratory is Herguth Laboratories, 101 Corporate Place, Vallejo CA 94590,

(800) 645-5227. More than one lab may be submitted for approval if desired.

PART 2 PRODUCTS - NOT USED

PART 3 EXECUTION

3.1 GENERAL

Before starting any work, all spill prevention measures must be in place.

See 01 57 20.00 25 ENVIRONMENTAL PROTECTION; also see paragraph 3.6 SPILL PREVENTION PLAN FOR OIL FLUSHING, below. The steps below describe the work only in a general outline. The details and ordering of the steps required to meet the specifications for flushing and oil cleanliness are the Contractor's responsibility. NOTE: (1) Flushing at McNary must be planned such that once every ten days, on a Monday-Thursday, the Government may use the piping to add oil to the units from 06:30 until 17:00 that day. (2) Work done on the drainage headers at Dworshak and McNary must be planned such that drainage of any unit could be begun within 1 hour of notice.

While high-velocity flushing is in progress, Contractor personnel must be in continuous attendance. Before starting any work, the Contractor must examine the reference drawings and perform a site visit to field-verify all details needed for the work, including but not limited to piping configuration and feasible connection points for flushing circuits.

3.2 SITE VISIT AND FLUSHING SURVEY

No later than 45 days after award, and a minimum of 60 days prior to start of onsite work, Contractor is to submit for approval a Site Visit Report and Flushing Survey at Dworshak, and a Site Visit Report and Flushing Survey at McNary, including but not limited to the items listed below.

1. A Site Visit Report for each powerhouse, with annotated photographs, indicating what information was field-verified and highlighting any discrepancies found. Photographs must include but not be limited to the locations in existing piping where Contractor intends to connect flushing system and "jumpers" (e.g. photos of valved tees in piping trench next to governor sump and in oil storage room). Field-verified information must include but not be limited to all points where Contractor will connect to existing piping as well as description/names/locations of valves which will isolate the proposed flushing loops from the operating units.

2. A High-Velocity Flushing Operations Survey Report for each powerhouse, including but not limited to proposed connection points, number of flushing circuits anticipated, proposed location of flushing equipment skid, and how the equipment will be moved into place (e.g.

requests for Project crane use).

3.3 HIGH-VELOCITY FLUSHING

3.3.1 General

Design, furnish, and install all necessary jumpers, hoses, and fittings to connect the Contractor's hot oil flush equipment to the Project's piping.

Install jumpers in the pipe trench adjacent to the each unit's governor sump, in erection bay at fill/discharge connections, and in oil storage room and oil purification rooms as required to create flushing circuits.

Piping to be flushed includes at a minimum the lubrication oil supply and drain headers from the vicinity of the oil storage room to the furthest unit in the powerhouse. Hydropower units will be isolated by closed valves from the piping loops being flushed; units will continue to operate during flushing.

3.3.2 Flushing Oil

Provide all necessary flushing oil. Submit for approval either an unadditized Flushing Oil of low viscosity or Mobil DTE Light ISO VG 32, along with documentation showing the oil properties and lab test results showing that the flushing oil is compatible with both the in-service oil at each powerhouse and the new Mobil DTE Oil per ASTM D7155 Tier 1. If a different type of very low viscosity oil is desired, Contractor may propose relevant testing to demonstrate that it will have no detrimental effect (e.g. ASTM D7155 Tier 2 testing with blends of 1% - 5% flushing oil with in-service oil). NOTE: Acceptance of alternative oils is not guaranteed even with results considered acceptable by laboratory standards.

Completely drain the oil used for high-velocity flushing, remove it from the site, recycle/dispose of the flushing oil properly, and submit an Oil Removal Report, including but not limited to the amount of oil removed.

3.3.3 Flushing Locations

At Dworshak, the flushing equipment is anticipated to remain connected in one location to the supply and drain headers, even if multiple piping circuits are to be flushed; valves would be used to direct flow through branch loops as needed. McNary headers are approximately a quarter mile long, so will likely require multiple locations for the flushing equipment and connections. Contractor must field-verify all information necessary to successfully perform the work. Flushing equipment may be difficult to move into oil storage rooms, due to stairways for instance. However, the distance between accessible flushing equipment locations and connections to piping are not expected to exceed 100 feet. Perform high-velocity flushing of piping areas listed below. NOTE: Powerhouse-specific details below are given for estimating purposes only, not for design/submittal purposes.

Dworshak Powerhouse:

a. Main lubrication oil supply and drain headers. Headers are 2" nominal diameter copper pipe, approximately 200 feet long with a crossover between headers at the unit furthest from the oil storage room. Anticipated location for flushing equipment, where crane can lower skid through hatches and/or forklift can move skid, is within 100 feet or less of anticipated connections to piping.

b. Branches from main headers which supply/drain lubrication oil to/from each unit. There are 3 sets of branches at Dworshak.

Supply branches are 1" diameter for units 1 and 2, and 2" diameter for unit 3. Drain branches are 2" diameter at all units.

Distance between main header and most likely valve location for temporary jumpers is approximately 40 feet.

c. Oil transfer piping from the oil fill/discharge cabinet in the erection bay to the oil storage tanks, and between the oil storage tanks and the purification equipment.

McNary Powerhouse:

a. Main lubrication oil supply and drain headers. Supply header is 2.5" copper pipe. Drain header is 3" cast iron pipe. Headers have 90-degree elbows at each unit. Headers are approximately 1300 feet long and do not have a crossover between the supply and drain headers.

b. Branches from main headers which supply/drain lubrication oil to/from each pair of units. There are 7 sets of branches at McNary. Supply branches are 2" diameter. Drain branches are 3" diameter. Distance between main header and most likely valve location for temporary jumpers is approximately 40 feet.

3.3.4 Flushing Procedure

Contractor must provide all expertise, equipment, and labor to perform this work. The hot oil flush equipment must be operated at a flow and temperature that achieves a minimum Reynolds number of 4000 in all segments of the piping to be flushed. Calibrated flow meters and temperature sensors must be used to measure flow and temperature. Unless otherwise approved in writing, the maximum allowable pressure in the piping will be 120 psi. Include a pressure relief valve close to the downstream side of the flushing pump to ensure that the piping is not subjected to higher-than-approved pressures. Full-flow filters must be used during flushing. Cleanliness of flushing oil must reach 15/13/10 (c); use a calibrated on-line particle counter to monitor oil cleanliness during all flushing operations. Oil used for high-velocity flushing must be moved to the Contractor's dirty oil tank immediately upon completion of flushing, to prevent settling of varnish particles in the pipes, and must be removed from the powerhouse as the property of the Contractor. At the completion of the work, remove all flushing and filtering equipment, hoses, fittings etc. from the Project site. A minimum of 30 days prior to start of onsite work, submit Flushing Procedures at Dworshak and Flushing Procedures at McNary for Government review. Procedures should include but not be limited to:

a. Detailed narrative description of sequence of all work necessary to completely clean and flush the piping systems specified herein to ISO 15/13/10 (c). Include detailed process for making the drainage header available for use within 1 hour of a Government request at any time. This should include but not be limited to the proposed schedule (e.g. 24 hours a day, for an estimated X number of days, starting on a Monday), equipment (e.g.

pump, filters etc.), number of personnel, order in which piping loops/circuits will be flushed, and relevant information from the previously approved Site Visit and Flushing Survey submittal.

b. Sketches and descriptions of "jumpers" to be installed to complete pipe loops. Sketches must show locations of temporary jumpers, the existing fittings they are being connected to, and the isolation valves between those locations and the hydropower unit as field-verified.

c. A product data sheet for the previously approved Flushing Oil.

d. Product data and calibration certificates for flushing equipment such as flowmeter, temperature sensor, pressure relief valve, and laser particle counter.

e. Calculations estimating the quantity of Contractor-provided flushing oil required.

f. Descriptions of sampling devices, containers, locations, and procedure. NOTE: sampling locations must include a location on the oil return line upstream of the full-flow filter.

g. Detailed computations showing the pressure, flow, and temperature of the approved flushing oil necessary to achieve a minimum Reynolds number of 4000 for flushing each section of piping. Among the factors considered for each section of piping must be the diameter of the piping and the temperature drop between the beginning and end of the piping circuit. Reynolds number of 4000 must be achieved throughout each flushing loop; it is acceptable to reverse flow in the flushing loop in order to meet this requirement if it is shown that the Reynolds number will exceed the required minimum for two-thirds of the loop in each direction.

3.3.5 Flushing Startup Requirements

Circulation of flushing fluid in the first piping loop must begin before noon on a Monday which is not a federal holiday. Each new loop of piping being flushed must also begin before noon Monday through Thursday, unless otherwise approved by the CO. Begin with low flowrate and ramp up such that piping may be inspected for any leaks prior to full flushing. After reaching full flushing flow, the Contractor must again inspect the full length of piping being flushed for any leaks. If there are leaks within the original lubrication system piping the Contractor must immediately notify the Contracting Officer, who will direct further actions. If there are any leaks within the Contractor's equipment and piping connections, the Contractor must correct the problem before proceeding. If there are no leaks detected or the observed leaking spots have been repaired, the Contracting Officer will verify that the fluid temperature, pressure and flow are at the required levels. Then continue the flushing process, monitoring to verify the correct temperature and pressure, until the required cleanliness is achieved in all required piping.

3.4 HIGH-VELOCITY FLUSHING TESTING AND REPORTING

3.4.1 Temperature and Flow Records

During flushing of each flushing circuit, the Contractor must record temperature and actual flow rate of flushing fluid achieved, and monitor oil cleanliness a minimum of every hour. The Contractor is to continue flushing the system until the last two consecutive readings, a minimum of 30 minutes apart, show the cleanliness level of ISO 15/13/10 (c) or better in accordance with ISO 4406. Immediately upon completion of flushing each piping circuit, the oil used for that flushing must be moved to the Contractor's dirty oil tank. Submit for approval a Final Flushing Test Report for Dworshak and a Final Flushing Test Report for McNary, including but not limited to oil cleanliness measurements, flow rates and temperatures for each section of flushed pipes.

3.4.2 Cleanliness Measurements

a. For measuring cleanliness of the flushing fluid during the flushing process, the Contractor must use a laser particle count instrument, calibrated to ISO 11171. The Contractor is required to have such particle counter instrument on site before the flushing process starts and for the duration of all flushing operations.

b. The Government may use a compatible particle counter instrument or an independent test laboratory to re-test all or a portion of the samples taken. Prior to the Contractor taking the first cleanliness measurement, the Contractor and the Government particle counter instruments must be tested against the same oil sample (oil from the same sample container) for verification of consistency. If the cleanliness readings between the Contractor's and Government's particle counter instruments are different, they must be re-tested using a calibrated fluid. ISO cleanliness code readings for both instruments must be within one code for each number interval for both instruments to be used for cleanliness measurements as specified above. Finally, if the Government's particle counter readings or lab test results are different from the Contractor's results, the Government's readings will be used.

c. Laser particle counters used by the Contractor and by the Corps must report measured values of greater than 4, 6, and 14 microns (c), as per ISO 4406. Report intervals are to be as stated above.

d. Each sample must be taken with clean sampling devices and placed in sampling containers. Samples must be tested for cleanliness after a minimum of 10 minutes settling period to minimize possible interference from the entrained air bubbles in flushing fluid.

e. ISO particle count cleanliness samples must be taken in the presence of the Contracting Officer and must be turned over to the Contracting Officer immediately after they tested. The sample containers are to be be provided by the Contractor and are to be clearly labeled with oil type, date, time, description of process step, and location of sample. Submit for approval Calibration Certificate for High-Velocity Flushing laser particle counter.

3.4.3 Flushing Oil Samples

Flushing oil samples must be analyzed by the Contractor on-site with a laser particle counter.

3.5 TANK CLEANING

Tanks must be thoroughly manually cleaned by the Contractor. The Contractor is to physically clean and wipe out all residues from the tanks using oil-absorbent and lint-free cloths to remove all visible dirt, varnish, and debris, to the point that no residual contamination can be detected on clean lint-free white cloths. If desired, the Contractor may propose for the Contracting Officer's approval, use of his own equipment other than cloths as a first cleaning, such as a vacuum, squeegee system or pump. This may be necessary to remove oil from the very bottom of tanks.

In any case, the final cleaning must be performed manually with oil absorbent and lint-free cloths. In this process, the Contractor must coordinate work with the Contracting Officer, perform all work in accordance with SECTION 01 11 01.00 28 SUPPLEMENTARY REQUIREMENTS, and comply with all confined space requirements and procedures. The plan must be a complete plan in accordance with 29 CFR 1910 and EM 385-1-1. Cleaning of tanks is to be considered completed when inspected and approved by the Contracting Officer. Up to three separate trips may be required to clean the Dworshak and McNary tanks listed below due to work by others;

coordinate the schedule with the CO.

Dworshak Powerhouse:

a. 12,000-gallon Clean Transformer Oil (CTO) tank.

b. 6,500-gallon Clean Lubrication Oil (CLO) tank.

c. 6,500-gallon Dirty Lubrication Oil (DLO) tank.

McNary Powerhouse:

a. 15,000-gallon New Transformer Oil (NTO) tank #2.

b. 15,000-gallon CTO tank #3.

c. 15,000-gallon DTO tank #1.

d. 10,000-gallon CLO tank #5.

e. 10,000-gallon New Lubrication Oil (NLO) tank #64.

f. 2,000-gallon Gravity Feed Lubricating Oil tank.

3.6 CLEANING AND DISPOSAL

3.6.1 Remaining Fluids

Collect all oil used in the high-velocity flushing and remove it from the Government premises in accordance with applicable laws.

3.6.2 Disposal of Materials

Collect all disposable material (rags, swabs, etc.) used for the cleaning of oil tanks, remove it from the site, and dispose/recycle in accordance with applicable laws and regulations. If the old oil was found to contain chlorinated solvents in concentrations above 1000 ppm, the rags, etc. must be disposed of in accordance with State hazardous waste rules.

3.6.3 Work-Site Equipment Removal

Remove Contractor-owned equipment from the work site, and the working area. The work will not be considered complete until the Contracting Officer has approved that the work area is clean of all oils and disposable materials.

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3.7 SPILL PREVENTION PLAN FOR OIL FLUSHING

The Contractor must submit a Spill Prevention Plan for Oil Flushing at Dworshak and a Spill Prevention Plan for Oil Flushing at McNary for approval prior to starting work. The plan must describe all measures to protect the powerhouse drains, powerhouse, hose connections, temporary connections, and temporary secondary containment for oil transfer to tanker truck (if applicable) and removal of oil used in high-velocity flushing.

This secondary containment must be large enough to contain the truck and to contain the maximum oil spill. The Contractor is responsible for providing all absorbents necessary to clean up any spills.

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3.7 SPILL PREVENTION PLAN FOR OIL FLUSHING