Amendment 0002 Tech Specs 21R0010.pdf

Lower Monumental Transformer T2 Leak & Bushing Repair W912EF21R0010 Amend-0002

SECTION TABLE OF CONTENTS

DIVISION 48 - ELECTRICAL POWER GENERATION

SECTION 48 19 23.20 26

CLASS II GSU POWER TRANSFORMER BUSHING & OIL LEAK REPAIR

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

1.2 REFERENCED PUBLICATIONS

1.3 SUBMITTALS

1.4 TRANSFORMER LAYOUT AND NAMEPLATE INFORMATION

1.4.1 Transformer T2A

1.4.2 Transformer T2B

1.4.3 Transformer T2C

1.5 WARRANTY REQUIREMENTS

1.6 FIELD SUPERVISOR

1.6.1 Experience

1.6.2 Responsibilities

1.6.3 Daily Reports

1.7 TEST ENGINEER

1.7.1 Test Engineer's Qualification

1.7.2 Responsibilities of Contractor's Test Engineer

1.8 EXISTING PAINT

1.9 REPAIRS

PART 2 PRODUCTS

2.1 TYPE AND RATING

2.1.1 Requirements

2.1.2 Standard Products

2.2 DRY-AIR

2.2.1 Dry-Air in Cylinders

2.2.2 Air Compressor Dryer

2.3 CONDUCTOR INSULATION

2.4 LEAD BRACING, INSULATING BOARD, AND SPACERS

2.5 GASKETS

2.6 CONNECTIONS

2.6.1 General

2.6.2 Stainless Steel

2.7 FANS

2.8 PRESSURE RELIEF DEVICE

2.8.1 General

2.8.2 Adapter Flange

2.8.3 Oil Discharge Piping

2.9 ANALOG TEMPERATURE INDICATING EQUIPMENT

2.9.1 Winding Temperature Indicator

2.9.2 Liquid Temperature Indicator

2.10 RAPID PRESSURE RISE RELAY

2.11 SEAL-IN RELAY

2.12 INSULATING OIL

2.12.1 Quantity and Transformer Oil Certification

2.12.2 Type of Oil

2.12.3 Chemical, Physical and Electrical Characteristics

SECTION 48 19 23.20 26

G4EDHCMP

Line

2.12.4 Sampling

2.12.5 Testing

2.13 INSULATED WIRE AND CABLE

2.14 CONDUIT SYSTEMS

2.14.1 General

2.14.2 Conduit and Fittings

2.14.3 Junction Boxes

2.15 SPARE PARTS

PART 3 EXECUTION

3.1 WORK PLAN AND SCHEDULE

3.2 INSPECTION, TEST, AND COMMISSIONING PLAN

3.3 REPLACEMENT GASKET INVENTORY

3.4 CONNECTING HARDWARE INVENTORY

3.5 PRE-WORK OIL SAMPLE

3.6 PRE-WORK INSPECTIONS AND TESTS

3.6.1 Pre-Work Inspection

3.6.2 Pre-Work Tests

3.6.3 Pre-Work Inspection And Test Report

3.7 OIL DRAINING

3.7.1 General

3.7.2 Insulating Oil Storage Tanks

3.7.3 Oil Containment

3.7.4 Oil Draining

3.7.5 Moisture Content

3.8 REQUIREMENTS FOR PERFORMANCE OF WORK WITHIN THE TRANSFORMER TANK

3.8.1 General

3.8.2 Tools and Parts Control and Accountability

3.8.2.1 Purpose

3.8.2.2 Tools and Parts Control

3.9 MATCHMARKING

3.10 CONNECTING HARDWARE REPLACEMENT

3.11 REPLACEMENT GASKET REQUIREMENTS

3.11.1 Gasket Sizing

3.11.2 Gasket Installation

3.12 FAN AND RADIATOR REMOVAL

3.12.1 Fan Removal

3.12.2 Radiator Removal

3.13 RADIATOR INSPECTION AND LEAK TESTING

3.14 BUSHING GASKET REPLACEMENT

3.14.1 General

3.14.2 High-Voltage And High-Voltage Neutral Bushing Removal

3.14.3 Low-Voltage Bushing Removal

3.14.4 Bushing Gasket Replacement

3.14.5 Bushing Installation

3.14.5.1 High-Voltage And High-Voltage Neutral Bushing Installation

3.14.5.2 Low-Voltage Bushing Installation

3.15 FLANGE & MANHOLE GASKET REPLACEMENT

3.16 CURRENT TRANSFORMER JUNCTION BOX GASKETS

3.17 WIRING AND CONDUIT

3.18 PRESSURE RELIEF DEVICE REPLACEMENT

3.18.1 Pressure Relief Device Removal

3.18.2 Pressure Relief Device Installation

3.18.3 Discharge Piping Installation

3.19 ANALOG TEMPERATURE INDICATOR REPLACEMENT

3.19.1 Analog Temperature Indicator Removal

3.19.2 Analog Temperature Indicator Installation

3.19.3 Winding Temperature Indicator Wiring

SECTION 48 19 23.20 26

G4EDHCMP

Line

G4EDHCMP

Line

3.19.4 Liquid Temperature Indicator Wiring

3.20 SUDDEN PRESSURE RELAY REPLACEMENT

3.20.1 Seal-In Relay Removal

3.20.2 Seal-In Relay Installation

3.20.3 Sudden Pressure Relay Removal

3.20.4 Rapid Pressure Rise Relay Installation

3.21 REPAIRS

3.22 RADIATOR AND FAN INSTALLATION

3.22.1 Radiator Installation

3.22.2 Fan Installation

3.23 TRANSFORMER OIL-FILLING AND PROCESSING

3.23.1 Oil Containment

3.23.2 Tank Pressure Test

3.23.3 Minimum Core and Coil Temperature

3.23.4 Transformer Dryout

3.23.5 Vacuum Leak Test

3.23.6 Vacuum Treatment

3.23.7 Vacuum Filling

3.23.7.1 Establishing the Correct Transformer Oil Level

3.23.8 Oil Circulation and Moisture Removal

3.23.8.1 Optional Addition of Oxidation Inhibitor

3.23.9 Hold Time Before Energization

3.23.10 Post-Filling Oil Sample

3.24 TRANSFORMER CLEANING

3.25 FINAL INSPECTION, TESTING AND COMMISSIONING

3.25.1 Final Inspection, Test and Commissioning Report

3.25.2 Pre-Operational Tests

3.25.3 Operational Tests

3.25.3.1 Initial Transformer Energization

3.25.3.2 Loading - Phase 1

3.25.3.3 Loading - Phase 2

3.26 PREPARATION OF BOLTED LV, HV NEUTRAL, AND HV CONNECTIONS

3.27 TRANSFORMER TESTING

3.27.1 Winding Insulation Resistance

3.27.2 Winding Insulation Power Factor Test

3.27.3 Single Phase Excitation Tests

3.27.4 Bushing Power Factor Test

3.27.5 Transformer Turns Ratio Test

3.27.6 Winding Resistance Measurement Test

3.27.7 Leakage Reactance Measurement Tests

3.27.8 Sweep Frequency Response Analysis Tests

3.27.8.1 Test Equipment and Test Parameters

3.27.8.2 Test Cable Integrity

3.27.8.3 Test Connections

3.27.8.4 Data Reporting

3.27.8.5 Data Interpretation

3.27.9 Leak Test

3.28 INSULATING OIL TESTS

3.29 OPERATION AND MAINTENANCE MANUAL UPDATE

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SECTION 48 19 23.20 26

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SECTION 48 19 23.20 26

SECTION 48 19 23.20 26

CLASS II GSU POWER TRANSFORMER BUSHING & OIL LEAK REPAIR

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

This Section covers the requirements for the on-site repairs for the three single-phase generator step up (GSU) transformers associated with Transformer Bank T2 at the Lower Monumental Dam Powerhouse. The work associated with this contract includes, but not limited to the work defined in Section 26 05 00.00 26 BASIC ELECTRICAL MATERIALS AND METHODS, and following work for each single-phase transformer:

a. Draw two oil samples from each transformer and send them out for analysis.

b. Perform visual inspection and document pre-work condition of the transformer. Perform a leak test and visual inspection on the radiators after the oil has been drained and the radiators are removed.

c. Perform and document pre-work transformer testing.

d. Provide temporary oil storage and oil processing equipment for draining the insulating oil from the transformer.

e. Drain the insulating oil from the transformer and introduce dry-air into the transformer to prevent moisture from entering the transformer tank.

f. Electrically disconnect, remove and dispose the existing fans, flexible cables, connectors, and mounting hardware.

g. Disconnect and remove the radiators. Place blank flanges on all openings. Inspect the radiators for leaks

h. Remove and dispose the low-voltage bushing at location Y1 on transformer T2C as solid waste in accordance with 01 57 20.00 28 , ENVIRONMENTAL PROTECTION.

i. Install the Government furnished replacement low-voltage bushing at location Y1 on transformer T2C. Provide new gasket for the Government provided replacement low-voltage bushing in accordance with paragraph

GASKETS.

j. Replace all gaskets on the transformer, including, but not limited to the gaskets for the following devices:

(1) Valve flanges

(2) Radiator flanges

(3) Inspection covers and manhole covers

(4) All high-voltage bushings, high-voltage neutral bushings, and low-voltage bushings.

k. Torque the hardware for all devices removed during the gasket replacement in accordance with the manufacturer's recommendations.

l. Disconnect the annunciation wires and remove and dispose of the existing pressure relief devices.

m. Provide new pressure relied devices, gaskets, and adapter plate.

Electrically reconnect the annunciation wires.

n. Disconnect the annunciation wires and remove and dispose of the existing winding temperature indicators.

o. Provide new winding temperature indicators and electrically reconnect the annunciation wires.

p. Disconnect the annunciation wires and remove and dispose of the existing oil temperature indicators.

q. Provide new oil temperature indicators and electrically reconnect the annunciation wires.

r. Disconnect the control and annunciation wires from the existing sudden pressure relay on the transformers, and the sudden pressure relay panel in the control cabinets. Remove the and dispose of the existing sudden pressure relays, and the sudden pressure relay panels.

s. Provide new rapid pressure rise relay with an adapter plate on top of the transformers. Provide a new seal-in relay in the control cabinets. Electrically reconnect the control and annunciation wires.

t. Re-install the the radiators with new gaskets. Provide new fans, cables, connectors, cable straps, and hardware.

u. Perform dewpoint measurement on the transformer tank.

v Perform a pressure test on the transformer with dry-air to ensure there are no leaks.

w. Isolate all devices not rated for vacuum and perform vacuum leak test on the transformer.

x. Perform vacuum treatment of the transformer.

y. Perform vacuum filling of the transformer.

An optional item for this project will be the addition of Oxidation Inhibitor to raise content of the oil to between 0.23 and 0.30 percent by mass.

z. Clean the outside of the transformer.

aa. Perform final transformer inspection, testing, and commissioning.

1.2 REFERENCED PUBLICATIONS

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.

ASME INTERNATIONAL (ASME)

ASME B1.1 (2019) Unified Inch Screw Threads (UN and UNR Thread Form)

ASME B1.20.1 (2013; R 2018) Pipe Threads, General Purpose (Inch)

ASTM INTERNATIONAL (ASTM)

ASTM D923 (2015) Standard Practice for Sampling Electrical Insulating Liquids

ASTM D1305 (2016) Standard Specification for Electrical Insulating Paper and Paperboard

- Sulfate (Kraft) Layer Type

ASTM D1533 (2012) Standard Test Method for Water in Insulating Liquids by Coulometric Karl Fischer Titration

ASTM D3283 (1998; R 2012) Standard Specification for Air as an Electrical Insulating Material

ASTM D3487 (2016; E 2017) Standard Specification for Mineral Insulating Oil Used in Electrical Apparatus

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 1248 (2020) IEEE Guide for the Commissioning of Electrical Systems in Hydroelectric Power Plants

IEEE C57.12.00 (2015) General Requirements for Liquid-Immersed Distribution, Power, and Regulating Transformers

IEEE C57.12.10 (2017) Requirements for Liquid-Immersed Power Transformers

IEEE C57.12.70 (2020) Standard Terminal Markings and Connections for Distribution and Power Transformers

IEEE C57.12.80 (2010) Standard Terminology for Power and Distribution Transformers

IEEE C57.12.90 (2015; Corr 2017) Test Code for Liquid-Immersed Distribution, Power, and Regulating Transformers

IEEE C57.93 (2019) Guide for Installation and Maintenance of Liquid-Immersed Power Transformers

IEEE C57.149 (2012) IEEE Guide for the Application and Interpretation of Frequency Response Analysis for Oil-Immersed Transformers

IEEE C57.152 (2013) Guide for Diagnostic Field Testing of Fluid-Filled Power Transformers, Regulators, and Reactors

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA C80.1 (2015) Electrical Rigid Steel Conduit

NEMA FB 1 (2014) Fittings, Cast Metal Boxes, and Conduit Bodies for Conduit, Electrical Metallic Tubing, and Cable

UNDERWRITERS LABORATORIES (UL)

UL 360 (2013; Reprint October 2020) UL Standard for Safety Liquid-Tight Flexible Metal Conduit

UL 514A (2013; Reprint Aug 2017) UL Standard for Safety Metallic Outlet Boxes

UL 514B (2012; Rev thru Nov 2020) Conduit, Tubing, and Cable Fittings

1.3 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", unless otherwise indicated below:

SD-01 Preconstruction Submittals

Field Supervisor Experience ; G, HDC

Submit qualifications for the field supervisor experience a minimum of 45 calendar days prior to the performance of sitework.

(see paragraph FIELD SUPERVISOR)

Test Engineer's Qualifications ; G, HDC

Submit qualifications for the test engineer's experience a minimum of 45 calendar days prior to the performance of sitework.

(see paragraph TEST ENGINEER)

Work Plan And Schedule ; G, HDC

Submit the work plan and schedule a minimum of 45 calendar days prior to the performance of sitework. (see paragraph WORK PLAN AND

SCHEDULE)

Inspection, Test, And Commissioning Plan ; G, HDC

Submit the inspection, test, and commissioning plan a minimum of 45 calendar days prior to the performance of sitework. (see paragraph "INSPECTION, TESTING AND COMMISSIONING PLAN")

Replacement Gasket Inventory ; G, HDC

Submit an inventory of the gaskets to be replaced on each transformer a minimum of 30 calendar days prior to beginning the transformer repairs (see paragraph REPLACEMENT GASKET INVENTORY).

Connecting Hardware Replacement Inventory ; G, HDC

Submit an inventory of the connecting hardware to be replaced on each transformer a minimum of 30 calendar days prior to beginning the transformer repairs (see paragraph CONNECTING

HARDWARE INVENTOR").

SD-03 Product Data

Submit descriptive data or catalog data of for the following items for approval within 45 calendar days after date of award, to demonstrate fully that all parts furnished will conform to the requirements and intent of the specifications.

Dry-Air ; G, HDC

Conductor Insulation ; G, HDC

Lead Bracing, Insulating Board, And Spacers ; G, HDC

Gaskets ; G, HDC

Connections ; G, HDC

Fans ; G, HDC

Pressure Relief Device ; G, HDC

Analog Temperature Indicating Equipment ; G, HDC

Insulating Oil ; G, HDC

Conduit Systems ; G, HDC

Conduit Joint Compound ; G, HDC

Oxidation Inhibitor ; G, HDC

Blank Flanges ; G, HDC

Temporary Gaskets ; G, HDC

Rapid Pressure Rise Relay ; G, HDC

Adapter Plate ; G, HDC

Seal-In Relay ; G, HDC

Valve Lubricant and Sealant ; G, HDC

Bolted Bottom Connection Hardware ; G, HDC

Oxide Inhibiting Electrical Joint Compound ; G, HDC

SD-05 Design Data

Spare Parts List ; G, HDC

A listing of all required spare parts to be provided shall be submitted for approval within 45 calendar days after date of award. (see paragraph "SPARE PARTS")

SD-06 Test Reports

Pre-Work Oil Sample Report ; G, HDC

The pre-work oil sample report shall be submitted for approval not later than 5 calendar days following completion drawing the sample. (see paragraph "PRE-WORK OIL SAMPLE").

Pre-Work Inspection And Test Report ; G, HDC

The pre-work inspection and test report shall be submitted for approval not later than 5 calendar days following completion of the inspections and tests. (see paragraph "PRE-WORK INSPECTIONS

AND TESTS").

Radiator Inspection Report ; G, HDC

The radiator inspection report shall be submitted for approval not later than 5 calendar days following completion of the inspections and tests. (see paragraph "RADIATOR INSPECTION AND

LEAK TESTING").

Final Inspection, Test And Commissioning Report ; G, HDC

The final inspection, test and commissioning report shall be submitted for approval not later than 5 calendar days following completion of the inspections and tests.(see paragraph "FINAL

INSPECTION, TESTING AND COMMISSIONING")

SD-07 Certificates

Transformer Oil Certification ; G, HDC

Transformer oil certification shall be submitted for approval a minimum of 14 calendar days prior to the delivery of transformer oil to the Lower Monumental power plant. (see paragraph "Quantity and Transformer Oil Certification").

Insulating Oil Storage Tank Inspection And Certification Report ;

G, HDC

Submit the insulated oil storage tank inspection and certification report shall be submitted a minimum of 60 calendar days prior to the start of on site-work. (see paragraph "Insulating Oil Storage Tanks")

Tools And Parts Control Checklist ; G, HDC

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

Post-Filling Oil Sample ; G, HDC

Submit the post-filling oil sample results within 7 days after the sample being taken. (see paragraph "Post-Filling Oil Sample").

SD-08 Manufacturer's Instructions

Transformer Oil-Filling And Processing Procedure ; G, HDC

Submit a transformer oil-filling and processing procedure, including environmental protection, for approval a minimum of 30 calendar days prior to the performance of the oil-filling on the first transformer (see paragraph "TRANSFORMER OIL-FILLING AND

PROCESSING").

1.4 TRANSFORMER LAYOUT AND NAMEPLATE INFORMATION

The GSU Transformer Bank T2 consist of three single-phase, three-winding transformers, designed for connection of two generators, each one on separate windings. The transformer banks are located on EL. 553 of the intake deck of the Lower Monumental Dam as indicated on contract drawings G-101, and G-301. The transformers have the following nameplate information:

1.4.1 Transformer T2A

Manufacturer: Westinghouse Serial No.: 7002634 HV KVA Ratings: 82,000/109,334 at 55 degree temperature rise 122,454 at 65 degree temperature rises LV KVA Ratings: 41,000/54,667 at 55 degree temperature rise 61,227 at 65 degree temperature rise

Voltage Rating: 500,000 Grd. Y/288,675 (H), 13.2 (X)13.2 (Y) Cooling Class: OA/FA DETC in H-winding: +3, -1 Impedances: 9.2% @ 41,000 KVA(H-X); 9.6% @ 41,000

(H-Y); 20.9% @ 41,000 KVA (X-Y)

Oil quantity: 10,667 gallons Approximate weight (lbs):

Total: 552,000 When Untanking: 211,000 Tank and Fittings: 61,000 Oil: 80,000

1.4.2 Transformer T2B

Manufacturer: Westinghouse Serial No.: 7002635 HV KVA Ratings: 82,000/109,334 at 55 degree temperature rise 122,454 at 65 degree temperature rise LV KVA Ratings: 41,000/54,667 at 55 degree temperature rise 61,227 at 65 degree temperature rise

Voltage Rating: 500,000 Grd. Y/288,675 (H), 13.2 (X)13.2 (Y) Cooling Class: OA/FA DETC in H-winding: +3, -1 Impedances: 9.1% @ 41,000 KVA(H-X); 9.5% @ 41,000

(H-Y); 20.7% @ 41,000 KVA (X-Y)

Oil quantity: 10,667 gallons Approximate weight (lbs):

Total: 552,000 When Untanking: 211,000 Tank and Fittings: 61,000 Oil: 80,000

1.4.3 Transformer T2C

Manufacturer: Westinghouse Serial No.: 7002633 HV KVA Ratings: 82,000/109,334 at 55 degree temperature rise 122,454 at 65 degree temperature rise LV KVA Ratings: 41,000/54,667 at 55 degree temperature rise 61,227 at 65 degree temperature rise

Voltage Rating: 500,000 Grd. Y/288,675 (H), 13.2 (X)13.2 (Y) Cooling Class: OA/FA DETC in H-winding: +3, -1 Impedances: 9.3% @ 41,000 KVA(H-X); 9.6% @ 41,000

(H-Y); 21.3% @ 41,000 KVA (X-Y)

Oil quantity: 10,667 gallons Approximate weight (lbs):

Total: 552,000 When Untanking: 211,000 Tank and Fittings: 61,000 Oil: 80,000

1.5 WARRANTY REQUIREMENTS

In addition to the requirements outlined in FAR 52.246-18, the Contractor's warranty for the power transformer equipment replaced shall continue for a period of five years from the date of final acceptance of the work. Transformer oil leaks around gaskets that were replaced by the Contractor shall be considered a warranty repair item. If the Government takes possession of any part of this work before final acceptance, this warranty shall continue for a period of five years from the date the Government takes possession.

1.6 FIELD SUPERVISOR

1.6.1 Experience

The field supervisor shall have been engaged in the draining, disassembly, repairs, assembly, vacuum treating, oil filling field drying and testing of similar power transformers with de-energized tap changers, as specified herein. Qualifying experience shall have been performed at a minimum of three projects within the previous 10 years. Provide a verifying contact, name and phone number for at least three such facilities. Submit the field supervisor experience for approval.

1.6.2 Responsibilities

The field supervisor shall be responsible for the performance, oversight and correctness of all site work identified in these specifications, including, but not limited to 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. Prepare all required submittals and documentation.

c. Secure 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. Include the following activities in the daily report, 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; and

h. Problems noted.

1.7 TEST ENGINEER

1.7.1 Test Engineer's Qualification

The Contractor's Test Engineer must have a minimum five years experience in preparing Testing plans and performing testing of Class II oil-filled GSU transformers of comparable type and complexity in the powerhouse. The Test Engineer's qualifications shall be submitted in résumé format for approval.

1.7.2 Responsibilities of Contractor's Test Engineer

The Test Engineer's responsibilities include, but not be limited to the following:

a. Preparation and execution of the inspection, test and commissioning plan, including activities of all involved subcontractors.

b. Participation in testing coordination meetings necessary to develop and execute the above plans.

c. Submit detailed Inspection, Test and Commissioning Plan

d. Oversee all transformer testing.

e. Certify by signature and submit the pre-work inspection and test report and the final test and commissioning report.

f. Comparing the transformer pre-work inspection and test results to the final inspection and test results and providing justification for differences between test results to the satisfaction of the Government.

g. During testing where the Government has lead responsibility, participate in testing coordination meetings to resolve interface issues between Contractor-installed equipment and the overall Government system.

1.8 EXISTING PAINT

The existing paint on the T2 transformers contain 6.46 parts per million of lead. Do not grind, sand or disturb the paint without taking the necessary environmental controls required in SECTION 01 57 20.00 28 .

1.9 REPAIRS

No repairs other than those outlined in this SECTION shall be performed without written authorization from the KO.

PART 2 PRODUCTS

2.1 TYPE AND RATING

2.1.1 Requirements

Except as otherwise specified herein, the transformers components, accessories, and spare parts shall conform to the applicable requirements of IEEE C57.12.00 , IEEE C57.12.10 , IEEE C57.12.70 , IEEE C57.12.80 , and IEEE C57.12.90 . Include all equipment being provided under PART 2 of these specifications in the descriptive data submittals. Unless otherwise specifically indicated, the requirements for PART 2 of these specifications are for each transformer being refurbished.

2.1.2 Standard Products

Material and equipment provided for the transformers shall be standard products of a manufacturer regularly engaged in their manufacture, and shall essentially duplicate items that have been in satisfactory use for at least three years prior to bid opening, unless otherwise specifically approved. All materials shall conform to the requirements of these specifications. Materials shall be of industrial quality, free from defects and imperfections, of current manufacture, and not discontinued items, and of the classification and grades designated. All materials, supplies, and articles not manufactured by the Contractor shall be the products of other recognized reputable manufacturers. If the Contractor desires for any reason to deviate from the standards designated in these specifications, submit a statement for approval describing the exact nature of the deviation, including complete specifications for the materials that are being proposed for use.

2.2 DRY-AIR

2.2.1 Dry-Air in Cylinders

Dry-air provided in cylinders shall be in accordance with ASTM D3283, Type I. As identified in the referenced standard, the composition and properties of the dry-air shall be as indicated below.

a. Oxygen, volume: 19.5 percent to 23.5 percent;

b. Carbon monoxide, max. volume: 0.0020 percent;

c. Carbon dioxide, max. volume: 0.10 percent;

d. Nitrogen: predominantly balance; and

e. Dew point, max.: -58 degrees Celsius (C).

2.2.2 Air Compressor Dryer

Oil-less compressors used to supply dry-air shall include the following, as a minimum:

a. Desiccant system on the output of the compressor designed 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 percent compressed air humidity.

c. Coalesce 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. Provide a filtration capacity up to 30 cubic feet per minute (CFM) at 175 pounds per square inch (psi).

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

2.3 CONDUCTOR INSULATION

Electrical-grade insulating kraft paper shall meet the requirements of ASTM D1305; be thermally upgraded; cellulose-based; and derived from unbleached, softwood pulp. The kraft paper shall be chemically neutral, with low ash, chloride and sulfate content, made specifically for the use of insulating conductors in oil-filled power transformers. Thermally upgraded, creped kraft paper may be used in-lieu of standard kraft paper.

2.4 LEAD BRACING, INSULATING BOARD, AND SPACERS

Lead bracing, insulating transformer board, spacers, and other winding bracing components shall meet the requirements of ASTM D1305; be manufactured of electrical grade, cellulose-based materials derived from unbleached, softwood pulp; be chemically neutral with low ash, chloride and sulfate content; and be made specifically for the use inside oil filled power transformers. Spacing and other bracing components shall be dried and pre-impregnated, as applicable.

2.5 GASKETS

Provide solid-one piece gaskets made of Nitrile NBR (Buna N), with the exception that gaskets for the low-voltage bushings shall be Viton, with a Durometer rating between 50 and 70. Gaskets shall be designed for compression by at least 25% of their original thickness. O-ring gaskets shall not be used for gasket grooves of rectangular cross-section.

2.6 CONNECTIONS

2.6.1 General

All bolts, studs, machine screws, nuts, and tapped holes designed for customer connection shall be in accordance with ASME B1.1 (inch fasteners). Bolting hardware shall be Grade 5 minimum, or equivalent, and and all hardware not internal to the tank shall be hot-dipped galvanized.

Threads for sizes 1/4-inch to 1-inch, inclusive, shall be NC or UN series. The sizes and threads of all valves, pipe and fittings, conduit and fittings, tubing and fittings, and connecting equipment, shall be in accordance with ASME B1.20.1 . Manufacturers' standard threads and construction may be used on small items which are integrally replaceable, except that threads for external connections to these items shall meet the above requirements.

2.6.2 Stainless Steel

All stainless steel connecting hardware shall be installed using an anti-galling compound such as molybdenum disulfide on the threads prior to connection, or the nuts may be of a Nitronic 60 grade material.

2.7 FANS

Provide 60, ABB replacement fans, 20 fans per transformer, with protective shroud, motor rated for 230V AC, 3 phase, 60Hz, with 8 foot long SOOW cables, part number TS01566. Provide mounting hardware in accordance with the CONNECTIONS paragraph, cable fittings and stainless steel cable ties to secure the cables. See contract drawing sheet G-502 for fan location.

2.8 PRESSURE RELIEF DEVICE

2.8.1 General

Provide a self resetting, mechanical-type high-flow pressure relief device to automatically relieve internal pressure and to protect the tank against rupture due to arcing below the surface of the oil for each transformer. The relief device shall be capable of withstanding full vacuum without rupture or loss of accuracy. This device shall be constructed to minimize oil discharge during operation, and to exclude air and water after it opens, and shall be mounted over the main tank at or above the normal oil level in the tank. It shall be equipped with a semaphore-type visual indicator and an alarm contact suitable for operation on a 125 V dc ungrounded circuit. The pressure relief device shall be a Qualitrol XPRD with oil-directed cover, or approved equal with the following features:

a. 12,600 standard cubic feet per minute flow rate at 15 pounds per square inch;.

SECTION 48 19 23.20 26

b. Dual spring-loaded valve;

c. SPDT switch with contacts rated for 10 @ 125V DC

2.8.2 Adapter Flange

Provide an adapter flange to install the new pressure relief device to the existing flange.

2.8.3 Oil Discharge Piping

Provide oil discharge piping for directing the oil discharged from the pressure relief device to the base of the transformer tank. The oil discharge piping shall be of metal construction, and the outlet shall be sized to match the outlet of the pressure relief device discharge outlet.

The discharge piping supports on the transformer tank shall not be more than 36 inches apart and may require welding to the transformer. The pressure relief device submittal shall include the method of securing the pipe to the transformer. The piping shall extend to approximately 24-inches above the base of the transformer, and the piping outlet shall be provided with a screen to discourage entry by animals, birds, and insects. The transformer outline drawings shall be updated with the details of the oil discharge piping.

2.9 ANALOG TEMPERATURE INDICATING EQUIPMENT

The thermowells for the analog temperature indicators are located at the top of segment 3 of the transformer approximately 20' from the analog temperature indicators. See drawings EBM1257-01 and EBM1257-02.

2.9.1 Winding Temperature Indicator

Provide two capillary based winding temperature indicators with bourdon tube measurements with glass faces for each transformer. The indicators shall have a range of 0 to 120 degrees Celsius. One for the low-voltage X winding and one for the low-voltage Y winding. The dial-type indicating thermometer shall be equipped with glass faces, four electrically-independent, self-resetting contacts suitable for use on 125 V ungrounded dc circuits for each transformer. Three switch contacts shall be used as follows:

a. One switch contact shall be used for energizing the forced cooling fans set at 65 degrees Celsius.

b. One switch contact shall be used for energizing the high temperature alarm set at 110 degrees Celsius.

c. One switch contact shall be used for winding over-temperature trip set at 117 degrees Celsius.

2.9.2 Liquid Temperature Indicator

Provide one capillary based liquid temperature indicators with bourdon tube measurements with glass faces for each transformer. Provide a dial-type indicating thermometer (liquid temperature indicator) with a dial indicator range of 0 to 120 degrees-C for each transformer. The dial-type indicating thermometer shall be equipped with two adjustable circuit closing alarm contacts suitable for use with an ungrounded 125 V dc circuit. The two contacts shall be used as follows:

a. One switch contact shall be used for the high oil temperature alarm set at 90 degrees Celsius.

b. One switch will be a spare.

2.10 RAPID PRESSURE RISE RELAY

Provide a rapid pressure rise relay for operating in gas space, and adapter plate to replace the existing Westinghouse sudden pressure relay.

The rapid pressure rise relay shall have the following features:

a. Designed for vertical mounting with a die cast aluminum housing with ANSI 70 powder coating, a 2-1/2-inch 8 NPT tapered pipe male thread mount with a 3-inch hex wrench flat.

b. Ambient operating range from -40 degrees Fahrenheit to 180 degrees Fahrenheit.

c. Rated pressure range of -14.7 to 20 pounds per square inch gauge.

d. A snap action, SPDT switch rated for 1/2 amp at 125V DC (resistive).

e. ANSI connector assembly 180-inches of cable.

2.11 SEAL-IN RELAY

Provide a seal-in relay rated for 125V DC operation to latch in the momentary switch actuation from the rapid pressure rise relay. with the following features:

a. LED Status indicating light and an LED Trip indicating light.

b. Two output relays with contacts rated for 8A at 250V DC.

c. Rest button to unlatch the relays.

d. Redundant make/break circuit requirements that protect against false trips.

e.Surrounding air temperature range of -49 degrees Fahrenheit to 158 degrees Fahrenheit.

2.12 INSULATING OIL

2.12.1 Quantity and Transformer Oil Certification

Provide 200 gallons of make-up oil required to fill each transformer to the proper operating level after oil filling. Prior to delivery of the transformer oil to the Lower Monumental Dam, submit the transformer oil certification stating that the oil furnished for placing the transformers in service will meet the requirements specified below.

2.12.2 Type of Oil

The grade of insulating oil furnished shall be produced from a predominately naphthenic base crude petroleum, shall be new, and shall be specifically prepared and refined for use in electrical equipment as an insulating and cooling medium. Except for the oxidation inhibitor, the insulating oil shall be free from additives of every kind, either natural or synthetic.

2.12.3 Chemical, Physical and Electrical Characteristics

The insulating oil provided shall have all tests performed per the requirements of the "Property Requirements" Table of ASTM D3487, for Type II, with an oxidation inhibitor content of between 0.25 and 0.30 percent by mass, prior to shipment. In addition to the requirements listed in the "Property Requirements" Table of ASTM D3487, the water content during final filling and assembly shall not exceed 20 parts-per-million (ppm) as tested in accordance with ASTM D1533. The Government, at point of delivery, may draw samples in accordance with ASTM sampling standards, for testing to determine whether the oil meets the specifications. Oil so tested and failing to meet the requirements will be removed and replaced by, and at the expense of, the Contractor.

2.12.4 Sampling

Samples for testing shall be obtained as specified in ASTM D923.

2.12.5 Testing

Chemical, physical, and electrical tests shall be conducted by the Contractor in accordance with the test methods listed in the "Property Requirements" Table of ASTM D3487. Certified electronic copy of the test reports shall be submitted for approval prior to shipment of the oil.

2.13 INSULATED WIRE AND CABLE

Provide insulated wire and cable that conforms to the requirements of Section 26 05 19.00 26 INSULATED WIRE AND CABLE.

2.14 CONDUIT SYSTEMS

2.14.1 General

All conduit used shall be a minimum of 1-inch diameter. Conduit fill shall not exceed 40% of conduit and the conduit runs shall include condulets to facilitate pulling insulated wires and conductors. The conduit systems shall be electrically continuous and all threaded conduit joints shall have the threads coated with an approved electrically-conductive, corrosion resistant conduit joint compound . The use of Teflon-tape at conduit threaded joint connections shall not be allowed. No continuously running threads on conduit will be allowed. Conduit runs shall be deburred and cleaned of shavings and debris prior to the routing of wire and cable.

2.14.2 Conduit and Fittings

a. Rigid Metal Conduit . Provide rigid metal conduit that conforms to NEMA C80.1 and is zinc-coated both inside and outside by hot-dip galvanizing method.

b. Liquid-Tight Flexible Metal Conduit . Provide liquid-tight flexible metal conduit made from steel strip that is zinc-coated by the hot-dip galvanizing method with a water-proof extruded PVC cover that conforms to UL 360 . the liquid-tight flexible metal conduit shall either have an integral bond wire or be an interlocked design with no bonding wire. Limit the use of liquid-tight flexible metal conduit to equipment connections not exceeding 36-inches. Liquid-tight flexible metal conduit shall be securely fastened to the transformer tank.

c. Rigid Metal Conduit Fittings . Provide threaded fittings for rigid conduit made of solid zinc or malleable iron that conforms UL 514B and/or NEMA FB 1 . Malleable iron fittings must be zinc-coated both inside and outside by hot-dip galvanizing method. Hubs must have a grounding screw on the locknut.

d. Liquid-Tight Flexible Metal Conduit Fittings . Provide fittings for liquid-tight flexible metal conduit made from steel or malleable iron with a zinc coating for flexible metal conduit with positive bonding, that conforms to UL 514B .

2.14.3 Junction Boxes

Provide junction boxes made of malleable iron conforming to UL 514A with threaded fittings and must be zinc-coated both inside and outside by hot-dip galvanizing method.

2.15 SPARE PARTS

All spare parts shall be duplicates of the original parts furnished and interchangeable therewith. The following spare parts shall be furnished, and a spare parts list shall be submitted for approval. The spare parts list shall indicate the quantity furnished, manufacturer, catalog or model number, and the retail cost of each item.

a. One 25 kV bushing for the transformer high-voltage neutral terminal, complete with gaskets and all the bushing manufacturer's recommended materials required for long-term storage.

b. One complete set of all gaskets used to seal all openings into the transformer tank at the cover, manholes, handholes, openings for accessory devices, openings for each type bushing, and pipe connections for radiators,

c. Ffour spare fan and motor assembly.

PART 3 EXECUTION

3.1 WORK PLAN AND SCHEDULE

Submit a detailed work plan that describes how the work identified in the DESCRIPTION OF WORK paragraph will be performed, what equipment will be used. The plan shall also include a detailed schedule that defines when the various task will be performed.

3.2 INSPECTION, TEST, AND COMMISSIONING PLAN

Prepare an inspection, test and commissioning plan that incorporates all Contract requirements, Government, and subcontractor's inspection, testing and commissioning activities. The plan shall be submitted for the pre-work inspections and test and final testing and commissioning, including the inspections and tests on existing equipment that required to be removed and reinstalled under this contract. The plan shall be specifically developed to confirm operation of individual components, as well as complete systems. The plan shall include, but not be limited to, the following:

a. A schedule for all Contractor, and Government testing and commissioning activities as noted in this section.

b. Receipt inspection of the replacement bushings upon receipt at Lower Monumental Dam.

c. Equipment inspections, detailed step-by-step test procedures, including the and reports to meet the requirements of the technical specifications, and applicable guidance for tests and test descriptions given in IEEE 1248 for all installed equipment.

d. A leakage reactance test procedure that identifies the proposed leakage reactance test equipment, setup, and test levels per the requirements of the Leakage Reactance Measurement Tests paragraph.

e. A SFRA test procedure that identifies the proposed SFRA test equipment, setup, and test procedure per the requirements of the Sweep Frequency Response Analysis Tests paragraph.

f. Calibration information, to include a list of the test equipment to be used during inspections, testing and commissioning, stating calibration requirements by the instrument manufacturer and certification that the instruments to be used have been calibrated within the past 6 months.

3.3 REPLACEMENT GASKET INVENTORY

Perform a replacement gasket inventory of all gaskets, including the type, size, location and quantity of each item, prior to the start of transformer repairs, review with the COR, and submit for approval.

3.4 CONNECTING HARDWARE INVENTORY

Perform a replacement connecting hardware inventory of all hardware that will be disturbed during the transformer repairs, including on devices or equipment to be replaced, and on man-hole covers which are being regasketed. Existing threaded studs on the transformer tank used for connecting devices or man-hole covers that are not damaged or broken will be reused. A connecting hardware replacement inventory of all hardware to be replaced, including the type, size, location and quantity of each item, shall be submitted for approval prior to the start of transformer repairs.

3.5 PRE-WORK OIL SAMPLE

Prior to performing any work on the transformers, take two samples from each transformer in accordance with paragraph INSULATING OIL TESTS. Send the samples out to two independent labs for analysis. The labs, such as Doble, SD Myers, etc., should perform the oxidation inhibitor content analysis in-house. These test results shall be documented in the pre-work oil sample report and shall be used to determine if the optional requirement to add oxidation inhibitor will be required.

3.6 PRE-WORK INSPECTIONS AND TESTS

After each transformer has been disconnected from the high-voltage conductors, high-voltage neutral conductor, and the low-voltage isophase, perform the pre-work inspections and test as follows:

3.6.1 Pre-Work Inspection

Perform an inspection of each transformer checking the following items.

The pre-work inspections shall also include a receipt inspection of the replacement bushings prior to installation. The bushing receipt inspections should look for shipping damage, incorrect parts, oil leaks, and/or incorrect parts. Document any discrepancies with photos and mark on drawings as applicable and include this documentation in the pre-work inspection and test report.

a. Oil leaks from connection, the transformer tank, devices, and/or radiators;

b. Operability of the valves.

c. Damaged or missing devices;

d. Damaged conduit and/or wiring.

3.6.2 Pre-Work Tests

Perform the transformer testing identified in paragraph TRANSFORMER TESTING, and as defined in the Contractor's test and commissioning plan.

Document the

3.6.3 Pre-Work Inspection And Test Report

Document the inspection and test results, including any discrepancies noted and recommendations for repairs that are not already identified in this specification in the pre-work inspection and test report. Do not proceed with any work that falls outside the scope of this specification without authorization from the KO.

3.7 OIL DRAINING

3.7.1 General

The existing transformer oil contains a maximum of 1.29 parts per million of Polychlorinated Biphenyls (PCBs). Provide the necessary labor, material, and equipment, including, but not limited to the following to drain the transformer:

a. Oil processing rig

b. Clean oil hose with fittings to connect to the upper filter valve, and the lower filter/drain valve. The valves are a 1-1/2-inch brass globe valve and the lower drain valve has a 3/8-inch sampling device.

c. Vacuum hose to connect to the oil processing rig and the two 3-inch vacuum connections on the top of the transformer.

d. Clean oil storage tanks per the requirements of paragraph

INSULATING OIL STORAGE TANKS.

e. Temporary oil containment for the oil processing rig, and oil storage tanks per the requirements of OIL CONTAINMENT.

f. A method of providing dry-air to the transformer as the oil is displaced. The dry-air shall be in accordance with DRY-AIR.

3.7.2 Insulating Oil Storage Tanks

The insulating oil storage tanks shall be double-walled, sized to contain all of the transformer oil from one transformer, and the interior walls of the storage tank lined with a chemical resistant coating. Provide insulating oil storage tanks as manufactured by Baker Corporation, or approved equal, for the duration of the work as necessary. Prior to usage, submit an insulating oil storage tank inspection and certification report for approval that includes the following:

a. Tank catalog data, including manufacturer's name, tank construction, and storage volume.

b. Certification of passing a 3 psi air pressure leak test performed within the 30 calendar days of submittal.

c. Certification that the tank interior was cleaned utilizing a caustic wash, or similar process that does not react with the tank lining, to remove all impurities.

Certification that the tank has been inspected, including the interior for cleanliness, and is suitable for use in storage of transformer insulating oil. No impurities shall be present in the storage tank prior to the introduction of insulating oil.

3.7.3 Oil Containment

Provide one-piece spill containment berms under the oil processing rig, and oil storage tanks, sized to completely surround the equipment. The berms shall be manufactured from a reinforced geomembrane of a minimum 30 mil thickness, chemically resistant to transformer oil, with supported collapsible walls. During the oil handling operations, all hose joints located outside of the spill containment berms shall have interlocking connections, be wrapped with an absorbent material, with 5-gallon buckets located beneath the joint to help avoid oil spills. Submit an oil spill plan and provide the necessary equipment to contain an oil spill, as required in Section 01 57 20.00 28 , ENVIRONMENTAL PROTECTION.

3.7.4 Oil Draining

Drain the transformer insulating oil from the transformer tank into a storage tank that meets the requirements of INSULATING OIL STORAGE TANKS.

After draining the transformers, locate the storage tanks in the laydown area as indicated on drawing G-101. Provide oil containment in accordance with OIL CONTAINMENT for all oil handling operations, oil storage, and any equipment used for transfer of the oil from the transformer to the storage tank. During the draining process, displace the oil with dry-air that meets the requirements of DRY-AIR.

3.7.5 Moisture Content

After the transformer has been drained and filled with dry-air for 24 hours, measure the dew point of the transformer.

SECTION 48 19 23.20 26

3.8 REQUIREMENTS FOR PERFORMANCE OF WORK WITHIN THE TRANSFORMER TANK

3.8.1 General

The following additional requirements shall be met by the contractor when working within, or around an opening of, the transformer tank:

a. Prior to the removal of any tank man-hole covers, the top of the transformer shall be thoroughly cleaned and vacuumed to minimize the possibility of contaminants entering the tank.

b. The temperature and relative humidity around the transformer shall be monitored during the performance of work, and tank shall not be opened if it is raining the measured relative humidity is greater than 60%, the temperature drops below the dewpoint, or if there are signs of external condensation on the tank surfaces.

c. Any time the transformer tank internals are exposed to the atmosphere, the tank shall be continuously purged with dry-air utilizing a dry-air compressor delivering moisture-free air at a maximum dew point of -40 degrees Fahrenheit. The dry-air shall be introduced at the lower filter valve at a minimum flowrate of 9.5 cubic-feet per minute.

d. Purge the tank with dry-air until analysis of the gas in the transformer indicates at least 19.5 percent oxygen, prior to personnel entry.

e. All personnel entering the transformer tank shall wear Tyvek suits, or equivalent, and a logbook shall be maintained of all items entering and leaving the transformer tank to assure nothing has inadvertently been left inside (See paragraph "Tools and Parts Control and Accountability Procedure").

f. All openings to the transformer tank shall be covered whenever possible to prevent any falling objects from entering the tank.

g. At the end of each working day, the tank shall be re-sealed and pressurized with 2.5 psi of dry-air using a dry-air cylinder.

3.8.2 Tools and Parts Control and Accountability

3.8.2.1 Purpose

A tool and parts control and accountability program is necessary to ensure that foreign objects are not left within the transformer tank during internal inspections and transformer reassembly work. The contractor shall be responsible for overall control of tools, parts and personnel entering the transformer tank.

3.8.2.2 Tools and Parts Control

A tool and parts control and accountability program is necessary to ensure that foreign objects are not left within the transformer tank during internal inspections and transformer reassembly work. Personnel shall remove all personal items from their person prior to entering the transformer tank. Log all tools and parts taken into the transformer tank, or which are used within the transformer tank, and any personal items which must remain with the contractor personnel when working within

SECTION 48 19 23.20 26

the tank, onto a Tools and Parts Control Checklist . At the end of each shift, and prior to resealing of the transformer tank, account for all tools and parts identified on the checklist, and the interior of the transformer tank inspected for any loose tools or parts. To maintain control of the tools entering the transformer tank, all personal transportable tools will be checked out of a controlled space, such as a tool bin, and checked back during each shift. The contractor Field Supervisor shall be responsible during each shift to assure that inventoried tools for each craftsperson are accounted and signed for, and logged on the Tools and Parts Control Checklist. To control parts entering the transformer tank, the Quality Control manager shall inventory and issue the parts during each shift. At the end of each shift, a count will be made of the installed parts to ensure that the quantity checked out matches what was installed. Provide a copy of the Tools and Parts Control Checklist to the COR at the end of each shift for work being performed within the transformer tank,or when the transformer tank is open, and discrepancies in tools or parts shall be brought to the attention of the COR

3.9 MATCHMARKING

All components shall be matchmarked prior to disassembly to ensure the transformer is assembled correctly. Utilize the existing matchmarking when ever possible as indicated in resource drawing R-002 when disassembling the transformer.

3.10 CONNECTING HARDWARE REPLACEMENT