B.08.03 Amend 0002_24Q0004 TechSpecs.pdf

Lower Monumental Fire Damaged Coolers W912EF24Q0004 Amend 0002

PROJECT TABLE OF CONTENTS

DI VI SI ON 01 - GENERAL REQUI REMENTS

01 33 00 SUBMITTAL PROCEDURES

DI VI SI ON 05 - METALS

05 50 03.00 26 METALWORK, FABRICATION, MACHINE WORK, AND MISCELLANEOUS

PROVISIONS

DI VI SI ON 40 - PROCESS I NTERCONNECTI ONS

40 05 13.96 26 WELDING

DI VI SI ON 42 - PROCESS HEATI NG, COOLI NG, AND DRYI NG EQUI PMENT

42 13 19.00 26 THRUST BEARING AND SURFACE AIR COOLERS

-- End of Project Table of Contents --

PROJECT TABLE OF CONTENTS Page 1

G4EDDRLM

Pencil

THIS PAGE INTENTIONALLY LEFT BLANK

PROJECT TABLE OF CONTENTS Page 2

SECTION TABLE OF CONTENTS

DIVISION 42 - PROCESS HEATING, COOLING, AND DRYING EQUIPMENT

SECTION 42 13 19.00 26

THRUST BEARING AND SURFACE AIR COOLERS

PART 1 GENERAL

1.1 SUBMITTALS

1.2 QUALITY ASSURANCE

1.2.1 Design Calculations

1.2.2 Purchase Orders

1.2.3 Product Data

1.2.4 Shop Drawings

1.3 DELIVERY REQUIREMENTS

1.4 PROTECTION OF WORK

1.4.1 Protection of Pipe, Coolers, and Related Materials

1.5 COOLING WATER

1.6 DISSIMILAR METALS

PART 2 PRODUCTS

2.1 GENERAL

2.1.1 Materials

2.1.2 Standard Products

2.1.2.1 Finned Tube Supplier Qualifications

2.1.3 Certificate of Compliance

2.2 PIPE AND FITTINGS

2.2.1 Stainless Steel Piping System

2.2.1.1 Stainless Steel Pipe

2.2.1.2 Stainless Steel Welding Fittings

2.2.1.3 Stainless Steel Flanges

2.2.2 Flange Gaskets

2.2.3 Water Box Gaskets

2.2.4 Welded Joints

2.2.5 Dielectric Connections

2.3 BOLTS, NUTS, STUDS, AND WASHERS

2.4 NAMEPLATES

2.5 THRUST BEARING OIL COOLER

2.5.1 Thrust Bearing Oil Coolers General

2.5.2 Existing Thrust Bearing Cooler Data

2.5.3 Finned Tubing

2.5.4 Water Boxes

2.5.5 Tube Sheets

2.5.6 Cooling Water Pipe and Fittings

2.5.7 Cooler Frame

2.5.8 Thrust Bearing Oil Cooling Water

2.6 SURFACE AIR COOLERS

2.6.1 Existing Surface Air Cooler Data

2.6.2 Finned Tubing

2.6.3 Water Boxes

2.6.4 Tube Sheets

2.6.5 Cooler Frame

2.6.6 Drains and Vents

2.6.7 Surface Air Cooling Water

2.6.8 Air Flow

SECTION 42 13 19.00 26

PART 3 EXECUTION

3.1 FABRICATION

3.1.1 Welding

3.1.2 Metal Work

3.1.3 Galvanizing

3.2 SHOP ASSEMBLY

3.3 SHOP PRESSURE TEST

3.3.1 Shop Pressure Test Plans

3.3.2 Shop Pressure Test Reports

-- End of Section Table of Contents --

SECTION 42 13 19.00 26

SECTION 42 13 19.00 26

THRUST BEARING AND SURFACE AIR COOLERS

PART 1 GENERAL

1.1 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

Thrust Bearing Cooler Shop Pressure Test Plan ; G, HDC

Surface Air Cooler Shop Pressure Test Plan ; G, HDC

Purchase Orders ; G, HDC

SD-02 Shop Drawings

Thrust Bearing Cooler Shop Drawings ; G, HDC

Surface Air Cooler Shop Drawings ; G, HDC

SD-03 Product Data

Thrust Bearing Cooler Descriptive Literature and Specifications ;

G, HDC

Surface Air Cooler Descriptive Literature and Specifications ; G, HDC

Product Data ; G, HDC

SD-05 Design Data

Thrust Bearing Cooler Design Calculations ; G, HDC

Surface Air Cooler Design Calculations ; G, HDC

SD-06 Test Reports

Thrust Bearing Cooler Shop Pressure Test Report ; G, HDC

Surface Air Cooler Shop Pressure Test Report ; G, HDC

SD-07 Certificates

Thrust Bearing Cooler Finned Tube Supplier ; G, HDC

Surface Air Cooler Finned Tube Supplier ; G, HDC

Thrust Bearing Cooler Shop Materials ; G, HDC

SECTION 42 13 19.00 26

Surface Air Cooler Shop Materials ; G, HDC

SD-08 Manufacturer's Instructions

Delivery/Shipping Plan ; G, HDC

Shop Pressure Test ; G, HDC

1.2 QUALITY ASSURANCE

1.2.1 Design Calculations

Submit Thrust Bearing Cooler Design Calculations and Surface Air Cooler Design Calculations .

Design calculations shall show the coolers meet or exceed all the criteria in this Contract. Calculations shall be written in a logical order with a full narrative description. Include notation or references for all assumptions that are made, all codes and standards that are used, and equations used. Note all specified or assumed efficiencies, fouling factors, and factors of safety. Clearly define all variables used.

If computer aids or programs are used to assist in the design, all results from the computer aid must be accompanied by a narrative that provides discussion of the inputs, calculations, equations and theory behind the computer aid, and results.

Reference or provide additional drawings as necessary to provide clarification to the calculations. Submit design calculations concurrent to or prior to the shop drawings.

1.2.2 Purchase Orders

Each purchase order issued by the Contractor for materials and equipment to be incorporated into the work must:

a. Clearly identify the applicable contract number,

b. Carry an identifying number

c. Be in sufficient details to identify the material being purchased, and

d. Indicate a definite delivery date.

Furnish copies of purchase orders to the Contracting Officer's Representative when requesting assistance for expediting deliveries of equipment or materials, or when requested by the Contracting Officer's Representative for the purpose of quality assurance review.

1.2.3 Product Data

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

1.2.4 Shop Drawings

Prepare and submit Thrust Bearing Cooler Shop Drawings and Surface Air Cooler Shop Drawings for the new thrust bearing oil cooler and surface air cooler assemblies. The drawings shall show the complete fabrication, assembly, and installation details of each of the coolers. Drawings shall show detail views, with appropriate tolerances and material callouts for all fabricated parts. A Bill of Materials or Parts List shall be included on the final drawings.

1.3 DELIVERY REQUIREMENTS

Submit Delivery/Shipping Plan drawings providing descriptions of methods of delivering the completed coolers, including details for support during shipment to prevent distortion, damage to the paint system or other structural members. Include the orientation and location of each cooler type on the delivery vehicles prior to shipment for Government approval.

Delivery/Shipping Plan shall be submitted for approval a minimum of 45 days prior to the first delivery date.

1.4 PROTECTION OF WORK

1.4.1 Protection of Pipe, Coolers, and Related Materials

Coolers shall be handled in a manner to prevent damages including but not limited to dents, scratches, etc. Openings on cooler flanges shall be tightly covered with caps or plugs during shipping to prevent entry of foreign material. Coolers shall be covered and protected against dirt, water, and chemical or mechanical damage.

1.5 COOLING WATER

All available cooling water for the coolers is due to gravity only. There is no pump at present to aid the water flow. Modifications of existing piping or installation of a pump will not be permitted. The maximum inlet water temperature is 24 degrees C (75.2 degrees F). This temperature shall be used in sizing the coolers. Flow rates required for each type of cooler are given in the respective sections for each cooler.

1.6 DISSIMILAR METALS

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

PART 2 PRODUCTS

2.1 GENERAL

2.1.1 Materials

Materials and equipment shall conform to the requirements of these specifications. When materials and equipment are specified to be replaced in kind, at minimum they shall be of equal design as existing equipment being replaced, unless specified otherwise.

Any materials required which are not covered in the drawings or these SPECIFICATIONS shall conform to applicable specifications. In cases where material is not covered by one of the listed specification groups, furnish the highest commercial grade of material or product available.

2.1.2 Standard Products

Materials and equipment provided shall be the standard products of manufacturers regularly engaged in the manufacture of such products.

Items of equipment provided shall essentially duplicate equipment that has been in satisfactory use at least two (2) years prior to award .

2.1.2.1 Finned Tube Supplier Qualifications

The supplier of the finned tubes shall have been in the business of producing finned tubes as specified herein for at least two (2) years prior to bid opening. During that time, the finned tube supplier shall have produced finned tubing for similar type of coolers for hydroelectric turbines that are specified herein.

Submit the qualifications and resume of the Thrust Bearing Cooler Finned Tube Supplier and Surface Air Cooler Finned Tube Supplier . The submittals shall include examples and references for each type of cooler that have been successfully installed.

2.1.3 Certificate of Compliance

Submit a Certificate of Compliance for Thrust Bearing Cooler Shop Materials and Surface Air Cooler Shop Materials certifying that the materials used in fabrication match this SPECIFICATION.

2.2 PIPE AND FITTINGS

2.2.1 Stainless Steel Piping System

The following applies to all stainless steel piping used in the thrust bearing oil cooler and surface air coolers.

2.2.1.1 Stainless Steel Pipe

Stainless steel piping shall be seamless Grade TP304L per ASTM A312/A312M .

Pipe dimensions shall be in accordance with ASME B36.19M, Schedule 10S.

2.2.1.2 Stainless Steel Welding Fittings

Stainless steel piping shall be joined by welding fittings. Stainless steel welding fittings shall be butt-welding. Welding fittings shall be forged austenitic stainless steel, ASTM A403/A403M , Grade TP304L.

Fittings shall conform to ASME B16.9 . All fittings shall meet or exceed the pressure rating of the line in which they are installed.

2.2.1.3 Stainless Steel Flanges

The internal diameter bores of flanges shall be the same as that of the associated pipe. The flanges shall be socket welding type with dimensions conforming to ASME B16.5 , Class 150. Flanges shall be flat or raised face to match existing connections. Flanges shall be made from forged austenitic stainless steel per ASTM A182/A182M , Grade TP304L.

2.2.2 Flange Gaskets

Flange gaskets shall be fiber, plastic, or other synthetic material suitable for the service and shall conform to ASME B16.21 . Electrically isolative flange gasket kits shall be used on any connection between dissimilar metals.

2.2.3 Water Box Gaskets

Water box gaskets must be single piece molded design of Nitrile Rubber (NBR) conforming to ASTM F104 or EPDM conforming to ASTM D1418. Gaskets must be ozone resistant and suited at the performance temperatures included in the applicable drawings.

2.2.4 Welded Joints

Joints shall meet the applicable requirements of ASME B31.1 . Welders and welding procedures shall be qualified in accordance with the requirements of ASME B31.1 . Butt-welding joints shall have pipe and fitting ends prepared in accordance with ASME B16.25 . Welding fitting wall thickness shall be equal to or thicker than the pipe wall thickness except where otherwise indicated.

2.2.5 Dielectric Connections

Any connections between dissimilar metals shall be made with insulated flanges. Insulated flanges shall prevent electrical current flow between the adjacent flanges. The insulation parts shall include flange gasket, bolt sleeves, and washers. Special flanges shall be provided if necessary.

All parts shall be suitable for the required operating pressure, temperature and fluid.

2.3 BOLTS, NUTS, STUDS, AND WASHERS

Dimensions of threaded bolts, nuts, lock and plain washers shall conform to the requirements of ASME B18.2.1 , ASME B18.2.2 , and ASME B18.21.1 , respectively.

Unless specified otherwise, bolts, nuts and washers shall be made from stainless steel. Bolts shall be per ASTM A193/A193M , Grade B8. Hex-nuts shall be per ASTM A194/A194M , Grade 8. Washers shall be made from UNS S30400.

2.4 NAMEPLATES

Each cooler section shall have a nameplate that is permanently affixed to the cooler. The nameplate shall be made from corrosion- and oil-resistant material. Letters on the nameplates shall be embossed or engraved.

Nameplates shall contain the following information, at a minimum:

a. Manufacturer name, address, and phone number;

b. Serial Number;

c. Model Number;

d. Manufacture date;

e. Maximum allowable working pressure, at temperature;

f. Weight, empty;

g. Weight, full of water;

h. Cooling capacity of each cooler.

2.5 THRUST BEARING OIL COOLER

2.5.1 Thrust Bearing Oil Coolers General

The thrust bearing cooler assemblies are original to the unit. The cooler is comprised of two semi-circular sections. Each cooler half is constructed of a frame supporting 24 finned tubes with a supply/discharge manifold at one end and a return header on the other end. There are two different length/radius combinations of the tubes; 12 each per section.

The length and radius of the tubes is shown on the Contract Drawings. The new thrust bearing coolers shall be designed for safe operation at a working water pressure of 100 psi . The new coolers shall provide equal or greater performance when compared to the existing coolers.

Provide one (1) new thrust bearing oil cooler assembly per the requirements of this SECTION and the Contract Drawings.

2.5.2 Existing Thrust Bearing Cooler Data

Known technical data for existing oil coolers is as follows. The exact materials of the existing cooler components are not known, as such general materials are stated:

Number of Sections: 2 Location: Thrust Bearing Oil Reservoir Manufacturer: Perfex, Wisconsin Medium Passed Over Fins: Turbine Oil ISO 68 Medium Passed Through Tubes Water Water Flow Through Both Halves: 240 GPM Inlet Cooling Water Temperature: 24 degrees Celsius Average Oil Temperature: 45 degrees Celsius Supply Piping: Carbon Steel Water Box Material: Carbon Steel Tubes: Copper Fins: Aluminum Tube Sheets: Brass

2.5.3 Finned Tubing

The finned tubes shall be a double tube configuration with an outer from which integral, helical, fins are continuously extruded. The inner tube shall be continuously mechanically bonded to the outer tube so as to totally enclose it, except at the tube ends.

Fins shall be made from aluminum or copper. Fin spacing shall be no more than nine (9) fins per inch . The maximum allowable outer diameter of the fins is two (2) inches .

The water tubes shall be made of 90/10 CuNi tubing, UNS C70600, in accordance with ASTM B111/B111M , with a minimum wall thickness of 0.049 inch . Maximum allowable wall thickness is 0.065 inch . Tubing outer diameter shall be 1.00 inch . The ends of the tubes shall be mechanically expanded into the new tube sheets.

2.5.4 Water Boxes

The new water boxes shall be made from stainless steel, per ASTM A240/A240M , UNS S30400. Water boxes shall each be machined from a single piece of stainless steel plate.

2.5.5 Tube Sheets

The new tube sheets shall be made from naval brass, per ASTM B171/B171M , UNS C46400.

2.5.6 Cooling Water Pipe and Fittings

Provide new supply and return water piping from the thrust tub to the water boxes. Existing drawings with detailed dimensions for the pipe routing do not exist. Show pipe routing dimensions on the shop drawings.

Cooling water pipe and fittings materials and construction shall be per the paragraph: Stainless Steel Piping System. Piping shall be welded to the water boxes.

2.5.7 Cooler Frame

The oil cooler frame shall be made from painted carbon steel. The frame shall support the weight of the full oil coolers. The new cooler frame shall use the same mounting points to the thrust tub as the existing oil cooler.

2.5.8 Thrust Bearing Oil Cooling Water

The cooling water flow rate through the new oil cooler shall be assumed to be the same as the existing coolers.

2.6 SURFACE AIR COOLERS

Each main unit has 12 surface air coolers connected by a header pipe that supplies water to the system. The coolers are straight tube type with water boxes on either end. Design and provide two (2) sets of twelve (12) new surface air coolers. Total cooling capacity of one (1) set cooler shall be at least 2600 250 kW. The new surface air coolers shall be designed for safe operation at a working water pressure of 50 psi. Coolers shall be designed to allow reversible supply and return connections thereby making the coolers usable in a right-hand or left-hand configuration.

Complete drawings do not exist for the existing surface air coolers.

Included drawings show the general outline and water connections for the

SECTION 42 13 19.00 26

existing coolers. The new coolers shall have the same general dimensions as the existing coolers. Modifications to the mounting technique, mounting clasps, supports, and flanges are not permitted with the exception of the water supply and return flanges which may be increased to 3 inch pipe flanges if required to meet water velocity criteria .

2.6.1 Existing Surface Air Cooler Data

Known technical data for existing coolers is as follows:

Number of Coolers: 12 Manufacturer: General Electric Model Number: Type SF, Form F Medium Passed Over Fins: Air Medium Passed Through Tubes Water Air Flow (Each Cooler): 14,000 CFM Water Flow (Each Cooler): 120125 GPM Water Box Material: Cast Iron - ASTM A48 CL30 Tubes: 90-10 CuNi ASTM B111 Fins: Copper ASTM B152 Type ETP Tube Sheets: Muntz ASTM B171 Frame: Carbon Steel

2.6.2 Finned Tubing

The finned tubes shall be a double tube configuration with an outer from which integral, helical, fins are continuously extruded. The inner tube shall be continuously mechanically bonded to the outer tube so as to totally enclose it, except at the tube ends.

Fins shall be made from an aluminum tube having a purity of not less than

99.5 percent, (AA 1 - Aluminum Association Alloy No. 1050).

The water tubes shall be made of 90/10 CuNi, UNS C70600, tubing with a minimum wall thickness of 0.049 inch . Maximum allowable wall thickness is

0.065 inch . Tubing outer diameter shall be at least 1 inch . Tubing shall be expanded into the tube sheets.

Tubes and fins shall be laterally supported as necessary to prevent resonant frequencies from occurring within plus or minus 15 percent of forcing frequencies with a generator speed of 90 rpm. The use of turbulators within the tubes will not be permitted.

2.6.3 Water Boxes

Water boxes shall be made from stainless steel, per ASTM A240/A240M , UNS 30400, and have removable cover plates to permit access to all the tubes.

Coolers shall be designed to permit removal of any cover for inspection and cleaning of the tubes without disturbing the cooler water supply or drain connections. The design of the connection with the supply and drain piping shall match the existing surface air coolers.

2.6.4 Tube Sheets

Tube sheets shall be naval brass, per ASTM B171/B171M , UNS C46400.

2.6.5 Cooler Frame

The cooler frame shall be made from galvanized carbon steel. The frame

SECTION 42 13 19.00 26

shall support the weight of the full coolers. The new cooler frame shall use the same support points as the existing coolers.

2.6.6 Drains and Vents

Drain connections shall be provided to permit complete draining of each cooler. Air vents shall be provided at the top of each cooler. Drain and vent connections shall be identical to those of the existing coolers. All vents and drains shall be plugged.

2.6.7 Surface Air Cooling Water

The cooling water flow rate through the new cooler shall be assumed to be the same as the existing coolers. The maximum allowable water velocity through the cooler is 7 feet per second. The minimum allowable water velocity through the cooler is 5 feet per second. Cooling water pressure drop across the cooler shall be less than or equal to the current coolers 9 pounds per square inch . New coolers shall have pressure taps installed on supply and discharge piping to measure the pressure drop. The maximum outlet water temperature shall be less than 90 degrees Fahrenheit .

2.6.8 Air Flow

Air flow rate through the new coolers shall be assumed to be the same as the existing coolers. Air discharged from the coolers shall be a maximum of 40 degrees Celsius. Air pressure drop across the coolers shall be less than or equal to the current coolers 0.99 inches of water . The maximum air temperature into the cooler is expected to be 160.4 degrees Fahrenheit .

PART 3 EXECUTION

3.1 FABRICATION

Fabricate the thrust bearing oil cooler and surface air coolers to the materials specified in this SECTION and quantities specified in the Contract Line Item Numbers.

3.1.1 Welding

Welding shall be in accordance the requirements of this SECTION and

SECTION 40 05 13.96 26 WELDING.

3.1.2 Metal Work

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

3.1.3 Galvanizing

All steel parts and hardware shall be hot dip galvanized per SECTION 05 50 03.00 26 unless otherwise specified.

3.2 SHOP ASSEMBLY

The thrust bearing oil cooler and surface air coolers shall be fully assembled at the fabricator's shop before shipping. The coolers shall not ship to the Project until they have been inspected by the Government.

Coolers shall be shipped fully assembled for inspection. Repair any

SECTION 42 13 19.00 26

damage, such as bent fins, before shipping the coolers. Prepare and package the coolers for shipping in a way that prevents the coolers from being damaged in transit.

3.3 SHOP PRESSURE TEST

Pressure test each cooler section before shipping the coolers to the Project. The Government will witness the test. Notify the Government a minimum of 30 calendar days prior to the starting of the test. Provide all equipment, materials, and personnel required to complete the pressure tests. During the test, orient and support the coolers in the same manner that they will be installed in. Verify correct operation of all vents and drains before performing the test.

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

The test pressure shall be 150 psi . The test period shall be a minimum of one (1) hour. The criteria for a successful test is: zero drop in pressure and zero leaks. Any drop in pressure or leak from any cooler will result in a failed test. If a leak is discovered during testing, repair the leak and re-perform the test in full.

3.3.1 Shop Pressure Test Plans

Submit a Thrust Bearing Cooler Shop Pressure Test Plan and Surface Air Cooler Shop Pressure Test Plan a minimum of 30 calendar days before the planned start date of the tests. The test plans shall include the following elements, at a minimum:

a. Date and planned location test will take place;

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

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

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

e. Detailed, step-by-step, repeatable testing procedure;

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

3.3.2 Shop Pressure Test Reports

Submit a Thrust Bearing Cooler Shop Pressure Test Report and Surface Air Cooler Shop Pressure Test Report no later than seven (7) calendar days after the successful completion of each test. The reports shall include the following elements at a minimum:

a. Date and location test took place;

b. Identify the type and quantity of each cooler tested that are covered by the report;

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

d. If a leak was discovered during the test, identify the location of the leak and the measures taken to fix it.

e. Names of Contractor Personnel involved with testing.

-- End of Section --

THIS PAGE INTENTIONALLY LEFT BLANK

2.1.3 Certificate of Compliance