Revised 48 20 00.pdf

Replace Transformers A & B, Fox Pnt. Hurricane Barrier, Prov., RI Amendment February 16, 2021

SECTION TABLE OF CONTENTS

DIVISION 48 - ELECTRICAL POWER GENERATION

SECTION 48 20 00

TRANSFORMER SHIPMENT, HAULING AND SITE ASSEMBLY

PART 1 GENERAL

1.1 GENERAL INFORMATION

1.2 DESCRIPTION OF WORK

1.3 REFERENCES

1.4 SUBMITTALS

1.5 POINT OF CONTACT FOR SITE ACCESS

1.6 FIELD SUPERVISOR EXPERIENCE AND RESPONSIBILITIES

1.6.1 Field Supervisor Experience

1.6.2 Responsibilities

1.6.3 Daily Reports

1.7 SITE ASSEMBLY CONTRACTOR EXPERIENCE

1.8 ERECTING ENGINEER SERVICES

1.8.1 General

1.8.2 Erecting Engineer's Qualifications

1.8.3 Responsibilities

1.8.4 Specialized Equipment Installation Services

1.8.5 Reporting

PART 2 PRODUCTS

2.1 DRY-AIR

2.1.1 Dry-Air in Cylinders

2.1.2 Air Compressor Dryer

PART 3 EXECUTION

3.1 PROTECTION OF MATERIAL AND WORK

3.2 TRANSFORMER SHIPMENT PREPARATION

3.2.1 General

3.2.2 Packaging and Marking for Shipment

3.3 SHIPPING

3.3.1 Preparation for Shipment

3.3.2 Shipment

3.3.3 Hauling

3.4 TRANSFORMER MOVEMENT PLAN

3.5 SITE DELIVERY INSPECTIONS

3.5.1 Site Delivery Inspection Procedure and Schedule

3.5.2 Sample Site Delivery Inspection Procedure

3.5.3 Site Delivery Inspection Report

3.6 TRANSFORMER DRY-OUT

3.7 TRANSFORMER CLEANING

3.8 SITE MOVEMENT AND ASSEMBLY

3.8.1 Transformer Movement and Site Placement

3.8.2 Transformer Site Assembly Procedure

3.9 REQUIREMENTS FOR PERFORMANCE OF WORK WITHIN THE TRANSFORMER TANK

3.9.1 General

3.9.2 Tools and Parts Control and Accountability

3.9.2.1 Purpose

3.9.2.2 Tools and Parts Control

SECTION 48 20 00 Page 1

3.10 TRANSFORMER OIL-FILLING AND PROCESSING

3.10.1 Tank Pressure Test

3.10.2 Vacuum Leak Test

3.10.3 Vacuum Treatment

3.10.4 Transformer Oil for Processing

3.10.5 Vacuum Filling

3.10.6 Oil Containment

3.11 TOUCH-UP PAINTING

3.12 FIELD TESTS

3.12.1 Electrical Tests

3.12.2 Oil Tests

3.13 CONTRACTOR-FURNISHED TRAINING OF GOVERNMENT PERSONNEL

3.13.1 Training General Requirements

3.13.2 Sample Training Outline

3.13.3 Training for Specialized Equipment

-- End of Section Table of Contents --

SECTION 48 20 00 Page 2

SECTION 48 20 00

TRANSFORMER SHIPMENT, HAULING AND SITE ASSEMBLY

PART 1 GENERAL

1.1 GENERAL INFORMATION

This Section, in conjunction with Sections 48 19 23 CLASS I POWER TRANSFORMERS and 01 57 19 TEMPORARY ENVIRONMENTAL CONTROLS covers the Contractor's responsibilities for shipment of the transformer for delivery f.o.b. destination Fox Point Hurricane Barrier, hauling, off-loading and placement, site assembly, oil-filling, field testing, and provision of Erecting Engineer and Commissioning Agent services.

1.2 DESCRIPTION OF WORK

All site work for removal of the existing transformers, modifications to the pumping station for acceptance of the new transformers, interconnection of the new transformer to the pumping station, and welding of the transformer base to the mounting pads for seismic anchoring will be performed under this Contract. The transformer shall be delivered to the Fox Point Hurricane Barrier pumping station per the required delivery schedule as included in Clause 52.211-8, "TIME OF DELIVERY", and the contractor shall be responsible for the following site work:

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

b. Perform transformer cleaning.

c. Off-load and coordinate movement of the transformer with the separate installations contractor, and locate the transformer on the mounting pad in the position as indicated by the installations contractor.

d. Off-load the accessory crates at the location directed by the Contracting Officer.

e. Perform transformer reassembly, vacuum treatment, oil-filling and processing, all required field tests, and final transformer cleaning and touch-up painting.

f. Provide manufacturer's Erecting Engineer services for witnessing all site movement and work performed, as required in paragraph, "ERECTING ENGINEER SERVICES".

g. Provide Commissioning Agent services as required in Section 26 08 01

SYSTEMS TESTING AND COMMISSIONING.

1.3 REFERENCES

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

SECTION 48 20 00 Page 3

ASTM INTERNATIONAL (ASTM)

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

ASTM D1933 (2003; R 2017) Standard Specification for Nitrogen Gas as an Electrical Insulating Material

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 C57.13 (2016) Requirements for Instrument Transformers

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

IEEE C57.149 (2012) 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

1.4 SUBMITTALS

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

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

SD-01 Preconstruction Submittals

Transformer Movement Plan; G, DO

A transformer movement plan detailing movement of the transformer to the Fox Point Hurricane Barrier pumping station shall be submitted for approval not later than 60 calendar days prior to delivery of the transformer (see Subpart "TRANSFORMER

MOVEMENT PLAN").

Transformer Site Assembly Procedure; G, DO

A transformer site assembly procedure and schedule detailing the reassembly of the transformer, vacuum treatment, heated oil-filling, final field testing, and durations shall be submitted for approval not later than 60 calendar days prior to delivery of the transformer (see Subpart "Transformer Site Assembly Procedure").

SECTION 48 20 00 Page 4

Field Supervisor Experience; G, RO

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

Erecting Engineer's Qualifications; G, RO

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

Site Assembly Contractor Experience List; G, RO

,,The site assembly contractor's experience list shall be submitted not later than 60 days prior to delivery of the transformer (see Subpart "Site Assembly Contractor Experience").

SD-03 Product Data

Insulating Oil Antioxidant Additive

SD-05 Design Data

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

Dry-Air; G, RO

SD-06 Test Reports

Delivery Transformer Oil Test Report; G, DO

A transformer oil field test report, showing that the transformer oil meets the requirements of ASTM D3487, Table I, Type II, with an oxidation inhibitor content of between 0.25 and

0.30 percent by mass, shall be submitted for approval not later than 15 working days following taking of the oil samples (see Subpart "Transformer Oil for Processing").

Transformer Field Test Report; G, DO

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

Oil-Filled Transformer Oil Test Report; G, DO

A transformer oil test report after the final transformer oil-filling process has been completed, showing that the transformer oil meets the requirements of TABLE 1, TRANSFORMER INSULATING OIL TEST REQUIREMENTS, included at the end of this section, shall be submitted for approval not later than 15 working days following taking of the oil samples (see Subpart "Oil

SECTION 48 20 00 Page 5

Tests").

SD-07 Certificates

Shipping Notices; G, RO

A list of articles shipped with descriptive data shall be submitted within 7 days of the shipment (see Subpart "Packaging and Marking for Shipment").

SD-08 Manufacturer's Instructions

Training Outline; G, RO

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

"CONTRACTOR-FURNISHED TRAINING OF GOVERNMENT PERSONNEL").

SD-09 Manufacturer's Field Reports

Field Supervisor Daily Report; G, RO

The field supervisor shall provide a copy of the daily report to the Contracting Officer at the end of every working day. (see Subpart "FIELD SUPERVISOR EXPERIENCE AND RESPONSIBILITIES").

Site Delivery Inspection Report; G, DO

The site delivery inspection report shall be submitted for approval within 48 hours following completion of the site delivery inspection for the transformer (see Subpart "Site Delivery Inspection Report").

Tools and Parts Control Checklist; G, RO

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

1.5 POINT OF CONTACT FOR SITE ACCESS

The contractor shall coordinate site access with the Contracting Officer no later than 30 business days prior to arrival on site.

1.6 FIELD SUPERVISOR EXPERIENCE AND RESPONSIBILITIES

1.6.1 Field Supervisor Experience

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

SECTION 48 20 00 Page 6 both are met.

1.6.2 Responsibilities

One full-time employee of the contractor shall be available at the worksite anytime other contractor or subcontractor personnel are working on the site, to supervise and direct the work specified herein. This field supervisor shall be fluent in the spoken and written English language. The supervisor shall be present at the Fox Point Hurricane Barrier pumping station during all site work including transformer site movement, reassembly, oil-filling and testing, and shall be responsible for following OSHA safe clearance procedures and the Government's Safe Clearance procedures. The supervisor shall keep all as-built drawings current and provide copies upon completion of the work. The field supervisor shall be responsible for the performance, oversight and correctness of all site work identified in these specifications, including the following:

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

b. Preparation of all required submittals and documentation.

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

1.6.3 Daily Reports

The field supervisor shall maintain a Field Supervisor daily report, and provide a copy to the Contracting Officer at the end of every working day.

The daily report shall include the following activities, at a minimum:

a. Weather conditions

b. References to Activity Hazard Analysis

c. Inspection activities

d. Detailed description of work performed

e. Photographs

f. Tests performed with results

g. Tools and parts control daily checklist

h. Problems noted

1.7 SITE ASSEMBLY CONTRACTOR EXPERIENCE

If the transformer site assembly contractor is other than the transformer manufacturer, provide a site assembly contractor experience list documenting that the proposed contractor has been engaged in the site assembly and oil filling of generator step-up transformers, rated greater than or equal to 69 kV and 20 MVA three-phase for the last five (5) or more years.

SECTION 48 20 00 Page 7

1.8 ERECTING ENGINEER SERVICES

1.8.1 General

The contractor shall give personal attention to the faithful execution and completion of this work and shall provide a transformer manufacturer’s erecting engineer on the site of the work continually during the progress of transformer delivery, movement, assembly, oil-filling and testing. The erecting engineer shall be fluent in the spoken and written English language. The erecting engineer and field supervisor may be the same person, provided the qualifications for both are met. The erecting engineer’s qualifications and identification shall be provided, as identified below.

1.8.2 Erecting Engineer's Qualifications

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

1.8.3 Responsibilities

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

a. Witness and guide off-loading and loading of the transformer at each transloading location (transferring a shipment from one mode of transportation to another) during shipment, and off-loading from the transport truck at the Fox Point Hurricane Barrier pumping station.

b. Witness and guide movement of the transformer to its final operating location, and coordinate placement on the mounting pad with the separate installations contractor supervisor.

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

d. Witness, guide or perform all transformer inspections and tests, and coordinate with the Commissioning Agent during the commissioning process.

e. Oversee the final installation and setup of the on-line dissolved gas and moisture content monitor by the specific equipment manufacturer.

f. After completion of all transformer site work, conduct training for Government personnel, per the requirements of paragraph

"CONTRACTOR-FURNISHED TRAINING OF GOVERNMENT PERSONNEL".

SECTION 48 20 00 Page 8

1.8.4 Specialized Equipment Installation Services

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

1.8.5 Reporting

The Erecting Engineer shall keep a record of all data taken during site assembly and installation, and shall provide this information to the Field Supervisor for inclusion in the daily reports. The Erecting Engineer's records shall include inspection activities, instructions provided, test results, recommendations and observations.

PART 2 PRODUCTS

2.1 DRY-AIR

Submit descriptive data for the proposed Dry-air for use onsite in conformance with the following paragraphs.

2.1.1 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 follows:

a. Oxygen, volume: 19.5% to 23.5%

b. Carbon monoxide, max. volume: 0.0020%

c. Carbon dioxide, max. volume: 0.10%

d. Nitrogen: predominantly balance

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

2.1.2 Air Compressor Dryer

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

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

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

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

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

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

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

SECTION 48 20 00 Page 9

PART 3 EXECUTION

3.1 PROTECTION OF MATERIAL AND WORK

At all times prior to delivery and during the assembly and testing process, all materials, supplies, and equipment of every description including property which may be Government-owned and all work performed shall be protected and preserved. If, as determined, material, equipment, supplies, and work performed are not adequately protected, such property may be protected by the Government and the cost thereof may be charged to the contractor or deducted from any payment due. All machinery, materials, and articles in a complete or incomplete state for which progress payment has been made prior to delivery shall be adequately protected from loss and from corrosion and all other forms of damage. The contractor shall also be responsible for, and make good for, any damages due through their fault or negligence occurring during assembly and testing of the equipment at the pumping station.

3.2 TRANSFORMER SHIPMENT PREPARATION

3.2.1 General

It is the contractor's responsibility to supply units of shipping dimensions and weight that allow for transport from the point of manufacture to the pumping station. If beams are required to distribute loading during shipment, their weight and height shall be taken into consideration when determining shipping dimensions and weight, and the beams shall be provided as part of the contract. Any internal blocking or bracing that is to be removed from the transformer at its destination shall be colored bright yellow, and specifically addressed in the transformer site assembly procedure. Any material to be returned to the vendor after transformer shipment shall be returned at the contractor's expense, and shall bear identification of material ownership and shipping address.

Materials not so marked will be disposed of at the Government's discretion.

3.2.2 Packaging and Marking for Shipment

a. All material and articles shall be prepared and loaded for shipment in such manner as to protect them from damage in transit, and any and all damage shall be made good until the equipment is delivered to the Government at the specified delivery point. At a minimum, the transformer shall be prepared for shipment as follows:

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

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

(3) The entire transformer must be covered with a marine/industrial shrink film of 7-mil thickness. When covered for transport, provisions shall be made for the following:

(a) Access to any transformer tank tie-down locations required during shipment.

(b) Exposure of the Lat-Lon impact recorder solar cells.

SECTION 48 20 00 Page 10

(c) Access to any testing terminals which require access during shipment.

(d) Access to the shipment dry-air gas cylinder regulator and gauges.

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

c. The transformer and accessories shall not be shipped until after the inspections by Government personnel have been performed with all noted deficiencies corrected (unless inspection of the equipment has been waived in writing), factory acceptance tests have been completed and the test reports approved, and the Transformer Movement Plan has been reviewed and approved with either an Action Code A or B. The Government shall be notified at least 15 days in advance as to the expected shipment dates of the equipment.

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

1. Manufacturer

2. Contract number

3. Each spare part or accessory shall be identified so that it can be easily matched against its entry on the packing list, and with the transformer layout drawing. The hardware included for installation of each accessory device shall be clearly identified, and fastened securely to the device.

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

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

SECTION 48 20 00 Page 11

3.3 SHIPPING

3.3.1 Preparation for Shipment

The transformer shallmay be delivered with or without oil. If shipped dry, theThe tank shall be purged, filled with dry air meeting the requirements of paragraph "DRY AIR", and plumbed with a dry air cylinder and pressure regulator set to at least 2.5 psi. The regulator assembly shall include gauges to indicate both the transformer tank pressure and bottle pressure.

A shipping marker shall be attached near the gas connection showing the regulator setting, bottle pressure, and date the tank was sealed. Prior to shipment, the tank shipping pressure shall be maintained for a minimum of 24 hours, and it shall be verified that there is no appreciable reduction in bottle pressure. At time of shipment, a dew point test shall be performed. The dew point temperature and the test method used shall also be shown on the shipping marker. If shipped by rail, the transformer shall be shipped on rail cars equipped with hydraulic draft gear and hydraulic snubbing devices.

Shipping of the transformers oil-filled will be acceptable when manufacturer recommended, as long as all environmental, weight, and size limitations for shipment are observed and the transformers are adequately designed for additional axial and lateral forces during transportation while filled with oil.

3.3.2 Shipment

After completion of factory testing and the transformer has been released for shipment by the manufacturer, the transformer and ancillary equipment shall be prepared for shipment and transported from the manufacturing facility. The Contractor shall be responsible for all transformer transloading operations, and perform the following at each occurrence:

a. Inspection and logging of the transformer tank dry air shipping pressure.

b. Inspection for any signs of transformer movement or shipping damage.

c. Take photos of the transformer and transloading movement operations.

3.3.3 Hauling

The dimensions and weight (without oil) of the largest piece as shipped by the manufacturer shall not exceed that allowed for truck transport and for movement to the Fox Point Hurricane Barrier pumping station. In the event the shipping dimensions or weight of the largest piece exceed those allowed for truck transport or at the project, the unit shall be manufactured such that its weight and dimension can be safely reduced in the field to that allowed for transport. Any limitations affecting transportation shall not become the basis for claims or damages, or for extension of time for completion of work.

3.4 TRANSFORMER MOVEMENT PLAN

The COntractor shall be responsible for and arrange for the transport and movement of the transformer to the pumping station by the manufacturer.

Government approval of the movement plan does not constitute approval by railroad or transportation authorities. Prior to transformer shipment, the transformer movement plan shall have been submitted and approved with

SECTION 48 20 00 Page 12 either an Action Code A or B. The transformer movement plan shall be submitted for approval, and shall include the following as a minimum:

a. The method and means of transformer lifting and movement from the manufacturing facility to the pumping station, including all transloading locations. Transloading locations shall be identified and scheduled for inspections during these occurrences.

b. Drawings or detailed maps showing the intended route to be taken by the the transporter to the pumping station.

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

d. The method and means of transformer off-loading and handling at the pumping station, including equipment, crane operations, loading plans for equipment, and intended route while on Government property at the pumping station.

3.5 SITE DELIVERY INSPECTIONS

3.5.1 Site Delivery Inspection Procedure and Schedule

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

3.5.2 Sample Site Delivery Inspection Procedure

The following outline is based on the expected site delivery inspection and shipping procedure, and is intended to show the scope of the required work. The actual step-by-step procedure submitted shall be applicable to the transformer actually furnished, may differ from the following procedure, and shall list methods of repair and/or retesting if unacceptable results of the inspections are obtained.

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

b. Record the transformer tank and bottle gas pressures at the shipping regulator gauges. Tank pressure shall be positive. If the tank pressure is found other than positive, the Contracting Officer and transformer manufacturer shall be notified to determine the necessity for field dry-out procedures, as described in paragraph "TRANSFORMER

DRY-OUT".

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

Comparisons shall be made, and if the transformer insulation is

SECTION 48 20 00 Page 13 determined to be wet, the manufacturer shall be contacted with respect to field dry-out procedures.

d. Inspect the analog impact recorder charts, and the digital GPS data files, in the presence of the Contracting Officer for any indication of excessive impacts during shipment. The transformer manufacturer shall be notified of any impacts greater than 3.0g in any axis. If damage due to shipment is suspected, or if impacts greater than 3.0g were noted, a core insulation test shall be performed.

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

f. Perform an SFRA test of the transformer in its shipping configuration, as specified in Section 48 19 23, paragraph "Sweep Frequency Response Analysis Tests", and paragraph "FIELD TESTS", below, and compare to the factory SFRA tests as performed with the transformer in its shipping configuration. Wavetrace comparisons are expected to match closely, with little differences between matched scans.

Wavetrace comparisons that do not match closely shall be explained to the satisfaction of the Contracting Officer, and may be grounds for transformer rejection, requiring an internal inspection of the transformer by the contractor to determine the cause of the deviations, or requiring the transformer to be sent back to the manufacturing facility for repair at no expense to the Government.

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

Reseal the transformer after the internal inspection has been completed, perform vacuum treatment, and repressurize the transformer to 2.5 psi with dry-air. Positive pressure shall be maintained during transportation of the transformer to the project, off loading, and until such time that the tank is opened during assembly. An additional dew point check shall be performed 24 hours after reseal of the transformer.

3.5.3 Site Delivery Inspection Report

After completion of the transformer site delivery inspections, the contractor shall submit a site delivery inspection report based upon the approved procedural outline. The Government will not accept delivery of the transformer until a Government review of the report verifies no damage to the transformer has occurred during shipping. The site delivery inspection report shall include, but not necessarily be limited to, the following:

a. Gas analysis, dew point and pressure.

b. Visual inspection log.

c. Core insulation test results. If the transformer fails the core insulation test, recommendations for repair shall be included in the site delivery inspection report.

SECTION 48 20 00 Page 14

d. Sweep Frequency Response Analysis test results.

e. Photos of any shipping damage, with a description, including any evidence of transformer shifting or movement.

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

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

3.6 TRANSFORMER DRY-OUT

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

however, if gas pressure has been lost during shipment or shipping damage is suspected, this dry-out may be necessary. The insulation shall be field dried using Method 2, high vacuum drying, as described in IEEE C57.93, paragraph 4.9.2. If it becomes necessary to dry-out any part of the transformer, the contractor shall perform all such operations as required at no additional cost to the Government.

3.7 TRANSFORMER CLEANING

Prior to movement of the transformer to its permanent operating location at the pumping station, it shall be thoroughly pressure-washed and cleaned if determined necessary by the Contracting Officer. This cleaning process may be performed on the transport truck, at a location approved by the COntracting Officer. Care shall be taken during steam cleaning to avoid the ingress of moisture into any electrical cabinets. Any cleaning agent used during this process shall be biodegradable, and subject to the approval of the Contracting Officer.

3.8 SITE MOVEMENT AND ASSEMBLY

3.8.1 Transformer Movement and Site Placement

The transformer shall be moved and off-loaded at the pumping station as indicated below.

a. Off-load the transformer and the accessory crates at the locations directed by the COntracting Officer. The transformer will require reassembly prior to moving into position, due to the presence of the takeoff tower restricting crane movement at the permanent operating location.

b. After completion of transformer reassembly, coordinate movement of the transformer with the separate installations contractor, and locate the transformer on the mounting pad in the position as indicated by the installations contractor.

c. After placement on the mounting pad, perform transformer vacuum processing, oil-filling, all required field tests, and final transformer cleaning and touch-up painting.

d. Provide manufacturer's Erecting Engineer services for witnessing all site movement and work performed, as required in paragraph, "ERECTING ENGINEER SERVICES".

SECTION 48 20 00 Page 15

3.8.2 Transformer Site Assembly Procedure

The contractor shall be responsible for the complete reassembly of the transformer, perform an operational verification of all transformer components, oil-filling and performance of the final field tests as required in paragraph "FIELD TESTS". A transformer site assembly procedure shall be submitted for approval, which includes a step-by-step activity listing and a proposed time line for each specific task, with references to the transformer manufacturer's instructions as applicable. Any activities that are hazardous, affect plant operation, or require participation by Government personnel, shall be included. As a minimum, the assembly procedure for the transformer shall include:

a. All bolted connections shall be torqued to the manufacturer's recommendations, and indicated with a permanent marker that the torquing process has been performed.

b. Perform an internal inspection of the transformer during the assembly process, by visual inspection through the manhole and bushing covers, for evidence of shifting components during transportation, condition of high-voltage lead insulation for evidence of abrasion, and verification that no tools or hardware were inadvertently left inside the tank after the manufacturing process. Any discovered anomalies shall immediately be brought to the attention of the Contracting Officer. Photos of the inside of the transformer shall be taken during this inspection process, and included in the field test report.

c. Remove any interior shipping braces. Install and connect the bushings, *radiators and accessory devices removed for shipment. All gasketed connections for installation of components removed for shipping purposes shall have new gaskets installed. All gasketed grooves and mating surfaces shall be thoroughly cleaned prior to installation of the new gasket, and a lubricant shall be applied to the gasket during installation, such as Dow Corning Molykote 111, or approved equal. During installation, the gasket shall be inspected to assure no damage exists, and the gasket is properly sized to provide approximately 25% compression for filling of the groove when installed, and not oversized causing the gasket to be compressed out of the groove and pinched between the mating surfaces.

d. Pressure test the assembled transformer.

e. Perform a vacuum leak test of the completely assembled transformer, per the requirements of IEEE C57.93, paragraph 4.8.3, and these specifications.

f. Perform vacuum treatment and hot oil-fill the transformer under vacuum to the normal operating level per the requirements of paragraph "TRANSFORMER OIL-FILLING AND PROCESSING", and the manufacturer's recommendations (whichever is more stringent). A listing of all equipment to be used during the filling process shall be provided.

g. Test all bushing current transformer ratios and polarity in accordance with IEEE C57.13, (paragraphs 6.1.4 and 6.4). Verify that all the shorting screws on the bushing current transformer terminal blocks within the control cabinet are installed, and the current transformer are shorted to ground.

h. Perform an inspection and verify the correct installation of the

SECTION 48 20 00 Page 16 transformer ancillary equipment and devices after reassembly.

i. Verify the tightness of all valve stem packing glands.

j. Completely clean the transformer after completion of the reassembly process, including the insulator sheds on the bushings, and perform touch-up painting.

3.9 REQUIREMENTS FOR PERFORMANCE OF WORK WITHIN THE TRANSFORMER TANK

3.9.1 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 the measured relative humidity is greater than 60%, 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.

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.

3.9.2 Tools and Parts Control and Accountability

3.9.2.1 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.

3.9.2.2 Tools and Parts Control

Personnel shall remove all personal items from their person prior to

SECTION 48 20 00 Page 17 entering the transformer tank. 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 the tank, shall be logged onto a Tools and Parts Control Checklist.

At the end of each shift, and prior to resealing of the transformer tank, all tools and parts shall be accounted for and 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 Quality Control manager 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. A copy of the Tools and Parts Control Checklist shall be turned in to the Contracting Officer at the end of each shift for work being performed within the transformer tank,or when the transformer tank is open. Any discrepancies in tools or parts shall be brought to the attention of the Contracting Officer's Representative.

3.10 TRANSFORMER OIL-FILLING AND PROCESSING

The contractor shall be responsible for the provision of all oil handling and high-vacuum processing equipment for filling of the transformer tank.

Transformer oil-filling and processing shall be performed per the requirements of IEEE C57.93, paragraph 4.8, or the manufacturer's recommendations, whichever is more stringent. The transformer oil-filling and processing procedure shall be included in the transformer site assembly procedure. No Government provided power source will be available to the contractor for this equipment.

3.10.1 Tank Pressure Test

Prior to performing the tank pressure test, the contractor shall verify that all bolted connections have been torque-checked for the correct tightness. After the transformer has been fully assembled, but prior to oil-filling, the transformer shall undergo pressure testing at a gauge pressure of 4 psi for a minimum of 8 hours. The gauge used for monitoring tank pressure shall have a pressure range of 10 psi. The tank shall hold pressure during the test duration without leakage, and any leaks detected resolved prior to proceeding to vacuum treatment.

3.10.2 Vacuum Leak Test

After the transformer has been fully assembled, but prior to oil-filling, the transformer shall undergo a vacuum leak test. During this test, the contractor shall ensure that all devices which are not suitable for vacuum have been valved off. A vacuum level of 0.25 Torr shall be achieved, and during the initial 30 minutes of the test the maximum allowable pressure rise shall not exceed 0.15 Torr. If more than 0.15 Torr of vacuum is lost during the first 30 minutes, or if the rate of loss of vacuum increases over time, corrective action shall be taken by the contractor to determine the source of the vacuum leak, and any necessary connections shall be tightened.

SECTION 48 20 00 Page 18

3.10.3 Vacuum Treatment

After an acceptable leak rate has been achieved, a transformer vacuum of a maximum of 0.25 Torr shall be held for a duration per the manufacturer's recommendations, but shall be a minimum of 24 hours. If a vacuum of 0.25 Torr cannot be achieved, all bolted fittings shall be checked for tightness, and explained to the satisfaction of the Contracting Officer.

During this period, hot oil at a temperature between 60 - 65 degrees Celsius may be introduced to aid in heating the windings for moisture removal, then drained to allow for moisture removal using vacuum.

3.10.4 Transformer Oil for Processing

Insulating oil provided for transformer oil-filling shall meet the requirements of ASTM D3487, Table 1, Type II, with an oxidation inhibitor content of between 0.25 and 0.30 percent by mass. Prior to filling, oil samples shall be taken and tested per the requirements of paragraph "Oil Tests". The contractor shall provide any temporary oil storage facilities required for handling and processing the transformer oil.

3.10.5 Vacuum Filling

After vacuum treatment, the oil shall be handled from the tanker trucks to the transformer via a high-vacuum purifier. The complete transformer shall be vacuum-filled with hot oil, at a temperature between 60 - 65 degrees Celsius. A minimum of two full volume passes of hot oil shall be circulated after the vacuum filling process to aid in moisture removal.

The transformer shall be filled in a continuous operation to the correct oil level based upon the oil temperature, per the manufacturer's recommendations as included in the Operations and Maintenance Manual. The nitrogen blanket system oil preservation system shall be established, and the nitrogen shall meet the requirements of ASTM D1933, Type III.

3.10.6 Oil Containment

The contractor shall utilize one-piece spill containment berms under the oil tanker trucks, vacuum processing trailers and generator, sized to completely surround the equipment, for all oil-handling operations. 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 which are 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. The contractor shall submit an oil spill plan and provide the necessary equipment to contain an oil spill, as required in Section 01 57 19

TEMPORARY ENVIRONMENTAL CONTROLS.

3.11 TOUCH-UP PAINTING

Any abrasions to the transformer paint shall be thoroughly cleaned, and the damaged areas shall be given one coat of primer and one finish coat of paint. All finished surfaces to receive primer on which the factory coating has deteriorated or been damaged shall be cleaned by means of solvents, degreasers, light sanding or polishing with 240 grit aluminum oxide paper or cloth moistened with Kerosene, or other approved means which removes all grease, paint markings, dirt, rust, and other foreign substances. Appropriate measures shall be taken to protect adjacent surfaces and equipment from overspray or paint splatter. The use of wet or

SECTION 48 20 00 Page 19 dry cloths or paper shall be as approved by the Contracting Officer on an individual basis. Primer paint and finish coats shall be as specified in Section 48 19 23 CLASS I POWER TRANSFORMERS, Subpart FACTORY CLEANING AND

PAINTING.

3.12 FIELD TESTS

The following transformer electrical and oil tests are to be completed, with results submitted for approval, prior to performance of any commissioning tests. All transformer device functional tests, pre-operational tests and operational tests shall be performed during the commissioning phases as required in Section 26 08 01 SYSTEMS TESTING AND

COMMISSIONING.

3.12.1 Electrical Tests

After the transformer has been filled with oil, the bushings installed, and assembly of the transformer is complete, the contractor shall perform electrical tests in accordance with the applicable requirements of IEEE C57.152 and the approved transformer site assembly procedure. A copy of the transformer factory acceptance test report shall be present during performance of the field tests, and test result comparisons made to verify an acceptable transformer condition after reassembly and oil-filling. Any deviations between the factory and field test results shall be brought to the attention of the Contracting Officer for determination of acceptance.

The contractor shall submit certified copies of the Transformer Field Test Report for approval. Electronic data test results for items a, b, e, f, h and i listed below must be provided in standard Doble file formats for uploading into the Doble online database, and comparison to factory and future tests performed by Government personnel. The witnessing representatives of the contractor and the Contracting Officer shall sign the reports of all witnessed tests. The following electrical tests shall be performed on the transformer prior to final acceptance by the Government:

a. Transformer Turns Ratio test (TTR) on each tap (IEEE C57.152, paragraph 7.2.10)

b. Exciting Current (IEEE C57.152, paragraph 7.2.11)

c. Winding insulation resistance of each winding to ground and between windings (IEEE C57.152, paragraph 7.2.13)

d. Winding resistance of each winding (IEEE C57.152, paragraph 7.2.7)

e. Polarization Index (IEEE C57.152, paragraph 7.2.13.4)

f. Power Factor test and excitation current of each transformer winding (IEEE C57.152, paragraph 7.2.14)

g. Power Factor Test of each transformer bushing (IEEE C57.152, paragraph 7.3.3)

h. Core insulation resistance (IEEE C57.152, paragraph 7.2.6.2), for both core-to-frame and frame-to-ground.

i. Leakage Reactance Measurement Tests, per the requirements of IEEE C57.152, paragraph 7.2.12. Leakage reactance measurement tests shall be performed between the high-voltage winding and the low-voltage winding, using the same model test equipment and methods as used in the

SECTION 48 20 00 Page 20 manufacturing facility. The leakage reactance test results shall not deviate more than 0.5 percentage points as compared to the factory test reports. Deviations in excess of 0.5 percentage points shall be explained to the satisfaction of the Contracting officer, and may be grounds for requiring an internal inspection of the transformer by the contractor, at no expense to the Government, to determine the cause.

j. Sweep Frequency Response Analysis Test. A sweep frequency response analysis (SFRA) test shall be performed per the requirements of IEEE C57.149, using the same equipment and methods as used during the transformer factory acceptance testing.