DOCUMENT RELEASE AND CHANGE FORM€¦ · DOCUMENT RELEASE AND CHANGE FORM Doc No: RPP -SPEC63855 Rev. 00 2 SPF-001 (Rev.D1) 14. Distribution Name Organization Smith, Kimball E WFD

1 SPF-001 (Rev.D1)

DOCUMENT RELEASE AND CHANGE FORMPrepared For the U.S. Department of Energy, Assistant Secretary for Environmental ManagementBy Washington River Protection Solutions, LLC., PO Box 850, Richland, WA 99352Contractor For U.S. Department of Energy, Office of River Protection, under Contract DE-AC27-08RV14800

TRADEMARK DISCLAIMER: Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof or its contractors or subcontractors. Printed in the United States of America.

Release Stamp

1. Doc No: RPP-SPEC-63855 Rev. 00

2. Title:Procurement Specification - Electric Boiler System for ETF Steam Strippers

3. Project Number:OP185

☐N/A 4. Design Verification Required:

☐Yes ☒No

5. USQ Number: ☒ N/AN/A-9

6. PrHA Number Rev. ☒ N/A

Clearance Review Restriction Type:public

7. Approvals

Title Name Signature DateClearance Review Raymer, Julia R Raymer, Julia R 12/17/2020Design Authority Wilson, Nathaniel W Wilson, Nathaniel W 12/16/2020Checker Quam, Paul R Quam, Paul R 12/17/2020Document Control Approval Scales, Anthony Scales, Anthony 12/17/2020Environmental Protection Beam, Tom Beam, Tom 12/16/2020Engineering Discipline Lead-Civil/Structural Mackey, Tom Mackey, Tom 12/15/2020Engineering Discipline Lead-Electrical Rambo, Charles L Rambo, Charles L 12/15/2020Engineering Discipline Lead-Mechanical Goessmann, Glen E Goessmann, Glen E 12/16/2020Engineering Discipline Lead-Ventilation Khabir, Sharok Khabir, Sharok 12/16/2020Originator Hall, Richard B Hall, Richard B 12/11/2020Other Approver Russell, Rose M Russell, Rose M 12/15/2020Quality Assurance Thompson, Tyler J Thompson, Tyler J 12/16/2020Responsible Engineering Manager Lehrman, Scott D Lehrman, Scott D 12/17/2020USQ Evaluator Wheeler, Ronnie Wheeler, Ronnie 12/16/2020Welding Engineer Berkey, James Berkey, James 12/15/2020

8. Description of Change and Justification

Initial Release.

9. TBDs or Holds ☒N/A

10. Related Structures, Systems, and Components

a. Related Building/Facilities ☐N/A b. Related Systems ☐N/A c. Related Equipment ID Nos. (EIN) ☐N/A

ETF FACILITIES ETFETF-60K

65A-B-00265A-B-003

11. Impacted Documents – Engineering ☒N/A

Document Number Rev. Title

12. Impacted Documents (Outside SPF):

N/A

13. Related Documents ☐N/A

Document Number Rev. TitleMT-50529 00 Effluent Treatment Facility Acetonitrile Steam Stripping SystemRPP-SPEC-63886 00 ETF Steam Stripper Construction Specification

14. Distribution

Name OrganizationBeam, Tom ENVIRONMENTAL PROTECTIONCassinelli, Andrew T COMMISSIONINGCorbett, John E COMMISSIONINGFilip, Jeff WFD PROJECTSGarrett Reed, Tara L WFD PROJECTSHalgren, Dale L ETF ENGINEERINGLehrman, Scott D ETF PROJECTS ENGINEERINGMcFerran, Brandon E 242-A/AW/ETF OPERATIONSMelvin, Max A ETF PROJECTS ENGINEERINGRussell, Rose M ETF ENGINEERINGRutherford, Wally PROD OPERATIONS ENGINEERINGSamoska, Jerry A INSTRUMENT & CNTRL ENGINEERINGSeverson, Brian D ETF PROJECTS ENGINEERING

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DATE:

Dec 17,2020

DOCUMENT RELEASE AND CHANGE FORM Doc No: RPP-SPEC-63855 Rev. 00

2 SPF-001 (Rev.D1)

14. Distribution

Name OrganizationSmith, Kimball E WFD PROJECTSThompson, Tyler J PROCUREMENT QAYarger, David J ETF ENGINEERINGYoung, Natalie M ETF PROJECTS ENGINEERING

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Approved for Public Release; Further Dissemination Unlimited

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TABLE OF CONTENTS

1.0 SCOPE ............................................................................................................................. 1-7

1.1 DESCRIPTION ............................................................................................................. 1-7

1.2 DOCUMENT OVERVIEW .......................................................................................... 1-7

1.2.1 Definitions.............................................................................................................. 1-8

1.3 BACKGROUND ........................................................................................................... 1-8

1.4 TRADEMARK DISCLAIMER .................................................................................... 1-9

1.5 ABBREVIATIONS AND ACRONYMS ..................................................................... 1-9

1.6 UNITS ......................................................................................................................... 1-10

2.0 APPLICABLE DOCUMENTS ..................................................................................... 2-11

2.1 GOVERNMENT DOCUMENTS ............................................................................... 2-11

2.2 NON-GOVERNMENT DOCUMENTS ..................................................................... 2-12

2.3 NON-GOVERNMENT NON-CODE OF RECORD DOCUMENTS ........................ 2-13

2.4 HIERARCHY OF CODE............................................................................................ 2-15

3.0 SSC CHARACTERISTICS AND REQUIREMENTS ................................................. 3-16

3.1 SSC FUNCTIONS AND FUNCTIONAL PERFORMANCE REQUIREMENTS .... 3-16

3.1.1 Mechanical Boiler Design.................................................................................... 3-16

3.1.2 Boiler Ratings ...................................................................................................... 3-16

3.1.3 Boiler Pressure Vessel ......................................................................................... 3-16

3.1.4 Boiler Internal Power Distribution ....................................................................... 3-18

3.1.5 Boiler Heating Elements ...................................................................................... 3-18

3.1.6 Boiler Controls ..................................................................................................... 3-18

3.1.7 Deaerator System Design ..................................................................................... 3-19

3.1.8 Deaerator System Controls & Instrumentation .................................................... 3-19

3.1.9 Deaerator/Boiler Feed Pump and Piping Design ................................................. 3-20

3.1.10 Blowdown Separator Design ............................................................................... 3-20

3.1.11 Handling Devices ................................................................................................. 3-21

3.1.12 On-Site Support ................................................................................................... 3-21

3.1.13 Work Not Included .............................................................................................. 3-21

3.2 SSC INTERFACES .................................................................................................... 3-21

3.2.1 External Interfaces ............................................................................................... 3-21

3.3 SSC CHARACTERISTICS ........................................................................................ 3-22

3.3.1 Functional Characteristics .................................................................................... 3-22

3.3.1.1 Design Pressure and Temperature ................................................................ 3-22

3.3.1.2 System Design Life ...................................................................................... 3-22

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3.3.1.3 Performance Requirements........................................................................... 3-22

3.3.1.4 Environmental Conditions ............................................................................ 3-23

3.3.1.5 Design Loads ................................................................................................ 3-23

3.4 DESIGN AND CONSTRUCTION REQUIREMENTS ............................................. 3-23

3.4.1 Materials .............................................................................................................. 3-24

3.4.2 Electrical .............................................................................................................. 3-24

3.4.3 Bolting.................................................................................................................. 3-24

3.4.4 Welding ................................................................................................................ 3-24

3.4.5 Gaskets ................................................................................................................. 3-25

3.4.6 System Filtration .................................................................................................. 3-25

3.4.7 Design for Equipment Installation ....................................................................... 3-25

3.4.8 Labeling ............................................................................................................... 3-25

3.4.9 Nameplates and Product Marketing ..................................................................... 3-26

3.4.10 Human Factors Engineering ................................................................................ 3-26

3.5 SYSTEM RELIABILITY AND MAINTAINABILITY REQUIREMENTS ............ 3-26

3.5.1 Reliability ............................................................................................................. 3-26

3.5.2 Maintainability ..................................................................................................... 3-27

4.0 FABRICATION REQUIREMENTS ............................................................................. 4-28

4.1 WELDING REQUIREMENTS .................................................................................. 4-28

4.1.1 Structural Welding ............................................................................................... 4-28

4.1.2 Weld Materials ..................................................................................................... 4-28

4.1.3 Welding Procedures and Qualifications............................................................... 4-29

4.1.4 Weld Inspection Requirements ............................................................................ 4-29

4.1.5 Additional Welding Requirements ...................................................................... 4-30

4.1.6 Workmanship ....................................................................................................... 4-30

4.2 CLEANLINESS .......................................................................................................... 4-30

4.2.1 Material Contamination Control .......................................................................... 4-31

4.2.2 Surfaces ................................................................................................................ 4-31

4.2.3 Cleaning ............................................................................................................... 4-31

4.3 LIFTING ATTACHMENTS....................................................................................... 4-32

5.0 PRODUCTION INSPECTION AND TESTING REQUIREMENTS .......................... 5-33

5.1 QUALIFICATIONS TESTING REQUIREMENTS .................................................. 5-33

5.2 INSPECTION.............................................................................................................. 5-33

5.2.1 General ................................................................................................................. 5-33

5.2.2 Structural .............................................................................................................. 5-34

5.2.3 Lifting Attachments ............................................................................................. 5-34

5.3 TESTING .................................................................................................................... 5-34

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5.3.1 Hydrostatic Test ................................................................................................... 5-34

5.3.1.1 General .......................................................................................................... 5-34

5.3.2 System Function Test ........................................................................................... 5-34

5.4 ELECTRICAL INSPECTION .................................................................................... 5-35

6.0 DELIVERY, STORAGE, AND HANDLING .............................................................. 6-36

6.1 DELIVERY, STORAGE, & LOAD HANDLING ..................................................... 6-36

6.1.1 General ................................................................................................................. 6-36

6.1.2 Transportability .................................................................................................... 6-36

6.1.3 Packaging ............................................................................................................. 6-36

6.1.3.1 Levels of Packaging ...................................................................................... 6-36

6.1.3.2 Cleaning Plan ................................................................................................ 6-37

6.1.3.3 Cleaning Records .......................................................................................... 6-37

6.1.3.4 Packaging List .............................................................................................. 6-37

6.1.3.5 Packaging Type ............................................................................................ 6-37

6.1.3.6 Packaging Materials ..................................................................................... 6-37

6.1.3.7 Packaging Materials Contacting Stainless Steel and Nickel Alloy .............. 6-37

6.1.3.8 Seal Openings ............................................................................................... 6-38

6.1.3.9 Protection from Corrosion ............................................................................ 6-38

6.1.3.10 Unprotected Steel ......................................................................................... 6-38

6.1.3.11 Shipment Load Protection ............................................................................ 6-38

6.1.3.12 Protection from Shock and Vibration ........................................................... 6-38

6.1.3.13 Other Protection ............................................................................................ 6-39

6.1.3.14 Protection of Machined Surfaces .................................................................. 6-39

6.1.3.15 Packaging Inspection .................................................................................... 6-39

6.1.4 Handling ............................................................................................................... 6-39

6.1.4.1 Lift and Rigging Plan ................................................................................... 6-39

6.1.4.2 Lift Point Marking ........................................................................................ 6-39

6.1.4.3 Lifting Attachments and Equipment............................................................. 6-39

6.1.4.4 Rated Temperature for Custom Lifting Devices .......................................... 6-39

6.1.4.5 Contact with Different Metals ...................................................................... 6-39

6.1.4.6 Critical Welds ............................................................................................... 6-39

6.1.4.7 Shipping and Handling Drawing .................................................................. 6-40

6.1.4.8 Unpacking and Assembly Drawing .............................................................. 6-40

6.1.4.9 Special Lifting Devices ................................................................................ 6-40

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6.1.4.10 Below-the-Hook Device Marking ................................................................ 6-40

6.1.4.11 Offloading ..................................................................................................... 6-40

6.1.5 Storage ................................................................................................................. 6-40

6.1.5.1 Level of Storage ............................................................................................ 6-41

6.1.5.2 Storage Areas ................................................................................................ 6-41

6.1.5.3 Storage Methods ........................................................................................... 6-41

6.1.5.4 Control of Items in Storage .......................................................................... 6-42

6.1.5.4.1 Inspections ................................................................................................ 6-42

6.1.5.4.2 Care of Items ............................................................................................ 6-42

6.1.5.4.3 Post-Fire Evaluations ............................................................................... 6-42

6.1.5.5 Removal of Items from Storage.................................................................... 6-43

6.1.5.6 Storage Records ............................................................................................ 6-43

6.1.5.7 Additional Storage Requirements ................................................................. 6-43

6.1.5.8 Environmental Storage Requirements .......................................................... 6-43

6.1.6 Delivery................................................................................................................ 6-43

6.1.7 Marking for Shipment .......................................................................................... 6-43

6.2 QUALITY ASSURANCE .......................................................................................... 6-44

6.3 SITE CONDITIONS ................................................................................................... 6-44

7.0 PROJECT MANAGEMENT ......................................................................................... 7-45

7.1 SUBMITTALS ............................................................................................................ 7-45

7.1.1 Submittals Required with Proposal ...................................................................... 7-45

7.1.2 Submittals Required Prior to Fabrication ............................................................ 7-46

7.1.3 Submittals Required Prior to Start of Testing ...................................................... 7-48

7.1.4 Submittals Required Prior to Shipping ................................................................ 7-48

7.1.5 Request for Information ....................................................................................... 7-50

7.2 QUALITY ASSURANCE PROGRAM ..................................................................... 7-50

7.2.1 Non-Conformance Reports .................................................................................. 7-50

7.2.2 Inspection/Examination ....................................................................................... 7-51

7.2.3 Suspect/Counterfeit Items .................................................................................... 7-51

7.2.4 Certificate of Conformance.................................................................................. 7-51

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LIST OF TABLES

Table 2-1. Government Documents .......................................................................................... 2-11 Table 2-2. Non-Government Documents (2 Pages). ................................................................. 2-12 Table 2-3. Non-Government Non-Code of Record Documents. .............................................. 2-14 Table 7-1. Submittals Required with Proposal. ........................................................................ 7-45

Table 7-2. Submittals Required Prior to Fabrication (2 Pages). ............................................... 7-46 Table 7-3. Submittals Required Prior to Start of Testing ......................................................... 7-48 Table 7-4. Submittals Required Prior to Shipping (2 pages). ................................................... 7-49

APPENDICES

Appendix A ……………………………………………………Equipment Data Sheets

Appendix B ……………………………………………………Vendor Boiler Data Sheet

Appendix C …………………………………………………… Equipment Interface Flange

Locations Sketches

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1.0 SCOPE

This Procurement Specification (hereafter referred to as Specification) provides baseline

requirements for design and procurement of one (1) Electric Steam Boiler and feedwater system

for the Effluent Treatment Facility (ETF) Steam Strippers. This Specification establishes the

functions, interfaces, functional performance requirements, applicable codes and standards,

requirements for the thermal design, mechanical design, materials, fabrication, assembly,

inspecting, testing, quality oversight, documentation, packaging, transportation, and delivery of

the Electric Steam Boiler and feedwater system, hence referred to as Boiler system, which

includes two (2) Electric Boilers, one (1) Deaerator, two (2) Boiler feed pumps, one (1)

blowdown separator, and the associated control valves, orifices, relief valves, etc. as detailed

herein for the ETF Steam Stripper System. The Electric Boilers shall be resistance element

steam boilers constructed in accordance with Section I of the American Society of Mechanical

Engineers (ASME) Boiler and Pressure Vessel Code (B&PVC).

The SELLER shall supply all equipment within the Vendor Package Outlines depicted on the

Process and Instrumentation Diagram (P&ID) drawing H-2-839043 sheet 1 and H-2-839044

sheet 1. The BUYER will provide all piping, electrical, and controls to/from the Vendor

Package equipment as outlined on H-2-839043 sheet 1, and H-2-839044 sheet 1, and in this

specification.

1.1 DESCRIPTION

Washington River Protection Solutions, LLC (WRPS), is the U.S. Department of Energy (DOE),

Office of River Protection (ORP) Tank Farm Operating Contract (TOC). WRPS is contracted to

provide safe, compliant, cost-effective, and energy-efficient services to further the DOE-ORP

River Protection Project (RPP) Mission. In order to safely complete the RPP Mission, various

permanent or temporary systems and associated components are required.

This Specification identifies and communicates the common inputs, requirements, and criteria

for the design and procurement of Electric Steam Boilers, Deaerator, Boiler feed pumps, and

blowdown separator for the ETF Steam Strippers. The function of the Electric Steam Boilers are

to produce steam that will be used to distill the acetonitrile out of the process waste fluid in the

Steam Stripper columns.

The Boiler equipment is designated General Service and Industrial Grade Quality.

1.2 DOCUMENT OVERVIEW

This Specification is a "design-build" specification, delineating the required functions and

requirements to which the VENDOR (SELLER) shall adhere in providing the finished

products/services to the BUYER. Where specific make and model of equipment and/or systems

are called out in this Specification, BUYER-approved equivalents will be considered.

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The equipment being procured via this Specification shall interface with BUYER provided

equipment and systems per Section 3.2.

Specific to this document, the following requirements and definitions are applicable.

1.2.1 Definitions

• DEVIATION – Any departure from the requirements contained in the purchase order and specification, which SELLER proposes to incorporate if approved by BUYER.

• PRODUCT DATA – Printed information including, but not limited to, catalog cuts, color charts, illustrations, diagrams, templates, performance curves, brochures, and other forms

of Product literature.

• Shall/Must – Denotes project requirements, compliance is required.

• Should – Denotes recommendation or expectation, compliance is expected. If a “should” recommendation cannot be satisfied, justification of an alternative design solution shall

be submitted to the BUYER for approval.

• Will – Denotes a statement of fact.

• May – Denotes a “permissive” for a stated action, or denotes a possible outcome depending on the context of the verbiage.

• BUYER – The TOC responsible for managing the design, procurement, and construction of the procured item.

• SELLER – Contracted fabricator, vendor, or subcontractor performing work to the contract drawings, procurement Data Sheets, and technical specifications.

• Substitution - Any change or deviation from issued approved drawings, designs, methods, or contract terms and conditions. Changes in products, materials, equipment,

methods of construction, and test criteria required by the Contract Documents proposed

by the SELLER after award of the Contract are considered to be requests for

substitution.

• WITNESS POINT – An inspection activity beyond which work shall not proceed until an inspector and/or BUYER is notified and (1) the inspection is performed and released, or

(2) the inspection is deferred and can be completed at a later time, or (3) a written waiver

is issued by the organization who established the witness point.

1.3 BACKGROUND

The Hanford Site located in Washington State contains the largest quantity of legacy tank waste

in the DOE complex. Most of these nuclear wastes, resulting from the processing operations of

defense nuclear materials, are stored in 177 underground storage tanks. The tanks contain an

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estimated 56 million gallons of hazardous and radioactive liquids, sludge, and salt cake with

approximately 175 million curies of radioactivity. These tanks are located on the Central Plateau

of the Hanford Site in 200 East and 200 West Areas.

The ETF treats secondary liquid waste generated from waste streams at the Hanford Site. This

Specification is prepared to detail requirements associated with the new ETF Acetonitrile Steam

Stripper system which will remove acetonitrile from the waste treatment plant effluent stream,

prior to delisting and disposal.

1.4 TRADEMARK DISCLAIMER

Reference herein to any specific commercial product, process, or service by trade name,

trademark, SELLER, or otherwise, does not necessarily constitute or imply endorsement,

recommendation, or favoring by the United States Government or any agency thereof or its

contractors or subcontractors.

1.5 ABBREVIATIONS AND ACRONYMS

ABBREVIATIONS AND ACRONYMS

AISC American Institute of Steel Construction

ASME American Society of Mechanical Engineers

ASNT American Society for Non-Destructive Testing

ASTM American Society for Testing and Materials

AWS American Welding Society

B&PVC Boiler and Pressure Vessel Code

BTH Below-the-Hook Lifting

CFR Code of Federal Regulations

CMTR Certified Material Test Report

COR Code of Record

CSD Controls and Safety Devices

DOE Department of Energy

ETF Effluent Treatment Facility

FIT Fabrication, Inspection, and Test

NDC Natural Phenomena Design Category

NDE Non-Destructive Examination

NEC National Electrical Code

NFPA National Fire Protection Association

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NPH Natural Phenomena Hazards

NPT National Pipe Thread

O&M Operation and Maintenance

ORP Office of River Protection

P&ID Process and Instrumentation Diagram

PSSH Packaging, Storage, Shipping, and Load Handling

QA Quality Assurance

QAP Quality Assurance Program

RFI Request for Information

RPP River Protection Project

SDC Seismic Design Category

SOW Statements of Work

SSC Structures, Systems, and Components

SCCR Short Circuit Current Rating

TOC Tank Farm Operating Contractor

UL Underwriters Laboratories

WAC Washington Administrative Code

WPQR Welder Procedure Qualification Record

WRPS Washington River Protection Solutions, LLC.

1.6 UNITS

°F degrees Fahrenheit

ft feet

gpm gallons per minute

hr hour

Hz hertz

in inch

kW kilowatt

lbs pounds

psig pounds-force per square inch gauge

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2.0 APPLICABLE DOCUMENTS

The following tables serve as the set of requirements that are used to design, construct, operate,

and decommission a nuclear facility or a mission critical, non-nuclear facility (or their structures,

systems, and components [SSC’s]) over its lifespan. When specifying requirements for

procurement, the Design Authority/Subject Matter Expert shall ensure that the specific

codes/standard and regulation references selected for the item’s design are included in the Code

of Record (COR) according to TFC-ENG-DESIGN-C-57, “Development and Maintenance of

Code of Record.”

The following documents may not be an all-inclusive list and considerations for the design for

specific farms, facilities, and projects must be taken into consideration. In the event of a conflict

between the documents referenced herein and the requirements of this specification, the

requirements of this specification shall take precedence over requirements in documents listed in

Table 2-1 and Table 2-2 only when the specification requirements are more stringent or

conservative.

2.1 GOVERNMENT DOCUMENTS

The following documents, of the exact issue shown in Table 2-1, form a part of this Specification

to the extent specified herein and establish of the Code of Record. Unless otherwise shown or

noted, the latest edition and addenda are applicable.

Table 2-1. Government Documents

Document Number Title

Code of Federal Regulations (CFR)

10 CFR 830 “Nuclear Safety Management”

U.S. Department of Energy (DOE)

DOE G 414.1-3 “Suspect/Counterfeit Items Guide for Use with 10 CFR 830

Subpart A, Quality Assurance Requirements, and DOE O 414.1B,

Quality Assurance”

DOE-RL-92-36 “Hanford Site Hoisting and Rigging Manual”

Washington Administrative Code (WAC)

WAC 246-247 “Radiation Protection – Air Emissions”

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2.2 NON-GOVERNMENT DOCUMENTS

The following documents establish the Code of Record, or basis of design of the new ETF

Boilers. Unless otherwise shown or noted, the latest edition and addenda are applicable.

Table 2-2. Non-Government Documents (2 Pages).

Document Number Title

American National Standards Institute/Institute of Electrical and Electronics Engineers

(ANSI/IEEE)

ANSI/IEEE 112 “Standard Test Procedure for Polyphase Induction Motors and

Generators”

American Society of Mechanical Engineers (ASME)

ASME B & PV “ASME Boiler and Pressure Vessel Code, Section I, Rules for

Construction of Power Boilers”

ASME B & PV “ASME Boiler and Pressure Vessel Code, Section II Parts A, B

and C for Ferrous Materials, Non-Ferrous Materials and

Specifications for Welding Rods, Electrodes and Filler Metals”

ASME B & PV “ASME Boiler and Pressure Vessel Code, Section V,

Nondestructive Examination”

ASME B & PV “ASME Boiler and Pressure Vessel Code, Section IX for Welding

and Brazing Qualifications”

ASME BTH-1 “Design of Below-The-Hook (BTH) Lifting Devices”

ASME B16.5 “Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24

Metric/ Inch Standard”

ASME B30.20 “Below the Hook Lifting Devices”

ASME B31.1, 2016 “Power Piping”

ASME B31.3, 2016 “Process Piping”

ASME CSD-1 “Controls and Safety Devices for Automatically Fired Boilers”

ASME NQA-1 “Quality Assurance Program Requirements for Nuclear Facilities

Applications”

American Society for Nondestructive Testing (ASNT)

ASNT SNT-TC-1A “Recommended Practice for Personal Qualification and

Certification in Nondestructive Testing”

American society for testing and materials (ASTM)

A193 “Standard Specification for Alloy-Steel and Stainless Steel Bolting

for High Temperature or High Pressure Service and Other Special

Purpose Applications”

A194 Standard Specification for Carbon Steel, Alloy Steel, and Stainless

Steel Nuts for Bolts for High Pressure or High Temperature

Service, or Both

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Table 2-2. Non-Government Documents (2 Pages).

Document Number Title

American Welding Society (AWS)

AWS D1.1/D1.1M “Structural Welding Code – Steel”

AWS D1.3/D1.3M “Structural Welding Code – Sheet Steel”

AWS D1.6/D1.6M “Structural Welding Code – Stainless Steel”

AWS D9.1/D9.1M “Sheet Metal Welding Code”

AWS D14.1 “Specification for Welding of Industrial and Mill Cranes and Other

Material Handling Equipment”

AWS B2.1/B2.1M-BMG “Base Metal Grouping for Welding Procedure and Performance

Qualification”

AWS QC1 “Standard for AWS Certification of Welding Inspectors”

International Code Council / International Building Code (ICC / IBC)

ICC IBC “International Building Code”

Military Standards (MIL)

MIL-STD-889C “Dissimilar Metals”

National Electrical Manufacturers Association (NEMA)

NEMA Standard MG-1 “Motors and Generators”

National Fire Protection Association (NFPA)

NFPA 70 “National Electrical Code (NEC)”

Underwriters (UL)

UL 834, 2014 “Standard for Heating, Water Supply, and Power Boilers -

Electric”

2.3 NON-GOVERNMENT NON-CODE OF RECORD DOCUMENTS

The SELLER shall draft a Request for Information (RFI) to inquire about specific TOC

standards, procedures, and documents. The following documents are utilized or referenced by

this Specification but are not considered part of the COR. Unless otherwise shown or noted, the

latest edition and addenda are applicable.

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Table 2-3. Non-Government Non-Code of Record Documents.

Document Number Title

Washington River Protection Solutions, LLC (WRPS)

Form A-6006-661 “Quality Assurance Requirements”

H-2-839028, Sheet 1 “ETF Steam Stripper Structural Equipment Anchorage Plan”

H-2-839043, Sheet 1 “ETF Steam Stripper P&ID Steam Boiler System”

H-2-839044, Sheet 1 “ETF Steam Stripper P&ID Steam Boiler System”

H-2-839053 “ETF Steam Stripper General Arrangement”

H-2-839080 “ETF Steam Stripper Electrical One-Line Diagram”

H-2-839087 “ETF Steam Stripper Electrical Interior Plan”

HNF-27957, Rev. 5 “200 Area ETF, Load-In, and LERF Pipe Class Specification”

QA-AVS-APPENDIX “Procurement Quality Clauses”

RPP-8360, Rev. 6 “Lifting Attachment and Lifted Item Evaluation”

RPP-CALC-63919 “ETF Steam Stripper PSV Sizing Calculation”

RPP-CALC-64071 “Effluent Treatment Facility (ETF) Steam Stripper Equipment

Anchorage Structural Evaluation”

RPP-CALC-64270 “Steam Stripper ASME B31.3 Piping Analysis”

RPP-CALC-64271 “Steam Stripper ASME B31.1 Piping Analysis”

TFC-BSM-IRM_DC-C-02 “Records Management”

TFC-BSM-IRM_DC-C-07 “Vendor Processes”

TFC-ENG-DESIGN-C-57 “Development and Maintenance of Code of Record”

TFC-ENG-DESIGN-D-71 “Elementary Diagram Guide”

TFC-ENG-FACSUP-C-25 “Hoisting and Rigging”

TFC-ENG-STD-06 “Design Loads for Tank Farm Facilities”

TFC-ENG-STD-15 “Standard for Raceway Systems and Flexible Cords and Cables”

TFC-ENG-STD-41 “Electrical Installations”

TFC-ENG-STD-52 “Subcontractor Welding Standard”

TFC-ESHQ-Q_C-C-03 “Control of Suspect/Counterfeit Items”

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2.4 HIERARCHY OF CODE

Except in those instances where Washington State has been granted regulatory authority by the

Federal Government, the hierarchical relationship among requirements specified in Section 2.0 is

as follows:

• Federal requirements (e.g. Code of Federal Regulations)

• Washington State requirements (e.g. Washington Administrative Code)

• Local ordinances

• U.S. Department of Energy Orders and Standards

• National consensus codes and standards

• Hanford Site-specific codes and standards.

This hierarchy establishes the order of precedence of requirements levied in this Specification.

In the event of a conflict between two requirements, the SELLER shall submit an RFI for

clarifications prior to use.

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3.0 SSC CHARACTERISTICS AND REQUIREMENTS

This section addresses the following SSC characteristics and requirements:

• SSC functions and function performance requirements are covered in Section 3.1,

• SSC interfaces are covered in Section 3.2,

• SSC Characteristics are covered in Section 3.3,

• Design and assembly requirements are covered in Section 3.4, and

• Reliability, availability, maintainability, and inspectability requirements are covered in

Section 3.5.

3.1 SSC FUNCTIONS AND FUNCTIONAL PERFORMANCE REQUIREMENTS

3.1.1 Mechanical Boiler Design

a. The Electric Steam Boilers shall be a resistance element steam Boiler, model number STR-4274-1240-4C-SS manufactured by Vapor Power International, designed and

fabricated in accordance with ASME Boiler and Pressure Vessel Code (B&PVC)

Section I, and any additional requirements of this Specification.

b. Boilers shall be used for continuous heating of incoming water. c. Boilers shall be Underwriters Laboratory (UL) labeled and comply with ASME Controls

and Safety Devices for Automatically Fired Boilers (CSD-1).

d. Boilers shall include an ASME Section I “S” Code pressure vessel which has been fabricated under inspection by an authorized inspector holding a National Board

commission and subsequently stamped and National Board registered.

e. Boilers shall meet the requirements of the Boiler Data Sheet. See Appendix A. f. Boilers shall be completely factory assembled and pre-tested prior to shipment. g. The allowable nozzle forces will be available upon request to the BUYER. The

allowable forces are an output from RPP-CALC-64270 and RPP-CALC-64271.

3.1.2 Boiler Ratings

a. Boilers shall be rated 1240 KW, designed and fabricated for a balanced 3-phase, 3-wire, delta load at 480 volts, 3-phase 60 hertz.

b. Ability to each generate 4,231 lbs of steam per hour from/at 212°F. c. The Boilers shall be designed for 200 psig (388°F), with an operating pressure at least

145 psig (364°F).

3.1.3 Boiler Pressure Vessel

a. The stamped pressure vessel and all trim shall be as set forth in the ASME Section I “S” Code.

b. Boilers shall include ASME “V” stamped safety relief valves, sized as required.

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c. The vessel shall be provided with a 2-1/2” flanged class 300, raised face, ASME 16.5 steam outlet, 1” flanged feed-water inlet, and 1” flanged blow-down connections as

required and as located per Appendix C.

d. The pressure vessel shall be housed in a 16-gauge steel enclosure allowing 2-in of insulation space around the vessel and filled with 3/4 pound density fiberglass insulation.

e. As sketched in Appendix C, sheet metal enclosure support stiffeners (angles, plate, etc) that can withstand two (2) 200 lb point loads with minimal deflection shall be placed

within the boxed region. Facility installed vertical piping supports will be placed here for

the PSV outlet piping.

f. The electric panel and vessel shall be mounted on a common, structural steel base with overall dimensions of the unit (not including level controls, valves, and trim) not to

exceed 60 inches (L) x 54 inches (W) x 63 inches (H).

g. All interface points shall be flanged. Piping, valves, instruments, manifolds shall be routed (combined as necessary) to the dimensioned locations sketched in Appendix C.

h. Steam piping shall be designed, fabricated, and tested to ASME B31.1 per the 303 piping code indicated in HNF-27957.

i. Liquid piping shall be designed, fabricated, and tested to ASME B31.3 for Normal Fluid Service per the 153S piping code indicated in HNF-27957.

j. Integrate by design, block and bleed valving, localized indicators, and transmitters where necessary and as shown on H-2-839043 and H-2-839044 and within the dimensioned

locations sketched in Appendix C.

k. Each Boiler shall include 2 ASME safety relief valves set to 200 psig. For the SELLER relief valve sizing calculations, inlet and outlet piping lengths and diameters and supports

will be provided on the mechanical layout drawings denoted on H-2-839053.

l. The safety relief valve vessel connection shall consider full discharge thrust and moment forces. Additionally, reference ETF Steam Stripper PSV Sizing Calculation for discharge

forces due to pipe routing and supports (RPP-CALC-63919, available upon request to the

BUYER).

m. Include surface and bottom blowdown manual valves with integrated sample port(s). n. Each Boiler shall have a common single interface point for low point draining provided

that is 16 inches to centerline above the floor to allow for connection to drain piping

header. See the dimensioned locations sketched in Appendix C.

o. The allowable interface nozzle loads at each point shall be per the nozzle load results for each load case in RPP-CALC-64270 and RPP-CALC-64271.

p. Each boiler feedwater piping shall include integrated modulating control valves, check valves, and stop valves as indicated on the P&ID (H-2-839044) and located as shown in

Appendix C .

q. The feedwater piping from the level control valves to the boiler shall be designated as “Boiler External Pipe” (BEP) with a design pressure of 250 psig, meeting the

requirements of B31.1, including but not limited to material certifications (CMTR’s),

Boiler code P-4A data report forms, Authorized Inspector review of the data, and

stamping of the piping with a PP stamp.

r. The steam piping outlet as it extends from the boiler to the flange is also “Boiler External Pipe”.

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3.1.4 Boiler Internal Power Distribution

a. The power distribution shall be through cable connection to mechanical lugs with minimum 65k ampere Short Circuit Current Rating.

b. Power shall be fed through current limiting fuses to heating element. c. Contactors shall be minimum UL tested for 500,000 cycles at full load. d. The coil voltage shall be 24 VDC. 24 VDC shall be in a separate enclosure. e. Internal wiring shall be in accordance with National Electrical Code/National Fire

Protection Association (NEC/NFPA) Article 425 and UL Subject 834.

3.1.5 Boiler Heating Elements

a. Elements shall be individually mounted in steel flanges for easy removal and replacement.

b. A quantity of 62 individually replaceable elements, each 20 kW. c. The flange size shall not exceed 2-1/2 inches square, with a maximum of three

single-bend U-shaped element blades per flange.

d. Element sheath material shall be Incoloy-sheathed. e. Element watt density shall be 75 watts per square inch.

3.1.6 Boiler Controls

a. The control circuit shall be 24 VDC wherever practicable. 24 VDC and 120 VAC/480 VAC shall be in separate enclosures. If other voltages are used for controls, a local

transformer shall be included.

b. The boiler shall be controlled by a Allen-Bradley1 CompactLogix 5370 1769-L30ER controller with a Prosoft MVI69E-MBTCP communications module installed.

c. All instruments and electrical systems shall be UL listed. d. The controls shall include:

1. ON/OFF switch

2. Proportional pressure control combined with a solid state proportional progressive

sequencing step control featuring 12 steps

3. Indicator lights and manual limiting switches for each step of heating

4. Combination float-type level control/low water cutoff

5. One probe type manual reset low water cutoff

6. One automatic reset high limit pressure switch

7. One secondary manual reset high limit pressure switch.

8. Integrated modulating feedwater control valves and checkvalves.

9. PanelView plus 7 HMI model 2711P-T15C22D9P.

1 Allen-Bradley® is a registered trademark of Rockwell Automation, Inc., Milwaukee, Wisconsin.

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3.1.7 Deaerator System Design

a. The Boiler system Deaerator shall be a pressurized spray type, model number SP9M-165D.

b. Deaerator vessel shall be a 36-in diameter and 94-in overall length. The vessel shall be designed, stamped, and built in accordance with ASME Section VIII, Division 1 for

50 psig at 400°F. All wetted components to be 304 stainless steel for service with

demineralized water.

c. Ensure Deaerator provides 11 minutes of feedwater storage to overflow. d. Deaerator shall meet the requirements of the Deaerator Data Sheet. See Appendix A. e. Supply Deaerator with a stand, height as determined taking into account the NPSHr of

the pumps, and low point drain connections as mentioned below. Maximum height of the

assembly shall be less than 11 feet.

f. Deaerator vent and orifice connection shall be provided. g. Provided full capacity safety relief valve set at 50 psi and a sentinel steam relief valve. h. Deaerator shall include ASME “UV” stamped safety relief valves, sized as required. i. For the SELLER relief valve sizing calculations, inlet and outlet piping lengths and

diameters and supports will be provided on the mechanical layout drawings denoted on

H-2-839053. Additionally, reference ETF Steam Stripper PSV Sizing Calculation (RPP-

CALC-63919, available upon request to the BUYER).

j. The safety relief valve vessel connection shall consider full discharge thrust forces. Additionally, reference ETF Steam Stripper PSV Sizing Calculation for discharge forces

due to pipe routing and supports (RPP-CALC-63919, available upon request to the

BUYER).

k. Include vacuum breaker check valve sized per industry standards. l. Include a manway for accessibility. m. Include an overflow float trap, shipped separately. n. A common single interface point for low point draining the deaerator tank and

instruments shall be provided that is higher than the inlet connection to the blowdown

tank. See the dimensioned locations sketched in Appendix C.

o. Steam piping shall be designed, fabricated, and tested to ASME B31.1 per the 303 piping code indicated in HNF-27957.

p. Liquid piping shall be designed, fabricated, and tested to ASME B31.3 per the 153S piping code indicated in HNF-27957.

q. The allowable interface nozzle loads at each point shall be per the nozzle load results for each load case in RPP-CALC-64270 and RPP-CALC-64271.

3.1.8 Deaerator System Controls & Instrumentation

a. UL listed, NEMA 12 rated control panel, input 24 VDC. Include in the control panel a power supply in separate enclosure, Interposing Relays for 120V equipment shall be in a

separate enclosure, alarm horn with silence switch, and low and high level pilot lights.

b. Modulating, fail closed, make-up water control valve differential pressure level sensor, and controller. Also, a flow orifice shall be sized and installed for a maximum flow of 15

gpm at 80 psi incoming water when the make-up water control valve is wide open.

Installation location on top of Deaerator shall be directly integrated by design and

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shipped loose to be installed by the BUYER. See the dimensioned location sketched in

Appendix C.

c. Steam pressure control valve assembly with 3-valve bypass. Installation location on top of Deaerator shall be as denoted on the Spence valve manufacturer installation

instructions with a flat-on-bottom eccentric reducer, directly integrated by design, and

shipped loose to be installed by the BUYER. See the dimensioned location sketched in

Appendix C.

d. Include high level alarm switch and low level alarm switch. e. Include water level sight gauge. f. Include pressure gauges for water inlet and steam. g. Include storage section temperature gauge with 24VDC switch for high temperature

detection.

3.1.9 Deaerator/Boiler Feed Pump and Piping Design

a. Provide two (2) pumps for Boiler Feed Water. b. Pumps shall be a low NPSH centrifugal Boiler feed pump with 10 HP TEFC motor. c. Pumps shall be sized to supply 16 gpm at the necessary total dynamic head for the steam

Boilers. One pump will be operating, one pump will be on standby. This includes the

estimated steam recirculation to the Deaerator spray nozzles, but not the minimum pump

recirculation through the BUYER sized orifice. See datasheet in Appendix A.

d. Pumps shall be interlocked to allow only one pump to operate at a time. e. Each pump suction piping to include double valve isolation and vent valve, and piping

from tank to pump suction inlet, as shown on the P&ID.

f. Each pump discharge piping to include pressure gauge, double valve isolation and vent valve, and check valve.

g. Pumps shall have a common discharge valve manifold from both pumps directly integrated by design with a minimum flow recirculation line, corresponding sized

recirculation orifice, recirculation check valve and return piping to Deaerator. See the

dimensioned interface flange location sketched in Appendix C.

h. A common single interface point for low point draining the inlet side of the pumps shall be provided to allow for connection to drain piping header. See the dimensioned

locations sketched in Appendix C.

i. Piping shall be designed, fabricated, and tested to ASME B31.3 per the 153S piping code indicated in HNF-27957.

j. Include block and bleed valving, localized indicators, and transmitters where necessary and as shown on H-2-839043 and H-2-839044.

3.1.10 Blowdown Separator Design

a. Provide a Blowdown Separator tank fabricated from stainless steel with a design pressure of 50 psig and design temperature of 400°F, model number BS1212.53-15 or equivalent.

b. The tank shall be ASME inspected and stamped in accordance with ASME Section VIII, Division 1 for 50 psig at 400°F.

c. Include a 1” flanged tangential inlet, 3” flanged atmospheric vent, and a 2 1/2” flanged drain.

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d. For cooling water inlet provide a 1 1/2” flange and 1 1/2” self-acting temperature regulating valve assembly with tank drain outlet integrated temperature sensing and

indication set to 110 °F.

e. All Blowdown Separator materials shall be 304 stainless steel for service with demineralized water.

f. Supply support legs as required. g. See the dimensioned locations and interface flange points sketched in Appendix C.

3.1.11 Handling Devices

a. Provision for lifting shall be included. b. Lifting attachments (lugs), if used, shall be designed by the SELLER. A minimum

factor of safety of two applied to the maximum permissible load shall be used to design

all lifting lugs.

c. SELLER is responsible for determining the size and quantity of lifting lugs.

3.1.12 On-Site Support

a. SELLER shall provide three (3) days of start-up, balancing, testing and BUYER training. Testing shall include written reports on Boiler firing rate, turndown, efficiency,

and all control settings.

3.1.13 Work Not Included

The SELLER’S scope of supply shall exclude the following:

a. Equipment off-loading and installation at the Site. b. Piping to/from equipment assemblies. c. Insulation of piping, Deaerator, and blowdown separator tank d. Start-up and commissioning Site work.

3.2 SSC INTERFACES

3.2.1 External Interfaces

The SELLER shall supply all equipment within the Vendor Package Outlines depicted on P&ID

drawing H-2-839043 sheet 1 and H-2-839044 sheet 1. The BUYER will provide all

interconnection piping to/from the Vendor Package equipment assemblies as depicted on

H-2-839043 sheet 1 and H-2-839044 sheet 1. Notice shall be given if the physical location, size,

and style of piping connections necessary for equipment interfaces deviates from the

dimensioned sketches in Appendix C. SELLER drawings shall be submitted to BUYER to

ensure proper installation. An updated BUYER-approved H-2-839043 sheet 1 and H-2-839044

sheet 1 P&ID shall be supplied by the SELLER.

The SELLER shall provide saddle support design and anchor bolt hole dimensions and layout

for all equipment assemblies provided. Assembly bases shall include post-installed anchor holes

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as required for anchoring to concrete floor. The information in Section 3.3.1.5 shall be used to

design the supports. SELLER shall provide equipment weight, size, and center of gravity for

BUYER to confirm anchorage design which assumes (4) 11/16” holes for 5/8” anchors

(Reference drawing H-2-839028 sheet 1 and calculation RPP-CALC-64071 available upon

request to the BUYER).

SELLER shall provide maintenance clearances for each side of the Boilers.

The SELLER shall supply boiler with electrical power distribution box and contents to support

connection to the BUYER provided 500kcmil conductors to the 480V, 3 phase facility power

supply via cable tray from above as depicted electrical drawings H-2-839080 and H-2-839087.

The SELLER shall supply boiler feed water pumps with compatibility with the BUYER

provided MCC at 480V, 3 phase via conduits as depicted electrical drawings H-2-839080 and H-

2-839087.

3.3 SSC CHARACTERISTICS

3.3.1 Functional Characteristics

This section provides requirements for the functional characteristics of each Boiler unit.

3.3.1.1 Design Pressure and Temperature

The design pressure and temperature of the vessels shall be as specified on the data sheets. See

Appendix A.

The design pressure and temperature of the piping shall be per pipe codes 153S and 303 as laid

out in HNF-27957.

Per ASME B31.3 and ASME B31.1, provision shall be made to safely contain or relieve any

expected pressures to which the piping may be subjected including ambient influences, pressure

oscillations and surges, improper operation, static head, and failure of control

devices. Occasional variations in pressure above the design pressure shall be considered.

The design and operation of all automatic valves shall consider and mitigate the transient

pressures and forces on the piping system. The full stroke closure rate of all automatic valves

shall be a minimum of 5 seconds.

3.3.1.2 System Design Life

Boiler system will have a design life of 30 years.

3.3.1.3 Performance Requirements

The Boiler system shall be capable of performing to the specifications in Appendix A.

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3.3.1.4 Environmental Conditions

The Boiler system will be installed indoors at ETF at the Hanford Site located in Washington

State. The expected environmental conditions during operation are shown below.

Relative Humidity: Up to 100%

Ground Elevation: 672 ft (above sea level)

Environment: Indoor

Minimum Indoor Ambient Temperature: 70°F

Maximum Indoor Ambient Temperature: 78°F

3.3.1.5 Design Loads

The SELLER shall provide rigid structural steel assembly frames and skids for the boiler

package equipment, and tanks, each designed as a single lift package with all equipment,

hardware, and instrumentation installed. Assembly frames and skids shall be a carbon steel

structural shape to accommodate anchoring of the assembly bases and skids to ETF concrete

floor during site field installation using post-installed anchor bolts.

Each boiler package assembly/skid shall be provided with lifting lugs for a four-point lift of

lifting via a forklift, see Section 3.4.7. Lifting and transport of the boiler package

assemblies/skids, complete with all equipment mounted, shall not permanently distort, or

otherwise damage assembly frames, skids, or the tank and equipment mounting surfaces.

The following information shall be used to design the assembly frames, skids, attached

equipment, and tanks:

a. Natural Phenomena Design Requirements shall be in accordance with TFC-ENG-STD-06.

b. Seismic Design Category (SDC) shall be SDC-2, Limit State B, the Natural Phenomena Hazard (NPH) Natural Phenomena Design Category (NDC) is NDC-2.

c. Seismic Performance: Equipment shall withstand the effects of earthquake motions determined according to TFC-ENG-STD-06.

1. The term "withstand" means "the unit will remain in place without separation of

any parts when subjected to the seismic forces specified and may be subject to

only moderate permanent deformation (Limit State B).”

2. Component Importance Factor: 1.5.

3.4 DESIGN AND CONSTRUCTION REQUIREMENTS

The SELLER shall supply all equipment within the Vendor Package Outlines depicted on the

BUYER-approved updated P&ID drawing H-2-839043 sheet 1 and H-2-839044 sheet 1. The

BUYER will provide all piping, electrical, and controls to/from the Vendor Package equipment

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depicted on H-2-839043 sheet 1 and H-2-839044 sheet 1. The physical location, size, and style

of piping connections necessary for equipment interfaces shall be shown on SELLER drawings

and submitted to BUYER to ensure proper installation.

3.4.1 Materials

a. Materials for Boilers and equipment specified herein shall comply with the requirements of ASME B&PVC, Section I and II, and ASME B31.1 and ASME B31.3 as applicable,

and as specified on the Data Sheet in Appendix A.

b. All major pressure boundary parts shall be furnished to ASTM material specifications, and be provided with Certified Material Test Reports (CMTRs) showing compliance with

physical and chemical requirements.

c. Piping shall comply with the pipe class 153S and 303 per HNF-27957. If class 153S piping is threaded, at least schedule 80S pipe shall be used and checked in accordance

with ASME B31.3 code. Threaded components shall facilitate easy removal, with unions

or flanges in close proximity. Every external interface point shall be flanged.

d. All wetted components shall utilize materials that are resistant to corrosion with demineralized water.

e. Materials for all structural members may be selected in accordance with AISC Manual as applicable.

f. Dissimilar metals, such as those defined by MIL-STD-889C, “Dissimilar Metals”, that have active electrolytic corrosion properties shall not be used in direct contact.

g. Instrumentation shall be NEMA 4 rated and manufactured by Rosemount Inc.

3.4.2 Electrical

All electrical equipment, panels, and wiring shall comply with TFC-ENG-STD-41, TFC-ENG-

STD-15, NFPA 70, and also UL 834.

3.4.3 Bolting

a. As specified in HNF-27957, all bolting shall be per the corresponding pipe classes 153S and 303.

b. Stud bolting shall be one diameter longer than the normal nut engagement. c. Any fasteners supplied with head marks matching those displayed in Appendix I,

Suspect/Counterfeit Fastener Head Mark List, or facsimiles thereof, shall be deemed to

be unacceptable under the terms of this Purchase Order/Contract Order. (Ref. DOE G

414.1-3)

3.4.4 Welding

The SELLER shall maintain a complete record of welding materials, including heat number, lot

number, flux and electrode manufacturer used, and shall be made available to the BUYER upon

request.

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3.4.5 Gaskets

a. All elastomers used shall be approved by the BUYER. Chemical and physical properties of the elastomers shall be suitable for the chemical environment in which they are used.

b. Gaskets shall be of one-piece construction. c. Spares: Ship one new and unused gasket per nozzle to be used as spares.

3.4.6 System Filtration

a. The BUYER will provide system filtration upstream. The SELLER shall not include any system filtration or strainers.

3.4.7 Design for Equipment Installation

The installation location within ETF requires the equipment to travel through an overhead door

with the clearance dimensions of 12-ft in height and 10-ft in width. Ensure each piece of

equipment can travel through this opening, including the necessary dimensions for applicable

rigging. If a piece of equipment needs to be disassembled due to this clearance requirement, the

disassembly shall occur prior to shipping. Include instructions, diagrams, and tooling necessary

for reassembly of the applicable equipment.

The SELLER shall provide drawings of the equipment footprint, including necessary

maintenance clearances for equipment assemblies.

It is the SELLER’s responsibility to design lifting points of equipment. If designed for lifting

via a forklift, ensure the equipment center of gravity for the lift is such that the resulting load

center is less than 4,000 lbs rated capacity at 24 inches load center (Hyster 40HSD3 or similar).

All equipment assemblies will be anchored to the ETF concrete floor in lieu of upon a built-up

concrete equipment pad. The SELLER shall provide boiler package assembly/skid weights and

center of gravity for BUYER to determine base anchorage requirements. All SELLER

equipment assembly frames/skids shall provide a minimum 6-in clearance from floor to bottom

of equipment to accommodate facility leak detection. This clearance applies to all equipment;

including piping, tanks, vessels, pumps, instrumentation and wiring.

Frames/Skids to provide locations for bolting connection of strut systems provided by the

BUYER for support of conduits and junction boxes as shown on Electrical drawings.

3.4.8 Labeling

Label all equipment, instrumentation, valves, and piping in accordance to the P&ID H-2-839043

and H-2-839044, using the same designations or abbreviations as on the Drawing. Pipe markers

shall conform to ASME A13.1 and TFC-ENG-STD-12. Include arrows indicating flow

direction.

In compliance with TFC-ENG-STD-12 ensure each piece of equipment is labeled with the full

identification number as depicted on P&IDs H-2-839043 and H-2-839044. This includes, but

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not limited to, piping, valves, tanks, pumps, motors, instruments and gauges, and electrical

equipment.

Temporary equipment utilized for testing purposes only does not need to comply with

TFC-ENG-STD-12, but does need to have a unique identifier to aid in control of testing

configuration and must be removed upon completion of test(s). Integration of Equipment

Identification Numbers (EINs) into the TOC database (SmartPlant Foundation) will be

coordinated by the BUYER and is not the responsibility of the SELLER.

3.4.9 Nameplates and Product Marketing

Each Boiler shall have a legibly marked nameplate permanently attached in accordance with

ASME B&PVC, Section I.

a. The nameplate shall be 300 Series stainless steel and shall be seal welded to a 300 Series stainless steel nameplate bracket.

b. The Boilers shall be Code stamped in accordance with ASME B&PVC, Section I.

A supplemental nameplate shall be provided in order to accommodate BUYER required

information in addition to Code information. The two boilers, deaerator, and the blowdown

separator tank shall each be labeled with the full identification number as depicted below and on

H-2-839043 and H-2-839044, with the additional information as follows:

a. Manufacturer b. Date of manufacture c. BUYER’s purchase order number d. BUYER’S specification number and revision e. Serial identification number f. Equipment Identification Number (EIN) as applicable: (see P&ID H-2-839043 and

H-2-839044)

1. 65A-B-002

2. 65A-B-003

3. 65A-TK-003

4. 65A-TK-004

3.4.10 Human Factors Engineering

The SELLER shall design the equipment for ease of operation and access for maintenance.

3.5 SYSTEM RELIABILITY AND MAINTAINABILITY REQUIREMENTS

This section specifies reliability and maintainability requirements.

3.5.1 Reliability

The Boiler system shall be designed for continuous operation for more than 30 years, with the

exception of consumable and easily replaceable materials.

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3.5.2 Maintainability

Critical equipment, instrumentation or high maintenance items shall be accessible for ease of

inspection and removal or replacement.

a. The system shall be designed to facilitate maintenance with commercially available tools wherever possible.

b. The SELLER shall furnish all special tools unique to the SELLER’s equipment that are necessary for installation, start-up, operation, maintenance, and adjustment of the

equipment and accessories furnished by the SELLER.

c. The SELLER is to supply spare parts if they require special tooling. SELLER is to recommend spare parts as part of submittal based on the design life per QA-AVS B82.

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4.0 FABRICATION REQUIREMENTS

The fabrication includes equipment procurement, component fabrication, assembly, and

fabrication inspection. The SELLER shall be responsible for the manpower, facilities and

equipment to complete purchasing, fabrication, assembly, and delivery of the equipment. The

SELLER shall also manage the fabrication activities, which include creating and maintaining

production schedule. The SELLER shall provide all special tools and calibrated equipment

necessary for assembly, operation, and maintenance.

4.1 WELDING REQUIREMENTS

Welding qualifications shall be in accordance with applicable fabrication standards or as

specified by the BUYER. ASME B&PVC Section IX, “Welding and Brazing Qualifications,”

may be used in lieu of these requirements. Weld size and type shall be selected by the Moisture

Separator manufacturer based on applicable loads and system pressure requirements established

within this Specification and must meet all applicable codes. The SELLER shall adhere to

welding requirements documented in TFC-ENG-STD-52.

Special care shall be taken to limit contamination of stainless steel components with halides,

which are common to adhesive products. When specified, stainless steel components shall be

cleaned with neutral detergent and water. Equipment shall have a name plate permanently

attached to the top or side of the case.

All weld joints and seams along the pressure boundaries shall be 100 percent continuously

welded. Weld joints and seams shall be wire brushed or buffed after final Nondestructive

Examination (NDE) and inspections as required to remove heat discoloration, oxidation, all

burrs, and sharp edges. For stainless steel material, the wire brush shall not be made of carbon

steel elements or a stainless brush previously used on carbon steel.

4.1.1 Structural Welding

All structural welding shall meet the requirements of the following codes as applicable and all

welds will be visually inspected per statically loaded American Welding Society (AWS) criteria:

• AWS D1.1/D1.1M, “Structural Welding Code – Steel,” for structural carbon steel

• AWS D1.3/D1.3M, “Structural Welding Code – Sheet Steel,” for sheet steel.

• AWS D1.6/D1.6M, “Structural Welding Code – Stainless Steel,” for structural

stainless steel and stainless steel to carbon steel

4.1.2 Weld Materials

All welding filler metals and fluxes used in the fabrication and repair of components shall be in

accordance with the requirements of ASME B&PVC, Sect. II, Part C, “Specifications for

Welding Rods, Electrodes, and Filler Metals” and/or AWS B2.1/B2.1MBMG, “Base Metal

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Grouping for Welding Procedure and Performance Qualification.” Legible CMTRs for all weld

materials shall be submitted to the BUYER.

4.1.3 Welding Procedures and Qualifications

All welding procedures shall meet the requirements set forth in the applicable fabrication code.

SELLER shall prepare written Welding Procedures. Welding procedures and performance

qualification shall be in accordance with the codes listed in Section 2.0.

SELLER shall submit copies of all Welding Procedures, Procedure Qualification Records, and

Welder Procedure Qualification Records (WPQRs) to be employed in the performance of this

Specification. SELLER shall provide records to indicate that welder/operator is qualified.

The SELLER’s quality control procedures shall include the requirement that no welders shall

have in their possession more than one type of filler metal at any one time, an exception is that

welders may have both bare wire and covered electrodes that deposit weld metal of the same A-

number class. The SELLER’s filler metal control procedure shall be submitted and approved.

All welding performed by the housing manufacturer shall be based on published consensus

standards, such as AWS D1.1/D1.1M, AWS D1.3/D1.3M, AWS D1.6/D1.6M,

AWS D9.1/D9.1M, ASME B&PV Code, Section IX.

Welder Performance Qualification Records shall be submitted for all personnel performing

welding, including tacking. Welders shall be qualified in accordance with the applicable

fabrication code.

4.1.4 Weld Inspection Requirements

a. Personnel performing visual weld inspections shall be a Certified Welding Inspector (CWI) (Minimum Level II) in accordance with the requirements specified in AWS QC1,

“Standard for AWS Certification of Welding Inspectors.” The following documentation

shall be submitted prior to the start of fabrication per QA-AVS B25:

b. Welds shall meet the visual acceptance criteria of codes listed in Section 2.0. c. NDE processes required within this purchase order shall require review and approval of

SELLER:

1. Personnel certification procedure,

2. The NDE operational procedures, and

3. Personnel certifications including current and valid visual acuity examination (< 1

year old). The examination must be performed annually by a certified medical

professional.

d. Per QA-AVS B31, the personnel certification procedure and certification package for NDE personnel shall accurately reflect the requirements embodied in the applicable issue

of ASNT SNT-TC-1A, “Standard Topical Outlines for Qualification of Nondestructive

Testing Personnel,” plus any other requirements of the SELLER.

e. The NDE operational procedures shall contain all applicable requirements of the documentation referenced in the purchase order including:

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1. Reference standard or image quality indicator information,

2. Chemical purity requirements per QA-AVS B46,

3. Calibration requirements per QA-AVS B58 and B61, and

4. Report forms, as a minimum per QA-AVS B52.

f. Data packages and changes thereto shall be submitted to the BUYER as identified in the purchase order.

g. Personnel performing NDE (Radiographical, Penetrant, Ultrasonic, Eddy Current, Leak, or Magnetic Particle Testing) shall be qualified/certified to ASNT SNT-TC-1A

(Minimum Level II) as identified in the codes listed in Section 2.0. The recommended

practices in ASNT SNT-TC-1A are mandatory requirements for this purchase order per

QA-AVS B31

h. The SELLER will maintain and submit weld history data for each weld per QA-AVS B13.

4.1.5 Additional Welding Requirements

a. All tools used for stainless steel shall be kept separate from any tools previously used or currently being used for cleaning carbon steel components. Tools for stainless steel shall

be used only on stainless steel surfaces. Similarly, appropriate controls shall be put into

place to ensure ferrous and non-ferrous material is properly segregated and that tools

specifically used on non-ferrous material be designated.

b. All areas from which temporary attachments have been removed shall be examined by the liquid penetrant method or magnetic particle method, as applicable, after the surface

has been restored.

c. Preparation for welds shall be by non-thermal methods where practical. d. Thermally cut surfaces shall be ground to provide slag-free metal and fit-up equivalent to

machining.

e. Where welding destroys protective plating on hardware items, the weld and surrounding area shall be thoroughly cleaned, primed, and painted as appropriate.

f. Where free iron contamination (shows up as rust streaks on stainless steel) is observed, the surface area shall be cleaned prior to welding.

g. All external supports, support rings, pads, and structural brackets attached to the vessel shall be seal-welded all around to prevent corrosion between the vessel and attachments.

h. All main seam welds (Category A and B joints) shall be full penetration and, where possible, double sided.

i. All nozzle-to-shell or head welds (Category D joints) shall be full penetration.

4.1.6 Workmanship

Acceptable workmanship shall be based on satisfactory completion of all specified fabrication

inspections.

4.2 CLEANLINESS

All cleaning shall be in accordance with the codes listed in Section 2.0. Before assembly, all

parts shall be clean to the extent that extraneous materials are not present:

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• Combustible dust (shop dust), chips, and turnings,

• Abrasive particles,

• Rust and other loose corrosion products,

• Magnetic/liquid penetrant residues, dye check, etc.

• Foreign material, such as paper, plastic, and wood,

• Cutting oils.

• Excess lubrication grease and oil.

• Marking dyes.

• Adhesives.

4.2.1 Material Contamination Control

a. Machining or grinding of stainless steel shall be done with tools that have never come in contact with materials other than stainless steel.

b. Material-handling devices used for machining, positioning, supporting, welding, etc., which come in contact with stainless steel, shall be made of stainless steel. If carbon

steel contamination is evident, the surface shall be ground, and the test shall be repeated

until the contamination is removed. This procedure shall be available at the SELLER’s

facility for the BUYER's review.

c. When forming stainless plate, care shall be taken to prevent carbon pickup or contamination of formed material.

4.2.2 Surfaces

a. All wetted surfaces shall be free of features that entrap solids. Sharp burrs or edges resulting from cutting or machining operations shall be rounded or ground smooth.

b. All nicks and gouges less than or equal to 0.012-in. deep may be removed by blend grinding. All nicks and gouges greater than 0.012-in. deep shall be filled with weld metal

and ground smooth.

c. If a thermal cutting process is used, the cut surface shall be ground smooth or machined to remove all adhering slag, gouges, and discoloration to produce a bright clean surface.

4.2.3 Cleaning

a. The equipment shall be delivered to the Site clean and free of any oils, tape adhesives, weld splatter, dirt, loose debris, and other contaminants.

b. Solvents and cleaning solutions used on stainless steels shall not exceed 50 ppm for chlorides.

c. Mechanical cleaning tools used on stainless steel shall not have been previously used on carbon steel or any other materials that would contaminate stainless steel surfaces.

1. Wire brushes used for cleaning stainless steel shall be stainless steel and free of

dirt and grease and either new or only previously used on stainless steel or nickel

alloys shall be used to clean between passes and on completed welds.

2. Grinding wheels used for cleaning shall be stainless steel, new or previously used

only on austenitic stainless steel or nickel alloys.

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4.3 LIFTING ATTACHMENTS

a. The welding of equipment lifting attachments, lifting lugs, or bails shall be performed in accordance with AWS D14.1.

b. Lifting attachment design shall consider the entire Boiler weight.

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5.0 PRODUCTION INSPECTION AND TESTING REQUIREMENTS

The entire Boiler assemblies shall be inspected and tested in accordance with the codes listed in

Section 2.0, or BUYER approved equivalent:

a. Test procedures, examinations, and inspections shall be certified and documented, and submitted for review and approval.

b. The BUYER reserves the right to witness any testing.

5.1 QUALIFICATIONS TESTING REQUIREMENTS

The results of inspections shall be documented and submitted to the BUYER for review and

approval before acceptance.

5.2 INSPECTION

The SELLER shall develop a fabrication, inspection, and test (FIT) plan that sequences the

fabrication operations and denotes the SELLER’s inspection and test points. The FIT plan shall

be reviewed and approved by the BUYER prior to the start of fabrication. At the time of the

review of the FIT plan, the BUYER shall specify all applicable witness and hold points.

The BUYER reserves the right to witness all test and inspections identified in the FIT plan and

shall be given a minimum of ten (10) working days written notice prior to each test or inspection

date. It should be noted that third party inspectors may be required to be required to be present

during testing/inspections as the representative for the BUYER or an independent representative

for the BUYER’s stakeholders.

Prior to the performance of tests/inspections, the SELLER shall submit a procedure for each test

to the BUYER for review and approval. Test/inspection information recorded or calculated shall

be documented and submitted to the BUYER.

5.2.1 General

a. The responsibility for inspection rests with the SELLER and shall be in accordance with Paragraph PG-90 of ASME Section I and this Specification.

b. Prior to final inspection, the inside and outside of the vessel shall be thoroughly cleaned and shall be free from all slag, scale, dirt, grit, weld splatter and pieces of metal, paint,

oil, etc. All welds shall be free of slag, oil, grease, paint and other foreign substances

which might prevent proper interpretation of the required tests.

c. The SELLER retains overall responsibility for ensuring, either directly or through sub-suppliers, that the inspections necessary for conformance to the purchase specifications

are conducted. The performance of quality surveillance by the BUYER’s representative

does not relieve the SELLER or sub-suppliers of responsibility for meeting the

specification requirements.

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5.2.2 Structural

Structural-related items shall be visually inspected in accordance with AWS D1.1/D1.6.

Acceptance criteria of welds shall be in accordance with requirements for statically loaded

structures in accordance with AWS D1.1/D1.6.

5.2.3 Lifting Attachments

Attachment welds as part of lifting lugs or bails, and welds on below-the-hook lifting devices

shall be visually examined in accordance with AWS D14.1, Paragraph 8.6. In addition, perform

either: 1) radiographic examination accordance with AWS D14.1, Paragraph 8.9, or 2) ultrasonic

examination and magnetic particle examination in accordance with AWS D14.1, Paragraphs 8.13

and 8.16, respectively. Document examinations.

5.3 TESTING

5.3.1 Hydrostatic Test

5.3.1.1 General

a. Prior to the performance of testing, the SELLER shall submit the test procedures to the BUYER for approval. The test procedures shall describe the method and set-up,

including instrumentation for the tests including acceptance criteria.

b. All equipment shall be pressure tested after fabrication and prior to shipment. Use design pressure specified within Section 3.0 as derivation for test pressure. Derive test pressure

and perform hydrostatic tests in accordance with Paragraph PG-99 of ASME Section I

and ASME B31.1 and ASME B31.3 as applicable, and in the presence of the Inspector.

Ensure a pressure relieving device is included for hydrostatic testing in accordance with

the above applicable codes.

c. The gaskets, and bolting, used on all flanged connections during pressure testing shall be identical to those for operation.

d. All welds shall be cleaned and free of scale prior to hydrostatic testing to permit proper examination for defects.

e. Water shall be used for the hydrostatic testing fluid. Water shall be tested for chlorides. The chloride content of the test medium shall not exceed 20 ppm (by mass) for water

temperatures of < 149°F.

f. After completion of the hydrostatic test, the vessel shall be drained, dried, and closed as quickly as practicable.

5.3.2 System Function Test

Key design features of the Boiler System equipment must be verified by acceptance testing by

completion of a factory acceptance test before it is packaged and shipped. Factory testing shall

be defined by the Boiler vendor and detailed in the FIT plan, including acceptance testing.

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5.4 ELECTRICAL INSPECTION

The Boiler units and pumps and controls shall be inspected by a certified electrical inspector to

assure NEC cod