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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-63856 Rev. 00
2. Title:Procurement Specification - Condensers for ETF Steam Strippers
3. Project Number:OP185
☐N/A 4. Design Verification Required:
☐Yes ☒No
5. USQ Number: ☒ N/ARPP-27195
6. PrHA Number Rev. ☒ N/A
Clearance Review Restriction Type:undefined
7. Approvals
Title Name Signature DateDesign Authority Melvin, Max AChecker Hall, Richard B Hall, Richard B 12/10/2020Environmental Protection Beam, TomEngineering Discipline Lead-Civil/Structural Mackey, TomEngineering Discipline Lead-Electrical Rambo, Charles LEngineering Discipline Lead-Mechanical Goessmann, Glen EEngineering Discipline Lead-Ventilation Khabir, SharokOriginator Quam, Paul R Quam, Paul R 12/10/2020Other Approver Young, Natalie MOther Approver Russell, Rose MOther Approver Marks, JeffOther Approver Thompson, Tyler JResponsible Engineering Manager Lehrman, Scott DWelding Engineer Berkey, James
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 ETF-60K 60K-CND-00160K-CND-201
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. TitleRPP-SPEC-64264 00 Procurement Specification - Pump Skids for ETF Steam Stripper
14. Distribution
Name OrganizationBeam, Tom ENVIRONMENTAL PROTECTIONCassinelli, Andrew T COMMISSIONINGCorbett, John E COMMISSIONINGDomnoske, Lisa A ETF ENGINEERINGFilip, 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 ENGINEERINGSeverson, Brian D ETF PROJECTS ENGINEERINGThompson, Tyler J PROCUREMENT QAYarger, David J ETF ENGINEERING
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DOCUMENT RELEASE AND CHANGE FORM Doc No: RPP-SPEC-63856 Rev. 00
2 SPF-001 (Rev.D1)
14. Distribution
Name OrganizationYoung, Natalie M ETF PROJECTS ENGINEERING
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Procurement Specification - Condensersfor ETF Steam Strippers
Prepared by
P.R. QuamSargent & Lundy for Washington River Protection Solutions, LLC
Date PublishedDecember 2020
11s1r?D1i!.'r.JNh1(.1lJ
Prepared for the U.S. Department of EnergyOffice of River Protection
Contract No. DE-AC27-08RV14800
B. -
siI/ 1<
o
A-6007-23 1 (REV-O)
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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............................................................................................ 2-14
3.0 STRUCTURES, SYSTEMS, AND COMPONENTS CHARACTERISTICS AND
REQUIREMENTS ..................................................................................................................... 3-15
3.1 STRUCTURES, SYSTEMS, AND COMPONENTS FUNCTIONS AND
FUNCTIONAL PERFORMANCE REQUIREMENTS ........................................................ 3-15
3.1.1 Mechanical Design............................................................................................... 3-15
3.1.2 Nozzles and Reinforcing Pads ............................................................................. 3-15
3.1.3 Shells and Shell Covers ....................................................................................... 3-16
3.1.4 Tubes, Tubesheets, and Tube End Fixing ............................................................ 3-16
3.1.5 Handling Devices ................................................................................................. 3-16
3.1.6 Shell Supports and Attachments .......................................................................... 3-16
3.1.7 Work Not Included .............................................................................................. 3-17
3.2 STRUCTURES, SYSTEMS, AND COMPONENTS INTERFACES ....................... 3-17
3.2.1 External Interfaces ............................................................................................... 3-17
3.2.2 Piping Interface .................................................................................................... 3-18
3.3 STRUCTURES, SYSTEMS, AND COMPONENTS CHARACTERISTICS ........... 3-18
3.3.1 Functional Characteristics .................................................................................... 3-18
3.3.1.1 Design Pressure ............................................................................................ 3-18
3.3.1.2 Design Temperature ..................................................................................... 3-18
3.3.1.3 Corrosion Allowance .................................................................................... 3-18
3.3.1.4 System Design Life ...................................................................................... 3-18
3.3.1.5 Performance Requirements........................................................................... 3-18
3.3.1.6 Environmental Conditions ............................................................................ 3-19
3.3.1.7 Design Loads ................................................................................................ 3-19
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3.3.2 Packaging, Storage, Shipping, and Handling ....................................................... 3-19
3.3.2.1 Transportability and Storage ........................................................................ 3-20
3.3.2.2 Hoisting and Rigging .................................................................................... 3-20
3.3.2.3 Equipment Handling ..................................................................................... 3-20
3.4 DESIGN AND CONSTRUCTION REQUIREMENTS ............................................. 3-20
3.4.1 Materials .............................................................................................................. 3-20
3.4.2 Bolting.................................................................................................................. 3-21
3.4.3 Welding ................................................................................................................ 3-22
3.4.4 Gaskets ................................................................................................................. 3-22
3.4.5 Nameplates and Product Marketing ..................................................................... 3-22
3.4.6 Human Factors Engineering ................................................................................ 3-22
3.5 SYSTEM RELIABILITY AND MAINTAINABILITY REQUIREMENTS ............ 3-22
3.5.1 Reliability ............................................................................................................. 3-23
3.5.2 Maintainability ..................................................................................................... 3-23
4.0 FABRICATION REQUIREMENTS ............................................................................. 4-24
4.1 WELDING REQUIREMENTS .................................................................................. 4-24
4.1.1 Structural Welding ............................................................................................... 4-24
4.1.2 Weld Materials ..................................................................................................... 4-24
4.1.3 Welding Procedures and Qualifications............................................................... 4-25
4.1.4 Weld Inspection Requirements ............................................................................ 4-25
4.1.5 Additional Welding Requirements ...................................................................... 4-26
4.2 WORKMANSHIP ....................................................................................................... 4-26
4.3 CLEANLINESS .......................................................................................................... 4-26
4.3.1 Material Contamination Control .......................................................................... 4-27
4.3.2 Surfaces ................................................................................................................ 4-27
4.3.3 Cleaning ............................................................................................................... 4-27
4.4 TOLERANCES ........................................................................................................... 4-28
4.5 PLATE LAYOUT AND FORMING .......................................................................... 4-28
4.6 LIFTING ATTACHMENTS....................................................................................... 4-28
4.7 TUBES-TO-TUBESHEET JOINTS ........................................................................... 4-28
5.0 PRODUCTION INSPECTION AND TESTING REQUIREMENTS .......................... 5-29
5.1 QUALIFICATIONS TESTING REQUIREMENTS .................................................. 5-29
5.2 INSPECTION.............................................................................................................. 5-29
5.2.1 General ................................................................................................................. 5-29
5.3 EXAMINATION ........................................................................................................ 5-30
5.3.1 Condenser ............................................................................................................ 5-30
5.3.2 Structural .............................................................................................................. 5-30
5.3.3 Lifting Attachments ............................................................................................. 5-30
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5.4 TESTING .................................................................................................................... 5-30
5.4.1 General ................................................................................................................. 5-30
6.0 DELIVERY, STORAGE, AND HANDLING .............................................................. 6-32
6.1 DELIVERY, STORAGE, & LOAD HANDLING ..................................................... 6-32
6.1.1 General ................................................................................................................. 6-32
6.1.2 Transportability .................................................................................................... 6-32
6.1.3 Packaging ............................................................................................................. 6-32
6.1.3.1 Levels of Packaging ...................................................................................... 6-32
6.1.3.2 Cleaning Plan ................................................................................................ 6-33
6.1.3.3 Cleaning Records .......................................................................................... 6-33
6.1.3.4 Packaging Type ............................................................................................ 6-33
6.1.3.5 Packaging Materials ..................................................................................... 6-33
6.1.3.6 Packaging Materials Contacting Stainless Steel and Nickel Alloy .............. 6-33
6.1.3.7 Seal Openings ............................................................................................... 6-34
6.1.3.8 Protection from Corrosion ............................................................................ 6-34
6.1.3.9 Unprotected Steel ......................................................................................... 6-34
6.1.3.10 Shipment Load Protection ............................................................................ 6-34
6.1.3.11 Protection from Shock and Vibration ........................................................... 6-34
6.1.3.12 Other Protection ............................................................................................ 6-34
6.1.3.13 Protection of Machined Surfaces .................................................................. 6-35
6.1.3.14 Packaging Inspection .................................................................................... 6-35
6.1.4 Handling ............................................................................................................... 6-35
6.1.4.1 Lift and Rigging Plan ................................................................................... 6-35
6.1.4.2 Lift Point Marking ........................................................................................ 6-35
6.1.4.3 Rated Temperature for Custom Lifting Devices .......................................... 6-35
6.1.4.4 Contact with Different Metals ...................................................................... 6-35
6.1.4.5 Critical Welds ............................................................................................... 6-35
6.1.4.6 Shipping and Handling Drawing .................................................................. 6-35
6.1.4.7 Unpacking and Assembly Drawing .............................................................. 6-36
6.1.4.8 Special Lifting Devices ................................................................................ 6-36
6.1.4.9 Below-the-Hook Device Marking ................................................................ 6-36
6.1.4.10 Offloading ..................................................................................................... 6-36
6.1.5 Storage ................................................................................................................. 6-36
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6.1.5.1 Level of Storage ............................................................................................ 6-36
6.1.5.2 Storage Areas ................................................................................................ 6-37
6.1.5.3 Storage Methods ........................................................................................... 6-37
6.1.5.4 Control of Items in Storage .......................................................................... 6-37
6.1.5.4.1 Inspections ................................................................................................ 6-38
6.1.5.4.2 Care of Items ............................................................................................ 6-38
6.1.5.4.3 Post-Fire Evaluations ............................................................................... 6-38
6.1.5.5 Removal of Items from Storage.................................................................... 6-38
6.1.5.6 Storage Records ............................................................................................ 6-39
6.1.5.7 Additional Storage Requirements ................................................................. 6-39
6.1.5.8 Environmental Storage Requirements .......................................................... 6-39
6.1.6 Delivery................................................................................................................ 6-39
6.1.7 Marking for Shipment .......................................................................................... 6-39
6.2 QUALITY ASSURANCE .......................................................................................... 6-40
6.3 SITE CONDITIONS ................................................................................................... 6-40
7.0 PROJECT MANAGEMENT ......................................................................................... 7-41
7.1 WORK PLAN ............................................................................................................. 7-41
7.2 SUBMITTALS ............................................................................................................ 7-41
7.2.1 Submittals Required with Proposal ...................................................................... 7-41
7.2.2 Submittals Required After Receipt of Order ....................................................... 7-42
7.2.3 Submittals Required Prior to Fabrication ............................................................ 7-42
7.2.4 Submittals Required Prior to Shipping ................................................................ 7-43
7.2.5 Request for Information ....................................................................................... 7-45
7.3 QUALITY ASSURANCE PROGRAM ..................................................................... 7-45
7.3.1 Non-Conformance Reports .................................................................................. 7-46
7.3.2 Inspection/Examination ....................................................................................... 7-46
7.3.3 Suspect/Counterfeit Items .................................................................................... 7-46
7.3.4 Certificate of Conformance.................................................................................. 7-46
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APPENDICES
Appendix A ………………………………………………………..Heat Exchanger Data Sheets
Appendix B ………………………………………………………… Large Condenser Drawing
Appendix C ………………………………………………………… Small Condenser Drawing
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 pages). .............................. 2-13 Table 7-1. Submittals Required with Proposal. ........................................................................ 7-41
Table 7-2. Submittals Required After Receipt of Order. .......................................................... 7-42 Table 7-3. Submittals Required Prior to Fabrication (2 Pages). ............................................... 7-42 Table 7-4. Submittals Required Prior to Shipping (2 pages). ................................................... 7-44
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1.0 SCOPE
This Procurement Specification (hereafter referred to as Specification) provides baseline
requirements for design and procurement of two (2) Condensers (one large and one small), shell
and tube style, for the Effluent Treatment Facility (ETF) Steam Strippers. This Specification
establishes the functions, interfaces, function performance requirements, applicable codes and
standards, and requirements for the thermal design, mechanical design, materials, fabrication,
assembly, inspecting, testing, quality oversight, documentation, packaging, transportation, and
delivery of the two Condensers for the ETF Steam Strippers. The Condensers shall be shell and
tube heat exchangers constructed in accordance with Section VIII, Division 1 of the American
Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (B&PVC) (hereafter
simply referred to as the Code) including stamping with the Code “U” symbol.
1.1 DESCRIPTION
Washington River Protection Solutions, LLC (WRPS), is the U.S. Department of Energy (DOE),
Office of River Protection (ORP) Tank Farm Operations 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 two Condensers for the ETF Steam Strippers. The functions
of the Condensers are to condense all of the acetonitrile containing distillate from the top of the
Steam Stripper and Steam Concentrator.
The two shell and tube Condensers procured by this specification are different sizes and are
specified in detail herein. The first and larger Condenser, 60K-CND-001, will be installed to
condense acetonitrile containing water following its removal from the main Steam Stripper
Column, 60K-CO-001, as shown on H-2-839035. The second and smaller Condenser, 60K-
CND-201, will be installed to condense concentrated acetonitrile containing water following its
removal from the Concentrator Column, 60K-CO-201, as shown on H-2-839038. See Appendix
A, Appendix B, and Appendix C for further details differentiating the two Condensers, including
the Condenser data sheets.
1.2 DOCUMENT OVERVIEW
This Specification is a "design-build" specification, delineating the required functions and
requirements to which the VENDOR (SELLER) shall adhere to 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 3.1.7.
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.
• RATED LOAD – The maximum load that can be lifted by the device.
• 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 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
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defense nuclear materials, are stored in 177 underground storage tanks. The tanks contain an
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.
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 (2 Sheets)
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
DOE Department of Energy
ETF Effluent Treatment Facility
FIT Fabrication, Inspection, and Test
NDE Non-Destructive Examination
ORP Office of River Protection
PSSH Packaging, Storage, Shipping, and Load Handling
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QA Quality Assurance
QAP Quality Assurance Program
RFI Request for Information
RPP River Protection project
SSC Structures, Systems, and Components
TOC Tank Farm operations Contractor
WRPS Washington River Protection Solutions, LLC.
1.6 UNITS
°F degrees Fahrenheit
ft feet
gpm gallons per minute
hr hour
in. inch
kW kilowatt
psi Pound-force per square inch
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 [SSCs]) 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 design of the item 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 through Table 2-3 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 through Table 2-3, 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”
WAC 173-303 “Dangerous Waste”
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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
Condensers. Unless otherwise shown or noted, the latest edition and addenda are applicable.
Table 2-2. Non-Government Documents (2 pages).
Document Number Title
American Society of Civil Engineers (ASCE)
ASCE 7-10 “Minimum Design Loads for Buildings and Other Structures”
American Institute of Steel Construction (AISC)
AISC 325 “Steel Construction Manual”
American Petroleum Institute
API 660 “Shell and Tube Heat Exchangers”
American Society of Mechanical Engineers (ASME)
Required Code year at
time of contract
ASME Boiler and Pressure Vessel Code (B&PVC)
ASME Section II “Materials”
ASME Section V “Nondestructive Examination”
ASME Section VIII, Division 1 “Pressure Vessels”
ASME Section IX “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 B31.3, 2016 “Process Piping”
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 D1.6/D1.6M “Structural Welding Code – Stainless Steel”
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”
Tubular Exchanger Manufacturers Association (TEMA)
TEMA - 2007 Standards of the Tubular Exchanger Manufacturers Association
(TEMA)
Other
L.P. Zick Method Stresses in Large Cylindrical pressure Vessels on Two Saddle
Supports, L.P. Zick, Pressure Vessels and Piping: Design and
Analysis, A Decade of Progress, Vol. 2, 1972
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.
Table 2-3. Non-Government Non-Code of Record Documents (2 pages).
Document Number Title
Washington River Protection Solutions, LLC (WRPS)
H-2-839035, Sheet 1 “ETF Steam Stripper P&ID Large Condenser and Pump Skid”
H-2-839038, Sheet 1 “ETF Steam Stripper P&ID Small Condenser and Pump Skid”
H-2-839039, Sheet 1 “ETF Steam Stripper P&ID Below Grade Lines”
H-2-839054, Sheet 1 “ETF Steam Stripper Mechanical Equipment Location Plan
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Table 2-3. Non-Government Non-Code of Record Documents (2 pages).
Document Number Title
MT-50529, Rev. 0 “Effluent Treatment Facility Acetonitrile Steam Stripping
System”
QA-AVS-APPENDIX “Procurement Quality Clauses”
RPP-8360, Rev. 6 “Lifting Attachment and Lifted Item Evaluation”
RPP-SPEC-64264 “Procurement Specification – Pump Skids for the ETF Steam
Stripper”
TFC-BSM-IRM_DC-C-02 “Records Management”
TFC-BSM-IRM_DC-C-07 “Vendor Processes”
TFC-ENG-DESIGN-C-10 “Calculation Format and Preparation Instructions"
TFC-ENG-DESIGN-C-57 “Development and Maintenance of Code of Record”
TFC-ENG-FACSUP-C-25 “Hoisting and Rigging”
TFC-ENG-STD-06 “Design Loads for Tank Farm Facilities”
TFC-ENG-STD-52 “Subcontractor Welding Standard”
TFC-ESHQ-Q_C-C-03 “Control of Suspect/Counterfeit Items”
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 STRUCTURES, SYSTEMS, AND COMPONENTS CHARACTERISTICS AND
REQUIREMENTS
This section addresses the following Structures, Systems, and Components (SSC) characteristics
and requirements:
• SSC functions and functional 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 construction requirements are covered in Section 3.4, and
• Reliability and maintainability requirements are covered in Section 3.5.
3.1 STRUCTURES, SYSTEMS, AND COMPONENTS FUNCTIONS AND
FUNCTIONAL PERFORMANCE REQUIREMENTS
3.1.1 Mechanical Design
a. The Condensers shall be designed and fabricated in accordance with ASME Boiler and
Pressure Vessel Code (B&PVC) Section VIII, Division 1 and Tubular Exchanger
Manufacturers Association (TEMA), TEMA Class B and any additional requirements of
this Specification and the referenced Drawings. Condensers shall be ASME U stamped
and a completed, signed and registered Form U-1 shall be provided for each condenser.
b. Components subject to both shell and tube side fluids (e.g., tubes, tube sheets, floating
heads) shall be designed for the most severe combination of pressure and temperature
that can apply.
c. The Condensers shall meet the requirements of the Heat Exchanger Data Sheet (see
Appendix A).
d. To provide operational margin. As noted in the remarks of both data sheets within
Appendix A, the SELLER is to design for a 20% excess area not counting U-portion of
the tubes.
e. Cooling water temperature rise shall be no more than 10 °F from inlet to outlet.
f. Manufacturer shall demonstrate successful installation for similar equipment that has
been in operation for at least 5 years.
3.1.2 Nozzles and Reinforcing Pads
a. All nozzles shall be set-in type or through type with full penetration welds. Nozzles with
internal projection shall have an additional fillet weld between the internal projection and
the inside surface of the shell or head.
b. All inside nozzle neck edges shall be rounded to 1/8 in. minimum radius. Nozzles shall
be flush with the inside wall.
c. Nozzles shall not be located on weld seams.
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d. All connections shall be 3000# NPT, or Class 150 or Class 300 raised face, weld neck
flanges as depicted in Appendix A, Appendix B, and Appendix C in accordance with
ASME B16.11 and B16.5 (including vent and drain connections).
e. If required, nozzle reinforcing pads shall be external and, when constructed in segments,
shall have the segments joined with full penetration butt welds, the location of which
shall be at least 45 degrees from the longitudinal axis of the vessel. Each pad segment
shall have one American Standard Taper Pipe Thread (NPT) 1/4-in. tell-tale hole for
testing purposes.
f. Nozzle reinforcing pads and all attachment pads, if not circular, shall have rounded
corners of 2-in. minimum radius.
g. Length of nozzle projections shall provide a minimum clearance between the back of the
flange and the outside of the vessel insulation equal to the length of the flange bolts
(studs) plus 1 in.
h. Allowable nozzle forces shall be per API 660 Table 2.
3.1.3 Shells and Shell Covers
a. The shell diameter shall be left to the discretion of the SELLER within the TEMA
Class B Mechanical Standards.
b. The minimum shell thickness shall be determined by the Code design formulas, including
corrosion allowance, but in no case shall the nominal thickness of the shell be less than
shown in TEMA Class B.
3.1.4 Tubes, Tubesheets, and Tube End Fixing
a. Tubing shall be seamless.
b. Each U-tube shall be formed from a single length and shall have no circumferential
welds.
c. Total leak tightness is required for this service; therefore, tube-to-tubesheet joint shall be
strength-welded.
3.1.5 Handling Devices
a. Provision for lifting shall be included for all channels, bonnets, and covers.
b. For bundle pulling, tapped holes for pulling eyes shall be provided. They shall be
designed for a load of 1.5 times the bundle weight and fitted with a plug for operation.
3.1.6 Shell Supports and Attachments
a. Condenser lifting attachments (lugs) 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 Condenser lifting lugs.
b. Lifting lugs shall be a weld-on lug provided with a hole not less than 1 1/2 in. in diameter
and be designed and attached in a manner that will not damage/distort the Condensers.
c. The lug(s) shall be located at the top of the component, above its center of gravity.
d. The projection of the lug shall be designed to accommodate the thickness of the
insulation, such that placement of a shackle will not require removal of insulation.
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e. The SELLER is responsible for determining the size and quantity of anchor bolts and the
design of the support saddle for horizontal installation.
f. Horizontal Condensers shall be designed for two saddle supports attached by welding.
Design of saddle supports and calculation of localized shell stress may be determined by
the SELLER in accordance with the L.P. Zick method, or equivalent method approved
by the BUYER.
g. One of the saddles shall be designated as the fixed saddle in which holes shall be
provided to receive the anchor bolts. The other saddle shall be designated as the sliding
saddle in which slotted holes shall be provided.
h. The bearing surface of the saddles shall be at least one-third of the circumference of the
shell.
i. Grounding Lugs: A grounding lug shall be provided on each vessel.
j. External attachments shall be of the same grade of material as the pressure shell, unless
agreed otherwise by the BUYER.
3.1.7 Work Not Included
The scope of supply of the SELLER shall exclude the following:
a. Condenser off-loading at the Site
b. Installation of Condensers on BUYER skid
c. Piping to/from Condenser
d. Start-up and commissioning Site work
e. Insulation and jacketing of the Condenser
3.2 STRUCTURES, SYSTEMS, AND COMPONENTS INTERFACES
The assembled Condensers will be bolted to the structural steel skids by the BUYER (reference
RPP-SPEC-64264).
3.2.1 External Interfaces
The Condensers shall fit within the maximum footprint requirements found in Appendix B and
Appendix C. If the overall dimensional size of the Condensers or the nozzle locations differ than
as shown in Appendix B and Appendix C, then approval for deviation is required by the
BUYER. See dimensional tolerances for nozzle locations as shown in Appendix B and
Appendix C for assurance of proper fit-up during installation.
The assembled Condensers will be bolted to the structural steel skid of the BUYER. For proper
anchorage to the structural steel skid of the BUYER, the SELLER shall provide saddle supports
with anchor bolt holes as dimensioned and depicted in Appendix B and Appendix C. See
dimensional tolerances as shown in Appendix B and Appendix C for assurance of proper fit-up
during installation. The information in Section 3.3.1.7 shall be used to design the supports.
SELLER shall provide equipment weight, size, and center of gravity for BUYER to determine
anchorage requirements.
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SELLER shall provide maintenance clearances for each side of the Condensers.
3.2.2 Piping Interface
The Condenser units shall each be configured with inlet and outlet nozzles as depicted in
Appendix A. Flanges shall be two-hole oriented with the long axis of the vessel.
3.3 STRUCTURES, SYSTEMS, AND COMPONENTS CHARACTERISTICS
3.3.1 Functional Characteristics
This section provides requirements for the functional characteristics of each Condenser unit.
3.3.1.1 Design Pressure
The design pressure specified on the Condenser data sheets (see Appendix A) shall be taken to
be the top of the vessel. The pressure used in calculations shall be the design pressure plus the
static head pressure of the contents (assuming shell is full of water) making due allowance of the
specific gravity.
A pressure safety valve will be located on the piping connected to the tube side, upstream of both
Condensers as depicted in H-2-839039. The pressure safety valves will be sized, installed by
Others, and are not the responsibility of the SELLER. Note that the shell size is open to the
Steam Stripper vessels which are also protected by pressure safety valves (H-2-839034 and H-2-
839037).
3.3.1.2 Design Temperature
Design temperatures for the shell and tube sides are specified on the Condenser data sheets (see
Appendix A).
3.3.1.3 Corrosion Allowance
The corrosion allowance for internal surfaces (for the specified design life) applies to pressure
retaining parts and non-pressure parts (e.g., tray supports, clips), shall be 0.06-inch for stainless
material (0.002 mpy). The corrosion allowance is to be applied per wetted surface. .
3.3.1.4 System Design Life
Condensers will have a design life of 30 years.
3.3.1.5 Performance Requirements
The Condensers shall be capable of performing to the specifications in Appendix A.
A thermal performance and vibration report shall be provided.
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3.3.1.6 Environmental Conditions
The Condensers will be installed indoors 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 ambient temperature: 70°F
Maximum ambient temperature: 78°F
3.3.1.7 Design Loads
Design loads shall comply with TFC-ENG-STD-06.
a. Seismic
1. Natural Phenomena Design Requirements shall be in accordance with
TFC-ENG-STD-06.
2. Seismic Design Category shall be SDC-1, Limit State B, the NPH Design
Category is NDC-2.
3. Seismic Performance: Equipment shall withstand the effects of earthquake
motions determined according to TFC-ENG-STD-06.
4. 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).”
5. Component Importance Factor: 1.5.
6. An amplification factor of 3 shall be applied to account for the potential
amplification of the steel frame which each of the Condensers will sit atop. This
amplification factor is incorporated into ASCE 7-2010, Equation 13.3-1
(1+2 x z/h) with z/h being equal to 1.
b. Thermal Insulation
1. The Condensers will be insulated and jacketed by Others. The density of the
insulation and jacketing will be: 6 lb/ft³.
2. Thermal insulation and jacketing will be 2-in. thick.
3.3.2 Packaging, Storage, Shipping, and Handling
When the SELLER has requirements for packaging, storage, shipping, and load handling
(PSSH), the PSSH requirements of the SELLER must be approved by the BUYER. Otherwise,
the SELLER shall use the requirements in Section 6.1 for those specified below for the
Condensers.
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3.3.2.1 Transportability and Storage
ASME NQA-1 Part 1 Requirement 13 shall be used in PSSH of Condensers while considering
the following requirements:
a. Condensers shall be individually packed to protect from damage during shipping. A
packaging and shipping plan shall be submitted, see Section 6.1.
b. One copy of the storage procedure shall be attached to the equipment or crate at the time
of shipment. The storage procedure shall cover both short term and long term (over six
months) storage maintenance programs.
UNLESS approved by the BUYER, the SELLER shall meet the transportability and storage in
Section 6.1.
3.3.2.2 Hoisting and Rigging
UNLESS approved by the BUYER, the SELLER shall meet the hoisting and rigging
requirements in Section 6.1.
3.3.2.3 Equipment Handling
UNLESS approved by the BUYER, the SELLER shall meet the equipment handling
requirements in Section 6.0.
3.4 DESIGN AND CONSTRUCTION REQUIREMENTS
Design and assembly activities shall be conducted in accordance with the codes listed in Section
2.0, to the extent evoked by this Specification. The SELLER shall meet or exceed the structural
loads listed in Section 3.3.1.7.
3.4.1 Materials
a. Materials for Condensers shall comply with the requirements of ASME B&PVC,
Section II and VIII, and as specified on the Data Sheets in Appendix A.
b. The Condensers shall be fabricated from 300 Series stainless steel for corrosion
resistance to acetonitrile steam service.
c. 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.
d. Materials used for other parts shall be clearly identified on the Bill of Materials as to
material type and grade; however, CMTRs are not required. Materials shall be
non-asbestos, non-absorbent, and suitable for the chemical and radiation environment in
which they are used.
e. No substitutions shall be allowed unless written approval is provided by the BUYER.
f. No suspect/counterfeit materials shall be used per QA-AVS B76.
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g. Metallic parts shall be of corrosion-resistant metal, or suitably finished to resist corrosion,
except temporary connection material (e.g., connecting ductwork and condensate piping
that can be easily replaced).
h. All other materials used in construction of the Condensers shall be provided with a
Certificate of Conformance/Compliance. Certificates of Conformance/Compliance shall
be traceable to the material used in the fabrication and conform to the requirements in
Section 7.3.4.
i. When specified, only stainless steel that is labeled with a heat number traceable to a
CMTR may be used in the construction of the pressure boundary. SELLER shall verify
that the contents of the CMTR demonstrate compliance with the appropriate ASTM or
ASME material specifications.
j. When the material is subdivided, the SELLER shall transfer the heat number to the part
and remnants using a certified low corrosion marker that has less than 200 ppm total
halogens, less than 200 ppm sulfur, and less than 300 ppm total low melting metals.
SELLER shall provide traceability of the certified marker to the BUYER. This will
ensure that all parts of the original stock piece are traceable. Small parts, such as
couplings, flanges, etc., may be kept in boxes that are labeled with heat numbers. Heat
numbers may be removed from parts or covered when the parts are assembled.
k. Materials shall be free from any defects or imperfections that may affect performance as
verified through qualification and production inspection tests in Section 4.3.1. The
SELLER shall not incorporate any rebuilt or refurbished parts into this assembly.
l. Bronze, copper, lead, zinc, tin, antimony, cadmium, or other low-melting point metals,
their alloys, or materials containing such metals as their basic constituents or
molybdenum, and halogens shall not be used in direct contact with stainless steel, with
the exception or materials used by the SELLER in handling, assembly, and storage of
stainless-steel parts.
m. The SELLER shall submit to the BUYER, for review, all high-strength materials to be
incorporated, and applicable heat treatments.
n. Materials for all structural members may be selected in accordance with AISC Manual as
applicable.
o. 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.
3.4.2 Bolting
a. Unless otherwise specified, all bolting shall be ASTM A193 GR B7 studs with
ASTM A194-2H heavy hex nuts.
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
unacceptable under the terms of this Purchase Order/Contract Order.
(Ref. DOE G 414.1-3)
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3.4.3 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.
3.4.4 Gaskets
a. All elastomers used shall be approved by the BUYER. Chemical and physical properties
of the elastomers shall be suitable for the chemical and radiation 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.
3.4.5 Nameplates and Product Marketing
Each Condenser shall have a legibly marked nameplate permanently attached in accordance with
UG-116 of ASME B&PVC, Section VIII, Division 1.
a. The nameplate shall be 300 Series stainless steel and shall be seal-welded to a 300 Series
stainless steel nameplate bracket.
b. The Condensers shall be Code stamped in accordance with ASME B&PVC, Section VIII,
Division 1.
A supplemental nameplate shall be provided in order to accommodate BUYER-required
information, in addition to Code information, as follows:
a. Manufacturer
b. Date of manufacture
c. Purchase order number of the BUYER
d. Specification number and revision of the BUYER
e. Serial identification number
f. Item Number: 60K-CND-001 or 60K-CND-201, as applicable
g. Differential pressure design
h. Tube material, number, and size of tubes, Birmingham Wire Gauge (BWG) minimum or
average wall, length, and square feet of surface area
i. Minimum design metal temperature and specified vacuum service and temperature
3.4.6 Human Factors Engineering
The SELLER shall design the Condensers for ease of operation and access for maintenance.
3.5 SYSTEM RELIABILITY AND MAINTAINABILITY REQUIREMENTS
This section specifies reliability and maintainability requirements.
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3.5.1 Reliability
The Condensers shall be designed for continuous operation for more than 30 years.
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 equipment of the SELLER 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 clause
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-,,.
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% 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 D1.6/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/B2.1M-BMG, “Base Metal
Grouping for Welding Procedure and Performance Qualification”. Legible CMTRs for all weld
materials shall be submitted to the BUYER.
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4.1.3 Welding Procedures and Qualifications
All Welding Procedures and Qualification 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 to be employed in the performance of this
Specification. SELLER shall provide records to indicate that welder/operator is qualified.
The quality control procedures of the SELLER 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 filler metal control procedure of the SELLER shall be submitted and
approved.
All welding performed by the housing manufacturer shall be based on published consensus
standards, such as AWS D1.6/D1.6M and/or ASME B&PV Code, Section IX, or ASME B31.3.
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
(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
(< 1year 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:
1. Reference standard or image quality indicator information,
2. Chemical purity requirements per QA-AVS B46,
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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 (RT, PT, UT, ET, LT, AC or MT) 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.
4.2 WORKMANSHIP
Acceptable workmanship shall be based on satisfactory completion of all specified fabrication
inspections.
4.3 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, and
• Adhesives.
4.3.1 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 facility of the
SELLER for the review of the BUYER.
c. When forming stainless plate, care shall be taken to prevent carbon pickup or
contamination of formed material.
4.3.2 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.
4.3.3 Cleaning
a. The Condenser 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, free of dirt
and grease, and either new or only previously used on stainless steel or nickel
alloys, 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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4.4 TOLERANCES
a. Standard tolerances, for the external dimensions of heat exchangers and for nozzles and
support locations, shall be in accordance with TEMA Standard Figure F-1.
b. Standard tolerances for tubesheets, partitions, covers, and girth flanges shall be in
accordance with TEMA Standard Figure F-2.
4.5 PLATE LAYOUT AND FORMING
a. Shell plates shall be rolled with plate manufacturer serial and heat numbers on the outside
of the vessel. All material shall be identified with the material manufacturer heat
numbers clearly visible during all stages of fabrication and testing.
b. Saddles shall be continuously welded to the shell. Longitudinal weld seams in the shell
shall not be located within 15 degrees of the horn of the saddle, since this is a location of
high stress.
c. Vessel parts that are being joined shall be fitted, aligned, and retained in position during
the welding operation, so that the permissible tolerances are not exceeded in the
completed assembly.
d. Longitudinal seams shall be staggered. Plate layouts shall be arranged so that, to the
maximum extent possible, longitudinal and circumferential weld seams clear all nozzles,
manways, and their reinforcing pads by 2-in. minimum, measured from weld edge to
weld edge.
e. When nozzles must penetrate welds seams, or when nozzle reinforcing pads must cover
weld seams, the seam shall be ground flush and radiographically examined before
welding the nozzle. The seam shall be radiographed per Code Paragraph UW-51.
4.6 LIFTING ATTACHMENTS
a. The welding of Condenser lifting attachments, lifting lugs, or bails shall be performed in
accordance with AWS D14.1.
b. Lifting attachment design shall consider the entire Condenser weight, i.e., including tube
bundle.
4.7 TUBES-TO-TUBESHEET JOINTS
Tube holes in tube sheets shall be deburred by chamfering 1/32-in. maximum on both sides of
the tubesheet.
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5.0 PRODUCTION INSPECTION AND TESTING REQUIREMENTS
The entire Condenser 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, 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 inspection and test points of the SELLER. 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 tests and inspections identified in the FIT plan, and
shall be given a minimum of ten working days written notice prior to each test or inspection date. It
should be noted that third party inspectors may be required to be present during testing/inspections as
the representative for the BUYER or an independent representative for the stakeholders of the
BUYER.
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 UG-90 of the Code 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 that
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
representative of the BUYER does not relieve the SELLER or sub-suppliers of
responsibility for meeting the specification requirements.
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5.3 EXAMINATION
5.3.1 Condenser
a. Radiographic examination of welded joints shall be performed when required by the
Code. Spot radiography, to obtain a joint efficiency of 85%, is the minimum
requirement.
b. Radiographic examination procedures and acceptance criteria shall be in accordance with
ASME B&PVC Section V, Article 2 and Section VIII, Division 1, Paragraphs UW-11
and UW-52.
c. All radiographs taken during fabrication shall be available for examination by the
BUYER or representative of the BUYER.
5.3.2 Structural
Structural-related items shall be visually inspected in accordance with AWS D1.6/D1.6M.
Acceptance criteria of welds shall be in accordance with requirements for statically loaded
structures in accordance with AWS D1.6/D1.6M, Section 6.29.
5.3.3 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 in 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.
5.4 TESTING
5.4.1 General
a. The BUYER reserves the right to witness all tests and shall be given a minimum of ten
working days written notice prior to each test date.
b. The Condensers shall be tested in the horizontal position with suitable support.
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 if
austenitic stainless steel wetted materials are present. The chloride content of the test
medium shall not exceed 20 ppm (by mass) for water temperatures of < 149°F.
f. Test Temperature: Before application of the test pressure, the test water and the vessel
material shall be allowed to equalize to approximately the same temperature.
g. After completion of the hydrostatic test, the vessel shall be drained, dried, and closed as
quickly as practicable.
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h. 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.
i. The shell side and the tube side of the Condensers shall be subjected to a pressure test, in
accordance with Paragraph UG-99 of the Code. See design/test pressures in the
datasheets in Appendix A. The test pressure shall be held for 30 minutes.
j. An independent hydrostatic test of the shell-side and the tube-side shall be performed.
k. The test pressure shall be measured at the high point of the vessel in the test position.
l. The final pressure test shall be held for a minimum of one hour.
m. If applicable, nozzle reinforcement pads shall be pneumatically tested at 25 psig.
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6.0 DELIVERY, STORAGE, AND HANDLING
6.1 DELIVERY, STORAGE, & LOAD HANDLING
6.1.1 General
a. All hoisting, rigging, transport, and load handling activities shall comply with
DOE-RL-92-36, RPP-8360 “Lifting Attachment and Lifted Item Evaluation,” and
TFC-ENG-STD-06.
b. SELLER shall receive, clean, package, store, preserve, handle, and ship SSCs to protect
against physical damage, or any effect that would affect quality or cause deterioration, at
all times, while items are located on the premises of the SELLER. Items shall also meet
the requirements of ASME NQA-1-2008/2009A, “Quality Assurance Requirements for
Nuclear Facility Applications,” Part 1, Requirement 13. Classification and packaging will
follow the guidelines of ASME-NQA-1.
c. SELLER shall follow manufacturer recommendation for storage and handling of all
purchased items.
d. SELLER shall submit a PSSH Plan in accordance with QA-AVS B85. The PSSH plan
shall include all plans, procedures, and Drawings that address how items will be
packaged, stored, shipped, and handled in accordance with the requirements described
throughout this Specification, with the exception of topics covered by the Lift and
Rigging Plan described in Section 6.1.4.1
6.1.2 Transportability
All transport activities shall comply with DOE-RL-92-36, RPP-8360, “Lifting Attachment and
Lifted Item Evaluation,” and TFC-ENG-STD-06.
Packaging, Shipping, Receiving, Storage, and Handling shall consider the following
requirements:
a. Units shall be individually packed to protect from damage during shipping.
b. One copy of the storage procedure shall be attached to the equipment or crate at the time
of shipment. The storage procedure shall cover both short term and long term (over six
months) storage maintenance programs.
6.1.3 Packaging
6.1.3.1 Levels of Packaging
The packaging requirements shall be based on the protection that is necessary during shipping,
handling, and storage of the item. Level of packaging requirements shall be in accordance with
protection requirements of NQA-1-2008/2009A, Part 1, Requirement 13. Note: The supplier QA
program is not required to be compliant to NQA-1 and can be based on another nationally
recognized standard as long as it adequately addresses the requirements drawn from NQA-1,
2008 + 1a 2009 addenda.
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6.1.3.2 Cleaning Plan
Prior to packaging an item, debris/contamination shall be removed using SELLER documented
and approved standard procedure, unless specified otherwise. Before delivery to the site, all
items shall be clean to the extent that extraneous materials, such as those listed below, are not
present:
• Metallic or other dusts (shop dust), chips, and turnings,
• Abrasive particles,
• Weld splatter,
• 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, and
• Fluid piping shall be flushed with inhibited water.
6.1.3.3 Cleaning Records
SELLER shall provide cleaning records showing the item has been cleaned, as appropriate, prior
to packaging.
6.1.3.4 Packaging Type
Package type shall provide the level of protection, as required, based on the equipment type.
Containers, crates, and skids shall be used as the foundation methodology for packaging.
6.1.3.5 Packaging Materials
Pressure sensitive tape should be used in lieu of adhesives in contact with bare metal.
6.1.3.6 Packaging Materials Contacting Stainless Steel and Nickel Alloy
Tapes, adhesives, desiccants, or any other packaging materials contacting austenitic stainless
steel and nickel alloy surfaces:
a. Shall not be compounded from, or treated with chemical compounds containing elements
in such quantities that harmful concentrations are leachable, or that they could be released
by breakdown under expected environmental conditions and could contribute to
intergranular cracking or stress corrosion cracking, such as those containing fluorides,
chlorides, sulfur, lead, zinc, copper, and mercury.
b. Paperbacked (masking) tape shall not be used.
c. Upon removal of tape, all residual adhesive shall be removed by wiping with a reagent
grade non-halogenated solvent (acetone, alcohol, or equal).
d. Starch, silicone, and epoxy tape material may be used for tape adhesive if the
requirements of this section are met.
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6.1.3.7 Seal Openings
All equipment openings shall be capped, plugged, or sealed. Clear plastic closures shall not be
used. Activities shall be in accordance with NQA-1-2008/2009A Part 1, Requirement 13 to
prevent entry of foreign material and humidity and protected against corrosion and physical
damage. Note: The supplier QA program is not required to be compliant to NQA-1 and can be
based on another nationally recognized standard as long as it adequately addresses the
requirements drawn from NQA-1, 2008 + 1a 2009 addenda.
a. Flanged openings shall be provided with gasketed closures.
b. Threaded openings shall be provided with steel caps or steel plugs.
c. All tell-tale and vent holes shall be packed with grease, to prevent water infiltration.
Plugs are not permitted.
6.1.3.8 Protection from Corrosion
Items subject to deleterious corrosion shall be protected. Activities shall be in accordance with
NQA-1-2008/2009A Part 1, Requirement 13 (e.g. using either contact-preservatives, inert gas
blankets, or vapor-proof barriers with desiccants to absorb any moisture inside the container).
Note: The supplier QA program is not required to be compliant to NQA-1 and can be based on
another nationally recognized standard as long as it adequately addresses the requirements drawn
from NQA-1, 2008 + 1a 2009 addenda.
6.1.3.9 Unprotected Steel
Uncoated carbon steel (where applicable) and all stainless steel materials shall be wrapped to
prevent exposure during shipment and storage.
6.1.3.10 Shipment Load Protection
All activities shall comply with DOE-RL-92-36, RPP-8360, “Lifting Attachment and Lifted Item
Evaluation,”.
6.1.3.11 Protection from Shock and Vibration
Cushioning, blocking, bracing, and anchoring shall be used where protection from shock and
vibration is required. Activities shall be in accordance with NQA-1-2008/2009A Part 1,
Requirement 13. Note: The supplier QA program is not required to be compliant to NQA-1 and
can be based on another nationally recognized standard as long as it adequately addresses the
requirements drawn from NQA-1, 2008 + 1a 2009 addenda and the protection level as specified.
6.1.3.12 Other Protection
Protect equipment and finishes against impact, abrasion, and other damage
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6.1.3.13 Protection of Machined Surfaces
Apply a rust preventative coating to machined carbon steel surfaces prior to shipment.
6.1.3.14 Packaging Inspection
Prior to shipment from the facilities of the SELLER, BUYER shall be provided opportunities
(as appropriate) to inspect shipments to assure that products comply with all requirements,
quantities are correct, products are undamaged, and packages are ready for shipment.
6.1.4 Handling
6.1.4.1 Lift and Rigging Plan
All activities shall comply with DOE-RL-92-36, RPP-8360, “Lifting Attachment and Lifted Item
Evaluation,” and TFC-ENG-STD-06.
6.1.4.2 Lift Point Marking
Lift points shall be clearly identified on the equipment.
6.1.4.3 Rated Temperature for Custom Lifting Devices
All custom designed Hanford Site lifting devices shall be rated for cold weather temperature of
10°F or below.
6.1.4.4 Contact with Different Metals
Any item, containing or comprised of austenitic stainless steel or nickel based alloys, shall be
stored, handled, and constructed in a manner that prevents direct contact with materials such as
carbon steel, lead, zinc, copper, mercury, halogenated material, low melting elements, and any
chloride containing material.
6.1.4.5 Critical Welds
All critical welds shall be identified in the design media of the SELLER. For the purpose of this
requirement, critical welds are defined as those welds whose failure could result in loss of load,
or loss of load control.
• All critical welds on lifting devices should be full-penetration welds, if possible.
• Critical welds shall be verified in accordance with Section 4.1.4.
6.1.4.6 Shipping and Handling Drawing
Prior to shipment, the SELLER shall provide detailed handling instructions, including a
dimensioned Drawing for each equipment/assembly, indicating all dimensions and tools
necessary for support, lift, and shipment of the completed equipment. Tolerances for such
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dimensions shall be noted either on the specific dimension or in general notes. Dimensions
locating centers of gravity shall be generated by SELLER calculation, shall be noted on the
Drawing, and the calculations shall be submitted with the Drawings. These Drawings shall be
provided with the PSSH plan described in Section 6.1.1.
6.1.4.7 Unpacking and Assembly Drawing
SELLER shall provide a dimensioned Drawing that includes receiving instructions, offloading
and unpacking instructions, and on-site assembly instructions (if equipment is shipped in a
disassembled state). These Drawings shall be provided with the PSSH plan described in
Section 6.1.1.
6.1.4.8 Special Lifting Devices
Any special handling devices, needed for assembly or installation, shall be identified and
supplied with the equipment. SELLER provided structural and mechanical lifting devices, as
defined by ASME B30.20, shall conform to the requirements of ASME B30.20 and
ASME BTH-1. Below-the-Hook devices shall be load tested in accordance with ASME B30.20.
All custom designed lifting devices, for use on the Hanford Site, shall be rated in accordance
with environmental conditions of Section 3.3.1.6.
6.1.4.9 Below-the-Hook Device Marking
All activities shall comply with DOE-RL-92-36, RPP-8360, “Lifting Attachment and Lifted Item
Evaluation,” and TFC-ENG-STD-06.
6.1.4.10 Offloading
Offloading at BUYER designated delivery site will be performed by the BUYER or a BUYER
designated representative
6.1.5 Storage
This section contains requirements that shall be fulfilled by the organization responsible for
performing the storage items. These storage requirements only apply after item fabrication has
been completed. Levels and methods of storage are defined to minimize the possibility of
damage or lowering of quality due to corrosion, contamination, deterioration, or physical damage
from the time an item is stored upon receipt until the item is removed from storage and placed in
its final location, is consumed, or is removed for its intended use. Special storage instructions
from the manufacturer, if specified, shall be addressed as part of the storage process for both
short and long term storage of items. Protection level(s) shall be as specified.
6.1.5.1 Level of Storage
Environmental conditions for items shall satisfy protection requirements of NQA-1-2008/2009A
Part 1, Requirement 13. Note: The supplier QA program is not required to be compliant to NQA-
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1 and can be based on another nationally recognized standard as long as it adequately addresses
the requirements drawn from NQA-1, 2008 + 1a 2009 addenda.
6.1.5.2 Storage Areas
Periodic inspections shall be performed to ensure that storage areas are being maintained in
accordance with applicable requirements.
a. Access to Storage Areas: Access to storage areas for Levels A, B, and C items shall be
controlled and limited only to personnel designated by the responsible organization.
Access to storage areas involving Level D items shall be controlled, as designated, by the
responsible organization.
b. Cleanness and Housekeeping Practices: Cleanness and good housekeeping practices
shall be enforced at all times in the storage areas. The storage areas shall be cleaned, as
required, to avoid the accumulation of trash, discarded packaging materials, and other
detrimental soil.
c. Fire Protection: Fire Protection, commensurate with the type of storage area and the
material involved, shall be provided and maintained.
d. Storage of Food and Associated Items: The use or storage of food, drinks, and salt tablet
dispensers, in controlled storage areas, shall not be permitted
e. Measures to Prevent Entrance of Animals: Measures shall be taken to prevent the
entrance of rodents and other animals into indoor storage areas or equipment, to minimize
possible contamination and mechanical damage to stored material.
6.1.5.3 Storage Methods
a. Ready Access to Stored Items: All items shall be stored in such a manner as to permit
ready access for inspection or maintenance, without excessive handling, to minimize risk
of damage.
b. Arrangement of Items: Items stacked for storage shall be arranged so that racks,
cribbing, or crates are bearing the full weight without distortion of the item.
c. Storage of Hazardous Material: Hazardous chemicals, paints, solvents, and other
materials, of a like nature, shall be stored in well ventilated areas and not within the same
room as the equipment.
d. Identification: Items and their containers shall be plainly marked so that they are easily
identified without excessive handling or unnecessary opening of crates and boxes.
e. Coverings: Weatherproof coverings, when used for outdoor storage, shall be of flame
resistant type sheeting or tarpaulins. They shall be placed to provide drainage and to
ensure air circulation minimizing condensation. They shall be tied down to prevent
moisture from entering and to protect the coverings from wind damage.
f. Outdoor Storage: Items stored outdoors shall be positioned or covered to avoid trapping
moisture in pockets or internally. For example, valves shall be positioned such that water
does not collect under the bonnet, but drains from the valve packing area.
6.1.5.4 Control of Items in Storage
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6.1.5.4.1 Inspections
Inspections shall be performed and documented, on a periodic basis, to ensure that the integrity
of the item and its container, as provided for under Section 6.1.3 and Section 6.1.5, is being
maintained. Deficiencies noted shall be corrected and documented. The characteristics verified
during this inspection shall include such items as:
• Identification and marking,
• Protective covers and seals,
• Coatings and preservatives,
• Desiccants and inert gas blankets,
• Physical damage, and
• Cleanness.
6.1.5.4.2 Care of Items
Requirements for proper maintenance, during storage, shall be documented in storage records
described by the PSSH plan of the SELLER. Care of items, in storage (includes storage in
place), shall be exercised in accordance with the following:
a. Items in storage shall have all covers, caps, plugs, or other closures intact. Methods used
to seal openings shall be in accordance with Section 6.1.3.9. Covers removed for internal
access shall be immediately replaced and resealed after completion of the purpose for
removal.
b. Temporary preservatives shall be left intact during storage. Should reapplication of
preservatives be required at the site, only those previously approved shall be used.
c. Items pressurized with inert gas shall be monitored at such a frequency as to ensure that
the gas pressure is maintained within specified limits during storage. Desiccant humidity
indicators shall also be monitored, and desiccants shall be changed or reprocessed when
specified.
d. Other maintenance requirements, specified by the manufacturer instructions for the item,
shall be performed.
6.1.5.4.3 Post-Fire Evaluations
In the event that a fire should occur in the storage area at any time, each item, known to have
been heated to an ambient temperature of over 150°F (65°C) or subjected to smoke
contamination, shall be withheld from installation or use until it has been thoroughly examined.
The item must be verified to be in conformance with specified requirements
6.1.5.5 Removal of Items from Storage
Only items, that have been inspected and are considered acceptable for installation or use in
accordance with the associated receiving inspection procedure (if applicable), shall be removed
from storage for installation or use.
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6.1.5.6 Storage Records
Preparation of written records shall include such pertinent information as storage location, results
of inspections, results of in-storage maintenance to include the results of configuration control
activities for the item while in storage, protection requirements, changes in item ownership
including (if applicable) certificates of conformance, and personnel authorized access to the
storage location(s).
6.1.5.7 Additional Storage Requirements
SELLER should refer to the approved PSSH plan for long term storage requirements (if
applicable).
6.1.5.8 Environmental Storage Requirements
SELLER shall specify any additional environmental storage requirements (e.g., temperature
range, humidity, range, protection from precipitation) and required maintenance during storage
(e.g., pump/rotor rotation schedule)
6.1.6 Delivery
All delivery activities shall comply with DOE-RL-92-36, RPP-8360, “Lifting Attachment and
Lifted Item Evaluation,” and TFC-ENG-STD-06.
a. The delivery address, for all equipment, will be designated by the BUYER and defined in
the procurement contract associated with the respective equipment.
6.1.7 Marking for Shipment
a. Marking of items for shipment shall follow the requirements of NQA-1-2008/2009A, Part
1, Requirement 13. Note: The supplier QA program is not required to be compliant to
NQA-1 and can be based on another nationally recognized standard as long as it
adequately addresses the requirements drawn from NQA-1, 2008 + 1a 2009 addenda.
b. All packages shall be clearly and suitably tagged, prior to shipment. All transport
activities shall comply with DOE-RL-92-36, RPP-8360, “Lifting Attachment and Lifted
Item Evaluation,” TFC-ENG-STD-06, and include the following:
1. Temporary marking of items for shipment not within a container, such as pipe,
tanks, and heat exchangers, shall exhibit the above specified information in a
location that is in plain unobstructed view. Marking may be applied directly to
bare metal surfaces, provided it has been established that the marking material is
not deleterious to the item. Stamping and etching are not allowed as temporary
marking methods.
2. If any hazardous chemicals are included with shipments, the transport vehicle
shall display the relevant Department of Transportation labels/placards.
c. For shipment packaging list requirements, refer to Section 6.1.3.
d. Package markings shall appear on a minimum of two sides of a container, preferably on
one side and one end.
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e. Package markings shall be applied with waterproof ink or paint in characters that are
legible. When information relative to handling and special instructions is required, such
information shall be preceded by the word “CAUTION” in letters that are at least
1/2 in. (12.7 mm), as permitted by package size. Alternatively, if tags or labels are used,
they shall be affixed to the container using a waterproof adhesive, tacks where practical,
or a corrosion-resistant wire.
f. Temporary supports shall be marked (tagged or painted).
g. Clearly mark partial deliveries of component parts of equipment to identify equipment
and contents, permitting easy accumulation of parts and facilitating assembly.
6.2 QUALITY ASSURANCE
Quality Assurance (QA)requirements have been interspersed through this Specification, where
appropriate. Regarding “Delivery, Storage, and Handling,” QA-AVS B85 shall be invoked,
where appropriate. At a minimum, a hold point shall apply “Prior to Packaging/Shipping.” At a
minimum, Quality Level (QL-3) must be used for all hoisting and rigging procurements. The
SELLER shall provide required notifications of verification points, and shall not proceed past
required hold point without written authorization from the BUYER.
6.3 SITE CONDITIONS
a. Storage condition requirements are specified in Section 6.1.5.
b. During delivery, all equipment may be exposed to the outdoor/environmental conditions
specified in Section 3.3.1.6.
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7.0 PROJECT MANAGEMENT
7.1 WORK PLAN
A work plan covering design, fabrication, testing, and submittal schedule dates shall be provided.
Any changes to the work plan will require written concurrence of the BUYER.
7.2 SUBMITTALS
Unless specified otherwise, submittals of the SELLER shall be per the following subsections.
All electronic submittals shall be in a suitable format per TFC-BSM-IRM_DC-C-02, “Records
Management,” and in compliance with TFC-BSM-IRM_DC-C-07, “Vendor Processes.”
Washington State Professional Engineering stamps are anticipated to be needed for several of the
design deliverables to support permitting. Stamped deliverables will be agreed on during the
kickoff meeting.
7.2.1 Submittals Required with Proposal
Table 7-1. Submittals Required with Proposal.
Item Title Description
1 Preliminary Drawing and
Documentation List
List of Drawings and documentation that will be
provided in completion of the contract.
2 Conceptual Layout
Drawings
The SELLER shall submit conceptual equipment
layout Drawings for the proposed Condenser units.
3 Preliminary System
Performance Analysis
The SELLER shall provide a preliminary system
performance evaluation, including equipment sizing
analysis, consistent with the performance
requirements identified in this specification.
4 Quality
Assurance Program
Copy of SELLER Quality Assurance Program.
5 Identification
of Subcontractors
List of all proposed subcontractors. The SELLER
shall flow down all requirements to subcontractors,
as applicable.
6 Preliminary Schedule Summary of activities required to design, fabricate,
test, and ship the Condensers.
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7.2.2 Submittals Required After Receipt of Order
Table 7-2. Submittals Required After Receipt of Order.
Item Title Description
7 Configuration Drawing Drawings detailing all major components and
orientation:
• Preliminary cross-section Drawing showing the
details of the proposed equipment (bundle
details, baffle locations, number of passes, and
number of tubes), with Bill of Materials.
• Preliminary Condenser outline Drawing with
location, orientation, and size of nozzles, and
major dimensions of the unit.
• Preliminary saddle support concept and anchor
details.
8 Preliminary System
Performance Analysis
Preliminary performance evaluation, including
equipment sizing analysis and Condenser performance
data, shell-side and tube-side pressure drop, and heat
transfer.
9 Code Deviations All deviations to the codes specified within this
Specification shall be clearly identified and must be
approved with submittal.
10 Work Plan A work plan shall be submitted per Section 7.1.
11 Detailed Schedule A detailed schedule showing the activities required to
design, fabricate, test, and ship the Condensers including
submittals and major procurements (long lead items).
7.2.3 Submittals Required Prior to Fabrication
Table 7-3. Submittals Required Prior to Fabrication (2 Pages).
Item Title Description
12 Fabrication Drawings All fabrication and assembly Drawings, including
manufacturer standard details associated with the
fabrication and assembly Drawings, shall be submitted.
Drawings shall include dimensions, required
maintenance clearances, part number callouts, associated
ASTM standard, all connection sizing and locations,
welding, and operating weight.
13 Factory Test
Procedures
FIT Plan and Test procedures shall be submitted for
review and approval for all factory tests, per
QA-AVS B52.
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Table 7-3. Submittals Required Prior to Fabrication (2 Pages).
Item Title Description
14 Vendor Data Sheets SELLER shall submit product data and rated
capacities/efficiencies of selected equipment and
accessories.
15 System Performance
Analysis. Stress and
Structural Analysis
Calculations
SELLER shall provide a system performance evaluation,
including equipment sizing analysis, indicating
compliance with the performance requirements identified
in this Specification.
16 Welding and NDE All Welding and NDE Procedures, as well as Procedure
Qualification Records, shall be submitted by the
SELLER in accordance with Section 4.1, per
QA-AVS B31, B25, and B28.
17 Authorization to Start
Fabrication
The SELLER shall not start fabrication until written
authorization has been received from the BUYER.
18 Packaging, Storage,
Shipping, and Load
Handling Plan
SELLER shall submit a PSSH Plan, for approval, by the
BUYER. The PSSH plan shall include all plans,
procedures, and Drawings that address how items will be
packaged, stored, shipped, and handled in accordance
with the requirements described throughout this
Specification. The plan shall be prepared per
Section 6.1.
19 Cleaning Records During/after fabrication and prior to packaging and
shipment, cleaning records must record cleaning
performed according to cleanliness level as specified in
Section 4.3 of this Specification.
20 Lifting and Rigging
Plan
SELLER shall provide a Lift and Rigging Plan to cover
the lifting and handling instructions for each lifted item
(entire package as well as individual items that are
uncrated). The plan shall describe the lift points, special
lifting devices, and/or hardware needs, and lift diagrams.
21 Site Assembly
Instructions
SELLER shall provide site assembly instructions,
including unpacking and installation Drawings.
22 Calculations Preliminary calculations shall be provided for review.
Calculations may include (but are not limited to)
structural calculations, lifting lug calculations, pressure
design, thermal design, and Condensers performance.
23 FIT Plan The SELLER shall submit a FIT Plan that sequences the
fabrication operations, inspections, and test points to the
BUYER for review and approval.
7.2.4 Submittals Required Prior to Shipping
The SELLER shall not ship the Condensers until all tests and inspections are performed and the
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documentation data package is complete and approved by the BUYER. The SELLER shall
notify the BUYER three weeks before the intended shipping date. The SELLER shall allow the
BUYER one week after receiving the package and before shipment to review the data package.
Table 7-4. Submittals Required Prior to Shipping (2 pages).
Item Title Description
24 As Built Drawings and
Specifications
The SELLER shall deliver, to the BUYER, one hard
copy and one electronic file in PDF format of the final
fabrication level as-built Drawings and specifications
accurately depicting the product delivered. Drawings
shall include dimensioned subassemblies, dimensioned
component details, material and fastener size, gasket
and insulation materials and thicknesses, descriptions,
weld symbols, center of gravity, references to
applicable ASTM/ASME Standard and Edition, and
notes. The designer name, responsible engineer name,
bill of materials, and Drawing number shall appear on
the index (cover sheet).
Drawings shall also include:
• Design pressure, test pressure design
temperature, minimum design metal
temperature, and any restriction on operation of
the heat exchanger.
• Interface connection details, including size, type
of connection and location, direction of flow,
and flange ratings.
• The dimensions, orientation, and location of
supports, including bolt holes and slots.
• Tube layout, number of tubes, number of baffles
dimensioned layouts.
25 Final Calculations Reviewed and approved calculations shall be legible
and prepared on 8 1/2 inch by 11 inch sheets with all
pages numbered and bound in a hard copy binder.
26 Inspection and Testing
Reports
Inspections, examinations, testing, and NDE activities
shall be documented and the documentation delivered
before shipment of the product. Inspection reports shall
provide actual inspection results, specifying what was
inspected, who inspected it, the characteristics that
were inspected, and the acceptance criteria. A thermal
performance and vibration report shall be submitted.
All test requirements called out in specification(s) and
fabricator Drawings shall be documented in the testing
reports.
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Table 7-4. Submittals Required Prior to Shipping (2 pages).
Item Title Description
27 Certified Material Test
Reports
CMTRs shall be provided for the Condenser
assemblies, per QA-AVS B49.
28 Welding Inspection Welding documentation shall meet QA-AVS B28 and
submitted in accordance with the requirements of
Section 4.1.4, prior to shipping.
29 Procedures for Repair The SELLER shall submit the procedures for repairs
of rejected items or parts.
30 Spare Parts List The SELLER shall provide a list of all spare parts,
identifying each specific subassembly to which it
applies.
31 Certificate of Conformance The Certificate of Conformance shall identify the
contract requirements met per QA-AVS B79 and
include a Suspect/Counterfeit Items statement per QA-
AVS B76
32 Completed FIT Plan The SELLER shall provide a completed FIT Plan that
includes inspections, examinations, testing and NDE
activities and the documentation delivered before
shipment of the product. Inspection reports shall
provide actual inspection results, specifying what was
inspected, who inspected it, the characteristics that
were inspected, and the acceptance criteria. All test
requirements called out in specification(s) and
fabricator drawings shall be documented in the testing
reports.
33 Manufacturer’s Data
Reports
ASME Section VIII, Division 1 required
Manufacturer’s Data Report.
34 Warranty Information The SELLER shall provide their warranty offer.
7.2.5 Request for Information
Any changes shall be submitted per the RFI process requirements detailed in
TFC-BSM-IRM_DC-C-07, “Vendor Processes.”
7.3 QUALITY ASSURANCE PROGRAM
The BUYER reserves the right to verify the quality of work at the facility of the SELLER,
including any sub-tier facilities. Access to sub-tier facilities shall be requested through the
SELLER and verification may be performed jointly with the SELLER. Seller shall have a
documented and implemented Quality Assurance Program that has an ASME B&PVC U Stamp
Certification.
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7.3.1 Non-Conformance Reports
Non-Conformance Reports identified at the facility of the SELLER or lower-tier subcontractor,
associated with this Procurement Specification, with a proposed disposition of “Accept as is” or
“Repair,” shall be submitted to and approved by WRPS Engineering and QA, before the
Subcontractor takes any corrective action on the nonconformance. Submittals must conform to
QA-AVS B22.
7.3.2 Inspection/Examination
The SELLER shall include the qualifications of the inspectors for all critical items or features
identified from the design.
7.3.3 Suspect/Counterfeit Items
Procurement of genuine, new, and unused parts shall conform to QA-AVS B76, “Procurement of
Potentially Suspect or Counterfeit Items.”
7.3.4 Certificate of Conformance
Objective evidence, in the form of a written document for all parts procured, shall be provided by
the SELLER. Documentation shall be in the form of a Certificate of Conformance or CMTR.
Certificates of Conformance shall be traceable to the material used in the fabrication, as required
by the codes listed in Section 2.0, and shall fulfill the requirements of NQA-1, Requirement 7,
and Paragraph 503, “Certificate of Conformance.” Note: The supplier QA program is not
required to be compliant to NQA-1 and can be based on another nationally recognized standard
as long as it adequately addresses the requirements drawn from NQA-1, 2008 + 1a 2009
addenda. Documentation shall conform to QA-AVS B79, “Certificate of Conformance.”
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APPENDIX A
HEAT EXCHANGER DATA SHEETS
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HEAT EXCHANGER SPECIFICATION SHEET
1 Project No.
2 Customer: Washington River Protection Solutions Reference No.
3 Address: Proposal No. Rev. 0
4 Plant Location Hanford, WA Date 12/10/2020
5 Service of Unit Stripper Overheads Condenser Item No. 60K-CND-001
6 Size: Type: S&T Vertical X Horiz. Connected In Parallel Series
7 Surf./Unit (Gross/Eff.) Sq Ft; Shells/U Surf/Shell (Gross) Sq Ft
8 PERFORMANCE OF ONE UNIT
9 Fluid Allocation Shell Side Tube Side
10 Fluid Name
11 Fluid Quantity, Total Lb/Hr
12 Vapor (In/Out)
13 Liquid (In/Out)
14 Steam (In/Out)
15 Water (In/Out)
16 Noncondensable (In/Out)
17 Temperature (In/Out) °F
18 Density @ Cond. Lb/Ft3
19 Viscosity, Vapor/Liquid Cp
20 Molecular Weight, Vapor/Liquid
21 Mol Wt, Noncondensable
22 Specif ic Heat, Vapor/Liquid BTU/Lb °F
23 Thermal Conductivity BTU/Ft/Hr Sq Ft°F
24 Latent Heat BTU/Lb @F
25 Inlet Pressure Psig
26 Velocity Ft/Sec
27 Pressure Drop, Allow /Calc Psi
28 Fouling Resistance (Min) Hr Sq Ft °F/BTU
29 Heat Exchanged BTU/Hr; MTD (Corrected) °F
30 Transfer Rate, Service Clean Actual BTU/Hr-Sq FT°F
31 CONSTRUCTION OF ONE SHELL Sketch (Bundle/Nozzle Orientation)
32 Shell Side Tube Side
33 Design/Test Pressure Psig 150 / 195 150 / 195
34 Design Temperature / C.E.T °F 400 / 400 /
35 No. Passes per Shell See Attached Sketch
36 Corrosion Allow ance In.
37 Connections In
38 Size Out
39 & Rating Non-condensible gas vent
40 Tube No. OD = In;Thk(Min/Av) 18ga min In.;Length Ft.;Pitch in. 30 60 90 45
41 Tube Type Finned Bare U-Tube Tube Material
42 Shell ID in. OD In. Shell Cover (Integ.)(Remov.)
43 Channel or Bonnet Channel Cover
44 Tubesheet-Stationary Tubesheet-Floating
45 Floating Head Cover Impingement Protection
46 Baffles-Cross Type % Cut (Diam) (Area) Spacing:c/c Inlet in.
47 Baffles- Long Seal Type
48 Supports-Tube U-Bend Type
49 Bypass Seal Arrangement Tube-Tubesheet Joint
50 Expansion Joint Type
51 r v2 - Inlet Nozzle Bundle Entrance Bundle Exit
52 Gaskets-Shell Side Tube Side
53 - Floating Head
54 Code requirements ASME Stamp TEMA Class B
55 Weights/Shell Filled w ith w ater Bundle Lb
56 Remarks:
57
58
59
60
61 304L stainless steel tubes and tube side components.
62 304L stainless steel construction balance of unit.
63 Commercial/industrial unit, mill f inish as-w elded.
64 1" 3000# NPT coupling shell vent connection.
65 Vendor to furnish or confirm data in lines 40 through 55.
DESIGNED BY: CHECKED BY: DATE
PRQ RBH 12/10/2020
60K-CND-001 is a total condenser. Condensed liquid temperature is an
estimate. Vendor to design for 20% excess area, not counting the
U-portion of the tubes.
10 /
0.0005
4,426,003
0.037
Minimum Design Internal Pressure is for a Full Vacuum.
1
6-in. / 300# / Flange
1.5-in. / 150# / Flange
6-in. / 150# / Flange
6-in. / 150# / Flange
1.0-in / 300# / Flange
0.06 inch
4,551
/
0.001
0.0123
0.451
0.0144
214
0
211
530,387
0.392
4,551
47
59.8
0.28
0.78
0.24
972
0.77
0.24
1.007
4,551 530,387
Stripper Overheads Cooling Water (50 vol% Eth. Glycol)
57
67
4.8
530,387
67
5.8
• U ----
•
T1 . E1 .1 UTr7
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HEAT EXCHANGER SPECIFICATION SHEET
1 Project No.
2 Customer: Washington River Protection Solutions Reference No.
3 Address: Proposal No. Rev. 0
4 Plant Location Hanford, WA Date 12/10/2020
5 Service of Unit Concentrator Overheads Condenser Item No. 60K-CND-201
6 Size: Type: S&T Vertical X Horiz. Connected In Parallel Series
7 Surf./Unit (Gross/Eff.) Sq Ft; Shells/U Surf/Shell (Gross) Sq Ft
8 PERFORMANCE OF ONE UNIT
9 Fluid Allocation Shell Side Tube Side
10 Fluid Name
11 Fluid Quantity, Total Lb/Hr
12 Vapor (In/Out)
13 Liquid (In/Out)
14 Steam (In/Out)
15 Water (In/Out)
16 Noncondensable (In/Out)
17 Temperature (In/Out) °F
18 Density @ Cond. Lb/Ft3
19 Viscosity, Vapor/Liquid Cp
20 Molecular Weight, Vapor/Liquid
21 Mol Wt, Noncondensable
22 Specif ic Heat, Vapor/Liquid BTU/Lb °F
23 Thermal Conductivity BTU/Ft/Hr Sq Ft°F
24 Latent Heat BTU/Lb @F
25 Inlet Pressure Psig
26 Velocity Ft/Sec
27 Pressure Drop, Allow /Calc Psi
28 Fouling Resistance (Min) Hr Sq Ft °F/BTU
29 Heat Exchanged BTU/Hr; MTD (Corrected) °F
30 Transfer Rate, Service Clean BTU/Hr-Sq FT°F
31 CONSTRUCTION OF ONE SHELL Sketch (Bundle/Nozzle Orientation)
32 Shell Side Tube Side
33 Design/Test Pressure Psig 150 / 195 150 / 195
34 Design Temperature / C.E.T °F 400 / 400 /
35 No. Passes per Shell See Attached Sketch
36 Corrosion Allow ance In.
37 Connections In
38 Size Out
39 & Rating Non-condensible gas vent
40 Tube No. OD = In;Thk(Min/Av) 18ga min In.;Length Ft.;Pitch in. 30 60 90 45
41 Tube Type Finned Bare U-Tube Tube Material
42 Shell ID in. OD In. Shell Cover (Integ.)(Remov.)
43 Channel or Bonnet Channel Cover
44 Tubesheet-Stationary Tubesheet-Floating
45 Floating Head Cover Impingement Protection
46 Baffles-Cross Type % Cut (Diam) (Area) Spacing:c/c Inlet in.
47 Baffles- Long Seal Type
48 Supports-Tube U-Bend Type
49 Bypass Seal Arrangement Tube-Tubesheet Joint
50 Expansion Joint Type
51 r v2 - Inlet Nozzle Bundle Entrance Bundle Exit
52 Gaskets-Shell Side Tube Side
53 - Floating Head
54 Code requirements ASME Stamp TEMA Class B
55 Weights/Shell Filled w ith w ater Bundle Lb
56 Remarks:
57
58
59
60
61 304L stainless steel tubes and tube side components.
62 304L stainless steel construction balance of unit.
63 Commercial/industrial unit, mill f inish as-w elded.
64 1" 3000# NPT coupling shell vent connection.
65 Vendor to furnish or confirm data in lines 40 through 55.
DESIGNED BY: CHECKED BY: DATE
PRQ RBH 12/10/2020
60K-CND-201 is a total condenser. Condensed liquid temperature is an
estimate. Vendor to design for 20% excess area, not counting the
U-portion of the tubes.
96 10,747
Concentrator Overheads Cooling Water (50 vol% Eth. Glycol)
57
67
4.8
10,747
0.78
0.24
0.77
0.24
1.007
10,747
47
67
5.8
96
96
/
0.001
0.0121
0.446
0.014
213
0
211
0.039
Minimum Design Internal Pressure is for a Full Vacuum.
1
2-in. / 300# / Flange
1.5-in. / 150# / Flange
1.5-in. / CL3000 / NPT
1.5-in. / CL3000 / NPT
1.0-in / 300# / Flange
972
0.06 inch
0.392
59.8
0.28
10 /
0.0005
93,330
PciNo
II II I I
F
I I
. Lurdy
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APPENDIX B
LARGE CONDENSER GENERAL ARRANGEMENT DRAWING 60K-CND-001
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LARGE CONDENSERSCALE: 1/4
LARGE CONDENSER SUPPORTSCALE: 1/4
A SKETCH PER RPP-SPEC-63856
NOZZLE SCHEDULENOZZLE QTY SIZE/INCHES RATING FUNCTION
N1 1 6 CL150 RF TUBE SIDE INLET
N2 1 6 CL150 RF TUBE SIDE OUTLET
N3 1 6 CL300 RF SHELL SIDE INLET
N4 1 1 1/2 CL150 RF SHELL SIDE OUTLET
N5 1 1 CL300 RF SHELL SIDE VENT
N1
N4
N3N2N2 N5 N3
N1 N4
NOTES:1. DIMENSIONS ARE IN INCHES, TOLERANCES SHALL BE ±1/16.
LARGE CONDENSER SUPPORTSEE DETAIL2 PL
6
(15 7/16)
20 15/16
28 9/16 20
68 15/16
75 7/16
N5
13
TYP
13 10 3/8
10
22
11
(6)
(4)
(2) 18
(1 3/4)
11/16 THRU2 PL
(ANGLE, 6 X 4 X 5/16ASTM A276)
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APPENDIX C
SMALL CONDENSER GENERAL ARRANGEMENT DRAWING 60K-CND-201
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SMALL CONDENSERSCALE: 1/2
SECTION A-ASCALE: 1/2(TYP, 2 PL)
A A
A SKETCH PER RPP-SPEC-63856
NOZZLE SCHEDULENOZZLE QTY SIZE/INCHES RATING FUNCTION
N1 1 1 1/2 FNPT TUBE INLET
N2 1 1 1/2 FNPT TUBE OUTLET
N3 1 2 CL300 RF SHELL INLET
N4 1 1 1/2 CL150 RF SHELL OUTLET
N5 1 1 CL300 RF SHELL VENT
N5N3
N4
N5 N3
N4
NOTES:1. DIMENSIONS ARE IN INCHES, TOLERANCES SHALL BE ±1/16.
1 1/8
2 1/4
6 1/4
TYP
6 1/2
N2
N1
40
36 9/16
10 9/16 16 1/4
6 9/16
(2 1/16)
2 1/2
1 1/8
(3/4)
4 1/2
(6)
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