am - Hanford Site

0601116 

TItle 

ECOLOGY APPROVAL OF THE CONSTRUCTION OF THE IN- 

CONTAINER VITRIFICATION SYSTEM AND THE OFF-GAS 

TREATMENT SYSTEM OF THE FINAL DANGEROUS AND/OR MIXED 

WASTE RESEARCH AND DEVELOPMENT AND DEMONSTRATION 

PERMIT (RD&D PERMIT) WA789000/8967 

DATE 07/24/2006 

J. A. HEDGES DOEC 

Recipient R. J. SCHEPENS, M.S. Recipient Co. DOE-ORP, CH2M 

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926 TA•111.2000 Pro equisdes: 

Construction, modifications, and repairs affecting the test bounda ry snali be complete and the inlet and discharge openings of the duct or housing 

(sealed before the test is sta rted. All elect rical, piping, and instrument connections shall be complete ant: all permanent seals shall be installed 

before the les t is starled, co' pressure deca y IaSbn^ the volurno of the ";es ura ; Z:alculated 'a 

927 TA•111.3000 Test Equipment: 

(a) pressurization source 

(b) covers to seal test boundaries 

(c) clock or timer accurate to + 1-1.0 second 

(d) pressure indicating device accurate to +1 . 0.1 in. 

(e) flowmeter or totalizing gas volume meter accurate to +1-5% (constant pressure method) 

(f) temperature indicating device accurate to +/- 0 .5 deg rees F 

(9) bubble solution for detecting air leaks (bubble method) 

(h) optional po rt able ele ct ronic sound detection equipment (audible leak method) 

ba ro meter 

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928 TA-111.4100 Constant Pressure Mefhod: 

(a) Connect the pressuriza ti on source to the duct or housing. 

(b) Connect the flowmeter or totalizing gas volume meter between the pressurization source and the housing (downstream of the th rottling valve. I 

if used). 

(c) Install temperature and p ressure indicating devices so that they will indicate representative temperature and press ure Inside the duct or 

housing being tested. 

(d) Seal test bou nd aries and close access doo rs In the normal manner. 

except for sealing the tempora ry blank-off panels, 

Do not use tempora ry sealants, duct tape, or similar tempora ry materials 

(e) Start the pressu ri r 

zation source and operate it until the maximum operating pressure Is acNeved. Maintain p ressure constant with the flow 

control device until temperature remains constant witfun +0.5 deg F (0.25 deg C) for a minimum of 10 minutes. Record the ini ti al stabilized 

.pressure, temperature and barometric pressure. 

929 TA-111.4100 Constant Pressure Method: 

(f) Measure the f low rate of the air being added to or removed from the duct or housin g while maintaining the maximum operating pressure within 

+/-0.1 in. w.g. (0.025 Kpa(gage)). When using the flow meter, record flow readings once a minute for a 5 minute continuous period and average the 

! readings to calculate the measured leak rate, When using a totalizing gas volume meter, measure the total volume of air for a 10 minute 

( 

period and divide the riiea5ured vuiurne dy time (10 rridrule5) iu caiuuiaie the measured ieak raie. 

and barometric p 

Record final preaaure, iemperaiura i 

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ssure. 

(g ) Conve rt the rinal calculated leak rate to standard cubic feet per minute (cubic meters per second) in accordance with the method illustrated In 

AC IH Indust ri a VerAila Icn A Manual of Recommended Practice. 

930 TA-111.4200 Pressure Dewy Test: 

(a) Connect the pressuriza tion source (with a leak tight shulo tf valve) to the duct or lousing. 

(b) Install the tempera ture and pressu re indicating deices where they will indicate representative temperature and pressu re Inside the duct or 

housing being tested. 

(c) Seal test boundaries and close access doors in the normal manner. Do not use tempora ry sealants, duct tape, or similar tempora ry materials 

except for sealing the tempora ry blank-off panels. 

(d) Sta rt the pressurization source and operate until the pressure is 1.25 t ; mes the maximum operat i ng pressure (but not to exceed the structural 

capability pres sure). Maintain this p r e ssure constant with a flow control device anti( temperature remains constant within + 1-0 .5 deg F (0,25 deg C) 

f r a minimum of 10 minute s. Close shutoff valve. 

Date Printed: 21-Dec-C4 Example ASME AG-1 Compliance Matrix Page 90 of 110 

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931 TA-III-4200 Pressure Decay Test: 

NCTE: If the structural capability pressure for the duct or hous ing is less than 1.25 times the maximum operating pressu re , the final test pressure 

shall be calc ul ated as follows to achieve an average test pressure equal to the maximum operating pressure: 

P, - C.6(OPm„) - (1.25(OP ,,,) - SCP) 

where 

P, = final lest pressure 

OPT„ = maximum operating pressure 

SCP - structural capability pressure 

;e) Re co rd the initial time, pressure, temperature, and barometric p re ssure. 

(f) Record pressure readings once a minute until pressure decays to 8C% of the maximum operating pressure, or for a minimum of 15 minutes 

(see NOTE in (a) above)• 

(g) Record final time, pressure, temperature, and 

barometric pressure. 

932 TA-111.4200 Pressure Decay Test: 

(h) Calculate the leak rate f ro m the following equation In English Units: 

Q,,. _ (P,T, - P,/T,) V / (R' 61'0.075) 

I 

I Metric units: I 

Q,,.. _ 0 .39 • 10"s) ' (P/T, - P,17,) ' V / (R-a t) 

where 

C.. = average leak rate, scfm (sm°IS). [air density = 0.075 Ibtft' (1.2 Kgs/M')] I 

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V = volume within lest bounda ry, R' (m) 

P; - initial pressure within test bounda ry, psf ASS ;Pa(absolute)) 

P, = final pressure wlGhln lest boundary, psf ABS ;Pa(absolulel) 

T, . absolute temperature at sta rt of test, R (K) 

T, = absolute temperature at end of lest, R (K) 

at = 4 . 4 time difference (minutes) 

1, - time at sta rt of test (minutes) 

4 = time at end of test (minutes) 

I i I R - gas constant for a!r, 53.35 ft-lb. (0.286 W, lb-R, kg-K) I I I 

933 TA- 111 -4300 Acceptance Criteria: 

If the calculated leak rate exceeds the Owner's acceptance c riteria, locate leaks in accordance with one of the techniques outlined in 111 .4400 or 

Ill•4 00. 

934 TA-111 -4400 Bubble Leak Location Method: 

(a) Pressu rize the lest bounda ry to the maximum operat.ng p re ssure for the system. 

(b) With the test bounda ry under continuous pressure, apply bubble solution to areas to be tested. Identify places where bubbles are found and 

perform corrective actions. 

Following corrective actions retest In accordance with 111 . 41CO or III-42C0. 

935 I TA-01 .4500 Audibie Leak Location Method! 

(a) Pressu rize the test bounda ry to the maximum operating pressure for the system. 

(b) With the test bounda ry continuously presw rized, locate audible leaks (electronic sound delectlon equipment optional) and perform cor re ctive 

actions. 

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Followinc corrective action retest in accordance with 111 -4100 c 111 -4200. 

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938 TA. iV-4000 Procedural Guidelines: 

(a) For each moisture separator, prefilter, and HEPA fi lter. measure the air velocity at the approximate centers of equal areas with at least one 

meaSuremen! per each moisture separator. pre filter. and HEPA niter. and a minimum of 9 measurements per bank. Adso"r velocity 

measurements shall be made in the approximate center of the flow slots. For low slots greater than 24 inches long (60 cm), measurements shall 

be nominally eve ry 12 inches (30 cm) a lo ng the length of the slot. 

(b) Ca lc ulate the average velocity (V,,,) using the following formula: 

V... LV; / n 

where 

LV, a sum of Individual velocity readings 

n • number of readings 

(c) Identify the highest and lowest velocity readings and calculate the percentage they va ry from t e average calculated above. 

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939 TAN-1100 System Test: 

Injection and sample Pon location sna p be located so that the enti re system, including housing bypass ducts and associated dampers, Is 

challenged for inadve rtent bypass flow paths around the HEPA filter or absorber banks. If this cannol be accomplished, and integrated system lest 

shall be included in addition to the bank rests o0inedl in Mandatory Appendices TA-V( TA-VII. ane TA-4940. 

940 TA-V.1300 lnfecl'on PW Selection Criteria: 

Injection pons should be located upstream of a flow disturbance to maximize mixing. The crallenge gas will pass through the HEPA bank and 

challenge the absorber bank. For systems with two or more HEPA fi lter banks in series, or two or more absorber banks in se ries • separate 

injection pons must be qualified for each bank. Use of injection manifolds may be necessa ry when the re is insufficient room between banks to 

provide adequate mixing, 

941 TA-V-2000 Prerequisites 

The system is operating within +/•10°6 of design !low rat e . rho airflow distribution has been verified in accordance with Mandato ry Appendix TA- 

IV 

942 TA-V-4000 JProcedural Guidelines: 

I (a) Connect challenge aerosol or gas generator to the injection po rt to be toslec. 

(b) Place the challenge ae ro sol or gas measuring Instrument sample p ro be upstream of the bang tb be tested with adequate hose length to reach 

an areas of the bar*._ 

(c) Stan the challenge ae ro sol or gas injection and establish a constant injection rate. 

(d) Take a concentration reading upstream of and at the approximate centers of equal areas, with at least one reading per HEPA filter and a 

minimum of 9 readings per HEPA bank. For ty pe n and type III adsorbe rs, readings shall be taken upstream of and In the app roximate center of 

each flow slot. For now slots greater than 24 inches (60 cm) in le ngth, a reading shall be taken romina ; ly eve ry 12 inches (30 cm) along the length 

Of the slot. 

943 TA•V-4000 Procedural Guide lines: 

(e) Calculate the average concentration (C,,,) readings using the following formula: 

1 C.,• - LC;1 n 

where 

LC, % sum of Individual velocity readings 

n . number of readings 

(f) identify the highest and lowest concentration readings and calculate the pe rc ,:s" 

entage they va ry from the average calculated above. 

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944 TA-VI-2000 Prerequisites: 

Alrf crw distribution shall be vert fled in accordance with Appendix TA-IV. The injection pan shall be qualified to p rovide uniform air ae ro sol mixing 

it accordance with Mandalt;ry Appendix TA•V 

Dale Pr9nled: 21-Dec -04 Example ASME AG-1 Compliance Matrix Page 92 of 110 

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545 TA-VI-4000 Procedural Gvidii ites: 

(a) Conned challenge aerosol generator to the qualified injection pon 

;b) Place the cha'l e rye aerosol measunng Instrument samole probes upst ream and downst re am of the bank to to tested. The sample tubing 

Si be of equal bore and approximately equal lengths and as sho rt as possible to minimize the measuring instn,mern response time. The 

upst re am sample p robe shall be located in approximately the center of the bank. The downstream sample probe shall be located in a downst re am 

sample manifold or downstream of a mixing source such as a turbulent fan discharge, 

(c) Sta rt the system and verify stable Gow rate within 210% of design flow rate. 

(d) Measure the upstream and downst re am aerosol background concentration. The pre-injection background levels shall be stable to ensure 

correct instrument response ano shall not interfere with the detectors abil ity to detect leaks in excess of the maximum ailowad by the acceptance 

criteria. 

946 TA-VI-4000 Procedural Guidelines: 

(e) Start the challenge aerosol injection. 

(q Record the upstream and downstream concentrations. Repeat until at least three of the readings are stable. 

(g) Slop the infection. 

(h) Using the final set of readings meeting the stability and tolerance criteria, calculate the bank leak rate using the formula below: 

L - (100)CwcC 

where 

L - %leak 

C, - downstream concentration 

C„ • upstream concentration 

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551 TA-Viii-4100 Leek Test Procedural Guidelines 

(a) Open all I nterconnecting manual system va lves, so,enoid and expansion valves to ensure access to :he ccmp:ete system volume. 

CAUTION: Du not exceed 'the safe test pressure " im i ts established by the ;,nit manufaUOrer. 

NOTE: It is advantageous and less cosdy to use an ine rt gas (nit ro gen or carbon dioxide) to tack up the refrgerent vapor pressu re . Only about 

5% to 10% of the total mixture need be refrigerant vapor for this method to work, 

(b) PfessUr 'z the entire system 10 the Man UfaCtUrerS recommended test pressure with Ine lest mixture. 

952 TA-VIII-4100 

NOTE. Allow time for the refrigerant and +nert gas to mix before checking (or leaks. 

Leak Test Procedural Guidelines: 

(c) LeaK test the enti re system, including facto ry joints, seals, and insulated lines wiln an electronic 'leak detector. Usually a one inch (2.5 em) 

per second Movement: of the detector probe is sufficient to picx up leaks. Soap solution may also be used to locate leaks. 

(d) Mark or identify any leaks located. 

CAUTION; Jse appropriate reclaim equipment to prevent release of re in gerant gas to the atmosphere. 

(e) Leak testing is complete when all leaks have been re pai red and the system has been re-pressurized and retested to verify that there are no 

leaks. 

953 TA- VIII .4200 Evacuat ion and Dehydration Procedure: 

Evacuate and dehydrate after leak testing per VIII . 410 0 . P ro per evacuation and dehydration p ro ve system tightness, expel non-condensaoles, 

and assure a dry system before charcing with refrigerant 

954 TA-VIII-4210 Deep ''Vacuum Method: 

(a) Vent all system p re ssure. 

CAUTION: Use app ropriate reclaim equipment to prevent release of refrigerant gas to the atmosphere. 

(b) Connect a tempora ry connection between the system high and low p re ssu re sides. Connect the vacuum pump, vacuum indicator, and 

refrigerant cylinder to the system. 

(c) Open the vacuum pump suc ti on and sta rt the evacuation. 

(d) When the system reaches less t.nan 500 micromete rs (Hg) absolute, it is isolated from the vacuum pump. 

(e) When the system holds 50C mi crometer (Hg) absolute for at least 15 minutes, w lh the vacuum source isolated, the system is f re e of moisture 

rid leaks and the vacuum should be released by chancing with refrigerant, 

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Date Printed: 21-Dec•04Example ASME AG-1 Compliance Mat rix 

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957 3 Habitabu4y Systems: 

Habitability systems (as defined in ASME N509), must meet the requirements of 10 Code of Federal Regulation (CFR), Appendix A, general 

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955 4.1.a General; 

Prefilters a re required in air-cleaning units when cesign inlet particu iste concentrations and particle size are such that the HEPA filter may be 

rende re d Ine ffective p re maturely. On other air-weaning units pre filters are recommended only when it is desired to increase HEPA filter life. 

959 4,1.b General: 

HEPA filte rs a re requi red In all air-cleaning units when fil tration of inlet pa rt iculate matter requires a minimum efficiency of 99.97% for panicles 

equal to 0.3 micrometer In size. 

96C 4.1.c General; 

Ad orb rs are re u!red when air-cle nin units are desi gned for removal of adso table compounds. 

961 I 4.t.d General: 

Moisture separators (demiste rs ) are required when entrained water d roplet concentration may be greater than 1 Ib (0.45 kg) of water per 1,000 c 

h (1,700 m3/hr) of airflow. 

962 4A.e General: 

Hasters should be utilized for air-cleaning units with adsorbers exceeds 70% based upon the 1% percentile meteo rological conditions (where 

applicable). For nuclear air treatment systems which are una ffected by outside air meteo rological conditions, heaters should be utilized when an 

accident would result In an air-stream exceeding 70% relative humidity for rrore than 1 hr. 

963 4.1.f General: 

When adsorbers are used in ESF aircieanirg units, provision shall be made for a postflter to retain carbon fines. Postfdters should also be 

c r. id red in mn-ESF air-cleaning units discharging into occupied spaces where carbon fine carryover Is nxitaccleiptable. 

964 4.2 Design Parameters: 

Values of the following design parameters shall be s pecified when invoking this standard and shall be used whenever refe re nced:. 

a) volumetric air flow rate, acfm (m3lhr); 

1) minimum flow rate; 

2) m imam flow rate: 

3) design flow rate; 

b) design pressu re s, in w.g.(Pa); 

1) maximum operating p ressu re ; 

2) leak test p ressure; 

3) maximum design pressure; 

4 structural capatilyly ressurusoally determined by component designer) 

965 4.2 Design Parameters: 

C) pressure-time transient (if applicable). In, w.g./sec (Pa/sec); 

d) maximum and minimum gas temperature (F) and density, ll (kgirri 

e) maximum Inlel relative humidity (percent); 

0 entrained liquid water (mass Sow rate), iblmin (kg/min); 

g) coreenlrations of specific contaminants in airstream; 

h) required deconlaminaVonYactors for each contaminant; 

0 component radiation integrated life dose (rad) and maximum dose rate (radlhr); 

j) maximum di rty fi ller p ressu re. differential, in. w.g (Pa); 

966 4.2 Design Fararnialws. 

k) structural loadings; 

1) duct and housing maximum permissible teak rate (acfm) (m'3/hr) and associated operating pressu re , in, w.g.(Pa); 

m) environmental design conditions including temperature, pressu re , and relative humidity; 

n) expected duration and environmental condit io ns of storage a re a; 

o) pa rticle size distribution and quantity of aerosols and contaminants under normal and accident conditions (if known); 

p) safety class fication (ESF or nos-ESF): 

q) number et adso bar test canisters per adsorber bank; 

r h alerts acit watts.volla a temperature d , fferertia! ifslicable 

Tale P(Inled; 21-Dec-04 Example ASME AG-1 Compliance Matrix Page 95 of 110 

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967 43 Size (installed Capacity) of Air-Cleaning Un t: 

The installed capacity ctm (m'31hr) of the air cleaning unit shall be no g reater than tre IimiUng Installed capacity of any bank of components 

contained In the air cleaning unit through which Ile ai;Row must pass. The lrstaite_ capacity of any bank o r stage of components shell not exceed 

Ih0 number of cdmponerHS in the bank times the rated capacity of the individual components. Test canisters shall not be included In determining 

. 

the Installed a aci of an bank or sta a of adsorbers. 

968 4 4 Environmental Design Conditions: 

All parts and components of the air-cleaning unit shall be selected or designed to operate under the envi ro nmentai conditions (temperature, 

relative humidity,. p re ssure, radiation, etc.) specified in paragraph 4.2. Materials of cons wiction and components snail be selected or treated to 

limit generation of combustibles and contaminants and to resist cor rosion and degradaton that would re sult In loss of function when exposed to the 

specified environmental conditions for the design life of the component. 

Environmental qualification requirements are contained in 10 CFR 50.49 and EEE 323 and ASME AG1, Section AA and various specific ASME 

AG-1 Code sec ti ons, 

969 4,5 Structural Load Requ ir 

ements: 

Engineered Safety Featu re (ESF) systems and ail of their components shall be shown, either by testing or by a mathematical technique, to 

remain functional under the structural loading speci fi 

ed in ASME AG-1, A rticle AA-4000 and various speci fic ASME AGA Code sections, 

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970 4.6 The maximum design p ressure shall be documented by calculation, including the basis for the condition, and included In p ro cu re ment speci fications 

for manufacturels design. 

971 4.6(a) Positive Pressure: Air-cleaning units and components including ducts Totaled on the discharge side of fan(s) which can be Isolated by closure of a 

downst ream damper, or pote ntially plugged components, shall be designed to withstand a positive Inte rn al pressure equal to or greater than the 

peak pressure of the fan(s). If p rovision is made to ceenergize fans on high differential p re ssure or low Row, lne components shall be designed to 

withstard the trip poi nt design pressu re plus a margin to include the rate of pressure ri se between re aching the pressu re setpotrm and the time for 

the instrumentation response, or 10%, whichever is greater. 

972 4.6 (b) Negative Pressu re . Air-cleaning units and components located on the inlet side of fans) which can be isolated by closure of an upst re am damper, 

or potentially plugged components shall be designed to withstand a negative inte rn al pressu re equal to or mo re negative than the peak pressure of 

the fan(s), If provision Is made to deenergize fans) on high differential pressure or low Row, the components shall be designed to withstand the tnp 

point design pressu re plus a margin to include the rate of p re ssure ri - 

se between reaching the press,.re selpoint and the time for the nstn:mentatlon 

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es c n se.or 1 0 whi e fr e ver is greater. cote 

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973 4.7 PPhysical location and arrangement ement of the components of a nuclear air-t reatment system in fl uence the requirements for leak lightness for the various 

pa rts of the p re ssure bounda ry. Air Row shout be f ro m potentially less contaminated areas to potentially more contaminated areas. Whenever 

possible, routing of co ntaminated air tnrougl clean spaces or inte rs pades should be avoided. If this can not be done. the general guidance In this 

Section should be followed. Figures 8. 1 4 1C • ',8 - 1410 .2. and B•1410.3 of ASME AG-1, Section $ A schemaCcally depict examples of possible 

combinations and location of fan and air-cleaning unit to minimize Impact of system Contaminated outieaKage on sur rounding risen s paces and 

Inters aces as well as contaminated inleaka a Into a cleaners stem corn onent. 

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982 4,7,2 a Recirculating system housings should be kept at a Positive pressure it located outside habitable bounda ry in a contaminated space or interspace. 

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983 4.7.3.a If an air-cleaning unit is located in a clean space or interspace outside of the space se rved, the tan should be located downst ream of the aircleaning 

unit. 

984 4.7.3.b Fans may be either upstream or downstream of aircleanin units i ! located totally within the space served. 

985 4.7.3.c The tenth of tluctwork outside the space se rved should be kept as short as radical 

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986 4.8.1 Access for Service . Testing, and Inspection: 

The air -c leaning unit shall be designed to keep radiation exposures du ring maintenance, testing, and Inspection as low as reasonably achievable 

ALARA $ me design features wNch cont ri bute to kesoinc these exposures ALARA are the folltiwinqq. 

987 4.8.1.a Man-ent ry air-cleaning units should be located at floor level or should be equipped with a permanent se rvice gallery at least 4 R (1.23 m) wide 

9e8 4.6.1.b 

with Permanent stairs or fixed ladders. 

Sma ll 

er ale-cleaning units should be located at a height above the floor or work galle ry level convenient for access, based on human factors and 

the -desi n of the housing. 

989 ) 4.8.1.c The a re a in which the air-weaning unit is iocaied snail be served by a clear aisle wide enough to accommodate se rvicing of internal components 

land equipment, 

990 4.8.1.0 Sufficiently wide clear area adjacent to the housing door or hatch shall be provided to allow se rvicing the air-cleaning unit; a space of at least 4 ft 

wide x 7 R (1.23m wide x 2.15 m) high is recommended, The clear work s pace may also se rve as aisle s pace as long as It can be used while 

servicing the air-cleaning unit or it may se rve as the clears ace for an adjacent air-cleaning unit. 

991 4.8. 1 .e Clearance of 18 in. 0.46 m is recommended above the housing for instaliaton and inspection. 

992 4.8.1.E Elevated work gatlerles servicing air-cleaning, uni;s shall be designed in accordance with Occupational Safety and Health Act (OSHA) 

re uirement . 

993 . Q Ducts that will have to be cleaned cu; pedodialiv shall bee ,.i oed with low 'eaka a access hatches at strategic points. 

994 4.8.2 Internal Space for Maintainence: For ease of maintenance, air-cleaning unit design should provide for a minimum of 3 ft (0.92 m) from mounting 

frame to mounting frame between banks of components. If components are to be replaced between mounting frames, the bank- lo-bank dimension 

should be the maximum de fl 

ated length of com p onent plus a minimum of 3 h (0.92 m). The designer should consider suscepGbilily of permanently 

installed testing manifolds to damage in determinat.cn of maintenance space. An extra 3 h (0.92 m) tank-to-bank spacing should De conside re d for 

testino manifold clearance when manifolds ereennanenll installed. 

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996 Where heal of radioactive decay or heat of oxidation or both may be significant. means shall be provided to re move this heat from the adsorbent 

beds to limit 

temperatures to values below 300'F (149 •,^) to Prevent signi ficant iodine desorption. 

For this purpose, a minimum circulato ry air fl 

ow shall be available for all opera tional modes of the air-cleaning unit and shalt be based on the 

maximum po ssible radioactivity 

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1007 4,11.4 Fro Hazard An alysis: 

A fire hazard analysis shall be performed for all air-cleaning units and components in accordance with 10 Code of Federal Regulations (CFR) 50, 

Appendix R and National Fire P rotection Agency (NFPA) 803, except that for adsorl:ers consideration shall be given to the type cf carbo n (or other . 

media) utilized in adsorters and the potential for fire. 

1001 4.11 .5 Fire Protection Systems. Fire protection systems, when provided. may use water deluge, fine r, gases (e.g., halon. CO2) or other extinguishing 

agents as app rop riate 

fcr the hazard and designed In accordance with all a olicable NFPA staroards. 

1002 4.11.6 Water Deluge Systems: 

Oaluge nozzles should be permanently mounted within the housing and :ecated to ensure that both deep-sealed or surface fires can be 

extinguished. Nozzles shall be piped to an accessible location outside the housing and p r o vided with redundant leak-tight Isolation valves and a 

connection suitable for manual attachenl to the plant's fire protection system. Permanently connected fire protection systems are not 

recommended, but may be used In lieu of manual hose connections. 

1003 4,11.7 Actuation of F ire Protection Systems. If the result of In e fi re hazard analysis requires that a fire prolecl!on system be provided for an air-cleaning 

unit, the fire p rotectlon system should be manually actuated. A utomatic actuating water deluge systems are not recommended because spurious 

actuation of deteclionfaulomatic p ro tec ti on systems will signif,canlly degrade adsorber capability ar ia damage the adsorber. 

10:,4 4,11,8 Permanen tly Connected F ile Prote ction System, When a;r-cleaning units are provided with perrnanent!y connected fire p rotection systems 

provisions shall be made to activate an alarm upon Initiation of flow of extinguishing agent (e.g., water, haion, CO,,). 

1005 4.11.9 Retumin , Air-C leaning Un it to Se rv ice: 

if carbon does become wel, the we( carbon shall be removed from (he adsorber 10 prevent structural damage to the adsorber due to chemical 

interaction, Before placing the ar- cleaning unit back in service, the adsorber shalt be thoroughly dried and visually Inspe cted for corrosion damage. 

Dried carbon shall be lab orat ory lesled pal ASME AG-1, Se ction FF and ads orber leak testing shall be perfo med per ASME AG-f, Section TA, 

1006 4.12 insulation: 

Acoustic linings, thermal insulation, and similar materials shall not be applied to the inside of air treatment system ducts and housings. Materials 

applied to the outside of ducts and housings shall not prevent ac cess tc any bolted. construction;oint, door, access hatch, or Instrument In the 

housing or ducts or result In penetrations through the pressure bounda ry which would result in exceeding allowable leakage rates in accordance 

with paragraph 4.14. of ASME N509. 

1007 4.13 a TesraorUly- 

0 BnSUR [hat [he least rig ie q ulrtlfneriLy of ibis Slanda,l car, be met, Su^diar't pe. arâr„^y f ' n,^^s,ai,a..J i ' ' ,, haLdc and DOP ir'edtlr v ;no rampling pnn< i 

shad be provided to permit accurate testing in accordance with ASME AG-t, Section TA, he required for pro pen challenge agent mixing end/or 

sampling, multiple inlet or outlet distribution manifolds shall be provided to allow inJectlon and sampling per ASME AG-1, Section TA. 

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1008 4.13,b Testab illty: 

Sufficient lest canniste rs or other means of obtaining samples (see Mandato ry Appendix 1) of used adsorbent shall be Installed In the adsorber 

system to provide a representatve delerminatlon of the re sponse of the adsorbent to the service envi ro nment over the predicted life of the 

adsorbent. Test cannisters shall be installed in a location where they will be exposed to the same air flow conditions as the adsorbent in the system, 

shall have the same adsorbent bedcepth as the adsorbent in the system, and shall be fi lled with representative adsorbent from the same batch of 

adsorbent as that of the system. 

The quanti ty of lest canniste rs to be provided shall be based on the e x pected frequency of operation. For continuously operating systems, where 

aboratory tes ting of carbon Is required eve ry 720 hr of operation, a minimum of 18 test cannisters is recommended. For tnose systems where 

I 

lab rato carbon testing Is required once every 18 months, a minimum of 6 test cannisters I recommended. If the adsorber operation may vary 

1009 4.13. 1b The type of test cannister design (Including connection to adsorber bank) shall be qualified by the manufacturer. Any change In the canister 

design or mounting to bank shall require a retest. The quali fication lest shall measure air veloci ty at the test cannister. Measured velocity shall be 

-/- 10% of adsorber bank design velocity. Tests on each productJon air-cleaning unit a re not required, 

1010 4.13.c Teslab#ily: 

1 

!I 

Access shall be provided between banks of components in he air-cleaning unit rwvsing to permit physical Inspection o f both sicez of each bank. 

Components shall not be Installed back-to-back on the same or opposite sides of the same mounting fr ame, or on adjacent mounting frame, or on 

^.. +^ tr ,i,{r: 

adjacent mo tin frames which are so close as not to ermit atle vale access space between banks 

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1011 4.14,1 Maximum Allowable Leakage: 

Maximum allowable leakage ac ross the p re ssure bounda ry of any po rtion of a nclear air-treatment system strait be based on health physics 

requiiements. ueakage into or cui df 

nuclear air treatment systems may a ffect: (a) control room habitability: 

(b) plant personnel exposure during normal plant operation due to contaminated outleakage in clean spaces or clean Interspaces; 

(c) plant personnel exposure due to excessive system Inleakage which prevents the nuclear air-treatment system from performing its design 

function in contaminated spaces or contaminated Inte rspaces during plant normal, upset, or accident conditions; 

during plant normal upset, or accident conditions. 

(d) o ffsite exposure 

1012 4 1 4.2 Calculation of Allowable Leakage: 

The system designer (Engineer) sha l determine leakage criteria and allowabê leakage to meet gove rn l 

. 

ing Codes. Standards, regula tions, and 

planl •spedlfic requirements for required 

por tions of the nuclear air-treatment system pressure bounda ry (ducts, housing, dampe rs , fans, etc.). The oasis for determining the leak rate, and 

coincident operating (sta tic) pressure shall be documented and provided to the owner. 

Additional leakage criteria may be applied to the pressure bounda ry as determined by the owner to meet plant-specific ALARA p ro grams and/or 

regulato ry requirements. 

Additional leakage c riteria can be found in nonmandato ry Appendix SA-8 of ASME AG-1, including examples of determining allowable leakage for 

i t ical instal ations. i 

1013 4.14.3 Leak Test Parameters, 

Components shall be designed, faoncated, and instalêd to not exceed allowable leakage at specified operating pressure. See nonmandato ry 

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1014 5.1 HEPA F il 

1 

ters: 

HEPA fliters fitters shalf meet the requirements of ASME AG-1 Section FC. 

1015 5.2 Tray-Type Bed and Deep Bed Adsorber Cells: Tray-type and deep bed adsorber cells shall meet the 

requi rements for Type II or Type III cells, respectively, of ASME AG-1, Sections FD. Type li Adsorbe rs. and FE. Type III Adsorbe rs ; and shall be 

filled with an adsorbent which meats the re uirements of ASME AG-1 Se lion FE. 

i 

1016 5.3 Prehliers and Post Filters: 

Meclium efficiency refute rs ano postfifters shalt meet the requirements of ACME AG-1 Section Fe. 

1017 5.4 Mo/sivre Separators: 

MO Sttre seoaralcrs shall meet the reouirements of ACb!E AG • 1, Section, FA. 

1016 5.5 Air Heaters: 

Heaters shall meet the re uirements of ACME AG-1, Section CA 

I 

1019 5 5.1 IHeaterStage: 

The heater stage shall be sized on the basis of heat transfer calculations snowing a capability of reducing the maximum expected re lative humidity 

lof the entering airstream mixture to pproximately 70% in the housing space between the moisture separator or housing Intel (w hichever is 

applicable) and the refiter stage, at the system design flow rate. The sensible heal p roduced by the heater stage shall not result in Increasing air 

temperatures to more than 225'F. An overtemperature cuto ff switch set at this value shall be p ro vided. Manually reset ove rtemperature cuto ff 

switches are net recommenced for ESF air-cleaning units located in areas not accessible following a CBA. 

1020 5,5.2 Drawings: 

Drawings s tr ewing the details of construction, d menslons, dimers'onal tolerances size and location of se rv ices (i.e.. etectncal conne ctions) and 

method of Installation of the air- cleaning unit heaters shall be furnished to the owner. 

1C21 5.5.3 Heaters for ESF Systems: 

requirements of IEEE 323, IEEE 344, and ACME AG-1 Section CA 

Heaters In ESF aircleaning units shall be qualiflad to meet the 

022 5.5.4 Documentation: 

A report containing descri ption and results of quali fications testing and the resistance, certification and se ri al number (s) of the air-cleaning unit 

heaters purchasec snail be fu rnished to the owner, If sma,t scale model tests are the bases of design. scaled-up calculations must be provided. 

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Heat transfer calculations shall be submi tted to the owner if requested. 

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1024 5.7.1 Fans shall meet the requirements of ASME AG-1. Section 6A, 

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1025 5.7.1 Fans shall be selected on the basis of detailed system pressure loss calculations, and shall be capable of producing the specified design flow 

rates. The system designer shall, in accordance with AMCA 201, prepa re a system characle ristc curve for design and limiting conditions under 

which il •e fans wit be re^tilled too erase. 

1026 5.7.1 Alf resistances in the system, including clean and di rty component p ressure drops (as well as test pressure differen tial), fuli•open and intermediate 

co nt ro l damper positions. duct inlet losses, and losses in ducts, housing inlets and outlets, and fan I nlets and outlets shall be considered in the 

estimate of the system characteristics. A set of constant speed fan pe rformance cu rv es, showing the static or total pressu re, corresponding 

efficiency, capacity, and braKe horsepower shall be obtained from the fan manufacturer for each fan configuration. Fan inlet and discharge 

f 

configurations, or other system characte ristics, that would adve rsely alter the published fan pe r ormance shall be avoided. Fan size shall be chosen 

after performing an analysis of the system characteristic and fan pe rformance cu rv es, conside ri ng all system fa ctors including temperature, 

pressure, requi re d airflow and, panicularly for fans operating in pos t-acciden t p ri ma ry containment atmospheres, density and viscosity of the air or 

air-steam-entralned water mixture. 

1027 5.7.7 Fan selection shall also allow for test conditions in accordance with ASME AG-1, Section TA. The system designer shall Identify the maximum 

aLowable di ff 

erential 

pressure foreach fi lter Dank plus a margin to accommodate filter basing which may occur p ri or to the next su rveillance (typically 25% of the 

coincident dirty filter differential pressure). The fan and system characte r istic cu rves shall be included in the system documentation. The fan shall 

be selected to operate on the stable po rt ion of Its pressure cu rve under all operating conditions. Provision shall be made in the design to maintain 

stable operation under the design flows and va rying pressure range. Inlet vanes, i nlet/outlet damper modulation, variable speed fan cont ro l are 

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1028 Fan drives shall meet the requirements of ACME AG-1, Section BA. 

1C29 5.8.1 integral Horsepower Motors •- General: 

Moto rs shall comply w4h and be tested and rated in accordance with applicable requirements of NEMA MG1, and IEEE 112A. Pe rformance snail 

be ve rifi ed by either lest or ce rt ification as specified for each requ irement. Rated se rvice factor shat; be a minimum of 1.0 unless specified 

1030 5.8.1 

otherwise, 

Motors shall be sized to supply maximum mechanical load demand without exceeding the rated horsepower under all iderltlfied operating 

conditions and to produce the required torque and acceleration as re quired by the driven equipment under the most adverse voltage, frequency and 

conditions s eci f.ed and shall be desi gned for the starting sequence specified by the Engineer. 

1031 5.6.2 Drives for ESF Systems: 

Drives In Enginee red Safety Feature (ESF) systems shall comply with Institute of Elect ri cal and Elect ro nic Engineers (IEEE) 323. In addition, 

drives of ESF systems located ; s da xMainmen! show! be qua!ifêd in " 

anroRl anre with IEEE 334. 

ESF fan drives shall be qualified in accordance with IEEE 344. Motor suppo rts and hange rs shall be designed 10 withstand al! seismic and 

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1035 7.1 Drawings: 

Complete air-cleaning system layout drawings showing the location of housing, ducts, tan dampe rs, and the other exte rn 

al co mponents In each of 

three mutually perpendicular planes shall be prepa re d prior to the sta rt of erection. Drawings shall show all connections, hangers, and anchors, the 

location and joint details for all welds, and the p rocedure speci fication for each weld. The layout drawings shall reference dimension and shop 

drawings of components, as applicable. Layout shall be checked for inte rferences with other items to be Installed in the area, and conflicts shall be 

resolved before instatlaUOn. 

1036 7.2 Erection: 

All ducts, housings, fans, dampers, hangers, anchors, and se rvices (electrical, steam, drains, etc.) shall be installed in st ri ct conformance with the 

i 

layout drawings; deviations of more than the design tolerance from the loca t on In any plane from the position shown in the drawings shall be 

approved by the system designer or other responsible Engineer, and shall be documenled by'as•built drawings.' Prefabricated duct 

subassemblies should be made as large as practicable to minimize field joints and field welding. Housings shall rot be used to suppo rt other 

"„ uipmemt of the facility for which it was rot designed: `field runs of pipe, dud, or conduit or other systems of the facility shall not be permitted to 

penetrate the housing. Inte rnal components (filters, acsorbers, etc.) shall not be installed until immediately before the system is presented for 

testing. and shall not be removed from their canons or crates until they are ready to be Installed. The recommendations for handling and installation 

lof 

HEPA filters riven in ASME AG-1, Section FC shall be oodles with 

Date Printed: 21 .09C-04 Example ASME AGO Compliance Mat ri x Page 1 OD of 110 

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1C37 7.3 Welding.: 

i O 38 7.4 

WeldiN procedures welders and welding c orators shall beua,irre ci in accordance w'th ASME AG-1. 

iinsla)lallonofmEPArwrersandAdsorbarx 

.nstalla tion personnel shall be Inslrucled in the proper handling of the HEPA filte rs and carbon cell adsorbers prior to the Installation and clamping 

of the Biters, 

1039 7.4 Components should not be removed from protective ca rtons, crates, pallets, or skids until immediately befo re they are to be installed. Each item 

should be checked for physical damage, or evidence of abuse. Replace or repair damaged items before use The position and alignment of 

foundallons. ancho rs , hangers, ducts, housings, dampers, tans, motors. and other components shall be checked and their locations shall be w it hin 

tolerance as shown on the drawings. Pleats of HEPA filters shall be vertical, gaskets of HEPA fi lte rs and adsorbers shall be se cu rely affixed so that 

they are not dis placed during Installation. Clamping devices shall be in place and completely lightened to produce the requi re d gasket 

1040 7 4 

compression. 

After filters and adsorbers a re unpacked and opened to the atmosphere, extreme care is requi re d to ensure that degradation does not occur either 

from exposure before loading or by system operation during testing, construction, repair, or plant modification. Re fi ners and HEPAs are pa rticularly 

vulnerable to degradat io . 

n due to construction dust. H additional welding Is required on the filter hous'ng after HEPA fillers or adsorbent is installed, 

the HEPA filters and adsorbent must be removed oefo re sta rt ing this work. HEPA fi lte rs a re ve ry susceptible to pinholes from welding sparks. 

Carbon adsorbent :s aged or po!so; ed by trace concentrations of vapo rs such as solvents, paint off-gassing, engine exhaust a nd welding fumes, or 

1 .t ' m.^ry^ YS,;;f4 .. 

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bv moisture condensation. 

QUALITYÂSSIJRAAICE 

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1041 The design organization, manufactu rers of components, and constructors ( including subcontractors) shall each establish and comply with a 

com rehensive ualit assurance ro ram and tan which meets the re uirements of ASME NQA•1. 

:` , ; Acce tariceTifstri. ,,°r r n rrr, ? `> ;r : ,. 

1042 9 Acceptance testing shall be in accordance with ASME AG-1, Section TA and operational testing shall be in accordance with ASME N510. II is 

recommenced that prefilters oe installed before fan is fi rst turned on to protect filte rs and fans f ro m construction deb ris, and the system tai nts) 

should be o perated for at least 25 hr be f ore installation of HEFA fi tters and adsorpers to clean up the wo rst of construc tion dirt (artificial resistance 

may have to be added during this operation to prevent overloading of the fan motor). Prefilers may have to be replaced after this evolu ti on. For 

pe rs onnel p ro tection, pe rsonnel sho ul d m oil enter housing until fan has operated for a sufficient pe ri od of time to remove air enlrainable debris. After 

installing the HEPA filte rs and adso(bers, the system heate rs should be operated, where p rovided, to reduce, if necessa ry. the relative humidity or 

the air rlor!o making tests on the adsorbers. 

f 1C43 I 9 IAII dampers, valves, and cont ro ls snail be exercised through their fu;; opeiat:ng range a n d slhovir. td be in good oper ating co nditio n, before the sta rt 

of testing. After completion of acceptance testing, the system shall oe sealed and the fan controls locked out to protect the components du ring the 

remainder of construction o eraticns at the site. 

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1049 5.1 Purpose: 

A vlsual inspection brine air treatment system, as specified by the lest program, shall be made in ccnjuncllon with each test se ries to Identify 

visual deficiencies in the

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058 5.5.1.4 Mounting Frames for Filters and Moisture Separators: 

(a) Continuous sea! weid between members of a l frames and between frame and housing.' 

(b) Adequate structural rigidity for suppo rting internal components during operating conditions without flexure.' 

(c) No unacceptable damage to the frames that may interfere with p roper sealing of components. 

(d) Sample canisters installed and unused connections capped or plugged leak-light. 

(e) No penetrations of the mounting frame except for test canisters. 

No sealant or caulking of any type. 

1059 5.5,1.5 Filter Clamping Devices: 

(a) Sufficient number of devices of adequate size to assure speci fi ed gasket compression. 

(b) Individual Clamping or filters and adsorbers.' 

(c) All clamping hardware complete and in good condition. 

tl Adequate clearances provided between filler and adsorder units in same bank to tightened damping devices.' 

1060 5.5.1.6 Moisture Separators: 

(a) No unacceptable damage to media, frame, or gasKels 

(b) No di rt or debris loading which creates a higher than the specified pressure drop ac ro ss the bank of components at the design airflow, rate. 

(c) Proper Instaf!aticn of moisture separators 

1061 5.5.1.7 Air Hearing Co ils — inside Housing- 

(a) No unacceptable damage to coils which may affect operability of the heaters, 

No unacceptable di rt or deb ri s on or between coils. 

1062 I 5.5.1.8 Pre-Filters: 

(a) No damage to media, frame, or gaskets which may affect operability of prefilters. 

ne filter banK at the design flow rate. 

(b) No di rt or deb ri 

s loading which creates higher than the specified pressure d rop across li 

c Proper Installation Of prefillers. 

1063 5.5.1.9 HEPA FNers. 

(a) No unacceptable damage to filter media. 

(b) Acceptable condition and seating of gaskets with at least 50% comp re ssion. 

(c) No di rt or debris loading which creates higher than the specified pressure drop across the fi lter bank at the design flow rate. 

(d) No sealant or caulking .of any type. 

( e) Filters ere nrn_ri installed with Weals v e rticai. 

1064 5.5.1.10 Adsorbers: 

(a) No unacceptable damage t0 adsorbe rs or adsoroent beds . 

I (b) Acceptable condition and sealing of gaskets with at least 50°o compression. 

(c) No th rough bolts on Type II adsorbers or other structure that could cause by p ass in an acsorber bank. 

d No sealant or caulking of any lv e. 

1 065 5.5 1.11 Dampers —Housing and Asso ciated Bypass Duct 

(a) No unacceptable damage to or disto rtion of frame or blades. 

(b) No missing seals or blade edging. 

(c) No unacceptable damage to shah, pivot pirs. operator linkages, operators, or packing. 

(d) Linkage connected and free f rom obstruction. 

e No unacceptable damage to gaskets. 

1066 5.5 Acceptance Crileria 

The acceptance ontena shall be in accordan c e with test program or proiect specifications. 

1067 5.7 Report: 

The test procedure shall document the results of the lest and conform to the owners test program, items dentiried as unacceptable shouid be 

ifuriher ddcurnented in thc mm M sec;Ion cf the test re Orr to assist Ne owner m -e aratlon of corrective action. 

D CT,ANG NO(J51NGL^Y^KÂNE'.STRUCTURIIL^:CAt?ABIl 1 T Y fESS0__T , , ..^x .s 

1066 6.1 Purpose: 

These lesl5 are to v rifv the leak tightness and struc t 5 c Nil ^L'^: 

ural me nt 

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of housings and d c s 

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1069 6.2.1 Structural capebd iry Test: 

Ducts and housings of once-th ro ugh and recirculation air treatment systems which could be subjected to etruciural capability pressure due to 

unsu 

re of dampers on suction or dischar9s of fa as shall be pressure tested a nd vent ad that there Is ao unacce ptable distortion or breach of 

( irte ri 

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T • Test I incorporated In the design) 

1070 6.2 .2 Duct and Mousing Leak Tests: 

Ducts and housings shall be pressurized to determine leak tightness, If the measured leakage is in excess of the acceptance Cmena, the ieaks 

should be located by one of the rnetnods listed in pans. 6.5.4 or 6.5.5. A fter ! y aks a re repaired, the housing or duct shall be retested. 

1071 63 Prerequisites: 

Construction, modifications, and repairs affecting the lest bounda ry stall be complete and the inlet and discharge openings of the duct or housing 

sealed before the lest is sta rted. All electrical, piping, and instrument connec tions shall be complete and all permanent seals installed before the 

1 .: , .. ^.-.a 

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test is started. 

APPARATUS rn... 1'Y 

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1072 6A.1.1 Test tan with Cow control, 

1073 .4.1.2 Covers to seal test boundaries. 

1074 6.4,1 .3 Clock or timer accurate to ''- 1.0 sec. 

4 

1075 

/;i, 

6.4.1.4 Pressure Indlcad Cevice'accur to to +/-0.1 in w. 

•c.- 

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43:':- : D11C7%A1JD HDCJSING!'LEAK RATS J7 ST '" 

.a 7 s.c y ,.1. r•, Yd 'Y' Ai?x rir 3y(` >'. *oi, v,: 

1 076 6. 4 .2.1 Test fan with now Control. 

1077 6.4.22 Flowmeter or totalt as volume meter accurate to . +-5h c' reading. 

1076 .4,2.3 'em erature Indicating device accurate t N• 5 de grees F. 

1079 6.4.2.4 Pressure imclicaling deice accurate to +/- 0 1 in w, 

i060 6.4.2.5 Covers to seal test boundaries. 

1081 1 6A.2.5 Clock ortmer accurate to +/- 1.0 sec. 

1062 I 6.4.3 Bubble Method: 

Bubble solution in a plastic squeeze-type laborato ry wash bottle (a commercial test solution or a so lution consisting of equal pa rts liquid 

deter ent glycerin. and water). 

1083 6.4,4 Audible Leak Method: 

Suitable electronic sound detection a ut merit (optional). 

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1084 6.5.1,1 Connect Vi e rest fan wile, now control to the housing and /or ductino. 

1085 6.5.1.2 Install a pressure indicating O ev ice so that it will indicate the pressure Inside the duct and/or ho usjnq bei . tested. I 

1066 6.5.1.3 Saal lest boundaries and dose acce6s openings In the normal manner. 

1087 $.5.1.4 Start the fan and operate until the strut r { capability pressure is achieved Maintain pressire for the duration of the i inspection 

1088 6.5 1.5 Inspect the pressure boundary for distortion or breach of integrity. 

1089 

xe 

t 

6.5.1.6 

c. 

Releas pressure and Ins ect for erman,nt tlistortion 

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1090 6.5.2.1 Connect the test fan with flow control to the housing and !of ducting. 

the housing (downstream of the throtillng valve if used 

Connect the Ctowmeler or lotallzing gas volume meter between the fan and 

1091 6.5.2.2 Install temperature and pressure devices to incicaie representative temperature and pressure ins;de the duct andlor housing oeing tested. 

032 6.5.2.3 Seal test boundaries and close access openings in the normal manner. Do not use tempora ry sealants, duct tape, or similar tempora ry mate ri als 

except fors alln and !emporary b lankoffs. 

1093 6.5.2.4 Start the fan and operate until the maximum o perating pressure is achieved, Maintain pressure constant with a flow cont ro l device until the 

temperature remains on sla n t wilMn •/-0,5 decrees F for a minimum of 10 min. 

1094 6.5.2,5 Measure the flow rate of the air being added to or removed from the duct/housing while maintaining the maximum operating p re ssure w.thin +i- 

0.1 in, w.g. The now rate should be measu red oy one of the following methods. 

a) For a flowmeter: record Cow readings once a minute for a 10 min continuou s_ pe riod and average the readin g s to calculate the measured 

akage Cow rate. 

b) For a totalizing gas volumemeter, measure the total volume of air for a 10 min continuous peroc anddivide the measured volume by time (10 

ti9ri) to calculate the measured leaks a now rate. 

1095 6.5.2.6 If the calculated leak rate exceeds the acceptance value, repo rt to the owner and locate the leaks in accordance with para. 5.5.4 and for para. 

fi..5 R air and re'est as •e wired, 

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Requirement I 

Number 


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i T • Test incorporated in the design) 

1097 6.5.3.2 Install temperature and pressure devices to indicate representat.ve temperatures and pressures Inside the duct and/or housing being tested. 

1 

l 

1 09 8 

6 5.3 .3 i Seat test boundaries and close access u erunes in the rom al marine' 

1099 6.5.3.4 Sta rt the fan and operate unti the maximum operating pressure is achieved. Maintain pressu re constant with a flow cont rol device until the 

temperature remains constant within -1-0.5 degrees F for a minimum of 10 min. Close shutoff valve. 

1100 6.5.3.5 Record initial time, pressure and temperature 

1101 6.5.3.6 Record baromet ric gressure. 

1102 6.5.3.7 Record pres4u re readin 5 one a minute until pressure decays tc 75 1/6 of the test pressure or fp r a maximum of 15 min. 

1103 65.3.8 Record final time pressure, and temperature, 

104 65.3.9 Calculation eakage f ro m the a ua tIcn:.. 

1105 6.5.3.10 If calculated leak rate exceeds the acceptance value, report to owner leaks in accordance with pares. 6.5.4 or 6.5.5. Repair and re test 

:^.: 

as re uired. 

:'As u^ +? ? + r^ :, .fis r ' r sYVt Y rn^ xF ,$ " •.*r >L„ kT 1 u , t 7 w rr , r a :< y, . x r Ft a it ,:' S, .. t N a ;;: , 

1109 6.5.5.1 Pressurize the test ;Endary to a r IeSsjre ado uate to detect leaks not to exceed structural capability pressure). 

1110 6.5.5.2 With test bounda ry under continuous pressure. located audible leaks (electronic sound detection equipme nt optiona l). Identify places where 

leaks are found. 

1 1 11 

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6.5.5.3 

-.,. y ! 

After re air of leaks retest as re 

'. ' 

uired. 

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1112 64 1 

ACC EPTANCERI7ERIA:r: 

Structural Capabili ty Test: 

Meets the requirements of ASME N509. test program and proiect specifications. 

1113 6.6.2 Duct and Housing Leak Test: 

1114 6.7 

Met the re uirements of ASME N509 test program and project specifications. 

Report 

The shall inclu a documentation of the results of the test and conform to the owners test program. 

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1115 7.1 Purpose: 

This optional test is used to verify the absence of leaks through seal welds of the HEPA filter and/or adsor per frames, and between the frames 

i 

z house 

' 116 7.2 Summa ry of Method: 

* 3t. f,.f 

Openings of the test bounda ry and mounting frame shalt be sealed with ;lank-off plates. The leak tightness of the mounting frames meets 

requirements of para. 6 6,2 when tested b the ressure deca method ara. 6.5.3 or the constant pressure method ara. 6.5.2), 

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1117 7 3 .1 Construction modi6cebon & and re airs of the test boundar y shall be completed. 

1116 7.3.2 Mounting frame blank-off plates installed. 

1119 7.3.3 Test bounda sealed and all doors and access panels closet Ir the normal manner. 

1120 7, 4 Apparatus: 

i 

The same as p ara. .4. 

1121 7.5 Procedure: 

The same as para . 6.5.2 or 6.5.3 

1122 7.6 Acceptance Cr iteria: 

Meets the eayl ,ement s of ASNIE N509 the lest program and rolect specifications. 

1 123 7.7 Report: 

The test procedure shall include documentation of the results of the test and conform to the owners test p rogram or p roject speci fications. 

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Number I Source Requirement Text 

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T" Test I Incorporated In the design) 

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1125 8.2.1 Airflow Capacity Test 

a is measured to veriy capacity at dean and dirty filter condi tions when the system is operated a! normal or simulated rr.!nlmum 8M 

maxium r", oesi n condilons. 

1'26 8 2.2 Aelow Distribution Test 

Velocity pro fil es of the filter bank(s) shall be made to evaluate uniform alrflo+ distribution The presence of uniform a i rflicw distribution for the 

upstream HEPA flier bank shall be adequate to venfy vni form dist ribution for the downstream ad so rber andlor HEPA fi ller banks It the banks have 

- . 

. 

relative unilcrm cieome t 

».g :i{. >ti 

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s:1 8.3 :.,;. RREREQIJISITE3, 

and ro 55-sec Tonal area n are not irtemu tetl rn or bends. 

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Number 

Source Requirement -ext 

R • Review 

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1137 8.7 Report: 

...^ 

Theo st rocedure shad include documentation of the results of the test and conform to the owner's test Wore 

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05 1R. AER;ì'Y ANMW—P :LACE'< TE57r, z. ,z, :;:.^,,..,_,, n^ x 

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1154 10.1 Purpose: 

This test is used for both acceptance ar,d su rveillance leak testing of the installed HEPA rifler bank. 

1155 10.2 Summary of Method: 

A DOP challenge is injected into the airstream upstream of the HEPA filler bank. Concentrations shalt be determined upstream and downstream 

of the filter bank. Percent penetration Is determined from the ratio of the downstream to upstream concentrations (Section 3). 

1156 10.3 Prerequisites: 

The upst re am sample and injection points to be used are those quali fied per Section. Single point downstream sample points shall be 

Downstream of a fan or downstrea m sam le manifolds hall be qualified er ASME N509 

^? tU ^^0^42 ;4PPf1FtA7;:i`f US .:'M.^.l ^3 j rrfk ,5 ] 'S ` 3 îr.i aYrr^,^}fi^:;ft?4^ x P. f7^.lF,f a~^`, .^.7.,. t F rr. !v NOW,,.2ai"C: "r, 

1157 10.4 .1 DOP aerosol or suitable ltemate . 

1156 10.4 1 P ae ro sol generator. 

1159 10.4.3 Aerosol delsolon instrument. 

,. 

1160 

t 1'p. i2.Jr t 

110 4.4 $518m fan cr a w is fan r'o. s stdm norâh^ wdhou^t fans) 

-. 

Y..)= Nr.7`w" , RI2{ ^` bS^RERF'?:'T . . •A. ît^ri ,`r ,, g., 

a idle of drodvcm he airflows ecified In the test 

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1161 10.5.1 Est b h airflow through the HEPA filler bank at the flow rate specified by the test program or project specifications 

1162 1 10.52 and record the pressure droR across the bank using system or!empa.-ary test Instrumentation. 

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Date Printed. 21-Dec-04 Example ASME AG-1 Compliance Matrix Page 107 of 110 

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Re q uirement 

Nurnbar 


1 163 1 1 .3 Connect a row detection instrument sample lines to the upstream and downs ream sample ports. 

11B4 10.5.4 Check the background particulate concentration upstream and downstream of the HEPA filler bank. The preirjection background levels shall be 

staoie iv ensure p roper instrument response. Tr;e levels shall not interfere wit the detecl0?s ability to cetect pe.-,vaticn smaller than the .maximum . 

.penetration all d by the tot program or project s ecification . 

1165 10.55 Cann ct DOP aerosol generator to in j ection port and start injection. 

1166 10. 5.0 Record ypstrearn concentration reading. 

1167 10,5.7 Record downstream concentration reading 

1168 10.5.8 Repeat steps from paras. 10.5.6 and 10.5.7 url:l readings are repeatable winln -/-5% of respective p r evious rsaoings. Use final set of readings 

to calculate penetration. 

1169 10.5 g Calculate penetration Section 31. If calculated Renetralion exceeds the acceptance cinteria, noti fy the owner. 

1170 10.5.10 When the housing contains more than one bank of HEPA Peters in series which are requi red to be leak lesled, re peat the procedure for each 

bank. 

+171 10.6 ACceplance Criteria: 

All waole penetration shall be as staled in the lest poo ,am or proiect specifications. 

1172 '0.7 Report., 

The test procecure shall include documentation of the results of the tests and conform to the owner's test program or P ro ject specifications. 

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I Design Document 

R • Rill 

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A •Analysts (Where is this requirement 

T • Test incorporated In the design) 

4w 

In^(^.R:^13J'^.`^`t . „t ABSORBER'B"AIIC)NI:Pl^4C.^'.LEAiC2`TEST"?S1F't3 ,4^'^êS^M,"S?^'i^ fA^'4?., ^?a^Yi ^fi^r ^s^.i^ .^ . .` . •b`'F „ >;,.':. ,a' +^,.. ., . ^., ,,; ^ , r .. _ *.^^ 

1173 11.1 Purpose: 

This test shell be used for both acceptance and su rveillance leak testing of the installed adsorber bank. It samples of adsorbent are to be taken 

for laboratory testing Section 15). remove such samples rior to this test. and restore bank to 0 erati co ndition. 

1174 11.2 Summary a Method' 

A ha lide challenge gas is Injected into the airstream upstream of the absorber bank. Concen trations shall be determined upstream and 

downstream of the bank. Percent penetration Is determined from the rat 'o of downstream to upstream concentral:on rSectlon 3 . 

1175 11.3 Prerequis il es" 

The upst ream sample one injection points to be used shall be (hose qualified per Section 9 Downstream tr sample p e po inis s h ait bbe downstream of 

+ 

Ji 1 I..4 

a fan or downstream sample manifolds shall be qualified per ASME N50 9 

.. 

vr 

Y 3814 r J T f` rb µ :,777 4F ^ 

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1176 11.4.1 Halide as R-1 1 is preferred: R-112 or R-1 2A is an acceptable,altemate. 

1 1177 1 11, 4 .2 Hailoe q as generator. 

1178 1 11.4.3 Halide gas deteclion instrument. 

1179 11.4.4 System fan or auxilia ry fan (for systems normally without fans) capable of producing the airflow specified In the test program or project 

specifications. 

NOTES: 

1) Sample line lengths should be minimized to reduce sample response time and of equal lengths to eliminate time delay er ro rs. 

2) It may be necessa ry to operate system for a pe riod to purge all resldual challenge gas fro m a prior lest to reduce background 

c 

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1180 

w :,,. 

^^^^1i.5.> 

11.5.1 

concentration Lip acceptable values 

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F^FYOCEDUREr?` .^ a ... r x,. y 

Establish airflow through the adsorber bank at the flow rate specified by the tes 

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Number I 

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Rtr r y_~ 12-4-M: I7CrrMr AMPERf8YP SS%TESF^^ Z"^ s frR s ^' 3 Y , F1,. 

1190 12.1 Purpose: 

To measure the eakage through ciosel d am e rs or valves rrtenaeo to ai:'minate flow ihrcv h a bypass duct. 

1191 12.2 I Summary of Method. 

For low leaka g e valves, a pressure decay test Is usually the method of choice. For higher leakage devices (a few tenths of a percent of rated 

flow or greater) a DCP aerosol or halide leak test may be more convenient, if a DOP aerosol or hafda leak lest is specified, o nl y one damper al a 

... 

time is to be tested The method shall be de fi ned in the test ro ram or 

123.',. ;; k t 1 

ro ect specifications 

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T • Test incorporated in the design) 

1214 14 ,1,1 Purpose: 

This test is used to veri ty that the nuclear air trealm w system an neater perforrnanc e m is the lest proQ ram or prD i ect s°eoific tions. 

121 t 14.2 Summary of Method. 

Power-en electrical and mechanical tests shall be performed to ven correct o ration and coh ikon of the air heater. 

41^Yr":EaEaurs)rES}. .^:• y_ ^f 

1216 14.3 1 VlsuaI ins ectton of the heater is com leled ara. 5.5.1.7 1. 

1217 

.'... ,:. 

14.3.2 

14:4 

Elect rical control and fe d ower is available and all safel mterlo ks have been checked, 

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1218 14.4.1 C!am -on ammeter and voltmeter accurate to +1 .5°,6 of reading. 

- 

1 1 g 14,4.2 Te rn eralure indiGeli device accurate to +1-1.0 da rees F. 

,.,745 

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. ,:.PROG'ECIURE` 

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t 220 14.5.1 Power-on Electrical Tests: 

With wer on ands stem operating at rated airflow. measure th e voltage and cu rrent of all power circuits. 

t 22 t 14.5.2 Power•On Mechanical Tests: 

With heater energized and system operating at rated air flow, measure the temperatu re of the ente ri ng and leaving air. A sufficient number of 

measurements shall ken to determine average entering and leaving temperatures 

1222 14.5.3 If measured values do not meet acceptance crite ria notify the owner. 

1223 14.6 Acceptance Criteria: 

1224 14.7 

Operating cu rrents volts es and chanoe in te rr erature shall be within the limits of test program or project specifications, 

Repo rt: 

The lest procedure shall include documentation of the results of the tests and conform to the owners test program or P roject speci fications. 

MIN 3u.r%N 

^4fit. 2^:, 

h ;^?rr 

#,. r a..... 

, 

lit 

'.n 1 S!^ :,N ..,s,UABb "fOR1!-'E5TIN 5'r.. .^+, p . 

1229 . 1 .5.1 Tel adsorbent m le In accordance with ASTM 0 3803 

1230 1 .5.2 If results Oo not meet acceptance criteria noVy the owner. 

1231 15.6 Acceptance Crilerla: 

Adsorbent test c ritera shall be as st t d In the test prcqrar. or -rciect s ecifications. 

1232 15.7 

' 

Report: 

The test procedure shall include documentation of the results of the tests and conform to the owner's test program or Project speci fications, 

Data P rinled: 21 •De c-04 Example ASME AG-1 Compliance Mat rix Page 110 of 110 

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,SA4%2 $mMkil?ml WeWel'AUSMnW Spide cSreetPê 

SA-33S Sea WM R kkAEoySW fto [a KoT ft p )a SW MM 

iM530 . OnnMal eegWieneln fix Wnbffnd Carbon and May SIM pipe 

a.I.9 

-SA-3it. SearnIm Fem'Iic and. Aug Ym Agoy Rol Roile, S"fmnn, and l tebebutga Tub" 

-SA-240 ChmnA un end cwwq w Nidoel Aainko stm "a Stem and Slap Poc Fuion-Nv ded EMC cd Preuuvo Vess,6 

'SA-2B5 Planet 6vne vie Yew, 

• 5h515 Cadwn SW Platesfoa pnesuu Wzck kc lwmmawe and prow Tenperanme 5vicv 

àA-SIG C chum Rqd FlaaS hx A¢Stneo Vgw&ID, Mmdu.and lawn Tcmp^ Senkz 

IA-165 FwgW or Rolled 9reak Pipe Ftinpq,fugidfimMgâM Ya0.xsaM parts tv f4yp-Tewpernwe Senicc 

SA-1 St Fw d ot RAWswa1.pipe F.taa&c,Faged fnfxgs,md Val.esad Tams nn Gen" Sek. 

SA-132 FaW ot Ro9ad Ahoy-Smad Pipeft.Vn,(bged Rftm and Wm and Pals W Ffgh-Tura ea&ce 5ervi(e 

:9ok; Fol., and Skmh 

- SA-}'97 .VI4JS2el BOhh g>•9aw+imh tmN I"onpernec sw a 

.SA 94 Cafiwa,d ARryAevl Nuts Fm Oohs For NighAmur¢adlGg4Tanyuavxa SnYice 

SAJOT LawCad^n$red EZeroOy and MlevRy TMeadd Rmlxd Fanemers 

. - 'SA354 Qoednid and Tempasd AlMy Ste90o7N UtSSMk nAh Snthk Nuts 

. 

: tamp 

. SA-2l6 Ca.ban Sxd Caging. Riabkkwf.sb. Weld ing ter l6gk.Temperamre SCnice 

SA 2tT AlbySed Ga ngs lw Pre Ame_Cwa fi mgPanFSybkkfw xgk Yempeuu a 2rc re 

3A'-35t ferl6cand A,urmhic5teetG9ingskr Hlgk-TanpaaMeService 

STsae Ural C—?-- .. 

.. S.A-76 Sw.1wa3 Real 

"X-263 Low and W&ondi Ton4e Samgh Cuban Unf Plana d Sau .lQua9y 

' ASMEM6mr,an, A4k "spw&,.t;om 

Ahuainanml ay soaa aAd Pbw 

118 

- 

fCrn^drarc 

Pfinteal On: 22-Dec-04 Page I of 2 

G5-250

RPP-24544 REV loll 

Exhibit A 

STD-ASNE AG-3-EN 6L 1447 i 0754670 0603315 316 M 

.ASME AGS-199'1 DA-3000—MATB6NLS Table DA-3480 

W211 A)Ominom A%r BUM Rudt and W" 

58-41 Aliutnnwn Mby Eanadcd 9UM wbdM a45hapa 

S9aatmadc mpantatt 

TABU EW3100 tCONr]Dl 

ALLOWABLE MATLRLMS 

A51M Fe M .W Sp GAMAn 

A36 A4ttutaFSa:ad 

. EL-logSkit 9x C eb COW Fi-WW, Sw-^z'atd (bWi t 

A176 SW OM ui vChpmio 'Ad-t Stud Nam. Sikh, and M+ 

A241 Yiigh-57trÊt [oVa APq Sba pwal Stet 

A-276 SW k-A and ilea-Re4sinj Siecl Bas WA%4P 

&284 Lm ad nretmedlax TMk 5bs>OCmbm Simi Males Fm MaMina%ata Om" Cmflmtt4m 

. AS75 Ac76an, CAM madam QMIj' 6V GI&S 

R-57b SIM4 Ran, CA", Nd-WtayJ+, SpttW QOa1R-r 

]M k,--i, and Strip 

A-J" 2.c Pk6Goban3tdlC.a,Vmfw&.k FA lewd hom WAled. Pmned:nd Fovd%M*-M, Kim Wn, ad 

:A-167 

.h.2a0 

Atp 

SW,.k..d Mraitepstktg l'3ranhma-Mad SIM Maw Slice{ and Shp 

W-*-Reisft Chrnuum xd ch..'om-Mcw4aW. Sml Mw. $hest aMA-p kr FW.. WOWA V.Gnd 

inYflnY YCRCk 

A166 

^., 4 

:A460 

COId.RMkd Q b. Sttd SAM. Caor ew QuaBy - 

Rtti 9n Zinc-C-Rd IGaNanizedl by die Lftt .Oip 1v.t SSruebsal WhpkaP QwU y 

Ctrotxal klWbc t f FIX4WdSU*A VQHrU-P.es-" S)td Pbte. Shea. and SWP . 

Â-)Ba 

Cty l RtpvSenmtm kc$ AAn and Heaa-RCSbdng Wt .Os Stmt ftdacn MKcpt4Wba 

'A-57S Grnt»t Rttryi emtcx ip 51cd 9 , Tmc Co ed br Hat-P:p 1',"W 

'A-526 Siml Sheet M=COU by Yo ip Piarns Cma httrial QuAky 

+527 SW 5ha, Tine I dW Kx.D"9 P+o .tuck F.-;%Qwhw 

A-570- "m Rolled Cabin Sxd 56tts aW SUSp,. lmamal ( YualKy 

ASR: Frt ^Wmg ST.Wm and Heat.Rot>imR $, N Aak alm-kaw m Cy'al.T% Amd 

A•606 $Led Mw ad Sate, Hat-and Collgaot Hryh S1nmgd , Low-Aitoy r Wh I pew d CO ve. Resislase 

.A-WT Reel Shea xd,St* /b6 and CohL%Mkd. li2•tt , 5:kpga,, L. A" Cobimb;. a 41U V m r..' 

A-6i)S;e. Cdkt-ROfl d Stitt. Cxb.. 5t .l , 

- 

T b{p^ 

9-68 Seamen Ameakd SOFt Coppo T^bipg 

-8=75 Sea tm COpm 

'a." Seamkss Ca tube 

A m NoeFt.nwu a wlj $pedfiofi0 

Printed Ora: 21-Dec-04 Page 2 of 2 

139 

G5-251

RPP-24544 REV Id 

Exhibit S 

STD-AM A6-S —ENG! 1997 ! 0759670 0603631 201 0 

love iC. Oo DMSM H — SFC1$GN FG AM" AC-1-t997 

- TAKEYG-3100 

AUDWAKE MATHDALS 

-ASTM ANSI 

De&l Deft 

Carbus Sind PAM andYtetls ...- 

1i 283 L tod iuemnd'ro4rwl¢Seg& Carhm Sted Pfas, Syedk d.4 Ar. 

9284 Pra Vrusa plarei; Carbon S*d LOWW4 In m.;ate S6mg4 SpedP['-ramn f6., 

aU 366. Steil, Cuba%Coot Rdkd Am. Comm al Quilky, SpettSGauaF 64 

iA 414 Cxbm Skd Area br Pesssae VaM6%-ptx0'rcasm fm, , 

:A$66 

Gw" nKrrK lm Secu4 Carb-vii no $1 0Ls AkoyHd-Roked A-et 

A569 St

'2,ba,dzad5ttd 3buaNûl Members 

A53 

C(lo3 


Exhibit B 

STD.ASHE A6-1 —EN6L 1997'1. 075967 11 0603632 14A 0 

;.A$]im A6'I•1593 M3040—MATESUAIS TRbh FG-3ll00 

A51M ANU 

taeboosted gw4O of Members 

A 36 

'A 106 

A 16a 

A SOD 

Â 501 

AWS 

A 516 

#S'i.UJiYi Skd'StniilWai Mtrobtrs 

A 226 

A Sat 

A 4T9 

Asti 

A s $4 

.SL'd R,d SOlb a,d Nuts 

A 193 

A}94 

x1493 

CSdwa S*d Baba,A [an 

A 307 

A 325 

A 449 

A549 

A 563 

JiM21.1 

Bill-n-2 

TAKE FG41001CONT921 

AMOWAKE WYERMAS 

sbuca" sbd, 5pedfiMM IN, 

s,AAm,[wbaa9,f P" for W.gb it.pemm* Sarks, SpcdkaAi -W 

Seel. em, Ca,ban, CoW lidded, SWndadQnlay,sp?e_B%C gtoo to, 

Cotddamm Wadded and &Notes Ca b. Rw4 S .MW TAaSY RNmds-4 

sh*m 5pi ifima"fo. 

HN.FNmiW Wdded.dSeam &H Carbon RedSbbctural Ttddng S'PmOkXM k:. 

Steel Sars,{?dw t Mtrdls Onray. MC,asdM 400ftAii a (a. 

sad Rars. Gxbw Hot W-%K Spea:Wl Q-14.SpeSRol (M, 

SWAIM arai Heat Rekfmt Bred Bars and shapes, wrwatma k,, 

seamlra and wcwd AOmas9destaf sled Pipe spedRada!.far. 

W.kia ad He -Resht tSad Wx Sari and 5.asaP&, kitBa tvWke s aad Odaa 

FfZdiortYCSfe545PKMR lm for, 

seamlex Sl bke 3•.ed ak

f ^. 


Exhibit B 

. :ST4'.gS IlE A6-3-ER6L 39`17 M 0759670 Gf,03633 054 ! 

T%wFEf3fa8. VIWWE$f B.— SEMON FG ASbtL AG•L-f997 

A" 

NoiilFemuf,Mrt" 

Caatt^ 

_ 

Ate 

TABLE FGJ1iq tGowm) 

ALLOWABLEMMEWAS 

F467 Rat for Cumd Vf spK&CAM fm 

.A 123 ZkKOionCair.NUdC"" mPmdu f9bîtaied km. WW, Fwwwd, and Fna 

Aed Slupm P-k; Bars. and Saip, Sped lm f b, 

vi,- 

'A 153 zinc'Goil11fto wapl m Arn and SftdR. wait. sNdkafi. fi , 

8364 lkamdt>)Ofilrf CO.&W of sow g1 101. 

e.®533 firaodepoald C"40'A Vi O. ft A .W 'S*dk*m4 

Printed On: 21 -Dec-04 

Sib 

G5-254 

Page of 3

ASM Deily .ASIM Deslg. 

Me. and Ship 

RPP-24544 REV ld 

Exhibit C 

TABLE NA-310 

ALLOWABLE ALATMAIS 

A 167 Raiders and i-mae Rest" Offoa+Mm ww Sloe PM% Shee4 and Strip 

SA-240 A I,* "a* Resisteg Chroace .m and C2vomkmn NHkd StaWm Steel Ptak, Shed, amt Strip 

for Prefw a Veoth 

.SA-X - A36 Sha c eaal Sred 

A 283 Low and loterm we Temile 90 agth Casbm Steel Plam 

.. _ A 284 Peamre Venal flares, Carbon Sled. Low and imesmedlate Smngth 

A366 Steel Cadwry Cri4d4WRed Sheet' CMMWdal Qua1Ry 

SA414 A414 Carbon Steel SMet kx Presiumi Vtmis 

A 446 Steel Shed, Zinc COaled (Cal,-mk ed) by TheF4t4Np Proc ess, StnKWml tPhysical 

Quality) 

... A 525 Steel Sheen, Tmc Coa ted (Calvanizedi by the Hd-00 prcce s, General Reoveieenh 

" A 526 Saw sf act, zinc Coated 1Cat,aolzedt by the Hot-Clio Puttees, Commesdal Quality 

A $21 Sled Sbzd, Tore Coaled Kxab.aaz cdll by durli t-Dlp home, Lock forming QgiRl• 

-.. AS68 CeneWR it in nenh foe Steel, Cesban, and HO-Stra 1%WwddlW. Hot-Wed Sheet/ 

and Cold 4tolled Sheet 

... A S69 Seat Carbon AIS matt U Hm-Rolled Shad and'Sbip, Canmereia) Quality 

.. _ A 520 "d-Rolw C.A on Stall Shm and Strip Suuch, aA Qua lity 

... A 611 Suet Cold-"r4 Sheet, Cadaon, S"cmral 

.,- A620 Steil, Shay Carbon Dmw&g Q%aA-. Special K illed, COfd4011ad 

A 621 Steil Sheet and Skips, Carbon, Fb4ROlk 4, DmA g Quality 

... A635 Sleek Shed and Ships 14mynirclaaas Ca$, Carbon, Hot-Rolled 

A"2 SW Shep, Zinc cv;n l ECalaanizodl by the lid-Dip Protest Drawing Quality Special 

Ow 

A 666 Auamibc S tainless Steel Sheet Rdp Pide, and flat Bar for Structural Appiirafmos 

5&204 $209 Alamiau.aa and Aiumirasm,AWT Slitd and Plait 

B 16 Standard 4Aerifpiiaa lot Free Cm6ag B*n Rod, 0x, and Shapes for k,c Mall.,a 

B 140 Standard SpeeiBmlion for Coppe 74,c-Lead (Leaded Red Rra,> o, Hardware llW e) 

" Rod, Be, and Shapes 

Stmcwal Bar and Shapes 

SA36 A36 Stn wl s%Y4 

A )0B Sleet Bar, Cf.bom Cold Finished, Standard Quality 

A276 S!ai rdez and Heck Resbu g Steel Bars and Sbipes 

... A 493 SiaWes9 and Heal Resisting St eel for Co ld Heading and Cold forging B at and me 

... A S00 Coed-Famed Welded and Seamless Cadet St eel Suoaural Tubing in Round and Shapes 

A S01 Hot fNw.,t Welded a.J Seamhss C,-b n Simi Smxmral T.bbg 

A S76 Sted Bat, C: rbm tit Wrought S,,îdl Q.Rwy 

"hardware 

SAJU A 162 Forged or Balled Alloy Steel Pipe Flanges, Forged fhfmgs, VANy , and Para for High 

Tempe a w 

225.11 

T+Ye 

fccounued) 

Printed On: 2I-Dec-04 Page I of 2. 

G5-255


Exhibit C 

f ^. . - .. - -..^.^,... -.. A 0751670 06211M 603.5 

TAU TtA. ve D1VISIM e — SECT" HA AS69 AG1t200 

TABLE 7U-3100 

AUDWAKEM MALS(COMM 

:. AMR 0*4 A$AtDki& .T-* . 

PPa7 *Ael,AW Ski 

.SA-193- Ain 

yM% A 19 

SA•3OT A307 

W2S 4725 

Al* Sxtl a.d 4awmska 0WPn8 rdat j Ngyl. TaepnssxeSrwice 

Cd&aa and Alb, Skd Nq fu WN fa MSA PR y eand 140 T.-Pt 

Gtoamm a.* } A sm&s 6RDC0 fa: T-d* S'#0 

^* &"h S-W Im St.tl A S'.6 W-w 

Service 

- 

. 

UAW 

&44" 

A40 

A }49 

A $93 

W.Is r Atirtmide su.bv Shea s +pfe$/.1r" p 

Qrc W vA Tempmd Slid BOOS and 51" 

sw W. Chlb n, CWdH -W41 QaafdP. Ica I*Pln6 n shm Aletal Screws 

- A$63 Cwbeo shed ma 

ANSI 01421.1 lock VVWx 

AN9 RI"2.s Fkt 1':as" 

F 467- A\xTb NtAt.Ip CC f (He 

JdJSl 81012.1 Flaf W}sbn 

P p.g and TAbg 

... .. AS3 

A}50 

ADI 

A 554 

AM 

A 375 

Pryq-RM%Ptaca aml Not.Qippcd Z."c C-IVA Wetrhd and 5mmMss 

C ARrlW .. W 1p Cabuq rxnic Allay. creel AOOj t Allay 5kd TRbc% 

Se}mtcs na.6, Skd Awbh kaf Tnb.% 

Welded $psalms Swot Mvhaniei! T4bing 

$m.w $peeJic#bn 1p Seaml and Wddad Maftemit[: Rablkss Steel Pye} 

Sur.dmd spmwation for sea-%% AvvenOiC WwN 5ra 1 r" fro sign Tavve - 

Ca+N 4xonServ'ma. 

A 632 

se}mkss srd •he'ted Aurae :, §ie spinhYf Skd Tw png fSmiRQlmnMalfp Gk^Rr}s 

^^^,: ÀN%CM.3 

sndn 

tlsôira! tACUIr^cTWalseg LPt Cvakd 

ca??cnc+ 

C}tki!I 

0514/ 

A5TA1()2088 

AnM 010% 

U.L-rd G.k Wsrttmve Coating Spndards:"h'vrh>• Prover Plano 

Neq-aenc .6as 6C 

5.13 r Ro6yer 

22M2 

Printed On- 21-Dec-04 Page 2 of 2 

G5-256


Exhibit D 

STD-AStiE A6-I—ENSL 1997 0 0759670 0603656 683 M 

-Ta5R ]A-3M DWISWN 9-5ECTMN IA 

TAKE "06 

ALLOWAOEE MATEMIS 

A 16p RmuJess and Hw4RetB6ng 0Mw Pilled Sted Kw, Sheer. 

am SAP 

:SA440 A240 C..wea and OOOmimA W.W 5a4akse Sa bel 

.. Plae, Shees.0 Stdp.for Yressm V&mh 

:A 366 Reek Carbm, Cold. ROW SheeL COFMMMW QmEay 

`'SA414 A414 Cwbws Shd Shee for Paessme Vessels 

A S25 Steel Shoe. 2lrc Ceased WahwkeM by fie Hm4 3lp Mean, C. 

- 

ad txgdarocm. 

A SO General RtWk ments k, %ftt Cubes, and High StreogOr LO 

ANOy HptRd4d Slxet and ColdRdWlShed. 

ASao Ha-tsdkd CxUon Steil Artes and9dp 34omva14uaRy 

A 666 Austinkfta6*ss53be19na4,S6sp6 HaWaul Fht9ar 

S&209 8309 Ale ydAluaA r...0AmxkwmAR% Shelf and PLae 

ihuch.j and 8a. 

1Grdsaart 

SX36 A36 Suueenal Sled 

A2].6 Sra"^ aKe ftsiaing Sxel&YS,W Shp, 

-.. 0187 Copper Br6 BU, Red. asd Shapes 

:SA-132 A 78.2 Fugal oa Rolled Agty Suel Pipef6'ya FOWA Mb%$, Vahat 

abed Pm far Ho Tempuabu9 

SM193 A193 Alloy Abet and SWa` SkHBOk'mgAtaavaliaslighTeOWaa- 

.. care S my 

SA4 94 A 194 Cabins ad ARoF Abed N.R Few eoh Fa High Pres5Vre and "h 

. - TaopsaamrO SCrvka 

:SA-325 A325 s8gh 5Ymgsh BVh Far Swamai SUj Ww 

%SA403 _ A 405 - WWq*Arch+e k R.Wess 5Md Pgriny 4dam91 

:SA449 A 449 QsBnched bead Fanpesed S ied Bags and Scads 

P1pe^TBkt 

Printed On _ 2]-Dec-Q4 

Sh312 A312 5evnl ess .awtt&d ,pe. 

A450 Genasl Rryaarmesds for Cad.N FesW.Andy, a rd Austmdie 

ARoy Sx41.bes 

... .A51c Sex lessA kdm. Seel aabaniol TVbsng . 

A 554 Welded Sw:Mess SW Mestokal.Tubkg 

A632 SeAeksbead itlelded AVaariti[StarNei Steel. Tubing L-1Vlaw 

- aedbr Gcsmal service 

066 Smmkss Copper Tube, &W, AINEOld 

.S817S 575 St seis Capp. 7sb. 

542 

G5-257 

Page 2 of 2


Exhibit D 

:STA-ASBE A6-2-EN&L 1997 M 0754b70 0603657 53a M 

-A9!LEdGIdSOT )A•3W0—. MATPdt)ALS Taut It-3100 

' TABLE fA-3100 tCQM'D) 

ALLOWABLE MATERIALS 

- AWE ASTM 

C4wdWlilnBt 

LtFttiud WlK imolNbn 

TO* 

Bet Starve G4Pe`tia?rt Tu6r 

BNo Abnronon and AWWa Allay Dfa Se miny TvA. 

D Sx.&Wal CW.W Pdynhe6* M Cmdml far Pm w bled 

3485 

IR9.e and Gbk 

- 

,.. e3 

B M 

SMmA..t"CappA'W.it 

Conn iap Skan&d Co" Cond^ Had N ¢ 

m Soh 

. lfb.d. 

.--- a," Tlm San m Ar .W Ceppa &r Lktlnol P.up 

_ 

_ 0.705 

0 2m 

Hard-Mown CoM- ABaYXVI s fk Ll Gv l Ca.dac+ao 

CWpn-H"&Zjinr Aft, MdA S ped WiK and CCWe -t rt 

ABOy»vc 

- 

- .-. 0450 

D 

Cmaril Pxyv`vemn.n &.1Yrougtk. Coppm AlSOy wrc 

M2. 

i]A6 

0x. limit ptrykne Pnpy KMwlatia %X Wire andc'bk 

Dmee RgBlyg ThtarMlpla¢Kflaawnr NtLrlation)m WY. and Ca• 

U4t 'l0'G Opetaian 

f \` 

Printed ®n_ 21-Dec-04 Page 2 of 

- 

313 

G5-258


Exhibit E 

' STD•ASME A6-1-ENGL 1497 ! 07S9670 0603350 410 M 

: *u SA-30043 ntVIMON H — SECTOM SA ASMB A&I-I 97 

TAVLESA—ANO'l' 

AUDWABLEMAlEAMS 

A" 

MOD 

ASIM 

D"Ill, Yt@e 

Car6ou Skd Plaleszed_Sheeh 

A2163 SondW Sp. 60CZf a fpr tw and lnlnIMJL 

- e TWJ fp Rap gdt 

- 

... A2M 

Cet AgSteel 

pblea 

Stpdmd spwkN krc EO•N mql ww,,wRate Te+6Rc sm-0S. 

C.&X.Sikm Swe; mam for Mw ine Pmts aw Genmaf C w 

mm aim 

'SA ;14 

._. 

A 366 Studard W-0s.,6MfmSteelSkwK CSrhon, Cori Rolled CaanneF 

dd ,d* 

A;I;Satdad $peprlKmlmlbf $1R4, SbEeC Cadxn, fm Plt9snp YCN44ti 

A$63 Sew."spcdcatian WStei45htey [aa6o!t:.: dH7ghSten$dt 

L&*Ailuva NoFRalled, and COldROged, li'm'ed Reg7TaHnenif 

. 

.._. 

... 

iA420 

-- 

_ 

A%O 

A 570 

A611 

A620 

A 421 

A635 

AM 

A. 

PercerA 

tl*ROlted SMes and Strap. Cymnmdal QuNdj 

S. Spedfv-.d. [he Steel Ska and Skip. C.O6 HotAdled 

S4 lal Q'Aly 

Sw and SpetiLofwn[o, 4.4 Sle Cwbm Co RuledSim- 

Wral 

4xtdxd:.pe akAicnf. Aed, A..% Cmbm, Drawing Qmrdy, 

$pud sp* ay Cdd-ROswe 

SbMlrndSpe['aKmion TOO Stee45bN. Camp, lkA-ReRad; OldMV1$ 

QL-ray 

Spndud Spey im fa keel. Skeet and W4, CammmM0"4. 

dy. Skay Tkirluea .Ccil3 Cmbm Ha-Rdkd 

Sr 694SpecYcttNn m5lK1, Ctha 0At6.Mn munmtl2S' 

Abx. P...0 Hu14o1w Shortaid 4rip, Comverwl 

Qnaldy 

M36 A36 Stendaet Spmficatim brsyU lked 

Sbidfs3led Nate aed Shhb 

... A I 67 Srandad spec lriopon for Suin7esY and Heal Resiurin$ C6mmwrry 

nlrid keel Wale, S rc f i and Sbip 

50. 240 A 3eD Aandard Specific Ste p1 seal Re Lbm Chmmiwn and V"elsvr 

nidStzet SpmTsa xaryl "Oc 4aMStrap 

wr Pfe4WC Vessel 

._- A666 

$tan w. SpmYG3obn la AviteMrie ksc Sled, 5bee1, S+Kp 

P late.aM Flat Bm 

.G*b Caed Sled Plaksmd Sheen 

' ..,. .A 444 

Swkivd Sp^cd^"Jn Red sl ¢ 7.mc{Omed{GaNanlzedj LY 

f. Ft sp w' tiimS cGm at Re ioOQn lay 

_ RS]5 

Aandmd Specgfol. o Hmtgxrems lvlSmf Shea. 

- 

A by 6^ 

A 52 sanded SpetifKattonfor Sted Sheet, SeacCoatzd lGabanKttO by 

Idsw Ptogo"r, mmssda"t, zi -c 

_.. A527 

StmdmdSpKdcauon(OZ Aeal5hce4IitwCWictl tWMadzed)by 

daeH 4XpPreces,tecbfamitt CWftj 

A S23 S1anUdSpce7$orcm ror Red S7ket,Tme-Coaled WAImdze ill by 

dm tbM-p Pros Dwft Qw* 

._. AS91 SaMlard Spmf 

i a nw Reel sfe Ele ro.bt'c Tim CnM4in, 

UgN C-ffig mw Appk fiom 

.._ A6e2 Sm.A a Sped6mHOn[or Smd ste . Lt¢ .C.W lC,ahaniaedt by 

do /ba3Fp AOass. D a-iiv (b'Ay' $oClal RArad 

[COneiwcrD 

Printed On: 21-Dec-04 Page 1 of 3 

G5-259


Exhibit E 

^• STD-ASK A6-1-ENGL 1997 i 0751670 OLD33SI 3S7 0 

a1PMAG-47997 SA^3M--MATERIALS T*WSA-VWI 

TAKE SA-3400-T 

_ ALLOWASLEMATERM4SECOISIM . . 

AVft AWM - 

' Gu;g. t3edg, Ttrk 

:'Casfiw Skd SMnwrd MWnr 

. SA 36 A )6. S mdaad5pe mma" Im umclaral SNel 

... A1rX. 5


Exhibit E 

STD-ASt1.E AG-1-EML 1497 0 0759670 0603352 293 f 

7R9k,SA-}SBPE ENVISSC9.2 It —. SEenm Sa, ASMB AG-Ilml 

TABEESA3MB61 

AEEOWAKE MA"ACS WOMB) 

- ASME ASTM TWe 

pAo 51td 1 3aad Jds 

- - SA T93 A 15 - 'mad±t85petY.rd:+lkaABq!3bdandSiaMkzcSWtl" MaxwsfwWiltTngvane5xv 

e. 

SA 394 A 191 Rd7Wd sqefAitRfbt For.Oe4i nd'ARW St l l4ub lw BOkt be 

'SA 302 A 30T 

Ffr21t Ptewe and no Tempe Rawae 

'41 a ;Xak4 Aw cabm S.6 eam ard Surds 

=5A R9 A325 SW"Spmkm' !dl Wog Amo be&$r-swcW-lw 

3[.449 A449 SwWed SpeGip1wQmnd*d W4 larfaw $k%4 VOU4.1 

A S49 smWed Speedka on Ar 5lca lvft COM CoW FItldrB 9ml. 

%. &o **oft sw mma M{niSSW^»a 

... ASO SW4W SpeeAWipn 6W CA"Wd Afley SW4 R;d tfm5 

ANU 918 11.1 LodnswhK ("Sukg 

ANA 818.22.1 nS Wasters 

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51 a.dsadARmk6 and SpeciBcation(rdAlumb+um Uby EVWed 

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"38)08 9383 Randbd SpKOr an p Ju AN dBad Array fB6i T6 SR.Awswa 

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' speeffipd, pw eènfent ASME NN1Cria[petH'inebn I 

maY b C A dmimkA 

Printed On_ 21-Dec-04 Page 3 of 3 

G5-261


Exhibit F 

f ASITE N504 89 i 02S967Q 005656 11 6 0 - 

ettptAx wvrBt PtAND .W WOMENIM 

ASlREN60&;tM9 uwrsANO WlAPO7iF#!B 

TAM94-1 INSTRUJINWATION f(R ESF AM41EAM r. UNICS 

FxW..vAdetimatlA+ 

Sdtve"MItlon 

tgmaMft" 

POPPf tT71 Low 

CarinalPeett 

Jhktnbt - PW gpeRatNy ptbnadmHa. 14 .RAKAM7 

I76ghVMoeleTPadmt; N n9wnMahasWwrtw.l7o•2m rq'.elratkeilttin 

- lta.< No.;O 

Oambtw 4P11AK'}IHOTE{171 ... 

Spann ... .. 

BoatlMNamLg Cad SL .._ ' 

6Paaa THAI,AlO Ttt.AFi/Jt,ATI 

Plnlltw a9Pft.AhT ... 

Pe MPA . m mu dPUK l-RAH) 

Ilj b M 

6PBea ... ... HWW(311 

Ad m 

SPaa® T9,AW2 STAG*I T#.AW,2STAeE) 

IttamtSN (K.W iml 

Poallhgf nPH,AtO ... 

space .... ... 

FE+: 7t6 SL I10otn ml NS.SC. 

(IMF'DWOs Sea lccaatneHn. t See WC.Om"mI 

f 4VO.chf Hw^7 

'wNeoompw Op t¢ SC (CJPto 1171. Si 

Fre vROFCviian9Ya[wn tAT INMOImt ATLVata i6)) 

Pavawota.v;A7 Jta 1 6)E Wmarmnt ionetbn WiNaee 1611 

F» Tbm I •: 7ndamda SL

NUCLEARRO AR PLANT ADlCLEAt•M. 

UNITSAPIDCDWONMM 


Exhibit F 

,SSFlE N5^5 89 ^ D759b?0 DID5DSb5 S tr 

TA&.E 4-2 1NSTAUIIMATiUIi.FOfi NON-ESr49WCLEAMGUWrS 

D NmdbePiNenn iemdm 

SenaleTimalbn 1{enrota hTanM 

R1DtelUi IeePLST9u 171! CPnhDlPe9P/ 

Um hdel G9{DItDNmMi{aehcwhDNe. tO. 

tfrgRVUleaTy'PatlMi 4 aKaDetp?y etixuilen Nw2UP 

4 

Space 

... 

DerbW Ul WPkWO AMA" 1vDa44711 

some 

Elabelc P4aGn9 Col 9L 

SINÂ T(HFL,AI,ATI - 

erotdtw dPR.A11i[NatD pR ._. 

Swcd ... 

Ao-LIFPA ap17,aN5 RttUD pS ... 

Spew __ ... 

AOwrbae .._ ... 

ASMP NW94SR9 

Spew Ti,*4.2 STAGE Diva 1411 TD.AIb2 STAGQ RIDb{411 

PaztN M(v ... 

swe- ... 

F?n NS's R 

Una ODUPt Sm ipeel`nn NP.: .._ 

IN(D1lvalcU.ty ibrtN01 

v;:reDnlnD+/oDmDea SL' (ND:e LT7{ . _ _ 

PIraP.omc6Dn SyaMm P7Di4(511 "9dote{611 

Pvemebra JAI1D1nm tM Mstwanant FVnU . NI Rms 1611 . 

G — ROW - 1 c 6p6cetima SL = Smma hx =;O. 

T - TempePSaur AN +lr hAlmn M a Nardew u 

AP = Dlnmmua RebsWr AL — L.Al. S a 7MnaU 

AT — Wp Alarm 

NOTES: - 

11) Th."SDmina Laev:an"Sdkms'be kMIM wiilunen rre u".IM MIL Wu re Ma epecFM 09 a SW be I*Wted. The 

rompFttaM qm 2-td in the eryuelmetW typlc yUe d. wkh' •Syme^ IAmtme Ne aem MnlbotwDat TWA.C.M 

.121 GIX BiI^^'a•'•T m11t91W.1, MdIGêSIDIiLIMlOn1' 11RreÎmtIXTCMfM LDCaLnRIImIS iR INm1$W1Uheer 110W V16Ltl11M^bf^ 

aNImP IDtMM d{NUIa1t18{WesfWD.NW PRd ld9h iL'W;,M M96{DmPDfabN Slmblmitecntrel: ehi_fl be[xaMd Mt^êl 

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1 AT FaalnnoUnvaorequvadslmepLihDDO rnYsM •4Man l'l i•.81Dh w.e rDaim•pWS4- 

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(61 U N Dtnt4l 1A19rT^`ta i-i. 

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l5 

Printed On. 21-Dee-04 Page 2 of 6 

G5-263

--` 

p30.9fi11W'J-ash 


ExbU)it F 

ASK N504 89 0 0754570 005057A 6 nE. 

TABLE 5-2 DAMPER CLAVOWWTi1DN FOR 

CONSTRNCTt= APIDtEAKAGE 

rPOP" O OanrLarMWLIR 

tsou 

"WOOD 

:xraeAa€orvs^rurtrAm-ctentaxb 

unDS AY6ffi+FPOHFIJIS 

tXiee 

Rdatspa 

Row Wnud $ IC. 

- FVddsws cexdM a ' lll 

salane5 n0 B N 

5004" f 

Est CentoMmotowsrawo AB 1 

04 NdaeatrreeLfemdWr taeent B fl 

P1wst4M - 

taetedm - 

(dfCelAafaleat00Wtitroom AD l 

aat NancrntonMetodtfr eseein a-. -. 3 

Womtall 

atlek"t crevenduD 

tnl Cm I tedehsennm %A L,a' 

(bl Abnr+AWntNtat9da'v Pnsam a n 

ulH^t4D 

Prot oftlwt a n 

aoTEa: ' 

fD 1KkHresdxNFaraanaamcrc tbunsm fuoete^n,fw exbm^ flan ru', grtil endabtitoff. tlwn 

tlnmwe etdrgentlHO4'ilb5sgevHtM. 

CEF Eta18ItOF-a9-a-s-'t-d- 

(3f eMSr to tvrL S.a,t.a. 

Ldy Wbswtbe wlevlHmdbbbaknlsavcU mmrptab darnCM Hama afa tw'.:Iinaoasnmenin( 

3HIdNktea f6f Cefpint+YJa ase!sure. tns au strywnmtyLaem4'tload+tomantsrt8wed. 

TABLES-3 NMtMl7PA PER=SS19LE DAMPER LEAK RATE. 

CLASS 0 AND 111 

_ rrkaLnari VemdaaNla 4Wt aata setmre9 it 

_ o[aenper Furs 7Gta.6tti!keH-& 

WtterorNN t"emsatrolNote ltA 

bonam atsW Laprb 

' Mbtonraar, N. uwsna ctaaaB - Lob" GWa ® 

12 to BD 

24 .10 40 

35 a 32 

da a 32 

WTF. 

lit b,t^pu bl .Rybd Wed to.".Wde E^.pfadmn lwt telYUrltl map& 

23 

Printed On: 21

TABLE 5-1 MULTIPLYING FACTORS FOR 

OBTAINING MAXIM M PERMISSIBLE 

LEAKAGE RATES AT MG((ER PRESSURES 

olfferendal. 

lrressws. In. w.g. 

- . Well"" 

INtirs (111 

_ 

2 

3 

4 _ 

.6 _. 

6 

7 

a - 

9 

10 

11 

12 

- 

- 

1.4 

to 

20 

2.2 

24 

2.6. 

2.8 

3.0 

3.2 

3;3 

3.5 

NOTE: 

(1) Multiplier = (differarAW pressure, kL w,g_) r12 whleh 1s 

applied m leakage toted in Table 5-3- 


Exhibit F 

PnIIted On: 21-Dee-04 Page 4 of 6 

G5-265

RPP 24544 REV 1d 

Exhibit F 

Printed On: 21-Dec-04 Page 5 of 6 

G5-266

A 

ASME'llED9t9tt4l 


Exhibit F 

ME BSB9 89 M 0759670 (1030586 5 W - 

_ W) CLEA7tPOWEAPLWTAL%Clzmtwq. 

UMiBNW1 t'!Ma'tMtEY7T$ 

TABLES-T summh tY or CRFTiNAF00AC1sEMi6BICE7E517N0 { M-0)- 

raWto 

"n" 

Hato 

34vWme 

tt4omtêpe4d 

otweb 

Dr 

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twos 

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mel^ elrv 

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OBKSan eWWOxe eniB 43 

OperveDp gvnsssvdBfnrer&et 4.8 

emtac.,mzlivnowvwmt*ntien ara 

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S4 

Pouted Or : e2I-Dee-04 

Page 6 of 

G5-267

ITT The anvi9ny Rams meYmat is a t 

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(sT Perledk wFNeo. tNk taTA d tptt 


Exhibit G 

- ^7//NiDFli41ClFAANftiRFA7NFNF3Y9JS)/6 . AWdEN6bl90a .. 

TA9tE i TWS AMD MPWn0NSWJMMWMMMW 

ittF.Ct1ENq Era 

' Yat 5ecs7oa W 52a14ed 'Aeummxl9H tsemlmPt8lwdaU 

iltwriimpetda. s "Bek'e sseAieNaerias i?ato m) 

'&uctbuYttat 0 Accvpm^ce lMvroUN 

"59uabnN ayArtiH1M 5 Aeeeamrtepbte l9N 

' mbbft maY tw B AtbpLncs 1W M ben Mcs OMb 70 "OR 

M11iu^GnvRras pitaaun teekaort 7 006tefel$t 6m 

AYtla mitt am d[mt pen a AmpmncaTttoto tql 

. - - - 

SwwR7ma}Nr+ts)I 

-aerotolmG0^9 a'nannnYriest a AcxeP7aa[spN 

tmpbwlvatttsy NEPAffiaR t0 A¢epmnna s0c e?x IEPA Mar tapft."M 

40At mv ital "A apaaduq nyda 0anms 

Pk W0 

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t7 WT 

5ua dsnper Y.yaxsaren 12 A oep aee and "'at bete mss sax oparoanit 

' '^Ûte+ve flk lWf 

. -'SYxtc? N'WSS rent 13 As-.5pgecc and u bast oKe v .b -PaMt nr 

ajGeprbta l7kt6TT . 

At basmr pt/,[ v .c. mat 14 Aecepmvve mid M bast once each apamtlng 

'WâormH mat[ d BdtotaeM 16 A WPta M botom Ova sdswDerlBPlntalnnaL 

" ad ft1"ttoxa aex oprvFnottc[e plxae 

{71, Pk teN 

: PI F Wd mat of m94arar WM sad dower aCWKM% sad F"VOWCOM Wamms OR acttwerad bV44Smetlsrd, 

W Fm ve^ itvan7eko bat/.vote and traps rYsj be aysha 4brtht cranial, abura iaaWtreteOYma, 

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5 I 

Printed0n. 21-Dec-04 Page I of I 

G5-268 

-

RPP-24544 REV Icl 

ft amecO 

TECHNICAL SPECIFICATION 

PRO_ JECT: Final DBVS Design _ 145579-D-SP-036 T 12EV. 1 

PROJECT NO-- 145579 

OFF-GAS TREATMENT SYSTEM HEPA 

FILTER SKID ASSEMBLY 

CLIENT: AMEC E&E - Richland, Washington DESIGN AND FABRICATION 

Appendix C 

Example Data Sheets 

C. - - \ '^l Af_ ^`K^:CsC'' 

'Y'^'(' f^.':w. jtC^y^ ^.^{l Y, 

'^. `. i< _ 'ir.^ lIQ1 11. 3;` a'^{ t ,y 1^ì^5-i Y 4Gi+ ^\i3^ 'F ti' ,^q 

{t Q n r J ''c,s t ^^t,^ 4^^^^...^j 

^}h^ )FI^r^f- t-^ s 

^F€ 

..i .h... . rJ-.s Y1_.-..Zla7... '^-îL,:\, â C3:, ' w.''''3Zy33.S,-. -.'L:i F^ w ze`n.:^.}• ^t+^'4^7s^'1î^D..^7:'.._Sx a & 

LT S^ô.^.-'LEFT: 

3u rh {¢p 1Q J 

îî^^3P„. 

•.+^ n[l',. 

Cover Page 1 

Control Valves, Example 

Valves (Full Port Ball Valve 300# Class), Example 

Filter DP, Example 

Distribution Panel (120/240V ac, single phase), Example 1 

Nonfused Disconnect Switch, Example 1 

7otal^paa^,S„heetrPark° 6 

OFF-GAS TREATMENT SYSTEM HEPA FILTER SKID ASSEMBLY DESIGN AND FABRICATION 

21-Dec (14 

G5-269 

1 

1 

1

Solids conc.l Parficivie size 

13. Pipe line Size In 16' Out 16' 

14 i Pipe Sct .Wthick. In 10 out W 

15 J Malerl A312 -- -ANSI Ins. _-- 

16 ' Type Butterfly Valve ' Std 1 Fu ll . 

2 ' Flow rate ACFM 

3 * Inlet P 

port Full 

17 ' Size 16' ANSI class 150# 

la 

19 

'Vaivemax P/T° ___ ........_. ..._ ._.... 

`Manufacturer _ Keystone Series 

-------- 

` Model Seller SeleGed_(e__g. K-Lc Fig 360-134) 

20. 1- Body I Bonnet Materl _ ASTM A351 CFeM (2) 

21 z • Liner Materl/In.Diam. 

22 m End In 16°Flange 

23 

24 

0 

m 

Connection Out 

Range Face Finish 

16" Flange 

J 

Face to Face dim. 

25 > End Ext I Mater? 

26 Flow Direction 

27 ' T,rye of Bonnet 

26 Lube & Iso Va lve ' ISO 

29 ' Packing Material. RTFE 

30 • Pecking Type 

re ssure PI - inw.g. 

4 

5 

6 

7 

a- 

• Outlet Pressure P2 

w 

a `D'bEerentFd4 Pressure dP=Pi-P2 

0 

inlet Temperature 

0 Spec.Weght 7 SpemGravly I Mot. Weight 

w Viscos ty f SpeaTlc Pleats Ratio 

y Vapor Pressure Pv ICrit Press PC 

in w.g. 

in w.g. 

F 

Cp 

9 % • Required Cv . 

t9 ° Travel 

11 Predicted Sound press. level (at 1 m.) dBA 

12 Compressibility (Z) 

32 Type 

33 ° Size ° Rated Travel 

34 'Characteristic 

35 ` Balanced I unbalanced 

36 ' Rated ' 

CV 

' FL ° XI 

37 rte- • PlugBalUDisk Matrl 316 SS 

36 ' Seat Material Bunn-N 

39 `CagelGuide Mtr1 

Stem Material 

43 6 

44 

45 a 

47 

48 vn 

dg Z 

so 


DBVS4IEPA- V xxz ___ Sernce_ V ..._ __ Hr--PA Sys: 

1 IFIwd Code: 

EC Gass Group Div. 

0% 1 1 

53- `Type- PrieumaticlSpring Realm 

fl 5d 'Manufacturer___—_KeysloneSeries .— 

55 ' Size Seiler ' ER Area 

57 Action Open i Ctose f Lock 

53 • Max Allowable Press. 125 _.__. psi ........ _. 

59 ' Min Required Press. 100 psig 

60 Available Air Supply Pressure: 

6 1 

62 

a Max 

' Bench R 

Min 

an ge 

63 Actuator Orientation 

64 Handwhl Type 

65 Air Failure Valve Sel at 

66 Fal Closed 

67 Input Signal 

68 • Type 

w Smarl . _ Communic. 

u1 

69 o • Mk & Model Keystone Series 

70 N -On Incr. Signal, Output Ina- I Derr_ 

71 n Gauges By Pass -. 

72 'Cam Charac t's. 

73 °Air Port size 'Boosters 

74 

75 

Type 

ù i ' Mir & Model 

24VDC Proximity (3) Ouantity 

Keystone Se 

2 

ri es 

76. ° No, contacts I rating. 

77 

w 

Acivatimr Points _ .. .. .... 

7a 

79.^ 'Mfr&Model - 

a ll 

'Set Press. 

SpEr- Na 

NO. BY' DATE 

REVISIM (ST ET. OF i 

r l 1 

S 

t 

7271612004 

ytI_ BY CHK'D I APPR 

100 to 125 rsig Compressed air is available 

wired if Avalable 

1 valve (if used) and proximity sensor sha ll be in NEMA 4 en closures. 

`: Information siimfied by Seder unlessal ready spec d_ 

G5-270 

lna vta 

0.07/1.4 07/1.4 1 0.0211.4 In 

11 1 

- 

_ 

D.: DBVSSK-P102 — 

Line I 

.81 a Filter Gauge 

83 m •. Hydro Pressu reper ASME 816.34 

94 . 

65 

in 

r- 

ANSI I FCI Leak- Class per ASME X509, sect.5.9.7 

Test. Results submittals reouired 

__ 

I 

_. S2D.50 

145579-DSP-036 Data Sheets-As

,clfflec 

' 

RPP-24544 REST id 

Valves SPEC. W. 

14W940.SP-036 

NO_ Wt DATE t REVISbN SHEET OF 

i 7 

P.0. 

Prvjed: Deaw"a0on BukWi Mieation :Project REO. 

L Type FMPMlIs.LVALVF-=CLASS 

2 Borh7Ske 

3. BOdpMalelkd SHia Se(e.g. Carbon SNe1 WCB1 

4. Port5Re FUR PORT 

5. Rumba 2 

& C,uirA q 

7. EMC=W.V ng Se9erSekdrd (ey. 1'Exterbed6u0 weMfm Sch407pe) 

& Pacl*male Agype UHWYPE 

2 LU6flmta 

10 [so Va Valve 

it, Bonnet Type 

17 Trho From 31655 Bag^ - 

ta. TrintMatedal Sea0Rug UHMMEw/Cav ity F iled Seals 

14. Shat Male" 37655 

15. Regadred SealT¢ Mn= 816.34 

I& MMAIbw Soued Leveld9A 65 ribs 

DrsgP Pressure 

DesignTwnpwawe 

T 

17. MFR FLOWFEKTRt4OSERIES 

16. model W. 

^/ 

JI 

CHILD 

Stier Sdected(e.g.i'fP-2-7-0M ,61, UNWPECaudY F9ed!' 

79: FpwCamposaon Ware[ 

20, Re*M Or - 120(Fbwthru) 

21. Intel Press Notsa@ft 

21 Raw Rate NWWMax 

23, dP0dax SMd OOH 

24. TenVOpeOMM 

25. Oper sP9Afac 

f t cp 

26. %SupedeatlRwit 

21. CAI PfeS$I% SDrdS 

26. Met WINOW 

29. Pred.Swod LeretdBA. 

30. SUppW UNIT PROCESS COMPANY 

31. Address .... Royal Cdy. WA 

32. Phone (5091346-9920 

33. Fax (5q 346-9951 - 

Rev. Tag. P:t. ti:ett. £Gum Fs.D Da Se al 

Wit 

T° 

Ma> Nunn. I 

Presswe 

Mac Range 

Service - .- Was 

DBvSdtEPA-V-XXX DRVSSK Pi p2 Fat. d Water. Cowdarsata 

.NOTES 

She ll 

and seat lest repujred wi th test report per ASTM BI 6-4, MSS-SP-61 and MSS-SP-72 

G5-271 

i455T9-0 SP-036_Data Sheetsxk 

DATE 

i'Pma 

APPR. 

c 

c 

520.41

RPP-24544 REV td 

AMEC E&C Smi=Limited Instrumentation Data Sheet 

Taal, BC Canada 

ASSET NUMBER: 145579-D-SP-036 TAG NUMBER: 36-PDIS-XXX 

SUBJECT: Bulk Vitrification HEPA Falter System 

SERVICE: Filter DP 

SUPPLIER 

MAKE: Dwyer P.O. No--. 

MODEL- Series 3000 Photchelic Pressure P&ID No.: D13VS-SK-P102 

Switch/Gage 

TRANSMITTER 

Model No.: 3310MRS Photobelic Output 

Power supply: 24V dc 

Range: 0-10inH10 Relay Output: PDAH TBD 

Calibrated Range: 0-10 in H>O Local Indication: 0-10 inH O 

Case Material: Aluminum (hammedoidfinish) Conduit Connect: 

Enclosure Rating: Mounting Bracket: 

TRANSDUCERS 

ModelNo.: 3310MRS-0-10-24V do 

Line Material: SS 

Lute Size/Seb'd: 

Transducer Mat'l.: 

Process: Connection: - 

Signal Cable Length: 

Mounting.: Vertical 

Classification: 

316SS Tags permanently affixed to instrument: 

OPTIONS Accuracy 0.25% span or better 

Display to read in `tin 11z0" 

Weather-proof housing 

SERVICE CONDITIONS: 

Line NoJSize/Sch Max. Velocity: 

Fluid: - Air Spec. Gravity: 

Flaw. Acidity: 

Temp Min.: Percent Solids: 

-Temp Oper_: Material Build-Up: - 

Temp Max.: Vibration:-- 

Press Oper.: 0-10 inHIO Line Material: - 

Press Max.- 

NOTES: 

1. The Buyer has reviewed the transmitters offered and found that the following ordering information from Dwyer 

Instruments, Series 3000 Photobelic model 3310MRS-0-10-24VDC maybe suitable. Ih any case, the final 

selection the component is the responsibility of the Seller as this is provided for. information -only: 

By- RW Chk: A pd. Date_ 101504 Pro ect: DBVS Rev:0 

G5-272 

rage I ar t

ame 

Demons"fim BrikY4n 4on Pr' 


NO. BY DATE 

t Vayt 12=4W m singlcphase % V;FR 

._- 

2. A%PS 

I Breakertype BoNOn 

C Main Breaker. 

------------------------ 

4a Ampslklpl 

4-h MFR 

4.c Model No. . 

5- Therm. Meg. breakers yes 

S.a MFR 

5b. Model NO. 

&GFGl breakers yes 

6,a. MFR 

&b. Model NO. 

7. GFPE breakers 

.__.._ 

yes 

73. MFR 

7.b. Model No- 

19. kteJ(4NO. 

11 Supplier 

6. DOomentahon delatled pond schedile.inside door 12 Add- 

9. Enclosure NHdA4 11 Phone 

G5-273 

td. Fax 

SPEC Na 

1455794)-SP-M 

IEET OF DATE 

I t wwât 

9V Own APPR 

JJI 

1955]9-DSPA76 Dala_Shec1sx15


,. VOr. Mw 6 WFL 

a roles 

S. E21n40nG 

a 

- - - -- ---.._ . _. 

NEMA


PROJECT, Final DBVS Design 145579-D-SP-036 I REV.1 

PROJECT NO.- 145579 


FILTER SKID ASSEINBLY 

CLIENT. AMEC E&E - Richland, Washington DESIGN AND FABRICATION 

Appendix D 

Bidder's Drawing and Data Commitments 

(4 pages including cover) 

OFF-GAS TREATMENT SYSTEM HEPA FILTER SIQD ASSEMBLY DESIGN AND FABRICATION 

G5-275 

rl 

w

a .: _ hlk^xrr 

TECHNICAL DATA SHEETS 


PROJECT: Final DBVS Design 145579-D-DS-036.1 I REV.1 


PROJECT NO.: 145579 FILTER SKID ASSEMBLY 

DESIGN AND FABRICATION 

CLIENT: AMEC E&E - Richland, Washington EQUIPMENT NO.: 36-135"03 

BIDDERS DRAWING AND DATA,-COMMITMENTS 

Vender shall supply A drawings, manuals and documentation in Me quantifies indicated. Approval drawings are due whin the 

listed number of calendar days aflerissue of the Purchase Order or.Letler of talent. The dates set out for drawing and data. 

submissions we gove rned by the engineering design schedule of the philecL The Vendor sha ll supply one Aulocad disk Ile 

and requested comber of co pies within the listed comber of calendar days. Final drawings must be cadged as correct and 

bear the Vendors name, equipment number and Purchase Order Number. Drawing Transmittals, listing the document numbers, 

revision numbers, quanlilfes, status and document types must be Inc luded withag submissions 

(iricluding electronic submittals) - 

SEND At L DOCUrAENTS TO: r - DMJMH+N, Inc. 

".. dba DMJM Technology 

Submit all documents via courier service r 3250 Port of Benton Blvd 

Faxed documents must be Followed by the originals. - Richland, WA 99354-1670 

Electronic E-mail or FTP transmissions of drawings & data must be copied to Attn: Project Records 

Document Control Phone: (509) 375-7856 

Always include a transmittal Fax: ^,509) 375-5331 

BIDDERS MUST PROVIDE ESTIMATED LEAD TIMES FOR APPROVAL DRAWINGS 

Proposal Bidder shall include this data for each Item REVIEW 

Review Required befo re orde ring or sta ITEMS DUE 

WITWN 

rt of fab rication 

Final 

Required wit hin 7 days pri or to shipment and before final payment 

PROPOSAL REVIEW FINAL .DESCRIPTION - 

E+3 - Proof of NQA-1 or equivalent OA program 

E+3 Experience fist and maintainability intonmation 

E+3 Completed data sheet 

E+3 Subcontractor list 

DAYS 

E+3 E+3 Design. fabrication, delivery schedule PO-7 

E+3 E+6 90% Design and Fabrica ti on Package in cluding: 

- Drawings 

- Calculations 

-Completed Equipment Data Sheets 

PO+21 

- Vendor Cm Sheets/Technical Brothers 

-Bi ll 

E+3 E+1 

of materials 

Test PlandTest P ro ced ur e PO-21 

E+1 .E+1 NDE personnel cer tifica tions PO+21 

E+1. E+1 VisualWWMDE procedures POr21 

VENDOR 

COMMITMENT 

E+1 E+1 Visual we ld examinationprocedurrlweld map Fab-10 . 

E+3. - E+1. Welding procedures, procedure qua lifica tion re co rds, 

an 

d welder procedure quabficafion records - 

Fab-10 

E+3 E+1 AM CWl cerflicate Fab-4o 

E+3 IMaterial Con trol Procedures Fab- 10 

(DAYS) 

E+3 E+3 Pmteclivecoaingspetfic lions - Fab-90 - 

- E+3 E+1 Fatrication travelers - Fab-10 - 

E+3 E+1 lCleaning procedures - Fab 10 

OFF-GAS TREATMENT SYSTEM HEPA FILTER SKID ASSEMBLY DESIGN AND FABRICATION 

21-Dec-04 

G5-276 

-



amdO 

PROJECT: Final DBVS Design 145579-D-DS-036.1 REV.1 


PROJECT NO.: 145579 FILTER SKID ASSEMBLY 


C LI ENT: AMECE&E- Richland, Washington EQUIPMENT NO.:36-D5a-oo3 

BIDDER'S DRAWING AND DATA COMMITMENTS 

Vendor Shall supply all drawings. manuals and documentation in the quamffes indicated Approval drawings are due within the 

fisted number of calandar days after issue of the Purchase Order or Letter of Intent. The dates set out W drawing and data 

submissions wegmuemed by 6te emjneering desgn.Sched le of the project. The Vendor shafsuppry one Autocad disk file 

and requested mmtber of copies wiihin the Istednunber of calendar days. Foul drawings must be certified as correct and 

bear the Vendors name, equipment number and Purchase Order Number. Omvimi; Transmittals listing the document numbers. 

revison numbers,.quantf des, status and document types must be Included with all submissions 

(frrclnding electronic submittals) 

SEND ALL DOCUMENTS TO: DMJMH+N, Inc. 

dba DMJIM Technology 

Submit all documents Via courier service r 3250 Port of Benton Blvd 

Faxed documents must be followed by the originals. - Richland, WA 99354-1670 

Electronic E-mad or FTP Uansmissions of drawings & data must be copied to Attn- Project Records 

Document Control Phone: (509) 375-7856 

Always include. a transmittal Fax: (509)375-5331 


Proposal Bidder shall Include this data for each fleet - - REVIEW 

Review Required before ordering or sta rt of fabrication 

Final Required within 7 days Odor to shipment a nd before final payment 

ITEMS DUE 

WITHIN 

PROPOSAL REVIEW FINAL DESCRIPTION 

DAYS 

E+3 E+6 100Y. Design and Fabdcat on Package including: 

- Mecharecak Structuraf and Electrical Drawings 

- Mechanical.Structural and Electrical Caludafionrs 

- Completed Equipment Data Sheers 

- Vendor Cut SheeWTedtnicaf Bmchers 

- BN of mat 

PO-21 

er ials 

When 

E:3 E+1 NCR's identified +3 

_ When 

E+3 

E+3 

E.3 

E+1 

Fabrication red-t'ure changes 

preliminary Data Package Incuding: 

-As-Bupf Drawings and Weld Maps 

- Fabrication Travler Closeout 

- Recommended spare parts and frequency of replacement 

- Rigging sketches 

- System assembly instructions 

i lentifred 

Prior 

FAT 

- Operation and maintenance manuals - 

- Completed Test results (document and video records) 

-Packing list and idenfrt lion of shipPmg supports 

Field Calibration Procedures and Reports 

- Inspection Reports 

-CoC's! C:MTRS 

-14ECinspection ceNfcate & electrornagnelic interference lest 

rest s 

OFF-GAS TREATMENT SYSTEM HEPA FILTER SVJD ASSEM13LY DESIGN AND FABRICATIOM 

21-Dec-D4. 

G5-277 

VENDOR 

COMMITMENT 

(DAYS)

todo^ 



M", 

PROJECT: Final DBVS Design 145579-D-DS-036.1 I REV.1 


PROJECT NO._ 145579 FILTER SKID ASSEMBLY 


CLIENT: AMEC E&E -Richland, VVashin ton EQUIPMENT NO.: 36-DSB-N 

BIDDER'S DRAWING AND DATA COMMITMENTS. 

VerMwsholl supply all drawings, manuals and documentarmn in the quard iIies indicated. Approval dravringsare duevoThin the 

listed number of calendar days alter issue at the Purchase Ordeedr Leffer of mtenL The dates set out for drawing and data 

submissions are govemed by the mginewmg design schedWe of owpr%ect The Vendor sha ll supply one Aulaad disk ne 

and requested number dcopieswithin the rated numberofcalendardays. Final tlmwirgs most W certified ascormcl an d 

bear the vendors name. equipment number and Purchase Order Number. Drawing Transmittals listing the document numbers, 

reviso r, numbers. quanttties, status arid dowmant types must be included with all submissions 

(including electronic submittals) 

SEND ALL DOCUMENTS TO: _ r 

DMJMHdN, Inc. 

dbaDMJIM Technology 

Submit all documents Via courier service r 3250 Port of Benton Blvd 

Faxed documents must be followed by the or ig 

inals_ Richland, WA 99354-1670 

Electronic E-mal or FTP transmissions of drawings & data must be copied to Attn: Project Records 

Document Control Phone: (509)375-7856 

Mways include a transmittal Fax: (509) 3755331 


Proposal Bidder shag include this data for each item REVIEN 

Review Required before ordering or sta rt of fabdca tion 

Final Required within 7 days polo` to shipment and before rims payment 

ITEMS DUE 

virmi N 

PROPOSAL REVIEW_ FINAL DESCRIPTION 

(DAYS) 

E+3 E+1 Packaging and Stepping Plan Def-21 

E+3 E+1 Final Data Package irrctWing. Del-1e 

- Approved Pregminary Data Package 

-Final FAT results 

THE TIMELY RECOPTOFTHE VENDOR DOCUMENTS I% rcunrnt TnT WSPRntr-nT - 

Buyer commits to a 15 working day tu rn a ro und cycle after reciept of approval documents.. 

1 agree to provide the listed documentaCion and data and the dates shown above_ 

Vendor ISArnalture Date 

OFF-OAS TREATMENT SYSTEM HEPA F ILTER SKID ASSEMBLY DESIGN AND FABRICATION 

- 21-Dec-04 

G5-278 

VENDOR 

COMMITMENT 

(DAYS)

t^cI> 


PROJECT: Final DBMS Design 145579-D-SP-036 I REV.1 

PROJECT NO _: 145579 


CLIENT: AMEC E&E - Richland, Washington 

Appendix E 




TFC-ESHQ-Q C-C-03, Revision B, Control of Suspect/Counterfeit Items 


.^^ OFF-GAS TREATMENT SYSTEM HEPA FI LTER SKID ASSEMBLY DESIGN AND FABRICATION 

21-Decc04 

G5-279


ESHQ Document TFC-ESHQ-Q_C-C-03, REV B 

Page 2 of 52 

f C014TROL OF SUSPECT/ Effective Date December 31, 2003 

COUNTERFEIT ITEMS 

Il.0 PURPOSE AND SCOPE 

This procedure describes the process for the identification, prevention, evaluation, notification, 

and disposition of suspeet/eounterfeit items (S/Cls) at CH2M HILL. This procedure applies to 

items that are: 

• In the procurement cycle 

• In source or receiving inspection 

• In inventory at warehouses and staging areas 

• Installed 

• In operation. 

This procedure applies to: 

• Company ordered material 

Material supplied by subcontractors 

• Material and test equipment supplied by test sponsors 

• Construction 

• Fabrication shops 

• Laboratory work and experiments 

• Surplus/excess property 

• Government property 

• Material obtained from U.S. Department of Energy (DOE) sources. 

2.0 IMPLEMENTATION 

This procedure is effective on the date shown in the header. 

3.0 RESPONSHiII.ITES 

3.1 Procurement Personnel 

Maintain awareness of S/Cl and support S/CI program implementation_ 

3.2 Inspection Personnel 

Perform inspections for conformance or acceptance of material including verifications that the 

item(s) being inspected do not exhibit indications attributed to potential suspectleounterfeit items. 

33 Quality Assurance Engineer 

I. Ensures appropriate procurement controls are implemented to preclude entry of S/CI to 

the site through review of procurement documents. 

2_ Notifies the S/Cl coordinator of nonconformance reports.(NCRs) associated with S/Cl- 

3.4 S/CI Coordinator 

Apprises company, DOE, and DOE local Office of the Inspector General personnel of S/CI status 

and final disposition. . 

G5-281


ESHQ Document TFC-ESHQ-Q_C-C-03; REV B 

Page 3 of 52 - 

CONTROL OF SUSPECT/ Effective Date December 31, 2003 


3.5 Assigned Engineering Personnel 

Evaluate S/CI information for applicability to design and procurement specifications, 

system configuration, and operating conditions. 

2. Provide technical specifications, critical characteristics, and acceptance methods in 

support of procurement and inspection activities to prevent introduction of S/CI. 

3.6 Responsible Managers and Supervisors 

1. Maintain awareness of S/CL 

2. Control potential S/CI. 

3. Evaluate training needs based on job classification and ensure individuals receive training 

in S/CI awareness, prevention, detection, and reporting, as appropriate, to respective 

assignments- 

4.0 PROCEDURE 

4.1 Introduction 

aThe two most common S/CIs found at DOE facilities have been threaded fasteners fraudulently 

marked as high-strength bolts, and refurbished electrical circuit breakers sold and distributed 

under false certifications. Purchasers have also been misled into accepting S/CIs that do not 

conform to specified requirements by falsified documentation. 

NOTE: Questions about a specific item should be referred to the S/CI coordinator_ 

Attachment A provides a historical listing of suspect components. Equipment/material types or 

classes have been established to identify those specific items which are classified as potentially 

misrepresented or S/CI. Attachment B provides a listing of those classifications and items subject 

to S/CI control at tank farm facilities. 

4.2 Procurement 

CH2M HILL 1. Ensure material requirements are specified in subcontracts to preclude 

Personnel the purchase or introduction of S/CL Use the information in 

Attachments A, B, C, D, E, F, G, H, and I to identify specific 

components, characteristics, precautions, and other considerations that 

are to be addressed during the procurement process to prevent 

introduction of S/CL 

2. Ensure material requests for quality level 1, 2, and 3 items and services 

include appropriate technical specifications, procurement quality 

clauses, documentation, and inspection requirements to prevent 

introduction of S/CL 

3. In maintenance and constrwtion/fabrication subcontracts, specify 

appropriate requirements to preclude the purchase or introduction of 

S/Cl. 

G5-282


ESHQ Document TFC ESHQ-Q-C-C-03, REV B 

Page d of 52 



Quality Assurance 4. Review procurement documents to ensure they contain the appropriate 

Engineer procurement controls to preclude entry of S/CI to the site. 

Procurement 5. Ensure vendor selection complies with qualification requirements for 

Personnel the quality level of the iterns and services and is based on the vendor's 

ability to demonstrate the capability of delivering acceptable items. 

4.3 Inspection for Potential S/CI 

Bill of Material 1. For quality level 0 and P-Card items listed in Attachment B, designate 

Preparers an S/CI inspection in the special instruction of the Bill of Material 

(BOM) in accordance with the requirements of 

TFC-BSM FPM MC-C-01 

2. Ensure quality level 0 and P-Card items are inspected prior 10 material 

issuance. 

First Line Manager 3. Obtain on-site S/CI inspection for quality level 0 and P-Card items 

prior to material issue and use. 

Engineering 4. Provide technical specifications, critical characteristics, and acceptance 

Personnel methods to facilitate inspection planning for S/CI prevention and 

detection. 

Quality Assurance 5. Ensure S/CI detection criteria is incorporated into QA inspection 

Engineer planning activities. 

Assigned Inspection 6_ Use Attachments G, H, and I as resources for detecting S/CIs during 

Personnel walkdowns and inspections. Specific items are subject to inspection. 

4.4 Control of Material Identified as S/CI 

7. Verify and document that the items being inspected do not exhibit 

indications attributed to potential S/CIs as described in Attachments G 

through L 

8. If an S/CI is detected during inspection activities, document and control 

the S/CI in accordance with TFC-ESHO-O ADM-C-02. 

Responsible Manager I _ Ensure items identified as potential S/CI are documented as 

or Delegate nonconforming and controlled in accordance with 

TFC-ESHO-Q ADM-C-02. Non. conformances identified as S/CI shall 

be reviewed and processed within four working days to determine 

" whether or not the items.are S/CL 

2. Transfer tagged S/CIs to 2301-HV for storage. 

Cognizant Quality 3. Notify the S/CI coordinator of all NCIts associated with the S/CI. 

Engineer 

G5-283


ESHQ Document TFC ESHQ-Q C-C-03,REV B 

Page 5 of 52 



4.5 Reporting of SICI 

Assigned Company I. Report all items identified as potential S/CI in accordance with 

Personnel TFC-OPS-OPER-C-24. Ca.p 

NOTE: Reporting of S/CIs is required regardless of safety class, where 

the S/Cls are located (receiving inspection, inventory/storage areas, 

fabrication and maintenance areas, installed, etc.), or their operating 

status. 

S/CT Coordinator 2. Notify the DOE SICI coordinator of all occurrence reports associated 

with S/Cis. As appropriate, transmit copies ofNCRs and applicable 

documentation. 

3. Notify the DOE local Office of Inspector General of all SICIs. 

Notification should be e-mailed to the DOE local Office of Inspector 

General points of contact providing information in the following 

foment: 

4.6 Acceptance, Removal, and Disposition of SICI 

• NCR number 

• Date NCR was written 

• Purchase order/job control number (if known) 

• End use of product 

• Name of manufacturer, distributor, supplier 

• Safety class (if known) 

• Occurrence report number 

• Value of item(s) 

• Point(s) of contact 

• Description of item(s) 

• Quantity 

• . Description of nonconformance . . 

• Any other pertinent information that would help the DOE local 

Office of Inspector General. 

SICI Coordinator 1 _ Notify responsible company personnel that SICI may not be destroyed 

or disposed of without written release from the DOE local Office of 

Inspector General. 

2 Prior to destroying or disposing of S/Cis, consult the Inspector General 

to determine if there is a need to retain the items as evidence for 

- - potential litigation_ Based on the Office of Inspector General's 

decision, either• 

a. Retain S/CI material as evidence for potential litigation, or 

b. Release SICI material for final disposition and/or disposal as 

directed by the SICI coordinator. 

G5-284



Page 6 of 52 

CONTROL OF SUSPECT/ Effective Date December 3l, 2003 


Engineering 3. Evaluate S/CI to determine if its use could create a safety hazard in its 

Personnel current/proposed application. 

Assigned Company 4. If the engineering evaluation of the S/CI has determined that its use 

Personnel could not create a safety hazard in its current/proposed application: 

a. Disposition the S/CI to remain in place. 

NOTE: Criteria for dispositioning S/CI is by acceptance, 

removal, or replacement after an engineering evaluation. This 

should be based on the deficient characteristic of the particular 

item. 

b. Identify the accepted S/CI by marking with orange paint or 

other appropriate methods and note its location. 

C. In areas where operating temperatures are 500°F and above or 

are subject to cyclic loading where fatigue failure is likely to 

occur, replace all grades 8 and 82 S/CI fasteners prior to 

further use of the equipment. 

d_ Engineering must also identify a way to prevent its reuse in an 

application it may not be suitable for. 

e. If removed, prepare the S/CI for disposal. 

5. If the engineering evaluation of the S/CI has determined that its use 

could create a safety hazard in its current/ proposed application: 

a. Contact Waste Feed Operations (WFO) Shift Operations to 

secure the equipment. 

b. Remove the S/CI as soon as practical. 

C. Tag, segregate, or otherwise control the S/CI to prevent 

inadvertent use- 

d. Prepare the S/CI for disposal. 

S/CI Coordinator 6. Ensure that all SICI material dispositioned for disposal is properly 

controlled and arranged for the material to be permanently and 

irrevocably altered so that it cannot be used. Examples of alterations 

include: 

• Melting 

• Shredding 

• Destroying the threads on fasteners. 

G5-285


ESHQ, Document TFC-ESHQ-Q_C-C-03, REV B 

Page 7 of 52 


COUNTERFEIT TTEMS 

4.7 Surplus/Excess Material 

7_ If the DOE/Office of Inspector General has approved disposal, arrange 

for pick-up and disposal of the altered S/CI material on a yearly. basis. 

Burying S/Cls may be acceptable if they do not contain hazardous 

material or material prohibited by federal, state, or local regulations. 

Responsible L Remove S/CI from surplus/excess material before they are released for 

Personnel sale or transfer of accountability. 

4.8 Assessments 

2. Ensure surplus items received from DOE or other facilities are 

inspected for S/CI prior to installation. 

Quality Assurance 1. Conduct assessments of the effectiveness of the S/CI program 

4.9 Training 

NOTE: The assessment should be performance based and designed to 

determine if company activities are conducted in accordance with this 

procedure, DOE 414. IA, DOE O 440.1A, DOE G 440.1-6, and 

10 CFR 830, Subpart A. 

2. Lines of inquiry will be used as appropriate during assessments in areas 

that interface with the S/CI process. See Attachment J. 

Managers and 1. Evaluate individual training needs of assigned personnel to ensure they 

Supervisors are proficient in S/CI identification and control procedures within their 

areas of responsibility. 

2. All personnel involved in the following specific areas will receive S/CI 

process and hands-on training, whether it be formal, continuing 

training, or required reading. The formal training course that is 

available is Module #1, Course 170720, "Suspect/Counterfeit Items.' 

• Quality Assurance/technicians 

• Engineers (design, systems, etc.) who procure 

materials/equipment 

• Maintenance personnel (electricians, pipefitters, millwrights, 

instrument technicians) 

+ Warehouse personnel who handle and process 

materials/equipment 

• Tool Crib attendants. 

G5-286

I--, 


. ESHQ Document TFC-ESHQ-Q_C-C-03, REV B 

Page 8 of 52 



5;0 DEFINITIONS 

Counterfeit part. Apart made or altered so as to imitate or resemble an "approved part" without 

authority or right, and with the intent to mislead or defraud by passing the imitation as original or 

genuine. (Source: U. S. Department ofTransportation Federal Aviation Administration Advisory 

Circular 21-29B, Detecting and Reporting Suspected Unapproved Parts). 

Fastcrcr (regardless of the safety classification). (Source: Fastener Quality Act, Public Law 

101-592 as amended by Public Law 104-113). 

A screw, nut, bolt'or stud with internal or external threads. or a load-indicating washer 

with a nominal diameter of 5 millimeters or greater in the case of such items described in 

metric terns; or I!4 inch or greater in the case of such items in terms of the English 

system of measurement which contains any quantity of metal and held out as meeting a 

standard or specification which requires through-hardening; or 

• A screw, nut, bolt, or stud having internal or external threads which bears a grade 

identification marking required by a standard or specification; or 

• A washer to the extent that it is subject to a standard or specification applicable to a 

screw, nut, bolt, or studs described above, except that such term does not include any 

screw, nut, bolt, or stud that is produced and marked as American Society for Testing and 

Materials (AM M) A 307 Grade A or produced in accordance with ASTM F432. 

Grade identification. Any symbol appearing on a fastener purporting to indicate that the 

fastener's base material, strength properties, or performance capabilities conform to a specific 

standard of a consensus standards organization or government agency. 

Graded classifications. System used to determine minimum requirements for structures, systems 

and components (e g., design, operation, procurement, and maintenance requirements). The 

graded classifications in order of precedence are safety class, safety significant, and enhanced 

quality general services. 

High strength eroded fastener..Fasteners having a minimum tensile strength of 75 ksi, including 

those produced and procured in accordance with the Society of Automotive Engineers Standard 

7429, Grades 5, 5.2, 8, and 8.2; ASTM Standard A325, Types 1, 2, and 3; ASTM A490, ASTM 

A354, ASTM A449 (IMI), and some ASTM F468. 

Item. An all-inclusive term used in place of any of the following: appurtenance; assembly, 

component, equipment; material, module, part, structure, subassembly, subsystem, system, or 

unit. (Source: ASMENQA-1-1989, Quality Assurance Requirements for Nuclear Facilities). 

An all-inclusive term used in place ofany of the following: appurtenance, facility, sample, 

assembly, component, equipment, material, module, part, structure, subassembly, subsystem, 

system, unit, documented.concept, or data. (Source: DOE G 440.1-6, Implementation Guide for 

use with Suspect/Counterfeit Items Requirements of DOE O 440.1, Worker Protection 

Management; 10 CFR 830.120; and DOE 5700.6C, Quality Assurance)_ 

G5-287


ESB Q Document TFC-EMQ-(QGC-03, REV B 

Page 9 of 52 

CONTROL OF SUSPECrf Effective Date December 31, 2003 


Substantial safety hazard. A loss of safety function to the extent that there is a major reduction in 

the degree ofpiotection to the public or employee health and safety_ (Source: U.S_ Department of 

Energy (DOE) M 232.1-1A, "Occurrence Reporting and Processing of Operations Information"). 

Susoecticounterfeit items. A suspect item is one in which there is an indication by visual 

inspection, testing, or other information that it may not conform to established Government or 

industry-accepted specifications or national consensus standards. A counterfeit item is a suspect 

item that is a copy or substitute without legal right or authority to do so or one whose material, 

performance, or characteristics are knowingly misrepresented by the vendor, supplier, distributor, 

or manufacturer. An item that does not conform to established requirements is not normally 

considered SICI ifthe nonconformity results from one or more of the following conditions, which 

should be controlled by site procedures as nonconforming items: 

• Defects resulting from inadequate design or production quality control 

• Damage during shipping, handling, or storage 

• Improper installation 

• Deterioration during service 

• Degradation during removal 

• Failure resulting from aging or misapplication, or 

• Other controllable causes. 

(Source: DOE G 440.1-6, Implementation Guide for use with Suspect/Counterfeit Items 

Requirements of DOE 0'440.1, "Worker Protection Management;" 10 CFR 830.120; and 

DOE 700.6C, "Quality Assurance'). 

6.0 RECORDS 

No records are generated during the performance of this procedure. 

7.0 SOURCES 

7.1 Requirements 

L DOE-0-232. IA Part 41 (1), "Occurrence Reporting and Processing of Operations 

Information." (SfRID) 

2. DOE O 414.1 A, "Quality Assurance." 

3. 10 CFR 830, Subpart A, "Quality Assurance Requirements_" 

4. DOE O 440.IA, "Worker Protection Management For DOE Federal and Contractor 

Employees." 

7.2 References 

I. IINF=SD-MP-SRID-001, "Standards/Requirements Identification Document for the Tank 

Farm Contractor-" 

G5-288

RPP-24544 REV id 


Page . 10 of 52 


COIINTERFEIT Isms 

2. DOE G440.1-6, "Implementation Guide for use with Suspect/Counterfeit Items 

Requirements of DOE 0 440. 1, Worker Protection Management; I OCFR830.120; and 

DOE57W.6C, Quality Assurance." 

3. NRC Information Notice-89-70: "Possible Indications of Misrepresented Vendor 

Products." 

4. NRC Information Notice 89-70, Supplement 1: "Possible Indications of Misrepresented 

Vendor Products." 

5. TFC-BSM-CP CPR-C-01, "Purchasing Card Q?-Card)." 

6. TFC-BSM-CP CM-C-03, Technical Representative Process." 

7. TFC-BSM-CP CPR-C-06, ."Procurement of Items (Materials)." 

8. TFC-BSM-CP CPR-C-09. "Supply Chain Process." 

9. TFC-BSM-CP CPR-C-I1, "Acquisition Planning." 

10. TFC-BSM-FPM MC-C-01, "Material Receipt, Storage, Issuance, Return, and Excess 

Control." 

11- TFC-ESHO-O ADM-C-02, "Nonconforming Item Reporting and Control." 

12. TFC-OPS-OPER-C-24, "Occurrence Reporting and Processing of Operations 

Information.' 

13. TFC-PLN-03, "Engineering Program Management Plan." 

G5-284


ESIIQ Document TFC-ESRQ-Q_C-C,03, REV B 

Page 

11 of 52 

CONTROL OF SUSPECT/Effective Date 


December 31, 2003 

Figure 1.. Management of SuspecttCounterfeit Items. 

Safety System Non-Safety System 

srca discovered, 

vIaORPSand ro 

loratOlG 

No 

Could 

SfCh in safety 

system mate safety 

hazard? Yes 

NnenSICI dlscovenrd. 

report naORPS and to 

IoW OIG 

MarkSlCl 

^.. Will SIC[ 

remora! be required Dre pashas SICI to 

' MentifyaM mark Lock ouWgout 

No 

the dining routine 

remain in place 

Sla sud to ation system mainAiaace? 

Win the S/Cl be 

Yes 

Reotove/repla¢dre Aemovrlreplace avd 

SiCI dispose ofthe SlCl 

{ Yes— ffispose of the SlCl 

NO KEY; 

OiG: 06rce of trrspecra General 

ORPS: 'Ocaareact Reponiig and P rc cesirg 

Disposition S[CI to Syskm 

mmaininplacc - SlCI: Susptrl/Counlerfril l[ems 

G5-290


ESHQ Dow-u n TFC-ESHQ-QGC-03, REV B 

Page 12 of 52 

CONTROL OF SUSPECT/ EffectiveDate December 31, 2003 


ATTACHMENT A - SUSPECT COMPONENTS LIST 

This list was extracted from the US. Department of Energy Quarterly Reports on the "Analysis and 

Trending of Suspect/Counterfeit Items at Department of Energy Facilities," July 1997. 

NOTE: It is not necessarily a negative reflection on supplier or manufacturer if SAM are reported 

regarding its particular product. Reputable manufacturers and suppliers have a vital interest in preventing 

the manufacture or distribution of S/CI associated with themselves. It may be that the supplier or 

manufacturer was victimized and is pursuing S/CI associated with its products in an aggressive, prudent, 

and professional manner in order to get such items off the market. Therefore, each particular case 

regarding the manufacture or supply of SICI must be examined on its own merit without making 

premature conclusions regarding fault orculpability of the manufacturer or supplier whose name is 

associated with the S/CL In short what follows is a "suspect components list" and not a "suspect 

manufacturer or supplier list" The manufacturer or supplier identified in the following table should not 

be considered to have engaged in any wrongdoing without additional information- 

G5-241



Page 13 of 52 

CONTROL OF SUSPECT! Effective Date Decemlber 31, 2003 


ATTACHMENT A - SUSPECT COMPONENTS LIST (cont.) 

Component Manufacturer)Type Description Supplier References 

- Circuit Breakers 

- 

General Electric 

.(Component Examples) 

Metal clad, low 

voltage; DC 

Satin America & Circuit 

Breaker Systems Inc 

NRC I.N. 8945, 

Supplements and 

Attachments SENS 

-•AKF-2-25. 

• EC Trip Types, E-C- 

1, E-C-2A 

• AK All 

- 

Report ID#6523/89 

Circuit Breakers General Electric 1, 2, & 3 pole, Bud Ferguson's Industrial NRC IN_ 8846 

(Component Examples) various amperages Control & Supply, Inc., Supplements and 

Altachments 

• AK-3A-25 General Circuit Breaker & 

• KHL-36125. - Electrical Supply 

• THEF 136050 

• AK-2.75-3 

HLC Electric Supply 

• AK-2 

. • AK-1-50 

NSSS, Inc. 

• AK-1-75 

• B 

California Breakers, Inc. 

• TDQ 

• TCVVFS 

Rosen Electric Equipment 

• TFl 

• TEB122015-WL 

• TEB132090-WL 

• TEI11015 

PENCON International 

(DBA) General Magnetics( 

Electric Wholesale 

• TED134060-WL Lakeland Engineering 

• TED124050-WL 

• THED13610O WL 

Equipment Co. 

• TED126050 ANTI THEFT Systems, Inc. NRC F.N. 90-46 

• THED13606OWL 

(DBA) ATS Circuit Breakers 

- 

- - 

• THGB2120 

• TEF134015 

• THEF136M1100 

•TED 134030-WL 

• AK2A25 

• THED-136100-WL 

and ACCircuit Breaker 

Electrical Supply 

California Breakers 

• THED-136050-W]. 

THED-136045-WL 

• THFK-236070-WL 

- • TF-122070 

• THED-136150-WI, 

-• THED-13600-WL 

Voyter Electric Co. ice of Nuclear 

Safety 93-5(#I1) 

- • TEDA 13020 

• TEC-360S0. 

- • THM124015-WL 

- 

G5-292


ESHQ Document TFGESHQ-Q_C-C-03, REV B 

Page 14 of 52 



ATTACHMENT A - SUSPECT COMPONENTS LIST (coat.) 

Ccatponent Manufaeturerfrype Description Supplier References 

Circuit Breakers Westinghouse 

(Component E)amples) 

• TF136090 

• TF36105OWL 

• TED] 130020 

• Not Provided Commercial Grade Westinghouse 

Electric Supply Co. 

NW I.N. 91-48 

- 

(WESCO) - 

• DB-25 & DS-416 

Low Voltage Satin America & Circuit NRC I.N. 89-45 & 

Breaker Systems, Inc." Supplement #2 

• FSN-5925-628-0641 

• DB-25 

• DB-50 

• HKB3150T 

• FB3020 

• FB3070 

Trip units; Navy 

Trip units; 1, 2, & 3 

pole various amp. 

ratings 

_ 

General Circuit Breaker& 


HLC Electrical 

Supply 

NRC LN. 88-46, 


Attachments 

Office Of 

Nuclear Safety93-9 

• FB3050 

• EH83025 

• LBB3125 

Califomia 

Breakers, Inc. 

• HKA31250 PENCON International 

• JA3200 (DBA) General 

• EH32100 

Magnetics/Electric 

• 225N 

Wholesale. 

- • EB 1020 - 

• HDEA 2030 

•. MCP3311 o0R 

• MCP431550CR 

• BAB3060H 

• GSGD 148G03 

ANTI THEFT Systems, 

Inc. (DBA) ATS 

Circuit Breakers 

and AC Circuit 

Breaker 


- •-FA-2100 

• EH-2050 

• HFB-3050. 

Molded Case 


• HFD(B)-3020 

• MA3600 

NSSS, Inc. 

• F2020 

• EH2100 

• EB3650 

Specu my Tech. 

• HMC380OF 

EA2090 

Rosen Electric. 

•.FA3125 

• HMCP 150 

- 

Luckow Circuit $reaker 

- G5-293 

..



Page 15 of 52 

CONTROL OF SUSPECT! Effective Date December 31, 2003 



Component Manufacturedrype Description Supplier References 

Circuit Breakers Westinghouse (coat.) 

(Component Examples) 

• HFD 

• EH2O70 

• FA2050 Shunt Trips Aux. General Circuit NRC T.N. 88-46 

• JA2225 Contacts 2 & 3 Breaker & Electrical Supply Supplements and 

•. JUBI25 

• JUB070 

• JL38150 

• JL313200 

• JUB090 

• JL313100 

pole circuit 

breakers of 

various amperages 

HLC Electrical Supply 


(DBA) General Magnetics/ 


Attachments 

• HI.M3800T 

• F310ON 



• MA3500 Circuit Breakers 

•. EH2O15 and AC Circuit 

• FA3035. Breaker- 

• FA2100 

• HLA2MOTM 

• EH2O90 

- Electrical Supply 

• JB3.100 

Molded Case 

• EB2030 


• 8MC800 

• CAH3200 

• EHB3040 

•713-B150 

• JL3-B200 

• JL3-B090 

Co. (MCCB) 

- • JL3-61000 

• HFA, HFB,FA 

• JB-(6)8090 

• 1L3-6125 

• EH-2020 

• FA-3035 

•EH-2050 

_ • FA-2100 

• FA-2050 

• HFB-3050 

• JA-2225 

• HLM3806T 

• F310ON 

• MA3500 

•-.EH2O15 

• LA320OWL 

• HLA3200T 

• 2602D58U9 

- 

G5-294


ESHQ 

CONTROL OF SUSPECT/ 


Docatueat 

Page 

Effective Date 

TFC-ESHQ-QQC-C-03, REV B 

16452 52 

December 31, 2003 


Component Manufacturer/Type Description Supplier References 

Circuit Breakers Westiaghouse(cont) 


: 

• HLB1200T 

• 262156GI9 

• ]A&IB 

NRC I.N. 8846 Supp. 

&Attach 

- 

• HL300T 

• HLA240OTM 

• HMA3600T 

• HMA3700T 

• H KA322S1' 

• HKA3225T 

• MDL#KAF 

• QNB3020 

• QNB3030 

• BA 

225 amp. 3 pole 

3 pole, 20 amp 


I pole, 20 & 30 amp 

2 pole, 20 & 30 amp 


Not Provided 

SENS ID 910 

3-17-89 

SENS ID #11 

3-3-89 

_ 

• BA 

3 pole, 20 amp Not Provided 

• BA 

. E3060 

• F3020 

Circuit Breakers FM (Component - 

Examples) . 

" SENS Report ID 02 

10-19-88 

NRC I.N. 88-46 

• Model - E43B015 370ase 480 volt Cal. Breakers/Elect SENS Report ID#8; 

" Wholesale Supply Co. 5-5-89 

• EQ-B Ipole, 20 amp Not Provided SENS ID#103-17-89 

_ 3 pole, 30 amp 

- • EE-3B030 - SENS ID #113-3-89 

• EF3B070 

• EF31-1050 

• EF3BI25 _ 

2 &3 pole various 

amperages 

- 

General Circuit 

Breaker& 


.NRC I.N. 8846, 


Attachments 

. 

• EF3B040 

. E42B020. - 

• QJ2B200 

• JBB400 

$LC Electrical 

Supply 

- 

G5-295

RPP-24544 REV "I d 


Page 17 of 52 

CONTROL OF SUSPECT( Effective Date December 31,'2003 


ATTACHMENT A -SUSPECT COMPONENTS LIST (cont.) 

Component ManufactmerfFype Description Supplier References 

Circuit Breakers ITE (con[.) 

(Component Exangrles) 

Circuit Breakers ITE, Gould & ITE 

Imperial 

• HE913040 California 

• EE3B050 

Breakers, Inc- 

• BQ0030 

• EE313070 

• MB700 

• EMO50 

• EE213030 

- 

PENCON 

International(I)BA) 

General Magnetics/ 


• FJ313225 

• ET 

• KA 

ATS Circuit 


• EH-313015 

• 1L-313070. 

• JL-313750 

Panel Board 

Specialties 

• E43BO15 Rosen Electric 

• E172-11030 

• EH3B100 

• QPIB020 

• QJ3B200 

• EF3B100 

• 1143 

Equipment 

Brown Boveri Elect. 

(BBE) 

ASEA Brown Boveri 

(Component Examples) Not Provided Brown Boveri NRC I.N. 89-86 

- ID-4KV ASEA Brown Boveri 

• Type HK NotProvided NRC I.N. 87-41 

• 5 HK 

NotProvided 

• 7.5 HK Not Provided Office of 

• ISHK 

Nuclear Safety, 

. 38HK 

• ITE.62-6 

92-25 

Circuit Breakers Square "D" Co. Molded Case General Circuit NRC I.N. 88-46 

Component Examples.: Breaker & Supp. & Attach- 

. Electrical Supply 

NRCB 88-10 


NRC LN, 90.-46 

• KHL36125 California 

(Any Type) 


G5-296 


(DBA)General 

Magnetici!F.lectrie 

Wholesale


ESHQ Document TFC-ESHQ-Q_GG03, REV B 

Page 18 of 52 





Circuit Breakers Square "D" Co. ANTI MIM Systems 

Component Examples Inc. (DBA) ATS 

(cont) . Circuit Breakers 

- and AC Circuit 

- Breaker- 


QOB220 1 pole, 15 amp Not Provided SENS ID #10 

- - 3-17-89 

• Q0220 2 &3 pole General Circuit NRC I.N. 89-45 & 

. LO-3 20 & 50 amp Breaker & Supplement #2 

breakers Electrical Supply 

• SBW-12 

• 989316 

• FAL3650-16M 

or 

3 pole - 200 amp 

breaker 


California 

Breakers, Inc 

• FAL36050-16M 

• KA36200 

30A/600V 

• 999330 

Not Provided PENCON International 

(DBA) General 

- Magnetics/Electric 

Wholesale 

Manufacturer not 

- Not Provided Stokely Enterprises DOE Letter 8-26-91. 

Provided 

.Reprinted 

Molded Case NuVEP. Bulletin 

" EH33025 Circuit Breakers 7-26-91 

Circuit Breakers Fed. pacific. General Circuit 

(Component Examples) Breaker& 


• NEF43102OR 3 pole, 20 amp 

• NEI 11020 L pole, 20 amp HLC Electric Supply 

• NE 1: pole, 15 amp 

- California 


G5-297 


(DBA) General 

MagneticstElecuic 

Wholesale 

SENS ID. #10 

3-17-89


ESHQ Document TFC-ESHQ-Q_GC-03, REV B 

Page 19 of 52 




Component Manufacturerffype Description Supplier References 

Circuit Breakers Fed Pacific 


(cont-) ANTI THEFT Systcros, SENS ID. B11 

Inc. (DBA) ATS 3-3-89 

• NF63-1100 1,&3pole- Circuit Breaker; 

• NE22AD60 

• NE22-4100 

• 14EF-433030 

30,60 & 100 amp 

breakers 


Breaker- 


- 

• 2PI25 

General Circuit NRC I.N. 88-06, 

Breaker & Supp. & Attach 



California 

Breaker s, Inc. 

Jefferson (Component 

Examples) 

Not Provided PENCON International 

(DBA) General . 

Magnetics/electric 

Wholesale 

NRC I.N. 8846, 

Supp. & Attach. 

- 


Inc (DBA) ATS 



Breaker- 


Mid West Co_ 

Circuit Breakers Superior (Component Not Provided General Circuit - NRC I.N. 88-46 

Examples) Breaker& Supp,&Attach. 

Electrical Supply . 

• 2461)-3 

- Rosen Electric 

. HLC Electric Supply 

- California 

Breakerg, Ine. 


--(DBA) General 

.Magnetics/Electric 

Wholesale 


ânc (DBA) ATS 



Breaker- 

- - I Electrical Supply 

G5-298


ESHQ Document TFC-ESHQ^Q_C-C-03, REV R 

Page 20 of 52 

CONTROL OF SUSPECTI Effective Date December 31, 2003 

COUNTERFM ][TENS 


Component Manufacturerfiype Description Supplier References 

Circuit Breakers Manufacturer Not General Circuit NRC LN..88-46, 

Provided ' Breaker & Supp. & Attach. 

(Component Examples) Electrical Supply - 

5ODHP250 2 pole - 50 amp HLC Electric Supply 

Califo rn ia 


PENCON 

International (DBA) 

- ATS Circuit 

Breake rs and AC 

Circuit Breaker- 


Circuit Breakers Cutler Hammer 


Heaters s 10177H13 Not Provided AAKER NRC IN-88-06, 

- 

General Circuit 

Supp. & Attach. 

0 10177H21 

Breaker & 

• 10177H32 


10177HO36 

0 10177HIG49 

- 

HLC Electrical 

Supply 

Califo rn ia 


- PENCON International 

(DBA)General 

MagneticslElecnic 

Wholesale 

- ANTI THEFT Systems, 

- Inc.(DBA)ATS. 

Cir cu it Breake rs 

and AC Cir cu it 

- Breaker - 


G5-299

le ° 

f—^ 


ESHQ Document TFC-ESHQ-Q C-C-03, REV s 

Page 21 ot'52 



ATTACHMENT A - SUSPECT COMPONENTS LIST (cone.) 

Component Manufacturer/Type Description Supplier . References 

switches (Component Examples) 

Crouse Hinds Tumbler, ft. op Platt Elect ric SENS ID #16 

REWC2129 Supply Co. 1-27-92 

Sq. D Type G. Class Gen. Motors, 

9012,9025,9016 Electro-Motive Office of 

Design Nuclear Safety 

93-24 & 

93-27 

Transmi tters Rosemount (Component Venctech E.L. Wilmot 

Examples) letter-dated 

8-1-91 

• Model 1151 GP' 

• Model 1151 DP 

H. Rich ar dson 

letter HR-81-91 

dated 8-15-91 

Motors - Siemen & Allis General Circuit NR.0 I.N. 88-46, 

(Component Examples) Breaker & Supplements and 

Electric al Supply Attachments 

NP 143 T 10 H.P. 

215 T HLC Electric Supply 

Ca li 

fo rn ia 

Breakers, Inc 

PENCON Interna tional 

(DBA) General 

- MagnetiostElectric 

Wholesale 

ANTI THEF1Systems, 

Inc- (DBA).A M 


G5-300 

and ACCircuit 

Breaker- 

Elect rical Supply 

_ 

- 

Rosen Electric 

Equipment


ESHQ Document TFC-ESHQi-Q_C-C-03, REV B 

Page 22 of 52 

m CONTROL OF SUSPECTI Effective Date December 3I, 2003 



Component Manufactarer)Type Description Supplier References 

Relays Potter & Brumfield Not-latching Stokely Enterprises NRC I.N. 90-57 & 


MDR-138,.173-1 

rotary 

Spectronics, lna, 

Attach. 

134-1,142-1 Nutherm International 

- 

The Martin Co. 

Teledyne All qualified to Not Provided - DOE-ID Wilmot 

MIL-R-28776 and letter, 7-16-91 

MIL-R-39016 - 

G.E. & Exide Overload & Aux. General Circuit NRC IN, it", Supp. 

(Component Examples) Breaker & & Attach. 

' Electrical Supply 

• 12HGA-I IS52 

• NX 400 

ALC Electric Supply 

California Breakers, Inc. 


(DBA) General 

Magoetics/Electric 

Wholesale 





Breaker- 


Manufacturer not Not Provided Stokely Enterprises DOE Letter 8-26-91 

provided - Reprinted 

NuVEP; Bulletin 

• FSC-5945 

7-26-91 

Amerace(or Agastat) Electro Amerace SENSID#I 11=1-91 


- 

Pneumatic Timing 

Relays Control Components NRC I.N. 92-24 

Models 

E7024 

E7022 

.. Supply 

A through :L 

Series Model 7032 - 

G5-301


ESHQ Doeutneut TFC-ESHQ-Q_C-C-03, REV B 

Page 23 of 52 




Component Manufach=drype Description Supplier References 

Fuses Busstrum Co. - I SA-250V & General Circuit NRC I.N. 88-46, 

(Component Examples) 30A-6WV Breaker& Supp.&Attach. 


REN . 15 & NOS-30 


California Breakers, lrr . 


(DBA) General 


Wholesale 

ANTI THEFT Systems; 


Circuit Breakers' 


Breaker - 


Class I All Supplied by -Preventive NRC I.N. 88-19 

- PMS Maintenance 

- Systems (PMS) 

Controllers Manufacturer Not Motor - Stokely DOE letter 8-26.91 

Listed Controllers Distributors& .&NUVEP Bulletin 

(Component Examples) Stokely 7-26-91 

Enterprises, Inc 

Starters Westinghouse Not Provided General' Circuit NRC 1.N. 88A5 

(Component. Examples) Breaker& Supp. & Attach. 


626DI87017 HLC Electric Supply 

626B187Gi3 - 

California Breakers, lac 

PENCONJnternational 

- (DBA) General 

Magnetics/Elecnic 

Wholesale 

ANTI THEFT Systems, - 

Inc- (DBA) ATS 



- - Breaker-. 

. - Electrical Supply - 

Resistors - - Unknown - All - Impala Electronics NRC I-N. 91-01 - 

(35-302


ESHQ Document TFC-ESHQ-QGC 03, REV R 

Page 24 of 52 

COMROL OF SUSPECT/ Effective Date December-31,2003 


ATTACHMF.iìT A - SUSPECT COMPONENTS LIST (cont.) 

Component Manufacturer(Type Description Supplier References 

Semiconductors Solid State Devices P-Channel MOSFET SSDI DOE Albuquerque 

Inc (SSDI) - Letter, 06-25-96 

SFF 9140 to DOD Inspector. 

General 

SPD 15 11-1 -11 Pin Diode 

(SA3059) 

2AI4/18 or 2A14/52 Ion Implanted 

Diode 

SSR4045CTTXV SCHOTTKY Diodes 

- . SFF9140TWX Power 

Transistors 

SPMFI06ANH Special Pack 

MOSFET switch 

SPD 5818 or Axial Leaded 

- IN58587TXV SCHOTTKYDiode 

Transistor 

2N797 

Diode (SA 3436) 

Unknown - 

Starter Controls Westinghouse Not Provided General Circuit NRC I.N. 8848 

(Component Examples) Breaker & 


• -A200MICAC HLC Electric Supply - 

•A201KICA 

California 

_ 

• A201 L2CA 

Breakers,lnc. - 

• AN13A 

- PENCON 

International (DBA) 

- General Magoetics/Electric 

Wholesale 

_ 

ANTI THEFTSystems, 




Breaker- 

_ I Electrical Supply - 

G5-303



Page 25 of 52 


COUNTERFEIT ITEMS . 


Component Manufacturertrype Description Supplier References 

Gauge Glasses Siemen & Allis Not Provided Rosen Electric Co. NRC LN. 8&46 

(Component Examples) - Supp.. & Attach. 

#00-737-637-118 

215 T 

Mercury Lamps Spectra Inc. Not Provided General Circuit NR.0 LN. 8846 

(Component Examples) Breaker & Electrical Supply 

V00014 HLC Electric Supply 

California Breakers, Inc 


(DBA) General 


Wholesale - 

ANTI THEFT System, . 




Breaker- 


Electrical Frames Westinghouse Not Provided .General Circuit NRC I.N. 8846 

(Component Examples) Breaker& Electrical Supply - 

LA260OF HLC Electric Supply 

LA360OF 

MA280OF California Breakers, Inc 


(DBA) General 

'MagacticstElectric 

Wholesale 





Breaker- 

Elemcal Supply 

Push button Crouse Hinds Single gang, Platt Electric SENS Report ID #16 

station 

(Component Examples) pushbutton Supply Co. 1-27-92 

#00-737-637-118 

G5-304

f 


ESHQ Document TFC-ESHQ-Q C-C-03, REV B 

Page 26 of 52 




Component ManufactureriType Description Supplier References 

OverhradRelay Square D (Component Not Provided NotProvided NRC LN. 88-46 

Thermal Unit Examples) 

819.5,1322 

Piping, Fittings Tube-line Corp. Subassemblies, Tube-line NRC IEB 83-06 

Flanges, and RayMille,lnc. fittings, flanges,& NRC LN.89-18 

Components other components Ray Miller, Inc. NRC IEB 83.07 

NRC I.N. 83-01 

(Carbon and 

Stainless Steel 

co rents). 

Piping, Fittings, Piping Supplies, Inc. Carbon and Piping Supplies, NRC Bulletin 8"S 

Flanges, and & West Jersey-Mfg. & Stainless Steel Inc. & West Jersey & Supplements 

Components Chews Landing Metal Fittings and Mfg. & Chews 

Mfg. Flanges Landing Metal Mfg. 

Valves VOGT Full port design CMA International NRC IN. 88-48 & 

2-inch Model IMA Valve Supplements 

SW-13111 & 1023 Refurbisher 

Crane 4"-1500psi, SouthemCal.Valve NRC LK91A9 

pressure sealed Maintenance co., 

Amesse Welding 

Se rv ice & CMA Int. 

- ITT Grinnell - Diaphragm valves ITT Grinnell Valve NRC Comp.. 

Valve Co., Inc - Co. Inc. Div- of Bulletin 87-02 

Dialio & ITT 

Engineered Valves 

- Crane, Pacific, Powell, Gate Valves Coffeyville Valve NFLCI.N.92-56 

. Walworth & Inc. 

Lunkenheimer 

- - Pacific 8" & 3" Globe CMA & IMA Valve NRC I.N. 88.48, 

Valve Refurbisher Supp. & Attach. 

Crane Chapman 24" Check Valve CMA &IMA Valve NRC I.N- 88-48, 

Refurbisher Supp. & Attach. 

Pacific - . Check Valve CMA & IMA Valve NRC Su I.11 88-48, 

Refurbishes 

pp. & Attach. 

G5-305

f ^, 


ESHQ Document TFC-ESHQ-Q_C-C-03, REV B- 

Page 27 of 52 

CONTROL OF SUSPECT'/Effective Date December 31, 2003 


ATTACHMENT A - SUSPECP COMPONENTS LIST (cont.) 

Component Manufactu rerffype Description Supplier References 

Valves Kerotest 8" Valve CMA & IMA Valve NRC I.N. 88-48 

Refuhisher .. Supp. & A ttach. 

Pack 4"Gate Valve CMA & IMA Valve NRC I.N. 88-48. 

Refurbishef Supp. & Attach. 

Lukenheimer 6"Model 1542 CMA & IMA Valve NRC IN. 88-08 

- 20" Model 3013 Refurbisher Supp. & Attach. 

Crane All CMA & IMA Valve NRC I.N. 88-48 

_ 

Refurbisher Supp . & Attach. 

Fl an ges. China DingZinang- 

Nan. 

Xi Li Fl 

Flanges,ASTM 

A105,ASMESAI05 

BilliongoidCo. 

LTD. - 

NRCIN-92-68 

an 

d Attachments 

an ge Co: Tain Gong Co. . . 

' Shou Gang Mach. En& Sanxi Province Office of 

Co. Overseas Nuclear Safety 

Trading Corp 92-25,93-23, 

an 

d 92-35 

- National Bo ar d of 

Boiler and Pressu re 

Vessel Inspectors 

(NBBI) Bulletin: 

Special Report, 1992, 

Volume 48, Number 2, 

The Chinese Flange 

Investigation 

Valve Masoneilian-Dresser Plug stem, stern 

Cor-Val, Control NRC I.N. 88-97 

Replacement indus tries plug anti-rotation Valve Specialists, Supp. & A ttach_ 

Parts. pin, seat ring, va lve H.H. Barnum & M.D. 

plugs, bushings, Norwood, Sample Webt rol 

cages & packing box 

components 

Con trols, Inc. 

. Pumps& Hayward Tyler Pump HTPCASME Hayward Tyler Pump Co. IEB 83-05& 

Replacement Co_ Nucle ar Code Attachments 

Parts - - - 

Channel Unistrut Corporation Contin uo Members 

- 

usly slotted 

channels, st 

Unistrut Corporation NRC I.N. 91-25 

ru ctural 

framing members, 

fasteners, nuts, 

- 

. fittirim pi damps 

- 

Fire Barrie rs 

Thermal. Scienc ce Ins. Themes-Log 330 None Listed ES&Q Update #8 

:NRC I.N. 92-55 

Valve Actuator Limitorque Eyebolts on housing None Listed Office of Nuclear 

cover Safety 93-25 

G5-306 

- NRC I.N. 93-37

ESHQ Document TFC-ESHQ-QS-C-03, REV B 

Page Z8 of 52 



ATTACHMENT A - SUSPECT COMPONENTS LIST (conk) 


" Steel Alloy & Carbon Steel Plate Meredith NRC.I.N..89-56, 

Co. Inc., Atlantic Steel Angle Corporation Attachments. and 

Co., Levingston Steel Flat Bar Pressure Vessel Supplements 

Co.,&Copperweld Bar Nuclear Alloy& 

Steel co. Carbon Steel Co- Inc. 

Fasteners (Bolts, (parentheses designated . Those with Note: Listed suppliers may Commercial 

Sams, Nuts, beadmark) suppliers or also be manufacturers Carrier Journal 

and Washers) - manufacturers - Articles for: 

Asabi(A) Lawrence Engineering& 6/88,1/90,2!90,3/90, 

Daiichi (D) . Those that are Supply Co. .4/90.6/9D, 7/90, 17190. 

Daiei(6) improperly Metal Building Bolts 

Fastener Co. of Japan eked Nichimin Corporation -INEL Suspect 

(FM) UNICO Headmark List 

Hinomoto Metal (H) . Those of foreign Ace Corporation 

Jin Her (J) manufacture that E. K. Fasteners; Inc. SENS Report #5 

Kyowa (K) do not meet M Y. Port Fasteners Co. - 2/6191 

Kosaka Kogyo(KS) Public Law 101- Kobayashi Metals; LTD. - 

Kyoei 592 Fastener Takai Screw Mfg. Co. LTD_ SENS Report #13 

Minamida Serybo-(M) Quality Act Yamaguchi Sesakusho Co. 2/6191 

Mnato Kogyo (MS) LTD. 

Nippon (NF) Highland Bolt & Nut HR 3000, U.S. House 

Takai (RT) Porteous Fastener Co. of Representatives; 

" Tsvkimori(S) Northwest Fasteners July 1988 

Unytte (UNY) Ziegler Bolts & Parts Co. 

Yamadai (Y) Edgewater Fasteners, Inc. J. A. Jones, Ur, 

Ivaco, Infasco (hollow Reynolds Fasteners 903192 

triangle_d) A & G Engineering. 

Memo from L 

- Kubicek, - 

3128/91 - - 

_ Memu from B: Sanow, 

" 318/91 - 

" "Fastener Technology 

International,-Feb., 

April, and June 1993 

Rep, J. Dingell 

- - Ltr to Comm. 

Dept&NRC 

- - June 19, 1993 - 

" - Office of Nuclear 

Safety 93-26,93-22, . 

93-11 

- DOE Quality Alert; 

Bulletin, Issue No. 92- 

4, August 19192 

G5-347 

FOR Hanford Suspect 

- Headmark List


ESHQ Document. TFC-ESHQ-QS-C-03, REV R 

Page 29 of 52 



ATTACHMENT A - SUSPECT COWONENTS LIST (cont.) 

Component ManufachwerPfype Description Supplier References 

Fasteners (Botts, - NUCOR I-1/4" x 2" Zme Cordova Box to— SENS ID #13 11-6191 

Screws, Nuts, Chromate plated 

and Washers) surface Hexhead cap 

screws 

Any Any - Aircom NRC Compliance 

Barnett Bolt Works Bulletin 87-02 

Bolts &Nuts, lnc. NRC IN. 89-59 

Glasser & Assoc. 

Knoxville Bolt & Screw 

. Metal Fastener Supply 

Phoell Mfg. Cm 

Service Supply Co. 

Southeastern Boh & Screw 

- Sure Loc 

Victory Bolt 

G5-308


ESHQ Document TFC-ESHQ-QGC-03, REV B 

Page 30 of 52 



ATTACHMENT B - CLASSIFICATION OF POTENTIALLY SUSPECT/COUNTERFEIT 

ITEMS 

A. ELECTRICAL ITEMS 

• Molded Case Circuit Breakers 

• Motor Control Centers 

- Complete Units 

- Components 

- Starters 

- Starting coils 

- Contactors 

- Overload relays 

- Starter control relays 

- Overload heaters 

Protectivelcontrol relays 

• DC power suppliestchargers 

• AC inverters 

• Current/potential transformers 

• Exciters/regulators 

• Bus transferdauto bus transfers 

• Motor generator sets 

• Generators 

• Rewindable motors 

Printed circuit boards 

• Bulk commodity items 

Fuses 

Splices 

Electrical connectors 

• Indicators/controIlers 

• Panel lightslswitches 

• Transmitters/instrument switches 

• Isolation devices_ 

The following items are excluded unless required by the applicable program/project: 600V or 

less: motors; outlets, switches, and plugs; boxes, conduit (i.e., bodies and covers, nipples, fittings, 

EMT, flex, liquid tight, rigid); wire; miscellaneous wire connections #10 and below; fixtures; 

lights: 

B. MECHANICAL ITEMS 

Welding materials 

Rod 

Wire 

Flux 

Structural members (pipe supports) 

Channel members 

G5-309


ESHQ Document TFC-ESHQ-Q_GG03, REV B 

Page 31 of 52 



ATTACHMENT B - CLASSIFICATION OF POTENTIALLY SUSPECT/COUNTERFEIT 

ITEMS (cont.) 

• Sheet 

Plate 

Bars 

• Round stock 

Other raw material which requires an ASTM.or national standard 

All lifting/rigging gear (wire rope shall be made in the United States by a member of 

the Wire Rope Technical Board (WRTB) or the Associated Wire Rope Fabricators 

(AWRF) (except stainless steel, and unless recommended otherwise by a crane or hoist 

manufacturer); stainless steel wire rope shall be made in the United States and shall be 

302 or 304 grade stainless steel unless otherwise recommended by a crane or hoist 

manufacturer) . 

• Ratchet tie-downs/strapping devices and come-a-longs, with fasteners. 

The following materials are excluded unless required by the applicable program/project: 

ASTM-A36, brass, copper, sheet metal 7 GA or less, and aluminum. 

C. PIPING - which requires an ASTM or ASME standard 

Fittings 

• Flanges 

Valves 

Pipe 

Components. 

The following materials are excluded unless required by the applicable program/project: 

ASTM-A-53, Swagelock; cast iron, galvanized, copper, bronze, and brass; PVC; and gaskets, 

D. FASTENERS - All fasteners 1/4" and above in diameter 

• Bolts 

• Studs 

• Cap screws 

• High-strength washers 

• Nuts 

• Anchors. 

NOTE: Attachment I identifies headmarkings for stainless steel and carbon steel high strength 

fasteners that are considered counterfeit. Fasteners exhibiting these headmarks are counterfeit 

and no further testing is required. 

The following items are excluded, unless required by the applicable program/project: sheetmetal 

screws, wood screws, stove bolts, pan heads, machine screws, lag bolts, threaded rod, rivets, and 

carriage bolts. 

G5-310


ESHQ Document TFC-ESHQ-Q C-C-03, REV B 

Page 32 of 52 



ATTACHMENT C - SUSPECT/COUNTERFEIT ITEMS INFORMATION SOURCE LIST 

A wide variety of industry and Government sources publish information relative to suspectteounterfeit 

products. The following sources provide information which is available on a continuing basis- 

Industrial Fasteners Institute (IFI) 

The following information is available from IFI via subscription. 

"Fastener Application Advisory" (Published Monthly) 

"North American Manufacturers Identification Marrdngs for Fasteners" 

Fastener-related video cassettes. 

The National Board of Pressure Vessel Inspectors (NBBI) 

The NBBI publishes "National Board Bulletins" to alert manufacturers and users of 

misrepresented products as they are discovered. 

National Highway Traffic Safety Administration (NHTSA) 

The NHTSA's Office of Defects Investigation issued a -Suspect Bolt List" in late 1440 

identifying numerous fasteners, which they determined to be misrepresented- 

Trade Journals and Magazines 

There are numerous trade-oriented magazines which have carried articles identifying incidents of 

failure of substandard parts in industry applications which have caused personal injury and death, 

as well as serious property damage_ 

Newspaper and Television Reports 

Another good source of information are news reports, which provide current accounts of 

problems encountered as a result of misrepresented products. 

U.S. Nuclear Regulatory Commission (NRC) 

The NRC issues bulletins, notices, and regulatory guidance on a continuing basis to alert nuclear_ 

power utilities ofpotential intrusion of misrepresented products into the operations environment 

of operating nuclear power plants. 

U.S- Department of Defense (DOD) and U.S- Department of Commerce publications are also 

monitored by the DOE to assure that the deficiencies identified do not contaminate DOE 

facilities. 

G5-311

C 


ESHHQ Document TFC-ESHQ-tZC-C-03, REV B 

Page 33 of.52 

CONTROL OF SUSPECT/ Effective Date December 3I, 2003 


ATTACHMENT C - SUSPECT/COUNTERFEIT ITEMS INFORMATION SOURCE LIST (coat.) 

Government Industry Data Exchange Program (GIDEP) 

The mission of this program, established by the Office of Management and Budget,.is to support 

government systems readiness, logistics effectiveness, productivity, and cost reduction through 

timely retrieval, storage, and distribution of data among government and industry organizations. 

U.S. Department of Energy 

The following documents are issued by the DOE to provide information and guidance relative to 

the suspect/counterfeit parts issue: 

• DOE Orders 

• Letters of Direction 

• Bulletins and Quality Alerts 

(in addition, the DOE periodically, sponsors serninars/workshops relative to the detection and 

control of suspect(counterfeit parts). 

U.S. Customs Service 

The U.S. Customs Service has published the Suspect Headmark List (Figure 1) identifying graded 

fasteners determined to be of indeterminate quality, which has been adopted by DOE and, 

ultimately, Project Hanford, as a formal guide for use when evaluating currently installed and 

newly procured graded fasteners to assure their fitness for use on the Hanford Site. 

G5-312

RPP 24544 REV Id 

EWQ Document TFC ESHQ-Q_C-C-03, REV B 

Page 34 of 52 


COUNTERFEFr ITEMS 

ATTACWAENT D- CHARACTERISTICS THAT hux MAKE PRODUCTS VULNERABLE TO 

MISREPRESENTATION, FRAUDULENT PRACTICES, AND COUNTERFEITING 

The following information has been extracted from the NRC Information Notice 89-70, Supplement 1, 

.Attachment 3: 

• High-turnover usage rate. 

a No easy or practical way to uniquely mark the component itself. 

• Critical characteristics, including environmental qualification not easily discernable in external 

visual inspection, or characteristics that are difficult to verify through receipt testing. 

* May be widely used in non-critical and critical applications. 

• Use may not result in used appearance_ 

• Often marketed through a supplier and dropped shipped from locations other than that of the 

original supplier. 

• Special processes for ASME materials may be subcontracted (heat treating, testing, and 

inspections). 

Easily copied by secondary market suppliers. 

• Viable salvage market. 

• Reduced number of original equipment manufacturers. 

• Obsolete or hard-to-get components. 

• Components manufactured by a company that is no longer in business. 

• Items with documentation from a plant where construction has been suspended, canceled, or 

deferred. 

• Moderate or low cost. 

• High potential for profit (r6ected.heats of-material are purchased and decertified). 

G5-313

RPP-24544 RFV Id 


Page 35 of 52 

/ CONTROL OF SUSPECT/ Effective Date December 31, 2003 


ATTACHMENT E WHERE TO LOOK FOR SUSPECT/COUNTERFEIT ITEMS 

The following areas should receive increased scrutiny to assure that suspect/counterfeit items are not 

evident 

Items in Supply 

a Company supply stock 

Wagon stock 

Other sources of supply contamination. 

Items in Use 

• - Plant facilities, components, and systems 

• Equipment 

• Operations and maintenance. 

Items Being Procured 

"Known" critical items 

Critical equipment and assemblies 

Non-critical "known" purchases. 

Operations Decisions 

• Major disaster risks 

• Personnel safety risks 

• Program/mission risks (cost and schedule). 

Cost of Implementation 

Potential consequential costs 

Management risk assessment 

o Cost of focusing established controls 

Impact on schedule and program mission. 

Cost of Focus on Known Suspect/Counterfeit Parts 

Uses existing procurement program 

Focuses on "known pads first" 

n Reduction in major disaster potential 

Program costs low/benefits high. 

G5-314


ESHQ Document TFC- ESHQ-Q_C-C-03, REV B 

Page 36 of 52 



ATTACHMENT F - SUSPECTICOUNTERFEIT PARTS DETECTION 

It is Army important to remember that just because an item is identified as being "suspect/counterfeit" it 

may not be appropriate to simply reject it A review should be performed prior to formal disposition of 

the item to assure that it is indeed unfit for the intended application. 

DETECTION METHODS 

Visual Inspection 

Items may be substandard or fraudulent when: 

Nameplates, labels, or tags have been altered, photocopied, painted over, are not secured well, 

show incomplete data, or are missing (e.g_, preprinted labels normally show typed entries). 

• Obvious attempts at beautification have been made, e.g.; excess painting or wire brushing, 

evidence of hand painting (touch-up), or stainless steel is painted. 

Handmade parts are evident, gaskets are rough cut, shims and thin metal part edges show 

evidence of cutting or dressing by hand tools (filing, hacksaw marking, use of tin snips or 

Rippers). 

Hand tool marks on fasteners or other assembly parts (upset metal exists on screw or bolt heads) 

or dissimilar parts are evident (e.g., seven or eight bolts are of the same material and one is a 

different material). 

o Poor fit between assembled items. 

Configuration is not consistent with other items from the same supplier or varies from that 

indicated in supplier literature or drawings. 

u Unusual box or packing of component or item. 

The supplier is not a factory-authorized distributor. 

" Dimensions of the item are inconsistent with the specifications requested on the purchase order 

and/or those provided by the supplier at the time of shipment. 

The item or component matches the description of one that is on a suspect items list (e.g., U.S. 

Customs Service "Suspect Headmark List," National Board of Boiler and Pressure Vessel 

Inspectors (NBBI) "Special Bulletin," etc.). 

G5-315

RPP-24544 REV I 

ESHQ Document TFC-ESHQ-Q_C-GO3, REV B 

Page 37 of 52 

CONTROL OF SUSPECT/ Effective Date Decemlkr 31, 2003 


]Documentation 

ATTACHMENT F - SUSPECT/COUNTERFEIT PARTS DETECTION (cont.) 

Documents may be suspect/counterfeit when: 

The use of correction fluid or correction tape is evident. Type or pitch change is evident. 

The document is not signed or initialed when required, is excessively faded or unclear (indicating 

multiple, sequential copying), or data are missing_ 

The name or title of the document approved cannot be determined. 

u Technical data is inconsistent (e.g., chemical analysis indicates one material and physical tests 

indicate another). 

Certification or test results are identical between items when normal variations should be 

expected. 

o Document traceability is not clear. The document should be traceable to the item(s). 

Technical data are not consistent with code or standard requirements (e.g., no impact test results 

provided when impact testing is required or CMTRS physical test data indicate no heat treatment 

and heat treatment is required). 

O Documentation is not delivered as required on the purchase.order or is in an unusual format. 

o Lines on forms are bent, broken, or interrupted indicating data has been deleted or exchanged (cut 

and paste). 

Handwritten entries of data are on the same document where typed or preprinted data exists. 

a Data on a single line located at different heights indicate the possibility of retyping. 

G5-316.

RPP 24544 REV 1d 

ESHQ Document TFC-ESHQ-Q_C-C-03,REV E 

Page 39 of 52 



Fasteners 

ATTACHMENT F - SUSPECT/COUNTERFEIT PARTS DETECTION (cont) 

W Headmarkings are marred, missing, or appear to have been altered. 

• Threads show evidence of dressing or wear (threads should be of uniform color and finish). 

• Headmarkings are inconsistent with a heat lot. 

• Headmarkings matching one of those identified on the U.S. Customs Service, "Suspect Headmark 

List" (Figure QP 32-1). 

Electrical Devices 

Headmarkings which depict both raised and hand-stamped markings, such as those 

described in WHC Quality Assurance Bulletin # 94-0I, "Discrepant Dual Head Stamped 

Stainless Steel Bolts." This bulletin documents the results of internal inspections and 

independent testing of stainless steel bolts purchased to ASTM Al 93, Grade B8, which 

were found to be substandard_ 

Only manufacturers listed on the "Suspect Fastener Headmark List" (Figure QP 3.2-1) 

are known to produce substandard graded fasteners.: If graded fasteners are discovered 

which exhibit headmarks matching those on the Suspect/Fastener Headmark List, they 

shall be considered to be defective without further testing, unless traceable 

manufacturer's certifications are received which provide documented evidence that the 

fasteners were not produced by the manufacturer listed on the Suspect Fastener 

Headmark List- 

Interpretation of headmark/manufacturers listed on the "Suspect Fastener Headmark 

List," including newly discovered variations thereto, shall only be provided by the. 

designated S/CI coordinator based on guidance received from the DOE. 

• Connections show evidence of previous attachment (metal upset or marring). 

• Connections show arcing or discoloration. 

• Fasteners are loose, missing, or show metal upset. 

• Molded case circuit breakers are not consistent with nmwfactrrer provided checklists for 

detecting substandardtf audulent breakers. 

•. . Missing or photocopied Underwriters Laboratories (UL) labels on products requiring such. 

G5-317


ESHQ Document T1


ESHQ Document TFC ESHQ-Q_C-C-03, REV B 

Page 40 of 52 



• Valve Body 

ATTACHMENT F - SUSPECT/COUNTERFErr PARTS DETECTION (cont) 

Ground off casting marks with other markings stamped in the area (OEM markings are. 

nearly always raised, not stamped) 

- Signs of weld repairs 

- Incorrect dimensions 

- Freshly sand-blasted appearance, including eye bolts, grease fittings, stem, etc. 

- Evidence of previous bolt head scoring on backsides of flanges, or evidence that this area 

has been ground to remove such marks 

- On a stainless valve, a finish that is unusually shiny indicates bead-blasting. A finish that 

is unusually dull indicates sand-blasting. The finish on a new valve is in-between. 

Manufacturer's Logo 

• Missing. 

• Logo plate looks newer than the valve. 

• Logo plate shows signs of discoloration from previous use_ 

Other 

• Foreign material inside the valve (e.g., metal shavings). 

• Valve stem packing that shows all the adjustments have been run out 

• In gate valves, a gate that is off-center when checked through the open end of the valve. 

• Obvious differences between valves in the same shipment. 

Price 

• Price is significantly less than that of the competition- 

G5-319

RPP-24544 REV I d 

ESHQ Document TFC ESHQ-Q_C-C-03, REV B 

Page 41 of 52 

CONTROL OF SUSPECT! Effective Date December 31, 2003 


ATTACHMENT G - FASTENERS 

I.0 CounterfeitlSubstandard High-Strength Bolts 

1.1 General Background 

Counterfeit bolts have been found in military and commercial aircraft, surface ships, 

submarines, nuclear weapon production facilities, bridges, buildings, and the space 

shuttle. These bolts .often do not possess the capabilities of the genuine bolts they 

counterfeit and can threaten the reliability of industrial and consumer products, National 

Security, or lives. At Congressional hearings in 1987, the Army testified that they had 

purchasedbolts that bore the headmarks of Grade 8 high-strength bolts, but that were 

actually inferior Grade 8.2 bolts. 

The International Fasteners Institute (IFI) reported finding substandard, mis-marked, 

and/or counterfeit high-strength Grade 8 bolts in the United States commercial 

marketplace. In 1988, IR reported that counterfeit medium- strength Grade 5 bolts had 

also been found_ 

Foreign bolts dominate the American marketplace due to their price advantage, and the 

majority of suspect/counterfeit bolts are imported. Identifying, testing, and replacing 

these bolts has proven expensive and difficult, both mechanically and technically. Not 

finding and replacing these bolts, however, has proven fatal in some instances. 

12 Headmarks 

Attachment I may be removed and photocopied, as needed, for use as a poster and 

reference to known suspect fastener headmarks. Bolts with the headmarkings shown 

have a significant likelihood of being found to be inferior to standards. Generally, the 

cost of replacement of these bolts is less than. the cost of chemical, hardness, and tensile 

strength testing. Note also that counterfeit bolts can be delivered with counterfeit 

certificates. Documentation alone is insufficient to demonstrate compliance with 

standards. 

1.3 Consensus Standards 

There are several consensus organizations that have published standards for the 

properties of fasteners. One of these is the Society of Automotive Engineers (SAE). The 

SAE grade (or alleged grade on a suspect item) of a bolt is indicated by raised or indented 

radial lines on the bolt's head, as shown in Attachment L These markings are ealted 

headmarks. DOE is currently concerned with two different grades of fasteners: one has 

three equally spaced radial lines on the head of a bolt which indicate that it should meet 

the specifications for a Grade 5 bolt; the other has six equally spaced radial lines which 

indicate a Grade 8 bolt. Letters or symbols on the head of a. bolt indicate the 

manufacturer- 

G5-320


ESHQ Document TFGESHQ-Q_C-C 03, REV B 

Page 42 of 52 

CONTROL OF SUSPECIY Effective Date Decemher 31, 2003 


ATTACHMENT G - FASTENERS (cont) 

Attachment I is a Suspect/Counterfeit Headmark List that was prepared by the United 

States Customs Service after extensive testing of many samples of bolts from around the 

nation. Any bolts anywhere in the DOE community that are currently in stock, in bins, or 

installed that are on the Customs Headmark List should be considered suspectf 

counterfeit. The headmarks on this list are those of manufacturers that have often been 

found to have sold bolts that did not meet the indicated consensus standards. Sufficient 

testing has been done on the bolts on this list to presume them defective without further 

testing. 

IA Precautions: Selective Testing 

Some facilities (manufacturers, distributors, etc.) perform selective testing of sample 

bolts rather than have an independent testing laboratory run all the tests required by 

consensus standards. In many cases, a new counterfeit bolt has roughly the same 

physical strength as the graded bolt it mimics, but does not have either the chemical 

composition or the heat treatment specified by the consensus standards. As a result, it 

will stretch, exhibit metal fatigue, or corrode under less harsh service than the genuine 

bolt. Simple tensile strength tests carmotbe used to identify substandard high-strength 

fasteners and should not be solely relied upon in performing acceptance test. 

1.5 Using SuspectlCounterfeit Grade 5 Bolts in Grade 2 Applications 

Some sites use suspect/counterfeit Grade 5 bolts in applications that only call for Grade 2 

bolts. Eventually, the suspect/counterfeit Grade 5 bolts may find its way into an 

application that requires a genuine Grade 5 bolt and that application may fail. In some 

cases, cheap imported graded bolts have been purchased in place of upgraded bolts 

because the small price differential made the extra quality seem to be a bargain. Given 

the expense of removing suspect bolts from DOE facilities, the practice of using suspect 

bolts for any application should be discontinued. 

1.6 Keep Bolts in Original Packages 

All bolts purchased should be kept in the original packages, not emptied into bins. The 

packages should have labels or other markings that would permit them to be associated 

with a particular procurement action and a specific vendor. Approved supplier lists 

should be checked to assure that fastener suppliers on that list have been recently 

qualified/audited for adequacy of their quality programs. 

G5-321



Page 43 of 52 

CONTROL OF SUSPECTI Effective Date December 31, 2003 


2.0 Stainless Steel fasteners 

2.1 Purpose 

ATTACHMENT G - FASTENERS (tout.) 

To provide follow-up information to the previous notification sent to the DOE field and 

contractor organizations in late 1996. 

22 Background 

In November 1993, the Industrial Fastener Institute (TI) issued a Fastener Advisory 

regarding 18-8 stainless steel bolts. The advisory warned about a "bait and switch" tactic 

in which a distributor takes an 18-8 bolt (indicated by two radial lines 90 degrees apart), 

but no manufacturer's marking, and setts them as ASTM A320 Grade B8 bolts after 

hand-stamping B8 on to the heads. 

As a result of this IFI Advisory, DOE sites conducted a search of facility stores for 

stainless steel fasteners with hand-stamped B8 grade marks. Hundreds of stainless steel 

bolts with hand-stamped B8 grade markings, along with a variety of other raised and 

depressed head and manufacturer's rankings were identified in facility stores throughout 

the DOE complex. 

For example, an inspection of shop stock at a Hanford Site facility revealed bolts with 

three different raised grade markings, 18-8, 304, and F593C, along with raised 

manufacturer's identifications of CK, H, HP, C, SO, CS, FMC, TH, THE, and a STAR. 

The majority of the remaining samples found at Hanford exhibited raised grade markings 

of 18-8 and 304, with a B8 grade marking and manufacturer's identification handstamped 

into the head of the bolt. 

Finally, a few samples didnot display any manufacturer's markings. Most of the bolts 

discovered were purchased with the specification to meet a national consensus standard, 

American Society forTesting and Materials (ASTM) At 93, B8 Class 1 rather than the 

ASTM A320 standard discussed in the IFl warning. 

The Savannah River Site also conducted a site-wide search of facility stores with similar 

results. A total of 159 stainless steel fasteners with hand-stamped B8 grade marks and 

raised or hand-stamped manufacturer's symbols were found. Fifteen stainless steel 

fasteners that had no manufacturer's symbol were also found. 

G5-322


ESHQ Document TFG ESHQ-Q C-C=03, REV B 

Page 44 of 52 



2:3 Issue 

ATTACHMENT G - FASTENERS (cant.) 

The requirements of the ASTM A193 standard regarding fastener marking and 

certification are very similar those required by the ASTM A320 standard discussed in the 

IFI advisory. The ASTM A193 standard requires that grade and manufacturer's 

identification symbols be applied to the heads of bolts that are larger than 114" in 

diameter. The standard, however, does not specifically differentiate between raised and 

depressed headmarkings, but states only that 'for the purposes of identification marking, 

the manufacturer is considered the organization that certifies the fastener was 

manufactured, sampled, tested, inspected in accordance with this specification! In other 

words, the standard allows for some of the required markings to be formed into the head 

of the bolt (either raised or lowered) during manufacturing, and the rest to be applied later 

on via hand-stamping. 

Since ASTM Al 93 does not differentiate between raised and depressed markings, these 

fasteners can be counterfeited in the same way as the ASTM A320 fasteners discussed in 

the November 1993 IN warning. For example, distributors_ can procure 18-8 stainless 

steel bolts that were manufactured by an anonymous party, and without conducting the 

necessary upgrading process or certification testing, a second party could hand-stamp B8 

and a manufacturer's marking into the heads to indicate that the fasteners exhibit the 

mechanical and chemical properties required of ASTM Al93Grade B8 Class 1. 

Unless the certification documentation is specifically requested, and in most cases it is 

not, there is no way to determine by visual inspection whether these fasteners were 

properly certified and tested to meet the requirements of the ASTM standard. 

G5-323


ESHQ Document TFC-ESHQ-QGC-03, REV B 

Page 45 of 52 

CONTROL OF SUSPECT/ Effective Date Decemtuer 31, 2003 


ATTACffiVIENT H -DOE HEADMARK LIST 

-- e^pltamp Out 

Suspects/Counterfeits 

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G5-324


ESHQ Document TFC-ESHQ-QGC43, REV B 

Page 46 of 52 

CONTROL OF SUSPECTI Effective Date December 3i, 2003 

COUNTERFEIT UEMS 

ATTACHMENT H -DOE HEADMARK LIST (coot,) 

Help Stamp Out Suspeda(counteneeits . (V) 

Suspect Fastener Headtnark List 

AN Grade 5 and Grade 8 fasteners of foreign origin which do not hex any 

manalaCtur V headmwk= 

K^N Grade 5 Grades 

Grade 5 faaterets Wi th the following Manufac turers' headmxkx 

M ar k Marmfacturar M ar k Mamrlaclufer 

J - Jhm Her (M rS Kosalm Kogyo(JP) 

r 

Grade sfameners with the Mowing Manufacturers' headmarkm 

Mark Manufacturer 

Mark Manufactu re r 

- -P A 

Asahi Mgt (JP) 

-KS- KS Kosaka Kogyo(JP) 

-NP- NP Nippon Fasteners (JP) - FIT- NT Takai Ltd (JP) 

^r^ 

r^ 

Q- N -) H Hlnonroto Metal (JP) I-FM-) FM Fastaaar Co. of Japan (JP) 

Q- M -j M Minamida Sieyho (KY-) KY Kyoei MIg (JP) 

br..11 

^l 

-MS-) MS Irwin Kogyo (JP) J-) J Iran H er (TWj 

Hollow 

,p. Triangle 

Imasco(CA;TW,JP,YG)(Cmata Manir&inch(rmmeter 

Gradde88 Hollow Triangle only) 

E_- E Ewe, (JP) (LM-p HNyUnytite (JP)" 

r.d 

Grade &2 fasteners with the following headmarks: . 

, Mark 

KS 

Manufacturer 

Kosaka Kogle (JP) 

Grade A325 fastenem Pennell Gemer target oniy) with the following headn arWo: 

M ar k Manutachner 

Type t S A325 KS Kosako Kogyo (JP) 

Type2 

Type 3" 

Key. CA-Canada, JPJapan.T1V•Talann.VlFYUgoalevie 

Arty. bolt on ibis fist should be treated as defective Without further testing. 

G5-325



Page 47 of 52 



ATTACEIMENT I - REFURBISHED MOLDED CASE CIRCUIT BREAKERS 

Investigations thus far of electrical components at DOE facilities uncovered over 700 suspect( counterfeit 

molded-case circuit breakers that were previously used, refurbished and sold to DOE contractors. 

I. Recognition Factors 

The following factors should be recognized regarding suspect or refurbished circuit breakers: 

A. The quality and safety of refurbished molded-case circuit breakers is questionable since 

they are not designed to betaken apart and serviced or refurbished. There are no 

electrical standards established by Underwriters Laboratory (UL) for the refurbishing of 

molded-case electrical circuit breakers, nor are there any "authorized" refurbishes of 

molded case circuit breakers. Therefore, "refurbished'' molded-case circuit breakers 

should not be accepted for use in any DOE facility. 

B. One source of refurbished molded-case circuit breakers is from the demolition of old 

buildings. Some refurbishes are junk dealers who may change the amperage labels on 

the circuit breakers to conform to the amperage ordered and then merely clean and shine 

the breakers. . 

This situation was brought to DOE's attention by the Nuclear Regulatory Commission 

(NRC), which, in turn, had been informed of the practice by the company that 

manufactures circuit breakers. In early 1988, a sales representative identified 

"refurbished" circuit breakers at Diablo Canyon Nuclear Power Plant. A subsequent 

investigation confirmed that circuit breakers sold to the power plant as new equipment 

were actually refurbished. The managers of the two firms that refurbished and sold these 

breakers have been convicted of fraud and have paid a substantial fine. 

C. NRC published informationNotice No. 8846 dated July 8, 1988, on the investigation 

findings and circulated it to all applicable government agencies, including DOE. On 

July 20, 1988, DOE notified all field offices that refurbished circuit breakers may have 

been installed in critical systems. Shortly thereafter, DOE established the Suspect 

Equipment Notification System (SENS), a sub-module of ES&H Events and News on 

the Safety Performance Measurement System (SPMS). SENS has since been replaced 

by the Supplier Evaluation and Suspect Equipment(SESE) sub-module which includes 

Suspect Equipment Reports. 

D. Some of DOE's older sites have circuit breakers in use that are no longer manufactured. 

According to the Nuclear Management and Resources Council (NUMARC), examples of 

such breakers are Westinghouse breakers with frames E, EA; F, and FA. If a DOE 

contractor has an electrical box that requires a breaker with one of these frame sizes, that 

contractor would not have been able to purchase it from Westinghouse for several years. 

If the contractor were to order a replacement breaker from an authorized Westinghouse 

dealer, the dealer could not get a new replacement breaker from the manufacturer. To 

fill the order, the dealer had to turn to the secondary or refurbished market. 

G5-326


ESHQ Document TFC-ESHQ-Q_GC-03, REV B 

Page 48 of 52 

° CONTROL OF SUSPECT/ Effective Date December-31,2003 


ATTACHMENT I - REFURBISHED MOLDED CASE CIRCUIT BREAKERS (tout.) 

Dealing with an authorized distributor does not preclude ending up with refurbished 

circuit breakers. Westinghouse has announced that it is considering satisfying this 

market by manufacturing circuit breakers that will fit in these applications. 

The solution, as recommended byNUMARC, is not to focus on the credentials of the 

distributor but on the traceability of the circuit breaker itself. A purchaser can be assured 

of having a new circuit breaker only if the breaker can be traced back to the original 

manufacturer. 

2. Indicators of Refurbished Breakers 

Typically, refurbished circuit breakers sold as new equipment have one or more of the following 

characteristics: 

• The style of breaker is no longer manufactured. 

• The breakers may have come in cheap, generic-type packaging instead of in the 

manufacturer's original boxes. 

• Refurbished circuit breakers are often bulk-packaged in plastic bags, brown paper bags, or 

cardboard boxes with handwritten labels. New circuit breakers are packed individually in 

boxes that are labeled with the manufacturer's name, which is usually in two or more 

colors, and are often date stamped. 

• The original manufacturer's labels and/or the Underwriter's Laboratory (UL) or Factory 

Mutual (FM) labels may have been counterfeited or removed from the breaker. 

Refurbishing operations have been known to use copying machines to produce poor 

quality copies of the original manufacturer's and the certifying body's labels. 

• Breakers may be labeled with the refurbisher's name rather than the label of a known 

manufacturer. 

• The manufacturer's seal (often multicolored) across the two halves of the case of the 

breaker is broken or missing. 

• Wire lugs (connectors) show evidence of tampering. 

• The surface of the circuit breaker may be nicked or scratched yet have a high gloss. 

Refurbishers often coat breakers with clear plastic to produce a high gloss that gives the 

casual observer the impression that the breaker is new. The plastic case of new circuit 

breakers often have a dull appearance: 

• Some rivets may have been removed and the case may be held together by wood screws, 

metal screws, or nuts and bolts. 

G5-327



Page 49 of 52 



ATTACHMENT I - REFURBISHED MOLDED CASE CIRCUIT BREAKERS (cont.) 

3. Testing 

Contradictory amperage ratings may appear on different parts of the same refurbished 

breaker. On a new breaker, the amperage rating is stamped into, raised from, or machinepainted 

on the handle of the circuit breaker. In order to supply a breaker with a 

hard-to-find rating, refurbishers have been known to file down the surface of the handle to 

remove the original rating and hand-paint the desired amperage rating. 

In a news release dated February 6, 1989, the National Electrical Manufacturers Association 

(NEMA) announced the cancellation of its Publication AB-2-1984 entitled, "Procedures_ for Field 

Inspection and Performance Verification of Molded-Case Circuit Breakers used in Commercial 

and ]industrial Applications," and stated the following: 

"These procedures were intended for use with breakers that had been originally tested and 

calibrated in accordance with NEMA Standards Publication AB 1 or Underwriters Laboratories 

Standard UL 489, and not subsequently opened, cleaned or modified... Therefore, the Standards 

Publication contained none of the destructive test procedures... necessary to verify the product's 

ability to withstand such conditions as full voltage overload or short circuit. Without such tests, 

even if a rebuilt breaker had passed the tests specified in AB-2, there would be no assurance that 

it would not fail under overload or short circuit conditions. It is NEMA's position that regardless 

of the results of electrical testing, refurbished electrical circuit breakers are not reliable and 

should not be used." 

4. Precautions 

Follow these precautions regarding suspect or refurbished circuit breakers 

A. Require that molded-case breakers be new and unaltered. Proof that they are new and 

unaltered requires the vendor to show traceability back to the original manufacturer_ 

B. Do not rely completely on dealing with authorized dealers for protection from 

purchasing refurbished molded-case circuit breakers_ 

C. Approve formal procedures for inspecting circuit breakers that are received and installed 

according to the indicators of refurbished breakers fisted above. 

D. Contact the original manufacturer if any indication of misrepresentation is encountered. 

There are many original manufacturers of molded-case circuit breakers whose products 

are being refurbished and sold as new: These manufacturers have the most specific 

information about how to ensure that their products have not been refurbished. 

G5-328

RPP-24544`REV Id 

BSBQ Document TFC-ESHQ-Q_C-C-03, REV B 

\ Page 50 of 52 


ATTACHMENT I REFURBISHED MOLDED CASE CIRCUIT BREAKERS (cont.) 

5. Disposition 

A. Segregate and retain all circuit breakers found with indications that they may be 

refurbished. 'These will be retained as potential evidence until specifically released by the 

Office of hispector General and the Office ofNuclear Safety for Price Anderson 

Enforcement. Circuit breakers that may be refurbished may only be disposed of when the 

above organizations no longer need them as evidence. 

B. Report suspect electrical components to Occurrence Reporting and Processing System 

(ORPS). The ORPS categorization group should be identified as "Cross-Category items, 

Potential Concerns or issues." The description of cause section in the ORPS report 

should included the text "suspect counterfeit parts." 

C. 

Witness and document the destruction of all suspeettcounterfeit circuit breakers when 

approval is given for disposal. 

G5-324



Page 51 of 52 

CONTROL OF SUSPECT/ Effecttve Date December 31, 2003 


ATTACHMENT .I - ASSESSMENT/SURVEILLANCE LINES OF INQUIRY 

1. S/CI processes and other S/CI related processes are effective in addressing the safety-related 

aspects of SICL 

2. Formal supplier qualification and re-qualification processes are established and implemented, 

including routine collection of evaluations of feedback on Vendor performance. 

3. Controls are established on a graded basis that considers the risks involved and historical 

experience with S/CIs. 

4. Controls are implemented for segregation and separate storage of material identified as 

suspect/counterfeit 

5. Subcontractors have established and implemented sufficient controls to preclude an introduction 

or use of S/CIs. These controls address construction materials, maintenance or modification 

equipment and components, and the use subcontractor owned or rented equipment (cranes, hoists, 

etc.) on site. 

6. S(CI processes, requirements, and controls are fully integrated into Integrated Safety 

Management (ISM) and quality assurance programs and procedures, e.g, training, procurement, 

:maintenance, and assessment) to ensure adequate linkage to S/CI elements. 

7. Expectations are established for timeliness in determining whether nonconforming items are S/CL 

8. Protocols are established for clearly identifying S/CIs that are determined to be acceptable for use 

4. Inspections for S/CI materials are incorporated into routine maintenance activities, and clear 

guidance is provided for the disposition of installed S/CI materials identified during routine 

inspections and maintenance activities. 

10. Expectations for S/CI controls are integrated within existing processes, such as routine and 

special inspections for S/CIs in site procedures, and guidance s provided for performing such 

inspections. 

11. Roles and responsibilities and interfaces for management of Was are clearly assigned, including 

provisions for the handling of sensitive information and interfacing with the local Office of the 

Inspector General (IG), to ensure effective, consistent, and timely communication of S/CI . 

information. 

12. S/CI reporting requirements are effectively integrated into the site contractors' processes for 

disposition ofnon-conforming items, such as NCR processes, as required by appropriate DOE 

directives. 

13. Lessons learned processes are evaluated to determine whether all available and relevant 

information resources, such as the Government Industry Data Exchange Program (GIDEP), are 

being utilized for screening S/CI and other relevant information for potential applicability to site 

activities. 

G5-330


ESHQ Document TFC-ESHQ-IZC-C-03, REV R 

Page 52 of 52 



ATTACHMENT J — .ASSESSMENT/SURVEH.LENCE LINES OF INQUIRY (cont) 

14. Lessons learned processes are evaluated to ensure that significant requirements and performance 

expectations have been established for the documentation of applicability reviews, needed 

actions, and actions taken for lessons learned that require line management attention and action. 

15. Lessons learned requiring line management actions are integrated with the site's corrective action 

management processes to ensure formal tracking, feedback, and closure of actions taken. 

16_ Corrective actions and management procedures include formal linkage to S/CI reporting 

requirements for the site office, Occurrence Reporting System (ORPS), contractor General 

Counsel, and the IG. 

17. Site mechanisms, such as a controlled product list, are established and used to maintain cement 

and accurate information on S/CIs_ Provisions are available for making this list readily available 

to site personnel who have S/C1 responsibilities for procurement, inspection, and other areas 

associated with the implementation of S/CI controls. 

18. S/CI training programs-include the identification of positions and associated personnel required 

to receive training, the processes for designating those personnel who must receive initial and 

refresher training, and the required frequencies for refresher training. 

19. All personnel involved in design, system engineering, procurement, inspection, maintenance, and 

other functions involving potential S/Cl materials receive S/CI process and hands-on training. 

20. Training programs place special emphasis on ensuring that system engineers involved in the 

design, procurement, and inspection of materials and components with the potential for S/CI 

receive such training. 

21. Subcontractors involved in the procurement or handling of potential S/CI materials and 

components receive initial and refresher training and are knowledgeable of site S/CI processes, 

procedures, requirements, and controls_ 

22. S/CI training addresses site-specific processes and procedures for identifying, dispositioning, and 

reporting S/'Cls, including reporting to the IG. 

23. S/CI processes are subject to regular self-assessment, consistent with site self-assessment 

protocol. 

24. Assessments are performed for S/CI processes to evaluate significant changes to the S/Cl 

processes and to establish a baseline for implementation where appropriate. Based on that 

baseline review; further assessments are tailored to the maturity of the S/CI processes. 

25. S/CI lines of inquiry are considered and evaluated, as appropriate, during assessments of areas 

that interface with S/CI processes (procurement process, NCR process, etc_)_ 

G5-331

E 



Appendix F 

Request for Information 


amecO 

PROJECT: Final DBdS Design 145579-DSP-636 REV.1 

PROJECT NO.: 145579 

OFF-GAS TREATMENT SYSTEM NEPA 



OFF-GAS TREATMENT SYSTEM NEPA FILTER SIQD ASSEMBLY DESIGN AND FABRICATION 

71-Dec-04 . 

G5-332

ul ay 



PROJECT* Final DHVS Design 245579-D-SP-036 I REV.1 

PROJECT NO.: 146379 

CLIENT- AMEC E&E - Richland, Washin n 

REQUEST FOR INFORMATION 

. 

CallraWPro" No. 

TO BE COMPLETED BY SUBCONTRACTOR- 

Inserl Title of FIR Hue 

Or' lor. &Co - 

ProblemlDehatencY: ClarHlmtipn Q Charms 

Proposed Solul'iom 

- Bass of Change: - 




ProjM #AFl.%%7T 

Rex 

Page i oIt 

Note_ Subcpmraclor to provide cost and schedule impacts associated with each discrete change line dem. 

Response: El Clarification(] Change COST 0 Yes E] No SCHEDULE I] Yes [] No 

blued Response Dater 

Cost Impact Schedule Impact 

Subcontractor (signtdate) - 

RR Approved E] Yes No 

CN Required: [] -CN # 

CN Not RegL"& [] 

As-Brig dce nentalion Required q 

AsBrtR documentation Not Required: E] 

5u ibfrkal Data Required: q Yes E] No 

iur.F[eww 

TO BE COMPLETED BY THE BUYER. 

COMMENTS 

Design Lead I Proj Mgr! Dale 

- OFF-GAS TREATMENT SYSTEIvI HEPA FILTER SKID ASSEMBLY DESIGN AND FABRICATION 

^7-Dec 04 

G5-333 

- 

#4


1=1-11^ 

PROJECT: Final DBVS Design 145579-D-SP-036 REV.1 

PROJECT NO.- 145579 




Appendix G 

Instrumentation Naming and Tagging Convention 


.OFF-GAS TREATMENT SYSTEM HEPA FILTER SKID ASSEMBLY DESIGN AND FABRICATION 

2f-Dm-G4 

G5-334



PROJECT_ Final DBVS Desi 145579-0-SP-036 REV, i 

PROJECT NO 

CLIENT, 

145579 

AMEC E&E - Richland, Washington 




G1 EQUIPMENT IDENTIFICATION NUMBER 

The equipment identification number'(EtN) is comprised of three fields, SYSTEM- 

COMPONENT-SEQUENCE Where SYSTEM is the plant Area. 00, 31-37, 

COMPONENT is the ISA-loop function code, and SEQUENCE is the device 

number within the Area_ 

Example: Waste dryer Area 33 instrument Junction Box 33-IJB-001. 

Note: The -Hanford FARM and LOCATION fields do not apply to the 

Demonstration. Bulk Vitrification System and have been dropped from this 

convention. 

G2 CABLE TAGGING 

Cables shall be tagged using From Source & To Destination information. The 

format will be "FROM-TO" or "FROM-TO-ff tfmore than one cable run. 

Example: 

Two Cables: From 36-CAB-123 to 36-IJB-123 

Cable Tag: "36CAB123-36[JB123-C1" 

Cable Tag- "36CAB123-361JB123-C2" 

G3 WIRE TAGGING 

Woes will be tagged using the equipment tag and polarity_ 

Example 1: Wires connected from instrument 36-FIT-123 (24V dc) 

Positive Tag "36FIT123(+)" 

Negative Tag "36FIT123(-)" 

Example 2: Wires connected from instrument 36-LSH-123 (110V ac) 

Positive Tag "36LSH123(H)" 

Negative Tag "36LSH123(N)" 

OFFGAS TREATMENT SYSTEM HEPA FILTER SKID ASSEMBLY DESIGN AND FABRICATION 

21-Dec-04 

G5-335



am.. 

PROJECT_ Final DBVS Design 145579-D-S"36 REV.1 

PROJECT NO : 

CLIIENT* 

145579 





G4 NOTES 

1. Cables shalt be identified with cable tag number 'source-destination-type. 

Types will be as follows 

M = Motor Feeder Cable; L = Local Control Station Cable; MH = Motor 

Stator Heater RTD = Motor Winding Temperature Detector, MA = Motor 

An-nature Cable; MF = Motor Field Cable; C = Control Cable; F = General 

Feeder Cable; A = Ammeter Cable; T = Tachometer Cable; 

COM = Communications Cable; RS484, Ethernet, Fibre- 

2. Analog cables from junction box to field instrument will only be tagged with 

the instrument tag number 

3. Cables will be tagged on both ends with the same cable tag number. 

4. Equipment, motor, and instrument tag numbers shown are for illustration 

purposes only. Use project specific equipment, motor, and instrument tags. 

OFF—GAS TREATMENT SYSTEM HEPA FILTER SKID ASSEMBLY DESIGN AND FABRICATION 

21-9ec-04 

G5-336

': 1 

tect yVllAl(/'tj 


CHANGE NOTICE 145579-036-CN-001 

Page 1 of 2 

Change Notice (CLNN) lCaattagory (Check 

One) Odginatoi's Name and Signature. Date 

Supplemental ® 

Direct.Revtslon q 

Cancel q 

Quality P rogram 

Procedure Change g q 

Affects Cost? Yes ® No q 

Affects Schedule? Yes q Na g 

Jack McCOnwe4 

n 

t i t.p-ûM 03107=05 

® yr.,! , 

ProjoctTltlal P roject No. 

Dto^^ration Bulk V itrification System 

P rimary Document Changed by this CN 

(include shoat no. and rav) 

Other Documents Affected by this CN: OGTS HEPA Fitter Skid Specification- 

'^ 145579-D-SP-036, Rev Y 

Reason for Change:. 

Design Ve rification Required 

(Independent Review} 

Safety Class (if Rqd) 

Yes E3- NOS N/A 

Affected Documents Superseded 

Yes q . No O 

contract No. 

1) Fabricator requested, in RR 23410.OGTS.PTI-RFI.004, R0, that the HEPA filter housing Level Switches be relocated to the 

condensate lines below the housing rather than an extra penetration in the Filter housingr The relocation of the fevel switch 

will remove a potential leak path from tha HEPA flier housing and allow detection of leaks prior to loading the bottom of the 

filter housing with condensate. 

Detailed Desc ription of Ch an ge (Use Continuation Sheet as App li cable): 

Sec ti on 3.3.1.1.1.10: Delete all text in paragraph and Change paragraph to read, "Not used." - 

Appendix A, Drawing DBVS-SK-P102; Rev C, move location of level switches LSH-402A, -4028, .404A, and -4048 from the filter 

housing to the condensate drain pipe above , the condensate va lve as shown on page 2 of this CN. 

ReviewfApprovafAuthorities: A= Approval, R= Review, ) = Information (Check where app li 

cable for change no lice) 

Printed Name/Signature Date R I A I Printed Name/Signature Date R .A O 

I 

ri . ginr. Jack Mc unwell q Process Technology Manager NA q q .q 

Pmt iManai;K,im Frederickson 0 0 Independent Re view' NA q 

P ram Director NA 0 0 0 P ro fessional Enginee r, if requi re d NA 

. 

I inek 

t uakty 

Kurt McCracken 

a i t< 

ice Row Truitt ^^ 

^cs' 

.511 El 

HNR P 

Cgertt )t E 

Director -NA 

.. . 

Manager of.Pmfe A fl q ' 

0 

f 

Client Q1i2MHILL 

* Design Verification per EP 3.8 required? Yes E No ® Assign Independent Reviewer y^ 

CN Incorporated? PM or designee sign and date: 

eP 3.8.1'F Octabm 2003 

G5-337


ffitedzdoff 2341o.OGTS.PTI-RF1.0o4 

Rev. 0 

Page t of 2 

Contract/Project No. 23410 (Subcontract No. 05-32SGA79787) 

Level Switch Location in HEPA Fitter Housin s 

Originator Name & Company: Jeff Schulte; Premier Technology, Inc. 

Problem/Defi6ency: q Clarification ® Change 

Level switches LSH 402A, 4028, 404A & 404B located in the filter housing (as shown on the 

P&iD — DBVS-SK-P102 Rev. C) will be difficult to access and maintain. 

Proposed Solution 

Premier would like to suggest that the level switches be moved to a "T" (between filter housing 

and valve) in each of the respective condensate drain lines. This will improve access while 

maintaining the desired function. Also for information, the proposed type of level switch is 

a:ftached. 

Basis of Change: 

Ease of access and fabrication. 

UT 2/03 

G5-339

mwlu^gy 


23410.00TS.PTI-RFL004 

Rev. 0 

Page 2 of 2 

TO BE COMPLETED BY'SUBCONTRACTOR 

Note: Subcontractor to provide cost and schedule Impacts associated with each discrete 

change line Item. 

Response: [] Clarification ® Change COST ® Yes ®No SCHEDULED Yes ®No 

Required Response Date: 319105 

Cost impact Schedule Impact 

None None 

Subcontractor (sign/date) 3171115 

TO BE COMPLETED BY THE BUYER 

9 171 Approved N Yes Lj No COMMENTS 

ON Required:[Z -CN 

ON Not Required: Lr'j 

T2tc cv1W.(k Curl scv; cG- is 

F4cep a bye iF tt 2n a-rR ' -s wi'f,-- 

{ rid / Z 1(ea ea.dt

Technical 

Information 

TI 244F/OD/en 

x, 

Y1^1Y 

RR 

1 ^^ 

vn 

apRR 

'iii 

8RR no RR 

lil3tt 


Limit Switch 

Iiquiphant T FTL 260 

Vibration limit switch for liquids 

The maintenance-free alternative to float 

switches 

Features =it 

• Small, slender design: low space 

requirement easy mounting in places 

w it 

h limited access 

Stainless steel housing: rugged 

• Switching status and wdemal testing: 

simple control 

• Plug connection: low-cost connect io n 

Measuring System 

The Ltquiphant FTL 260 is a compact 

fimit switch, to which miniature 

Contactors, magnetic valves and 

programmable logic cont rollers (PLC) 

can be directly connected. 

G5-341 

Application 

The Uqulphant is a limit switch for liquid 

level detection in storage tanks, tanks 

With agitators, and piping. 

It can be used as an a lte rnative to float 

switches as well as in applications 

where build-up, turbulence, liquid flow 

and gas bubbles are present. 

Endress + Hauser 

The Power of Know How WOP

ant ion 

and 

Dimensions 


The symmetrical vibra ting fork is excited 

to its resonant frequency which changes 

when the fork is submerged to liquid. 

The charge is registered by the 

electronics, which actuate an electronic 

switch. 

The Lfquiphant FL 264 can be 

operated in both mfniRertn or maximum 

fail-safe erode, i.e. the electronic switch 

opens on reaching the Dint value, in 

cases of fault or a loss of powe r, 

2 

G5-342 

Marimum hSNinum 

green g re 

en red gram green red 

Dle(aem shawbg ine 

etectronim6tdland! 

LED depmtling m9re 

WTI end rat'sah mode 

A Elech'r2l oonnedlm 

whin .standard plug 

amt wAhmare,le nd 

Pg it (IP 6616]1 

or palmmuntly . 

adeebadcabte 

gPO). 

Th e falt.WD mods is 

determined by me 

nay the connec tion 

tswlred 

e The stainless steel 

housing pmtecls the 

poNedelacimNSs 

C The s ilchm, knctren 

cants, cbecked 

salemany hY piadn, 

amagretimme 

housing 

b Process tannin 

"Mims: 

G d A (yamlie ) 

t-1tNa NPr.(fapemd) 

R 7 ospered) 

inslabless ateel. 

E visiting bile inaond 

stateless steel 

F G^reen LED 

Vpm*V mode' 

G Red LEDWMicete 

'C,cmteperC 

H TtwpNghMrLV ar 

also Leftind Wlset 

by 59V 

immm nsiamm 

foomm=2aAin 

tin=26Amm

Technical Data 

Output AC VVERIM 

Output DC version 

Output 

Process tond4tions 

Mecba dml cto snucclon 

OuleSng 

T1244pMWel0IMI 

EHFICVS 


P(pn suppy a lPSmTal419..263 V,Salm W.mpsenl MnwmOL'mlelaTdM)rtax.41M 

Comeelleetool SWRe,,o14DEUk nnx.lSA;. 3T5 VA WMV n. MVAM 24V 

Ibed.''W*dvverlhrslilox ",Wmb (not0mnebcwlprspec6.ry . 

tnepoxcrsuppy cbrn^ CuRlupuc mac 9TVA M250V(M mq,nnx.$A Met 24 v PM IuA) . 

mp.2.5VAM250V (101mxo,o,M VAet24 V(2Dmn) 

vofegoxtopasrosoMM.- meul2v 

FbeNPM4m0M: mo%41M4uI110pwtBysisinislerdby) 

Poo.towl, 

Cmnembblced 

Nbe MOtlbsvnldmdvb PNP.trms¢tor) 

19:_SSY.rmp'smax.iTV,9..

Installation 

The Llyufpham FTL tall can he moo unt In any 

pmlfmn In a tank or In a semen of p 1ptn9. 

A VankatmpuMing 

@.HOrRantaf mewling 

C Mounting In a 1"nozzle 

(AtoC for theanlim MARC of dScoayes 

upto10000mm°!s) 

D'Prmgailmumfimb a rr=66 

(L(nPG fnlsprerred M Nnd lbnga}, 

Range of v cosia lses m aN 50 

LgMmac2t)07 mmJls 

E For easy mountdlg In lknftd spas: 

mount w it 

h 41 AF h=Spauea 

(Enaiess+Hauser accessory) 

C• swikhpotat 

Electrical 

Connection 

Elemr'ral mnwrlkm 

deparclingonveraion 

and lalLSala mode 

Max.=maximum 

bilsa(emoda 

Fhh—Mmmum 

ralFsere mode 

Q>vab'econnemlal 

aU =due 

@K =black 

2N =bream 

GNYE=weawyelkm 

OD =Plug eom;enioa 

R=externalload 

Q. 

6U 1 

(BK) (2) .^^ 

MAX. 

A 

Lit 

eN 3 R N 

Gh"YE l+(aL--pE 

Mar. 

BU L— 

EK 

V 

aN L+ 

GNY PE 

Prod.dSWCluee 


AC Vemlan 

MIA, 

a O A 

au t u 

BK 2 E' R N 

(BN) (3) 

FTL 215 9 Llm3lswhch 

GNYE u---PF 

De ver¢fon 

2 

FOSA 

GedRte be 

o Standard(nma Med) 

3 CSA Gemral puipeee 

PE 

Fraoees canneeden 

D 91Atpar allel 

1 1-1134 NPTaaperad) 

2 R 1 tapered) 

Eledrados 

1 Tw Wl a AC 

cwneofw/9 ... 2534 

2 Tfveewdre r)C 

W—W—t=l 

3 

G5-344 

Version 

Mtn, 

D rack Obmgpoll 

) 

O 

AC Version 

A load must be connected in series with 

the Liquiphant, whereby: 

• the voltage drop across the Liquiphant 

in closed mode (ON) may be up to 

12V 

• a minimum terminal voltage of 19 V is 

fi—A fir the Dnit tD switch carr=ony 

(check in pa rticular fora tow fine 

voltage), 

In open mode (OP9 a . residual cu rr 

ent 

of max. 3.8 mA flows. 

DC Version 

Recommended when used with 

p rogrammable logic controllers (PLC). 

Pos itive signal at the switching output of 

the Liquiphant (PNP), 

Th e fail-sale mode is detarrnined by the 

way the output is connected up. 

c 

J 

.s 

.ao 

Wt 

fin 

1oD 1 ^ 

t har-1a.a per 

m 

.d0 a 56 tee 150 ^ 

TO graph: Barren graph: 

Permleslble vabestw Pamllsslq'evaluo br 

amblent temperature operalbgpressu re pe 

T•atlemsingare aredeperdenallhe 

dependent An the operating lowerilue 

operably tamparature To in the tank 

Temthetank

logy 

EP 3.&lF Octo6tt2003 


CN No. 


Page t of 

Change Notice (CN) Catego ry (Check 

One) O ri ginators Name and Signatu re . Date 

Supplemental ® 

Di re ct Revision q _ / d7 04/15!2005 

Cancel q 

Jack NlcCOnwelt /gfu^' /K. 

Qua lit y Program 

Procedure Change 13 

PmjactTdlelProject No. 

Affects Cost? 'Yes q No 0 

Demonstra tion Bulk Vitrification System 

145579 

Affects Schedule? Yes q No 121 

Other Documents Affected by this CN: OGTS HEPA Filter Skid Speci fication 

NIA 145579-D-SP-036, Rev 1 

Reason for Change:. 

Design verification Requi re d 

(independe nt Review) 

Safety Class (if Rcfd) 

Yes I] NON NIA 

Primary Document Charged by this CN Affected Documents Superseded Contract No. 

(include sheet no. and rev) 

Yes ® No N. 

1) Fab ricator requested, in RFI 23410.CGTS.PT1-RFI.014, R0, the use of 1" thick insulation material on the condensate lines. 

Based on the heat trace calculations using 1' at an R-value of 3.7 in lieu of 6.0 does not significantly impact the calculated 

heat t race wattage. 

Detailed Description of Change (Use Continuation Sheet, as Applicable): 

Change paragraph 3.3.1.1.9.2 as follows: 

The insulation material shall have a minimum 'W ^—^f ^ thickness of 1" and shall meet the 

requirements of the Midwest Insulation Contractors Association for materials, design, and 

application, and shall not interfere with the operating, testing, maintenance, and se rvice of any 

components or systems. Insulation shall be removable and re-installable from components 

requiring periodic maintenance and inspection. Insulation mate ri 

al shall be free of halogenated 

hydrocarbons. 

Review/Approval Authorities: A = Approval, R = Review, l = Informa tion (Check where applicable for change notice) 

Printed NamelSignaturs Date R A I P ri nted Name/Signatute Gala. R. A 1 

Program Dire ctor.. Michael wiemers q q q Inde nt Review': q q q 

Pro M J' rededckson ^^ q ® q AM EPM ides' neG r ® q 

Oft 

me an 

Luey 

Elecld 

i E ee agar. Ja-Kael 

Enginee ring WOW. Dave King 

is q 

q 

0 

11 

El 

13 

& 

CH2M H nvir tat or designee 

B 

q 

q 

W El 

q q 

Process Manager. Karyn q . q CH2 61 3 or 

VIA 'I] 

. q 

Quardy nce Trudt 

^^ 

q Other q 

o3 

* Design Verification peg EP 3.9 required? Yes q No ® Assign Independent Reviewer 

CN Incorporated? PM or designee sign and date: 

G5-345

^. a 

n, 

010 vl J 

CN No. 


Page lof2 

Change Notice (CN) Catego ry (Check 

One) Originator's Name and Signature. Date 

Supplemental ® _ 

Direct Revision q 

Jack McComaeA 

/ y 

JYnc, /O^- ' ""' yfn^^ 

Cancel q / 

Quality Program Project Title/ Project No. 

Procedure Ch ange 13 

Affects Cost? Yes q No ® 

Affects Schedule? Yes q No [ 

Demonstration Bulk Vitrification System 

Other Documents Affected by this CN: OGTS HEPA Fitter Skid Specification 

NW 145579-D-SP-036, Rev I 

Reason for Change: 

0411912005 

Design Ve rifica tion Required 

(Independent Review) 

Safety Class (If Rq'd) 

Yes El No ® NIA 

Prima ry Dominant Changed by this CN Affected Documents Supe rseded Contract No. 

(,include sheet no, and rev) 

Yes q No 23 

1) Fabricator requested, in-RFI 23410.OGTS.PTI-RFI-015, RO, that the fluid service catego ry and testing requirements be 

evaluated for the piping se rvices on the HEPA filter skid. 

Detailed Description of Change (Use Continuation Sheet as Appli cable):. 

Change the specification to allow the compressed air and filtered water systems to be designed, fab ricated, installed, 

inspected, examined, and tested in accordance with ASME 831.3 Category D fluid se rv ice. This fluid se rvice for these 

two systems is consistent wi th the designations throughout the DBVS p roject. The condensate collection piping will 

remain ASME B31.3 "Normal Fluid Se rvice:' The addi tional sensitive leak test imposed on the condensate collection 

piping will be deleted from the specification, however, the pressure decay test on the condensate collection system will 

remain.. For changes to the specification see the continuation sheet. 

Review/Approval Authorities:. A =. Approval, R = Review, I = Informa tion (Check where applicable for change notice) 

Printed Name/Signature 'Date R A i Printed Name/Signature Date R A I 

Program Director. Michael Wiemers q q q independent Review": q q q 

Projactiman geF=31m Ft degckson q ® q - M ' E PM or desi ee q Ig 11 

L y 

icat gi r- g Man ger. Ja-Kae1 

i 


i a3{a 

RECORD COPY 

l9 q (^ q - EC E&E QA or d e El 21 11 

Electricallfftindering Manager. Dave King q q q CH2WHILLE ftnmpfflalordeslgnea q q q 

PmoessTechnology Manager. Karyn q q q CH2M H i nee y q q 

Wiemers AWL— 

Quality a z: Ross T itt t q @ Other q q q 

D " n Verifi cation per EP 3 .9 required? Yes 0 No N Assign Independent Reviewer 

GN incorporated? PM or designee sign and date: 

EP3.&.iF Oaober 2003 

G5-346


CONTINUATION SHEET CHANGE NOTICE CN No_145579-036-CN-003 

Page2 of 2 

"3.3.1.2 Piping — Design 

Piping systems for the system and interconnecting piping for the Condensate 

Collection system piping, Filkered Water ._a n,...,., ..., sed A ir System shall be 

designed, J bricated, inspected, examined, and tested in accordance with the 

ASME 1331.3 piping code for "Normal Fluid Service." Piping systems for the system 

and interconnecting piping for the Filtered Water and Compressed Air Systems 

shall be designed, fabricated, inspected, examined, and tested in accordance with 

the ASME B31.3 piping code for "Category D Fluid Service." Piping systems 

include all piping components and supports. The minimum design pressure for the 

HEPA filter skid piping and components, including instrumentation shall be 

determined by the Seller for the design flow rate. The design temperature shall be 

determined by the Seller for the design flow rate taking into account insulation, air 

stream temperature, and environmental conditions." 

2. ChangePamgmph423 u follows: 

4.2.3 Pressure-leak Test 

The tHEPA filter skid assembly Condensate Collection system piping and 

components shall be pressure-leak tested in accordance with the ASME 831.3 

piping code for "Normal Fluid Service.' A sensitive leak test in aGGOFdanee with 

hubble test ham.^ ^.,f dentnsith4b,- The -'HEPA filter skid assembly 

Compressed Air and Filtered Water system piping and components shall be 

pressure-leak tested in accordance with the ASME 831.3 piping code for 

"Category D Service." 

Results shall be recorded and shall be submitted to the Buyer with test 

records/documents, 

G5-347 

i

lwamciogy 


1 " IN' i c 

- CN No, . 

CHANGE NOTICE 145579-OWCN-00,6 

Page t 2 - 

Charge Notice (CN) Category (Check 

One) Originator's Name and Signature. Date 

Supplemental eMai 

. 

Direct Revision 

Cancel 

q 

C9 

J!/^pG/^l'• 

adc lNcConwel 

05/}7P2005 

OuatityProgram 

Procedure Change [3 


ProjedTliet Proje ct No. 

Demonstration t Bulk Vilification System 

Design Ver ification Required 

(independent Review) 

Yes ® No 0 

Safety Class (If Pod) 

NIA 


Primary Document Changed byth -is CN 

(mdude sheet no. and rev) 

Affected Documents Supe rseded Contract No. 

Other Documents Aflected by this CN: OGTâ HEPA Filter Skid Spedlication 

N1A Yes q No ® 

145579-D-W-036, Rev 1 


1) Du ri ng the design review of the Projects 900/6 design for the Off-Gas Treatment System, the fail posi ti on of the inlet valves to 

the HEPA filter housing was changed from fail closed to the fail open positron. 

2) Change equipment identification to match the AMEC generated P&ID, F-145579-36-A-0107, Rev C. 

3) The P&IDis also being updated fo reflect the Vendor's 90 0/4 design submittals. 

- Detailed Descrip ti on of Change (Use Continua tion Sheet as Applicable), - 

1. Cancel CN 145579-036-CN-004 

2. Change Valves HV-401A and HV-401B to HV- 313 and HV-309 respectively and from Fail Closed (FC) to Fail Open 

(FO) to match AMEC drawing F-145579-36-A- 0107, Rev C. 

3. Add Valve and instrument numbers to match AMEG drawing F-145579-36-A- 0107, Rev C. 

4. Add Quick conned numbers for all quick disconnects to match AMEC drawing F-1455 .79-36-A-0107, Rev C. 

5. Add depiction of Condensate collection tank pump within a pump enclosure. 

6. Add sight glass to P&ID as called out in the Specification paragraph 3-3.1.1.8.2 

ReviewlApproval Autho rities: A = Approval, R = Review, l = Information (Check where applicable for change notice) 

Printed NamatSignature Date R A 1 Printed Name/Signature Date R I A I I 

Program Director Michael Wierners q q q We dent Review^ - q q q 

Proj nagx JiinFredericksan /rib q q E PM or designee q q 

Mecynical icai - î ng a r. "Gael q q _ 

Luey Zel 

Electrical um'Mara .Dave King. q q q tCH2M L viro ntalordssignee q q q 

- 

101 N q 

Process Technology Manager. Ka ryn Ll CH2M HILL PfA shrr/ q ( q 

Wiemers !T 

ailtyAssu nce: Ross Tmdt 

cc^/ 

q ® q Other ... 

q . q q 

L- • FR 

ryf7a 

* Design Verification per EP 3.9 required? Yes q No ID Assign Independent Reviewer 

CN incorporated? PUI or designee sign and date: 

(N- Z55 

E1? 3.8:1 1F OCtobe 201)3 

G5-348

yq 

CHANG£ NOtiC€ CONTINUATION 5H££t 


cN 145579-036'-C`N'-005 

--- 

PAGE 2 OF 2 4ATE 05-1 5- 8 16"05 

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G5-349

1 

Change No ti ce (CN) Category (Check 

One) 


CHANGE NOTICE -036-CFI-006 

Page T of 2 

originators Name and Signature. - 

tDale 

Supplemental 

. Direct Revision 

10 

q 

Jack McCunwetl 

//^^ yy / 

Lnyvv-'f/' 

- 0111 2 /200 6 

Cancel q 

Qua li ty Program 

Procedure Change q 



P roject Title/ Project No 

Demonstration Bulk Ydrifica tion System 

1145579 

Primary Document Changed by this CN - 

(inc 

Design verifica tion Required 

(Independent Review) 

Yes q Now 

Affected Documents Superseded 

Safety Class (If nq'd) 

N/A 

Contract No. 

lu de sheet no. and rev) 

OGTS HEPA Filter Skid Specification Other Documents Affected by this CN: 

NtA 145579-DSP-036, Rev 1 


1) Incorporate International shipping stand ards to the specitication in accordance with the response to RR-23. 

2) Add normally closed tank vents and valves to the condensate and seconda ry confinement tanks per client comments to FAT. 

Detailed Description of Change (Use Continua tion Sheet as Applicable): 

1. Specification 145579-D-SP-036, Revision 1, change paragraph 5.3-1 as follows: 

5.3.1The Seller shall require vendorslsuppliers to package equipment for international 

transportation in solid wood crates to the Seller's facility to protect items during shipping. 

The seller shall package equipment for shipment to the buyer to protect items during 

shipping. Bracing structures shall be installed where items could be damaged or vibrate 

loose during transpo rtation. All bracing must be clearly identified, loth in the packaging 

instruction and by labeling on the outside of the crates ceseigf -taAks. 

2. Specification 145579-D-SP-036, Revision 1, Appendix A, change drawing DBVS-SK-P102, Rev C as shown on Page 

2 of this ECN 

Review/Approval Authorities: A = Approval, R= Review, I = Information (Check where applicable for change notice) 

Printed Name/Signature Date R A I Printed Name/Signature Date A A 1 

Program Director: U q U Independent Review: q q 

Projec nager;Jim Fred@ rickson 

âr 

. f l C.^— 

M ` 'cat i M ager: r: Ja-Kael 

Y 

1^12/6i. 

q 

q 

® 

AMEC E&E PM or designee 

AMEC E&EGA or designee q 

9 q 

q 

Electrical heeling Marf6ger. Dave King CH2M HILL Environmental or designee q q q 

Process Technology Manages CH2M HILL PM or designee q q 

Quality A: ce: 1l - 0 Other q q q 

s)o^ 

`^ 

4 Design Verification per EP 3.9 required? Yes © No © Assign Independent Reviewer 

ON Incorporated? PM or designee sign and date: 

E1' 3.8.1 F Oc rober 2003 

G5-350 

Yes

I 1513 


CHANGE NOTICE CONTINUATION SHEET 

PAGE 2 OF 2 

CN 145579-036—CN-006 

DATE 01-12- 06" 

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G5-351

Nt(flimlogy 


RPP-24544 R F V Id 

The document revision number is indicated below. Please replace all revised pages of this 

document and destroy the superseded copies. 

PROJECT: Final DBVS Design 145579-D-SP-037 REV. 1 

PROJECT NO: :i 145579 WET SCRUBBER SKID ASSEMBLY 

CLIENT: _C AMEC E&E - Richland, Washington DESIGN AND FABRICATION 

"S 

AMU-, ' aT ^T '4'.: i::ti : _cp C7 

::. 

îY 

r`.. 

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_—^y:^;:__/_i^L1:o _l: 

QIÎh^^1 -^ I :a^sa^^

a tedux^ 




PROJECT NO.: 145579 WET SCRUBBER SKID ASSEMBLY 



TABLE OF CONTENTS 

1 SCOPE.. .............................................................................................................. 7 

1 .1 INCLUDED IN SCOPE.... ................ ........................................................7 

1 .2 NOT INCLUDED IN SCOPE ......................... ..:......._.:.......................:...9 

2 

Page 

APPLICABLE DOCUMENTS ............................................................................10 

2.1 GOVERNMENT DOCUMENTS ........... ....... .... .... .................................. ..10 

2.2 NON-GOVERNMENT DOCUMENTS .....................................................10 

3 TECHNICAL REQUIREMENTS ........................................................................17 

3.1 ITEM DEFINITION . .................................................. ..........- _-------..........17 

3.1A Item Diagram ...................... . ............... .. ............................. .... 17 

3.1.2 Interface Definition ... ...... .... ... ................................................ 18 

3.2 CHARACTERISTICS . ............. ...............................................................24 

32 1 Functional Characteristics.. ....... _ .... .............................. _ ---- 24 

3.2.2 Physical Characteristics .........................................................27 

3.2.3 Reliability - .................... ............ ......... -......_---- ..................27 

12.4 Maintainability --------..._:...- .....................................:................28 

3.2.5 Environment ........... ....................................... .....................29 

3 .2.6 Transpo rtability and Storage... ........... ............. ........ __ ..... _ 30 

3 .2.7 Safety..._ ............................_......_..........................................31 

3.3 DESIGN AND CONSTRUCTION... .............. ..................... __ ... ........... 31 

3,3.1 Pa rts/MaterialsFProcesses ................................._.................. -31 

3 .3.2 Industry and Government Standards ......................................58 

3'.3.3 Radiation......- ............._.................._....--.........:...................59 

3.3.4 

3..3.5 

3.3.6 

Cleanliness .......... 

- ..............................................60 

Corrosion of Pa rts._ ...........................-... ............................... 61 

Protective Coatings .... ......... .................... ................... . ........... 61 

33.7 

3.3.8 

3.19 

33.10 

3.3.11 

Interchangeability .... ................................ .............................63 

Identification and Marking . .................... .... .................. . .......... 63 

Nameplates ............... ..:. ............. ... ........ .-.. ..... .......... ......... ---.67 

Human Engineering ...................... .......................................67 

Design and Qualification ........................................................67 

3.3.12 

3.3.13 

Document Submittal.............. .................................................73 

Personnel and Training_ ........ ........ ................... ... . ...............77 

4 QUALITY ASSURANCE REQUIREMENTS ......................................................79 

4.1 GENERAL...-. ......... _ ........_......---------- ............:.... .... .........................79 

........... .... .......... .............. ... ............................ 79 

4.1-1 Design-- . 

4.1.2 Procurement Document Control ..... . 79 

............................ ... ........ 

4.1.3 Instructions, Procedures, and Drawings,... -------- ................. _ 81 

4.1.4 Identification and Control of Items .............. _ ...... ........ . ........... 82 

WET SCRUBBER SKID ASSEMBLY DESIGN AND FABRICATION Page o 2 101 

03-Nov-05 

G5-353

ted>oak 




I 


CLIENT: I' 



4A.5 Control of Processes 

4.1.6 Verification and Verification Methods ......................... 

4.1.7 Test Control ............................ ........ ..........°............... 

4.1.8 Control of Measuring and Test Equipment ................. 

4..1.9 Handling, Storage, and Shipping ................................ 

4.1.10 Inspection, Test, and Operating Status ...................... 

4.1_11 Control of Nonconforming Items.. ..... _ ........................ 

4.1.12 Corrective Action ........................................................ 

4.1.13 Quality Assurance Records ................................... 

4.1.14 Control of Graded Fasteners ................................. 

INSPECTIONSAND TESTS ................................ ................. 

4.2 88 

4.2.1 Electrical Testing ... ........................ .............::........ 

422 

........89 

Remote O p.......-°----..._................. 

erated Valve Tests 

........90 

4.2.3 Pressure Leak Test ........................................................ ...91 

4.2.4 Wet Scrubber System Testing... ..................................... .....91 

4.2.5 Secondary Containment Leak Test ................................ ........92 

4.2.6 Lift Tests ........................................................................ ........ 93 

5 PRESERVATION AND DELIVERY .........:.........................................................94 

5.1 GENERAL ................ ..................... ....................._...:.............................94 

5.1.1 Packaging and Shipping Instruction Manual ...........................94 

5.1.2 Operation and Maintenance Manual ._ ...................................94 

5.2 PRESERVATION AND PACKAGING... ...................... - .... ..................... 95 

5.3 PACKING.. ...... ..................................................... ........................ ....... 95 

5.4 MARKING ... .. ..................................... ........ ........................................... 98 

5.5 HANDLING ..... ....:............. ....................................................................98 

5.6 SHIPPING.---_ ............ .......... .................. ................. ............................... 98 

5.7 RECEIVING ..................... ... .... ......... ... ....... .. ..... .................................... 98 

6 NOTES.- ..................................................................................................... ... 100 

7 APPENDICES .................................................................................................101 

A 

B 

C 

APPENDICES 

Drawings and Sketches 

ASME AG-1 Compliance Requirements 


D 

E 

F 

G 

TFC-ESIHQ-Q_C-C-03, Revision C-2, Control of Suspect/Counterfeit Items 

Request for Information 

Bidder's Drawing and Data Commitments 

Instrumentation Naming and Tagging Convention 

---. ..... 82 

..........83 

..........84 

..........85 

..........86 

..........86 

..... 86 

......87 

..........88 

..........88 

..........88 

WET SCRUBBER SKID ASSEMBLY DESIGN AND FABRICATION Page 3 of 101 

03-Nov-05 

G5-354

matedinob-gy 







FIGURE 

Figure 3-1: Interface Panel Wiring to Instrument/Component Drawing (Example)........ 55 

TABLES 

Table2-1: Government Documents... ........................ ............................ __ ....... .10 

Table2-2: Non-Government Documents ....................... ............................................... 10 

Table 3-1: Wet Scrubber Skid Assembly Interface Connections (2 sheets) ..................19 

Table3-2: Incoming Stream Properties....__ ................................................................ 25 

Table3-3: Environmental Conditions ............................................................................ 30 

Table3-4: Wire Color Coding Requirements... ................... ......... ................... ........... 48 

Table3-5: Standard Drawing Dimension Tolerances ................... ................................ 58 

Table3-6: Pipe Labeling Format .... .... .......................................... ..........-....................65 

Table 3-7: Wet Scrubber Skid Assembly Piping Design Conditions .............................. 72 

WET SCRUBBER SKID ASSEMBLY DESIGN AND FABRICATION 

03-Nov-05 

G5-355 

Page 4 of 101


Etedlixilogy ame 






ABBREVIATIONS AND ACRONYMS 

AISC American Institute for Steel Construction 

ANSI American National Standards Institute, Inc. 

ASCE American Society of Civil Engineers 

ASHRAE American Society of Heating, Refrigerating, and Air Conditioning 

Engineers 

ASME American Society of Mechanical Engineers 

ASNT American Society of Nondestructive Testing 

ASTM American Society for Testing and Materials 

AWG American wire gauge 

AWS American Welding Society 

B&PV Boiler and Pressure Vessel 

CFR Code of Federal Regulations 

CH2M HILL CH2M HILL Hanford Group, Inc. 

CMTR Certified Material Test Reports 

CoC Certificate of Conformance 

CWI Certified Welding Inspector 

DBVS Demonstration Bulk Vitrification System 

DOE U.S. Department of Energy 

EIN Equipment Identification Number 

FAT Factory Acceptance Test 

HEPA high-efficiency particulate air 

IEEE . Institute of Electrical and Electronics Engineers 

MCS Monitoring and Control System 

NCR nonconformance report 

NDE nondestructive examination 

NECO National Electric Code 

NEMA National Electrical Manufacturers Association 

NFPA National Fire Protection Association 

NIST National Institute of Standards and Technology 

NRTL Nationally Recognized Testing Laboratory 

WET SCRUBBER SKID ASSEMBLY DESIGN AND FABRICATION Page 5 of 

03-Nov-05 - 

G5-356

a tedlraia 







OGTS 

P&ID 

QA 

QD 

RGS 

RTD 

SAE 

UBC 

UL 

WAC 

TRADEMARKS 

AutoCAD 

Bray 

Buna N . 

Electromark 

Keystone 

LineBacker 

Loctite 

Mini Power-Zone 

NEC 

Neo-tube 

Square D 

Sta-kon 

Super Therm 

Swagelok 

Teflon 

Viton 

Weidmuller 

Off-Gas Treatment System 

piping and instrumentation diagram 

quality assurance 

quick disconnect 

rigid galvanized steel 

resistance temperature detector 

Society of Automotive Engineers 

Uniform Building Code 

Underwriters Laboratories, Inc. 

Washington Administrative Code 

Registered trademark of AutoDesk, Inc. 

Registered trademark of BRAY INTERNATIONAL, Inc. 

Registered trademark of Buna Werke Huts G.m.b.h. 

Registered trademark of Permar Systems, Incorporated dba 

Electromark Company. 

Trademark of Tyco Industries. 

Registered trademark of ProfessionaV Services Industries, Inc. 

Registered trademark of Henkel Loctite. 

Registered trademark of Square D Company Corporation. 

Registered trademark of the National Fire Protection Association. 

Registered trademark of Watson Bowman ACME Corporation. 

Registered trademark of Square D Company Corporation. 

Registered trademark of Thomas & Betts Corporation. 

Registered trademark of Superior Products International It 

Incorporated dba Superior Products Corporation. 

Registered trademark of Swagelok Company. 

Registered trademark of E. I. Du Pont De Nemours and Company. 

Registered trademark of DuPont DOW Elastomers. 

Registered trademark of C. A. Weidmuller K.G. Company, 

WET SCRUBBER SKID ASSEMBLY DESIGN AND FABRICATION Page 6 of 101. 

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PROJECT: Final DBVS Design 145579-D-SP-037 I REV.1 



CLIENT: AMIEC E&E -Richland, Washington 

1 SCOPE 

Throughout this specification, Contract Responder shall act as the Seller and 

AMEC Earth and Environmental, Inc. shall act as the Buyer. 

The Demonstration Bulk Vitrification System (DBVS) will demonstrate a 

treatment process for radioactive waste located on the Hanford Site in Richland, 

Washington. This specification is for a wet scrubber skid assembly. Deviations 

from the treatment equipment are allowed, as long as all other requirements in 

the specification are met, but will require justification by the Seller with Buyer 

approval, contingent on discussions with the owners. 

Unless otherwise stated, alternative equipment designs are permissible, if proven 

to be effective in meeting the requirements in this specification. Any alternative 

design must be thoroughly explained with text supplemented by drawings or 

Sketches and proposed with the original bid. Buyer approval is required before 

proceeding with an alternative equipment design. 

A Turn-Key Packaged System is preferred which would include all equipment 

and controls to meet the pe rformance requirements fisted in this specification. 

To allow for both a designed system and a packaged system, certain items will 

indicate an option within the body of this specification. 

1.1 INCLUDED IN SCOPE 

Conceptual piping and instrumentation diagram (P&ID) and electrical one-line 

diagrams (Appendix A) for the Off-Gas Treatment System (OGTS) wet scrubber 

skid assembly are provided to the Seller to illustrate design considerations 

currently identified by the Buyer. This specification provides the minimum 

requirements for design, analysis, fabrication, inspection, testing, documentation, 

packaging, and shipping of a wet scrubber skid assembly. The following lists 

equipment and design activities to be provided by the Seller: 

1. .A skid with leak catch pans, and piping and electrical connections. The 

skid will be installed on a concrete pad. The Seller is responsible for 

providing anchor points. 

2. Venturi scrubber(s), quencher(s), condenser, mist eliminators, outlet 

heater, ductwork and enclosures, pressure control valves, and manual 

isolation valves. 


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3. Scrubber collection tank subsystem with pumps, flow control valves, 

manual isolation valves; piping and supports, and process instrumentation. 

4. Makeup solution subsystem with caustic storage tank, mixer, centrifugal 

pump, isolation valves, piping and supports, and process instrumentation. 

5. Eiectrical distribution equipment, including transformer (as required), 

distribution panel, wiring, conduit, local pushbutton stations, and 

convenience receptacles. 

6. Instrumentation and control wiring from skid-based equipment connected to 

terminal box(s). For a packaged system, terminations for remote 

shutdown, alarm and run status signals shall be provided. 

7, Support structure for component assembly and skid shipping. 

8. Design, fabrication, assembly, inspection, testing, packaging, shipping, and 

test work plan, including Factory Acceptance Tests (FAT) for systems, 

subsystems, and components shall be provided (see Sections 4.1 and 

4.2). The wet scrubber skid FAT will be performed at the Seller's facility. 

9. Develop wet scrubber skid assembly design documentation, supporting 

calculations, and fabrication drawings; Drawings and sketches provided. 

with this specification represent a minimum set of Buyer expectations for 

the assembled system. The Seller shall use this information, along with 

additional material in the specification, to generate a set of design and 

fabrication drawings with sufficient detail for construction. Examples of 

information to be developed by the Seller includes, but is not limited to 

dimensioning and associated tolerances, mounting and weld details, and 

material types and quantities. 

10, Develop complete quality assurance (QA) data package for the design and 

assembly of one wet scrubber skid assembly. 

11. The material handled is considered hazardous and radioactive waste that is 

regulated under the requirements of 40 CFR 264, Subpart J; 10 CFR 830; 

and WAC 173-303-640. The design shall take into consideration potential 

hazards during operation of the system and include in the design measures 

to prevent the hazardous conditions to operating personnel_ 


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12. Component information provided on data sheets with this specification 

contain preferences identified by the Buyer for the assembled system. The 

Seller shall use this information, along with performance requirements 

either in the specification or generated from Seller prepared calculations, to 

generate a completed set of data sheets for components of the assembled 

system. Form, fit, and function shalt be evaluated by the Seller in the 

course of design work and development of the design and fabrication 

drawings. 

13. Any discrepancies noted in this specification or between this specification 

and other documentation shall be noted and referred to the Buyer for 

resolution before proceeding with design or fabrication of the item in 

question. 

1.2 NOT INCLUDED IN SCOPE 

Work not included in this specification is as follows: 

1. Installation of the wet scrubber skid assembly at the Buyer's facilities. 

2. Design and manufacture of connected ductwork or piping systems (external 

to the skid assembly) that are a part of the overall OGTS. 

3. Design or manufacture of the electrical conductors on the line side of the 

480V power terminal box. 

4. No electric motor starters are required. The Buyer will provide starters 

located in a motor control center that is external to the wet scrubber skid 

assembly. 

5. Chiller unit for the wet scrubber skid condenser. The Seller shalE interface 

with Buyer-provided chiller unit. 

6. Monitoring and Control System (MCS) is not included, however, if the 

proposed system is a packaged unit, it shall include all monitoring and 

control equipment. 

7. Seller to provide option to support unit installation and testing at the Buyer 

facility. Option shall provide per diem rates for field support. 

WET SCRUBBER SKID ASSEMBLY DESIGN AND FABRICATION - Page 9 of 101 

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APPLICABLE DOCUMENTS 

The -odes, standards, and other documents listed in Table 2-1 and Table 2-2 are 

of the latest issue and addenda in effect at the time of procurement (unless 

otherwise specified). These documents form a part of the basis of design for this 

procurement to the extent specified in the applicable sections of this 

Specification. All conflicts between documents referenced herein and the 

requirements of this specification, recommendations of alternative standards, or 

identification of omissions shall be brought to the attention of the Buyer for 

resolution. 

GOVERNMENT DOCUMENTS 

Table 2-1: Government Documents 

Government Documents< Title 

10 CFIR 830 "Nuclear Safety Management," Code of Federal 

Regulations, as amended. 

29 CFR 1910 "Occupational Safety and Health Standards," Code of 

Federal Regulations, as amended_ 

40 C:FR 264 "Standards for Owners and Operators of Hazardous 

Waste Treatment, Storage, and Disposal Facilities," 

Subpart J, Code of Federal Regulations, as amended. 

47 CFR 15 

"Radio Frequency Devices," Code of Federal Regulations, 

as amended. 

DOEIRL-92-36 Hanford Site Hoisting and Rigging Manual, 

U.S. Departme nt of Energy, Richland, Wash ington. 

WAC '173-303-640 'Tank Systems," Washington Administrative Code, as 

amended. 

NON-GOVERNMENT DOCUMENTS 

Table 2-2: Non-Government Documents (7 sheets) 

c.ode/S>fadard' Title T' 

AISC: Manual of Steel Construction—Allowable Stress Design, 

Ninth Edition, American Institute of Steel Construction, 

Chicago, I llinois. 

AISC Manual of Steel Construction--Load and Resistance 

Factor Design, Third Edition, American Institute of Steel 

Construction, Chicago, Illinois. 


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-fable 2-2: Non-Government Documents (7 sheets) 

CoteLS dard e 

ANSI/AWS D1.3 Structural Welding Code—Sheet Steel, American Welding 

Societ y, Miami, Florida. 

ANSI C63.16 American National Standard Guide for Electrostatic 

Discharge Test Methodologies and Criteria for Electronic 

Equipment, American National Standards Institute, 

Washington, D.C. 

ANSI/H( 3.1-3.5 American National Standard for Rotary Pumps for 

Nomenclature, Definitions, Applications and Operation, 

Hydraulic Institute, Parsippany, New Jersey. 

ANSI/Hl 3.6 American National Standard for Rotary Pump Tests, 

Hyd raulic Institute, Parsippany, New ,Jersey. 

ANSI/HI 5.1-5.6 Sealless Centrifugal Pumps For Nomenclature, 

Definitions, Application, Operation and Test, Hydraulic 

Institute, P arsi ppany, N ew Jersey. 

ANSI Y14.1 Drawing Sheet Size and Format, American National 

Standard s Institute, Inc., New York, New Yor k. 

ANSI Y14.5M Dimensioning and Tolerancing, American National 

Standard s Institute, New York, New Yor k. 

ASCE 4-98 

Seismic Analysis of Safety-Related Nuclear Structures, 

American Society of Civil En gineers, Resto n , Virginia. 

ASCE 7-98 Minimum Design Loads for Buildings and Other 

Structures, American Society of Civil Engineers, Reston, 

Virginia. 

ASHRAE Fundamentals 2001 ASHRAE Handbook - Fundamentals, American 

Handbook Society of Heating, Refrigerating, and Air Conditioning 

Engineers, Atlanta, Geo rgia. 

ASME: AG-1 Code on Nuclear Air and Gas Treatment, American 

Society of Mechanical Engineers, New York, New York. 

ASME B&PV Code ASME Boiler and Pressure Vessel Code, American 


Section VIII, "Rules for Construction of Pressure Vessels" 

Section IX, "Welding a nd Brazing Qualificat ions" 

ASME 1316.5 Pipe Flanges and Flanged Fittings, American Society of 

Mechanical E ngineers, New York, New York. 

ASNIE: 1316.9 Factory-Made Wrought Steel Buttwelding Fittings, 

American Society of Mechanical Engineers, New York, 

New York. 


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-- — - DESIGN AND FABRICATION 



G^Qd/Santai^ I*t°#^ 

ASME B16.11 Forged Fittings, Socket Welding and Threaded, American 


ASME 816.34 Valves — Flanged, Threaded and Welding End, American 


ASME B18.2.1 Square and Hex Bolts and Screws Inch Series, American 


ASME: 8182.2 Square and Hex Nuts, American Society of Mechanical 

Engineers, New York, New York. 

ASME: B30.20 Below-the-Hook Lifting Devices, American Society of 

Mechanical Engineers, New York, New York. 

ASME B31.1 Power Piping, American Society of Mechanical Engineers, 

New York, New York. 

ASME B31.3 Process Piping, American Society of Mechanical 

Engineers, New York, New York. 

ASME N509 Nuclear Power Plant Air-Cleaning Units and Components, 

American Society of Mechanical Engineers, New York, 

New York. 

ASME NOA-1, 1997' Quality Assurance Program Requirements for Nuclear 

Facilities, American Society of Mechanical Engineers, 


ASM:= PCC-1 Guidelines for Pressure Boundary Bolted Flange Joint 

Assembly, American Society of Mechanical Engineers, 


ASNT SNT-TC--1A Recommended Practice, American Society of 

Nondestructive Testing, Columbus, Ohio. 

ASTM A 36/A 36M Standard Specification for Carbon Structural Steel, 

American Society of Testing and Materials, New York, 

New York. 

ASTM A 53 1A 53M Standard Specification for Pipe, Steel, Black and Hot- 

Dipped, Zinc-Coated, Welded and Seamless, American 

Society of Testing and Materials, New York, New York. 

ASTM A 105/A 105M Standard Specification for Carbon Steel Forgings for 

Piping Applications, American Society for Testing and 

_ Materials, West Conshohocken, Pennsylvania. 

ASTM A 106 Standard Specification for Seamless Carbon Steel Pipe 

for High-Temperature Service, American Society for 

Testing and Materials, West Conshohocken, 

Pennsylvania- 


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TECHNICAL SPECIFICATION ! y 


PROJECT NO.: 

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145579 WET SCRUBBER SKID ASSEMBLY 


CLIENT: AMEC EB.E - Richland, Washington 

'Table 2-2: Non-Government Documents (7 sheets) 

CadelStand i i y d 4 

.Y.4?^..4.^-. ,J.^9^.0.'L it.:$S>ih^. 

ASTM A 108 

ASTiA A 1821A 182M 

ASTIM A 193/A 193M 

9. ,.. 

\^tletl1 

Standard Specification for Steel Bars, Carbon, Cold- 

Finished, Standard Quality, American Society for Testing 

and Materials, West Conshohocken, Pennsylvania. 

Standard Specification for Forged or Rolled Alloy-Steel 

Pipe Flanges, Forged Fittings, and Valves and Parts for 

High-Temperature Service, American Society for Testing 


Standard Specification for Alloy-Steel and Stainless Steel 

Bolting Materials for High-Temperature Service, American 

Society for Testing and Materials, West Conshohocken, 

Pennsylvania. 

ASTM A 1941A 194M Standard Specification for Carbon and Alloy Steel Nuts for 

Bolts for High Pressure and High Temperature Service, or 

Both, American Society for Testing and Materials, West 

Conshohocken, Pennsylvania. 

ASTM A 234/4 234M Standard Specification for Piping Fittings of Wrought 

Carbon Steel and Alloy Steel for Moderate and High 

Temperature Service, American Society for Testing and 

Materials, West Conshohocken, Pennsylvania. 

ASTM A 240 0, 240M Standard Specification for Chromium and Chromium- 

Nickel Stainless Steel Plate, Sheet, and Strip for Pressure 

Vessels and for General Applications, American Society 

for Testing and Materials, West Conshohocken, 

Pennsylvania. 

ASTI'vi A 269 

Standard Specification for Seamless and Welded 

Austenitic Stainless Steel Tubing for General Service, 

American Society of Testing and Materials, New York, 

New York. 

ASTM A 276 Standard Specification for Stainless Steel Bars and 

Shapes, American Society of Testing and Materials, New 

York, New York. 

AST M A 307 

ASTM A. 3121A 312M 

Standard Specification for Carbon Steel Bolts and Studs, 

60 000 PSI Tensile Strength, American Society for 


Pennsylvania. 

Standard Specification for Seamless and Welded 

Austenitic Stainless Steel Pipes, American Society for 


Pennsylvania. 


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Table 2-2: Non -Government Documents (7 sheets) 

ASTM A 325 Standard Specification for Structural Bolts, Steel, Heat 

Treated, 120/105 ksi Minimum Tensile Strength, 

American Society for Testing and Materials, West 


ASTM A 351 Standard Specification for Castings, Austenitic, for 

Pressure-Containing Parts, American Society for Testing 


ASTPvI A 354 

Standard Specification for Quenched and Tempered Alloy 

Steel Bolts, Studs, and other Externally Threaded 

Fasteners, American Society for Testing and Materials, 

West Conshohocken, Penns ylvania. 

ASTM A 403/A 403M Standard Specification for Wrought Austenitic Stainless 

Steel Piping Fittings, American Society for Testing and 

Materials, West Cons hohocken, P ennsylvania. 

ASTM A 480/A 480M Standard Specification for General Requirements for Flat- 

Rolled Stainless and Heat-Resisting Steel Plate, Sheet, 

and Strip, American Society for Testing and Materials, 

West Conshohocken, Pennsylvania. 

ASTM A 500 Standard Specification for Cold-Formed Welded and 

Seamless Carbon Steel Structural Tubing in Rounds and 

Shapes, American Society for Testing and Materials, 

West Conshohocken, Pennsylvania. 

ASTM A 563a Standard Specification for Carbon and Alloy Steel Nuts, 



ASTM A 569 Standard Specification for Steel, Carbon (0.15 Maximum, 

Percent), Hot-Rolled Sheet and Strip Commercial, 


Conshohocken, Penn sylvania. 

ASTM F 436 Standard Specification for Hardened Steel Washers, 


Cons hohocke n, Pennsylvania. 

AWS D1.1/D1 1 M 

Structural Welding Code—Steel, American Welding 

Society, Miami, Florida. 

AWS D1.6 Structural Welding Code—Stainless Steel, American 

Welding Society, Miami, Florida. 

AWS D9.1/D9.1 M Sheet Metal Welding Code, American Welding Society, 

Miami, Florida. 

AWS QC-1 Standard for AWS Certification of Welding Inspectors, 

American Welding Society, Miami, Florida. 

WET SCRUBBER SKID ASSEME31 - Y DESIGN AND FABRICATION Page 14 of 101 

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CLIENT: AMEC E8E - Richland, Washington 

'Table 2-2: Non-Government Documents (7 sheets) 

HNF--2962 A List of EMI/EMC Requirements, Rev. 0, Numatec 

Hanford Corporation for Fluor Daniel Hanford, Inc., 

Richland, Washington. 

HNF-SD-GN-ER-501 !Natural Phenomena Hazards, Hanford Site, Washington, 

Revision 1 B, Westinghouse Hanford Company, Richland, 

Wash ington. 

IEEE: C62.41.1 

IEEE C62.41.2 

IEEE Guide on the Surge Environment in Low-Voltage 

(1000 V and Less) AC Power Circuits, Institute of 

Electrical and Electronics Engineers, New York, 

New York. 

IEEE Recommended Practice on Characterization of 

Surges in Low Voltage (1000 V and Less) AC Power 

Circuits, Institute of Electrical and Electronics Engineers, 


IEEE Std C37.90.2 IEEE Standard for Withstand Capability of Relay Systems 

to Radiated Electromagnetic Interference from 

Transceivers, Institute of Electrical and Electronics 

Engineers, Ne w York, New York. 

IEEE Std 141 IEEE Recommended Practice for Electric Power 

Distribution for Industrial Plants, Institute of Electrical and 

Electronics En gineers, New York, New York. 

IEEE Std 142 IEEE Recommended Practice for Grounding of Industrial 

and Commercial Power Systems, Institute of Electrical 

and Electronics Engineers, New York, New York. 

IEEE Std 242 IEEE Recommended Practice for Protection and 

Coordination of Industrial and Commercial Power 

Systems, Institute of Electrical and Electronics Engineers, 


IEEE Std 519 

MSS SP-67 

Recommended Practices and Requirements for Harmonic 

Control in Electrical Power Systems, Institute of Electrical 

and Electronics Engineers, New York, New York. 

Butterfly Valves, Manufacturing Standardization Society of 

the Valve and Fittings Indus try, Inc., Vienna, Virginia. 

MSS SP-72 Ball Valves with Flanged or Butt-Welding Ends for 

General Service, Manufacturing Standardization Society 

of the Valve and Fittings Industry, Inc., Vienna, Virginia. 

MSS SP-82 Valve Pressure Testing Methods, Manufacturing 

Standardization Society of the Valve and Fittings Industry, 

Inc., Vienna, Virgi nia. 


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- DESIGN AND FABRICATION 



^^det l Sfar^da^rd^Y F ^^ ,=Y ^T^tl^;, _ yam' 

NEMA MG-1 Motors and Generators, National Electrical Manufacturers 

Association, Rosslyn, Virginia. 

NFPA 70 National Electrical Code, 2002 Edition, National Fire 

Protection Association, Quincy, Massachusetts_ 

SAE J429 Mechanical and Material Requirements for Externally 

Threaded Fasteners, Society of Automotive Engineers, 

Warrendale, Pennsylvania. 

UBC; 1997 9997 Uniform Building Code, International Conference of 

Building Officials, Whittier, California. 

UL 508A Standard for Industrial Control Panels, UndeRvriters 

Laboratories, Inc., Northbrook, Illinois. 

*NQA-I (the relevant requirements of NQA-I are included in Section 4). 


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3 TECHNICAL REQUIREMENTS 

3.1 ITEM DEFINITION 

The wet scrubber skid assembly consists of: (1) ductwork and enclosures for 

quencher(s), venturi scrubber(s), mist eliminators, condenser, outlet heater, and 

collection tanks; (2) a chilled water piping system containing heat exchangers, 

pipirlq, and valves; (3) process instrumentation and termination panels; 

(4) electrical power components; (5) a caustic makeup system; and, (6) a support 

structure skid onto which the ductwork and piping system will be mounted and 

secured. Functionally, the wet scrubber skid assembly will receive a partially 

conditioned radioactive-contaminated air stream from a set of sintered metal 

filters (particulate removed), treat the air stream (remove particulate, remove acid 

gases, and cool the air stream), then route the scrubbed air stream to a highefficiency 

particulate air (HEPA) filter skid assembly with containment pan. The 

skid assembly contains instruments to monitor the flow, pressure, and 

temperature of the air stream and the operating characteristics of the scrubber 

support systems. 

3.1.1 Item Diagram 

The ),vet scrubber skid assembly shall be designed to comply with 

Drawings F-45579-00-A-0099, F-145579-00-A-0100, F-145579-36-A-0100, 

F-145579-36-A-0102, and H-14-106796, and Sketch DBVS-SK-E104 provided in 

Appendix A for information. 

Major components of the wet scrubber skid assembly include: 

Air quencher(s); 

2. Venturi scrubber(s); 

3. Condenser; 

4. Mist eliminator(s); 

5. Interconnecting ductwork with valve(s) and ductwork supports; 

6. Caustic circulation piping system with pump(s), valves, and heat 

exchanger(s); 


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CLIENT: AIVIEC E&E - Richland, Washington — 

7. Chilled water system piping, valves and heat exchanger(s); 

8. Compressed air system piping; 

9. Caustic addition tank with mixer and pump; 

10. Electric heater at system outlet; 

11. OGTS inte rfacing piping; 

12. Process instrumentation; and 

13. Electrical power distribution equipment. 

3.1.2 Interface Definition 

The wet scrubber skid assembly will interface with an incoming contaminated air 

stream, a downstream HEPA Filter System, a Chilled Water System, a 

Seconda ry Waste Storage System, electrical supply, a Monitoring and Control 

System, a Filtered Water System, and a Compressed Air System. System 

interface requirements for the wet scrubber skid assembly are shown on 

Sketches DBVS-SK-E104 and DBVS-SK-M103 and Drawings 

F-145579-36-A-0100, F-145579-36-A-0102, and H-14-106796 (Appendix A), and 

the inte rfacing process and electrical connections noted in Table 3-1. 

The relative location for connection points discussed in Table 3-1 shall be as 

follows: 

1. Inlet from Sintered Metal Filters – east side; 

2. Outlet to HEPA Filter System – west side; 

3. Chilled Water supply and return – east side; 

4. Secondary containment drain – north side; 

5. Seconda ry waste bleed to Buyer tanks — north side; 

6. Filtered water and caustic supply from Buyer — north side; 


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7- Compressed air supply — no rth side; 

8. Make-up air — east side; 

9. Main electrical distribution terminal box — south side; 

10. Flush Button station — no rth side; and 

11. Monitoring and Control termination panel — south side. 

Specific interface locations on the skid shall be shown on conceptual sketches 

reviewed by the Buyer. Critical interface information, such as elevation and 

location relative to the skid, shall be shown so that the Buyer can reconcile Wet 

Scrubber Skid interfaces with other equipment located on the Buyer's site. 

Table 3-1: Wet Scrubber Skid Assembly Inte rface Connections (2 sheets) 

Gorl^nt 'o^PDnt 

Description Conne tjon{at 

CP-101 Manifold inlet from the • Ductwork Termination: 16-in. 150-lb 

sintered metal filters RF flange, ASTM A 105/A 105M (r'). 

CP-10 2 Chilled water supply Piping Termination: 3-in. 150-lb RF 

flange, ASTM A 105/A 105M"'. 

CP-103 Compressed air Piping Termination: 1/2-in. threaded 

supply coupling, ASTM A 105/A 105M (b) 

Grade C with quick disconnect. 

CP-104 Scrubber tank 

Piping Termination: 1-1/2-in. 

secondary threaded coupling, 

containment drains ASTM A 105/A 105M Ib), Grade C 

with quick disconnect. 

CP-106 Secondary waste Inner Pipe Connection: 2-in. CJ Stud, 

bleed to Buyer tanks River Bend Hose Specialty, Part 

No. JBW6-8, 316L stainless. 

Encasement Flange Termination: 

6-in. Class 150 RF, 

ASTM A 105/A 105M[b). 

CP-107 Chilled water return Piping Termination: 3-in. 150-lb RF 

flange, ASTM A 105/A 105M"'. 


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Tab l1e 3-1: Wet Scrubber Skid Assembly Interface Connections (2 sheets) 

M = a 1 

Clr v „I oin 

.X 'a 4 1 Y 

i 

Y+t \ "S .^ Fs. TTt '.. 1 4 

r 

^tM a7 i^^ 

t 

14^ 

CP-108 Manifold outlet to the Ductwork Termination: 16-in. 150-lb 

Nigh-Efficiency RF flange, ASTM A 105/ 

Particulate Filter A 105M" ).Piping Termination: 1-in. 

System threaded coupling, 

ASTM A 105/A 105M "' l, Grade C with 

quick disconnect. 

CP-109 Caustic supply from Piping Termination: 1-in. 150-lb RF 

Buyer tank flange, ASTM A 105/A 1050 l. 

CP-110 Filtered water supply 1-in. threaded coupling, 

ASTM A 105/A 105M 1 , Grade C with 

quick disconnect. 

CP-111 Make-up air Piping Termination: 8-in. 150-lb RF 

flange, ASTM A 105 1A 1050'. 

N/A Main electrical Terminal box (480V ac). 

distribution 

connection 

N/A Motor circuit and Terminal box (480V ac). 

heater connections 

N/A Pushbutton stations Terminal box (120V ac). 

N/A Main electrical ground Grounding Lug 

connection 

N/A Main Monitoring and Generic termination panel. 

Control System 

connection 

NA nut applicable. RF = raised-face. 

( ' ) All piping connectors shall have a suitable blank cover installed during storage or shipment of the skid 

assembly. 

tt'IAs ,rM A 105/A 105M, Standard SpecificationJor Carbon Steel Fogings for Piping Applications, 

Am.rican Society for Testing and Materials, West Conshohocken, Pennsylvania. 

3.1.2.1 Process Conditions 

The process air stream entering the wet scrubber skid assembly originates from 

the OGTS sintered metal filters. The air stream process parameters are 

described in 'Section 3.2.1.1. 


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3.1.2.2 Process Connection Interface 

The piping and ducting connections at the wet scrubber skid assembly are noted 

in Table 3-1. These ducting connections constitute the primary interface 

between the interfacing systems and the wet scrubber skid assembly. The main 

inlet and outlet connections shall be a 16-in. standard 150-lb raised-face flanged 

connection. A connection for make-up air shall be provided that consists of an 

8-in. standard 150-lb raised-face flanged. 

3.1.2.3 , Scrubber Bleed Storage Tank Interface 

The connection piping to the Buyer's waste storage tanks will be provided by the 

Buyer. 

3.12.4 Chilled Water Connection Interface 

The. connection piping to the Buyer's chilled water supply and return will be 

provided by the Buyer. Three-inch standard 150-lb raised-face flanged 

connections shall be provided on these lines. 

3.1.2.5 Scrubber Tank Secondary Containment 

Drain Interface 

Removable scrubber tank secondary containment drain valve and quick 

disconnect (QD) shall be provided by the Seller. The drain valve and QD shall 

be removed for shipment. 

3.1.2.6 Filtered Water Interface 

Filtered water will be provided to the skid assembly at a maximum of 5 gal/min 

and 100 psig at the filtered water inlet penetration. 

3.1.2.7 Compressed Air Interface 

Compressed air (filtered and dried) will be provided to the skid assembly at a 

maximum of 5ft3/min, and 100 psig, at the Compressed Air System inlet 

penetration. 


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3.1.2.8 Electrical Connection Interface 

A one-fine diagram of the electrical connections is shown on Sketch 

DBVS-SK-E104 (Appendix A). The following subsections describe the 

connections in more detail 

3.12.8.1 480V Power Connection 

The wet scrubber skid assembly shall receive five sources of 480V ac power 

from an external source. One single-phase, 480V ac circuit shall be provided for 

a transformer and distribution panel. Three-phase, 3-wire, 480V ac circuits shall 

be provided for the remaining loads. 

All 480V ac circuits shall terminate in a terminal box on the skid., All terminals in 

terminal boxes shall be rated for 194 O F (90 °C). 25 percent spare terminals shall 

be provided in all terminal boxes. 

Power described above shall be routed from the terminal box to disconnect 

switches for the loads. 

3.128.2 Grounding Connection 

A grounding lug, suitable for #410 bare copper, shall be provided on the outside 

frame of the skid to facilitate attachment of the skid grounding electrode. The 

location of the grounding lug shall be shown on the shop drawings. See 

Section 3.3.1.9.3 and Sketch DBVS-SK-E104 for grounding requirements. 

3.1.2.8.3 Monitoring and Control System Connection 

Monitoring and Control System functions that are automatic or remote will be 

provided by the Buyer via the instrumentation interface described below. The 

local monitoring and control functions for the wet scrubber skid assembly shall be 

identified by the Seller for off-the-shelf components. The general control and 

operation philosophy for the unit, in order to be compatible with practices at the 

Buyer's Site, include the following_ 

1. Operation of valves is performed in such a way as to not expose an 

operator to a hazard. Acceptable methods include remote actuated valves 

(operated from a local control station or through the Buyer's MCS) or reach 

rods through a physical barrier between the process system and operator. 


03-Nov-05 

G5-373







2. Operation of pumps to drain and fill the scrub solution tanks will be 

performed using local push button stations or via the MCS, requires 

continuous auto-bleed top-off from the. MCS. The station shall be located 

so that the operator can terminate the action upon detection of a leak. 

3_ Critical operating parameters shall be identified by the Seller. These 

parameters shall be displayed locally at the enclosure to allow for an 

assessment of operating conditions during operator rounds. These 

parameters shall also be accessible by the Buyer's MCS. 

The Seller shall interface with the physical instruments and components through 

the use of a Seller-provided termination panel mounted on the skid. This panel 

shall be rated NEMA 4x and the external top coat shall be Super Therm® 

coating; color shall be white, provided by G.E.M.S., Inc., Collins, Georgia. This 

surface will reduce the affects on direct sunlight thermal effects. 

Fora packaged system, terminations for remote shutdown, alarm, and run status 

may be on the skid. 

Each wet scrubber skid MCS connection shall be capable of operating the 

contained process and utility equipment from either a 24V do (preferable) or 

12011 ac termination (note that the Buyer has determined that solenoid valves 

shall be 24V do for all systems). The MCS interfaces are identified as 

instruments or components shown on the system P&ID (Appendix A). The 

termination panel shall have a 20 percent spare capacity. For a packaged 

system, these requirements are not applicable. Interfacing with the external 

MCS shall be by dry contacts, rated at 120V ac, 5 amps for a remote shutdown, 

run, and alarm status. 

See Section 3.3.1.15 for MCS termination details. 

3.1.2.9 Skid Assembly Transport and 

Installation Interface 

The wet scrubber skid assembly shall be configured for conventional transport by 

truck. over public goads and lifted by crane for installation at the Buyer's 

designated location. The skid assembly shall be secured during transport and lift 

points provided for loading and unloading the assembly. The skid shall have a 

minimum of four anchor points designed for 112-in. or larger anchor bolts installed 


03-Nov-05 

G5-374 

s

0 ' techrnt^= 



PROJECT: Final DBVS Design 145579-0-SP-037 REV.1 

PROJECT NO., 145579 WET SCRUBBER SKID ASSEMBLY 



in the concrete pad. Anchor points shall be shown on drawings with size and 

number clearly labeled_ 

3.2 CHARACTERISTICS 

The characte ri 

stics (e.g., functional, physical, and environmental) that the wet 

scrubber skid assembly must comply with to satisfy the requirements of this 

specification are desc ribed below and on the datasheet. 

3.2.1 Functional Characteristics 

The wet scrubber skid assembly shall be designed to receive off-gas from the 

vitrification process, process the contaminated air stream (remove pa rticulate 

and acid gases, and cool the air stream), and transfer the processed air to a 

HEPA Filte ring System. 

3.2.1 1Air Stream Properties 

The air stream prope rties entering the wet scrubber skid assembly are shown in 

Table 3-2. 

WET SCRUBBER SKIDASSEMB!_Y DESIGN AND FABRICATION Page 24 of 101 

03-Nov-05 

G5-375

$ 

aF 






CLIENT: AMEC ESE - Richland, Washington 

Table 3-2: Incoming Stream Properties 

^^ ^ ^ r 

e esu 

Design Air Flow Rate @ CP-101 3,115 acfm (12,375 lb/hr) 

Estimated Te rn perature ta) @ CP-101 134 -F (57°C) 

Estimated Pressureta) @ CP-101 —13.6 in. w.g. 

Relative Humidity @CP-101 100% 

Chemical Components @ CP-101 SOx = 72 ppmV = 159 ppmM 

N%lc) = 6,930 ppmV = 7,455 ppmM 

HCI = 7 ppmV = 8.75 ppmM 

HF 170 ppbV = 117 ppbM 

CO = 806 ppmV = 780 ppmM 

CO 2 = 1,880 ppmV = 2,863 ppmM 

Design Air Flow Rate @ CP-111 198 acfm (874 Lb/hr) 

Estimated Temperature (3) @CP-111 77 -F (25 °C) 

Estimated Pressure ta) @CP-111 -80.1 in. w.g. 

Relative Humidity @CP-111 100% 

ppmV = parts per million by volume. 

ppbM = parts per billion by mass. 

w.g. = water gauge. 

I'lThe Seller shall verify design conditions based on performance crite ria of selected equipment. 

(b) The concentration of SOx shall be assumed to be 100% SO2. 

(`) The concen tration of NOx shall be assumed to be 10% NO 2 and 90% NO. 

Note: The values represent normal operating conditions. Du ring abnormal operating conditions the air 

flow carte may be as low as 862 acfm while the temperature could be as high as 572 °F. 

3.2.1.2 Performance Range 

Characteristics and requirements for the wet scrubber skid assembly shall be as 

specified below. Facto ry Acceptance Testing of the equipment is required. 

Factory Acceptance Test specifications, procedures, and documentation of test 

results shall be prepared and submitted. All tempora ry elect rical equipment 

including wiring and instruments necessa ry to allow component testing will be 

provided by the Seller. 

3.2.1.2:1 Air Stream Transfer Rate and Pressure 

Flow through the wet scrubber skid assembly will be provided by the Buyers 

exhaust fan located down stream of the assembly. This fan w ill provide a static 

pressure at the discharge of -90 in. w.g. and an estimated flow of 4,700 acfm. 


63-Nov-05 

G5-376 

^.W 

v 

t,

' bSP 



am 

PROJECT: Final DBVS Design 145579-DSP-037 I REV. 1 

PROJECT NO.: 145579 WETSCRUBBER SKID ASSEMBLY 


CLIENT: AMEC E&E -Richland, Washington 

The Seller shall target a maximum pressure drop through the system of no more 

than 60 in. w.g. Using this discharge pressure and the characteristics of the 

selected_ equipment, the Seller shall determine the design pressures as 

described in ASME N509. 

3.2.12.2 Air Stream Discharge Conditions 

A condenser and mist eliminator will remove excess moisture from the airstream 

before delivery to the final stage heater. The discharge temperature shall be 

based on a minimum 40 °F delta across the final stage heater. The minimum 

discharge temperature shall be 167 °F (75 °C) and the maximum shall be 200 °F 

(93 °C). The Seller's calculations shall identify the estimated maximum relative 

humidity at the heater outlet. The discharge from the heater will go to a 

downstream HEPA filter skid (HEPA filter skid not in the Seller's scope). 

3.2.1.2.3 Scrubber. Removal Efficiency Requirements 

The following shall be the maximum required chemical compositions removal 

efficiencies (= 1 — Out/in) resulting from the nominal scrubber operation: 

1. S02 = 97 percent by mass removal 

2. NO = 0 percent by mass removal (Seller to provide incidental estimate), 

3. NO2 = 40 percent by mass removal, 

4. HCI = 97 percent by mass removal, 

5. HF = 97 percent by mass removal, 

6. CO = 0 percent by mass removal (Seller to provide incidental estimate), 

7. CO2 = 0 percent by mass removal (Seller to provide incidental estimate), 

8. Particulate = 99 percent above 1.0 -micron particle size, and 

9. Particulate = 0 percent above 0.3-micron but less than 1 micron particle 

size (Seller to provide incidental estimate). 


03-Nov-05 

G5-377

a" '^ tnol0aq 







12.1.2.4 Seconda ry Containment 

The secondary containment requirement for the enclosure (or inse rt) is for the 

containment to be capable of holding at least the total Capacity of the caustic 

recirculation system invento ry. The wet scrubber skid assembly will contain leak 

detection capability and a pump-out po rt for removal of any liquid contained in 

the skid assembly. The sump shall be designed such that 1.5 gal of liquid will 

provide a pool depth of at least 1 in. Leak detection shall provide dry contacts to 

the IVICS termination panel or be pa rt of a packaged system alarm status signal. 

A leak catch pan will be included for leak detection. 

3.2.2 Physical Characteristics 

The system with associated suppo rts, piping, instruments, and electrical 

infrastructure shall be installed on the skid. Sizing shall be based on the 

contained processing equipment and on the dimensions allowed for 

transpo rtation, however the maximum dimensions shall not exceed 10 it in width 

and 40 ft in length. The skid will sit on a concrete pad. See Section 3.1.2.9 for 

anchor point requirements. 

3.2.3 Reliability 

All wet scrubber skid assembly equipment including, but not limited to, the piping, 

pumps and motors, casings, shafts, valves, filters, bearings, seals, and fasteners 

shall have a minimum se rvice life of 2 years and a design life of 5 years. 

Documentation to demonstrate this requirement is met shall be collected and 

prepared by the Selle r, Documentation shall be submitted to and verified by the 

Buyer before .fabrication. Redundancy of wet scrubber skid assembly active 

components (e.g., pumps) shall be considered and incorporated into the 

assembly design as appropriate to minimize the possibility of a single active 

failure resulting in loss of wet scrubber function. 

WET SCRUBBER SKIDASSEMBLY DESIGN AND FABRICATION Page 27 of 101 

03-Nov-05 

G5-378 

s



PROJECT: Final DBVS Design 145579-D SP-Q37 REV.1 




3.2.4 Maintainability 

Maintainability characteristics that affect the design (lubrication, parts 

replacement and repair, spares, modular construction, test points, etc.), 

including, but not limited to, shall include the following_ 

1. Maintenance and Repair Cycles. The Seller shall specify frequency or 

availability requirements for maintenance of the component 

(e.g., scheduled maintenance every 40 operating hours). 

2. Service and Access. The Seller shall specify requirements for ease of 

service (access openings/spacing, self-test capability, inspection windows, 

test fixtures, sealed bearings, etc.). Include requirements for service 

(remove and replace only, bench repair, special tools, remote 

handling/maintenance, etc.), and for capability of the item to be drained, 

connected, discharged, etc. Adequate working space shall be provided 

around all electrical equipment in accordance with the NEC® (NFPA 70)_ 

Critical equipment, instrumentation, or high maintenance items shall be 

accessible for ease of inspection and removal and replacement. Adequate 

space and accessibility shall be provided for removal and replacement of 

individual instruments or equipment without removal of adjacent equipment. 

Valves, test points or ports, and calibration adjustments shall be accessible. 

3. Decontamination. All components in contact with processing fluids must be 

capable of being decontaminated and ultimately decommissioned, 

dismantled, and disposed of as radioactive waste. All material and 

equipment shall be fabricated and installed to facilitate routine removal, 

cleaning, or decontamination. Attention shall be paid to eliminating 

crevices and obtaining smooth weldments through the entire process flow 

stream. 

4. Spares and Spare Parts. The Seller shall specify identification of 

recommended spares and spare parts and provide a listing to the Buyer. 

5. Special Tools. The system shall facilitate maintenance with .commercially 

available tools, wherever possible. The Seller shall furnish all special tools 

unique to the Seller's equipment that are necessary for installation, startup, 

operation, maintenance, and adjustment of the equipment and accessories 

furnished by the Seller. The special tools become the property of the 

Buyer. If supplied, the Seller shall also provide a list of all special tools 


03-Nov- 

G5-379

Rd =100M. 



PROJECT: Final DBVS Design 145579-DSP-637 I REV. T 



CLIENT: AMECE&E - Richland,Washington 

furnished, identifying the function of each tool and the specific item(s) for 

which the tool is used. The Seller shall also indicate if the tool is required 

for assembly, disassembly, installation, startup, operation, maintenance, or 

adjustment. The Seller shall provide detailed drawings or procurement 

information for the special tools. 

6. Maintenance Considerations. The design of the assembled system shall 

follow a minimum maintenance philosophy (i.e., selection of components 

should take into consideration potential maintenance in addition to other 

considerations). Components shall be designed to allow handling and 

maintenance by personnel outfitted in protective clothing and gloves. 

Components shall also be designed so they can be removed and replaced 

in a modular manner. 

7- Lock and Tag. Both mechanical and electrical systems shall be designed 

to be locked out and tagged out during maintenance actions. Where 

r applicable, the Seller shall identify on fabrication drawings those 

components which have a built-in feature that support the application of a 

lock and tag. 

8. Standardization. To the extent practical, common components shall be 

used to minimize spare parts, tools, and procedures. Fastener sizes, drive 

size, and type shall also be standardized to effect maintenance with a 

minimum number of tools. 

3.2.5 Environment 

The wet scrubber skid assembly shall be designed to operate and be stored in 

the climatic and environmental conditions listed in Table 3-3. 


03-Nov-05 

G5-380 

Page 29 of 101








Table 3-3: Environmental Conditions 

^ Ha tea'-x 

Ambient air temperature —25 to 115 OF with a maximum 24-h differential of 52 -F(b) 

range(a) 

Relalive humidity range ta) 

Near 0 to 100% 

Maximum precipitation (a) 2.5 in. in a 6-h period 

Sand and dust 

concentrations(a) 

1.10 z 105 Ibm/fe with a size of 150 pm or less 

Solar insulation (a) 

900 langleys, distributed over a 12-h period 

Heating basis wind Derive from ASHRAE Fundamentals Handbook(c) for the 

factors (for freeze Hanford Site 

protection) 

` IHNF-SD-GWER-501, Natural Phenomena Hazards, Hanford Site, Washington, 

Revision 1B, Westinghouse Hanford Company, Richland, Washington. 

(brT'he system is not expected to operate below 0 °F, only provide freeze protection below 

0 °F. 

(°1200 1 ASHRAE Handbook— Fundamentals, American Society of Heating, Refrigerating, 

and Air Conditioning Engineers, Atlanta, Georgia. 

3.2.6 Transportability and Storage 

The wet scrubber skid assembly equipment shall have a modular design to 

facilitate disassembly and relocation to the final des ti 

nation at the Hanford Site. 

1. The wet scrubber skid assembly equipment and components shall be 

capable of being moved by crane or truck with no modifications. 

2. Lift points shall be provided for the lifting and handling of equipment and 

Components. Lift points shall be determined by the Seller in calculations 

(see Section 3.3.11.1.8). 

3. The wet scrubber skid assembly equipment packaging shalt suppo rt the 

contained equipment so it can withstand 0.75-gravity (forward), hardbraking 

stop and a rearward acceleration of 025 gravity, as well as shock 

and vibration loads associated with transportation. 

4. The wet scrubber skid assembly and any accessories shall be sized for 

transport using local roadways and freeways (i.e., less than 12 ft wide, 53 ft 

WET SCRUBBER SKID ASSEMBLY DESIGN AND Page 30 of 101 

03-Nov-05 - 

G5-381







CLIENT: AMEC E&E- Richland, Washington 

3.2.7 Safety 

long, and 13.5 ft tall). The height limit may be relaxed based on design 

requirements, but must not exceed limits allowed for road transportation. 

5. The wet scrubber skid assembly shall be stored and operated outside for 

an extended period of time, five years maximum, and will be exposed to the 

environmental conditions found at the Hanford Site as identified in 

Section 3.2.5. 

The equipment shall be designed to maintain the safety of operators and the 

general public. The Seller shall provide all necessary guards, lockouts, and other 

safety equipment for safe operation as required under 29 CFR 1910. 

3.3 DESIGN AND CONSTRUCTION 

^. 3.3.1 Parts/Materials/Processes 

It is the Seller's responsibility to develop a complete data sheet for the 

components identified in the Seller's design drawings. Completed data sheets,. 

as well as vendor information (catalog cut sheets, vendor drawings, etc.) for 

components shall be developed by the Seller. The Seller shall provide data 

sheets and catalog cut sheets for all components. The data sheet format shall 

be in conformance with the Buyer-supplied forms contained in Appendix C 

(electronic forms can be provided by the Buyer). 

Component substitutions may be proposed by the Seller on the fabrication 

drawings for approval by the Buyer. Substitutions will be considered if a 

component is no longer available, or the proposed substitution improves the 

design, reduces cost, or improves the production schedule. 

Only new parts and materials shall be used for the assembly. Used, surplus, or 

reconditioned parts and materials are prohibited. 

All components shall be installed in accordance with manufactulees instructions. 

If conflicts arise with the specified components or component interfaces (line 

sizes, fittings, electrical requirements, etc.) during design and fabrication, they 

shall be brought to the attention of the Buyer for resolution. 


03-NOV-05 

G5-382


RPP-245441ZEV Id 




CLIEN T: AMEC E&E -Richland, Washington 

No aluminum or "yellow" metals are to be used. No beryllium shall be present. 

Lead shall not be used Unless the lead is fully encapsulated and identified with a 

permanent tag. Exposed polymer materials shall be constructed of anti-static 

materials. Polychlorinated biphenyls shalt not be used in the design of the 

assembled system. No asbestos shall be used. 

3.3.1.1 Components 

3.3.1.1.1 Scrubber Mechanical Components 

All equipment and components shall have an Equipment Identification Number 

(EIN) provided by the Buyer following a P&ID- The air stream handling 

components are listed below. The configuration us shown on the P&ID. As noted 

in Section 1, deviations are allowed, but must be approved by the Buyer. 

Packaged, off-the-shelf, demonstrated treatment units are encouraged as long as 

the performance, quality, and fabrication requirements of this specification are 

met- 

1. A. short diameter spoof piece with standard 150-lb raised-face flanges, 

2. An isolation valve, 

3. Quencher(s), 

4. Venturi scrubber(s) with recirculation system, 

5. Mist eliminator(s), 

6. An outlet header for the scrubber system(s), 

7. A chilled water based condenser, 

8. A final mist eliminator. 

9. An electric air heater, 

10. An isolation valve, 

11- A short spool piece with standard 156-lb raised-face flanges, 


03-Nov-05 

G5-383 

Page 32 of 101

ffitec ^° 







12. Collection tanks, and 

13. A single caustic makeup subsystem. 

Scrubber system components shall be fab ri 

cated and/or assembled and tested to 

meet the latest requirements of ASME N509 and ASME AG-1 (as indicated in 

Appendix B) or ASME B&PV Code, Section Vlll. The buyer in accordance with 

AGA Sections HA-4530 and SA-4530 shall determine allowable 

system/component leakage rates. Where conflicts occur, ASME AG-1 or ASME 

B&PV Code, Section Vlli takes precedence. 

33.1.1.2 Pumps and Motor 

The venturi circulation transfer pumps shall be of the sealed canned motor-type 

rated for continuous duty and constructed with 316 stainless-steel wetted pa rts. 

The transfer pump shall be coupling driven by an electric motor (the Seller to 

confirm horsepower size ). Motor voltage shall be 480V, 3 phase, 60 Hz. Total 

head loss and pump motor size shall be determined by the Seller. The pumps 

shall meet the requirements of ANSI/HI 3.1-3.5, ANSILHI 3.6, or ANSUHI 5.1-5.6, 

as applicable. 

3.3. 1.1.3 Isolation Dampers or Valves and Installation 

All air stream and waste contacting valves/dampers shall be tested in 

accordance with AG-1, Sec ti 

on DA, Mandatory Appendix DA-1 for zero 

leakage. Valve leak test reports shall be prepared and submitted to the Buyer for 

review and approval 

All valves shall be installed per manufacturer's instructions. 

The Seller shall review manufacturer's supplied informa tion for unique installation 

requirements and request written clarification if installation requirements do not 

match the design. 

3.3.1.1A Thermal Insulation Material Requirements 

The need for thermal insulation of components shall he determined by the Seller 

based on Seller-generated heat transfer calcula ti 

ons. At a minimum, freeze 

protec ti 

on will be determined using the provided environmental conditions, 


03-Nov-05 

G5-384 

IS%

s technoto^t° 



PROJECT: Final DBVS Design 145579-D SP 037 REV. 4 




operating parameters for Seller-p rovided processing equipment. Insulation, if 

required, shall meet the following requirements: 

1. Installed insulation shall not interfere with the operating, testing, 

maintenance, and service of any components or systems. 

2. Insulation shall be removable and re-installable from components requiring 

periodic maintenance and inspection. 

3. The use of lead or asbestos material is not permitted. 

4. Insulation material shall be free of halogenated hydrocarbons. 

The insulation jacket shall allow for ease of decontamination. Ce rtificates of 

Conformance (CoC) shall be provided. 

3.3.1.1.5 Pressure Monitoring 

The system shall be instrumented with differential pressure transmitters to 

monitor the condition of the Wet Scrubber System. Signals shall be routed to a 

termination panel for access by the Buyer-provided MCS. 

3.3.1.1.6 Temperature Monitoring 

Temperature monitoring system shall consist of 100 ohm platinum resistance 

temperature detector (RTD) probes. The RTDs shall be installed in thermowells.. 

The RTD signals sha ll be input to the MCS and shall be indicated on the control 

panel with digital indicators. 

3.3.1.1.7 Liquid Monito ring 

The caustic reservoir shall have a level transmi tt 

er. The liquid level 

measurement system shall be an impedance type of instrument with a 4 20-mA 

signal fed to the MCS termination panel, unless the system proposed is a 

packaged system. The system will be equipped with a low liquid level and high 

liquid Revel (30 and 80 percent of the liquid volume) alarms. For a packaged 

system, alarm contacts to indicate an off-normal condition shall be provided to a 

termination panel, which may be inside the enclosure. This contact will supply 

the MCS with a dry contact rated at 120V ac, 5 amps.. 


03-Nov-05 

G5-385

` 








3.3.1.1.8 pH Monitoring 

The caustic reservoir shall have a pH monitoring transmitter capable of operation 

at 5-10 percent caustic solutions. The liquid pH measurement system shall be 

an impedance type of instrument with a 4-20-mA signal fed to the MCS. For a 

packaged system, alarm contacts to indicate an off-normal condition shall be 

provided to a termination panel, which may be inside the enclosure. This contact 

will supply the MCS with a dry contact rated at 120V ac, 5 amps. 

3.3.1.2 Piping — Design 

Piping systems for the system and interconnecting piping for the caustic, chilled 

water, Filtered Water and Compressed Air Systems shall be designed, 

fabricated, inspected, examined, and tested in accordance with the ASME 1331.3 

piping code for "Normal Fluid Service." Piping systems include all piping 

components and supports. 

The minimum design pressure for the wet scrubber skid piping and components, 

including instrumentation shall be determined by the Seller based on selected 

equipment and operating conditions. The design temperature shall be 

determined by the Seller based on selected equipment and operating conditions. 

3.3.1.3 Piping — Line Routing 

The proposed installation layouts shall meet the requirements of the 

ASME 831.3 piping code for "Normal Fluid Service 

The Seller shall provide detailed fabrication drawings of the required piping, 

including welding details, for review and approval. 

3.3.1.4 Piping — Vents and Drains 

High-point vent(s) shall be installed as required for venting air in preparation for 

testing or operation. Low-point drain(s) shall be installed as required for draining 

the system before maintenance or lay-up. Eliminate low spots to minimize 

freestanding liquids in the piping. Gravity draining of the piping system is 

preferred- The Seller shall provide basis for draining method if other than gravity 

draining. 

WET SCRUBBER SKID ASSEMBLY DESIGN AND FABRICATION Page. 35 of 101 

03-Nov-05 

G5-386

t 



PROJECT: Final DBVS Design 145579-D-SP-037 J REV. 1 



CLIENT: AMEC 'E&E - Richland; Washington 

3.3.1.5 Piping — Pipe and Equipment Supports 

Piping attached to equipment shall be installed with fasteners made finger-tight 

until alignment is achieved, at which time all fasteners shalt be tightened- 

Tightening tcrque shall be that which is recommended by the ASME 631.3 piping 

code for "Normal Fluid Service, or gasket manufacturer recommended torque 

values for the gasket system used. Flange assembly and bolting shall be 

performed in accordance with ASME PCC-1. Piping support bolting shall be 

installed and torqued in accordance with manufacturer's recommendations. 

Inspection documentation shall be provided as evidence of proper bolt torquing. 

Piping and equipment shall be supported by pipe supports attached to the 

enclosure using strut. The Seller shall develop detailed fabrication drawings of 

the required piping and equipment supports, including welding details. Location 

of frames members and supports shall be based on analyses performed by the 

Seller (see Section 3.3.11.1 for required analyses). 

All piping supports shall conform to the ASME B31.3 piping code for "Normal 

Fluid Service," with additional support at valves, elbows, tees, and equipment as 

required. Additional supports shall be provided, if necessary, to comply with the 

requirements stated in the design loads section, Section 3.3.11.2. 

Piping supports shall be capable of supporting the piping in all conditions of 

operation. The supports shall allow free expansion and contraction of the piping 

and prevent excessive stress resulting from transferred weight being introduced 

into the piping of connected equipment. 

Equipment that could be subjected to water damage shall be raised above the 

skid to protect components in the event of a piping leak. 

The Seller shall level-plumb piping using shims, etc., to support the pipe and to 

avoid forced piping deflections at support points. The pipe supports may be 

stainless or painted carbon steel. 

The Seller shall provide detailed fabrication drawings of the required piping 

supports, including welding details, for review and approval. 


03-Nov-O5 

G5-387

^ ^ tecl.Imbgi 







3.3.1.6 Piping Materials 

Piping components shall be listed components in accordance with ASME 831.3 

(Table 326.1). 

The Seller shall select materials based on acceptable lifetime pe rformance of 

materials subjected to the chemical and radiation exposures described in this 

specification- All pa rts and materials shall be new. No aluminum or "yellow" 

metals are to be used. No be ryllium shall be present. Exposed polymer 

materials shall be constructed of anti-static materials. No lead shall be used in 

the design unless it is fully encapsulated and identified with a permanent tag. 

No equipment shall use or require the use of polychlorinated biphenyls. Mate rial 

selection shall be identified in the Seller documents to the Buyer. 

The Seller shall provide CoCs for review of all materials. 

3.3.1.6.1 Screwed Pipe Fittings 

Screwed pipe fi ttings shall be in accordance with ASME 816.11. Screwed fittings 

are acceptable for instrumentation taps, drains, and vents, and the filter water 

and Compressed Air Systems; but shall be avoided for main process pipe runs. 

Close or butt nipples are not permitted. For ail male-tapered pipe threads, use 

polytetrafluoroethylene (TFE) tape, or equivalent. Threaded joints in process 

lines shall be joined using low-chloride, Loctite® PST. 

3. 11-6- Flanged Pipe Fittings 

Flanges for pipe greater than 112 in. shall be standard 150-lb or 300-1b raisedface 

flanges in accordance with ASME B16.5 and shalt be made from the same 

type of steel as the pipe in which it will be welded. Flange assembly and bolting 

shall be pe rformed in accordance with ASME PCC-1. 

3.3.1.6.3 Socket Welded Pipe Fittings 

Socket welded pipe fi tt 

ings shall be in accordance with ASME 816.11. Socket 

welds shall be avoided for main pipe runs. 

3.3.1.6.4 Butt-Welded Fittings 

Bu tt-welded fittings shall be in accordance with ASME B16.9. 


03-Nov-05. 

G5-388 

Page 37 of 1

wardNy 





DESIGN_ AND FABRICATION 


3.3.1.6.5 Stainless-Steel Pipe Materials 

Stainless-steel pipe shall be ASTM A 312/A 312M, Schedule 40 or 80 (as 

required), seamless, 300-series, Type 304, 304L, 316, or 316L. Stainless-steel 

.pipe flanges and flanged, socket weld, or screwed fittings shall be 

ASTM A 182/A 182M, Grade F, 300-series, Type 304, 304L, 316, or 316L. 

Stainless-steel butt-welded fittings shall be ASTM A 403/A 403M, Grade WP-S,. 

300-series, Type 304, 304L, 316, or 316L. 

1. All grades of stainless steel may be substituted for one another depending 

on availability and provided the substitution still complies with the above 

specifications and has prior approval of the Buyer. 

2. Piping shall be a listed component as stated in ASME B31.3 (Table 326.1). 

3.3.1.6.6 Carbon-Steel Pipe Materials 

3.3.16.7 Carbon-steel pipe having a diameter of 1-1/2 in. and smaller shall be 

ASTIN A 106, Grade B, seamless. Carbon-steel pipe having a diameter of 2 in 

and greater shall be ASTM A 53/A 53M, Type S, Grade B. Carbon-steel pipe 

flanges and flanged, socket weld, or screwed fittings shall be 

ASTM A 1051A 105M. Material for butt-welded fittings shall be 

ASTM A 234/A 234M, Grade A WPB. Piping shall be a listed component as 

stated in ASME B31.3 (Table 326.1). Stainless-Steel Tubing 

All stainless-steel tubing shall be seamless and shall meet the chemical and 

physical characteristics given in ASTM A 269. Tubing shall be a listed 

component as stated in ASME B31.3. 

3.3.1.6.8 Stainless-Steel Tubing Fittings 

Fittings for instrument air tubing may be Swagelok O compression fittings or 

approved equivalent, stainless steel, 300 series, per ASTM A 276 or 

ASTM A 182/A 182M. CoCs shall be provided. 

3.3.1.6.9 Steel Forgings and Wrought Piping Fittings 

All forgings, including flanges, and wrought piping fittings shall be listed 

components as stated in ASME B31.3 (Table 326.1), and shall meet the 

requirements of ASTM A 1821A 182M. All stainless-steel forgings and wrought 

WET SCRUBBER SKID ASSEMBLY DESIGN AND FABRICATION Page 38of 101 

03-Nov-O5 

G5-389

e edxx 






CLIENT: AMEC ERE - Richland, Washington 

piping fittings used in the fabrication shall be 300-series stainless steel and shall 

meet the requirements of ASTM A 403/A 403M, Grade WP-S. Carbon-steel pipe 

flanges and flanged fittings, and socket weld or screwed fittings shall be 

ASTM A 1051A 105M. Material for carbon-steel butt-weld fittings shall be 

ASTM A 2341A 234M, Grade A WPB. 

3.3.1.6.10 Piping Gaskets/Seals 

Pipe flange connections shall use PSI Inc., LineBacker® seating gaskets with 

stainless steel as the retainer material and Viton® as the sealing element. 

LineBacker® Type F sealing gaskets shall be used for raised face flanges and 

LineBacker0 Type E sealing gaskets shall be used for flat-face flanges. 

1. All elastomeric seals shall have radiation resistance for the radiation dose 

levels shown in this specification. Viton® is acceptable for the radiation 

levels specified. 

Z CoCs shall be provided. 

3.3.1.6.11 Weld Filler 

The weld filler material shall be as specified in the approved Welding Procedure 

Specification, see Section 3.3.1.13. 

3.11.6.12 Pipe Bends - 

03-Nov-05 

Considerations for pipe bending are listed below: 

1. Elbows and pipe bends not manufactured in accordance with listed 

standards in ASME B31.3 (Table 326.1) may be provided in accordance 

with ASME B31.3 (Paragraphs 304.2 and 332). 

a. The material shall be suitable for the bending process. 

b. The finish shall be free of cracks and substantially free from buckling. 

C. The wall thickness after bending shall not be less than minimum wall 

thickness considering corrosion-erosion and mill under-run tolerance. 

SKID ASSEMBLY DESIGN AND FABRICATION Page 39 of 101 

G5-390

$ _ tedn 



PROJECT: Finial DBVS Design 145579-D-SP-037 I REV. 1 




3.3.1.7 Structural Materials 

3.11.7.1 Weld Studs 

d. The minimum wall thickness of the bend intrados and extrados shall 

not be less than that calculated by equations listed in ASME 8313 

(Paragraph 304,2). 

e. Bend flattening (the difference between maximum and minimum 

diameters at any cross section) shall not exceed 8 percent of nominal 

outside diameter for internal pressure. Metal shall not be removed to 

achieve these requirements. 

f. The proposed assembly layouts shall meet the requirements of 

ASME 831.3. 

Weld studs shall be metallurgically compatible with the material in which they are 

welded. Weld studs shall be made from stock material that meets the 

requirements of ASTM A 108 for mild carbon steel 

3.3.1.7.2 Carbon-Steel Plate and Sheet 

All carbon-steel plate shall be general purpose, hot-rolled, low-carbon steel in 

accordance with ASTM A 36/A 36M. Carbon-steel sheet shall be provided in 

accordance with ASTM A 569. 

3.3.1.7.3 Carbon-Steel Shapes 

Carbon-steel structural shapes shall conform to the requirements of 

ASTM A 36/A 36M. 

3.3.1.7.4 Carbon-Steel Bars and Rods 

Carbon-steel bars and rods shall conform to ASTM A 108 with a minimum yield 

of 36,000 psi and maximum carbon content 0.35 percent. 

3.3.1.7.5 Carbon-Steel Structural Rectangular Tube 

Structural carbon-steel, rectangular tubing shall conform to the requirements of 

ASTM A 500, Grade B. 

WET SCRUBBER SKtDASSEMBLY DESIGN AND FABRICATION Page 40 of 101 

03-Nov 05 

G5-391

Nteduft._ 






CLIENT: AMEC E&E- Richland, Washington 

3.3.1.7.6 Stainless-Steel Sheet and Plate 

Stainless-steel sheet shall meet the chemical and physical requirements of 

ASTM A 240/A 240M and ASTM A 480/A 480M. Stainless-steel plate shall meet 

the chemical and physical requirements of ASTM A 2401A 240M. The plate shall 

be provided with a cleaned finish. 

3.3.1.7.7 Stainless-Steel Bars and Shapes 

Parts made from stainless-steel bars and shapes shall be Series 300 stainless 

steel. Stainless-steel bars and shapes shall meet the chemical and physical 

requirements of ASTM A 276. 

3.3.1.8 Fasteners 

The Seller shall select fasteners, when they are not specifically called out in this 

specification, using the following guidelines: 

1: Carbon-steel bolts, nuts, and washers shall be used where matin g parts are 

not stainless steel; 

2. Stainless-steel bolts, nuts, and washers shall be used when the mating 

parts are stainless steel; 

3. Pipe flange bolting components shall be listed in ASME B31.3 

(Table 326.1) meeting the requirements of ASME B18.2.1 and 

ASME 1318.2.2. 

4. No fasteners shall be capable of vibrating loose under operating conditions. 

All such joints should be tack welded or have some equivalent means of 

ensuring they remain intact. Double-nutting is not an acceptable method of 

securing fasteners. Low-chloride, Loctite® threadlock may be used where 

applicable. 

5. Low-chloride, anti-galling compound (e.g., Loctite0 8013 or 8009 or Neo- 

Lube(D) shall be applied where stainless-steel bolts are used. 

6. Stainless-steel bolts, cap screws, and washers shall be 

ASTM A 193/A 193M, Grade 138. Stainless-steel nuts shall be heavy hex 

nuts in accordance with ASTM A 1941A 194M, Grade 8. Stainless-steel 

WET SCRUBBER SK[D ASSEMBLY DESIGN AND FABRICATION Page 41 of 101 

03-Nov-05 

G5-392

Etrank.ay 







washers shall be ASTM F 436. Bolts and cap screws shall be grade 

marked. 

7. General purpose carbon-steel bolts shall be ASTM A 307 or better, 

depending on strength and torque requirements. Carbon-steel nuts shall 

be ASTM A 563a Bolts and cap screws shall be grade marked. 

8. Structural bolts shall be grade-marked and shall conform to ASTM A 325. 

9. CoCs shall be provided for all fasteners used for piping, pipe supports, or 

component support structures. 

10. All graded fasteners shall conform to ASME 818.2.1, SAE J429, and 

ASTM A 354. 

11. The Seller shall ensure that suspect or counterfeit fasteners and 

components are not used. Suspect fasteners can be identified by the 

following inspection methods: 

a. Head markings are marred, missing, or appear to have been altered; 

b. Threads show evidence of dressing or wear (threads should be of 

uniform color and finish); 

C. Head markings are inconsistent within a heat lot; and 

d. Head markings matching one of those identified on the U.S. Customs 

Service Control of Suspect/Counterfeit Items (see Appendix D). 

3.3.1.9 Electrical — Design and Component 

Selection 

3.3.1.9.1 General 

The electrical installation shall meet the requirements of the NEC@ (NFPA 70), 

as administered by the CH2M HILL Hanford Group, Inc. (CH2M HILL) electrical 

inspector. 

Electrical equipment shall be listed or labeled by a Nationally Recognized Testing 

Laboratory (NRTL), such as Underwriters Laboratories, Inc. (UL), when a 


03-Nov-05 

G5-393

Rdlociam 


RPP-24544 REV 

arise 

PROJECT: Final DBMS Design 145579-DSP-037 REV.1 




category exists. Note: NRTl2s are listed on the Occupational Safety and Health 

Administration website at http://www.osha-slc.govldtslotpca/nrtl/index.htmi . It is 

the Seller's responsibility to ensure the listing is appropriate for the equipment 

specified. 

It is the Seller's responsibility to obtain a listing or label for equipment without a 

listing or label by a NRTL 

When a listing or label can not be obtained, it is the Seller's responsibility to 

provide equipment critical characteristics, engineering data, and test data for the 

Buyers engineer to evaluate the acceptance of the product. 

Any component, equipment, assembly, or system without a NRTL listing or label 

shall be subject to the approval of the CH2M HILL electrical inspector. 

Where NECO inspection is required, the Seller shall arrange for a CH2M HILL 

NEC@ inspection to occur at the Seller's facility before shipping any assembly 

not covered in whole by a NRTL listing or label. The .Seller shall perform 

modifications as required by the NEC@ inspector before shipping. 

Cabinets containing assembled control systems shall be designed, constructed; 

and listed or labeled to LIL 508A, as applicable. 

Design and operation of the assembled system shall meet the requirements of 

IEEE Std 141, IEEE Std 142, IEEE Std 242, and IEEE Std 519. 

A permanent plaque or directory shall be installed at each feed and branch circuit 

disconnect location denoting all other services, feeder or branch circuits 

supplying the skid. 

3.3.1.92 Electrical - Routing 

The Seller shall select the routing of conduits between devices and the power 

and instrumentation and control enclosures. Care shall be taken to run conduit 

along the frame members where they can be mounted. Care shall be taken to 

select routes where conduit does not interfere with maintenance or replacement 

access to devices such as pumps or valves. Sketches of the routing locations 

shall be submitted to the Buyer for review and approval before proceeding with 

the work. 


03-Nov-05 

G5-394

NW10010.0y 



LOJECT: 

Final DBVS Design 145579-DSP-037 REV. 1 

OJ12CT NO-- 

145579 

IENT: AMEC E&E - Richland, Washington 

33.193 Electrical — Grounding 

WET SCRUBBER SKID ASSEMBLY 


1. All power circuits shall include a ground wire that serves as the equipment 

grounding conductor, independent from the neutral wire. All powered 

devices shall be connected to the ground circuit wire. In addition, the skid 

frame, enclosures, raceways, covers, and enclosure doors shall be 

attached to the electrical ground. This may be accomplished by means of a 

screw, lock washer, and ring connector attachment at a spot where all paint 

and surface corrosion has been cleaned from the frame. The frame shall 

not be used as a current carrying conductor between devices. 

2. Ground wires shall be green-insulated or bare-stranded copper wire_ 

3- Ground conductors shall be unspliced and continuous between termination 

points. Ground distribution shall be through terminal blocks or a ground 

bus. Wire nuts or butt splices are not acceptable. 

4. The resistance between the main ground connection to the skid and any 

point in the ground circuit shall be less than 0.1 ohm as measured with a 

calibrated ohm meter. 

5. The instrument ground circuit shall be separate and isolated from the power 

ground circuit to the extent allowed by the NEC® (NFPA 70). The 

requirements for the instrument ground circuit installation are the same as 

the power ground requirements given above. 

3.3.1.9.4 Electrical — Conduit Fill 

The sum of the cross-sectional areas of all contained conductors shall not 

exceed the interior cross-sectional area of the raceway as calculated in the 

tables in Chapter 9 of the NEC® (NFPA 70) for raceway fill. 

3.3.1.9.5 Electrical —Strain Relief 

Strain relief shall be provided for all cables. The strain relief device shall comply 

with the following: 

Strength - The device shall be capable of withstanding a 35 lb pull for one minute 

(from any direction) without allowing movement of the raceway or cable that 

could damage the conductor insulation or strain the conductor terminations. 


03-Nov-05 

G5-395

® >t= 




PROJECT: Final DBVS Design 145579-DSP-037 I REV.1 




3.3.1.9.6 Electrical — Conduit Support 

Conduit shall be supported by attachment to the frame. The Seller shall provide 

rigid brackets or additional frame members for attaching conduit when frame 

members are not in a convenient location. Attachment shall be on regular 

intervals per NECO (NFPA 70). Attachment shall be made using "U" clips which 

may be connected to the frame using either weld studs and nuts or bolts or 

approved NEC@ (NFPA 70) method. 

3.3.1 9.7 Electrical — Segregation of Control and Power Wiring 

Power circuit wiring and control circuit signal wiring shall be run in separate 

conduits. Signal wiring that transmits ac signals shall be run in separate conduits 

from signal wiring that transmits do signals. 

3.3.1.9.8 Electrical — Splicing 

No splicing is allowed. The Seller shall provide junction boxes with terminal 

blocks for connection of devices such as valves and instrument sensors that are 

provided with pigtail leads. 

3.3.1:.9.9 Eleci.ncal — Enclosure Wiring 

All enclosure wiring shall be routed, harnessed, appropriately laced, or in plastic 

wiring ducts. Where possible, all electrical penetrations into cabinets shall be 

from the bottom of the cabinet. 

3.3.1.9.10 Electrical —Instrument Enclosures 

Exposed live parts and contacts (greater than 50V) in enclosures shall be 

guarded to prevent unintentional contact during maintenance activities. Doormounted 

equipment shall be constructed or shielded so that no' live parts will be 

exposed to unintentional contact when the door is open. 

3.3.1.9.11 Electrical — Enclosures 

Unless otherwise noted, outdoor enclosures shall be rated NEMA 4; indoor 

enclosures shall be rated a minimum of NEMA 12. 


03-Nov-05 

G5-396

y.. 

LLItIR)C6 



/^(\//rte 

a I1V 





3.3. 1.9.12 Disconnect Switches 

As shown on Sketch DBVS-SK-E104, 480V ac, nonfused, horsepower-rated, 

disconnect switches shall be installed on the skid assembly. They shall be 

accessible to maintenance personnel, be within sight of the associated load, and 

be Labeled clearly with the equipment number and description of the load that 

they serve in accordance with Sketch DBVS-SK-E104. Disconnect switches 

shall be designed to be locked and tagged out. Disconnect switches shall be 

labeled with the load they serve. Incomplete load designators will be revised at 

the time of bid. 

Component data sheets for the disconnect switches are provided in Appendix C. 

3.3.1.9.13 Transformer and Dis tribution Panel 

A 480-120/240V ac single-phase transformer and associated distribution panel 

shall be installed on the skid assembly. The dis tribution panel and transformer 

may be combined as a single unit (e.g., Square DO Mini Power-Zone@). 

A detailed panel schedule listing breaker sizes and loads shall be located inside 

the panel door and provided as one of the shop drawings. 

Electrical power shall be distributed to all electrical components (except 3-phase 

motors) from this distribution panel Circuit breakers se rving convenience 

receptacles shall be protected by GFCI circuit breakers. GFPE breakers shall be 

used for heat-trace applications. 

3.3:1.9.14 Electric Motors 

1. Electrical motors shall be designed and tested in accordance with 

NEMA MG-1. 

2. Motors 1 hp and greater shall be 3 phase. 

3. Electrical motors shall be rated at 460V ac, 3 phase, 60 Hz. 

4. Electrical motors shall have a minimum service factor of 1.15. 

5. Electrical motors shall have a minimum insulation class of F, as defined in 

f^ NEMA MG-1, 


Q3-Nov-05. 

G5-397

a. _ Eeduxlo,^,g 







6. The Seiler shall provide the electrical motor specifications and data sheet to 

the Buyer for approval before final selection. 

3.3-1.9A5 Pushbutton Stations 

Local pushbu tton stations shall be provided for the pumps and motors, and shall 

be located on the support structure in a readily accessible location within sight of 

the motors. The Seller may combine the pushbutton stations into a single 

enclosure, providing that the o rientation of the pushbuttons and lights remains 

the same for each motor, labeling is clear, and a terminal strip is provided in the 

enclosure. Each pushbutton station shall be labeled with its respective 

designator in accordance with Sketch DBVS-SK-E104 (Appendix A). Control 

wi ri ng from pushbu tton stations for Scrubber Tank Pump A and Scrubber Tank 

Pump B shall be routed to an external terminal box and labeled in accordance 

with Drawings F-145579-00-E-0111 (Sheets 1 and 2) and F-145579-00-E-0112 

(Sheets 1 and 2) (Appendix A). Schematics shall be provided for other motor 

loads at the time of bid. 

Component data sheets for the Pushbu tton Stations are provided in Appendix C. 

3.3.1.9.16 Receptacles 

3.3.1.9.17 Lighting 

Convenience receptacles shall conform to NEMA 5-15R. Duplex receptacles 

shall be installed for general purpose use. 

The Seiler shall provide photo-cell-activated skid-mounted, weatherproof, highpressure 

sodium light fixtures as required around the pe rimeter of the skid. 

Lighting levels shall be confirmed by light meter test before delive ry . 

3.3.1.10 Electrical Materials 

3.3-1.10.1 Conduit 

Rigid galvanized steel (RGS) conduit or electrical metallic tubing shall be used in 

accordance with the NEC@ (NFPA 70). The RGS shall be UL-approved standard 

weight, 1/2 in. minimum size for control wi ring and 314 in. minimum size for power 

wiring. 


W-Nov-OS 

G5-398

ffitedloob9i 



PROJECT: Final DBVS Design 145579-D-SP-037 I REV, i 




Liquid-fight flexible conduit shall be installed where flexible conduit is required or 

where connecting to vibrating loads. Liquid-tight flexible conduit shall be 

grounding type with a polyvinyl chloride jacket. 

Conduit fi tt 

ings shall be standard steel threaded, liquid-tight, type-RGS fittings. 

3.3.1.10.2 Wire and Cable 

Conductors shall be stranded copper for all sizes of wire and cable unless 

specifically designated otherwise on the drawings. 

Wire insulation shall be Type THHN (heat-resistant, thermoplastic)/THWN 

(moisture and heat-resistant thermoplastic) for all 600V conductors unless 

specifically noted otherwise on the drawings. 

Minimum size of power conductors, 600V and below shall be No. 12 American 

wire gauge (AWG). 

Conductors for control circuits shall be No. 14 AWG minimum, except that 

remote control circuits, signaling circuits, instrumentation, and power limited 

circuits may he sized smaller in accordance with the NEC® (NFPA 70). 

Power wiring shall have color-coded insulation as indicated in Table 3-4. 

Table 3-4: Wire Color Coding Requirements 

W ;^ '^^^^' ^ uctor^`^ ";^ ^ ^J su a 

ôr^pacrch^Cl^rcult^^' 

iom- ^for 

x nsulat anp^^' TYNe^' 

=`^ _^, ^^ ^ ^ . ^ gip.- 

^, ... ^ ,:> , `^ ^ , 

480V ac, 

Phase A Red THWN/THHN 

3-phase systems 

Phase B Yellow 

120/240V ac, 

1-phase systems 

Phase C Blue 

Equipment Grounding 

Conductor 

Green (or bare) 

Hot No, 1 Black 

Hot No. 2 Brown 

Neutral White or Gray 

Equipment Grounding 

Conductor 

Green (or bare) 


W-Nov-05 

G5-399

f 

^ 

... 







Instrumentation cable shall be 600V, multiconductor for discrete signals, flame 

retardant, jacketed cable suitable for installa ti 

on in wet or dry locations. 

Conductors shall be a minimum of No. 18 AWG stranded, tinned copper, in 

twisted pairs/triads with ethylene propylene insulation. Each pair/triad shall be 

shielded with a drain wire and metallic tape. Multipair cables shall have an 

individual shield and an overall shield of metallic tape and drain wire. Conductor 

color coding shall be black, white (and red if triad). Temperature rating shall be 

194 °F (90 °C). Each pair/triad shall be numbered for simpli fied termination. 

Control and power multiconductor cable shall be 600V, flame resistant, radiation 

resistant, jacketed cable suitable for wet or dry locations. Conductors shall be 

stranded copper with ethylene propylene insulation with a temperature rating of 

194 -F (90 °C). 

3.3.1.10.3 Connectors 

Crimp-on, flat, loop connectors (i.e., Sta-kon( D) shall be used. Crimp-on 

connections shall be pe rformed in accordance with manufacturers-recommended 

crimping procedures. Flat-spade connectors shall not be permitted. 

3.3.1.10.4 Electrical Wire/Cable Markers 

3.3.1.11 Drawings 

Conductors shall be identi fi 

ed with white heat-shrink tubing with indelible black 

typed-on letters. Hand-lettered labels shall not be used. 

The Seller shall provide all design drawings necessary for the wet scrubber skid 

assembly which includes, but is not limited to, drawing outlines, inte rface 

drawings, electrical wiring diagrams, control wiring diagrams, ,pipe suppo rt 

drawings, dimensional drawings, rigging sketches, and as-built drawings. 

Drawings shall be submitted to the Buyer for review and approval 

The Seller shall deve lop drawings that detail how the specified pa rts and 

materials.will be assembled to meet the requirements of this specification. The 

drawing package shall include detail fabrication drawings, assembly drawings, 

arrangement drawings, general electrical drawings, electrical wiring and conduit 

schedule, and final as-built drawings. Drawings shall have a parts and materials 

list, as applicable, that clearly identifies quantity, manufacturer, the part or model 

number, material type and grade, electrical characteristics, size, and general 

WET SCRUBBER SKID ASSEMBLY DESIGN AND FABRICATION 101 

03-Nov-05 

G5-400 

ra

s ^ _ (L'd5[^lOoY' 

a- 



PROJECT: Final DBVS Design 145579-D-SP-037 I 

REV. 

RIM I 

1 




descriptions. Drawings shall include dimensional layouts, dimensioned 

subassemblies, dimensioned component details (if not included on 

manufacturer's cut sheets), flow and electrical diagrams, mate ri al and fastener 

sizes, descriptions, weld symbols, and notes. The arrangement drawings shall 

provide weight and center of gravity locations for the overall assembly as well as 

for major subassemblies (e.g., skid-mounted equipment within a larger assembly 

or large equipment moved and mounted as a unit). 

The assembled system shall be designed to comply with the P&ID and include all 

components specified on the P&ID provided in Appendix A. If conflicts arise 

between the proposed design and the P&ID, they shall be b rought to the 

a ttention of the Buyer for resolution. Any changes from the approved drawings 

shall be iden ti 

fied to the Buyer using the Request for Information form 

(Appendix E) for review of the change. The change shall then be controlled by 

the Seller to ensure the fab rication drawings are properly updated to incorporate 

the change. Final as-built drawings shall be prepared by the Seller at the 

conclusion of fabrication and testing. 

Drawing size shall be per ANSI Y14.1. Pa rts and materials list shall include 

quantity, manufacturer, the pa rt or model number, material type and grade, 

electrical characteristics, size, and general descriptions. All component parts 

shall refer to applicable mate ri al specifications, such as the milita ry, ASME, 

ASTM, federal, or other specifications. As-built drawings shall be verified in 

accordance with QA Program Controls before submittal, and shall be in 

accordance with Buyer-supplied drawing procedures. 

Drawings shall be prepared using AUtOCADO compatible drafting software. 

A copy of all as-built d rawing files (one of which shall be an electronic AutoCAD® 

release 2000 or higher compa ti 

ble file format) shall be included in the final 

drawing package. Drawings shall use the ROMANS AutoCAD® text font and the 

minimum text height shall be 1/Bin. 

3.3.1.12 Material Control Process 

The Seller shall develop a material control procedure to be used in the execution 

of the work. The material control procedure shall address procurement. controls, 

segregation, and traceability of mate rials including weld filler rod f rom receipt at 

the shop through processing. 

WET SCRUBBER SKID ASSEMBLY DESIGN AND FABRICATION. -Page 50 of 101 

03-Nov-05 

G5-401

+ trdut 






CLIENT: AMEC E&E'- Richland, Washington 

3.11:12.1 Exposure of Stainless Steel to Chloride Materials 

Stainless steel shall not be in contact with materials containing more than 

250-pm chlorine. Low-chloride markers shall be used. Chlorinated solvents shall 

not be used to clean stainless steel. 

Contact of Stainless and Carbon Steel Contact between carbon steel and 

stainless steel shall be avoided during fabrication. Temporary carbon-steel 

clamps, supports, braces, and fixtures shall not come into direct contact with 

stainless-steel surfaces. Galvanized-steel clamps or fixtures may not be used on 

stainless-steel piping or components. Wire brushes shall be stainless steel. 

Grinding wheels and wire brushes shall be new or used previously on stainless. 

stee p only. 

3.3.1.13 Welding Process 

All welding performed by the equipment housing manufacturer and/or the 

scrubber train fabricatorlmanufacturer shall be in accordance with ASME N509 

and ASME AG-1 (see Appendix B) and based on published consensus standards 

such as AWS D1.101.11vl, ANSI/AWS D1.3, AWS D1.6, AWS D9.11D9.1M, and 

ASMIE 1331.3. 

Weld size and type shall be selected by the equipment housing manufacturer 

and/or the scrubber train fabricator/manufacturer based on applicable seismic, 

wind loading, and system pressure requirements established within this 

specification. 

Welding of all pressure piping shall be performed in accordance with the 

ASME B31.3 piping code for "Normal Fluid Service," at a minimum. 

Certified welders shall perform welding of all structural steel in accordance with 

AWS D1.1/1]11AM or AWS D1.6 (depending on material). 

Welding Procedures, Procedure Qualification Records, and Welder Procedure 

Qualification Records shall be submitted for review and approval 

3.3.1.13.1 Welding Procedure Requirements 

All welding shall be performed in accordance with the Seller's approved Welding 

Procedure Specification. Each Welding Procedure Specification shall be 


D3-Nov-05 

G5-402

Niecludon 






-CLIENT: AMEC L&E - Richland, Washington 

qualif6ed with a Procedure Qualification Record as required in ASME B&PV 

Code, Section IX; AWS D1.11D1.1 M; and AWS D1.6, as applicable. 

Welding of all stainless steel including, but not limited to, structural shapes, 

rectangular tubing, plate, and sheet shall be performed in accordance with 

AWS D1.6 nontubular, statically-loaded conditions. Welding of stainless-steel or 

carbon-steel piping shall be performed in accordance with the ASME B31.3 

piping code 'for "Normal Fluid Service." Automatic pipe welding equipment and 

techniques may be used. 

Welding of all carbon steel including, but not limited to, structural shapes, 

rectangular tubing, plate, and sheet shall be performed in accordance with 

AWS D1.1/D1.1M nontubular, statically-loaded conditions. 

Welded connections on the lifting components shall be 100 percent visual and 

100 percent Dye-Penetrant Test or Magnetic-Particle Test inspected. If a weld is 

% in a radioactive material boundary (e.g., process piping); then these welds will 

require a minimum of a visual inspection and additional nondestructive 

examination (NDE) (dye penetrant, magnetic particle, or x-ray, as appropriate). 

All load bearing welds, or welds deemed critical by the Buyer, shall be inspected 

with liquid penetrant by the Buyer. Examples of critical weldments are the venturi 

and ductwork connections that are deemed critical by the structural and applied 

loads analyses. 

If the equipment housing manufacturer's weld inspection procedures defining 

specific weld acceptance criteria are based on, include or exceed this 

specification's referenced requirements of ASME N509 (Section 7.3), then a copy 

of their procedure, marked to indicate the applicable requirements, shall be 

submitted as part of the NDE procedures package for approval before the start of 

fabrication. 

3.3.1.132 Weld Joints and Preparation 

Weld joints are as permitted by the referenced standards. Weld joint design, as 

noted on the fabrication drawings, shall be sent to the Buyer for review and 

approval before fabrication. 

Post-weld heat treatment of carbon-steel piping is not required. 


03-Nov-05 

G5-403

B. ' :' NL'ldll&llV'nF 



PROJECT: Final DBVS Design 145579-DSP-037 I REVA 




3.3.1.13.3 Wend Repairs 

3.3.1.13.4 Weld Map 

Weld defects shall be removed and repaired as allowed by the referenced 

standards. The original Welding Procedure Specification shall be used for weld 

repair. Welds that fail inspection shall not be ground out and repaired more than 

twice before the section is abandoned and replaced. 

Welds (including typical welds) shall have unique numbering listed on a weld 

map(s). The weld map(s) shall include the weld number, weld procedure 

number, filler material control number, welder identification, NDE procedure 

number, and examiner identification. Individual weld maps are to be provided 

per component when multiple components are produced. 

Weld identification shall be performed as follows: 

1. Prepare weld identification drawings, isometric or spool, which show 

relative position of pressure containing welds and attachment welds to 

pressure retaining components. 

2. Assign weld numbers to pressure-containing welds and attachment welds 

to pressure retaining components as made. Record weld numbers on weld 

identification drawings as welds are made. 

3. Place the welder bonder identification symbol and weld number adjacent to 

welds on completion. Place the identification symbol approximately every 

3 ft on long seams or large welds. 

4. Do not reuse weld numbers. If a weld is completely replaced, assign a new 

number. 

5. Show heat and lot numbers on weld identification drawings for materials. 

Weld identification documentation shall be submitted to the Buyer for review and 

approval 

WET SCRUBBER SKID ASSEMBLY DESIGN AND Page 53 of 101 

03-Nov-05 

G5-404


Otedunlogy s311'?e 





CLIENT: AM EC E&E-Richland, Washington 

3.3.1.14 Fabrication Traveler 

The Seller shall provide fabrication traveler(s) for the fabrication and testing of 

the above described wet scrubber skid assembly equipment. The fabrication 

traveler(s) shall include detailed procurement, fabrication, assembly, testing, 

shipping, and handling steps required to properly fabricate, assemble, and test 

the equipment in accordance with the drawings and specifications_ 

3.3.1.15 Monitoring and Control System 

The MCS philosophy is a combination of focal and remote operations 

(Section 3.1.2.8:3). The Seller shall interlace with the physical instruments and 

components through the use of a Seller-provided termination panel. The 

termination panel shall be located on the outside, shall meet UL 508A (as 

required), shall be rated for outside environmental condition, shall be easily 

accessible for maintenance (approximately 60 in. high from the ground), and 

shall meet NEC® (NFPA 70) requirements for working clearances. The exact 

location of the panel will be determined based on minimization of wiring, internal 

skid interferences, and external connection routing. 

Only local instruments and components are required to be wired and terminated 

to the termination panel. The local instruments and components' shall be routed 

in conduit and terminated at the local termination panel. Terminations shall be 

tension-clamp terminals capable of individual replacement (i.e., DIN rail 

mounted). An example is a Weidmuller0 type WDU. Alternating current power 

and alternating current/direct current inputs shall be physically separated. 

The normal field voltages from or to the MCS is 24V dc, which enhances 

personal safety during maintenance. Over 50V represent hazardous voltage 

which should be avoided unless authorized by the Buyer. This does not apply to 

equipment that requires 120V ac, but with low voltage interfaces to the MCS. 

The Seller shall provide an interface panel wiring to an instrument/component 

drawing. See Figure 3-1 as an example. 

Instruments shown on the drawings with a box around the symbol are Monitoring and Control 

System virtual displays or controls and require no action by the Seller. 


03-Nav-05 

G5-405



mi 





.. 

€ 

I 

I 

---------------- 

1 I 

f 

t 

H Pt ° - ^ m ^ n b ti 

Figure 3-1: Interface Panel Wiring to Instrument/Component Drawing (Example) 


03-Nov-05 

G5-406 

k 

I 

I 

55 of 101

s 71ÎOnF 



M 





Twisted shielded pair shall be used for analog instrument signal wi ring. 

Individual wires shall be labeled for the destination with the cable being labeled 

with both FROM and TO information (see Appendix G). 

3.3.1.16 Instrument Calibration and Characteristics 

All instrument transmitters shall provide an isolated 4-20-mA signal to the MCS, 

unless a different output is required for the process. Justi fication shall be clearly 

indicated on the completed component data sheet. All pneumatic control valves 

shall accept a 4-20-mA control signal from the MCS and p rovide position 

indication to the MCS. Inte rface connections shall be through wire termination 

points on the instruments. Ins truments, tubing, piping, and wiring shall be 

installed in accordance with the instrument manufacturer's recommendations and 

the best practice for the indust ry. Purchasing and installation of the MCS 

inputtoutput modules are not included in this contract. Locally indicating 

instruments/sensors shall be installed such that they are easily readable by an 

operator standing on the floor at the entry access point to the wet scrubber skid 

assembly skid. The Buyer shall provide guidance with positioning based on best 

available knowledge of the configuration. 

All instruments shall be facto ry-calibrated and a calibration data package shall be 

provided including a Certi ficate of Calibration traceable to the National Institute of 

Standards and Technology (NIST), for each arti cle contracted. In addition, the 

actual Calibration Records for each instrument shall also be included containing 

the instrument identification, accuracy requirements and results, the as-found 

and as-left data, and the calibration expiration date. 

Each calibration certificate shall be signed by the Seller's representative 

responsible for calibration, attesting to its authenticity and shall be identified with 

the: 

1. Buyers contract number, 

2. identification of the a rticle to which the ce rtificates applies, and 

3. Standards used for calibration_ 

The Ce rtificates of Calibration will be held on file by the Buyer's Records 

Management as objec tive evidence to suppo rt the actual test results and a ttest to 

the fact that the calibrated item(s) met requirements. 


02-Nov-05 - 

G5-407







Certification stating the equipment furnished to the contract requirements has 

been calibrated using standards whose calibration is traceable to the NIST or 

other documented evidence, must be submitted stating the basis of the 

calibration. In addition, the Seller shall submit a report of actual calibration 

results. The report shall be identifiable to the acceptance criteria of the items 

submitted and shall meet contract requirements. The report shall contain the 

signature of the authorized representative of the agency verifying compliance. 

One copy of the documentation, unless otherwise specified, shall accompany the 

applicable item(s) shipped. 

The Seller shall provide Instrumentation types and manufacturer to the Buyer for 

approval before purchase of the instrument. Recommended field recalibration 

procedures shall also be provided in the final data package along with a list of 

special tools required for recalibration. 

Component data sheets for the process instrumentation are provided in the 

Bidder's Drawing and Data Commitments sheet (Appendix F). 

3.3.1.17 Mechanical Assembly Requirements 

All equipment shall be assembled to the structural frame observing the 

equipment manufacturer's recommended assembly instructions: Equipment 

shall be checked to ensure that it is provided with adequate amounts of fresh 

lubricants of the proper selection. 

3.3.1.18 Workmanship 

General: Remove all burrs and break all sharp edges. 

1. Drawings: 

a. Dimensioning and tolerancing shall be interpreted per ANSI Y14.5M 

and 


03-Nov-05 

G5-408 

Page 57 of 101







- tr 

b. Tolerances not specified on drawings shalt be as shown in Table 3-5. 

2. Welding to ball valves: 

Table 3-5: Standard Drawing Dimension Tolerances 

a. Ball valves shall be disassembled before welding to the valve body. 

3. Piping and components: 

a. Pipe flange, man-way, and flange faces shall be within ± 2 0 of vertical 

or horizontal, whichever is appropriate; 

b. Pipe flange bolt holes shall straddle centerlines; 

C. Material and debris shall be removed from piping and components 

before welding/assembly; and 

d. Secondary containment housing flanges shall be flat. 

3.3.2 Industry and Government Standards 

The codes, standards, and source documents that provide the design fabrication 

and testing requirements are listed in Section 2. Sections within this specification 

provide specific details or reference for application of the codes and standards 

documents: Conflicts found between the referenced codes and standards will be 

referred to the Buyer for resolution. 


03-NOV-05 

G5-409







3.3.3 Radiation 

3.3.3.1 Electromagnetic Interference/ 

Electromagnetic Compatibility 

The equipment shall be designed in accordance with the limits set forth in 

HNF-2962 as summarized in the following subsections. 

13.3.11.1 Unintentional Radiators 

Equipment shall comply with the emission limits specified in 47 CFR 15, 

Subpart B. The Seller must provide certification that the emissions from 

equipment or the device are within the limits specified in 47 CFR 15 or a Federal 

Communications Commission-accepted international standard. 

3.3.3.1.2 Radio Frequency Interference Susceptibility 

Applicable equipment shall be tested and evaluated for the immunity to radio 

frequency interference from portable communications equipment. The testing 

method and procedure for testing process instrumentation are found in 

IEEE Std C37.90.2. 

Since the frequencies of interest are in the bands of 120 to 190 MHz and 420 to 

480 MHz, the equipment shall be evaluated from 20 to 1,000 MHz. The electric 

field intensity of 30V/m shall be used for testing. 

3.3.3.1.3 Equipment Alternating Current Mains Surge Protection 

Applicable equipment shall be designed to withstand the surge waves specified 

in IEEE C62.41.1 and C62.41.2. The equipment shall be type tested by the 

manufacturer in accordance with this standard, and certification provided by the 

Seller. 

3.3.3.1.4 Electrostatic Discharge Protection 

The system or individual parts of the system shall not be damaged and shall 

continue to function after being subject to electrostatic discharge on operating 

panels and other controls normally available to operating personnel The 

manufacturer shall provide certification that electrostatic discharge testing was 

performed according to the methodologies found in ANSI 063.16. The test 


03-Nov-05 

Cis-410 

G

- ' tfdinolo 6 






CLIENT: AMEC Ei£E - Richland, Washington 

3.3.3.2 Nuclear 

voltage should be at least 4 kV. ANSI C63.16 provides additional references to 

selecting the proper voltage ranges to be used. 

All materials of fabrication shall be evaluated to be able to operate without loss of 

service while exposed to the maximum estimated unshielded contact radiation 

dose of 4.5 x 10 4 R based on a 5-yeas design life. 

3.3.4 Cleanliness 

Before assembly, and before preparing for shipment, all components shall be 

cleaned by flushing clean water and/or blown clean and dry with compressed air 

to the extent that extraneous materials, such as those listed below, are not 

present: 

1. Metallic or other dusts (shop dust), chips, turnings, and weld splatter; 

2. Abrasive particles; 

3. Rust and other loose corrosion particles; 

4. Magnetic/liquid penetrant residues, dye check, etc.; 

5. Foreign material (i.e., paper, tape, plastic, sand, and wood); 

6. Cutting oils; 

7. Excess lubrication, grease, and oil; and 

8. Marking dyes. 

The fabrication traveler shall describe the cleaning and packaging steps taken. 

The wet scrubber skid assembly equipment ports and pipe openings shall be 

temporarily capped following cleaning and drying for shipment. Packaging 

requirements following cleaning are documented in Section 5.2. 

WET SCRUBBER. SKID ASSEMBLY DESIGN AND FABRICATION Page 

Q3-Nov-05 

G5-411 

s

- , - leduxa'oa 







3.3.5 Corrosion of Parts 

Solvents and cleaning solutions used on stainless steel shall be chloride-free. 

Stainless-steel components do not require painting except as required for 

identification or other markings. Paint, if used, used on stainless steel shall be 

epoxy-phenolic. 

All exposed surfaces of carbon-steel parts shalt/ be protected from corrosion by 

priming and painting (see Section 3.3.6 for protective coating requirements). 

To the extent practical, connections between dissimilar metals shall be avoided. 

3.3.6 Protective Coatings 

Protective - coatings shall be used on equipment where specified in this 

specification and shall be compatible with the process fluid streams. Protective 

coatings shall be used on the appropriate equipment in order to meet the 

reliability and maintainability requirements; to protect equipment from the 

environmental conditions; and to provide a clean, smooth surface for 

decontamination. The weldments shall be completed and painted entirely before 

installation of piping and components in the frames. Care shall be taken to 

protect the paint during equipment installation. Touch-up shall be performed to 

repair paint defects after the equipment installation is completed. Protective 

coating specifications shall be submitted to the Buyer for review and approval 

before fabrication. All exposed carbon-steel surfaces shall be painted with the 

manufacturer's standard color. 

3.3.6.1 Painting Preparation 

The Seller shall prepare all surfaces in accordance with the manufacturer's 

instructions. Painting shall be performed in a clean, well-ventilated area 

separated from airborne particulates generated by shop operations. 

3.3.6.2 Paint Application 

1. All exposed carbon-steel surfaces shall be prepared and painted with a 

minimum of one coat of primer and a minimum of two finish coats. 

2. Paint shall be applied to dry, clean, and adequately prepared surfaces in 

accordance with manufacturers instructions. Each coat of paint shall be 


D3-NOV-05 

G5-412

uwlo 







3.3.6.3 Primer 

3.3.6.4 Paint 

properly cured according to manufacturer's instructions before applying 

additional coats. 

3. All paint containers shall remain closed until required for use. Paint shall 

be mixed before use in accordance with manufacturer's instructions. 

Agitation during application must be provided where specified by the 

manufacturer. 

4. Paint may be applied with a brush or sprayer according to manufacturer's 

instructions. 

5. All coats shall be applied in such a manner as to produce a film of uniform 

smoothness. Special attention shall be paid to crevices, weld lines, 

corners, and edges to obtain the required thickness. 

6. The manufacturer's instructions for thinning, mixing, handling, and applying 

the products shall be considered to be part of this specification. 

7. All coats shall be applied to produce a film of uniform smoothness and 

nominal thickness of not less than 3 mils with a total minimum thickness 

(with primer and top coat) of 5 mils. Special attention shall be paid to 

crevices, weld lines, corners, and edges to obtain the required thickness. 

The Seller shall use standard zinc-rich primer for carbon-steel structures or 

piping. Precoated or stainless-steel pipe support components do not require 

painting. 

1. The Seller shall use a standard top coat compatible with the primer for 

finish coats on carbon-steel structures or piping. 

2. Precoated or stainless-steel pipe support components do not require 

painting. 

3. The top coat of painted equipment shall be white to minimize solar 

heat load. 


03-Nov-05 

G5-413




PROJECT NO.- 145579 WET SCRUBBER SKID ASSEMBLY 



3.3.7 Interchangeability 

The Seller shall specify the assembly level at which components shall be 

interchangeable or replaceable. This is a design consideration to be reflected on 

the design drawings and/or supporting documents (such as calculations and 

analyses). 

3.3.8 Identification and Marking 

Component identification labeling shall be performed in accordance with the 

following guidelines and shall match the final P&ID or electrical one-line diagram 

for the assembled system. 

13.8.1 . Equipment Labeling 

The Seller shall label all valves, instruments, and mechanical equipment in 

accordance with this specification. Equipment to be labeled shall include, as a 

minimum: 

I. Valves or dampers; 

2. Label external valves; 

3. Instruments and gauges, pumps, motors, and filters; 

4. Transformers, distribution panels, instrument enclosures, and switches; and 

5. Junction boxes shall follow the labeling convention below: 

a. Instrument (24V dc): 36-IJB-549 

b. Electrical (110V ac): 36-EJB-5## 

C. Power (110V ac): 36-PJB-5## 

Only the EIN is required to be on the tag. Tags shall be 1-3/8 in. by 2-3/4 in. 

minimum and use 3116-in.-high black text on white background. The tags shall 

be plastic and have at least a single hole for attaching to components. 


03-Nov-Z 

G5-414 

e

Rcllro%y 







Tags shall be attached to components without a flat surface using a nylon tie 

wrap. Tags shall be attached to components with a flat surface using clear 

silicon rubber adhesive. Equipment tags shall be located where they are readily 

visible and not subject to damage or accidental removal during equipment 

operation. Tags shall be suitable for the environment on which they are installed. 

3.3.8.2 Piping Labeling 

Piping shall be marked with arrows and fluid type to denote the direction and the 

fluid conveyed. The fluid conveyed shall be marked as "PROCESS," 

"CAUSTIC," "CHILLED WATER," "FILTERED WATER," or "COMPRESSED 

AIR," etc. as applicable. Text shall be all capital letters. The label background 

and lettering colors shall be as follows: 

1. Process fluid or caustic piping shall be yellow field with black letters. 

2. Chilled water or refrigerant piping/tubing shall be blue field with white 

letters. 

1 Compressed air piping/tubing shall be blue field with white letters. 

4. Filtered water piping/tubing shall be green field with white letters. 

5. Labels shall be made from self-sticking polyester or vinyl (Electromark& 

part number P400 series or approved equal). For pipes that are less than 

314 in. in diameter, the label size and lettering shall be appropriately sized 

to the size of the pipe. Pipe that is greater than 314 in. in diameter, the 

Fettering shall be sized in accordance with Table 3-6. 

6. The labels shall be placed on pipes in the location most readable from the 

operator's normal viewing position. 

7. Piping labels shall be placed before and after each valve and piping joint. 


03-Nov-05 

G5-415

: uroto, 


TECHNICAL SPECIFICATION =I' ^ 





i 

Table 3-6: Pipe Labeling Format 

, PrR ^^ Ousttle ^. ^s 1' e "` *-t^ ^ê^^x ,r "^` ^ o q - 

^^ ^ ^ o L er^fb s 

3.3.8.3 Wire and Cable Labeling 

0.75 1.25 8 05 

1.5 2 8 015 

2.5 6 12 1.25 

8 10 24 2.5 

10 -- 32 3.5 

All wires and cables shall be labeled at both terminations with the identification 

specified on the contract drawings. Labels for instrumentation wire and cabling 

shall follow the convention in Appendix G. Wire label mate ri al requirements and 

color coding are given in Table 34. 

3.3.8.4 Terminal Labeling 

Terminal block label tags shall be a durable plastic material. The tag color shall 

be white background with black le ttering. Each terminal on the terminal block 

shall be labeled with a clearly visible terminal number. Numbered terminal block 

covers may be used for this purpose. 

The tag may be mounted on a surface of the enclosure in close proximity of the 

terminal block. Tags shall be attached securely by means of durable stranded 

stainless-steel cable, clamps, or chains. 

3.3.8.5 Conduit Labeling 

1. All conduits shall be labeled with the identi fication tag on the contract 

drawings and the highest voltage contained in the conduit as in the 

following example: 

E-123 - 110 VAC 1 PH 


03-Nov-05 

G5-416

f 







2. The minimum letter height shall be 114 in. The label length shall be as long 

as required to contain the required information. The label color shall be 

white background with black lettering. Text shall be all capital letters. The 

labels shall be a durable material that is permanently secured to the conduit 

by an adhesive or mechanical means. The label may be metallic or 

plastic. The label shall be affixed securely in place in a manner to prevent 

their loss, damage, slippage, or accidental removal. However, the means 

used to mount the label should permit its removal when necessary without 

damage to the surface to which it was attached. 

3.3.8.6 Labeling of Handling and Lifting Devices 

All equipment that is designed to be mechanically lifted shall have lifting points, 

the center of gravity, and the lifting weight marked. Lift points shall be identified 

with yellow paint. All specialized lifting devices shall be marked in accordance 

with DOE/RL-92-36, as follows. 

Structural and mechanical below-the-hook devices shall be provided with 

identification displaying the following data, as a minimum: 

1. Rated load, 

2. Manufacturer's name, 

3. Lifting device weight (if over 100 lb), 

4. Drawing number (if applicable), and 

5. Serial number (if applicable). 

The identification data may be displayed on a nametag, nameplate, metal stamp, 

or other permanent marker. If the lifting device comprises several lifting devices 

that can be detached from the assembly, these individual lifting devices shall be 

marked with their individual load rating also. 

Clearly mark and identify'any components required for removal before equipment 

installation (e.g., shipping blocks): 


Q3-Nov-05 

G5-417

i..tedu ôa ' 







3.3.8.7 Electric Motor Labeling 

The markings on all motors shall be in accordance with the NEC@ (NFPA 70) 

and NEMA MG -1. Care should be taken when painting, such that the motor 

nameplates, Lifting eyes, or lifting swivel manufacture nameplates are not to be 

painted. 

3.3.9 Nameplates 

The wet scrubber skid assembly enclosure shall have a manufacturer's 

nameplate. The nameplate shall include: the project number, purchase order 

number, equipment name and number (provided by the Buyer), assembly weight; 

this specification number, latest revision, and other data to be supplied_ 

The wet scrubber skid assembly shall also have an EW label (36-D58-002) 

centrally affixed to the skid. Letter height for this label shall be 3 in., minimum. 

3.3.10 Human Engineering 

Human factors engineering principles and criteria shall be integrated into the 

design of systems and the facilities that house and suppo rt these systems. 

Operator movements and accessibility of equipment and controls in the work 

area shall be considered. Clear and unobstructed access shall be provided to 

each system component for operation and maintenance. 

3.3.11 Design and Qualification 

The drawings, calculations, and associated design media shall show full 

compliance with this specification and Buyer-approved exceptions or 

modifications. Portions of drawings originated by others, such as as-built 

vendor information on P&IDs, shall be clearly iden ti 

fied. 

To obtain approval for the design of the fabricated system the Seller shall 

perform the following: 

1. Prepare calculations, required by this specification, and document how the 

results of the calculations were incorporated into the design and fabrication 

drawings (e.g., adequacy of pump to meet calculated demand, selection of 

weld size to meet structural requirement). 


03-Nov-05 

G5-418 

s.

Rdwolm 






CLIENT: AMEG E&E - Richland, Washington 

2. Identify those materials and/or components that require.a CDC. 

3. Prepare complete data sheets and obtain vendor cut sheets for major 

components of the assembled system_ At a minimum, the set of major 

components shall be those shown on the P&ID (valves, instruments, 

equipment, etc.). This information package will be used to evaluate how 

the Seiler has evaluated the form, fit, and function of components for their 

intended use as shown on drawings and in supporting calculations. 

3.3.11.1 Structural Calculations 

In general, equipment and structures shall be analyzed and designed in 

accordance with ASME AG-1, UBC (1997) and ASCE 7-98, as the minimum 

requirements. The loads and load combinations used in the analysis shall be as 

defined in UBC (1997) or other national codes and standards, as referenced in 

this section or as otherwise defined in this specification. In addition, the Hanford 

Site-specific design requirements are included as part of this specification and 

shall be incorporated in the analysis, as applicable, in determining the loads, load 

combinations, and allowable stresses to which the equipment or structures shall 

be designed. 

Calculations shall demonstrate that equipment will withstand applied loads 

without loss of integrity or release of radioactive/hazardous material. The 

calculations shall also show that the skid will not tip over nor slide, the use of a 

friction factor shall be either justified or conservatively not allowed. 

3.3.11.1.1 Dead Loads 

Dead loads include the weight of all permanent materials and equipment, 

including the assembled system equipment weight, with and without the weights 

of fluids and materials being handled. 

The unit weights of material and construction assemblies shall be those given in 

ASCE 7-98. Where unit weights are neither established in that standard nor 

determined by test or analysis, the weights shall be determined from data in the 

Seller design and fabrication drawings or from catalog cut sheets. 


03-Nov-05 

G5-419

' ` iednI 



WET SCRUBBER. SKID ASSEMBLY DESIGN AND FABRICATION 

03-Nov-05 - 

c^/l'T 

PROJECT: (Final DBVS Design 145579-D-SP-037 I REV. 1 



CLIENT: AMEC EI£E -Richland, Washington 

3.3.11.1.2 Live Loads 

Live loads are those loads produced by the use and occupancy of the unit and do 

not include construction and environmental loads such as wind load, snow load, 

rain load, ea rthquake load, flood load, or dead load. Live loads are produced by 

operations, maintenance workers, and equipment. 

1. Live loads shall be not less than the minimum uniform load or concentrated 

load stipulated in ASCE 7-98. 

3.3.11.1.3 Ea rthquake Loads 

The weight of'service equipment that may be removed with change of use 

of a given area shall be considered as live load. 

Ea rthquake induced design loads, as a minimum, shall comply with the 

UBC (1997) Seismic Zone 2 13 for essential facilities. Seismic assessments shall 

use the UBC (1997) (Section 1632) or ASCE 4-98, with an importance factor, 1 p = 

1.5 for structures, systems and components and seismic zone factor, Z = 0.2. 

The soil profile type as defined by UBC (1997) (Section 1636.2) is taken as SC 

and with a seismic coefficient, C a = 0.24, for conservatism. 

For load combination evaluations per ASME AG-1 (Table AA-4212), only levels A 

and B apply. 

3.3.11. 1.4 Snow toads 

Snow loads for the equipment shall be in conformance with ASCE 7-98. 

A ground snow load, Pg of 15 Ibfffe shall be used for calculating roof snow load. 

Unbalanced snow loads resulting from drifting or sliding shall be considered. 

Live roof loads are not necessary when there is no enclosure of equipment. 

3.3.11.1.5 Wind Loads 

The equipment, if subjected to a wind load, shall be designed to resist pressures 

from wind from any direction. Partial wind loading shall be considered if it 

produces a more severe effect. Wind load design shall comply with ASCE 7-98, 

using the 85 mph "3-second gust wind veloc ity" with an impo rtance factor of 1,15, 

exposure Category C. 

G5-420 

Page 69 of 161

wwnftoy 






CLIENT: AMEC E8E - Richland, Washington 

3.3.11.1.6 Ash Loads 

An ash loading of 5 Ib/ft2 shall be considered in the design of equipment or 

support structures exposed to the elements. The ash loading shall be evaluated 

using the load combination, S = D + L + A in addition to other load combinations, 

defined by the referenced codes and standards in determining the governing 

loads for design and analysis_ 

3.3.11.1.7 Load Combinations and Stresses 

Load combinations, allowable stresses, and strength requirements as defined in 

ASPAE AG-1 (as identified in Appendix B), UBC (1997) and ASCE 7-98 shall be 

used in determining the governing load combination(s), acceptability of the 

design, and stability of the equipment or structure. 

The stability of the equipment or structure against overturning and sliding shall be 

determined and the stability maintained, based on a safety factor of 1.5. 

Anchorage of the equipment components to the support structure(s) shall be 

designed using the methods in UBC (1997) for life-safety systems (importance 

factor, I = 1.5). 

Anchorage shall comply with UBC (1997). Acceptable types of concrete 

anchorages include industry-standard, wedge-type, expansion-type anchors 

having capacities published by the International Conference of Building Officials. 

Anchor size shall be a minimum diameter of 1t2 in. (12 mm) regardless of 

calculated anchorage requirements. Alternative anchorage methods or types 

may be proposed for Buyer consideration. 

3.3.11.1.8 Hoisting and (Rigging Loads 

The lifting apparatus (eyebolts, hoist rings, and lifting baits) shall be designed in 

accordance with the AISC Manual of Steel Construction—Allowable Stress 

Design, the RISC Manual of Steel Construction—Load and Resistance Factor 

Design, ASME B30.20, and DOE/RL-92-36. Equipment designed and fabricated 

by the Setter shalt have a safety factor of 3 based on yield strength. Equipment 

purchased by the Seller shall have a safety factor of 5 based on ultimate 

strength. Documents shall be provided to the Buyer demonstrating incorporation 

of these safety factors. The Seiler shall identify the total weight, the center of 

gravity, and the lift points and rigging methods necessary for lifting each 

component. lift points shall be identified with yellow paint. Any special tooling, 

WET SCRUBBER SKRO ASSEMBLY DESIGN AND FABRICATION Page 70 of 161 

03-NOV-105 

G5-421

Wy4ay 






CLIENT: AMEC E8E -Richland, Washington 

spreader bars, or other recommended fabricated devices for lifting shall be 

provided by the Seller. 

3.3.11.1.9 Secondary Containment Hydrostatic Load 

For the secondary containment, the containment structure shall safely contain 

the volume of waste specified in Section 3.2.1.2.4. 

3.3.11.2 Mechanical Calculations 

Mechanical calculations performed for the piping system shall be prepared in 

accordance with piping code requirements in ASME 831:3- As a minimum, 

calculation shall include the following subjects: 

1. Pipe wall thickness calculations for pressure (ASME B31.3, 

Paragraph 304.1). 

2. Stress calculations for sustained loads because of pressure, dead load, 

and any other sustained loads (ASME 631.3, Paragraph 302-3:5). 

3. Stress calculations for displacement stresses, such as thermal loads. Use 

Equation (16) in ASME 631.3 (Paragraph 319.4) for flexibility analysis on 

simple systems. 

4. Stress calculations for occasional load such as pressure, dead weight, 

other sustained loads, and earthquake loads (ASME 831.3, 

Paragraph 302.3:6). 

5. Hanger stress calculations for dead weight, wind, thermal, and seismic 

loads [ASME 1331.3, Section 321; ASCE 7-98; UBC (1997); and the AISC 

Manual of Steel Construction—Allowable Stress Design for source 

reference, in addition use an Importance factor - Ip = 1.5 and seismic• 

coefficient - Ca = 0.341 

The Seller shall determine the need for a corrosion allowance for the processing 

fluid and operating conditions. This assessment shall be documented and any 

allowance clearly identified in design calculations and/or material specifications. 


03-Nov-a5 

G5-422 

Page 71 of 101

mwwft . 







3.3.1 1.2.1 Normal Operating Pressure Loads 

Normal operating pressure loads in the piping resulting from the liquid flow 

condition sha ll be considered and are to be addressed in the design of the skid 

assembly_ For the design analyses pe rformed in accordance with this 

specification, the design flow, pressure, and temperature for the various piping 

systems are listed in Table 3-7. 

e ^^ 

^^YC . `.AYA:bM1 3:"vs`Y.a.... ^`..i '?^v.^ 

Table 3-7: Wet Scrubber Skid Assembly 

Piping Design Conditions (2 sheets) 

W. na 

* 

4kù^^`'xriv` _xc a. . sly:':-i`.•A 'Ûx•^v :;}^'" `^^w'.CS.â 

Main air stream flow To be specified by the Seller 

Chilled water supply/return Design pressure of 30 psig at 50 °F. Available flow is 

to skid assembly 120 gal/min at 22 psig developed head. Chilled water 

will be 50/50 propylene glycol and water. The Seller to 

specify the required flow for the wet scrubber 

assembly. 

Caustic System To be specified by the Seller. 

Filtered Water System Design pressure of 150 psig at 150 °F. 

Compressed air supply to Maximum normal condition of 5 cfm air at 100 psig 

skid assembly and 125 °F. 

w.g. = water gauge. 

3.3.11.2.2 Additional Mechanical Calculations 

Design pressure of 150 psig at 150 °F. 

Addi ti 

onal calculations that shall be pe rformed, if applicable for the assembled 

system, include: head loss (for pump sizing ), valve actuator sizing, air stream 

relative humidity evaluations, heater sizing, and piping and equipment heat-trace 

load determinations (for freeze protection), if required. 


03-Nov-05 

G5-423 

¢ 

a 

Y 

Page 72 of 101

n .. ,.. >F 







3.3.11.3 Electrical Calculations 

Electrical calculations shall be done in support of NEC® (NFPA 70) requirements 

and requirements of this specification. Calculations shall include, but are not 

limited to: 

1. Electrical load calculation, with any assumptions regarding demand factors 

or load diversity clearly stated. 

2. Wire sizing calculation for all power conductors, with all assumptions 

regarding duty cycle clearly stated.. 

3. Equipment sizing/selection calculation (transformers, distribution panels, 

over current protection, etc.), with any assumptions clearly stated. 

4. Raceway sizing calculation, for ail conduit and other raceways. 

Care shall betaken to ensure that ambient temperature considerations and heat 

gain from direct sun are considered appropriately when performing calculations 

for wire and equipment size. 

3.3.12 Document Submittal 

The following subsections provide the minimum document requirement 

submittals. 

3.3.12.1 General Requirements 

Information to be supplied with the bid, for review and as final is shown on the 

Bidder's Drawing and Data Commitments sheet (Appendix F). The submittals 

presented on this sheet shall be delivered as the delineated packages for review 

and approval- 

Each document submittal shall be identified with this specification number, item 

number, purchase order number, and Seller's identification number. Submittals 

shall be transmitted to the Buyer in accordance with the directions found in the 

Request for Quote. 

Data shall be sufficiently clear to allow legible copies to be made on standard 

reproduction equipment after microfilming. 


03-Nov-05 

G5-424

wmam 







Approval by the Buyer does not relieve the Seller from the responsibility for 

accuracy or adequacy of design under this specification. 

Submittals are divided into two types: (1) those requiring "approval before 

proceeding" (I.e.,.weld procedures or prepurchase evaluation data) and (2)those 

requiring "approval before shipment" (i.e., vendor information data). 

Submittals requiring approval before shipment will be reviewed to verify 

completeness and adequacy for their intended purposes. 

Unacceptable items that require approval before proceeding will be handled as 

specified below_ 

A submittal requiring approval that is not approved by the Buyer will be 

dispositional as: 

1. "Not Approved, Revise and Resubmit." The submittal is considered 

technically deficient, or incomplete, and is therefore unacceptable. 

Resubmittal is required; hence fabrication, procurement, or performance of 

procedures shall not proceed_ 

2. "Approved with Exception." Fabrication, procurement, and performance of 

procedures may proceed, and resubmittal is required to verify incorporation 

of the exception. Final acceptance of the item is contingent on the Buyer's 

receipt and approval of the corrected submittal. 

Submittals requiring approval before shipment that are determined to be 

incomplete or inadequate will be marked "Resubmit" and will be returned. An 

explanation of the deficiencies will be included for corrective action by the Seiler. 

3.3.12.1.1. Design Documentation 

The Seller shall provide all shop fabrication drawings that detail how the specified 

parts and materials will be assembled to meet the requirements of this 

specification. Shop fabrication drawings shall clearly identify the material type 

and grade on the Bill of Material. The Seiler shall include a Bill of Material and 

submit to the Buyer for review and approval. Final as-built drawings shall be 

provided by the Seller at the conclusion of fabrication and testing_ Modifications 

to the arrangement drawing can be proposed by the Seller to improve the 

fabrication of the total assembly; however, modifications and the detailed 

.WET SCRUBBER SKID ASSEMBLY DESIGN AND FABRICATION. Page 74 of 101 

03-Nov-05 

(35-42$ 

i

Wdmdog ^TECHNICAL SPECIFICATION 

WET SCRUBBER SKID ASSEMBLY DESIGN AND 

03-Nov-05 


hin 

amecy 





fabrication drawings are to be approved by the Buyer before procurement of 

material or initiation of fab rication. 

The Seiler shall fabricate the equipment according to the approved design 

drawings submi tt 

ed to the Buyer. 

The Seller shall submit design questions and request design changes in writing 

to the Buyer for resolution or concurrence. 

The Seller shall maintain designated full-size drawing sets for incorporating 

design changes concurred with the Buyer. The Seller shall incorporate all redline 

changes on the drawings and submit both paper and electronic copies of the 

as-built drawings to the Buyer. 

All design calculations required for the ASME piping, suppo rt structure, and lifting 

and handling shall be included in repo rts that have undergone independent 

review by the Seller's qualified personnel. Design calculation reports shall be 

submitted to the Buyer for review and approval before the sta rt of fabrication. 

3.3.12.1.2 As-Built. Drawings 

The Seller shall deliver to the Buyer three hard copies and one electronic copy of 

the final fabrication level as-built drawings and specifications accurately depicting 

the product delivered. Drawings shall include dimensional layouts, dimensioned 

subassemblies, dimensioned component details (if not included on 

manufacturer's cut sheets), flow and electrical diagrams, material and fastener 

sizes, descriptions, weld symbols, and notes_ The designer's name, responsible 

engineer's name, Bill of Materials, and drawing numbers shall appear on the 

index (cover sheet). 

3.3.12.2 Fabrication Traveler Submittal 

The Buyer will inse rt witness and hold points in the fab ri 

cation traveler during 

their review and approval of the fabrication traveler. Witness points can be 

waived by the Buyer, but must be documented in writing. Hold points require the 

Buyer personnel to be present during the fabrication, inspec ti 

on, or test step. 

G5-426 

Page 75 of 161

i leduroIohy 

TECH141CAL SPECIFICATION 



PROJECT NO-: 145579 WET SCRUBBER SKID ASSEMBLY 



3.3.12.3 Schedule and Component Lead Time 

A proposed schedule of fabrication, inspection, and testing of all wet scrubber 

skid assembly equipment shall be submitted for review with the bid and approval 

with the submittal of the fabrication traveler(s). 

A proposed schedule shall be provided showing the discrete steps and schedule 

to complete ail work described in this specification. The schedule shall identify 

fabrication drawings, engineering, parts procurements, fabrication, examination, 

inspection, and testing activities. A list of components and lead time delivery for 

each component shall be provided to the Buyer. Component substitutions can 

be proposed by the Seller to improve the fabrication, schedule, or cost; provided 

such substitutions are approved by the Buyer. 

The schedule shall allow two weeks for review and approval of structural 

calculations and one week for review and approval of all other documents. The 

Buyer shall provide a calculation review sheet identifying requirements for the 

calculations. 

3.3.12.4 Spare Parts List and Special Tool 

Requirements 

The Seller shall provide the following, as required for installation, maintenance, 

and operation of the assembly. 

1. Recommended spare parts list for Buyer concurrence. The spare parts 

lists shall be based on equipment mean time between failures and long 

lead procurement items (long lead defined as longer than four weeks from 

order placement to delivery). 

2. List of required special tools. 

1 Special tools manufactured during fabrication shall also be provided on 

delivery. 

4. List of required lubricants. 

5. Lubricant required for startup and operations shall be delivered with 

Material Safety Data Sheets and shall be provided on delivery of.related 

equipment. 

WET SCRUBBER SKID ASSEM3LY DESIGN AND FABRICATION Page 76 of 101 

03-Nov-05 

G5-427

_. 

rRr1ualone 

SPECIFICATION 







Submit spare parts, special tool, and supporting vendor data for review and 

approval. 

3.3.12.5 Final Data Package 

The Seller shall not ship the skid assembly and ancillary hardware until all tests 

and inspections including the FAT have been performed and the final data 

package is complete and approved by the Buyer (as defined in Appendix F). 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. The final data package shall include all 

items specified on the Bidder's Drawing and Data Commitments sheet 

(Appendix F). 

3.3.13 Personnel and Training 

Records for the following areas shall be prepared and made available for the 

Buyer. Review of the qualifications may be subject to a surveillance or source 

inspection by the Buyer. 

3.3.13.1 Welder Qualification 

Welder shall be qualified in accordance with ASME B&PV Code, Section IX and 

AWS D1.1/131.1 M, as applicable. Documentation' for personnel performing 

welding, including tacking, shall be maintained in a Welder Performance 

Qualification Record. 

3.3.13.2 Weld Examination 

Welds shall be examined per ASME 831.3 at a minimum for piping and pipe 

supports and per AWS D1.1/D1.1M for structural steel An ASME 831.3 weld 

examiner shall meet the code requirements. Welded connections on the lifting 

components shall be 100 percent visual and 100 percent Dye-Penetrant Test or 

Magnetic-Particle Test inspected. 


03-NOV-05 

G5-428


PROJECT: Final DBVS Design 145579-DSP-037 REV. 1 




34.13.3 Electrical Inspection 

The Hanford Site CH2M HILL NEC® Electrical inspector shall inspect equipment 

fabricated under this contract that is not NRTL-listed or labeled. All deficiencies 

found shall be corrected or dispositioned before shipment. 


03-Nov-05 

G5-429

^t 




PROJECT: Final DBVS Design 145579-D-SP-037 F REV. 1 




4 QUALITY ASSURANCE REQUIREMENTS 

The following subsections provide the minimum QA requirements for this 


4.1 GENERAL 

4.1.1 Des6gn 

The Seller shall document, implement, and maintain a QA Program that identi fies 

the activities and items to which it applies. The QA Program must address each 

of the areas discussed within this QA requirements flowdown. The Seller must 

submit the QA Program to the Buyer for review before award of contract. 

The Seller shall assess its QA Program regularly to ensure its effective 

implementation. 

The QA Program shall provide for indoctrination and training, as necessa ry, of 

personnel performing activities affecting quality to ensure that suitable proficiency 

is achieved and maintained. Personnel who conduct inspection and test 

activities shall be qualified to conduct those activities and ce rtification of the 

qualification must be submitted to the Buyer on request. 

The Seller must define, control, and ver ify designs developed for this contract. 

Design inputs must be specified and correctly translated into design documents. 

Design interfaces must be identified and controlled. Persons who did not design 

the item must be used to verify design adequacy. Design changes, including 

field changes, must be reviewed and approved by the same personnel who 

reviewed and approved the initial designs. 

4.1.2 Procurement Document Control 

Procurement documents must include or reference sufficient quality and 

technical requirements in order to describe the items and services requested. 

Procurement documents must be reviewed and approved by the authorized 

personnel within the Seller's organization, and changes must be reviewed and 

approved by the same individuals who reviewed and approved the original 

procurement documents. 


03-Nov-05 

G5-430

n wuxi)gy 



9 






The Seller must have a process for accepting procured items. This process must 

include one or a combination of the following: Certificate of Conformance, 

source verification, receiving inspection, and post-installation testing. 

The Seller shall provide a legible and reproducible CDC. The CoC shall be 

signed by the Seller's authorized representative responsible for quality 

assurance. 

The CDC shall contain, as a minimum, the following information: 

1. Identification of the Buyer's contract or purchase order number under which 

the materials, equipment, component, or service is being purchased. 

2. Provide traceability by means of positive identification from the material, 

equipment, component, or service to the CDC. 

3. Identify the specific procurement requirements met by the material, 

equipment, component, or service supplied (i.e., codes, standards, or other 

applicable specification). The procurement requirements shall include any 

approved changes, waivers, or deviations applicable to the subject 

materials, equipment, component, or service. 

4. Identify any procurement requirements that have not been met, together 

with an explanation and the means for resolving the nonconformance. 

The Seller's certification system, including the procedures to be followed in filling 

out a certificate and the administrative procedures for review and approval of the 

certificates, shall be described in the Seller's QA Program. 

The certification system shall provide a means to verify the validity of the Seller's 

certificates. 

The Seller is required to flowdown applicable QA requirements based upon a 

graded approach from this contract to any subtler subcontractor/suppliers. Any 

access to the subtler subcontractor/suppliers' facilities for verification activities 

will be requested through the Seller before access, and verification activities may 

be performed jointly. 

The Seller shall warrant that all items furnished under the contract are genuine 

(i.e., new; not refurbished and/or counterfeit) and match the quality, test reports, 


03-Nov-05 

G5-431

^ = lmdogs 



PROJECT: Finai DBVS Design 145579-D-SP-037 I REV. 1 




markings, and/or fitness for intended use as required by. the contract. Any 

materials furnished as pa rt of the contract that the government or other duly 

recognized agency had been previously found to be suspect/counterfeit shall not 

be used. 

All items are subject to inspection at the Seller's facility or lower-tier 

subcontractor's facility. The Seller shall notify the Buyer, at least seven working 

days in advance, of the time when such items or activities will reach the Buyer's 

identified inspection hold points. As a minimum, final inspection before 

packaging for shipment shall be considered such a hold point; unless specifically 

waived by the Buyer. 

The Seller shall obtain all mate ri als to be delivered under the contract directly 

from the original manufacturer or an authorized manufacturer's representative. 

The Seller shall provide legible and reproducible documentation, with the 

materials, that provides objective evidence that the items were provided by the 

original manufacturer. Such documentation may include a copy of the purchase 

order to the manufacturer and shipping documentation or manufacturer invoice 

(each of which would identify that the materials were obtained from the original 

manufacturer). 

The Seller sha ll submit, with or prior to item shipment, a recommended spa re 

pa rts list. The list shall provide the name and address of the o ri ginal supplier of 

the replacement part, and the pa rt's drawings, specification, or catalog identity 

including applicable change or revision information. 

The Seller shall grant access to the Seller's facilities and records for inspec ti 

on or 

audit by the Buyer, his designated representative, and/or other pa rties authorized 

by the Buyer. 

4.1.3 Instructions, Procedures, and Drawings 

The Seller must document and implement appropriate instruc ti 

ons, procedures, 

and drawings. Instructions and procedures must include or reference 

appropriate quantitative or qualitative acceptance criteria for determining that 

prescribed activities have been satisfactorily accomplished. 


03-Nov-05 

G5-432

a p}' 

SPECIFICATION 







4.1.4 Identification and Control of Items 

The Seller shall establish controls to ensure that only correct and accepted items 

are used or installed. 

All items shall be identified with the appilcable part number, model number, or 

other identifier prescribed in this specification. Identification shall be on the item 

or the package containing the item. When the identification is on the item, such 

marking shall not impair the service of the item or violate dimensional, chemical, 

or physical requirements. 

The Seller shall submit a legible and reproducible copy of the product data sheet 

(e.g_, drawing, catalog cut sheet, brochure) that provides adequate information to 

enable the Buyer to verify the form and function of the articles procured. One 

copy of such documentation, unless otherwise specified, shall accompany the 

item. 

The Seller shall identify each item, assembly, package, container, or material, 

having limited shelf life, with the cure date or date of manufacture and the 

expiration date. The Seller shall specify any storage temperatures, humidity and 

environmental conditions that should be maintained. Material shall not be 

furnished having less than 75 percent of the total shelf life available at the time of 

shipment. 

4.1.5 Control of Processes 

The Seller shall have processes to control processes, including special 

processes that control or verify quality (e.g., welding, heat treating, and NDE). 

Special processes must be performed by qualified personnel using qualified 

procedures in accordance with specked requirements, 

Seller personnel performing weld inspections shall be certified as a Certified 

Welding Inspector (CWI) in accordance with the requirements of AWS QC-1. 

The following documentation shall be submitted for Buyer approval before the 

start of fabrication: 

1. Current AWS CWI certification; 

2. Current(valid visual acuity examination (must be given every three years); 

and 


03-Nov-o5 

G5-433




PROJECT NQ.: 145579 WET SCRUBBER SKID ASSEMBLY 



3. Visual weld inspection procedure(s). 

Welding procedures and personnel shall be qualified in accordance with 

applicable AWS or ASME requirements specified in the contract. The Seiler shall 

submit copies of all welding procedures; procedure qual ification records, and 

welder qualification records to be employed. Buyer review and approval of these 

documents is required before start of fabrication. 

Nondestructive examination personnel shall be qualified and certified in 

accordance with the recommended guidelines of ASNT SNT-TC-1A. The Seller 

is not authorized to begin fabrication until the following documentation has been 

approved by the Buyer: 

NDE personnel qualification and certification procedure; 

2. Level I, II, and/or III personnel qualification and certification records, 

- including objective evidence of NDE training, formal education, 

examination, experience, date of hire, and current visual acuity exam; and 

3. NDE method procedure(s) compliant with the applicable requirements of 

the Buyer's contract. 

Nondestructive examination reports and radiographs shall be traceable to the 

item examined, shall include all essential examination parameters, and shall be 

signed and dated by a qualified/certified NDE examiner. All NDE reports and 

radiographs shall accompany or preceded shipment of the item or component. 

Radiographs and radiographic technique and examination reports shall be 

subject to approval by the Buyer before shipment. 

These requirements shall be passed to lower-tier subcontractors. 

4.1.6 Verification and Verification Methods 

The Seller shall have a process to plan and execute inspections to verify 

conformance of an item or activity to specified requirements. The process shall 

document the characteristics to be inspected and inspection methods to be 

employed. The Seller shall document the results of inspections. Inspections for 

acceptance shall be performed by persons other than those who performed or 

directly supervised the work being inspected. 


03-NOV-05 - 

G5-434 

r 

Page 83 of 109

ffited>y 






CLIENT:. AMEC E&E -Richland, Washington 

The Seller shall submit, as required by the contract, legible, reproducible copies 

of inspection and/or test reports. The reports shall include, as a rninimum, the 

following information: 

1. Identification of applicable inspection and/or test procedure; 

2_ Resulting data for all characteristics evaluated, as required by inspection or 

test procedures, including reference to information on action taken in 

connection with nonconformances; 

1 Traceability to the item inspected/tested (e.g., serial number, part number, 

lot number), date of inspection, name of inspector, type of observation; and 

4. Signature of the Seller's authorized representative or agency performing 

the inspection or test. 

4.1.7 Test Control 

The Seller shall have a process (to plan and execute tests) to verify conformance 

of an item or activity to specified requirements. The process shall document the 

characteristics to be tested and test methods to be employed. Tests required to 

collect data, such as for siting or design input, shall be evaluated. 

The Seller shall prepare a detailed test.plan. Before starting work, the plan shall 

be submitted to the Buyer for approval and insertion of Buyer's designated 

source inspection and witness notification points. The test plan shall provide the 

following, at a minimum: 

1. Traceability to the Buyer's purchase/contract order document number, 

2. Name or description of the item to be tested (e.g., components, 

assemblies, subassemblies); 

3. Method/procedure to be used during test; and 

4. Subsequent revisions/modifications to the test plan require review and 

approval by the Buyer before implementation of the changes. 


03-Nov-05 - 

G5-435 

Page 84 of 101

tedan&gy 



eme 





The Seller shall provide test reports that include, as a minimum: 

1. Item tested, 

2. Date of test, 

3. Tester or data recorder, 

4. Type of observation, 

5. Results and acceptability, 

6. Action taken in connection with any deviations noted, and 

7. Person evaluating test results. 

Test plans and test reports must be submitted to the Buyer for the project 

records. 

4.1.8 Control of Measuring and Test Equipment 

The Seller shall control tools, gauges, instruments, and other measuring and 

testing equipment used for activities affecting quality, and shall calibrate at 

specified periods and adjust to maintain accuracy within necessary limits. 

The Seller shall maintain legible, reproducible copies of the Certificates of 

Calibration, traceable to the NISI. Each Certificate of Calibration shall be signed 

by the Sellers representative responsible for calibration, attesting to its 

authenticity, and shall be identified with the following information: 

1. Buyer's contract number, 

2. Identification of the article to which the Certificate of Calibration applies, 

and 

3. Standards used for calibration- 


03-Nov-05 

G5-436

1. 

4 



me 





In addition, the Seller shall submit a report of actual calibration results. The 

report shall be identifiable to the acceptance criteria of the items submitted and 

shall meet the contract requirements. The report shall contain the signature of 

the authorized representative of the agency verifying compliance. One copy of 

the documentation, unless otherwise specified, shall accompany the applicable 

item(s) shipped. 

4.1.9 Handling, Storage, and Shipping 

The Seiler shall prepare and submit for Buyer review and approval, before use, 

procedure(s) or plan(s) for the packaging and shipping of materials, equipment, 

or components to be furnished under the Contract. The procedure(s) or plan(s) 

shall include, as appropriate, cleanliness inspection before packaging, use of 

preservatives and coatings, descriptions of specially designed shipping 

containers, handling and rigging data, final inspections, and the type of transfer 

and shipping vehicles. 

4.1.10 Inspection, Test, and Operating Status 

The Seller shall have a process to identify the status of inspection and test 

activities on items or in documents traceable to the items, and to ensure that 

items which have not passed the required inspections and tests are not 

inadvertently installed, used, or operated. Status shall be maintained through 

indicators (i.e., physical location) and tags; markings, shop travelers, stamps, 

inspection records, or other suitable means. The Seller must specify the 

authority for application and removal of tags, markings, labels, and stamps. 

4.1.11 Control of Nonconforming Items 

The Seller must have a process to control items that do not conform to specified 

requirements to prevent inadvertent installation or use. These controls must 

provide for identification, documentation, evaluation, segregation (when 

practical), and disposition of nonconforming items, and for notification to affected 

organizations. 


03-Nov--05 

G5-437 

Page 86 of IGI

mi g tedurobogr 




PROJECT: final DBVS Design 145579-D-SP-037 REV.1 


DESIGN AND FABRI CATION 

CLIENT: AMEG ERE -Richland, Washington 

All nonconforming conditions identified at the Seller's facility, with a proposed 

disposition of "Accept-As-Is" or "Repair," as defined below, shall be approved by 

the Buyer before supplier implementation of the nonconformance report (NCR) 

disposition: 

1. Accept-As-Is: Nonconforming materials will perform its intended function. 

2. Repair: Nonconforming item can be corrected so that its characteristics 

meet requirements of the contract. 

Nonconforming items identified as `Repair" or "Rework" shall be re-examined in 

accordance with applicable procedures and with the original acceptance criteria, 

unless the nonconforming item disposition has established alternate acceptance 

criteria. 

Nonconformances shall be documented by the Seller on their own 

nonconformance form or one provided by the Buyer. After documenting the 

nonconformance and providing a proposed disposition and technical justification, 

the report shalt be submitted to the Buyer. 

After the proposed disposition has been evaluated, and approved or rejected by 

the Buyer, the form shall be returned to the Seller. Corrective action may only 

take place after Buyer approval. Copies of completed, Buyer-approved, NCRs 

shall be shipped to the Buyer with the affected item_ 

4.1.12 Corrective Action 

The Seller shall have a process to promptly identify conditions adverse to quality, 

and to correct them as soon as practical. The identification, cause, and 

corrective action for conditions adverse to quality shall be documented and 

reported to appropriate levels of management. Follow-up action shall be taken to 

verify implementation of this cor rective action. 

During the period of performance of work for this contract, the Seller shall 

provide, to the Buyer, copies of all documents that constitute reports of 

conditions adverse to quality (e.g., deficiencies, weaknesses, nonconformances, 

or noncompliances with established requirements) related to items or services 

provided to the Buyer. 

- WET SCRUBBER SKID ASSEMBLY DESIGN AND FABRICATION Page 87 of 161 

03-Nov-D5 - 

G5-438

a = 

103AoF' 







4.1.13 Quality Assurance Records 

The Seller shall have a process to specify, prepare, and maintain records that 

furnish documentary evidence of quality. Records shall be legible, identifiable, 

retrievable, and protected against damage, deterioration, or loss. The process 

shall establish and document responsibilities and requirements for records 

transmittal, distribution, retention, maintenance, and disposition. 

4.1.14 Control of Graded Fasteners 

The following are minimum requirements for high strength graded fasteners 

produced in compliance with national consensus standards (i.e., SAE, ASTM, 

ASME): 

1. Fasteners shall exhibit grade marks and manufacturers identification 

symbols (headmarks) as required in the specifications referenced in the 

contract. 

2. When requested by the Buyer, the Seller shall provide legible and 

reproducible copies of the manufacturers Certified Material Test Reports 

(CMTR). These CMTRs shall report the values of the actual chemical and 

physical tests performed on the represented fastener lot and material heat. 

Fastener packaging and labeling shall be traceable by lot number or other 

means to the CMTR. 

3. Fasteners shall be inspected and documented to verify compliance with this 

QA Clause. Additionally, fasteners may also be subject to destructive 

testing by the Buyer to verify compliance. 

4.2 INSPECTIONS AND TESTS 

Each component, instrument, sensor, and valve shall be tested to verify that it is 

functional. In order to complete these functional check-out tests, the Seller will 

have to provide temporary power and switches for each valve activation and 

component activation circuit in the system. Compressed air or bottled nitrogen is 

also required for pneumatically-actuated valves. All electrical devices shall be 

tested from the skid junction box to the end device and all instrumentation shall 

be tested from the skid junction box termination. 

WET SCRUBBER SKID ASSEMBLY DESIGN AND FABRICATION Page 88. of 101 

03-Nov-05 

G5-439 

#s1

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eme 





Dated calibration labels shall be visible on all test equipment. Measuring and 

test equipment used for acceptance inspections and tests shalt be controlled in 

accordance with the Seller's QA Program and shall be traceable to a national 

measurement standard. 

4.2.1 Electrical Testing 

The following sections detail the requirements for electrical testing. 

4.2.1.1 Motor Test 

All motors shalt be given a routine test to demonstrate that the motors are 

installed correctly and free from mechanical and electrical defects. Motor tests 

shall be performed in accordance with the Seller's standard practice. Tests shall 

include but are not limited to: 

1. Motors shall be designed and tested by the manufacturer. Certificates of 

Conformance and/or certified test results shall be supplied for the following 

tests: 

a. Rated load readings of current, power, and speed at rated voltage and 

frequencies; 

b. No load readings of current, power, and speed at rated voltage and 

frequencies; 

C. Mechanical vibration and motor balance test results in accordance 

with NEMA MG 1-12.06; 

d. High potential test results in accordance with NEMA MG 11-12.03; and 

e. 1000V do Megger test for one minute, phase to ground. 

2_ Motors shall be checked for correct rotation and incoming power terminals 

shall be labeled by phase for proper rotation. 

4.2.1.2 Wiring and Breaker Test 

All wiring and breakers shall be given routine tests to demonstrate that they are 

free from mechanical and electrical defeats. Wiring and breaker tests shall be 


03-Nov-05 

G5-440

tecimofoas 







performed in accordance with the Seller's standard practice. The Seller shall 

provide wiring and breakers test data that include, but are not limited to: 

1. Megger tests are required for all electrical power wiring; 

2. Continuity testing is required for all electrical power and instrumentation 

wiring; and 

3. Circuit breakers are to be inspected for proper size, correct installation, 

manual operation of handles, and suspect/counterfeit parts. 

4.2.1.3 Instrumentation Testing 

Each instrument will be tested for proper operation. This may require applying 

temporary power, a 4-20-mA loop with indicators, or other methods to verify 

proper indication and function. All signals that are fed to the termination panel 

shall be verified at the termination panel. The device should be tested with fluid 

to physically activate the devices for detecting level, pressure, flow, eta, as 

applicable. 

For control loops provided by the MCS, no testing will be required except the 

individual sensors/switches and starters. Example: A level switch feeds the 

Programmable Logic Controller which controls the feed pump. The level switch 

shall be tested, but the shutdown signal to the pump can not be verified without 

the MCS hardware and program, provided later. 

For local control function, the system shall be provided with the normal fluid, 

where practical, to operationally test the control loop. Example: Level interlock 

to the feed pump shutdown will be tested by filling the tank above the level switch 

position and verifying the pump shuts down. 

The Seller shall prepare a log of instruments tested by a certified-Electrical 

Inspector. All testing performed shall be reported to the Buyer in a factory 

acceptance report. 

4.2.2 Remote Operated Valve Tests 

Verify remote operated valves cycle through an open and close cycle and 

achieve their specified fail position on loss of compressed air or loss of electric 

WET SCRUBBER SKID ASSEMBLY. DESIGN AND FABRICATION Page 90 of 101 

03-Nov-05 

G5-441 

h




03-Nov-05. 





CLIENT: AM EC E&E -Richland, Washington 

power. Times from open to closed, and closed to open shall be recorded and 

provided to the Buyer. 

Each valve shall be activated to verify that the valve functions and that valveposition-switch-contacts 

are properly made (using an ohmmeter), The valve 

shall be activated from the skid junction box and verify limit-switch-contacts 

change state at the skid junction box. The Seller shall make a checklist that 

indicates all contacts checked. The Valve-Test Checklist shall be submitted to 

the Buyer for review and approval. The checklist shall include all contacts where 

application of voltage would fire a solenoid, actuate an air-operated valve, and 

change positions between switch contacts. 

4.2.3 Pressure Leak Test 

The wet scrubber skid assembly piping and components shall be pressure-leak 

tested to 1.25 times the maximum operating pressure of the system (negative 

r and positive.). Water used for hydrostatic testing shall be tested for chlorides 

before use. The chloride content of the test medium shall not exceed 250 ppm 

for water temperatures of 149 °F or less. 

Results shall be recorded and shall be submitted to the Buyer with test 

records/documents. 

4.2.4 Wet Scrubber System Testing 

The tests (below) may be performed concurrently as practicable. 

4.2.4.1 Wet Scrubber Air Stream Housing 

Testing 

The housing assemblies, including inlet and outlet transitions and ductwork, shall 

be visually inspected in accordance with the requirements of ASME AG-1 (as 

identified in Appendix B) . Observed deficiencies shall be documented on the 

inspection checklist and as a NCR if needed. A corrective action shall be noted 

and re-inspection results documented on the inspection checklist and on the 

NCR disposition. The Seller shalt submit NCRs, as applicable, to the Buyer in 

accordance with the Bidder's Drawing and Data Commitments sheet 

(Appendix F). 

G5-442 

Page 91 of 101

l3n bgl 



came 




CLIENT: FAMEG E&E -Richland, Washington 

4.2.4.2 Scrubber System Structural Capability 

Tests 

The wet scrubber ductwork and housings and complete assemblies, shall have a. 

structural integrity test performed under vacuum. The structural integrity test 

shall be conducted in compliance with ASME AGA as identified in Appendix B. 

4.2.4.3 Ductwork and Housing Leak Tests 

Perform ductwork and housing leakage testing after the Structural Capability Test 

has been successfully completed. Leakage testing shall be in accordance with 

ASME AG-1 as identified in Appendix B. Allowable leakage rate of duct and 

housing sections shall be determined in accordance with ASME AG-1 as 

identified in Appendix B. Maximum allowable leakage shall be in accordance 

with ASME AG-1 as identified in Appendix B. 

., A Buyer's representative may be present to witness the decay leak test of the 

housings. The Seller shall give a minimum of five days advance notice before 

performing the test(s). 

4.2.4.4 Alarm Check 

This check will verify that switches perform as required to specific set-point 

conditions. 

4.2.4.5 Caustic System Check 

This check will verify that the caustic circulation pump functions properly. This 

will also perform a capacity check of the pump to verify the pump is operating 

Within the limits of its pump curve. 

4.2.5 Secondary Containment Leak Test 

The Secondary containment pan shall be static leak tested by filling the 

secondary containment system with water to the calculated fill level and left 

standing for a period of 24 hours. No visible drop in water level or other signs of 

leakage shall be evident. Equipment, wiring, insulation, or other materials that 

may be damaged by the water shall be removed before the test or protected from 

damage. 


03-Now05 

G5-443

s . tCdHJ(k 




03-Nov-05 


PROJECT: Final DBVS Design 145579-D-SP-037 T REV.1 



CLIENT: AMEC E$E -Richland, Washington 

4.2.6 Lift Tests 

The fully assembled wet scrubber skid assembly shall be lifted from a horizontal 

position without incurring any damage. The lifting points shall be shown to 

account for the offset loads, such that the skid assembly hangs with its vertical 

axis within ten degrees of vertical. All lifting accessories or components shall be 

load tested to 125 percent of the rated load capacity. 

Verify the weight and center of gravity of the overall assembly. 

G5-444 

Iffh 

Page 93 of 101

a uv 







5 PRESERVATION AND DELIVERY 

The following subsections provide the minimum requirements for packaging, 

labeling, handling, shipping, and receiving. 

5.1 GENERAL 

Every item that is shipped shall arrive at the jobsite in the same condition when it 

passed all quality control inspections and tests. 

The equipment shall be prepared for delivery to the Buyers specified site located 

near the U.S. Department of Energy's Hanford Site in Richland, Washington in a 

manner that can easily be inspected by the Buyers personnel. The Seller shall 

be responsible for the equipment and associated components provided by the 

Seller through shipping and receiving of the equipment. The Seller shall be 

responsible for any damage that occurred during shipping. 

The equipment will remain the property of the Seller until the Buyer has 

completed a receipt inspection at the Buyer's facility. 

5.1.1 Packaging and Shipping Instruction Manual 

The Seller shall prepare an instruction manual(s) that includes packaging 

information, handling information, shipping information, storage information, 

operational procedures, maintenance procedures, and special assembly 

procedures. The instruction manual(s) shall be submitted to the Buyer for 

approval before shipment. 

A recommended spare parts list shall be prepared and provided to the Buyer. 

5.1.2 Operation and Maintenance Manual 

Provide an Operation and Maintenance Manual containing all information and 

procedures necessary to operate and maintain the assembled system. 

Component manuals and other vendor data such as the following shall be 

provided, as applicable: 

1. One-line diagram, layout drawings, schematic and wiring diagrams; 

2. Illustrated parts lists with manufacturer catalog numbers; 


03-Nov-o5. 

G5-445



.^ 1 

Cl /L 

PROJECT: Final DBVS Design 745579-DSP-037 REV. 1 



CLIENT: AMEGE$E- Richland, Washington 

3. Ce rtified copy of facto ry test results 

4. Recommended maintenance schedule; 

5. Maintenance procedures; and 

6. Operating procedures. 

Submit Operation and Maintenance Manual, component manuals, and other 

vendor data to the Buyer for approval before shipment. 

5.2 PRESERVATION AND PACKAGING 

Before packaging, all residual water present in the systems from acceptance 

testing shall be thoroughly drained and dried by purging oil-free d ry air th rough 

the system. All open pipe ends shall be sealed to prevent ingress of debris and 

vermin into the system. The assembly shall be thoroughly cleaned to remove 

any dirt or dust that may have accumulated on the equipment during testing. 

Defects in the paint shall be touched-up. Moving pa rts shall be secured to 

prevent movement du ring shipping. 

5.3 PACKING 

1. The Seller shall package equipment to protect items during shipping. 

Bracing structures shall be installed where items could be damaged or 

vibrate loose du ri ng transpo rtation. All bracing must be clearly identified, 

both in the packaging instruction and by labeling on the outside of the 

receipt tanks. 

2. Rigging sketches or a handling procedure shall be pre pared by the Seller 

for items that require special handling. These sketches will identify 

weights, sling locations, balance points, methods of a tt 

achment, and other 

information necessary for safe handling. 

3. Packaging or preservative coatings shall be visually inspected after loading. 

Damaged areas shall be repaired. Items shipped with desiccants shall be 

inspected after loading to verify that seats are intact. 

4. Cushioning shall be used where protection from shock and vibration is 

required. Cushioning mate rials shall have sufficient strength to provide the 


03-Nov-05 

G5-446


} Mme 





CLIENT: AMEC ES,E -Richland, Washington 

required protection, shall exhibit no corrosive effect when in contact with 

the item being cushioned, and shall not readily support combustion. 

5. Temporary cushioning, blocking, bracing, or anchoring placed within an 

item for shipping protection that shall be removed before operation of the 

item, shall be identified by a warning(s) placed in a conspicuous manner to 

effect proper removal of the packing material. 

6. Blocking and bracing used for protection of the load shall prevent item 

movement and withstand thrust and impact applied in any direction. 

Blocking and bracing used in direct contact with the item being blocked 

shall not have a corrosive effect on the item. 

7. The weight, lifting points, or center of gravity indicated on the crate, skid, or 

package of major components shall be used to ensure proper handling 

during loading- 

8. Written instructions covering the location and stacking limits of the crates or 

boxes on the transport vehicle shall be specified, as appropriate. These 

instructions should be marked on the container. 

9. Precautions shall be taken to minimize marring of the finish of painted 

surfaces during handling and shipping, as practicable. 

10. Cables, slings, chain falls, etc., shall not be placed where they can cause 

damage to any component part. Mating surfaces, machined areas, etc., 

shall be avoided. 

11. All items shall be protected from the deleterious effects of shock, vibration, 

physical damage, moisture, salt spray, condensation, and weather during 

shipping, as applicable. 

12. Items shall be inspected for cleanliness before packaging. Dirt, oil, residue, 

metal chips, or other forms of contamination shall be removed in 

accordance with Section 3.3.4. Any entrapped water shall be removed. 

13. All openings into items shall be capped, plugged, and sealed with materials 

which perform their intended function without causing deleterious effects on 

the equipment or its operation. 

WET SCRUBBER SKID ASSEMBLY DESIGN AND FABRICATION. Page 96 of 161. 

03-Nov-05 

G5-447

s wdirob9y 



PROJECT`. Final DBVS Design 145579-D-SP-037 REV.1 



CLIENT: AMEC Ei£E - Richland, Washington 

14. Nonmetallic plugs and caps shall be brightly colored. Clear plastic caps or 

plugs are not to be used except when specified. 

15. Plugs or caps shall be prevented from falling into, or being pushed into, 

openings after installation and shah be secured to prevent accidental 

removal. 

16. Items subject to corrosion, either internal or external, shall be suitably 

protected. 

17. Items packed in containers shall be blocked, braced, or cushioned to 

prevent physical damage. 

18. Instrumentation, electrical and electronic equipment, motors, and other 

electrical assemblies and equipment shall be packaged in a waterproof 

enclosure. This maybe the enclosure the item will operate in. For items 

without waterproof enclosures, a vapor barrier shall be placed around the 

enclosure. In either case, the enclosure shall be able to exclude dirt and 

facilitate handling and marking of the item. Barrier materials shall be 

nonhalogenated if used in contact with austenitic stainless steels, shall be 

noncorrosive, shall not readily support combustion, and shall not be, 

otherwise harmful to the item being packaged. Desiccants may be used 

inside the enclosure or vapor barrier. 

19. "Anchoring" of the item within a crate or on a skid means to adequately 

fasten the item during shipment and protect the item from potential damage 

as a result of rough handling. Bolting is preferred. When bolts are used for 

anchoring, the following criteria shall apply: 

a. If precision holes in the item are used for anchoring, properly fitting 

bolts shall be used to prevent marring or elongation of the holes. 

b. Items shall be marked to preserve identity during shipping, receiving, 

and storage per the following requirements: 

L Identification shall be stamped, etched, stenciled, or otherwise 

marked on the item or on tags affixed to the item. 

ii. The marking shall not be deleterious to the material nor violate 

any other section of this specification. 

WET SCRUBBER SKID ASSEMBLY DESIGN AND FABRICATION Page 97 of 

03-Nov-05 

G5-448

n in t ..- 







iii. When tags are employed, they shall be of material that will 

retain the marking and withstand weathering deterioration and - 

other normal shipping and handling effects. 

20. Items not specifically covered by these requirements shall be handled in 

accordance with sound material handling practices. 

5.4 MARKING 

Packages shall be properly and clearly marked. At a minimum, the required 

information shall include the contract number, the name and equipment number 

of the item within the package, the actual weight of the package and its contents, 

and the orientation of the equipment within the crate. Each package shall be 

labeled as part of the entire shipment, such as "Crate 1 of 2." 

5.5 HANDLING 

The Seller shall lift equipment using a forklift or crane, using the lifting points 

designed for that purpose. 

5.6 SHIPPING 

The Seller's truck driver shall carry bills of lading for each shippable unit that is 

delivered to the Buyer. 

The Seller shall obtain approval to ship from the Buyer before the equipment is 

prepared for shipment. 

5.7 RECEIVING 

The Buyer's agent will perform a receipt inspection on receipt of the equipment at 

the Buyer's specified site. 

This receipt inspection shall consist of the following: 

1. Verify all parts are present and not damaged during shipping_ 

2. Documentation review—determine that documentation required by contract 

to accompany equipment is present and traceable to the equipment 

WET SCRUBBER SKID ASSEMBLY DESIGN AND FABRICATION Page 9a of 101 

03-Nov-05 

G5-449 

v


'1 

teciu ctoay t' me 






shipped as required by the Bidder's Drawing and Data Commitments sheet 

(Appendix F). 

The Seller is responsible for accommodating the receipt inspection process by: 

1. Designing and using packaging that allows for easy opening or 

disassembly to reveal the item(s) for inspection, then reclosing to permit the 

same packaging to be used for post-receipt transportation on the Hanford 

Site. 

2. Selecting locations on equipment for identification numbers that promotes 

easy identification without extensive disassembly of packaging materials. It 

is preferred that packaging be marked to indicate the approximate position 

of identification numbers on equipment within the packaging. 

3. Ensuring that all required documentation accompanying the equipment is 

present and obvious on, or within, the packaging. 

WET SERUBSER SIOD ASSEMBLY DESIGNAND FABMCATION 

03-Nov-05 

G5-450 

Page 99 of 101

s , M10g 







6 NOTES 

1. Unless otherwise specified, equipment furnished under this section shall be 

fabricated and installed in compliance with the instructions of the 

manufacturer. 

2. The Seller shall ensure that all equipment, accessories, and installation 

materials comply with the specification and that adequate provision is made 

in the skid assembly design and fabrication for mounting the specified 

system equipment and accessories. 

3. The Seller is solely responsible for construction means, methods, 

techniques, sequences, procedures, and safety precautions and programs. 

4. The Seller shall provide all labor, equipment, and material required to 

provide a complete and functional system. 

5. To avoid delays in construction, the Seller shall ensure that all components 

of the system are available to meet the required schedule. 

6. The Seller shall obtain necessary permits, arrange for inspections, and 

obtain approval of the appropriate Seller's local "Authority Having 

Jurisdiction' over the work described. 


03-NOV-05 - 

G5-451

tedludo 




IPROJEGT: Final DBVS Design 145579-D-SP-037 I REV.1 

IPROJECT NO.: 145579 WET SCRUBBER SKID ASSEMBLY 



7 APPENDICES 

The following appendices make up part of this specification: 

Appendices Description 

A Drawings and Sketches 

B ASME AGA Compliance Requirements 

Cam—Example Data Sheets 

C D TFC-ESHQ-Q_C-C-03 Revision C-2, Control of 

_Suspect/CounterfeitItems 

E Request for Information 

F Bidder's Drawing and Data Commitments 

G Instrumentation Naming and Tagging Convention 


Q3-Nov-05 

G5-452

! tedu 



PROJECT: Final DBVS Desi n 145579-D-SP-037 I REV. 1 

PROJECr NO.: 145579 WET SCRUBBER SKID ASSEMBLY 


CLIENT: AMEC EBÊ -Richland, Washington 

_ 

^^ €S `43 

Appendix A 

Drawings and Sketches 

a %. ^"' H z 3°Yt e "'" 

z., ,4 .yk"4i 'YU.*. i :.9'y u 'sS y rWk4 3^ 

F-145579-00-A.-0099 I 1 Bulk Vit ri 

fication P&ID "Typicals' Legend 

F-145579.00-A-0100 N 1 Bulk Vitrification P&ID Symbol Legend 

F-145579-00-E-0107 C 1 Bulk Vitri fi 

cation Off-Gas Caustic Pump Schematic 

Diagram 


cation Off-Gas Caustic Pump Wiring 



cation Off-Gas Caustic Mixer Schematic 


F-145579-00-E-0108 C 2 Bulk Vitri fication Off-Gas Caustic Mixer Wiring 


F-145579-00-E-0111 C 1 Bulk Vitrification Scrubber TK Pump No. 1 

Schematic Diagram 

F-145579-00-E-0111 C 2 Bulk Vitrification Scrubber TK Pump No. 1 Wiring 


F-145579-00-E-0179 C 1 Bulk Vit rification Off-Gas HEPA Heater 

Schem/Wiring Diagram 

F-145579-36-A-0100 L 1 Bulk Vitri fication Wet Scrubber Skid No. 1 P&ID 

F-145579-36-A-0102 L 1 Bulk Vitri fi 

cation Off-Gas Trailer Scuubber Filter 

P&ID 

H-14-106796 0 1 Bulk Vitrification Off-Gas Area FDNS — Plans & 

Sections 

DBVS-SK-E104 E 1 DBVS Scrubber Skid One-Line & Grounding 


DBVS-SK-M103 B 1 Bulk Vitrification HIHTL Penetration Details 

rEs Y 

kl^ Qf` 


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G5-467






Appendix B 

ASME AG-1 Compliance Requirements 



03-Nov-O5 

G5-468

"' 


ASME-AG-1-2003 CODE ON NUCLEAR AIR AND GAS TREATMENT 

COMPLIANCE REQUIREMENTS 

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AA-1130 

SCOPE (AA-1100) - Purpose; Applicability; Definitions and Terms 

z a 

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Referenced Documents 

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These requirements are applicable to equipment housings and ductwork. 

-Ô y 4 1 G1' R 10 11I G t W1 ti { IG s ^: 1NG ^, EGA 11 C O IN 

; 

, 

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a N Q I IY.'^'TAL. + 

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AA-6110 G ENERAL (AA-6100) — Scope and Applicabili ty; Materials; Control of 

To Fabrication and Installation Processes 

AA-6130 These requirements are applicable to equipment housings and ductwork. 

AA-6200 FABRICATION PROCESS (AA-6200) — Cutting; Forming and Bending; 

To Forming_ Tolerances; Fitting and_Alignin^ 


AA-6240 FABRICATION PROCESS (AA-6200) —Welded Joints 

_ These requirements are applicable to equipment housings and ductwork. 

AA-6250 FABRICATION PROCESS (AA-67.00) — Mechanical Joints 

To 

AA-6258 

hese requirements are applicable to equipment housings and ductwork. 

_ 

AA-6300 WELDING REQUIREMENTS (AA-6300) - General; Workmanship; 

to Inspection and Testing of Welds 


AA-6400 BRAZING (AA-6400) - General; Workmanship; Cleaning; Inspection and 

To Testing 

AA-6434.1 These requirements are applicable to equipment housings and ductwork. 

AA-6500 CLEANING AND COATING (AA-6500) — General; Su rface Preparation; 

To Coating; Repair of Coating System; Inspection; Quality Assurance 

AA-6560 Reg uirements and Documentation 

These requirements are applicable to equipment housings and ductwork. 

AA 6600 INSTALLATION REQUIREMENTS (AA-6600) — Handling and Rigging 

To 

AA-661 0 _ 

hese requirements are applicable to equipment housings and ductwork. 

AA-6620 INSTALLATION REQUIREMENTS (AA-6600) — Field Assembly & 

To TemDorarV Field Attachments__ 


r,"` w 

w,.AA^700t1 PA IN SHWIIIN"E.0,0.VlN.STORaG:^; AI^D'H.,NDLING,:: — - — 

AA-7100 GENERAL (AA-7100) — Scope and Applicability; Responsibility 

To GENERAL REQUIREMENTS (AA-7200) — Planning, Procedures, and 

AA-7410 Instructions; Personnel Qualifications; Classification of Items 

PACKAGING (AA-7300) — General; Level of Packaging 

SHIPPING (AA-7400) - General 

Documentation verifying compliance with NQA-1 is not required. This 

requirement shall be met in accordance with Tank Farm Contractor QAPD 

procedures. 

♦A 

.: 8Q,V0^^r e^, 0.0 ^" ClAWM "A^7.a^ fShtNM'.' 

AA-8100 GENERAL (AA-8100) — Scope and Applicability; Responsibility; 

To Responsibilities of Fab ricators, Material Suppliers, and Material 

AA-8130 Manufacturers 

B-2 

G5-470 

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The manufacturer(s)s quality assurance (QA) program shall meet the 

requirements of ASME NOA 1 or may be based on another accepted 

industry standard that meets the requirements of ASME NQA-1. 

The tank farm contractor evaluates vendor QA programs for acceptability. 

Vendor QA programs can be based on QA program requirements other than 

ASIWE NQA-1 as long as the vendor's QA program is shown by evaluation to 

be equivalent to being based on NQA-1. As the requirement is stated, the 

quality assurance program do not have to be certified in accordance with 

A SME NQA -1, as long as the requirements specified as applicable in 

rocurement documentation are addressed. The tank farm contractor has a 

quality assurance program compliant with ASME NQA-1 and has experience 

in evaluating quality assurance programs. The tank farm contractor's gradeo 

approach causes consideration of the ASME AG-1 requirements for quality 

assurance, and is used to establish the applicable QA program requirements 

assed to vendors in procurement documents. Guidance on the use of a 

graded approach to quality is provided in ASME NQA-1, Appendix 2A-2, 

Section 502. 

QA program requirements are flowed down to vendors through procurement 

documents. Additional quality assurance requirements of speci fic items are 

passed on by the tank farm contractor as applicable. 

The tank f ar m contactor has procedures in place for assuring fabricators, 

material suppliers, and material manufacturers deliver the intended product. 

Records and documentation for QA program compliance are generated and 

retained in accordance with the tank farm contractor's QA pro 

, 

AA-8200 IDENFIFICATION AND CONTROL OF ITEMS (AA-8200) — Documentation; 

To Identification and Completed Item; Marking Requirements for Small 

AA-8300 Products; Geftified-Material-T-est-Repert ; Records of Examinations and 

Tests 

QUALITY ASSURANCE RECORDSLAA-8300) 

his requirement shall be met in accordance with the speci fication and Tank 

Farm Contractor QAPD procedures. Control of welding fi ller metal shall be 

in accordance with approved welding procedures. Certified Material Test 

reports are riot required. 

AA-90:00 "NAmfPL7ATEs - 

ÀND STAM P 1 A, - 

AA-9110 GENERAL_ 00) — General; Requirements; Attachment of Nameplates; 

To Location of Nameplates 

AA-9140 This requirement shall be met in accordance with this speci fication and Tank 

Farm Contractor procedures. Manufacturer's standard nameplates shall he 

required. Information required by ASME AG-1, such as capacity and 

operating temperature and pressure may be impractical for manufacturers to 

include on component nameplates. Standard nameplates include adequate 

information necessary to verify correct installation, such as make, model 

number, and serial number. This information also allows traceability to 

additional technical information, if required, during system operation. 

Nameplates attachments by standard industrial practices follow this 

requirement. During assembly, any nameplate that interferes with operation 

is relocated as appropriate. 

Nameplates may not be shown on drawings. Showing the nameplate 

location on manufacturer's drawings may be impractical- Compliance with 

the other provisions of this section ensures adequate accessibility to the 

B-3 

G5-471 

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his section encompasses the minimum requirements for the design, 

abrication, materials, pe rformance, acceptance testing, and quali ty 

assurance, as well as component nomenclature, for dampers and louvers 

used as components in nuclear safe ty-related air or gas treatment systems 

in nuclear facilities. Also included in this section are minimum design 

speci fication requirements for actuators and other control-related 

accessories used in conjunction with nuclear safe ty-related dampers and 

louvers. _ 

Purpose: The purpose of this section is to identify and establish the 

requirements for the design, manufacture, shop test and installation of 

dampers and louvers for use in air and gas treatment systems which are 

associated with nuclear facilities. 

This, section further identifies and establishes requirements for the 

installation of actuators and accessories and for the pe rformance of a 

,damper and louver assembly. 

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DA-1210 Exclusion of Items: Valves whose design, manufacture, test, and installation 

are covered by the ASME Code, Section 111, or ASME B31.1, are excluded 

from this section even though they may be used to pe rform the function of a 

DA-1220 

damper. — 

Exclusion of Specific Designs: While certain minimum functional 

requirements of damper actuators and accessories are included in this 

section, it is not intended to include specific dimensional or material design 

— for these items. 

--- -- 

requirements 

. 

DA-1230 Bounda ry Limits: The requirements of this Code are limited to those pa rt s 

which comprise a damper or louver assembly as defined in DA-1310. While 

general requirements are included for mating flanges and similar suppo rts, 

the boundary limits are the damper or louver assembly, flange, or frame. 

DA :30Qs t DEF llV1. 1 141 WO 

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DA-3110 Materials of Construction: Materials used in the construction of frames, 

blades, shafts, and linkages shall conform to requirements of specifications 

or materials given in Table DA-31 10. 

DA-3120 AIIUNable Stress: Allowable stress values for the design of frames, blades, 

shafts, and linkages are specified in A rticle AA-4000. 

At temperatures above 650 °F (343 °C) for ferrous material or 200 °F (93 °C) 

or nonferrous material, the special limitations cited in DA-3211 shall apply. 

DA-3130 Bearing Materials: Bea ring materials shall conform to the requirements of 

DA-4250. 

DA-3140 Seal Materials: Seal mate ri als shall conform to the requirements of DA-4260. 

k.QA^320Q.,_k . - ÎAI >LIMI;TATIONS'ON tuIATERIALS.._ rw i^ 4..-.- .,.^:`_ . srr 

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DA-3211 Ph c al P roeriies Reduction 

DA-3212 Galvanic Corrosion 

DA-3213 _Corrosive Vapors 

DA-3220 Non metallic Materials 

DA-3230 Deterioration of Materials in Service 

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DA-3300 Certification of Materials: The Manufacturer shall make available, as a 

minimum, se0 ef1ed ^ t st FepoF sef-e I-properties-ef 

atE. ria l and hardwaFe foF stiress Go., 10RtS SUGh as related-a GGesseries 

'nsluding frames b ' a d'e° sha4s-,ar+E4ipka9es---For those ASTM materials 

which do not have physical testing required by the ASTM specification, 

testing should be performed per ASTM A370. All Ether cornoonents used in 

he construction of the damper shall be provided with a manufacturer's 

e rti;icate of compliance covering the ASME or ASTM material speci fication, 

rade, and class , if applicable. 

Damper materials shall be in conformance with the allowable materials of 

SME AG- 1, Table DA-3100. Manufacturer's Ce rtificates of Conformance 

with the ASMF- or ASTM designations of Table DA-3100 shall be provided. 

Certified test reports shall not be required. 

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DA 4 .00' ' 

DA-4100 General Design: Design of dampers and louvers shall be in accordance with 

he requirements of Section DA and of those po rtions of Section AA invoked 

_ in Section DA. 

DA-4110 Requirements of Design Speci fication: Design specifications prepared by the 

Owner or his designee in sufficient detail to provide a complete basis for 

design and manufacture in accordance with this Code shall include, as 

---applicable: 

DA-4120 DA-4120, Requirements of the Manufacturer: 

When required by the design speci fi cations, documentation provided by the 

Manufacturer to the Owner or his designee shall include the fo llowing, as 

applicable: 

a through (o) 

DA X130 ;;.ERFORMAN;At~QuREMENTS 

DA-4131 Seat Leakage: Seat leakage shall be equal to or less than the amount shown 

in Mandato ry Appendix DA-1 for the class specified in the design 

DA-4132 Frame leakage: Frame leakage shall be equal to or less than the amount 

shown in Mandato ry Appendix DA-1 for the class specified in the design 

_ 

DA-4133 


Pressure drop: Pressure drop shall be less than or equal to that stated in the 

desuln speci fication at the design volumetric flow ra_te .__ 

^q yygH p e 

DA-4131 Fire Ratings 

DA-4135 Fire Damper Closure 

DA-4136 C cle Time 

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DA-4212.2 Documentation: 

The damper or louver Manufacturer shall be responsible for providing all 

information necessa ry to define the support bounda ry inte rfaces. The 

interface control information to be specified shall include but not necessarily 

be limited to the following: 

DA-4212.2 (a) Identification of any special support requirements as well as the 

configuration and size of the damper Flanges; 

DA-4212.2 (b) magnitudes and directions of all loads imposed on the anchorage points, 

including ail static, dynamic, and operational loads resulting from the 

installed assembly. Load data shall be provided in a form which shall allow 

combinations to be considered as required in A rticle AA 4000. 

DA-42122 (c) Other information, such as bending moments, shear forces, axial loads, 

torsional moments, or stiffness requirements necessa ry to assure that the 

damper or louver can pe rform its required safety function under all design 

DA-4213 Loads (entire section): 

Loads to be considered are as given in AA-4211 and AA 4212 with the 

following clarifications 

DA-4213.1 Normal Loads 

DA-4213.2 Thermal Loads 

DA-4213.3 Other Loads 

DA-4214 Structural Ve rification: 

The technical and documentation requirements of AA-4000 shall apply to 

erification of design by analysis, test, or comparison. 

DA-4215 Special Considerations 

DA-4220 Thermal Expansion 

DA^•4230r, z" '0RQUEV .. 

--- --- — --- — ----- — ^ 

DA-4231 Torque Determinations: In determining the torque required to actuate the 

blades, the Manufacturer shall consider the blade position and direction of 

he applied torque to produce 'he desired movement. At the maximum 

specified operating pressure this determination shall include, as a minimum, 

the following torque components: 

a) breakaway torque 

b) dynamic torque 

c} friction torque 

_d) seating torque 

DA-4232 Actuator torque: The Actuator and associated linkage shall deliver to the 

damper or louver a minimurn of 1 -112 times the maximum torque as 

determined in DA-4231, except for self-contained actuators used to 

counterbalance a specific force, and must be designed to match the required 

torque. Actuators shall be evaluated in both directions for the maximum 

torque, at the beginning of the blade movement, while stroking the blades 

through the full range of movement. 

044Z403' >^.>CNKAGE..^. 

DA-4241 Linkage Components 

DA-4242 Linkage Design: Linkage design shall include the following minimum 

--requirements: 

DA-4242 (a) Brackets, arms, and levers shall be of a length and sti ffness to provide stable 

operation of the blades at the maximum specified operating pressure and 

airflow without flu tter or binding at all blade positions. 

DA-4242 (b) The linkage system shall be designed to transmit sufficient torque to each 

blade to set the seals of each and eve ry blade at the maximum speci fied 

operating pressure and airflow to limit leakage to less than the specified 

leakage. 

DA-4242 (c) All linkage components shall be designed to transmit a minimum of 1-112 

Imes the torque required by DA-4231 without exceeding the allowable stres 

listed in Article AA-4000. 

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DA-4242 (d) If a linkage system is designed to be field adjustable, suitable locking 

devices such as jam nuts, etc., shall be provided. 

01 

DA-4242 (e) The linkage system shall be designed to be compatible with the actuator 

selected for the application, 

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DA-4251 (a) Bearings shall permit axial shaft movement to provide for operating 

^ 

learances and differential expansion in both vertical and Horizontal 

installations. 

6A-4251 (b) Bearing materials shall be selected for the loading and environmental 

conditions to which the bea ri ngs will be subjected. 

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D_A 4252.2 Nonmetallic Sleeve Bearings - 

DA-4252.3 Rolling Element Bearings 

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DA4253 (a) Bearing running su rfaces of sleeve bea rings shall have a finish as 

__ _ recommended by the bearing Manufacturer. 

- 

DA-4253 (b) Sleeve bearings shall be contained to prevent axial displacement and to 

DA-4253 (c) 

rev.ant rotational movement except between the intended_bearing surfaces. 

Sleeve bearings shall have a bearing load surface di aer metdifference 

as 

recommended by the bea ri 

DA-4253 (d) 

_ 

ng Manufacturer. 

Sleeve bearing wall thickness shall be as recommended by the bearing 

Manufacturer. 

DA 4253 (e) Rolling element bearings shall be sized to allow bearings to be slipped onto 

the shaft. The maximum clearance in shaft diameter shall be as 

(recommended by the bearing Manufacturer, plus clearance for thermal 

ex ansion. 

s DA;454. 

DA-4254 a 

Bearrng L:oadmg`" 

Sleeve bea ring loading on 

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DA-4294 ( b) - 

DA-42 54 (c) - - 

DA-4254 (d) - Y— -- 

--- --- 

DA-4254 e 

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DA-4261 General: Seals may be utilized to reduce seat leakage and frame leakage to 

the degree required by the design specification " The control of seat leakage 

requires seals such as metal or elastomer blade edges, stops, or seats. 

Control of frame leakage may require shaft seals such as stuffing boxes or 

over dates. 

- 

DA-4262 Design - - - — 

DA-4263 Material -^ -- 

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DA-4271 Frame Construction Class A or _B 

DA-4272 Gasket and Packirig Material Requirements 

DR`4si. MdUNTIN QEgGTUAT..URAND AC.CESSOf^^'ES f: 

DA-4281 Mounting Structure 

DA4282 ccessibility - 

DA-4283 Mounting Structure Mate ri al: - 

The structure for mounting actuators and accessories shall be fab ricated of 

mate rial listed in Table DA-3 1 10. Structures shall be designed as required 

_ ^y Article AA-4000. 

DA-4284 Pachment of Actuators and Accessones: 

tuators and accesso ries shall be attached to the mounting structure with 

removable fasteners, of materials listed in Table DA 3 110, sized to conform 

^_ _ 10 the stress limitations stated in Article AA-4000. 

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DA-4285 Linkage Adjustability: The actuator mounting or linkage shall per adjustment 

to achieve the required positioning of the blades at each end of the actuator 

movement. 

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DA-4311 Torque Required 

DA-4312 Forces and Loads on Actuators 

DA-4313 cceleration and Deceleration Loads 

DA-4314 Actuator Voltage or Pressure Load Rating 

DA-4315 Power Actuator Speci fication Requirements 

DA-4320 Manual Actuators: Manual actuators should be equipped with locking 

devices and position indicators.— 

--DA-4321 -- Torque Requirements: 

Manual actuators shall be capable of delivering the torque required by DA- 

232. Manual actuator components shall be sized as required by Article AA- 

00-D. 

DA-4322 Forces and Loads on Actuators 

DA-4323 Maximum Input Forces 

DA-4330 Self-Contained Actuators 

DA-4340 Heat- or Femperature-Operated Actuators 

. I . I 444 P 11 . 

DA-4410 Accessory Requirements: As required by the design speci fi cation, the 

damper or louver assembly shall be provided with appropriate accessory 

e qu -ient 

pm to provide proper function and performance of the assembly. 

DA-4420 Auxiliary Energy Source: When required by the design specification, 

actuators shall be provided with an auxiliary energy source, such as springs, 

counterweights, or accumulators. 

A-4430 Modulating Actuator Requirements: When required by the design 

specification, actuators for modulating service shall be provided with a pilot 

positioner or similar device to assure controlled positioning of the damper in 

resoonse to the control signal. 

DA-4440 Position indicators: When required by the design specification, local position 

indicators shall be provided to enable surveillance and operability 

verification. 

DA-4450 Environmental Design Requirements: Electrical devices such as position 

indicating switches, limit switches, and all other electrical components shall 

comply with the applicable IEEE standards stated in the design specification. 

All cther pneumatic, hydraulic, Z other type of accessories shall be suitable 

for the environment speci fi ed in the design specification. 

DA-4460 Piping of Pneumatic Actuators: 

DA-1470 Electrical Wiring Requirements 

0 --* 606 INSPECTION 'A 

DA-5000 Inspection and testing of louvers and dampers shall be in accordance with 

the requirements of this Article and of AA 5100, AA-5200, AA-5300, AA- 

5410, AA-5500, and AA 5800. The Manufacturer shall be responsible for 

establishing the written visual examination procedures and necessary 

tolerances to ensure that the products are built to the Manufacturers 

drawings. Examination procedures shall include appropriate checklists to 

verify that the required observations were performed. Written reports of 

visual inspection shall contain, as a minimum, the require rents of AA 5200. 

DA-5100 Testinq 

DA-`5110 Pressure Drop Testing 

DA-5121 Re wired Cycles: 

DA-5122 Pneumatic Air Pressure: 

DA-5123 C ycle Time: 

E EPffTLTION 

B-8 

G5-476 

..............

DA-5124 erational Requirements 


ASME-AG-1 .2003 CODE ON NUCLEAR AIR AND GAS TREATMENT 


Frame Leakage Testing for Frame Leakage Classes A and B 

DA-5140 Seat Leakage Testing 

DA-5141 Seal; Leakage Test for Leakage Class 0 Dampers (Bubble Method) 

DA-5142 Seat Leakage Test for Leakage Class 11 or I II Dampers or Louvers 

DA-5143 Seat Leakage Test for Leakaqe Class I Dampers 

15A-5144 Fire Dam 

per Closure Test 

Nt'pk 14 -LIAM70 

DA-6000 Fabrication, Finishing, and Installation — General: 

Article AA-6000 shall apply for fabrication, finishing, and installation, except 

that the design and seismic qualifications of the damper assembly are based 

on the damper assembly being adequately supported for the appropriate 

loads. The Owner or his designee shall provide supports for the damper 

assembly to ensure that the damper is adequately supported as required by 

the Manufacturer's requirements and DA-4212. All of the welding codes or 

standards listed are allowed. In addition, installation of Underwriters 

Laboratory (UL) fi re dampers shall be in accordance with the Manufacturer's 

UL installation instructions. 

DA-6100 Welding and Brazing: ------- 

Spec,i fi c welding and brazing parameters shall conform to the requirements 

of Article AA-6000. 

.:">^ QA47 P-;, KKAd IN 

DA-7000 Packaging, shipping, and storage of damper and louver assemblies shall be 

in accordance with the requirements of Article AA-7000. Implementation 

requires an ANSI /ASME NQA-2 classification level for packaging, shipping, 

receiving, storage, and handling of all items. 

Packaging, shipping, and storage of damper and louver assemblies shall be 

in accordance with Article AA-7000. Implementation requires an 

ANSUASIVIE NQA-2 classification level for packaging, shipping, receiving, 

storage, and handling of all items. Such classi fi cation is as follows: 

(a) dampers or louvers only: Level C 

(b) electric actuator: Level B 

(c) actuator, other than electric: Level C 

(d) accessories: Level B 

(e) dampers o r louvers with electric actuators or accessories: Level B 

Manufacturer's recommended practices in accordance with procurement 

documents and procurement procedures that incorporate the features of this 

section as applicable. 

L SSURA j4 

DA-8000 Quality Assurance of dampers and louvers shall be in accordance with the 

requirements of Section DA and Article AA-8000. 

-DA41 

00--- Damper and Louver Performance: Documentation shall be established to 

verif/ that damper and louver performance complies with the testing criteria 

of DA-5000. 

DA-8300 QUalit Assurance Records 

B-9 

G5-477 

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So^cRgîrer ex^ 

DA-9000 Article AA-9000 requirements for nameplates, stampings, and manuals shall 

apply, except that the nameplate shall require only the following information: 

a) Manufacturer's name 

(b) E=quipment, tag, or mark number information as supplied by the 

purchaser 

(c) Size 

All items manufactured under the requirements of this Section shall be 

identified to assure compliance with the requirements of Subarticle AA-8200, 

and Suba rticles AA-9130 and AA•'9140. Records, as necessa ry to assure 

compliance with Sub-a rticle AA-8200, shall be maintained by the responsible 

_ _ organization in accordance with the approved quality assur ance program. 

D9100 A- Nameplates and Stampings: 

DA-9200 Manuals: -- 

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SA-4211 Normal Operating Pressure Differential (NOPD): 

For ease of design, a duct system may be designed using one pressure 

alue that envelopes NOPD and SOPT (AA-4211). NOPD and SOPT may 

be positive or negative pressures. Worse case shall be considered in the 

SA-4211 Seismic loads (SL): 

Loads that are the result of the envelope of the operating basis earthquake 

(OBE) and the safe shutdown earthquake (SSE). As overall system 

functionalism is not generally compromised by loads from the OBE, the SSE 

will govem the design. As an option, the OBE, and SSE may be considered 

separately with the OBE loads used for the Level B load combination. The 

horizontal and ve rtical components of the seismic excitation shall be app lied 

simultaneously in the direction that will produce worst-case stresses and 

deflections. These components may be combined by the square root of the 

__sum of the squares (SR S) method. 

SA-4211 Hydrostatic loads from accumulated condensate, water deluge systems, or 

moisture separators: The hydrostatic load shall be conservatively 

established by documented analysis base on ductwork configuration, 

accessories, and component function. Hydrostatic load shall be added to 

_ 

he dead weight as applicable _ 

SA-4211 Design Pressure Differential (DPD): 

The dynamic pressure loads resulting from a design basis accident (DBA), 

intermediate break accident (IBA), or small break accident (SBA). Generally, 

HVAC should be routed outside the local pipe break a ffected area. If HVAC 

is subjected to these loads, the Design Specification (SA- 4600) shall 

address the station specific design requirements considering a Service Level 

NA 

_ 

D combination. 

SA-421 1 For component load crite ri a see the following sections: 

(1) HEPA filters — FC-4300 

2) Mounting frames — FG-4200 

3) Fans — BA-4000 

4) Dampers — DA-4000 

( 5 ) Refrigeration equipment -- RA-4000 

(6) Conditioning — CA-4000 

(7) Moisture separators — FA-4000 

(8) Pre- fi lters — FB-4000 

9 Instrumentation — IA-4000 

SA-4212 Ductwork Load Combinations: 

NA 

The applicable component loading shall be combined in accordance with 

Table SA-4212. 

SA-4214 Design and Service Limits: NA 

he requirements of AA-4214 apply. 

SA-4215 Ductwork Suppo rt Loads: 

Loads per SA-4211 for L, NOPD, SL DW, EL, and ADL shall also be used for 

duc t, suppo rts. Hydrostatic loads shall be treated as DW load when the 

loads have an effect on the suppo rts. Hydrostatic loads as de fined in para. 

SA-4211 (g) shall be treated as a DW load when the loads have an effect on 

he suppo rts. The fluid momentum load as defined in para. SA-4211 (c) is 

not ly icalâ significant load for suppo rts ands be ne lected. 

SA-4216 Ductwork Suppo rt Load Combinations: 

The applicable suppo rt shall be combined in accordance vvith Table SA- 

216. 

SA-4220 

Stress Crite ri a: 

The ductwork stress shall be based upon the AISI "Speci fications for the 

Design of Cold Formed Steel Structural Members-" The ductwork suppo rt 

stress shall be based upon the AISC "Specification for the Design, 

Fab rication and erection of Structural Steel for Buildings." 

B-13 

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SA-4243 Tolerances- 

Installation and fabrication tolerances for duct-work shall be accounted for in 

the design of the ductwork and supports. Fabrication tolerances shall 

omply with SA-6400. 

SA-4244 Permanent Attachments: 

The attachment design shall include all Service Conditions and Load 

combinations set forth in SA-4212 and SA-4213, or as required by the 

Design Specification- The permissible types of welded joints shall be in 

accordance with AWS D1.1, or AWS D1.3, as applicable. Attachments may 

be either the welded or bolted type and shall be considered as follows: 

SA-4244 (a) Welded Attachments: 

Consideration shall be given to local stresses induced in tho ductwork by 

integral attachments as defined in AA-4243. For items used as part of an 

assembly for the support or guiding of ductwork, the materials shall be 

compatible for welding, see Article AA-6000. 

SA-4244 (b) Bolted Attachments: 

MM 00 - 

>, 

^V^ti iR' 

Consideration shall be given to the mechanical connection and local 

stresses induced in the ductwork by nonintegral attachments as defined in 

paragraph AA-4243. The design of bolts for structural supports s hall meet 

the requirements of Sub-article AA-4360. 

SA-4310 Ductwork Joints and Seams—General: 

Selection of joints and seams used in the assembly of ductwork sections 

shall be based on the required Structural integrity, leak tightness, and the 

fluid flow within the system. Duct-housing interconnections shall he 

d signed with consideration of the air distribution ulniformi . 

,^vA-4320 ,Duct JomCs grid Searriii 

SA-4321 The following longitudinal seams are acceptable for use in ductwork sections NA 

subject to the limitations of SA-4324. 

(a) groove weld 

(b) lock type 

(c) Pittsburgh lock 

_(d) Fillet weld 

SA-4322 The following longitudinal types of transverse joints are acceptable for use in 

ductwork sections: 

(a) welded flange 

(b) companion angle 

(c) Vanstone flange 

1(d) Welded Coupling_ 

SA-4323 Other types of rigid transverse connections may be acceptable provided that 

the structural characteristics are documented by engineering evaluation and 

tested per SA-5400 

& 

SA-4324 (a) Longitudinal seams and transverse joints whose structural integrity is NA 

dependent on the folded or punched metal, shall be pressure tested. Test 

pressure shall be the structural_ capabilit 

SA-4324 (b) Longitudinal seams using sealants or elastomers to meet the leakage 

requirements shall be qualified by test, analysis, or test and analysis to 

assure meeting the design criteria of SA-4600. Brazed welding may 

for sealing purposes. 

B-15 

G5-483 

H 

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SA-4325 Bolts and Fasteners: 




Requirements for bolted connections of duct-to-duct and duct-to-housing, 

ith a design pressure differential less than 15 in, w.g. shall be as follows: 

(a) Maximum bolt spacing shall be four inches on center unless otherwise 

speci fi ed by the Design Speci fication. The adequacy of bolt spacing 

greater than four inches on center, for pressure boundary integrity, shall 

be documented by calculation or testing. 

(b) Minimum bolt diameter shall be three-eighths inches unless otherwise 

specified by the Design Specification. The adequacy of bolt diameters 

less than three-eighths shall be documented by calculations or testing. 

SA-4325 (a) Requirements for bolted connections for duct with design pressure 

differentials exceeding 15 in. vv.g. shall be determined by calculations or 

----testing. 

SA-4325 (b) Nontiolted, nonwelded type fastening devices (e.g., screws, rivets, etc__) shallr 

have their adequacy demonstrated for the load combinations of SA-4212 

and documented by calculation or testing. 

SA-4325 (c) Bolted connections shall be verified as being capable of sustaining all 

loaclinR combinations using an appropriate stress intensification factor. 

SA-4410 Flexible Connections: 

SA-4410 

Flexible connections shall be designed to meet the requirements for design 

given by SA-42-12, SA-4500_ ,i44d-NFPA 90A. Allowable leakage (fabric 

leakage and _joint Ieakage^ shaHbe determined in accordance with SA-4500. 

Flexible connections shall be rated by pressure and qualified life. The 

qualified life shall be determined by testing, or calculation, or both and be 

based on the environmental conditions provided by the Design Speci fi cation. 

Minimum physical properties (i.e., tensile strength", subje ct to degradation 

due to the environments required to satisfy design, shall be the basis of 

(11-1alified life. 

SA-47410 Flexible le)— connection pressure rating shall be determined by an ultimate NA 

strength test. The pressure rating of the connection shall be no greater than 

50'/; of burst pressure. Calculation of burst pressure can Lie don e in lieu of 

he test. Burst pressure shall exceed structural capability pressure. 

SA-4410 If adhesive i-s-used in fabrication or installation of flexible connections, it shall 

be environmentally conditions. 

SA-4420 Gaskets: 

Gaskets shall be made of materials which are compatible with the Service 

Conditions (see SA-4600). Gasket material dimensions shall be based on 

joint. design. An acceptable criterion for compression of gasket material shall 

be established on the basis of the gasket chosen. This acceptance criterion 

and the service life of the gasket material shall he documented by an 

___ enqineerinq evaluation or testing_ 

SA-4430 Access Doors and Panels: 

Construction of doors/panels and door frames shall be selected to meet the 

allowable leakage determined in SA-4500. Sealing surfaces between the 

door/panel frame shall be designed for compression sealing. The design 

shadI incorporate means for adjusting compression forces, gasket 

compression, and alignment. 

SA-4430 (a) Spacing of hinges, latches, and bolts shall _beW determined by calculation or 

test to ensure a uniform compression of the gasket. Spacing shall enable a 

compression of at least 50% of nominal gasket thickness and provide a 

__ g et compression uniformity(2f+/-20"/"_ 

SA-4430 (b) Door hinges shall be de s igned to minimize damage to compression seals 

due to friction and shear forces during and closing of the doors. 

SA-4430 0 Dogs, hinges, latches, etc. shall be designed such that lubrication materials 

shall not enter the interior of the ductwork. 

B-16 

G5-484 

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SA-4441 Provisions for Testing and Maintenance—Test Ports. 

The engineer shall evaluate the design function of the equipment to 

determine where test ports (including injection and sampling po rts) are 

_ re u ired. 

SA-4451 Miscellaneous—Drains: 

a) Consideration shall be given to drains depending on requirements, 

services, or components within ductwork. 

(b) Drains form as integral part of the ductwork system pressure bounda ry 

and are subject to air leakage requirements establish ed in SA-4500. 

SA-4452 Insulation: - 

-a) Insulation shall be provided as required to ensure air conditioning 

function, limit condensation, or provide acoustic noise . reduction. 

(b) Acoustic lining and thermal insulation shall not be applied to the inside 

of ducts which may become contaminated during nonnal plant 

operations. 

c) Insulation applied to the outside of ducts shall not prevent access to 

doors, access hatches, or other components requiring adjustment or 

maintenance. 

(d) The fi re hazard classi fication of applied insulation, adhesive, and sealer 

shall not exceed a flame spread of 25 and smoke developed of 50 in 

accordance with NFPA-90A 

(e) Insulation shall be attached to ductwork using a method which will not 

adversely affect the systemlcorn onent safe ty fu nction_._ 

SA-4453 it Distribution Devices: NA 

Des!gn of air distribution devices and their attachments shall comply with 

SA-4200 and AA-4300. The performance rating of air distribution devices 

shall be determined by actual tests pe rformed in accordance with the Air 

Diffu sion Council standard listed in SA-2000. 

SA-4454 Security Barriers: NA 

The requirements for internal and bullet resistant barriers installed for the 

purpose of security shall b e. consistent with appropriate federal regulations. 

Consideration shall be given to the impact (pressure, noise, etc.) the 

installation of security and bullet resistant barriers will have on the overall 

pe rformance of the air treatment system in which they are installed. The 

dead weight of the security and bullet resistant barriers shall be included in 

he desig n of ductwork supports. 

SA 4510 Pressure Boundary Leakage—General 

Pressure bounda ry leakage shall be limited that allowed by the system 

functional and environmental design requirements. Allowable leakage for a 

system, or portion of a system, shall be determined considering the following 

actors (as a minimum): 

a) control of airborne contamination 

b)–con}tr4-4spase pree 

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SA-4520 Applicability: 

Pressure bounda ry leakage shall apply to air cleaning, air cooling, and 

enfilation systems. Each system's pressure bounda ry shall include, but not 

be limited to, the following items as applicable: 

(a) ductwork as defined I Suba rticle SA-1130; 

(b) fan housings; 

(c,) damper frames and valve bodies (and seats, where used for 

pressure bounda ry isolation); 

(d) heatiFig-ar4-GGeling-seif-housings (or f;a ps EIuG nted 

(e) mounting frames for components used for the reduction of 

radioactive contamination; 

(f) instrumentation or other components connected ':o the ductwork; 

c) air cleaning unit housings_ 

SA-4531 Evaluation—Responsibili ty : 

The Engineer shall evaluate each systern to establish the allowable leakage 

Ito assure its design ventilation, temperature, and contamination control 

function is achi evable. 

SA-4532 Allowable Leakage Determination: 

The following criteria shall be utilized in the determination of allowable 

leakage: 

(a) application of governing codes, regulations, and plant. speci fic 

requirements; 

(b) consideration of each system's operating mode, including anticipated 

system upset conditions such as rapid closure of dampers; 

{c) normal and maximum operating static pressures throughout the 

pressure bounda ry; and 

_ d system internal and externa l environmental conditions. 

SA-4 533 Exceptions to Leakage Requirements (however, all audible leaks shall be NA 

sealed): 

(a) all ducts serving the protected space and located within a protected 

space, regardless of length; 

(b) plant vent stacks or ducts outside plant buildings, when high level or 

mixed mode release credit is not required to meet off-site dose limits; 

(c) systems which provide air cooling or heating function only located 

entirely in a clean interspace; 

(d) other exceptions to quantitative measurement of leakage requirements 

shall be technically justified and specifically documented with basis by 

_ the Owner or his agent. 

SA-4534 Documentation. 

Evaluation for allowable leakage of each system, or po rtion thereof, shall be 

documented. This documentation shall include the following: 

(a) identification of system or po rtion of system 

b) governing codes, regulations, and plant specific requirements 

c) purpose of leakage control; see SA-4510 

d) system modes of operation 

(e) normal operating pressure di fferential (NOPD) and system operating 

pressure transient (SOPT) 

(f) method of derivation of allowable leakage 

c test pressures and associated allowable leakage 

SA-4540 Leakage Testing: 

hen specified for a system, shall be pe rformed in accordance with SA- 

530t:) and Section TA of this C ode. 

B-18 

G5-486 

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SA-4600 Design Specification: 




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design specification shall be prepared which consists, as a minimum, of 

the following information which is relevant to the ductwork and ductwork 

supports covered by this Section: 

(a) loads as defined by SA-4211; 

(b) environmental conditions 

(1) ductwork external design environmental conditions including 

pressure, temperature, relative humidity, radiation exposure, and 

hostile environmental factors for all plant conditions; 

(2) ductwork intemal design environmental conditions for all system 

operating conditions; 

(c) service conditions as defined by AA-4213; 

(d) design and service limits as defined by AA-4214; 

t 4 

(e) allowable ductwork leakage, as de fi ned by SA-4500; and 

(f) system safety related function: Identify the function of the ductwork 

system for each plant condition. The function shall consist of purpose 

and operational parameters (i.e., flow, leakage, pressure, temperature.) 

Plant conditions and service limits are defined by AA-4213 and AA- 

4214. 

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SA-5100 General: 

Inspection and testing shall be in accordance with the requirements of Subarticles 

AA-5100, AA-5200, AA-5300, TA-3300, and the additional 

requirements of this Section. 

SA-5120 Responsibility for Procedures: 

When an inspection or test is required herein, written inspection or testing 

procedures shall be developed (by the parties performing the test or 

inspection), to the specified requirements of this Section. The inspection or 

testing shall be performed by personnel qualified in accordance with ASN 11' 

SNT-TC-1A as amended by ASME NQA-1 and AA-6433. 

SA-5210 Visual Inspection—General Requirements: 

Visual Inspections shall be performed in accordance with AA-5200 and TA- 

35M 

SA-5220 Welded Connections: 

Inspection and testing of welds shall be performed in accordance with AA- 

5300 and AA-6000. 

SA-5230 Ductwork: 

Duclwork shall be visually inspected for proper dimensions- including 

tolerances, as required by SA-6500 and governing construction documents. 

Ductwork fabrication shall meet the applicable requiremen ts of SA-6000. 

SA-5231 Joints and Seams- 

Joints and Seams shall be visually inspected. Acceptance criteria shall be 

as follows: 

(a) Joints and seams shall comply with the requirements of SA-6400 and 

SA-6500. 

(b) Gasketed joints shall provide uniform gasket compression. Gaskets 

shall be installed per construction documents. 

c Brazed joints shall comply with the requirements of AA-6430. 

d) Longitudinal or transverse welded joints shall comply with the 

requirements of SA-5220. 

e) Threaded fasteners shall be provided with locking devices in 

accordance with AA-6258. 

B-19 

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SA-5240 Stiffeners: 

Stiffeners shall be visually inspected to ensure compliance with the following 

acceptance c ri teria: 

a) Stiffeners shall comply with the fab rication and installation requirements 

of SA-6000. 

(b) Welds shall comply with the requirements of SA-5220. 

c) Threaded fasteners shall be provided with locking devices in 


Removal of tempora ry attach _ ments shall be con fi rmed. 

SA-5240 Ductwork Suppo rts: 

Suppo rts shall be visually inspected du ring installation, after installation, or 

both in accordance with the following acceptance crite ri a: 

(a) Supports shall comply with the fabrication and installation requirements 

of SA-6400 and SA-6500. 

(b) Welded joints shall comply with the requirements of SA-5220. 

(c) Threaded fasteners shall be provided with locking devices in 


__(d) Removal of tempora ry attachments shall be confirmed_.__ 

SA-5300 Pressure Boundary Leakage Testing—General: 

SA-5310 The ductwork: system shall be tested to demonstrate compliance with the 

design leakage requirements identified in SA-4500, unless exempted by SA- 

53 3. 

SA-5320 Systems Completeness: 

Prior to testing, the system shall be complete including all pressure boundary 

items identified in SA-4520, with the following exceptions: 

(a) Terminal air distribution devices may be excluded from the test. 

(b) Pressure bounda ry items not yet installed may be excluded from the 

testing with the approval of the Engineer. In such cases, prototype 

testing shall be pe rformed to determine the typical leakage rate for the 

installation method. Detailed procedures shall be prepared to control 

installation of items not tested with the system. Procedures shall specify 

any hold points, special su rface preparation or finish, and final 

inspection requirements to ensure that the itern is installed similar to the 

proto type. Typical leak test values shall be increased by a factor of 10 

percent and added to the actual leakage in the test repo rt , and noted as 

such. 

(c) Systems may be testes in sections, if necessa ry , as allowed by SA- 

5330. Testing shall be in accordance with SA-5 3_00. 

SA-5330 Allowances for Testing System Leakage Rates by Sections: Tempora ry 

isolation at a transverse joint shall be allowed subject to the following 

requirements: 

(a) Traverse joints not subjected to a quantitative leak test shall be 

companion angle type or other types which enable visual inspection of 

the sealing mechanism between mating ductwork sections_ 

(b) Assembled joints utilizing mastic or liquid sealant shall be visually 

inspected to ensure uniformity of gasket compression. 

c) Assembled joints utilizing mastic or liquid sealant shall be visually 

inspected to ensure that such mate rial has been applied in accordance 

with the procedure approved by the Engineer. 

d) The reduced allowable leakage (Lr) of ductwork sections shall be as 

_ follows: Lr = Ls - R.... 

SA-5340 esUng Procedures: 

Prior to pressure bounda ry leakage testing, test procedures shall be 

developed in accordance with TA-3400. All test equipment shall be specified 

with the proper range and required accuracy. Test procedures shall include 

acceptance ante criteria determined by SA-4500, and SA-5320 and SA-5330. 

B-20 

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SA-5350 Documentation: 

test report shall be prepared to document the pressure bounda ry leakage 

est. This report shall include, as a minimum, the following information: 

a) system or po rtion of system tested; 

b) speci fied allowable leakage and test pressure; 

(c) calculations for ductwork square footage for systems tested by sections; 

(1) adjustments to allowable leakage per SA-5330 (d); 

e) measured leak rates; 

(f) list of pressure bounda ry components which were not installed during 

the pressure bounda ry leakage test; 

g) test equipment used; including Model No., Serial No., and evidence of 

calibration; 

(h) names of test personnel; 

SA-5361 

(9_ date of test. 

Quantitative Leakage Tests: 

Acceptance criteria for quantitative leakage tests shall comply with SA-4500 

— — and SA-5350(d). 

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Non-quantitative Leakage Tests: 

For non-quantitative leakage tests allowed by SA-4533, the acceptance 

criteria shall be that audible leaks ha ve been sealed. 

- --- 

SA-5410 Ductwork Pressure Test: 

pressure test shall be performed at the structural capability pressure per 

A-3522. This test pressure shall be maintained for the cluration of the 

inspection. Upon completion of this pressure test, duct-work and equipment 

exhibiting permanent disto rtion or breach of integrity shall be repaired or 

replaced. The pressure test shall be repeated after repair or replacement 

until no permanent disto rtion or breach of integrity is observed. This test is 

not required if duct construction allowed in the SMACNA standards listed in 

Article SA-2000 for the system operational pressure trans ient ( S OPT). 

SA-5420 Longitudinal Seam Qualification Test: NA^ 

Ductwork utilizing folded or punched metal longitudinal seams, shall be 

pressure tested to qualify the structural design capability of those seams. 

I his pressure test shall be conducted at the beginning of fab rication and 

before any ductwork with these seams is installed in the facility. The 

pressure test shall be conducted on each sheet metal gauge utilizing these 

seams. Seams shall be tested at the structural capability pressure for the 

system(s). 

SA.GQO^ _. FAI3RIC4TIOIAt+1. ^1VA^LAT[0^k ^ .. .... ....: a^....b .. Cst` 


Ductwork and suppo rts shall be fabricated and installed in accordance with 

SA-6121 

his Section and A rticle AA-6000_ 

Mate ri al Selection: 

Materials used in fabrication and installation performed under this Section 

shall conform to the requirements of SA-3000__ 

SA-6122 Material identification: 

Materials to be utilized in the fabrication and installation of components, 

parts, and appu rtenances shall be identified on fabrication or installation 

y 

SA-6123 

lan_s, or both and in the specifications, as_re_ — qui red i n AA-8000. 

Repair of Material With Defects: 

Material with defects that are discovered or produced during the fab ri cation 

and installation process may be used, provided the defects are repaired in 

accordance with the requirements of AA-8000, and for weld repairs, in 


SA-6130 Control of Installation and Fabrication Process: 

Quality control procedures shall be prepared and maintained current for all 

abrication and installation processes in accordance with the requirements of 

-8000. 

-- - - — 

B-21 

G5-489 

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The welding of ductwork and ductwork supports shalt comply with the 

requirements of AWS D1.1, AWS D1-3, AWS-D9.1 and A 13ME Code, Section 

IX, as applicable. Welding and brazing performed in accordance with this 

Section shall meet the requirements of AA-6300 and AA- 6400. 

SA-6210 Fabrication Process--Cutting, Forming, Bending, Aligning, and Fi tting: 

a) Uncoated metal may be cut, formed, or bent by any means that does 

not degrade the mechanical or chemical properties of the material. 

(b) Coated metal may be cut, formed, or bent as described in SA-6211. 

Coating damaged by scratches, gouge marks or the removal of coating 

shall be repaired in accordance with AA-6540. 

c) Inside bend radii shall not be less than the values given in the 

approp ri ate ASTM standard for the mate ri 

al grade. 

(d) Parts that are to be joined may be fitted, aligned and retained in position 

during the joining by the use of bars, jacks, clamps, drift pins, tack welds 

or other tempora ry attachment. The fitting and alignment process shall 

not cause damage to the joined parts, or their su rfaces, or cause 

enlargement of bolt holes greater than 20% of hole diameter, or 118 in., 

whichever is greater. 

(e) Tempora ry welded a ttachments shall be completely removed after each 

use- They are subject to the following requirements: 

(1) Material shall be suitable for welding with no reduction in the 

structural integrity of the member to which the attachment is 

secured. 

(2) Attachment material shall be identified as required by SA-3000 

(3) The welder and welding procedure shall be qualified in accordance 

with SA-6140. 

(4) The immediate area around and including the tempora ry 

attachment shall be marked in a suitable manner so that after 

attachment removal, the area can be examined in accordance with 

SA-5000. 

I(f) 

Access doors and access panels shall be fabricated and designed to 

(g) 

meet the design requirements of SA-4000. 

Grilles, registers, diffusers and their accesso ri es shall be designed to 

meet the desiqn req uirements of SA-4000. 

SA-6300 Mechanical Fastening—General: 

SA-6310 (a) Nuts for all bolts and studs shall be engaged for the full length of the nut 

thread. Margins shall be allotted to prevent nut from engaging the 

unthreaded portion of bolt or stud. 

(b) High strength bolts, used in making bolted joints, shall be installed in 

accordance with the requirements of the "Specification for Structural 

Joints Using A325 or A490 Bolts" AISC Code- Standard bolts used in 

making bolted joints shall be installed in accordance with the 

requirements of paras. 1 4.4 and 1.5.2 of the "Specification or the 

Design, Fabrication and Erection of Structural Steel for Buildings" AISC 

Code. 

(c) Self-drilling or self-threading screws are permissible if they are qualified 

in accordance with the design crite ri (d) 

a in SA-4000. 

Rivets must be quali fi 

e) 

ed in accordance with SA-4000. 

Pins for secu ri ng insulation should be secured to the metal su rface by 

welding. Other attachment methods are acceptable, if allowed by the 

Design Specification. Justification of the method of a tt achment used 

shall be suppo rted by evaluation or calculation, considering the 

requirements of Suba rticle SA-4600. 

(f) Flange faces shall be free of joint crevices at corners. These defects 

shall be e li minated by welding and grinding. 

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SA-6400 Fabrication Tolerances—General: 

SA-6410 The fabrication of ductwork shall be accomplished within tolerances detailed 

in the following tables. These fabrication tolerances provide a method of 

quality control. Installation tolerances listed below are maximum deviations 

permitted from design dimensions. Greater deviations, due to rol ling mill 

olerances are not permi tted. 

a) Rectangular ducts, measured inside the duct at the joint end or stiffener, 

shall conform to Table SA-6400-1. 

(b) Circular ducts, measured by outside circurnference or two interior 

diameters at 90 deg. (+/- 5) to each other, shall conform to fable SA- 

6400-2. 

(c) After fabrication is complete, flat sheet or plate su rfaces shall not have a 

waviness, or bulge, greater than the flatness tolerance given in Table 

SA-6400-3. 

(d) The tolerances given in -Tables SA-6400-1, 2, and 3 are for 

manufacturing. Maximum operating deflections are given SA-4230. 

(e) Holes prepared for joining mating Flanges shall not exceed the required 

bolt diameter by more than 20%, or 1/8 in., whichever is larger, of bolt 

diameter. The center-to-center alignment of holes rnust be held to meet 

this tolerance or one flange must be drilled. Hole spacing shall be a 

maximum of 4 in. center-to-center, with holes at corners of the flange. 

(f) Grilles, registers, and diffusers shall be fabricated to manufacturer's 

_ 

dimensions and tolera_n_ce_s._ 

SA-6500 Installation Tolerances: 

Ductwork and their supports shall be installed within the tolerance specified 

by approved construction documents. 1 hose tolerances shall comply with 

he design requirements of SA-4000. 

SA-6600 Cleaning, Finishing, and Coating: 

Galvanized surfaces shall be free of damage which impairs the effectiveness 

of the coating. Su rfaces shall be repaired in accordance with AA-6540. 

Painted su rfaces shall be prepared and fi nished as described in AA-6000. 

Painted su rfaces shall be free of scratches and welding damage. Surfaces 

shall be repaired and repainted in accordance with AA-6000. Required 

marking, for identification, shall be on the exterior o f each section. 

SA=70Q0' ' PACt(AG:ING,:SHIPPLNG; RECEIVING.S,TORAGE; AND HAN©LItJG 7 S 


Packaging, shipping, receiving, storage, and handling requirements shall be 

in a ccordance with Article AA-7000 and this Sectio n. 

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Equipment and material covered under this Section shall be manufactured, 

fabricated, installed, inspected, and tested in accordance with the provisions 

of a Quality Assurance Program meeting the requirements of Article AA- 

8000. 

SA-8200 Mate ri al Identification: 

Measures shall be established for controlling and identifying mate ri al 

throughout the manufactu ring process and during shipment in accordance 

with A rticle AA-8000. 

SA-8300 Drawings and Documentation: 

s a minimum, the following drawings and documentation shall be provided 

to the Owner: 

(a) design parameters 

material cert+fiGatiens 

(c) maximum operating pressure 

d) structural capability pressure 

e) test pressures 

f) basis and quantity for maximum allowable leakage 

y) system layout drawings 

(h) welding procedures 

(i) visual inspection repo rt s 

(j) test acceptance c ri teria 

(k) leak test reports 

(1) environmental qualification repo rt s 

m ductwork and ductwork suppo rt fabricatio n details 

r SA=9000-_ : NAMEPLG^1 E AIyDSTAMPING. =.d. d — - 


All items manufactured under the requirements of this Section shall be 

- 

identified to assure compliance with the requirements of Subarticle AA-8200, 

and Subarticles AA-9130 and AA-9140. Records, as necessa ry to assure 

compliance with Sub-article AA-8200, shall be maintained by the responsible 

Va 

SA-9111 

orcianization in accordance with the approved quality assu rance program. 

Ducts: 

Each duct section shall have noncorrosive, permanent identification 

markings. Identi fication markings shall relate each duct section to the 

applicable design and fab rication documents. Markings shall be located on 

he exterior of the duct. Markings need not be visible after installation is 

complete-, however, markings shall be retrievable. It is recommended that 

the identification markings be placed on the "incoming air" end of the duct 

oint, as close to the end of the joint as possible, and not in such position as 

o be hidden or nonreadable. 

NA 

SA-911 2 Ductwork Suppo rts: 

Each duct support shall have noncorrosive, permanent identi fication 

markings. Identification markings shall relate each ductwork suppo rt to the 

applicable design and fabricat ion documents. 

NA 

SA-9113 Air Distribution Accessories: 

Air distribution devices (i.e., g rilles, registers, diffusers, louvers, etc.) shall be 

mar-ed, stamped or provided with a nameplate which shall relate to the 

design and fabrication documents. Identification shall be retrievable after 

completed installation. 

NA 

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HA-1100 Scope: 

HA-1110 This Section provides requirements for the design, construction, 

HA-1120 pe rformance, fabrication, inspection, acceptance testing, and quality 

HA-1130 assurance for housings and housing supports in nuclear-safe ty related air 

treatment systems. 

Purpose: The purpose of this section is to ensure that the 

housings have acceptable design, pe rformance, and construction. 

pplicability: This section applies to housings containing air cleaning, air 

handling, and air conditioning components. Internal components of housings 

including, but not necessarily limited to, HEPA filters, prefilters, adsorbers, 

moisture separators, cooling and heating coils, dampers, mounting frarnes, 

and fans are covered in other Division It Code sections. 

This section does not apply to sizing of housings, nor does it apply to the 

design of the nuclear air cleaning, air conditioning, or air handling systems in 

which the housings are installed. 

Housing inte rface bounda ries, as applied to this section are shown on Figs. 

HA-1120-1, HA-1120-2, and I IA-1 120-3. Inte rface boundaries occur 

between housing penetrations and external piping, instrumentation, and 

conduit. Interface bounda ries also occur between internal and external 

components and structural support members directly attached to the 

housing_ 

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HA-3100 Allowable Materials (General Requirements): 

HA-3110 (a) Material used shall have properties and composition suitable for the 

application as defined by the Design Specification and the service 

conditions, as defined in AA-4213. Materials shall be in conformance 

with the ASME and the ASTM mate ri als listed in Table HA-3100. 

Substitute materials shall be approved by the Owner or designee. 

(b) Materials that are part of the pressure bounda ry or equipment support 

shall meet the structural requirement of HA-4000. 

(c) Materials expressly prohibited or limited shall be explicitly described in 

_ the Design Specification. 

HA-3111 Protective Coatings: 

II carbon steel su rfaces shall be painted to protect against corrosion and to 

facilitate cleaning and decontamination. Coatings shall comply with the 

requirements of Section AA-6500 and ASTM D5144. Coatings shall meet 

radiation resistance, chemical resistance, and decontamination requirements 

in accordance with the Design Specification. Stainless steel (galvanized), 

_ bronze, copper, aluminum, and glass su rfaces are not required to be coated. 

14A-3200 Special Limitations on Materials (Metals): 

HA-3210 Physical Properties: Changes in the physical prope rties of metals at 

HA-3211 minimum and maximum design temperatures must be recognized and 

factored into the design of housings. 

HA-3212 Galvanic Corrosion: 

The possibility of galvanic corrosion clue to the relative potentials of 

aluminum, copper, and their alloys should be considered when used in 

_ on unction with each other, or with steel or other metals and their alloys. 

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HA-3213 Cor rosive Vapors: 

Aluminum and zinc shall not be used in the presence of corrosive vapors 

unless protected by coatings designed to prevent deterioration of the metal. 

Protective measures other than coating shall be approved by the Owner or 

_ desigr eeT_ 

HA-3214 Nonmetallic Materials: 

The use of nonmetallic materials such as plastics, elastomers, and similar 

substances is permi tted in the construction of housings provided that in the 

selection of these materials, consideration is given to: 

a) emission of toxic vapors; 

(b) degradation of prope rties caused by temperature extremes, radiation 

exposure, chemical exposure, and aging; and 

c maintainabili ty . 

HA-3215 Deterioration of Materials in Service: 

It is the responsibility of the Owner or designee to identify the environment in 

hich housings must operate so that the Manufacturer can select the grade 

_ of materials to meet the conditions stated in the Design Specifica tion. 

HA-3300 lCerlification of Material: 

For structural and pressure bounda ry materials, the supplier shall make 

available sehifiPdte° + For those 

ASTM materials which do not have physical testing required by the AS TM 

specification, tensile testing shall be pe rformed per ASTM A370. All ether 

matenals used in the construction of housings shall be provided with a 

manufacturer's Certificate of Compliance covering the ASME, ASTM, or 

other mate ri al specification, grade, and class, if applicable. 

.A141' 0 ..DES.1Gi^} __-_— 

- - 

HA-4100 General Design: 

Housings shall be designed in accordance with the requirements of AA-4000 

and this Section. The design shall incorporate requirements for structural 

strength, rigidity, and sealing su rfaces to provide leak-tightness of internal 

mounting frames to the housing. Pe,(3eataMination--requiiefnf>44+° shall be 

_ cifie(i-iff-the-ge6ig"pee-tfiea4op-tb he-©w ^desiqRep _ 

HA-4200 Design Criteria (Load Criteria): 

HA 4210 Loads: Loads to be considered in the structural design of housings are listed 

HA-4211 

HA-4211 (a) 

in A A-4211 with the following additions and cla rifications. 

Dead weight (DW): the weight of the Housing members excluding the dead 

eight of internal equipment such as HEPA filters and their respective 

mounting frames. DW includes sheet metal panels, door panels, frame 

members, and stiffeners. 

w 

HA-4211 (b) Component load (CL): The force of the internally mounted components 

imposed on the housing. CL is separated into four po rtions: dead weight, 

normal operating pressure differential (NOPD) for the pa rticular component, 

OBE, and SSE. Additional dynamic loads (ADL), will be provided by the 

_ Des ign Specifi cation, as applicable. 

HA-4211 (c) External load (EL): as defined i n_AA-4211. 

HA-4211 (d) Fluid momentum load (FML): as defined in AA-4211. Housing internal 

components shall be designed to withstand the FML resulting from air 

turbulence, from fan discharges into the housing. The housing po rtion where 

his load is significant is determined by the length required to regain uniform 

air flow as given by AMCA201 Fig 3-3. 

NA 

HA-4211 (e) Hydrostatic load (HL): shall be added to the dead weight (DW) as 

applicable. Hydrostatic loads from accumulated condensate, water deluge 

syslems, moisture separators, and associated housing flooding. The 

hydrostatic load shall be established by documented analysis base on 

NA 

_ housinginter nal and component function. 

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HA-4211 1 (f), Live load includes a construction manload of 250 lb on the roof o the 

housing. Housing sheet metal floors shall be designed for at least a 50 psf 

live load when no other floor system is provided (e.g., grating, concrete 

slab). 

HA-4' 2 11 (g) Normal operating pressure differential (component) (NOPDc): the opening 

pressure differential across the component from upstream to downstream of 

the -component included in the housing. See applicable Division 11 

component sections for all component NOPD's. 

HA-4211 (h) Normal operating pressure differential (housing) (NOPDh ): The maximum 

pressure differential between inside the housing and external to the 

housings. For ease of design, a housing may be designed using one 

pressure value that envelopes SOPT and NOPD. 

HA-4211 (i) System operational pressure transient (SOPT): as defi ned in AA-4211 or 

— _,may be enveloped with NOPD h and NOPDc. 

HA-4211 (j) Seismic loads (SL): Loads that are the result of the envelope of the 

operating basis earthquake (OBE) and the safe shutdown earthquake (SSE). 

As an option, the OBE, and SSE may be considered separately with the 

OBE: loads used for the Level B load combination. Both orthogonal 

components of horizontal and vertical components of the seismic excitation 

shall be applied simultaneously in the direction that will produce worst-case 

stre s ses and deflections. These components may be combined by the 

square root of the sum of the squares (SRSS) method. 

HA-4211 (k) T and N: de fi ned in AA-4211 

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HA-4211 (1) Design pressure differential (DPD): The dynamic pressure loads resulting 

from a design basis accident (DBA), intermediate break accident (IBA), or 

small break accident (SBA). H ousings should be located outside the local 

pipe break affected area. If housings are subjected to these loads, the 

Design Speci fi cation (HA-4600) shall address the speci fi c design 

requirements considering a Service Level D combinaflon. 

HA-4211 (m) For other component load criteria see the following sections: NA 

(10) HEPA filters — FC-4300 

(11) Type 11 adsorbers — FD-4400 

( 1 21 Type III adsorbers — FE-4400 

(13) Mounting frames — FG-4200 

(141 Dampers — DA-4000 

(15) Moisture separators — FA-4000 

(16) Pre-filters — FB-4000 

(17) Coils — CA-4000 

(18) Fans — BA-4000 

(19) Ductwork — SA — 4200 

(20) Type IV adsorbers — FH-4300 

HA-4212 Load Combinations: 

he_appl icable loads are given in Table HA-4212. 

HA-4213 Service Conditions: 

heraui rerneqts of AA-4213 apply. 

HA-42114 Design and Service Limits: 

he^yirements of AA-4214 apply. 

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HA-4215 Housing Supports: 

Housing supports shall be designed per the loads and load combinations in 

HA-4211 and HA-4212. The stress criteria for each load combination shall 

be Per HA-4220. 

Floor mounted housing supports shall be designed to act as an integral base 

of the housing. Anchorage to the floor shall be designed to transfer the 

lateral forces without overturning or deformation of the housing unit. Units 

with internal mounting frames where leakage is a design consideration, shall 

have fl oor anchorages near the junction of the mounting frame and base. 

Small units which are typically provided with the base from the vendors 

facility shall be designed for the installation/erection loads associated with a 

package unit. Larger units that are installed using modular construction 

need only consider the installation loads associated with each piece. 

HA-4220 Stress Criteria: 

The allowable stresses for housing sheet metal material arid cold formed 

members shall be as defined in the AISI "Speci fi cation for the Design of Cold 

Formed Steel Structural Members." The allowable stresses for hot rolled 

shapes and plates shall be as defined in the AISC "Specifi cation for the 

Design, Fabrication and Erection of Structural Steel for Buildings." 

The basic general membrane design stress for the SefViCE! Level A condition 

shall not exceed 0.6 F, and shall be reduced as appropriate to consider 

lateral-torsional buckling of bending members and effective lengths of 

compression members. The basic general membrane design stress for the 

Level C condition shall riot exceed 1.2 x 0.6 Fy per.ALA-432 I . 

The combined membrane and bending design stre s s for Service Level A 

shall riot exceed 1.5 x 0.6 Fy and shall be reduced as appropriate to consider 

laternktorsional buckling of bending members and effective lengths of 

compression members. The combined membrane and bending design 

stress for the Level C condition shall not exceed 1.8 x 0.6 Fy per AA-4321. 

HA-4230 Deflection Criteria (Deflection Limits): 

HA-4231 The deflection limits shall be specified in the Design Specification and shall 

be in accordance with AA-4231. 

HA-4232 Deflection Limits for Mounting Frames and Equipment Interfaces: 

For walk-in housings, the deflection limits for the mounting frames shall also 

be considered at the interface between the frame and the housing. For 

de flection limitations of other equipment (e.g., fans, dampers, ductwork) see 

the applicable Division [I Code Sections. 

HA-4240 Other Criteria: 

HA-4241 Vibration Isolation: Vibration isolation requirements shall be specified by the 

Owner or designee in the Design Specification. 

HA-4242 Provisions for Relative Movement: 

Clearance shall be provided to allow for relative movement of the internal 

_eqyipment during operation and during maintenance of the equipment. 

HA-4243 Tolerances: 

_ 

Folerances shall be specified for all external and internal interface 

boundaries. Tolerances shall be specified in the design documents. 

Tolerances shall be accounted for in applicable design analysis (e.g., 

location of applied load).__ 

HA-4244 Housing Attachments: 

Housing attachment design shall include all Service Links and Load 

Combinations set forth in HA-4212 and HA-4213, or as required by the 

Design Specification. Attachments shall be either the welded or bolted type. 

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HA-4245 Welded A ttachments: 

Consideration shall be given to local stresses induced in the housing wall by 

ntegral a ttachments as defined in AA-4243. A ttachment and housing 

material shall be compatible for welding. See AA-6000. The permissible 

types of welded joints shall be in accordance with AWS D1.1, AWS D9.1, 

WS D1.3, or ASME Section IX_, as applicable. 

HA-4246 Bolted A ttachments: 

Consideration shall be given to bolting and local stresses induced in the 

housing wall by integral a ttachments as defined in AA-4243. The design of 

bolts for structural suppo rts shall meet the requirernents of AISC 

Speci fi cation for the Design, Fabrication, and Erection of Structural Steel, 

Edition, Pa rt — 4. 

Ninth 

HA-4247 Fatigue Considerations: 

Internal housing components subjected FML should be designed for fatigue 

based on cyclic loading of the element. See HA-4211 to determine the 

po rtion of the affected internal housing components. The appropriate 

reductions in allowable stresses are given in Section 5, Appendix B of the 

ISC Specification for the Design, Fabrication, and Erection of Structural 

Steel, Ninth Ed ition, Pa rt 4. 

NA 

HA-4248 Fire Protection: 

Fire protection requirements shall be specified by the Owner or designee 

commensurate with individual component requirements. Fire protection for 

Type I II adsorbers shall h epr( vided per FE-4620. 

NA 

HA-4300 Housing Joints and Seams (General Requirements): 

HA-4310 Selection of joints and seams used in the assembly of housing sections shall 

be based on the required structural integri ty , leak-tightness, and the fluid 

Flow within the system. Duct-housing interconnections shall be designed 

_ with consideration of the air distribution unifor ming _ _ 

HA-4320 Housing Joints and Seams: 

HA-4321 Acceptable Longitudinal Seams and .Joints: The following longitudinal seams 

and joints are acceptable for use in housing sections subject to limitations of 

HA-4330, -4340, -4500: 

(a) welded lap joint 

(b) welded butt joint 

(c) welded flange 

d fi llet corner welds 

HA-4322 cceptable Transverse Joints: 

he following types of transverse joints are acceptable for use in housing 

sections subject to limitations of I-IA-4330, -4340, -4500: 

(a) welded lap joint 

(b) welded bu tt joint 

(c) welded flange 

d companion angle: gas keted & bolted_ 

HA-4323 Other types of Connections: 

Other types of rigid longitudinal and transverse connections may be 

acceptable provided that the design structural characteristics are qualified. 

Qualification shall be documented by engineering evaluation or test as 

specified by the Owner or designee. Qualification test shall demonstrate the 

joint's ability to withstand load combinations in HA-4212. .Joint design 

_ uglification shall be complete d prior to the start of fabrication. 

HA-4324 Bolls and Fasteners: 

Connections shall be designed to sustain all loading combinations. Bolted 

connection and joint design shall be designed to meet allowable leakage of 

HA-4500. 

HA-4330 it Cleaning Units Joints and Seams: 

HA-4331 the pressure bounda ry joints and seams for all air cleaning unit housings 

shal l be continuous) y welded__– 

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HA4332 Seals: 

Penetrations on housings shall be sealed by welding, with a sealant qualified 

or the housing's environment, or with adjustable compression or gland-type 

seals. Gland-type seals include but are not limited to "O" rings, gaskets, and 

other nonmetallic mate ri als. 

HA-4333 Elect rical Conduits and Drains: 

II penetrations by electrical conduit and drains shall be arranged and 

individually sealed or valved so that bypassing of HEPA filter banks or 

adsorber banks cannot take place. Electrical conduit open to the inside shall 

be internally sealed to meet allowableleakage determined in HA-4500. 

HA-4334 Separate Moun ti ng Frames: 

Where separate mounting frames for HEPA filters and adsorbers are 

_-- required, they shall be continuo_us!y seal welded to the housing. 

HA-4340 Air Conditioning and Air Handling Units Housing Joints and Seams: NA 

These unit joints and Seams shall be of either welded or bolted construction 

or other types meeting the requirements of HA-4323 and the allowable 

leakage criteria specified in the Design Specification. 

HA-4341 Penetrations: 

Penetrations on housings shall be sealed by welding, adjustable 

compression, gland-type seals, or other method capable of meeting 

allowable leakage c ri teria for the_housing s determined in HA-4500. 

I IA-4400 Accessories: 

HA-4410 Gaskets shall be made of materials which are compatible with the conditions 

of HA-4600. Gasket dimensions shall be based on joint design. An 

Acceptable crite rion for compression of gasket material shall be established 

on the basis of the gasket chosen. This acceptance criterion and the service 

life of the gasket and joint shall be documented by evaluation or testing as 

determined by the Owner or designee. 

HA-4420 Access Doors and Panels: 

Construction of doors/panels and door frames shall be selected to meet the 

allowable leakage determined in HA-4500. Sealing su rfaces between the 

door/panel and frame shall be designed for compression sealing. The 

design shall incorporate means for adjusting compression forces, gasket 

compression, and alignment. Spacing of hinges, latches, and bots shall be 

determined by calculation or test to ensure a uniform compression of the 

gasket. Sparing shall enable a compression tight enough to assure leakage 

requirements are met (HA-4500) and provide a gasket compression 

uniformity of +/-20 deg. Hinged, if specified, shalt be designed to minimize 

damage to compression seals due to friction and shear forces du ring 

opening and closing of the doors- Doors shall be designed for ease of 

operation by one person. Man ent ry housing doors shall be operable from 

both inside and outside the housing and be clearly labeled for open and 

closed latch position. Hinges and latches shall be designed such that 

lubrication materials shall not enter the interior of the housing. See Nonmandato 

ry Appendix HA-B (B-1110) for additional guidance on the design of 

access doors. 

HA-4430 Provisions for Testing and Maintenance: 

HA-4431 Test Po rts: The Owner or designee shall evaluate the design function of the 

equipment to determine where test po rts (including injection and sampling 

po rt s) are required. The penetration shall comply with HA-4332, and have a 

cap or plug that is suitable to meet the pressure requirem ents of the housing. 

B-31 

G5-499

IIA-4432 Manifolds: 

10P-24544 REV Id 



-------------- .............. 

The Owner or designee shall determine where injection and sampling 

manifolds are required. Injection and sampling manifolds shall be 

consiructed of metal to minimize damage potential and to maintain manifold 

qualification. Sampling and injection manifolds which are required to be 

installed within the filter housing should be designed for permanent 

installation within the housing. If permanently installed manifolds cannot be 

provided, then manifolds shall be designed to be removable, with each 

manifold piece numbered, tagged, and marked for reinstalling prior to each 

test. Permanent manifold installation is recommended to obtain better 

repeatability of test results. When an air cleaning unit contains two or more 

HEPA fi lter banks or adsorber banks in series, or both, injection and 

sampling manifolds for the respective test agents are required for each of tile 

filter and/or adsorber banks. General guidance for manifolds is given in 

Nonmandatory Appendix HA-C. Injection manifolds. shall be quali fied in 

accordance with HA-5800. 

FIA-4433 Housing Access: NA 

Walk-in housings shall be protected and braced to prevent damage by 

personnel entering for inspection and maintenance. Walk-in access doors 

(20 in. wide by 50 in. high, minimum) shall be provided on each side of each 

component section when housing size permits. A permanent platform shall 

be installed internal to the housing to provide access to filt e rs for filter banks 

greater than or equal to six ft. in height. Platform shall not interfere with filter 

access or air flow distribution. Space ,;hall be provided both internal and 

external to the housing for equipment removal and maintenance. See 

tory Appendix^ 

HA-B for additional g u idance. _ 

HA-4434 Lighting: 

Walk-in housings shall be fitted with vapor-tight lights between each bank of 

components. For walk-in air cleaning unit housings, fixtures shall be flush 

mounted and serviceable from outside of the housing. Lighting levels shall 

be determined based on personnel safety visual requirements as given in 

the Design Speci fication and guidance provided by IES Lighting [ landbook 

NA 

as published Illu _min Society of North America. 

WA-444-0 Miscellaneous: 

HA-4441 Drains: Consideration shall be given to drains depending on requirements, 

services, or components within each compartment. For example, drains 

shall be required for: 

( a) fi re protection systems 

(b) removal of decontamination liquids 

(c) moisture separators 

(d) condensing cooling coils 

Drains form an integral part of the housing pressure boundary and are 

subject to air leakage requirements established in HA 4500. The size 

selected for each drain furnished in the housing as well as the collection 

point for each drain shall be documented by calculation or test as 

Ideterminied by the Owner or designee. For the additional guidance in the 

_Jdesign of drains, see Nonmandatory Appendix HA-B. 

B-32 

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a) Insulation shall be provided as specified by the Owner or designee 

'lo ensure air conditioning function, limit condensation, or provide 

acoustic noise reduction as required. 

(b) Acoustic linings and thermal insulation shall not be applied to the 

inside of housings that may become contaminated. 

(c) Insulation applied to the outside of housings shat: not prevent 

access to doors, access panels, or other components requi ring 

adjustment or maintenance. 

(d) The fire hazard classification of applied insulation, adhesive, and 

sealer shall not exceed a flame spread of 25 and smoke developed of 50 

in accordance with NFPA-90A. 

HA-4443 Clamping Mechanism: 

Side access housings shall have a clamping mechanism, filter ret rieval 

features, and filter indexing mechanisms. The clamping mechanism shall be 

individually adjustable for each HEPA filter or adsorber. For side access 

housings with fluid seals, the filter clamping mechanism shall be capable of 

moving the filter on and off through adequate travel to ensure the knife edge 

is embedded into the p liable sealant and provides seal for the complete 

perimeter of each filter or adsorber. The clamping mechanism shall provide 

or uniform gasket compression. The slampi=R^ ism €oFwall

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„ HA-4533 Exceptions to Leakage Requirements: 

Air cleaning, air conditioning, and air handling housings exhibiting one of the 

following conditions need not be subjected to quantitative measurement of 

leakage unless otherwise required by the Design Specification. 

(a) Housings in systems serving only the protected space and located 

only within the same protected space. 

b) Housings under negative pressure which are located entirely in a 

clean interspace, and only provide air cooling or heating function. 

However, the housing shall be pressurized to locate and seal all audible 

leaks. Reference Section SA, Nonmandato ry Appendix SA-B, Figs. B-1410- 

1 through B-1410-3 for typical system configurations._ 

HA-4534 Documentation: 

Derivation of allowable leakage for each housing, or portion thereof, shall be 

documented by the Owner or designee. This documentaton shall include 

the following: 

(a) identification of housing or portion of housing 

(b) gove rn ing codes, regulations, and plant-specific requirements 

(c) purpose of leakage control; see HA-4510 

(d) system mode of operation 

(e) normal and maximum operating pressure 

(f) method of derivation of allowable leakage 

jqj test pressures and associated allowable leakage 

HA-4600 Design Speci fication: 

The Owner Design Specification shall contain the following information which 

is relevant to the housing and housing suppo rts covered by this Section. 

(a) Loads as defined by HA-4211. 

(b) Environmental conditions. 

(1) Housing external-design environmental conditiois including, but 

not limited to pressure, temperature, relative humidity, radiation 

exposure, and hostile environmental factors for all plant conditions. 

(2) Housing internal-design environmental conditions for all system 

operating conditions. 

(c) Service conditions as defined by AA-4213. 

(d) Design and se rvice limits as defined by AA-4214. 

(e) Allowable housing leakage: as defined HA-4500. 

(f) System safety-related function: Identify the function of the housing for 

each plant condition. The function shall consist of purpose and 

operational parameters (i.e., flow, leakage, pressure, temperature). 

Plant conditions and service limits are defined by AA-4213 and AA- 

4214. 

(g) Fire protection requirements. 

(h) Material certification requirements. 

(i) Tolerance requirements. 

(j) Inlet and outlet configurations. 

(k) Housing components: adsorbers, fans, filters, moisture separators, 

dampers, heaters, coils, insulation, access requirements (i.e., doors, 

access panels), instrumentation and controls, spray-type conditioners. 

v 5,00a" INSPEG ION_AN^TE TiNG° k? rF^ 

HA-5100 General (Scope and Applicability): 

HA-5110 This Section contains general requirements for the inspection and testing of 

housings and housing suppo rts. 

HA-5120 Recpon sibility for Procedures: 

When an inspection or test is required herein, written inspection or testing 

procedures shall be developed, by the parties pe rforming the test or 

inspection, to the specific requirements of this Section. The inspection or 

testing shall be pe rformed by personnel qualified in accordance with ASNT 

SNT-TC-1A as amended by ASME NOA-1 and AA-6433. 

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ASME-AG-1-200:3 CODE ON NUCLEAR AIR AND GAS TREATMENT 


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HA-5200 Inspection (General Requirements): 

I IA-5210 Visual inspections shall be performed in accordance with X4-5200 and TA- 

3410. Inspection and testing of welds shall be pe rformed in accordance with 

-: 300 and AA-6000. 

HA-52_ 20 Housings: 

Housings shall be inspected for proper dimensions including tolerances, as 

specified by HA-6400 and gov erning construction documents. 

HA-5221 Joints and Seams: 

Joints and seams shall be visually inspected. Acceptance criteria shall be as 

follows. 

(a) Joints and seams shall comply with the requirements of HA-6400 

and HA-6500. 

(b) Gasketed joints shall provide uniform gasket compression. 

Gaskets shall be installed per construction documents. 

(c) Longitudinal or transverse welded joints shall comply with AA-6000 

requirements. 

(d) Threaded fasteners shall be provided with locking devices in 

HA-5222 

--- accordance with AA-6_258. 

Stiffeners: 

Stiffeners shall be visually inspected to ensure compliance with the following 

acceptance criteria. 

— 

(a) Stiffeners shall comply with the fabrication and installation 

requirements of HA-6000. 

(b) Welds shall comply with AA-6000 requirements. 



HA-5230 

d Removal of temporary attachments shall be ver i_fle_ d. 

Housing Supports: 

Sup ports shall be visually inspected du ring installation, after installation, or 

both in accordance with the following acceptance criteria. 

(a) Supports shall comply with the fabrication and installation 

requirements of HA-6400. 

(b) Welded joints shall comply with AA-6000 requirements. 



HA-5240 

(d) Removal of tem porary attachments shall be verified. 

Filter hounting Frame to Housing Weld Inspection:` 

The housing filter mounting frame for HEPA filter and adsorbers shall be 

- 

inspected u sing visual and nonde structive test method_ s per AA-6330. 

I IA-5300 

HA-5310 

Pressure Bounda ry Leakage Testing (General): 

Temporary isolation at a transverse joint shall be allowed subject to the 

allowing requirements. 

(a) Transverse joints not subjected to a quantitative leak test shall be 

companion angle type or other types which enable visual inspection of 

the sealing mechanism between mating housing sections. 

(b) Assembled joints utilizing gasketing shall be visually inspected to 

ensure uniformity of gasket compression. 

(c) The reduced allowable leakage (L,) of housing sections shall be as 

follows: 

Lr =Ls — R 

R = (Ci / C7)Ls 

__ _ _Where... 

HA-5320 Ilouvances for Housing Leakage Rates by Sections: 

empora ry isolation at a transverse joint shall be allowed subject to the 

following requirements. 

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HA-5330 Testing Procedures: 

Prior to pressure boundary leakage testing, test procedures shall be 

Jeveloped in accordance with TA-3330. All test equipment shall be specified 

vvith the proper range and required accuracy. -rest procedures shall include 

acceptance criteria determined by HA -4500, IA-5320, and HA-5350. 

HA-5340 Documentation: 

test report shall be prepared to document the Pressure Boundary Leakage 

Test. This report shall include the following information. 

(a) housing or portion of housing tested 

(b) speci fied allowable leakage and test pressure 

(c) calculations for housing section square footage for housings tested 

by sections 

(d) adjustments to allowable leakage per HA-5310(c) 

(e) measured leakage test 

(f) list of pressure boundary components which were not installed 

during the pressure boundary leakage test 

(g) test equipment used: including model number, serial number, and 

evidence of calibration 

(h) names of test personnel 

(i) date of test 

HA-5350 Acceptance Criteria (Quantitative Leakage Tests): 

HA-5351 Acceptance criteria for quantitative leakage tests shall comply with HA-4500 

and HA-53101c) 

HA-5352 Non-quantitative Leakage Tests: 

For non-quantitative leakage tests allowed by HA-4533, the acceptance 

criteria shall be that audible leaks have been sealed. 

HA-5400 Mounting Frame to Housing Leakage Test: 

A mounting frame pressure leak test may be used to detect leaks in the 

HEPA fi lter and adsorber mounting frames that could affect the results of the 

in-place leak test I TA-4300 The test, if used, shall be. conducted in 

accordance with Nonmandatory Appendix TA A. 

HA-5500 Structural Capability Tests (Housing Pressure Test): 

HA-5510 A pressure test shall be performed at the structural capability pressure per 

TA-3422. This test shall be maintained for the duration of the inspection. 

Upon completion of this pressure test, housings exhibiting permanent 

distortion or breach of integrity shall be repeated after repair or replacement 

unti l . no permanent distortion or breach of irate 

qri!êrvecl. 

HA-5600 it Flow Distribution Tests: NA 

When required by the Owner, air fl ow distribution qualification test for 

housings containing more than one HEPA filter or adsorber bank shall be 

made in the shop in accordance with Section TA-4600. This requirement 

shall be specified in the Owner's Specification. Acceptance criteria shall be 

in accordance with TA-4600. Housings containing HEPA fifter(s), adsorbers, 

or both shall be fi eld tested to demonstrate adequate air flow distribution in 

accordance with TA-4600. Tests shall be performed with components in the 

housing and the housing complete (i.e., assembled), Minor items such as 

temperature elements, pressure taps, etc., do not need to be installed as 

[thes e components do not significantly in fl uence air flow distribution. 

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HA-5700 Air-Aerosol Mixing Uniformity Tests: NA 

When required by the Owner or designee, air-aerosol quali fication test for 

housings containing more than one HEPA/adsorber shall be made in the 

shop in accordance with TA-4600 for each manifold design. This 

requirement shall be specifi ed in the Owner's Specification. Acceptance 

criteria shall be in accordance with TA-4600. Tests shall be performed with 

components in the housing and the housing complete (i.e., assembled). 

Minor items such as temperature elements, pressure taps, etc., do not need 

to be installed as these components do not significantly influence mixing- 

HA-5800 

This design qualification test may be performed once and submitted to the 

Owner or designee for approval. This design quali fi cation test may be 

performed once and submitted to the Owner or designee for approval. The 

,design of the manifold and its location in the housing must be the same as 

quali fi ed or a new aerosol mixing q test is required. 

Sample Manifold Testing: 

Sampling manifolds shall be qualified to demonstrate that they collect a 

representable sample equivalent to a single point sample taken at a point at 

least ton duct diameters downstream of the filters. Refer 

NA 

to Nonmandatory 

Appendix D for performance test guidance- To ensure required leakage 

detection, acceptance criteria for sampling manifold shall he equal to or 

- 9realer than the concentration detected with the single point sample-_ 

HA-5900 it Conditioning and Air Handling Unit Testing: NA 

When required by the Owner or designee, integrated component functional 

acceptance testing shall be performed in the shop per TA-4000. This 

requ -irement shall be included in the Owner's Speci fication. 

,,,A^,HA.60Q0 5 FA CA BIÎ- 

FIA-61 00 General: 

it cleaning ,-aiF-G4a"tiof4ifi"nd-aif^hand ling uni housings and supports 

shall be fabricated in accordance with this Section and AA-6000. 

HA-6120 Materials (Material Selection): 

HA-5121 Materials used in fabrication performed under this Section shall conform to 

HA-3000 requirements. 

HA-6122 Material Identification: 

Materials to be utilized in the fabrication and installation of components, 

parts, and appurtenances shall be identified on fabrication drawings and in 

the specification, as required in AA-6000. 

HA-6123 Repair of Material with Defects: 

Matorial with defects that are discovered or produced during the fabrication 

process may be used, provided the defects are repaired in accordance with 

the requirements of AA-8000, and for weld repairs, in accordance with AA- 

6300. 

HA-6130 Control of Installation and Fabrication Process: 

Quality control procedures shall be prepared and maintained current for all 

brication pro esses in accordance with AA-8000 re uirqments. 

HA-6140 Welding: 

The welding of filter housings and supports shall comply with the 

requirements of AWS D1.1, AWS D1.3, AWS D9.1, or ASME Boiler and 

Pressure Vessel Code, Section IX Welding and brazing performed in 

accordance with this Section shall meet the requirements of AA-6300 

andAA-6400. 

HA-6210 Cutting, Forming, Bending, Aligning, and Fitting 

HA-6211 Uncoated Metal: 

Uncoated metal may be cut, formed, or bent by any means that does not 

deg ade the mechanical or chemical properties of the material. 

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HA-6420 Side Access Housing and Gasket Seal Su rfaces: NA 

HA-6421 Flatness: Each HEPA filter/adsorber housing seating su rface shall be plane 

within 1/16 in. 

HA-6422 

Su rface Finish: 

Pits, roll scratches, weld spatter, and other su rface defects within the sealing 

areas shall be ground smooth After welding, ground areas shall merge 

smoothly with the surrounding base metal. 

HA-6430 Side Access Housing Filter Fluid Seal Surfaces: 

HA-6431 Flatness: The tolerance on each knife edge shall be plane within 1/8 in. 

B-38 

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HA-6500 Cleaning: 

II su rfaces shall be cleaned per AA-6500 prior to acceptance. No halogenbearing 

mate ri als or carbon steel tools shall be used to clean housings or 

components constructed of stainless steel. Cleaning shall be pe rformed in 

accordance with the Manufacturer's written procedures. 

; î r.7pt , , ^. .ACkCACI.riJC `. E11.PPING }:R Ct IVlNfarST9RAG ,,'Al I j IANC} :.f IC S` ° 

HA-7100 General: 

Packaging, shipping, receiving, storage, and handling requirements shall be 

in accordance with AA-7000 and this Section. 

MA.11 .1'_. ^ ? t :: "s< 

HA-7210 Packaging (General): 

Air cleaning, air conditioning, and air handling unit housing packaging 

requirements are dependent upon the protection level as described in AA- 

7230. Additional cla rification or exceptions are provided below. 

HA-7211 Packaging (Protection): 

Air cleaning, air conditioning, and air handling unit housings shall be 

protected to prevent physical damage. All openings shall be covered with 

wood, metal, or plastic. Waterproofing is required to exclude moisture from 

interior spaces and external devices. Mating su rfaces shall be identified and 

specifically protected from damage. Protection equal to Level "D” is required 

for the basic unit. Protection for housing components must be equal to that 

-- required by the level of protection specified in the applicable Code section. 

HA-7300 Shipping: 

This Sub-article relates to transportation methods from the manufacturer or 

supplier, to the job site. Shipping shall comply with the provisions of AA- 

7100, AA-7200, and AA-7300._ 

HA-1400 Receiving: 

Receiving at the job site or intermediate location, where additional work is to 

be pe rformed or for long term storage, shall be accomplished in accordance 

with the provisions of AA-7000. It shall be the requirement, at any receiving 

HA-7510 

point, to have adequate descriptions of items to permit suitable inspection for 

conformance, damage acknowledgment, and primer docurnentation. 

Storage (General): 

Housing storage requirements are dependent upon the protection level 

described by AA-7230. Protection equal to Level "D" is required for the basic 

unit. Protection for housing components must be equal to that required by 

he level of protection speci fi ed in the applicable Code section. These levels 

shall be the required storage requirements along with the requirements of 

HA-7511 and HA-7512. 

HA-7511 Storage (Drains and Vents): 

II housing drains or vents shall be sealed or closed as speci fied by the 

Owner or designee. Provisions may be made to use ce rtain drains or vents 

or assurance that water or other objectionable material does not accumulate 

within the housing. 

HA-7512 Storage (Other Components): 

Components covered by other Sections of this Code, that are installed into 

and integral assembly which is covered by this Section, shall be stored in 


M Ha 8r7Q0` ' UAL'11YASSURANC 


Equipment and material covered under this Section shall be manufactured, 

fabricated, installed, inspected, and tested in accordance with the provisions 

of a Quality Assurance Program meeting AA-8000 requirements. 

HA-8200 Materialldentification: 

Measures shall be established for controlling and identifying material 

hroughout the manufactu ring process and during shipment in accordance 

ith AA-8000. 

B-39 

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Drawings and Documentation: 

The Design Specification shall list the documentation requirements for the 

housing and list when this documentation is to be provided by the 

manufacturer, supplied to the Owner or designee. Housing-related items 

shall include, but not be limited to the following: 

,,,•,togas ,ems+ - 

Ge FtA Gati 9R and reports 

(b) housing drawings including: 

(1) outline drawings 

(2) piping and instrumentation diagrams 

(3) wi ri ng diagrams 

c) mate ri al list 

(d) welding procedures and procedure qualification records as required by 

applicable welding codes listed in HA-6140 

(e) reports for tests an inspections required by HA-5000 

(f) seismic and environmental qualification reports 

o eratin , installation, anti maintenance manuals. 

' NAMERLì4TE001 STAMPIN(zff 

^rt at ^ , s Mai 


II items manufactured under the requirements of this Section shall be 

identified to assure compliance with AA-9000 requirements. 

Records, as necessa ry to assure compliance with AA-8200, shall be 

maintained by the responsible organization in accordance with the approved 

uality assurance program. 

HA-9110 Stamping/Marking: 

Starnping/marking, as used herein, provides a means of maintaining 

identification of finished products for the purpose of retaining traceability of 

material. 

HA-9111 Housings: 

Housings shall be provided with nameplates, in accordance with AA-9120, 

which relate the housings to the applicable design and fabrication 

documents. Housings fabricated in multiple sections need only one 

nameplate. Easl} ses +e+^ mall f }ve ideet+€+ markings-ebsee,a' v==b4—a per 

relate all-sestiG+4s Nameplates shall be visible 

after completed installation. 

HA-9112 Housing Accessories: 

Housing accessories shall be marked, stamped, or provided with a 

nameplate which shall relate to the design and fabrication drawings. 

` Identification shall be observable after completed installation. 

B-40 

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ASME-AG-1-2003 CODE ON NUCLEAR: AIR AND GAS TREATMENT 


Section CA (Conditioning Equipment) 

Not Applicable 

None of the applicable components listed in CA-1110 are part of the OGTS. Section CA states the following: 

"Applicabilily: 

This Section establishes requirements for the design, manufacture, testing, and documentation for forced circulation air 

cooling ands heating coils, air washers, evaporative coolers, and electric heating coils used in nuclear safety-related air 

conditioning and air and gas treatment systems in nuclear facilities." 

The applicable components called out in GA-1110, General Requirements, are eliminated as part of this ventilation system as 

follows: 

Forced circulation air cooling anti heating coils > Air heater type used in ventilation system does not use forced air 

circulation but uses a glycol heat exchanger that may be covered in ASME AG-1 future section GA. 

• Air washers > None in this ventilation system 

• Evaporative coolers > None in this ventilation system 

• Electric; Heating Coils > Heater does not have electric heating coils to directly heat the process air. The heat exchanger 

referenced in the future GA section is the closest component description to the heater used in this ventilation system. 

The excluded components are called in CA-1132, Exclusion of Components as follows: 

"Conditioning equipment and associated accessories not included in this section are humidifiers, dehumidifiers of the 

adsorption type, infrared heating devices, controllers, valves, strainers, traps, pumps, refrigerant expansion valves, shell- and 

tube-type refrigerant evaporators and condensers, and compressors." 

CH21MHill Environmental discussions with the Washington State Department of Health (WDOH) in May 2004 verified that WDOH 

considers this section only applicable to electric heaters with coils exposed directly to the air stream. 

Q-41 

G5-509

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FA-1100 Scope: 

FA-1110 This section of the Code provides requirements for the performance, design, 

FA-1120 construction, acceptance testing, and quality assurance for moisture 

FA-1130 separators use in air and gas cleaning systems in nuclear safety-related air 

or gas treatment systems. 

Purpose: 

The purpose of this Code is to assure that moisture separators used in 

nuclear safety-related air and gas treatment systems are acceptable in all 

aspects of performance, design, construction, and testing. 

Applicability: 

This section applies to modular, impingement-type liquid droplet separators 

which typically employ layers of fibers, layers of mesh, or -alternating layers 

of each. This section does not include the integration of the moisture 

separators into a complete air cleaning system. It only applies to moisture 

separators ready for installation in air cleaning systems. 


2,0^ REFERI^NG ER`D' 0CUME4 W&A 

FA-2000 Referenced Documents 

MM1 

NA 

7777 

FA-3100 Allowable Materials: 

Pads: the pad is usually constructed of glass fiber arid/or corrosion resistant 

(stainless steel) wire. Other materials that have demonstrated equal or 

better corrosion resistance are allowable if they meet the requirements of UL 

900, Class 1 filters and the design conditions. 

Frames, cross-grids, and supports: material shall meet the requirements of 

ASTM-A 240, Type 304, stainless steel or as required to meet design 

conditions. 

Rivets: when rivets are used for fabrication or attachment: shall be 300 

series austenitic steel meeting the minimum requirements of ASTM-A 581, 

Type 303. 

Gaskets: the material for these parts shall be closed cell silicone rubber 

sponge, Grade SCE-43-1 or SCE-44-1, in accordance with ASTM-D 1056. 

Adhesive: adhesive used to splice gaskets or to fasten gasket to cell shall 

be clrppatible wit gasket material and appropriate to intended application. 

FA-3200 Limills: 

FA-3300 

Materials of construction specified here for the moisture separator are 

typical. Alternative materials are acceptable as long as they meet the 

design conditions, UL 900, Class I filter requirements and pass the 

qualification test of FA-5000. 

Mate Material Certification: 

The Manufacturer shall supply certification to the purchaser that all materials 

used in fabrication of the moisture separator conform to the requirements of 

FA-3200 

tip, F1 

W. DESIWO0111ORS N 

7 

FA-4000 General: 

Design conditions for moisture separators are a maximum relative humidity 

of 100%, operating temperature of up to 285 degrees F, and a total 

integrated radiation environment of 8 x 10 7 Rads unless otherwise specified 

in the design specifications. 

B-42 

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FA-4100 General Design: 

Moisture separators shall consist of frames designed to retain the deep bed 

fibrous pads. The pad shall be held in place in the frame by a retaining 

rid(s) or mechanism. Frames shall be designed to include drain holes to 

prevent re-entrainment of trapped liquids. Seals shall be provided as 

necessa ry to prevent bypass of entrained liquid droplets. (Refer to Nonmandato 

ry Appendix FA-A for a typical configuration). 

FA-4210 Design Requirements: 

The moisture separator shall meet the requirements given in Table FA-4200- 

FA-4220 

1. 

Pad: 

— ----- 

FA-4230 

The pad shall be fabricated of approved mate rial (FA-3100). Fabrication of 

he pad shall be controlled as to provide the required pad density. 

IMoisture Separator Assembly: 

he frame shall be fabricated from corrosion resistant non-perforated steel 

sheet and shall be formed and assembled in a manner that no bypassing of 

the separator pad is possible. Drain holes shall be provided in the bottom of 

he frame. Design shall include provisions to assure that the pad is 

Imaintained in its operating position and that the pad does not settle, pack 

_ Idown, or pull away from the top or sid es of the frame when installed. 

FA-4300 Structural Requirements: 

FA-4310 The moisture separators shall be designed in accordance with the structural 

requirements given in AA-4000 or quali fied by test in accordance with AA- 

350 or FA-52 10. 

FA-4320 Load Definition: 

Loads to be considered in the structural design of the moisture separator 

de fined in AA-4211 are as follows. 

(a) Deadweight (DW) consists of the metal frame that contains the pad, and 

bolting integral to the moisture separator. instrumentation and ancilla ry 

equipment attached to the moisture separator are treated as external 

loads (EL). 

(b) The pressure (NOPD) differential which must be considered is from the 

upstream to downstream side of the pad. 

(c) The seismic acceleration and response spectra (OBE and SSE) shall be 

as provided in the Design Specification. Additional dynamic loads 

(ADL) will also be provided by the Design Specification, as a Ipp icabl e. 

FA-4330 

Load Combinations: 

Unless stated otherwise in the Design Specification, the applicable loading 

conditions noted in Table AA-421 2 for moisture separators are as follows: 

a) Service Level A — DW r EL + NOPD 

(b) Service Level B — DW + EL + NOPD + OBE 

(c) Service Level C — DW + EL + NOPD * SSE + ADL 

_ d Service Level D — not applicable 

FA-4340 Acceptance Criteria: 

The acceptance criteria are listed in Table AA-4321. The design stress 

values S shall be 0.6 S, 

F 500U - INSPECTION /aNO TESTI J ,, a ." a .r r '? N 

FA-5000 Inspection and Testing: 

Inspection and testing of the moisture separator shall conform to 

requirements of this Section and to specific requirements set fo rt h in A rticle 

AA-5000. 

FA-5100 Qualification Tests: 

A design qualification test shall be pe rformed on each specific moisture 

rator design. Four units of each design shall be tested to all 

rements of FA-5200. New or revised designs shall require 

Lre)1ification- 

B-43 

G5-511 

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FA-7100 Packaging: 

Each moisture separator shall be individually wrapped and enclosed in a 

ood or heavy corrugated paperboard carton with inte rn al cushioning to 

ecouple shock and vibration under accelerations up to 50 g. Separators 

shall be oriented in the ca rton or crate with the top of the frame up_ The 

cartons or crates shall be clearly marked with the legend "THIS SIDE UP" or 

a similar imprint to ensure proper orientation of ca rtons and crates during 

han dling, shipping, and storage ._ 

FA-7200 Loading for Shipment: 

Cartons shall be banded to skids or pallets in the orientation speci fied in FA- 

7100. Wood separators and strapping protectors shall be provided between 

tiers of cartons and above the topmost ca rtons in the load. Sufficient steel 

strapping shall be used to prevent shifting of the load on the skid or pallet. 

Separators shall not be stacked higher than three ca rtons on a skid or pallet. 

Skids shall not be stacked more than two high unless bracing is provided to 

supportrt the upper tiers to prevent damage to the bottom separators. 

FA-7300 Storage: i 

Sttor age sha 

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a cordance with ANSI/ASME NQA-2, Pa rt 2.2, Level C. 

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he moisture separator manufacturer shall establish and comply with a 

comprehensive quality assurance program and plan in accordance with 

Article AA-8000. 

FA-8100 Documentation: 

The following documentation shall be provided to the Purchaser: 

(a) Drawing giving outline and interface dimensions of the separator; 

(b) List of materials of construction; 

(c) Quali fication Repo rts; (Seismic) 

(d) Ce rtification of Pe rformance (resistance and performance tests); 

(e) Installation and maintenance instructions; and 

Storage and handling instructions. 

FA=Jt)0^ t [ MEPLATE$^$U P,IINO$ ANE7 MANQALS :,. ^^ < 


Each separator shall have a nameplate permanently attached to the top or 

side of the frame with the following information: 

(a) Moisture separator; 

(b) Manufacturer's name or symbol; 

(c) Weight of separator; 

(d) Pressure drop across separator (clean) airflow velocity specified; 

(e) Serial number (each separator shall be identified by a nonrecurring 

alpha-numeric symbol which shall also identify all documentation for the 

separator); 

f) Direction of flow; and 

Mounting orientation. 

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IA-1100 Scope: 

IA-1110 This section establishes requirements for the design, manufacture, 

IA-1120 installation, testing, and documentation for instrumentation, control 

IA-1130 components, and control panels used in conjunction with nuclear safetyrelated 

air and gas treatment systems. 

Purpose: 

The purpose of this section is to ensure that the instrumentation and control 

equipment included herein are adequate for use in safe ty-related systems. 

pplicability: 

This section applies only to permanently installed instrumentation and 

control systems associated with safety-related nuclear air and gas treatment 

systems. This section does not cover the requirements for portable 

instr U mentation or controls used for in-place testing or inspection of nuclear 

air and gas treatment systems. This section does not cover the requirements 

of tempora ry instrumentation and controls used for testing or inspection of 

nuclear air and gas treatment systems during fab ri cation or installation. The 

responsibility for meeting the requirements of this section shall be assigned 

by the Owner or his designee using Nonmandato ry Appendix IA-A as a 

uido. 


REFFRENCEQ DOCUMENTS 

gm 

IA-2000 Referenced D ocuments NA 

771A*-,Z000 

IA' 30p0. - MRT,ERtP L S< z,.. _""S av : 

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IA-3100 Materials of Construction: 

II materials used shall have properties and composition suitable for the 

appli ration as defined by the Design Specification and the operating 

environmental conditions as defined in Subarticle IA-4120. Materials shall 

be in conformance with the latest revision of the ASME and ASTM materials 

listed in Table IA-3100. Substitute materials shall be equivalent to or exceed 

he requirements in Table IA-3100. Materials that are part of the pressure 

bounda ry or support equipment shall meet the structural requirements of 

Article AA-4000. 

IA-3200 Nonpermissable Materials: 

Use of the following materials is prohibited in the manufacture and 

installation of instrumentation and controls in nuclear air arid treatment 

systems: 

a) mercu ry 

(b) radiologically unstable fluo rinated polymers 

_ c asbestos 

IA-3300 Restricted Materials: 

II material shall be compatible with the operating environment. The 

following mate rial shall not be used unless approved by the Owner or his 

designee: 

(a) Aluminum and zinc in the presence of corrosive vapors 

(b) Adjoining materials which may cause galvanic corrosion. 

c Chlorine producing materials, e.g. Polyvinylchloride (F'yC)- 

B-46 

G5-514 

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Certification of Material: 

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The Manufacturer shall make available a Certificate of Conformance for 

panel structural material and tubing to the ASTM numbers listed in Table IA- 

100. For those materials which do not have ASTM ratings, testing should 

be pe rformed oer ASTM A370. All other components used in the 

construction of the panel assembly shall be provided with a Manufacturer's 

Ce rtificate of C ompliance to the requirements in the Desig n S ecification 

r1^1^-4000. x : FSIGWEEQUIREMETV GS r^ ^ ^^ ^^ ^^ ^'^^ ^^:^ > ^^^^ .^Y^ 

IA-4120 Design Specification: 

The Design Specification shall establish the purpose (design function) of the 

instrumentation and control components. The Design Specification shall 

also ,.dentify the instrumentation and control component safety 

classifications. For guidance in determining instrumentation and controls for 

nuclear air and gas treatment systems refer to Nonmandalo ry Appendix IA- 

C. The Design Specification shall provide requirements for the design, 

fabrication, and selection of instrumentation and control systems in 

accordance with this Code and shall include, as applicable: 

(a) Pe rformance requirements for all plant operating modes (accident and 

normal) wherein the equipment is expected to perform an intended 

function. 

(b) Ambient and process operating conditions including the measured 

variable for each of the applicable operating modes described in 

Suba rticle IA-4120(x). 

(1) Temperature: the minimum and maximum temperatures to which 

the instrumentation and control system devices will be subjected. 

(2) Pressure: the minimum and maximum pressures to which the 

instrumentation and control system devices will be subjected. 

3) Relative Humidity: the minimum and maximum relative humidity's to 

which the instrumentation and control system devices will be 

subjected. 

(4) Radiation – alpha, beta, and gamma: the cumulative dosage levels 

and maximum dose rates to which the equipment: will be subjected. 

;5) Chemicals: concentration and duration of chemical exposure to 

which the equipment will be subjected. 

y6) Electrical: all electrical power transients to which the 

instrumentation and control system devices may be subjected. 

Variations in parameters such as voltage, frequency, and current 

shall include minimum and maximum values and their duration. 

;7) Structural: structural loads to which the instrumentation and control 

system components will be subjected. The loads shall include as a 

minimum the applicable loads listed in para. AA- 1211. 

t^ 

B-47 

G5-515 

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IA-4130 Manufacturer's Documentation Requirements: 

When required by the Design Specification, documentation provided by the 

Manufacturer to the Owner or his designee shall include the following, as 

applicable: 

(a) mounting connection details 

) weighttand 

center of gravity 

) service connections, size, type, and locations 

(d) materials of construction 

(e) design life 

f) environmental and seismic qualifications 

(g) mounting restrictions and instructions 

h) loop and logic diagrams 

(i) electric schematic and wiring drawings 

(j) panel general arrangement and construction drawings 

(k) instrument piping and tubing drawings 

(1) Ce rtificate of Conformance 

(m) Calibration procedures and data 

(n) Panel mounted instrument list including nameplate engraving 

o Maintenance and surve i llance requirements 

IA-4140 Clari fication of Code Applicabili ty : 

Pressure retaining pa rt whose design, materials, manufacture, test, and 

documentation are covered by ASME Section III shall be in accordance with 

the applicable requirements of that Code. When conflict exists between this 

Section and ASME Section 111, th e la tter shall take preced ence. 

IA-4200 Single Failure Crite ria: 

Where redundant safety channels are required by the Design Specification, 

the shall meet the single failure requirements of AN SI/IEEE 379. 

. M I .,430Q,,.. ^, e aratibn Criteria „., . - 

_ 

IA-4311 Physical separation of nuclear safety-related circuits and devices shall be in NA 

_ accordance with IEEE Standard s_ 384. 

IA-4312 Instrument Cables, including but not limited to computer, transducer, 

thermocouple, resistance temperature detector, or other low level signal 

_cables shall be installed in separate raceways from power_car in cables. 

IA-4321 Instrument sensing lines and interconnecting tubing for redundant safety 

channels shall be routed a minimum of 18 in. apa rt from each other, in areas 

NA 

_ ree of or protected from missiles, hlgh-enema jet streams, and ip pe wh i s. 

IA-4322 here 18 in. of separation cannot be maintained each line shall be 

separated by a barrier extending at least 1 in. beyond the line of sight 

between redundant sensing lines. The design and installation of separation 

barrier shall b e in accordance with the requirements of A rticle AA-4000. 

NA 

IA-4323 Tubing shall not rest against su rfaces that can cause wear or mechanical 

_ damage. 

IA-4324 Sensing lines shall be routed to ensure that the intended function is not 

-eopardized due to high vibration, abnormal temperature or stresses due to 

thermal expansion. _ _ 

- 

IA-4325 Divisional separation of permanently fi lled capillaries, sensing lines and 

interconnecting tubing for nuclear safety-related devices shall be identi fied 

NA 

_ by color coding and taggincf_as a minimum, at both ends. 

IA-4326 Red undant tubing inside pane ls shall be separated by a minimum of 1 in. NA 

IA-4400 Qualification of Equipment: 

II components shall be operable when exposed to the range of operating 

conditions speci fied du ri ng normal and accident conditions. Manufacturer 

installation and maintenance requirements that are needed to maintain 

qualification of the equipment shall be identified by the Manufacturer and 

followed in th e qualification program. 

B-48 

G5-516

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IA-4410 Normal Operating Conditions: 

All components shall be specified, manufactured, and qualified to ensure 

Aeration within pe rformance limits (e.g., accuracy) when exposed to their 

normal operating conditions. Normal operating conditions include but are 

not limited to exposure to the following: temperature, pressure, humidi ty , 

vibration, chemicals, power levels _and Fluctuations, radiation. 

1,44420 Environmental Qualification: 

Safety related components operating in a harsh environment (as defined in 

10CFR50. 49) shall be quali fied in accordance with IEEE Standard 323. 

NA 

IA-4430 Seismic Qualification: 

Safety related components and mounting shall be seismically qualified using 

he guidelines of IEEE Standard 344 to the Owners required response 

spectra, plus applicable amplification factors, for the components location 

and mounting. Components that do not perform a safe ty-related function but 

must retain their structural integrity so as not to damage, degrade or inte rfer 

with the pe rformance of safety functions by any safety related equipment or 

components shall maintain their structural integrity when subjected to 

_ applicable se ismic loads. 

NA 

IA-4440 Quali fication Documentation: 

The Owner shall have documentation demonstrating the qualification of 

components and showing the Owner's acceptance of the qualification testing 

and results. 

MtR"45t?0 E?anels. ^^ , , 

IA-4511 Control panels shall be designed to support and protect the nuclear safe tyrelated 

instrumentation and controls and to facilitate the monitoring and 

_ control of the mechanical equipment operation and pe rformance. 

IA-4512 Instrumentation and control devices on the front and the inside of control 

panels shall be arranged in accordance with the requirements of ISA- 

RP60.3. 

IA-4513 Temperature limits inside a control panel shall be maintained within the 

allowable specified design temperature range for all components mounted 

_inside th e panel. 

IA-4521 Material for enclosures, stiffeners, braces, suppo rts and frames shall be 

selected to meet the structura l deli n requirements of A rticle AA-4000. 

IA-4522 Support shall be provided for incoming cables, wiring, piping, and other 

appurtenances. 

IA-4523 Subpanels and brackets for mounting instruments shalt meet the structural 

oasis and load combinations set forth by the Design Spec i fication. 

IA-4524 Panels weighing over 200lbs shall be provided with removable lifting eyes or 

other means as required for loading, unloading, and moving the panels to 

heir final installation location. 

IA-4525 All tubing, wire troughs or raceways used in the panel shall be of the metallic 

type or shall be manufactured from fire retardant or self-extinguishing 

mate rial. Nonmetallic components and devices shall be manufactured from 

self-extinguishing materials, as classified by ASTM Standard D635, 

Standard Method of Test for Flammability of Self-Support ive Plastics. 

IA-4526 Panels shall be provided with an integral mounting plate or a separate 

structural channel member, as required by the Design Specification, to 

facilitate the mounting of panels on imbedment plates or anchor bolts 

royided in walls or Floors. 

IA-4531 Wiring bundles shall be suppo rted by such devices as clamps, straps, wire 

_ ties, wire wrap, etc. Uninsulated metallic/wire ties shall not be used. 

IA-4532 Insulating grommets shall be installed through all openings provided in 

partitions for the passage of wires or cables. 

IA533 -4 here a cable crosses a panel hinge, multi-stranded flexible wire shall be 

used. The cable shall also be secured on each side of the hinge, protected 

from damage. 

B-49 

G5-517 

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IA-4534 Both ends of each wire shall be marked with color-coded wire markers as 

_ required by the Design Specification. 

IA-4535 All wiring shall have current capaci ty, mechanical strength, thermal rating, 

and insulation characteristics to meet the circuit. and installation 

requirements :required by the Design Specification and NFPA 70, para. 384- 

9. The wire insulation and Class 1 E cables shall meet the requirements of 

_ NSUIEEE 383. 

IA-4536 Terminal blocks shall be installed on subpanels for terminating cables 

entering and leaving the panels, except that wire leads from thermocouples 

and ce rtain other temperature-detecting devices may be brought directly to 

he terminal blocks in the instrument cases. 

IA-4537 Terminal blocks shall be provided with a marking strip, and terminals shall b 

_ clearly identified. 

IA-4538 The terminal blocks used for the termination of power voltage circuits, the 

control voltage circuits, and signal circuits (low voltage or current) shall be 

-------physically separate from each other. 

IA-4539 The control panel and its appu rtenant equipment shall be connected to a 

round bus inside the panel for personal safety. The method of grounding 

shall not compromise the independence of the redundant safety-related 

'instmments and shall be in accordance with IEEE 1050. A method of 

erminating to the Owner's station ground bus shall be provided. 

NA 

IA-4541 Power supplies within control panels shall be provided with branch circuit 

overload protection and a means to disconnect incoming power. 

IA-4542 Fuses shall be installed in locations free from obstructions. 

IA-4543 Fuses shall be sized to limit fault currents within the requirements of the 

cable insulation. 

IA-4551 Process sensing lines, fittings and valves installed within panels shall meet 

_ he requirements irements of Suba rticle_IA-4600. 

IA-4552 All non-process piping, tubing, or valves installed inside panels shall be in 

accordance with ANSI B31.1 unless otherwise required by the Design 

S ecification. _ 

IA-4553 Tubing bends shall be smooth and formed to avoid flattened, kinked, or 

_ wrinkled bends. 

IA-4554 Panel piping or tubing installation shall not interfere with panel mounted 

_ instrument removal or access to the instrument for maintenance purposes. 

IA-4555 isolation valves and test connections shall be installed in an easily 

accessible_ location to allow in-place calibration of all instrumentation. 

IA-4556 Isolation valves shall not be solely suppo rted by the instrument tubing. 

Isolation valve suppo rts shalt be secured to the panel structure or 

_ sub:;tructure to prevent torque being a plied to the tubing. 

IA-4557 Bulkhead fittings shall be used for termination of the control tubing from 

inside and outside of the panel. 

IA-4558 Instrument lines shall have permanent tags on both ends where required to 

assure proper identification. The type of material, color coding, and method 

of ta tacgq nc1shall be as required by the Design Specification. 

IA-4561 Where required, pressure reducing valves, complete with isolation valves, 

(relief valves, and gauges, shall be installed inside the panel to provide a 

_ re ulated instrument air supply to an instrument air header. 

IA-4562 The instrument air header shall be provided with isolation valves for each 

branch line. 

IA-4570 Permanent nameplates shall be installed on control panels to designate 

instrument function and tag number. Nameplates shall be in accordance 

ith ISA-RP60.6 or the Owner's requirements. 

h^ 

B-50 

G5-518 

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............ 

----- 

IA-1600 IMounted Instruments and Sensors: 

Instruments shall not be mounted in locations where their performance will 

be adversely affected by equipment vibration. Instrument chassis and 

ttached capillary tubing shall be supported to meet the seismic 

requirements for their particular location. 

IA-4 7500— Interconnecting Wiring for Skid Mounted Components: Interconnecting 

circuits between components mounted on a skid shall meet the requirements 

of the National Electric Code, Sections 250-59 and 250-95, and paras. IA- 

4534 and IA-4535. 

kkk W.W M 

IA-1811 Instrument piping, tubing, isolation valves, and permanently filled capillaries 

in systems designed to ASME Section III shall be designed and constructed 

to the requirements of ISA Standard S67.02 as supplemented below: 

NA 

(a) Instrument sensing lines that are connected to Class 2 process piping or 

vessels shall not be less than Class 2 Seismic Category I from their 

connections to the process piping or vessel to and including the 

a ccessible isolation valve. 

.b) Instrument sensing lines that are connected to Class 2 processing 

piping or vessels and that are used to actuate or monitor safety related 

systems shall not be less than Class 2 Seismic Category I from their 

connections to the process piping or vessel to the sensing 

instrumentation. 

(c) Instrument sensing lines that are connected to Class 3 processing 

piping or vessels and that are used to actuate or monitor safety related 

systems shall not be less than Class 3 Seismic Category I from their 

connections to the process piping or ves s el to the sensing 

instrumentation. 

IA-4812 Ins ,irument sensing lines not connected to ASME Section III Class 2 or 3 

vessels or ductwork shall meet the requirements of ANSI B31.1. 

[A-4813 Fitting material shall be compatible with the tube or pipe material to avoid 

-- galvanic corrosion and proLid e _wcepta ble soldering azing joints. 

IA-4820 Tube Pitch and Condensate Trap: 

Nhere the potential for condensation or oil migration exists, condensate or 

oil :raps with valved drain legs shall be provided at the low points of the 

tubing. 

IA-4831 Sensing lines and tubing shall be installed in a continuous support system 

such as metal trays wherever practical. Sensing lines and tubing shall be 

run along walls, columns and ceilings to avoid damage by pipe whip, 

missiles. Jet forces or falling objects. .. 

[A-4832 The support system for instrument sensing or interconnecting lilies shall be 

taken into account in the tray or duct hanger loading requirements. 

IA-4833 Supports for nuclear safety-related sensing lines shall be designed using the 

of Article AA-4000 

--- requirements 

IA-4834 Loads such as thermal expansion and weight of insulatiol shall be evaluated 

in accordance with para. AA-4212 for instrument 

IA-4841 Root valves shall be located in the vicinity of the point of connection to the 

Precess I El or duct. 

IA-4842 Isolation valves and test connections shall be installed in a location to allow 

iA 

IA-4910 

in-place calibration of instrumentation. 

777= 

The 

Owner shall establish setpoints for nuclear safety-related air and gas 

X^ 

re3tment systems with allowance for loop inaccuracy anti 

,—,--margin to assure that systems perform within their de sign limits. 

provision for 

IA-4920 Sa rety-related setpoints and loop error determinations shall be determined 

,using the methodology of ISA Standard S67.04. 

B-51 

G5-519 

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IA-5100 Inspection and testing of instrumentation and control components shall be in 

accordance with IEEE 336. In addition, the requirements of Article AA-5000 

supplemented by the following shall apply. 

IA-5111 Written procedures with acceptance criteria for visual examination, 

inspection and functional testing shall be developed in accordance with 

Subarticle AA-5120 and Article TA-3000 for instrumentation and control 

components. 

IA-5112 The procedures shall be reviewed and approved _ the gNner or designee. 

IA-5120 Test Reports: 

After inspection and testing is completed a written test report shall be 

prepared by personnel performing the test in accordance With Subarticle AA- 

5250. 

IA-5200 Visual Inspection: 

Visual inspection shall be performed in accordance with a written checklist 

per Subarticle AA-5240. For example of a checklist see Nonmandatory 

_Appendix IA-B. 

IA-5220 Methods of Visual Examination: 

Visual examination shall be performed by either method of direct visual or 

— remote visual_ examination in accordance with Subarticle AA-5220. 

IA-5230 Writlen Procedures: 

Visual examination shall be performed in accordance with approved written 

----pror-edures. 

IA-5300 Calibration and Testing: 

Manufacturer's calibration and test instrumentation shall be in accordance 

ith Article TA-3000 and traceable to NIST. 

IA-531 1 11 in s truments and devices shall be calibrated and tested in accordance with 

Drocedures developed for para. IA-5111. 

IA-5312 iring for control power shall be subjected to a Megger test at the panel 

IA-5313 

assembly facility. Megger or other high voltage test shall not be applied to 

instrumentation or shielded cables. 

An electrical continuity test shall be performed to demonstrate the 

correctness of the wiring termination of all panel Mounted instruments. 

Functional tests shall be performed in accordance with written test 

--- procedures approved by the Owner or designee: 

IA-5321 All local mounted instruments and devices shall be calibrated and tested in 

accordance with the Manufacturer's calibration and test procedures and the 

rocedures developed for para. IA-5111 

IA-5331 Pressure testing of pneumatic control circuits shall be performed in NA 

accordance with ISA Standard RP7.1. 

_ IA-5 332 Pressure testing of sensing lines shall be performed in accordance with 

ANSI/ASME 831.1 or ASME Section III as applicable 

^ P'A t,IEN RIC"AT -1 QN. ANOM SE ka, ^YYril.,,; 00"', ,,, WN t 

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IA-0100 General Requirements: 

In addition to the requirements of Article A-6000, the following requirements 

shall apply. 

IA-6111.1 Materials: 

Materials to be used in the fabrication of control panels, instruments, 

devices, components, parts, sensing lines: and support systems, anchors 

and bolts shallconform to the requirements of Article IA-3000. 

IA-6111.2 Materials: 

Thickness of plate material for the enclosure skin, stiffeners braces, and 

frame shall be selected to meet the structural loadings and applicable 

seismic _u i of Article IA-4000 and the Design Specification. 

IA-6112 Repair of materials and surfaces with defects shall be performed in 

accordance with para- AA-6123. 

B-52 

G5-520 

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IA-62:10 Cutting, forming, and bending shall be in accordance with Sub-article AAA- 

6210. 

IA-6211 _ - Thernial cutting shall be in accordance with paq. AA-6212 

IA-6212.1 Paneli Fabrication by Welding: 

hen the control panel enclosure is fabricated by welding more than one 

piece of sheet steel, the welding joint shall be made in accordance with the 

requirements of Sub-article AA-6300. Warping or distortion from cutting, 

punching or welding operations shall not extend beyond the outer edge of 

he panel mounted device. 

IA-6212.2 Panel Fabrication by Welding: 

The control panel shall be all welded sheet steel or plate construction_ 

Reinforcing shall be provided so that the deflection due, to the added weight 

of the instruments will not exceed 0.125 in. for any 4 ft ,o^f panel surface. 

IA-6220 Fittings and Aligning: 

Fitting ij1(^ ni N_ 

q shall be in accordance with Sub-article AA-6230. 

1 0 0 Mechanical Joints: 

Mechanical joints shall be in accordance with Sub-article-AA-6230. .-- 

IA-6300 Welding: 

Welding shall be in accordance_ with Sub-article AA-6300. 

IA-6400 Brazing: 

Brazing shall be in accordance with Sub-article AA-6400. 

IA-6500 Cleaning and Coating: 

CleanLn^ d coating shall be in accordance with Sub-article AA-6500. 

IA-6600 Installation Requirements — Handling and Rigging: 

Handling and rigging shall be in accordance with Sub-article AA-661 0. 

IA-6700 Material Identi fi cation: 

Materials of construction of the control panel shall be as specified by the 

Owner or designee. A Certificate of Conformance shall be supplied as 

re wired by the Design Specification and Sub-article IA-3400- 

Jtt'lx P^^',QKA IN SHIPPJING'^*i.^R RECEIVING EQ1E . _G TORAW 

H.- A N 00 1 

IA-7100 General Requirements: 

Packaging, shipping, receiving, storage, and handling of all control panels, 

instrumentation, and accessories shall be in accordance with Article AA- 

7000 and ANSI/ASME NQA-2, Part 2.2. 

IA-7200 

IA-7300 Shipping: 

IA-7410 

Any control panel made of items requiring different levels of handling shall 

be classified to the highest leve l designated for any of the respective itqms___ 

Packaging: 

All control parels and sensitive instrumentation (if packaged separately) 

shall meet the requirements of packaging level B in accordance with 

ANSI/ASME NQA-2, Part 2.2 paras. 2.2.2 and 3.2.2. 

When bulk accessories are packaged separately (i.e., valves, sensing lines, 

instrument cables) the packaging shall meet the requirements of packaging 

level C in accordance with ANSI/ASME NQA-2, Part 2.2 paras. 2.2.3 and 

3.2.3- 

Identification and marking on the outside of all packages shall be maintained 

and Weather-proofed. 

The mode of transportation used shall be consistent with the protection 

classification of the item and with the packaging rr!ethod_p emo _lk_yed. 

Inspection (Receiving): 

Preliminary visual inspection shall be performed prior to or immediately a fter 

unloading to determine if any damage occurred during shipping. Unless the 

packaging marking prohibits unpacking, the contents of all shipments shall 

be visually inspected to verify that the specified packaging and shipping 

requirements have been maintained. The inspection shall be performed in 

an area equivalent to the level of storage requirement for the item (see Subarticle 

IA-7500. 

B-53 

G5-521

0 




wi 

IA-7420 jDisposition: 

Packages shall be controlled in accordance with ASME NQA-1. 

1^^TE^0_0 torage: 

Control panels and sensitive instruments shall be stored indoors. This area 

shall have paved floor or equal and shall not be subject to flooding. The 

area shall be well ventilated and shall be provided with uniform temperature 

control to prevent condensation and corrosion. Original packaging is 

recommended if item is to be stored for a long period of time. 

Miscellaneous accessories such as valves, sensing lines, and instrument 

cables shall be stored as described above, except that temperature control is 

not required. 

All items shall be plainly marked so that they are easily identi fi ed, and shall 

be stored in a manner as to permit ready access for inspection, 

maintenance, or retrieval without excessive handling to minimize risk of 

damage. 

IA-8100 General: 

Qual,ty assurance for instrumentation and controls shall be! in accordance 

with the requirements of A rti cle AA-8000 and the requirements below. 

IA-8210 Test Reports and Data: 

IA-8211 The following test reports and data supporting the design and installation of 

IA-8212 instrumentation and control devices used in nuclear facilities air and gas 

treatment systems shall be maintained in records: 

(1) All records and procedures that are required to be maintained by ANSI 

1331.1 for the portion of installation designed to ANSI 1331.1 and ASME 

Section III for the portions of installation designed to ANSI 8 31.1 and 

ASME Section Ill. 

_ 2 Documentation as identified in Sub-articles IA-4130 and IA-4440. 

77777777 5,7 

'A f^R* 

IA-9100 General: 

Permanent types of nameplates shall be designed, manufactured, and 

installed in accordance with the requirements of Article AA-9000 and the 

requirements below. 

IA-9200 Requirements,: 

Each instrument and control device shall be provided with a permanent type 

of Ma nufacturer's nameplate. 

IA-9310 Nameplate (Material): 

Nameplates supplied and installed by the manufacturer -,hall be made from 

noncorrosive material. 

IA-63_20 _ Nameplate (Siz_ e): 

Nameplates shall be sized to accommodate all pertinent information. 

IA-9330 Information: 

The following information shall be stamped or engraved on each nameplate 

in lieu of requirements of Sub-article AA-9120: 

a) Manufacturer; 

b) Model or catalog number: 

( c) Serial number; 

j(d)_Range. 

B-54 

G5-5212 

--------------------------------------------- ................................. 

............................ 

. . . 

M:

I 




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ry 

TA-II-1000 Summa ry of Method: 

Ducts and housings which form the pressure boundary of the system shall 

be pressure tested, with air, to the structural capability pressure to verify that 

here is no breach of integrity or unacceptable distortion. Fans, dampers, 

and other components which farm pa rts of the pressure bounda ry shall be 

installed and tested with the ducts and housings to verify the interface 

connection integrity. 

TA-II-2000 Prerequisites: 

Construction, modifications, or repairs affecting the test bounda ry shall be 

complete and inlet and discharge openings of the duct or housing sealed 

before the test is started. Electrical, piping, and instrument connections shall 

be complete and all permanent seals installed before the test is sta rted. 

TA-II-3000 Test Equipment: 

a) pressurization source 

(b) covers to seal test boundaries 

c pressure indicating device accurate_ to +/-0.1 in. w^c 

TA-II-4000 Procedural Guidelines: 

a) Connect the pressurization source to the duct or housing. 

(b) Install instrumentation to indicate the pressure inside the duct or 

!housing being tested. 

(c) Sta rt the pressurization source and operate until the structural capability 

pressure is achieved. Maintain pressure for the duration of the 

inspection. 

(d) Inspect the test bounda ry for breach of integrity or distortion. 

e Release pressure and inspect for permanent disto rt ion_. 

TA-II-5000 Acceptance Criteria: 

II disto rtion shall be measured and compared to the acceptance limits of 

he Owner's Design Specification. 

^,,iFI'anakoryR 

^^.^ ^ } ^ 

^.iy 

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{^11 yIdr ^ ^^' } f 

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^^^ 1$"^ 1^+ ^ 

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TA-III-1100 Summa ry of Method: 

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Ducts and housings that form the pressure bounda ry of the system shall be 

leak tested, with air, using one of the methods listed in this, procedure. 

Either method may be used and will produce a similar result. The constant 

pressure method is useful in testing small volumes whereas the pressure 

decay method is useful in testing large volumes. Fans, dampers, and other 

components that are pa rt of the pressure bounda ry shall be installed and 

tested with the pressure bounda ry to verify inte rface connection leak 

tightness. If the measured leak rate is in excess of the acceptance crite ria. 

he leaks shall be located by one of the methods listed in this procedure. 

After* leaks are repaired, the duct and housing shall be re-?ested to verify 

leak tightness. 

TA-111-2000 Prerequisites: 

Construction, modifications, and repairs affecting the test bounda ry shall be 

comljlete and the inlet and discharge openings of the duct or housing sealed 

before the test is sta rted. All elect rical, piping, and instrument connections 

shall be complete and all permanent seals shall be installed before the test i 

started. For pressure decay testing, the volume of the pressure test 

bound must be calculated. 

B-55 

G5-523 

s lK^' ^^ 

'2'S3 

t 

a




^. Sours ^ eg cede. xZ"e . =v: ^` 5j , ^ ^ r 

TA-III-:3000 

_ . f F'4,r rT. 2«. ---- 

- .AVE.,h ^- 2 _I 

est Equipment: 

(a) pressurization source 

b) covers to seal test bounda ri es 

c) clock or timer accurate to +1-1.0 second 

d) pressure indicating device accurate to +1- 0.1 in. 

(e) flowmeter or totalizing gas volume meter accurate to +1-5% (constant 

pressure method) 

t) temperature indicating device accurate to +1-0.5 degrees F 

(g) bubble solution for detecting air leaks (bubble method) 

(h) optional portable electronic sound detection equipment (audible leak 

method) 

i barometer 

J 

!^$ Qn VW„ 

TA-1 II-4100 Constant Pressure Method... see this a rticle in AG-1 for test procedure) 

TA-III-4200 _ Pres sure Decay Test ... (see this a rticle in AG-1 for test pro cedure 

TA-III-4300 Acceptance Crite ri a: 

If the calculated leak rate exceeds the Owner's acceptance; criteria, locate 

leaks in accordance with one of the techniques outlined in III-4400 or III- 

500. 

TA-111-4400 Bubble Leak Location Method . _(see this article in AG-1 fo r test procedure) 

TA-III-4500 Audible Leak Location Method._. see this a rticle in AG-1 fo r 

^, 

test procedure) 

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10- 1 

'TECHNICAL SPECIFICATION 

IZPP-24544 REV Id 

ameell 



-- DESIGN AND FABRICATION 


Appendix C 


Cover 1 

Butte rfly Control Valves, Example 1 

Full Port Ball Valve, Example 

Check Valve, Example 

Quick Disconnects, Example 1 

Single-Phase Transformer, Example 1 

Distribution Panel, Example 1 

Nonfused Disconnect Switch, Example 1 

Lighting Fixtures, Example 1 

Local Control Station, Example 1 


03-Nov-05 

Cis-525 

Total gta,Sh`^,ex [?ags 10 

1 

1

amec.*- 


Butterfly Control Valves SPEC No. 

10.5579-DSP-037: 

NO. BY DATE REVISION SHEET OF DATE' 

r` 1 t-- 11 1412005 

P.O. 

BY CHK'D APPR. 

Project. Qernons[[a6on,BulkUitnfica6or^^Prolect `- 

1 #Tag No.: DBVSSCBR-HU xoa,^'' i- Se 

REQ. 

rv ice: - 

... .. 

• ' "Scmbber$ys:"' P&ID: DBVSK-_P101- S 

Fluid Code; Desc.: _ _Line 

2 ` Flow rate 

3 * Inlet Pressu re Pt in w.g. 

4 

y *.Outlet Pressure P2 in w.g. 

0 'Differential Pressure dP =P7 - P2 in w.g. 

5 

Q. 

' Inlet Temperature. F 

6 zo ' Speo.Weight I Spec.Gravi ty /Mo l. Weight 

7 m ° Viscosity / Specific Heats Ratio cp 

8 j ' Vapor Pressure Pv I Crit P res s PC 

Units Max Flow Norm F low Min Flow Shut Off 

ACFM -_- 

I 

A 

- - _ 

9 N ' Required Cv - Flow Thru 

io 'Travel l 0 

11 * Predicted Sound press. level (at 1 m.) dBA - Max. 85 dbA 

12 Compressibility (Z) 

Solids conc. I Pa rticule size 0% 

13 Pipe Line Size In - Out 53 'Type 

14 ? Pipe Sch.IW.thick. In - Out 54 ' Manufacturer - Keystone Series 

15 Materl ANSI Ins. 'Model 

16 * Type Bu tterfly Valve ` Std I Full po rt Full 

55 `Size ` Eff Area 

17 

18 

' Size _— __—.__ 

`Valve max P! T° 

ANSI class . _...___ _...._. 57 

56 ^ 

Action Open t Close I Lock 

'Max Allowable Press 

..___.. ..__._._.._.. ....____. 

19 *Manufacturer s'. Keystcne.series 

`Model - 

ss 

60 

a 

' Min Required Press. 

Available Air Supply Pressure: 

- 20 

21 

w 

z 

'Body/Bonnet Maters 

* Liner Mater'I / In Diam. 

_ 

61 

62 

¢ Max. 

* Bench Range 

Min 

22 m End In 63 Actuator O rientation 

23 

24 

o 

m 

Connection Out 

Flange Face Finish 

64 

65 

Handwh'1 Type 

Air Failure Valve Set at 

> ' Face to Face dim. 66 

25 > End Ext 1 Mated 67 Input Signal 

26 ' Flow Direc ti 27 

28 

on 

` Type of Bonnet 

' Lube & Iso Valve 

..... 

_ 

68 

69 

w 

0 

'Type 

Sma rt Commurnc 

' M 29 * Packing Mate rial .. 70 lz 

fr & Model Keystone Se ries 

*.On Incr. Signal, Outpu t. Incr.I Deer. 

30 `Packing Type 71 a Gauges By pass 

32 ' Type 

72 'Cam Chamct's. 

33 ' Size 'Rated Travel 73 Âir Port size ' Boosters 

34 Characteristic 74 Type 24VDC Proximity (3) Quan tity 

35 

36 

'Balanced !Unbalanced 

' Rated ' Cv ' FL ` Xt 

.___ 75 

76 

in s * Mfr & Model —_ 

Nb_ contacts f ra ting 

Keystone 

—_._ 

Series 

_.._._._ 

37 ^r ' PlugBalllDjsk MaVI 77 3: Points 

38 ' Seat Material 78 

39 ' Cage/Guide Mtrl 79 r- ' Mfr & Model 

40 

41 

' Stem Mate rial 80 

81 

0 

a 

' Set Press. 

Filter Gauge ........... 

43 y NEC Crass Group Div. 83 ' Hydro Pressure 

44 

45 

0 

a 

_..... . . '_ 

___ ._.____._ 

84 

85 

'o Leak. Class ---------... 

.......- 

Test Results submi ttals required 

...... ._. 

A7 

48 w 

49 0 

50 $20.50 

G5-526

-- 


Valves SPEC. No. 

145579-D SP=037 

NO. BY DATE REVISION SHEET OF DATE 

amec 

: ' >.1 

BY 

JI 

P.O. 

1-: ` 

CHK'D 

1114/2005 

APPR. 

Project: .Derionstretion-Bulk Vit rification Project • -- -' RED- 

1. Type FULL PORT BALL VALVE 17. MFR. FCOWTEK 

2. Body Size 

3. Body Mate rial 

4. Port Size 

5.Numberof Pods 

6. Guiding _ 

T End ConnlRaing 

8. Packing MatenaVType 

9, Lub ricator 

tO.IsoValve 

11. Bonnet Type 

- 

12. Trim From --_ _ - - ----- _--- - 

13. Trim Material SeaL'Plug 

14. Shaft Mate rial 

15. Required Seat Tightness 

16. Max Al low Sound Level dBA 

Oesign Pressure 

Design Temperature 

Rev: 'Tag. No. Line no. !Equip. P&ID D'a.Seal 

!lath 

NOTES 

-- 

T` 

Max. 

G5-527 

18. hdodel No: ^= 

.- 

19. Flow Carposibon 

20. Required Cv 

21. Wet Press Na TrdMax 

22. Flow Rate NomVMax 

23. dPIMex Shut 08 dP 

24. Temp OperlMex 

25. Oper sp grN'isc 

26. % Supa'heaVFlash 

27. C ritPreW So lids -_---- -_^-^ 

28. M at WtVapor 

29. Fred. Sound Level dBA - 

30. Supp li 

er 

31. Address 

32. Phone 

33. Fax 

Pressure Service Notes 

Norm. Max. Range 

Raw Water, Caus tic 

a 

' ^^ 

RPP-24:544 REV Id 

Valves SPED No. 

145579-0.SP 037 

ND. BY DATE REVISION SHEET OF 

DATE 

l "" 1114=06 

BY JI CHK'D APPR. 

Project: -Uerilonstmbon.6ulk:ViWfifion ca Proleot 

P.D. 

RED. - - 

1. Type CHECKVALVE 17..IAFR. CHECK-A LL 

2. Body S lae 

3. Body Matedal 

4. Port Sae 

5. Number ct Ports 

S. Quidug 

7- End Com Rating 

B. Pscldrg Matedal/fype 

9. Lubricbr_ 

10.'suv*e _— --- 

fl. BonnetFype 

12. Trim From 

— 

43. T rim Material SeetiPlâg _ _ 

- 

_ -- 

14. She Maledal -- 

15. Requied Seat Tightness 

15. MasAllow Sound ttuel dBA 

Design Pressure 

Design Temp erature 

Rev. 'Tag-ft Line M. icquip. MD Da Sea: 

Malrl 

NOTES 

T° 

Max 

1 11 Model NO. 

19. Flow Composition 

20. Required Cv 

21. Inlet Press NmMMax 

22. Flow Rate Na ululm 

23. dFlMax Shut Off tlP 

24. Temp OpedMax 

25. Oper sp grMsc 

26. %SuperheaUFlash 

27. Oil Pressl% SoSds 

28. Mot WINapor 

29. Red. Sound Level dBA 

30. Supplier 

G5-528 

31. Addres s 

32 Phone 

33. Fax 

Pressure 3enice Holes 

Ncrn. -.•. Hanne 

ameO 


Quick Disconnects SPEC. No. 

445579-DSP-637.1.. 

NO. BY DATE REVISION SHEET OF DATE 

BY 

P.O. 

J{ 

IIMO05 -. 

CHK'p APPR. 

Project: Demonstration.BulkiVdrificaGon Protect ^ :ì; ' REO.. - 

IX .. 

1. Type 

"Andrews"f °Boa-Lodc'Ty pe A Adapters 

4. MFR. D ON VALVE &COUPLING 

.._ 

2. Material - — 

5. Model No _... - 

.. ...: 

Gouphng 

3. Body Size 

4. NPT Thread Sze - _-- ---- 

5. Flow at 180 psi 

Rev. .'Tag. No. Line no. Equip, P&ID Dia.Seal 

Matr7 

NOTES 

T° 

Max 

G5-529 

6. Supplier DIXON VALVE & COUPLING 

7. Address PORTLAND, OR 

8. Phone (503) 289-0400 

9. Fax - 

Pressure Service Notes 

Non. Max. Range 

... 

- 

- 

4 

G 

G 

- 

520.41

am - Hanford Site

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