View Document Here - Hanford Site

Document # 

Title 

DATE 

0601116 

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 

07/24/2006 

Originator J. A. HEDGES Originator Co. DOEC 

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

SPEARS

f 

amece 

Project: Demonstration - Bulk .Viteirication Project 

RPP-24544 REV Id 

Single-Phase Transformer 

NO. ' BY DATE I REVISION 

1. Volts 460-120/240V m. single-phase 6. MFR. 

2. kVA _ _ 7. Model No 

3. Coil material copper 

4. Temperature rise 115 deg C (min) 

G5-530 

8. Supplier 

9. Address 

10.Phone 

11. Fax 

SPEC. No 

i45519-0.5P-037'.a 

IEET OF DATE 

,;c1 'jai 11/412005 

BY CHK'D APPR. 

EO. 

Kim 

c 

c 

c 

4 

4 

4

Project: Deoxins Ttron Bulk Varification^P.rgect- 

VIMIDntlon Yanel 

W. BY DATE RE 

1. Volts 1201240V ac, single-phase 9. MFR 

2. Amps 

10, Model No. 

3. Breaker type Bolton 

4. Main Breaker Yes 

4.a. Amps (trip) 

4.b. MFR 

4.c. Model No. - 

5. Therm. Mag. breakers yes 

5.a. MFR 

5.6. Model No. 

6. GFCI breakers yes 

6.a. MFR 

6.b.Model No. 

7. GFPEbmkers Yes 

7a MFR 

7.6. Model No. 11. Supp lier 

6. Documentation detaged panel schedule, inside door 12: Address 

Rev. - 7ag. No, Line no./Equip. FWD 

G5-531 

13.Phone 

14.Fax 

SPEC. No. 

DATE 

v 

c 

4 

c 

4 

4 

4 

4 

4 

c 

4 

4 

4 

4

ameO 


Nonfused Disconnect Switeh SPEC No. 

1h3643^^D-SP-037 :c 

_ 

NO. BY DATE REVISION SHEET OF 

1 =Y': 

roject: Demonstration Bulk Vit rifica tion Project IREQ. - 

1. Volts 480V ac 

2 Amps (frame) — ---^ 

3. Poles 3 — 

4. Enclosure NEMA4 

5. Options 1 NO, INC auxiliary contact (tor motor circuits only) 

-- —__--..— 

- 

6. MFR 

7. Model No. 

8. Supplies 

9. Address 

10. Phone 

P.O. 

BY 

JJ1 

DATE 

ft/42005 

CHKD APPR 

Rev. 'Tag. No. Line no: tEguip. _-- — P81D --_ ^ --- -----. Notes 

G5-532 

11. Fax 

- 

4 

ame& 

RPP-24544 REV P.d 

Lighting Fixtures 

NO. BY DATE RE 

Project: Demonstrat5on Bulk.Vitrifica tion Project '-' 

1. VORS 

2. Watts ----- _----_-^-- 

9. MFR. 

10.lode]l 

3. Quantity 

4. Flxlure type 

5. lamp Type 

6. Ba ll 

ast 

7. Diffuser -- --- — 

8. Mounting 

9. Operating temp. wits 

G5-533 

11. Supplier 

12.Address 

13. Phone 

14. Fax


ame 

TECHNICAL DATA SHEETS 

PROJECT: Final DBVS Design 145579-DSP-037 

;PROJECT NO.: 

:.LIENTc 

c--^ 

145579 

AMEC ERE -Richland Washington 

Local Control Station 

No. Required TBA Area 

PFD # Stream No. 

Quality Assurance Level Commercial 

Operating Conditions Rev Rev 

Location (Indoorstoutdoors) 

Operation - Days per year 

365 

Operation (continuousimtermittent) 

- Hours per day 

24 

Max. Ambient Air Temp. (° F) 

Availability % 90 

Min Ambient Aar Temp. (° F) RS,.-25 Elevation (ft) 

663 

Equipment Numbers 

Environment - Radioactive 

Yes 

-Toxic 

No 

-Corrosive 

No 

- Flammable 

No 

. 

Equipment data A-B Part # Materials 

Enclosure (surface mount)) 

NEMA 4 8007-4TZ Enclosure 

Die Cast 

Dielectric strength (> 1 minute) 

>1000V Standard Legend Plate 

Aluminum 

Push Button-red (1N.0+1 N.C.)'Start" 

Momentary 800T-A6A 

Push Button-green (1N.0+1 N.C.)"Stop" 

Momenta 800T-A1A 

Pilot light -red 020VAC, LED type with transformer) Running 80OT-PH16R 

Pilot light -green (120VAC, LED type with transform Ready 80OT-PH160 

Standard legend plate.- START 

80OT-X547 

Standard legend plate - STOP 

80OT-X550 

Voltage (continuous) (v) 120 

Ampere (max continuous rate) (A) 

10 

Approvals UL Listed 

mish Enclosure Layout 

By VENDOR (Yes/No) 

Yes Conduit entries (bottom only) 

Painting -External 

-Internal 

READY 

Comments/Notes: - 

1) All items with an shall be filled in by the Seller. 

2 Allen-Bradley Catalog have been indicated. Approved equals may be submitted. 

G5-534 

0START 

RUNNING 

STOP


PROJECT: Final DBVS Design 145579-D-SP-037 I REV.1 

PROJECT NO.: 145579 WET SCRUBBER SKID ASSEMBLY 

DESIGN AND FABRICATION 

CLIENT: AMEC E&E - Richland, Washington 

Appendix D 

TFC-ESHQ-Q_C-C-03, Revision C-2, Control of Suspect/counterfeltitems 

(54 pages including cover) 

WET SCRUBBER SKID ASSEMBLY DESIGN AND FABRICATION 

03-Nov-05 

G5-535


CH2M HILL Hanford Group, Inc. Manual ESHQ 

Document TFC-ESHQ-QS-C-03, REV C-2 

CONTROL OF SUSPECT/ Page 1 of 53 

COUNTERFEIT ITEMS Issue Date October 5, 2005 

Effective Date October 5 2005 

APPROVAL AUTHORITY: G. M. Giant 

DOCUMENT OWNER: J. L. Logston 

TABLE OF CONTENTS 

1.0 PURPOSE AND SCOPE ................................................................................. ............................... 2 

2.0 IMPLEMENTATION- ....... :............ .. ............ ............. .... ......... ........... ... ....................................... 2 

3.0 RESPONSIBILITES .................. ........... .......................................................................................... 2 

3.1 Procurement Personnel ..................... ..........`--°--................................. ...................:........... 2 

3.2 Inspection Personnel ................ ............................ ............. :.............. ... ....... ......................... 2 

3.3 Quality Assurance Engineer.. ........ -- ................................ - ................... .......................... 2 

3.4 S/CI Coordinator... .................:.................................._........................ ............................... 2 

3.5 Assigned Engineering Personnel ...................................... ....:............................. ............ .... 3 

3.6 Responsible Managers and Supervisors .............................................. ............................... 3 

4.0 PROCEDURE ............................ ..................... .......................... .. ........................... ...- .................3 

4.1 Introduction ........................................................................................ ............................... 3 

4.2 Procurement ......................................................................................................................3 

4.3 Inspection for Potential S/CI .......... .... ............................. ................................................... 4 

4.4 Control of Material Identified as S/CI ..... ................................ --- ...... ....:.......................... 4 

4.5 Reporting of S/Cl ......... .. ........................................................... .. ....... ................................ 5 

4.6 Acceptance, Removal, and Disposition of S/CI .................................. ............................... 5 

4.7 Surplus/Excess Material._ .............. .............. ................................................ ...................... 7 

4.8 Assessments..... ... ................... ................. ....... ..... - ................................... 7 

4.9 Training .......... ........... ............... ................................ ............................................... 7 

5.0 DEF'INITIONS ................................................._................... 

............................. 8 

6.0 RECORDS...... ......... ........ ............... .................................... 

...................................... 9 

7.0 SOURCES . --- _ ....................................................__...._.._. ............................................... 9 

7.1 Requirements ............................................................ .............................................. 9 

7.2 References .........._ ........................................._.......... ..................... .....................10 

TABLE OF FIGURES 

Figure 1. Management of Suspect/Counterfeit Items. I 

TABLE OF ATTACHMENTS 

ATTACHMENTA - SUSPECT COMPONENTS LIST.. ............................ .........................................._. 12 

ATTACHMENT B - CLASSIFICATION OF POTENTIALLY SUSPECT/COUNTERFEIT ITEMS.... 30 

ATTACHMENT C - SUSPECT/COUNTERFEIT ITEMS INFORMATION SOURCE LIST ................ 32 

ATTACHMENT D - CHARACTERISTICS THAT MAY MAKE PRODUCTS VULNERABLE TO 

MISREPRESENTATION, FRAUDULENT PRACTICES, AND COUNTERFEITING......... 34 

ATTACHMENT E - WHERE TO LOOK FOR SUSPECT/COUNTERFEIT ITEMS ................._....._. - 35 

ATTACHMENTF - SUSPECT/COUNTERFEIT PARTS DETECTION ..... :....................................... ... 36 

ATTACHMENTG-FASTENERS ........................................... -------.41 

ATTACHMENTH - DOE HEADMARK LIST ............ --------- ........................._.......__-:---------................. 45 

ATTACHMENT I - REFURBISHED MOLDED CASE CIRCUIT BREAKERS...__ ............................. 47 

ATTACHMENT J - ASSESSMENT/SURVEILLANCE LINES OF INQUIRY .... ---- ............... .---- - 51 

ATTACHMENTK - RECENTLY IDENTIFIED S/CI ISSUES ....-- ................................................. 53 

G5-536

RPP-24544 REV ld 

ESHQ Document TFC-ESHQ-Q_C-C-03, REV C-2 

Page 2 of 53 

CONTROL OF SUSPECT/ Effective Date Ocitober 5, 2005 

COUNTERFEIT ITEMS 

1.0 PURPOSE AND SCOPE 

(z.l.t) 

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

and disposition of suspect/counterfeit items (S/CIs) 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 RESPONSIBILITIES 

3.1 Procurement Personnel 

Maintain awareness of S/C1 and support S/CI program implementation. 

3.2 Inspection Personnel 

Perform inspections for conformance or acceptance of material including verifications that die 

item(s) being inspected do not exhibit indications attributed to potential suspect/counterfeit items. 

3.3 Quality Assurance Engineer 

1. Ensures appropriate procurement controls are implemented to preclude entry of S/Cl to 

the site through review of procurement documents. 

2. Notifies the S/CI 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. 

G5-537



Page 3 of 53 

CONTROL OF SUSPECT/ Effective Date October 5, 2005 


3.5 Assigned Engineering Personnel 

I. Evaluate S/CI information for applicability to design and procurement specifications, 

system configuration, and operating conditions. 

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 

Maintain awareness of S/CI. 

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 

The 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 I. Ensure material requirements are specified in subcontracts to preclude 

Personnel the purchase or introduction of S/CI. 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/CI_ 

2. Ensure material requests for quality level I, 2, and 3 items and services 

include appropriate technical specifications, procurement quality 

clauses, documentation, and inspection requirements to prevent 

introduction of S/CI. 

3. In maintenance and construction/fabrication subcontracts, specify 

appropriate requirements to preclude the purchase or introduction of 

S/CI. 

G5-538



Page 4 of 53 



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 items and services and is based on the vendor's 

ability to demonstrate the capability of delivering acceptable items. 

43 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 in 

accordance with the requirements of TFC-BSM-FPM MC-C-01. 

2. Ensure quality level 0 and P-Card items are inspected prior to material 

issuance. 

First Line Manager 3. Obtain on-site S/CI inspection for quality Ievel 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 J. 

S. If an S/CI is detected during inspection activities, document and control 

the S/Cl 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-O 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/CI. 

2. Transfer tagged S/CIs to 2101-HV for storage. 

Cognizant Quality 3. Notify the S/CI coordinator of all NCRs associated with the S/CI. 

Engineer 

G5-539

RPP 24544 REV lid 


Page 5 of 53 



4.5 Reporting of S/CI 

Assigned Company 1. Report all items identified as potential S/CI in accordance with 

Personnel TFC-OPS-OPER-C-24. (7.1.1) 

NOTE: Reporting of S/CIs is required regardless of safety class, where 

the S/CIs are located (receiving inspection, inventory/storage areas, 

fabrication and maintenance areas, installed, etc.), or their operating 

status. 

S/Ci Coordinator 2. Notify the DOE S/CI 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 S/CIs. 

Notification should be e-mailed to the DOE local Office of Inspector 

General points of contact providing information in the following 

format: 

4.6 Acceptance, Removal, and Disposition of S/CI 

• 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. 

S/CI Coordinator 1. Notify responsible company personnel that S/CI 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 GenemI 

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 S/CI material for final disposition and/or disposal as 

directed by the S/CI coordinator. 

G5-540



Page 6 of 53 



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/Cl 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 8.2 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 S/CI 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. 

GS-541



Page 7 of 53 


. COUNTERFEIT ITEMS 

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/CIs may be acceptable if they do not contain hazardous 

material or material prohibited by federal, state, or Iocal regulations. 

Responsible 1. 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. 

- Performance 1. Conduct assessments of the effectiveness of the S/CI program. 

Assurance 

NOTE: The assessment should be performance based and designed to 

determine if company activities are conducted in accordance with this 

procedure, DOE 414.1 B, DOE 0 440.1 A; DOE G 41.4.1-3, and 

10 CFR 830, Subpart A. 

4.9 Training 

2. Lines of inquiry will be used as appropriate during assessments in areas 

that interface with the S/CI process. See Attachment L 

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 SICI 

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 Assuraneeltechnieians 

• Engineers (design, systems, etc.) who procure materials/ 

equipment 

• Maintenance personnel (electricians, pipefitters, millwriglits, 

instrument technicians) 

• Warehouse personnel who handle and process materials/ 

equipment 

• Tool crib attendants- 

G5-542


FSHQ Document TFC-ESHQ-Q_C-C-03, REV C-2 

Page 8 of 53 



S/CI Coordinator 3. Collect, maintain, disseminate, and use the most accurate, up-to-date 

information on S/Cls and suppliers using all available sources, 

including: 

5.0 DEFINITIONS 

• Govemment-Industry Data Exchange Program 

(www.Q den.orr ) 

• Institute of Nuclear Operators ( www.inpo.orgl 

• DOE Occurrence Reporting and Processing System 

• DOE Suspect/Counterfeit web site 

(http://tis.eli.doe. goylpaa/sci1. 

NOTE: Information identified during this review that may be 

applicable to CH2M HILL's on-site suspect/counterfeit program will be 

provided to the appropriate personnel using one of the following 

methods: lessons learned, required reading, briefings, training, or 

changes to this procedure. 

Counterfeit M. A part 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: 

Fastener (regardless of the safety classification). 

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 terms; or 1/4 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 (ASTM) A 307 Grade A or produced in accordance with ASTM F432. 

Grade identification. Any symbol appearing on a fastener purporting to indicate that the 

fasteners 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 graded fastener. Fasteners having a minimum tensile strength of 75 ksi, including 

those produced and procured in accordance with the Society of Automotive Engineers Standard 

G5-543


ESHQ Document TFC-ESHQ-QS-C-03, REV C-2 

Page 9 of 53 

CONTROL OF SUSPECT/ Effective Date October5, 2005 


J429, Grades 5, 5.2, 8; and 8.2; ASTM Standard A325, Types 1, 2, and 3; ASTM A490, 

ASTM A354, ASTM A449 (I&II), 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. 

An all-inclusive term used in place of any of the following: appurtenance, facility, sample, 

assembly, component, equipment, material, module, part, structure, subassembly, subsystem, 

system, unit, documented concept, or data. 

Substantial safety hazard. A loss of safety function to the extent that there is a major reduction in 

the degree of protection to the public or employee health and safety. 

Suspect/counterfeit 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 S/CI if the nonconformity results from one or more of the following conditions, which 

should be controlled by site procedures as nonconforming items: 

6.0 RECORDS 

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. 

No records are generated during the performance of this procedure. 

7.0 SOURCES 

7.1 Requirements 

TFC-PLN-02, "Quality Assurance Program Description." 

G5-544

RPP-24544 REV 1d 

ESHQ Document TFC-ESHQ-Q_C-C-03; REV C-2 

Page 10 of 53 



7.2 References 

1. DOE G 414.1-3, "Suspect/Counterfeit Items Guide for Use with 10 CFR 830 Subpart A, 

Quality Assurance Requirements, and DOE O 414.1B, Quality Assurance." 

2. HNF-SD-MP-SRID-001, "Standards/Requirements Identification Document for the Tank 

Farm Contractor." 

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 (P-Card)." 

6. TFC-BSM-CP_CPR-C-03, "Buyer's 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-1 I, "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, Èngineering Program Management Plan." 

G5-545

No 

Identify and mark 

8/0 and iocaiion 

Will the S/Cl be 

removed/rcplaecd du 

maintenance" 

Disposition SIC[ to 

^reman in place 

RPP-24544 REV id 


Page 11 of 53 



Figure 1. Management of Suspect/Counterfeit Items. 

Safety System Non-Safety System 

When.SlC[discovered, When SlCi diswveteA 

n: via ORPS and to report vra ORPS and to 

local OIG focal OlG 

Conduct engineering 

evaluation 

Could 

S/CI in safety 

system create safety i 

No hazard? Yes 

Lock out/tag out the 

system 

Dispose ofthe SiCl 

KrY: 

,^ Will S/CI ^ 

removal be required 

during routine 

Yes 

Remove/replace the Remove/replace and 

S/Cl dispose of the S/Cl 

G5-546 

Mark S/CI 

OIG: Office oflnspwor Geneml 

ORPS: Occu rrence Reporting and Processing 

System 

S/CI: Smpect/Counterfeh Items 

isposition SICi 

remain in place



Page 12 of 53 



ATTACHMENT A - SUSPECT COMPONENTS LIST 

This list was extracted from the U.S. 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 a supplier or manufacturer if S/CIs 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 S/CI must be examined on its own merit without making 

premature conclusions regarding fault or culpability of the manufacturer or supplier whose name is 

associated with the S/CI. 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. 

G5-547



Page 13 of 53 


COUNTERFEITITEMS 

ATTACHMENT A - SUSPECT COMPONENTS LIST (cont.) 

Component Manufacturer/Type Description Supplier References 

Circuit Breakers General Electric Metal clad, low Satin America & Circuit NRC I.N. 89-45, 

(Component Examples) voltage, DC Breaker Systems Inc. Supplements and 

Attachments SENS 

• A.KF-2-25 

• EC Trip Types, E-C- 

1, E-C-2A 

• AK All Types 

Report ID #6 5/23/89 

Circuit Breakers General Electric 1, 2, & 3 pole, Bud Ferguson's Industrial NRC LN. 88-46 

(Component Examples) various amperages Control & Supply, Inc., Supplements and 

Attachments 

• AK-3A-25 General Circuit Breaker & 

• KHL-36 125 

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 

' TI-) 

• TEB 122015-WL 

• TEB132090-WL 

• T.E111015 

PENCON International 

(DBA). General Magnetics/ 

Electric Wholesale 

• JED134060-WL Lakeland Engineering 

• TEB124050-WL 

• THED136100 WL 

Equipment Co. 

• TED126050 ANTITHEFT Systems, Inc. NRC I.N. 90-46 

• THEDI36060 WL 

• THGB2120 

• TEF 134015 

(DBA) ATS Circuit Breakers 

and AC. Circuit Breaker 


• THEF136M 1100 

CaliforniaBreakers 

• TED 134030-WL 

• AK2A25 

• TIIED-136100-WL 

• THED-136050-WL Voyter Electric Co. Office of Nuclear 

• THED-136045-WL Safety 93-5(#11) 

• THFK-236070-WL 

• TE-122070 

• THED-136150-WL 

• THED-13600-WL 

• TED-113020 

• TEC-36050 

• THED-124015-WL 

GS-548



Page 14 of 53 





Circuit Breakers Westinghouse 

(Component Examples) 

• TF136090 

- • TF36105OWL 

• TED 1130020 

• Not Provided Commercial Grade Westinghouse NRC I.N. 9148 

Electric Supply Co. 

(WESCO) 

• DB-25 & DS-416 

Low Voltage Satin America & Circuit NRC I.N. 89-45.& 

Breaker Systems, Inc. Supplement 92 

- • 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 I.N. 88-46, 

Supplements and 

Attachments 

Office Of 

Nuclear Safety 93-9 

• FB3050 California 

• EHB3025 

• LBB3125 

Breakers, Inc. 

• HKA31250 PENCON International 

• IA3200 (DBA) General 

• EHB2100 Magnetics/Electric 

• 225N 

Wholesale 

• EB 1020 

ANTI THEFT Systems, 

• HDEA 2030 

Inc. (DBA) ATS 

• MCP331IOOR 

• MCP431550CR 

• BAB3060H 

• 656D 14 8G03 

Circuit Breakers 

I and AC Circuit 

Breaker - 


• FA-2100 

• EH-2050 

• HFB-3050 

Molded Case 


• HFD(B)-3020 

• MA3600 

NSSS, Inc. 

• F2020 

• EH2100 

• EB3050 

• HMC380OF 

Spectrum, Tech. 

• EA2090 

Rosen Electric 

• FA3125 

• HMCP 150 - Luckow Circuit Breaker 

G5-549



Page 15 of 53 




Component. Manufacturer/Type Description Supplier References 

Circuit Breakers Westinghouse (cont.) 


• HFD 

• EH2O70 

• FA2050 

• JA2225 

• JL313125 

• R313070 

• JL3BI50 

• JL3B200. 

• JL313090 

• JL313100 

- .Shunt Trips Aux. 

Contacts 2 & 3 

pole circuit 

breakers of 

various amperages 

General Circuit 

Breaker & Electrical Supply 

HLC Electrical Supply 

(DBA) G International Ma nat 

{DBA) General Magnetics/ 


NRC I.N. 8846 


Attachments 

• HLM3800T. 

• F310ON 

• MA3500 

• EH2O15 

ANT! THEFT Systems, 



and AC Circuit 

• FA3035 Breaker - 

• FA2100 Electrical Supply 

• HLA2125OTM 

• EH2O70 

• JB3100 

Molded Case 

• EB2030 


• 8MC800 

• CAH3200 

• EHB3040 

• JL3-B150 

• 31,3-13200 

• JL3-13090 

• JL3-131000 

• HFA, HFB, FA 

• JL3-(B)8070 

• JL3-13125 

• EH-2020 

• FA-3035 

• EH-2050 

• FA-2100 

• FA-2050 

• HFB-3050 

• JA-2225 

• HLM3800T 

• F3100N 

• MA3500 

• EH2O15 

• LA320OWL 

• HLA3200T 

- Co. (MCCB) 

• 2602D58U9 - 

G5-550



Page 16 of 53 




Component ManufacturerfFype Description Supplier References 

Circuit Breakers Westinghouse (cent.) 


• HLB3200T 

• 262I56GI9 

NRC I.N- 88-46 Sapp. 

• T A & 1 B 

& Attach. 

• HL300T 

• HLA240OTM 

• HMA3600T 

• HMA3700T 

• HKA3225T 

• HKA3225T 

225 amp, 3 pole 

3 pole, 20 amp 


I .pole, 20 & 30 amp 

2 pole, 20 & 30 amp 


Not Provided 

• MDL#KAF 

• QNB3020 

• QN33030 

• BA 

SENSID#10 

3-17-89 

SENSID#11 

3-3-89 

3 pole, 20 amp Not Provided 

• BA ° 

• BA 

Circuit Breakers ITE (Component 

Examples) 

• E3060 (. 

SENS Report ID #12 

• F3020 I0-19-88 

NRC LN. 88-46 

• Model - E43BO15 3-phase 480 volt Cal. Breakers/Elect. SENS Report ID #8, 

Wholesale Supply Co. 5-5-89 

• EQ-B I pole, 20 amp 


Not Provided SENS ID #10 3-17-89 

• EE-3B030 

SENS ID #11 3-3-89 

• EF313070 

• EF3H050 

• EF3BI25 

2 & 3 pole various 

amperages 


Breaker & 


NRC I.N. 88-46, 


Attachments 

• EF3B040 

• E42BO20 


• QJ213200 

• JUB400 

Supply 

G5-551



Page 17 of 53 


COUNTERFEIT STEMS 



Circuit Breakers ITE (cont.) 


Circuit Breakers ITE, Gould & ITE 

Imperial 

• HE913040 California 

• EE313050 


• BQ2B030 

• EE313070 

• EE213100 

• EE2B050 

• EE213030 

PENCON 

International(DBA) 

General Magnetics/ 


. 

• FJ313225 

ATS Circuit 

• ET 

• KA 


• EH-313015 

• JL-3B070 

• JL-3BI50 

Panel Board 

Specialties 

• E43BO15 Rosen Electric 

• EF2-B030 

• EH36200 

• QPIB020 

• QJ3B200 

• EF3B100 

Equipment 

• 1193 

Brown Boveri Elect. 

(BBE) 

ASEA Brown Boveri 

(Component Examples) Not Provided Brown Boveri NRC LN. 89-86 

ID-4KV ASEA Brown Boveri 

• Type HK Not Provided NRC I.N. 87-41 

• 5 H Not Provided - 

• 7.5 HK Not Provided Office of 

• 45 HK Nuclear Safety, 

• 38 HK 

• ITE 62-6 

92-25 

Circuit Breakers Square "D° Co. 

Component Examples 

Molded Case General Circuit 

Breaker & 


NRC I.N. 88-46 

Supp. &.Attach- 

NRCB 88-10 


NRC LN.90-46 

• KHL 36125 

(Any Type) 

California 


G5-552 


(DBA) General 

Magnetics/Electric 

Wholesale



Page IS of 53 





Circuit Breakers Square °D" Co. ANTI THEFT Systems 

Component Examples Inc. (DBA) ATS 

(cont.) Circuit Breakers 


Breaker - 


• QOB220 I 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 

breakers 

Breaker & 


Supplement 42 

• SBW-12 

• 989316 

• FAL3650-16M 

or 

• FAL36050-16M 

• KA36200 

3 pole -200 amp 

breaker 

30AI600V 


California 


• 999330 

Not Provided PENCON International 

(DBA) General 


Wholesale 

Manufacturer not 

Not Provided Stokely Enterprises DOE Letter 8-26-91 

Provided 

Reprinted 

Molded Case NuVEP: Bulletin 

• EHB3025. Circuit Breakers 7-26.91 

Circuit Breakers Fed. Pacific General Circuit 

(Component Examples) Breaker& 


• NEF431020R 3 pole, 20 amp. 

• NEI 11020 1 pole, 20 amp HLC Electric Supply 

Y • NE I pole, 15 amp 

California 

{ Breakers, Inc. 


(DBA) General 

- . Magnetics/Electric 

Wholesale 

G5-553 

SENS ID. #10 

3-17-89


ESHQ Document 'ITC-ESHQ-QS-C-03, REV C-2 

Page 19 of 53 





Circuit Breakers Fed. Pacific 


(cont.) ANTI THEFT Systems, SENS ID. 911 

Inc. (DBA) ATS 3-3-89 

• NF63-1100 1, & 3 pole- Circuit Breakers 

• NE224060 30, 60 & 100 amp and AC Circuit 

• NE22-4100 breakers Breaker- 

• NEF-433030 


{ 

• 2P 125 

General Circuit NRC I.N. 88-46, 

Breaker& Supp.&Attach. 


HLC EIectric Supply 

California 


Jefferson (Component Not Provided PENCON International NRC I.N. 88-46, 

Examples) (DBA) General Supp. & Attach. 

Magnetiesletectric 

Wholesale 


Inc (DBA) ATS 



Breaker - 

. Electrical Supply 

Mid Nest Co. 

Circuit. Breakers Superior(ComponcnR Not Provided General Circuit NRC I.N. 88-46 

Examples) Breaker & Supp.& Attach_ 


• 246U-3 - 


G5-554 


California 


PENCON International - 

(DBA) Gene ra ( 

MagneticstElectric 

Wholesale 


Inc (DBA) ATS 



Breaker - 

Etectricat Supply


ESHQ Document TFC-ESHQ-Q_C-C-1)3,REV C-2 

Page 20 of 53 





Circuit Breakers Manufacturer Not General Circuit NRC LN. 88-46, 

Provided Breaker & Supp. & Attach. 

(Component Examples) Electrical Supply 

50DHP250 2 pole - 50 amp HLC Electric Supply 

Circuit Breakers Cutler Hammer 


California 


PENCON 

International (DBA) 

ATS Circuit 

Breakers and AC 

Circuit Breaker - 

- Electrical Supply 

Heaters . €0177HI3 Not Provided AAKER 


NRC I.N. 8846, 

Supp. & Attach. 

• 10177H21 Breaker& 

• 10177H32 


• 10177HO36 

• 10177H 1049 

- 


Supply 

G5-555 

California 



(DBA) General 

Magneti&Electric 

Wholesale 





Breaker- 

Electrical Supply

f 



Page 22 of 53 



ATTACHMENT A - SUSPECT' COMPONENTS LIST (cont.) 


Switches (Component Examples) 

Crouse Hinds Tumbler, ft. op Platt Electric SENS ID #16 

#EDSC2129 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 

Transmitters Rosemount (Component Venetech E.L. Wilmot 

Examples) letter dated 

8-1-91 

• Model 1151 GP 

• Model 1151 DP 

H. Richardson 

letter HR-81-91 

dated 8-15-91 

Motors Siemen & Allis General Circuit NRC I.N. 88-46, 

(Component Examples) Breaker & Supplements and 

Electrical Supply Attachments 

INP 143 T 10 H.P. 

215 T HLC Electric Supply 

California 



(DBA) General 


Wholesale 

i 


1 Inc. (DBA) ATS 



Breaker - 


G5-556 


Equipment -


Page 22 of 53 

CONTROL, OF SUSPECT/ Effective Date October 5, 2005 




Relays Potter & Brumfield Not-latching Stokely Enterprises NRC I.N. 90-57 & 

(Component Examples) rotary Attach. 

Spectronics, Inc. 

MDR-139,173-1 

134-1; 142-1 Nutherm International 

The Martin Co. 

Teledyne All qualified to Not Provided DOE-ID Wilmot 

M1L-R-28776 and letter, 7-16-91 

MIL-R-39016 

G.E. & Exide Overload & Aux. General Circuit NRC I N. 88-46, Supp. 


• 12HGA-11552 

Breaker & 


& Attach. - 

• NX 400 




(DBA) General 


'j Wholesale 


Inc. (DBA)ATS 



Breaker- 


Manufacturer not Not Provided Stokely Enterprises DOE Letter 8-26-91 

provided 

Reprinted 

NuVEP: Bulletin 

• FSC-5945 

7-26-91 

Amerace.(or Agastat) Electra Amerace SENS ID#111-1-91 

(Component Examples) Pneumatic Timing 

Relays Control Components NRC I.N. 92-24 

Models: 

E7024 

E7022 

Supply 

A through L 

Series Mode l[ 7032 

PRI3 

G5-557



Page 23 of 53 





Fuses Bussman Co. 15A-250V & General Circuit NRC I.N. 88=46, 

(Component Examples) 3OA-600V Breaker & Supp. & Attach. 


REN 15 & NOS-30 




(DBA) General 

Magnetics/Eleetric 

Wholesale 





Breaker- 


Class I All Supplied by Preventive NRC I.N. 88-19 

PMS Maintenance 

Systems (PMS) 

Controllers S 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 I.N. 88-45 

(Component Examples) Breaker & Supp. & Attach. 

Electrical s Supply 

626B] 87GI7 HLC Electric Supply 

626BI87GI3 

California Breakers, Inc 


(DBA). General 


Wholesale 

. ANTI THEFT Systems, 

Inc (DBA) ATS . 



Breaker- 


Resistors Unknown All Impala Electronics NRC I.N. 91-01 

G5-558


ESIIQ Document TFC-ESHQ-QS-C-03, REV C-2 

Page 24 of 53 





Semiconductors Solid State Devices P-Channel MOSFET SSDI DOE Albuquerque 

Inc..(SSDI) Letter, 06-25-96 

SFF 9140 to DOD Inspector 

General 

SPD 1511-1-I l - Pin Diode 

(SA3059) 

2A 14/18 or 2A 14152 Ion Implanted 

Diode 

SSR4045CTTXV SCHOTTKY Diodes 

SFF9140TWX Power 

Transistors 

SPMFI06ANH Special Pack 

MOSFET Switch 

SPD 5818 or Axial Leaded 

IN5858JTXV SCHOTTKY Diode 

2N797 

Unknown 

Transistor 

Diode (SA 3436) 

Starter Controls Westinghouse Not Provided General Circuit NRC I.N. 88-48 

(Component Examples) Breaker & 

Electrical. Supply 

• A200MICAC HLC Electric Supply 

• A201KICA 

• A201L2CA 

• AN13A 

G5-559 

California 


PENCON 


General Magnetics/Electric 

Wholesale 





Breaker- 

Electrical Supply


Page 25 of 53 





Gauge Glasses Siemen & Allis Not Provided Rosen Electric Co. NRC F.N. 88-46 

(Component Examples) - Supp. & Attach. 

#00-737-637-118 

215 T 

Mercury Lamps Spectra Inc. Not Provided. General Circuit NRC I.N. 88-46 

(Component Examples) Breaker & Electrical Supply 

V00014 HLC Electric Supply 



(DBA) General 


Wholesale 





Breaker- 


Electrical Frames Westinghouse Not Provided General Circuit 14RC I.N. 88-46 

(Component Examples) j Breaker & Electrical Supply 

LA2600F '! HLC Electric Supply 

LA360OF 

MA280OF California Breakers, Inc 


(DBA) General 


Wholesale 

_ ANTI THEFT Systems, 

Inc- (DBA) ATS 



Breaker - 


Push button Crouse Hinds Single gang, tt Electric Pla 

SENS Report ID #16 

station 

(Component Examples) pushbutton Supply Co. I-27-92 

400-737-637-118 . 

G5-560



Page 26 of 53 



ATTACHMENT A SUSPECT COMPONENTS LIST (cont.) 


Overload Relay Square D (Component Not Provided Not Provided NRC I.N. 88-46 

Thermal Unit Examples) 

B19.5, B22 

Piping, Fittings Tube-line Corp. Subassemblies, Tube-line NRC IEB 83-06 

Flanges, and Ray. Miller, Inc. 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 

components) 

Piping, Fittings, Piping Supplies, Inc. Carbon and Piping Supplies, NRC Bulletin 88-05 

Flanges, and & West Jersey Mfg. & Stainless Steel Inc. & West Jersey & Supplements 

Components Chews Landing Metal Fittings and Mfg. & Chews 

Mtg. Flanges Landing Metal Mfg- 

Valves VOGT Full port design CMA International NRC I.N. 88-48 & 

2-inch Model IMA Valve Supplements 

SW-13111 & 1023 Refurbisher 

1 

E Pacific 

Crane 4"-1500psi, Southern Cat. Valve NRC I.N. 91-09 

pressure sealed Maintenance co., 

Amesse Welding 

Service &CMA In[. 

ITT Grinnell Diaphragm valves ITT Grinnell Valve NRC Comp, 

Valve Co.' Inc Co. Inc. Div. of Bulletin 87-02 

Diaflo & ITT 

Engineered Valves 

Crane, Pacific, Powell, Gate Valves Coffeyville Valve NRC I.N. 92-56 

Walworth & - Inc 

Lunkenheimer 

8" & 3" Globe CMA & IMA Valve NRC IN- 88-48, 

Valve Refurbisher Supp. & Attach. 

Crane Chapman 24" Check Valve CMA & IMA Valve NRC 1.N. 88-48; 

- Refurbisher Supp. & Attach. 

Pacific Check Valve CMA & IMA Valve - NRC I.N. 88-48, 

Refurbisher Supp, & Attach. 

G5-561



Page 27 of 53 



ATTACHMENT A - SUSPECT COMPONENTS LIST (coot.) 


Valves Kerotest 8" Valve CMA&IMAValve NRC LN.88-48 

Refurbisher Supp. & Attach. 

Pacific 4" Gate Valve CMA & IMA Valve NRC I.N. 88-48 

Refurbisher Supp.&Attach. 

Lukenheimer 6" Model 1542 CMA & IMA Valve NRC I.N. 88-48 

20" Model 3013 Refirrbisher Supp. & Attach. 

Crane All CMA & IMA Valve NRC I.N. 8848 


Flanges China Ding Zinang Flanges, ASTM Billiongold Co. NRC I.N. 92-68 

Nan _ A105, ASME SA105 LTD. and Attachments 

Xi Li Flange Co. 'Gain Gong Co. 

Shen Gang Mach. Eng. Sanxi Province Office of 

Co. Overseas Nuclear Safety 

Trading Corp 92-25,93-23, 

and 92-35 

National Board of 

Boiler.and Pressure 

Vessel Inspectors 

(;14661) Bulletin: 

.Special Report, 1992, 

Volume 48, Numbcr 2, 

The Chinese Flange 

- Investigation 

Valve Masoneilian-Dresser Plug stem, stem to Cor-Val, Control NRC I.N. 88-97 

Replacement Industries plug anti-rotation Valve Specialists, Supp. & Attach. 

Parts pin, seat ring, valve H.H. Barnum & M.D. 

plugs, bushings, Norwood, Sample Webtrol 

cages & packing box Controls, Inc. 

components 

Pumps & Hayward Tyler Pump 14TPC ASME Hayward Tyler Pump Co. IEB 83-05 & 

Replacement Co. Nuclear Code Attachments 

Parts 

Channel Unistrut Corporation Continuously slotted Unistrut Corporation NRC J.N. 91-25 

-Members channels, structural 

framing members, 

fasteners, nuts, 

fittings, pipe clams 

Fire Barriers Thermal Science Inc. Therm-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 

G5-562 

NRC I.N. 93-37



Page 28 of 53 

CONTROL OF SUSPECT/ Effective Date October 5, 2005. 



Component Manufacturerfrype Description Supplier References 

Steel - Alloy & Carbon Steel 

Co. Inc., Atlantic Steel 

Co.; Levingston Steel 

Plate 

Angle 

Flat Bar 

Meredith 

Corporation 

Pressure Vessel 

NRC I.N. 89-56, 

Attachments and 

Supplements 

Co., & Copperweld Bar Nuclear Alloy & 

Steel co. 

Carbon Steel Co., Inc. 

. 

Fasteners (Bolts, 

Screws, Nuts,. 

and Washers) 

(parentheses designated 

headmark) 

Asahi (A) 

Dafichi (D) 

Daiei (E) 

Fastener Co. of Japan 

(FM) 

Hinomoto Metal (14) 

Jin Her (1) 

Kyowa (K) 

Kosaka Kogyo(KS) 

Kyoei 

Minamida Seiybo (M) 

Mnato Kogyo (MS) 

Nippon (NF) 

Takai (RT) ._ 

Tsukimon (S) 

Unytte (UNY) 

Yamadai (Y) 

Ivaco, Infasco (hollow 

. Those with 

suppliers or 

manufacturers 

. Those that are 

improperly 

marked 

. Those of foreign 

manufacture that 

do not meet 

Public Law 101- 

592. Fastener 

Quality Act 

Note: Listed suppliers may 

also be manufacturers 

Lawrence Engineering & 

Supply Co. 

Metal Building Bolts 

Nichimin Corporation 

UNICO 

Ace Corporation 

E. K. Fasteners, Inc. 

H. Y. Port Fasteners Co. 

Kobayashi Metals, LTD. 

Takai Screw Mfg. Co. LTD. 

Yamaguchi Sesakusho Co. 

LTD. 

Highland Bolt & Nut 

Porteous Fastener Co. 

Northwest Fasteners 

Ziegler Bolts & Parts Co. 

Edgewater Fasteners, Inc. 

Reynolds Fastene rs 

Commercial 

Carrier Journal 

Articles for. 

6,188, 1 /90, 2190, 3/90, 

4190,6190,7/90,12/90 

INEL Suspect 

Headmark List 

SENS Report 95 

216/91 

SENS Report 913 

2/6/91 

HR 3000, U.S. House 

of Representatives, 

July 1988 

J. A. Jones, La, 

923192 

triangled) 

A.& G Engineering 

Memo from L. 

- 

_ 

I:ubicek, 

3/28/91 

Memo from D. Sanow, 

3/8191 

'Fastener Technology 

International,'' Feb., 

- .April, and June 1993 

Rep. J. Dingell 

Ltr to Comm. 

Dept. & NRC 

June 18, 1993 

Office of Nuclear 

Safety 93-26,93-22, 

93-11 

DOE Quality Alert, 

- Bulletin, Issue No. 92- 

4, August 1992 

G5-563 

FDH Hanford Suspect 

Headmark List



Page 29 of 53 



ATTACHMENT A - SUSPECT COMPONENTS LIST (coot.) 


Fasteners (Bolts, NUCOR 1-1/4" x 2" Zinc Cordova Bolt, Inc. SENS 1D 413 11-6/91 

Screws, Nuts, -- Chromate plated 

and Washers) - surface Hexhead cap 

screws 

Any Any Aircom NRC Compliance 

Barnett Bolt Works Bulletin S7-02 

Bolts & Nuts, Inc. NRC I.N. 89-59 

Glasser & Assoc. 

Knoxville Bolt & Screw 

Metal Fastener Supply 

Phoell Mfg. Co. 

Service Supply Co. 

Southeastern Bolt & Screw 

Sure Lee 

Victory Bolt 

G5-564


ESHQ Document TFC-ESHQ-Q_C-C-03; REV C-2 

Page 

30 of 53 

CONTROL OF SUSPECT/ 


Effective Date October 5, 2005 

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 

• Protective/control relays 

• DC power supplies/chargers 

• AC inverters 

• Current/potential transformers 

• Exciters/regulators 

• Bus transfers/auto bus transfers 

• Motor generator sets 

Generators 

• Rewindable motors 

• Printed circuit boards 

• Bulk commodity items 

Fuses 

Splices 

Electrical connectors 

• Indicators/controllers 

• Panellights/switches 

• 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 

G5-565

REV 

ESHQ Document 

Page 

TFC-ESHQ-Q_C-C-03, REV C-2 

31 of 53 





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. 


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- 

G5-566

-As 


ESHQ Document TFC-ESHQ-Q C-C-iO3, REV C-2 

Page 

32 of 53 




ATTACHMENT C - SUSPECT/COUNTERFEIT ITEMS INFORMATION SOURCE LIST 

A wide variety of industry and Government sources publish information relative to suspect/counterfeit 

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 Markings for Fasteners" 

Fastener-related video cassettes. 

The National Board of Pressure Vessel Inspectors (NBBI) 

The IdBBI publishes "National Board Bulletins" to alert manufacturers and users of 

misrepresented products as they are discovered. 

National Highway Traffic Safety Administration (NHTSA) 

The 114HTSA's Office of Defects Investigation issued a "Suspect Bolt List" in late 1990 

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 of potential intrusion of misrepresented products into the operations environment 

of operating nuclear power plants. 

US. 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. 

G5-567

RPP-24544 REV I d 


Page 33 of 53 



ATTACHMENT C - SUSPECT/COUNTERFEIT ITEMS INFORMATION SOURCE LIST (cont.) 

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 seminars/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. 

G5-568



Page 34 of 53 

CONTROL OF SUSPECT! Effective Date October 5, 2005 

COUNTERFEIT ITEMS . 


MISREPRESENTATION, FRAUDULENT PRACTICES, AND COUNTERFEITING 

The following information has been extracted from theNRC Information Notice 89-70, Supplement 1, 

Attachment 3: 

• High-turnover usage rate. 

• 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 (rejected heats of material are purchased and decertified). 

G5-569


ESHQ Document TFC-ESHQ-tZC-C-03, REV C-2 

Page 35 of 53 


COUNTERFFEIT ITEMS 

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 

• 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 

• 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 parts first' 

• Reduction in major disaster potential 

• Program costs lawlbenefits high. 

G5-570



Page 

36 of 53 




ATTACHMENT F - SUSPECTICOUNTERFEIT PARTS DETECTION 

It is very 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 

nippers). 

• 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). 

• 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. 

• 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.). 

G5-571



Page 

37 of 53 


COUNTERFFEIT ITEMS 


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. 

• 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. 

• 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). 

• Documentation is not delivered as required on the purchase order or is in an unusual format. 

• 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. 

• Data on a single line located at different heights indicate the possibility of retyping. 

G5-572



Page 38 of 53 



Fasteners 


• 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 3.2-1). 

Electrical Devices 

Headmarkings which depict both raised and hand-stamped markings, such as those 

described in WHC Quality Assurance Bulletin # 94-01, "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 A193, Grade B8, which 

were found to be substandard. 

Only manufacturers listed on the "Suspect Fastener Headmark List" (Figure QP 32-1) 

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 f irther 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 manufacturer-provided checklists for 

detecting substandard/fraudulent breakers. 

• Missing or photocopied Underwriters Laboratories (UL) labels on products requiring such- 

G5-573

RPP-24544 REV I 


Page 

39 of 53 




ATTACHMENT F - SUSPECT/COUNTERFEIT PARTS DETECTION (coot.) 

Rotating Machinery and Valve Internal Parts 

• 

Shows marring, tool impressions, wear marks, traces of Prussian blue or lapping compound, or 

other evidence of previous attempts at fit up or assembly. 

• Heat discoloration is evident. 

• Evidence of erosion, corrosion, wire-drawing or "dimples" (inverted cone-shaped impressions) on 

valve discs, seats, or pump impellers. 

Valves 

• Paint 

- Valve appears to be freshly painted and valve stem has paint on it 

- Wear marks on any painted surface 

- Valve stem is protected, but protection has paint on it 

- Paint does not match standard Original Equipment Manufacturer (OEM) color. 

• Valve Tags 

- Tags attached with screws instead of rivets 

- Tags attached in a different location than normal 

- Tags appear to be wom or old 

- Tags with paint on them 

- Tags that look newer than the valve 

- Tags with no part numbers 

- Tags with irregular stamping. 

• Hand Wheels 

• Bolts and Nuts 

Old looking hand wheels on new looking valves 

Hand wheels that look sand blasted or newer than the valve 

Different types of hand wheels on valves of the same manufacturer. 

Bolts and nuts have a used appearance (excessive wrench marks on flats) 

Improper bolt/nut material (e.g., a bronze nut on a stainless stem). 

G5-574



Page 40 of 53 




Valve Body 

- 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 eyebolts, grease fittings, stem, etc. 

- Evidence of previous bolt head scoring on backsides of flanges, or evidence that this area 

- 

Manufacturer's Logo 

Other 

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. 

Missing. 

Logo plate looks newer than the valve. 

Logo plate shows signs of discoloration from previous use. 

• 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. 

G5-575

ESHQ 


Document TFC-ESHQ-Q_C-C-03, REV C-2 

Page 

41 of 53 




LO 

Counterfeit/Substandard High-Strength Bolts 

1.1 General Background 

ATTACHMENT G - FASTENERS 

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 

purchased bolts 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, IFI 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. 

I.2 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 I. These markings are called 

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. 

G5-576


EsHQ Document 

Page 

TFC-ESHQ-QS-C-03, REV C-2 

42 of 53 




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 suspect/ 

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. 

1.4 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. Asa result, it 

will stretch, exhibit metal fatigue, or corrode under less harsh service than the genuine 

bolt. Simple tensile strength tests cannot be used to identify substandard high-strength 

fasteners and should not be solely relied upon in performing acceptance test. 

1.5 Using Suspect/Counterfeit 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 

qualiffied/audited for adequacy of their quality programs. 

G5-577

ESHQ 


Document TFC-ESHQ-QS-C-03, REV C-2 

Page 

43 of 53 




2.0 Stainless Steel fasteners 

2.1 Purpose 


To provide follow-up information to the previous notification sent to the DOE field and 

contractor organizations in late 1996. 

2.2 Background 

In November 1993, the Industrial Fastener Institute (IFI) 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 sells 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 markings were identified in facility stores throughout 

the DOE complex. 

For example, ail 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, PMC, TH, THE, and a STAR. 

The majority of the remaining samples found of 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 did not display any manufacturer's markings. Most of the bolts 

discovered were purchased with the specification to meet a national consensus standard, 

American Society for Testing and Materials (ASTM) Al 93, B8 Class 1 rather than the 

ASTM A320 standard discussed in the IFI 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. 

G5-578

° 



Page 44 of 53 



2.3 Issue 


The requirements of the ASTM Al 93 standard regarding fastener marking and 

certification are very similar those required by the ASTM A320 standard discussed in the 

IFI advisory. The ASTM Al 93 standard requires that grade and manufacturer's 

identification symbols be applied to the heads of bolts that are larger than 1/4" 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 IFI 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 A193Grade 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. 

G5-579



Page 45 of 53 



ATTACHMENT H - DOE HEADMARK LIST 

Examples of stainless steel 

la stoners that have been upgraded 

Iran 19-8 to ASTM A320 or ASTM 

A193 Grade B8 after hand 

slam ping. The last three examples 

show samples of fasteners to 

Indicate conformance to two 

non-compatible standards, 

ASTM A193 and ASTM F 593C. 

r Any bolt on this list should 

bo treated as defective 

without fu rt her testing and 

process In accordance with 

HNF-PRO-301. Note: T hi s list 

was o riginally Published by 

DOE /EH-0196, Issue No. 97-6 

a= 

If any of these fasteners n re located, 

contact your facility SICI Point of 

Contact (POC) for Instruc tions. The 

POC list is on the Hanford Intranet 

at: htip://docs.ri.gov/Mn.InfN 

hlnnsck/hianscl.doc. Scroll to the end 

of the document for the list. 

Surrounding 

White Color 

C Illustrates 

Head 

W.304 Markings 

Before and '. 

Stamping 

88 C 

elp Stamp Out 

Suspects/Counterfeits 

\H^ r 89P 

F593C F593C 

Be 

1 H TH TH 

:013:010 

0000 

G5-590

00-- 

?0-^ 



Page 46 of 53 



ATTACIIMENT H - DOE HEADMARK LIST (cont.) 

Help Stamp Out Suspects/Counterfeits 

Suspect Fastener Headmark List 

All Grade 5 and Grade 8 fasteners of foreign origin which do not bear any 

manufacturers' headmarks: 

i 

Grade 5 - - Grade 8 

Grade 5 fasteners with the following Manufacturers' headmarks: 

i^ 

Mark Manufacturer Mark Manufacturer 

J 

Jinn Her (TW) KS KS Kosaka Kogyo (JP) 

^ 


Mark Manulacturer Mark Manufacturer 

Q â A Asahi Mgf (JP) 

1 

-KS- KS Kosaka Kogyo (JP) 

-NF- NF Nippon Fasteners (JP) - R7- RT Takai Ltd (JP) 

- H- ` H Hinomoto Metal (JP) FM- FM Fastener Co. of Japan (JP) 

Q M - â M Minamida Sieybo (JP) 

1 

-t, KY Kyoei Mfg (JP) 

r, 

MS Minato Kogyo (JP) - J -> J Jinn Her UM 

Hollow 

Triangle 

Inlasco (CA, TW, JP, YU) (Greater than 1 12-inch diameter 

Grade 8 Hollow Triangle only) 

- E - E Daiei (JP) -UNY- >UNY Unytite (JP) 

Grade 8.2 fasteners with the following headmarks: 

Mark 

KS 

Manufacturer 

Kosaka Kogyo (JP) 

Grade A325 fasteners (Benne tt Denver target only) with the following headmarks: 

Type 1 

KS 

Type 2 al 

KS 

Type 3 KS 

Mark Manufacturer 

A325 KS Kosaka Kogyo (JP) 

Key: CA-Canada, JP-Japan, TW-Taiwan, YU-Yugoslavia 

Any bolt on this list should be treated as defective without further testing. 

G5-5S1



Page 47 of 53 



ATTACHMENT 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. 

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 be taken 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 information Notice No. 88-45 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- 

G5-582



Page 48 of 53 



ATTACHMENT I - REFURBISHED MOLDED CASE CIRCUIT BREAKERS (cont.) 

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 by NUMARC, 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. 

G5-583



Page 

49 of 53 





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 machine-painted 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 handpaint 

the desired amperage rating. 

3. Testing 

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 I 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 listed 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. 

G5-5$4



Page 50 of 53 




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 Inspector General and the Office of Nuclear 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 suspecticounterfeit circuit breakers when 

approval is given for disposal. 

G5-585



Page 51 of 53 



ATTACHMENT J - ASSESSMENT/SURVEILLANCE LINES OF INQUBX 

1. S/CI processes and other S/Cl related processes are effective in addressing the safety-related 

aspects of S/Cl. 

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/Cls. 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 (ISIvt) and quality assurance programs and procedures, e.g., training, procurement, 

maintenance, and assessment) to ensure adequate linkage to S/CI elements. 

T Expectations are established for timeliness in determining whether nonconforming items are S/CI. 

8. Protocols are established for clearly identifying S/CIs that are determined to be acceptable for use 

9. 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 is provided for perfornung such 

inspections. 

11. Roles and responsibilities and interfaces for management of S/CIs 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. 

11 SICI reporting requirements are effectively integrated into the site contractors' processes for 

disposition of non-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, 

G5-586



Page 52 of 53 



14. 

15. 

16. 

ATTACHMENT J — ASSESSMENT/SURVEILLENCE LINES OF INQUIRY (cont.) 

Lessons Teamed 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. 

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. 

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 current 

and accurate information on S/CIs. Provisions are available for making this list readily available 

to site personnel who have S/CI responsibilities for procurement, inspection, and other areas 

associated with the implementation of S/CI controls. 

18. 

S/Cl 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/CI 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/CIs, including reporting to the IG. 

21 S/Cl 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/CI 

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.). 

G5-587



Page 53 of 53 



ATTACHMENT K— RECENTLY IDENTIFIED S/CI ISSUES 

Suspect/Counterfeit Fasteners not Listed on Attachment H. 

A. 

Several metric bolts with head markings of 8.8 have been identified without 

manufacturer's head markings. Although metric bolts are not included on the DOE 

Headmark List, a suspect item is defined as 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. ASTM 

F 568M-04, "Standard Specification for Carbon and Alloy Steel Externally Threaded 

Metric Fasteners," states the following: `Bolts and screws, except those ... (smaller than 

M5), shall be marked permanently and clearly to identify the property class and the 

manufacturer. The manufacturer's identification symbol shall be of his design." The 

property class symbols for metric bolts include 4.6, 4.8, 5.8, 8.8, 9.8, 10.9, and 119. 

When metric bolts marked with property class symbols that do not have the 

manufacturer's identification symbol in accordance with ASTM F 568M-04 are 

identified, these bolts shall be treated as suspect. 

B "7 "KS,'- and "K7 manufacturers head markings are still being received. These items still 

G5-588

mlecludogy 

TECHNICAL SPECIFICATION 

RPP-24544 REV ICI 

eme 

PROJECT: Final DBVS Design 145579-D-SP-037 I REV. 1 




Appendix E 

Request for Information 



03-NOV-05 

G5-589

Nwinology 


F ].Feb 2004 


ame 

PROJECT: Final DBVS Design 145579-0-SP-037 REV. 1 




REQUEST FOR INFORMATION 

Project #AFl.%)02 

. FieV. 

Pagel 0i 

ContracUPro ct No: 

TO BE COMPLETED BY SUBCONTRACTOR 

Insert Title of RFl Here 

Originator Name & Coman 

Problem/Deficiency: Clamscation [I Change 

Proposed Solution: 

Basis of Change: 

Note: Subcontractor to provide cost and schedule impacts associated with each discrete change line item. 

Response: I] Clarification © Change COST q Yes (] No SCHEDULE q Yes q No 

Required Response Date: 

Cost Impact Schedule impact 

Subcontractor (sign/date) 

RR Approved q Yes q No 

CN Required: q -CN#_ 

CN Not Required: (] 

As-Built documentation Required: q 

As-Built documentation Not Required: q 

Submittal Data Required: OYes I] No 

TO BE COMPLETED BY THE. BUYER 

COMMENTS 


03-Nov-05 

G5-590 

Design Lead / Prol Mgr! Date



acme 

PROJECT: Final DBVS Design 145579-DSP-037 REV. 1 




Appendix F 

Bidder's Drawing and Data Commitments 


WE" SCRUBBER SKID ASSEMBLY DESIGN AND FABRICATION 

03-Nov-D5 

G5-541

steciltift0y 



PROJECT: Final DBVS Design 145579-D-DS-037.1 REV.1 

WET SCRUBBER SKID ASSEMBLY 

PROJECT' NO.: 145579 DESIGN AND FABRICATION 

EQUIPMENT NO.: 36D58-002 


BIDDER'S DRAWING AND DATA COMMITMENTS 

Vendor shall supply all drawings, manuals and documentation in the quantities indicated. Approval drawings are due within the 

listed number of calendar days after issue of the Purchase Order or Letter of Intent. The dates set out for drawing and data 

submissions are governed by the engineeringdesign schedule of the pmjecL The Vendor shall supply one Autorad disk file 

and requested number of copies within the fisted number of calendar days. Final drawings must be certified as correct an d 

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

revison numbers, quantities, status and document types must be included with all submissions 

(including electronic submittals). 

SEND ALL DOCUMENTS TO: 

DMJMH+N, Inc. 

dba DMJM Technology 

Submit all documents via courier service 

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 before orde ri ng or start of fabrication 

Final Required within 7 days prior to shipment and before final payment 

PROPOSAL REVIEW I FINAL DESCRIPTION 

E+3 Proof of NQA-1 or equivalentQA program 

E+3 Expe ri ence list and maintainabili ty intonation 

E+3 ! Completed data sheet 

E+3 Subcontractor list 

ITEMS DUE 

WITHIN 

(DAYS) 

E+3 E+3 Design, fabrica ti on & delivery schedule PO+7' 

'E+3 E+6 90% Design and Fabrication Package including: 

-Drawings 

-Calculations 

- Instrumentation and Control design 

- Completed Equipment Data Sheets 

- Vendor Cut Sheets/Technical Brochers 

- Bill of materials 

PQ+21 

E+3 E+1 Test Plan/Test Procedure PO+21 

E+1 E+1 NOE Personnel certifications PO+21 

E+1 E+1 Visual WeldNDE,Procedures PO+21 

E+1 E+t Visual weld examination pmcedure/wetd map Fab-10 

E+3 E+i Welding procedures, procedure qualification records. 

Fab-10 

E+3 E+i 

and welder procedure qualification records 

AWS CWI certificate Fab-1D 

E+3 E+1 Material Control Procedures Fab-10 

E+3 E+3 Protective coaling specifi cations Fab-10 

E+3 E+7 lFabrituttion travelers Fab-10 

E+3 E+1 lCleaning procedures Fab-10 


03-Nov-05 

G5-592 

VENDOR 

COMMITMENT 

(DAYS)

,: : art, 



PROJECT: Final DBVS Design 145579-D-DS-037.1 I REV. 1 

PROJECT'NO.: 145579 





EQUIPMENT NO.: 36-D58-002 


listed number of calendar days after issue of the Purchase Order a Letter of Intent The dates set out for drawing and data 

submissions are governed by the engineering design schedule.of the project. The Vendor shall supply one Autocad disk file 

and requested number of copies within the listed number of calendar days. Final drawings must be cerfified as correct and 

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

revisan numbers quardities, status and document types must be included with all submissions 

(Including electronic submittals) 

SEND ALL DOCUMENTS TO; 

DMJMH+N, Inc. 


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


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

Document Control - Phone: (509) 375-7856 

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


Proposal Bidder shall include this data for each item - REVIEW 

Review Required before ordering or start of fbricafion 

Final Required within 7 days p rior to shipment and before final payment 

ITEMS DUE 

WITHIN 

PROPOSAL REVIEW FINAL DESCRIPTION 

(DAYS) 

E+3 E+6 100% Design and Fabrication Package including: 

- Mechanic l,, Structural and Electrical Drawings 

- Mechanical, Structural and Electrical Calculations 

-Completed Equipment Data Sheets 

- Vendor Cut Sheets!Technical Brothers 

- Bill of materials 

PO+21 

When 

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

When 

E+3 E+3 Fabrication red-line changes identified 

E+3 E+1 Preliminary Data Package Including: Prior to FAT 

-As-Built Drawings and Weld Maps 

- Fabrication Tmvler Closeout 

- Recommended spare parts and frequency of replacement 

- Pigging sketches 

-System assembly instructions 

- Operation and maintenance manuals 

- Completed Test results (document and video records) 

j - Packing list and identfication of shipping supports 

- Feld Calibration Procedures and Reports - 

- Inspection Reports 

-CoUsl CMTRs 

- NEC inspection certificate 8 electromagnetic interference test 

results 


03.-Nov-05 

G5-593 

VENDOR 

COMMITMENT 

(DAYS)

^ 



amen 

PROJECT: Final DBVS Design 145579-D-DS-037.1 REV. 1 

13ROJECT NO.: 145579 

-- 





EQUIPMENT NO.: 36-D58-002 

Vendor shall supply all drawings, manuals and documentation in the quan ti ties indicated. Approval drawings ant due within the 

listed number of calendar days after issue of the Purchase Order or Leiter of Intent. The dates set out for drawing and data 

submissions are governed by the engineering design schedule of the project. The Vendor shall supply one Aulocad disk file 

and requested rurnber of copies within the listed number of calendar days. Final drawings must be certified as correct and 

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

revison numbers, quantities, status and document types must be -included with all submissions 

(including electronic submi ttals) 

SEND ALL DOCUMENTS TO: DMJMH +N, Inc. 


Submit all documents via courier service 3250 Port of Benton Blvd 


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

Document Control Phone: (509) 375-7856 

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



Review_ Required before ordering or sta rt of fabrication _ 

Final Required within 7 days prior to shipment and before final payment 

ITEMS DUE 

WITHIN 

PROPOSAL R EVIEW FINAL DESCRIPTI ON 

(DAYS) 

F + 3 E+1 Packag ing and Shipping Plan Del .21 

E+3 F+1 Final Data Package including: J Del-'10 

Approved Prelimina ry Data Package 

Final FAT results 

VENDOR 

COMMITMENT 

(DAYS) 

Legend. 

`- y s: :. r^-y'+ t

ludo 



ame 

PROJECT: Final DBVS Design 145579-D-SP-037 I REV.1 




Appendix G 

Instrumentation Naming and Tagging Convention 



03-Nov-05 

G5-595

• ` - Il7010nV - • 



PROJECT: Final DBVS Design 145579-D-SP-037 REV. 1 




G1 EQUIPMENT IDENTIFICATION NUMBER 

The equipment identification number (EIN) 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-h#" if more than one cable run. 

Example: 

Two Cables: From 36-CAB-123 to 36-1JB-123 

Cable Tag: "36CAB123-361JB123-C1" 

Cable Tag: "36CAB123-361JB123-C2" 

G3 WIRE TAGGING 

Wires 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 "36 FIT1 23(-)" 

Example 2: Wires connected from instrument 36-LSH-123 (110V ac) 

Positive Tag "36LSH123(H)' 

Negative Tag "36LSH123(N)" 

WET SCRUBBER SKID ASSEMBLY DESFGN AND FABRICATION 

03-NOV-05 

G5-596


teduxâAg a 


PROJECT: Final DBVS Design 145579-D-SP-037 I REV. 1 




G4 NOTES 

1. Cables shall be identi fied with cable tag number "source-destination -type." 

Types will be as follows 

M = Motor Feeder Cable; L = Local Con trol Station Cable; MH = Motor 

Stator Heater; RTD = Motor Winding Temperature Detector; MA = Motor 

Armature 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. 


03-NOV-05 

Ca5-547

TECHNICAL DATA SHEET 

AMEC Americas Limited 


The document revision number is indicated below. Please replace all revised pages of this 

document and destro]t the superseded copies. 

r^ _ 

PROJECT: Final DBVS Design 145579-E-DS-013.01 REV. 0 

PROJECT NO..: 145579 Off-Gas Bypass UPS - 

Uninterruptible Power Supply 


RSV 

Al4 

_...___ 

1 SUER O 

-- _ 

1 1 

h, ;:^, _:; :;: 

Qt N _ j 

A. Internal Review DR 12/1/2005 

0 approval val SJH 1/10/2006 

DOCUMENT APPROVAL 

_..... RA'r 1t C^ Ad- 

CLIENT APPROVAL (AMEC RICHLAND) DMJM APPROVAL 

Original Approvals on File I Original Approvals on File 

Project Manager: t 

Date: 

O.A. Rep.: d4 

Date: ^} 

LENT APPROVAL (CH2 HILL) 

roject Manager:( 

Date: t SU 

Project Manager: 

Date: 

Discipline Lead: 

Date: 

G5-598 

Originator. 

Fb,e JW 0 

f/, a/off 

;i 

Date: 4) 7'l._ 

7, 

i 

y

TECHNICAL DATA SKEET 

DOCIG^GAI/^C C'OCIHGtPTTAÎ 


PROJECT: Final DBVS'Desgn 145579-E-DS-013.01 REV. 0 

PROJECT NO.: 145579 Off Gas Bypass UPS - t}ninYerruptibla 

Power Suppty 


Document No. Specification 

NIA N/A 

CONTENTS 

Data Sheet 2 Pages 

Bidders Drawing & Data Commitments Sheet 1 Page 

G5-599

Frs NUTAt nera -qmsFrs - 


. PROJECT: - Final-DBVS Design 145579-E-DS-013:01 - . REV, 0 

PROJECT NO.: 

CLIENT: 

145579 

AMEC, E&E - Richland Washington 

Off-Gas Bypass UPS - 1lninterrupftble Power Supply 

No. Required , 1 Area 36 

',. PFD If - - - Stream No. 

- Reference Spectflcation: NIA lQuallity Assurance Level Enhanced 

Operating Conditions 

Location (IndoorstOutdoors) - Indoors 

-Rev 

A - Opera 

Rev 

Operation (continuousfinlamtittent) 

Max. Ambient Air Temp. CF) 

Min Ambient Air Temp. - C F) 

Normal Pressure 

ti c 

on - - Maximum days per event 

10 A . 

Continuous A - Hours per day 

24 A 

85 0 Availability % 100 A 

40- 6 Eleva tion (H) 

Sm A 

Atmosphe' A .Environment- Radioactive 

No A 

-Toxic 

No A 

- Corrosive 

No A 

- Flammable 

No A 

Specifications 

Interface: 

Model / Make 

Minimum capacity 

- 

(kVA) * 

NRTL-listed and labeled 

NFPA 110 Class (see Note 2) (his) 

NFPA 110 Type (sec) 

NFPA 110 Level 

Motor star ti ng kVA (minimum-see notes on page 2) 

Lamacoid nameplate w(equipment no. and designation 

INPUT 

Voltage (Vac) 

Frequency (Hz) 

Phase 

Power Factor 

- 

OUTPUT 

Volage (Vac) 

F re 40 

A 

A Audible Noise 

^^ 

szaa 

0 

Yes 0 

0:0633 A 

10 A Dimensions W x H x D (in) 

A 

1 A 

40 A 

Yes 0 Weight lb 

A. 

Double Conversion 

Yes A 

480(-201+t0%)- Continuous Duty Sta tic Switch 

Yes A 

60 A Maimen arce Bypass Switch4ritemal - 

Yes A 

3ph, 3 W A Solid State inverter 

Yes A 

.97 min A Rectifiedbattery charger 

Battery Data (internal) 

Yes A 

Type 

Seated A 

Size 

A 

480(-201 +1 Back up time (minimum) 

see note 2 A 

quency (Hz) 60 HA 

Phase 

3ph, 3 W A Equipment Designations and Numbers 

Power Factor 

.9 min A 36-E00-148 OFF-GAS BYPASS UPS 

Efficiency 

> 90% A 

Ovedoad capacity 

T29%T0-r-K 

see 

A Suggested Manufacturers: 

Monitoring & Control 

Manufacturer standard 

Protection 

OverlUnder Voltage 

Output Short Circuit 

Ove rload . 

Overtemperalrue 

Surge Protection 

Current Total Harmonic Distortion (THD) 

Notes: 

I. All items with an' shalt be filled in by the VENDOR 

?. Vendor to provide options for 5, 10, and 15 minute battery. backup. 

Profesiomat Parer P ro tection 

16524 E Laser Drive, Suite 10 

Fountain Hills, AZ 85268 

(480)916-3363 

Alarm A contact vkior Cots 

AulnShuh)ovm 

a r25 P0We o 

rc sec 

Auto-Shutdwm 1612 State Street 

Yes A. Santa Barbara. CA 93101 

(486) 816-3363 

TECmicAL DATA SHEus - 

2of2. 

Notes and Comments, 

1) AD iterns with an * shall be filled in by the VENDOR 

2) See Application of UPS below 

[NORMA 


AUTQMATIC 

TRANSFER GENERATOR 

OWERLSWITCH ( 5 HP 1 

ate 1-Dec-05 40-Jan-06 

,BY DR &IH 

UPS 

5 HP t 

- (SPARE). 

Chkedt1 - 

Rev. A 0 

G5-601

e^^ 



PROJECT: Final DBVS Design 145579-E-DS-01101 REV. 0 

PROJECT NO.: 145579 Off-Gas Bypass UPS - Uninterrupitble 

Power Supply 

CLIENT: AEVIEC E&E -Richland, Washington 

BIDDER'S DRAWING AND DATA COMMITMEIVTS 

Vendor shall supply all dravings, manuals and documentation in the quantities indicated. Approval drawings are due within the listed 

number of calendar days after issue of the Purchase Order or Letter of Intent. The dates set out for drawing and data submissions are 

governed by the engineering design schedule of the project The Vendor shall supply one AutoCAD disk file and requested number of 

copies within the listed number of calendar days. Final-drawings must be certified as correct and bear the Vendors name, equipment 

number and Purchase Order Number. Drawing Transmittals listing the document numbers, revisions numbers, quantities, status and 

document types must be included with all submissions (including electronic submittals). 

m 


DMJMH+N, Inc. 



3250 Port of Benton Blvd. 

Faxed documents must be followed by the originals. 

Richland, WA 993541670 

Electronic E.-mail or FTP transmissions of drawings & data must be copied to 

Attn: Project Records 


Phone: (509) 375-7856 



Proposal Bidder shall include [his data for each item REVIEW 

Review Required before orde ring or start of fabrication _ 

Final 

ITEMS DUE 

Required within 7 nays prior to shipment and befora final pa menl WITHIN 


E+3 E+3 E+1 Systern configuration with Single line Diagram Bud 

E+3 E+1 E + 1 We ights, dimensions and heat dissipation Bid 

E +3 List of devotions from this Data Sheet Bid 

E+3 E+3 E+6 

F + 

Detailed specifications for p roposed equipment, including 

customer poumr and cont rol connections 

Installa tion and maintenance manuals, with technu:al rterature for 

all equipment and devices 

VENDOR 

COMMITMENT 

(DAYS) (DAYS) 

Por7 

Del-14 

Final Data Package including ^ 

-As-built drawings 

E+ 3 E+1 -Complete set of instruction Manual Del-10 

-Final Test results 

-Inspection results 

Va 

.^ 

,•^- w -- 

E..;t?Wl9r NG'G^W=^17. _^91!'HN^D ^-CPfetldaY.VByaAf3z.;A iRSVpTFR^:; .^d , f„?:tk)6 rMtu1*E;,CE1en0Y doy^cFA^Brt G^3M?f^YAu3+^dNh1_tefddaL'tFOysoftmm^ki97Drnh^^ 

..... [ 

THE TIMELY RECEIPT OF THE VENDOR DOCUMENTS IS CRITICAL TO THIS PROJECT 

agree to provide the listed documentation and data and the dates shown above. 

Vendor Signature Date 

G5-602


AMEC .Americas Limited 


gar, it if 7 e C 


document and destroy , the superseded copies. 

PROJECT: Final DBVS Design 145579-E-DS-013,02T REV. 0 

PROJECT NO.:: 145579 OGTS Bypass UPS; - 

CLIE:NT: AMEC E&E - Richland, Washington 

Automatic Transfer Switch 

. _..,... .. Q-F_:::,;- 

A Internal Review BJH 1219/2005 B H 

0 For Approval BJH 1/10/2006 

_ _ _D_OCUMENT APPROVAL 

CLIENT APPROVAL (AMEC RICHLAND)DMJM APPROVAL 

Original Approvals on File I Original Approvals on File 

Project Manager: , 3 

Date: > 

Q-A. Rep.: 

Date- D t— t l AG 

C 111" NT APPROVAL (CH2 HILL) 

, ect Manager. . 

Date: 4 Q ^j 


Date: 

G5-603 


lA-0/o6 

Date: t !! o 

Originator: 

Date: ' ^f 

r


PROJECT: Final DBVS Design 145579-E-DS-013-02 REV. 0 

PROJECT NO._ 145579 OGTS Bypass UPS - 

CLIENT: 

AAMEC E&E - Richland, Washington 


REFERENCE SPECIFICATION 

Data Sheet 

CONTENTS 

1 Page 

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

Bidders Drawing & Data Commitments Sheet -----------_ 1 Page 

G5-604


RPP-24544 REV Id 0 

ame 

PROJECT: Final DBVS Design 145579-E-DS-073.02 I REV. 0 

PROJECT No.: 145679 OGTS Bypass UPS - 

CLIENT: 

AMEC ESE- Richland Washington 

Automatic TransferSwitch 

No. Required: 1 Area - 36 

pFp )f SVeam No. 

Reference Specification: 6tuality Assurance Level Enhanced 

Operating. Conditions Ravi Rev 

Location (Indoors/Outdoors) 

Operation (continuous lintermi ttent) 

Outdoors A Opera tion - Days per year 

- Fou 

Max. Ambient Air Temp. 

Min Ambient Air Temp. 


(°F) 

(° F) 

Dusty environment 

Maximum available tanit cu rrent 

rs per day 

Availability 

Eleva ti on (ft) 

Envi ro nment -Radioactive 

- Toxic 

-Co rr Con tinuous A 

365 

24. 

A 

A 

115 

-25 

Atmospheric 

A 

A 

A 

100 

663 

No 

A 

A 

A 

Yes 

31kA 

A 

0 osive 

Mo A 

No A 

Specifications - Flammable 

No A 

Voltage (at60Hz) (V) 

Phase 

Current (min) (A) 

Compliant with NFPA 110, Level 1 ATS rquirements 

Tolerant of non-linear loads 

Open transition operation 

Adjustable time delays (m fixed delays) 

Auxiliary contacts (for monitoring) 

Microprocess or-based coniroi 

Manual ove rr 480 A 

3-PH, 3W A 

60 A ISuggested Manufacturers: 

Yes A Cummins Northwest 

111 34 West Westbow Blvd. 

Spokane, WA 99204 

(800) 8252122 

ide switch 

Kohler Power Systems 

(Distributor: Pacific Power Genera 

Electrically operated, mechanically held 

NRTL-listed and labeled 

NEMA 4 enclosure 

Lockable cabinet 

Lamacoid nameplate wfeguipment designation & no- 

ti Yes A 

Yes A 

Yes A 

Yes A 

Yes 

Yes 

A 

A 

on) 

Yes A 5808 S. 196th SL, Su ite B100 

Yes A Kent, WA 98032 

Yes A (253 )-395-9077 

Yes A 

Yes A jEctuipment Designations and Numbers 

Notes and Comments: 

The generator will be used in conjunct ion with an in-line UPS as shown in the following b lock dagram: 

h10RMAt 

POWER 

Date 9-Dec-05 19-Jan-06 

ByBJH BJH 

Chked JL Pi iL 

Rev_ i A. g 

36-E40-146 OFF-GAS BYPASS AUTOMATIC TRANSFER SWITCH 

AUTOK4TIC 

7RANSFEP. rENEPATOR 

SVNI t^H 

fHP 'I 

LIPS 

( 5W 1 

- i56l^REi 

G5-605

r 


RPP-24544 REV l d 

amec- 

PROJECT: Final DBVS Design 1 45579-E-DS-013.02 REV. 0 

PROJEC7 NO.: 145579 OGTS Bypass UPS - 



BIDDER'S DRAWING AND DATA COMMITME NTS 

Vendor shall supply all drawings, manuals and documentation in the quantities indicated. Approval drawings are due within the listed 

number of calendar days after issue of the Purchase Order or Letter of Intent. The dates set oull for drawing and data submissions are 

governed by the enginee ri ng design scnedule of the project. The Vendor shall supply one AutoCAD disk file and requested number of 

copies within the listed number of calendar days. Final dravdngs must be ce rtified as correct and bear the Vendors name, equipment 

number and Purchase Order Number. Drawing Transmittals lis ting the document numbers, revisions numbers, quantities, status and 

document types must be included with all submissions (including elect ronic submittals). 

SEND ALL DOCUMENTS TO: DMJMH+N, Inc. 


Submit all documents via courier se rv ice 3250 Po rt of Benton Blvd. 


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

Document Con trol Phone: (509) 375-7856 


BIDDERS MUSIr PROVIDE ESTIMATED LEAD TIMES FOR APPROVAL DRAWINGS 

Proposal Bidder shall include this data for each item _ 

REVIEW 

_ 

Review Required before ordering or sta rt of fab rication ^ 

Filial 

_ 

ITEMS DUE 

Required within 7 days prior to shipment and before final payment WITHIN 

PROPOSAL REVIEW FINAL DESCRIPTION _ 

E +3 E+3 E+6 

Detailed specifications and manufacturers data sheets for 

proposed equipment (including wi ring diagram) 

E+3 E +6 

Installation and maintenance manuals, with technical literature for 

a7 equipment and devices 

VENDOR: 

COMMITMENT 

(DAYS) (DAYS) 

P+7 

Del-14 

E+6 Recommended spare pa rts list Del-14 

E+6 CoCs on all manufacturer specs and data sheet fequirerrents DeF14 

^^-l`' 

EsÊtecbonc ... ` c^7+k^scWsv^tkrm,.l catuiv_1aN, of P 6^s:!!4r+2a

01/12/2006 14:09 PAX 5093763407 DBV Protect MWA [A 003 

TECHNWAL DATA SHEET 



The document revision number is frxNcated below. Please replace all revised pages of this 

docuammt and destroy the aupwwded copies. 

W: 

Final DBVS Design 146579-F-DSAXM1 I REV. I 

RrF= 

NO.- 145579 - 

OFF-GAS STACK MONITORING 

ECMPMEW DATA SHEET 

EJN T: 

AMEC E&E - Richland, Washington 

At 7 

A IrAmal Review DR) 17-Sep-04 DRJ 

B internal Approval DRJ 20-Oct-04 DRJ 

C ' CH2M H41 Review DRJ 4-Nov-04 DRJ 

DC) 1 H2M Hill Review DRJ 12-Jan-05 DRJ 

Bid ReW 3st DRJ 2-Feb-05 DRJ 

i RecLuest GN 10-Jan-06 


CLIENT APPROVAL (ANIEC RICHLAND) DMJM (RICHLAND) 

Original Approvals on Fife Original Approvais, an F-716 

Project Manager: Project Manager 

Date: Date: --Z—Otlo —61— 

Q-A- Rep.: Discipline Lead- 

Date: Date: 

CLIENT ROVAL (CH2M HILL) 

Project: 

Date: Jlxlac 

originalor. 

Date: 

G5-607 

4. 

I 06 0 

U

PROJECT: Final DOVS Design 145574-F-DS-0621 I REV: t 

PROJECT NO.:: -14SS79 OFF-GAS STACK MONITORING 

EQUIPMENT DATA SHEET 

CLIENT: AMEC E&E -Richland; Washin on 

DATA SHEET OFF-GAS STACK MONITORING EQUIPMENT DATA SHEET 

Document No. REV. Description 

36 AIT 7006 C OFF-GAS STACK GAS MONITORING SYSTEM 

REFERENCE DRAWING 

Document No. I REV. IDescription 

EX-STOCK I A' I Exhaust Stack Assembly 

'As modified by K.J. McCracken on 12127/05. 

CONTENTS 


Data Sheet I Page 

Reference Drawing _ f Page 

G5-608



yr r rw w 

PROJECT: Final DBVS Design 145579-F-DS-002.1 REV.1 - 

PROJECT NO.: 145579 OFF-OAS STACK MONITORRmG. E-OUIPMENT DATA - 

SHEET 

CUENT: AMEC E&E - Richland, Washington 

BIDDERS DRAWING AND DATA COMMITMENTS 

Vendor shall supply all drawings, manuals and documentation in the quantities indicated. Approval drawings are due within the listed 

number of calendar days after issue of the Purchase Omer or Letter of Intent The dates set out for drawing. and data submissions are 

gove rn ed by the engineering design schedule of the project. The Vendor shall supply one AutoCAD disk file and requested number of 

copies within the listed number of calendar days. Final drawings must be certified as correct and bear the Vendors name, equipment 

number and Purchase Order Number. Drawing Transmittals fis ting the document numbers,: revisions numbers; quantities,. status 

and document types must be Included with all submissions (including electronic submi ttals). - 


Submit all documents via courier se rvice 

Faxed documents must be followed by the o riginals 

Electronic E-mail or FTP transmissions of drawings & data must be copied to 

Document Control. 

Always include a t ransmittal 

DMJMH+N,. Inc. 


3250 Port of Benton Blvd 

Richland, WA. 99354-1670 


Phone: (509) 375-7856 

Fax: (509) 375-5331 



Review Required befora ordering ar sta rt of fabdcton 

Final Required within 7 days prior to shipment and befo re 6naf payment 

PROPOSAL RE VI EW FINAL DESCRIPTION 

ITEMS DUE 

WITHIN 

(DAYS), 

1 UAProgram that addresses the re uirements of NOA-1-1994 Bid 

E+3 E+3 Design. fabrication & delivery schedule 

Outline drawings and layout drawings recommending component 

PO+7 

E+3 Ef3 E+6 locations PO+14 

E+3 E+3 E+6 Technical brochures on purchased components PO+14 

E+3 E+3 E+6 Electrical schematics, wi ring, diag rams and nameplate rsts PO+14 

E+1 E+6 Spare parts fist - Del-14 

installation ard maintenance mamrals including techracanderatu re 

E+1. E+6 for all equipment and devices Del-14 

E+6 18ite comm-ssicning record S test results. COM+1.4 

E=BarJmnb COw PON-=auewiNm+taleatlaraays of P.O.issuarre nerd-=diva mNio+J-cerwWraarsd OeNrC01.1N-=DUe uStltin M-caip+tlar OaY%d commi^W^g 

THE TIMELY RECEIPT OF THE VEI4DOR DOCUMENTS IS CR IT 

ICAL TO THIS PROJECT 

Buyer will take 10 days for review of vendor irdormadon.. 

I agree to provide the listed documentation and data and the dates Shown 

G5-609 

VENDOR 

COMMITMENT 

.(SEE NOTE 4) 

(DAYS)

AMECAmoiru'EVned 

Instrumentation. Data Sheet 

TAG NUMBER: 36-AIT-700B 

- UBIECT: OFF QtS, STACK-GAS ANALYZER 

ERVXF-- OFF GAS STACK MONITORMG SYSTEM PLC Number: 501 

PPLIEP-- - PWD NO.: F145579-36.A-0105 

DEU P.Q NO.: 

CMIFONENTS: Gras Composition Analyz er(s) for the Off Gas Stream Cktraduents listed Below 

Indas Probes for a 4' Diameter Stack with 6'onter lining.including mounting Flanges. 

Confirmous Indication of Stream Composition to the Monitoring and Current System 

Data Acquisition and Archiving System with.Non-resetable Totalizers and an Interface to CommlNet 

Veodmrba Provide Start-up Assistance and Field Support and Training:2uromtnwdations at per diem rates as mqukW 

Teat Off--gas Volumetric Flow Meter (qualified by Seller), located in the stack. 

Recoil Sampling for FM-10 Particulate 

Vendarto Provide a suitable enclosure having a comroged ambient atttmosphaeand radio frequency shielding protection 

The System should have a MamNacturm s nameplate using . the Seller's standard practice. 

Vender m Supply Calibration Gasses, Bo lc(s). Regulators) and valving' 

Repartmg Package tailored to sun Operating Permit and Regulatory Requiremeats 

Unit In Operate on 120 VAC - Vendor to Supply local disconnect switch, terminals and electrical box 

Provide llaer Manuals, drawings and recommended spare parts list-6 Hard copies and I Electronic copy 

Vendorshall mark the location of the monitoring probe on the provided stack drawings. 

Vendor shall supply the accuracy of the equipment provided. 

Vector shall provide a calculation to verify that the design of the sample line wi g not impact the integrity of the sample 

data - 

Buyer preference is for the sample cabinet to be placed at groundleve. - 

Vardar shall provide a F" female . NPf fining on the cabinet for Buyer to interface with for sampling the cabinet 

Stack temperature monitor with a range of -25 deg F to 500 deg F. 

Hest Available Control Technmlogyffoxke Best Available Control Technology emission controls must be used 

Quantity:1 

. 

Off-gas; .Conditiosc 

Stack GuTea pemmm: 370°F Stack Height: 155 Fee. 

Stack Gras Pressure: 

Stack Design Flow Rate: 

Stack Max Flow: 

Ambient Air Temp: 

Gass to be Analyzed ° 

0b" Water Column. 

9,SW ACFM 

IO.00OACFM 

.25-Fro 115°F 

Stack Diameter. 

Steam H2O: 

Stack Material: 

Life Span: 

4' with 6' outer lining (drwg EX-STOCK) 

2081bAus point int 86°F) 

Cuban Steel 

2 Yrs. Operation 15 Yrs. Design (24 hr(day- 

365 da ) 

NOx "' _ 92 pPmv Pb and Cd < 120 µg/dsem combined 

tat 

S02 (`) 1.1 PPmv C12 :M ppmv` a 

HCI Q08ppmv-2 1 ppmv NHr 6ppmvu) 

.4s: Be, Cr. < 97 pgIdsan combined Fumn TEQ


PROJECT: 

PROJECT NO.: 

CLIENT: 

Final DBVS Design 

145579-F-DS-002.1 

145579 OFF-GAS STACK MONITORING EQUIPMENT DATA SHEET 

AMEC E&E - Richland, Wash 

REV. 1 

G5-611

?0-1 

r^ 

'12/2006 14:08 FAR 5033763407 

TECHN)CAL DATA SHEET 

AA9ECAmeticas Limited 

Project Manager- 

J^fP {tS 

Date: 

(1.A. Rep.: 

hok el}F F Zia 

Date: 


DBE' Projeci 272WA 

The documenk revision number is indicated below. Please replace all.revlsed pages of this 

document and destroy the superseded copies. 

amec^ 

IPROJ4CT: _ 

Final DBVS Design 14551! -F-DS 002.2 REV. D 

PFIOJgCT NO_.: _ 

145578 OFF-GAS RADIATION MOMTORING 

EOUPMENT'DATA SHEET 

CLIENT: AMEC E&E - Richland Washinqlan 

`^_ 

.its S3 ,4.... I^.k•:k 

11EQ yyp^ 

>.v^-.. FF^^ .ice ^ 

ir^ ... ^:

i 

TECHNICAL ]DATA SHEET 


PROJECT: Final DBVS Design 1455792 -P-DS-002. REV. 0 

PROJECT NO.: 145579 OFF-GAS RADIATION MONITORING 

EQUIPMENT DATA SHEET 

CLIENT: AMEC E&E - Richland. Washin on 

DATA SHEET OFF-GAS RADIATION MON IT 

ORING EQUIPMENT DATA SHEET 

Document No. I REV. Descri tion -. 

36-AIT-700A I C OFF-GAS RADIATION MONITOR AND RECORD SAMPLER 

REFERENCE DRAWING 

Document No. I REV. Descrfi ion 

EX-STOCK I A' Exhaust Stack Assembly 

E-145579-36-)1-0034 I E lBulk Vitrification Off-Gas Treatment Scrub & Stack Sections 

`'As modified by K.J. McCracken on 12127105. 

CONTENTS 

Bidders Drawing & Data Commihnents Sheet 1 Page 

Data Sheet ^_._._^.:_..4. Page 

Reference Drawing 2 Pages 

G5-613

TFir:HNICAL DATA SHFETS 


amedy 

PROJECT- Final DBVS Design 145579-F-U,002,2 REV.O 

PROJECT NO.: 145579 OFF-Gus RADIATION MOMTOMG EQUIPMENT DAT 

SHEET 

CLIENT. AMEC E&E- Richland, WashingtoD 


Vendor sha ll 

Supply all drawings, manuals and documentation in the quan tities indicated. Approval drawings are due within the listed 

number of calendar days after issue of the Purchase Order or Latter of I ntent. The dates set out for d rawing and data submissions are 

gmamed by the engineering design schedule of the project. The Vender sha ll supply one AutoCAD disk file and requested number of 

copies within the listed number of calendar days. Final drawings must be cem-fied as correct and bear the Vendors name, equipment 

number and Purchase Order Number. Drawing T ransmittals listing the document numbers, revisions numbers, quantities, status 

and dom in ant types must be included with all Submissions (including elec tronic submittals). 


Submit all documents via cou rier service 

Faxed documents must be fo ll owed by the originals. 



Always Include a. transmittal 

BIDDERS MUST PROVIDE ESTIMATED LEAD TIMESJFOR APPROVAL DRAWINGS 

Proposal B-odiershall include Ibis data lot each item REVIEW 

Review Required before ordering or stan of iabricatiun 

Final Required rMlifn 7 days prior to sUpmem and befo re Sinai payment 

PROPOSAL REVIEW FINAL DESCRIPTION. 

DMJMH+N, Inc. 


3250 Port of Ben'VOn Blvd 

Richland, WA 99354-1670 


Phone: (509) 375-7856 

Fax:• (5D9) 375-5331 

ITEMS DUE 

WITHIN 

(DAYS) 

1 O/A Program that addresses the requirements of NOA-i-1994 Bid 

E+3 E+3 Design, labriraDon& derive?..heduie 

Outline drawings antl layout dramngs recommending component 

PO+7 

E+3 E+3 E+6 locations P0+14 

E+3 E+3 E+6 Tecbraal brochu res on pur h ed components PO+14 

E+3 E+6 Elec tricalschnmafics, wiring,diag ninis and nameplate rats PO+14 

E+1 E+6 Spare Paris list 

Inste®alion and maintenaxe manueis inWurfing technical Irteralure 

Del-14 

E+1 E+6 for an equipment and devices DeM4 

E+6 Site lostfor4DCFR 52 Ap.E 168 F low Meter Test (7WA orgy) COM+14 

E+6 Sle commissiDNng record & rest results COM+14 

E>EktTwic COyy Pp N-ewe UMH-wlBnOm 4aysdP 0.'¢sucrta Dar N-=DUewitin N-carardar Nysd4e4regbl N--DUa xledn N-calatl'vewrysMmn^n4isdtlng 

THE TIMELY RECEIPT OFTHE VENDOR DOCUMENTS IS CRITICAL TO THIS PROJECT 

G5-614 

VENDOR 

COMMITMENT 

(SEE NOTE 4) 

(DAYS)


Instrumentation Data Sheet 

' TAGNLWEP- 36-AIT-700A 

SUBJECT. OFF GAS RADIATION MONITOR AND RECORD SAMPLER 

SERVICE OFF GAS RADIATION MONITORM SYSTEM PICNumber 501 

pLIER; • P&ID NO.: F-145579-36-Afi105 

MODEL •. P.O.NO.:. 

COMPONEM., Vendor to provide sep arate cabi ne t forbeta/gammu CAM syscm in duct and oae for 

a rd sampler in slack 

Boa and Gamm a, Continuous Monitori agwith Integral Check Source in iortalled induct 

Stackwooedsmmpla Aalle tainat7terho4dertocollecttheraewdwmp)m 

Record sampleup riatoms shoo}d indicate the date, exa ct plaee, and time o f'sampling 

Sample7'ransport System (Tubing, Vacumm Pump(s), Bow comrolkr(s), valvimg) ANSI 13.1 -1999 Compliant 

Shrouded Sample Robe in stark (venmor in 

lo cation) ANSI 13.1 -1999 Compliant 

Shrouded Sample Probe for a 16°Diameter Duct ANSI 13 . 1 4 999 Compliam 

Data Acqu isition and. Archiving Sys ran with Non-re clable Totalizers and an Interface to ControMet 

Vendor w Provide a Written Technical Basis Document required by Section 4 of ANSI 13.1-1999. Submit with layo ut 

drawings 

Vend or to Provide Sum-up Assistance and Field Support and TrainingRewtmmetdations at per dicm rater as required 

Vend or to Supply a suitab le enclosue having a cut m0ed ambient atmospbee and radio frequency shi eldingpmW dion. 

Tae System should b erve a lvlanufacturers namepl at e using the S eller's standard praaica 

Repm6.g Package tailored to suit Operating Permit and Regulato ry Requirements 

Unit to Op er ateon 120 VAC- Vendor to Supply local discorountsw itch, terarmils and electrical junction box 

nrovidc Uscr Manuals, drawings and recommended spate parts list- 6 Hard topics and t Electronic copy 

Vend or sball m ar k the location oflhe monitoring and no ad samp li ng probes on the provided duct 

stack layout 

drawings (duct line to beused is i6-VOCr3&,0266) (EX-STOCK, Rev.A as modified by KJ- MCC ackeo 12/37/05 and F 

145579-36-W0034, Rev. E) 

V'endm shall provide a 14" female NPT fitting on the ca binet fm Buyer to interface with for sampling the cabin et. 

VYmdor to provide amp le ac ce ss to equipm en t inside cabincts for maintenance ac tivities. - 

Best Available Radionu clide Control Tech no logy emission controls most be used. 

Quantity: t - 

Do" Off-gas Cardidams: 

net Gas Temperature. 1677 Duct Diameter.. I G% Horicamad Run 

Duct Gas Pressor. -100-Wata Column Water Vapor. 17116dms 

Duct Design Flow Rate. 8,000 ACFM Duct Mat erial: Snodera Steel 

Duct Max Flow: 

Ambient Air Tamp:. 

10,O00 ACFM 

-2YF to 115°F 

Life Span: 

2 Yrs. Opera tion 15 Yrs. Design (24hrlday, 365 

day/yr) 

Sink Off-Gas Coud-uimm! 

ck GasTenpe ni.m. 370°F Stack Height 155 Feet 

Stack Gas Presswe: 0.6° Water Column Stack 4* see with 6' outer linen (dnv EX-STOCK) 

Stack Design Flow Rate: 9,500 ACFM Si cam B2O: 208 Idlas (dew point 86°F) 

Stack M. Flow: 10,000 ACFM Stack Mat,. iak Carbon Steel 

Ambient Air Temp: 

Off-gas Cmadments: Expected Dosages' 

-25-Fto 115-F 

Life Span: 

2 Ys. Op eration 1 5 Yrs. Design (24loidag 365 

) 

d 

n'Cs 46E-10 Mi, Transuranic (IRU) 2.7E-15 CUk 

'Ate 1.8E- 1) Cidm t°C TED (Permit Limit: 5 x Ie mi cr o Ci/mLr 

1391 55E-13 CWhe r"Sr TBD (Permit Limit:4 x 10-u micmC/mL)" 

SO2 1.1 ppmv 140 0.09 ppmv 

NOx 3425 ppmv 

• V en dor to provide measurable rangewhen nominal value is not given Otherwise, tinge= nominal value given increased by a fac to r of 1.2 

to the minimum detection limits in air permit 

[NOTES: 

Re ulalory Rmuirements 

Compliance with WAC 246-247-075 Reluncosents wbae app licable to this instal lation. 

Com oliame with 40 CFR 52, 60 and 61 Regulations wbae applicable to this lnsraltao.- 

Compliancewi[h 40 CFR 52 Appendix E Flow Meta Qualification. 

Compliance with ANSI N1 1 14 M, N42AS, N317 and N323 wh ere applicable to this ins tallation. 

Complancc with NFPA70 and 01 com ponents most bave NRTLlistingRabeling. 

Software a gpalify under TFC-ESM-IRM-HSC-0 1. 

Other Reouiamrots S 

Quality ASSmance shall be per ASMENQAL 

All valves must betae eel m libew the su 1ia for can durin Zion and main.evanca 

B .CN Gvk: ' ^^ A Dale: 10.fan-0b Protect: 145579 Rev-. C 

G5-6t 5

TECHNICAL DATA SHEET ame&_ 

PROJECT: Final DBVS Design 145579-F-DS-002.2 REV. 0 

PROJECT NO.: 145579 


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Trw-^ +^F ^y M .v¢ A:ate tr.... aM r .0 w r ti awa y, r^^' ^ ^^ ./ s 

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1 f-1155»-OO-D-0008 Off- ! ELECT. MAKEAS CA - MAN 

2 F-I4S5 711-00- 0007 OFT-fay TRFATYDET - P T LAYOUT F 

] F-I.55»-oO-P-OD12 OFT--GS TwE+IYFNT - PRw SfCDDNS 

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6 F-1135»-J6-V-0021 OFF-G$ EX14U51 S1ACK DET)AS 

Ii11fS: 

1. OWY V TEIATKIN UUCiB9RK PIPING M S18P0R11N0 faRLE T RAYS ST—L All OMFR 

Pn1 N0 CABLE ]RAYS OLKITED FOR Cl 0TITY. 

2. UWTN S M0 LOUT10N5 OF "ITS TO BE COWWA" BT 5ELEC ED VENDOR. 

J. VEM PON DOC)MVRK PPR.Y TO DE I9NIYUY 1BK)WCS SCHmULE 10 EXCTPI AS IRTI 1 

4. DUCMORR WTERVL M. 1A9RCATICN SHALL CC4YOf6F 10 A37JE 811.1 POMER PIPING E 

S. D XII&O K FTTTI T:5 M PER A ITEC NYG. N0. F-IS55)f-36-V On STAMIARD 

DET7w5 - STD. I. 

IL La DESIWATES ISDIAFION WYPERS 70 DE FLANDERS ILA' 1N0 0rD9 1XE-WW 

(RAT' (1l/IOE TT`C). TI/JICfS TO YATCN 150( ORLLW, ^ 

2. KNIUNOFI DU(:—" SUPPDITIS -j RfPR6rHTm - A IIF)IACON. 

DS- 

°-0°400000 FOR 'VS TYPE SUPPORTS SEE 0R'C. F-1.15)9-16-0024. 

FOR A LL 01 11f3I SUPPORTS SEE OPAwATCS f-1155)9-00-P-0001 TO -OD04. 

a. SEE 13R N H REPigFLL1ENT DUAL M D , r-145171 -x-V-0023 FOR 

FFFT S SNOAN S-DED. 

NAYE 

--145579-FINAL DBMS OES16N 

U.S. DEPARTMENT OF ENERGY 

BULK VITRIFICATION 

OFF-GAS TREATMENT 

SCRUB .& STACK SECTIONS 

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1 z 

i "^ [ l3AKP M ./Oaptol _ m rAFT,DD.Iw.^ t4F^,m D.f 

i EL Q DUCT ffm4o 1a aRN Nu Yw/1^ larch IA.TA >• »Yam m FIR: 

1 r 666'-2 1/2- us'm m omF Rat A[w:7//Ra loran 4.AU >s 49I m^ « - r1eF 

— EpR Mrtwul .r/IiOaM. ^ M ^ 

iJ 

aR

m 

TECHNICAL DATA SHEET ame __ 

PROJECT: Final DBVS Design 145579-F-DS-002.2 REV. 0 

PROJECT NO.: 

-- — 

145579 

- 

CLIENT: 


OFF-GAS RADIATION MONITORING EQUIPMENT DATA SHEET 

RPP-24544 REV 1 d 

G5-617

TECHNICAL DATA SHEETS - 


air& 

PROJECT. Final DBVS Design 745579-V-DS-012-1 I REV. 2 

PROJECT NO-_ 145579 Air-Cooled Scroll Chiller 

CLIENT: AMEC E&E- Richland Washington EQ. NO:: 3GDS"56 

No. Required I Area Off Gas 36 

P &fD# F-.145579-36-A-0106 Stream No, 

Reference Specification: N/A lQuadity Assumnee Level C 

Operating Conditions Rev Rev 

Location:(IndoomfOutdoots) 

Outdoors Environmental Conditions 

Operation (Continuous / Intermittent) 

intermittent Ambient Temperature Range l°F) -25 to 115 

Days per year 

365 Relative Humidity Range (%) Win 100 

Hoursperday 

24 Hail Diameter (in)

ATM--, 

RPP-24544 REV l d 

TECHMCAL DATA SHEETS 

Data sheet 2 of 2 - 

omments: 

} 

amec0 

One Air-Cooled) Scroll Chiller for the Demonstration Bulk Vitrification System project will be procured in accordance with York® 

Millennium® Air-Coded. Scroll Chiller (Style C) catalog specifications for theYork® YCAL0042EC Air-Cooled Scroll Chiller (Appendix A) 

or equivalent, in accordance with requirements for general service equipment. Note that general service equipment does not perform a safety 

function. Requirements in addition to the Millennium® Air-Cooled Scroll Chiller (Style C) catalog specifications are provided in this data 

sheet. The chiller will be used to provide cooling for the Off-Gas System.. 

2 

APPLICABLE STANDARDS 

The Air-Cooled Scroll Chiller shall be Designed, Tested, Rated, and Certified in accordance with, and installed in compliance with applicable 

sections ofthe following Standards and Codes: 

• ANSIIASHRAE Standard 1S- Safety Codefor Mechanical Refrigeration 

• ASHRAE 90.1— Energy Egiciency Compliance 

•. ANSI/NFPA Standard 70.— National Electrical Code(N&C) 

• ASME Boiler & Pressure Vessel Code, Section WE, Division I 

• AR} Standard :5501590- Positive Displacnanent Compressors and Air Cooled Rotary Screw Water-Chilling Packages. 

• Conform to Intertek Testing Service, formerly ETL; for construction of chillers and provide ETUcEPI- Listing label. 

• Manufactured in facility registered to ISO 9002 

3 

GENERAL 

- The Air-Cooled Scroll Chiller shall conform to all aspects of the product data sheets and drawings provided in Appendix A, unless otherwise 

specified. 

- The Air-Cooled Scroll Chiller shall be designed to be relocated at least twice during its operational life. The chiller shall be designed to be 

transported over th;e road- Note: The Buyer shall lift the equipment using a forklift or crane, using the lifting points designed for that purpose. 

- .Flange faces shall be covered to prevent damage and prevent ingress of debris during shipment. Blind flanges shall be installed on flange 

connection points Co. prevent damage to flange faces during shipment- 

- **The - Air-Cooled Scroll Chiller shall have single-point non fused disconnect switch: field provided branch circuit shall connect to a singlepoint 

non-fused disconnect with lockable external handle in compliance with the National Electrical Code (NEC®), Article 440-14, with factory 

provided interconnecting wiring to, individual system circuit breakers and coorpressor motor start components in the motor control center 

cabinets. 

4 

- Items marked with an - shall be filled by VENDOR - 

Date 12-Oct-04 22-Oct-04 3-Nov-04 15-Dec-04 7-Ian-05 2-Feb-05 

By FS FS FS FS MEP AP 

Cbked AP AP AP AP AP DW 

Rev. A - B C 0 1 2 

(35-619


AWCAmerkas.Limited 


The docwnent revision number is indicated below. Please replace all revised pages of this 


?e 

PROJECT: Final DBVS Design 1455794-136—M.1 I REV.3 

PROJECTNOa 145579 

EXHAUST FAHS 

CLIENT: AMEC E&E - Richland, I EQUIPMENT NO.: 36-N31.025, -026 

REV. 

NO. 

ISSUED FOR ORIGIN DATE INITIAL 

A Internal Review DW &Oct-04 DW 

B Internal Approval DW 22-Oct-04 DW 

C CH2M Hill Review DW 4-Nov-04 DW 

0 Bid Request DW 21-Dec-04 DW 

I IB1d Request I 6-Jan-05 I DW 

2 jBid Request TM 19-Oct-05 TM 

3 jBidRaquest JCMc 13-Fe6-06 

CLIENT APPROVAL (AMEC RICHLAND) 

Original Approvals on fife 

Project Manager. 

Date: ? !7 FiE 

O.A. Rep.: s; 

Date: R^â 

CLIENT APPROVAL (C 

Project Manage 

Date. Lt L> c^sa 

DMJM (RICHLAND) 

Project Managc 

A1,71016 

mlAPProvals on Fire 

Date: C p 

Discipline Lead:° =ci .rte 

Date: 

a/rte/e^ 

Originator r f/` 

Date: 

G5-912

PROJECT: Firml DBVS Design 145579-V-DS-004.1 REV. 3 

PROJECT NO.. 145579 EXHAUST FANS 

CLIENT: AMEC ME - Richland, Washington 

EC WPBAENT No.; 36 N31dlz5, 026 


Doconry_ent No, Specification 

145579-V-SP-004 EXHAUST FANS 

CONTENTS 

Data Sheet 

---2 Page 

Bidders Drawing & Data Commitments Sheet ___..1 Page 

G5-913 

W

TFPWH At :nATA c 4PSTC 

PROJEG'f:. - Final UPS Design-=:145579- Y-DS-06t.1 REV-3 

PROJECT 11O:: 

CLIENT: 

-145574 - - 

A66C-G E&E-Rfti6l3W..Wastongton 

EXHAUST PANS 

GQUUh1I3NfF10:36-N31.025,-026 

No. R aired 2 Area' - 36 

FD # - F 145579-00-A-0023 Stremia No. 45 

Refereace Spec ¢ai?on: 145579-V-SP-OD4 lQuality Assmrance Level - EQ 

Operating Conditions - Rev Rev 

Location (IndtwrslOutdoors) 

Owdoors Favironment 

Operation (Continuous f Intermittent) 

Days yet year. - 

Cbndmiaus 

365 

-Radioactive 

-Toxic: 

No 

Yu 

-B- 

, 1 

Hours per day 

24 - -Corrosive 

No 

Availability of eaelh fan (sr:) 95 - 1 -Flammable ' 

No 

Ambient temp-min ("D -25 -Beryllium : No 2 

Ambient temp - max CF) 115 

Devation ft MSL 

663 -3 

InleR 

Description 

Flow Rate 

Temperature (" E:) 

Fan Data 

Manufacturer 

Model number * 

Size 

x 

Inlet Static Pressure (in wg) 

Outlet Static Pressum (in wg) 

Total External Static Pressure (in wg) 

Max Speed - (RPM) * 

Operating Speed (RPM) * 

Air Displacement (SCFK * 

BHP, at Std Air (hp) s 

BHP, at Oper. Temp.. (hp) * 

Inlet 

-Diameter (in) * 

-Flangespecification * 

-Position * 

Outlet 

-Diameter (in) 

-Flange specification 

-Position 36-N31-025 * 

36-N31-026 *. 

Air 

JFootprint 

Max base length (h) * 

1 2 IMax base width 01) = 

248 B 

-120 B 

I I 

-121 1 

2. 

2 

BAUCW 3 

BAUCCW 3 

Hub (externalCntenal) 

-Material 

Fan Wheel 

- Material 

-Type 

-Diameter (in) $ 

-Blade Thickness (in) * 

-Hardness (BHN) 

-Tip Speed (fps) 

-Direction of curvature 

-Max. Allow tip speed (fps) 

-Min. Allow. Flow (C" 

Rotation (viewed from driver. end) 

36-N31-025 

36-N31-026 

3 

- 

2 

2 

-CW 3 

CCW 3 

Additional Features: lCoupling 

Speed Sen" (YeslNo) Yes 2 Manufacturer 

Anti-static Features (YeSINo) No Type 

Coupling Guard (YesNo) Yes Gear Ratio 

Inlet Filter - (YeRtNo) No MmerW 

Case Drain 

tY=ft4o) Yes Service factor (based on motor Hp) 

15 

Split taper4odc bushings 

Thermai Isolation regd * 

ves 

Date S-Oct-04 22-Oct-04 i-Nov-04. 21-Dec-04 64an-05 19-Oct-05 13-Feb-06 

By DW DW DW DW DW TM 3CMc 

Chked AP 

A 

AP 

B 

AP 

C 

AP 

0 

AP 

1 

TM 

2 3 

G5-914 

B



Data sheet 2of2 - 

Motor - - Ravi 

_ 

Manufacturer 

Pull-up torque %of locked ro tor torque 

Power 

Friona size 

(HP) 

c: - 

400 

- 

3 Speed 

Efficiency.. 

(RPL1) - 

s 

NEMA 

Service Factor _ 

Duty 

Corrosion protection 

Enclosure Type and Rating. - 

voltage 

(Y) - 

Frequency - (M)_. 

Phases 

Materials or construction 

Housing 

Fan Shag 

Fan Base 

Spacer Ping 

ry= 

Torque 

(0-ibs) 

1-0(MIN) 3 Current - (A) 

INVERTER 3 Paint Finish 

- Weight ob). 

TEPC Position - - - 

460 JVSDcapable 

: Ya . 3 

-60 Insulation Class (NEMAMG-1) 

F. 

3' RTD(3phases) (ohms) 

- loo. B 

- 

Motor Enclosure 

Guards 

Bearing Pedestal 

Bearings Boltum Material - 

Maunfacturer + 

Bolts 

Size - 

-size ( in) 

Number 

- number 

- 

Type 

LtoLi£e 

* 

(his) - 100.000 

B Nuts 

-size 

- 

feral 

VibrationTransduicer/Switch ** 

-number 

RTD fan drive bearing - (ohms) 100 3 

Surface Preparation and: Finish 

Weight 

Total Shipping Wei ght fib) 

By VENDOR (YeslNO) 

Surface Preparation 

yes 

System 

Finish type 

- 

- 

Finish Dry Film Thickness (n) 

Comments- 

1. Items marked with an ^ shall be fi lled in by VENDOR 

Vendor to recommend type 

The fan is to meet applicable requirements of the ASME AG-i Sections per appendix B of the Specification 145579-V-SP- 004. 

The fans shall be minor image discharge as shown on drawing 36-V^D007 

Date -8-Oct-04 22-Oct-04 I-Nov-04 21-Dec-04 6-Jan-05 19-Oct-0S 13-Feb-06 

By DW DW DW DW DW TM dCMc 

Chked AP AP AP AP AP - TM 

Rev. A B C 0 1 2 3 

G5-915 

Rev

f 



'T omwU ll I: r-UA 

PROJECT: Final DBVS Design 145579-V-DS-004.1 I REV. 3 

PROJECT NO.: 145579 EXHAUST FANS 

EQUIPMENT NCO.: 36-N31-025,-026 



BIDDERS DRAWING AND DATACOMMITMENTS 

Vendor shall supply all drawings, manuals and documentation in the quantities indicated. Approval drawings arc due within the 


submissions am governed by the en.-ineerine design schedule of the project. The Vendor shall supply one Autocad disk file 

and requ stud number of copies within the listed number of calendar clays. hind drawings nnust he certified as cotn:ct and 

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

revison numbers, quantities, status and document types roust be included with all submissions 

(including electronic twbmittals) 

Submit all documents via courier service. 

Faxed documents nu.tst be followed by the originals. 

Electronic E-mail or FTP transmissions of drawings 

& data must he copi;:d to 

DOCWTIent Control 

Always include a t-ansrnittal 

AMEC E&E 

1 135 Jadwin Avenut, 

Richland, WA 99352 

Attn: Document Control 

Phone: (509) 942-1114, Ex I. 118 

Fax: 009) 942-1122 

BIDDEB:S MUST PROVIDE ESTIMATED LEAD'I'IMES FOR APPROVAL DRAWINGS 

Proposal Ridded shall include this data for each item REVIEW 

Rceiew Required before ordering or start of fabrication 

rrENIS DUE 

Fimal Required within 7 days prior to shipment and before final payment WITHIN 

PROPCKSAI, REVIEW FINAL _ 

DESCRIPTION 

(DAYS) 

I 

QA Program that satisfies the requirement:; of NQA-1-1994 Bid 

I Experience list and maintainability information Bid 

E+3 E 0 Design, fabrication & delivery schedule PO+7 

E+3 Eta E+6 Outline drawings and layout drawings indicating weights and dimensions P0,04 

E+3 E+3 E+6 Technical brochures on purchased components P0+21 

E+3 E+6 Calculations PO+21 

E+I E+6 Spare parts list RI-14 

E+1 E+6 

Set of installation and rtutintenance manuals c/w technical literature for all 

equipment and devices Del-14 

6 NEC ins °coon certificate Sc electromagnetic interference test results Dal-7 

6 U/L and motor lists _ 

Del-7 

6 Sitecommissioninv re cord & test rnnlrs COM+14 

- 0- WE 

TO —0— 

TIIE TINIELY RECF.IF'r OF THE VENDOR DOCUMENTS IS CRITICAL TO THIS PROJECT 

--- -6-5 

BUYER COMMITS TO A 10 WORKING DAY TURNAROUND ON REVIEW ITEMS 

l agree to provide the listed documentation and data and the dates shown above. 


G5-916 

VENDOR 

COMMITMENT 

(SEE NOTE 4) 

(DAYS)

I— 


AME*C Americas Limited 


'nie document revision number is indicated below. Please replace all revised pages of this 


amec`4y 

PROJECT: Final DBVS Design 145579-V-DS-004.02 —[ REV. A 

PROJECT NO.: 145579 Exhaust Fan 

Variable Frequency Drive 


V 

-MMI W - 

A Intemal Review DAK 2/13/2006 


CLIENT APPROVAL (AMEC RICHLAND) DMJM APPROVAL 

Original Approvals on File Original Approvals on File 

Project Manager. 1-) '44^----Rroject Manager: 1). 

Date: Date: V 

O.A. Rep.: Discipline Lead: 

Date: Date: 2- /13 /o 

CLIENT APPROVAL (CH 

Project Maria r: 

Date: L- 7 6 

-^, 

Originator 

Date: 

G5-917 

0 A 

^C_^ M _ `l^^

RPP-24544 REV Pd 

PROJECT: Final DBVS Design 145579-V-DS-004.02 REV. A 

PROJECT ND.: 145579 

I 


REFERENCE_ SPECIFICATION 

CONTENTS 

Data Sheet _ _. 1 Page 


G5-918 

Exhaust Fan 

Variable Frequency Drive

RPP-24544 REV lid 

TEM-INICAL DATA SHEETS: 

PROJECT: 

PROJEG'l fiCT.: 

.: 

- Final OWS Design 

145579- 

AMEGEBE - Richland Washington 

- 145579-V-DS-00442 

Exhaust Fan 

Variable Frequency! Drive 

REV, A 

Regadred: 2 

JLrea 

No- PROA - 

Referellse 0 Specigeatnon: 

- Fi45SM-00-A-0023 

145579•V-SP-004 

Stream No. 

lQualiur Assurance Level 

45 

Enhanced 

Operagng Conditions - 

Location (dderns/Outdoors) 

Operation 

(ContinuousRntermiUent) 

Max. Arnbiant Air Temp. (°F) 

Min Ambient Air Tamp. (°F). 

Indoors 

Continuous 

65 

40 

Rev 

..Operation - Maximum days per event 

-Hours per day 

Availability 

Elevation (,it) 

% 

.365 

24 

95 

663 

- 


Atmospheric Envimrxnent-Radioactive 

NO 

- 

- Toxic 

No 

. 

- Conosivir 

No 

Flammable 

No 

Speciticattom[interface: 

Model f Matte 

IMnensions W x H x D (n) 

Minimum Capacity 

(HP). 400 Weight Ib 

NRTL-psted and Labeled 

Yes 

Efficiency, Full Load (min.) % 06 Programmable Analog Inputs 

2 

Starling Torque. of Rated Torque % 100 Programmable Digital Inputs 

4 

Speed Regulation 

% 

1 Loss of Input Signal Detection 

Yes 

Short Clmult Rating (min.) kA 22 Disconnect Switch. Sensing Function (Note 2) 

Yes 

Enclosure 

NEMA 1 Power Tenninal Blocks Rating cc) 90 

. Nameplate wlequipment no, and designation 

Yes 

Communication Interface 

Controwef 

INPUT 

Operator.nterface 

LCD HMi 

Voltage _ (Vac) 46Oa-/-10% Numeric Keypad 

Yes 

Frequency 

(Hz) 60+1-5% 

Phase 

3ph, 3 W 

Primary Side Power Factor (min.) 

0.97 

Transient Surge Protection 

Yes. Equipment Designations and Numbers 

AC Lure Reactor 

Yes 

OUTPUT 

36•E41.025A OGTS EXHAUST FAN VFD 

Control Mode 

-Sensortess 

vector 

36-E41.026A OGTS EXHAUST FAN VFD - 

Modulation 

Pulse Width Suggested:Manufacturers and Models: 

Drivers 

IGBT 

Frequency Range (min.) 

(Hz) 0'.-320 Allan-Bradley(PowerFlex 700H) 

Load Duty Rating 

Normal Columbia Electric Supply 

Brake IGST 

No 1913 W 'A' Street 

Brake Resistor 

No Pasco, WA 99301 

Peak Overload Current 

110% for 1 

min. 

(509) 547-9733. 

Contact: Jack Wood - 

Protection 

- Loss of Phase 

Short Circuit 

Acguslable Overload Protection 

Yes 

Yes 

Yes 

ABB Inc. (ACH550-UH) 

Drives, Motors and Power Electronics 

:(6250 W. Glendate Drive 

New Bedie, Wisconsin 53151 

(262) 785-3200 

Notes: 

1. Aa items with an'shan be Kited in bylhe VENDOR 

2. The VFD shalt incorporate adisconnect switch sensing function. This sensing (unction shall allowthe VFD tashut down normally when 

apowerdiscorin switchlocatedbetween the VFD and the associated moorisopeneddumpoperaticri. 

Date 13-Feb-0E 

By D 

Chked 

Rev. A 

l3J-Y f Y 

g 

Rev

TFCHWICAt_ DATA SHFETSi 


amec"' 

RECT: Final DBVS Design 1145579-V-DS-004.02 REV-Q 

CT NO.: 145579 ExhaustFan 

r 

F: AMEC E&E - Richland, Washington 

Va riable Frequency Drive 


Vendor shall supply all drawings, manuals and documentation in the quanti ties in dicated. Approval drawings are due within the listed 

number of calendar dW; after issue of the Purchase Order or Le tter of Intent. The dates set out for drawing and data submissions are 

governed by the enginee ring design schedule of the project. The Vendor shall supply one AutoCAD disk file and requested number of 

copies within the li 

sted rwmber of calendar days. Final drawings must be certified as correct and bear the Vendors name, equipment 

number and Purchase Cider Number_ Drawing Transmittals listing the document numbers, revisions numbers, quantities, status and 

document types must be included with all submissions (ncluding elect ronic submi ttals). 

SEND ALL DOCUMENTS TO: DMJMH+N, Inc. 


Submit all documents via co urier service 3250 Port of Benton Blvd. 

Faxed cocuments must be followed by the originals. Richland, WA 99354.1670 

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



BIDDERS MUST PROVIDE ESTIMATED LEAD TIMES FOR AP'P'ROVAL DRAWINGS 

- 

Proposal Bidder sha ll in clude this data for each Item REVIEW 

Review Requ ITEMS DUE 

ir 

ed before orde ring or start of fabrfcation 

_ 

Final 

Requ ired within 7 days pr io r to shipment and behxe Ikna%payment WITHIN 


E 43 E +1 E+1 Proof atcerWicatontoQuably Standards Bid 

E+3 E+1 E+1 We ights, dunen&ons and heat dissipation Bid 

E-i3 List of deviations from this Data Sheet Bid 

Ei3 E+3 E+6 

E+3 E+6 

Delaled specif ications for proposed equipment, V' cludinq 

customer power and control connec tions 

Installation and maintenance manuals. with technical literature for 

all equipment and dev ices 

VENDOR 

COMMITMENT 

(DAYS) (DAYS) 

PO+7 

Del-14 

Final Data Package Including 

Shop drawings 

E+3 E+1 Schematics Del- 1 0 

Wiring Diagrams 

- Recommended spare parts list 

Zf 

-i^< • E. I onclycC{.f,4 

' 

t?iw ^^` 

+eîl IN 3.1,s!''uv!.cnmi'f+rd?N+2Cs' ^,',=r,. 

THE TIMELY RECEIPT OF THE VENDOR DOCUMENTS IS CRITICAL TO THIS PROJECT 

I agree to provide the listed documentation and data and the dates shown above. 


G5-920



p.Yf^b/IMUSpÂc^bco00t-SMI*MMV,4O (GM R-20x 

lO.AnDG 

RPP-24544 REV 1 d 


document +and destroy the superseded copies. 

PROJECT:, Final DBVS Design 145579 -V-SP-001 L 

amec'O 

REV. 2 

PROJECT 140: 145579 SPECIFICATION FOR SELECTIVE 


CATALYTIC REDUCTION UNIT (SCR) 


Original Apprpvals On pile 

Proje ct Wanager: LeLjktx—,^ 

Date: (? ^°'^ °5 

QA. Rep.:: 

Date: G r5^^ 

CLIENT APPROVALL. (C 142M HILL) 


Date: 1 ^.1 


G5-620 

AMEC AMERICAS LIMITED (TRAIL) 

Original Approvals On File 

Project Manager:, 

Date: ^^ 

Discipline Lead. 

Date: l0 Qoos 

O riginator: 

l 

Date: 1t9F aC,cg 5 - 

Page 1 of 45


TECHNICAL SPECIFICATION c3ll?E'C 

AMEC Americas Limited ^r 

' Afl-OCE'.N.TPNjetlsi'ival Tear2U0FDBV5ATT9RRge q 20 Wt"4W(bm^wtlwx:e, A4AWes(Oh^4T0.tt3 T2nwihlakUIZ TFGVWTMR-TfG012(Trd^l-22(b}relivtl.PIG2325Cfn]e55]&KSP-0Ol 

(scR>R^. ^^^ Page 2 of 45 

G5-621



AMEC' Americas Limited 

PROJECT: Final DBVS Design 145579-V-SP-001 I REV. 2 

PROJECT NO.: 145579 SPECIFICATION FOR SELECTIVE 

CATALYTIC REDUCTION UNIT (SCR} 

CLIENT: 

AMEC E&E — Richland, WA 

4.2 

4.3 

4.4 

4.1.5 Control of Processes ..............................................................37 

4.1.6 Inspection ................................ ................. .............................39 

4.1.7 Test Control ...... ... .................................... ............................... 39 

4 .1 .8 Control of Nonconforming Items...................... .--------- .............40 

4.1.9 Corrective Action ..........:.................................................:.......41 

4.1.10 Control of Graded Fasteners ...................................................42 

QUALIFICATION VERIFICATION ................................................ ..........42 

INSPECTIONS AND TESTS ..................................................................43 

TRAINING OF INSPECTION AND TEST PERSONNEL .........................43 

5.0 PREPARATION FOR DELIVERY ......................................................................44 

5.1 GENERAL ................. ............ ......................................... ....................... 44 

5.2 PRESERVATION AND PACKAGING .....................................................44 

5.3 PACKING ......................................................................:.......................44 

5.4 MARKING ......... .... . ............... . ............... ...................................... ........... 44 

5.5 HANDLING................... ......... ..... .................... .............. ---.....................44 

5.6 SHIPPING__ ........................ ........... _ ..... ........................ .................. _44 

6.0 APPENDICES ....................................................................................................45 

7.0 ATTACHMENTS.. .............................................................................................. 45 

APPENDICES 

A Control of Suspect! Counterfeit Items (TFC-ESHQ-Q_C-C-03) 

ATTACHMENTS 

143643-V-DS-001.1 Technical Data Sheet 

TABLES 

Table 2-1: Applicable Government Documents........... ................... 9 

Table 2-2: Applicable Non-Government Documents... ........ ................. 9 

wt:tsaararawî^^r^rea. zamwsys nnsn vAl^zamwoocon ^,aen^,ramnes(msiw>o-an rm^mmaûrtrFawrren-hcozz Rraw2onw:,^mczaz 

scxvssngvsPmatsca)Aw.z.ax 

r.wvas 

G5-623 

Page 4 

o 45




PROJECT- Final DBVS Desi n 145579-V-SP-001 I REV. 2 



CLIENT: AMEC E&E— Richland, WA 

ABBREVIATIONS AND ACRONYMS 

°C Degrees Celsius 

°F Degrees Fahrenheit 

Nm Micrometers 

AG Alternating Current 

ACFM Actual Cubic Feet Per Minute 

ACGIH American Conference of Governmental Indus trial Hygienists 

AISC American Institute for Steel Construc ti 

on 

ASHRAE American Society of Heating, Refrigera ting and Air 

Conditioning Engineers 

ASCE Ame rican Society of Civil Engineers 

ASME Ame rican Society of Mechanical Engineers 

ASNT Ame rican Society of Nondestructive Testing 

ASTM American Society for Testing and Materials 

AWG American Wire Gauge 

AWS American Welding Society 

BTU British Thermal Unit 

CFR 'Code of Federal Regulations 

CH2M HILL CH2M HILL Hanford Group, Inc. 

Ci Cu ries 

CoC Certificate of Conformance 

CMTR Certified Material Test Repo rt 

CPE Customer-Provided Equipment 

CWI Certified Welding inspector 

DBVS Demonstration Bulk Vitrification System 

DCS Dis tributed Control System 

DOE Depa rtment of Energy 

ERDA Energy, Research and Development Administration 

ft 3 Cubic Feet 

hp Horsepower 

Hz Hertz 

ICV IM In Container Vitrification 

IEEE Institute of Electrical and Electronic Engineers 

ISO Inte rn 

ational Organization for Standardization 

in. Hg Inches of Mercury 

kw Kilowa tt 

MWC&RMiRmjeUS Fast Year 2036â ATi Pmje1 Trmmn31m.9 iFCS RW-iFG {Tm1ZW,mPU 'G 232 

scm+atisisysvow(1R^.zax Page of 45 

n wvrs 

G5-624 

n




PROJECT: Final DBVS Design 145579-V SP-001 REV. 2 



CLIENT: AMEC E&E - Richland, WA 

lb Pound 

Ibm Pound Mass 

mA Milliamp 

mph Miles Per Hour 

MSDS Material Safety Data Sheet 

NCR Nonconformance report 

NDE Nondestructive Examination 

NEC National Electrical Code 

NEMA National Equipment Manufacturers Association 

NFPA National Fire Protection Association 

NOx Oxides of Nitrogen 

NPT National Pipe Thread 

NQA Nuclear Quality Assurance 

OGTS Off Gas Treatment System 

PID Proportional, Integral, Deriva ti 

ve 

PFD Process Flow Diagram 

PLC Programmable Logic Controller 

ppb Pa rts Per Billion 

PPm Parts Per Million 

psig Pounds Per Square Inch Gage 

PVC Polyvinyl Chloride 

QA Quality Assurance 

RGS Rigid Galvanized Steel 

SAE Society of Automotive Engineers 

SCR Selective Catalytic Reduction 

Sox Oxides of Sulphur 

TED To Be Determined 

TEFC Totally Enclosed Fan Cooled 

TOE Total Operating Efficiency 

UBC Uniform Building Code 

UL Underw riters Laboratories 

US United States 

V Volt 

Vol Volume 

WAC Washington Administrative Code 

wt% Weight Percent 

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PROJECT: Final DBVS Design 145579-V-SP-001 REV. 2 



CLIENT: AMEC E&E- Richland, WA 

1.0 SCOPE OF WORK 

1.1 PURPOSE 

AMEC is part of a team that has been selected by the CH2M HILL Hanford 

Group, Inc. (CH2M HILL) to design, fabricate, test, and deploy a Demonstration 

Bulk Vitrification System (DBVS) to receive, dry, and immobilize , waste from an 

underground storage tank located in the 200 West Area of the Hanford Nuclear 

reservation. A main subsystem of the DBVS is the Off-Gas Treatment System 

(OGTS). The primary function of the OGTS is to filter radioactive particulate 

and reduce NOx and SOx emissions produced from the melt process. A major 

component of the OGTS is a Selective Catalytic Reduction (SCR) Unit that will 

remove the majority of the NOx produced in the process_ 

Throughout this specification, Contract Responder shall act as the Seller and 

AMEC shall act as the Buyer. 

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 SCOPE OF SUPPLY 

The Seller's Scope of Supply shall include, but not be limited to, the design, 

analysis, fabrication, inspection, testing, documentation, packaging, and 

shipping of the following components associated with the SCR System, and as 

shown at the end of this section on Diagram 1-1. Note that all temperatures 

shown on Diagram 1-1 are estimated by Buyer; Seller to provide actual 

operating temperature for their units. All equipment, as much as practical, 

shall be mounted on a common skid for operation. 

SCR Heat Exchanger — Air-to-Air heat exchanger used to pre-heat the SCR 

inlet air stream with the outlet exhaust stream; 

SCR Heater — Electric in-line heater used to heat the inlet air stream to the 

required catalyst reaction temperature, including the Silicon Controlled 

Rectifier; 

MA- SRW;01e¢a Yea 2ooaDBVSwn9R 232 

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21 + 

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MD RPP-24544 REV id 

TEC14NICAL SPECIFICATION 


a z^ 

PROJECT: Final DBVS Desi n 145579-V-SP-001 I REV. 2' 



CLIENT: AMEC E&E—Richland, WA 

Selective Catalytic Reduction Unit - Contains the reaction catalyst bed; 

Ammonia Atomizer — Located within the SCR and used to atomize the 

ammonia prior to reaction with the catalyst bed; 

Interconnecting Ducting — Any interconnecting ducting required, if 

components are not integral. The Seller shall provide a single inlet and exhaust 

duct connection including sizes and details; 

Instrumentation — The Seller shall provide their recommended instrumentation 

requirements to maintain both steady state and transient system operation. 

Proposed instrument locations are shown on Diagram 1-1. The Seller's 

proposal shall include separate op ti 

onal pricing for the supply of all instruments 

and control valves. 

Ammonia Supply System — Skid mounted equipment required to supply 

anhydrous ammonia to the SCR unit consisting of the following: 

(2) two only—Anhydrous Ammonia Supply Pumps c/w motors; 

(2) two only - Anhydrous Ammonia Vaporizers; 

All interconnecting piping and valving; 

relief valves; 

Optional Supply: 

(1) one only- ASME Coded Ammonia Storage Tank (8000 lb capacity) 

Field Support and Start-up Assistance — Seller to provide per diem rates for 

technical field suppo rt during construction and system start-up. 

Work not included in the Seller Scope of Supply is as follows: 

a. Site installation of system; 

b. Design and manufacture of connecting systems to and from the SCR to the 

rest of the OGTS such as, process off-gas stream ducting, any electrical 

supply, and DCS PLC connections; 

c. SCR supply or exhaust fans or blowers. 

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TECHNICAL. SPECIFICATION 


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CLIENT: AMEC E$E — Ricand, hl WA 

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PROJECT: Final DBVS Design _ 145579-V-SP-001 REV. 2 


CLIENT: AMEC E&E — Richland, WA 


2.0 APPLICABLE DOCUMENTS 

Documents applicable to the work scope are shown in Tables 2-1 and 2-2. The 

latest issue and addenda to the documents in effect at the time of procurement 

(unless otherwise specified) shall apply and form a part of the basis of design 

for this specification to the extent specified in the applicable sections of this 

document. In the event of a conflict between documents referenced herein and 

the requirements of this specification, the requirements of this specification 

shall take precedence. All conflicts shall be brought to the attention of the 

Buyer for resolution. 

2.1 GOVERNMENT DOCUMENTS 

Table 2-1: Applicable Government Documents 

o- .l'k 3A' 

Nv's.i-'4.4.,7 a! ew y/ r .c S - ^+ v } xr ? 

Governme^np^^c>er>er1tîtle. 0 r^` 

WAC 173-303 _ Dangerous Waste Regulations 

WAC 173-400 General Regulations for Air Pollution Sources 

WAC 173-460 Controls for New Sources of Toxic Air Pollutants 

10CFR835 Occupational Radiation Protection 

29CFR 1910 

_ 

Occupational Safety and Health Standards — Code of 

Federal Regulations 

Note: RPP-8530 that was previously noted under table 2.1 has been moved to table 2.2. 

2.2 NON-GOVERNMENT DOCUMENTS 

^^ K a a a 7^ `c^ 

t h^del^Sta^.cârd^t .,^ 

Table 2-2: Applicable Non-Government Documents 

y c r:. r r `. ^^ , w o 

, 

ACGIH Industrial Ventilation Manual 

AISC Manual of Allowable Stress Design 

ASCE 4-98 Seismic Analysis of Safety-Related Nuclear Structures 

ASHRAE Handbooks 

ASME 1330.20 Below-The-Hook Lifting Devices 

ASME B31.3-2002 13 31-3, Process Piping 

ASME NQA-1-1994* 

See note at end of table 

Quality Assurance Requirements for Nuclear Facility 

Applications 

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21-Nor-06 

G5-629 

•

111*1' 


TECHNICAL. SPECIFICATION As 


PROJECT: Final DBVS Design _ 145579-V-SP-001 REV. 2 


CLIENT AMEC E&E — Richland, WA 


Table 2-2: Applicable Non .-Government Documents 

d.Dj.. `^r^..{ E 3:,«ra:.. Ta^ 7c". ..a,iaik . ;14zt^„,..4 .;o`z^.^^^_"x".,v"E `..' a»t _ 

ASTM A108-99 Standard specification for Steel Bars, Carbon, Cold 

_ 

Finished, Standard Quality 

ASTM A182-02 

Standard specification for Forged or Rolled Alloy-Steel 

Pipe Flanges, Forged Fittings, and Valves and Pa rts for 

High-Temperature Service 

ASTM A193-01 Standard specification for Alloy-Steel and Stainless Steel 

Bolting Materials for High-Temperature Service 

ASTM A194-01 Standard specification for Carbon and Alloy Nuts for Bolts 

for High-Pressure and High-Temperature Service 

ASTM A240-02 Standard specification for Heat-Resisting Chromium and 

Chromium Nickel Stainless Steel Plate, Sheet, and Strip 

for Pressure Vessels 

ASTM A276-02A Standard specification for Stainless and Heat-Resisting 

_ 

Steel Bars and Shapes 

ASTM A307-02 Standard specification for Carbon Steel Bolts and Studs, 

60,000 psi Tensile Strength 

ASTM A312-02 Standard specification for Seamless and Welded 

Austenitic Stainless Steel Pipes 

ASTM A354-01 Standard specification for Quenched and Tempered Alloy 

Steel Bolts, Studs and other Externally Threaded 

Fasteners 

ASTM A36-01 Standard specification for Structural Steel 

ASTM A403-02 Standard specification for Wrought Austenitic Stainless 

Steel Piping F=ittings 

ASTM A480-02 Standard specification for General Requirements for Flat- 

Rolled Stainless Heat-Resisting Steel Plate, Sheet, and 

Strip 

ASTM A500-01a Standard specification for Cold-Formed Welded and 

Seamless Carbon Steel Structural Tubing in Rounds and 

Shapes 

ASTM A516-03 

Pressure Vessel Plates, Carbon Steel for Moderate- and 

Lower-Temperature Service 

ASTM A563-00 Standard specification for Carbon and Alloy Steel Nuts 

ASTM A569-98 Standard specification for Steel, Carbon, (0.15 Maximum, 

Percent), Hot-Rolled Sheet and Strip Commercial Quality 

ASTM F436-02 Standard Specification for Hardened Steel Washers 

AWS Standards for Welding of Stainless Steel 

AWS D1.1-02 Structural Welding Code — Steel 

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AWS D1.6-99 Structural Welding Code — Stainless Steel 

HNF 2962 List of EMI/EMC Requirements, Numetec Hanford 

Corporation for Fluor Daniel Corporation Hanford, Inc , 

Richland, WA 

IEEE 142, 1991 

Recommended Practice for Grounding of Industrial & 

Commercial Power Supplies, Institute of Electrical and 

Electronics Engineers, Piscataway, New Jersey. 

IEEE 242, 2001 Recommended Practice for Protection and Coordination 

of Industrial and Commercial Power Systems, Institute of 

Electrical and Electronics Engineers, Piscataway, 

New Jersey. 

IEEE C37 IEEE Standards Collection: Power and Energy — 

Switchgear, Circuit Breakers and Substations, Institute of 

Electrical and E=lectronics Engineers, Piscataway, 

New Jersey. 

IEEE C37.90.1, 2002 Surge Withstand Capability (SWC) Tests for Relays and 

Relay Systems Associated with Electrical Power 

Apparatus, Institute of Electrical and Electronics 

Engineers, Piscataway, New Jersey. 

IEEE C62.41, 1995 IEEE Recommended Practice on Surge Voltages in 

Low-Voltage AC Power Circuits, Institute of Electrical and 

Electronics Engineers, Piscataway, New Jersey. 

NEMA MG-1-2001 Motors and Generators 

NEMA MG-13 Frame Assignments for Alternating Current Integral 

Horsepower Induction Motors 

NFPA 70 National Electric: Code, 2002 Edition 

Standard for the Installation of Air Conditioning and 

NFPA 90A Ventilating y tems 

NFPA 91 Standard for Exhaust Systems for Air Conveying of 

Vapors, Gases, Mists and Non-Combustible Particulate 

Solids 

RPP-8530, Rev. 0 Tank Farm Labeling Standard 

SATE J429 Mechanical and Material Requirements for Externally 

Threaded Fasteners, Standard 

UBC 1997 Uniform Building_Code, Volume 2 and Seismic Zone 213 

UL 508A Standard for Industrial Control Panels 

The relevant requirernents of NQA-1 are included in Section 4.0. 

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21-H-05 

G5-631







CLIENT: AMEC E8E —Richland, WA 

3.0 TECHNICAL REQUIREMENTS 

The following section is a proposed process desc ri ption of the SCR system and 

components. The Seller shall provide a similar process operating description, 

including the calculated opera ti 

ng temperatures for their equipment; if their 

equipment deviates in operation from that described below_ 

See Technical Data Sheet 143643-V-DS-001.1 for complete list of inlet 

conditions and exhaust requirements. 

3.1 ITEM DEFINITION 

The system description is shown below, please refer to diagram 1-1 in section 

1.2. 

First Stage Heat Recovery 

The process Off-Gas air stream is mixed with ambient air prior to the SCR to 

dilute the inlet NOx concentration to the speci fied condition. It enters the 

Vendor supplied SCR Heat Exchanger, an air-to-air heat exchanger, to pre- 

heat the Off-Gas stream to the SCR. The hot exhaust stream from the SCR 

passes through the opposite sides of the heat exchanger and is cooled prior to 

being exhausted_ The heat exchanger efficiency shall be specified by the 

Seller but shall have a minimum e ffi 

ciency as speci fied on the Technical Data 

Sheet. 

The air-to-air heat exchanger helps to reduce the electrical energy input 

required to preheat the off-gas stream ahead of the SCR bed_ The Seller shall 

specify the type of heat exchanger to be provided in their supply. 

In-Line Heating System 

From the SCR Heat Exchanger the Off-Gas stream will next pass through the 

SCR Heater. This heater is to be an electric heater and control is by 

temperature PID loop and S il 

icon Controlled Rectifier. The heater system will 

raise the Off-Gas stream temperature up to the design operating temperature 

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G5-632




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of the SCR. The Seller shall provide the power requirements for the SCR 

Heater and required inlet temperature to their SCR. 

Ammonia Injection System 

Anhydrous ammonia is pumped from a storage tank through an elect ric 

vaporizer and is injected into a ventu ri within the SCR unit. The ammonia is 

atomized within the high velocity air stream to provide uniform distribution 

throughout the fluid stream. 

The Seller supplied Ventu ri Injector shall be designed to minimize ammonia 

"slip"; the carry over of ammonia into the SCR exhaust stream. The allowable 

ammonia slip shall not exceed the value speci fied in the TechnicaC Data Sheet. 

Selective Catalytic Reduction (SCR) Bed 

A multi-pass catalyst bed will be used to provide very high removal efficiency of 

NOx and CO. The removal efficiencies shall not be less than those specified in 

the Technical Data Sheet. The multiple bed catalyst shall provide a SCR Off- 

Gas exhaust concen tration of NOx and CO that does not exceed the values 

specified in the Technical Data Sheet_ 

The Seller shall provide the temperature of the Off-Gas exhaust from the SCR. 

The Seller shall provide NOx and CO removal e fficiency rates vs exhaust flow 

rate for a range of +1- 25% of operating flow rate. 

3.1.1 Item Diagram 

See Diagram 1-1 for SCR system components. 

3.1.2 Interface Definition 

The SCR shalt be skid mounted as a single unit, incorporating as much as 

possible, all components including the Ammonia Supply Pumps, Vapo rizers 

and optional Ammonia Storage Tank. The Seiler shall provide their actual 

ammonia usage in their proposal_ 

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Any u tility connections shall be specified and brought out to a common 

interface point on the skid 

3.2 CHARACTERISTICS 

3.2.1 Functional Characteristics 

As specified on the Technical Data Sheet, 143643-V-DS-001.1. 

3.2.2 Physical Characteristics 

The SCR shall be skid mounted, and not exceed the footprint shown on the 

Technical Data Sheet, 143643-V-DS-001.1 

3.2.3 Reliability 

The Bulk Vitrifica tion plant is expected to operate 24 hours per day, 7 days per 

week_ Se rvice work will be done during scheduled downtimes. High reliability 

is required for any moving parts in the SCR. The operating life is 3 years. 

3.2.4 Maintainability 

Maintainability characteristics of the design (lubrication, parts replacement and 

repair, spares, modular construction, test points, etc.), should include, but not 

be limited to, the following: 

a. Maintenance and Repair Cycles. Expected inspec tion of the SCR will be 

once per week by the Buyer. The Seiler shall provide typical maintenance 

schedule. 

b. Spares and Spare Parts. The Seller sha ll identify recommended spares 

and spare parts. 

a Service and Access. SCR shall be designed for ease of se rvice (access . 

openings/spacing, self-test capability, inspection windows, test fixtures, 

sealed bearings, etc.). The Seller shall identify requirements for se rvice 

(remove and replace only, bench repair, special tools, remote 

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G5-634

- RPP-24544 REV Id 



PROJECT: Final DBVS Design 145579-VSP-001 1 REV. 2 




3.2.5 Environment 

handling/maintenance, etc.) and for capability of the unit to be connected, 

discharged, catalyst replacement, etc. 

This equipment is anticipated to be operated outdoors. Any equipment and 

related enclosures installed outside shall be designed to operate and be stored 

in the climatic and environmental conditions listed below. 

a. Ambient air temperature range is -30°F to 117°F with a maximum 24-hour 

differential of 50°F; 

b. Relative humidity ranges from near 0 to 100%; 

c. Maximum precipitation is 2.5 inches in a 6-hour pe riod; 

d. Sand and dust concentrations are 1.10 x 10 "5 ibmlft3 with a typical size of 

150 µm; 

e. Solar radiation is expected to be a maximum 900 Langieys. 

3.2.6 Transportability and Storage 

3.2.7 Safety 

The SCR shall be sized for transport using local roadways and freeways (i.e., 

less than 14 feet tall, 8 feet 6 inches wide, and 53 feet long; while mounted on 

the transport trailer). The system shall be separated into the largest 

components/sections (if necessary) to minimize system teardown time, 

readying for transpo rt, and reassembly effo rt. 

Pa rts removed for transpo rt shall be match marked for assembly upon delive ry. 

The SCR shall be designed to maintain the safety of operators, general public, 

and equipment. The Seller shall provide all necessa ry guards, lockouts, and 

other safety equipment for safe .operation. The Seller shall provide all 

documentation (i.e. MSDS) for inte rn 

al components such as catalyst plates. 

Table 2-1 shows all codes that are to be followed. The following codes 

concerning safety a re in table 2-1 and are copied here for convenience: 

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WAC 173-303 Dangerous Waste Regulations 

WAC 173-400 General Regulations for Air Pollution Sources 

10CFR835 Occupational Radia tion Protection 

Occupational Safety and health Standards — Code of 

29CFR 1910 


3.3 DESIGN AND CONSTRUCTION 

The Seller shall provide or provide access to all design calculations necessa ry 

for the SCR which includes, but is not limited to, catalyst bed sizing 

calculations, heater and air to air heat exchanger sizing calcula tions, duct 

sizing calculations, motor current starting calculation, motor sizing calculations 

if necessa ry, electrical system calcula ti ons (i.e_ load, voltage, and fault), and 

structural calculations. Calculations shall be submi tted to the Buyer in 

accordance with the Technical Data Sheet, 143643-V-DS-001.1E The Seller 

sha ll provide all design drawings necessa ry for the SCR which includes, but is 

not limited to, drawing outlines, inte rface drawings, electrical wiring diagrams, 

control elementa ry diagrams, elect ri cal equipment layout, elect ri cal one line 

diagram, electrical panel schedule, ductipipe support drawings, dimensional 

drawings, structural framework drawings, rigging sketches, and as-built 

drawings. Drawings shall be submitted to the Buyer in accordance with the 

Technical Data Sheet, 143643-V-DS-001 A. 

Alternative equipment designs and/or materials of construction are permissible 

if the Vendor demonstrates that they are able to meet or exceed the durability 

and reliability of the materials specified in Section 3.3.1= 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. 

3.3.1 Parts/Materials/Processes 

Major components in the SCR shall be fab ricated from materials as specified 

on the Technical Data Sheet, 143643 `V-DS-001.1. 

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(35-636

TECHNICAL_ SPECIFICATION 

AME:C Americas Limited 


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CLIENT: AMEC E8E — Richland, MIA 

3.3.1.1 Electric Motor 

If any electric motors are necessa ry, they shall meet the following 

requirements: 

a. Electric motors shall be non-overloading when operating at any point during 

normal operation of the SCR. 

b. Motors shall be suitable for future use with a variable frequency drive with a 

reduced voltage soft sta rt . 

c. Motors above '/z hp shall be rated 460 AC volts/3 phase/60 Hz. 

d. The motor shall be sized to run at no more than 80% of nameplate ra ti 

ng 

under normal operation conditions, includes se rvice factor if applicable. 

e. The motor shall have a minimum insulation class of F as defined in 

National Equipment Manufacturer's Association (NEMA) MG 1. 

f. Motor shall comply with the frame size assignments of NEMA MG 13. 

g. Motor balance and vibration shall meet NEMA standards MG 1-12.06 and - 

12.07. 

h_ The motors shall operate in an outdoor environment under conditions 

described in Section 42.6 of this document. 

i. The Seller shall totally enclosed fan cooled (TEFC) enclosures. 

j. The Seller shall provide the motor specifications and data sheets. 

k. The Seller shall provide megger test data, 1000Vdc @ 1 minute. 

3.3. 1 .2 Electric Wiring 

All electrical wi ring is to terminate in a NEMA 4 terminal box mounted on the 

SCR frame. 

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Page 18 of 45 

G5-637



AME:CAmericas Limited 





3.3.1 3 Piping 

3.3.13.1 General 

Piping systems for the SCR shalt be fabricated, inspected, examined, and 

tested in accordance with ASME B31.3, normal service. If there is a conflict 

between this po rtion of this specification and ASME 831.3, then ASME B31.3 

shall be deemed to be correct. Anytime the requirements in this speci fication 

are more stringent, or are in addition to code requirements, the requirements in 

this specification shall be followed. Piping systems include all piping 

components and suppo rt 

s. 

3.3.1:3.2 Line Rou ti 

ng 

If pipe bending is necessa ry, the pipe shall be bent in such a manner to 

minimize pipe wall thinning and shall have a minimum bend radius of six times 

the nominal pipe diameter. 

The proposed installation layouts shall meet the requirements of ASME 831.3. 

3.3.1.3.3 Line Suppo rt 

M;FM8PM1F JW lW 

Piping shall be suppo rted by attachment to the skid frame. The Seller shalt 

provide rigid brackets or additional frame members for a ttaching piping when 

frame members are not in a convenient location_ The pipe suppo rts may be 

stainless or painted carbon steel 

Ali piping suppo rts shall conform to ASME .B31.3, with additional suppo rt at 

valves, elbows, tees, and equipment as required. Piping suppo rts shall be 

capable of suppo rting the piping in all conditions of opera ti 

on. 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. 

Seller shall level-plumb piping using shims, etc., to suppo rt the pipe and to 

avoid forced piping deflections at suppo rt points. 

P ri 

or to fab rication, the Seller shall provide shop drawings of the required 

piping supports for review and approval 

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21- -M - 

G5-638

RPP-24544 REV td 



PROJECT: Final DRVS Design 145579 -V-SP-001 I REV. 2 

PROJECT NO.: 145579 1 SPECIFICATION FOR SELECTIVE 

CLIENIT: AMEC E&E — Richland, WA 

13.13.4 Flange Joints 

I 


All flanges shalt be standard ANSI 150 lb raised face flanges, except where 

otherwise specified in this document and per ASME B 1 6.5, and shall be made 

from the same type of steel as, the pipe they are welded or threaded to, unless 

otherwise noted. 

3.3.1.3.5 Threaded Joints 

Threaded joints in lines shall be joined using Loctiteo PST. 

111.3.6 Valves and Installation 

The main process isolation valves and bypass valves shall be full po rt ball 

valves (suggested vendor: Keystone or Bray). All valves shall be installed per 

Manufacturer's instructions. 

Seller shall review Manufacturer's supplied information for unique installation 

requirements and request written cla rification if installation requirements do not 

match the design. 

3.3.1.4 Insulation 

The temperature on the external of the SCR housing is expected to be near 

process temperature (-600 1F). Insulation is necessa ry to reduce the exposed 

SCR outer temperature to less than 140°F_ Insulation and jacketing shall be 

installed on all heated or cooled components and piping by the Seller in 

accordance with Manufacturer's recommendations. The proposed insulation 

shall be non-asbestos and shall.be submitted to the Buyer for review and 

approval before installation. The insulation shall not impede component 

performance or normal maintenance access. 

3.3.1..5 Electrical 

Design and installation of electrical equipment shall be in accordance with the 

NFPA 70 (Na tional Elect ric Code (NEC)) and IEEE standards listed in Table 3- 

1. The SCR Unit shall be labeled by a na ti 

onally recognized testing laboratory 

or inspected and passed by the CH2M Hill Hanford Inspector. Elect rical and 

Control panels shall be labeled as UL-508A compliant, where applicable: 

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G5-639 

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AMEC Americas Limited E LM 11M 

PROJECT: Final DBVS Design 145579•V-SP-001 REV. 2 



CLIENT: AMEC ERE — Richland, WA 

3.3.1.5-1 Conduit 

Rigid galvanized steel (RGS) or electrical metallic tubing (EMT) conduit shall 

be used_ RGS or EMT shall be UL approved, standard weight, 

electro-galvanized steel, 1/2 inch minimum size for control wiring and 3/4 inch 

minimum size for power wiring. 

a. Liquid tight flexible conduit shall be installed where flexible conduit is 

required such as when connec ti 

ng to vibrating equipment. Liquid-tight 

flexible conduit shall be grounded type with a Polyvinyl Chlo ride (PVC) 

jacket. 

b. Conduit fittings shall be standard steel threaded, liquid-tight, type RGS 

fittings. 

c. EMT fittings shall comply with provisions in NEC 2002. 

3.3.1.5.2 Wire and Cable 

a. Conductors shall be stranded copper for all sizes of wire and cable. 

b. Wire insulation shall be Type THHN (heat resistant thermoplastic) / THWN 

(moisture and heat resistant thermoplastic) for all 600V conductors. 

c. Minimum size of power conductors, 600V and below, shall be No. 12 AWG. 

Conductors shall be derated as required by NFPA 70 for proximity to 

heated equipment and summer outdoor ambient conditions specified in 

Section 4.2.6. 

d. Conductors for control circuits shall be No. 14 AWG minimum, except that 

remote control circuits, sign aling circuits, instrumentation, and power limited 

circuits may be sized smaller in accordance with the National Electric 

Code (NEC). 

e. Power wiring for single phase systems (120/240 V) shall have color coded 

insulation as follows: Hot = Black, Brown; Neutral = White or Gray; Ground 

= Green or Bare. 

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CATALYTIC REDUCTION UN IT (SCR) 

CLIENT: AMEC EBE -- Richland, WA 

f. Power wiring for 3-phase systems (480 / 277 V A, B, C) sha ll have color 

coded insulation as follows: Red, Yellow, Blue; Ground = Green or Bare, 

Neutral = White or Gray. 

g, Instrumentation cable shall be 600V, multiconductor for discrete signals, 

flame retardant, jacketed cable suitable for installation in wet or d ry 

locations. Conductors shall be #18 AWG stranded, copper, in twisted 

pairs/triads with ethylene propylene insulation. Each pair/triad shall be 

shielded wi th a drain wire and metallic tape. Mul ti-pair 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. Each pair/triad shall be numbered for simplified 

termination. 

h. Control and power multi-conductor cable shall be 600V, flame resistant, 

radiation resistant, jacketed cable suitable for wet or dry loca tions. 

Conductors shall be stranded copper with crosslinked polyethylene 

ethylene propylene insulation with a temperature rating of 194°F 

3.3.1.5.3 Wire / Cable Markers 

Conductors shall be identified with white heat sh rink tubing with indelible black 

typed on le tters. Hand le tt 

ered labels shall not be used. 

3.3.1.5.4 Junction Boxes 

Junction boxes shall be NEMA 4 rated. 

3.3.1.5.5 Electrical Components 

All electrical components, where a UL Catego ry exists, such as contactors, 

motor starters, and power controllers, etc. shall be UL-listed. Motor sta rters 

and contactors shall be NEMA rated. 

3.3.1.6 Instrumentation and Installation 

In general, all instrument transmitters shall provide an isolated 4-20mA signal 

to the DCS, all pneuma ti 

c control valves shall accept a 4-20mA control signal 

from the DCS and provide position indication to the DCS. Instruments, tubing, 

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SCFat64579NSPlM (SCM w+.2s - Page 22 of 45 

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AMEC Amedcas Limited 


PROJECT NO.: 145579 SPECIFICATION FOR SELECT IVE 



piping, and wiring shall be installed in accordance with the instrument 

manufacturers recommendations and the best prac ti 

ce for the industry_ 

Purchasing and installation of the DCS input/output 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 ground at the entry 

access point to the SCR skid. The Buyer shall provide guidance with 

posi ti 

oning based on best available knowledge of the configuration. 

Certificates of calibration shall be provided with all instruments in the final data 

package and shall include the instrument accuracy and d rift. When 

purchasing instrumenta ti 

on, the instrumentation shall be in accordance with 

the data sheets provided by AMEC, or AMEC will provide the necessary 

instrumenta ti 

on. The Seller shall provide the data sheets to the component 

Manufacturer. Recommended field re-calibra tion procedures shall also be 

provided in the final data package along wi th a list of special tools required for 

recalibration. 

3.3.1.7 Mechanical Assembly Requirements 

All equipment shalt be assembled to the structural frame observing the 

equipment Manufacturer's recommended assembly instructions. During 

fabrication, the Seller shall submit all fab rication red-line changes to the Buyer 

for review and approval before implementation of the change with the 

exception of any minor red-line changes that do not affect form, fit; or function 

of the equipment. The Seller shalt submit as-built drawings as well as final redlined 

fabrication drawings to the BuYer with delive ry. The Seller shall denote 

mounting configuration and details on the red-lined fabrication drawings. 

Piping, a tt 

ached to equipment shall be installed with fasteners made finger-tight 

until alignment is achieved, at which time all fasteners shall be tightened. 

Tightening torque shall be that which is recommended by ASME B31-3 or 

gasket Manufacturer recommended torque values for the gasket system used. 

Flange assembly and bolting shall be performed in accordance with ASME 

PCC-1-2000. Inspection documentation shall be provided in accordance with 

the Bidders Drawing and Data Commitments Sheet located on the Technical 

Data Sheet, 143643-V-DS-001.1, as evidence of proper bolt torquing. 

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CLIENT: AMECE&E - RirJrland,VllA 

3.3.1.8 Materials 

The Seller shall select materials based upon acceptable performance of 

materials subjected to the chemical exposures. All parts and materials shall be 

new. All parts shall be made of corrosion-resistant materials that are suitable 

for this environment Material selection shall be identified in the Seller 

documents to the Buyer. 

Material type and grade shall be clearly identified on the bill of materials. 

Certified Material Test Reports (CMTRs) are required for all materials coming 

in contact with the air stream. The Seller shall identify any materials that do not 

have CMTRs for review, approval, and final records. 

SCR and piping materials in contact with the air stream shall resist the 

conditions specified in the Technical Data Sheet, 143643-V-DS-001.1. No 

aluminum or "yellow" metals are to be used. No beryllium shall be present. 

Exposed polymer materials shall be constructed of anti-static materials. 

3.3.1,.9 Fasteners 

No fasteners shall be capable of vibrating loose under operating conditions. All 

such joints should be tack welded or have some equivalent means of 

assurance of remaining intact. Double-nutting is not an acceptable method of 

securing fasteners. Loctite o threadlock may be used where applicable. 

Stainless-steel bolts, cap screws, and washers shall be per ASTM Al 93 Grade 

B8, and nuts shalt be heavy hex nuts per ASTM A194 Grade 8. Bolts and cap 

screws shall be grade marked. Carbon-steel bolts shall be per ASTM A307 or 

better, nuts per ASTM A563, Grade C Heavy Hex, and washers per ASTM 

F436. 

All graded fasteners shall. conform to ASME 818.2.1, Society of Automotive 

Engineers (SAE) J429, and ASTM A354. 

The Seller shall select fasteners where they are not specifically called out in, 

this specification using the following guidance: 

a. Anti-galling compound (e.g., Loctite° 8013 or 8009) shall be applied where 

stainless-steel bolts are used. 

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scm,a32sv-sam,t,cR1R«.z.aoc Page 24 of 45 

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3.3.1.10 Gaskets 

b_ Stainless-steel bolts, nuts, and washers shall be used when the mating 

pa rts are stainless steel. 

c_ Carbon-steel bolts, nuts, and washers shall be used where mating pa rts are 

not stainless steel. 

d. The Seller shall ensure that suspecticounterfeit fasteners and components 

are not used for the construction of the SCR assembly and its components. 

Suspect fasteners can be identified by the following inspection methods: 

(i) Head markings are marred, missing, or appear to have been 

altered, 

{ii) Threads show evidence of dressing or wear (threads should be of 

uniform color and finish), 

Head markings are inconsistent with a heat lot, and 

{iv) Head markings matching one of those identified on the United 

States Customs Service, "Suspect Headmark List", in Appendix A. 

Pipe flange connections shall be approp riate for the temperature and sealing 

application of the system to which they will be sealing. The Seller shall provide 

manufacture cut-sheets and application data for gaskets du ring the design for 

Buyer approval- 

3.3.1.11 Stainless-Steel Handling Requirements 

The Seller shall submit a Mate rial Control procedure to be used in the 

execution of the work The Material Control procedure shall address 

procurement controls, segrega ti 

on, and traceability of materials including weld 

filter rod from receipt at the shop through processing, 

3.3.1.11.1 Exposure of Stainless Steel to Chlo ri 

de Mate rials 

Stainless steel shall not be in contact wi th materials containing more than 250 

ppm chlo rine. Low chlo ride markers shall be used. Chlo rinated solvents shall 

not be used to clean stainless steel. 

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PROJECT NO. : 145579 SPECIFICATION FOR SELECTIVE 


CUBIT: AMEC E&E—Richland, WA 

3.3.1.11.2 Contact with Carbon Steel 

3.3.1.12 Welding 

Contact between carbon steel and stainless steel shall be avoided during 

fabrica ti 

on. Temporary carbon steel clamps, supports, braces, and fixtures 

shall not come into direct contact with stainless-steel su rfaces. Galvanized 

steel clamps or fixtures may not be used. Wire brushes shall be stainless 

steel. Grinding wheels and wire brushes shall be new or used previously on 

stainless steel only. 

Welding of all pressure piping shall be pe rf 

ormed in accordance with ASM E, 

B3 1.3, normal service at a minimum. Certified welders shall pe rform welding of 

all structural steel in accordance with American Welding Society (AWS) D1.1 or 

AWS D1.6 (depending on material). Welding Procedures, Procedure 

Qualification Records, and Welder Procedure Qualification Records shall be 

submitted for review and approval to the Buyer before welding is pe rformed_ 

3.3.1.12.1 Allowable Welding Methods 

Welding of all stainless steel, including but not limited to structural shapes, 

rectangular tubing, plate, and sheet shall be pe rformed in accordance with 

AWS D1.6 nontubular, statically-loaded conditions. Welding of stainless steel 

piping shall be pe rformed in accordance with ASME 831.3. Automatic pipe 

welding equipment and techniques may be used. Fabrication of tanks shall be 

in accordance with ASME Boiler and Pressure Vessel Code, Section VIII. 

Welding of all carbon steel, including but not limited to structural shapes, 

rectangular tubing, plate, and sheet shall be pe rformed in accordance with 

AWS D1.1 nontubular, statically- loaded conditions_ Welding of carbon steel 

portions of piping systems shall be as required in ASME 831.3. 

3.3.1:12.2 Welding Procedure Requirements 

All welding shall be pe rformed in accordance with the Seller's approved 

Welding Procedure specification. Each Welding Procedure specification shall 

be quali fied with a Procedure Qualifica ti 

on Record as requred in ASME 

Section IX, AWS D1;1, and AWS D1.6 as applicable_ 

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scm,as^sysP-ao, lsca^Ra 2. Page 26 of 45 

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AME'C Americas Limited 

ame& 





3.3.1.12.3 Welder Qualification 

Welder Performance Qualification Records shall be submi tted for all personnel 

performing welding, including tacking. Welders shall be quali fied in accordance 

with ASMESecUon IX, AWS D 1. 1, and AWS D1.6, as applicable. 

3.3.1.12.4 Weld Joints and Preparation 

Weld joints are as permi tted by the referenced standards. 

3.3.1.12.5 Weld Repair 

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 irepaired more 

than twice before the section is abandoned and replaced. 

3.3.1.12.6 Inspection 

Inspection shall be done in accordance with the Seller's standard practice. A 

certified dimensional drawing and weldmap shalt be produced from this 

inspection. 

Prior to fab rica tion, a weld map shall be produced and delivered to the Buyer 

for review and approval. Welds shall be inspected per ASME B31.3, normal 

service at a minimum for pressure piping and per AWS D1.1 or D1.6 

(depending on material) for s tructural steel. An AWS Certi fied Weld Inspector 

(CWI) shall perform visual inspections and inspectors certified to ASNT-TC-1A 

shall perform NDEs. Visual and NDE weld inspection procedures shall be 

submi tted along with the personnel certifications to the Buyer for review and 

approval, before pe rformance of the inspections and examinations. Welded 

connections on the lif ti ng components shall be 100% visual and 100 % Dye- 

Penetrant Test or Magnetic Particle Test inspected. 

3.3.2 industry and Government Standards 

Heater shall comply with requirements of Facto ry Mutual 

Heat exchanger shall be tested for leakage to less then 0.01% as per indust ry 

standards. 

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scmiassmv-sem+ysca^R^.ze^ Page 27 of 45 

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AM1 C AmericasLimited 






3.3.2.1 Design Loads 

The SCR equipment shall conform to allowable loading factors as de fined by 

the Ame ri 

can ins ti 

tute for Steel Construction (AISC) for the five loads identified 

below. The structural analysis is to be submi tted with the shipment. 

3.32.1.1 Dead Loads 

Dead loads include the weight of all permanent materials and equipment, 

including the SCR equipment weight and the weights of fluids and materials 

being handled. 

The unit weights of material and construction assemblies shall be those given 

in ASCE 7. Where unit weights are neither established in that standard nor 

determined by test or analysis, the weights shall be determined from data in 

manufacturer drawings or catalogs. 

3.3-2.1.2 Live Loads 

Live loads are those loads produced by the use and occupancy of the SCR unit 

and do not include construction and environmental loads such as wind load, 

snow load, rain load, earthquake Ooad, flood load, of dead load. Live loads are 

produced by operations and maintenance workers and equipment. 

• Live loads shall be not less than the minimum uniform load or concentrated 

load stipulated in ASCE 7. 

• The minimum roof design live load shall be 20 Ibfft2 (includes ashfall). 

• The weight of service equipment that may be removed with change of 

occupancy of a given area shall be considered as live load. 

3.3.2.1.3 Ea rthquake Loads 

Earthquake induced design loads, as a minimum, shall comply with the 1997- 

UBC Seismic Zone 2B for essential facilities. 

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scmu:snsv-âo, ^scrtiak..zeao Page 28 of 45 

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3.3.2.1,4 Snow Loads 

Snow loads for the SCR shall be in conformance with ASCE 7. A ground snow 

load, Pg of 15 Ibf/fe shall be used for calculating roof snow load. Unbalanced 

snow toads resulting from drifting or sliding shall be considered_ Snow loads, 

full or unbalanced, shall be substituted for roof live loads where such loading 

results in larger members or connections_ 

3.32.1.5 Wind Loads 

The SCR shall be designed to resist pressures from wind from any direction. 

Pa rtial wind loading shall be considered if it produces a more severe effect. 

Wind load design shall comply with ASCE 7, using the 85 mph "three-second 

gust wind velocity" with an impo rtance factor of 1.15 exposure catego ry C. 

3.3.2.1.6 Load Combina ti 

ons and Stresses 

Load combinations, allowable stresses and strength requirements shall comply 

with 1997-UBC. 

3.3.2.1.7 Hoisting and Rigging Loads 

The lifting apparatus (eyebolts, hoist rings, and li fting bails) shall be designed in 

accordance with the ASME 830.20. Equipment lift points designed and 

fabricated by Seller shall have a factor of safety of 3 based on yield strength. 

Equipment purchased by Seller shall have a factor of safety of 3 based on yield 

strength. Documents shall be provided to the Buyer demons trating 

incorporation of these safety factors. The Seller shall identify the total weight, 

the center of gravity, and the lift points and rigging methods necessary for lifting 

each SCR component. Lift points shall be identified with yellow paint. Any 

special tooling, spreader bars or other recommended fabricated devices for 

lifting shall be provided by the Seller_ 

3.3.3 Radiation 

a. Electromagnetic. The SCR shall comply with the requirements in HNF- 

2962 on electromagnetic radiation. 

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b. Nuclear. The SCR is located downstream of the Off-Gas Scrubbing 

System and Carbon Filter and it is therefore expected that it will not be 

exposed to a signi ficant radiation field; 

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 d ry with compressed 

air to the extent that extraneous materials, such as those listed below, are not 

present: 

a. Metallic or other dusts (shop dust ), chips, turnings, and weld splatter; 

b. Abrasive particles; 

C. Rust and other loose corrosion particles; 

d. Magnetic/liquid penetrant residues, dye check, etc.; 

e. Foreign material, such as paper, tape, plastic, sand, and wood; 

f. Cu tt 

ing oils; 

g. Excess lubrication, grease, and oil; and 

h. Marking dyes. 

The fabrication procedure shall desc ri be the cleaning and packaging steps 

taken. 

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 used on stainless steel shall be epoxyphenolic. 

The SCR equipment ports and pipe openings shall be temporarily capped 

following cleaning and d rying for shipment. Packaging requirements following 

cleaning are documented in Section 6.3. 

.3.3.5 .Corrosion of Parts 

SCR design shall include requirements for corrosion protection, especially 

restrictions on dissimilar metal couples. 

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PROJECT: Final DBVS Desi n 145579-V-SP-001 I REV. 2 




3.3.6 Protective Coatings 

No protective coatings are required, as all exposed parts are stainless steel. 

3.3.7 Interchangeability 

The catalyst bed design shall ensure interchangeability of components, to 

minimize consumable parts storage. 

3.3.8 Identification and Marking 

The SCR shall have a Manufacturer's nameplate using the Seller's standard 

practice. The nameplate shall include: the equipment number (provided by the 

Buyer, per the requirements of 4.3.9); assembly weight (d ry and wet); purchase 

order number; lif ting bail working load limits; Manufacturer data for swivel hoist 

rings (as applicable); and this speci fication number, 143643-V-SP-001, latest 

revision- Clearly mark and identify any components required for removal 

before equipment installation (e.g., shipping blocks). 

The markings on all motors shall be in accordance with the NEC and NEMA 

MG-1. Care should be taken when painting such that the motor nameplates, 

lifting eyes, or lifting swivel Manufacture nameplates are not painted. 

3.3.9 Nameplate 

Seller shall provide a nameplate which conforms to RPP-8530 which will be 

provided later. 

3.3.10 Human Engineering 

There are no special human enginee ring requirements for this equipment. 

3.3.111 Qualification 

Equipment supplied by the Seller shall be subject to Facto ry Acceptance 

Testing. The Seller will be expected to provide a shop simulation of the inlet 

conditions of their equipment under normal and transient operating conditions 

to demonstrate the operational efficiency of the equipment. The Seller shall 

provide a FAT plan for operational testing and leak testing of their equipment in 

acwcamra.o;aasr ir^ 2ms VS 9n cmae2^ nsm JMTa 73Tâ 72Wcs MW-hcmzlmuzos)narive CM 

sa







CLIENT: AMEC E&E-Richland, WA 

their proposal in accordance with the ve rification, inspection and test 

requirements specified in sections 4.2 and 4.3. 

3.3.1:? Document Submittal 

Each document submi ttal shall be identified with this specification number, item 

number, purchase order number, and Seller's identifica ti on number. Submi ttals 

shall be transmi tted to the Buyer in accordance with the directions found in the 

Drawing and Data Commitment sheet in the Technical Data Sheet 143643-V- 

DS-001.1 

Data shall be sufficiently clear to allow legible copies to be made on standard 

reproduction equipment after microfilming. 

Along with the bid submittal, the items shown in the Drawing and Data 

Commitment sheets, shall be included. The schedule shall show equipment 

fab ri cation, testing, and delivery as noted on the inquiry. The drawings shall 

show full compliance with this specification (and the associated 

drawings/documents) or note any exceptions. The Seller shall a llow 10 

working days for the Buyer to review and state the disposition of each 

submittal. 

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 pre-purchase evaluation data); and (2) 

Those requiring "approval before shipment" (i.e., vendor information data). 

Submi ttals requi ring approv al 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 requi ring approval that is not approved by the Buyer, will be 

dispositional as: 

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semiass2sysvmr(sere^ner.2.e« Page 32 of 45 

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CLIENT: 

AMEC E&E—Richland, WA 


1. "Not Approved, Revise and Resubmit " The submittal is considered 

technically deficient, or incomplete, and is therefore unacceptable. Resubmittal 

is required; hence fabrication, p rocurement, or pe rformance of 

procedures shall not proceed. 

2. "Approved with Exception." Fabrication, procurement, and pe rformance of 

procedures may proceed, and re-submi ttal is required to verify 

incorporation of the exception. Final acceptance of the item is contingent 

upon the Buye (s receipt and approval of the corrected submi ttal 

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 

Seller. 

The Seiler shall provide fabrication travelers) for the fabrication and testing of 

the above-described SCR equipment. The fab ri cation traveler(s) shall include 

detailed procurement, fabrication, assembly, testing, shipping, and handling 

steps required to prope rly fabricate; assemble, and test the equipment in 

accordance with the drawings and specifications. 

A proposed schedule of fabrication, inspection, and testing of all SCR 

equipment shall be submi tt ed for review with the bid and approval with the 

submittal of the fab rication traveler(s). 

The Buyer will inse rt witness/hold points in the fabrication traveler during their 

review and approval of the fab rication traveler. Witness points can be waived 

by the Buyer but must be document in writing. Hold points require the Buyer 

personnel to be present du ring the fabrication, inspection, or test step. 

3.3.13 Personnel and Training 

The Seller's equipment and systems shall be designed so that it is operable 

and maintainable by the Buyer's operations and maintenance personnel. If 

specialized technical education or training is required by the Buyer's personnel 

the Seller shall advise in their proposal. 

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Page 33 of 45








4.0 QUALITY ASSURANCE REQUIREMENTS 

4.1.1 Quality Assurance Program 

4.1.2Design 

The Subcontractor/Supplier shall have a documented, implemented and 

maintained Quality Assurance Program that is based on a national standard 

and identifies the activities and items to which it applies: Instructions and 

procedures must include or reference approp riate quantitative or qualitative 

acceptance crite ri a for determining that prescribed activities have been 

satisfacto ri ly accomplished. The Quality Assurance Program must address 

each of the areas discussed within this QA Requirements Flow-down. The 

Subcontractor/Supplier must submit the Quality Assurance Program to the 

Buyer for review p rior to award of contract. 

The Subcontractor/Supplier shall assess its Quality Assurance Program 

regularly to assure its effective implementation. 

The Quality Assurance Program shall provide for indoctrination and training, as 

necessa ry, of personnel performing activities affecting quality to assure that 

suitable proficiency ismachieved and maintained. Personnel who conduct 

inspection and test activities shall be qualified to conduct those activities and 

ce rtification of the quali fica tion must be submitted to the Buyer upon request. 

The Subcontractor/Supplier must define, control, and ve rify designs developed 

for this contract. Design inputs must be specified on a timely basis 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 .3 Procurement Document Control 

Procurement documents must include or reference sufficient quali ty and 

technical requirements in order to describe the items and services requested. 

Procurement documents must be reviewed and approved by the autho ri zed 

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G5-653

TECHNICAL SPECIFICATION, 

AME+C Americas Limited 



PROJECT NO.: 145579 SPECIFICATION FOR :SELECTIVE 


CLIENT: AMEC E8E—Richland, WA 

personnel within the Subcontractoes,'Supplier's organization, and changes 

must be reviewed and approved by the same individuals who reviewed and 

approved the original procurement documents. 

The Subcontractor/Supplier must have a process for accep ti ng p ro cured items. 

This process must include one or a combination of the following: Cert ificate of 

Conformance, source verification, receiving inspection, and post-installa tion . 

testing. 

The Subcontractor/Supplier shall provide a legible and rep roducible Certificate 

of Conformance. The Certificate of Conformance shall be signed by the 

Subcontractor's/Supplier's autho rized representative responsible for quality 

assurance. 

The Certificate of Conformance shall contain, as a minimum, the following 

information: 

• Identification of the Buyer's contract or purchase order number under which 

the materials, equipment, component, or service is being purchased; 

• Provide traceability by means of positive identi fica ti on from the material, 

equipment, component, or service to the Certificate of Conformance; 

• Identify the specific procurement requirements met by the material, 

equipment, component, or service supplied (i.e_, codes, standards, or o ther 

applicable speci fica tion). The procurement requirements shall include any 

approved. changes, waivers, or deviations applicable to the subject 

mate rials, equipment, component, or service; 

• Identify any procurement requirements that have not been met, together 

wi th an explana tion and the means for resolving the nonconformance. 

The Subcontractor's/Supplier's ce rtification system, including the procedures to 

be followed in filling out a certificate and the administrative procedures for 

review and approval of the ce rtificates, shall be desc ribed in the 

Subcontractor's/Suppliers QA Program. 

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The ce rtification system shalt provide a means to verify the validity of 

Subcontractor/Supplier ce rtificates and the e ff 

ec ti veness of the ce rtifica ti on 

system, such as during the pe rformance of audits of the Subcontracto r/Supplier 

or independent inspection or test of the items_ The Buyer shall conduct this 

verifica ti on at intervals commensurate with the Subcontractor's/Supplier's past 

quality performance. 

The Subcontractor/Supplier is required to flow-down all quality assurance 

requirements from this contract to any sub-tier suppliers / Subcontractor / 

Suppliers. Any access to the sub-tier suppliers'/Subcon tractor/Suppliers' 

facilities for verifica ti on activities will be requested th rough the 

Subcontractor/Supplier prior to access, and veri fi cation activities may be 

performed jointly. 

The Subcontractor/Supplier shall warrant that all items furnished under the 

contract are genuine (i.e., new, not refurbished, not counte rfeit) and match the 

quality, test repo rts, 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/counte rfeit shall not be used. 

All items are subject to inspection at the Subcontractor's/Supplier's facility or 

lower-tier subcontractors facility. The Subcontractor/Supplier shall notify the 

Buyer at least 7 working days in advance of the time when such items or 

ac ti vities will reach the Buyer's identified inspection hold points. As a 

minimum, final inspection p rior to packaging for shipment shall be considered 

such a hold point, unless specifically waived by the Buyer. 

The Subcontractor/Supplier shall . obtain all mate rials to be delivered under the 

contract directly from the original manufacturer or an authorized manufacturer's 

representative_ The , Subcon tractor/Supplier 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, 

shipping documentation or manufacturer invoice; each of which would identify 

that the mate rials were obtained from the original manufacturer. 

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G5-655








The Subcon tractor/Supplier shall submit, with or prior to item shipment, a 

recommended spare pa rts list_ The list shall provide the name and address of 

the original supplier of the replacement part, and the part's drawings, 

specification, or catalog identity including applicable change or revision 

information. 

All items and/or services procured under this speci fi 

cation shall be subject to 

inspection by the Buyer or Buyer's representative throughout the contract. 

Additionally, procured items and/or services shall be subject to inspection for 

acceptance. 

The Subcon tractor/Supplier shall grant access to the Subcontractor's/Supplier's 

plant facilities and records for inspection or audit by the Buyer, his :designated 

representative, and/or other parties autho ri zed by the Buyer. 

4.1.4 identification and Control of Items 

The Subcontractor/Supplier shall establish con trols to assure that only correct 

and accepted items are used or installed. 

All items shall be identified with the applicable part number, model number, or 

other identifier presc ri bed in the specification. Iden tification shall be on the 

item or the package containing the item. When the identification is on the item, 

such marking shall not impair the se rvice of the item or violate dimensional, 

chemical, or physical requirements. 

The Subcontractor/Supplier shall submit a legible and reproducible copy of the 

product data sheet (e.g., drawing, catalog cut sheet, brochure, etc.) 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 speci fied, shall accompany the item. 

The Subcontractor/Supplier shall identify each item, assembly, package, 

container, or mate rial, having limited shelf life, with the cure date or date of 

manufacture and the expira tion date. The Subcontractor/Supplier shall specify 

any storage temperatures, humidity and environmental condi tions that should 

be maintained. Mate rial shall not be furnished having less than 75 percent of 

total shelf life available at time of shipment. 

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Ca5-656




amec'^ 




CLIENT: AMEC ERE — chland Ri, WA 

Certified Material Test Reports (CMTRs) containing actual chemical analysis 

and mechanical properties of the material being supplied shall be submitted 

p rior to or with each shipment of material. Each CMTR shall contain the 

following information as a minimum: 

Product Desc ription - specification(s), codes; type of material, etc.; 

• Actual results of chemical analysis/mechanical testing in accordance with 

the provisions of the code, standard, and/or specifica ti 

on; 

The specification and material grade; 

• Traceability to the item tested (e.g., heat number, lot number, etc.); 

• Name and address of manufacturer (may be identified by letterhead, logo, 

etc.); 

• Manufacturer's ASME ce rtificate number and expiration date; 

• Buyer's contract number and item number to which the repo rt applies; 

The repo rt shall be signed by an authorized representative of the manufacturer. 

In addition to the ASTM/ASME marking, the Subcontractor/Supplier shall 

physically identify each item/part furnished to the Buyer with the heat number 

(or identification number that is traceable to the heat number) and the contract 

number. Methods and mate ri als used to accomplish required markings shall 

be compatible with the mate ri al being marked. Small items shall be 

bagged/wrapped and tagged. 

4.1.5 Control of Processes 

The Subcontractor/Supplier shall have processes to control processes, 

including special processes that control or verify quality (e.g., welding, heat 

treating, and nondestructive examination). ` Special processes must be 

performed by qualified personnel using quali fied procedures in accordance with 

specified requirements. 

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21+ - 

C85-657




PROJECT: Final DBVS Design 145579-1 SP-OOi REV. 2 




Subcontractor/Supplier personnel performing weld inspections shall be ce rtified 

as a CWI in accordance with the requirements of the American Welding 

Society (AWS), QC-1. The following documenta ti 

on shall be submitted for 

Buyer approval p rior to the sta rt of fabrication: 

• Current AWS CWI certifica ti 

on; 

• Current/valid visual acuity examination (must be given eve ry 3 years); and 

• 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 

Subcontractor/Supplier shall submit copies of all welding procedures, 

procedure qualification records, and welder qualification records to be 

employed. Buyer review and approvaU of these documents is required prior to 

sta rt of fab rication_ 

Nondestructive Examination (NDE) personnel shall be qualified and certified in 

accordance with the recommended guidelines of the American Society of 

Nondestructive Testing (ASNT) SNT-TC-1A. The Supplier is not authorized to 

begin fabrication until the following documentation has been approved by the 

Buyer: 

• NDE personnel qualification and ce rtification procedure; 

• Level I, 11, and/or III personnel quali fication and certification records, 

including objective evidence of NDE training, formal education, 

examination, experience, date of hire and current visual acuity exam; 

• NDE method procedure(s) compliant with the applicable requirements of 

the Buyer's contract 

NDE 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/ce rtified NDE examiner. All NDE reports and radiographs shall 

accompany or preceded shipment of the item or component_ Radiographs and 

radiographic technique and examina ti 

on repo rts shall be subject to approval by 

the Buyer prior to shipment. 

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G5-658



AMECAmedcas Limited 

amecO 

PROJECT: Final DBVS Design 145579-VSP-001 I REV. 2 



CLIENT: AMEC ESE —Richland, WA 

These requirements shall be passed to lower-tier subcontractors. 

4.1.6 Inspection 

The Subcontractor/Supplier shalt have a process to plan and execute 

inspections to ve rify 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 Subcontractor/Supplier shall 

document the results of inspections. Inspections for . acceptance shall be 

performed by persons other than those who pe rformed or directly supervised 

the work being inspected_ 

The Subcontractor/Supplier shall submit, as required by the contract, legible, 

reproducible copies of inspection and/or test repo rts. The reports shall include, 

as a minimum, the following information: 

Identification of applicable inspection and/or test procedure; 

• Resulting data for all characteristics evaluated, as required by inspection or 

test procedures, in cluding reference to information on action taken in 

connec ti 

on with nonconformances; 

• Traceability to the item inspected/tested (e.g., serial number, pa rt number, 

lot number, etc.), date of inspection, name of inspector, type of observation; 

and 

4.1.7 Test Control 

Signature of the Subcontractor/Supplier's authorized representative or 

agency performing the inspection or test. 

The Subcon tractor/Supplier 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. 

The Subcontractor/Supplier shall prepare a detailed test plan. Prior to starting 

work, the plan shall be submi tt 

ed to the Buyer for approval and inse rtion of 

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G5-659

A, 




PROJECT: Final.DBVS Design 145579-V-SP-001 I REV. 2 



CLIENT: AMEC £&E — Richland, WA 

Buyer's designated source inspection/witness notification points. The test plan 

shall provide the following at a minimum: 

• Traceability to Buyer's purchase/contract order document number; 

• Name or description of the item to be tested (e.g., components, assemblies, 

subassemblies); and 

• Method/procedure to be used du ri ng test. 

Subsequent revisions/modifications to the test plan require review and approval 

by the Buyer prior to implementation of the changes. 

The Subcontractor/Supplier shall provide test repo rts that include, as a 

minimum: 

• Item tested, 

• Date of test, 

• Tester or data recorder, 

• Type of observation, 

• Results and acceptability, 

+ Action taken in connection with any deviations noted, and 

• Person evaluating test results. 

Test plans and test repo rts must be submi tted to the Buyer for the project 

records. 

4.1.8 Control of Nonconforming Items 

The Subcontractor/Supplier must have a process to control items that do not 

conform to specified requirements to prevent inadve rtent installation or use. 

These controls must provide for identification, documentation, evaluation, 

segrega ti 

on (when practical), and disposition of nonconforming items, and for 

notification to affected organizations. 

All nonconforming conditions identified at the Subcontractor/Supplier's facility, 

with a proposed disposition of "Accept-as-Is' or "Repair," as de fined below, 

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G5-660

. RPP-24544 REV Id 







shall be approved by the Buyer before Supplier implementation of the 

Nonconformance Repo rt (NCR) disposition: 

• Accept-as-Is: Nonconforming materials will pe rform its intended function. 

• Repair: Nonconforming item can be corrected so that its characteristics 

meet requirements of the contract. 

Nonconforming items iden tified as "Repair" or "Rework" shall be re-examined in 

accordance with applicable procedures and with the o riginal acceptance 

criteria, unless the nonconforming item disposition has established alternate 

acceptance criteria. 

Nonconformances shall be documented by the Subcontractor/Supplier 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 shall be submi tted to the Buyer_ 

After the proposed disposition has been evaluated, and approved or rejected 

by the Buyer, the form shall be retu rn ed to the Subcontractor/Supplier. 

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. 

4.1.9 Corrective Action 

The SubcontractodSupplier shall have a p rocess to promptly identify conditions 

adverse to quality, and to correct there 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 ve rify implementation of this corrective ac tion. 

During the period of performance of work for this contract, the 

Subcontractor/Supplier shall provide to the Buyer copies of all documents that 

constitute repo rts of cond it ions adverse to quality (e.g., deficiencies, 

weaknesses, nonconformances, or noncompliance's with established 

requirements) related to items or services provided to the Buyer. 

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In addition, the Subcontractor/Supplier shall assure flow down of these 

requirements to its sub-tier subcontractors/suppliers of quality-affecting items 

and/or services procured for work performed for this contractor. 

4.1.10 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): 

• Fasteners shall exhibit grade marks and manufacturers identi fication 

symbols (headmarks) as required in the specifications referenced in the 

contract. 

When requested by the Buyer, the Subcontractor/Supplier shall provide 

legible and reproducible copies of the manufacturers Ce rti fied Material Test 

Report (CMTR). These CMTR's shall repo rt the values of the actual 

chemical and physical tests performed on the represented fastener 

lot/material heat number. Fastener packaging and labeling shall be 

traceable by lot number or other means to the CMTR. 

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 QUALIFICATION VERIFICATION 

Items to be veri fied: 

a. Heat exchanger efficiency 

b_ Heater output 

c. Heater propo rt ional con trol 

d. Ammonia flowrate. 

e. NOx and CO des truction efficiency 

f. Ammonia slip 

g. Pressure drop at specified flowrate 

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CLIENT: 

AMEC E&E- Richland, WA 


4.3 INSPECTIONS AND TESTS 

Seller shall provide all necessary reviews, inspections, tests, analyses, 

demonstrations, and documentation required to verify that all quali fications 

have been satisfied, including: 

a. Testing to ensure satisfaction of the specified functional characteristics, as 

specified in section 3.21, including teak and pressure testing. 

b. Measurement of the specified physical characteristics and comparison with 

previous tests on similar equipment. 

c. Examination for workmanship. 

4.4 TRAINING OF INSPECTION AND TEST PERSONNEL 

The Seiler shall qualify Inspection and Test Personnel pe rforming acceptance 

inspections and testing: In addition, the Seller shall document all quali fications. 

Review of the quali fications may be subject to a surveillance or source 

inspection by the Buyer. 

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G5-663 

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PROJECT NO.: 145579 "A SPECIFICATION FOR SELECTIVE 

CLIENT: AMEC E&E — Richland, 

5.0 PREPARATION FOR DELIVERY 

5.1 GENERAL 


The equipment shall be shipped via covered truck, and disassembled only as 

necessa ry to meet truck dimensional requirements. All pa rts shall be match 

marked and shown on the general assembly drawings. 

5.2 PRESERVATION AND PACKAGING 

Seller shall p rovide all necessa ry packaging, supports, cushioning, and 

wrapping to protect the SCR and all internal components from damage during 

shipping. 

5.3 PACKING 

The SCR shall be packed appropriately to protect the exte rior su rfaces during 

shipping and handling. 

5.4 MARKING 

All shipping containers shall be marked and labeled for safety, protection, and 

identification. If the unit must be disassembled for shipping, containers shall be 

identified as to their contents. 

5.5 HANDLING 

The seller shall identify any special handling requirements for the SCR, such as 

loading and unloading limitations, and res trictions regarding hooks, bails, 

forklifts, etc. 

5.6 SHIPPING 

Seller shall specify limitations or special ins tructions on shipping. 

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6.0 APPENDICES 

A i Control of Suspect ( Counte rfeit Items (TFC-ESHQ-Q_C-C-03) 

7.0 ATTACHMENTS 

Document No. Description 1 Rev. 

s 145579-V-DS-001.1 s Technical D ata Sheet 1 

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G5-665 

ô



PROJECT. Final DBVS Des!- n 145579-V-SP-001 

PROJECT NO.: 145579 APPENDIX A 

TFC-ESHQ-Q_C-C-03 (REV. B) 


APPENDIX A 

TFC-ESHQ-Q._C-C -OW, REV. B 

CONTROL OF SUSPECT COUNTERFEIT ITEMS 

- P!Dn9oWVCl9Petlfio6om=f-SCMIt 57"ZP-0P ft d AT PW)AE Appendix A 

SJViM 

G5-666 

m


C112M HILL Hanford Group, Inc. Manual ESHQ 

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

CONTROL OF SUSPECT/ Page 1 of 52 

COUNTERFEIT ITEMS Issue Date December3l, 2003 

Effective Date December 31, 2003 

APPROVAL AUTHORITY: R. L. Higgins 

DOCUMENT OWNER: 


1.0 PURPOSE AND SCOPE ................................._.............................:...............................................2 

2.0 IMPLEMENTATION ............... ... ................................................ ............. ................................... ... 2 

3.0 RESPONSIBILITES_ ............................................... ..................•--............................ ................... .2 

3.1 Procurement Personnel ... ............... ............................... — ............. °.................................. 2 

3.2 Inspection Personnel ................. ......................... ........ ..::.......... ...... .................. .................. 2 

3.3 Quality Assurance Engineer ................................................................. ................... --------.2 

3.4 S/CI Coordinator ..................... ...._.. ........... ...................... ............ ............................:.........2 

3.5 Assigned Engineering Personnel ........................................................................................3 

3.6 Responsible Managers and Supervisors.. .......... ............................................... ....... .... --3 

4.0 PROCEDURE. ....... _ ...:.........................................-----..............---.................3 

° _ _-° ... _ 

4.1 Introduction ............................ _...................................................----°...... ...------------------ 

°............ °'--°----- 3 

4.2 Procurement ................ ......................... ............................................... .............................. ..3 

43 

4.4 

Inspection for Potential S/CI .... .... .... ...... ..................................... ......................... ............... 4 

Control of Material Identified as S/CI ................. .................... ....... ........ ............................ 4 

4.5 Reporting of S/CI---• .......... ...................................................... ............_,..._..................5 

4-6 Acceptance, Removal, and Disposition of S/CI .................................................................. 5 

4.7 

4.8 

Surplus/Excess Material ...... ................. .. ........._............................. ............ ... ........ ........ 7 

Assessments ..................... --- ........ ..... _ ...................................°.......................................7 

4.9 Training ............................... ..... ......... .............................. .. .................................................. 7 

5.0 DEFINITIONS .................................. .......................................... .............................................. --..8 

6.0 RECORDS ... ......... -- ... ...................... ........._.........................................••••...........:...........................9 

7.0 SOURCES— ........... ._.....-•° .................._...................................................°•...--....................._....::9 

7.1 Requirements .............. ......... .................. .. ......... . ... ................. - ..................... ................ .. ..... .9 

7.2 References ................................................................................ ......................................9 

TABLE OF FIGURES 

Figure 1. Management of Suspect/Counterfeit Items. II 

TABLE OF ATTACHMENTS 

ATTACHMENTA - SUSPECT COMPONENTS LIST ..... ....................... ................... .. ......... .............. ...12 

ATTACHMENT B - CLASSIFICATION OF POTENTIALLY SUSPECT/COUNTERFEIT ITEMS .... 30 

ATTACHMENT C - SUSPECT/COUNTERFEIT ITEMS INFORMATION SOURCE LIST .................32 


MISREPRESENTATION, FRAUDULENT PRACTICES, AND COUNTERFEITING ..........._34 

ATTACHMENT E - WHERE TO LOOK FOR SUSPECT/COUNTERFEIT ITEMS ..... ...................... ...35 

ATTACHMENTF - SUSPECT/COUNTERFEIT PARTS DETECTION ................................................36 

ATTACHMENTG - FASTENERS ------ ................. .......................................... 

ATTACHMENTH - DOE HEADMARK LIST ................ ............... :................... 45 


ATTACHMENT I - ASSESSMENTISURVEILLANCE LINES OF INQUIRY .. 

G5-667

ESHQ 


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

Page 

2 of 52 




1.0 PURPOSE AND SCOPE 

(7.1.1, 7.1.2,7,1-3, 7.1.4) 

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

and disposition of suspect/counterfeit items (S/CIs) at C112M HILL_ This procedure applies to 

items that are: 

• In the procurement cycle 

• Ira 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 properly 

• 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 RESPONSIBILITES 

3.1 Procurement Personnel 

Maintain awareness of S/CI and support S/CI program implementation. 

3.2 Inspection Personnel 

Perform inspections for conformance or acceptance of material including verifications that the 

items) being inspected do not exhibit indications attributed to potential suspect/counterfeit items. 

3.3 Quality Assurance Engineer 

1. Ensures appropriate procurement controls are implemented to preclude entry of S/CI to 

the site through review of procurement documents. 

2. Notifies the S/CI coordinator of nonconformance reports (VCRs) associated with S/CI. 

3.4 S/CI[ Coordinator 

Apprises company, DOE, and DOE local Office of the Inspector General personnel of S/CI status 

and final disposition. 

GS-668


ESHQ Document TFC-ESHQ-QS-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 specification, 

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/CI. 

2. Control potential S/CI. 

4.0 PROCEDURE 

4.1 Introduction 

Evaluate training needs based on job classification and ensure individuals receive training 

in WI awareness, prevention, detection, and reporting, as appropriate, to respective 

assignments. 

The 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 SlCI 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 


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 


3. In maintenance and construction/fabrication subcontracts, specify 

appropriate requirements to preclude the purchase or introduction of 

S/CL 

G5-669

ESHQ 


Document 

Page 

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

4 of 52 

CONTROL, OF SUSPECT/ 



Quality Assurance 

Engineer 

Procurement 

Personnel 

4.3 Inspection for Potential S/CI 

Bill of Material 

Preparers 

4. Review procurement documents to ensure they contain the appropriate 

procurement controls to preclude entry of S/CI to the site. 

5. Ensure vendor selection complies with qualification requirements for 

the quality level of the items and services and is based on the vendor's 

ability to demonstrate the capability of delivering acceptable items. 

1. For quality level 0 and P-Card items listed in Attachment B, designate 

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 to 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 SiCIs 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 I. 

8. If an S/CI is detected during inspection activities, document and control 

the S/CI in accordance with TFC-ESHQ-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 s Non conformances identified as S/CI shall 

be reviewed and processed,within four working days to determine 

whether or not the items are S/CI. 

2. Transfer tagged S/CIs to 2101-14V for storage. 

Cognizant Quality 3. Notify the S/CI coordinator of all NCRs associated with the S/CI. 

Engineer 

G5-670


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

Page 5 of 52 

CONTROL OF SUSPECT/ Effective Date December 31, 2003 


4.5 Reporting of S/CI 

Assigned Company L Report all items identified as potential S/CI in accordance with 

Personnel TFC-OPS-OPER-C-24. (zt.p 

NOTE: Reporting of S/CIs is required regardless of safety class, where 

the S/CIs are located (receiving inspection, inventory/storage areas, 

fabrication and maintenance areas, installed, etc.), or their operating 

status. 

S/CI Coordinator 2. Notify the DOE S/CI 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 S/CIs. 

Notification should be e-mailed to the DOE local Office of Inspector 

General points of contact providing information in the following 

format: 

4.6 Acceptance, Removal, and Disposition of S/CI 

• 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 ofitem(s) 

• Quantity 

• Description of nonconformance 

• Any other pertinent information that would help the DOE local 

Office of Inspector General. 

S/CI Coordinator 1. Notify responsible company personnel that S/CI 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 S/CI material for final disposition and/or disposal as 

directed by the SICI coordinator. 

G5-671



Page 6 of 52 



Engineering 3. Evaluate S/CI to determine if its use could create a safety hazard in its 

Personnel current1proposed 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 SICI 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 SICI by marking with orange paint or 

other appropriate methods and note its location. 

C. In areas where operating temperatures are 5WF and above or 

are subject to cyclic loading where fatigue failure is likely to 

occur, replace all grades 8 and 8.2 SICI 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 SICI for disposal- 

5. If the engineering evaluation of the SICI 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 SICI as soon as practical. 

C. Tag, segregate, or otherwise control the S/CI to prevent 

inadvertent use- 

d. Prepare the S/Cl for disposal. 

S/CI Coordinator 6_ Ensure that all S/CI 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. 

G5-672



Page 7 of 52 



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 SICI 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, 1. 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 414.1 A, DOE O 440.1 A, 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 SICI 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/Counteifeit 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. 

G5-673

ESHQ 



RPP 24544 REV I d 


Page 

Effective Date 

TFC-ESHQ-QC-C-03; REV B 

8 of 52 

Decemlber 31, 2003 

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 bypassing the imitation as original or 

genuine. (Source: U. S. Department of Transportation Federal Aviation Administration Advisory 

Circular 21-29B, Detecting and Reporting Suspected Unapproved Parts). 

Fastener (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 1/4 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 (ASTM) 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 graded fastener. Fasteners having a minimum tensile strength of 75 Iasi, including 

those produced and procured in accordance with the Society of Automotive Engineers Standard 

J429, Grades 5, 5.2, 8, and 8.2; ASTM Standard A325, Types 1, 2, and 3; ASTM A.490, ASTM 

A354, ASTM A449 (1&II); 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: ASME-NQA-1-1989; Quality Assurance Requirements for Nuclear Facilities). 

An all-inclusive term used in place of any 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). 

G5-674



Page 9 of 52 



Substantial safety hazard. A loss of safety function to the extent that there is a major reduction in 

the degree of protection to the public or employee health and safety. (Source: U.S. Department of 

Energy (DOE) M 232.I-1 A, "Occurrence Reporting and Processing of Operations Information'). 

Suspect/counterfeit 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 S/CI if the 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 O 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 

I. DOE-0-232.IA Part 41 (1), "Occurrence Reporting and Processing of Operations 

Information." (S/RID) 

2. DOE O 414.IA, "Quality Assurance. 

3. 10 CFR 830, Subpart A, "Quality Assurance Requirements." 

4, DOE O 440.1 A, "Worker Protection Management for DOE Federal and Contractor 

Employees_" 

7.2 • References 

HNF-SD-MP-SAID-001; "Standards/Requirements Identification Document for the Tank 

Farm Contractor." 

G5-675

44 REV I 


Page 10 of 52 



2. DOE G 440.1-6, "Implementation Guide for use with Suspect(Counterfeit Items 

Requirements of DOE O 440, 1, Worker Protection Management; 1 OCFR830.120; and 

DOE5700.6C, 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 (P-Card)." 

6_ TFC-BSM-CP CPR-C-03 `Buyer's 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-11, "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." 

G5-676



Page 11 of 52 

CONTROL, OF SUSPECT/ Effective Date December 31, 2003 


Figure 1. Management of Suspect/Counterfeit Items.. 

Safety System Non-Safety System 

W hen SIC[ discovered, 

report via ORPS and to 

Ioaal OIG 

Conduct enginee ring 

evaluation 

Could 

S/CI in safety 

rystem create safety 

Nohoard? Yes 

I I 

When S/CI discovered, 

report via ORPS and m. J^ 

local OIG 

Conduct engine 

evaluation 

Mark S/C{ 

/"'' 

Identify and mark 

S/Cl andJocation 

- Lock out/tag out the 

system 

Wi{I 

removal be 'S'C' required 

during routine 

maintenance? 

No 

° 

Disposition S/CI to 

remain in place 

-Will the sici he 

removed/replaced during 

RemoveJreplace the Remove/replace and 

SIC[ dispose of the S/CI 

maintenance? - - - 

Yes Dispose o(the 5/CI 

No KEY: 

OIG: Office oflnspector General 

ORPS: Occurrence Reporting and P rocessing 

Disposition S/Cl io System 

remain in place SICI: Suspect/Counterfeit Items 

G5-677 

Yes

RPP-24544-REV Id 


Page 12 of 52 

CONTROL, OF SUSPECT/ Effective Date Deeember31, 2003 


ATTACHMENT A - SUSPECT COMPONENTS LIST 

This list was extracted from the U.S. 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 a supplier or manufacturer if S/CIs 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 S/CI must be examined on its own merit without making 

premature conclusions regarding fault or culpability of the manufacturer or supplier whose name is 

associated with the S/CI. 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. 

G5-67&



Page 13 of 52 

CONTROL OF SUSPECT/ Effective Date December3l, 2003 

COUNTERIFEIT ITEMS 



Circuit Breakers General Electric Metal clad, low Satin America & Circuit NRC I.N- 8945, 

(Component Examples) voltage, DC Breaker Systems Inc Supplements and 

Attachments SENS 

• AKF-2-25 Report ID #6 5/23/89 

• EC Trip Types, E-C- 

1, E-C-2A 

• AK All Types 

Circuit Breakers General Electric 1, 2, & 3 pole, Bud Ferguson's Industrial NRC I.N. 88-46 

(Component Examples) various amperages Control & Supply, Inc., Supplements and 

Attachments 

• AK-3A-25 

• KHL-36 125 

General Circuit Breaker &. 


• THEF 136050 

• AX-2-75-3. 


• AK-2. 

• AK-1-50 

NSSS, Inc. 

• AK-1-75 

• E 


• TDQ 

• TCVVFS 

Rosen Electric Equipment 

TFI 

• TEB122015-WL 

• TEB132090-WL 

• TEI11015 


(DBA) General Magnetics/ 


• TED134060-WL Lakeland Engineering 

• TEB124050-WL 

• THED 136100 WL 

Equipment Co. - 

• TED126050 ANTI THEFT Systems, Inc. NRC I-N. 90-46 

• THED13606O WL 

• THGW120 

• TEF134015 

(DBA) ATS Circuit Breakers 

and AC Circuit Breaker 


• THEF136MI 100 

California Breakers 

• TED134030-WL 

• A.K2A25- 

• THED-136100-WL 

•THE))-136050-WL Voyter Electric Co. Office of Nuclear 

• THED-136045-WL Safety 93-5 (911) 

- • THFK-236070-WL 

• TE-122070 

• THED-136150-WL 

• THED-13600-WL 

• TED-113020 

• TEC-360SO 

• THED-124015-WL 

G5-679


Page 14 of 52 

CONTROL OF SUSPECT/ Effective Date Decemlber 31, 2003 




Circuit Breakers Westinghouse 


• TF136090 

• TF36105OWL - 

• TED1130020 

• Not Provided Commercial Grade Westinghouse NRC I.N. 91-48 

' Electric Supply Co. 

(WESCO) 

• DB-25 & DS416 Low Voltage Satin America & Circuit NRC I.N. 89-45 & 

Breaker Systems, Inc. Supplement #2 

• 1FSN-5925-628-0641 

• 1DB-25 

• 1DB-50 

• HKB3150T 

• 1FB3020 

• IFB300 

Trip units; Navy 

Trip units; 1, 2, & 3 

pole various amp. 

ratings 

General Circuit Breaker & 


- 


Supply 

NRC I.N. 88-46, 


Attachments 

Office Of 

Nuclear Safety 93-9 

• FB3050 

• EHB3025 

• 1LBB3125 

California 


• HKA31250 PENCON International 

• IA3200 (DBA) General 

• EHB2100 Magnetics/Electric 

• 225N Wholesale 

• EB 1020 


• HDEA 2030 


• MCP331100R 


• MCP431550CR 


• BAB3060H 

• 656DI4 8G03 

Breaker- 


• FA-2100 

• EH-2050 

• HFB-3050 

Molded Case 


- 

- 

• HFD(B)-3020 

• MA3600 

NSSS, Inc_ 

• F2020 

• EH2100 

• EB3050 

• HMC380OF 

Spectrum, Tech. 

• EA2090 Rosen Electric 

• FA3125 - 

• HMCP 150 Luckow Circuit Breaker - 

G5-680

RPP-24544 REV lal 


Page 15 of 52 







• HFD 

• EH2O70 

• FA2050 

• JA2225 

• 71,311125 

• JL3B070 

• J1,311150 

• JL3B200 

Shunt Trips Aux. 

Contacts 2 & 3 

pole circuit 

breakers of 

various amperages 


Breaker & Electrical Supply 

HLC Electrical Supply 

(DBA)G 

(DBA) General Whole Magnetics/ Mane 

NRC I.N_ 88-46 


Attachments 

• JUB090 

- 


• JL3B100 .. 

• HLM3800T ANTI THEFT Systems, 

• F310ON Inc. (DBA) ATS 

• MA3500 Circuit Breakers 

• EH2O15 and AC Circuit 

• FA3035 Breaker - 

• FA2100 Electrical Supply 

• HLA2125OTM 

• EH2O70 

• JB3100 

Molded Case 

• EB2030 


• 8MC800 

Co. (MCCB) 

• CAH3200 

• EHB3040 

• JL3-11150 

• JL3-B200 

• JL3-B090 

• JL3-131000 

• HFA, HFB, FA 

• JL3-(B)8070 

• JL3-11325 

• EH-2020 

• FA-3035 - 

• EH-2050 

• FA-2100 

• FA-2050 

• HFB-3050 

• JA-2225 

• HLM3800T 

• F3100N 

• AAA3500 

• EH2O15 

• LA320OWL 

• HLA3200T 

• 2602D58U9 

G5-681



Page 16 of 52 



ATTACHMENT A - SUSPECT COMPONENTS LIST (cont,) 

Component Manufacturerfrype Description Supplier References 



• HLB3200T 

• 262156G19 

NRC I.N. 88-46 Supp- 

• IA& IB 

&Attach. 

• HL300T 

• HLA240OTM 

• HMA3600T 

• IIMA3700T 

• HKA3225T 

• HNB2700T 

225 amp, 3 pole 



I pole, 20 & 30 amp 

2 pole, 20 & 30 amp 


Not Provided 

•. MDL#KAF 

• QNB3020 

• QNB3030 

• BA 

_ 

SENS ID # 10 

3-17.89 

SENS ID # I i 

3-3-89 

3 pole, 20 amp Not Provided 

• BA 

• BA 

• E3060 

• F3020 

Circuit Breakers ITC (Component 

Examples) 

SENS Report ID # 12 

10-19-88 

I4RC I.N. 88-46 

• Model - E43B015 3-phase 480 volt Cal. Breakers/Elect. SENS Report ID #8, 

Wholesale Supply Co. 5-5-89 

• EQ-B 1 pole, 20 amp 


Not Provided SENS ID #10 3-17-89 

• EE-3B030 

SENS ID # 113-3-89 

• E173B070 

• EF3H050 

• EF3B125 

2 & 3 pole various 

amperages 


Breaker& 


NRCI.N- 88-46, 


Attachments 

• EF3B040 

• E42B020 

Q72B200 

• IL3B400 


Supply - 

G5-682

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

Page 17 of 52 

CONTROL OF SUSPECT/ Effeetive Date December 31, 2003 




Circuit Breakers ITE (cont.) 


• 11E913040 California 

• EE313050 


• BQ213030 

• EE313070 

• EE213100 

• EE2BO50 

• EE213030 

- 

- 

PENCON 


General Magnetics/ 


- 

•'FJ3B225 

• ET 

-KA 

ATS Circuit 


• EH-313015 

• JL-36070 

• JL-313150 

Panel Board 

Specialties 

• E43BO15 Rosen Electric 

• EF2-BO30 

• EH3B100 

• QPIB020 

• QJ313200 

• EF3B100 

• 9193 

Equipment 

Circuit Breakers ITE, Gould & ITE 

Imperial 

Brown Boveri Elect, 

(BBE) 

ASEA Brown Boveri 

(Component Examples) Not Provided Brown Boveri NRC I.N_ 89-86 

ID4KV ASEA Brown Boveri 

• Type HK Not Provided NRC I.N. 87-4I 

• 5 HK 

Not Provided 

• 7.5 HK 

• 15 HK 

• 38 HK 

• ITE 62-6 

Not Provided Office of 

Nuclear Safety; 

92-25 

Circuit Breakers Square "D" Co.. 

Component Examples 

Molded Case General Circuit 

Breaker & 


- 

NRC I.N. 88-46 


NRCB 88-10 


_ 

NRC I.N. 90-46 

' • KHL 36125 

California 

(Any Type) Breakers, Inc. 

G5-683 


(DBA) General 


Wholesale



Page 18 of 52 





. 

Circuit Breakers Square "D" Co. ANTI THEFT Systems 

Component Examples Inc. (DBA) ATS 

(cont-) 



Breaker- 


- • QOB220 I pole, 15 amp Not Provided SENS ID #10 

3-17-89 

. 

• Q0220 2 & 3 pole General Circuit NRC LN.8945 & 

• LO-3 20 & 50 amp 

breakers 

Breaker & 


Supplement #2 

• SBW-12 

• 989316: 

• FAL3650-16M 

or 

• FAL36050-16M 

• KA36200 

3 pole -200 amp 

breaker 

30A/600V 


California 


• .999330 


(DBA) General 


Wholesale 

Manufacturer not 

Not Provided Stokely Enterprises 'DOE Letter 8-26-91 

Provided 

Reprinted 

Molded Case NuVEPi Bulletin 

• ERB3025 Circuit Breakers - 7-26-91 

- Circuit Breakers Fed. Pacific General Circuit 



• NEF431020R 3 pole, 20 amp 

• NEI 11020 1 pole, 20 amp HLC Electric Supply 

• NE 1 pole, 15 amp 

California 


G5-684 

- PENCON International 

(DBA) General 


Wholesale 

SENS ID. # 10 

3-17-89

0 


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

Page 19 of 52 



ATTACHMENT A - SUSPECT COMPONENTS LIST (cant.) 

Component ManufactureriType Description Supplier References 

Circuit Breakers Fed. Pacific 


(cont-) ANTI THEFT Systems, SENS ID. #I I 

Inc. (DBA) ATS 3-3-89 

• NF63-1100 t, & 3 pole - Circuit Breakers 

• NE224060 30,60 & 100 amp and AC Circuit 

• NE224100 breakers Breaker- 

. • NEF433030 Electrical Supply 

• 2PI25 

General Circuit DIRC I.N. 88-46, 

Breaker & Supp. & Attach. 



California 


Jefferson (Component 

Examples) 


(DBA) General 

Magnetics/electric 

Wholesale 

14RC I.N. 88-46, 


AIM THEFT Systems, 




Breaker- 


Mid West Co. 

Circuit Breakers Superior (Component Not Provided General Circuit NRC I.N. 88-46 

Examples) Breaker& Supp.&Attach. 


• 246U-3 


G5-685 


California 



(DBA) General 


Wholesale 




and AC Circuit- 

Breaker- 

Electrical Supply

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

Page 20 of 52 




Component ManufacturedType Description Supplier References 

Circuit Breakers Manufacturer Not General Circuit NRC I.N. 88-46, 

Provided - Breaker& Supp.& Attach, . 

(Component Examples) Electrical Supply 

5ODHP250 2 pole - 50 amp HLC Electric Supply 

Circuit Breakers Cutler Hammer 


California 


PENCON 


ATS Circuit 

- Breakers and AC 

Circuit Breaker- 


Heaters • W1771113 Not Provided AAKER 


NRC LN. 88-46, 

Supp. & Attach_ 

•. 101771-121 

Breaker & 

• 10177H32 


• 10177HO36 

• 10177HI049 


supply 

California 

Breakers, Inc_ 


(DBA) General 

Magnctics/Electric 

Wholesale 

ANTI THEFT. Systems, 



- and AC Circuit 

Breaker- 


G5-686

REP-24544 REV I 


Page 21 of 52 



ATTACHMENT A - SUSPECT COMPONENTS LIST (coat.) 


Switches (Component Examples) 

Crouse Hinds Tumbler, It. op Platt Electric SENSID #l6 

#EDSC2129 Supply Co. I-27-92 

Sq_ D Type G. Class Gen- Motors, 

9012, 9025, 9016 Electro-Motive Office of 

Design Nuclear Safety 

93-24 & 

1 93-27 

Transmitters Rosemount (Component Venetech E.L. Wilmot 

Examples) letter dated 

8-1-91 

• Model 1151 GP 

• Model I t51 DP 

- H. Richardson 

letter HR-81-91 

dated8-15-91 

Motors Siemen & Allis General Circuit NRC I.N. 88-46,. 

(Component Examples) Breaker & Supplements and 

Electrical Supply Attachments 

- INP 143 T 10 H.P, 

215 T HLC Electric Supply 

California 



(DBA) General 


Wholesale 


Inc. (DBA) An 

- Circuit Breakers 


Breaker- 


G5-687 


Equipment -



Page 22 of 52 




Component ManufacturerlType Description Supplier References 

Relays Potter& Brumfield Not-latching Stokely Enterprises NRC I.N. 90-57 & 

(Component Examples) rotary Attach 

Spectronics, Inc. 

MDR-139,173-1 

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 I.N. 88-46, Supp. 



& Attach. 

• 12HGA-IIS52 

• NX 400 


- California Breakers, Inc. 


(DBA) General 

MagneticsUectric 

Wholesale 



- Circuit Breakers 

- and AC Circuit 

Breaker- 


Manufacturer not Not Provided Stokely. Enterprises DOE Letter 8-26-91 

provided 

Reprinted 

NuVEP: Bulletin 

FSC-5945 

7-26-91 

Arnerace(or Agastat) Electra Amemce SENSID#111-1-91 

(Component Examples) Pneumatic Timing 

Relays Control Components NRC LN. 92-24 

Models 

E7024 

E7022 

Supply 

A through L PRB - 

SeriesModel 7032 

G5-688



Page 23 of 52 





Fuses Bussman Co. 15A-250V & General Circuit NRC I.N. 88-46, 

(Component Examples) 3OA-600V Breaker & Supp. & Attach. 


REN 15&NOS-30 




(DBA) General 


Wholesale 


CeC Inc. (DBA) ATS 



Breaker- 


Class IE All Supplied by Preventive NRC LN, 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 I.N. 88-45 

(Component Examples) Breaker & Supp. & Attach 


626BI87017. HLC Electric Supply 

626B187G13 


- PENCON International 

(DBA) General 


Wholesale 

ANTI THEFT Systems;. 




Breaker- 


Resstors Unknown All Impala Electronics NRC I.N. 91-01 

G5-689

ESHQ 



Page 24 of 52 


COUNTERFETT ITEMS 

Effective Date December 31,2003 2003 



Semiconductors Solid State Devices P-Channel MOSFET SSDI DOE Albuquerque 

Inc. (SSDI) Letter, 06-25-96 

SFF 9140 

to DOD Inspector 

General 

SPD 1511-1-I1 Pin Diode 

(SA3059) 

2A 14118 or 2AI4152 Ion Implanted 

Diode 

SSR4045CTTXV SCHOTTKY Diodes 

SFF9140TWX Power 

Transistors 

SPMFI06ANH Special Pack 

MOSFET Switch 

SPD 5818 or Axial Leaded 

IN58581TXV SCHOTTKY Diode 

2N797 

Unknown 

Transistor 

Diode (SA 3436) 

Starter Controls Westinghouse Not Provided General Circuit NRC LN: 88-48 

(Component ExampHes) Breaker& 


• A200MICAC HLC Electric Supply 

• A201KICA 

• A201L2CA 

• AN13A 

California 


PENCON 


General Magnet5cs/Eleciric 

Wholesale 

ANTI THEFT Systems; 

Inc- (DBA) ATS 



. Breaker - 


G5-690


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

Page 25 of 52 





Gauge Glasses Siemen & Allis Not Provided Rosen Electric Co. NRC I.N. 88-46 

(Component Examples) Stipp. & Attach. 

400-737-637-118 

215 T 

Mercury Lamps Spectro Inc Not Provided General Circuit NRC I.N. 88-46 

(Component Examples) i Breaker & Electrical Supply 

V00014 HLC Electric Supply 


PENCON Internafional 

(DBA) General 


Wholesale 





Breaker-. 


Electrical Frames Westinghouse Not Provided General Circuit NRC I-N. 88-46 

(Component Examples) Breaker & Electrical Supply 

LA260OF HLC Electric Supply 

LA360OF 

MA2800F California Breakers, Inc. 


(DBA) General 


Wholesale 


lnc(DBA)ATS 



Breaker- 


Pushbutton Crouse Hinds Single gang, Platt Electric SENS Report IDH16 

station 

(Component Examples) pushbutton Supply Co.. 1-27-92 

400-737-637-118 . 

G5-691


F,SHQ Document TFC-ESHQ-QS-C-03,REV B 

Page 26 of 52 





Overload Relay. Square D (Component Not Provided Not Provided NRC I.N. 8846 

Thermal Unit Examples) 

B19.5, B22 

Piping, Fittings 

Flanges, 

Tube-line Corp. Subassemblies, Tube-line NRC IEB 83-06 

and 

Components 

Ray Miller, Inc. finings, flanges, & 

other components 

(Carbon and 


components) 

Ray Miller, Inc. 

NRC LM 89-18 

NRC:IEB 83-07 

NRC I.N. 83-01 

Piping, Fittings, Piping Supplies, Inc. Carbon and 

]Piping Supplies, NRC Bulletin 88-05 

Flanges, and 

Components 

& West Jersey Mfg. & 

Chews Landing Metal 


Fittings 

Inc. & West Jersey & Supplements 

and 

Mfg. & Chews 

Mf Flan es Landing Metal Mfg. 

Valves VOGT Full port design CMA International NRC I.N. 88-48 & 

2-inch Model IMA Valve Supplements 

SW-I3111 & 1023 Refurbisher 

Crane 4"-1500psi, Southern Valve NRC I.N. 91-09 

pressure sealed Maintenance co., 

Amesse Welding 

Service & CMA Int 

ITT Grinnell Diaphragm valves ITT Grinnell Valve NRC Comp. 

Valve Co., Inc Co. Inc Div. of Bulletin 97-02 

Diaflo & ITT 

Engineered Valves 

Crane, Pacific, Powell, Gate Valves Coffeyville Valve NRC I.N. 92-56 

Walworth & Inc 

Lunkenheimer 

Pacific. 8" & 3" Globe CMA & IMA Valve NRC LN. 88-48,. 

Valve Refurbisher Supp. & Attach. 

Crane Chapman 24" Check Valve CMA & IMA Valve NRC IN. 88-48, 


Pacific - Check Valve CMA & IMA Valve NRC I.N. 88-48, 

Refurbisher S M . & Attach- 

(35-692

ESHQ 

RPP-24544 REV let 


Page 


27 of 52 

CONTROL OF SUSPECT! 





Valves Kerotest. 8" Valve CMA & IMA Valve NRC I.N. 8848 


Pacific 4" Gate Valve CMA & IMA Valve NRC I.N. 88-48 


Lukenheimer C' Model 1542 CMA & IMA Valve NRC I.N. 8848 

20" Model 3013 Refurbisher Supp. & Attach. 

Crane All CMA & IMA Valve NRC LN. 8848 

Refurbisber Supp. & Attach. 

Flanges China Ding Zinang . Flanges, ASTM Billiongold Co. NRC I.N. 92-68 

i Nan A105, ASME SA105 . LTD. and Attachments 

Xi Li Flange Co. Tain Gong Co. 

Shou Gang Mach. Eng. Sanxi Province Office of 

Co. Overseas Nuclear Safety 

Trading Corp 92-25,93-23, 

and 92-35 

National Board of 

Boiler and Pressure 

Vessel Inspectors 

(NBBI) Bulletin: 

Special Report, 1992, 

Volume 48, Number 2, 

The Chinese Flange 

Investigation 

Valve Masoneilian-Dresser Plug stem, stem to Cor-Val, Control NRC I.N. 88-97 

Replacement Industries plug anti-rotation Valve Specialists, Supp. & Attach 

Parts pin, seat ring, valve H.H. Barnum & M.D. 

plugs, bushings, Norwood, Sample Webtrol 

cages & packing box 

components onents 

Controls, Inc. 

Pumps & Hayward Tyler Pump HTPC AS-ME Hayward Tyler Pump Co. IEB 83-05 & 

Replacement Co. Nuclear Code Attachments 

Parts 

Channel Unistrut Corporation Continuously slotted Unistrut Corporation NRC I.N. 91-25 

Members channels, structural 

framing members, 

fasteners, nuts, 

fittirt s, nineclams 

Fire Barriers Thermal Science Inc. Thermo-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 

G5-693 

NRC I.N. 93-37


ESHQ Document TFC-ESHQ-QS-C-03, REV R 

Page 

28 of 52 




ATTACHMENT A - SUSPECT COMPONENTS LIST (cost.) 


Steel Alloy & Carbon Steel Plate Meredith NRC I.N. 89-56, 

Co. Inc., Atlantic Steel Angle Corporation Attachments and 

Co., Levingston Steel 

Co., & Copperwetd. 

Fiat Bar 

Bar 

Pressure Vessel 

Nuclear Alloy & 

Supplements 

Steel co.. 

Carbon Steel Co., Inc. 

Fasteners (Bolts, (parentheses designated • Those with Note: Listed suppliers may Commercial 

Screws, Nuts, headmark) suppliers or also be: manufacturers Carrier Journal 

and Washers) - manufacturers .Articles for: 

Asahi (A) Lawrence Engineering & X6/88; 1/90,2/90,3/90, 

Daiichi (D) • Those that me I Supply Co. 4/90, 6/90,7190,12190 

Daiei (E) improperly', Metal Building Bolts 

Fastener Co. of Japan marked Nicbimin Corporation INEL Suspect 

(Fld) UNICO HeadmarkList 

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 H. Y. Port Fasteners Co. 216/91 

Kcsaka Kogyo (KS) Public Law 101- Kobayashi Metals, LTD- 

Kyoei 592, Fastener Takai Screw Mfg. Co. LTD. SENS Report. # 13 

Minamida Seiybo (M) Quality Act Yamaguchi Sesakusho Co. 2/6/91 

Mnato Kogyo (MS) LTD. 

Nippon (NF) Highland Bolt & Nut HR 3000, U.S. House 

Takai (RT) Porteous Fastener Co. of Representatives, 

Tsukimori (S) Northwest Fasteners July 1988 

Unytte (UNY) Ziegler Botts & Parts Co. 

Yamadai (Y) Edgewater Fasteners,. Inc. J. A. Jones, Lu, 

Ivaco, Infasco (hollow Reynolds Fasteners 9/23/92. 

triangled) A & G Engineering 

Memo from L. 

Kubicek, 

3(2g/9I 

(35-694 

Memo from D. Sanow, 

3/8/91, 

-Fastener Technology 

International," Feb., 

April, and June 1993 

Rep. J. Dingell 

Ltr to Comm. 

Dept. & NRC 

June 18, 1993 

Office of Nuclear 

Safety 93-26,93-22, 

93-11 

DOE Quality Alert, 

Bulletin, Issue No. 92- 

4, August 1992 

FDH Hanford Suspect 

Headmark List

RPP-24544 REV_Idl 


Page 29 of 52 



ATTACHMENT A - SUSPECT COMPONENTS LIST (cont) 

Component Manufacturerffype Description Supplier References 

Fasteners (Bolts, NUCOR 1-1(4" x 2" Zinc Cordova Bolt, Inc. SENS ID p 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, Inc. NRC I.N. 99-59 

Glasser & Assoc.. 

" Knoxville Bolt & Screw 

Metal Fastener Supply 

Phoell Mfg. Co. 

Service Supply Co. 

Southeastern Bolt & Screw 

Sure Loc 

Victory Bolt - 

G5-695


ESHQ Document TFC-ESHQ-Q_C4C-03, REV B 

Page 30 of 52 




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 supplies/chargers 

• AC inverters 

• Current/potential transformers 

• Exciters/regulators 

• Bus transfers/auto bus transfers 

• Motor generator sets 

• Generators 

• Rewindable motors 

Printed circuit boards 

Bulk commodity items 

Fuses 

Splices 

Electrical connectors 

• Indicators/controllers 

• Panel lights/switches 

• 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 

G5-696

ESHQ 

44 REV ld 


Page 

TFC-ESHQ-QS-C-03, REV B 

31 of 52 





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. 


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. 


ASTIR-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. 

G5-697



Page 32 of 52 



ATTACHMENT C - SUSPECT/COUNTERFEIT ITEMS INFORMATION SOURCE LIST 

A wide variety of industry and Government sources publish information relative to suspect/counterfeit 

products. The following sources provide information which is available on a continuing basis: 

Industrial Fasteners Institute (IFI) 

The following information is available feom IFH via subscription: 

"Fastener Application Advisory" (Published Monthly) 

"North American Manufacturers Identification Markings 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 1990 

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 

probllems 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 of potential 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- 

G5-698



Page 33 of 52 



ATTACHMENT C - SUSPECT/COUNTERFEIT ITEMS INFORMATION SOURCE LIST (cont.) 

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 fbllowing 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 seminars/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 fatness for use on the Hanford Site. 

G5-699



Page 34 of 52 



ATTACHMENT D -• CHARACTERISTICS THAT MAY 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. 

• 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. 

„c 0 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 Vow cost. 

• High potential for profit (rejected heats of material are purchased and decertified). 

G5-700



Page 35 of 52 

CONTROL, OF SUSPECT/ Effective Date December-31,2003 

COUNTERFEIT I"I'EMS 

ATTACHMENT E - WHERE TO LOOK FOR SUSPECT/COUNTERFEIT ITEMS 

The following; areas should receive increased scrutiny to assure that suspecticounterfeit items are not 

evident: 

Items in Supply 

• 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 

• 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 parts first" 

• Reduction in major disaster potential 

• Program costs low/benefits high. 

G5-701



Page 36 of 52 



ATTACHMENT F - SUSPECT/COUNTERFEIT PARTS DETECTION 

It is very 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 

nippers). 

• 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 thesame material and one is a 

different material). 

• 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. 

• 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_). 

G5-702

ESHQ 





Page 


TFC-ESHQ-QC-C-03, REV B 

37 of 52 

December 31, 2003 

Documentation 


Documents may be suspecttcounterfeit 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. 

• 

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. 

• 

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). 

• Documentation is not delivered as required on the purchase order or is in an unusual format. 

• 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. 

• Data on a single line located at different heights indicate the possibility of retyping. 

G5-703

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

Page 38 of 52 

CONTROL OF SUSPECT/Effective Date December 31, 2003 


Fasteners 

ATTACHMENT F - SUSPECTICOUNTERFEIT PARTS DETECTION (cont.) 

• 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 12-1). 

Electrical Devices 

Headmarkings which depict both raised and hand-stamped markings, such as those 

described in WHC Quality Assurance Bulletin # 94-01, "Discrepant Dual I-Iead Stamped 

Stainless Steel Bolts" This bulletin documents the results of internal inspections and 

independent testing of stainless steel bolts purchased to ASTM A193, 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 SICI coordinator based on guidance received from the DOE. 

Connections show evidence of previous attachment (metal upset or marring). 

0 Connections show arcing or discoloration. 

• Fasteners are loose, missing, or show metal upset. 

• Molded case circuit breakers are not consistent with manufacturer-provided checklists for 

detecting substandard fraudulent breakers. 

• Missing orphotocopied Underwriters Laboratories (UL) labels on products requiring such- 

G5-704

RPP- 4544 RF.V t d 

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

Page 39 of 52 



ATTACHMENT F - SUSPECTICOUNTERFEIT PARTS DETECTION (cont.) 

Rotating Machinery and Valve Internal Parts 

• Shows marring, tool impressions, wear marks, traces of Prussian blue or lapping compound, or 

other evidence of previous attempts at fit up or assembly. 

• Heat discoloration is evident. 

• Evidence of erosion, corrosion; wire-drawing or "dimples" (inverted cone-shaped impressions) on 

valve discs, seats, or pump impellers. 

Valves 

• Paint 

- Valve appears to he freshly painted and valve stem has paint on it 

- Wear marks on any painted surface 

- Valve stem is protected, but protection has paint on it 

- Paint does not match standard Original Equipment Manufacturer (OEM) color. 

• Valve Tags 

- Tags attached with screws instead of rivets 

- Tags attached in a different location than normal 

- Tags appear to be worn or old 

- Tags with paint on them 

- Tags that look newer than the valve 

- Tags with no part numbers 

- Tags with irregular stamping. 

• Hand Wheels 

• Bolts and Nuts 

Old looking hand wheels on new looking valves 

Hand wheels that look sand blasted or newer than the valve 

Different types of hand wheels on valves of the same manufacturer. 

Botts and nuts have a used appearance (excessive wrench marks on flats) 

Improper bolt/nut material (e.g., a bronze nut on a stainless stem). 

G5-705


Page 40 of 52 

CON'T'ROL OF SUSPECT/ Effective Date December3l, 2003 


• Valve Body 


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. 

G5-706.



Page 41 of 52 



ATTACHMENT:G - FASTENERS 

I.0 Counterfeit/Substandard 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 I987, the Army testified that they had 

purchased bolts 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, IFI 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. 

1.2 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 I. These markings are called 

beadmarks. DOE is currently concerned with two different grades of fasteners: one has 

three equally spaced radial lines on the head of 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. 

G5-707

ESHQ 



Page 

TFC-ESHQ-QS-C-03, REV B 

42 of 52 

CONTROL OF SUSPECT/ ' 




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 suspect/ 

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. - 

1.4 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, anew 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 cannot be used to identify substandard high-strength 

fasteners and should not be solely relied upon in performing acceptance test. 

1.5 Using Suspect/Counterfeit 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 suspecticounterfeit 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 Botts 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- 

G5-708


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

Page 43 of 52 

CONTROL! OF SUSPECT/ Effective Date December 31, 2003 


2.0 Stainless Steel fasteners 

2.I Purpose 


To provide follow-up information to the previous notification sent to the DOE field and 

contractor organizations in late 1996. 

2.2 Background 

In November 1993, the Industrial Fastener Institute (IFI) 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 sells 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 manufacture's markings 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, PMC, 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 did not display any manufacturer's markings. Most of the bolts 

discovered were purchased with the specification to meet a national consensus standard, 

American Society for Testing and Materials (ASTM) AI93, B8 Class I rather than the 

ASTM A320 standard discussed in the IFI 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. 

G5-709



Page 44 of 52 



2.3 Issue 

ATTACHMENT G - FASTENERS (coat.) 

The requirements of the ASTM AI93 standard regarding fastener marking and 

certification are very similar those required bit 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 AI93 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 IM 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 A193Grade B8 Class 1. 

Unless the certification documentation is specifically requested, and in most cases it is 

rot, 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. 

G5-710

Examples of stainless at" 

batenem that have been upgraded 

from 18-8 to ASTM A320 or ASTM 

A103 Grade 88 after hand 

stamping. The fast three examples 

show samples of fasteners to 

:w Indicate conformance to two 

nen• oomp.W. standards, 


Any bolt on this flat should 

>o treated at defective 

without further testing and 

Process In accordance with 

HNIF-PRO-301. Note: This list 

was onginalty, Published by 

130E 1EH-0196, Issue No- 9716 

ll any of these fastervere are located, 

contact your facility S/Cl Point of 

Contact (POC) for instructions. The 

P10C list Is on the Hanford Intranet 

! it http:]/docs.ri.goy/han.infol 

ilanscithlanscl.doc. Scroll to the end 

! :)t the document for the list. 

[ L3O4^ 

C 

Surrounding 

While Color 

Markings 

Before Hand 

Stamping 

Surrounding 

^ ÎLk C Wor 


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

Page 45 of 52 



ATTACHMENT H - DOE HEADMARK LIST 

_t_...:-; : ; :.......Help Stamp Out 


G5-711 

a 

121593C 

Bs a Bs 

H 

F593C FS9 

CS Bs CS Bs 

TH

I,— 



Page 46 of 52 



ATTACHMENT H - DOE HEADMARK LIST (cont.) 


Suspect Fastener Headmark List N%Z, 

All Grade 5 and Grade 8lasteners of foreign origin which do not bear any 

manufacturers' headmarks: 

s 

Grade 5 \- Grade 8 



J Jinn Her (TW)KS KS Kosaka Kogyo (JP) 



4 A -p A Asahl Mgt (JP) -KS- KS Kosaka Kogyo (JP) 

-NF- NF Nippon Fasteners (JP) - 

IT ' FIT Takai Ltd (JP) 

- H - H Hinomoto Metal (J p) -FM- ' FM Fastener Co. of Japan (JP) 

M`- M 

Minamida Sieybo (JP) -KY- , KY Kyoei Mfg (JP) 

-Ms- MS Minato Kogyo (JP) -`J J Jinn Her (TVY) 

Hollow 

Triangle 

Infasco (CA, TW, JP, YU) (Greater than 1f2-inch diameter 

Grade 8 Hollow Triangle only) 

- E - E Daiei (JP) -UNY- I UNY Unytitc (JP) 

Grade 82 fasteners with the following headmarks: 


KS Kosaka Kogyo (JP) 

Grade A325 fasteners (Bennett Denver target only) with the following headmarks: 

Type 1 

Type K 

Type 3 


KS A325 KS Kosaka Kogyo (JP) 

Key: CA-Canada. JPlapan,TW-Taiwan,W-Yugostavia 

Any bolt on this list should be treated as defective without further testing. 

G5-712

ESHQ 





Page 


TFC-ESHQ-Q C-C-03, REV B 

47 of 52 

December 31, 2003 


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. 

1. Recognition Factors 

The following factors should be recognized regarding suspect or refurbished circuit breakers: 

A. 

B. 

The quality and safety of refurbished molded-case circuit breakers is questionable since 

they are not designed to be taken 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. 

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 information Notice No. 88-45 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 ofDOE'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 Name 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. 

G5-713



Page 48 of 52 

CONTROL OF SUSPECPI Effective Date December 3l, 2003 



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 by NUMARC, 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. 

1 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. 

G5-714



Page 49 of 52 




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 listed 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. 

G5-715

,_ I. 



Page 50 of 52 




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 Inspector General and the Office of Nuclear 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 suspecticounterfeit circuit breakers when 

approval is given for disposal. 

G5-716

f 

ESHQ 



Page 


51 of 52 




1. 

2. 

3. 

ATTACHMENT J - ASSESSMENTISURVEILLANCE LINES OF INQUIRY 

S/CI processes and other S/CI related processes are effective in addressing the safety-related 

aspects of S/CI. 

Formal supplier qualification and re-qualification processes are established and implemented, 

including routine collection of evaluations of feedback on vendor performance_ 

Controls are established on a graded basis that considers the risks involved and historical 

experience with S/Cls. 

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/Cl 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 SlCI. 

8_ Protocols are established for clearly identifying S/CIs that are determined to be acceptable for use 

9. Inspections for S/CI materials are incorporated into routine maintenance activities, and clear 

guidance is provided for the disposition of installed S/Cl materials identified during routine 

inspections and maintenance activities. 

10. Expectations for S/Cl controls are integrated within existing processes, such as routine and 

special inspections for S/Cls in site procedures, and guidance is provided for performing such 

inspections. 

IL Roles and responsibilities and interfaces for management of S/CIs 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/Cl reporting requirements are effectively integrated into the site contractors' processes for 

disposition of non-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. 

G5-717

ESHQ 



Page 

52 of 52 




14. 

I5. 

ATTACHMENT J—ASSESSMENT/SURVEILLENCE LINES OF INQUIRY (coat.) 

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. 

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/Cl 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 current 

and accurate information on S/CIs. Provisions are available for making this list readily available 

to site personnel who have S/CI responsibilities for procurement, inspection, and other areas 

associated with the implementation of S/CI controls. 

19. 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/CI 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/Cl. training addresses site-specific processes and procedures for identifying, dispositioning, and 

reporting S/Cls, including reporting to the IG. 

23. S/Cl. 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/CI 

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.). 

G5-718

f 






PROJECT: Final DBVS Design 145579-V-DS-001.1 I REV. 1 





CLIENT APPROVAL (AMEC RICHLAND) AMEC AMERICAS LIMITED (TRAIL) 

Original Signatures on Fife I Origin! Signatures on File 

Project Manager: Project Manager: 

Date: Date: 

Q.A. Rep.: Discipline Lead: 

Date: Date: 

CLIENT APPROVAL (CH2M HILL) 

Project Manages 

Date: 

G5-719 

Originator: 

Date: 

e

f 



PROJECT. Final DEVS Design 945579-V4DS•OD•!.1 REV- 1 

PROJECT NO.', 145579 SELECTNE CATALYTIC REDUCTION UNIT 

ER NO--36 DS9 003 

CLIENT. AMEC ME - Richland, Washington 


Document N®. 5 caftan 

145579 V--SP-001 ISpecification for Selective CataiftReduction Unit (SCti 

CONTENTS 

Data Sheet 1 page 

Bidders Drawing & Data Commitments Sheet .1 Page


a 


ROJECT: Final DBVS Design 145579.V4DS-001.1 REV. 1 

OJECT NO.: - 145579 SELECTIVE CATALYTIC REDUCTION UNIT 

IENT: AMEC E&E - Richland Washington 

- EQ. NO.: 36-D59-003 

Required 1 A rea OGTS 

D # 

Stream No. 

ference Specification: 145579-V-SP-001 Quality. Assurance Level EQL 

[No. 

perating Conditions Rev Rev 

Location(Indoors/Outdoors) 

Outdoors Operation -Days per year 

365 

Operating Pressure (in WG). -98.4 1 - Hours per day 

24 

Max pressure drop across system (in WG) 20 Operation (continuous/intermittent) Continuous 

Normal Net Temp (7) 129 1 Availability 

Inlet Gas Vol at Normal Temp (ACFM) 7862 1 Elevation. (ft asl) 663 

Max. Allowable Flow (ACM * 

D Environment -Radioactive * Potential D 

Efficiency, NOx removal ("/o) 973 B -Toxic 

Yes 

Efficiency, CO removal ("/o) 90 0 -Corrosive 

Yes 

Max. outlet NH3 concentration (ppmV) * 

D -Flammable 

No 

Max. outlet CO concentration (ppmV) 40.2 1 

Max. outlet NOx concentration (ppmV) 84 1 Inlet gas composition 

Mat'1Data - N2 (V%) 77.1 1 

Design temperature Min/Max ("F) * / D 02 (V%) 20.63 1 

Design Pressure Min/Max (in WG) * / D Steam (V%) 1.92 1 

Interconnecting duct 

316 SS CO2 (ppmV) 28 0 

Air/air heat exchanger 

309 SS CO (ppmV) 403 I 

Heater housing 

304L SS HCl (ppmV) 0.1 

Venturi injector 

304L SS Sox (ppmV) 1.1 1 

Ammonia gas piping 

Carbon St. NOx (ppmV) 3121 1 

All hardware 

316 SS HF (ppbV) 2.5 0 

Catalyst * 

D 137Cs (Ci/hr) 4.6E-10 I 

Unit Inlet Flange size (in) * 

D 99Tc -(CVhr) 1.8E-I1 1 

Unit Outlet Flange size (in) * 

D TRU (Ci/hr) 2.7E-15 1 

Insulation T /Thickness (in) * 

D 129I (Ci/hr) 5.5E-13 1 

Heat exchanger In-Line Heating System 

SCRH/X Outlet gas temp. ("F) * 

D Heater type - - Electric 

Catalyst inlet gas temp. ("F) * 

D Efficiency ("/o) * 

D 

Outlet gas exhaust temp. 

Approach delta T 

("F) * 

("F) * 

D 

D 

Inlet temp. 

Outlet temp. 

("F) * 

("F) * 

D 

D 

Min. efficiency (%) * 

D Total neat input (kW) * 

D 

Ammonia Injection System Controls stem 

PID too 

Injector type 

Venturi Lifting 

Ammonia consumption Min/Max (lb/hr) *. / D Unit Break Down Lifting (Yes/No) 

Connection size/t a (in) * 

D 

Utility Requirements D Unit Assembly and Weights 

Volts/Phase(Hertz 

480/3/60. Mixing Section (Modular/one unit) One unit 

Circuit Amps Max (A) * 

D Max. footprint dimension (ft) IOx24 I 

PLC Compatible (Yes/No) 

Yes Total shipping weight (lb) * 

Control Voltage (V) * 

- SCR Total Operating Weight (lb) * 

B 

Inst.Air VoVPressu!re 

Comments: 

(CFM/psig) * 

D Ammonia System Total Operating Weight (lb) * 

B 

All items with an * shall be filled in by the Seller - 

Vendor to supply NH3 support system data for pumps and optional tankage .D 

Vendor to provide list of instruments supplied and expected vendors. D 

I 

CO, reduction by the SCR to be 90% minimum - D 

Insulation external allowable surface max temp 120 F D 

Date 27-Feb-04 I 22-Mar-041 I-A r-04 I 13-May-04 I 18-May-04 I 6-Jan-05 

By JSM JFS JFS JDS IDS MEP 

Cbked FWS FWS 

Rev. A B C D 0 1 

G5-721

TECHN ICAL DATA SHEETS 


amec'.0r1tL 

PROJECT: Final DBVS Design 145579-V-DS-001.1 REV. 1 

PROJECT NO.: 145579 SELECTIVE CATALYTIC REDUCTION UNIT 




EQ. NO.: 36-D59-003 



submissions are governed by the engineering design schedule of the project. 'I he Vendor shall supply one Autocad disk file 

and requested number of copies within the listed number of calendar days. Final drawings must be certified as correct and 

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

revison numbers, quantities, status and document types must be included with all submissions 

(including electronic submittals) 


Faxed documents must be followed by the originals. 


1385 Cedar Avenue 

Trait:, BC, Canada 

V I R 4C3 

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


:lhvays include a transmitht'l Fax: (250) 368-2401 

BIDDERS MUST PROVIDE ESTIMATED LEAD TIDIES FOR APPROVAL DRAWINGS 

Proposal Bidder shall include (his data for cach item REVIEW 

Review Required before ordering or start of fabrication 

ITEMS DUE 

Final Required within 7 cla ys prior to shipmen t and before final payment WITHIN 

PROPOSAL REVIEW FINAL DESCRIP7 ION 

(DAYS) 

E+l QA program that addresses the requ irements of NQA-1-1894 Bid 

E+ I Experience list and maintainabilit) , information Bid 

E+3 Design, fabrication & delivery schedule Bid 

E+3 E+3 E-6 Outline drawings and layout drawings ind •wing weights and dimensions PO Q0 

E+3 E+3 E16 Technical brochures on purchased components 130+21 

E_,+3 EF3 F,+6 F:lectrcal schematics, wiring, diagrams and nameplate lists 110+20 

E+3 E+6 Calculations and technical datasheets for all equipment PO+20 

E F I E+6 Spare parts fist PO+40 

EF I E+6 

Set of installation and maintenance manuals c/w technical literature for all 

equipment and devices PO+40 

6 NEC inspection certificate & electromag netic interference test results Del-7 

6 U L and motor lists Del-7 

6 Site co mm issioning record & test reults _ 

COM+14 

E+1 Ef 1 6 

1 Factory Acceptance Testing Plan (FAT) PO+21 

W- NO 

1 

h 

n 

THE'1'INIE1.1 RECEIPT OF'ri1F. VENDOR DOCUMEN'l:S IS CRITICAL I'O TH1S 1'RO.IEC'I' 

BUYER COMMITS TO A 10 WORKING DAY TURNAROUND ON REVIEW ITEMS 

I agree to provide the listed documentation anti data anti the dates shown above. 

/1"`., Vendor Signature Date 

G5-722 

VENDOR 

.'OMMITMEN'r 

(SEE NOTE 4) 

(DAYS)

][N-CONTAINER 

VITRIFICATION SYSTEM 

AND 

OFF-GAS TREATMENT SYSTEM 

DESIGN 

SUBMITTALS 

J 

JULY 2006

?10..- 


RPP-24544 REV it d 

The document revision number Is indicated below. Please replace all revised pages of this 


MawIp^JNf' '+Îb,. • 97AA 14667WV-9P-" MWom+ wd FVw) Rte,. 2eoc 

s.N..1xi 

amecO 

PROJECT: Final DBVS Design 145579-V-SP-OQ2 REV. 2 

PROJECT NO: 145579 


e R 

Y 

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Page 1 of 52 

.'C y a 

A For Client Review I Request for Quotation KM 26-Feb-04 FWS for KM 

B Request for Quotation - Revised JFS 06-A r-04 JFS 

C For Approval JDS 19-May-04 JDS 

0 For Construction JDS/FWS 20-May-04 JDS/FWS 

1 For Construction (Previously Issued under p roject 143643) AP 04-May-05 AP 

2 For Construction FWS 03-Jun-05 

CLIENT APPROVAL (AMEC RICHLAND) I 


Date: 

Q.A. Rep.: 


Date: f6 2 j 


Project Man er: 

Date: 

Jy^ 


G5-723 

.AMEC 

AMERICAS LIMITED (TRAIL) 



Date: ^^^Q D . C 

Discipline Lead: - 

Date: ^, 3 acb IS 

Originator 

Date: Z ^ `^ DCDe>


wmkyff a ►mee 


PRO' ECT: Final DBVS Design 146679-V. SP-002 REV. 2 





1.0 SCOPE OF WORK ...........................:..................................... ..............................7 

PAGE 

2.0 APPLICABLE DOCUMENTS ...........................................................».................. 9 

2.1 GOVERNMENT:DOCUMENTS ..:.............................. ..............................9 

2.2 NON-GOVERNMENT DOCUMENTS .............................................. ......... 9 

3.0 TECHNICAL REQUIREMENTS ..........................................................................12 

3.1 ITEM DEFINITION..... .... ........... ............ ........................... ..............12 

3.1.1 Item Diagram ...........................................................................12 

3:1.2 Interface De fi nition ..................................................................12 

3.2 CHARACTERISTICS ..........................:....................................................13 

3.2.1 Functional Characte ri stics .......................................................13 

3.2.2 Physical Characteristics ..................:.........................:.............14 

3.23 Reliabi lity .................................................. ° ..........................14 

32.4 Maintainability ...................... ... .......... ......... ........................... 14 

3.2.5 Environment ............................................................................15 

3.2.6 Transportability and Storage ...................................................15 

3.2.7 Safety ...................................................................... .......15 

3.3 DESIGN AND CONSTRUCTION ...........................:....:...........................16 

3.3.1 Parts/Materials/Processes ......................................................16 

3.3.2 Industry and Gove rnment Standards ...................................... 28 

3.3.3 Radiation ............................................... ................................30 

33.4 Cleanliness .......................................................:......................30 

3.3.5 Corrosion of Parts ...................................................................31 

3.3.6 Protective Coatings... ....... .... _ .......................... ...... ............. 31 

3.3.7 Interchangeability ................................... ..::............................. 31 

3.3.8 Identification and Marking... ............... ___ ............................... 31 

3.3.9 Nameplate ...... ... .............:............ ____ ....... ................... ......... 31 

3.3.10 Human Engineering ................................................................32 

3.3.11 Qualification ............................................................................32 

3.3.12 Document Submi tt al ................................................................32 

3.3.13 Personnel and Training ..................:........................................34 

4.0 QUALITY ASSURANCE REQUIREMENTS .......................................................35 

4.1 GENERAL_.. ............................................................................ ! ............. 35 

4.1.1 Organization .................................................................1........... 35 

4.1.2 Quality Assurance Program .................................................... 35 

4.1.3 Design .....................................................................................35 

4.1.4 Procurement Document Control ..............................................36 

4.1.5 Identi fi 

cation and Control of Items ........................................... 38 

4.1.6 Control of Processes ......................... :..................................... 39 

4.1.7 Inspection ................................................................................ 41 

rw..^n++ronswû^wr .moz.icsys ysvmzt=.axrwraia^w..w« Page 2 o 52 

G5-724



ame& 

RROJiECT: Final DBVS Desi n 145579-V SP-002 REV. 2 

PROJECT NO'.: 145579 


SINTERED METAL FILTER . 

4.1.8 

4.1.9 

4.1.10 

4.1.11 

4.1.12 

4.1.13 

4.1.14 

4.1.15 

4.1:16 

4.1.17 

4.1.18 

Test Control .............................................................................41 

Control of Measuring and Test Equipment .............................. 42 

Handling, Storage, and Shipping ............................................43 

Inspection, Test, and Operating Status ...................................43 

Control of Nonconforming Items .............................................43 

Corrective Action ..................................................................... 44 

Quality Assurance Records .....................................................44 

Audits ......................................................................................44 

Quality System for Material Specifying Addi tional Testing — ASME 

I I I NI I I ........ ............... :.............................. ............................... .. 45 

Control of Graded Fasteners.. .................... ......... ........ 45 

Hanford Analytical Se rvices Quality Assurance Requirements 

Document(HASQARD) — Volumes 1 and 2., ................. ........ 45 

4.1.19 Hanford Analytical Se rvices Quality Assurance Requirements 

Document (HASQARD) — Volumes 1 and 3 ............................45 

4.1.20 Hanford Analytical Se rvices Quality Assurance Requirements 

Document(HASQARD) -Volumes 1 and 4.-,... ........ ............. 45 

4.2 

43 

4.1.21 Nuclear Hazards Indemnity.. ......................... .................. ...... 46 

4.1.22 Computer Software .................................... .............................46 

QUALIFICATION VERIFICATION.. ............ ...... ......... .............. _ 47 

INSPECTIONS AND TESTS ...................................................................47 

4.3.1 Manufacturer Test ...:...........'....................................................48 

4.3.2 Electrical Testing ...............................................................:.....48 

4.3.3 Hydrostatic Test ..... ............... ....... : ......................... ..... ............ 49 

4.3.4 Performance Tests ..................................................................49 

4.3.5 Acceptance Criteria .................................................................49 

4.3.6 Suspect / Counterfeit Parts Inspection .................................... 49 

. 

5.0 PRESERVATION AND DELIVERY...... ...............................................................50 

5.1 GENERAL ...........................:...................................... ..:..:.......................50 

5:2 PRESERVATION AND PACKAGING .................................. ................ ...50 

5.3 OPERATING PROCEDURES .................................. ............................... 50 

5.4 PACKAGING .............................................................. .............................50 

5.5- MARKING...... ............................ .................... ........................................ 51 

5.6 HANDLING ....... ........................................................ ................... ............ 51 

5.7 SHIPPING(TRANSPORTATION ................................ .............................52 

6.0 APPENDICES .....................................................................................................52 

7.0 ATTACHMENTS ...................................................:.............................................52 

o+o^m^;va!nsns^.rc^moa.s^,usus y snoutsv+^.dr.wfmnnrr.z.ea Page 3 o 52. 

^z.os 

G5-725

Weblary 




CLIENT, AMEC E&E — Richland, WA 

A Suspect Fastener Headmark List 


APPENDICES 

ATTACHMENTS 


145579-V-DS-002.1 Sintered Metal Filters Equipment No. 36-NO2-019 & 36-NO2-020 

FIGURES 

Figure 1. SMF Interface Sketch ............... ...... 

TABLES 

....... — .......... ...................... 

Table I-1: Scope of Supply .................... -.0—.... .......... — ................ 0 ..................... 8 

Table2-1: Applicable Government Documents ............................................................... 9 

Table2-2- Applicable Non-Government Documents ........... ............ 0...........--..........-9 

/'°'`. rwssgnwvc^soeenwaa.cwc¢-^mûs^s-vsvaozmraemrawi^.zaa Page 4 of 52 

G5-726 

13

thaiicx,7• 



amec.P 

PROJECT: Final DBVS Des n 145579-VSP-002 REV.2 

PROJECT NO-_ 1455!8 

CLIENT: AMEC E&E - Richland WA 


°C degrees Celsius 

°F degrees Fahrenheit 

Pm micrometers 

AC alternating current 

acfm Actual Cubic Feet per Minute 

AISC American Institute for Steel Construction 

ANSI American National Standards Institute 

ASCE American Society of Civil Engineers 

ASME American Society of Mechanical Engineers 

ASNT American Society of Nondestructive Testing 


AWG American wire gauge 


BTU British thermal unit 


Ci Curies 

CO2 Carbon Dioxide 

Coc Certificate of Conformance 

cfm_ Cubic Feet per Minute 

CMTR Certified Mate ri 

al Test Repo rt 

CPE Customer-provided equipment 

CWi Certified Welding Inspector 

DCS Distributed Control System 

DBVS Demonstra ti 

on Bulk Vitrification System 

EMT electrical metallic tubing 

ft, cubic feet 

gpd gallons per day 

gpm gallons per minute 

HCl Hydrochloric Acid 

HEPA High Efficiency Pa rticulate Air 

hp horsepower 

Hz hertz 

ICVTM In-Container Vitrification 



P..IDO. *PIasp^.cW2-MKI nevavm rre M" Mm RW.2a Page .50f'52 

ama 

G5-727


RPP-24544 RENT td 

PROJECT: Final DBVS Design.. 145579-VSP-062 REV.2 

PROJECT NO., 145579 

CLIENT. AMECE&E— Richland, WA. 

in. Hg inches of mercury 

in. WG inches of water gauge 

lb pound 

lbm pound mass 

mA miiliamp 

mph miles per hour 

MSS Manufacture Standard Practice 

NCR nonconformance report 



NEMA National Equipment Manufacturers Association 



NPT National Pipe Thread 


OGTS Off Gas.Treatment System 

PLC Programmable Logic Con troller 

ppm pa rts per mi llion 

psi pounds per square inch 

psig pounds per square inch gage 

PVC Polyvinyl Chlo ride 

QA quality assurance 

RGS rigid galvanized steel 


SMF Sintered Metal Filter 

SOx Oxides of Sulphur 

TBD to be determined 

TEFC totally enclosed fan cooled 

TEMA Tank Equipment Manufacturers Association 


UL Underwriters Laboratories 

US United States 

V volt 

Vol volume 

wJt% weight percent 


rro®rgwinsn•^^ ewawoz.snrt^r^ss».usnaozi^^êuuemêmal Rev.zax Page 6 of 

s^mos 

G5-728 

Y


Mudiak"iy cameo 


PROJECT: Final DBVS Desi n 145679 -V-SP-002 REV. 2 

PROJECT NO,: 145579 

CLIENT: AMEC E&E — Richland WA 

1.0 . SCOPE OF WORK 

Purpose 


AMEC is pa rt of a team that has been selected by the CH2M HILL Hanford Group, 

Inc. (CH2M HILL) to design, fab ri cate, test, and deploy a Demons tration Bulk 

Vitrification System (DBVS) using a process referred to as In-Container Vit ri fication 

(ICVTm) to receive, dry, and immobilize waste from an underg round storage tank 

located in the 200 West Area of the Hanford Nuclear reserva tion. , A main 

subsystem of the DBVS is the Off-Gas Treatment System`(OGTS). The prima ry 

function of the OGTS is to filter radioactive pa rticulate and reduce NOx and SOx 

emissions produced from the ICVT 11 melt process. A major component of the 

OGTS is a back-pulsatile Sintered Metal Filter assembly that will pre-filter a 

majority of the melt-oft-gas. The process intent is to remove radioactive pa rticulate 

early in the system thereby limiting the amount of radioactive material as close to 

the melt process as possible. 

Throughout this specifica ti on, Contract Responder shall act as the Seller and 



other documentation shall be noted and referred to the Buyer for resolution before 

proceeding with design or fabrication of the item in question. 

Scope of Supply 

The Scope of Supply included in this speci fication consists of the design, analysis, 

fabrication, inspection, testing, documentation, packaging, and shipping of a HEPA. 

rated Sintered Metal Filter or series of filters. Each filter shall be a self contained 

unit that includes an automatic back-pulsing system capable of purging the filter 

elements without having to bypass the filter. The back-pulsing system shall be 

operated on a timed basis or when the filter 

differential pressure reaches a predetermined 

value. The filter shall consist of a multiple filter element a rrangement 

housed within the filter body. The Seller shall determine if mul tiple fitters arranged 

in se ries are required to meet the specified removal efficiency. The filter or fi lters 

shall be supplied loose for mounting and installation by the Buyer. Table 1-1 below 

summarizes the Sellers Scope of Supply. 

amûiveuaas.uasmz-s^,.n7s ysvcn:,ewnm uew nu.zax Page 7 of 52 

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G5-729


( P^llpnpW@-SMFl1^55]9V-9F-002i+`^^^Q^d#kLIMn)Rev.2IIx 

s Twos 


amec 

PROJECT: Final DBVS Desicin 145579-V-SP-002 REV. 2 



Equipment Te # Descri lion 

Table 1-1: Scope of Supplv 

36-NO2-019 Sintered Metal Filter No. 1 


36-NO2-020 Sintered Metal Filter No. 2; if (2) two filters in 

series are specified by the Seller. 

N/A All ` on-filter" piping or tubing and solenoid 

valves associated with the filter element backpulse 

system, included any compressed air 

reservoir if re uired . 

N/A Sack-pulse system con trol system, including 

electrical terminal box and electrical 

connections. 

N/A Connections to filter body required for 

differential pressure measurement for backpulse 

system. 

N/A Sample ports in filter each housing. P rovide (1) 

2 0 dia. Flanged and (1) 3/

TECHP41CAL SPECIFICATION 


amec 

PROJECT: Final DSVS Design 145579.V-SP-002 REV. 2 



2.0 APPLICABLE DOCUMENTS 


Documents applicable to the work scope are shown in Tables 2-1 and 2-2. The 

latest issue and addenda to the documents in effect at the time of procurement 

(unless otherwise specified) shall apply and form a part of the basis of design for 

this specifica ti 

on to the extent specified in the applicable sections of this document. 

in the event of a conflict between documents referenced herein and the 

requirements of this specification, the requirements of this specification shall take 

precedence. All conflicts shall be brought to the a ttention of the Buyer for 

resolution. 

2.1 GOVERNMENT DOCUMENTS 

Table 2-1: Applicable Gove rnment Documents 

Government Documents . `` Title 

ERDA 76-21 Nuclear Air Cleaning Handbook 

10 CFR 830 °Nuclear Safety Management,' Code of Federal 

Regulations, as amended. 

10 CFR 835 OccupationW Radiation Protection 

Occupational Safety and Health Standards — Code of 

29 CFR 1910_ _ Federal Regulations_ 

2.2 NON-GOVERNMENT DOCUMENTS 


Code/Standard = Title 

AIRS Deleted 

ARM 4 98 Deleted 

ASME AG-1-2000 Code on Nuclear Air and Gas Treatment 

ASME B16.5 Pipe Flanges and Flared Fittings 

ASME 1318.21 -1999 Squa re and Hex Bolts and Screws Inch Se ri 

es Including 

Hex Cap Screws and Lag Screws 

ASME B30.20 Below-The-Hook Lifting Devices 

ASME ^ °' w --^ Deleted 

Deleted 

vô.^vrveaw=rwaue^.swm:srani^snswsn.nuz(smn,.n^v.z.aw Page 9 o 52 

z.wn os 

G5-731


RPP-24544 REN' ld 

aimeG' 

PROJECT: Final DBVS Design 145579-V-1 P-002 REV. 2 


CLIENT: AMEC E&E =Richland, WA 


SINTERED METAL (FILTER 

Cade/Sfandaid 

Srt1e 

ASME Boiler and Pressure 

Vessel Code 

ASME Boiler and Pressure Vessel Code, American 

Society of Mechanical Engineers. 

Section VIII, "Rules for Construction of Pressure Vessels" 

Section IX, "Welding and Brazing Qualifications' 

ASME NQA-1-1994* Quality Assurance Requirements for Nuclear Facility 

(See note at end of table) Applications 

AS(+AE PCC-1-2000 Guidelines for Pressure Bounda ry Bolted Flange Joint 

Assembly 

ASNT—TC-1A Recommended Practice 

ASTM Al 08-99 Standard Speci fication for Steel Bars, Carbon, Cold 

Finish, Standard Quality 

ASTM A132-02 Standard specification for Forged or Rolled Alloy-Steel 

Pipe Flanges, Forged Fittings, and Valves and Pa rts for 

High-Temperature Service 

ASTM At 93-01 Standard specification for Alloy-Steel and Stainless Steel 

Bolting Materials for High-Temperature Se rvice 

ASTM A194-01 Standard specification for Carbon and Alloy Nuts for Bolts 

for High-Pressure and High-Temperature Se rvice 

ASTM A240-02 Standard specification for Heat-Resisting Chromium and 

Chromium Nickel Stainless Steel Plate, Sheet, and Strip 

for Pressure Vessels 

ASTM A276-02A Standard specification for Stainless and Heat-Resis ting 

Steel Bars and Shapes 

ASTM A307-02 Standard specification for Carbon Steel Bo lt s and Studs, 


ASTM A312-02 Standard specification for Seamless and Welded 

Austenitic Stainless Steel Pipes 

ASTM A354-01 Standard specification for Quenched and Tempered Alloy 

Steel Bolts, Studs and other Externa lly Threaded 

Fasteners 

A$;gPM 436 04 Deleted 

ASTM A403-02 Standard specification for Wrought Austenitic Stainless 

Steel Piping Fit tings 

ASTM A480-02 Standard specification for General Requirements for Flat- 

Rolled Stainless Heal-Resisting Steel Plate, Sheet, and 

St ri 

p 

ASTV14i '309-91a Deleted 

P^P6tIy.UNC 60MiU^2-9.IAl^S]9N+4P.W2 JSAMeGMeW Mi )Rm 2L 

a.nmas .. 

G5-732 

Page 10 of 52

I 


RPP-24544 REV 1 d 

a^mec 


PROJECT NO.: 146VS 

CLIENT: AMECE&E- Richland, WA 


Table 2-2: ADDlicable Non-Government Documents 

Code)Staiidard ;t Title 

AS 44 A &4R 02 Deleted 

ASTM A563-00 Standard speci fi 

cation for Carbon and Attoy Steel Nuts 

ARq:M ASR9 Q8 Deleted 

ASTM F436-02 Standard Specification for Hardened Steel Washers 

AWS D1:1-02 Structural Welding Code - Steel 

AWS D1.6-99 Structural Welding Code -Stainless Steel 


Corporation for Fluor Daniel Corporation Hanford, Inc., 

Richland, WA 

EE9 4 

,^ 442-,-,'004 Deleted 

1COC ' .49" Deleted 

I EEE G33? Deleted 

Ic Al. Deleted 

,^^- 999 624 ^° 4, 9O 

Deleted 

Ism 20&1-2909*- Deleted 

ISS^b8821994`- Deleted 

MSS SIP R7 Deleted 

NEM nn 

..,-.-.^ G4.°90^-4 Deleted - 

NEILIA hh643 Deleted 

HNF SD-GN-ER-501 Natural Phenomena Hazards, Hanford Site, Washington 

NFPA 70 National Electric Code, 2D02 Edition 

RPP-8530 Tank Farm Labeling Standard 

SAE J429 Mechanical and Mate rial Requirements for Externally 

Threaded Fasteners, Standard 

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

UBC 1987 Uniform Building Code 

UL 508A Standard for Industrial Control Panels 

The relevant requirements of N CIA-1 are included in Section 4.0. 

Pao,•m^!w^•du^.eeomoz : sanussrs ysr.aoz(^de ram r^ Zd a Page II of 52 

vu.0 

G5-733

o ^ : • ltklutt7itxn•. 


F.9niynf HVQSpeub«6 1fA2- 6MRt YvSI&V^`•P-0U21aMa

' 

Waalaygy 


P.We FNWMWPe16eMwu=-. SMF\USS"VS -WF i&n d WWI FNen Rov. 7Ae 

a•i^nas 





EQUIPMENT REQUIRED 

BY THIS SPECIFICATION 

ONSIDE BROKEN LINE) 

A,IR 

SOURCE 

i—MNP(^ 

SACK-PULSE SOLENOID —JJ E 

VALVES (AS REQ.) \ 

CONTROLLED FROM 

' PRESSURE SWITCH OR 

'TRANSMITTER 

(BY SELLER) 

PROCESS 

INLET 


PRESSURE CONTROL 

VALVE AND RELIEF 

VALVE (BY BUYER) 

COMPRESSED AIR 

RESERVIOR 

r^ —! (BY SELLER) 

I ^ i 

II ___ ^J 

I ! PROCESS 

I ,'^ 1 ÔU TLET 

J 

D5 

' FILTER 3YBASS 

(BY BUYER) 

FILTER (BY SELLER) 

DAMPER 

(BY BUYER- TYP) PARTICULATE 

DISCHARGE 

FLANGE 

(BY BUYER). 

PARTICULATE DISCHARGE 

VALVE (BY BUYER) 


Figure 1. SMF Interface Sketch 

The characteristics (e.g., functional, physical, performance, and environmental) 

With which the Sintered Metal Filter system must comply with in order to satisfy the 

requirements of this specification are described in Sections 3.2.1 through 3.2.7. 

3.2.1 Functional Characte ristics 

The SMF system shall be designed to filter radioactive off-gas, back-pulse the filter 

clean while on-line, be capable of discharging back-pulsed contents into a vacuum 

conveying system, and be transportable as a single self contained unit. The 

performance range and operating conditions for the SMF are described in this 

section and on the Technical Data Sheet, 145579-V-DS-002.1. 

G5-735 

Page 13 of 52

'.warfpnYrvmepewYmmrw1003-SMatassievspmz{sunena Mew Flgeri^'-1^ 

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PROJECT NC.: 145579 




Each SMF shall be shipped loose for skid mounting by the Buyer. The Seller may 

be asked to provide pricing for the skid mounting of the units and the supply of 

interconnecting ducting and valving at a later date. 


The Bulk Vitrification plant is expected to operate 24 hours per day, 7 days per 

week. Service work will be done during scheduled downtimes. High reliability is 

required for any moving parts. 

3.2.4 MauntMfflibility 

All SMF assembly, including but not limited to, the filter cartridges, filter housing, 

back-pulsing system, and fasteners shall be designed to have a minimum service 

life of 1 112 years without maintenance. All minimum service life requirements for 

the SMF equipment shall be submitted to the Buyer before fabrication. 


repair, spares, modular construction, test points, etc.), should include, but not be 

limited to, the following: 

a. Maintenance and Repair Cycles. Expected inspection of the SMF will be once 

per week by the Buyer- The Seller shall provide typical maintenance schedule. 

b. Spares and Spare Parts. The Seller shall identify recommended spares and 

spare parts. 

c. Service and Access. SMF shall be designed for ease of service (access 

openings/spacing, self-test capability, inspection windows, test fixtures, sealed 

bearings, etc.). The Seller shall identify requirements for service (remove and 

replace only, bench repair, special tools, remote handling/maintenance, etc.). 

G5-736 

Page 14 of 52

P terfixibr 



PROJECT: Final DBVS Design 145579-V-SP-002 REV, 2 




• 


This equipment is anticipated to be operated outdoors. Any equipment and related 

enclosures installed outside shall be designed to operate and be stored in the 

climatic and environmental conditions listed below, taken from HNF-SD-GN-ER- 

501 "Natural Phenomena H azards, Hanford Site, Washington', TFC-ENG-STD-06 

"Design Loads for Tank Farm Facilities", and UBC 1997. 

a. Ambient air temperature range is -25°F to 115°F. 

b. Relative humidity ranges from near to 100%, 

c. Maximum precipitation is 1.6 inches in a 24-hour period. 

d. Sand and dust concentrations are 1.10 x 10-5 lbm/tt3 with a typical size of 150 

pm, 

e. Solar radiation is expected to be a maximum 900 Langleys over a '12 hr period. 

f. Three - second gust wind velocity of 85 mph and impo rtance factor of 1.15 and 

exposure catego ry C (Table3 ofTFC-ENG-STD-06, Rev. B-1). 

UBC 1997 Section 1632, equation 32-2, seismic zone 2B, soil pro file Sc, and 

occupational catego ry 1. 


3.2.7 Safety 

The filters shall be sized for transpo rt using local roadways and freeways (i.e., less 

than 14 feet tall, 8 feet 6 inches wide, and .53 feet long; while mounted on the 

transpo rt trailer). 

Pa rts removed for transpo rt shall be match marked for assembly upon delive ry . 

The filters shall be designed to maintain the safety of operators, general public, 

and equipment. The equipment supplied by the Seller shall incorporate any design 

features to comply with the applicable subparts. of 29 CFR 1910, "Occupational 

Safety and Health Standards" and 10 ' CFR 835 "Occupational Radiation 

Protection" 

See Table 2-1 for reference safety codes f standards. 

PADeib^b1YC15^1se6[a6ms1 W1-YAf1faS5iAY.6PdU2 ^ûAKietl MN^ Flger)Rau.3.dx 

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G5-737 

i 

15 of 52

RPP-24544 RENT Id 

P tmuW b y cameo 


PROJECT: Final DSVS Desligin 145579-V-SP-002 REV. 2 





The Seller shall provide or provide access to all design calculations necessa ry for 

the SMF which includes, but is not limited to, filter sizing calculations, filter vessel 

sizing calculations, etc. Calcula tions shah be submi tted to the Buyer in accordance 

with the Bidders Drawing and Data Commitments Sheet a ttached to the Technical 

Data Sheet, 145579-V-DS-002.1. The Seller shall provide all design drawings 

necessa ry for the SMF which include, but are not limited to, drawing outlines, 

interface drawings, electrical wiring diagrams, control wiring diagrams, dimensional 

drawings, process and instrumentation drawings, rigging sketches, and as-built 

drawings. Drawings shall be submi tted to the Buyer in accordance with the 

Bidders Drawing and Data Commitments Sheet a ttached to the Technical Data 

Sheet, 145579-V-DS-002.1. 

Alternative equipment designs are permissible if proven to be effective in meeting 

the reliability specified in Sec ti 

on 3.2.3. 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. 


Major components of the SM Filters shall be fabricated from materials as specified 

on the Technical Data Sheet 145579-V-DS-002.1. 

3.3.1.1 Sintered Metal Filter 

3.3.1.1.1 Back Pulse Filter 

The Sintered Metal Filter a rrangement shalt be designed to the particle removal 

efficiency specified in the Technical Data Sheet, 145579-V-DS-002.1. Filters will 

be subjected to water vapor, NOx, SOx, HCI, Cs137, pa rticulate, and other 

gaseous constituents in air stream and be required to remove pa rticulates before 

the remaining components of the OOTS. Pulsed jet cleaning shall be used for insitu 

removal of accumulated particulate from the filter elements. if fa lt 

er elements 

should become contaminated or laden wi th particles, a short pulse of air shall be 

blown back through the Seller's predetermined number of elements to discharge 

P.M1DnipnVNC^ês'fim6onaWOZ-SMFlf455i3VSPC p2{Sln4rtdMda^ FAo-1Rev.S,YOo Page 

b.NM^S 

G5-738


Sioduitfty r 

TECH141CAL SPECIFICATION 

PROJECT: Final DBVS Design . 14567944 REV. 2 


CLIENT: AMECE&E— Richland, WA 


the contaminates and allow them to drop into an accumulation area inte rn al to the 

filter housing: When required, the particulate discharge valve will be opened 

directing the back-pulsed particulates into a Buyer supplied vacuum conveying 

system. The filter housing shall be designed to the intent of ASMEB&PV Code 

Section Vlll, constructed of stainless steel. ASME code stamping is not seen as 

required. The filter elements are to be mounted to a removable top on the fitter 

unit for maintenance purposes. The Seller shall provide a pneumatic pulsejet 

control system, including electrical termina ti 

on box and electrical connections that 

provides cy cled automatic filter element cleaning without causing process 

interruption. The filter housing shall have two (2) sets of NPT couplings; one on 

the filter inlet and one on the filter outlet for a differential pressure transmi tter. Each 

Filter shalt have sample ports in the filter housing. The Seller shalt provide (1) one 

- 2" dia. Flanged and (1) one - W NPT sample ports in the lower po rtion of the filter 

casing to collect samples of rejected material. 

The filters will need to be decontaminated during their operating life. The Seller is 

to consider this in his design and allow for nozzles and/or internal distribution 

piping to int roduce decontamination liquids. Liquids shall be removed from the 

filter through low point nozzles provided by the Seller. 

3.3.1.1.2 Type of Construction 

The SMF shall be a ve rtical flow filter with air towards the bo tt 

om and an outlet 

towards the top with a pa rticulate discharge in the bottom center. If necessary, 

multiple filters in series shall be used to meet the overall HEPA filtration 

efficiencies listed in the Technical Data Sheet, 145579-V-DS-002.1, each with an 

independent particulate discharge. 

3.3. 1.1.3 Pressure bating Construction 

The filter bodies shall be designed and constructed for full vacuum and positive 

100 psig. The operating conditions are specified on the Technical Data Sheet 

3.3.1.1,4 Materials of Construction 

Ali pro ce ss contacting surfaces shall be constructed of 300 series stainless steel 

and comply with ASTM A240, 

vweey^wuc^sy.,•wsM>wez swnHSnsusROUWwoR FWA rs...zaa Page 17 of 52. 

S.Mw05 

G5-739

i 

rrintt^Cxg 



PROJECT: Final DBVS Design 145579-V-1 002 REV. 2 



3.3.1.1.5 Electric Motor 

None are anticipated in this design. 

3.3.1.1.6 Elect rical Wiring 

SINTERED METALFVLTER 

All electrical wiring is to terminate in a NEMA 4 terminal box mounted on the SMF 

frame. 

3.3.1.1,7 Particulate Discharge Valve 

3.3.1.2 Piping 

3.31.2.1 General 

The particulate discharge valve will be provided by the Buyer to match the flange 

on the Fitter. 

Any piping for the SMF shall be fabricated, inspected, examined, and tested in 

accordance with ASME B31.3, normal se rvice. Piping systems include all piping 

components and supports. 

The only piping anticipated on the SMF will be the small bore compressed air 

piping for the back-pulse system. 

3.3.1.3 Electrical 

3.3.1.3.:1. Conduit 

Design and installation of electrical equipment shall be in accordan ce with the 

NFPA 70 (National Electric Code (NEC)) listed in table 2-2. 

When required, conduit shall be electrical, metallic tubing (EMT). EMT shall be UL 

approved, standard weight, electro-galvanized steel, 1/2 inch minimum size for 

control wiring and 314 inch minimum size for power wiring. 

a. Liquid fight flexible conduit shall be installed whe re flexible conduit is required 

such as when connecting to vibrating equipment; Liquid-tight flexible conduit 

shall be grounding type with a Polyvinyl Chloride (PVC) jacket. 

awntauwcisy aa..emhooz-sntAla¢smusoeoz@nmearxmotr,^w)aev.zam 

Nmn 

G5-740


RPP-24544 REV Yd 

amen 

PROJECT. Final DBVS Design 145579-VSP-002 I REV. 2 

PROJECT NC.: 145579 

CLIENT: AMEC ERE — Richland, WA 


b. Conduit fittings shall be su itable for use with the type of conduit selected, and 

in accordan ce with NEC 2002. 

3.3.1.32 Wire and Cable 

a. Conductors shall be stranded copper for all sizes of wire and cable unless 

specifica lly designated otherwise on the drawings. 

b. 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 dra wings. 

c. Minimum size of power conductors, 600V and.below, shall be No. 12 AWG. 

Conductors shall be derated as required by NFPA 70 for proximity to heated 

equipment and summer outdoor ambient conditions speci fied in Section 4.2.3. 

d, Conductors for control circuits shall be No. 14 AWG minimum, except that 

remote control circuits, signaling circuits, instrumentation, and power limited 


Code (NEC). 

e. Power wiring for single phase systems shall have color coded insulation as 

follows: 120/240V Hot = Black or Brown; Neutral = White or Gray; G round = 

Green or bare. 

f. Power wiring for 3-phase systems shall have color coded insulation as follows: 

480/277 V (A;B,C) Red, Yellow, Blue; Ground = Green or bare; Neutral = White 

or Gray. 2081120V (A,B,C) Black, Purple, Brown; Ground = Green or bare; 


g. Instrumentation cable shall be 600V, multiconductor for discrete signals, flame 

retardant, jacketed cable suitable for installation in wet or d ry locations. 

Conductors shall be #18 AWG stranded, copper, in twisted pairs/t riads with 

ethylene propylene insulation. Each pair/t riad shall be shielded with a drain 

Wire and meta llic tape. Multi-pair 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 t riad). Temperature rating shall be 90°C. Each 

pair/triad shall be numbered for simplified termina ti 

on. 

a.ô.,^sH+wasc sW„war-suAUSmvsraozrs;^w,awwemMrs...zex Page 19 of 52 

u^ws 

G5-741

m 

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1 - er yov. arnel 


ECT: Final DBVS Desi n 145579-VSP-002 REV. 2 

ECT NO.: 

145579 

ET: 



h. Control and power mul ti-conductor cable shall be 600V, flame resistant, 

radiation resistant, jacketed cable suitable for wet or d ry locations. Conductors 

shall be stranded copper with ethylene propylene insulation with a temperature 

rating of 90°C. 

3.3. 1.3.3 Wire/Cable Markers 

Conductors shall be identified with white heat shrink tubing with indelible black 

typed on letters. Hand le tt 

ered labels shall not be used. 

3.3.1.3.4 Junction Boxes 


3.3.1.3.5 Electrical Components 

Where a category exists, all electrical components, such as contactors, motor 

starters, and power controllers, etc. shall be UL-listed. 

3.3.1.4 .Instrumentation and Installation 

In general, all instrument transmi tters shall provide an isolated 4-20mA signal to 

the DCS, all pneumatic control valves shall accept a 4-20mA control signal from 

the DCS and provide position indication to the DCS. Instruments, tubing, piping, 

and wiring shall be installed in accordance with the instrument manufacturers' 

recommendations and the best practice for the indust ry. Purchasing and 

installation of the DCS input/output 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 ground in front of the filter skid. The 

Buyer shall provide guidance with positioning based on best available knowledge 

of the configuration. 


package and shall include the instrument accuracy and dri ft 

. When purchasing 

instrumentation, the instrumenta ti 

on shall be in accordance with the data sheets 

provided by the Buyer, or the Buyer will provide the necessa ry instrumentation. 

The Seller shall provide the data sheets to the component Manufacturer. 

(35-742 

Page 20 of 52







Recommended field re-calibration procedures shall also be provided in the final 

data package along with a list of special tools required for recalibration. 

3.3.1,.5 Mechanical Assembly Requirements 

The SMF will be mounted to structural supports and installed by the Buyer 

observing the equipment Manufacturer's recommended assembly instructions. 

The Seller shall denote moun ti 

ng configuration, details, special instructions and 

equipment loads on the general arrangement drawings. 

3.3.1.5 Electrical Assembly Requirements 

3.3.1.6.1 General 

Insta ll conduit, duct, wiring, cables, connectors, instrumentation, and devices in 

accordance with manufacturer's w ritt 

en instructions, applicable requirements of the 

NEC and National Electrical Contractor Association's "Standard of Installation," 

and with recognized industry practices. All electrical panels shall meet UL 508A 

listings, where required. 

3.3.1.6.2 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 rou ti 

ng locations shall be 

submitted to the Buyer for review and approval before proceeding with the work. 

3.3.1,63 Grounding 

a- All power circuits shall include a ground wire that se rves as the equipment 

grounding conductor, independent from the neutral wire. All powered devices 

shall be connected to the ground circu it wire. In addi ti 

on, the skid frame, 

enclosures, raceways, covers, enclosure doors shall be a ttached to the ground. 

This may be accomplished by means of a screw, lock washer, and . ring 

connector attachment at a spot where all paint and su rface corrosion has been 

r+amemn+"aso.emueensmz- smr^ûsiausvmz tslw..ee um+raeq aev, zeec. Page 21 of 52 

arvmss 

G5-743


3 : ledry*k,Y came 


PROJECT: Final DBVS Design 145579-VSP-002 REV. 2 




cleaned from the frame. The frame shall not be used as a current ca rrying 

conductor between devices. 

b. Ground wires shall be green-insulated stranded copper wire. 

c. Ground conductors shall be unspliced and continuous between termina tion 

points. Ground distribution sha ll be through terminal blocks or a ground bus. 

ìre nuts or bu tt 

splices are not acceptable. 

d. The resistance between the main ground connection to the skid and any point 

in the ground circuit shall be less than 9 ohm as measured with a calibrated 

ohm meter. 

e. The instrument ground circuit shall be separate and isolated from the power 

ground circuit, to the extent allowed by NEC. The requirements for the 

instrument ground circuit installation are the same as the power ground 

requirements given above. 

3.31.6.4 Conduit Fill 

The sum of the cross sectional areas of all contained conductors shall not exceed 

the NEC limits. The tables in Chapter S of the NEC shall be used for calculating 

the raceway fill. 

3.3,1.6.5 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 cable that could damage the 

conductor insulation or strain the conductor termina ti 

ons. 

3.3.1.e'.6 Conduit Support 

Conduit shall be supported by attachment to the frame. The Seiler shall p rovide 

b rigid brackets or additional frame members for attaching conduit when frame 

members are not in a convenient loca tion. Conduit installation shall comply with 

NEC 2002. 

P.WesIpnY1VCL9p^dfc6ad'003-SbFlt^55H-VSRW21IemdMJtl HhegRw.2Eac Page 

3.FmdS 

G5-744

RdIml(gy a>fraec 


P.'^[elg[\ITWISpa[Yxatim[Ipp(.9Ne71t55i9-VSP-062 (SIMUM IMbIRII q}RGY. P,E[[ 

say[ ns 


AN 

PROJECT: Final DBVS Design 145579-V-SP 002 REV. 2 


CUEhff: AMEC E8[E-Richland, WA 

3.3.1.6.7 Segregation of Control and Power Wiring 

3.3.1.45.8 Splicing 


Power circuit wi ring and control circuit signal wi ri 

ng sha ll be run in separate 

conduits. Signal wiring that transmits ac signals shall be run in separate conduits 

from signal wiring that transmits do signals. 

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. 

3.3.1.6.8 Electrical Enclosure Wiring 

All enclosure wi ring shall be routed, harnessed, approp riately laced or in plastic 

wiring ducts. 


The Seller shall select materials based upon acceptable performance of materials 

subjected to the chemical and radiation exposures described in the Technical Data 

Sheet, 145579-V-DS-002.1. All parts and materials shall be new. A[t parts shall 

be made of corrosion-resistant materials that are suitable for this environment. 

Material selection shall be iden tified in the Seller documents to the Buyer. 

Material type and grade shall be clearly iden tified on the bill of mate rials. Certified 

Mate ri 

al Test Reports (CMTRs) are required for all materials coming in contact with. 

the air stream. The Seller shall identify any materials that do not have CMTRs for 

review, approval, and final records. 

Filter and piping materials in contact with the air stream shall resist the condi ti 

ons 

discussed specified in the Technical Data Sheet, 145579-V-DS-002.1. No 

aluminum or °yellow" metals are to be used. No beryllium shall be present. 

Exposed polymer materials shall be constructed of an ti-sta tic materials. 

It is not anticipated that lead or polychlo rinated biphenyls (PCBs) will be contained 

in the equipment. The Seller shall advise if these mate rials are part of the 

construction of the equipment. 

G5-745 

Page 23 of 52


u.^lNUkm, aimed 


PROJECT: Final DSVS Design 145579 V-SP-002 I REV. 2 


CLIENT: AMEO E&E — Richland, WA 

3.31 „8 Metal Products 

3.3.1.&1 Stainless-Steel Products 


All stainless steel used in fab ri 

cation shall be 300 series, Type 304, 304L, 316, or 

316L and shall meet the following mate rial requirements of this section. All grades 

of stainless steel may be substituted for one another depending upon availability 

and providing the substitution still complies with the following speci fications and 

has prior approval of the Buyer, 

3:3.1.8.2 Stainless-Steel Sheetand Plate 

Stainless-steel sheet shall meet the chemical and physical requirements of ASTM 

A240 and ASTM A480. 

Stainless-steel plate shall meet the chemical and physical requirements of ASTM 

A240. The plate shall be provided with a cleaned finish. 

3.3A8.3 Stainless-Steel Forgings.and Wrought Piping Fittings 

All stainless-steel forged couplings, forged pieces, and flanges used in the 

fabrication shall be Series. 300 stainless steel as defined in Section 3.3.1.1.4. All 

forgings, including flanges, shall be listed components as stated in ASME B31.3 

and shall meet the requirements of ASTM A182. All stainless-steel wrought piping 

fittings used in the fabrication shall be Series 300 stainless steel as determined in 

Section 3.3.1.1.4. All wrought piping fittings shall be listed components as stated 

in ASME B31.3 and shall meet the requirements of ASTM A403 Grade WP. 

3.3.1.8.4 Stainless-Steel Bars and Shapes 

Parts made from stainless-steel bars and shapes shall be Series 300 stainless 

steel as determined in Section 3.3.1.1.4. Stainless-steel bars and shapes shall 

meet the chemical and physical requirements of ASTM A276., 

3.3.1.8.6 Stainless-Steel Pipe 

All stainless-steel pipe shall be seamless schedule 40 and shall meetthe chemical 

and physical characteris ti 

cs given in ASTM A312. Piping shall be a listed 

P9pe,lP„W NC1^M^bn^.W 02- RAFlt ^J]9-VSPLU2 Îned Meltl Fplu) Ra.2dee 

smn as 

G5-746 

Page 24



amec 

PROJECT: Final DBVS Design 1465794-SP-002 REV. 2 




component as stated in ASME B31.3. If threaded joints are used, Seller is to apply 

anti-galling compound du ring shop assemb ly (Loctite® PST 580). 

3.3.1.0 Weld Studs 

Weld studs, if necessa ry, shall be metallurgically compatible with the . mate rial that 

they are welded to. Weld studs shall be made from stock mate ri al that meets the 

requirements of ASTM A108 for mild carbon steel. 

3.3.1,8.7 Fasteners 


such joints should be tack welded or have some equivalent means of assurance of 

remaining intact. Double-nutting is not an acceptable method of securing fasteners. 

Loctite® threadlock may be used where applicable. 

Stainless-steel bolts, cap screws, and washers shall be per ASTM A193 Grade B8, 

and nuts shall be heavy hex nuts per ASTM A194 Grade 8; nuts shah be supplied 

with mill certificates. Bolts and cap screws shall be grade marked. Carbon-steel 

bolts shall be per ASTM A307 or better, nuts per ASTM A563, Grade C Heavy 

Hex, and washers per ASTM F436. 

All graded fasteners shall conform to ASME B18.2.1, Society of Automotive 

Engineers (SAE) J429, and ASTM A354, 

The Seller shall select fasteners where they are not specifically called out in this 

specification using the following guidance: 

a. Anti-galling compound (e.g., Loctite® 8013 or 8009) shall be applied where 


b. Stainless-steel bolts, nuts, and washers shall be used when the mating pa rts 

are stainless steel. 

c. Carbon-steel bolts, nuts, and washers shall be used where ma ting parts are not 

stainless steel 

. A.Nea9^\MYCISy.dGoSonswn-as,fus^s-vsraozl .rcq Me FlnnFrjev.xax Page 

G5-747

s - - e'd11XA)g% - 





CLIENT:' AMEC E&E — Richland, WA 

aamec 


d. The Seller shall ensure that suspectleounterfeit fasteners and components are 

not used for the construction of the filter assembly and its components. 

Suspect fasteners can be identified by the following inspection methods: 


1. Head markings are marred, missing, or appear to have been altered, 

ii. Threads show evidence of dressing or wear (threads should be of uniform 

color and finish), 

M. Head markings are inconsistent with a heat lot, and 

iv. Head markings matching one of those identified on the United States 

Customs Service, "Suspect Headmark List" (see Appendix A). 

Any pipe or ducting gaskets for the Off-Gas portion will be supplied by the Buyer. 

The Seller shall provide all seals and gaskets for the back-pulse system. 

3.3.1.10 Stainless-Steel Handling Requirements 

The Seller shall submit 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 materials including weld filler rod from receipt at the 

shop through processing. 

3.3.t.1o.1 Exposure of Stainless Steel to Chloride Materials 

Stainless steel shall not be in contact with materials containing more than 250 ppm 

chlorine. Low chloride markers sha ll be used. Chlorinated so lvents shall not be 

used to clean stainless steel 

3.3.1.10.2 Contact with Carbon Steel 

Contact between carbon steel and stainless steel shall be avoided during 

fabrication. Tempora ry carbon steel clamps, supports, braces, and fixtures shall 

not come into direct contact w it 

h stainless-steel surfaces. Galvanized steel damps 

or fixtures may not be used. Wire brushes shall be stainless steel. Grinding 

wheels and wire brushes shall be new or used previously on stainless steel only. 

nio.awwvcvq,ear^,ae^coaz. svtiiassrsv-sMOêsmeeamaawÂ.u« Page 26 of 52 

G5-748


P , ftdrv€g'c amet 


PRO.IECT: Final DBVS Design 145579-VSP-002 REV. 2 


CLIENT: AMEC E&E — Richland, INA 

3.3.1.11 Welding 


Welding of all pressure piping shall be pe rformed in accordance with ASME 831.3, 

normal service as a minimum. Certified welders shall pe rform welding of all 

structural steel in accordance with American Welding Society (AWS) D1.1 or AWS 

D1.6 (depending on mate rial). Welding Procedures, Procedure Qualification 

Records, and Welder Procedure Qualification Records shall be submitted for 

review and approval to the Buyer before welding being performed in accordance 

With Technical Data Sheet,145579-V-DS-002.1, Submittals List. 

3.8.1.11.1 Allowable. WeldingMethods 


rectangular tubing, plate, and sheet shall be performed in accordance With AWS 

D1.6 nontubular, statically-loaded conditions. Welding of :stainless steel piping 

shall be performed in accordance with ASME 831.3. Automatic pipe welding 

equipment and techniques may be used. Fab ri 

cation of tanks shall be in 

accordance with ASME Boiler and Pressure Vessel Code, Section Vill. 


rectangular tubing, plate, and sheet shall be performed in accordance with AWS 

D1.1 nontubular, statically- loaded conditions. Welding of carbon steel portions of 

piping systems shall be as required in ASME 831.3. 

3.3.1.112 Welding Procedure Requirements 

All welding shall be performed in accordance with the Seller's approved Welding 

Procedure specification. Each Welding P rocedure specification shall be qualified 

with a Procedure Qualification Record as required in ASME Section IX, AWS D1.1, 

and AWS D1.6 as applicable. 

3.3.1.11.3 Welder Quali fication 

Welder Pe rformance Qualification Records shall be submitted for all personnel 

pe rforming welding, including tacking. Welders sha ll be qualified in accordance 

with ASME Section IX, AWS D1.1, and AWS D1.6, as applicable. 

P-m **WMSP neeao^.,ôoz-SM14u &v P.mz W^dM. Fa R^ ..xaa Page 27 of 52 

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3.11A IA Weld Joints and Preparation 

Weld joints are as permi tted by the referenced standards. 

3.3.1.11.5 Weld Repair 



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. 

3.3. 1. 1 1.6 Inspection 


certified dimensional drawing and weldmap shall be produced from this inspection. 

Prior to fabrication, a weld map shall be produced and delivered to the Buyer for 

review and approval. Welds shall be inspected per ASME B31.3, normal se rvice at 

a minimum for pressure piping and per AWS D1.1 or D1.6 (depending on material) 

for structural steel. An AWS Certified Weld Inspector (CWI) shall perform visual 

inspections and inspectors certified to ASNT-TC-1A shall pe rform NDEs. Visual 

and NDE weld inspection procedures shall be submi tt 

ed along with the personnel 

certifications to the Buyer for review and approval, before performance of the 

inspections and examinations. Welded connections on the lifting components and 

on components that form pa rt of the radioactive pressure bounda ry shell shall be 

100% visual and 100% Dye-Penetrant Test or Magne ti 

c Particle Test inspected. 

3.3.2 Industry and Government Standards 

The SMF shall comply with all applicable indust ry and government standards 

called out herein. 

3.3.2.1 Design Loads 

The SMF equipment shall conform to allowable loading factors as defined by the 

American Institute for Steel Construction (RISC) for the loads ident ified below. The 

Seller shall submit details of structural [mounting brackets and a ttachments to the 

equipment for loading analysis by the Buyer. 

+rvasy,arwse.woz-sns 1u 7s vsocoziw^^ rmnin^..zce^ .. Page 28 of 52 

G5-750

t?CllnollN.;r 

TECHNICAL SPECIPtCATION 


amec 

PROJECT: Final DSVS Design 145579-V-SP-002 7 REV. 2 

PROJECT NO.- 145579 

CLIENT: AMEC E8,E — Richland, WA 

3.3.2.2 Dead Loads 


Dead loads include the weight of all permanent mate ri als and equipment, including 

the SMF equipment weight and the weights of fluids and materials being handled. 

The unit weights of material and construction assemblies shah be those given in 

ASCE 7. Where unit weights are neither established in that standard nor 

determined by test or analysis, the weights shall be determined from data in 

manufacturer drawings or catalogs. 

3.3.2.3 Live Loads 

Live loads are those loads produced by the use of the SM Filter 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 

and maintenance workers and equipment. 

3.3.2.4 Snow Loads 

Live loads shall be not less than the minimum uniform load or concentrated 

load stipulated in ASCE 7. 

The minimum roof design live load shall be 20 Iblft2 (includes ashfall). 

The weight of service equipment that may be removed with change of 

occupancy of a given area shall be considered as live load. 

Snow loads for the SM Filter shall be in conformance with ASCE 7. A g ro und 

snow load, Pg of 15 Ibf& shall be used for calculating roof snow load. 

Unbalanced snow loads resul ti 

ng from drifting or sliding shall be considered. Snow 

loads, full or unbalanced, shall be substituted for roof live loads where such loading 

results in larger members or connections. 

3.3.2.5 Wind Loads 

The SMF Filter shall be designed to resist pressures from wind from any direction. 

Partial wind loading shall be considered if fl produces a more severe effect. Wind 

load design shall comply with ASCE 7, using the 85 mph "three-second gust wind 

velocity" with an importance factor of 1.15 exposure category C. 

'. ne+sp.oue.swnmz-sMnuanusn.00-e t^ MMMFk ft zaoc Page 29 of 52 

G5-751


x ' IlYllllt^tk^4' amec0 


PROJECT: Final DSVS Design 145579-V-SP-002 REY. 2 



3.3.2.6 Hoisting and Rigging Loads 

SINTERED METAL IF}LTER 

The lifting apparatus (eyebolts, hoist rings, and ri fting bails) shall be designed in 

accordance with the ASME B30.20. Equipment designed and fabricated by Se il 

er 

shall have a factor of safety of 3 based on yield strength. Equipment purchased by 

Seller shall have a factor of safety of 3 based on yield strength. Documents shall 

be provided to the Buyer demonstrating incorporation of these safety 'factors. The 

Se ller shall identify the total weight, the center of gravity, and the lift points and 

rigging methods necessary for lifting each SMF component. Lift points shall be 

identi fi 

ed with yellow paint. Any special tooling, spreader bars or other 

recommended fab ri cated devices for lifting shall be provided by the Seller. 


1. Electromagnetic. The SM Filters shall comply with the requirements in HNF- 

2962 on electromagnetic radiation. 

2. Nuclear. The SMF will be exposed to nuclear radiation from the process. 

This exposure must not affect the operation of the equipment. 


Before assembly, and before prepa ri 

ng 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: 

a. Metallic or other dusts (shop dust), chips, turnings, and weld splatter; 

b. Abrasive pa rticles; 

c. Rust and other loose corrosion particles; 

d. Magnetic/liquid penetrant residues, dye check, etc.; 

e. Foreign material, such as paper, tape, plastic, sand, and wood; 

f. Cutting oils; 

g. Excess lubrica tion, grease, and oil; and 

h. Marking dyes. 

woorvcvsy.dnec=ouooz . amussesva+.00z^s.+.RUmm^rxunrsn.zaa Page 30 of 52 

YJUm^ 

G5-752



amec 

PROJECT: Final DBVS Desi n 14-5579 -V-SP-002 REV. 2 




The fabrication traveler shall desc ribe the cleaning and packaging steps taken. 

Solvents and cleaning solutions used on stainless steel shall be chloride- free. 



The SMF equipment ports and pipe openings shall be temporarily capped following 

cleaning and d rying for shipment. Packaging requirements following cleaning are 

documented in Section 6.4. 

3.3 .6 Corrosion of Parts 

SMF design shall include requirements for corrosion protection, especially 

restrictions on dissimilar metal couples. 

3.3.6Protective Coatings 

No protective coatings are required, as all exposed parts are stainless steel. 

3.3.7Interchangeability 

The SMF units shalt ensure interchangeability of components, to minimize 

consumable parts storage. 


The SMF shall have a tempora ry Manufacturer's nameplate using the Seller's 

standard practice for delive ry and storage of the equipment. The nameplate shall 

include the equipment number (provided by the Buyer), assembly weight (dry and 

wet), purchase order number, lifting bail working load limits, Manufacturer data for 

swivel hoist rings (as applicable), and this specification number, 1455'79-V-SP-002, 

latest revision. Clearly mark and identify any components required for removal 

before equipment installation (e.g., shipping blocks). 


Seller shall provide a nameplate which conforms to the relevant sections of the 

Hanford speci fication, RPP-8530 Tank Farm Labeling Standard. 

aw..;pnvac^yp..auunmrooz - smm asasVSn-ooz fsmnâ exm Flx„> nn, zs« 

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G5-753

Kdmmff 



PROJECT. Final DSVS Design 145579-V-SP-002 REV. 2 


CLIENT: AMEC UE— Richland, WA 



There are no special human engineering requirements for this equipment. 


Equipment supplied by the Seller shall be subject to Factory Acceptance Testing 

(FAT). The Seller will be expected to provide a shop simulation of the inlet 

conditions of their equipment under normal and transient opera ting condi ti 

ons to 

demonstrate the operational ef ficiency of the equipment. The Seller shall provide a 

FAT plan for operational testing and leak testing of their equipment in their 

proposal 

3.3.12 Document Submittal 

Each document submi ttal shall be identified with this specification number, item 

number, purchase order number, and Seller's identi fication number. Submi ttals 

' shall be transmitted to the Buyer in accordance with the directions found in the 

Request for Quote. 


reproduction equipment after micro filming. 

Along with the bid submittal, the items shown on the Technical Data Sheet 

148579-V-DS-002.1, Data and Document Requirements Sheet, shall be included. 

The drawings shall show full compliance with this specification (and the associated 

drawings/documents) or note any exceptions. The Seller sha ll allow 10 working 

days for the Buyer to review and state the disposition of each submittal. 



Submittals are divided into two types_ (1) Those requiring "approval before 

proceeding" (i.e., weld procedures or pre-purchase evalua ti 

on data); and (2) Those 

requiring "approval before shipment" (i.e., vendor information data). 

Submi tt 

als requiring approval before . shipment will be reviewed to verify 


Pmwcauuc^sp..mamoaroz-s aasnnwswoozcsi.. aewaeao>rsr.zaa - - Page 32 of 52 

sa^.ws 

G5-754


a d111R)ItSS,R` )^ ^ 


a/ 1 / ^V 

1PROJlECT. Final DBVS Design 145579-V-SPA02 REV. 2 

PROJiECT NO.: 145579 





A submittal requiring app roval that is not approved by the Buyer, will be 


1. Not Approved, Revise and Resubmit" The submittal is considered technically 

deficient, or incomplete, and is therefore unacceptable. Re-submi ttal is 

required; hence fabrication, procurement, or performance of procedures shall 

not proceed. 

2. "Approved with Exception" Fabrication, procurement, and pe rformance of 

procedures may proceed, and re-submittal is required to verify incorporation of 

the exception. Final acceptance of the item is contingent upon the Buyer's 

receipt and approval of the corrected submi ttal. 

Submittals requiring approval' before shipment that are determined to be 


explanation of the deficiencies will be included for co rrective action by the Seller. 

The Bidders Drawing and Data Commitments Sheet, provides a list of the required 

submittals, the number of copies, schedule, and app roval information for each 

submi ttal 

The Seller shall provide fab rication traveler(s) for the fabrication and testing of the 

above described SMF 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_ 

A proposed schedule of fabrication, inspec tion, and testing of all SMF equipment 

shall be submi tt 

ed for review with the bid and approval with the submittal of the 

fabrication traveler(s). 

The Buyer will insert witness/hold points in the fabrication `traveler du ri ng their 

review and approval of the fabrication traveler. Witness points can be waived by 

'\ wowvcx^mewrc-sus».ssray.svaoz wa.w,eM^twenw^+.xao< Page 

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G5-755 

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MWIM5Ay 


PROJECT. Final DBVS Design 145579-VSP-002 REV. 2 



CLIENT: AMEC ERE - Richland, WA 


the Buyer but must be documented in writing. Hold points require the Buyer 

personnel to be present during the fabrication, inspection, or test step. 


The Seller's equipment and systems shall be designed so that it is operable and 

maintainable by the Buyer's operations and maintenance personnel. If specialized 

technical education or training is required by the Buyer's personnel the Seller shall 

advise in their proposal. 

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G5-756

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CLIENT: AMECERE— Richland, WA 


4.1 GENERAL 

4.1.1 Organization 

Not applicable. 


4.1.3 Design 


The SubcontractorfSupplier shall have a documented, implemented and 

maintained Quality Assurance Program that is based on a na tional standard and 

identifies the activities and items to which it applies. Instructions and procedures 

must include or reference appropriate quantitative or qualitative acceptance crite ria 

for determining that prescribed activi ti 

es have been satisfactorily accomplished. 

The Quality Assurance Program must address each of the areas discussed within 

this QA Requirements Flow-down. The Subcontractor/Supplier must subm it the 

Quality Assurance Program to the Buyer for review prior to award of contract. 

The Subcontractor/Supplier shall assess its Quality Assurance Program regularly 

to assure its effective implementation. 


necessa ry, of personnel pe rforming activities affecting quality to assure that 

suitable proficiency is achieved and maintained. Personnel who conduct 


certification of the quali fication must be submitted to the Buyer upon request. 

The Subcontractor/Supplier must define, control, and ve ri 

fy designs developed for 

this con tract. Design inputs must be speci fied on a timely basis and correctly 

translated into design documents. Design inte rfaces 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 ini tial designs. 

G5-757 

Page 35 of

RPP-24544 REV ld- 

icdux' gy dmec 





4.1.4 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 

Subcontractor `s/Supplier's organization, and changes must be reviewed and 

approved by 'the same individuals who reviewed and app roved the o ri ginal 

procurement documents. 

The Subcontractor/Supplier 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 Subcontractor/Supplier shall provide a legible and.reproducibie Ce rtificate of 

Conformance. The Certificate of Conformance shall be signed by the 

Subcontractor's/Suppliers authorized representative responsible for quality 

assurance. 

The Certificate of Conformance shall contain, as a minimum, the following 

information: 

• Identification of the Buyer's contract or purchase order number under which the 

materials, equipment, component, or service is being purchased; 

Provide traceabil it 

y by means of positive identifica tion from the material, 

equipment, component, or se rvice to the Ce rtificate of Conformance; 

• 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 mate rials, equipment, 

component, or service; 

• Identify any procurement requirements that have not been met, together with 

an explanation and the means for resolving the nonconformance. 

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The Subcontractors/Supplier's ce rtification system, including the procedures to be 

followed in filling out a ce rtificate and the administrative procedures for review and 

approval of the ce rtificates, shall be described in the Subcontractor's/Supplier's QA 

Program. 

The ce rtification system shall provide a means . to verify the validity of 

Subcontractor/Supplier certificates and the effec ti 

veness of the certification 

system, such as during the pe rformance of audits of the Subcontractor/Supp lier or 

independent inspection or test of the items. The Buyer shall conduct this 

verification at intervals commensurate with the Subcontractor's/Supplier's past 

quality pe rformance. 

The Subcontractor/Supplier is required to flow-down all quality assurance 

requirements from this contract to any sub-tier suppliers/Subcontractor/Suppliers. 

Any access to the sub-tier suppliers'/Subcontractor/Suppliers' facilities for 

veri fication activities will be requested through the Subcontractor/Supplier prior to 

access, and verification activities may be pe rformed jointly. 

The Subcontractor/Supplier shall warrant that all items furnished under the contract 

are genuine (i.e., new, not refurbished, not counte rfeit) and match the quality, test 

repo rts, 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/counte rfeit shall not 

be used. 

All items are subject to inspection at the Subcontractor's/Suppl'ier's facility or lowertier 

subcontractor's facility. The Subcontractor/Supplier shalt notify the Buyer at 

least 7 working days in advance of the time when such items or activities will reach 

the Buyer's identified inspection hold points. Asa minimum, final inspection p ri or 

to packaging for shipment sha ll 

be considered such a hold point, unless specifically 

waived by the Buyer. 

The Subcontractor/Supplier shall obtain all materials to be delivered under the 

contract direct ly from the o riginal manufacturer or an authorized manufacturer's 

representative. The Subcontractor/Supplier shall provide legible and reproducible 

documentation, with the materials, that provides objec ti 

ve evidence that the items 

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• _Ik, 

PRO'IECT: Final DSVS Desi n 145579-V-SP 002 REV. 2 


CLIENT: AMECERE — Richland, WA 


were provided by the o riginal manufacturer. Such documentation may include a 

copy of the purchase order to the manufacturer, shipping documentation or 

manufacturer invoice; each of which would identify that the materials were 

obtained from the original manufacturer. 

The Subcontractor/Supplier shall submit, with or prior to item shipment, a 

recommended spare parts list. The list shall provide the name and address of the 

o ri 

ginal supplier of the replacement part, and the part's drawings, specification, or 

catalog identify including applicable change or revision information. 

All items and/or services procured under this speci fication shall be subject to 

inspec ti 

on by the Buyer or Buyer's representative throughout the contract. 


acceptance. 

The Subcontractor/Supplier shall grant access to the Subcontractor's/Supplier's 

plant facilities and records for inspection or audit by the Buyer, his designated 

representative, and/or other parties authorized by the Buyer. 

4.1.5 Identification and Control of Items 

The Subcontractor/Supplier shall establish. controls to assure that only correct and 

accepted items are used or installed. 


other identifier prescribed in the 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. 


product data sheet (e.g., drawing, catalog cut sheet, brochure, etc.) that provides 

adequate information to enable the Buyer to ve rify the form and function of the 

articles procured. One copy of such documentation, unless otherwise specified, 

shall accompany the item, 

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G5-760

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PROJECT NO:. 145579 



The SubcontractodSupplier shall identify each item, assembly, package, container, 

or mate rial, having limited shelf life, with the cure date or date of manufacture and 

the expiration date. The Subcontractor/Supplier shall specify any storage 

temperatures, humidity and environmental conditions that should be maintained. 

Material shall not be furnished having less than 75 percent of total shelf fife 

available at time of shipment. 

Certified Material Test Repo rts (CMTRs) containing actual chemical analysis and 

mechanical prope rties of the material being supplied shall be submitted prior to or 

with each shipment of material. Each CMTR shall contain the following information 

as a minimum: 

• Product Description—specification(s), codes, type of material, etc.; 

• Actual results of chemical analysislmechanical testing in accordance with the 

provisions of the code, standard, and/or speci fi cation; 

• The specification and material grade; 

• Traceability to the item tested (e.g., heat number, lot number, etc.); 

• Name and address of manufacturer (may be identified by letterhead, logo, 

etc.); 

• Manufacturer's ASME ce rtificate number and expiration date; 

Buyer's contract number and item number to which the repo rt applies; 

• The report shall be signed by an authorized representative of the manufacturer. 


The Subcontractor/Supplier shall have processes to control processes, including 

special processes that control or verify quality (e.g., welding, heat heating, and 

nondestructive examination). Special pro cesses must be performed by qualified 

personnel using qua lifi 

ed procedures in accordan ce with speci fied requirements. 

G5-761 

Page

e . milfx:l(gw 



PROJECT: Final DBVS Design 145579-V-SP-002 I Rev. 2 




Subcontractor/Supplier personnel performing weld inspections shall be ce rtified as 

a CWI in accordance with the requi rements of the American Welding Society 

(AWS), QC-1. The following documentation shall be submitted for Buyer approval 

prior to the sta rt of fab ri cation: 

• Current AWS CWI certification; 

• Currentivalid visual acuity examination (must be given eve ry 3 years); and 

• Visual weld inspec ti 

on procedure(s). 

Welding procedures and personnel shall be quali fied in accordance with applicable 

AWS or ASME requirements specked in the contract. The Subcontractor/Supplier 

sha ll submit copies of all welding procedures, procedure qualification records, and 

welder qualfcation records to be employed. Buyer review and approval of these 

documents is required prior to sta rt of fabrication. 

Nondestructive Examination (NDE) personnel shalt be qualified and ce rtified in 




Buyer: 

• NDE personnel qualification and ce rtification procedure; 

• Level 1,11, and/or III personnel qualification and ce rtifica tion records, including 

objective evidence of NDE training, formal education, examination, experience, 

date of hire and current visual acuity exam; 

• NDE method procedure(s) compliant with the applicable requirements of the 

Buyer's contract. 

NDE repo rts and radiographs shall be traceable to the item examined, shall include 

all essential examination parameters, and shall be signed and dated; by a 

qualified/ce rtified NDE examiner. Ali NDE repo rts and radiographs shall 

accompany or preceded shipment of the item or component. Radiographs and 

radiographic technique and examina tion reports shall be subject to approval by the 

Buyer prior to shipment. 

These requirements shall be passed to lower- tier subcontractors. 

\.. rm.w^zwh^cmemaz. snmcassrausemzts p ..amm^rFU^nn^,^z.a« Page 40 of 52 

G5-762 

V

o. icninwlctgr 



PROJECT: Final DBVS Design 145579-VSP-002 I REV. 2, 


CLIENT: AMECEBE— Richland, WA 



The SubcontractorlSupplier 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 Subcontractor/Supplier shall document the results of inspections. 

Inspec ti 

ons for acceptance shall be pe rformed by persons other than those who 

performed or directly supervised the work being inspected. 


reproducible copies of inspection and/or test repo rts. The reports shall include, as 

a minimum, the following information: 

• Identification of applicable inspection and/or test procedure; 

® Resulting data for all characteristics evaluated, as required by inspection or test 

procedures, including reference to information on ac ti 

on taken in connection 

with nonconformances; 

• Traceability to the item inspected/tested (e.g., serial number, pa rt number, Jot 

number, etc.), date of inspec tion, name of inspector, type of obse rvation; and 

• Signature of the Subcontractor/Supplier's autho ri zed representative or agency 

performing the inspection or test. 


The Subcontractor/Supplier shall have a process to plan and execute tests to verify 

conformance of an item or activity to speci fied requirements. The process shall 

document the characte ristics to be tested and test methods to be employed. 

The Subcontractor/Supplier shall prepare a detailed test plan. Prior to sta rting 

work, the plan shall be submi tted to the Buyer for approval and insertion of Buyer's 

designated source inspection/witness noti fication points. The test plan shall 

provide the following at a minimum: 

• Traceability to Buyer's purchaselcontract order document number; 

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G5-763 

w

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PROJECT: Final DBVS Design 145579 -V-SP-002 REV. 2 







• Method/procedure to be used during test. 

Subsequent revisions/modifications to the test plan require review and approval by 

the Buyer prior to implementation of the changes. 

The Subcontracto r/Supp lier shall provide test repo rts that include, as a minimum: 

• Item tested. 

C 

Test plans and test repo rts must be submitted to the Buyer for the project records. 

4.1.9 Control of Measuring and Test Equipment 

The Subcontractor/Supplier shalt control toots, gages, instruments, and other 

measuring and test equipment used for activities affecting quality, and shall 

calibrate at specified periods and adjust to maintain accuracy within necessa ry 

limits. 

The Subcontractor/Supplier shall maintain legible, reproducible copies of the 

Certi fi 

cates of Calibration, traceable to the National Institute of Standards and 

Technology (NIST), for each article contracted. Each Cert ificate of Calibration 

sha3 be sighed by the Supplier's representative responsible for calibration, 

attesting to its authenticity, and shall be identi fi 

ed with the following information: 

• Buyers contract number; 

• Identification of the article to which the Ce rtificate of Calibration applies; and 

• Standards used for calibration 

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3Jw,M 

G5-764

n:rlumlc ,G 

' TECHNICAL SPECIFICATION 


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PROJECT: Final DBVS Design 145579-V-SPA02 - REV. 2 




In addition, the Subcontractor/Supplier shall submit a report of actual calibration 

results. The repo rt 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 speci fied, shall accompany the 

applicable item(s) shipped_ 

The Certification of Calibration will be held on file by AMEC as objective evidence 

to support the actual test results and a ttest to the fact that the calibrated item(s) 

met requirements. 

4.1.10 handling, Storage, and Shipping 

The Subcontracto r/Supplier shall prepare and submit for Buyer review and 

approval, prior to 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) shalt include, as appropriate, cleanliness inspection prior to 

packaging, use of prese rvatives and coatings, descriptions of specially designed 

shipping containers, handling and rigging data, final inspections and the type of 

transfer and shipping vehicles. 

4.1.11 Inspection, Test, and Operating Status 

The Subcontractor/Supplier shall have a process to identify the status of inspection 

and activities on 'items or in documents traceable to the items, and to assure 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 Subcontractor/Supplier must 

specify the autho rity for application and removal of tags, markings, labels, and 

stamps. 

4.1.12 Control of Nonconforming Items 


conform to specified requirements to prevent inadvertent installation or use. These 

controls must provide for identi ficafton, documentation, evaluation, segregation 

/""'' vao..k^^rvc^sw^rmu,m+coz. uuvau^sysaoort^=^na•irmmua zua Page 43 of 52 

G5-765

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n3W e,*W syea^-s 1455aVs 6su dM"nt.0 ,-zaec 

3. 


PROJECT: Final DBVS Design 146679-W REV. 2 




(when practical), and disposition of nonconforming items, and for notification to 

affected organizations. 

All nonconforming condi ti 

ons identified at the Subcontractor/Suppliers facility, with 

a proposed disposition of °Accept-as- Is" or "Repair," as defined below, shall be 

approved by the Buyer before Supplier impiementafion of the Nonconformance 

Repo rt (NCR) disposition: 

I Accept-as-Is: Nonconforming materials will pe rform its intended function. 

• 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 o ri 

ginal acceptance c ri 

teria, 

unless the nonconforming item disposition has established alternatee acceptance 

criteria. 

Nonconformances shall be documented by the Sub contractor/Supplier on their 

own nonconformance form or one provided by the Buyer. A fter documenting the 

nonconformance and providing a proposed disposition and technical justification, 

the repo rt shall 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 Subcontractor/Supp lier. Correc ti 

ve 

action may only take place after Buyer approval. Copies of completed, Buyer 

approved, NCRs shall be shipped to the Buyer with the affected item. 

4.1.13 Corrective Action 


4.1.14 Quality Assurance Records 

4.1.15 Audits 



G5-766 

Page 44 of 52.

„ n'um@oy 



PROJECT: Final DBVS Desicin 145579-V-SP-002 REV. 2 


CLIENT: AMECE&E — Richland, WA 

0 


4.1.16 Quality System for Material Specifying Additional Testing — ASME IIIIViIi 


4.1.17 Control of Graded Fasteners 

The following are minimum requirements for high s trength graded fasteners 

produced in compliance with national consensus standards (i.e., SAE, ASTM, 

ASME): 

• Fasteners shall exhibit grade marks and manufacturers identification symbols 

(headmarks) as required in the specifications referenced in the con tract. 

• When requested by the Buyer, the Subcontractor/Supplier shall provide legible 

and reproducible copies of the manufacturers Certified Material Test Report 

(CMTR). These CMTR's shalt repo rt the values of the actual chemical and 

physical tests performed on the represented fastener lot/material heat number. 

Fastener packaging and labeling shalt be traceable by lot number or other 

means to the CMTR. 

• 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. 

4.1.18 Hanford Analytical Services Quality Assurance Requirements Document 

(HASQARD) — Volumes 1 and 2 


4.1.19 Hanford Analytical Se rvices Quality Assurance Requirements Document 



4.1.20 Hanford Analytical Se rvices Quality Assurance Requirements Document 



Pa0e+1a^VNG^.Veeixaum wu-sA'b^tasia .^/somz(sduevn wamAp.gFevzax Page 45 of 52 

simws 

G5-767

RPP-24544 RED' I d 

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PROJECT: Final DSVS Design 145679 -V-SP-002 REV. 2 

PROJECT NO.; 145579 

CLIENT., AMEC E&E - Richland, WA 

4.1.21 Nuclear Hazards Indemnity 


4.1.22 Computer Software 


The Subcontractor/Supplier shall have a documented software quality assurance 

program that meets the requirements of ASME-NQA-1-1994, Subpart 2.7. This 

program shall include the following areas: ve rification and validation, configuration 

control, documentation, verification reviews, problem repo rting and corrective 

action, access control, and procurement of software and software se rvices. 

Software veri fication and validation activities shall be planned, documented, and 

pe rformed for each system configura tion that may impact the software by 

indtdiduals other than those who designed the software. Software verification 

reviews must include a software requirements review, software design review, and 

a development documentation review. 

Changes to software shall be formally documented, including a descrip ti on of the 

change, the rationale for the change, and the identifica ti on of affected baselines. 

Changes shall be formally evaluated and approved by the organization responsible 

for the original design. Software veri fication must be performed for the change, as 

necessary, to ensure the change is appropriately re fl ected in software 

documentation, and to ensure document traceability is maintained. Software 

validation shall be pe rformed for the change, as necessa ry . 

Software documentation shall include a software quality assurance plan, software 

requirements documentation, software design and implementa tion documentation, 

software verifica ti on and valida ti on documentation, and user documentation. 

The software quality assurance program must establish a formal procedure of 

software problem and corrective action for software errors and failures to assure 

that problems are promptly reported to affected organizations, and to assure formal 

processing of problem resolutions. 

Any software or softwa re services procured for this contract shall be evaluated by 

the Subcontractor/Supplierfor compliance to ASME NQA-1-1994, Subpart 2.7 prior 

v»e.buuwcsm. -sraûss^sysv ooz r.m.a M.R" a^..zax Page 46 of 52 

aam os 

G5-768

, iuziu Xiogy 



PROJECT: Final DSVS Design 145579-V-SP-002 I REV. 2 




to order or contract award. In addition, software that has not been previously 

approved under a p rogram consistent with ASME N CIA-1-1994, Subpart 2.7, for 

use in its intended application (e.g., freeware, shareware, procured commercial offthe-shelf, 

or otherwise acquired software) shall be evaluated by the 

Subcontractor/Supplier in accordance with the requirements of the subpa rt. 

4.1.22 .1 Commercial Off-the-Shelf Computer Software 

The Subcontractor/Supplier shall perform a validation via hand calculation for any 

commercial, off-the-shelf computer software used on this contract. The purpose of 

this verification is to con firm the computer software will work as expected using the 

machine the Subcontractor/Supplier plans to use for the project. 

4.2 QUALIFICATION VERIFiCATION 

Stems to be verified: 

a. Filtering efficiency 

b: Pressure/vacuum integrity of fi lter 

C. Pressure/vacuum integrity of air receiver 

d. Solenoid Operation 

4.3 INSPECTIONS AND TESTS 

The test plans shall be submi tted to the Buyer for review and approval a minimum" 

of 10 working days before tes ti 

ng. The Buyer rese rves the right to witness all tests 

and shall be given a minimum of 10 working days wri tten notice before each test 

date. 

The results of these inspec ti 

ons and tests shall be documented and submi tted to 

the Buyer for review and approval. For the SMF equipment hydrostatic and 

simulated performance test described in Section 4.3.3 and 4.3.4; respec ti 

vely, a 

video record shall be submi tt 

with 

ed to the Buyer test records/documents. 

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G5-769


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4.3.1 Manufacturer Test 


Performance testing of the SMF equipment is required. All tempora ry elect ri 

cal 

equipment including wi ri 

ng and instruments necessary to allow component testing. 

will be provided by the Seller. 

Water used for hydrostatic and performance tes ting shall be tested for chlorides 

before use. The chloride content of the test medium shall not exceed 250 ppm for 

water temperatures of 149 0F or less. 

Dated calibration labels shall be visible on all test equipment. Measuring and test 

equipment used for acceptance inspections and tests . shall be controlled in 

accordance with the Seller's QA Program and shall meet the requirements of NQA- 

1 Basic Requirement 12 "Control of Measuring and Test Equipment," and shall be 

traceable to a national measurement standard. 

4.3.2 Electrical Testing 

The following sections detail the requirements for electrical tes ti 

ng, 

4.3.2.1 Motor Test 

No motors are expected to be part of the Seller's scope of supply. 

4.3.21 Wiring and Breaker Test 

All wiring and breakers shall be given routine tests to demonstrate that they are 

free from mechanical and electrical defects. Wiring and breaker tests shall be 

pe rformed in accordance with the Seller's standard prac tice. The Seller shall 

provide wiring and breakers test data that include, but are not limited to: 

a. Megger tests are required for all electrical power wiring; 

b. Continuity testing is required for all elect rical power and instrumentation 

wiring; and 

C. Circuit breakers are to be inspected for proper size, correct installa tion, and 

manual operation of handles. 

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I_ 

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4.3.3 Hydrostatic Test 


Each SMF shall be hydrostatically or pneumatically tested in accordance with 

ASME B31.3 or ASME B&PV Code, Section VIII as applicable at 1-1/2 times 

maximum operating pressure. Results shall be recorded. A video record of the 

hydrostatic tests shall be submitted to the Buyer with test records/documents. 

4.3.4 Performance Tests 

Earn SMF shall be tested for Structural Capability and Leak Tested in Accordance 

with ASME AG-1 Section TA-3422 and Section TA-3423 respectively. An in-place 

leak test shall be performed on the filter system in accordance with ASME AG-1 

Section TA-4744 and Mandatory Appendix TA-VI by injecting aerosol upstream as 

directed by ASME AG-1 Section TA Mandatory Appendix TA-V and measuring the 

filter system outlet aerosol count. 

4.3.6 Acceptance Criteria 

The process side of the filter assembly shall show no signs of leakage for the 

hydrostatic tests, no deformations after the structural capability test, and leakage 

for the ASME AG-1 leak tests previously described. The combined filters in series 

shall remove 99.97% of 0.3 micron particulate or better as determined by the 

aerosol penetration test (ASME AG-1 Section TA Mandatory Appendix TA-VI.) 

4.3.6 Suspect t Counterfeit Parts Inspection 

The Seller shall document and submit an inspection report of all parts and 

components of the equipment to certify that no Suspect or Counterfeit components 

have been identified. 

P..âeslpnUNC`SpedMe6waW 02-SWP1655i¢VS pAp2 ry'mRredNeW FBer} Rer.3.loe Page 49 of 52 

3.MmM 

G5-771


+ edn rt amec 


PROJECT:. Final DBVS Design 145579-VSP-002 REV. 2 


CLIENT: AMECEBE—Richland,WA 

5.0 PRESERVATION AND DELIVERY 

5.1 GENERAL 


Eve ry item that is shipped shall ar ri ve at the job site in the same condition as when 

it passed all quality control inspec ti ons and tests. 

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 through 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 di rt or 

dust that may have accumulated on the equipment during testing per Section 

4.3.5. Defects in the paint shall be touched-up. Moving pa rts shall be secured to 

prevent movement du ri ng shipping. 

5.3 OPERATING PROCEDURES 

The Seller shall prepare an instruction manual(s) that includes packaging 

information, handling information, shipping information, storage Informa ti on, 

opera ti onal and maintenance procedures, and special assembly procedures. The 

instruc ti on manual(s) shall be submi tt ed to the Buyer for approval before shipment. 

A recommended spare pa rts list shall be prepared and provided to the Buyer. 

5.4 PACKAGING 

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 

transportation_ All bracing must be clearly ident ified both in the unpacking 

instructions and by labeling on the outside of the SMF equipment. 

Rigging sketches or a handling procedure shall be prepared by the Seller for items 

that require special handling. These sketches will identify weights, sling locations, 

balance points, methods of attachment, and other informa ti on necessa ry for safe 

hand ling. 

v;»esîu^w^waeinceamcwnz-^faâmtaate dMWROMae.-:Lax Page 50 of 52 

iwnos 

G5-772


Pi@tlgpHVLISp[dl eUai5WY2-S p1FliG5$]AVSP-W2l5iNe.MMWfFiIM Rev-3A[[ 

a. xncs 


PROJECT. Final DSVS Design 145579 -V- DOY REV. Z 

PROJECT NO.: 

145579 



Packaging and/or preservative coatings shall be visually inspected after loading. 

Damaged areas shalt be repaired. Items shipped with desiccants shall be 

inspected after loading to verify that seals are intact 

Cushioning shall be used where protection from shock and vibration is required. 

Cushioning materials shall have sufficient .strength to provide the required 

protection, shall exhibit no corrosive effect when in contact with the item being 

cushioned, and shall not readily support combustion. 

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. 

Instrumentation, electrical and electronic equipment, motors, and other electrical 

assemblies and equipment shall be packaged in a waterproof enclosure. This may 

be the enclosure the item will operate in. For items without waterproof enclosures, 

a vapor battier 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, shalt 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. 

5.5 MARKING 

Packages shall be properly and clearly marked. At a minimum, the required 

information shall include the contract number, the name 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 

5.6 HANDLING 

The Seiler sha g lift equipment using a forklift or crane, utilizing the lifting points 

designed for that purpose. 

G5-773 

"I 

Page 51.or 52

,llm4y 


PROJECT: Final DBVS Design 145579-V-SP•002 REV. 2 


RPP-24544 REAT 1d 


5.7 SHIPPINGITRANSPORTATION 


The Seller's truck driver shall carry bills of lading for each shippable unit that is 

delivered to the Buyer. 

The Seller shalt obtain approval to ship from the Buyer before the equipment is 

prepared for shipment. 

6.0 APPENDICES 

The following appendices make up pa rt of this specification: 

Appendix Description __` 

j A Suspect Fastener Headmark List 

7.0 ATTACHMENTS 

Document No. i Title V_ 

1455794-DS-002.1 Sintered Sintered Metal Filters 

t Equipment No. 35-NO2-019 & 36-NO2-020 

^. P.VJesIpnWULL4ped0otbmW^2^SMFlf4iiT9V.5v.Op2(SNtm¢dMtlal FQ" Rw.2A 

/ SJUnAS 

G5-774 

1 

Page 52 of 52

• tu'htx^kxri} 



PROJECT: Final DBVS Desf n 145579-VSP-002 

PROJECT NO.: .145579 APPENDIX A 



MnTrWrvclSpeofioewnc 2 - SMU%MV, nD=ftMr A>doo 

44NÔ 

APPENDIX A 


G5-775

TECH141CAL SPECIFICATION 

Examples of stalnless *toot 

fasteners that his" been upgraded 

from 19-0 to AST M A320 or ASTM 

A193 Grade BS after hand 

etemping. The lmst three exmnploa 

show samples of fastene rs to 

Indlcel0 conformnnoo to two 

non-compaUDle standards, 


Any toil on th is fist should 

be tteetad as detective 

without funkier tasting and 

prooeaa In acootdanoo with 

HNFPRC-301. Note: This I let 

was originally Publlshed by 

DOE /EH-01 DE, Issue No, 97-6 

If any of Inane fasteners ura located, 

contact your facility =1 Point of 

Contest TOC) for ins truction*. Th e 

POC list la on the Hanford Int ranet 

Fit h ttp:ffdocs.ri.govlhan.infof 

hlnnscbhlans cl.dae. Seroli to the end 

of the document for the lint. 

Su rrounding 

White Color 

Iffue tratea 

O4 Markin 

Before Hand 

J Stamping 

O C 

RPP-24 544 REV I d 

PROJECT: Final DBVS Design 145579-V-SP-002 

ame.r.."^ 

PROJECT NO,.: 145579 _ APPENDIX A 

CLIENT: AMEC E&E —Richland, WA 

Suspect Fastener Headrnark List 

Ft:^ µ ,Help.. Stamp out 


P tDeaignlHVC)Spedtcaeo ps1002 - SMRI45579-V.SP.002 (Appendix A).doo Page 2 of 3 

4-May 05 

G5-776


R-11 -ehlutkx."y amec 

TECHINICAL :iPECIFICATION 

PROJECT: Final DBVS Design 145579-V-SP-002 

PROJ ECT NO.: 145579 APPENDIX A 

CLIENT: AMEC E8E —Richland, WA 




All Grade 5 and Grade 8 fastene rs of foreign origin which do not bear any 

manuracturcrs' headmarks: 

r^ 

r) 

q ^l 

(" j Grads 5 

^ ~o 

- .-I Grade 8 

,C 


Mark Manulacturer Mark Manufacturer 

J Jinn Her (TW)NS KS Kosaka Kogyo (JP) 

Grade 8 fasteners with the following Manulachuers' headmarks: 



^\ 

O A O-f A Asahl Mgf (JP) 

/ 

y' KS- KS Kosake Kogyo (JP) 

-NF-/NF 

r^ 

Nippon Fasteners (JP) \- RT- RT Takai Ltd (JP) 

r^ 

H - H Hinomolo Motal (JP) -FM- FM Fastener Co. of Japan (JP) 

Q M-) Pd Minamida Sieybo (JP) -KY- KY Kyoei Mtg (JP) 

-Ms- M $ Mlnato Kogyo(JP) - J - J Jinn Her (TW) 

Hollow 

Triangle 

Infasco (CA, TW, JP, YU) (Greater then f!2-inch diameter 

Grade 8 hollow Triangle only) 

- E\I-_ Gaiei (JP) (UNY-^ UNY Uhylile (JP) 

Grade B.2 fasteners with the following headmarks: 

Mark 

KS 

Manulacturer 

Kosaka Kogyo(JP) 

Grade A325 las:eners (Benne tt Denver target only) with the following headmarks: 


Type 1 KS A325 KS Kosaka Kogyo (JP) 

i 

Ty pe 2 `.au 

K5 

Type 3 

Key: CA-Canada, JP-Japan, TWTalvran, W-Yugoslavia 

Any bolt on this list should be treated as detective without further tes ting. 

P1 13e, 4pN1VC%Spe fiwli m1002-SMFI745579-V•SP. 002(P.pp-di, A).doe —T 

4-May-os 

G5-777 

Page 3 of 3

—, 


AMEC Americas Lirnited 




PROJECT: Final DBVS Design 145579-V-DS-002.1 T REV. 1 

PROJECT NO.: 145579 SINTERED METAL FILTER 

CLIENT: I AMEC E&E - Richland, Washington 

EQUIP. NO.: 36-NO2-019 & 36-NO2-020 

^ î^t-^^°L^ 

SaS ... ^v.a;r ^4 iL ^yt^^•^ r` ^ ` .y ...ov 't's e 7uk'^t2r'f°t{s 1.^^ 

f ^> tl.Xf^,rf..n. r 

ci1Sl1rG'^'x'^,^`^,c 

i .'.i y^ -... ,d^^';Y`,'4^,J,r..^ .1' Il . L .1^:1:'^ 't£i C:iWi ve-.., 

Gipa' r t k^ % yp^. 

, ry Sl^.nbin,?$lt.CX-fug S?'.'K."tis^: ^;$^','?; 

A For Client Review / Request for Quotation KM 26-Feb-04 FWS for KM 

B Request for Quotation - Revision JFS 06-Apr-04 JFS 

C I For Construction FWS 18-Ma -04 FWS 

0 For Construction FWS 20-May-04 FWS 

1 For Construction (Previously issued under project 143643) AP 04-May-05 


CLIENT APPROVAL (AMEC RICHLAND) AMEC AMERICAS LIMITED (TRAIL) 

Original Signatures on File I Original Signatures on File 


Date: U s-' 

Q.A. Rep.: 

Date: 

t t 


Project Mlanag9r: 

Date: 

X ^,^ 

G5-778 


Date: J14 QO _ 


cli 

Date. Ôt► 

Originator: 

Date: O^l M/^y ^?d45

i 



PROJECT: Final DBVS Design 145579 V-DS-002.1 REV. 1 

PROJECT NO.: 145579 SINTERED METAL (FILTER 

EQUIP. NO.: 36-NO2-019 & 36-NO2 020 

CLIENT: AMEC ME - Richland, Washington 


Document No. I Specification 

145579-VS'P-002 Sintered Metal Filter 

CONTENTS 

Data Sheet _.. t Page 


G5-779 

a 

e,


7ECHhWAL DATA SNEETS 

PROJECT: Final DBVS Design 145679-V-08.00'2.1REV. 1 

PROJECT NW, 145579 SINTERED METAL. FILTER 

LtENT: AMECE&E- Richland Washington 

EM NO.: 38-NO2-019&36402.020 

No. Re 

. 

ed 2 (estimated) • rea 36 

# F-145579 00-A-0022 Stream No. 15 

Reference Spedifiication: 145579-V-SP-002 'ty Assuratice Level EQ 

Operating/ BesignConditions Rev - Rev 

Location (hicoots/Outdoors) 

outdoors Operation - Days per year 

365 

F InletAirTemperature CF) $72 -Hours per day 

74 

TOatsideAixTemp. 

M 25 1 Availability * 

C 

Operation (continnons/intenninen0. 

Min. Design Preassmie Drop (in WG) 

conflaqous 

-8 C 

Elevation(it) 

Environment - Radioactive. 

(Rasp 663 

Yes 

C 

Max. Design Pressure drop (inWG) -150 C -Toxic 

Ym 

Plow Direction 

Up - corrosive 

Yes 

Operating Flow Rate (ACeM) 862 -Flammable 

No 

Design Flow Rate (AC I) 1000 B 111det Composition 

Mass Flow Rate (1W5r) 2006 B Process Fluid 

Aldsk-am 

MinimtmtDesign Temperature CF) 572 0 Particulate Type 

Radioactive 

Maximum Design Temperature CF) " 

Mean particle size (ffivoq) 

1 B 

Minimum Design Pressure 

aximi nDes' Pressure 

(prig) 

(pst) 

Full vac 

100 

C 

C 

Particulate Rate 

Na 

(Ib/hr) 

(Ibhr) 

5 

0:55 

B 

C 

Filter Data (see note 1) 

Sintered filter type (filers/mesh/ powder) * 

S02 gas . 

NOX gas 

(ppmV) 

(ppmV). 

666 

80592 

C 

C 

Sintered filter material 

Material layering (lsyered/Homogeneous) * 

ECI gas 

137Cs 

(ppmV) 

(ai&) 

64 

154E-02 

C 

C 

Filter housing material * 

B 99TC (Ci)M) 6.17B-04 C 

Filter elements area (ft) * 

B TRU (CUhr) 9.02E-08 C 

Quantity of filter elements * 

Solids removal eff. (forparticles>0.3micmn -9o) 

Filter size (micron) * 

Allow clean delut P @1000 cfm (in wr,) 

Connection flange type 

99.97 

8 

ANS1150# 

C 

B 

129I 

CO2 

CO 

(Cil1q') 

(ppmV) 

(ppmV) 

1.84E-D5 

1.75E+04 

7484 

C 

C 

C 

Inlet connection size (in) * 

B 

Outlet connection size 

Rejects connection size 

fq) * 

(n) * 

B 

B 

Filter rejects .'city (fts) 72 C wefghts 

Auto backpulse mechanism (see Note 2) Unit Break Down Lifting (Yes/No) 

Type 

Compressed air pressure req'd 

Compressed air consumption 

(psi) * 

(CFMavg.)* 

Back pulse 

B 

C 

Total shipping weight 

0 ting FJeight (each fiItex) - 

Ob) * 

(1b) * 

B 

Maximum Clrouit Amps (A) * 

Solenoid Control Voltage 

PLC Compatible (Yes/No) 

M * 

Yes 

B 

B 

Compressed ed airconneetion size 

comments/Notes: 

(m) * 

C 

All its with an * shall be filled in by the VENDOR 

1. Filter data isfor two filteis in series 

2. Filter to include all solenoids for auto backpulse system 

Date 26-Feb-Q4 06-Feb-04 I 19-May-04 20-May-04 O4-Ma S . 

By KM IFS FWS FWS 

Chked 3DS JDS 

Rev. A - B C 0 i 

G5-780

1,_ 



PROJECT: Final DBVS Design _ 145579-V-DF-002.11 REV.1 

PROJECT NO.: 145579 SINTERED METAL FILTERS 

EQ. NO 36-NIO2-019 & 36- 1402-020 


SEND ALL DOCt7NUMS TO: 


Vendor sball supply a ll drawings, manuals and documenta tion in the quantities indicated. Approval drawings are due, within the 

listed number of calendar days after issue of the Purchase Order or Le tter of Intent. The dates set out for drawing and data 

submissions are governed by the engineering design schedule of the project. The Vendor sha ll supply one Autocad disk file 

and requested number of copies within the fisted number of calendar days. Final drawings must be cer tified as correct and 

bear the Vendors name, equipment number and Purchase Order Number. Dr awing'rransmittals lis ting the document numbers, 

revison numbers, quan tities, status and document types must be inducted with all submissions 

(including electronic submittals) 

Submit all documents via Courier service 

Faxed'. docmnenls must be fo llowed by the originals. 



Always include a transmittal 


1385 Cedar Avenue 

Trail, BC, Canada 

V1R 40 

Attn: Document Control 

Phone:: (250) 368-2400 

Fax: (250) 368-2401 

BIDDERS MUST ]PROVIDE ESTEVIATED LEAD TIMES FOR APPROVAL, DRAWINGS 

Proposal Ilidder sha ll 

include this data for each item REVIEW 

Review .Required before ordering or st ar t of fabrica tion 

'Final Required within 7 days p rior to shipment and before final payment 

PROPOSAL REVIEW FINAL DFSCRIYCION 

_ 

ITEMS DUE 

WITHIN 

(DAYS) 

E+1 Proof of NQA-1 or equivalent pro gram :Bid 

E+ 1 Expe rience list and maintainabi lity informa tion Bid 

E+3 Desi gn , fabrication & de livery schedule Bid 

E+3 E+3 E+6 Out li 

ne drawings and layout drawings indica ting weights and dimensions PO+20 

E+3 E+3 E+6 Technical brochures on purchased components PO+21 

E+3 E+3 E+6 Elect rical schema tics, wiring, diagraras :md nameplate lists P0+20 

E+3 E+6 Calculations _ 

PO+20 

E+1 E+6 

E+1 E+6 

1 

_ 

Spare parts list POJA0 

Set of installation and maintenance manuals c/w technical literature for all 

equipment and devices _ 

111J+40 

Hardware Delivery PO+100 

6 Site Commissioning record & test mults COM+14 

Ê+1 E+1 6 Factory Acceptance Tes ting Plan (FAT) P0+21 

6 ASME U-1 Form for Air Reciever Del-10 

VENDOR 

COi 1 NT 

(SEE NOTE 4) 

(DAYS) 

- :^'i.^ - 1,/:: "scar' iS ° 9 ^:1• ,z7:^`-. i xcf a - 'iJZ1 . l.i: u>.F'r,':. 'nC . - . Qy.3 

'Vy'^{^} Ga—.. c .s.Kî.Y'^ ..f.. ^.^,` ..^. 

L •.1' ." rM1F^.`. .4 `ti .V:â?l`,t.. ..r^. Y.^',J^Y=.,T:L.•',r ,xf 1j:: 

"F%^•2 a;]' t.:':^.. F°•% J ^x= 1^'T•L y 41.v.r6'. •il ?;aW. i t 

^^ 

l•60etSp ., f râ:° ti t ! :' JY !`' C. ;.%t';.x^r..^., T .ems 

N v, 

°>,w %d •.^r .:, 'v k.., ;. , .. ,Q . v'^S''S,i^'„^:ti u.^:i;+-rl:e. 'Lis:a'.n^. E G. ^¢, s'`î''., r S.K -'iris S 4i '^kY ,S T^„ •"„ 1. . 5 '^q ^'^,t'6 

cft ., tc_ .t^ :.aj'`, zs .. ^Pxr:^-+'."fir. .^rA. :>.'s", ^. .t...l.w>^..,• d_s; ^. 2 

^^ ,Tîli., ^k r,.-t.A.a4Y..%.}{ J: "^).^. ^{v, :„. .VlX.. .:.t J:^+ ^.:ji{J I'^.^^l:^r^.{,i+. n^ .T j(.8: x^ 1C .Li:'.>l'•I S,•5^. 1' •-. ^:^^n ^ Y,^.. `;!£.â.l;..,e^... :^'4 s1nF''i.t^. ^t,t14.'1 :., ^•FI. T'+l' ^ji 

E•4EIeclSgtNâ4P.Y^CProcs,!'^^^`t)uq,W,Ihin^,^^citeticTA^t'têYs;1.^;1r _ ^^ 

THE TWELY RECEIPT OF THE VENDOR DOCUMENTS IS CRITICAL TO THIS PROJECT 

i agree to provide the listed documentation and data and the dates shown above. 


G5-781


TECHNICAL SPECIFICATION ^p'^ f^ 

AMEC Americas Limited a , • 4+ 




PROJECT NO: 145579 

CLIENT: 

REV 

N0. 

'. 


EXHAUST FANS 

ISSUED FOR ORIGIN `DATE INITIAL 

A Internal Review DW 08-Oct-04 DW 

B Intemal Approval DW 22-Oct-04 DW 

C CH2M Hill Review DW 02-Nov-04 DW 

0 Bid Request DW 21-Dec-04 DW 

1 Bid Re uest DW 06-Jan-05 DW 

2 Bid Request DW 01-Feb-05 I 3 

AP for DW 

Bid Request 

DW 10-Feb-05 DW 

4 Bid R nest 

TM 19 Oct-05 TM 



Date: 

Q.A. Rep.: 

S010IR'^f ^.In 

ì final Approvals on File 

671zy10 

Date: E0-'2aÔj 

Date: 

AMERICAS LIMITED (TRAIL) 


Date: 

CLIENT APPROVAL (CH2M 

HILL) Originator. 

roject. Manager: 

3 

G 

/ 

Date: i a f - jz,r 

G5-782 

7., 

Original Approvals on 

Page


AMEC Americas Limited . 


PROJECT: Final DBVS Design 145579-V-SP-004 I REV. 

- NO.: 

PROJECT 

CLIENT: 

145579 

AMEC E&E - Richland, WA 


EXHAUST FANS 

1.0 SCOPE ................................................................................................................ 7 

1.1 PURPOSE ........................................ ................................... ................... 7 

1.2 SCOPE OF SUPPLY ....... ................ ....................................................... 7 

2.0 APPLICABLE DOCUMENTS .............................................................................. 9 

2AGOVERNMENT DOCUMENTS ..... ................. - ....................................... 9 

2.2 NON-GOVERNMENT DOCUMENTS ......................... ..............................9 

3.0 

Page 

TECHNICAL REQUIREMENTS ......................................................................... 11 

:3.1 ITEM DEFINITION.....:: ................................. ........................................ 11 

3.1.1 Item Diagram . ...................................................................... -11 

3-1.2 Interface Definition ................. ..................... ......................... 12 

3.2 CHARACTERISTICS ...... .......................... ............... ......... - .................. 12 

3.2.1 Functional Characteristics ......................... .............................12 

3.2.2 Physical Characteristics ............................ .............................12 

3.2.3 Reliability ................. ...................................... ................. 13 

3.2.4 Maintainability ... ......................................................... .......... 13 

3.2.5 Environment ............................................... ....... ............... ... 13 

3.2.6 Transportability and Storage ..................... .............................14 

3.2.7 Safety .......... ......... ............... .......................................... ..... 14 

3.3 DESIGN AND CONSTRUCTION ........................... ...... ........ ............... 14 

3.3.1 Parts/Materials/Processes ......................... ...........:.................15 

3.3.2 Industry and Government Standards ...................................... 22 

13.3 Radiation ......................... ........................ ............................. 23 

3.3.4 Cleanliness ....... - ................. ........................... ................... -24 

3.3.5 Corrosion of Parts .................................................................. 25 

3.3.6 Protective Coatings. ............................... ............................... 25 

3-3.7 Interchangeability .......... - ... ................................................... 25 

3.3.8 Identification and Marking ...................................................... 25 

3.3.9 Nameplate ............................................. ................................ 26 

3.3-10 Human Engineering .......... .................................................... 27 

3.3.11 Qualification .................... ............. .......................... ............. 27 

3.3.12 Document Submittal ................................................... ........... 27 

3.3.13 Personnel and Training .............................. .............................29 

4.0 QUALITY ASSURANCE REQUIREMENTS ......................... .............................30 

4.1 GENERAL ........................ ............ ................... ....................... * ............ 30 

4.1.1 Quality Assurance Program ...................... .............................30 

4.1.2 Design ................................................................................... .30 

4.1.3 Computer Software Important to Safety ................................. 31 

4.1.4 Procurement Document Control .............................................31 

(35-783 

Page 2 of



PROJECT: 


= s 

Final DBVS Design 145579-V.SP-004 REV. 4 

PRO J NO. : 145579 EXHAUST FANS 

CLIENT: EC 

AMEC E&E— Richland, WA 

4.1.5 Identification and Control of Items ......................... ..............:..33 

4.1.6 Control of Processes .............:............................... ..................34 

4.1.7 Inspection .............................................................. .................. 35 

4.1.8 Test Control .......................................................... ...........36 

4.1.9 Control of Measuring and Test Equipment............ ..................37 

4.1.10 Handling, Storage, and Shipping ........................... .................38 

4.1.11 Control of Nonconforming Items ............................ .................38 

4.2 QUALIFICATION VERIFICATION ......................................... .................39 

4.3 INSPECTIONS AND TESTS ................................................. .................39 

-4.3.1 Vibration Testing ................................................... .................39 

=4.4 TRAINING OF INSPECTION AND TEST PERSONNEL ....... .................40 

4.5 QUALITY ASSURANCE RECORDS ..................................... .............40 

5.0 PREPARATION FOR DELIVERY ............................................. 

5:1 GENERAL .....................................................°--............ 

5.2 PRESERVATION AND PACKAGING ............................ 

5.3 PACKING .....................°........ -.. .............. ................. 

5.4 MARKING ..................................................................... 

5.5 HANDLING .................°------------.................................°-- 

5.6 SHIPPING... ........... ...................................................... 

6.0 NOTES ..................................................................................... 

7.0 APPENDICES .......................................................................... 

8.0 ATTACHMENTS ...................................................................... 

APPENDICES 

..................40 

..................40 

.................40 

.................. 41 

.................41 

.................. 41 

........--°-.....41 

A Control of Suspect/ Counterfeit Items (TFC-ESHQ-Q_C-C-03) 

B Exhaust Fan requirement schedule per AG-1, Section BA, Fans and Blowers 

145579-V-DS=004.1 

36-VIT-515 

36-TE 516 

36-VIT-518 

36-TE-519 

F-145579-36-V-0007 

H-14-106796 

ATTACHMENTS 

Exhaust Fan Data Sheet 

Vibration Transmitter 

Resistance Temperature Detector 

Vibration Transmitter 

Resistance Temperature Detector 

Off Gas Area — Scrub & Stack Area Plan 

Off Gas Area — FDNS Plans & Sections 

G5-784 

.41 

.41 

Page 3 of 42

TECHNICAL SPECIFICATION RPP-24544 REV 1d 





FIGURES 

Figure3-1: Exhausts Fan System Diagram ......................................................................11 

TABLES 

Table2-1: Applicable Government Documents ...................................................................9 

Table2-2: Applicable Non-Government Documents ...........................................................9 

G5-785 

1I 

Page 4 of 42



AMEC Americas Limited u i 



CLIENT: 



°C 

Degrees Celsius 

OF Degrees Fahrenheit 

pm Micrometers 

AC Alternating Current 

AMCA Air Moving and Control Association 

EXHAUST FANS 

ASHRAIE American Society of Heating, Refrigerating and Air Conditioning Engineers 

ASME American Society of Mechanical Engineers 

ASNT 

American Society of Nondestructive Testing 


AWG American Wire Gauge 


CFR Code of Federal Regulations 


CoC Certificate of Conformance 

CWI Certified Welding Inspector 

DBVS Demonstration Bulk Vitrification System 

DOE Department of Energy 

ft3Cubic Feet 

hp Horsepower 

Hz Hertz 


lb Pound 

Ibm Pound Mass 

mA Milliamp 

MCS Monitoring and Control System 

mph Miles Per Hour 

NCR Nonconformance report 



G5-786 

Page 5 of 42







NEMA 

National Equipment Manufacturers Association 


NRTL Nationally Recognized Testing Laboratory 



OGTS Off Gas Treatment System 

PLC Programmable Logic Controller 

psig Pounds Per Square Inch Gauge 

PVC Polyvinyl Chloride 

QA Quality Assurance 

RGS Rigid Galvanized Steel 


Sox Oxides of Sulfur 

SS Stainless Steel 

TBD To Be Determined 

TEFL Totally Enclosed Fan Cooled 

TM Trademark 


UL !Underwriters Laboratories 

V Volt 

Vol Volume 

G5-787 

EXHAUST FANS 

Page of 42



ROJECT: OJECT NO.: 


rIENT: 

AMEC E&E— Richland, MIA 

1.0 SCOPE 

1.1 PURPOSE 

Final DBVS Desi n 145579-V-SP-004 REV. 4 

145579 

EXHAUST FANS 

AMEC is part of a team that has been selected by the CH2M HILL Hanford 

Group, Inc. (CH2M HILL) to design, fabricate, test, and deploy a Demonstration 

Bulk Vitrification System (DBVS) to receive, dry, and immobilize waste from an 

underground storage tank located in the 200 West Area of the Hanford Nuclear 

reservation. A main subsystem of the DBVS is the Off-Gas Treatment System 

(OGTS). The primary function of the OGTS is to filter radioactive particulate and 

reduce NOx and SOx emissions produced from the melt process. A major 

component of the OGTS are Off-Gas Exhaust Fans or blowers that will provide 

large negative pressures in order to transport the off gas exhaust through the 

extensive series of filtration devices and then push it through the off-gas exhaust 

stack. 

Throughout this specification, Contract Responder shall act as the Seller 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 SCOPE OF SUPPLY 

The Seller's Scope of Supply shall include, but not be limited to, the design, 

analysis, fabrication, inspection, testing, documentation, packaging, and shipping 

of the following components associated with the Exhaust Fans. All equipment 

shall be mounted on a common mounting skid for operation. 

Fans — The Exhaust fans or blowers 

Fan Motor — TEFC housing, NEMA rated 

Fan Drive— Direct drive or belt drive 

Safety Guards — To enclose all moving parts, attached to mounting base. 

G5-788 

Page 7 of 42







EXHAUST FANS 

Mounting base - Vibration isolating, rigid steel frame, motor slide base, to mount 

fan and motor, also referred to as `skid'. 

Flange Connection — The Seller shall provide a flexible inlet and exhaust duct 

connection along with details. 

Factory Acceptance Testing — and associated test reports 

Field Support and Start-up Assistance — Seller to provide per diem rates for 

technical field support during construction and system start -up. 

Special Tools — Seller to provide special tools, lifting spreader bars, maintenance 

tools or equipment required to service, maintain and operate the Exhaust Fans. 

Work not included in the Seller Scope of Supply is as follows: 

(a) Site installation of Exhaust Fans. 

(b) Design and manufacture of connecting systems to and from the Exhaust 

Fans to the rest of the OGTS such as, process off-gas stream ducting, any 

electrical supply, starters, local pushbuttons, local disconnect switches, MCS 

and PLC connections. 

G5-789 

Page 8 o 42



2.1 

2.2 


ame 


PROJECT NO.: 

CLIENT: 

145579 


APPLICABLE DOCUMENTS 

EXHAUST FANS 

Documents applicable to the work scope are shown in Table 2-1 and Table 2-2. 

The latest issue and addenda to the documents in effect at the time of 

procurement (unless otherwise specified) shall apply and form a part of the basis 

of design for this specification to the extent specified in the applicable sections of 

this document. In the event of a conflict between documents referenced herein 

and the requirements of this specification, the requirements of this specification 

shall take precedence. All conflicts shall be brought to the attention of the Buyer 

for resolution. 

GOVERNMENT DOCUMENTS 

Table 2-1: Annlicable Government Documents 

Code/Standard " Title 

10 CFR 830 Nuclear Safety Management 

29 CFR 1910 Occupational Safety and Health Standards — Code of 


47 CFR 15 Code of Federal Regulations, Telecommunication, Federal 

Communications Commission, Radio Frequency Devices. 

DOE-RL-92-36 Hanford Site Hoisting an Rigging Manual 

NON-GOVERNMENT DOCUMENTS 

Tnhle 2-2- Annlicahle Nnn-Gnvernment Documents 

Code/Standard Title 

AFBMA 9 or 11 Anti-friction Bearing Manufacturers Association 

AMCA 201, 210, 300 Fans and Systems 

AMCA 204 Balance Quality and Vibration Levels for Fans 

ANSI C63.16 American National Standard Guide for Electrostatic 

Discharge Test Methodologies and Criteria for Electronic 

Equipment 

ASCE 7-98 Minimum Design Loads for Buildings and Other Structures, 

American Society of Civil Engineers, Reston,'Arginia. 

ASME AG-1 Code on Nuclear air and Gas Treatment 

ASME 818.2.1 Square and Hex Bolts and Screws, Inch Series 

ASME B30.20 Below-The-Hook Lifting Devices 

G5-790 

Page 9 of 42




PROJECT: Final DBVS Design 145579-V-SP-004 REV:4 



EXHAUST FADS 

Tahiti P-P- AnnlicahIp Non-Government Documents 

,C+bdelStandartl` . -' ;Tiff ^ ^` 

ASME NQA-1-1994* 

(See Note at end of Table) 

Quality Assurance Requirements for Nuclear Facility 

Applications 

ASNT-TC-1A American Society for Nondestructive Testing - 

Recommended Practice 

ASTM A193 Standard specification for Alloy-Steel and Stainless Steel 

Bolting Materials for High-Temperature Service 

ASTM A194 Standard specification for Carbon and Alloy Nuts for Bolts 

for High-Pressure and High-Temperature Service 

ASTM A307 Standard specification for Carbon Steel Bolts and Studs, 


ASTM A354 Standard specification for Quenched and Tempered Alloy 

Steel Bo lt s, Studs and other Externally Threaded Fasteners 

ASTM A36 Standard specification for Structural Steel 

ASTM A563 Standard specification for Carbon and Alloy Steel Nuts 

ASTM F436 Standard Specification for Hardened Steel Washers 

AW S DI A Structural Welding Code — Steel 

AWS D1.6 Structural Welding Code—Stainless Steel 


Corporation for Fluor Daniel Corporation Hanford, Inc, 

Richland, WA 

HNF-SD-GN-ER-501 Natural Phenomena Hazards, Hanford Site, Washington 

IEEE C62.41 IEEE Recommended Practice for Surge Voltages in Low- 

Voltage AC Power Circuits 

IEEE Std C37.90.2 Standard for Withstand Capability of relay Systems to 

Radiated Electromagnetic Interference from Transceivers 

ISA 5.1 Instrument Symbols and Iden ti fication 

NEMA MG-1 Motors and Generators 

NFPA 70 National Electric Code 

TFC-ENG-STD-12 Tank Farm Equipment Identification Numbering and 

Labelino Standard 

SAE J429 Mechanical and Material Requirements for Externally 

Threaded Fasteners 

SAE J534 Lubrication Fittings 

UBC 1997 1 Uniform Building Code 

'The relevant requirements of NQA-1 are included in Section 4.0 

G5-791 

Page 10 of 42




PROJECT: Final DBVS Design 145579-V SP-004 REV. 4 


CLIENT:. AMEC E&E — Richland, WA 

3.0 TECHNICAL REQUIREMENTS 

EXHAUST FANS 

The following section is a proposed process description of the Exhaust Fans 

system and components. The Seller shall provide a similar process operating 

description, including the calculated operating temperatures for their equipment, if 

their equipment deviates in operation from that described below. 

See Technical Data Sheet 145579-V-DS-004.1 for complete list of inlet conditions 

and exhaust requirements. 

3.1 ITEM DEFINITION 

The Exhaust Fans will provide the negative pressure to move the exhaust gas 

through the OGTS. 

3.1.1 Item Diagram 

SCOPE OF I L Ê g ,- ^ 

SUPPLY-^j. ^ ----------- 

\5 

---I.0 

CONTAINED IN 

DOTTED LINE I S -i „ TE - 

-r - - - - - 

NO 

acs 

NC 

I 

36-N31-025 

- - - 

ill ► 

i I 

I 

1E 

I 

1 ---` ______- 

I 

_L M TE __L___---- 

I I 

I I 

I i 

I I 

I I 

I I 

I I 

I t—► 

I 

1 76-N31-026 

Figure 3-1: Exhausts Fan System Diagram 

G5-792 

I 

1 

NO 

NC 

- - M 

-- PAC 

1 

11 

Page 11 of 42




amec 




3.1.2 Interface Definition 

EXHAUST FANS 

The Seller shall provide actual power requirements and performance 

specifications in their proposal. 

Any utility or instrumentation connections shall be specified and brought out to a 

common interface point on the drive base. 


3.2.1 Functional Characteristics 

As specified on the Technical Data Sheet, 145579-V-DS-004.1. Table 3-2 lists air 

stream properties. 

Table 3-1: SCR Outlet Air Stream Properties 

Properties Data 

Design Air Flow Rate 11,400 acfm nominalhsNii 

Estimated Temperature (a) 

248 OF 

Estimated inlet Pressure (a) -120 in. w.g. 

Relative Humidity 100% 

Chemical Components 

SOZ = 1.1 ppmV 

NO, = 92 ppmV 

HCl = 0.1 ppmV 

ppmV = parts per million by volume. 

w.g. = water gauge. 

"'The Seller shall verify design conditions based on performance criteria of selected equipment. 

The Exhaust Fan housings shall be pressure and leak tested per AG-1 section BA 

5142 assuming atmospheric suction pressure to the fans. 


The Exhaust Fans shall be drive, base mounted, and not exceed the footprint 

shown on the drawing, H-14-106796. If the footprint is not configuration friendly, 

please provide the proposed footprint in the sellers proposal. 

G5-793 

Page. 12 of 42








EXHAUST FANS 

The Bulk Vitrification plant is expected to operate 24 hours per day, 7 days per 

week. Service work will be done during scheduled downtimes. The service life is 

2 years and the operating life is 5 years. 

3.2.4 Maintainability 


repair, spares, modular construction, test points, etc.), should include; but not be 

limited to, the following: 

(a) Maintenance and Repair Cycles - Expected inspection of the Exhaust Fans 

will be once per week by the Buyer. The Seller shall provide typical 

maintenance schedule. 

(b) Spares and Spare Parts -The Seller shall identify recommended spares and 

spare parts. 

(c) Service and Access - Exhaust Fans shall be designed for ease of service 

(access openings/spacing, self-test capability, inspection windows, test 

fixtures, sealed bearings, etc.). The Seller shall identify requirements for 

service (remove and replace only, bench repair, special tools, remote 

handling/maintenance, etc.). 

(d) The casing shall be of split design to permit removal of the impeller without 

dismantling ductwork. 


This equipment is to be operated outdoors. Any equipment and related 

enclosures installed outside shall be designed to operate and be stored in the 

climatic and environmental conditions listed below, and UBC 1997 

(a) Ambient air temperature range is -25°F to 115°F; 

(b) Relative humidity ranges from near 0 to 140%; 

G5-794 

.Page 13 of 42




avnec'^ 


PROJECT NO.: 145579 ' 

CLIENT: 

AMEC E&E - Richland, WA 

(c) Maximum precipitation is 2.5 inches in a 24-hour period; 

EXHAUST FAIJS 

(d) Sand and dust concentrations are 1.10 x 10-5 Ibm/ft3 with a typical size of 

150 µm; 

(e) Solar radiation is expected to be a maximum 900 Langleys over a 12 hr 

period; 

(f) Three — second gust wind velocity of 85 mph "3-second gust: wind velocity" 

and impo rtance factor of 1.15 and exposure category C (ASCE 7-98).. 

(g) UBC 1997 section 1632, equation 32-2, seismic zone 2B, soil profile Sc, and 

occupational catego ry 1. 


3.2.7 Safety 

The Exhaust Fans shall be sized for transpo rt using local roadways and freeways 

(i.e., less than 14 feet tall, 8 feet 6 inches wide, and 53 feet long; while mounted 

on the transpo rt trailer). The system shall be separated into the largest 

components/sections (if necessary) to minimize system teardown time, readying 

for transport, and reassembly effo rt . 

Pa rts removed for transpo rt shall be match marked for assembly upon delivery. 

The Exhaust Fans shall be designed to maintain the safety of operators, general 

public, and equipment. The Seller shall provide all necessary gu ards, lockouts, 

and other safety equipment for safe operation. 


The Seller shall provide all design calculations necessary for the Exhaust Fans, 

which includes, but is not limited to, motor-sizing calculations, drive components 

sizing calculations, motor current sta rting calculation, elect rical system 

calculations (i.e. load; voltage, and fault), pressure calculations and structural 

calculations. Fan housing shall be design to withstand winds and seismic forces 

per Natural Phenomena Hazard without loss of integrity. Calculations shall be 

G5-795 

Page 14 of 42





PROJECT NO.. 

145579 


EXHAUST FANS 

submitted to the Buyer in accordance with the Technical Data Sheet, 145579-V- 

DS-004.1- The Seller shall provide all design drawings necessary for the Exhaust 

Fans which includes, but is not limited to, drawing outlines, interface drawings, 

electrical wiring diagrams, control elementary diagrams, electrical equipment 

layout, duct/pipe support drawings, dimensional drawings, structural framework 

drawings, rigging sketches, and as-built drawings. 

Design drawings shall be provided as per the attached bidder drawings and 

documentation form. Drawings shall show all details of construction, accessories; 

and loading including but not limited to the following: 

• Empty weight, static and dynamic loads 

• Location of name plate and data to be stamped on it (see Section 3.3.8) 

• Necessary structural details and dimensions 

• Location of any necessary ductwork and electrical connections. 

Seller shall provide following information: 

E=quipment schedules 

• Fan performance Curves showing CFM 

• Static pressure 

• Fan RPM 

® BHP 

m Efficiencies. 


3.3.1.1 Casing 

The Exhaust fans shall be designed to fit on the concrete pad as detailed in 

attached drawings F-145579-V-007 and H-1 4-106796 (see section 3.2.2). 

The casing material shall be in conformance with the ASME or ASTM materials 

listed in AG-1 Table BA-3100 and the structural requirements of AA-4000. 

A quick-release cleanout/inspection door shall be provided at mid-scroll height. 

G5-796 

Page. 15 of 42







3.3.1.2 Drive Guard 

3.3.1.3 Electrical 

3.3.1.3.1 Conduit 

EXHAUST FANS 

The drive guard shall be fabricated of steel frame and steel sheet or expanded 

metal, of closed top and bottom design meeting appropriate safety standards, and 

shall have an access port for the measurement of fan RPM. 

Desogn and installation of electrical equipment shall be in accordance with the 

NFPA 70 "National Electric Code (NEC)" and IEEE Ìnstitute of Electrical and 

Electronics Engineers" standards listed in Table 2-2. The motors shall meet the 

requirements of NEMA MG-1 The Exhaust Fans shall be labeled by a nationally 

recognized testing laboratory, AMCA rated, or inspected and passed by the 

CH2M Hill Hanford Inspector. 

Rigid galvanized steel (RGS) or electrical metallic tubing (EMT) conduit shall be 

used. RGS or EMT shall be UL approved, standard weight, electro-galvanized 

steel, 1/2 inch minimum size for control wiring and 3/4 inch minimum for power 

wiring. 

(a) Liquid tight flexible metallic conduit shall be installed where flexible conduit is 

required such as when connecting to vibrating equipment. Liquid-tight 

flexible conduit shall be grounded type with a Polyvinyl Chloride (PVC) 

jacket. 

(b) Conduit fittings shall be standard steel threaded, liquid-tight, type RGS 

fittings. 

(c) EMT fittings shall comply with provisions in NFPA 70. 

3.3-1.3.2 Wire and Cable 

(a) Conductors shall be stranded copper for all sizes of wire and cable. 

(b) Wire insulation shall be Type THHN (heat resistant thermoplastic) / THWN 

(moisture and heat resistant thermoplastic) for all 600V conductors. 

G5-797 

Page 16 of 42





PROJECT NO.: 

CLIENT: 

145579 


EXHAUST FANS 

(c) Minimum size of power conductors, 600V and below, shall be No. 12 AWG. 

Conductors shall be de-rated as required by NFPA 70 for proximity to heated 

equipment and summer outdoor ambient conditions specified in Section 

3.2.5. 

(d) Conductors for control circuits shall be No. 14 AWG minimum, except that 

remote control circuits, signaling circuits, instrumentation, and power limited 


Code (NEC). 

(e) Power wiring for single-phase systems (1201240 V) shall have color-coded 

insulation as follows: Hot = Black, Brown; Neutral = White or Gray, Ground = 

Green or Bare. 

(f) Power wiring for 3-phase systems (480 / 277 V A, B, C) shall have colorcoded 

insulation as follows: Red, Yellow, Blue; Ground = Green or Bare, 


(g) Instrumentation cable shall be 600V, multi-conductor for discrete signals, 

flame retardant, jacketed cable suitable for installation in wet or dry 

locations. Conductors shall be #18 AWG stranded, copper, in twisted 

pairs/triads with ethylene propylene insulation. Each pair, !triad shall be 

shielded with a drain wire and metallic tape. Multi-pair 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. Each pair/triad shall be numbered for simplified 

termination- 

(h) Control and power multi-conductor cable shall be 600V, flame resistant, 

radiation resistant, jacketed cable suitable for wet or dry locations. 

Conductors shall be stranded copper with cross-linked polyethylene ethylene 

propylene insulation with a temperature rating of 194°F. 

3.3:1.3:3 Wire / Cable Markers 

Conductors shall be identified with while heat shrink tubing with indelible black 

typed on letters. Hand lettered labels shall be used. 

G5-798 

Page 17 of



PROJECT: 



[ CLIENT: AMEC E&E— Richland, WA 

3.3.1.3.4 ,function Boxes 

Final DBVS Design 145579-V-SP-004 REV. 4 


3.3.1.4 Instrumentation and Installation 

EXHAUST FANS 

In general, all instrument transmitters shall provide an isolated 4-20 mA signal to 

the MCS. Instruments, tubing, piping, and wiring shall be installed in accordance 

with the instrument manufacturers recommendations and the best practice for the 

industry. Purchasing and installation of the MCS input/output modules are not 

included in this contract. Local indicating instruments/sensors shall be installed 

so they are easily readable by an operator standing on the ground. The Buyer 

shall provide guidance with positioning based on best available knowledge of the 

configuration. 


package and shall include the instrument accuracy and drift. When purchasing 

instrumentation, the instrumentation shall be in accordance with the data sheets 

provided by Buyer, or Buyer will provide the necessary instrumentation. The 

Seller shall provide the data sheets to the component Manufacturer. 

Recommended field re-calibration procedures shall also be provided in the final 

data package along with a list of special tools required for recalibration. 

3.3.1.5 Mechanical Assembly Requirements 

All equipment shall be assembled to the structural frame observing the equipment 

Manufacturer's recommended assembly instructions. During fabrication, the 

Seller shall submit all fabrication redline changes to the Buyer for review and 

approval before implementation of the change with the exception of any minor 

red-line changes that do not affect form, fit, or function of the equipment. The 

Seller shall submit as-built drawings as well as final redlined fabrication drawings 

to the Buyer with delivery. The Seller shall denote mounting configuration and 

details on the redlined fabrication drawings. 

The Seller shall provide Owner's Maintenance and Operation Manuals in "ward 

copy' and in electronic format. 

G5-799 

Page 18 of 42






CLIENT: 

AMECE&E—Richland, WA 

EXHAUST FANS 

The technical documentation shall also be bound in 3-Ring Binders, complete with 

Indexed Tabs, Table of Contents, drawings, illustrations, catalog cuts, etc. 


OM manuals shall include recommended Spare Parts with catalog identifications 

and points of contact/addresses & telephone numbers, detailed operating and 

maintenance instructions. 

The Seller shall select materials based upon acceptable performance of materials 

subjected to the chemical exposures. AVl parts.and materials shall be new. All 

parts shall be made of corrosion-resistant materials that are suitable for this 

environment. Material selection shall be identified in the Seller documents to the 

Buyer. 

Material type and grade shall be clearly identified on the bilk of materials. 

Certificates of Conformance (COCs) are required for all materials coming in 

contact with the air stream. Structural steel shall be ASTM A36 "Standard 

specification for Structural Steel" or better. 

Exhaust Fans materials in contact with the air stream shall be compatible with the 

conditions identified on Technical Data Sheet, 145579-V-DS-004.1; No aluminum 

or "yellow" metals are to be used. No beryllium shall be present. Exposed 

polymer materials shall be constructed of anti-static materials. 

3.3.1.7 Fasteners 


such joints should be tack welded or have some equivalent means of assurance 

of remaining intact. Double-nutting is not an acceptable method of securing 

fasteners. Loctite' threadlock may be used where applicable. 

Stainless steel bolts, cap screws, and washers shall be per ASTM A193 

'Standard specification for Alloy-Steel and Stainless Steel Bolting Materials for 

High-Temperature Service" Grade B8, and nuts shall be heavy hex nuts per 

ASTM At 94 `Standard specification for Carbon and Alloy Nuts for Bolts for High- 

Pressure and High-Temperature Service"Grade 8. Bolts and cap screws shall be 

Loctite is a registered trademark of Henkel Corporation 

G5-800 

Page 19 of 42


TECHNICAL SPECIFICATION s xw 




CLIENT: AMEC E&E- Richland, WA 

EXHAUST FANS 

grade marked. Carbon-steel bolts shall be per ASTM A307 `Standard 

specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength" or 

better, nuts per ASTM A563 "Standard specification for Carbon and Alloy Steel 

Nuts,"Grade C Heavy Hex, and washers per ASTM F436 "Standard Specification 

for Hardened Steel Washers." 

All graded fasteners shall conform to ASME B18.2.1 "Square and Hex Bolts and 

Screws, Inch Series,"Society of Automotive Engineers (SAE) J429 Mechanical 

and Material Requirements for Externally Threaded Fasteners", and. ASTM A354 

"Standard specification for Quenched and Tempered Alloy Steel Bolts, Studs and 

other Externally Threaded Fasteners." 

The Seller shall select fasteners where they are not specifically called out in this 

specification using the following guidance: 

(a) Anti-galling compound (e.g., Loctite© 8013 or 8009) shall be applied where 


(b) Stainless-steel bolts, nuts, and washers shall be used when the mating parts 

are stainless steel. 

(c) Carbon-steel bolts, nuts, and washers shall be used where mating parts are 

not stainless steel. 

(d) The Seller shall ensure that suspect/counterfeit fasteners and components 

are not used for the construction of the Exhaust Fans assembly and its 

components. Suspect fasteners can be identified by the following inspection 

methods: 

(i) Head markings are marred, missing, or appear to have been altered, 

(ii) Threads show evidence of dressing or wear (threads should be of 

uniform color and finish), 

(iii) Head markings are inconsistent with a heat lot, and 

(iv) Head markings matching one of those identified on the United States 

Customs Service, "Suspect Headmark List", in Appendix A. 

G5-801 

Page 20 of 42




PROJECT: Final DSVS Design 145579-V-SP-004 I REV. 4 

PROJECT NO.: 

145579 

CLIENT: AMECE&E — Richland, WA 


EXHAUST FANS 

Flanged connections shall be appropriate for the temperature and sealing 

application of the system to which they will be sealing. The Seller shall provide 

manufacture-cut-sheets and application data for gaskets during the design for 

Buyer approval. 

3.3.1.9 Wielding 

Certified welders shall perform welding of all structural steel in accordance with 

American Welding Society (AWS) D1.1 "Structural Welding Code — Steel"or AWS 

D1.6 "Structural Welding Code — Stainless Steel' (depending on material). 

Welding Procedures, Procedure Qualification Records, and Welder Procedure 

Qualification Records shall be submitted for review and approval to the Buyer 

before welding is performed. 

3.3.1.9.1 Allowable Welding Methods 



D1.6 nontubular; statically loaded conditions. 



D1.1 nontubular, statically- loaded conditions. 

3.3.1.9.2 Welding Procedure Requirements 

All welding shall be performed in accordance with the Seller's approved Welding 

Procedure specification. Each Welding Procedure specification shall be qualified 

with a Procedure Qualification Record as required in ASME Section IX, AWS 

DI A, and AWS D1.6 as applicable. 

3.3.1.9.3 Welder Qualification 

Welder Performance Qualification Records shall be submitted for all personnel 

performing welding, including tacking. Welders shall be qualified in accordance 

with ASME Section IX, AWS D1.1, and AWS D1.6, as applicable. 

G5-802 

Page 21 of 42




amec^ 


PROJECT NO.: 

CLIENT: 

3.3.1.9. 4 Weld Repair 

145579 

AMEC E&E-Richland, WA 

EXHAUST FANS 


standards. The original Welding Procedu re 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. 

3.3.1.9.5 Inspection 


certified dimensional drawing and weldmap shall be produced from this 

inspection. 

Prior to fabrication, a weld map shall be produced and delivered to the Buyer for 

review and approval Welds shall be inspected per AWS D1.1 or D1.6 

(depending on material) for structural steel. An AWS Certified Weld Inspector 

(C WI) shall perform visual inspections and inspectors certified to ASNT-TC-1A 

Àmerican Society for Nondestructive Testing - Recommended .Practice shall 

pe rform NDEs. Visual and NDE weld inspection procedures shall be submi tted 

along with the personnel certifications to the Buyer for review and approval, 

before pe rformance of the inspections and examinations. Welded connections on 

the lifting components shall be 100% visual and 100% Dye-Penetrant Test or 

Magnetic Particle Test inspected. 

3.3.2 Industry and Government Standards 

3.3.2.1 Design Loads - Hoisting and Rigging 

The lifting apparatus (eyebolts, hoist rings, and lifting bails) shall be designed in 

accordance with the ASME B30.20 'Below-The-Hook Lifting Devices' and DOE- 

RL-92-36 "Hanford Site Hosting and Rigging Manua l. " Equipment lift points 

designed and fabricated by Seller shall have a factor of safety of 3 based on yield 

strength. Equipment purchased by Seller shall have a factor of safety of 3 based 

on yield strength. Documents shall be provided to the Buyer demonstrating 

incorporation of these safety factors. The Seller shall identify the total weight, the 

center of gravity, and the lift points and rigging methods necessary for lifting each 

Fan/motor/base assembly. Lift points shall be identified with yellow paint. Any 

G5-803 

Page 22. of 42




/11 " PROJECT: Final DBVS Design 145579-V-SP-004 I REV. 4 


CLIENT: 



special tooling, spreader bars or other recommended fabricated devices for lifting 

to be provided by Seller. 

3.3.3.1 Electromagnetic 

The Exhaust Fans shall comply with the limits set forth in HNF-2962, "List of 

EMI/EMC Requirements, Numetec Hanford Corporation for Fluor Daniel 

Corporation Hanford, Inc, Richland, WA," as summarized in the following 

subsections. 

3.3.11.1 Unintentional Radiators 

Applicable equipment shall comply with the emission limits specified in 47 CFR 15 

"Code of Federal Regulations, Telecommunication, Federal Communications 

Commission, Radio Frequency Devices," 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 "Standard for Withstand Capability of relay Systems to Radiated 

Electromagnetic interference from Transceivers." 

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 MHz to 1,000 MHz. The 

electric field intensity of 30V/m shall be used for testing. 

3.3.3.13 Equipment Alternating Current Mains Surge Protection 

Applicable equipment shall be designed to withstand the surge waves specified in 

IEEE C62.41 "IEEE Recommended Practice for Surge Voltages in Low-Voltage 

AC Power Circuits" Category B. The equipment shall be type tested by the 

G5-804 

Page 23 of 42





PROJECT NO.: 

145579 

CLIENT: AMEC E &E— Richland, WA 

EXHAUST FANS 

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 C63.16 Àmerican 

National Standard Guide for Electrostatic Discharge Test Methodologies and 

Criteria for Electronic Equipment. The test voltage should be at least 4 W. ANSI 

C63.16 provides additional references to selecting the proper voltage ranges to 

be used. 

3.3.3.2 Nuclear 

The Exhaust Fans shall be ASME AG-1-2003, "Code on Nuclear Air and Gas 

Treatment" as indicated in Appendix B. 


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: 

(a) Metallic or other dusts (shop dust), chips, turnings, and weld splatter; 

(b) Abrasive particles; 

(c) Rust and other loose corrosion particles; 

(d) Magnetic/liquid penetrantln2i residues, dye check, etc.; 

(e) Foreign material, such as paper, tape; plastic, sand, and wood; 

(f) Cutting oils; 

(g) Excess lubrication, grease, and oil; and 

(h) Marking dyes. 

The fabrication procedure shalt describe the cleaning and packaging steps taken. 

G5-805 

Page 24 of 42

RPP-24544 REV , Id 

TECHNICAL SPECIFICATION +^,m 


1 




EXHAUST FANS 

Solvents and cleaning solutions used on stainless steel shall be chloride-free. 



The Exhaust Fan po rts and pipe openings shall be temporarily capped following 

cleaning and drying for shipment. Packaging requirements following cleaning are 

documented in Section 5.3. 

3.3.5 Corrosion of Parts 

The Exhaust Fans design shall include requirements for corrosion protection, 

especially restrictions on dissimilar metal couples. 

3.3.6 Protective Coatings 

All components shall be corrosion protected. Su rfaces shall be cleaned, primed 

and painted such that corrosion shall not be a factor for the design life of the 

equipment. The protective coatings shall resist physical wear and the p ri mer shall 

be of the zinc-rich variety to ensure corrosion protection in the event of coating 

penetration. Hot dipped galvanization of the mounting frame is also an 

acceptable option. 

3.3.7 Interchangeability 

The Exhaust Fan Unit design shall ensure interchangeability of components, to 

minimize consumable pa rts storage. 


The Exhaust Fans shall have a Manufacturer's nameplate using the Seller's 

standard practice. The nameplate shall include: the equipment number (provided' 

by the Buyer, per the requirements of Section 3.3.9); assembly weight (dry and 

wet); purchase order number; lif ti 

ng bail working load limits; Manufacturer data for 

swivel hoist rings (as applicable); and this specification number, 145579-V-SP- 

004, latest revision. Clearly mark and identify any components required for 

removal before equipment installation (e.g., shipping blocks). 

G5-806 

Page 25 of 42






CLIENT: 


s 

s w 

The markings on all motors shall be in accordance with the NEC and NEMA MG-1 

"Motors and Generators." Frame size shall be selected according to NEMA MG- 

13 `Frame Assignments for Alternating Current Integral Horsepower Induction 

Motors" Care should be taken when painting such that the motor nameplates, 

lifting eyes, or lifting swivel Manufacture nameplates are not painted. 

Manufacturer's nameplate shall be stainless steel, permanently engraved and 

permanently attached to the equipment and major accessories (i.e. fans, motors, 

drives, etc.) and shall include the following information: 

• Fan capacity CFM 

• Fan operating static pressure in. W.G. 

• Fan RPM 

• Break Horse Power 

• Centrifugal wheel size in. 

•. Fan bearings: size, identification number, lubricant used, etc. 

• Fan weight 

• Motor: type, RPM, HP, frame, bearings, insulation class, NEMA 

characteristics, weight, etc 

• Drive 

• Manufacturer's Model identifications and serial numbers 

• Year of manufacture 

Motor power terminals shall come pre-labeled by phase to ensure correct motor 

rotation the first time. 


Seller shall supply a nameplate conforming to relevant sections of TFC-ENG- 

STD-12 "Tank Farm Equipment Identification Numbering and Labeling Standard, 

which will be provided upon award of the fabrication contract. 

G5-807 

Page 26 of 42




PROJECT: Final DSVS Design 145579-V-SP-004 REV. 4 

PROJECT' NO.: 145579 



EXHAUST FANS 

Any sensor indication must be easily visible to an operator standing on the 

ground. 


Equipment supplied by the Seller shall be subject to Factory Acceptance Testing. 

The Seller will be expected to provide a shop simulation of the inlet conditions of 

their equipment under normal and transient operating conditions to demonstrate 

the operational efficiency of the equipment. The Seller shall provide a FAT plan 

for operational testing and leak testing of their equipment in their proposal in 

accordance with the verification, inspection and test requirements specified in 

sections 4.2 and 4.3. 

3.3.12 Document Submittal 

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 

Drawing and Data Commitment sheet in the Technical Data Sheet 145579-V-DS- 

004A 


reproduction equipment after microfilming. 

The items shown in the Drawing and Data Commitment sheets shall be included 

along with the bid submittal. The schedule shall show equipment fabrication, 

testing, and delivery as noted on the inquiry. The drawings shall show full 

compliance with this specification (and the associated drawings/documents) or 

note any exceptions.. The Seller shall allow 10 working days foir the Buyer to 

review and state the disposition of each submittal. 



Submittals are divided into two types: (1) Those requiring "approval before 

proceeding" (i.e., weld procedures or pre-purchase evaluation data); and (2) 

Those requiring "approval before shipment' (i.e., vendor information data). 

G5-808 

Page 27 of 42




PROdEC'T: Final DBVS Design 145579-V-SP-004 I REV. 4 

PIOJEC'T NO.: 145579 

CLIENT: 


EXHAUST FANS 

on 

s^^ 

Pt 

Submi ttals requiring approval before shipment will be reviewed to verify 




A submittal requiring approval that is not approved by the Buyer, will be 


1. "Not Approved, Revise and Resubmit." The submittal is considered 

technically deficient, or incomplete, and is therefore unacceptable. Resubmi 

ttal is required; hence fabrication, procurement, or pe rformance of 

procedures shall not proceed. 

2. "Approved with Exception." Fabrication, procurement, and pe rformance of 

procedures may proceed, and re-submi ttal is required to verify incorporation 

of the exception. Final acceptance of the item is contingent upon the 

Buyer's receipt and approval of the corrected submi ttal. 

Submittals requiring approval before shipment that are determined to be 


explanation of the deficiencies will be included for corrective action by the Seller. 

The Seller shall provide fabrication traveler(s) for the fabrication and testing of the 

above-described Exhaust Fans. 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. 

A proposed schedule of fabrication, inspection, and testing of all Exhaust Fans 

equipment shall be submitted for review with the bid and approval with the 

submittal of the fabrication traveler(s). 

The Seller shall provide Owner's Maintenance and Operation Manuals in "hard 

copy" and in electronic format. 

The technical documentation shall also be bound in 3-Ring Binders, complete with 

Indexed Tabs, Table of Contents, drawings, illustrations, catalog cuts, etc. 

G5-809 

Page 26 of 42






CLIENT: 


EXHAUST FANS 

The Owner's Maintenance and Operation Manuals shall include recommended 

Spare Parts with catalog identifications and points of contactladdresses & 

telephone numbers, detailed operating and maintenance instructions. 

The Buyer will insert witness/hold points in the fabrication traveler during their 

review and approval of the fabrication traveler. Witness points can be waived by 

the Buyer but must be document in writing. Hold points require the Buyer 

personnel to be present during the fabrication, inspection, or test step. 


The Seller's equipment and systems shall be designed so that it is operable and 

maintainable by the Buyer's operations and maintenance personnel. If 

specialized technical education or training is required by the Buyer's personnel 

the Seller shall advise in their proposal 

G5-810 

Page 29 of 42




PROJECT: Final DBVS Design 145579.V-SP-004 I REV. 4 




4.1 GENERAL 


4.1.2 Design 

EXHAUST FANS 

The Subcontractor/Supplier shall have a documented, implemented and 

maintained Quality Assurance Program that is based on ASME NQA-1-1994, 

Quality Assurance Requirements for Nuclear Facility Applications, or other 

consensus standards that provide an equivalent level of quality assurance 

requirements. The Quality Assurance Program shall national standard and 

identifies the activities and items to which it applies. Instructions and procedures 

must include or reference appropriate quantitative or qualitative acceptance 

criteria for determining that prescribed activities have been satisfactorily 

accomplished. 

The Quality Assurance Program must address each of the areas discussed within 

this QA Requirements Flow-down. The Subcontractor/Supplier must submit the 

Quality Assurance Program to the Buyer for review prior to award of contract. 

The Subcontractor/Supplier shall assess its Quality Assurance Program regularly 

to assure its effective implementation. 


necessary, of personnel performing activities affecting quality to assure that 

suitable proficiency is achieved and maintained. Personnel who conduct 


certification of the qualification must be submitted to the Buyer upon request. 

The Subcontractor/Supplier must define, control, and verify designs developed for 

this contract. Design inputs must be specified on a timely basis 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. 

G5-811 

Page 30 of 42







4.1.3 Computer Software Important to Safety 

EXHAUST FANS 

When applicable, software applications impo rtant to safety shall meet the 

requirements of ASME NQA-1-1994 subpart 2.7, Quality Assurance 

Requirements for Nuclear Facility Applications. 

Safety software includes safety system software, safety and hazard analysis 

software and design software, and safety management and administrative control 

software. 

So ft 

ware documentation shall include identification of any computer calculation, 

including computer type, computer program (e.g., name), revision identification, 

inputs, outputs, evidence of or reference to computer program verification, and 

the bases (or reference thereto) supporting application of the computer program 

to the specific physical problem. 

4.1.4 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 Subcontractor's/Supplier's organization; and changes must be reviewed and 

approved by the same individuals who reviewed and approved the original 

procurement documents. 

The Subcontractor/Supplier must have a process for accepting procured items. 

This process must include one or a combination of the following: Ce rtificate of 

Conformance, source verification, receiving inspection, and post-installation 

testing. 

The Subcontractor/Supplier shall provide a legible and reproducible Certificate of 

Conformance. The Certificate of Conformance shall be signed by the 

Subcontractor's/Supplier's authorized representative responsible' for quality 

assurance. 

The Ce rtificate of Conformance shall contain, as a minimum, the following 

information: 

G5-812 

tt^ 

Page 31 of 42





PROJECIr NO.: 145579 


EXHAUST FANS 

• Identification of the Buyer's contract or purchase order number under which 

the materials, equipment, component, , or service is being purchased; 

• Provide traceability by means of positive identification from the material, 

equipment, component, or service to the Certificate of Conformance; 

• 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; 

• Identify any procurement requirements that have not been met, together with 

an explanation and the means for resolving the nonconformance. 

The Subcontractor's/Suppliers 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 

Subcontractor's/Supplier's QA Program. 

The certification system shall provide a means to verify the validity of 

Subcontractor/Supplier certificates and the effectiveness of the certification 

system, such as during the performance of audits of the Subcontractor/Supplier or 

independent inspection or test of the items. The Buyer shall conduct this 

verification at intervals commensurate with the Subcontractor's/Supplier's past 

quality performance. 

The Seller is required to flowdown applicable QA requirements based upon a 

graded approach from this contract to any subtier subGontractor/suppliers. 

Any access to the sub-tier suppliers7Subcontractor/Suppliers' facilities for 

verification activities will be requested through the Subcontractor/Supplier prior to 

access, and verification activities maybe performed jointly. 

The Subcontractor/Supplier shall warrant that all items furnished under the 

contract are genuine (i.e., new, not refurbished, not counterfeit} and match the 

quality, test reports, markings,. and/or fitness for intended use as required by the 

contract. Any materials furnished as part of the contract that the government or 

G5-813 

Page 32 of 42


AMEC Americas limited 


amec^ 


PROJECT NO.: 

CLIENT: 

145579 


EXHAUST FAPIS 

other duly recognized agency had been previously found to be suspect/counterfeit 

shall not be used. 

All items are subject to inspection at the Subcontractor's/Supplier's facility or 

lower-tier subcontractor's facility. The Subcontractor/Supplier shall notify the 

Buyer at least 7 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 prior to packaging for shipment shall be considered such a hold point, 

unless specifically waived by the Buyer. 

The Subcontractor/Supplier shall obtain all materials to be delivered under the 

contract directly from the original manufacturer or an authorized manufacturer's 

representative. The Subcontractor/Supplier 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, shipping documentation or 

manufacturer invoice; each of which would identify that the materials were 

obtained from the original manufacturer. 

The Subcontractor/Supplier shall submit, with or prior to item shipment, a 

recommended spare pa rts list. The list shall provide the name and address of the 

original supplier of the replacement pa rt, and the pa rt's drawings, specification, or 

catalog identity including applicable change or revision information. 

All items and/or services procured under this specification shall be subject to 

inspection by the Buyer or Buyer's representative throughout the contract. 


acceptance. 

The Subcontractor/Supplier shall grant access to the Subcontractor's/Supplier's 

plant facilities and records for inspection or audit by the Buyer, his designated 

representative, and/or other pa rties authorized by the Buyer. 

4.1.5 identification and Control of Items 

The Subcontractor/Supplier shall establish controls to assure that only correct and 

accepted items are used or installed. 

G5-814 

33 of 42







s 

EXHAUST FANS 


other identifier prescribed in the 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. 


product data sheet (e.g., drawing, catalog cut sheet, brochure, etc.) 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 Subcontractor/Supplier 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 Subcontractor/Supplier shall specify 

any storage temperatures, humidity and environmental conditions that should be 

maintained. Material shall not be furnished having less than 75 percent of total 

shelf life available at time of shipment. 


The Subcontractor/Supplier shall have processes to control processes, including 

special processes that control or verify quality (e.g., welding, heat treating, and 

nondestructive examination). Special processes must be performed by qualified 

personnel using qualified procedures in accordance with specified requirements. 

Subcontractor/Supplier personnel performing weld inspections shall be certified 

as a CWI in accordance with the requirements of the American Welding Society 

(AWS), OC-1. The following documentation shall be submitted for Buyer approval 

prior to the start of fabrication: 

U Current AWS CWlcertification; 

Current/valid visual acuity examination (must be given every 3 years); and 

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 

G5-815 

Page 34 of 42


TECHNICAL SPECIFICATION o 





EXHAUST FANS 

Subcontractor/Supplier shall submit copies of all welding procedures, procedure 

qualification records, and welder qualification records to be employed. Buyer 

review and approval of these documents is required prior to start of fabrication. 

Nondestructive Examination (NDE) personnel shall be qualified and certified in 




Buyer: 

0 NDE personnel qualification and certification procedure; 

o Level I, 11, 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; 

NDE method procedure(s) compliant with the applicable requirements of the 

Buyer's contract. 

NDE 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 prior to shipment. 

These requirements shall be passed to lower-tier subcontractors. 


The Subcontractor/Supplier 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 Subcontractor/Supplier 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. 

G5-816 

35 of 42




PROJECT: Final DBVS Design 145579-V-SP-004 REV. 4. 



EXHAUST FANS 


reproducible copies of inspection and/or test reports. The reports shall include, as 

a minimum, the following information: 

• Identification of applicable inspection and/or test procedure; 

• Resulting data for all characteristics evaluated, as required by inspection or 

test procedures, including reference to information on action taken in 

connection with nonconformances; 

• Traceability to the item inspected/tested (e.g., serial number, part number, lot 

number, etc.), date of inspection, name of inspector, type of observation; and 

• Signature of the Subcontractor/Supplier's authorized representative or agency 

performing the inspection or test. 


The Subcontractor/Supplier 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. 

The Subcontractor/Supplier shall prepare a detailed test plan. Prior to starting 

work, the plan shall be submitted to the Buyer for approval and insertion of 

Buyer's designated source inspection/witness notification points. The test plan 

shall provide the following at a minimum: 

• Traceability to Buyer's purchase/contract order document number; 



• Method/procedure to be used during test. 

Subsequent revisions/modifications to the test plan require review and approval 

by the Buyer prior to implementation of the changes. 

The Subcontractor/Supplier shall provide test, reports that include, as a minimum: 

G5-817 

AX 

Page 36 of 42




PROJECT: Final DSVS Design 145579-V-SP-004 REV. 4 


CUENT: AMEG E&E - Richland, WA 

• Item tested, 

• Date of test, 

• Tester or data recorder, 

• Type of observation, 

• Results and acceptability, 

• Action taken in connection with any deviations noted, and 

• Person evaluating test results. 

EXHAUST FANS 

Test plans and test reports must be submitted to the Buyer for the project records. 

4.1.9 Control of Measuring and Test Equipment 

The Subcontractor/Supplier shall control tools, gages, instruments, and other 

measuring and test equipment used for activities affecting quality, and shall 

calibrate at specified periods and adjust to maintain accuracy within necessary 

limits. 

The Subcontractor/Supplier shall maintain legible, reproducible copies of the 

Certificates of Calibration, traceable to the National Institute of Standards and 

Technology (NIST), for each article contracted. Each Certificate of Calibration 

shall be signed by the Supplier's representative responsible for calibration, 

attesting to its authenticity, and shall be identified with the following information: 

• Buyer's contract number; 

• Odentification of the article to which the Certificate of Calibration applies; and 

• Standards used for calibration. 

In addition, the Subcontractor/Supplier 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. 

The Certification of Calibration will be held on file by AMEC as objective evidence 

to support the actual test results and attest to the fact that the calibrated item(s) 

met requirements. 

G5-818 

m 

Page 37 of 42







4.1.10 Handling, Storage, and Shipping 

EXHAUST FANS 

The Subcontractor/Supplier shall prepare and submit for Buyer review and 

approval, prior to 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 prior 

to 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. 

4.1.11 Control of Nonconforming items 


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. 

All nonconforming conditions identified at the Subcontractor/Supplier'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: 

• Accept-as-Is: Nonconforming materials will perform its intended function. 

• 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 Subcontractor/Supplier 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 shall be submitted to the Buyer. 

Ci5-819 

Page 38 of 42

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