Technical Specification 

Including 

Attachments and Drawings 

SJRPP NOx Reduction Project 

Air Heater Modifications 

144805.62.1215.1 

PO Issue 

28Mar2007 

Black & Veatch Corporation 

Raleigh, NC 
Table of Contents

01400 - Technical Supplemental Specifications ......................................................................................5

01400.1 Summary of Applicable Supplementals.....................................................................................5 

01400.2 Technical Supplemental Specifications.....................................................................................5 

D100 Site Meteorological and Seismic Data ...........................................................................................5 

D200 Design Ambients............................................................................................................................6 

D300 Property Tables..............................................................................................................................6 

E000 Electrical Equipment and System Voltages ...................................................................................9 

E100 Wiring Methods, Cable, and Raceway...........................................................................................9 

E100.1 General Requirements............................................................................................................9 

E100.2 Equipment Safety Grounding (Earthing)...............................................................................11 

E100.3 Electrical Interconnections....................................................................................................11 

E100.4 Cable.....................................................................................................................................11 

E100.5 Conduit..................................................................................................................................12 

E100.6 Not Used ...............................................................................................................................13 

E100.7 Terminations .........................................................................................................................13 

E210 Electrical Enclosure Assemblies ..................................................................................................14 

E210.1 General Requirements..........................................................................................................14 

E210.2 Electrical Enclosure Heating.................................................................................................14 

E230 Control Panel Receptacles, Lights, and Communications...........................................................15 

E400 Motor Control................................................................................................................................15 

E400.1 General Requirements..........................................................................................................15 

E400.2 NEMA - Combination AC Motor Starters ..............................................................................16 

E400.3 Not Used ...............................................................................................................................16 

E400.4 DC Motor Starters .................................................................................................................16 

E510 Molded Case Circuit Breakers .....................................................................................................17 

E520 Terminal Blocks and Fuse Holders ...............................................................................................17 

E520.1 General .................................................................................................................................17 

E520.2 Not Used ...............................................................................................................................18 

E520.3 Strap Screw Terminal Blocks................................................................................................18 

E520.4 Power Terminal Blocks .........................................................................................................18 

E520.5 Thermocouple Terminal Blocks ............................................................................................18 

E520.6 Fuse Holders for Power Circuits ...........................................................................................18 

E530 Electrical Accessory Devices .......................................................................................................19 

E530.1 Electrical Indicating Instruments ...........................................................................................19 

E530.2 Control Relays ......................................................................................................................19 

E530.3 Electrical Switches ................................................................................................................19 

E530.4 Indicating Lights ....................................................................................................................20 

E530.5 Contacts................................................................................................................................20 

E530.6 Fuses ....................................................................................................................................20 

E530.7 Colors of Indicating Devices and Actuators..........................................................................20 

E640 Low Voltage Induction Motors......................................................................................................23 

E640.1 General .................................................................................................................................23 

E640.2 Products................................................................................................................................24 

E640.3 Drawings and Engineering Data ...........................................................................................26 

E642 Single-Phase Induction Motors ....................................................................................................28 

E642.1 General .................................................................................................................................28 

E642.2 Products................................................................................................................................28 

K100 Instrumentation.............................................................................................................................30 

K100.1 General Requirements..........................................................................................................30 

K100.2 Local Indicators.....................................................................................................................31 

K100.3 Process Actuated Switches ..................................................................................................32 

K100.4 Temperature Element Assemblies........................................................................................32 

K100.5 Not Used ...............................................................................................................................33 

K100.6 Not Used ...............................................................................................................................33 
K100.7 Solenoid Valves ....................................................................................................................33 

K100.8 Position Switches..................................................................................................................34 

K120 Instrument Valves and Instrument Primary Piping and/or Tubing ...............................................34 

K120.1 General Requirements..........................................................................................................34 

K120.2 Instrument Primary Piping.....................................................................................................34 

K120.3 Instrument Primary Tubing....................................................................................................34 

K120.4 Control and Instrument Enclosure/Rack Tubing...................................................................34 

K120.5 Instrument Valves and Valve Manifolds................................................................................35

K120.6 Blowdown Valves..................................................................................................................35 

K120.7 Instrument Valves, Fittings, and Support Tray......................................................................35 

M200 Piping...........................................................................................................................................36 

M400 Safety Guards..............................................................................................................................40 

M400.1 Horizontal Shaft Equipment..................................................................................................40 

M400.2 Vertical Shaft Equipment......................................................................................................40 

M400.3 Belt Guards ..........................................................................................................................41 

M720 Equipment Cooling Water............................................................................................................41 

Q002 Quality System Requirements .....................................................................................................41 

Q002.1 General Quality System Requirements................................................................................41 

Q100 General Welding Requirements...................................................................................................44 

Q100.1 General.................................................................................................................................44 

Q100.2 Welding Processes...............................................................................................................44 

Q100.3 Welding Procedure Qualification ..........................................................................................44 

Q100.4 Welder/Welding Operator Performance Qualification ..........................................................45 

Q100.5 Filler Materials ......................................................................................................................45 

Q100.6 Fabrication Controls .............................................................................................................47 

Q100.7 Nondestructive Examination (NDE)......................................................................................51 

Q100.8 Records ................................................................................................................................52 

Q121 Welding of Carbon, Low Alloy, and Stainless Structural Steel ....................................................52 

Q121.1 General.................................................................................................................................52 

Q121.2 Welding Processes...............................................................................................................52 

Q121.3 Welding Procedure Qualification ..........................................................................................53 

Q121.4 Welder/Welding Operator Performance Qualification ..........................................................53 

Q121.5 Fabrication Control ...............................................................................................................53 

Q121.6 Nondestructive Examination (NDE)......................................................................................53 

Q122 Welding of Abrasion-Resistant Steel Plate..................................................................................54 

Q122.1 General.................................................................................................................................54 

Q122.2 Welding Processes...............................................................................................................54 

Q122.3 Welding Procedure Qualification ..........................................................................................54 

Q122.4 Welder/Welding Operator Performance Qualification ..........................................................54 

Q122.5 Fabrication Control ...............................................................................................................54 

Q122.6 Nondestructive Examination (NDE)......................................................................................55 

Q301 Manufacturer's Standard Coating ................................................................................................55 

Q301.1 Control and Electrical Equipment .........................................................................................55 

Q301.2 Mechanical Equipment .........................................................................................................55 

Q301.3 Documentation .....................................................................................................................55 

Q400 General Equipment Requirements ..............................................................................................56 

Q400.1 Miscellaneous Materials and Services .................................................................................56

Q400.2 Fabrication Restrictions........................................................................................................56 

Q400.3 Nameplates and Tags ..........................................................................................................57 

Q400.4 Factory Assembly .................................................................................................................57 

Q400.5 Tools.....................................................................................................................................57 

Q500 Shop Drawings and Instruction Manuals .....................................................................................58 

Q500.1 Submittal Requirements .......................................................................................................58 

Q500.2 Compliance Reports.............................................................................................................58 

Q500.3 Motor and Electric Actuator Information...............................................................................58 

Q500.4 Drawings...............................................................................................................................58 
Q500.5 Wiring Diagrams ...................................................................................................................61 

Q500.6 Instruction Manuals. .............................................................................................................61 

Q501 Instruction Manuals......................................................................................................................61 

Q501.1 Submittal Requirements .......................................................................................................61 

Q501.2 Instruction Manuals. .............................................................................................................61 

Q502 Electrical Data..............................................................................................................................65 

Q502.1 Submittal Requirements .......................................................................................................65 

Q502.2 Motor and Electric Actuator Information...............................................................................65 

Q502.3 Wiring Diagrams ...................................................................................................................65 

V100 Noise Abatement..........................................................................................................................69 

15541 - Air Heater Modifications .............................................................................................................70

15541.1 General ....................................................................................................................................70 

15541.1.1 Arrangement.....................................................................................................................70 

15541.1.2 Scope of Supply ................................................................................................................70 

15541.1.3 Items Furnished by Others and Interfaces.......................................................................71 

15541.1.4 Codes and Standards.......................................................................................................72 

15541.1.5 Materials...........................................................................................................................72 

15541.1.6 Approved Manufacturers of Components .........................................................................72 

15541.1.7 Test Requirements............................................................................................................72 

15541.1.8 Technical Attachments.....................................................................................................73 

15541.2 Performance and Design Requirements .................................................................................73

15541.2.1 Design Performance Conditions ......................................................................................73 

15541.2.2 Performance Guarantees..................................................................................................75 

15541.2.3 Performance Tests............................................................................................................75 

15541.3 Equipment Design Requirements............................................................................................75 

15541.3.1 Rotor..................................................................................................................................76 

15541.3.2 Seals..................................................................................................................................76 

15541.3.3 Heat Transfer Surfaces .....................................................................................................76 

15541.3.4 Bearing Lubrication and Cooling.......................................................................................76 

15541.3.5 Housing .............................................................................................................................76 

15541.3.6 Drive ..................................................................................................................................77 

15541.3.7 Gearbox Upgrade.............................................................................................................77 

15541.3.8 Sector Plate Adjusters......................................................................................................77 

Attachments ..............................................................................................................................................78

Attachment A – Schedule .......................................................................................................................78 

Attachment B – Schedule of Submittals .................................................................................................78 

ATTACHMENT A........................................................................................................................................79

Schedule ....................................................................................................................................................79
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01400 - Technical Supplemental Specifications 

This section contains technical supplemental specifications that provide additional requirements 

applicable to the work covered under the technical sections which follow this Section 01400. 

01400.1 Summary of Applicable Supplementals 

The technical supplementals applicable to each technical section are indicated below. 

Technical 

Section 

Number 

Technical Section 

Name Applicable Technical Supplementals 

1 15541 Air Heater Modifications D100, D200, D300, E000, E100, E210, E230, E400, 

E510, E520, E530, E640, E642, K100, K120, M200, 

M400, M720, Q002, Q100, Q121, Q122, Q301, 

Q400, Q500, Q501, Q502, V100 

01400.2 Technical Supplemental Specifications 

The technical supplemental specifications follow. 

D100 Site Meteorological and Seismic Data 

(Source: 16Feb05 - Revised by Project: 07Jul06)

Work shall be designed according to the following building code and site conditions: 

Building Code: FLORIDA BUILDING CODE, 2004 

EDITION (see Note 1 below) 

Classification Category BUILDING III 

Meteorological Data: 

Basic Wind Speed, V, 3 second gust speed with 

50 year mean recurrence interval, mph 

120 

Exposure C 

Importance Factor 1.15 

Ground Snow Load, Pg, 50 year mean 

recurrence interval 

0 

Site Elevation (mean sea level), ft (m) 18 

Seismic Design Data: Not Required 

Note1. The code can be found online at: http://www2.iccsafe.org/states/2004_florida_codes/
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D200 Design Ambients 

(Source: 27Jan04 - Revised by Project: 07Jul06) 

Area Specific Design 

The general design ambient air conditions shall be used unless area specific or equipment specific 

conditions are indicated in the contract documents: 

 Temperature, °F Relative Humidity, % 

Area Minimum Maximum Minimum Maximum 

General Outdoor Area 7 103 48 92 

D300 Property Tables 

(Source: 27Jan04 - Revised by Project: 07Jul06)

Fuel Characteristics 

Coal - Eastern Kentucky (Domestic) Design Maximum Minimum 

Ultimate Fuel Analysis (% by mass): 

Carbon 68.00 80 50

Hydrogen 4.40 6 3.5

Sulfur 0.85 1.8 0.5

Nitrogen 1.50 1.9 0.4

Oxygen 8.15 9.5 3

Chlorine 0.10 0.3

Ash 11.00 15

Moisture 6.00 15.0 4.0

Higher Heating Value (Btu/lb) 12,000 12,913 11,143 

Ash Mineral Analysis (% by mass): 

Silica (silicon oxide) 53.00 58.0 30.0 

Alumina (aluminum oxide) 31.70 36.0 18.0 

Titania (titanium oxide) 1.40 3.0 0.3 

Calcium Oxide 1.20 6.5 0.5 

Potassium Oxide 2.00 4.0 0.1 

Phosphorus Pentoxide 0.40 3.0 0.1 

Magnesium Oxide 1.30 2.0 0.1 

Sodium Oxide 0.60 2.0 0.1 

Iron Oxide 6.00 30.0 5.0 

Sulfur Trioxide 0.40 7.0 0.1 
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Undetermined 2.00 

Trace Metal Analysis 

Vanadium (ppm) 48.30 54.53 17.27 

Lead (ppm) 16.94 16.94 3.03 

Arsenic (ppm) 28.92 28.92 1.88 

Coal - Columbia, South America Design Maximum Minimum 

Ultimate Fuel Analysis (% by mass): 

Carbon 63.90 73.26 62.10

Hydrogen 4.60 4.90 4.30

Sulfur 0.70 0.82 0.53

Nitrogen 1.18 1.38 1.08

Oxygen 7.99 9.89 6.09

Chlorine 0.03 0.06 0.01

Ash 9.60 11.90 5.07

Moisture 12.00 13.60 10.50

Higher Heating Value (Btu/lb) 11,300 11,696 11,100 

Ash Mineral Analysis (% by mass): 

Silica (silicon oxide) 60.20 62.20 58.20

Alumina (aluminum oxide) 20.20 22.20 18.20

Titania (titanium oxide) 1.00 1.20 0.80

Calcium Oxide 2.50 3.40 1.60

Potassium Oxide 2.30 3.00 1.60

Phosphorus Pentoxide 0.24 0.29 0.19

Magnesium Oxide 2.3 3.10 1.5

Sodium Oxide 0.60 0.90 0.30

Iron Oxide 8.40 9.80 7.00

Sulfur Trioxide 2.10 2.90 1.50

Manganese 0.06 0.09 0.03 

Undetermined 0.10 

Trace Metal Analysis 

Vanadium (ppm) 55.70 55.70 16.07 

Lead (ppm) 6.20 6.72 2.01 

Arsenic (ppm) 4.17 4.17 1.77 

Petroleum Coke Design Maximum Minimum 
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Petroleum Coke Design Maximum Minimum 

Ultimate Fuel Analysis (% by mass): 

Carbon 79.94 87.15 68.34

Hydrogen 3.22 4.11 3.22

Sulfur 5.79 6.94 3.49

Nitrogen 1.56 1.70 1.49

Oxygen 0.72 2.53 0.28

Chlorine 0.17 

Ash 0.6 9.80 0.53

Moisture 8 8.55 4.30

Higher Heating Value (Btu/lb) 14,000 17,377 13,142 

Ash Mineral Analysis (% by mass): 

Silica (silicon oxide) 27.48 53.91 13.00

Alumina (aluminum oxide) 8.85 26.53 3.24

Titania (titanium oxide) 0.57 1.37 0.21

Calcium Oxide 3.25 6.59 1.49

Potassium Oxide 0.89 2.82 0.30

Phosphorus Pentoxide 0.06 0.20 0.01

Magnesium Oxide 0.98 1.57 0.57

Sodium Oxide 2.43 3.99 0.47

Iron Oxide 4.83 16.39 2.35

Sulfur Trioxide 2.60 6.58 0.06

Nickle Oxide 7.87 16.77 3.53

Vanadium Pentoxide 39.27 57.30 0.00

Undetermined 0.86 

Trace Metal Analysis 

Vanadium (ppm) 2,042 2,042

Lead (ppm) 29.90 29.90 3.26 

Arsenic (ppm) 13.54 13.54 5.79 
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E000 Electrical Equipment and System Voltages 

(Source: 27Jan04 - Revised by Project: 07Jul06) 

Continuous 

Voltage 

(Volts) 

Frequency 

(Hz) 

Max Sym 

Short-Circuit 

at Max 

Voltage 

(Amps) 

Power 

Supply 

Code 

Nom 

Max 

Min 

Momentary 

Voltage 

Dip (% of 

Nom) 

Nom 

Max 

Min Configuration 

System 

Neutral 

Grounding 

Transfer to 

Alternate 

Source 

3-Phase 

Ph-Gnd 

LV-1 

Low 

Voltage 

(Power) 

480 

504 

432 

80 60 

60 

60 

3-Phase, 

3 Wire, 

Wye 

High 

Resistance 

Fast 

Transfer 

65,00010 

LV-2 

Low 

Voltage 

(Lighting) 

208Y/120 

220Y/127 

187Y/108 

80 60 

60 

60 

3-Phase, 

4 Wire, 

Wye 

Solidly 

Grounded 

N/A 10,000 

10,000 

LV-3 

Low 

Voltage 

(Power) 

208Y/120 

220Y/127 

187Y/108 

80 60 

60 

60 

3-Phase, 

4 Wire, 

Wye 

Solidly 

Grounded 

N/A 10,000 

10,000 

UPS-1 

UPS 

Power 

120 

126 

108 

95 60 

60 

60 

Single-Phase, 

2 Wire 

Solidly 

Grounded 

Static 1/2 

Cycle 

N/A 

10,000 

DC-1 

DC Power 

125 

140 

100 

70 0 

0 

0 

Two-Pole Ungrounded N/A N/A 

N/A 

CP-1 

Control 

Power 

(AC) 

120 

126 

108 

80 60 

60 

60 

Single-Phase, 

2 Wire 

Solidly 

Grounded 

N/A N/A 

N/A 

E100 Wiring Methods, Cable, and Raceway 

(Source: 14Apr04 - Revised by Project: 07Jul06)

E100.1 General Requirements 

In general, all devices furnished under these specifications and requiring electrical connections shall be 

designed for wiring into electrical enclosures with terminal blocks. Terminal blocks shall be furnished for 

conductors requiring connection to circuits external to the specified equipment, for internal circuits 

crossing shipping splits, and where equipment parts replacement and maintenance will be facilitated. 

Splices will not be permitted. 

Unless otherwise specified, one spare normally open and one spare normally closed contact on each 

control switch and lockout relay shall be wired out to terminal blocks. 

All wiring leaving an enclosure shall leave from terminal blocks and not from other devices in the 

enclosure. 

Auxiliary equipment such as terminal blocks, auxiliary relays, or contactors shall be readily accessible. 

Auxiliary equipment shall be located in compartments, enclosures, or junction boxes in such an 
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arrangement that service personnel will have direct access to the equipment without removal of barriers, 

cover plates, or wiring. 

Terminal blocks for external connections shall be grouped in the instrument and control compartment for 

easy accessibility, unrestricted by interference from structural members and instruments. Sufficient space 

shall be provided on each side of each terminal block to allow an orderly arrangement of all leads to be 

terminated on the block. 

Terminal blocks shall not be mounted in compartments containing uninsulated conductors operating at 

voltages above 1000 volts. 

When current transformers are supplied with the equipment furnished under these specifications, a 

shorting type terminal block shall be installed at an accessible location for each set of current 

transformers. The shorting terminal blocks shall be the nearest the current transformers. No other 

shorting type terminal blocks are required unless specified otherwise. The shorting terminal blocks shall 

be furnished with white marking strips. 

For safety reasons, the current transformer shall be grounded but the grounding shall occur only at the 

shorting terminal blocks. The grounding conductor shall be identified so that it may be disconnected in 

the field as required. 

Materials containing asbestos shall not be used in any of the wiring devices or cable. 

Control conductors 8 AWG and smaller shall be terminated with compression type connectors properly 

sized for the conductor and the terminal. Terminal connectors for connecting to screw terminals shall be 

preinsulated ring type or preinsulated snap spade type terminal connectors. Except for internal wiring of 

factory prewired electronic system cabinets, ferrules shall be provided on all stranded control conductors 

that are to be terminated to compression Type IEC terminal blocks. Conductors for current transformer 

circuits shall be terminated with preinsulated ring type terminal connectors. 

Each terminal block, terminal, conductor, relay, breaker, fuse block, and other auxiliary devices shall be 

permanently labeled to coincide with the identification indicated on the drawings. All terminals provided 

for termination of external circuits shall be identified by inscribing terminal designations acceptable to the 

Purchaser on the terminal block white marking strips with permanent black ink. All internal wiring 

terminations shall be identified by printing on conductor identification sleeves. A conductor identification 

sleeve shall be provided on each end of each internal conductor. Each sleeve shall be marked with the 

opposite end destination identification using permanent black ink. Conductor identification shall be 

permanent, unaffected by age, heat, or solvents and not easily dislodged. Adhesive labels are not 

acceptable. 

The arrangement of connections on terminal blocks shall be acceptable to the Purchaser. 

All connections requiring disconnect plug and receptacle type devices shall be provided with factory 

terminated conductors on each plug and receptacle. Plugs and receptacles shall be factory wired into 

junction boxes containing terminal blocks for external connections. All conductors on the disconnect 

portion of plug-receptacle assemblies shall be in a common jacket. The plug-receptacle assemblies shall 

have provisions for locking the devices together. The assembly shall also be watertight when installed 

outdoors. 

All temporary wiring installed in the factory for equipment testing shall be removed prior to shipment of the 

equipment. 

Reference to NEC means the codes and standards as defined by the USA National Electrical Code, 

ANSI/NFPA 70. 
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E100.2 Equipment Safety Grounding (Earthing) 

All electrical equipment that is part of an integral shipping unit or assembly shall be furnished with a bare 

copper grounding pad. The pad shall be suitable for field connection to the station ground grid by others. 

Isolated logic system or single-point ground connections required for proper operation of electronic 

equipment shall be insulated from the equipment safety ground. Such connections will be extended, 

using insulated cable, to a single termination point suitable for field connections to the appropriate ground 

system by others. 

Electrical equipment requiring grounding provisions shall include all enclosures containing electrical 

connections or bare conductors with the exception of control devices, such as solenoids, pressure 

switches, and limit switches, unless such devices require grounding for proper operation. 

The raceway system shall not be considered to be a ground conductor except for itself. All metal 

conduits containing power circuits shall be provided with grounding type bushings and shall be wired 

together inside enclosures and connected internally to the enclosure grounding pad or grounding bus with 

bare copper conductor. The grounding bushing ground conductor shall be sized in accordance with NEC 

or other internationally recognized standard but shall not be less than 8 AWG bare copper conductor. 

Ground conductors shall be soft drawn, bare stranded copper strand Class B as defined in ICEA S-19-81. 

All clamps, conductors, bolts, washers, nuts, and other hardware used with the grounding system shall be 

copper. 

E100.3 Electrical Interconnections 

All electrical interconnections between devices, panels, and boxes shall use one of the following wiring 

methods as specified on the table at the end of this section: 

Nonarmored Cable/Conduit. Nonarmored cable which is continuously supported and 

protected by conduit. 

Armored Cable/Tray. Armored cable which is continuously supported by metal cable 

ladder. The armored cable shall be terminated with cable glands. 

Manufacturer's Standard. The manufacturer shall choose between either nonarmored 

cable/conduit or armored cable/tray construction. 

The installation of the cable and raceway system shall meet the requirements of NEC or other 

internationally recognized standard. 

E100.4 Cable 

Unless otherwise specified on the table at the end of this section, both nonarmored and armored cable 

shall meet the following requirements: 

Stranded copper conductors. 

Ethylene propylene rubber insulation all cables. 

CPE jacket on all multi-conductor cables. 

Minimum size of 16 AWG for control cables. 

Minimum size of 14 AWG for power cables. 

Minimum size of 12 AWG for current transformer cables. 

Minimum size of 12 AWG for potential transformer cables. 
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Minimum size of 20 AWG for instrument and thermocouple extension cables. 

General service power and control cables, integral to the equipment furnished but not 

internal wiring of control cabinets or panels, shall be rated for the maximum service 

voltage but not less than 600 volts. 

Cables which are routed through environmental conditions that differ along the cable run 

shall be selected using the environmental condition that results in the largest cable size. 

All thermocouple cable shall use solid conductors with twisted and shielded pairs. Unless 

otherwise noted, insulation shall be color coded in accordance with ANSI/MC96.1. This 

requirement also applies to thermocouple extension wire which is furnished internal to 

Supplier-furnished equipment. 

All instrument cable shall use stranded copper conductors with twisted and shielded pairs 

or triads. These requirements also apply to instrument cable which is furnished internal 

to Supplier-furnished equipment. 

Shielding of thermocouple and instrument cables shall consist of aluminum-polyester 

tape and copper drain wire. 

Finished cables shall be capable of passing the IEEE 383 (70,000 Btu/h) vertical tray 

flame test. This requirement also applies to multi-conductor control cable, 

instrumentation cable, and thermocouple cable which are furnished internal to Supplierfurnished equipment including control panels and cabinets. 

Single conductor cables used for internal wiring of control panels and cabinets may be 

installed according to the Supplier's standard as to wire size, insulation, and method of 

termination on internal equipment, except that insulation for all wires shall meet the UL 

1581 VW-1 flame test. 

Additional requirements as defined in each applicable section. 

Armored (armoured) cables shall meet the following additional requirements: 

Armor shall be steel wires on multi-conductor cables and shall be aluminum wires on 

single conductor cables. 

A CPE jacket shall be extruded over the armor wires. 

The cables shall be capable of passing the IEEE 383 (70,000 Btu/h) vertical tray flame 

test. 

E100.5 Conduit 

All conduit interconnections between devices, panels, boxes, and fittings shall be rigid metal conduit 

which conforms to ANSI C80.1 and UL 6. All conduit connections shall be of the threaded type, and all 

conduit, couplings, and fittings shall be hot-dipped galvanized steel. The interior and exterior surfaces of 

all rigid metal conduit, couplings, and fittings shall have a continuous zinc coating with an overcoat of 

transparent enamel, lacquer, or zinc chromate. Liquidtight flexible metal conduit may be used as long as 

the length does not exceed 3 feet. All conduit which enters the top of an enclosure or which enters 

outdoor enclosures shall enter through raintight steel or malleable iron hubs or threaded openings. 

All liquidtight flexible metal conduit shall be constructed of continuously interlocked rust resistant metal 

core. Conduit shall be coated with sunlight resistant thermoplastic jacket. The conduit shall also resist 

heat, oil, and chemical breakdown and shall be UL listed. 
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One exterior locknut, one interior locknut, and one bushing shall be provided at the termination of each 

rigid metal conduit not terminated in a hub. 

Grounding type insulated bushings with insulating inserts in metal housings shall be provided on all 

conduits not terminated in hubs and couplings. Bushings shall be galvanized. 

All conduit fittings shall conform to the requirements of UL 514. All liquidtight flexible metal conduit fittings 

shall be galvanized steel or malleable iron with insulated throat. 

Conduit fittings used on outdoor equipment shall be gasketed. 

All conduit shall be installed in exposed runs parallel or perpendicular to dominant surfaces with right 

angle turns made of symmetrical bends or fittings. Conduit shall be supported by means of conduit 

clamps and clamp-backs. 

Moisture pockets shall be eliminated from conduits. If water cannot drain to the natural opening in the 

conduit system, a hole shall be drilled in the bottom of a pull box or conduit fitting provided in the low point 

of the conduit run. 

E100.6 Not Used 

E100.7 Terminations 

The capacities of conduit entrances and terminal enclosures for terminating the Purchaser's cable shall 

be coordinated with the Purchaser. Final sizes shall be acceptable to the Purchaser. 

The following criteria apply to wiring methods, cable, and raceway specified herein: 

Wiring Methods, Cable, and Raceway 

Electrical Interconnections Between 

Electrical Enclosures and Devices Nonarmored cable routed in tray or conduit 

Thermocouple Cable Insulation Color Coding ANSI MC96.1 

Cable - Additional Requirements 600 volt power and control cable shall supply power 

to loads at 480 VAC and 125 VDC or less. These 

cables shall have EPR insulation with flame retardant 

CPE and CSPE jacket. 

 All cables shall be UL listed for tray installation. 

 Instrument cable shall be twisted shielded pairs or 

triads with 300 volt class insulation (minimum). This 

cable shall have EPR insulation with flame retardant 

CPE jacket. Single and multiple pairs shall have an 

overall shield. Multiple pairs shall also have pairs 

shielded. 

 Thermocouple extension cable shall be rated 

300 volts minimum. 

 Switchboard and panel wire shall be multi-stranded 

Type SIS VW-1, XLPE insulated for 600 volts. 
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E210 Electrical Enclosure Assemblies 

(Source: 14Apr04 - Revised by Project: 07Jul06)

E210.1 General Requirements 

Electrical enclosures shall be in accordance with the tables at the end of this section and the following. 

Electrical enclosures constructed from steel plate shall be reinforced as required to provide a true surface 

and adequate support for devices mounted thereon. Enclosures shall be of adequate strength to support 

mounted components during shipment. 

Junction boxes and pull boxes shall be provided without knockouts. 

All junction boxes or pull boxes 4 inch trade size or smaller in any dimension shall be galvanized 

malleable iron or acceptable equal cast ferrous metal. 

If epoxy coatings are specified, the coating shall consist of a coat of zinc rich epoxy primer followed by a 

finish coat of epoxy. 

All enclosures shall be manufactured from materials that will not degrade when subjected to sunlight. 

Junction boxes, electrical control panels, and cabinets shall be provided with an identification nameplate 

mounted on the front of the enclosure. The nameplate inscription shall be acceptable to the Purchaser. 

E210.2 Electrical Enclosure Heating 

Where electrical enclosure heating is specified, electrical space heaters, one adjustable thermostat, one 

fuse and fuse block or circuit breaker or other means of disconnect shall be provided completely wired in 

the enclosure. The space heaters, thermostat, and circuit disconnect device shall not interfere with 

normal cable entrance into the enclosure or with maintenance or replacement of devices within the 

enclosure. Normal use of space heaters shall not change or discolor any painted surface. 

Unless otherwise indicated, the operating range of the thermostat shall be coordinated with the project 

ambient temperature conditions. 

Space heater capacity shall be as required to maintain the enclosure internal temperature above the dew 

point under the specified site conditions. 

Space heater sheaths shall be of a corrosion-resistant, nonoxidizing material. 

Electrical Enclosure Assemblies

Location Classification NEMA Std. 250 Materials 

Indoor Dry Nonhazardous Type 12 Galvanized sheet steel 

Indoor Wet or Outdoor Nonhazardous Type 4 Stainless Steel 

Wet-Chemical Corrosive Nonhazardous Type 4X Stainless Steel 

Enclosure Space Heaters 

Rated Voltage 240 volts ac 

Power Source 

Power Supply Code LV-3 

Voltage 120 volts 
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E230 Control Panel Receptacles, Lights, and Communications 

(Source: 07May04 - Revised by Project: N/A)

Receptacles 

Description 

Rated 

Voltage Frequency Ampacity 

GFCI/

RCD Configuration Protection 

Manufacturer/ 

Model 

Socket Outlet 125, 2P + E 60 Hz 15 A 10 mA NEMA 5-15R Damp 

Location 

Appleton Electric 

Co. 

Switch IPDT 120 60 Hz 30 A NEMA 5-20R Wet Location Hubbell 

Switch 277 60 Hz 60 A BS 1363-13A Dry Location Pass & Seymour 

Switch IPDT 125, 2P + E 60 Hz 10 A 10 mA DIN 49400/0873 Legrand 

Lighting 

Application Fixture Lamp Ballast 

Rated 

Voltage Frequency 

Manufacturer/

Model 

Control Panel Interior Fluorescent T-8 Core and Coil Thermally 

Protected 

120 60 Hz Day-Brite 

Illumination Fluorescent T-8 Electronic Thermally Protected 120 60 Hz Sylvania 

E400 Motor Control 

(Source: 14Apr04 - Revised by Project: 07Jul06)

The ac and dc motor starters specified to be furnished with the equipment shall conform to the 

requirements herein and shall be manufactured to the standards identified herein. The general 

requirements apply to all standards. 

E400.1 General Requirements 

Each starter that interfaces with the Purchaser's control system shall be provided with terminal blocks for 

termination of the Purchaser's cable. 

The interrupting capacity of each combination starter (direct on-line starter, unless otherwise specified) 

shall be sufficient for the available fault current without damage to the breaker or to the starter. 

Each 3-phase, ac single-speed starter shall be furnished with one 3-phase set of manually reset thermal 

overload relays. Each 3-phase, ac two-speed starter shall be furnished with two 3-phase sets of 

manually reset thermal overload relays. Each overload relay shall have a trip class suitable for proper 

operation and protection of the equipment served by the starter. 

Auxiliary contacts shall be mechanically operated by the starter contactor. Unless otherwise specified, 

the quantity of auxiliary contacts for starters that interface with the Purchaser's control system shall be as 

required by the Supplier's design. A minimum of one normally open and two normally closed contacts 

shall be wired to terminal blocks for Purchaser's use. 

For each ac starter, a dry type control power transformer shall be furnished complete with each primary 

lead fused and one secondary lead fused with the other secondary lead grounded (earthed). The primary 

leads shall be connected to two phases of the power conducting circuits. 

Large ac size starters which require line voltage to energize the operating starter coils shall be equipped 

with auxiliary interposing relays for use in the operating coil circuit. These interposing relays shall be 

operated from the low voltage circuit of the control transformers. 
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Two-speed starters and reversing starters, where required, shall be mechanically and electrically 

interlocked so that only one set of contacts can be closed at any one time. 

Unless otherwise specified, any starter that uses remote control from the Purchaser's control system shall 

be provided with an interposing relay to interface with the contactor coil if the contactor coil inrush 

exceeds 600 volt-amperes. 

Any dc starter that uses remote control from the Purchaser's control system shall have arc suppression 

devices installed across the contactor coil (or interposing relay coil) to protect the remote signal source. 

Single-phase ac starters shall be similar to 3-phase starters, except that a single-phase set of manually 

reset thermal overload relays shall be provided, and control power transformers will not be required if the 

line voltage is the same value as the specified control voltage. 

Ac contactors shall be similar to ac starters, except that no overload protection shall be required. 

E400.2 NEMA - Combination AC Motor Starters 

Combination ac motor starters shall be in accordance with NEMA ICS 2 and shall consist of the following: 

An isolating device consisting of a 3-phase molded case adjustable magnetic trip only 

circuit breaker. 

Contactors with manually reset thermal overload relays. 

Ac operating coils at specified control voltage. 

E400.3 Not Used 

E400.4 DC Motor Starters 

Magnetic starters for dc motors shall include, but not be limited to, the following: 

Dc operating coils. 

Contactors at specified control voltage. 

Starting resistors as required to limit the inrush current to approximately 350-500 percent 

of motor full load current (to be finalized during detailed design). 

A shunt field slide wire resistor. 

For non-reversing contactors, six electrically separate contactor auxiliary contacts (three 

normally open and three normally closed); for reversing contactors, the same quantity of 

contacts per contactor. 

One overload relay. The overload relay shall provide an alarm (Form C contact) and 

shall not trip the dc motor. 

For non-reversing contactors, a means to monitor the integrity of the shunt field and main 

contactor coil (to warn operator that the dc starter and its timing scheme are not armed) 

shall be provided and shall be the Supplier's standard design. A normally open and 

normally closed contact of the coil monitor relay shall be wired out to terminal block for 

external use. For reversing contactors, the monitoring scheme shall be as for nonreversing contactors for the contactor considered critical by Purchaser. 

A space heater wired out to terminal block points. 
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All auxiliary and overload contacts shall be wired to terminal blocks for external use. 

The dc motor starters design shall be coordinated with the characteristics of the motors that the starters 

are intended to operate. 

Unless otherwise specified, the following criteria apply to the starters specified to be furnished: 

Standard to Which Motor Starters Shall Be Manufactured NEMA 

AC Motor Starter Control Voltage 120 volts, 60 hertz 

DC Motor Starter Control Voltage 125 volts dc 

Spare Terminal Points 20 percent 

E510 Molded Case Circuit Breakers 

(Source: 14Apr04 - Revised by Project: 07Jul06)

Unless otherwise specified, molded case circuit breakers used in equipment furnished under these 

specifications shall have a symmetrical RMS ampere interrupting capacity equal to or greater than the 

maximum short-circuit current values specified on the E000 Electrical Equipment and System Voltages 

Supplemental Specification for the appropriate Power Supply Code. 

The breakers shall have a thermal magnetic type trip and shall be in accordance with UL 489. In addition 

to the ac interrupting ratings, all single-pole breakers, 2-pole breakers, and 3-pole breakers shall have the 

following minimum dc interrupting ratings: 

Single-pole breakers 10,000 amperes at 125 volts dc 

2-pole breakers 10,000 amperes at 250 volts dc 

3-pole breakers 10,000 amperes at 250 volts dc 

If the Power Supply Code is not specified at the time of purchase order, the Supplier shall furnish, at no 

additional charge, molded case breakers that meet or exceed system short-circuit requirements as 

determined during detailed design. 

E520 Terminal Blocks and Fuse Holders 

(Source: 27Jan04 - Revised by Project: 07Jul06)

E520.1 General 

In general, manufacturer standard terminal blocks will be accepted provided they meet the requirements 

of this specification and quality levels equivalent to the manufacturer's terminal blocks listed in the table at 

the end of this section. Self-stripping terminal blocks, multiple deck (step type) terminal blocks, and 

angled terminal blocks will not be acceptable. Screw type terminals suitable for ring lug termination shall 

be furnished for all current transformer secondary lead connections. 

Each terminal block shall be provided with a unique identifier. All terminal points shall have provisions to 

be uniquely identified on the terminal block white marking strip and, where permitted by the safety codes 

and standards, shall be without covers. Spare points shall be provided with blank strips that can be field 

marked with a permanent ink marking pen. Spare (unused) terminals shall be furnished evenly 

distributed on the terminal blocks for circuit modifications. No fewer than two spare unused terminals 

shall be furnished for every ten terminals used. Fuses may be mounted on terminal blocks. 
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Terminal blocks shall be manufactured from materials that will not support combustion. Terminal blocks 

shall meet the Inflammability Class V0 rating in accordance with UL 94. All terminal blocks, except 

internal terminal blocks in factory prewired electronic systems cabinets and terminal blocks for 

thermocouple extension wire, shall be rated for 600 volts or greater. No more than two conductors shall 

be terminated at one connection point. For terminal blocks interfacing with the Purchaser's field cabling, 

one side of the terminal block shall be used by the equipment manufacturer for factory wiring and the 

other side of the terminal block shall be reserved for the Purchaser's field cabling terminations. 

E520.2 Not Used 

E520.3 Strap Screw Terminal Blocks 

Strap screw terminal blocks shall be of heavy-duty construction capable of terminating a conductor from 

16 AWG to 10 AWG . The point-to-point spacing shall not be less than 0.375 inch. 

E520.4 Power Terminal Blocks 

Power terminal blocks shall be used for conductors 8 AWG and larger. 

E520.5 Thermocouple Terminal Blocks 

Thermocouple terminal blocks shall be provided for terminating thermocouple extension cable. The 

terminal blocks shall be capable of terminating solid conductors ranging from 20 AWG to 16 AWG. The 

current carrying parts of the terminal block shall be of the same materials as the thermocouple extension 

wire. Termination points for extending the shield wire of the thermocouple extension cable shall be 

provided adjacent to the block or shall be integral to the block. 

E520.6 Fuse Holders for Power Circuits 

When fuses rated from 1 to 30 amperes at 250 volts maximum are required, the fuse holders shall be 

suitable for 30 ampere, 250 volt, Class H cartridge fuses. The fuse holders shall be in accordance with 

ANSI/UL 521, shall have a withstand rating of 10,000 rms symmetrical amperes, and shall have 

reinforced fuse contact clips. 

The bases shall be molded phenolic, polyester, or other plastic having a Flammability Rating of V-0 when 

tested in accordance with UL 94. Porcelain, slate, and marble are not acceptable materials for fuse 

holder bases. 

The following criteria shall apply to terminal blocks and fuse holders: 

Terminal Blocks and Fuse Holders 

Terminal 

Block Type Applications 

Acceptable 

Termination 

Methods 

Acceptable 

Construction 

Acceptable 

Manufacturers 

FeedThrough Thermocouple 

Extension Wire 

Strap Screw, 

Compression 

Manufacturer's 

Standard 

Manufacturer's Standard 

FeedThrough DCS I/O and 

PLC I/O 

Compression, 

Strap Screw 

Modular, Rail, 

Grouped Block, 

Bolted 

Manufacturer's Standard 

FeedThrough General Purpose Strap Screw Grouped Block, 

Bolted, Modular, 

Rail 

Marathon 1500 Series or 

Purchaser-Approved 

Equal 

Shorting Current 

Transformer 

Strap Screw Grouped Block, 

Bolted 

Marathon 1500 Series or 

Purchaser-Approved 

Equal 
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Terminal Blocks and Fuse Holders 

Terminal 

Block Type Applications 

Acceptable 

Termination 

Methods 

Acceptable 

Construction 

Acceptable 

Manufacturers 

Power 600 Volt Power 

(8 AWG through 

4/0 AWG) 

Screw, 

Compression, 

Stud 

Grouped Block, 

Bolted 

Manufacturer's Standard 

E530 Electrical Accessory Devices 

(Source: 27Jan04 - Revised by Project: N/A)

E530.1 Electrical Indicating Instruments 

All metering devices shall be designed for flush mounting. All analog instrument scales shall consist of 

black markings on a white background. 

All instrumentation with current elements shall be designed for use with current transformers having high 

overcurrent capability. The current elements shall be capable of 10 times the rated end scale overload 

values for a period of 1/2 second duration for a minimum of nine successive overloads with 1 minute 

between overloads without exceeding the deviations defined in the specified standard. Switchboard 

meters shall not open the circuit when subjected to 30 times the rated secondary current of the 

associated current transformer circuit for a period of 2 seconds. 

The electrical indicating instruments shall be as specified on the E530 Electrical Accessory Devices - 

Supplemental Requirements sheets. 

E530.2 Control Relays 

General service auxiliary relays shall be Allen-Bradley Bulletin 700 Type P or Purchaser approved equal. 

Where current carrying requirements exceed the capacity of the general service auxiliary relays, auxiliary 

relays shall be Allen-Bradley Bulletin 700 Type PK, General Electric Type HFA or HGA, Westinghouse 

Type MG-6, or Purchaser approved equal. 

Timing relays for general service where the delay period is 1 minute or less shall be either pneumatic or 

solid-state. Timing relays for critical service shall be solid-state. Timing relays shall be Agastat Series 

7000 or Purchaser approved equal. 

If the manufacturer proposes the use of auxiliary or timing relays other than the ones listed above, 

technical data sheets for the proposed relays shall be submitted for approval by the Purchaser. 

Unless otherwise specified, dc relays that interface with the Purchaser's control system shall have a diode 

surge suppressor installed across the relay coil. 

E530.3 Electrical Switches 

Control switches shall be 600 volt, 20 ampere, multistage, rotary type. Unless otherwise specified, 

switches shall have black, fixed, modern, pistol grip type handles and engraved black plastic escutcheon 

plates with targets. 

Push buttons and selector switches shall be heavy-duty oiltight. 

The electrical switches shall be as specified on the E530 Electrical Accessory Devices - Supplemental 

Requirements sheets. 
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E530.4 Indicating Lights 

Indicating lights for local control stations shall be heavy-duty oiltight and shall permit light changing from 

the front. Luminous output shall be suitable for the location and ambient lighting conditions. Unless 

otherwise specified, LED type indicators are preferred on panels. 

Indicating light lens colors shall be coordinated with the indicated conditions identified on the E530 

Electrical Accessory Devices - Supplemental Requirements sheets. Indicating lights shall be energized 

when the condition exists and shall be de-energized when the condition does not exist. 

E530.5 Contacts 

Contact ratings for all electrical accessory devices shall be suitable for interface with the Purchaser's 

control system. The Purchaser's control system interrogation voltages will range up to 230 volts ac and 

between 24 and 250 volts dc. 

All contacts that interface with the Purchaser's control system shall be electrically "dry." Solid-state 

switches or triac outputs are not acceptable for contacts that interface with the Purchaser's electronic 

control system. 

Alarm contacts shall consist of one normally open and one normally closed contact "Form C." 

Electrical accessory device contacts, including alarm contacts, wired to the Purchaser's control system 

consisting of DCS or PLC I/O cards, shall be suitable for switching currents in the milliampere range for 

the range of voltages listed above. The electrical accessory device contacts, including alarm contacts, 

shall allow the Purchaser's I/O cards to distinguish between a normally open and a normally closed 

contact. 

E530.6 Fuses 

Fuses shall be provided with ampere ratings sized for the application. The types and manufacturers of 

fuses shall be as specified on the E530 Electrical Accessory Devices - Supplemental Requirements 

sheets. 

E530.7 Colors of Indicating Devices and Actuators 

Coding of indicating devices and switch actuators (push button, knob, selector switch, or handle) shall be 

subject to Purchaser review. If words or recognized abbreviations are required to describe the function of 

the indicating device or actuator, the language used shall be English. Indicating lights shall be energized 

when the condition described in the following table exists, and shall be de-energized when the condition 

does not exist. Unless permitted otherwise in the individual equipment specification, indicating light lens 

colors and CRT graphic display colors shall be as specified on the E530 Electrical Accessory Devices - 

Supplemental Requirements sheets. 

E530 Electrical Accessory Devices - Supplemental Requirements 

Colors of Indicating Devices 

Color Meaning Explanation Examples 

Green Equipment de-energized; 

process stopped 

Normal off condition 

requiring no action by 

the operator 

Motor stopped; valve 

(damper) closed; breaker 

open, contactor deenergized 
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Colors of Indicating Devices 

Color Meaning Explanation Examples 

Red Equipment energized; 

process normal 

Normal running 

condition requiring no 

action by the operator 

Motor running; valve 

(damper) open; breaker 

closed, contactor 

energized; process within 

normal limits; 

cabinet/panel power 

available 

White Equipment abnormality; 

process abnormality 

Abnormal condition 

requiring monitoring 

and/or intervention by 

the operator 

Motor trip; breaker trip, 

contactor trip; tripping by a 

protective device or 

interlock; electrical lockout 

relay tripped; position 

change from normal; 

pressure or temperature 

beyond normal limits; 

overload 

White Flashing Emergency Dangerous condition 

requiring immediate 

action by the operator 

Pressure or temperature 

beyond safe limits; loss of 

critical process 

Blue Mandatory Indication of a 

condition which 

requires action by the 

operator 

Instruction to enter a 

value; paralleled electrical 

power sources to bus 

causing bus rating to be 

exceeded 

Amber Permissive Equipment start 

permissive; 

equipment protective 

relay reset 

General information; 

electrical lockout relay 

reset 

Colors of Actuators 

Color Meaning Examples 

Red Emergency Emergency-stop/off 

Black Normal stop/off Normal stop; open breaker, 

contactor de-energized 

Black Normal start/on Normal start; closed breaker, 

energize contactor 
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Electrical Switches 

Application Description Manufacturer/Style 

Control Switches Control Panel General Electric Type SB-1 with 

large cover 

General Electric Type SB-10 with 

large cover 

Electro-Switch Type 24 

Electro-Switch Type W 

Electro-Switch Type 20K 

Purchaser Approved Equal 

Push Buttons and 

Selector Switches 

Control Panel or Local Honeywell Micro Switch Type PT 

Square D Class 9001 Type K 

Purchaser Approved Equal 

Toggle Switches Control Panel Honeywell Micro Switch Type TL 

Purchaser Approved Equal 

Fuses and Fuse Blocks 

Application Manufacturer/Style 

Slow Blow Fuses Purchaser Approved Equal 

Gould Shawmut/GDL 

Bussman/MDL 

Fast Acting Fuses Purchaser Approved Equal 

Gould Shawmut/OT 

Bussman/NON 

Extremely Fast Acting Fuses Purchaser Approved Equal 

Bussman/KAB 

Electrical Indicating Instruments 

 Input Range 

Meter 

Type Standard 

Voltage 

Element 

Current 

Element Transducer Manufacturer 

Accuracy 

Class (% of 

Fiducial 

Value) 

Size 

(approximate) Display 

Panel 

Meter 

 0-150 V 0-5 A 4-20 mA Yokogawa 

Weschler Electric 

Corporation 

Crompton 

Instruments 

Purchaser 

Approved Equal 

3 3.5 in2

(90 mm2

) 

Analog 

and 

Digital 

LCD 

SwitchBoard 

Meters 

 0-150 V 0-5 A 4-20 mA Yokogawa 

Weschler Electric 

Corporation 

Crompton 

Instruments 

Purchaser 

Approved Equal 

1 4.5 in2

(115 mm2

) 

Analog 

and 

Digital 

LCD 
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E640 Low Voltage Induction Motors 

(Source: 25May04 - Revised by Project: 18Jul06)

E640.1 General 

E640.1.1 Scope of Supply

Scope of supply shall include furnishing the low voltage induction motors as specified herein and in the 

E640 Low Voltage Induction Motors Specification Sheets at the end of this section. 

E640.1.2 Codes and Standards 

Work performed under these specifications shall be done in accordance with the following codes and 

standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all 

references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved 

edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and 

addenda in effect at the date of this document shall apply. These references shall govern the work 

except where they conflict with the Purchaser's specifications. In case of conflict, the latter shall govern 

to the extent of such difference: 

Work In Accordance With 

NEMA/IEEE designed motors NEMA MG1, ANSI C50.41, IEEE 112 

E640.1.3 Approved Manufacturers of Components 

For the following components, only the listed manufacturers are recognized by Purchaser as maintaining 

the level of quality of workmanship required by these specifications. If the Supplier wants to propose a 

nonlisted manufacturer that is considered to provide an equivalent level of quality, this manufacturer must 

be identified and supporting testimony provided. Acceptance of the manufacturer as a substitute is at the 

discretion of the Purchaser: 

Component Manufacturer 

Low voltage induction motors Baldor, General Electric, Reliance Electric, Siemens, 

Toshiba-USA, TECO - Westinghouse Motor, U.S. 

Motors, Marathon 

E640.1.4 Test Requirements 

Each motor shall be tested and inspected at the manufacturer's factory to determine that it is free from 

electrical or mechanical defects and to provide assurance that it meets the requirements of these 

specifications. Test procedures shall be in accordance with IEEE/NEMA test procedures for 3-phase 

induction motors. The routine tests listed in NEMA shall be performed on each motor by the motor 

manufacturer. 

This testing is to be considered part of the defined scope of work, and all associated costs are the 

responsibility of the Supplier unless specifically identified as a Bid Option or Purchaser-conducted. Tests 

identified as an option are to be priced separately. If identified as Purchaser-conducted, costs for the 

initial test will be the responsibility of the Purchaser. However, the Supplier is responsible for all costs 

associated with correcting deficiencies and retesting in the event of a test failure: 

Copies of reports of the quality control tests and inspections for each motor shall be submitted prior to 

shipment of the motor from the manufacturer's factory. 

Tests In Accordance With Conducted By 

NEMA/IEEE designed 

motors 

NEMA MG1, IEEE 112, ANSI 

C50.41 

Motor manufacturer 
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E640.2 Products 

E640.2.1 Design and Construction 

Motors shall be designed for direct-on-line (full voltage) starting. All motors shall be capable of continuous 

running duty in the specified ambient. Intermittent duty motors may be furnished where recognized and 

defined as standard by the equipment standards and codes. Motors driven by VFDs shall comply with 

the requirements of supplemental specification E410 VFDs for Induction Motors 50 HP or Less, 

specifically section E410.3. 

E640.2.1.1 Nameplates. All motor nameplate data shall conform to the requirements of the standards 

listed in Article E640.1.2. The following additional nameplate data shall be included: 

Insulation system class designation. 

Maximum ambient temperature for which motor is designed and temperature rise by 

resistance. 

Starting limitations, if any. 

Direction of rotation and voltage sequence. 

Type and grade of bearing lubricant, attached adjacent to lubricant filling devices. 

Complete nameplate data shall be included on the motor dimensional drawing submitted for final review. 

All motor nameplates and attachment pins shall be corrosion-resistant metal. 

E640.2.1.2 Enclosures. Enclosure parts for all motors (e.g., frames, bearing brackets, terminal 

housings, external fan covers) shall be made of cast iron, cast steel, sheet steel, or steel plates. 

Aluminum enclosure parts are not acceptable. 

Motors located in areas classified as hazardous shall be furnished with enclosures certified for use in the 

classified area. 

Totally enclosed motors shall be furnished with drain holes and rotating shaft seals. Drain holes shall be 

provided with combination water drain-breather plugs. External cooling fans for fan cooled motors shall be 

fabricated of brass, bronze, or aluminum alloy containing not more than 0.2 percent copper, malleable 

iron, or plastic. All plastic fans shall be fabricated of a reinforced thermosetting plastic. 

Totally enclosed motors shall have all exposed metal surfaces protected with a corrosion-resistant 

polyester paint or coating and shall have enclosure interior surfaces and the stator and rotor air gap 

surfaces protected with a corrosion-resistant alkyd enamel or with polyester or epoxy paint or coating. 

Bolts, nuts, screws, and other hardware items shall be corrosion-resistant or zinc dichromate treated 

metal. 

E640.2.1.3 Insulation and Windings. All stator winding materials shall have a Class F 311° F (155° C) 

thermal classification. The stator insulation system shall include two dips and bakes of varnish. All 

insulated stator conductors shall be copper. 

E640.2.1.4 Temperature Rise. The temperature rises at rated output shall not exceed those for a Class 

B thermal insulation classification. 

E640.2.1.5 Space Heaters. Space heaters shall be furnished as specified on the E640 Specification 

Sheets. Heaters shall be located and insulated so they do not damage motor components or finish. 
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Space heaters shall be sized as required to maintain the motor internal temperature above the dew point 

when the motor is idle. 

E640.2.1.6 Terminal Housings. A single terminal housing for motor power leads and accessory leads 

shall be furnished on all motors. All terminal housings shall be externally mounted on the motor frame 

enclosure. Terminal housings for all motors shall be cast iron or sheet steel. Minimum protection 

requirements shall be equivalent to NEMA 4. All motors shall be furnished with an oversized terminal 

housing. Location and dimensions of terminal housings shall be acceptable to the Purchaser. 

E640.2.1.7 Leads. All leads, including motor power leads, space heater leads, and temperature sensing 

device leads, shall be wired into the terminal housing. All motor leads located in the housings shall be 

permanently marked for ease of identification. 

All motors shall have the direction of rotation marked by an arrow mounted visibly on the stator frame 

near the terminal housing or on the nameplate and the leads marked for phase sequence to correspond 

to the direction of rotation and supply voltage sequence. 

Cable motor leads shall use stranded copper conductors insulated with silicone rubber covered with a 

glass braid or acceptable equal. 

E640.2.1.8 Ground Connectors. Each motor shall be furnished with a grounding connector attached to 

the motor frame inside the motor terminal housing. The grounding connector may be a lug or terminal or 

other acceptable grounding connector. The grounding connector size shall be in accordance with NEC 

requirements based on the motor full load amperes unless otherwise specified on the E640 Specification 

Sheets. 

E640.2.1.9 Bearings. The Supplier shall determine the type of bearings to be furnished based upon the 

load, speed, and thrust conditions of the driven equipment. All bearing mountings shall be designed to 

prevent the entrance of lubricant into the motor enclosure or dirt into the bearings. Bearings and bearing 

housings shall be designed to permit disassembly in the field for inspection of the bearings or removal of 

the rotor. 

Antifriction bearings shall be designed and fabricated to have a life as specified on the E640 Specification 

Sheets. Antifriction bearings shall be grease lubricated, self-lubricating, and regreaseable. Grease fittings 

for lubrication shall be arranged for safe, easy addition of lubricant from the outside of the motor while the 

motor is in service. 

Bearing lubricants shall contain a corrosion inhibitor. The type and grade of lubricant shall be indicated 

on a nameplate attached to the motor frame or end shield adjacent to the lubricant filling device. The 

Supplier shall furnish all lubrication information required to assure proper equipment startup and 

subsequent bearing maintenance. 

E640.2.1.10 Rotors. All induction motors shall have squirrel-cage rotors. Rotors shall be adequately 

sized to avoid overheating during acceleration of the motor and driven equipment. Rotors shall be diecast aluminum construction or shall have copper or copper alloy cage material except that aluminum cage 

materials will be considered on 2-pole motors only. 

All fabricated cage rotors shall include a swaging or wedging method during the installation of rotor bars 

to prevent rotor bar vibration. 

E640.2.1.11 Shafts. All shafts shall be solid. Each shaft shall be furnished with a corrosion-resistant 

treatment or shall be made of a corrosion-resistant material. 

E640.2.1.12 Torque Characteristics. Breakaway, run-up/pull-up, and pull-out/breakdown torque shall 

at all times be at least 10 percent higher than the load-torque of the driven machine, even at minimum 

specified starting voltage. Load-torque characteristics will be furnished by the driven equipment supplier; 
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however, the responsibility for successful starting under the given conditions rests with the motor 

manufacturer. 

E640.2.1.13 Critical Speeds. Motors shall be designed to keep torsional and rotational natural 

frequencies of vibration at least 25 percent above or below, preferably above, the motor rated speed 

ranges to avoid resonant vibration over the operating speed range of the equipment-motor unit. 

E640.2.1.14 Variations from Rated Voltage and Rated Frequency. Unless specified otherwise in 

Articles E640.1.2 through E640.1.4, induction motors shall operate successfully under running conditions 

at rated load with a variation in the voltage or the frequency as follows: 

Plus or minus 10 percent of rated voltage with rated frequency. 

Plus or minus 5 percent of rated frequency with rated voltage. 

A combined variation in voltage and frequency of 10 percent (sum of absolute values) of 

the rated values, provided the frequency variation does not exceed plus or minus 

5 percent of rated frequency. 

E640.3 Drawings and Engineering Data 

Motor dimensional drawings shall be provided in accordance with Q500 Shop Drawings and Instruction 

Manuals and include the following information: 

Complete nameplate data. 

Rotor weight and motor total weight. 

Special requirements, if any, for provisions by others for control of shaft end float during 

starting, operating, or stopping of the motor. 
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E640 Low Voltage Induction Motors Specification Sheet 

Application Indoor or outdoor areas, general purpose 

This motor data sheet is applicable for motors with nameplate ratings: 

Including and below 299 hp 

Including and above 3/4 hp 

Rated voltage / frequency 460 volts / 60 Hz 

Speed Coordinated with driven equipment 

Motors shall be manufactured to NEMA/IEEE Standards 

The following features shall be provided 

Feature NEMA/IEEE 

Enclosure/degree of protection Totally enclosed fan-cooled 

Method of cooling Not Applicable 

Hazardous classification Not Applicable 

Maximum ambient temperature, Indoor/Outdoor °F (°C) 110 (43) / 104 (40) 

Minimum ambient temperature, Indoor/Outdoor °F (°C) 32 (0) / 7 (-14) 

Motor nameplate horsepower multiplied by the motor nameplate service factor for NEMA/IEEE motors shall be at 

least 15 percent greater than the driven equipment operating range maximum brake horsepower. 

Starting voltage range 

Minimum (percent) 80 

Maximum (percent) 110 

Starting current during a full voltage across-the-line start shall not 

exceed percent of rated current 650 

Altitude above sea level Less than 3,300 ft (1,000 m) 

Bearings on horizontal motors shall have a life when operating under the load, speed, and thrust requirements of 

the driven equipment of not less than the following: 

Direct coupled service, hours 40,000 

Belt or chain connected service, hours 20,000 

Bearings on vertical motors shall have a life (hours) of not less than 40,000 

Anticondensation space heaters shall be provided on all motors equal to 

or above 25 hp 

Space heaters shall be rated 240 VAC, single-phase 

Space heaters shall be energized at 120 VAC, single-phase 

Additional Requirements Standard efficiency; standard balanced rotors or better 
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E642 Single-Phase Induction Motors 

(Source: 15Apr04 - Revised by Project: 07Jul06)

E642.1 General 

E642.1.1 Scope of Supply 

The scope of supply shall include furnishing the single-phase induction motors as defined herein and on 

the E642 Single-Phase Induction Motors Specification Sheet at the end of this section. 

E642.1.2 Codes and Standards 

Work performed under these specifications shall be done in accordance with the following codes and 

standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all 

references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved 

edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and 

addenda in effect at the date of this document shall apply. These references shall govern the work 

except where they conflict with the Purchaser's specifications. In case of conflict, the latter shall govern 

to the extent of such difference: 

Work In Accordance With 

NEMA/IEEE designed motors NEMA MG1, IEEE 114 

E642.1.3 Approved Manufacturers of Components 

For the following components, only the listed manufacturers are recognized by Purchaser as maintaining 

the level of quality of workmanship required by these specifications. If the Supplier wants to propose a 

nonlisted manufacturer that is considered to provide an equivalent level of quality, this manufacturer must 

be identified and supporting testimony provided. Acceptance of the manufacturer as a substitute is at the 

discretion of the Purchaser: 

Component Manufacturer 

Motors General Electric, Reliance, U.S. Motors, 

Toshiba, Siemens, Marathon, Baldor 

E642.1.4 Test Requirements 

Each motor shall be tested and inspected at the manufacturer's factory to determine that it is free from 

electrical or mechanical defects and to provide assurance that it meets the requirements of these 

specifications. Test procedures for single-phase motors shall be in accordance with IEEE/NEMA test 

procedures for single-phase induction motors. 

This testing is to be considered part of the defined scope of work, and all associated costs are the 

responsibility of the Supplier unless specifically identified as a Bid Option or Purchaser-conducted. Tests 

identified as an option are to be priced separately. If identified as Purchaser-conducted, costs for the 

initial test will be the responsibility of the Purchaser. However, the Supplier is responsible for all costs 

associated with correcting deficiencies and retesting in the event of a test failure: 

Tests In Accordance With Conducted By 

NEMA/IEEE designed motors NEMA MG1, IEEE 114 Supplier 

E642.2 Products 

Single-phase motors furnished under these specifications, including gear motors and those constructed 

integrally with the driven equipment, shall be of the manufacturer's proven design. Motors shall be 

designed for direct-on-line (full voltage) starting, frequent starting where required, and shall be suitable for 
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continuous running duty in the specified ambient. Intermittent duty motors may be furnished where 

recognized and defined as standard by the equipment standards and codes. 

E642.2.1 Design and Construction 

The type, design, and construction of each motor shall be coordinated with the driven equipment 

requirements as specified in the individual technical sections. 

E642.2.1.1 Enclosures. All motors shall be self-ventilated. Motors shall be totally enclosed unless 

specified otherwise. Frames, brackets, external terminal housings where furnished, and fan covers for 

fan cooled motors shall be cast iron. All exposed metal surfaces shall be protected, where practical, with 

a corrosion-resistant paint or coating. Exposed unpainted and uncoated surfaces shall be of a corrosionresistant metal. 

Motors located in classified hazardous areas shall be furnished with enclosures certified for use in the 

classified area. 

E642.2.1.2 Insulation and Windings. Motors shall have either a Class B 266° F or a Class F 311° F 

insulation system. The motor temperature rise shall be in accordance with values for Class B insulation 

when a Class B insulation system is used, and with values for Class F insulation when a Class F 

insulation system is used. All insulated stator conductors shall be copper. 

E642.2.1.3 Terminal Housings. An externally mounted terminal housing shall be provided. 

E642.2.1.4 Leads. Terminal identification shall be furnished. Where supplied, terminal boards shall be 

fabricated of nonhygroscopic material. Permanent instructions for making these connections shall be 

furnished inside the terminal housing or on the motor frame or nameplate. 

E642.2.1.5 Terminals. Cable type leads shall be provided with compression type connectors. 

E642.2.1.6 Ground Connectors. All motors, including those with resilient mountings, shall be furnished 

with a ground connection. A ground connector shall be provided inside the motor terminal housing. 

E642.2.1.7 Bearings. Bearings shall be double sealed ball bearings. 

E642.2.1.8 Shafts. Shafts of motors shall be furnished with corrosion-resistant treatment or shall be of a 

corrosion-resistant metal. 

E642.2.1.9 Capacitors. Capacitors, as required, shall be furnished in removable metal enclosures 

mounted on the motor frame. 

E642.2.1.10 Thermal Protection. Manual reset thermal protection, for both stalled rotor and overload 

protection, shall be furnished on all motors. 

E642.2.1.11 Torque Characteristics. The torque characteristics of all motors at the starting voltage 

specified on the E642 Specification Sheets shall be as required to accelerate to full speed the inertia 

loads of the motor and driven equipment without damage to the motor or the equipment. All motors shall 

be designed and fabricated to withstand the forces of across-the-line starting. 

E642.2.2 Assembly. All motors shall be completely assembled with the driven equipment, lubricated, 

and ready for operation. 
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E642 Single-Phase Induction Motors Specification Sheet 

Application Indoor or outdoor areas, general purpose 

This motor data sheet is applicable for motors with nameplate ratings 

Less than: 3/4 hp 

Rated voltage / frequency 115 volts / 60 Hz 

Motors shall be manufactured to NEMA/IEEE Standards 

The following features shall be provided: 

Feature NEMA/IEEE IEC 

Enclosure/degree of protection Totally enclosed fan-cooled 

Method of cooling Not Applicable 

Hazardous classification Not Applicable 

Maximum ambient temperature, Indoor/Outdoor °F (°C) 110 (43) / 104 (40) 

Minimum ambient temperature, Indoor/Outdoor °F (°C) 32 (0) / 7 (-14) 

Starting voltage range 

Minimum (percent) 80 

Maximum (percent) 110 

Altitude above sea level Less than 3,300 ft (1,000 m) 

Motor nameplate horsepower multiplied by the motor nameplate service factor for NEMA/IEEE motors 

shall be at least 15 percent greater than the driven equipment operating range maximum brake 

horsepower. 

Additional Requirements: 

K100 Instrumentation 

(Source: 13Apr04 - Revised by Project: 07Jul06) 

The tables at the end of this section identify specific project requirements. 

K100.1 General Requirements 

Unless specified otherwise in other sections, all instrumentation components furnished with equipment 

shall be in accordance with the following articles. Instrument air for pneumatic instrument and control 

devices will be clean, dry, and oil free. 

All instrumentation shall be provided with a stainless steel tag. All instruments requiring electrical wiring 

shall be provided with threaded connections to either 3/4 inch conduit or gland seal as appropriate. 

Electrical housings shall be dustproof and moisture-proof in accordance with NEMA 4 (IP65) 

requirements or, if they are installed in a hazardous area, shall be of a design suitable for the specific 

area classification. 

Components of the instrument that contact the process media shall be stainless steel or a material 

suitable for service. Coatings shall not be considered adequate protection to resist process corrosion. 
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Pressure and differential pressure measuring instruments for corrosive or thick, plugging process fluids 

shall be equipped with a threaded remote diaphragm seal assembly complete with flushing connection. 

The seal diaphragm and housing material shall be suitable for the service required. Capillary tubing shall 

be armored stainless steel at least 30 feet in length. 

Pressure instruments shall be capable of withstanding sustained over-pressurization to 150 percent of the 

maximum service pressure with no subsequent loss of function or change in measurement accuracy. 

The process connection on each pressure instrument shall be 1/2 inch MNPT for bottom connection static 

pressure indicators, at least 1/8 inch FNPT for draft differential pressure devices, and at least 1/4 inch 

FNPT for all others. 

K100.2 Local Indicators 

Each local indicator shall have the service legend engraved on the dial or have a tag, engraved with the 

Purchaser's ID number and the service legend, attached to it. Each tag shall be engraved laminated 

phenolic or stainless steel. Legend and tag number will be provided by the Purchaser. 

The scale range of each indicator shall be selected so that the normal operating condition is 

approximately mid scale (between one third and two thirds of full scale of the dial). Except for pressure 

differential gauges, rotary type indicator full scale pointer travel shall be a minimum of 270 degrees. 

Indicator dial size shall be at least 4-1/2 inches. Accuracy shall be ±1 percent of full scale range. 

Differential pressure indicator full scale pointer travel shall be at least 80 degrees. Indicator dial size shall 

be at least 4 inches. Accuracy shall be 2 to 3 percent of full scale range. 

K100.2.1 Pressure Indicators (Gauges)

Each static pressure indicator shall be equipped with a blowout disk. Each indicator shall have a 

stainless steel movement, wetted parts, and socket unless the application requires other materials. The 

housing shall be dust- and moisture-resistant and shall be furnished with laminated safety glass. Each 

indicator shall be provided with overpressure stops to protect against pressure surges outside the scale 

range limits. Each pressure indicator indicating supply air pressure to an instrument shall be in 

accordance with the Supplier’s standards. 

A piston type pulsation damper shall be furnished on each indicator to protect against process fluid 

oscillations of ±3 percent or more of the full scale range. The piston shall be adjustable with the pressure 

indicator installed on the process line. 

Pressure Indicator 

Description Material Wetted Parts Acceptable Manufacturer/Model 

Pressure Indicator - Gauge 316 SS or better Weksler 

Ashcroft (Dresser) 1279 

US Gauge 

WIKA 

K100.2.2 Temperature Indicators

Each temperature indicator for local mounting shall be a bimetal or gas actuated, filled thermal system 

type, gauge with at least a 5 inch dial having an every-angle adjustability. Temperature indicators shall 

be furnished with a compression union so that the stem will bottom out when placed in the thermowell. 

Each gas actuated indicator shall be furnished with armored stainless steel capillary tubing of the length 

required for the installation. If required, thermowells with lagging extensions shall be furnished for all 

indicators and shall be as specified under the article entitled Thermowells, Protecting Tubes, and Test 

Wells, except that extension nipples shall not be furnished for temperature indicators. 
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Temperature Indicator 

Description Grounding Construction 

Switch 

Contact 

Ratings 

Acceptable 

Manufacturer/Model 

Bimetallic N/A 5-inch dial, every 

angle adjustable 

N/A Ashcroft 

US Gauge 

WIKA 

K100.3 Process Actuated Switches 

K100.3.1 Pressure and Temperature Switches

Switch accuracy shall be ±1 percent of full scale range. Pressure switch sensing elements shall be 

bellows, diaphragm, or piston. Wetted parts shall be suitable for the application. Each temperature 

switch shall be furnished with a thermowell (as specified under Thermowells, Protecting Tubes, and Test 

Wells). Each temperature switch sensing element shall be of the bimetal or filled thermal system type. 

Pressure Switch 

Description 

Energizing 

Power 

Material 

Wetted 

Parts Manifold? 

FailSafe? Deadband 

Acceptable 

Manufacturer/ 

Model 

Pressure 

Switch -

Gauge 

N/A SPDT, 

120 VAC 

Stainless 

Steel 

No N/A Manufacturer's 

Standard 

Dwyer Instruments, Inc. 

– (Capsu- Photohelic) 

S-O-R, Inc. 

Purchaser Approved 

Equal 

Pressure 

Switch - 

Differential 

(Static 

Pressure < 

500 psi) 

110 VAC, 

60 Hz 

DPDT, 

120 VAC 

Stainless 

Steel 

Yes Yes Dwyer Instruments, Inc. 

– (Capsu- Photohelic) 

S-O-R, Inc. 

Purchaser Approved 

Equal 

Pressure 

Switch - 

Differential 

(Static 

Pressure > 

500 psi) 

None DPDT, 

120 VAC 

Stainless 

Steel 

Yes N/A 2% Dwyer Instruments, Inc. 

– (Capsu- Photohelic) 

S-O-R, Inc. 

Purchaser Approved 

Equal 

Temperature Switch 

Description Grounding Construction 

Switch 

Contact 

Ratings 

Acceptable 

Manufacturer/Model 

Gas Filled N/A filled thermal system 

assembly, with 

thermowell 

5A at 120 

VAC 

Allen-Bradley Bulletin 837 

Ashcroft Type 400B 

United Electric Series 400 

K100.4 Temperature Element Assemblies 

Each temperature element assembly shall be a thermocouple or resistance temperature detector 

equipped with a thermowell. Each temperature element and thermowell shall be spring-loaded and 

furnished as a complete assembly, including well, nipple, and weatherproof connecting head. 
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K100.4.1 Thermocouples

Each thermocouple shall be furnished packed in a stainless steel sheath with magnesium oxide insulation 

and shall have an ungrounded measuring junction. Each thermocouple shall be type "E" (chromelconstantan) unless otherwise specified, and shall meet the standard limits of error specified in ANSI 

MC96.1. Extension wire shall be coordinated with the thermocouple type. 

K100.4.2 Resistance Temperature Detectors (RTDs) 

Each RTD shall be 100 ohm platinum, 3 wire type, with stainless steel sheath, packed in magnesium 

oxide. Each RTD shall meet the standard limits of error. 

Temperature Element 

Description Grounding Construction 

Switch 

Contact 

Ratings 

Acceptable 

Manufacturer/Model 

Thermocouple Ungrounded ISA Type E 

(ChromelConstantan) with 

EX Extension 

Wiring 

N/A Manufacturer's Standard 

JMS Southeast, Inc.-

Statesville, NC USA 

Sandelius Instruments – 

Houston, TX 

TSC – Garland, TX 

Resistance 

Temperature 

Detector 

N/A Pt 100-ohm (at 

0°C), 3-wire type 

N/A Manufacturer’s Standard 

JMS Southeast, Inc. – 

Statesville, NC USA 

Sandelius Instruments – 

Houston, TX 

TSC – Garland, TX 

Special 

Requirements: 

 Type E thermocouples are the Purchaser's standard and are the likely 

selection. If the temperature requirements exceed the Type E application, the 

ISA type may change with Purchaser’s approval. RTDs will be used only when 

an equipment supplier feels it is prudent for a performance reason. 

K100.5 Not Used 

K100.6 Not Used 

K100.7 Solenoid Valves 

Solenoid valves shall be selected to incorporate body construction, trim materials, and internal 

arrangements suitable to the application. Each solenoid coil shall be Class H high temperature 

construction and shall be suitable for continuous duty. 

Solenoid Valve 

Coil Type Coil Rating 

Manual 

Operator Acceptable Manufacturer/Model 

Type H 120 VAC, 60 Hz Yes ASCO – EFHB8320G200xx (Stainless Steel ExP) 

Purchaser Approved Equal 

Type H 240 VAC, 50 Hz Yes ASCO – EFHB8320G200xx (Stainless Steel ExP) 

Purchaser Approved Equal 
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Filter Regulators 

Type Output Range Acceptable Manufacturer/Model 

Small – Volume Regulator 

with Filter and O.P. 

3 to 80 psig Fisher 67CFR 

K100.8 Position Switches 

Position switches shall be provided for the indication of each remotely actuated device. 

These devices do not include pilot solenoids and primary drive motors. 

Position switches shall be provided in both the "Open" and "Closed" positions of these devices. For 

devices that modulate (i.e., are controlled by an external modulating signal), a proximity position switch 

shall be provided in the de-energized position of the device unless a position transmitter is furnished. 

Additional position switches shall be provided as specified herein. Purchaser prefers proximity switches 

for all applications. Lever type switches shall only be provided with Purchaser’s approval. 

Switch - Proximity 

Description Switch Contacts Deadband Acceptable Manufacturer/Model 

Proximity 

(Leverless) 

DPDT, 120 VAC Manufacturer's 

Standard 

Topworx (Go Switch) 7G23528-A2 

K120 Instrument Valves and Instrument Primary Piping and/or Tubing 

(Source: 07May04 - Revised by Project: 07Jul06) 

K120.1 General Requirements 

All instrument primary piping and tubing, instrument valve manifolds, instrument shutoff valves, instrument 

equalizing valves, and instrument blowdown valves shall be supplied, installed and tested in accordance 

with ASME B31.1 - Power Piping and Technical Supplemental M200. 

Instrument primary piping and tubing is defined as the piping or tubing from the process connection root 

valve to the blowdown and the instrument valves. 

Changes in tubing direction shall be made only with tube fittings or tube bending. Tubing bends shall be 

made without reducing the internal diameter of the tubing. All tubing shall be blown clean with dry 

compressed air after installation, but prior to attachment to devices at either end. 

Piping and tubing schematic, connection, and interconnection diagrams shall be submitted to the 

Purchaser for acceptance. 

K120.2 Instrument Primary Piping 

Instrument primary piping external to instrument enclosures or racks shall meet the requirements stated in 

M200. 

K120.3 Instrument Primary Tubing 

Tubing shall be supported to allow thermal expansion, minimize vibration and protect it from damage. 

Tubing runs shall be supported both horizontally and vertically. Where continuous support is required, 

support using tubing tray is preferred. Support using connection to structural steel is allowable when it 

provides equivalent protection from damage and vibration. 

K120.4 Control and Instrument Enclosure/Rack Tubing 

Instrument tubing within enclosures or racks shall be arranged to allow any device to be serviced, 

disconnected, or removed from the enclosure or rack without disconnecting tubing to other devices. 
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Tubing for external connections shall be terminated on a bulkhead plate, utilizing bulkhead fittings for 

enclosures, or unions for open racks. Each bulkhead termination shall be identified with a nameplate. 

K120.5 Instrument Valves and Valve Manifolds 

Each pressure instrument shall be installed downstream of an instrument shutoff valve or instrument 

valve manifold designed for instrument shutoff service. In addition, each liquid filled instrument primary 

line shall be provided with a tee upstream of the instrument valve/manifold and blowdown valve(s). Each 

differential pressure instrument, when not provided with an instrument valve manifold, shall be provided 

with an instrument equalizing valve, two instrument shutoff valves, and two test tees with 1/4 inch tube 

plugs. 

Each remotely mounted static pressure instrument shall be provided with a two-valve manifold. Each 

differential pressure instrument shall be provided with a three-valve manifold. Each instrument valve shall 

have stainless steel construction and a grafoil packed stem. In addition, each instrument valve manifold 

shall be provided with test elbows with 1/4 inch tube plugs (instrument side) and dual ferrule grip type 

tube fittings for process connections. 

Flange type (direct mounting) manifolds are preferred by the Purchaser. Coplanar style manifolds will be 

considered only on a case-by-case basis. 

K120.6 Blowdown Valves 

A blowdown valve shall be provided for each instrument primary line except oil, ammonia, draft, and 

vacuum services. Each blowdown valve shall have a globe pattern design, stainless steel construction, a 

grafoil packed stem, and a minimum 0.25 inch orifice. 

K120.7 Instrument Valves, Fittings, and Support Tray 

Instrument Process Components Acceptable Manufacturer/Model 

Tubing - Grip Type Fittings Swagelok 

Tubing - Socket-Weld Fittings Swagelok 

Valve Manifolds Swagelok 

Instrument Shutoff Valve Swagelok Stainless Steel, Series SS-6DBS8 with Grafoil Packing 

Instrument Equalizing Valve Swagelok Stainless Steel, Series SS-6DBS8 with Grafoil Packing 

Instrument Blowdown Valve Swagelok Stainless Steel, Series SS-6DBS8 with Grafoil Packing 

Instrument Tubing Support Tray James C. White Company, Inc., Series “Tubetrack” 

Purchaser Approved Equal 
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M200 Piping 

(Source: 23Jun04 - Revised by Project: 07Jul06) 

All piping and pipe supports shall be in accordance with ASME B31.1 - Power Piping. Materials and wall 

thickness of piping and fittings will be selected based on design conditions established for the piping 

system. The following minimum requirements shall apply: 

Table 1 - General Pipe and Tubing Selection Criteria 

Minimum Wall 

Thickness 

Material 

Typical 

Standard 

Typical 

Temperature 

Range 

Diameter 

Less Than 

or Equal to 

2 Inches (50 

mm) 

Diameter 

Greater 

Than 

2 Inches 

(50 mm) Notes 

Carbon steel A53, 

A106, 

A134, 

A672 

-20o F to 775o F 

(-29o C to 415o C) 

Sch XS Std wt For lined pipe, 

other criteria may 

be used as 

approved by 

Engineer. 

Stainless 

steel 

A312 -20o F to 1,200o F 

(-29o C to 650o C) 

Sch 10S* Sch 10S Min carbon 0.04 

percent 

TP 304 over 1000o 

F (540o C) 

TP 316 over 1000o 

F (540o C) 

SS tubing A213 

TP316 

-20o F to 1,200o F 

(-29o C to 650o C) 

Refer to 

Table 4 

-- EAW and U not 

allowed, min 

carbon 0.04 percent for 

temperatures 

>1000o F, 

Rockwell 

hardness less 

than B90 (B80 or 

less preferred) 

The following pipe sizes shall be used for carbon steel. Other sizes shall not be used. 

Table 2 - Carbon Steel Pipe 

NPS Service Schedules Connections 

1 inch (25 mm) All XS, XXS SW or flanged 

2 inch (50 mm) All XS, 160, XXS SW or flanged 

2-1/2 inch (65 mm) 

and up 

All Std wt min BW or flanged 

The following pipe sizes shall be used for stainless steel pipe. Other sizes shall not be used: 
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Table 3 - Stainless Steel Pipe 

NPS Service Schedules Connections 

1 inch (25 mm) All 10S, 40S, 80S SW, flanged 

2 inch (50 mm) All 10S, 40S, 80S SW, flanged 

2-1/2 inch (65 mm) 

and up 

All 10S and up BW or flanged 

The following tubing specifications shall be used for chemical feed, instrumentation, compressed air, and 

sample line systems. 

Tubing material shall be stainless steel tubing and shall be joined with automatic butt-welding fittings, grip 

fittings, or socket-welded fittings as described below: 

Table 4 - Tubing Requirements 

Tubing Design Parameter Project Design Basis 

Tubing fittings (wall less than 0.083 inch) Swagelok - 316 SS butt-weld or grip 

type fittings* 

Tubing fittings (wall 0.083 inch) and 

greater) 

Swagelok - 316 SS butt-weld or socketweld fittings* 

Tubing direction changes Tubing fitting or bending (bending will 

affect pressure and temperature rating) 

Tubing supports Per B31.1 and as required supported to 

allow thermal expansion or to protect 

tube from damage 

Tubing design pressure and temperature In accordance with mechanical design 

criteria for process pipe and B31.1 

Tubing Sizing 

Pressure measurement tubing, sample 

lines, chemical lines, compressed air 

1/2 inch OD with minimal wall thickness 

(average wall thickness not acceptable) 

of 0.049, 0.065, or 0.083 inch, 

depending on process design pressures 

and temperatures and B31.1 

Sample lines, compressed air 3/8 inch OD with minimal wall thickness 

(average wall thickness not acceptable) 

of 0.049, 0.065, or 0.083 inch, 

depending on process design pressures 

and temperatures and B31.1 

Flow and level measurement by differential 

pressure 

Use pressure tubing criteria except for 

steam applications with condensate pots 

(piped) 

Using separate instrument manifolds (not 

direct mounted) 

1/4 inch OD with minimal wall thickness 

of 0.049 inch as flex lines (less than 36 

inch length) 
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Table 4 - Tubing Requirements 

Tubing Design Parameter Project Design Basis 

*Minimum carbon content of 0.04 percent required when temperatures are greater 

than 1000o F. 

Note: Direct manifold mounting to the instrument is preferred. 

Seam Welded Pipe 

Seam welded pipe may be used in the following applications as determined by the Engineer, or where 

seamless pipe is not available: 

Table 5 - Seam Welded Pipe 

System/Application Limitations 

Stainless steel No limitations when design complies with B31.1 

Steam and water systems Class 300 systems and lower, carbon steel only 

Fittings, Flanges, and Valves 

Fittings, flanges, and valves shall be in accordance with the requirements which follow: 

Table 6 - Fittings and Flanges 

System/Application Limitations 

Fittings 2-1/2 inches and 

larger 

Butt-weld type, in accordance with ASME B16.9 

Fittings 2 inches and 

smaller 

Forged steel socket-welded type, in accordance with 

ANSI B16.11 

Flanges, nonmetallic with 

metallic backing ring 

Flat faced slip-on or socket-welded for thermal or 

solvent welding 

Flanges, cast iron or steel, 

to mate with nonmetallic 

flanges 

Flat faced slip-on type or threaded, in accordance with 

B16.5 

Flanges, 150 class Raised face weld neck or slip-on type, in accordance 

with B16.5 

Flanges, 300 class and 

higher 

Raised face weld neck type only, in accordance with 

B16.5 

Grooved pipe joints Rolled or cut grooved joints in accordance with AWWA 

C-606 (rolled grooves preferred) 

All welded fittings shall be of the same material as the pipe. Forged steel socket-welded and threaded 

fittings shall have the minimum class rating described below: 

Table 7 - Forged Steel Fittings Minimum Class Ratings 

Pipe Wall Thickness Threaded Fittings Socket-Welded Fittings 

Schedule 80 and less 3,000 3,000 
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Table 7 - Forged Steel Fittings Minimum Class Ratings 

Pipe Wall Thickness Threaded Fittings Socket-Welded Fittings 

Over Schedule 80 to 

Schedule 160 

3,000 6,000 

Over Schedule 160 to 

Schedule XXS 

6,000 9,000 

Over Schedule XXS 

(minimum wall pipe) 

Engineered fittings only Engineered fittings only 

Integrally reinforced branch fittings shall have the minimum class rating described below. All welded 

fittings shall be of the same material as the header pipe. Fittings between dissimilar branch/header 

materials shall be considered on a case-by-case basis: 

Table 8 - Integrally Reinforced Branch Fittings Minimum Class Ratings 

Pipe Wall Thickness Threaded Fittings Socket-Welded Fittings 

Schedule 80 and less 3,000 3,000 

Over Schedule 80 to 

Schedule 160 

6,000 6,000 

Over Schedule 160 to 

Schedule XXS 

9,000* 9,000 

Over Schedule XXS 

(minimum wall pipe) 

Engineered fittings only Engineered fittings only 

*Fitting supplier must verify that the class is suitable for the application. 

Table 9 - Valves 

System/Application Limitations 

2-1/2 inch and larger Carbon steel, alloy, stainless steel, or other, 

corresponding to pipe material; ASME Pressure 

Class 150 minimum; butt-welded, flanged, or 

grooved ends; cast or forged steel bodies, with 

pressure/temperature ratings in accordance with 

ANSI B16.34 

2 inch and smaller Carbon steel, ASME Pressure Class 600 

minimum, socket-welded ends, forged steel 

bodies, with pressure/temperature ratings in 

accordance with ASME B16.34. Control valves 

and other special applications may deviate from 

these requirements. 

Joints shall be provided as required to facilitate assembly or disassembly of equipment. Pipe unions shall 

not be used. 

Pipe ends for socket-welded connections shall be reamed to full inside diameter to remove all burrs and 

obstructions. Fittings shall be used for all changes in direction. 

Butt-weld end preparations shall be in accordance with Technical Supplemental Q210, Welding of Power 

Piping. 
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Gaskets 

Some chemical and glycol systems may require the use of different gasket materials. Gaskets shall be as 

follows: 

Table 10 - Gaskets 

Joint Gasket Limitations 

Class 150 SW flanges 

and RF SO flanges 

1/16 inch compressed fiber 

type, non-asbestos 

Class 150 systems or lower 

within temperature limits of 

gasket material 

FF, nonmetallic, and 

cast iron flanges 

1/8 inch red rubber type 

(EPDM for hot service) 

With backing rings as 

needed. Up to 150° F only; 

above 150° F to 215° F, use 

EPDM. 

RF flanges (except as 

above) 

Spiral wound type, nonasbestos -- 

Grooved pipe joints EPDM (water) or nitrile (air) 

rubber 

Cold air and water systems 

(less than or equal to 215° F 

and less than or equal to 

300 psig) 

Bell and spigot cast iron 

and ductile iron 

EPDM Gravity drains less than or 

equal to 215° F and roof 

conduits 

Mechanical joints and 

bell and spigot cast iron 

and ductile iron with 

restrained joints 

EPDM Cold water systems (less 

than or equal to 215° F and 

less than or equal to 

300 psig) 

M400 Safety Guards 

(Source: 20May04 - Revised by Project: N/A) 

Guards shall be provided for protection of personnel from all exposed moving and/or rotating machine 

elements. Guards shall be in accordance with OSHA requirements and as specified herein. 

Each guard shall be fabricated from ASTM A36 steel plate having a minimum thickness of 3/16 inch and 

designed for easy installation and removal. Necessary supports and accessories shall be furnished with 

each guard. 

Guards for outdoor installation shall be galvanized. 

M400.1 Horizontal Shaft Equipment 

Safety guards for horizontal shafts, shaft couplings, belt sheaves, etc., shall be of the inverted "U" design 

with sides extending to the equipment base or baseplate. 

M400.2 Vertical Shaft Equipment 

Safety guards for vertical shafts, shaft couplings, etc., shall be of 360 degree construction with bolted 

vertical joints. Hinged sections shall be provided for inspection of couplings and glands, and shall be 

sized to allow removal of couplings and glands without complete guard removal. 
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M400.3 Belt Guards 

Belt guards shall be fabricated from 0.5 inch flattened, carbon steel expanded metal. Belt guards shall be 

complete with supports of 0.125 inch minimum thickness, accessories, and braces. The entire assembly 

shall be hot-dip galvanized after fabrication. 

A permanent metal tag shall be attached to each belt guard. The tag shall indicate the manufacturer's 

model number, size, and style of replacement belt sets. 

Grease fittings shall be extended through the safety guards. Each belt guard shall also be furnished with 

holes suitable for insertion of a tachometer to measure both driver and driven shaft speed. 

M720 Equipment Cooling Water 

(Source: 27Jan04 - Revised by Project: 07Jul06) 

A complete listing of all equipment requiring cooling water shall be submitted by Supplier, including flows, 

pressure drops, and temperature rise or heat load. 

Q002 Quality System Requirements 

(Source: 04Nov05 - Revised by Project: 24May06) 

The purpose of this document is to establish a set of requirements pertaining to the quality of supplied 

equipment, commodities, and/or services. 

These requirements do not supersede any requirements of the purchase order. If the Supplier believes 

that an inconsistency exists between this document and the specification(s) and referenced codes and 

standards, the Supplier shall immediately notify Engineer for resolution. 

Q002.1 General Quality System Requirements 

ASME Section IX shall be used as the primary code for WPS qualification. Visual wled inspection will be 

per AWS D1.1. NDE testing will be performed per ASME and ASTM requirements. 

Q002.1.1 Quality System 

It is the Supplier's responsibility to define and implement a detailed and documented quality management 

system which ensures that all equipment and commodities supplied are in conformance with the required 

drawings and/or specifications. The Supplier shall meet all the guidelines (requirements) set forth in this 

document. The quality management system shall be capable of providing assurance that design, 

purchasing, materials, manufacturing, examination and testing of equipment, shipping, storage, and 

related services comply with the purchase order requirements. 

The Supplier's quality management system shall include, at a minimum, procedures and/or methods that 

ensure the following processes are controlled and implemented: 

Design documents, drawings, specifications, procedures, inspection and test status, and 

procurement documents are current and accurate. 

Materials, equipment, and services conform to the requirements of the purchase order. 

Receipt inspection, in-process inspection, examination, testing, checkout, and final 

acceptance testing are conducted. 

Shipping, storage, and preservation of equipment and commodities are adequate to 

prevent damage during the delivery and storage of the equipment. 
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Quality system requirements are passed on to subtier suppliers for subcontracted work, 

and the Supplier has adequate oversight of subtier supplier activities. 

Special processes, such as welding, heat treatment, hot forming, bending and 

nondestructive examination, are monitored. 

Personnel performing special processes, such as welding, nondestructive examinations, 

coatings, heat treatment, etc., are qualified. 

Inspection, measuring, and test equipment is appropriately maintained. 

Processes exist for verification, storage, use, and maintenance of client supplied product. 

Applicable industry standards (such as ANSI, API, ASME, IEEE, AISC, etc.) shall be incorporated into the 

quality management system. The quality management system shall be made available to the Engineer 

for review, inspection, and/or audit upon request at the Supplier's facility. 

Q002.1.2 Quality System Manual 

The quality management system shall be documented in a quality system manual. One uncontrolled 

copy of the manual shall be submitted to the Engineer. If the Supplier's program has been certified by a 

registered certification agency as satisfying the requirements of the governing code (e.g., ISO 9001 or 

ASME), a copy of the Certification Letter or Certificate of Authorization shall be submitted along with the 

required manual. The quality system manual shall be kept current by submittal of revisions as applicable 

throughout the life of this purchase order 

Q002.1.3 Subsuppliers and Subcontractors 

The Supplier shall obtain the Engineer’s approval in writing prior to using subtier suppliers for 

manufacturing activities. Material suppliers are exempted from these requirements. 

All applicable requirements of the purchase order (i.e., technical, quality, and administrative) shall be 

passed on to the applicable organizations within the Supplier and subtier supplier's company. The 

Supplier shall ensure that subtier suppliers have the capabilities to fulfill purchase order requirements. 

Suppliers shall submit required procedures, drawings, and/or other submittals when required for approval 

and/or information of subtier supplier's capabilities, processes, or in-process work involving the fabricating 

and manufacturing of equipment and commodities for the Purchaser. 

In accordance with this Supplemental Specification, subtier supplier qualification and monitoring are the 

responsibility of the Supplier to ensure adherence to the same high quality standards of the Supplier. 

When deemed necessary, the Purchaser and Engineer have the authority to perform quality audits and 

inspections, and monitor and/or review subtier supplier processes and facilities. 

Q002.1.4 Inspection and Test Plan 

In accordance with the Schedule of Contract Submittals, a detailed inspection and test plan (i.e., a Quality 

Assurance/Quality Control Plan) for the work/equipment shall be submitted to the Purchaser and 

Engineer as specified in the purchase order prior to starting fabrication. The Engineer will designate any 

test witness points or other inspection points required. The inspection and test plan shall identify the 

inspection and testing points, including the acceptance criteria, for major components of the work and it 

shall be maintained current throughout the contract. The plan shall include the Supplier's strategy for 

inspecting subtier supplier's work, including inspection by the Supplier at his subtier supplier's facilities. 

The Supplier shall inspect the work of subtier suppliers to the extent necessary to ensure that proper 

materials and equipment are furnished and that fabrication and assembly are accomplished in 

accordance with the contract documents. Commercial off-the-shelf manufactured items may be 

exempted from these requirements. 

The Supplier shall keep the Purchaser and Engineer informed of the progress of the work and shall notify 

the Purchaser and Engineer at least 10 working days in advance of the appropriate times for inspections 
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and testing, when such inspection and test points have been designated by the Engineer as witness 

and/or hold points. The work shall not progress past the Engineer’s designated hold point until the 

Purchaser and Engineer have verified the work or witnessed the designated test. 

A witness point is an important step in manufacturing in which the Supplier is obligated to notify the 

Purchaser and Engineer in advance of the performed operation so that it may be witnessed. If the 

Purchaser or Engineer is not present at the time and date specified by the Supplier, the Supplier may 

proceed. 

A hold point is a designated stopping place during or following a specific activity at which the Engineer’s 

inspection or witness is required before further work can be performed. The Supplier may not proceed 

beyond the hold point without inspection or witness by the Engineer unless prior written authorization is 

obtained from the Purchaser. 

The Purchaser or Engineer may waive the witness of tests; waivers for hold points shall be in writing. 

Waivers in no way absolve or relieve the Supplier of complying with contractual requirements. 

If the Supplier has notified the Purchaser and Engineer defining the specific test date and time and the 

Supplier is not ready to conduct the test at the stated date and time, the Supplier shall be accountable for 

expenses incurred by the Purchaser. 

Q002.1.5 Inspections by Engineer 

The Engineer may elect to perform assessments, quality audits, or witness testing at any time during the 

manufacturing process. The Engineer may designate an authorized agent for assessments, witness 

testing, or quality audits. Authorized agent may be an employee of the Engineer or an outside agency. 

When an outside agency is designated as an authorized agent for the Engineer, such designation will be 

in writing with a copy provided to the Supplier. Hereinafter, when the term "Engineer’s representative" is 

used, it may also mean the Engineer or the authorized agent. 

The following requirements shall apply for Engineer’s inspection at the Supplier's mill, factory, yard, 

warehouse, or subtier supplier's facilities. 

Q002.1.5.1 Access. The Purchaser and Engineer shall have the right to access the Supplier's and 

subtier supplier's work and related documents during the manufacturing process without delaying the 

schedule. The Supplier shall provide, without cost, reasonable facilities including tools, personnel, and 

instruments for demonstrating acceptability of the work. 

Q002.1.5.2 Surveillance Activities. In accordance with the purchase order designated hold points for 

witnessing, mill and/or factory tests shall be performed in the presence of the Engineer’s representative 

unless waived in writing by the Engineer’s representative. The Supplier shall bear all costs for such tests, 

except the compensation and expense of the Purchaser's representative. 

Q002.1.5.3 Control of Special Processes. It is Supplier's responsibility to ensure that qualified 

personnel are employed to perform special processes such as welding, nondestructive examination 

(NDE), coating, painting, etc. If special processes were conducted by unqualified employees, the 

Purchaser and Engineer have the right to validate and test the product at Supplier's expense and/or reject 

the product. 

Q002.1.5.4 Corrective Action. Upon identification of a noncompliance with the requirements of the 

purchase order, the Supplier shall document the noncompliance issue. For noncompliance issues where 

the nonconforming characteristic can be restored to a condition such that the capability of an item to 

function reliably and safely is unimpaired, even though that item still does not conform to the original 

requirement, the Supplier shall submit the noncompliance to the Purchaser and Engineer for approval. 

During witness and hold point activities, if the Engineer’s representative identifies a noncompliance issue, 

the Supplier shall document the noncompliance issue and provide a copy of the report to the Engineer’s 

representative. If the Supplier disagrees and does not document the noncompliance, the Engineer’s 
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representative shall issue a corrective action report to the Supplier for disposition and action. The 

Supplier shall correct, in a timely manner, all deficiencies identified. 

Q002.1.5.5 Rejection. If any items or articles are identified that do not meet the requirements of the 

specifications, the lot, or any faulty portion thereof, may be rejected. Before offering specified materials 

or equipment for shipment, the Supplier shall inspect the material and equipment and eliminate any items 

that are defective or do not meet the requirements of the purchase order. The fact that equipment or 

materials have been previously inspected, tested, and accepted does not relieve the Supplier of 

responsibility in the case of later discovery of flaws or defects. 

Q002.1.5.6 Receipt Inspection 

Materials or equipment purchased under this purchase order may be inspected at the specified receiving 

points and will either be accepted or rejected. Receipt inspection will include testing to determine 

compliance with the purchase specifications. Initial receipt inspection acceptance tests will be performed 

by the Purchaser at the Purchaser's expense. Items found to be defective may be returned to the 

Supplier for correction at the Supplier's expense, including shipping cost, or the cost to correct and 

inspect the item will be charged to the Supplier. 

Q100 General Welding Requirements 

(Source: 11Nov05 - Revised by Project: 09Jun06) 

Unless otherwise specified, the applicable governing edition and addenda to be used for all references to 

codes or standards specified herein shall be interpreted to be the jurisdictionally approved edition and 

addenda. If a code or standard is not jurisdictionally mandated, then the current edition and addenda in 

effect at the time of (contract or specification) approval shall govern. 

Q100.1 General 

Section Q100 shall be used in conjunction with the other Welding Technical Supplemental Specification 

sections, except Q151 Brazing of Copper Tubing and Q152 Soldering of Copper Tubing. 

Where requirements of a referenced code or standard differ from the Welding Technical Supplemental 

Specification sections, the more stringent or restrictive requirements shall apply. 

Any request for deviation from specified requirements shall be submitted in writing and shall include the 

proposed deviation, rationale for the deviation, any technical data supporting the deviation, and historical 

experience supporting the deviation. 

Q100.2 Welding Processes 

Unless otherwise specified, only shielded metal arc welding (SMAW), gas metal arc welding (GMAW), 

flux cored arc welding (FCAW), submerged arc welding (SAW), plasma arc welding (PAW), stud welding, 

and gas tungsten arc welding (GTAW) processes shall be permitted within the restrictions or limitations 

specified in the applicable Welding Technical Supplemental Specification section. Any limitation or 

restriction specified for GMAW short-circuit arc transfer or a variation of GMAW short-circuit arc transfer 

marketed by welding equipment manufacturers shall be applied the same, whether a constant voltage 

(CV) power supply or other power supply developed by a welding equipment manufacturer is used. Other 

welding processes may be used, provided the governing code or standard permits it and written approval 

has been granted by the Engineer. 

Q100.3 Welding Procedure Qualification 

Welding procedures shall be prepared and qualified in accordance with the referenced code. 

Any change in the flux trade name or designation shall require a new welding procedure qualification. 
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Welding procedure qualification with GMAW short-circuit arc transfer using a CV power supply shall not 

qualify a welding procedure for GMAW using a controlled variation of short-circuit arc transfer by a power 

supply other than CV or vice versa. 

Welding Procedure Specifications (WPS) and applicable Procedure Qualification Records (PQRs) shall 

be submitted for review by the B&V Materials Applications Section prior to start of fabrication. Submittal 

of welding procedures and applicable PQRs shall apply to all suppliers and subsuppliers. Suppliers shall 

review the documents in accordance with the applicable code and specification requirements and shall 

accept all of their subsuppliers' welding procedures and applicable PQRs prior to submitting accepted 

documents to the B&V Materials Applications Section. 

Due to the number of different nickel alloys within a nickel alloy P-number or S-number, WPSs for welding 

P-number or S-number 41 through 49, nickel alloy materials should identify the base materials by the 

Unified Numbering System (UNS) to aid in the proper application of the WPS, e.g., P45 (UNS N08367). 

As an alternative to identifying the UNS number on the WPS, the UNS number of the base material from 

the WPS may be cross referenced to the WPS by other means. 

Standard Welding Procedure Specifications (SWPSs) produced by the American Welding Society (AWS) 

may be used when permitted by the jurisdictional code. Any supplemental requirements mandated by the 

jurisdictional code shall be met. 

Q100.4 Welder/Welding Operator Performance Qualification 

Welders and welding operators shall be qualified in accordance with the referenced code. The welder 

and welding operator qualification records shall be available at the shop facility or construction site and 

shall be made available for review when requested. 

Welders and welding operators qualified for GMAW short-circuit arc transfer using a CV power supply 

shall not qualify a welder or welding operator for GMAW using a controlled variation of short-circuit arc 

transfer by a power supply other than CV or vice versa. 

Each manufacturer or contractor is responsible for the qualification of welders or welding operators. Field 

welder or welding operator performance qualification testing shall be performed under the full supervision 

and control of the manufacturer or contractor at the project site or approved offsite testing facility. 

Q100.5 Filler Materials 

Welding filler metal shall comply with the requirements of the referenced code and any modified 

requirements specified herein. The filler metal shall be as specified in the applicable WPS. 

Unless otherwise specified, the welding filler metal shall have a chemical composition as similar as 

possible to the base materials to be welded. The finished weld as deposited, or after postweld heat 

treatment (PWHT) when required, shall be at least equal to the base metal as to strength, ductility, notch 

toughness, corrosion-erosion resistance, or other physical or thermal properties. 

Unless otherwise approved in writing, the GTAW process shall require the addition of filler metal. 

Unless otherwise specified, the use of the -G electrode/wire classification is prohibited. 

SAW multipass weld deposits shall use an essentially neutral flux. Alloy, semiactive, or active fluxes shall 

not be used except as specified otherwise. Fluxes that compensate for losses of alloying elements are 

permitted. Active flux may be used for single pass welding of carbon steels, provided the weld deposit 

thickness is approximately 1/4 inch maximum each side for a double-V-groove joint design or 

approximately 1/4 inch one side for a single-V-groove joint design. The joint thickness shall not exceed 

1/2 inch nominal. 

The SAW process shall not use recrushed slag. 
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SMAW low-hydrogen type electrodes, including stainless steel and nickel and nickel alloy electrodes, 

shall be purchased in hermetically sealed or vacuum packed containers only. 

Q100.5.1 Not Used 

Q100.5.2 Filler Material for Welding Miscellaneous Materials 

For the SMAW process, all filler metal shall be of the low-hydrogen type when welding on either carbon 

steel or low alloy steel materials. Nonlow-hydrogen type electrodes (E6010 or E7010-A1 only) may be 

used only for root pass welding on carbon steel piping, unless otherwise specified by other Welding 

Technical Supplemental Specification sections. SMAW low-hydrogen type ferrous electrodes for all fill 

passes shall have a minimum tensile strength of 70,000 psi (495 MPa) as defined by the applicable SFA 

or AWS specification. When welding is required for existing unknown carbon steel materials, the carbon 

content shall not exceed 0.30 percent or 0.40 percent carbon equivalent [CE] as determined by CE=C%+ 

[Mn%/6+Si%/6]). 

For the FCAW process of carbon steel materials, only E7XT-1, -5, -9, -12, or E7XT-1M, -5M, -9M, or -12M 

carbon steel electrodes with shielding gas shall be used. 

The low carbon (-B2L, -B3L, -B6L, and -B8L), low alloy filler metal classifications are prohibited for 

welding of 1-1/4 Cr - 1/2 Mo, 2-1/4 Cr - 1 Mo, 5 Cr-Mo, and 9 Cr-Mo alloy materials. The filler metal for 

welding these materials shall have carbon content greater than 0.05 percent. 

Filler metals for welding pressure retaining component materials of carbon steel or low alloy steel to 

austenitic stainless steel shall be in accordance with the following: 

Service <500° F (260° C) Service >500° F (260° C) 

ASME 

Specification 

AWS 

Classification 

ASME 

Specification 

AWS 

Classification 

SFA 5.9 or 

SFA 5.14 

ER309 or ER309L 

ERNiCr-3 

SFA 5.14 ERNiCr-3 

SFA 5.4 or 

SFA 5.11 

E309 or E309L 

ENiCrFe-3 

SFA 5.11 ENiCrFe-3 

SFA 5.22 E309TX-X or 

E309LTX-X 

N/A N/A 

Where carbon steel or low alloy steel piping is to be welded to austenitic stainless steel components, and 

the carbon or low alloy steel piping is of such a thickness as to require PWHT, the end of the carbon or 

low alloy steel pipe shall be buttered with Type 309L, ERNiCr-3, or ENiCrFe-3 filler metal for system 

service <500° F and shall be buttered with Type ERNiCr-3 or ENiCrFe-3 filler metal for system service 

>500° F; the end shall be postweld heat treated. The weld joint shall then be made between the 

austenitic stainless steel and the buttering on the carbon or low alloy steel as applicable. This joining 

method is applicable only to groove welds unless written approval has been granted by the Engineer. 

Filler metals for welding carbon steel to nickel alloy steel shall be in accordance with the following: 

ASME Specification AWS Classification 

SFA 5.14 ERNiCr-3 

SFA 5.11 ENiCrFe-3 

Filler metals for welding carbon steel to superaustenitic stainless steel Alloy AL6XN, UNS N08367, Pnumber 45 shall be in accordance with the following: 
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ASME Specification AWS Classification 

SFA 5.14 ERNiCrMo-3 or ERNiCr-3 

SFA 5.11 ENiCrMo-3 or ENiCrFe-3 

Filler metals for welding superaustenitic stainless steel Alloy AL6XN, UNS N08367, P-number 45 shall be 

in accordance with the following: 

ASME Specification AWS Classification 

SFA 5.14 ERNiCrMo-3 

SFA 5.11 ENiCrMo-3 

Filler metals for welding stainless steel Alloy 20, UNS N08020, P-number 45 shall be in accordance with 

the following: 

ASME Specification AWS Classification 

SFA 5.9 ER320LR 

SFA 5.4 E320LR 

Filler metal for welding austenitic stainless steel, ASME P-number 8 or S-Number 8 base materials shall 

be in accordance with the following: 

Base Material Type/Grade 304 shall use Type 308 or 308L filler metal. 

Base Material Type/Grade 304L shall use Type 308L filler metal. 

Base Material Type/Grade 316, shall use Type 316 or 316L filler metal. 

Base Material Type/Grade 316L shall use Type 316L filler metal. 

Q100.5.3 Filler Material Control 

Storage, handling, and drying of SMAW electrodes and SAW flux shall, as a minimum, be in accordance 

with the manufacturers' recommendations. In addition, SMAW low-hydrogen type carbon and low alloy 

steel electrodes shall be stored in ovens at 250° F minimum after the hermetically sealed or vacuum 

packed container is opened. Bare rod in straight lengths shall be individually flag tagged, stamped, or 

otherwise identified with the AWS classification or product classification. Each spool of solid or cored rod 

shall be tagged, labeled, or otherwise identified with the AWS classification or product classification. 

SMAW low-hydrogen type covered electrodes shall only be reconditioned one time. Any SMAW lowhydrogen type electrodes that have been wet or have damaged coatings shall not be used. Any welding 

filler metals or fluxes not readily identifiable shall not be used. 

A written procedure for storing, handling, issuing, and reconditioning electrodes, wires, and fluxes shall be 

submitted for review by the B&V Materials Applications Section. 

Q100.6 Fabrication Controls 

Q100.6.1 Welding Preheat and Interpass Temperature 

The preheat and interpass temperature requirements are mandatory values and shall be in accordance 

with the referenced code and as specified herein. The WPS for the material being welded shall specify 

the minimum preheat and maximum interpass temperature requirements. The thickness used to 
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determine preheat requirements shall be the thickness of the thickest part at the point of welding. 

Preheating shall be applied prior to any welding or thermal removal process. 

Preheat and interpass temperatures shall be monitored and checked by temperature indicating crayons, 

thermocouples, surface contact pyrometers or thermometers, or other suitable methods. 

Preheating shall be performed using electric resistance, induction heating, or oxyfuel heating methods 

that will provide uniform heating over the complete weld or thermal removal process area. 

Preheat of pressure retaining components for carbon steel P-number 1 or S-number 1 materials shall be 

175° F when the material specified carbon content is in excess of 0.30 percent and the nominal thickness 

at the joint is in excess of 1 inch. In addition, 200° F minimum preheat is required for nominal thickness 

over 1.25 inches, regardless of carbon content. A minimum preheat temperature of 50° F is required for 

all other carbon steel P-number 1 or S-number 1 materials. 

The maximum interpass temperature for welding carbon steel and low alloy steels shall be 600° F. The 

maximum interpass temperature for welding carbon steel when impact testing is required shall be 500° F. 

The maximum preheat and interpass temperature for stainless steel, nickel alloy, copper alloy, and 

titanium alloy materials shall be 350° F. The minimum preheat temperature shall be 50° F. 

Q100.6.2 Not Used

Q100.6.3 Postweld Heat Treatment (PWHT)

PWHT shall be performed in accordance with the referenced code and any modified requirements 

specified herein. 

Postweld heat treating may be accomplished by electric resistance heating, furnace heating, or other 

suitable heating methods that will provide the desired heating and cooling rates, the required metal 

temperature, temperature uniformity, and temperature control. Direct flame heating shall not be used for 

PWHT. 

When PWHT is performed in a furnace or locally, sufficient thermocouples shall be properly attached 

directly to the materials to accurately indicate the metal temperature uniformity throughout the heat 

treating cycle. PWHT equipment recorders shall be calibrated in accordance with the manufacturer's 

standard or other suitable standard to ensure the accuracy of the recorded temperatures. 

Thermocouples and thermocouple wire shall be Type K chromel/alumel. 

Thermocouple wire may be temporarily attached directly to materials by using the capacitor discharge 

method of welding. The capacitor discharge method of welding shall be performed in accordance with 

the referenced code, as applicable. 

A time-temperature recording chart/record traceable to the item being postweld heat treated shall be 

made for all PWHTs and shall be made available to the B&V Materials Applications Section when 

requested. 

Detailed PWHT procedures shall be submitted for review by the B&V Materials Applications Section. The 

PWHT procedure shall provide details to accomplish the code required PWHT, including PWHT operator 

qualification, weld joint preparation, weld joint documentation, heating and cooling rates, holding times, 

holding temperatures, minimum size of heated zones, precautions to preclude damage, attachment of 

thermocouples, welding specifications for attaching welding thermocouple wire using the capacitor 

discharge method (when used), weld joint insulation, defined nominal thickness, and recorder calibration. 

Q100.6.4 Not Used 
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Q100.6.5 Fabrication Controls for Austenitic Stainless, Superaustenitic Stainless, or Nickel Alloy 

Steels 

The following requirements shall apply when fabricating austenitic stainless, superaustenitic stainless, or 

nickel alloy steel components. 

Grinding shall be by aluminum oxide, zirconium oxide, or silicon carbide grinding wheels that shall not 

have been used on carbon or low alloy steels. Hand or power wire brushing shall be by stainless steel 

brushes that shall not have been used on carbon or low alloy steels. All tools used in fabrication shall be 

protected to minimize contact with steel alloys or free iron. Grinding wheels and brushes shall be 

identified and controlled for their use on these materials only to ensure that contamination of these 

materials does not occur. 

Antispatter compounds, marking fluids, marking pens, tape, temperature indicating crayons, and other 

tools shall have a total halogen content of less than 200 parts per million. 

Materials that have been contaminated with steel alloys or free iron shall not be used until all 

contamination is removed. When required, cleaning shall be performed in accordance with ASTM A380, 

Code D requirements. 

Heat input control for welding shall be specified in the applicable WPS and shall not exceed 55,000 joules 

per inch) as determined by the following formula: 

Heat Input [J/in. (J/mm)] = Travel Speed [in./ min ( ) mm / min ]

Voltage x Amperage x 60

Austenitic stainless steel instrument tubing shall be welded using only the GTAW process. 

Socket welds or butt welds in all austenitic stainless steel instrument tubing lines shall require an inert gas 

backing (purge) using argon during welding to avoid oxidation. 

When service conditions require that austenitic stainless steel material maintain its corrosion resistance, 

the austenitic stainless steel material shall not be postweld heat treated except by solution annealing. If 

solution annealing is performed, a procedure detailing the solution annealing process shall be submitted 

for review by the B&V Materials Applications Section prior to performing solution annealing. 

For materials that have been contaminated with iron, the B&V Materials Applications Section may request 

a ferroxyl test after cleaning. If requested, a ferroxyl test procedure shall be submitted for review by the 

B&V Materials Applications Section. 

Q100.6.6 Miscellaneous Fabrication Control Requirements

Welding shall not be performed when surfaces of the parts to be welded are wet. The parts to be welded 

shall be protected from deleterious contamination and from rain, snow, and excessive wind during 

welding. 

Prior to welding, the weld preparation and adjacent base material surfaces shall be cleaned and kept free 

from paint, oil, grease, dirt, scale, rust, and other foreign materials. 

The weld end preparation on carbon and low alloy steel materials that will be stored for extended periods 

of time may consist of coating with deoxaluminate or an equivalent protective material. This coating may 

be welded through if applied within the manufacturer's maximum weldable limit of 1.25 mils. Complete 

removal of the coating is neither required nor prohibited, unless signs of rust or other foreign materials 

such as oil, grease, dirt, or excessive coating are apparent, in which case these areas shall be cleaned. 
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Acceptable cleaning solvents include new or redistilled acetone (acetone reclaimed by other methods 

shall not be used), alcohol (ethyl, methanol, or isopropanol), methyl ethyl ketone, or toluene (toluol). 

Halogenated cleaning solvents shall not be used for cleaning or degreasing. 

All groove butt joints shall be complete joint penetration unless specified otherwise by design documents 

or the applicable code. Partial penetration weld joints not specified by design shall require written 

approval by B&V design engineering. 

Complete penetration joints welded from both sides shall have the root of the first layer or pass chipped, 

gouged, ground, or machined to sound metal prior to welding from the second side. 

Welded joints shall be made by completing each weld layer before succeeding weld layers are deposited. 

Partial fill passes are permitted to correct localized underfill conditions and for the purpose of maintaining 

alignment. Block welding is prohibited. 

As-welded surfaces are permitted; however, the surfaces of welds shall be uniform in width and size 

throughout their full length. The cover pass shall be free from coarse ripples, grooves, overlaps, abrupt 

ridges, and valleys. The surface condition of the finished welds shall be suitable for the proper 

interpretation of nondestructive examination. If the surface of the weld requires grinding to meet the 

above criteria, care shall be taken to avoid reducing the weld or base material below the minimum 

required thickness. 

All socket welds shall be welded using only the GTAW or SMAW welding processes and shall meet the 

following requirements: 

A minimum of two weld layers is required for pipe or tube over 1/2 inch nominal pipe size. 

Either GTAW or manual SMAW processes may be used. 

For pipe or tube 1/2 inch or less in nominal pipe size, the GTAW process should be used 

and a single weld layer is permitted. The SMAW process may be used provided a 

minimum of two weld layers is deposited. 

Welding slag and spatter shall be removed from all welds. 

A gas or gas mixture used for shielding shall be welding grade or shall meet Specification SFA-5.32 and 

have a dew point of -40° F or lower. 

Fabricators and suppliers shall check for residual magnetism at each end of the machined field pipe weld 

bevels. Weld bevels containing residual magnetism greater than 5 gauss shall be demagnetized. 

Arc strikes outside of the area of permanent welds should be avoided on any base metal. Cracks or 

blemishes caused by arc strikes shall be ground to a smooth contour and checked to ensure soundness. 

Peening is prohibited. The use of power tools for slag removal is not considered peening. 

The application of heat to correct weld distortion and dimensional deviation without prior written approval 

from the B&V Materials Applications Section is prohibited. 

Complete joint penetration welds welded from one side without backing, weld repairs welded from one 

side without backing, or weld repairs in which the base metal remaining after excavation is less than 

0.1875 inch from being through wall, which are fabricated from materials with an ASME P-number of 5B 

or higher or unassigned metals with similar chemical compositions, shall have the root side of the weld 

purged with an argon backing gas prior to welding. Backing gas (purge) shall only be argon. The argon 

backing gas shall be classified as welding grade argon or shall meet Specification SFA-5.32, AWS 

Classification SG-A. The backing gas (purge) shall be maintained until a minimum of two layers of weld 

metal have been deposited. 
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Temporary attachments to pressure boundary components should be avoided and only used when 

absolutely necessary. When required, clamps, welded clips, tack welds, or other appropriate means shall 

be used to properly align the joint for welding. Welded attachments used for fit-up shall be compatible 

with the base material and shall be welded with a qualified welding procedure. Attachments shall not be 

knocked off base material. The attachments shall be removed by suitable methods, such as grinding, 

machining, or sawing, followed by grinding flush with the base material. When thermal cutting is used to 

remove attachments, approximately 3/16 inch of material shall be left for final removal by grinding. The 

ground area shall then be visually examined for defects. The area from which attachments have been 

removed shall be examined as required by the governing code or specification. Any defects found shall 

be repaired. 

All defects in welds or base materials shall be removed and repaired in accordance with the referenced 

code. 

A written procedure for root side purging shall be described in detail and shall be submitted concurrently 

with the welding procedures for review by the B&V Materials Applications Section. 

Welding machine ground leads and clamps shall be located to avoid passing welding current through 

equipment, snubbers, bearings, or any other items where transfer of electrical current may result in 

damage to equipment. 

A complete repair procedure for repairs that are documented as the basis of a nonconformance report 

shall be submitted to the B&V Materials Applications Section for review and approval in writing prior to 

performing the repair. If repair by welding is required, the applicable WPSs and supporting PQRs shall 

be submitted with the repair procedure. All nonconformance report dispositions shall comply with 

applicable code requirements. 

Q100.7 Nondestructive Examination (NDE) 

All NDE shall be performed in accordance with the methods specified in the AWS D1.1 code and any 

supplemental NDE specified within the other Welding Technical Supplemental Specification sections. 

NDE shall be performed in accordance with written procedures that are prepared in accordance with the 

referenced code and as specified herein. NDE procedures shall be submitted for review by the B&V 

Materials Applications Section prior to their use. 

NDE personnel performing NDE other than visual shall be qualified and certified for the applicable NDE 

method. Personnel shall meet written practice ASNT SNT-TC-1A, unless permitted otherwise by the 

referencing code or prior written approval from the B&V Materials Applications Section is obtained. NDE 

personnel qualification records shall be made available for review when requested. 

Personnel performing or supervising the visual examination of welds, including ASME Boiler and 

Pressure Vessel components, shall be qualified as a Certified Welding Inspector (CWI) in accordance 

with the American Welding Society AWS QC 1 or previously approved equivalent program as determined 

by the B&V Materials Applications Section. Visual inspectors' qualifications and certificates shall be 

submitted for review and verification. 

All welds shall receive 100 percent visual examination. Visual weld examination acceptance criteria and 

other NDE acceptance criteria shall be in accordance with applicable referenced codes and design 

documents. Records of these examinations shall be documented. 

The NDE results shall be provided in a NDE Report that is evaluated, interpreted, and accepted by a 

Level II or Level III NDE personnel. 

If specified, the Supplier or Purchaser (whichever is applicable) shall obtain and pay for the services of an 

independent testing laboratory to provide the required field nondestructive testing. Any defective weld 
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shall be removed, repaired, and retested at the Supplier's expense, regardless of whether the testing is 

Supplier provided. 

The Purchaser may order NDE by an independent laboratory in addition to any examinations specified 

herein. The NDE type, extent, and method shall be the same as that required for the original weld. If the 

weld is defective, the laboratory costs shall be paid by the Supplier. If the weld is not defective, the 

laboratory costs will be paid by the Purchaser. Repair of defective welds and reexamination shall be at 

the Supplier's expense. Weld acceptance standards shall be in accordance with applicable codes and 

design specifications. If an individual interpretation is in question, the final authority shall be the 

responsibility of the Purchaser. 

Q100.8 Records 

Records of inspections, NDE, impact testing, hardness testing, PWHT charts or records, base material 

test reports, filler material test reports, radiographic film with applicable reader sheets, deviation requests 

including resolution documentation, nonconformance reports, and other records, as required, shall be 

retained by the Supplier for 5 years after completion of the work. Records shall be submitted to B&V, if 

requested. 

Q121 Welding of Carbon, Low Alloy, and Stainless Structural Steel 

(Source: 11Nov05 - Revised by Project: 23May06) 

Q121.1 General 

This Technical Supplemental Specification provides requirements for welding carbon, low alloy, and 

stainless structural steel, ductwork, stacks, and other welded steel structures as required by design in 

accordance with AWS D1.1, Structural Welding Code - Steel or AWS D1.6 Structural Welding Code – 

Stainless Steel. This Supplemental Specification shall be used in conjunction with Section Q100 of the 

Welding Technical Supplemental Specifications. 

Q121.2 Welding Processes 

Permitted welding processes shall be as specified in Section Q100 and shall include the restrictions and 

limitations applicable to those processes as specified herein. 

Q121.2.1 Welding Process Restrictions and Limitations 

For AWS D1.1, the Gas Metal Arc Welding (GMAW) process utilizing the short-circuiting transfer mode 

shall not be used in any application. 

For AWS D1.6, GMAW-S (short-circuiting transfer mode) may be used on base metal with a thickness of 

3/16 inch maximum. 

The weld progression for manual or semiautomatic vertical position welds shall be uphill, with the 

following exceptions: 

For AWS D1.1, undercut may be repaired vertically downward, provided the preheat is in 

accordance with AWS D1.1, Table 3.2 but not lower than 70° F. 

For AWS D1.1, when tubular products are welded, the progression of vertical welding 

may be upward or downward, but only in the direction in which the welder is qualified and 

as permitted by the Welding Procedure Specification (WPS). 

For AWS D1.6 using the prequalified Gas Tungsten Arc Welding (GTAW), GMAW-S, and 

Flux Cored Arc Welding (FCAW-G) processes, progression may be vertically downward 

for base metal with a 3/16 inch maximum thickness. 

For AWS D1.6, undercut may be repaired vertically downward on the joint faces only, 

without any base metal thickness limitation when using the prequalified GTAW and 

FCAW-G processes. When using the prequalified GMAW-S process, undercut may be 
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repaired vertically downward on the joint faces only for base metal with a 3/16 inch 

maximum thickness. 

For AWS D1.1 and AWS D1.6, the FCAW process shall only be used with shielding gas, except that 

FCAW without shielding gas is permitted within the limitations specified below for AWS D1.1 welding: 

For welding structural items with a base metal thickness not exceeding 0.500 inch using 

seal welds or fillet welds only and using filler metal Classifications E71T-8 or E71T-11. 

Q121.3 Welding Procedure Qualification 

Welding procedures shall be prepared and qualified or shall be prepared as prequalified in accordance 

with AWS D1.1 or AWS D1.6, as applicable. All prequalified WPSs shall be in the form of a written 

document. For a WPS to be prequalified, conformance with all the applicable requirements of AWS D1.1, 

Section 3 or AWS D1.6, Section 3 shall be required. 

Q121.4 Welder/Welding Operator Performance Qualification 

Welders and welding operators shall be qualified in accordance with AWS D1.1 or AWS D1.6, as 

applicable. As an alternative, welders and welding operators may be qualified in accordance with ASME 

Section IX within the welding personnel performance essential variable limitations permitted by AWS D1.1 

or AWS D1.6, as applicable. 

Q121.5 Fabrication Control 

Fabrication, assembly, and erection shall be in accordance with AWS D1.1 or AWS D1.6 (as applicable) 

and the design documents. 

When tensile forces are to be transmitted through full penetration groove welds on AISC material Groups 

4 and 5 rolled shapes, or shapes built up by welding plates more than 2 inches thick together to form the 

cross section, the requirements of AISC J1.7 shall apply. 

Q121.5.1 Backing and Retainers 

When required, backing shall be in accordance with AWS D1.1 or AWS D1.6, as applicable. 

Nonmetallic retainers or nonfusing metal retainers shall not be used unless specified in the WPS. When 

used, they shall be removed. 

Q121.5.2 Preheat and Postweld Heat Treatment 

For AWS D1.1 prequalified carbon and low alloy steels, preheat shall be performed in accordance with 

AWS D1.1, Table 3.2, applicable to the materials listed and the design documents. The minimum preheat 

temperature shall be specified in the WPS. 

For AWS D1.6 prequalified austenitic stainless steels, the minimum preheat temperature shall be 50° F. 

The minimum preheat temperature shall be specified in the WPS. 

For AWS D1.1 or AWS D1.6 materials that are not prequalified, the minimum preheat temperature shall 

be in accordance with the preheat temperature established from the welding procedure qualification. The 

minimum preheat temperature shall be specified in the WPS. 

When required by design, postweld heat treatment shall be performed in accordance with AWS D1.1 or 

AWS D1.6 (as applicable) and the design documents. 

Q121.5.3 Weld End Preparation 

When weld joint details are specified by the design documents, they shall be prepared in accordance with 

the design documents. 

Q121.6 Nondestructive Examination (NDE) 

100 percent visual examination is required of all welds. 
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Unless otherwise specified, any weld defects identified by NDE shall have additional examinations 

conducted as required by Section 6.15 of AWS D1.1 or Section 6.8 of AWS D1.6, as applicable. All 

defects found shall be removed, repaired, and reexamined by the same NDE method that identified the 

original defect. 

Q122 Welding of Abrasion-Resistant Steel Plate 

(Source: 20Sep04 - Revised by Project: N/A) 

Q122.1 General 

This Technical Supplemental Specification provides requirements for welding of abrasion-resistant steel 

plate as required by design. This Supplemental Specification shall be used in conjunction with Section 

Q100 of the Welding Technical Supplemental Specifications. 

Q122.2 Welding Processes 

Permitted welding processes shall be as specified in Section Q100 and shall include the restrictions and 

limitations applicable to those processes as specified herein. 

Q122.2.1 Welding Process Restrictions and Limitations 

The Gas Metal Arc Welding (GMAW) process utilizing the short-circuiting transfer mode shall not be used 

in any application. 

The weld progression for manual or semiautomatic vertical position welds shall be uphill. 

The Flux Cored Arc Welding (FCAW) process shall only be used with shielding gas. 

Q122.3 Welding Procedure Qualification 

Welding procedures shall be prepared and qualified in accordance with AWS D1.1 or ASME Section IX, 

except that the required guided bend test is not required. 

Q122.4 Welder/Welding Operator Performance Qualification 

Welders and welding operators shall be qualified in accordance with AWS D1.1 or ASME Section IX, 

except as modified in the following paragraph. 

Welders or welding operators qualified on P-number 1 through 11, S-number 1 through 11, or base 

metals listed in AWS D1.1, Table 3.1 may be deemed qualified to weld abrasion-resistant steel plate 

within the qualified process limitations. If the actual material is required to be welded in a performance 

test, the required guided bend test is not required. 

Q122.5 Fabrication Control 

Fabrication, assembly, and erection shall be in accordance with AWS D1.1 and the design documents. 

Q122.5.1 Backing and Retainers 

When required, backing shall be in accordance with the Welding Procedure Specification (WPS). 

Nonmetallic retainers or nonfusing metal retainers shall not be used unless specified in the WPS. When 

used, they shall be removed. 

Q122.5.2 Preheat and Postweld Heat Treatment 

Preheat shall be performed in accordance with the applicable WPS. 

 

When required by design, postweld heat treatment shall be performed in accordance with the WPS and 

the design documents. 
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Q122.5.3 Weld End Preparation 

When weld joint details are specified by the design documents, they shall be prepared in accordance with 

the design documents. 

Q122.6 Nondestructive Examination (NDE) 

Visual examination of all welds shall be performed in accordance with Section 6.9 of AWS D1.1 and the 

design documents. Any other methods of required NDE and acceptance criteria shall be as specified in 

the design documents. 

Q301 Manufacturer's Standard Coating 

(Source: 27Jan04 - Revised by Project: N/A) 

Unless otherwise specified, the manufacturer's standard coating systems shall be applied in the shop to 

ferrous metal surfaces of equipment and materials. The coating systems shall provide resistance to 

corrosion caused by weather and industrial environments. Surfaces that will be inaccessible after 

assembly shall be protected for the life of the equipment. 

Coating material and application shall conform to the regulations of the air quality management agency 

having jurisdiction. Materials shall be formulated to contain less than 0.06 percent lead or chromium in 

the dried film. 

Surfaces shall be cleaned, prepared, and coated in accordance with the coating manufacturer's 

instructions and specified codes. Surfaces to be painted shall be filled, as necessary, to provide a 

smooth, uniform base for painting. 

Surfaces to be finish painted after installation shall be shop painted with one coat of manufacturer's 

standard primer. 

Touchup paint shall be provided for repair painting of at least 10 percent of the finish painted equipment 

surface. The touchup paint shall be the same type and color as the shop applied material. Application 

instructions shall be provided. 

No coating shall be applied to surfaces within 3 inches of field welded connections. 

Q301.1 Control and Electrical Equipment 

Control and electrical equipment, including panels, cabinets, switchgear, transformers, and motors, shall 

be finish painted. Exterior surfaces shall be the manufacturer's standard color unless specified otherwise. 

The interior portions of cabinets shall be painted a light reflecting color. 

Q301.2 Mechanical Equipment 

Mechanical equipment, including pumps, compressors, valves, valve operators, external piping surfaces, 

and other similar equipment, shall be cleaned, prepared, and primed. If mechanical equipment will 

operate at temperatures above 200° F and will not be insulated, a high temperature coating system 

designed for the operating temperatures shall be applied. 

Q301.3 Documentation 

Shop drawings shall identify the shop applied coating systems. Data to be provided shall include the 

coating system manufacturer's name and product designation, the degree of surface preparation, dry film 

thickness, finish color, and Material Safety and Data Sheets (MSDS). 
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Q400 General Equipment Requirements 

(Source: 17Oct05 - Revised by Project: 07Jul06) 

Q400.1 Miscellaneous Materials and Services 

Miscellaneous materials and services not otherwise specifically called for shall be furnished by the 

Supplier in accordance with the following, as applicable: 

All nuts, bolts, gaskets, special fasteners, backing rings, etc., between components and 

equipment furnished under these specifications. 

All necessary connections for the Purchaser's piping and instruments. 

All necessary instrument, power, and control wiring and raceways integral to any 

equipment furnished under these specifications. This shall include terminal blocks and 

internal wiring to these terminal blocks for equipment requiring external connection. 

Coupling guards for all exposed shafts and couplings. 

Leveling blocks, soleplates, thrust blocks, matching blocks, and shims. 

Erection drawings, prints, information, instructions, and other data for use by the 

Purchaser's erection contractor. 

Detailed storage requirements and lubrication requirements (including frequencies) for 

use by the Purchaser's erection contractor. 

All special tools or lifting beams. 

Lifting eyes and lugs for offloading and setting equipment. 

Q400.2 Fabrication Restrictions 

Unless specifically provided otherwise in each case, all materials and equipment furnished for permanent 

installation in the work shall conform to applicable standard specifications and shall be new, unused, and 

undamaged. 

Asbestos containing materials will not be allowed. 

Flanges, fittings, and valves manufactured in the People's Republic of China shall meet following 

requirements. 

Manufacturer’s quality system shall be in accordance with ISO 9001 and the 

manufacturer shall hold a valid ISO 9001 certificate issued by the certified ISO 9000 

certification organization. 

Manufacturer shall hold a manufacture license issued by the Center of Boiler and 

Pressure Vessel Inspection and Research (CBPVI) under General Administration of 

Quality Supervision, Inspection and Quarantine of the People's Republic of China 

(AQSIQ). 

Products shall have markings as required by ANSI B16.1, ANSI B16.5, ANSI B16.9, 

ANSI B16.10, ANSI B16.11, B16.25, or ANSI B16.34 as applicable. 

The final quality certificate and quality inspection documents shall bear the official stamp 

of CBPVI or its branches. 
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Individual parts shall be manufactured to standard sizes and gauges so that repair parts furnished at any 

time can be installed in the field. Like parts of duplicate units shall be interchangeable. 

Q400.3 Nameplates and Tags 

Nameplates and tags shall be furnished for all equipment with a Purchaser's identification number based 

upon the guidelines provided herein. The Engineer will annotate the Supplier's drawings on initial 

submittals of technical drawings of the equipment. The information will include the equipment description, 

tag number, physical size, and lettering height. The type of nameplate will vary because of size 

constraints, equipment location and/or orientation, or the environment in which the equipment is located. 

In general, nameplates shall be furnished for major equipment, including all operator interfaces, control 

and electrical panels, cabinets, and instrument racks. The nameplates shall be beveled, laminated white 

phenolic plastic engraving stock with black core or beveled, two-ply vinyl white with reverse engraved 

black fill. These nameplates shall be 2 inches by 8 inches with three lines of text. The top two lines of 

text shall be a brief description of the equipment. These lines of text shall be 3/8 inch high. The bottom 

line of text shall be the Purchaser's identification number of the equipment. This line of text shall be 3/16 

inch high. Nameplates that are to be mounted on equipment to be installed in non air-conditioned areas 

shall be attached with stainless steel panhead screws, rivets, drive screws, or epoxy glue. Nameplates 

that are to be mounted on equipment to be installed in heated and air-conditioned areas shall be attached 

with high performance adhesive tape. Nameplates shall be 1/16 to 1/8 inch thick. 

Stainless steel tags shall be furnished for field instrumentation, process valves, and other small devices 

that a plant operator is not likely to have any direct interface with, as directed by the Engineer. These 

stainless steel tags shall be permanently attached to the equipment with stainless steel panhead screws, 

rivets, drive screws, or, with the Purchaser's acceptance, stainless steel wire. The size of these tags shall 

be a minimum of 3/4 inch by 3 inches and include the Purchaser's identification number. The text shall be 

sized as large as possible within the size constraints. 

Separate nameplates are not required for pressure indicators. They may be provided instead with 

nameplate information, as described above, permanently engraved on the faces. Face engraving text 

size and layout shall be readable without magnification. 

Q400.4 Factory Assembly 

Equipment shall be shipped completely factory assembled, except when the physical size, arrangement 

or configuration of the equipment, or shipping and handling limitations make the shipment of completely 

assembled equipment impracticable, in which case the equipment shall be assembled and shipped as 

stated in the Supplier's proposal. Any deviations after Purchase Order award could result in Supplier's 

performance of some assembly at the site or backcharges to the Supplier for others required to perform 

such assembly. When proposals are submitted without statements describing sectional shipments, it will 

be understood that no field assembly of the equipment will be required and the Supplier shall be 

responsible for all costs encountered in the field for assembly of sections, accessories, or appurtenances 

not listed in the Proposal as requiring field assembly. 

All separately packaged accessory items and parts shall be shipped with the equipment. Containers for 

separately packaged items shall be marked so that they are identified with the main equipment. An 

itemized packing slip indicating what is in that container only shall be attached to the outside of each 

container used for packaging. A similar list shall be inside each container. A master packing slip 

covering all accessory items for a given piece of equipment which are shipped in separate containers 

shall be attached to one container. 

Q400.5 Tools 

The Supplier shall furnish and ship with each piece of equipment one set of all special tools required for 

dismantling, maintenance, and overhaul of the equipment. The tools shall be shipped in separate, heavily 

constructed wooden boxes provided with hinged covers and padlock hasps. 
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Maintenance tools for each piece of equipment shall be boxed separately and the boxes shall be marked 

with the name of the project and the name of the equipment. 

The maintenance tools shall include all special handling rigs, bars, slings, and cable. All maintenance 

tools shall be in new and unused condition and shall become the property of the Purchaser. The bidder's 

proposal shall include the list of maintenance tools which shall be furnished with the equipment. 

In addition to the tools for maintenance and dismantling, the Supplier shall furnish the use of all special 

tools required for erection of the equipment. Erection tools shall remain the property of the Supplier and 

all shipping costs to and from the jobsite shall be at the Supplier's expense. Erection tools for each piece 

of equipment shall be boxed separately. Erection tools shall not be boxed with maintenance tools. 

Q500 Shop Drawings and Instruction Manuals 

(Source: 21Sep05 - Revised by Project: 07Jul06) 

This section, in conjunction with the Schedule of Submittals, stipulates the requirements for engineering 

data that Supplier shall submit for design information and review. Document submittal procedures shall 

be in accordance with the requirements of this Purchase Order. 

Q500.1 Submittal Requirements 

Technical data shall be submitted in electronic format. 

Electronic technical data submittals shall be made using IBackup, a Web-based file transfer service. If 

Supplier does not already have IBackup transmittal capability, information is available at 

http://www.ibackup.com/. (The Uniform Resource Locator [URL] to be used for electronic file submittals 

will be made available upon Purchase Order award.) 

Notification to Purchaser and Engineer that submittals have been posted to IBackup shall be in 

accordance with the correspondence requirements of this Purchase Order. 

The following number of prints shall be submitted unless otherwise indicated in the Schedule of 

Submittals: 

Submittal Description Copies Required 

Performance Curves Electronic Copy 

Design Data Electronic Copy 

Test and Inspection Data Electronic Copy 

Drawings Electronic Copy 

Q500.2 Compliance Reports 

Reports shall be submitted that record the tests and/or calculations required in the specification technical 

sections. Reports shall be submitted for each piece of equipment or each plant system. Specified 

drawings shall be submitted with the compliance reports. 

Q500.3 Motor and Electric Actuator Information 

If required by the Specifications, Motor and Electric Actuator Information shall be submitted in accordance 

with Supplemental Q502. 

Q500.4 Drawings 

Drawings shall be in sufficient detail to indicate the kind, size, arrangement, component weight, 

breakdown for shipment, and operation of component materials and devices; the external connections, 
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anchorages, and supports required; the dimensions needed for installation and correlation with other 

materials and equipment; and the information specifically requested in the Schedule of Submittals. 

Supplier shall fully complete and certify drawings for compliance with the Purchase Order requirements. 

Drawings shall have title block entries that clearly indicate the drawing is certified. 

Each submitted drawing shall be project unique, except where standard Supplier drawings are used, and 

shall be clearly marked with the name of the project, unit designation, Purchase Order title, Purchase 

Order file number, project equipment or structure nomenclature, component identification numbers, and 

Purchaser's name. Equipment, instrumentation, and other components requiring Purchaser-assigned 

identification tag numbers shall be clearly identified on the drawings. If standard drawings are submitted, 

the applicable equipment and devices furnished for the project shall be clearly marked. 

Transmittal letters shall identify which Schedule of Submittals item (by item number) is satisfied by each 

drawing or group of drawings. The transmittal letter shall include the manufacturer’s drawing number, 

revision number, and title for each drawing attached. Each drawing title shall be unique and shall be 

descriptive of the specific drawing content. Transmittal letters for resubmitted drawings shall include the 

Engineer’s drawing numbers. 

Catalog pages are not acceptable, except as drawings for standard non-engineered products and when 

the catalog pages provide all dimensional data, all external termination data, and mounting data. The 

catalog page shall be submitted with a typed cover page clearly indicating the name of the project, unit 

designation, specification title, specification number, component identification numbers, model number, 

Supplier’s drawing number, and Purchaser's name. 

Drawings shall be submitted with all numerical values in English and/or metric (SI) units. 

Q500.4.1 Drawing Submittal 

Drawings shall be submitted for review electronically in Tagged Image File Format (TIFF) - Group 4. 

Final drawings shall be submitted electronically in both PDF format and Tagged Image File Format (TIFF) 

– Group 4. 

Q500.4.2 Drawing Processing 

Supplier’s engineering schedule shall allow a minimum of three (3) weeks for mailing, processing, and 

review of drawings and data by the Engineer. 

Unless this Purchase Order indicates that a drawing or engineering data submittal by Supplier is to be for 

Engineer's information only, Engineer, upon receipt of submittals, shall review and return same to 

Supplier, marked "No Exceptions Noted," "Exceptions Noted," “Received for Distribution," "Returned for 

Corrections," “Release for Record,” “Void,” or “Superseded.” The timing of Supplier’s submittals and 

Engineer’s review shall be in accordance with the Completion Dates for same as set forth in the Purchase 

Order. The submittal of any drawing or other submittal document by Supplier to Engineer under this 

Purchase Order will be certification by Supplier that the information set forth therein is accurate in all 

material respects. 

Q500.4.2.1 No Exceptions Noted (NE) or Received for Distribution (RD). Upon receipt of a submittal 

marked "No Exceptions Noted" or "Received for Distribution," Supplier may proceed with its Work to the 

extent of and in accordance with the submittal. No further submittal is required unless the drawing or 

document is revised, in which case it shall be resubmitted in accordance with Q500.4.2.6. 

Q500.4.2.2 Exceptions Noted (EN). Upon receipt of a submittal marked "Exceptions Noted" and if 

Supplier concurs with Engineer's comments, Supplier shall incorporate same and may proceed with its 

Work to the extent of and in accordance with the annotated submittal. Supplier shall submit to Engineer 

within fourteen calendar days a revision to the original submittal in which Engineer's comments have 

been incorporated. If Supplier determines that it cannot incorporate Engineer’s comments without 

prejudice to Supplier’s warranty or other obligations under this Purchase Order, Supplier shall so advise 
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Engineer in writing within seven calendar days of its receipt of Engineer’s comments, stating the reasons 

therefore. Supplier may proceed with its Work to the extent of and in accordance with the annotated 

submittal only upon Engineer and Supplier resolving Engineer’s comments. 

Q500.4.2.3 Returned for Corrections (RC). Upon receipt of a submittal marked "Returned for 

Corrections," Supplier shall immediately take all necessary action to revise its submittal in accordance 

with Engineer's comments, the Specification, and the Drawings, and shall resubmit to Engineer for review

the corrected original submittal, voiding previous information and adding new documents if required. In 

no event shall Supplier proceed with the affected Work until its revised submittals have been returned to 

Supplier marked "No Exceptions Noted" or "Exceptions Noted" by Engineer. 

Q500.4.2.4 Release for Record (RR). Receipt of a submittal marked “Release for Record” indicates that 

there are no specific objections to the document. Work may proceed. Certain required project information 

has been added electronically to the drawing and provided to Supplier for the record. Resubmittal by 

Supplier is not required. Only future revisions of the document shall be submitted. Engineer's projectspecific information shall be added if future revisions and submittals are made. 

Q500.4.2.5 Void (VO) or Superseded (SS). Receipt of a submittal marked “Void” or “Superseded” does 

not require any action by Supplier. “Void” indicates that the submittal is no longer applicable to the 

project and is not being replaced by other drawings or data. “Superseded” indicates that different 

drawings or data have replaced the previously submitted drawings and data; this status does not pertain 

to revisions of the same drawings and data. 

Q500.4.2.6 Hold (HO). A submittal may be given a status of "Hold" by the Engineer, or the Supplier may 

have "Holds" on the submitted drawing. 

For a Hold status designated by the Engineer, the Supplier shall not proceed with the work that is 

designated on "Hold" except as specifically directed by the Engineer. Additional information required for 

the Supplier to release the "Hold" will be transmitted from the Engineer later. 

The Supplier shall provide information to the Engineer about the cause for any "Holds" designated on the 

drawing and immediately take all action necessary to resolve the "Holds". The Supplier shall resubmit the 

drawing for review once the "Holds" are removed from the drawing and should make all efforts to not 

submit drawings to the Engineer until drawing review comments have been received back from the 

Engineer. 

Q500.4.2.7 Resubmittals. If during or subsequent to the completion of the submittal process, Supplier 

makes further changes to the equipment and materials shown on submittals that have been reviewed by 

Engineer, the changes shall be clearly marked on the submittal by Supplier and the submittal process 

shall be repeated. If changes are made by Supplier after delivery to the Jobsite, as-built drawings 

indicating the changes shall be prepared by Supplier and submitted to Engineer for review. Any 

resubmittal of information shall clearly identify the revisions by footnote or by a form of back-circle, with 

revision block update, as appropriate. 

Q500.4.2.8 Engineer’s Review. Engineer’s review of drawings and other submittals will cover only 

general conformity of the data to the Specifications and Drawings, external connections, interfaces with 

equipment and materials furnished under separate specifications, and dimensions that affect plant 

arrangements. Engineer’s review does not include a thorough review of all dimensions, quantities, and 

details of the equipment, material, device, or item indicated or the accuracy of the information submitted. 

Review and comment by Engineer of Supplier's Drawings or other submittals shall not relieve Supplier of 

its sole responsibility to meet the Completion Dates requirement of this Purchase Order and to supply 

Goods that conform to the requirements of this Purchase Order. 

Q500.4.2.9 File Returns to Supplier. The IBackup web service will be used by Engineer to return TIFF 

files to Supplier. 
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Each packet of drawings returned to Supplier will include a manifest generated by Engineer. The 

manifest will include a list of drawings transmitted, manufacturer's drawing numbers, Purchaser's 

assigned drawing numbers, Purchaser's drawing titles, and the status of the drawings. 

Files returned to Supplier will be in TIFF Group 4 format unless another format is agreed upon by 

Engineer and Supplier. 

Q500.4.3 As-Built Drawings 

As-built prints of each final electrical wiring and elementary diagram for equipment shall be furnished in 

accordance with Article Q500.5. An electronic copy of each drawing shall be submitted to Purchaser and 

Engineer. 

Q500.5 Wiring Diagrams 

Wiring Diagrams shall be submitted in accordance with Supplemental Q502. 

Q500.6 Instruction Manuals. 

Instruction Manuals shall be submitted in accordance with Supplemental Q501. 

Q501 Instruction Manuals 

(Source: 21Sep05 - Revised by Project: 07Jul06) 

This section, in conjunction with Section Q500 and the Schedule of Submittals included in the 

Supplemental Terms and Conditions of this Purchase Order, stipulates the requirements for Instruction 

Manuals that Supplier shall submit for design information and review. Document submittal procedures 

shall be in accordance with the requirements of this Purchase Order, Section Q500, and the following. 

The existing SJRPP Air Heater Operating and Installation Manual shall be updated to include scope of 

supply under this contract. 

Air Heater Soot Blower information shall be provided by the Engineer to the Supplier. The Supplier shall 

provide Air Heater soot blowing limitations and recommendations for the basket elements. 

Q501.1 Submittal Requirements 

Hard copies shall be submitted to the address indicated for Technical Documents in the Supplementary 

Terms and Conditions of this Purchase Order for the documents listed below. The following number of 

copies shall be submitted unless otherwise indicated in the Schedule of Submittals: 

Submittal Description Copies Required 

Proof Copies 2 

Final Copies 10 

Q501.2 Instruction Manuals. 

Supplier shall furnish proof and final instruction manuals for the unloading, storage, installation, operation, 

and maintenance of the equipment. The manuals shall be delivered as specified in the Schedule of 

Submittals. 

Manuals shall include the following information specific to the furnished equipment: 

Table of contents and index tabs. (If multiple volumes are required, a table of contents 

listing materials included in each volume shall be supplied for each volume.) 
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Specifications, test data, and all performance curves specified in the technical 

specifications. 

Description of the equipment, including illustrations showing elevations, cross section, 

and all details of the equipment with all parts named, numbered, and identified with 

Purchaser's tag numbers. When multiple model numbers are shown on the drawings, the 

equipment supplied for the project shall be clearly identified. 

Complete and detailed operating instructions, including safety precautions, philosophy of 

operation and, where applicable, process optimization techniques. 

Detailed minor and major maintenance instructions, including description, use of special 

tools furnished, and preventive maintenance schedule. 

Instructions for receiving, inspection, storage, and handling of equipment prior to 

installation. 

Installation instructions. 

Inspection procedures. 

Troubleshooting guide. 

All fluid systems schematics and piping diagrams. 

Control logic diagrams, as applicable. 

Electrical wiring diagrams, as applicable. 

Calibration Data Sheet for each adjustable instrument included in the scope of supply. 

Motor Information Sheets, as applicable. 

Electric Actuator Information Sheets, as applicable. 

Control Panel Arrangements, as applicable. 

Supplier and Sub-supplier operating and maintenance manuals. 

Illustrated parts breakdown. 

Assembly drawings. 

Parts lists. 

List of acceptable lubricants. 

Nameplate information and shop order numbers for each item of equipment and 

associated component parts thereof. 

List of recommended spare parts. 

List of maintenance tools furnished with the equipment. 
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The above listed requirements are the minimum requirements; however, requirements that are clearly not 

applicable to the equipment may be deleted with Engineer's approval. Additional information that is 

necessary for proper operation and care of the equipment shall also be included. 

Q501.2.1 Binding 

Each copy of the manuals shall be assembled and bound in three-ring or post binders designed for rough 

usage. Light-duty binders will not be acceptable. 

Front covers and backbones of the manuals shall be permanently marked with lettering per the Typical 

Instruction Book Cover attached at the end of this section. 
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TYPICAL INSTRUCTION BOOK COVER 

NAME 

OF 

EQUIPMENT 

SJRPP 

UNITS 1 & 2 

PURCHASE ORDER 

NUMBER** 

VOLUME 

NUMBER* 

 

SJRPP 

UNITS 1 & 2

INSTRUCTION BOOK 

FOR 

NAME OF EQUIPMENT 

VOLUME NUMBER* 

PURCHASE ORDER NUMBER** 

MANUFACTURER'S NAME 

MANUFACTURER'S ADDRESS

BLACK & VEATCH 

CARY, NC 

36 

24 

24

36 

36 

36 

36

24 

24 

24

14 

14 

 (Backbone) (Cover) 

NOTES: 

1. All lettering shall be a block style font such as Arial. 

2. All backbone lettering shall be 14 point. 

3. Cover lettering shall be point sizes indicated in column to right of cover illustration. 

4. *Volume number required only if instructions are contained in more than one volume. 

5. **Engineer assigned Purchase Order number. 
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Q502 Electrical Data 

(Source: 09Jun06 - Revised by Project: 07Jul06) 

This section, in conjunction with Section Q500 and the Schedule of Submittals included in the 

Supplemental Terms and Conditions of this Purchase Order, stipulates the requirements for Electrical 

Data that Supplier shall submit for design information and review. Document submittal procedures shall 

be in accordance with the requirements of this Purchase Order, Section Q500, and the following. 

Q502.1 Submittal Requirements 

Electronic copies shall be submitted to the address indicated for Technical Documents in the 

Supplementary Terms and Conditions of this Purchase Order for the documents listed below. The 

following number of copies shall be submitted unless otherwise indicated in the Schedule of Submittals: 

Submittal Description Copies Required 

Motor Information Sheets Electronic 

Electric Actuator Information Sheets Electronic 

Wiring Diagrams Electronic 

Q502.2 Motor and Electric Actuator Information 

Copies of Motor Information Sheets and Electric Actuator Information Sheet are included at the end of 

this section. (Electronic copies of these information sheets will be made available upon Purchase Order 

award.) An information sheet shall be completed for each motor and electric actuator furnished under the 

Purchase Order. 

Q502.3 Wiring Diagrams 

Connection and interconnection wiring diagrams furnished by Supplier shall be drawn with all devices 

indicated in their relative physical locations and shall accurately show the equipment and terminals 

arranged as they would appear to a person wiring the equipment. When approved by Purchaser, 

termination schedules identifying field terminations may be substituted for wiring diagrams for 

connections external to equipment. 

Where interconnecting wiring from different items of equipment or sectional wiring diagrams of the same 

item of equipment appear on different wiring diagram sheets, all interconnections shall be clearly 

identified. Where sectional wiring diagrams are required for a single item of equipment, such as a relay 

panel or control panel, the section of the panel that is represented by each individual wiring diagram 

sheet shall be keyed on that sheet in a manner acceptable to Purchaser. 

Information indicated on Supplier's drawings shall include wiring and terminal numbers of the individual 

panel items as they actually will appear in the panel, set points, contact arrangements of switches and 

relays (state of device and device contacts shall be clearly indicated), and internal wiring of relays and 

instruments. Spare terminals and all unused contacts of the individual panel items shall be shown on the 

drawings. 

Elementary diagrams shall be cross-referenced to terminal markings on the connection and 

interconnection diagrams, but do not need to indicate complete details of circuits external to the panels, 

unless required by Purchaser. Each item of panel mounted equipment indicated on the diagrams shall be 

identified by item number and name. 

Q502.3.1 As-Built Drawings 

As-built prints of each final electrical wiring and elementary diagram for equipment shall be furnished in 

accordance with Article Q500.5. An electronic copy of each drawing shall be submitted to Purchaser. 
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MOTOR INFORMATION SHEET

Sheet 1 of 2 

Driven Equipment Data

NAME 

ID(s) 

MANUFACTURER 

DRIVEN EQUIP MAX BRAKE LOAD HP* OR kW AT DESIGN COND 

MOTOR DATA - ALL MOTORS (CIRCLE CHOICES) HORIZONTAL, VERTICAL, INDUCTION, SYNCHRONOUS 

MANUFACTURER , 

MODEL 

OUTLINE/WIRING/CONNECTION DRAWING NUMBERS 

DESIGN STANDARD (NEMA, IEC, etc.) NAMEPLATE VOLTS/PH/HZ / / 

FOR NEMA MTRS - NAMEPLATE HP/SERVICE FACTOR / 

LOCKED-ROTOR CODE LETTER NEMA DESIGN LETTER 

FOR IEC MOTORS - NAMEPLATE kW 

MAX CONTINUOUS VOLTAGE (RATED FREQ) MIN CONTINUOUS VOLTAGE (RATED FREQ) 

DUTY TYPE (CONTINUOUS, DEFINITE TIME - MIN) FULL LOAD SPEED RPM 

FULL LOAD CURRENT RATED HP OR kW _____________AMP LOCKED-ROTOR CURRENT AMP 

NEMA OR IEC ENCLOSURE FRAME SIZE 

IEC COOLING (IC CODE) IEC MOUNTING (IM CODE) 

DESIGN AMB TEMP °C INSULATION SYSTEM CLASS 

TEMP RISE BY RESISTANCE (AT SERVICE FACTOR LOAD) FOR NEMA MOTOR °C 

SPACE HEATERS (SP) FURNISHED: YES NO TOTAL SP LOAD WATTS/VOLTS/PHASE / / 

BEARINGS: TYPE 

 LUBRICATION TYPE SYSTEM 

 ABMA L-10 RATING LIFE, NOT LESS THAN HOURS 

 CONNECTION (CIRCLE ONE): DIRECT BELT CHAIN 

OVERALL MEAN NO-LOAD SOUND PRESSURE LEVEL RE MICROPASCALS 

(0.0002 MICROBAR) REFERENCE DISTANCE OF 3 FEET FREE AIR 

TOTAL MOTOR WT LB IS MOTOR REVERSIBLE? YES NO 

FOR MULTI-CONNECTABLE MOTORS (CIRCLE CORRECT CHOICE(S)): PART WINDING, STAR-DELTA, 

VARIABLE TORQUE, CONSTANT TORQUE, CONSTANT HORSEPOWER, PAM, TWO WINDING, ONE WINDING, 

OTHER 

RPM FL AMPS LR AMPS : RPM FL AMPS LR AMPS 

RPM FL AMPS LR AMPS : RPM FL AMPS LR AMPS 

FOR MOTORS IN HAZARDOUS LOCATIONS: MOTOR ENCLOSURE MAXIMUM SURFACE TEMPERATURE, °C 

WILL MOTOR CONTAIN A SURFACE TEMPERATURE CONTROL THERMOSTAT REQUIRING CONNECTION INTO THE MOTOR 

STARTER CONTROL CIRCUIT: YES NO 
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MOTOR INFORMATION SHEET

Sheet 2 of 2

MOTOR 

ADDITIONAL MOTOR DATA TO BE SUBMITTED FOR MOTORS 100 HP (75 kW) AND LARGER AND FOR ALL MOTORS RATED ABOVE 

1000 VOLTS

EFFICIENCY, PERCENT GUARANTEED, LOAD: 1/2 3/4 4/4 

POWER FACTOR, PERCENT GUARANTEED, LOAD: 1/2 3/4 4/4 

MINIMUM STARTING VOLTAGE IN PERCENT OF RATED VOLTAGE: CALCULATED: __________ SPECIFIED: _

ACCELERATING TIME: 

 AT RATED VOLTAGE (SECONDS): _

 AT MINIMUM SPECIFIED STARTING VOLTAGE (SECONDS) _

LOCKED-ROTOR SAFE STALLED TIME, SECONDS MINIMUM SPECIFIED 

 RATED VOLTAGE STARTING VOLTAGE 

 MOTOR INITIALLY AT MAXIMUM SPECIFIED 

 AMBIENT TEMPERATURE 

 MOTOR INITIALLY AT SERVICE FACTOR 

 LOAD OPERATING TEMPERATURE 

ADDITIONAL MOTOR DATA TO BE SUBMITTED FOR ALL MOTORS RATED ABOVE 1000 VOLTS

CURRENT AND TORQUE VERSUS SPEED CURVES AT MAXIMUM, RATED, AND MINIMUM SPECIFIED STARTING VOLTAGE, 

DRAWING NUMBER (ATTACH CURVES *) 

POWER FACTOR AND EFFICIENCY VERSUS SPEED CURVES AT RATED VOLTAGE, 

DRAWING NUMBER (ATTACH CURVES *) 

CURRENT VERSUS TIME CURVES AT MAXIMUM, RATED, AND MINIMUM SPECIFIED STARTING VOLTAGE, 

DRAWING NUMBER (ATTACH CURVES *) 

LOCKED-ROTOR THERMAL LIMIT CURVES (CURRENT VERSUS TIME) CURVES IN BOTH COLD AND HOT OPERATING 

CONDITIONS, AND STATOR RUNNING THERMAL OVERLOAD CURVES AT RATED VOLTAGE, 

DRAWING NUMBER (ATTACH CURVES *) 

TORQUE IN (CIRCLE ONE) LB-FT OR N-METER 

LOCKED-ROTOR TORQUE PULL-UP TORQUE BREAKDOWN TORQUE 

INERTIA IN (CIRCLE ONE) LB-FT2 GD2 

MOTOR RATED , MOTOR ROTOR , DRIVEN EQUIP , COUPLING ___________

TEMPERATURE ALARMS AND TRIPS FOR MOTORS EQUIPPED WITH SENSORS 

STATOR WINDING RTD ALARM °C TRIP 

BEARING TEMPERATURE ALARM °C TRIP 

MOTOR SUBTRANSIENT REACTANCE _______________ MOTOR OPEN CIRCUIT TIME CONSTRAINT _________________ 

SHORT CIRCUIT TIME CONSTRAINT _______________ STARTING POWER FACTOR _____________________________ 

NUMBER OF SUCCESSIVE STARTS: AT RATED VOLTAGE

 MOTOR INITIALLY AT MAXIMUM SPECIFIED AMBIENT TEMPERATURE 

 (COLD WITH DRIVEN EQUIPMENT CONNECTED), NUMBER 

 MOTOR AT RATED TEMPERATURE RISE PRIOR TO STARTING 

 (HOT WITH MOTOR COUPLED), NUMBER 

 COOLING PERIOD REQUIRED AFTER COMPLETION OF THE PRECEDING MAXIMUM 

 NUMBER OF SUCCESSIVE STARTS BEFORE MAKING ADDITIONAL STARTS, MINUTES 

 

 MOTOR STOPPED COOLING TIME CONSTANT, MINUTES 

 MOTOR RUNNING COOLING TIME CONSTANT, MINUTES 

LIST OF DRAWINGS AND SPECIFICATIONS FOR 

 LUBRICATION OILS AND GREASES, DRAWINGS 

 EXTERNAL FLUID CIRCUITS FOR BEARING COOLING, DRAWINGS 

 EXTERNAL FLUID CIRCUITS FOR STATOR COOLING, DRAWINGS 

* SUBMIT TABULATED DATA WITH CURVES FOR HIGH INERTIA LOADS 
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ELECTRIC ACTUATOR INFORMATION SHEET

NAME AND ID NUMBER 

NAME ID NUMBER 

GENERAL INFORMATION 

MANUFACTURER 

MODEL NO. 

RATED OUTPUT TORQUE, FT-LB 

FACTORY TORQUE SWITCH SETTINGS 

OPEN 

CLOSE 

TORQUE CLOSE SEATING REQUIRED FOR THIS APPLICATION, YES/NO 

SPEED OF OPERATION 

OPEN TO CLOSE, SEC 

CLOSE TO OPEN, SEC 

MAXIMUM DIFFERENTIAL PRESSURE WHICH ACTUATOR IS CAPABLE OF 

OPERATING AGAINST, PSI 

VALVE STEM DIAMETER, IN. 

THRUST ALLOWANCE FOR VALVE PACKING FRICTION 

WEIGHT, LB 

GEAR HOUSING MATERIAL 

SELF-LOCKING GEARING, YES/NO 

MOTOR DATA 

MANUFACTURER 

ENCLOSURE/COOLING RATING / 

HP/RPM / 

VOLTAGE/PHASE/HZ / / 

FULL LOAD CURRENT, AMPS 

LOCKED-ROTOR CURRENT, AMPS 

LOAD CURRENT FOR SETTING OVERLOAD RELAY PROTECTION, AMPS 

MOTOR TIME RATING AT MAXIMUM DRIVEN EQUIPMENT TORQUE IN A 50°

C AMBIENT, MINUTES 

MOTOR SPACE HEATER, WATTS/VOLTS / 

ARE MOTOR SELF-RESET THERMAL SWITCHES, IF PROVIDED, REQUIRED 

TO BE WIRED IN PURCHASER'S STARTER COIL CIRCUIT, 

YES/NO/RECOMMENDED / 

CONTROLS DATA 

ENCLOSURE RATING 

NETWORK COMMUNICATIONS, IF APPLICABLE 

ENCLOSURE SPACE HEATER, WATTS/VOLTS / 

INTEGRAL STARTER, YES/NO / 

DRAWINGS 

ITEM DRAWING TITLE DRAWING NUMBER REVISION 

OUTLINE DIAGRAM 

SCHEMATIC/WIRING 

DIAGRAM 

 
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V100 Noise Abatement 

(Source: 27Jan04 - Revised by Project: N/A) 

The equivalent A-weighted sound pressure level for equipment furnished under these specifications shall 

not exceed 85 dBA free field measured 3 feet horizontally from the base of the equipment and 5 feet 

above floor level or any personnel platforms. If the drive motors for the equipment are also furnished 

under these specifications, the sound pressure level of the motor and driven equipment combined, 

operating at design load, shall not exceed 85 dBA free field. The sound pressure levels stated are 

decibels to a reference of 20 micropascals. 
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15541 - Air Heater Modifications 

15541.1 General 

The St. Johns River Power Park consists of two 640 MW power generating units. Each unit includes two 

regenerative air heaters originally manufactured by Air Preheater Company. The existing air heaters are 

model 33-VI-68, tri-sector design, with vertical shaft orientation. The air heaters have 3 layers of heating 

elements and conventional single seal arrangement. 

The work under these specifications includes furnishing the design, equipment, and materials described 

herein to modify the existing air heaters to an ammonium bisulfate tolerant design as part of the 

installation of selective catalytic reduction (SCR) systems on Units 1 and 2 at the St. John’s River Power 

Park. The air heater modifications shall be designed in accordance with the design and performance 

criteria specified herein. 

15541.1.1 Arrangement 

The air heaters are installed outside the existing boiler structure. Two air heaters per unit for a total of 

four air heaters shall be modified as necessary to meet the required performance as stated herein. 

15541.1.2 Scope of Supply 

The air heaters shall be modified and furnished complete with all equipment and accessories required for 

a complete operating system. 

The work under these specifications shall include furnishing all steel required for reinforcing the rotor and 

air heater housing assembly, rotor modules including baskets and basket elements, duplex radial and 

axial seals, bypass seals, rotor post seals, static seals, and providing miscellaneous materials and 

services complete as specified herein. 

All equipment and materials will be shipped to the project site by the Supplier. All materials will be 

shipped in a manner allowing proper outdoor storage in the field, marked to allow identification for 

erection, and in a manner that shall prevent rusting or deterioration of any of the components. 

The work under these specifications shall also include the following: 

Manufacturer’s field technical services onsite during modification work to assist in field erection 

coordination. 

Unit 1 Main Drive Motors– Replace-in-kind the Main and Auxiliary Pneumatic Motors 

Unit 2 Main Drive Motors – Replace-in-kind the Main and Auxiliary Pneumatic Motors 

Provide support information to assist the Purchaser to integrate the control of the Air Pre Heater (APH) 

Leakage Control System (LCS) into the plant's distributed control system. In order to proceed on this 

issue, non-disclosure agreements have been executed with all parties that will have access to the design 

information that the Supplier will be required to submit. 

Develop and provide an overview of the control requirements for the APH LCS equipment, as well as 

ladder logic. The Supplier will not accept responsibility for the consequences of attaching hardware 

provided by others to these air preheaters.

Gearbox upgrade for all air heaters. The new gearbox shall be Lufkin Model TCBL80-270CHS. 

Technical services for the assessment of the condition of the sealing system during the Unit 1 and 2 2007 

outages. 
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The equipment will be tested by the Purchaser after erection to demonstrate its ability to operate under 

the conditions and fulfill the guarantees as set forth herein. If the tests indicate the equipment fails to 

meet the guaranteed performance, the Supplier shall provide material and recommendations for 

modifications to correct any deficiencies in the air heater equipment. 

The Supplier shall provide drawings and other engineering data, manufacturer’s field services, tools, 

instruction manuals, recommended spare parts list, and miscellaneous materials and services, and shall 

participate in design conferences, all as specified herein. 

Equipment, materials, and accessories shall be delivered to the St. John’s River Power Park where they 

will be received, unloaded, stored, and erected by the Purchaser’s erection contractor. Deficiencies shall 

be sufficient to reject equipment CIP carrier. Unloading from carrier and storing will not constitute 

acceptance. 

15541.1.2.1 Miscellaneous Materials and Services 

Miscellaneous materials and services not otherwise specifically called for shall be furnished by the 

Supplier in accordance with the following: 

All crating/packaging and freight of any equipment furnished under these specifications. 

The use of all special tools required for erection of the equipment, exclusive of the 

maintenance tools specified to be furnished. Erection tools shall remain the property of 

the Supplier and all shipping costs to and from the Jobsite shall be at the Supplier's 

expense. 

Manufacturer's field technical services. 

The Supplier's design engineer or other Alstom representative shall attend two design 

conferences, at a time and place selected by the Engineer to discuss matters relative to 

the execution of the contract. The Supplier's design engineer shall be available as 

required by the Engineer to expedite the work. 

Prime painting of all equipment for protection in transit to project site, during storage, and 

prior to insulation. The shop-installed baskets in the modules will not be painted, but will 

be shipped tarped and should be stored in the field tarped and above ground on timbers. 

The rotor modules will be prime painted. 

The smaller items will ship in weather protective boxes. 

For all non-insulated equipment, Manufacturer’s standard finish coat shall be applied. 

All spare parts required during startup and initial operation of the equipment. 

Equipment nameplates and tags. 

15541.1.3 Items Furnished by Others and Interfaces 

Items furnished by others and not in this scope of supply include the following: 

Selective Catalytic Reduction (SCR) system. 

Receiving, unloading, storing, and field erection of all equipment. 

Motor controls and starters not otherwise specified to be furnished under these specifications. 

Foundations, foundation bolts, bolt sleeves, and equipment bases. 
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Multi-media Cleaners 

Grouting materials and the placing thereof. 

Permanent electric wiring to connect equipment terminal boxes to the plant electrical system. 

Lubricants and fuels for operation. 

Solvents and cleaning materials. 

Finish painting of all equipment except as specified herein. 

Operating personnel for startup and tests. 

Physical equipment or hardware for the APH LCS. 

15541.1.4 Codes and Standards 

Work performed under these specifications shall be done in accordance with the following codes and 

standards. Unless otherwise specified, the applicable governing edition and addenda to be used for all 

references to codes or standards specified herein shall be interpreted to be the jurisdictionally approved 

edition and addenda. If a code or standard is not jurisdictionally mandated, then the current edition and 

addenda in effect at the date of this document shall apply. These references shall govern the work 

except where they conflict with the Engineer’s specifications. In case of conflict, the latter shall govern to 

the extent of such differences: 

Work In Accordance With 

Air heater and associated equipment 

design 

ASME, AISC, ANSI, NEMA, IEEE, NEC, 

NFPA 

Welding AWS 

Personnel protection OSHA 

15541.1.5 Materials 

The following materials shall be used: 

Component Material 

Air heater basket assemblies Manufacturer’s standard 

15541.1.6 Approved Manufacturers of Components 

For the following components, only the listed manufacturers are recognized as maintaining the level of 

quality of workmanship required by these specifications. If the Supplier wants to propose a nonlisted 

manufacturer that is considered to provide an equivalent level of quality, this manufacturer must be 

identified and supporting testimony provided. Acceptance of the manufacturer as a substitute is at the 

discretion of the Engineer: 

Component Manufacturer 

Instrumentation In accordance with Technical Supplemental Specifications 

K100 

15541.1.7 Test Requirements 

The following testing shall be conducted in accordance with the specified source. This testing is to be 

considered part of the defined Scope of Work, and all associated costs are the responsibility of the 
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Supplier unless specifically identified as a Bid Option or Purchaser-conducted. Tests identified as an 

option are to be priced separately. If identified as Purchaser-conducted, costs for the test will be the 

responsibility of the Purchaser. However, the Supplier is responsible for material and Supplier 

representative time costs associated with correcting deficiencies. 

Tests In Accordance With Conducted By 

Performance Guarantee ASME-PTC 4.3 Purchaser 

15541.1.8 Technical Attachments 

This article lists the drawings and other technical attachments that have been prepared for the work under 

these specifications. 

Drawing No. Rev. No. Title 

930791 C General Arrangement 

930980 A Rotor Assembly 

63054 0 Air Heater Modified Rotor Post Seal 

77400 A Rotor Drive Assembly 

OM-2224 Support Bearing 

OM-2228 Guide Bearing 

OM-2262 Support Bearing – Pin Type Leveling Plates, 

Shoes and Runner 

OM-2413 Auxiliary Drive Assembly 

OM-2427 Fluid Coupling 

OM-2429 Rotor Drive Pinion Hub 

OM-2609 Rotor Seal Assembly – Radial Seals 

OM-2610 Rotor Seal Assembly – Bypass & Axial Seals 

OM-2612 Seal Setting 

15541.2 Performance and Design Requirements 

15541.2.1 Design Performance Conditions 

The air heater shall be modified to minimize the build-up of ammonium bisulfate and to ease its removal 

by soot blowing during operation. The air heaters shall be modified to meet the performance 

requirements specified and shall be corrosion-resistant. 

The air heaters shall be guaranteed to meet the design performance as listed in the attached Alstom 

Performance Data and Performance Guarantee. The Supplier shall provide the maximum pressure on 

the primary air side that will not require replacing the current components, such as bearings and drive 

unit, during an upset/transient case along with the ±35 in wg in the gas and secondary air ducts. 

Air Heater Design Performance 

Conditions 

Design Minimum Maximum

Air Heater flow rates per heater (lb/hr) 

 Flue gas entering 3,064,115 1,652,350 3,257,280 
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Source: 15541, 2005, v.1.0 Air Heaters Page 74 of 79

 Total primary air 559,607 342,252 562,800 

Primary air leaving 250,807 203,652 255,500 

Primary air bypass 308,800 138,600 307,300 

 Total secondary air leaving 2,273,102 1,196,231 2,458,886 

 Maximum air heater leakage, % 6.2 9.9 5.9 

Temperature, (oF) 

 Gas entering air heater 750 640 750 

 Gas leaving the air heater (excluding 

leakage) 

331 218 345 

 Gas leaving the air heater (including 

leakage) 

318 202 333 

 Primary Air entering air heater 104 28 128 

 Primary Air leaving air heater 684 572 686 

 Primary Mix Air 368 355 385 

 Secondary Air entering air heater 85 11 108 

 Secondary Air leaving air heater 623 539 622 

Pressure (in wg) 

 Air heater primary air outlet pressure 62.2 60.8 62.24 

 Air heater secondary air outlet pressure 7.4 1.9 8.7 

 Air heater gas inlet pressure -13.5 -3.93 -15.2 

 Air heater primary air side design / 

transient pressure 

+98 +98 +98 

 Air heater secondary air side transient 

pressure 

±35 ±35 ±35 

 Air heater gas side transient pressure ±35 ±35 ±35 

Pressure Drop (in wg) 

 Primary air side (maximum) 0.55 0.4 0.6 

 Secondary air side (maximum) 2.2 0.7 2.55 

 Gas side (maximum) 2.6 0.85 2.9 

The air heater shall be designed to withstand a maximum continuous gas entering temperature of 800 °F. 

The air heater shall also be able to withstand short-term gas temperature excursions to 824 °F. 

The flows indicated above are MCR unit load with the seals and sealing system set in accordance with 

manufacturer’s instructions. As the seals leave adjustment, and at higher loads, the flow rates may 

increase. The air heater and air heater elements shall be designed to withstand flow rates of up to 

20 percent higher than those indicated without suffering flow induced damage. 
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15541.2.1.1 Coal Analysis 

The air heater performance guarantee shall be based on the coal analysis given in Technical 

Supplemental D300. The air heater shall be capable of operation without any deterioration effect for 

normal variations of the constituents given in D300. 

15541.2.1.2 Flue Gas Analysis 

The air heater performance guarantee shall be based on the typical flue gas analysis specified below 

entering the air heater. The air heater shall be capable of operation without any deterioration effect for 

normal variations of the constituents given below. 

Flue Gas Analysis (%vol) Typical Range

Oxygen 3.25 3.2 – 4.8 

Nitrogen 73.65 73 - 74 

Carbon Dioxide 14.04 12.77 – 14.1 

Sulfur Dioxide 0.18 0.06 – 0.2 

Moisture 8.88 8.3 – 9.6 

Ammonia slip (ppm) 2.0 1.0 – 5.0 

Sulfur Trioxide (lb/hr) 917 503 – 1,781 

Ash loading (gr/acf) 1.39 1.32 – 2.3 

15541.2.1.3 Ash Analysis 

The air heater performance guarantee shall be based on the ash analysis range specified in Technical 

Supplemental D300. The air heater shall be capable of operation without any deterioration effect for 

normal variations of the constituents given in D300. 

Operation of the SCR system may result in an average ammonia slip of 2 ppmvd. This ammonia content 

is included in the flue gas analysis. 

15541.2.2 Performance Guarantees 

The Supplier shall guarantee that when delivering the combustion air under the Design Performance 

conditions stated herein, the average flue gas exit temperature will be reduced to the temperature 

specified herein with a maximum air and flue gas pressure drop across the air heater and a maximum air 

leakage to the gas stream as also stated in the performance table under Design Performance conditions. 

The correction curves for the correlation of ASME test results to the corrected to the design case shall 

also be provided by the Supplier. 

15541.2.3 Performance Tests 

To establish compliance with this guarantee, the air heater will be tested by the Purchaser in accordance 

with ASME-PTC 4.3. The test will be performed within 90 days of return to commercial operation. 

If the test(s) indicate that the air heater fails to meet the guarantees, the Supplier shall make corrections 

at the earliest opportune time convenient to the Purchaser. All repairs shall be made such that there will 

be no impact to the overall plant arrangement, design, or operation. Any repairs which require shutdown 

of the associated unit shall be conducted during a scheduled outage. Costs for the modifications, 

materials and Supplier service time, shall be borne by the Supplier. 

15541.3 Equipment Design Requirements 

The rotating heating element air heater shall be designed and installed in accordance with the following. 
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15541.3.1 Rotor 

The existing rotor modules shall be replaced with a similar design consisting of individual modules that 

attach to the existing central post via pinned connection without requiring any field welding between the 

rotor structure and rotor post. The rotor modules shall be shop fabricated to the greatest extent practical, 

and the number of heating element baskets shipped pre-loaded into the rotor modules shall be 

maximized. New pin rack drive components and rotor T-bars shall be included with the rotors. The 

Supplier shall provide all materials necessary to modify the depth and baskets as required to minimize the 

effects of ammonia bisulfate. 

The rotor modules including the air heater basket assemblies shall be supported from the rotor post 

through pinned connections. The rotor modules shall be shop fabricated to the greatest extent practical 

and designed for ease of replacement. 

The existing shaft is vertical and mounted in oil cooled and lubricated bearings designed for the imposed 

radial and thrust loads. The Supplier confirms that the existing bearings are adequate to handle any 

additional radial and/or thrust loads, which could be imposed as a result of modifying the rotor, assuming 

the bearings have been properly maintained and are in good operating condition. 

Seals shall be provided to minimize gas and air leakage around the rotor. An inspection will be 

performed by the Supplier during the outages to confirm that sealing surface are in good condition, per 

Item B.4. in the attached Alstom Performance Guarantee. Recommendations for alignment or 

replacement will be made by the Supplier accordingly. 

15541.3.2 Seals 

Replacement rotor seals shall be provided. Duplex sealing system shall be integrated into the air heater 

modifications. Each air heater shall also be provided with new bypass and rotor post seals, holding 

strips, T-bars and fasteners, and static seals to provide a complete sealing system. 

The Supplier will inspect the existing sealing system during the Unit 1 and 2 2007 outages. The Supplier 

will provide an assessment of the existing seal plate conditions and any recommendations as a result of 

the inspection. 

15541.3.3 Heat Transfer Surfaces 

The air heater shall be modified from a three layer basket arrangement to a two layer basket 

arrangement. The depth of the cold end baskets shall be selected such that formation of ammonium 

bisulfate and condensation of sulfuric acid occurs within the cold end baskets. The air heater baskets 

shall be arranged for ease of maintenance and ease of replacement for the operating conditions 

specified. The hot end layers and cold end layers shall be mounted in reversible baskets. 

The hot and cold end elements and basket frames shall be constructed of materials in accordance with 

the manufacturer’s recommendations for the flue gas temperature and composition. The hot end 

elements shall have a minimum of 0.028 inch (22 gauge) and cold end elements shall have a metal 

thickness greater than or equal to 0.035 inch (20 gauge). 

15541.3.4 Bearing Lubrication and Cooling 

The Supplier confirms that the existing bearing lubrication and cooling system does not need to be 

replaced on account of the Air Heater Modifcations as defined in this contract. 

Option 3.1 and 3.2 on the bid form are Alstom’s standard oil circulation and cooling systems, which are 

similar to the existing system. 

15541.3.5 Housing 

 The Supplier shall reuse the existing air heater housing. 
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15541.3.6 Drive 

The rotor is driven by an electric motor through reduction gearing. An air motor is available for 

emergency and maintenance operation. 

The Supplier shall furnish replacement motors. The replace-in-kind main drive electric motors and 

auxiliary pneumatic motor drives will be supplied per the original SJRPP supply specifications. The new 

motors shall have insulation class F. 

15541.3.7 Gearbox Upgrade 

Supplier shall provide a new gearbox with extended capacity rating as compared to the existing 

Philadelphia 8AP drive reducers. The new gearbox shall be suitable for air heater modifications. The 

gearbox shall be Lufkin Model TCBL80-270CHS. The Supplier confirms the existing external oil 

circulating system is adequate for the new gearbox. 

15541.3.8 Sector Plate Adjusters 

The Supplier shall provide all materials to reinforce the sector plate adjusters as required to meet the 

transient pressure rating specified in Section 15541.2.1. 

The Supplier shall provide support information, which will assist the Purchaser in integrating the control of 

the APH Leakage Control System into the plant's distributed control system. 
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 Attachments Page 78 of 79

Attachments 

Attachment A – Schedule 

Attachment B – Schedule of Submittals 

Drawings as listed in Technical Section 15541.1.8
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ATTACHMENT A 

Schedule

 No Earlier Than No Later Than

Unit 1 Delivery to site December 19, 2008 February 15, 2009 

Unit 2 Delivery to site December 27, 2007 February 15, 2008 

Project Outage 

 Start Date End Date

Unit 1 Outage March 1, 2009 April 26, 2009 

Unit 2 Outage March 1, 2008 April 26, 2008 
SJRPP NOx Reduction Project PO Issue

144805.62.1215.1

Event Due Date

203 Insurance Certificates 30 After Effective Date and Supplier's 

Receipt of Insureds from 

Purchaser

No

301 Engineering/Procurement/Production/Testing and Inspection/Shipping Schedule and 

Status Report

30 After Effective Date with Monthly 

Updates

No

302 Preshipment Inspection Notice 30 Before Shipment of Equipment No

303 Electronic Material List 30 Before Shipment of Equipment No

304 Shipping Notice 2 Full Work Days Notice No

305 Detailed Final Packing List of Shipment of Equipment Upon Shipment and With 

Materials List

No

306 15541 Hazardous materials documentation With Each Shipment and With 

Materials List

No

307 Proof Copy of Instruction Manuals updated pages to existing (LCS, motors, and reducer 

by supplier)

90 Before Shipment of Equipment No

308 Final Copy of Instruction Manuals updated pages to existing (LCS, motors, and reducer 

by supplier)

15 Before Shipment of Equipment No

309 Recommended Spare Parts List, with Unit Prices and Names of Suppliers, Necessary to 

Cover a Full Maintenance Cycle (3 years)

90 120 After Effective Date No

401 15541 Quality system manual 30 After Effective Date No 

402 15541 Name, type, location, and qualification documenation of subsuppliers to the Contractor 5 Before Mailing of Subsuppliers 

Purchaser Order No 

201 15541 Contractor to participate in design conferences 30 and 

90 After Effective Date No 

501 15541 Air heater rotor seal drawings 60 After Effective Date No 

502 15541 Air heater static seal drawings 60 After Effective Date No 

503 15541 Rotor drawing detailing the basket support system modifications 60 After Effective Date No 

504 15541 Air heater basket arrangement 60 After Effective Date No 

505 15541 Gearbox drawings - cut sheets, details and installation 60 After Effective Date No 

603 15541 Bill of material 60 After Effective Date No 

507 15541 Electrical wiring schematics & Main Drive Motor cut sheet and installation details 60 After Effective Date Yes 

509 15541 Control Logic/description for Leakage Control System 60 After Effective Date No 

701 15541 Recommended erection sequence and installation procedure 45 60 After Effective Date No 

604 15541 Shop applied coating data - Specifications for prime coat 30 Before Start of shop coating activity No 

403 15541 Inspection and test plan 30 Before First fabrication No 

404 15541 Notification of tests/inspections 10 Before Inspection No 

405 15541 Welding procedures and applicable procedure qualification records 60 Before Start of welding No 

702 15541 Procedures for storing, handling, issuing and reconditioning of electrodes, wires, and 

fluxes With Welding procedures No 

703 15541 Obtain approval of repair procedures in accordance with Section Q002.1.5.4 Corrective 

Action Before Start of repair work No 

406 15541 Visual inspector's qualifications and certificates With Welding procedures No 

407 15541 Nondestructive examination procedures With Welding procedures No 

605 15541 Itemized list of auxiliary power and air consumption 30 After Effective Date No 

408 15541 Test and inspection results After Test / Inspection No 

Item 

No.

Reference 

Document Submittal Item

Submittal Dates

Air Heater Modifications

Schedule of Submittals

28-Mar-07

Attachment B

Commercial Submittals

Technical Submittals

LD's 

Calendar Days Apply?