Technical Specification Including Attachments and Drawings

SJRPP NOx Reduction Project



### Air Heater Modifications

144805.62.1215.1

PO Issue 28Mar2007

Black & Veatch Corporation Raleigh, NCTable of Contents

01400 - Technical Supplem ental Specif ications .................................................................................. ....5 01400.1 Summary of App licable Supp lementals................................................................................... ..5 01400.2 Technical Supplem ental Specif ications................................................................................. ....5 D100 Site Meteorol ogical and Seis mic Data ..................................................................................... ......5 D200 Design Ambients.......................................................................................................... ..................6 D300 Prope rty Tables.......................................................................................................... ....................6 E000 Electrical Equipm ent and System Voltages ................................................................................. ..9 E100 Wiring Methods, Cable, and Raceway....................................................................................... ....9 E100.1 General Requirements................................................................................................... .........9 E100.2 Equipment Safety Grounding (E arthing)...............................................................................11 E100.3 Electrical Interconnections............................................................................................ ........11 E100.4 Cable.................................................................................................................. ...................11 E100.5 Conduit................................................................................................................ ..................12 E100.6 No t Used ............................................................................................................... ................13 E100.7 Term inations ........................................................................................................... ..............13 E210 Electrical En closure Assemblies .......................................................................................... ........14 E210.1 General Requirements................................................................................................... .......14 E210.2 Electrical Enclosure Heating........................................................................................... ......14 E230 Control Panel Receptacles, Lights, and Comm unications...........................................................15 E400 Motor Control............................................................................................................ ....................15 E400.1 General Requirements................................................................................................... .......15 E400.2 NEMA - Combinati on AC Motor Starters ..............................................................................16 E400.3 No t Used ............................................................................................................... ................16 E400.4 DC Moto r Starters ...................................................................................................... ...........16 E510 Molded Case Circuit Br eakers ............................................................................................. ........17 E520 Terminal Blocks and Fuse Holders .......................................................................................... .....17 E520.1 Ge neral ................................................................................................................ .................17 E520.2 No t Used ............................................................................................................... ................18 E520.3 Strap Screw Terminal Blocks............................................................................................ ....18 E520.4 Power Te rminal Blocks .................................................................................................. .......18 E520.5 Thermocouple Terminal Blocks ........................................................................................... .18 E520.6 Fuse Holders for Power Circuits ........................................................................................ ...18 E530 Electrical Ac cessory Devices ............................................................................................. ..........19 E530.1 Electrical Indi cating Inst ruments ...................................................................................... .....19 E530.2 Cont rol Re lays ......................................................................................................... .............19 E530.3 Electric al Switches .................................................................................................... ............19 E530.4 Indica ting Li ghts ...................................................................................................... ..............20 E530.5 C ontac ts............................................................................................................... .................20 E530.6 Fuses .................................................................................................................. ..................20 E530.7 Colors of Indicating Devices and Actuator s..........................................................................20 E640 Low Voltage I nduction Motors............................................................................................. .........23 E640.1 Ge neral ................................................................................................................ .................23 E640.2 Pr oducts............................................................................................................... .................24 E640.3 Drawings a nd Engineeri ng Data .......................................................................................... .26 E642 Single-Phase Induction Motors ............................................................................................ ........28 E642.1 Ge neral ................................................................................................................ .................28 E642.2 Pr oducts............................................................................................................... .................28 K100 Instru mentation.......................................................................................................... ...................30 K100.1 General Requirements................................................................................................... .......30 K100.2 Local Indica tors....................................................................................................... ..............31 K100.3 Process Ac tuated Switches .............................................................................................. ....32 K100.4 Temperature El ement Assemblies........................................................................................3 2 K100.5 No t Used ............................................................................................................... ................33 K100.6 No t Used ............................................................................................................... ................33K100.7 Sole noid Va lves ........................................................................................................ ............33 K100.8 Positi on Swit ches...................................................................................................... ............34 K120 Instrument Valves and Instrume nt Primary Piping and/or T ubing ...............................................34 K120.1 General Requirements................................................................................................... .......34 K120.2 Instrument Primary Piping.............................................................................................. .......34 K120.3 Instrument Primary Tubing.............................................................................................. ......34 K120.4 Control and Instrument Enclosure/Ra ck Tubi ng...................................................................34 K120.5 Instrument Valves and Valve M anifolds................................................................................35 K120.6 Blow down Va lves........................................................................................................ ..........35 K120.7 Instrument Valves, Fittings, and S upport Tr ay......................................................................35 M200 Pi ping................................................................................................................... ........................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 Syst em Requir ements .............................................................................................. .......41 Q002.1 General Quality System Requ irements................................................................................41 Q100 General Weld ing Requirements............................................................................................. ......44 Q100.1 G eneral................................................................................................................ .................44 Q100.2 Weldi ng Processes...................................................................................................... .........44 Q100.3 Welding Proced ure Qualification ........................................................................................ ..44 Q100.4 Welder/Welding Operator Performance Qual ificatio n ..........................................................45 Q100.5 Filler Materi als ....................................................................................................... ...............45 Q100.6 Fabricat ion Controls ................................................................................................... ..........47 Q100.7 Nondestructive Examination (NDE)......................................................................................5 1 Q100.8 Re cords ................................................................................................................ ................52 Q121 Welding of Carbon, Low Alloy, and Stainless St ructural Steel ....................................................52 Q121.1 G eneral................................................................................................................ .................52 Q121.2 Weldi ng Processes...................................................................................................... .........52 Q121.3 Welding Proced ure Qualification ........................................................................................ ..53 Q121.4 Welder/Welding Operator Performance Qual ificatio n ..........................................................53 Q121.5 Fabricat ion Control .................................................................................................... ...........53 Q121.6 Nondestructive Examination (NDE)......................................................................................5 3 Q122 Welding of Abrasion -Resistant St eel Plate................................................................................ ..54 Q122.1 G eneral................................................................................................................ .................54 Q122.2 Weldi ng Processes...................................................................................................... .........54 Q122.3 Welding Proced ure Qualification ........................................................................................ ..54 Q122.4 Welder/Welding Operator Performance Qual ificatio n ..........................................................54 Q122.5 Fabricat ion Control .................................................................................................... ...........54 Q122.6 Nondestructive Examination (NDE)......................................................................................5 5 Q301 Manufacturer's Standard Coating .......................................................................................... ......55 Q301.1 Control and Elec trical Equipment ....................................................................................... ..55 Q301.2 Mechani cal Equi pment ................................................................................................... ......55 Q301.3 Docu mentation .......................................................................................................... ...........55 Q400 General Equipm ent Requirements ........................................................................................... ...56 Q400.1 Miscellaneous Ma terials and Services .................................................................................56 Q400.2 Fabricati on Restri ctions............................................................................................... .........56 Q400.3 Namepl ates and Tags .................................................................................................... ......57 Q400.4 Factor y Assembly ....................................................................................................... ..........57 Q400.5 Tools.................................................................................................................. ...................57 Q500 Shop Drawings an d Instructi on Manual s .................................................................................... .58 Q500.1 Submitta l Require ments ................................................................................................. ......58 Q500.2 Complia nce Reports..................................................................................................... ........58 Q500.3 Motor and Electric Actuator Info rmation...............................................................................5 8 Q500.4 Dr awings............................................................................................................... ................58Q500.5 Wiring Diagrams ........................................................................................................ ...........61 Q500.6 Instruct ion Manuals. ................................................................................................... ..........61 Q501 Instruct ion M anuals...................................................................................................... ................61 Q501.1 Submitta l Require ments ................................................................................................. ......61 Q501.2 Instruct ion Manuals. ................................................................................................... ..........61 Q502 Electr ical Data.......................................................................................................... ....................65 Q502.1 Submitta l Require ments ................................................................................................. ......65 Q502.2 Motor and Electric Actuator Info rmation...............................................................................6 5 Q502.3 Wiring Diagrams ........................................................................................................ ...........65 V100 Noise Abatem ent.......................................................................................................... ................69 15541 - Air Heater Modifi cations ............................................................................................... ..............70 15541.1 Ge neral ............................................................................................................... .....................70 15541.1.1 A rrangem ent......................................................................................................... ............70 15541.1.2 Scope of Supply ...................................................................................................... ..........70 15541.1.3 Items Furnished by Others and In terfac es.......................................................................71 15541.1.4 Code s and Sta ndards................................................................................................. ......72 15541.1.5 Ma terials........................................................................................................... ................72 15541.1.6 Approved Manufactu rers of Co mponents .........................................................................72 15541.1.7 Test Requirements.................................................................................................... ........72 15541.1.8 Technica l Attachments............................................................................................... ......73 15541.2 Performance and Design Require ments .................................................................................73 15541.2.1 Design Perf ormance Co nditions ......................................................................................7 3 15541.2.2 Performa nce Guarantees............................................................................................... ...75 15541.2.3 Perfor mance Tests.................................................................................................... ........75 15541.3 Equipment De sign Requirements......................................................................................... ...75 15541.3.1 Rotor................................................................................................................ ..................76 15541.3.2 Seals................................................................................................................ ..................76 15541.3.3 Heat Tran sfer Su rfaces ............................................................................................... ......76 15541.3.4 Bearing Lubr ication and Cooling...................................................................................... .76 15541.3.5 Ho using .............................................................................................................. ...............76 15541.3.6 Drive ................................................................................................................ ..................77 15541.3.7 Gear box Upgrade..................................................................................................... ........77 15541.3.8 Sector Plate Adjusters.............................................................................................. ........77 Attachments .................................................................................................................... ..........................78 Attachment A – Sc hedule ........................................................................................................ ...............78 Attachment B – Schedul e of Submittals .......................................................................................... .......78 ATTACHME NT A................................................................................................................... .....................79 Schedule

............................................................................................................................... .....................79SJRPP NOx Reduction Project PO Issue
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### 01400 - Technical Supplemental Specifications

This section contains technical supplemental spec ifications 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 eac h technical section are indicated below.

Technical Section Number Technical Section Name Applicable Technical Supplementals

1 15541 Air Heater Modifications D100, D2 00, 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 Cat egory 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, P g , 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/SJRPP NOx Reduction Project PO Issue
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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 0.1SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 7 of 79 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 MinimumSJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 8 of 79 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 5.79SJRPP NOx Reduction Project PO Issue
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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 specificat ions 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 part s 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 te rminal 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 anSJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 10 of 79 arrangement that service personnel will have direct access to the equipm ent without removal of barriers, cover plates, or wiring.

Terminal blocks for external connections shall be gr ouped in the instrument and control compartment for easy accessibility, unrestricted by in terference from structural member s 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 specif ied 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 us ed in any of the wiring devices or cable.

Control conductors 8 AWG and smaller shall be term inated 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, ferrule s shall be provided on all stranded control conductors that are to be terminated to compression Type IEC te rminal blocks. Conductors for current transformer circuits shall be terminated with prei nsulated ring type terminal connectors.

Each terminal block, terminal, conductor, relay, br eaker, fuse block, and other auxiliary devices shall be permanently labeled to coincide with the identificati on 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 conduct or 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 bl ocks shall be acceptable to the Purchaser.

All connections requiring disconnect plug and recept acle 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 exte rnal 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.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 11 of 79 E100.2 Equipment Safety Grounding (Earthing) All electrical equipment that is part of an integral sh ipping unit or assembly shall be furnished with a bare copper grounding pad. The pad shall be suitable for fi eld connection to the station ground grid by others.

Isolated logic system or single-p oint ground connections required fo r proper operation of electronic equipment shall be insulated from the equipment safe ty 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 sh all include all enclosures containing electrical connections or bare conductors with the exceptio n 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 s hall 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, was hers, 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 tabl e 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.SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 12 of 79 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 pa nels, 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 conditi on that results in the largest cable size.

All thermocouple cable shall use solid conductor s 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 cabl es shall consist of aluminum-polyester tape and copper drain wire.

Finished cables shall be capabl e 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 co ntrol 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-conduct or 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 condui t connections shall be of the threaded type, and all conduit, couplings, and fittings shall be hot-dipped galvani zed steel. The interior and exterior surfaces of all rigid metal conduit, couplings, and fittings shall ha ve a continuous zinc coating with an overcoat of transparent enamel, lacquer, or zinc chromate. Liqui dtight flexible metal conduit may be used as long as the length does not exceed 3 feet. All conduit wh ich 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 construc ted 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.SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 13 of 79 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 encl osures for terminating the Purchaser's cable shall be coordinated with the Purchaser. Final si zes 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 pow er 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 pai rs 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.SJRPP NOx Reduction Project PO Issue
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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 t he tables at the end of this section and the following.

Electrical enclosures constructed from steel plate s hall 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 cabinet s 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, elec trical space heaters, one adjustable thermostat, one fuse and fuse block or circuit breaker or other mean s of disconnect shall be provided completely wired in the enclosure. The space heaters, thermostat, and ci rcuit disconnect device shall not interfere with normal cable entrance into the enclosure or with ma intenance or replacement of devices within the enclosure. Normal use of space heaters sha ll 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 mainta in 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 NE MA Std. 250 Materials

Indoor Dry Nonhazardous Type 12 Galvanized sheet steel

Indoor Wet or Outdoor Nonhaz ardous Type 4 Stainless Steel

Wet-Chemical Corrosive Nonhaz ardous Type 4X Stainless Steel

Enclosure Space Heaters

Rated Voltage 240 volts ac

Power Source

Power Supply Code LV-3

Voltage 120 voltsSJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 15 of 79 

### 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 furn ished 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 c ontrol 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, unl ess 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 furnis hed with one 3-phase set of manually reset thermal overload relays. Each 3-phase, ac two-speed star ter shall be furnished with two 3-phase sets of manually reset thermal overload relays. Each overlo ad 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 t he starter contactor. Unless otherwise specified, the quantity of auxiliary contacts for st arters that interface with the Purc haser'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 transf ormer shall be furnished complete with each primary lead fused and one secondary lead fused with the othe r 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 operat ing coil circuit. These interposing relays shall be operated from the low voltage circui t of the control transformers.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 16 of 79 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 star ter that uses remote control from the Purchaser's control system shall be provided with an interposing relay to interface wi th 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, e xcept 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-phas e molded case adjustable magnetic trip only circuit breaker.

Contactors with manually rese t 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 in rush 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, si x electrically separate contac tor 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 moni tor 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 Supplie r's standard design. A normally open and normally closed contact of the coil monitor rela y shall be wired out to terminal block forexternal 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.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 17 of 79 All auxiliary and overload contacts shall be wir ed to terminal blocks for external use.

The dc motor starters design shall be coordinated with t he characteristics of the motors that the starters are intended to operate.

Unless otherwise specified, the fo llowing 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 t he 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 breake rs, 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 t hey 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 bl ocks, 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 identif ier. All terminal points shall have provisions to be uniquely identified on the terminal block white markin g strip and, where permi tted 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. S pare (unused) terminals shall be furnished evenly distributed on the terminal blocks for circuit modi fications. No fewer than two spare unused terminals shall be furnished for every ten terminals used. Fuses may be mounted on terminal blocks.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 18 of 79 Terminal blocks shall be manufactured from materials that will not support combustion. Terminal blocks shall meet the Inflammability Class V0 rating in acco rdance with UL 94. All terminal blocks, except internal terminal blocks in factory prewired el ectronic systems cabinets and terminal blocks for thermocouple extension wire, shall be rated for 600 volt s or greater. No more than two conductors shall be terminated at one connection point. For terminal bl ocks 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 c onstruction 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 fuse s. 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 EqualSJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 19 of 79 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 mounti ng. 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 mi nimum 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 circ uit 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-Brad ley Bulletin 700 Type P or Purchaser approved equal. Where current carrying requirements exceed the capaci ty 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 critic al 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 s hall be submitted for approval by the Purchaser.

Unless otherwise specified, dc relays that interface with the Purchaser's contro l system shall have a diode surge suppressor installed across the relay coil.

E530.3 Electrical Switches Control switches shall be 600 volt, 20 ampere, multis tage, rotary type. Unless otherwise specified, switches shall have black, fixed, modern, pistol grip type handles a nd 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 t he E530 Electrical Accessory Devices - Supplemental Requirements sheets.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 20 of 79 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 Requi rements sheets. Indicati ng lights shall be energized when the condition exists and shall be de-e nergized 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 t he Purchaser's control system shall be electrically "dry." Solid-state switches or triac outputs are not acceptable for cont acts 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 suitabl e 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 s hall be English. Indicating lights shall be energized when the condition described in the following tabl e exists, and shall be de-energized when the condition does not exist. Unless permitted otherwise in the indi vidual equipment specification, indicating light lens colors and CRT graphic display colors shall be as sp ecified 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; breakeropen, contactor deenergizedSJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 21 of 79 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 contactorSJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 22 of 79 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 in 2 (90 mm 2 ) 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 in 2 (115 mm 2 ) Analog and Digital LCDSJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 23 of 79 

### 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 volt age induction motors as specified herein and in the E640 Low Voltage Induction Motors Specificatio n 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 sha ll 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 manufact urers 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 pr ovided. Acceptance of the manufac turer as a substitute is at the discretion of the Purchaser:

Component Manufacturer

Low voltage induction motors Baldor, Gene ral 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 manufact urer's factory to determine that it is free from electrical or mechanical defects and to provide as surance that it meets t he requirements of these specifications. Test procedures shall be in accor dance with IEEE/NEMA test procedures for 3-phase induction motors. The routine tests listed in NE MA shall be performed on each motor by the motor manufacturer.

This testing is to be considered part of the def ined scope of work, and all associated costs are the responsibility of the Supplier unless specifically ident ified as a Bid Option or Pu rchaser-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 re testing in the event of a test failure:

Copies of reports of the quality control tests and in spections 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 manufacturerSJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 24 of 79 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 E 410 VFDs for Induction Motors 50 HP or Less, specifically section E410.3.

E640.2.1.1 Nameplates . All motor nameplate data shall confor m 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 pi ns 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) sha ll 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 c ontaining 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 out put 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.SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 25 of 79 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 hou sings 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 housi ng. All motor leads located in the housings shall be permanently marked for ease of identification.

All motors shall have the direction of rotation mark ed 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 unle ss 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 eq uipment. All bearing mountings shall be designed to prevent the entrance of lubricant into the motor encl osure 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 lubric ated, 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 t he 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 sh all 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-tor que characteristics will be furnished by the driven equipment supplier;SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 26 of 79 however, the responsibility for successful starting under the given condition s 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 t he 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 va riation does not exceed plus or minus 5 percent of rated frequency.

E640.3 Drawings and Engineering Data Motor dimensional drawings shall be provided in ac cordance 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.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 27 of 79 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 mu ltiplied by the motor nameplate service fa ctor for NEMA/IEEE motors shall be at least 15 percent greater than the driven equipm ent 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 op erating 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 connect ed service, hours 20,000

Bearings on vertical motors shall ha ve 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 betterSJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 28 of 79 

### 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 si ngle-phase induction motors as defined herein and on the E642 Single-Phase Induction Motors Specif ication 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 sha ll 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 manufact urers 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 pr ovided. Acceptance of the manufac turer 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 manufact urer's factory to determine that it is free from electrical or mechanical defects and to provide as surance that it meets t he 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 def ined scope of work, and all associated costs are the responsibility of the Supplier unless specifically ident ified as a Bid Option or Pu rchaser-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 re testing in the event of a test failure:

Tests In Accordance With Conducted By

NEMA/IEEE designed motors NE MA MG1, IEEE 114 Supplier

E642.2 Products Single-phase motors furnished under these specificat ions, 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, freq uent starting where required, and shall be suitable forSJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 29 of 79 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 moto r 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 te rminal 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 unpa inted 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 insulat ed 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 inst ructions 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 sha ll 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 co rrosion-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 t he 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.SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 30 of 79 E642 Single-Phase Induction Moto rs 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 manufactu red 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 multiplie d by the motor nameplate servic e 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 id entify 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 in struments 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 mois ture-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.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 31 of 79 Pressure and differential pressure measuring instrum ents for corrosive or thic k, 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 suit able 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 dra ft 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 eng raved on the dial or have a tag, engraved with the Purchaser's ID number and the service legend, atta ched 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 select ed so that the normal operating condition is approximately mid scale (between one th ird 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 s hall 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 unle ss 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 s hall 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 ever y-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 ar mored stainless steel capi llary tubing of the length required for the installation. If required, thermowe lls with lagging extensions shall be furnished for all indicators and shall be as specified under the arti cle entitled Thermowells, Protecting Tubes, and Test Wells, except that extension nipples shal l not be furnished for temperature indicators.SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 32 of 79 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 sh all 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 t hermocouple 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.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 33 of 79 K100.4.1 Thermocouples Each thermocouple shall be furnished packed in a stainless steel sheath with magnesium oxide insulationand shall have an ungrounded measuring junction. Each thermocouple shall be type "E" (chromelconstantan) unless otherwise specified, and shall me et the standard limits of error specified in ANSI MC96.1. Extension wire shall be coor dinated with the thermocouple type.

K100.4.2 Resistance Temperature Detectors (RTDs) Each RTD shall be 100 ohm platinum, 3 wire type, wi th 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 Purc haser's standard and are the likely selection. If the temperature require ments exceed the Type E application, the ISA type may change with Purchaser’s a pproval. 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 EqualSJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 34 of 79 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 i ndication of each remotely actuated device.

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

Position switches shall be provided in both the "O pen" and "Closed" positions of these devices. For devices that modulate (i.e., are controlled by an exter nal modulating signal), a proximity position switch shall be provided in the de-energiz ed position of the device unless a position transmitter is furnished. Additional position switches shall be provided as specif ied 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 va lve manifolds, instrument shutoff valves, instrument equalizing valves, and instrument blowdown valves sha ll 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 t he 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 enclo sures or racks shall meet the requirements stated in M200.

K120.3 Instrument Primary Tubing Tubing shall be supported to allow thermal expansion, mi nimize vibration and protect it from damage. Tubing runs shall be supported both horizontally and ve rtically. Where continuo us support is required, support using tubing tray is preferr ed. 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 s hall be arranged to allow any device to be serviced, disconnected, or removed from the enclosure or ra ck without disconnecting t ubing to other devices.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 35 of 79 Tubing for external connections shall be terminat ed on a bulkhead plate, utilizing bulkhead fittings for enclosures, or unions for open racks. Each bulkhe ad termination shall be identified with a nameplate.

K120.5 Instrument Valves and Valve Manifolds Each pressure instrument shall be installed downst ream of an instrument shutoff valve or instrument valve manifold designed for instrument shutoff servic e. In addition, each liquid filled instrument primary line shall be provided with a tee upstream of the instru ment 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 sh utoff valves, and two test tees with 1/4 inch tube plugs.

Each remotely mounted static pressure instrument sh all 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 provi ded 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 EqualSJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 36 of 79 

### 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 ba sed on design condi tions establish ed 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, mincarbon 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 stainles s steel pipe. Other sizes shall not be used:SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 37 of 79 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, instrument ation, compressed air, and sample line systems.

Tubing material shall be stainless steel tubing and shal l 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)SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 38 of 79 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 applic ations 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 sy stems 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 acco rdance 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 3,000SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 39 of 79 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 t he minimum class rating described below. All welded fittings shall be of the same material as the hea der pipe. Fittings between dissimilar branch/header materials shall be considered on a case-by-case basis:

Table 8 - Integrally Reinforced Br anch 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 as sembly 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.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 40 of 79 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 pl ate having a minimum thickness of 3/16 inch and designed for easy installation and removal. Necessar y 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, bel t 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, et c., 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.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 41 of 79 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 thickn ess, 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 immediat ely 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 im plement a detailed and documented quality management system which ensures that all equipment and commodit ies supplied are in conformance with the required drawings and/or specifications. The Supplier shall m eet all the guidelines (requirements) set forth in this document. The quality management system shall be capable of providing as surance that design, purchasing, materials, manufacturing, examinati on and testing of equipment, shipping, storage, and related services comply with t he 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.SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 42 of 79 Quality system requirements are passed on to subtier suppliers for subcontracted work, and the Supplier has adequate oversigh t 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, et c.) shall be incorporated into the quality management system. The quality management sy stem 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 Engine er. If the Supplier's program has been certified by a registered certification agency as satisfying the requirements of th e governing code (e.g., ISO 9001 or ASME), a copy of the Certification Letter or Certificat e of Authorization shall be submitted along with the required manual. The quality system manual shall be k ept 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 supplie rs 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 fu lfill 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-pro cess work involving the fabricating and manufacturing of equipment and commodities for the Purchaser.

In accordance with this Supplemental Specificati on, subtier supplier qualific ation 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/equ ipment 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 requir ed. 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 supp lier's work, includ ing inspection by the Supplier at his subtier supplie r's facilities. The Supplier shall inspect the work of subtier supplie rs 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 info rmed 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 inspectionsSJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 43 of 79 and testing, when such inspection and test poi nts 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 oper ation 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 fo llowing 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 te sts; 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, qualit y audits, or witness testing at any time during the manufacturing process. The Engineer may desig nate an authorized agent fo r 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 authoriz ed agent for the Engineer, such designation will be in writing with a copy provided to the Supplier. Here inafter, when the term "E ngineer’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 duri ng the manufacturing process without delaying the schedule. The Supplier shall provi de, without cost, reasonable faciliti es including tools, personnel, and instruments for dem onstrating acceptab ility of the work.

Q002.1.5.2 Surveillance Activities . In accordance with the purchas e 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 processe s such as welding, nondestructive examination (NDE), coating, painting, etc. If special processes were conduc ted by unqualified employees, the Purchaser and Engineer have the right to validate and test the product at Supplie r's expense and/or reject the product.

Q002.1.5.4 Corrective Action . Upon identification of a noncomp liance with the requirements of the purchase order, the Supplier shall do cument 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 noncompli ance to the Purchaser and Engineer for approval. During witness and hold point activities, if the Enginee r’s representative identifie s a noncompliance issue, the Supplier shall document the noncompliance issue and provide a copy of the r eport to the Engineer’s representative. If the Supplier disagrees and do es not document the noncompliance, the Engineer’sSJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 44 of 79 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 identifi ed 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 inspec t 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 late r discovery of flaws or defects.

Q002.1.5.6 Receipt Inspection Materials or equipment purchased under this purchas e 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 specif ications. Initial receipt inspecti on acceptance tests will be performed by the Purchaser at the Purchaser's expense. Ite ms found to be defective may be returned to the Supplier for correction at the Supplier's expense, in cluding 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 app licable 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 jurisdicti onally 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 te chnical data supporting the deviation, and historical experience supporting the deviation.

Q100.2 Welding Processes Unless otherwise specified, only shielded metal ar c 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) pr ocesses shall be permitted within t he restrictions or limitations specified in the applicable Welding Technical Supplem ental 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 governi ng 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 shal l require a new welding procedure qualification.SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 45 of 79 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 subsup pliers. Suppliers shall review the documents in accordance with the appl icable code and specification requirements and shall accept all of their subsuppliers' welding procedur es 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 th e 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 co de. 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 ava ilable 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 th e qualification of welders or welding operators. Field welder or welding operator performance qualificatio n testing shall be performed under the full supervision and control of the manufacturer or c ontractor at the project site or approved offsite testing facility.

Q100.5 Filler Materials Welding filler metal shall comply with the require ments of the referenced code and any modified requirements specified herein. The filler metal shall be as specified in the applicable WPS.

Unless otherwise spec ified, the welding filler metal shall have a chemical composit ion as similar as possible to the base materials to be welded. The fi nished weld as deposited, or after postweld heat treatment (PWHT) when requir ed, 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 writ ing, the GTAW process shall requ ire 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 neutra l flux. Alloy, semiactive , or active fluxes shall not be used except as specified otherwise. Fluxes th at 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 ea ch side for a double-V-groove joint design or approximately 1/4 inch one side for a single-V-groove jo int design. The joint thickness shall not exceed 1/2 inch nominal.

The SAW process shall not use recrushed slag.SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 46 of 79 SMAW low-hydrogen type electrodes, including stainles s steel and nickel and nickel alloy electrodes, shall be purchased in hermetically se aled 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-hyd rogen type electrodes (E6010 or E7010-A1 only) may be used only for root pass welding on carbon steel pi ping, unless otherwise specified by other Welding Technical Supplemental Specification sections. SM AW 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 fo r existing unknown carbon st eel materials, the carbon content shall not exceed 0.30 perce nt or 0.40 percent carbon equival ent [CE] as determined by CE=C%+ [Mn%/6+Si%/6]).

For the FCAW process of ca rbon 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 allo y filler metal classifications are prohibited for welding of 1-1/4 Cr - 1/2 Mo, 2-1/4 Cr - 1 Mo, 5 Cr-M o, and 9 Cr-Mo alloy materials. The filler metal for welding these materials shall have ca rbon 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 stai nless steel components, and the carbon or low alloy steel piping is of such a th ickness 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 carb on or low alloy steel as applicable. This joining method is applicable only to groove welds unless wr itten 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 superaus tenitic stainless steel Alloy AL6XN, UNS N08367, Pnumber 45 shall be in accordance with the following:SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 47 of 79 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 N0 8367, 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 addi tion, 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 produc t 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 read ily 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 temper ature requirements. The thickness used toSJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 48 of 79 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 resist ance, induction heating, or oxyfuel heating methods that will provide uniform heating over the comp lete 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 mi nimum 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 t he referenced code and any modified requirements specified herein.

Postweld heat treating may be accomplished by electr ic resistance heating, fur nace heating, or other suitable heating methods that will provide the desir ed 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 direct ly 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 traceabl e 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 procedure s shall be submitted for review by the B&V Materials Applications Section. The PWHT procedure shall provide details to accompli sh 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 UsedSJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 49 of 79 Q100.6.5 Fabrication Controls for Austenitic St ainless, Superaustenitic Stainless, or Nickel Alloy Steels The following requirements shall apply when fabricating austenitic stainless, supera ustenitic 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 mate rials only to ensure that contamination of these materials does not occur.

Antispatter compounds, marking fluids, marking pens , tape, temperature indi cating 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)] = 

## ( ) ] min / min /

. [ mm in Speed Travel x Amperage x Voltage 60

Austenitic stainless steel inst rument tubing shall be welded us ing 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 stainle ss steel material maintain its corrosion resistance, the austenitic stainless steel material shall not be po stweld 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 perform ing solution annealing.

For materials that have bee n contaminated with iron, the B&V Materi als 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 contaminati on 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 prohibit ed, 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.SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 50 of 79 Acceptable cleaning solvents include new or redist illed 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 penetra tion unless specified otherwise by design documents or the applicable code. Partial penetration weld join ts not specified by design shall require written approval by B&V design engineering.

Complete penetration joints welded from both sides sha ll 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 surfac es 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 GT AW 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 weld ing 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 magnet ism greater than 5 gauss shall be demagnetized.

Arc strikes outside of the area of permanent welds sh ould 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 Applicat ions 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 fabric ated 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 ar gon 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.SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 51 of 79 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 q ualified 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 materi al 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 governi ng code or specification. Any defects found shall be repaired.

All defects in welds or base materials shall be remo ved and repaired in accordance with the referenced code.

A written procedure for root side purging shall be de scribed in detail and shall be submitted concurrently with the welding procedures for review by the B&V Materi als 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 el ectrical current may result in damage to equipment.

A complete repair procedure for repairs that are do cumented as the basis of a nonconformance report shall be submitted to the B&V Materials Applications Se ction for review and approv al in writing prior to performing the repair. If repair by welding is requ ired, the applicable WPSs and supporting PQRs shall be submitted with the repair procedure. All nonc onformance 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 Weld ing Technical Supplemental Specification sections.

NDE shall be performed in accordance with written proc edures that are prepared in accordance with the referenced code and as specified here in. 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 s hall 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 app roval from the B&V Materials Applic ations Section is obtained. NDE personnel qualification records shall be m ade 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 pr eviously 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 weldSJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 52 of 79 shall be removed, repaired, and retested at the Supplie r's expense, regardless of whether the testing is Supplier provided. The Purchaser may order NDE by an independent laborat ory in addition to any examinations specified herein. The NDE type, extent, and method shall be the sa me 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 acce ptance 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 appl icable 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 stru ctures 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 sh all 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 vertica lly 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 pr equalified GMAW-S process, undercut may beSJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 53 of 79 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 sha ll 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 prequ alified WPSs shall be in the form of a written document. For a WPS to be prequalified, conformanc e 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 acco rdance 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 pl ates 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 establis hed 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 doc uments, they shall be prepared in accordance with the design documents.

Q121.6 Nondestructive Examination (NDE) 100 percent visual examination is required of all welds.SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 54 of 79 Unless otherwise specified, any weld defects id entified 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 reexam ined 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 Specif ication 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) pr ocess 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 wi th 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.SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 55 of 79 Q122.5.3 Weld End Preparation When weld joint details are specified by the design doc uments, 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 ND E 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 m anufacturer'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 environme nts. 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 an d 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, ca binets, switchgear, transformers, and motors, shall be finish painted. Exterior surfaces shall be the m anufacturer'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, va lves, 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 desi gnation, the degree of surfac e preparation, dry film thickness, finish color, and Material Safety and Data Sheets (MSDS).SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 56 of 79 

### 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, in structions, and other data for use by the Purchaser's erection contractor.

Detailed storage requirements and lubricati on 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 applicabl e standard specifications and shall be new, unused, and undamaged.

Asbestos containing materi als will not be allowed.

Flanges, fittings, and valves manufactured in the Pe ople'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 ce rtificate 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 Ge neral Administration of Quality Supervision, Inspection and Quaranti ne 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 inspec tion documents shall bear the official stamp of CBPVI or its branches.SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 57 of 79 Individual parts shall be manufactured to standard size s 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 e quipment, 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 li nes of text. The top two lines of text shall be a brief description of the equipment. Thes e 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 e quipment 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 inst rumentation, 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 require d 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 assemb led, except when the physical size, arrangement or configuration of the equipment, or shipping and hand ling 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 a fter Purchase Order award could result in Supplier's performance of some assembly at the site or backch arges to the Supplier for others required to perform such assembly. When proposals are submitted withou t statements describing sectional shipments, it will be understood that no field assembly of the equi pment will be required and the Supplier shall be responsible for all costs encountered in the field for as sembly of sections, accessories, or appurtenances not listed in the Proposal as requiring field assembly.

All separately packaged accessory items and parts sh all 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 cont ainer 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 overh aul of the equipment. The tools shall be shipped in separate, heavily constructed wooden boxes provided with hinged covers and padlock hasps.SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 58 of 79 Maintenance tools for each piece of equipment sha ll 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 handlin g rigs, bars, slings, and cable. All maintenance tools shall be in new and unused condition and shall becom e 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 t ools 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 wi th maintenance tools.



### Q500 Shop Drawings and Instruction Manuals (Source: 21Sep05 - Revised by Project: 07Jul06 )

This section, in conjunction with the Schedule of Su bmittals, stipulates the requirements for engineering data that Supplier shall submit for design information and review. Document submittal procedures shall be in accordance with the require ments of this Purchase Order.

Q500.1 Submittal Requirements Technical data shall be submitted in electronic format.

Electronic technical data submittals shall be made usi ng IBackup, a Web-based file transfer service. If Supplier does not already have IBackup transmi ttal 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 s ubmittals have been posted to IBackup shall be in accordance with the correspondence re quirements of this Purchase Order.

The following number of prints shall be submitt ed 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 piec e 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 Ac tuator 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,SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 59 of 79 anchorages, and supports required; the dimensions needed for installation and correlation with other materials and equipment; and the information specific ally 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, exc ept where standard Supplie r drawings are used, and shall be clearly marked with the name of the projec t, unit designation, Purchase Order title, Purchase Order file number, project equipment or structur e 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 S ubmittals 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. Transmitt al letters for resubmitted drawings shall include the Engineer’s drawing numbers.

Catalog pages are not acceptable, except as draw ings 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 p age clearly indicating the name of the project, unit designation, specification title, specification numbe r, component identification numbers, model number, Supplier’s drawing number, and Purchaser's name.

Drawings shall be submitted with all numerical va lues in English and/or metric (SI) units.

Q500.4.1 Drawing Submittal Drawings shall be submitted for review electronica lly 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 No ted," "Exceptions Noted," “Receiv ed for Distribution," "Returned for Corrections," “Release for Record,” “Void,” or “S uperseded.” 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 s ubmittal 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 Distri bution," 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 ann otated 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 adviseSJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 60 of 79 Engineer in writing within seven calendar days of it s receipt of Engineer’s comments, stating the reasons therefore. Supplier may proceed with its Work to the extent of and in acco rdance 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 Spec ification, 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. Wo rk may proceed. Certain required project information has been added electronically to the drawing and pr ovided 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” indicate s 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 submi tted 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 "H old" 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 Engi neer about the cause for any "Holds" designated on the drawing and immediately take all action necessary to re solve 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 material s shown on submittals that have been reviewed by Engineer, the changes shall be clearly marked on t he 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 revi sions by footnote or by a fo rm 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, exter nal connections, interfaces with equipment and materials furnished under separate spec ifications, 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 indica ted 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.SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 61 of 79 Each packet of drawings returned to Supplier will include a manifest generated by Engineer. The manifest will include a list of drawings transmi tted, manufacturer' s drawing number s, Purchaser's assigned drawing numbers, Purchaser's drawin g titles, and the status of the drawings.

Files returned to Supplier will be in TIFF Group 4 format unless a nother format is agreed upon by Engineer and Supplier.

Q500.4.3 As-Built Drawings As-built prints of each final electrical wiring and el ementary diagram for equipment shall be furnished in accordance with Article Q500.5. An electronic c opy 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 Q 500 and the Schedule of Submittals included in the Supplemental Terms and Conditions of this Purchase Or der, stipulates the requirements for Instruction Manuals that Supplier shall submit for design inform ation and review. Document submittal procedures shall be in accordance with the requirements of th is Purchase Order, Section Q500, and the following.

The existing SJRPP Air Heater Operating and Installa tion 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 indi cated for Technical Documents in the Supplementary Terms and Conditions of this Purchase Order for t he documents listed below. The following number of copies shall be submitted unless otherwis e 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 multip le volumes are required, a table of contents listing materials included in each volume shall be supplied for each volume.)SJRPP NOx Reduction Project PO Issue
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Source: 01400, 2005 Technical Supplemental Specifications Page 62 of 79 Specifications, test data, and all perform ance curves specified in the technical specifications.

Description of the equipment, including illustra tions showing elevations, cross section, and all details of the equipment with all par ts 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 instructio ns, including description, use of special tools furnished, and preventive maintenance schedule.

Instructions for receiving, inspection, st orage, 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 inst rument 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 operati ng 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.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 63 of 79 The above listed requirements are the minimum requirem ents; however, requirement s 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.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 64 of 79 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 indica ted in column to right of cover illustration. 4. *Volume number required only if instruct ions are contained in more than one volume. 5. **Engineer assigned Purchase Order number.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 65 of 79 

### Q502 Electrical Data (Source: 09Jun06 - Revised by Project: 07Jul06 )

This section, in conjunction with Section Q 500 and the Schedule of Submittals included in the Supplemental Terms and Conditions of this Purchase Or der, stipulates the requirements for Electrical Data that Supplier shall submit for design informati on 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 unle ss 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 Ac tuator Information Sheet are included at the end of this section. (Electronic copies of these info rmation sheets will be made av ailable 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 a nd shall accurately show the equipment and terminals arranged as they would appear to a person wiri ng 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 e quipment 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 contac ts 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 co mplete 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 el ementary diagram for equipment shall be furnished in accordance with Article Q500.5. An electronic c opy of each drawing shall be submitted to Purchaser.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 66 of 79 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 NOSJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 67 of 79 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 SPECIFI ED 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, RATE D, 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 LOADSSJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 68 of 79 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 DIAGRAMSJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 01400, 2005 Technical Supplemental Specifications Page 69 of 79 

### V100 Noise Abatement (Source: 27Jan04 - Revised by Project: N/A )

The equivalent A-weighted sound pressure level for e quipment furnished under these specifications shall not exceed 85 dBA free field measured 3 feet horiz ontally from the base of the equipment and 5 feet above floor level or any personnel platforms. If t he drive motors for the equipment are also furnished under these specifications, the sound pressure le vel 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.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 15541, 2005, v.1.0 Air Heaters Page 70 of 79 

### 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. Th e existing air heaters are model 33-VI-68, tri-sector design, with vertical sha ft orientation. The air heaters have 3 layers of heating elements and conventional single seal arrangement.

The work under these specifications includes fu rnishing the design, equipment, and materials described herein to modify the existing air heaters to an ammo nium bisulfate tolerant design as part of the installation of selective catalyti c reduction (SCR) systems on Units 1 and 2 at the St. John’s River Power Park. The air heater modifications shall be design ed 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 furn ishing all steel required for reinforcing the rotor and air heater housing assembly, rotor modules includ ing baskets and basket elements, duplex radial and axial seals, bypass seals, rotor post seals, static seals, and pr oviding miscellaneous materials and services complete as specified herein.

All equipment and materials will be shipped to the projec t 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 rustin g 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-ki nd 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 distri buted 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 re quirements 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 conditi on of the sealing system during the Unit 1 and 2 2007 outages.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 15541, 2005, v.1.0 Air Heaters Page 71 of 79 The equipment will be tested by the Purchaser after er ection to demonstrate its ability to operate under the conditions and fulfill the guarantees as set forth he rein. 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 engine ering 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 deliver ed to the St. John’s River Power Park where they will be received, unloaded, stored, and erected by the Pu rchaser’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 equipm ent furnished under these specifications.

The use of all special tools required for er ection of the equipment, exclusive of the maintenance tools specified to be furnished. Er ection 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 Alst om 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 Supplie r'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 spec ified to be furnished under these specifications.

Foundations, foundation bolts, bolt sleeves, and equipment bases.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 15541, 2005, v.1.0 Air Heaters Page 72 of 79 Multi-media Cleaners

Grouting materials and the placing thereof.

Permanent electric wiring to connect equipment te rminal 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 sha ll apply. These references shall govern the work except where they conflict with the E ngineer’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 manufact urers are recognized as maintaining the level of quality of workmanship required by these specificatio ns. If the Supplier wants to propose a nonlisted manufacturer that is considered to provide an equiva lent level of quality, this manufacturer must be identified and supporting testimony pr ovided. Acceptance of the manufac turer 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 theSJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 15541, 2005, v.1.0 Air Heaters Page 73 of 79 Supplier unless specifically identified as a Bid Opti on 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 associat ed 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 a ttachments 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 bui ld-up of ammonium bisulfate and to ease its removal by soot blowing during operation. The air heat ers shall be modified to meet the performance requirements specified and shall be corrosion-resistant.

The air heaters shall be guaranteed to meet the des ign 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 an d 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 3,257,280SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

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, ( o F)

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 maximu m 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 th e 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.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 15541, 2005, v.1.0 Air Heaters Page 75 of 79 15541.2.1.1 Coal Analysis The air heater performance guarantee shall be bas ed 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 capabl e 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 re sult 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 perfo rmance 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 t he Purchaser in accordance with ASME-PTC 4.3. The test will be performed wi thin 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 Purchas er. 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.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 15541, 2005, v.1.0 Air Heaters Page 76 of 79 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 connec tion 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 modi fy 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 t hat the existing bearings are adequate to handle any additional radial and/or thrust loads, which could be im posed 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 confir m 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 prov ided. 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 seal s 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 s hall 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 la yers shall be mounted in reversible baskets.

The hot and cold end elements and basket frames sha ll 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 lu brication and cooling system does not need to be replaced on account of the Air Heater M odifcations as defined in this contract.

Option 3.1 and 3.2 on the bid form are Alstom’s stand ard 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.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Source: 15541, 2005, v.1.0 Air Heaters Page 77 of 79 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 dr ives will be supplied per the original SJ RPP 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 S upplier 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 sp ecified in Section 15541.2.1.

The Supplier shall provide support information, which w ill assist the Purchaser in integrating the control of the APH Leakage Control System into the plant's distributed control system.SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Attachments Page 78 of 79 

### Attachments

Attachment A – Schedule Attachment B – Schedule of Submittals Drawings as listed in Technical Section 15541.1.8SJRPP NOx Reduction Project PO Issue
144805.62.1215.1 Air Heater Modifications 28Mar2007

Attachments Page 79 of 79 

### 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, 2008SJRPP 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 Apply? Calendar Days