document release and change form - hanford site€¦ · clearance review restriction type: public...

1 SPF-001 (Rev.D1)

DOCUMENT RELEASE AND CHANGE FORMPrepared For the U.S. Department of Energy, Assistant Secretary for Environmental ManagementBy Washington River Protection Solutions, LLC., PO Box 850, Richland, WA 99352Contractor For U.S. Department of Energy, Office of River Protection, under Contract DE-AC27-08RV14800

TRADEMARK DISCLAIMER: Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof or its contractors or subcontractors. Printed in the United States of America.

Release Stamp

1. Doc No: RPP-SPEC-62012 Rev. 00

2. Title:Specification for Fabricating, Inspecting, Testing, and Shipping the 241-A Slurry and 241-AP Supernatant Adjustable Submersible Pump Assemblies

3. Project Number:T2R41

☐N/A 4. Design Verification Required:

☐Yes ☒No

5. USQ Number: ☒ N/AN/A-8

6. PrHA Number Rev. ☐ N/APRHA-02042 00PRHA-02043 00PRHA-02044 00PRHA-02047 00

Clearance Review Restriction Type:public

7. Approvals

Title Name Signature DateClearance Review Aardal, Janis D Aardal, Janis D 09/25/2019Design Authority ANDERSON, CRAIG H Anderson, Craig H 09/24/2019Checker Hagensen, Alan R Hagensen, Alan R 09/23/2019Document Control Approval Hood, Evan Hood, Evan 09/25/2019Originator Hall, Richard B Hall, Richard B 09/23/2019Other Approver Sinclair, Trevor J Sinclair, Trevor J 09/24/2019Other Approver Robinson, Randall S Robinson, Randall S 09/24/2019PrHA Lead Smith, Ryan D Smith, Ryan D 09/24/2019Quality Assurance Harper, Jerry G Harper, Jerry G 09/24/2019Responsible Engineer Goodnight, Tyler K Goodnight, Tyler K 09/24/2019Responsible Engineering Manager CARPENTER, KEITH E Carpenter, Keith E 09/24/2019USQ Evaluator Smith, Ryan D Smith, Ryan D 09/24/2019

8. Description of Change and Justification

Initial release.

Design checks were performed in accordance with ARES ESD (Sargent & Lundy) Quality Assurance Procedures (QAP) 3.2 and 3.6. Because of the relatively simple nature of the document, a graded approach was applied and design verification was not performed as allowed by ARES ESD (Sargent & Lundy) QAP 3.5, Design Verification.

9. TBDs or Holds ☒N/A

10. Related Structures, Systems, and Components

a. Related Building/Facilities ☐N/A b. Related Systems ☐N/A c. Related Equipment ID Nos. (EIN) ☒N/A

241-A241-AP-101

241-RC241-WT

11. Impacted Documents – Engineering ☒N/A

Document Number Rev. Title

12. Impacted Documents (Outside SPF):

N/A

13. Related Documents ☐N/A

Document Number Rev. TitleH-14-111017 SH 001 00 A-FARM RETRIEVAL ADJUSTABLE SN PUMP GENERAL NOTESH-14-111018 SH 001 00 A-FARM RETRIEVAL ADJUSTABLE SL PUMP GENERAL NOTESMT-50281 00 A-Farm Retrieval System Installation DesignRPP-SPEC-62013 00 Procurement Specification for Submersible Slurry and Supernatant Pumps for the 241-A Farm Waste Retrieval

Project

14. Distribution

Name OrganizationAhmid-Kargbo, Jamal AY/AX FARM RETRIEVAL ENGRNGAnderson, Craig H A/C FARM RETRIEVAL ENGRNGBoettger, Jeff A/C FARM RETRIEVAL ENGRNGBuchanan, Joseph R A/C FARM RETRIEVAL ENGRNGCarpenter, Keith E A/C FARM RETRIEVAL ENGRNGGoodnight, Tyler K A/C FARM RETRIEVAL ENGRNG

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 1 of 24

DATE:

Sep 25,2019

DOCUMENT RELEASE AND CHANGE FORM Doc No: RPP-SPEC-62012 Rev. 00

2 SPF-001 (Rev.D1)

14. Distribution

Name OrganizationHull, Kevin J ELECTRICAL ENGINEERINGRobinson, Randall S AY/AX FARM RETRIEVAL ENGRNGSinclair, Trevor J A/C FARM RETRIEVAL ENGRNGStephens, Randall F A/C FARM RETRIEVAL ENGRNGStowe, Garth J SST RETRIEVALS PROJECT MGMTTworek, Ray F OPERATIONS QA SUPPORT

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 2 of 24

A-6007-231 (REV 0)

RPP-SPEC-62012Revision 0

Specification for Fabricating, Inspecting, Testing, and Shipping the 241-A Slurry and 241-AP Supernatant Adjustable Submersible Pump Assemblies

Prepared by

RB HallSargent & Lundy for Washington River Protection Solutions, LLC

Date PublishedSeptember 2019

Prepared for the U.S. Department of EnergyOffice of River Protection

Contract No. DE-AC27-08RV14800

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 3 of 24

Approved for Public Release; Further Dissemination Unlimited

RPP-SPEC-62012, Rev. 0

i

SPECIFICATION FOR FABRICATING, INSPECTING, TESTING, AND SHIPPING THE 241-A SLURRY AND 241-AP-101 SUPERNATANTADJUSTABLE SUBMERSIBLE PUMP ASSEMBLIES

September 2019

prepared by

Sargent & Lundy 1100 Jadwin Avenue, Suite 400Richland, Washington 99352

(509) 946-3300

prepared for

Washington River Protection Solutions, LLC

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 4 of 24


ii

TABLE OF CONTENTS

1.0 SCOPE ....................................................................................................................................51.1 Specification...................................................................................................................5

2.0 APPLICABLE DOCUMENTS ..............................................................................................52.1 Government Documents.................................................................................................52.2 Non-Government Documents.........................................................................................62.3 Non-Code of Record Documents ...................................................................................6

3.0 TECHNICAL REQUIREMENTS..........................................................................................83.1 Inspections and Tests .....................................................................................................8

3.1.1 Equipment ..........................................................................................................93.1.2 Weld Inspection and Examination .....................................................................93.1.3 Wire Rope Load Test .........................................................................................93.1.4 Hydrostatic Test .................................................................................................93.1.5 Pump Clearance Test .......................................................................................103.1.6 Pump Suction Elevation Cycle and Position Indication Test ..........................103.1.7 Pump Start-Up Prerequisites............................................................................103.1.8 Pump Speed Indication Test ............................................................................113.1.9 Pump Start-Up Test..........................................................................................123.1.10 Performance Test .............................................................................................123.1.11 Pump In-Line Dilution Flow Test....................................................................133.1.12 Initial Run-In Test............................................................................................133.1.13 Challenge Tests................................................................................................143.1.14 Final Run-In Test .............................................................................................143.1.15 Periodic Maintenance and Manually Operated Hand Pump Testing...............143.1.16 Electrical Inspections and Testing ...................................................................153.1.17 Electric Winch Control Tests...........................................................................16

4.0 QUALITY ASSURANCE....................................................................................................164.1 Qualifications ...............................................................................................................16

4.1.1 Welding Personnel and Procedures .................................................................174.1.2 Weld Inspectors and Procedures ......................................................................17

4.2 Materials.......................................................................................................................174.2.1 Materials Traceability for Safety-Significant Items ........................................17

4.3 Suspect/Counterfeit Items ............................................................................................18

5.0 DOCUMENT SUBMITTALS..............................................................................................185.1 Approval of Submittals ................................................................................................185.2 List of Submittals .........................................................................................................19

6.0 PACKAGING, STORAGE, TRANSPORT AND LOAD HANDLING .............................206.1 General .........................................................................................................................206.2 Preservation and Packaging..........................................................................................206.3 Marking........................................................................................................................216.4 Shipping and Handling.................................................................................................21

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 5 of 24


iii

LIST OF TABLES

Table 2-1. Government Documents. ...............................................................................................6

Table 2-2. Non-Government Documents........................................................................................6

Table 2-3. Non-Code of Record Documents. (3 sheets)................................................................6

Table 5-1. Summary of Submittals. ..............................................................................................20

LIST OF TERMS

Abbreviations and Acronyms

ANSI American National Standards Institute

ASME American Society of Mechanical Engineers

ASNT American Society of Nondestructive Testing

AWS American Welding Society

B&PVC Boiler and Pressure Vessel Code

DOE U.S. Department of Energy

HI Hydraulic Institute

HPU Hydraulic Power Unit

M&TE Measuring and Testing Equipment

MSR Master Submittal Register

NDE Nondestructive Examination

NFPA National Fire Protection Association

NIST National Institute of Standards and Technology

QA Quality Assurance

RMA Rubber Manufacturers Association

RT Radiographic Testing

TOC Tank Operating Contractor

UL Underwriters Laboratories

UT Ultrasonic Testing

WRPS Washington River Protection Solutions, LLC

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 6 of 24


iv

Units

°F degrees Fahrenheit

ft foot

gpm gallons per minute

in. inch

psig pounds per square inch (gauge)

RPM Revolutions Per Minute

V volt

VDC Volts direct current

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 7 of 24


5

1.0 SCOPE

1.1 SPECIFICATION

This Specification provides the requirements for fabricating, inspecting, testing, and shipping the 241-A Adjustable Submersible Slurry Pump and 241-AP-101 Adjustable Submersible Supernatant Pump Assemblies for use at the U.S. Department of Energy’s (DOE’s) Hanford Reservation located in Washington State. These shall be fabricated in accordance with drawings listed in Table 2-3 below.

This Specification pertains to either assembly (slurry pump or supernatant pump), as purchasedby the BUYER. The fabrication and test requirements that follow incorporate features that may pertain to either the slurry pump assembly or the supernatant pump assembly. If a requirement within this Specification does not pertain to the pump assembly being fabricated and/or tested(i.e. in-line dilution system, electric winch drives), then that requirement may be omitted with the written approval from the BUYER. Otherwise, the SELLER shall meet all requirements of this Specification for either assembly, or both, as directed by the BUYER.

The submersible pumps are hydraulically driven. In order to perform operational tests on the adjustable submersible pump assemblies, a Hydraulic Power Unit (HPU) will be required. HPUs and hydraulic extension hoses will be supplied by the BUYER for these tests as required. The SELLER shall provide 480V power cords and will be responsible for initial configuration of the HPUs as required to support testing.

2.0 APPLICABLE DOCUMENTS

The following documents form a part of the basis of design to the extent specified in the applicable sections of this Specification. In the event that the requirements of this Specification are more restrictive than the requirements of the documents referenced herein, the requirements of this Specification take precedence. The Level 2 Specification for 241-A Waste Retrieval (RPP-SPEC-61269, “Level 2 Specification for the 241-A Tanks Waste Retrieval Systems”) defines technical design criteria for this work, including the applicable Code of Record.

Copies of specifications, standards, drawings, and publications required by suppliers in connection with specified procurement functions should be obtained from the contracting agency or as directed by the contracting agent.

2.1 GOVERNMENT DOCUMENTS

Applicable federal and state specifications, standards, regulations, drawings, and other publications are shown in Table 2-1. Documents listed in Table 2-1 constitute a part of this Specification to the extent specified herein. Current versions shall be used unless otherwise noted.

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 8 of 24


6

Table 2-1. Government Documents.

Document Number Title

10 CFR 436 Title 10, Code of Federal Regulations, Part 436, “Federal Energy Management and Planning Programs.”

29 CFR 1910 Title 29, Code of Federal Regulations, Part 1910, “Occupational Safety and Health Standards.”

DOE/RL-92-36 Hanford Site Hoisting and Rigging Manual, DOE, Richland, Washington.

DOE G 414.1-3 Suspect/Counterfeit Items Guide for Use with 10 CFR 830 Subpart A, Quality Assurance Requirements, DOE, Washington, D.C.

2.2 NON-GOVERNMENT DOCUMENTS

National codes and standards listed in Table 2-2 constitute a part of this Specification to the extent specified herein. In the event of conflict between the documents referenced herein and the contents of this Specification, the contents of this Specification shall be considered a superseding requirement. Current versions shall be used unless otherwise noted.

Table 2-2. Non-Government Documents.


ASME B&PVC, Section IX - 2017

Boiler and Pressure Vessel Code (B&PVC), Section IX, “Welding and Brazing Qualifications,” American Society of Mechanical Engineers (ASME), New York, New York.

ASME B31.3-2016 Process Piping, ASME, New York, New York.

AWS D1.1-2010 Structural Welding Code Steel, American Welding Society (AWS), Miami, Florida.

AWS D1.6, 2007 Structural Welding Code – Stainless Steel, AWS, Miami, Florida.

AWS QC1, 2007 Qualification and Certification of Welding Inspectors, AWS, Miami, Florida.

RPP-SPEC-61269 Level 2 Specification for the 241-A Tanks Waste Retrieval Systems, Washington River Protection Solutions, LLC (WRPS), Richland, Washington.

2.3 NON-CODE OF RECORD DOCUMENTS

Applicable non-code of record federal and state specifications, standards, regulations, drawings, and other publications are shown in Table 2-3.

Table 2-3. Non-Code of Record Documents. (3 sheets)


ANSI/IEEE Standard 43, 2000

Institute of Electrical and Electronics Engineers (IEEE) Recommended Practice for Testing Insulation Resistance of Rotating Machinery, American National Standards Institute (ANSI)/IEEE, New York, New York.

ANSI/HI 11.6, 2012 Rotodynamic Submersible Pumps: for Hydraulic Performance, Hydrostatic Pressure, Mechanical and Electrical Acceptance Tests, American National Standards Institute (ANSI)/Hydraulic Institute (HI), Parsippany, New Jersey.

ASME B30.9, 2014 Slings, ASME, New York, New York.

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 9 of 24


7



ASNT SNT-TC-1ARecommended Practice No. SNT-TC-1A and ASNT Standard Topical Outlines for Qualification of Nondestructive Testing Personnel, American Society for Nondestructive Testing (ASNT), Columbus, Ohio.

RMA IP-2, 2003 Hose Manufacturer’s Handbook, The Rubber Manufacturers Association, Inc. (RMA), Washington, D.C.

RPP-CALC-62756 Structural Analysis of Slurry Pump, Washington River Protection Solutions, LLC, Richland, Washington.

RPP-CALC-63015 Structural Analysis of Supernatant Pump, Washington River Protection Solutions, LLC, Richland, Washington.

RPP-CALC-63344 Supernatant and Slurry Pumps – Rigging Analysis, Washington River Protection Solutions, LLC, Richland, Washington.

TFC-BSM-IRM_DC-C-07 “Vendor Processes,” Washington River Protection Solutions, LLC, Richland, Washington.

TFC-ENG-STD-22 “Piping, Jumpers, and Valves,” Washington River Protection Solutions, LLCRichland, Washington.

TFC-ENG-STD-41 “Electrical Installations,” Washington River Protection Solutions, LLC, Richland, Washington.

Supernatant Pump Mechanical Drawings

H-14-111017, Sh. 1 “A-Farm Retrieval Adjustable SN Pump General Notes” H-14-111017, Sh. 2 “A-Farm Retrieval Adjustable SN Pump Parts List”H-14-111017, Sh. 3 “A-Farm Retrieval Adjustable SN Pump Parts List”H-14-111017, Sh. 4 “A-Farm Retrieval Adjustable SN Pump Assembly”H-14-111017, Sh. 5 “A-Farm Retrieval Adjustable SN Pump Assembly Details”H-14-111017, Sh. 6 “A-Farm Retrieval Adjustable SN Pump Assembly Details”H-14-111017, Sh. 7 “A-Farm Retrieval Adjustable SN Pump Upper Mast Details”H-14-111017, Sh. 8 “A-Farm Retrieval Adjustable SN Pump Upper Mast Details”H-14-111017, Sh. 9 “A-Farm Retrieval Adjustable SN Pump Upper Mast Details”H-14-111017, Sh. 10 “A-Farm Retrieval Adjustable SN Pump Upper Mast Details”H-14-111017, Sh. 11 “A-Farm Retrieval Adjustable SN Pump Lower Mast Details”H-14-111017, Sh. 12 “A-Farm Retrieval Adjustable SN Pump Details”H-14-111017, Sh. 13 “A-Farm Retrieval Adjustable SN Pump Details”H-14-111017, Sh. 14 “A-Farm Retrieval Adjustable SN Pump Details”H-14-111017, Sh. 15 “A-Farm Retrieval Adjustable SN Pump Details”H-14-111017, Sh. 16 “A-Farm Retrieval Adjustable SN Pump Details”H-14-111017, Sh. 17 “A-Farm Retrieval Adjustable SN Pump Upper Mast Details”

Slurry Pump Mechanical DrawingsH-14-111018, Sh. 1 “A-Farm Retrieval Adjustable SL Pump General Notes” H-14-111018, Sh. 2 “A-Farm Retrieval Adjustable SL Pump Parts List”H-14-111018, Sh. 3 “A-Farm Retrieval Adjustable SL Pump Parts List”H-14-111018, Sh. 4 “A-Farm Retrieval Adjustable SL Pump Assembly”H-14-111018, Sh. 5 “A-Farm Retrieval Adjustable SL Pump Assembly Details”H-14-111018, Sh. 6 “A-Farm Retrieval Adjustable SL Pump Assembly Details”H-14-111018, Sh. 7 “A-Farm Retrieval Adjustable SL Pump Upper Mast Details”H-14-111018, Sh. 8 “A-Farm Retrieval Adjustable SL Pump Upper Mast Details”

Slurry Pump Mechanical Drawings Cont.H-14-111018, Sh. 9 “A-Farm Retrieval Adjustable SL Pump Upper Mast Details”H-14-111018, Sh. 10 “A-Farm Retrieval Adjustable SL Pump Upper Mast Details”H-14-111018, Sh. 11 “A-Farm Retrieval Adjustable SL Pump Lower Mast Details”H-14-111018, Sh. 12 “A-Farm Retrieval Adjustable SL Pump Details”H-14-111018, Sh. 13 “A-Farm Retrieval Adjustable SL Pump Details”

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 10 of 24


8



H-14-111018, Sh. 14 “A-Farm Retrieval Adjustable SL Pump Details”H-14-111018, Sh. 15 “A-Farm Retrieval Adjustable SL Pump Details”H-14-111018, Sh. 16 “A-Farm Retrieval Adjustable SL Pump Details”H-14-111018, Sh. 17 “A-Farm Retrieval Adjustable SL Pump Upper Mast Details”

Electric Winch Drive DrawingsH-14-111069 Sh 1 “A-Farm Retrieval Assemblies POR584/595-WT-EES-001”H-14-111069 Sh 2 “A-Farm Retrieval POR584-WT-EES-001 Winch Assembly”H-14-111069 Sh 3 “A-Farm Retrieval POR595-WT-EES-001 Winch Assembly”H-14-111070 Sh 1 “A-Farm Retrieval Assemblies POR606/617-WT-EES-001”H-14-111070 Sh 2 “A-Farm Retrieval Assemblies POR606-WT-EES-001 Winch Assembly”H-14-111070 Sh 3 “A-Farm Retrieval Assemblies POR617-WT-EES-001 Winch Assembly”H-14-110716, All Sheets “AX Retrieval Electric Winch Drive”

Note: All drawings are Current Revision and were prepared for the DOE, Richland, Washington.

3.0 TECHNICAL REQUIREMENTS

Technical requirements for the fabrication of the adjustable submersible pump assemblies are covered in the fabrication drawings listed in Table 2-3 above.

3.1 INSPECTIONS AND TESTS

Perform inspection and testing of the adjustable submersible pump assemblies in accordance with the specified requirements. Provide the test location, equipment, instrumentation of certified accuracy, and any supplementary temporary connections and auxiliary parts necessary to fully execute the tests. Provide test personnel qualified to conduct, record, and verify test results. All electrical components to be approved by a nationally recognized testing laboratory.

Provide BUYER with a minimum of five working day advance written notice of shop acceptance tests. Submit the test results as part of the QA Program in accordance with the Procurement Documents.

Prior to the performance of these tests, the SELLER shall submit a procedure for each test to theBUYER for review and approval (not required for weld inspection and examination). Test information recorded or calculated shall be documented and submitted to the BUYER.

Provide test reports as required by ASME B31.3, the subcontract documents, the drawings, and this Specification. The following information shall be included in the test report:

A. Pump Assemblies identification.

B. Pump Serial Number.

C. Date of test.

D. Name and signature of the certified test operator.

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 11 of 24


9

E. Location and description of indications.

F. Description of repairs and retest.

G. Signature of witness.

3.1.1 Equipment

M&TE used shall be calibrated and traceable to the National Institute of Standards and Technology (NIST) or other nationally recognized standards.

3.1.2 Weld Inspection and Examination

Weld inspection and examination of pressure-retaining components shall be performed in accordance with ASME B31.3 for normal fluid service. Volumetric examination (Radiographic Testing [RT] or Ultrasonic Testing [UT]) of welds where specified by ASME B31.3 shall be performed where possible (i.e., in-process examination shall not be specified). In those cases where volumetric examination is not possible (e.g., orientation of the weld), the subject welds shall have documented in-process examination in accordance with ASME B31.3, paragraph 344.7 with liquid penetrant or magnetic particle examination specified for the root pass [see paragraph 344.7.1(e)] in accordance with the conditions stated within TFC-ENG-STD-22. BUYER approval for substitution of in-process inspection in lieu of full volumetric inspection of a weld is required.

Weld inspections and examinations of structural components shall be performed in accordance with AWS D1.1 (welding qualifications and procedures per ASME B&PVC, Section IX, are acceptable).

All welds shall be visually inspected as a minimum. Weld maps shall be prepared and submitted. NDEs, including Visual, Penetrant Test, RT, or Magnetic Particle Test examinations, shall be recorded and submitted. RT film shall be included as part of the weld documentation submittal.

3.1.3 Wire Rope Load Test

SELLER shall submit test reports in accordance with ASME B30.9 from the wire rope Supplier for load testing of wire ropes used in the adjustable submersible pump assemblies.

3.1.4 Hydrostatic Test

A hydrostatic leak pressure test shall be conducted and documented for all waste transfer hoses and piping (including pump discharge) and for all dilution water line hoses and piping of the fabricated adjustable submersible pump assemblies in accordance with ASME B31.3 for category Normal Fluid Service. The test boundary shall include all pressure-retaining components with the exception of those exempted on the fabrication drawings above. Test

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 12 of 24


10

pressure shall be as specified on the applicable fabrication drawings. The system shall be held at test pressure for ten minutes (minimum) and inspected for leaks. No leaks are permitted.

A hydrostatic leak pressure test shall be conducted and documented for all hydraulic hoses and fittings (assembled). The test pressure for hydraulic hoses and piping shall be 2 times the working pressure of 3000 psig (6000 psig -0/+200 psig) and performed in accordance with Rubber Manufacturers Association (RMA) procedure RMA IP-2.

3.1.5 Pump Clearance Test

Following final pump assembly of each pump, slurry or supernatant, a clearance test shall be performed on each fabricated pump assembly to demonstrate adequate clearance to support installation into a 35-in. riser. The test shall be performed by demonstrating the components of the completed assembly located below the adapter flange will fit within a 5 ft (minimum) length of 36-in. STD pipe (nominal inside diameter of 35.25 in.).

3.1.6 Pump Suction Elevation Cycle and Position Indication Test

A pump suction elevation cycle test shall be conducted on the fabricated pump assemblies. The pump assembly winches shall be used to cycle the submersible pumps up and down within their full range of motion a minimum of three times. The winches shall be operated by hand, with low speed powered hand tools, or with the electric winch drive assembly for slurry pumps.Additionally, the position indicator on the pump shall be connected and tested during the course of the pump elevation cycle test. Readings on the indicator shall be within ±1-in. If indication is out of this range the BUYER shall be notified. This test shall be completed prior to pump operation tests (Sections 3.1.9– 3.1.14).

Careful note shall be taken to ensure adequate slack and proper tracking of the energy chain and the equipment within the energy chain (discharge hose, hydraulic hoses, wiring). Verify that there is no visible abrading, kinking or wear on the entire length of the equipment, including at the interface points.

Pump travel stops, included as part of the pump assemblies, shall be tested for functionality without the pump travel limit switch in place to allow full travel to the hard stops without damaging the limit switch. The pump travel limit switch shall be tested for proper adjustment such that the switch is tripped correctly and consistently prior to the pump hitting the hard stops, and resets correctly when the pump is lowered away from the switch. Functional testing of the pump travel limit switch is described in Section 3.1.17.

3.1.7 Pump Start-Up Prerequisites

For each pump, prior to initial pump start-up, prepare the HPU for operation. Install the HPU in accordance with the manufacturer’s Operation and Maintenance Manual. This includes (but is not limited to):

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 13 of 24


11

Leveling the HPU;

Checking HPU Reservoir Oil Level;

Hydraulic Hose Connection, including verification on the pump/HPU case drain hose line

that all of the hydraulic hose connection internal check valves have been removed;

Connection of 480V Power and Checking Phase/Motor Rotation; and

Breather Filter and Heat Exchanger Preparation.

When starting the pump, follow the Startup Procedure located in the manufacturer’s Operation and Maintenance Manual. Particular attention shall be made to the items listed below.

Always verify the HPU flow control is closed before starting the HPU motor. Slowly

open the flow control to obtain the pump pressure and flow desired.

Do not run the pump shaft speed greater than 3450 RPM.

Follow the Cold Weather Instructions. The HPU contains immersion heaters to maintain

the oil temperature between ~70°F - 80°F. Ensure the oil in the hydraulic reservoir is up

to the operating temperature (minimum of 70°F) prior to pump operation.

Add hydraulic fluid to the reservoir as required (initial filling of the hydraulic lines will

lower the reservoir) in accordance with the manufacturer’s recommendations.

Do not operate the pump at flow rates less than 40 gpm. A low flow interlock (with no

time delay) shall be installed and used to shut down the pump if flows of less than 35

gpm are experienced.

Perform a leak check on the hydraulic hoses and their connections.

3.1.8 Pump Speed Indication Test

For each pump, each of the 3 speed sensors mounted at the pump hydraulic motor coupling shall be checked independently at all 7 different performance test pump speeds [2500, 2750, 2900, 3000, 3100, 3200, and 3300 RPM (or maximum achievable RPM)]. At each shaft speed, record pump shaft speed measured by the M&TE, the pump shaft speed as indicated by the HPU speed indicator and data logger (if available), the HPU hydraulic fluid flow rate, the hydraulic oil temperature, the hydraulic pressure, the HPU motor current, and the HPU motor voltage. If the measured shaft speed and the HPU indication vary by more than +/- 50 RPM for any measurement, contact the WRPS Engineer.

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 14 of 24


12

3.1.9 Pump Start-Up Test

For each pump, a pump start-up test shall be conducted on the fabricated adjustable submersible pump assembly. The pump assembly winch shall be used to cycle the submersible pump up and down within its full range of motion, with the pump stopped and re-started at 1-ft intervals. During elevation adjustments, the pump shall be removed from the tank, allowed to drain back completely, and then re-submerged into the tank (this ensures potential seal loops in the hose management system will not impact pump start-up). All winch operation shall be performed manually, with low speed powered hand tools, or with the electric winch drive assembly for slurry pump assemblies. The pump shall be operated a minimum of 5 minutes between intervals with the pump assembly discharging 110 gpm (-0/+10 gpm) at ~3000 RPM. The liquid level for this test shall be sufficient to cover the pump suction (a maximum of 2 ft at all elevations) and shall be recorded. Pump flow and pressure (measured from the assembly discharge nozzle located above the pump mounting plate), HPU hydraulic fluid flow rate, hydraulic pressure, hydraulic oil temperature, HPU motor current, HPU motor voltage, and water temperature shall be recorded at all test elevations. The pump flow shall be monitored and recorded during the duration of the test to verify lower flows (i.e., a reduction of greater than 15 gpm) are not observed. If lower flows are observed, checks shall be made to determine if the lower flow is due to hose kinks.

3.1.10 Performance Test

For each pump, a performance test shall be conducted using the fabricated adjustable submersible pump assembly. The test shall be performed following ANSI/HI 11.6, Section 11.6.4, with the pump assembly extended to its design full length. The distance from the bottom of the assembly flange to the bottom of the pump shall be recorded. The performance test is to be performed by adjusting the hydraulic flow control valve to achieve the shaft speed specified for the test. Once the desired pump speed is achieved, leave the hydraulic flow control valve set. Throttle back the discharge valve to achieve the desired flow rate specified for data collection. Perform system adjustments as required to obtain the desired flow/speed condition.

The performance test shall obtain sufficient data points to plot a full performance curve at all operating speeds tested. One of the data points shall be obtained at pump run-out.

The minimum shaft speeds to be addressed during the performance test are (speed is as measured at the pump shaft):

Performance Test 1: 2,500 RPM






Performance Test 7: 3,300 RPM (or maximum achievable RPM)

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 15 of 24


13

All specified pump speeds are +/- 25 RPM.

Operate the pump per the pump manufacturer’s instructions. For each of the specified performance tests, collect data at approximately 40 gpm intervals, from 40 gpm to maximum flow that can be achieved given the test set up. The following shall be recorded at each data point: pump flow rate and pressure (measured from the assembly discharge nozzle located above the pump mounting plate), actual pump RPM, hydraulic pressure, HPU hydraulic fluid flow rate, hydraulic oil temperature, HPU motor current, HPU motor voltage, and water temperature. Pump shaft speeds recorded during performance testing shall include pump shaft speed measured by M&TE and pump shaft speed indicated by the HPU speed indicator. The liquid level for this test shall be sufficient to cover the pump suction (maximum of 1-ft above suction screen) and shall be recorded. Following pump testing, the SELLER shall prepare a pump curve reflecting pump performance at the discharge nozzle with water.

The test procedure shall include a sketch detailing the test loop. Hose/pipe lengths and sizes, fittings, instrumentation and valves shall be shown and located on the drawings. Component elevations shall also be identified.

3.1.11 Pump In-Line Dilution Flow Test

For each pump assembly that contains an in-line dilution line (i.e., slurry pump assemblies), a flow rate versus pressure test shall be conducted for the in-line dilution feature with the pump operating and discharging 100 gpm. A performance curve shall be generated from the results, and at a minimum, shall include data points at in-line dilution flow rates of 5 gpm, 10 gpm, 15 gpm, 20 gpm, 25 gpm, and 30 gpm (with an inlet pressure of a maximum of 60 psig measured at or near the hose connection on the pump assembly plate). During testing a vacuum breaker shall be installed on the in-line dilution lines to simulate actual field conditions. Test shall be completed at pump assembly full extension and full retraction.

3.1.12 Initial Run-In Test

For each pump, a run-in test shall be conducted using the fabricated pump assembly. The run-in test shall be conducted for a minimum of 24 hours of continuous operation, with the pump assembly discharging 110 gpm (-0/+10 gpm) at ~3300 RPM (or maximum achievable RPM). As a minimum, the following readings shall be recorded every 30 minutes during the test: pump speed, pump flow rate and pressure (measured from the assembly discharge nozzle located above the pump mounting plate), water temperature, hydraulic pressure, HPU hydraulic oil temperature, HPU hydraulic fluid flow rate, pump suction elevation, HPU motor current, HPU motor voltage; and, if a feature on the pump assembly, record the in-line dilution pressure and flow rate. The liquid level for this test shall be sufficient to cover the pump suction (maximum of 2 ft at all elevations) and shall be recorded. The pump suction elevation shall be moved 6 in. every 1/2 hour such that a minimum of one complete up and down cycle of the pump assembly is completed over the duration of the test. At no time during operation shall the pump suction be allowed to be submerged less than 6 in.

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 16 of 24


14

During the middle of this initial run-in test, if the in-line dilution is a feature on the pump assembly, the in-line dilution shall be operated at 30, 20, 10 and 5 gpm for a minimum of fourhours. The first and last four hours of testing are to be performed with no dilution flow.

Following pump elevation adjustments, inspect the hose management system to ensure adequate slack, and proper tracking of the energy chain and the equipment within the energy chain (discharge hose, hydraulic hoses, wiring). Verify that there is no visible abrading, kinking or wear on the entire length of the equipment, including at the interface points.

3.1.13 Challenge Tests

For each pump, two challenge tests (one low flow, one high flow) shall be conducted following the initial run-in test. The first challenge test shall be conducted for a minimum of 24 hours of operation, with the adjustable submersible pump assembly discharging 50 gpm (-0/+10 gpm) at ~3300 RPM (or maximum achievable RPM). The second challenge test shall also be conducted for a minimum of 24 hours of operation, with the pump assembly discharging 250 gpm (-0/+10 gpm) at ~3300 RPM (or maximum achievable RPM). During the last two hours of each of the challenge tests, start and stop the pump 6 times each hour (approximately every 10 minutes, for a total of 12 times). Record the start and stop times. As a minimum, the following readings shall be recorded every 30 minutes during the test: pump speed, pump flow rate and pressure (measured from the assembly discharge nozzle located above the pump mounting plate), water temperature, hydraulic pressure, HPU hydraulic oil temperature, pump suction elevation, HPU motor current, and HPU motor voltage. The liquid level for this test shall be sufficient to cover the pump suction (a maximum of 2 ft at all elevations) and shall be recorded. At no time during operation shall the pump suction be allowed to be submerged less than 6 in. The maximum submerged liquid level for testing shall be 2 ft.

3.1.14 Final Run-In Test

For each pump, a final run-in test shall be conducted following the two challenge tests. The final run-in test shall be conducted for a minimum of 24 hours of continuous operation, with the adjustable submersible pump assembly discharging 110 gpm (-0/+10 gpm) at ~3300 RPM (or maximum achievable RPM). As a minimum, the following readings shall be recorded every 30 minutes during the test: pump speed, pump flow rate and pressure (measured from the assembly discharge nozzle located above the pump mounting plate), water temperature, hydraulic pressure, HPU hydraulic oil temperature, and pump suction elevation, HPU motor current, and HPU motor voltage. The liquid level for this test shall be sufficient to cover the pump suction (a maximum of 2 ft at all elevations) and shall be recorded. At no time during operation shall the pump suction be allowed to be submerged less than 6 in.

3.1.15 Periodic Maintenance and Manually Operated Hand Pump Testing

While in the fabricator’s possession, prior to shipment, the slurry or supernatant pump is required to undergo periodic maintenance per the manufacturer’s procedures. The SELLER shall submit

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 17 of 24


15

a procedure to the BUYER for approval prior to receipt of the pump and shall perform and document the maintenance accordingly.

The HPU manually operated hand pump shall be functionally tested according to the manufacturer’s specifications. Verify the number of rotations required to fully rotate the slurry or supernatant pump.

3.1.16 Electrical Inspections and Testing

The SELLER shall inspect and test the equipment and perform operational tests on the components installed as a part of this Specification and provide records of all inspections and testing as part of the final submittal. Before attempting to operate equipment, perform the following inspections, tests and verifications, and record results.

The SELLER shall perform the following electrical inspections as a minimum:

Observe conductors and cables during the installation process.

- Reject and replace entire reels, rolls, or boxes containing conductors or cables with material or manufacturing defects.

- Reject and replace cable or conductor segments that have been kinked, dented, or otherwise damaged during handling or installation.

Inspect conductors and cables for:

- Freedom from material defect or physical damage;

- Correct conductor size, material, and insulation type; and

- Correct color coding and identification.

The SELLER shall perform the following electrical tests as a minimum:

Perform continuity test on all conductors to ensure correct cable connection and record

test values/results.

On wiring 120V and below, perform continuity test on each conductor with respect to

ground and record test values.

Perform heat trace tests using a calibrated megger at 500, 1000, and 2500V for 1 minute

(refer to manufacturer’s instructions). First, measure the resistance between the heating

cable bus wires and the braid. Next, measure the insulation resistance between the braid

and the metal pipe or hose. Resistance to ground shall be 1000 megohm minimum. All

completed test procedures and test records shall be submitted.

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 18 of 24


16

A megger test shall be conducted on the electric winch drive assembly motor in

accordance with ANSI/IEEE Standard 43. The megger test shall be conducted between

each phase and the ground at 500 VDC. The acceptable value is greater than or equal to

the values stated in ANSI/IEEE Standard 43. Continuity between the phases shall be

recorded.

3.1.17 Electric Winch Control Tests

The electric winch drive assembly and controls shall be assembled and tested with the slurry or supernatant1 pump assembly in the upright and vertical position. The pump shall be completely stroked a minimum of three times, twice using the electric motor and once using the manual drive. Record number of revolutions of the manual winch drive handle per foot the pump is raised, at one-ft intervals. A shorter winch drive shaft may be used to facilitate test equipment setup. All functions of the electric winch control shall be tested for functionality. These include the jog up, jog down, up park, and manual stop functions. Additionally, the pump travel limit switch shall be tested to ensure it correctly shuts the electric motor off and stops the winch when tripped, and that it resets when the jog down function is activated.

4.0 QUALITY ASSURANCE

4.1 QUALIFICATIONS

The SELLER’s Quality Assurance (QA) Program shall control a combination of design, materials, preparation, fabrication, inspection, testing, cleaning, packaging, and shipping that have to be done correctly to ensure the production of an acceptable finished product. The QA Program shall be submitted for BUYER approval.

The SELLER shall have a formal redline procedure addressing configuration control of BUYER supplied fabrication details during the fabrication process which is equivalent to that specified in TFC-ENG-DESIGN-C-61, Fabrication Change Control. The redline procedure shall be submitted by the SELLER and reviewed and approved by the BUYER prior to the initiation of fabrication. Alternatively, the SELLER may implement TFC-ENG-DESIGN-C-61. Work shall not be initiated on design changes until such time as authorization is received by SELLER. The BUYER will be responsible for incorporation of redline changes into the final drawings.

The SELLER shall submit requested design and fabrication changes to the BUYER for approval via the Request for Information process. All changes must be approved by the BUYER prior to implementation.

1 Note that an electric winch drive is not planned to be provided for the supernatant pump, however a limit switch is included in the design to provide flexibility if desired at a future time. The supernatant pump assembly limit switch shall be tested per this specification using a winch drive from one of the slurry pumps, if available, or one shall be provided by the BUYER.

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 19 of 24


17

Portions of the pumps are designated as safety-significant by the BUYER. BUYER hold points shall be established in fabrication control documents to allow BUYER supervision of work.

The SELLER shall comply with the quality assurance requirements stated in the procurement documents.

4.1.1 Welding Personnel and Procedures

Personnel and procedures for welding pressure-retaining components and pressure-boundary attachments shall be qualified in accordance with ASME B31.3 prior to the start of welding. Personnel and procedures for welding structural components shall be qualified in accordance with AWS D1.1 prior to the start of welding. Welding qualifications and procedures per ASME B&PVC, Section IX, are acceptable for both piping and structural welding. A copy of welder performance qualification test results and renewal of qualification documentation shall be maintained at the job site for evaluation at the BUYER’s discretion. A copy of the Weld Procedure Specifications, Procedure Qualification Records, and Supporting Demonstration Records, as applicable, shall be maintained at the job site for evaluation at the BUYER’s discretion.

4.1.2 Weld Inspectors and Procedures

Weld inspection shall be performed as specified by the design drawings and applicable construction codes. As a minimum, all welds shall be visually inspected. Visual weld examinations shall be performed and appropriate documentation prepared by the Certified Welding Inspectors who have received certification in accordance with AWS QC1. Certified Associate Welding Inspectors, certified in accordance with above standard, may perform examinations when under immediate direction of Certified Welding Inspectors.

Personnel performing NDE shall be certified in accordance with the SELLER’s written practice, which shall meet the requirements of ASNT SNT-TC-1A. Level II or III personnel shall be used to interpret test results.

The SELLER shall maintain a file containing personnel certifications and NDE procedures, as applicable, at the fabrication site for evaluation at the BUYER’s discretion.

4.2 MATERIALS

4.2.1 Materials Traceability for Safety-Significant Items

SELLER shall prepare and maintain a log of all materials used in fabrication that are indicated by the BUYER as safety significant. Certified Material Test Reports shall be submitted to the BUYER for all safety-significant materials, components, and weld filler used to join safety-significant components.

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 20 of 24


18

4.3 SUSPECT/COUNTERFEIT ITEMS

The Supplier shall ensure that no suspect or counterfeit parts or components are provided in conjunction with this procurement. Suspect counterfeit items are described in DOE G 414.1-3.

Seller shall warrant that “all items furnished under this purchase order are genuine (i.e., not counterfeit) and match the quality, test reports, markings and/or fitness for use required by the purchase order”.

5.0 DOCUMENT SUBMITTALS

In support of the work scope established in Section 3.0 above, submittals are listed on the Master Submittal Register (MSR). The MSR is used to identify the minimum submittals required by this Specification and when the submittals are required to be submitted in the procurement process. The MSR included with the purchase order will constitute the governing MSR.

Submittals shall be provided using the TOC Incoming Letter of Transmittal form provided by the Procurement Specialist. All transmittal subject headings shall contain, at a minimum, the subcontract number, submittal number, and submittal description.

Submittals shall be provided in electronic format unless available only as a hard copy. Electronic submittals shall be sent in accordance with instructions provided by the Procurement Specialist. Electronic formats must be non-password protected in one of the formats noted on the Procurement Website located and the following web address: http://www.hanford.gov/tocpmm/files.cfm/APPROVED_ELECTRONIC_RECORD_FORMATS.pdf

All deliverable documentation shall be complete, accurate, legible, and reproducible. Before delivery, design media and documents shall be reviewed by qualified Subcontractor personnel for technical adequacy and appropriate content. The Subcontractor shall attest, in writing, to the accuracy and completeness of the information contained in the final deliverables.

5.1 APPROVAL OF SUBMITTALS

All Submittals transmitted shall include the designation in the MSR per TOC Vendor Processes stated in TFC-BSM-IRM_DC-C-07. Submittals are divided into two types: 1) those requiring “approval” (e.g., approval data or pre-purchase evaluation data); and 2) those “not requiring approval” (e.g., vendor information data). Submittals “not requiring approval” will be reviewed to verify completeness and adequacy for their intended purposes. A submittal requiring approval that is not approved is identified as: 1) “Not Approved Revise and Resubmit.” The submittal is considered technically deficient, or incomplete, and therefore unacceptable. Resubmittal is required, hence the fabrication, procurement, or performance of procedures shall not proceed; or 2) “Approved with Exception.” Fabrication, procurement, and performance may proceed, and resubmittal is required to verify incorporation of the exception. Submittals “not requiring approval” that are determined to be incomplete or inadequate will be marked “Resubmit.” An explanation of the deficiencies will be included for corrective action by the Seller.

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 21 of 24

http://www.hanford.gov/tocpmm/files.cfm/APPROVED_ELECTRONIC_RECORD_FORMATS.pdf


19

Approval by the Buyer does not relieve the Seller of responsibility for accuracy or adequacy of design under this Specification.

If any revision has been made to previously submitted items, the Seller shall resubmit updated versions of said items for approval, in addition to the items listed above.

Certified data shall be defined to mean that the design adequacy of a given item (document, drawing, calculation, etc.) be verified by persons other than those who prepared the item. Each deliverable (drawing, calculation, etc.) shall have at least an originator’s/preparer’s signature and a checked-by or approved-by signature.

5.2 LIST OF SUBMITTALS

The SELLER shall submit the specified documents (as a minimum) to the BUYER at the address specified in the procurement documentation. Each submittal shall be marked with this Specification number, the item number, the purchase order number, Pump Serial Number, and the SELLER’s identification number. All of this information shall become the property of the BUYER. See Table 5-1 for deliverables and schedule information.

All data shall be sufficiently clear to allow legible copies to be made on standard reproduction equipment after microfilming.

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 22 of 24


20

Table 5-1. Summary of Submittals.

Item Title Copies Purpose When required

1 Redline Procedure (4.1) 1 Approval With Proposal

2 Redline Drawings and Change Log (4.1) 1 Approval Prior to shipment

3 Certified Material Test Reports (4.2.1) 1 Approval Prior to fabrication

4 Test Procedures (3.1) 1 Approval Prior to test

5Measuring and Testing Equipment (M&TE) Instrument Calibration Data (3.1.1)

1 Approval Prior to shipment

6Weld Inspection and Examination Documentation, including RT film (3.1.2)


7 Wire Rope Load Test Report (3.1.3) 1 Approval Prior to shipment

8 Piping Hydrostatic Test Results (3.1.4) 1 Approval Prior to shipment

9 Pump Clearance Test Results (3.1.5) 1 Approval Prior to shipment

10Pump Suction Elevation Cycle and Position Indication Test Results (3.1.6)


11 Pump Speed Indication Test Results (3.1.8) 1 Approval Prior to shipment

12 Pump Start-Up Test Results (3.1.9) 1 Approval Prior to shipment

13Pump Performance Test Curve and Test Data (see Section 3.1.10)


14 Pump In-Line Dilution Flow Test (3.1.11) 1 Approval Prior to shipment

15 Pump Initial Run-In Test Data (3.1.12) 1 Approval Prior to shipment

16 Pump Challenge Test Data (3.1.13) 1 Approval Prior to shipment

17 Pump Final Run-In Test Data (3.1.14) 1 Approval Prior to shipment

18Pump Periodic Maintenance Procedures and Records (3.1.15)


19Electrical Inspections and Test Results (3.1.16)


20 Electric Winch Control Test Results (3.1.17) 1 Approval Prior to shipment

21 Certification of Conformance 1 Approval Prior to shipment

22 Shipping and Handling Plan (6.4) 1 Approval Prior to shipment

23 Requests for Information (4.1) 1 Approval As needed

6.0 PACKAGING, STORAGE, TRANSPORT AND LOAD HANDLING

6.1 GENERAL

All items shipped are to arrive at the job site in the same condition as when they passed all QA Program inspections and tests.

6.2 PRESERVATION AND PACKAGING

All items shall be dried and cleaned to protect against rust and corrosion. All items shall be protected from dirt, soil, and moisture and packaged for long-term storage in an unprotected outdoor environment. All items shall be boxed or crated, as required to eliminate damage during

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 23 of 24


21

shipping, handling, and storage. Temporary bracing, fixtures, or hardware installed to stabilize furnished items during shipment or handling (excluding packaging materials) shall be tagged or otherwise identified so that it can be removed before installation or operation of the item. Hydraulic line ends shall be sealed and secured to prevent moisture and debris entry into line. Electrical cable ends shall be sealed and secured to prevent moisture entry into cable.

6.3 MARKING

Packages shall be suitably marked on the outside to facilitate identification of the purchase order, the procurement specification, the package contents, and any special handling instructions.

6.4 SHIPPING AND HANDLING

Equipment handling shall be per the drawings and RPP-CALC-63344, “Supernatant and Slurry Pumps – Rigging Analysis”.

All equipment shall be shipped in accordance with the applicable U.S. Department of Transportation standards and in an orientation ready for lifting. Additional handling of the equipment to orient it for lifting is not acceptable. Transport and tie-down instructions and diagrams shall be provided. Lift points shall not be used for transport tie-downs.

The SELLER shall recommend the preferred transportation method and provide protection of the equipment during transit and storage. The SELLER shall submit to the BUYER, for review and approval, a Shipping and Handling Plan that includes assembly preservation, packaging, shipping, off-loading and storage procedures. The storage instructions shall specify required blocking during storage. BUYER approval of the plan is required before packaging and shipment. If a special type of transportation to protect equipment is required, those devices shall be part of the SELLER’s package and identified as special equipment. The Shipping and Handling Plan shall be included with the shipment.

RPP-SPEC-62012 Rev.00 9/25/2019 - 8:38 AM 24 of 24