DOCUMENT RELEASE AND CHANGE FORMANSI/HI 14.6, 2011 Rotodynamic Pumps for Hydraulic Performance...

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-41919 Rev. 01

2. Title:SPECIFICATION FOR RECIRCULATION PUMP P-B-1

3. Project Number: ☒ N/A 4. Design Verification Required:

☐ Yes ☒ No5. USQ Number: ☒ N/A

N/A-3

6. PrHA Number Rev. ☒ N/A

Clearance Review Restriction Type:public

7. Approvals

Title Name Signature DateClearance Review Raymer, Julia R Raymer, Julia R 08/16/2018Design Authority Servin, Mario A Servin, Mario A 08/14/2018Checker Sanders, Karen M Sanders, Karen M 08/07/2018Document Control Approval Hood, Evan Hood, Evan 08/16/2018Originator Servin, Mario A Servin, Mario A 08/13/2018Other Approver Goessmann, Glen E Goessmann, Glen E 08/13/2018Other Approver Scott, Mark A Scott, Mark A 08/15/2018Other Approver Mackey, Tom Mackey, Tom 08/08/2018Other Approver Rambo, Charles L Rambo, Charles L 08/13/2018Other Approver Balint, Gregory G Balint, Gregory G 08/13/2018Quality Assurance Thompson, Tyler J Thompson, Tyler J 08/13/2018Responsible Engineering Manager Smith, Gregory E Smith, Gregory E 08/15/2018USQ Evaluator Wheeler, Ronnie Wheeler, Ronnie 08/15/2018Welding Engineer Berkey, James Berkey, James 08/13/2018

8. Description of Change and Justification

Update to include latest requirements.

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

242-A EVAPORATOR FACILITIES 242A P-B-1P-B-1-M

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. Title

14. Distribution

Name OrganizationBalint, Gregory G COGNIZANT SYSTEM ENGINEERINGBentley, Kenneth 242-A EVAPORATOR ENGINEERINGCastleberry, Jim L TFP PROJECT MANAGEMENTSmith, Gregory E TANK FARM PROJECTS ENGINEERINGTrevino, Johnny M 242-A EVAPORATOR ENGINEERING

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Aug 16, 2018DATE:

A-6002-767 (REV 3)

RPP-SPEC-41919, Rev. 1

Procurement Specification for Recirculation Pump P-B-1

Author Name:

M.A. Servin

Tank Farm Projects EngineeringWashington River Protection Solutions, LLC

Richland, WA 99352U.S. Department of Energy Contract DE-AC27-08RV14800

EDT/ECN: UC:

Cost Center: Charge Code:

B&R Code: Total Pages:

Key Words: P-B-1 Pump, Recirculation Pump, Procurement Specification, 242-A Evaporator

Abstract: This Specification provides the minimum requirements for the design and fabrication of the P-B-1 Pump for use at the 242-A Evaporator, which is located in the 200 East Area of the U.S.Department of Energy’s Hanford Nuclear Waste Site. Construction of the 242-A Evaporator started in 1974 and operation began in 1977. The mission of the 242-A Evaporator is to support environmental restoration and remediation of the Hanford Site by optimizing the 200 Area double-shell tank waste volumes through radioactive liquid waste volume reduction. Volume reduction is accomplished through an evaporation process that uses a conventional forced-circulation, vacuum evaporation system operating at low pressure to concentrate radioactive waste solutions. The P-B-1 pump function is to recirculate withn the evaporator recirculation waste loop.

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.

Release Approval Date Release Stamp

Approved For Public Release

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By Julia Raymer at 8:07 am, Aug 16, 2018

Aug 16, 2018DATE:


Procurement Specification for Recirculation Pump P-B-1

K. Bentley 242-A Evaporator Engineering

M.A. ServinTank Farm Projects EngineeringWashington River Protection Solutions LLC

Date PublishedAugust 2018

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

P.O. Box 850Richland, Washington

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TABLE OF CONTENTS

1.0 SCOPE ............................................................................................................................ 1-1

2.0 APPLICABLE DOCUMENTS..................................................................................... 2-1

2.1 NON-GOVERNMENT DOCUMENTS.............................................................. 2-1

2.2 NON-CODE OF RECORD DOCUMENTS ....................................................... 2-2

2.3 GOVERNMENT DOCUMENTS........................................................................ 2-3

3.0 TECHNICAL REQUIREMENTS ............................................................................... 3-1

3.1 ITEM DEFINITION ............................................................................................ 3-1

3.2 INTERFACE DEFINITION................................................................................ 3-33.2.1 Pump Assembly Interface with 242-A Evaporator .................................. 3-33.2.2 Rotating Assembly Interface with Pump Casing ..................................... 3-33.2.3 Interface Critical Dimensions .................................................................. 3-3

3.3 CHARACTERISTICS ......................................................................................... 3-43.3.1 General Requirements.............................................................................. 3-43.3.2 Fluid Characteristics ................................................................................ 3-43.3.3 Pump Functional Characteristics ............................................................. 3-53.3.4 Pump Physical Characteristics................................................................. 3-53.3.5 Reliability................................................................................................. 3-83.3.6 Maintainability......................................................................................... 3-83.3.7 Environment............................................................................................. 3-8

3.4 DESIGN AND CONSTRUCTION ..................................................................... 3-83.4.1 Seismic Design/Analysis ......................................................................... 3-93.4.2 Rotor Dynamic Analysis.......................................................................... 3-93.4.3 Critical Speed Analysis............................................................................ 3-93.4.4 Pump Assembly Installation and Lifting & Handling Design/Analysis 3-103.4.5 Materials ................................................................................................ 3-113.4.6 Welds / Critical Welds........................................................................... 3-12

3.5 DRAWINGS AND MANUALS........................................................................ 3-12

3.6 FABRICATION/ASSEMBLY PROCESSES ................................................... 3-133.6.1 Cleaning and Painting ............................................................................ 3-133.6.2 Special Tools.......................................................................................... 3-143.6.3 Marking.................................................................................................. 3-15

4.0 QUALITY ASSURANCE REQUIREMENTS............................................................ 4-1

4.1 QUALITY ASSURANCE PROGRAM .............................................................. 4-1

4.2 QUALIFICATIONS ............................................................................................ 4-14.2.1 Welding Personnel and Procedures ......................................................... 4-14.2.2 Welding Inspectors and Procedures......................................................... 4-2

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4.3 INSPECTIONS AND TESTING......................................................................... 4-24.3.1 Weld Inspection and Examination ........................................................... 4-44.3.2 Radiographic Examination of Impeller.................................................... 4-44.3.3 Megger Test ............................................................................................. 4-44.3.4 Pump Motor Driver Testing..................................................................... 4-54.3.5 Hydrostatic Test ....................................................................................... 4-54.3.6 Pre-Pump Run-In Performance Test ........................................................ 4-54.3.7 Pump Run-in Test .................................................................................... 4-64.3.8 Pump Sealing System Leak Inspection.................................................... 4-64.3.9 Post-Pump Run-In Performance Test ...................................................... 4-6

5.0 DOCUMENT SUBMITTAL......................................................................................... 5-1

5.1 APPROVAL OF SUBMITTALS ........................................................................ 5-1

5.2 LIST OF SUBMITTALS..................................................................................... 5-2

6.0 PREPARATION FOR DELIVERY............................................................................. 6-1

6.1 PRESERVATION AND PACKAGING ............................................................. 6-1

6.2 MARKING .......................................................................................................... 6-1

6.3 SHIPPING AND HANDLING............................................................................ 6-1

6.4 TRANSPORTATION.......................................................................................... 6-2

7.0 NOTES............................................................................................................................ 7-1

7.1 LIST OF ACRONYMS ....................................................................................... 7-1

7.2 UNITS.................................................................................................................. 7-2

8.0 APPENDIX A – PUMP CURVE FOR FACILITY PUMP........................................ 8-1

LIST OF FIGURES

Figure 3-1 ASSEMBLY DRAWING OF CURRENT RECIRCULATION PUMP ................... 3-2Figure 8-1 PUMP CURVE FOR P-B-1 PUMP ........................................................................... 8-2

LIST OF TABLES

Table 2-1. Non-Government Code of Record Documents .......................................................... 2-1Table 2-2. Non-Government Non-Code of Record Documents ................................................. 2-2Table 2-3. Government Documents............................................................................................. 2-3Table 3-1. Fluid Properties (Slurry)............................................................................................. 3-4Table 3-2. Pump Performance Characteristics............................................................................. 3-5Table 5-1. Summary of Submittals .............................................................................................. 5-1

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1.0 SCOPE

This Specification provides the minimum requirements for the design and fabrication of the P-B-1 Pump for use at the 242-A Evaporator, which is located in the 200 East Area of the U.S. Department of Energy’s Hanford Nuclear Waste Site. Construction of the 242-A Evaporator started in 1974 and operation began in 1977. The mission of the 242-A Evaporator is to support environmental restoration and remediation of the Hanford Site by optimizing the 200 Area double-shell tank waste volumes through radioactive liquid waste volume reduction. Volume reduction is accomplished through an evaporation process that uses a conventional forced-circulation, vacuum evaporation system operating at low pressure to concentrate radioactive waste solutions.

The 242-A Evaporator has been identified as a critical facility for continued and future Hanford operations. The P-B-1 pump (vertical axial impeller type pump) is an integral component of the 242-A Evaporator, in which the function of P-B-1 pump is to recirculate slurry within the evaporator recirculation waste loop.

For this scope, work includes design, fabrication, assembly, inspection, testing, documentation, packaging, and shipping of a vertical axial impeller type pump designed to interface with the existing 242-A Evaporator. This scope includes the pump rotating assembly (motor-shaft-impeller assembly), remotable gasket, stand, and any custom handling equipment required to maneuver the pump assembly. The intent for replacement pump assembly is to procure a unit on,as much as possible, a “like-for-like” basis to the P-B-1 pump design. The intent is for the Buyerto install the motor-impeller assembly into an existing pump casing installed at the facility.

All requirements in this Specification are applicable to a single pump assembly. Associated Procurement Documentation might specify different quantities or specific requirements for additional pumps to be procured.

Work does not include site services, installation, or operation of equipment. Additionally, work does not include fabrication of the items provided by Buyer (e.g., interfacing connectors) to be installed on the P-B-1 Pump assembly. Government furnished equipment (GFE) include:

Pump Casing (Lawrence Pump Inc. Drawing E25252), Long & Short Alignment Dowel (H-2-57331, “Mechanical Equipment Details Short & Long

Dowels”) Stud & Locking Pin (H-2-57332, “Mechanical EQPT Detail-Stud”) 2”, 3-Way Connector Nozzles (H-2-32447, “Details & Assy. Stainless Steel 2”-3” Way

Conn. Nozzle”) 2”, 3-Way Vertical Connector Nozzle (H-2-32427, “Horizontal and Vertical 3 Way Type 2”

Connector”) Free Nuts, 1-1/4 inch (H-2-52963, “Mechanical Equipment Details – Free Nut”) Lower Electrical Connector (H-2-32401, “Assembly Lower Electrical Equip. Connector”)

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2.0 APPLICABLE DOCUMENTS

2.1 NON-GOVERNMENT DOCUMENTS

The following documents of the exact issue shown in Table 2-1 form a part of this Specificationto the extent specified herein and establish the Code of Record (COR). In the event of a conflict between documents referenced herein and the requirements of this Specification, the Buyer shall be notified to obtain interpretation and clarification. Minimum Design Loads for Buildings and Other Structures, American Society of Civil Soceity, Reston, Virginia.

Table 2-1. Non-Government Code of Record Documents

Industry Consensus Codes And Standards

Document Number Title

ANSI/HI 14.6, 2011 Rotodynamic Pumps for Hydraulic Performance Acceptance Tests, ANSI/Hydraulic Institute (HI), New York, New York.

API 541, 2014 Form-wound Squirrel Cage Induction Motors—375 kW (500 Horsepower) and Larger, American Petroleum Institute (API), NW, Washington, DC.

ASCE 07, 2015 Minimum Design Loads for Buildings and Other Structures, American Society of Civil Society, Reston, Virginia.

ASME B&PVC,Section IX, 2017

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

ASME B31.1, 2016 Power Piping, American Society of Mechanical Engineers, New York, New York.

ASME BTH-1, 2014 Design of Below-the-Hook Lifting Devices, ASME, New York, New York.

ASME B30.20, 2013 Below-the-Hook Lifting Devices, ASME, New York, New York.

ASME NQA-1, 2008w/ 2009a

Quality Assurance Requirements for Nuclear Facility Applications, American Society of Mechanical Engineers, New York, New York.

ASME Y14.1, 2012 Decimal Inch Drawing Sheet Size and Format, American Society of Mechanical Engineers, New York, New York.

ASME Y14.2M, 2008 Line Conventions and Lettering, American Society of Mechanical Engineers, New York, New York.

ASME Y14.3M, 2003 Multi and Sectional View Drawings, American Society of Mechanical Engineers, New York, New York.

ASME Y14.5M, 2009 Dimensioning and Tolerancing, American Society of Mechanical Engineers, New York, New York.

ASME Y14.38, 2007 Abbreviations and Acronyms, American Society of Mechanical Engineers, New York, New York.

ASNT SNT-TC-1A, 2011

Recommended Practice, American Society for Nondestructive Testing (ASNT), Columbus, Ohio.

ASTM E A-890 Standard Specification for Castings, Iron-Chromium-Nickel-Molybdenum Corrosion-Resistant, Duplex (Austenitic/Ferritic) for General ApplicationAmerican Society for Testing and Materials (ASTM International), West Conshohocken, PA.

ASTM E 186 Standard Reference Radiographs for Heavy Walled (2 to 4 1/2 in. Steel Castings) American Society for Testing and Materials (ASTM International), West Conshohocken, Pennsylvania.

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ASTM E 446 Standard Reference Radiographs for Steel Castings up to 2-in, in ThicknessAmerican Society for Testing and Materials (ASTM International), West Conshohocken, Pennsylvania..

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

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

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

IEC 60034-14, 2007 Rotating electrical machines – Part 14: Mechanical vibration of certain machines with shaft heights 56 mm and higher – Measurement, evaluation and limits of vibration severity, International Electrotechnical Commission, Geneva, Switzerland.

IEEE 112, 2017 IEEE Standard Test Procedure for Polyphase Induction Motors and Generators, Institute of Electrical and Electronics Engineers, New York, New York.

ISO 1940-1, 2003 Mechanical Vibration Balance Requirements for Rotors in a Rigid State. International Organization for Standardization, Geneva, Switzerland.

Hydraulic Institute Hydraulic Institute Standards, ANSI/Hydraulic Institute (HI), New York, New York.

NEMA Standard MG-1, 2016

Motors and Generators, National Electrical Manufacturers Association (NEMA), Arlington, Virginia.

NIST Handbook 143,5th Edition, 2007

State Weights and Measures Laboratories Program Handbook, National Institute of Standards and Technology (NIST), Harris, G.L., Gaithersburg, Maryland.

Technical society and technical association Specifications and standards are generally available for reference from libraries or they may be obtained directly from the Technical Society/Association.

2.2 NON-CODE OF RECORD DOCUMENTS

The following documents of the exact issue shown in Table 2-2 are utilized in, or referenced by this document, form a part of this Specification to the extent specified herein but are not considered to be COR documents.

Table 2-2. Non-Government Non-Code of Record Documents


H-2-32427 Horizontal and Vertical 3 Way Type 2” Connector

H-2-99028, Sheet 1-4 Pump Assembly P-B-1

H- 2-52963 Mechanical Equipment Details – Free Nut

H-2-31103, Sheet 1-4 Canyon Impact Wrench PUREX Type

H-2-32447 Details & Assy. Stainless Steel 2”-3” Way Conn. Nozzle

H-2-32401 Assembly Lower Electrical Equip. Connector

H-2-57331 Mechanical Equipment Details Short & Long Dowels

H-2-57332 Mechanical EQPT Detail-Stud

H-2-99046 Lifting Yoke P-B-1 Pump

E-25252 Detail of Casing for 28-in. Vertical impeller pump

TFC-BSM-IRM_DC-C-07 Vendor Processes

TFC-ENG-STD-34 Standard for the Selection of Non-Metallic Materials in Contact with Tank Waste

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2.3 GOVERNMENT DOCUMENTS

Documents listed in Table 2-3 constitute a part of this Specification to the extent specified herein. The most current version of the documents shall be used unless otherwise specified. In the event of conflict between the documents referenced herein and the contents of this Specification, the Buyer shall be notified to obtain interpretation and clarification.

Table 2-3. Government Documents


49 CFR 393, Subpart I Protection Against Shifting and Falling Cargo

DOE-RL-92-36 Hanford Site Hoisting and Rigging Manual

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3.0 TECHNICAL REQUIREMENTS

3.1 ITEM DEFINITION

The P-B-1 pump assembly is a vertical axial flow pump driven by an electrical induction motor. The pump assembly shall conform to Hydraulic Institute Standards, or a proven alternative design, except as modified and supplemented by this Specification. The assembly drawing of the pump currently installed is shown in Figure 3-1. The P-B-1 pump is in a heavily shielded pump room, in which maintenance, installation and removal activities are conducted via remotely operated tools suspended from an overhead 5-ton bridge crane.

The P-B-1 pump assembly consists of a rotating assembly (motor-shaft-impeller assembly)attached via a gasketed and bolted flange joint to the pump casing. The pump casing is a bottom suction, side discharge design and the casing is flanged to 28-inch recirculation pipework. The design of the flanged joint between the rotating assembly and pump casing is such that the pump assembly components can be dismantled, and assembled for maintenance. Current maintenance on the pump is performed by removing the rotating assembly from pump casing, where the rotating assembly is placed on a stand.

The installed pump casing at the facility will be re-used with new rotating assembly. The Buyer will provide a spare pump casing to the Seller for testing purposes.

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Figure 3-1 ASSEMBLY DRAWING OF CURRENT RECIRCULATION PUMP

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BEST AVAILABLE COPY


3-3

3.2 INTERFACE DEFINITION

3.2.1 Pump Assembly Interface with 242-A Evaporator

The P-B-1 pump assembly will be installed on an existing, 28 in. diameter recirculation piping via bolted flange connections. The pump axial impeller extends down the through the pump casing to a profiled section just past the pump discharge (see Figure 3-1). This profiled section will interface with the pump impeller to minimize flow losses in the system.

The P-B-1 pump interfaces with the evaporation recirculation loop, seal water piping, electrical service, vibration monitoring system, and motor grease bearing lines. The pump is lifted using a custom lifting yoke. Mechanical and electrical interfaces are made using specialty mechanical and electrical connectors, which will be supplied by Buyer for pump construction. The interfaces are defined on existing design details. The following interfaces are identified for the pump:

Evaporator Recirculation Waste Loop Interface. Seal Water Interface. Vibration Monitoring System Interface. Electrical Service Interface. Motor Bearing Grease Lines Interface. Lifting Yoke Interface.

NOTE: The original design includes a 2-in, 3-way connector for a motor bearing grease lines, which are no longer used. The pump currently installed at the facility has been refurbished by replacing the lower radial bearing for the pump motor with a sealed bearing and replacing the grease supply lines localized zerk fittings.

3.2.2 Rotating Assembly Interface with Pump Casing

The new P-B-1 pump rotating assembly must be able to be flanged to the existing pump casing at the facility. The pump casing is shown on Lawrence Pumps Inc. Drawing E25252, Shts. 1 and 2.

3.2.3 Interface Critical Dimensions

The new P-B-1 pump will be installed in an existing recirculation loop in which the piping has little tolerance for modification. Therefore, the critical dimensions of the P-B-1 pump are the dimensions that affect the interface points of the pump rotating assembly with the facility which include, but not limited to:

1. The rotating assembly flange dimensions,2. Location of all connections to existing facility utilities including vibration transducer

signals,3. Pump casing and its internal features.4. Lifting bail location.

The Seller is responsible for identifying any modification to the pump that can affect the critical dimensions. The Buyer shall review and approve any of these modifications.

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3.3 CHARACTERISTICS

3.3.1 General Requirements

The P-B-1 pump shall be designed, fabricated, examined, tested, packaged, and shipped inaccordance with, codes and standards, and drawings listed in this Specification. Any deviation from the referenced drawings or codes and standards shall have prior approval from the Buyer. It should be noted that drawing H-2-99028, Sht. 1-4, and the Seller provided Lawrence Pump Inc. Drawings, represent an existing installed pump and shall be used for component type, location and dimensions to ensure interchangeability of the pump assemblies. This Specificationsupersedes any equivalent references found on the drawing. Unless specifically approved by the Buyer, all components, fabricated parts, and assemblies supplied by the Seller shall be fullycompatible with the pump casing furnished by the Buyer.

It is understood that there might be changes to materials, components, construction, applicable design standards and other aspects of pump design and fabrication to the original unit. The Buyer is prepared to consider the incorporation of such differences where this reduces the cost, improves the value or reduces the delivery schedule of the specified pump.

3.3.2 Fluid Characteristics

The pump shall move a radioactive slurry with a range of physical properties listed in Table 3-1.

Table 3-1. Fluid Properties (Slurry)

Waste Property Range

Specific Gravity 1.0 – 1.8

Viscosity, cP 1 - 140

Temperature (flushes/transfers) 110 to 200F

pH range - Normal 7-15

pH range – Acid Flush 1 - 7

Particle Size (Micron) 15 – 1000

Hardness 3 – 5 MOHS Scale

Abrasiveness, Miller Number (ASTM G75-82) < 100

Solids Loading (vol %) 0% - 30% by vol

Sodium Hydroxide 0 – 8.0 M

Sodium Aluminate 0 – 3.0 M

Sodium Nitrate (NaNO3) 0 – 5.0 M

Sodium Nitrate (NaNO2) 0 – 4.43 M

Sodium Carbonate 0 – 2.0 M

Sodium Phosphate 0 – 0.21 M

Water 100 – 30% by weight

Total Organic Constituents 0 – 80 gm/L

NaF (for pH 7 only) 0 – 0.6 M

Ammonia 0 – 0.4 M

NaCl (for pH 7 only) 0 – 0.6 M

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The P-B-1 pump will recirculate a slurry stream that is being evaporated. The process begins by introducing and recirculating water. Then vacuum is applied (to nominally 60 torr) and steam is applied to heat the recirculating fluid to the boiling point. The liquid portion of the tank waste (supernatant) is added continuously to the evaporator/separator system until the slurry is concentrated to a density which provides the required volume reduction. Once the target density is reached, flow to a receiver tank is initiated (via another pump), and the process runs continuously until the source material is exhausted, or processing objectives are met.

When concentrated, the stream being recirculated is a slurry, consisting of a concentrated salt solution with precipitated salts. The precipitated salts are predominantly natroxalate (sodium oxalate), thermonatrite (sodium carbonate), natrophosphate, kogarkoite, and nitratine (sodium nitrate). Small volumes of other salts or insoluble solids are possible.

3.3.3 Pump Functional Characteristics

The P-B-1 pump shall have a stable head/capacity curve that continuously rises from run-out to shut-off. The hydraulic requirements of the pump are detailed in Case 1, shown in Table 3-2. Pump maintenance will be preceded by pumping a decontamination solution described in Case 2. Attachment A provides the pump curve for the current pump.

Table 3-2. Pump Performance Characteristics

Parameter Case 1 Case 2

Media Pumped Slurry per table 3-1 Water

Temperature 200 oF (max) 210 oF

Specific Gravity 1.8 (max) 0.96

pH Normal 7 - 15 7.0

pH Acid Flush 1 - 7 -

Vapor Pressure 12 psia 14.1 psia

Viscosity 10 – 140 cP 0.3 cP

Rated Conditions Case 1 Case 2

Flow 14,000 GPM 16,100 GPM

Total Dynamic Head 21.0 ft. 10.85 ft.

Static Suction Head 26.4 ft. 26.4 ft.

Suction Pressure 3.91 psig 10.22 psig

3.3.4 Pump Physical Characteristics

3.3.4.1 Pump External Physical Characteristics

a) The design pressure in the shaft seal chamber shall be a minimum of 90 psig.

b) The design shall minimize the collection or holdup of waste on the external pump surfaces. The design shall allow for easy wash-down of external surfaces during removal.

c) The pump shall be self-draining with no internal or external traps or pockets which can retain liquid.

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d) The pump assembly shall be a pullout design (e.g. rotating assembly to be removed without removing pump casing). The pump casing, rotating assembly section, the remotely installed gasket, and all services to the pump will be installed and removed by a remotely controlled 5-ton bridge crane and a remotely controlled impact wrench.

e) Provision shall be made for supplying seal water to the pump through a jumper that mates with the Buyer furnished 2-inch and 3-way connector nozzle. See Drawing H-2-32447.

f) Adequate clearance must be maintained around nut retainers for access by remotely operated impact wrench (reference drawing H-2-31103). For this reason, motor diameter must not exceed 36”.

3.3.4.2 Pump Internal Physical Characteristics

a) The pump shall be provided with balanced double silicon carbide mechanical seals, unless specifically agreed otherwise with the Buyer in writing. Five-micron filtered water or process condensate [120 °F, pH 9-11, with up to 0.15 mol/l ammonia (6.8 g/L)] shall be used for shaft seal purge and cooling. Static pressure of the pumped fluid at the pump cover shall be no greater than 10 psig. Seal water pressure shall be between 35 psig and 90 psig.

b) The rotor assembly shall be sized and supported to minimize vibration and promote maximum bearing life.

c) The impeller shall be dynamically balanced in accordance with ISO 1940-1.

d) The pump shall be designed such that there is no significant (first or second, as a minimum) critical speed within 25% (above or below) of operating speed at any operating condition, as verified in the Seller’s calculations.

e) Bearings shall be anti-friction type, 60,000 hour, shielded and mounted in large pre-packed grease chambers, incorporating heavy-duty shaft seals, if needed, to prevent grease from entering the motor. Sealed bearings are preferred, bearings that can be greased routinely are acceptable.

f) Surfaces that will be regularly wetted with the pumped process fluid require special considerations to minimize areas that could trap or hold contamination. Areas of concern include:

Exposed bolt threads, Crevices between pump and seal flanges, Impeller hub area.

3.3.4.3 Pump Motor Characteristics

a) Electric power shall be supplied for the pump through an electrical jumper that includes an upper terminal connector. The Seller is responsible for providing a NEMA 3R motor connection box.

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b) The motor #1 wire leads from the windings shall be spliced to the #4 SA 125 leads in the motor J Box using bolted type connections and encased from there in a flexible carbon steel liquid tight conduit that is connected to the lower electrical connector.

c) Motor horsepower capacity shall not be exceeded when operating at any point on the pump curve, with the fluid specified in Section 3.3.2 of this Specification.

d) The procedures given in IEEE STD. 118 and IEEE STD. 119 should be used when measuring the resistance of the stator winding (and the rotor winding on wound-rotor machines).

e) The motor shall be in accordance with NEMA Standard MG-1, Type/Design B. The motor shall be totally enclosed fan-cooled (TEFC), and shall be 460 V, 3-phase, 60 Hz., operating at 720 rpm rated at 200 HP (electric). The insulation system shall consist of minimum Class H, or better, insulation material.

f) Motor bearings shall be constructed and lubricated to maximize service life. The motor thrust bearing can carry the thrust load of the pump as well as the rotor weight.

g) A vibration monitoring system shall be provided which shall include monitoring in 3 axes (e.g., vertical, horizontal & lateral). Three wire pairs are available for this application. The vibration monitoring transducers communicate with the facility Monitor and Control System (MCS) via 4-20mA signals. Additionally, plug connections, where manual data can be collected, for each vibration sensor are available at the facility. The current design includes the vibration transducers, shown on H-2-99028, Sheet 1, and indicating signal conditioning amplifiers for rack mounting. The vibration monitoring system components shall be in accordance with the following description:

1. Vibration Transducer(s) with matching connector and 8 ft. length of manufacturer's standard pigtail cable assembly shall be installed on the motor. The cable shall be terminated in a NEMA 3R junction box installed on the motor frame.

2. Signal conditioning amplifier for peak to peak (mils) displacement monitoring and indication, with high and low alarms, and internal calibration and controls, in a rack mountable case for Buyer's 120V AC, 60 Hz power supply.

3. The three vibration sensors are required to be located on the motor. These three vibration sensors will be routed from the side of the motor to a junction box that is mounted on the outside of the motor case. From the junction box the vibration sensors will terminate at a 13-point lower electrical connector. Connections to site MCS shall be provided by Buyer. Seller to provide a recommendation ifadditional vibration monitors/signals are needed to adequately monitor the pumps performance. For additional signals, wireless sensors are desired.

4. Vibration spectrum analysis capability is a desired upgrade from original.

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3.3.5 Reliability

To meet reliability requirements, the following concepts shall be used:

a) The operating regime for the P-B-1 pump includes up to 4, short duration campaigns, of approximately two weeks each through a typical year. The recirculation pump shall operate for up to 5,000 hours of intermittent operation over a 10-year period with minimum preventive maintenance, which may include no maintanance.

b) During the intervening periods of downtime restrictions due to radiation prevent personnel access to perform manual maintenance servicing or repair in situ. The pump shall be designed to accommodate this duty.

3.3.6 Maintainability

a) The P-B-1 pump is flanged into a recirculation loop in a high radiation environment that that requires remote operations for maintenance. All design changes that affect maintenance requirements for the pump shall be approved by the Buyer.

b) The pump assembly shall be interchangeable as a complete unit and in component partsfor ease of maintenance.

c) Preventive maintenance provisions to account for layups and long term storage shall be considered by Seller. Seller shall provide a recommendation for such provisions to be approved by Buyer.

3.3.7 Environment

The following are the ambient conditions for which the P-B-1 pump assembly shall be designed:

Temperature, °F: 120

Pressure: Atmospheric

Relative humidity, %: 15 to 90

Radiation Level, R/hr: 300

3.4 DESIGN AND CONSTRUCTION

Hydraulic Institute Standards, or proven alternative design standards, shall be considered an integral part of this Specification, and shall be complied with except as modified or supplemented herein. The pump shall be designed and constructed in accordance with the manufacturer’s standard practices and approved design and fabrication details.

The Seller shall prepare a Pump Design Report that documents the material selection, design, analysis (calc package), component Specification data, electrical product acceptability, drawings for the pump and motor driver, and a 3-dimensional computer aided design solid body model of the pump assembly.

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Following completion of fabrication, assembly and testing, a Final Pump Data Package shall be developed to include Pump Design Report, all testing procedures and results documentation; completed shop travelers, welder qualifications and nondestructive examination (NDE)procedures with NDE personnel qualifications; chemical and physical test reports; inspection/examination reports; updated vendor data and as-built drawings including a finalized 3-dimensional computer aided design solid body model of the pump assembly; installation, operation and maintenance manuals; and spare parts list.

3.4.1 Seismic Design/Analysis

The Seller shall provide a seismic analysis to ensure the pump maintains structural integrity after a seismic event. For the structural analysis the following input requirements and assumptions shall be used:

a. Load combinations, allowable stresses and strength requirements shall comply with the International Building Code (IBC) and American Society of Civil Engineers (ASCE) 7.

b. Design spectral response accelerations applicable:

SDS (short periods) Vertical = 0.346g Horizontal = 0.588g

SD1 (1 second period) Vertical = 0.098g Horizontal = 0.192g

c. IBC Seismic Use Risk Category I/II, Seismic Design Category D, with Importance Factor of 1.0.

d. There is no design requirement that the pump remain functional following a seismic event; however, it is a design requirement that the pump assembly retain its structural integrity and to be removable following such a seismic event.

e. Additional inputs for seismic analysis to be provided by Buyer as needed.

3.4.2 Rotor Dynamic Analysis

The Seller shall provide a rotor dynamic analysis supporting the rotating element design and support features, ensuring minimum vibration and high reliability. This analysis shall be used to verify that there are no damaging responses in the lateral or torsional rotor dynamic modes of vibration at the operating speed of the pump.

3.4.3 Critical Speed Analysis

The Seller shall provide a natural frequency analysis to demonstrate that there is no significant (first or second, as a minimum) critical speed (wet) within 25% (above or below) of the pump assembly operating speed.

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3.4.4 Pump Assembly Installation and Lifting & Handling Design/Analysis

Installation of the pump will be by overhead bridge crane with 5-ton capacity. The rotating assembly of the pump will be lifted in the vertical position using lifting attachments on the assembly and a lifting yoke (H-2-99046). The pump shall be designed to accommodate this handling, and the Seller shall provide rigging and handling instructions.

All crane and rigging shall be in accordance with DOE/RL-92-36 the Hanford Site Hoisting and Rigging Manual, and the Buyer’s procedures. The manufacturer may use the following Specifications for hoisting and rigging or provide lifting instructions proprietary to the manufacturer.

3.4.4.1 Lifting Attachments and Equipment Design

The pump should use the lifting bail design of the current pump configuration. The current design and/or alternative designs for the lifting attachment(s) on the equipment (lifting eyes, lugs, ears, etc.) and the lifted item shall be designed/evaluated in accordance with RPP-8360 except ASME BTH-1 should be used to verify lifting lugs hole diameter compared to the shackle pin diameter (the D to d ratio). The design shall consider equipment orientation, i.e., vertical. Other appropriate design standards may be used with the approval of the Buyer. Hoisting and rigging device or equipment designs, tests, and reports shall be submitted to the Buyer for safety evaluation and approval during design review.

3.4.4.2 Below-the-Hook Lifting Device Requirements

If a below the hook (BTH) lifting device is needed, then the structural and mechanical below the hook lifting devices, as defined by ASME B30.20, Below-the-Hook Lifting Devices, shall conform to the requirements of ASME B30.20. The design of BTH devices shall conform to the requirements of ASME BTH-1, Design of Below- The-Hook Lifting Devices. Load supporting devices not clearly defined as BTH shall be clarified by contacting the Hanford Site Hoisting and Rigging Committee for interpretation.

Documentation and calculations shall be submitted as evidence that the appropriate welding codes, qualified welders, non-destructive examination procedures, testing requirements, etc., have been used. Calculations will be required for the design of all BTH devices and associated lifting points. Below-the-hook lifting devices shall be load tested to 125% of the rated load as required by DOE-RL-92-36. All custom designed Hanford Site lifting devices shall be rated for cold weather temperature of at least 10 °F.

BTH lifting devices shall be provided with markings in accordance with ASME B30.20 and tags in accordance with DOE/RL-92-36. In addition to the requirements of ASME B30.20 and DOE/RL-92- 36, the marking shall include Hanford drawing number (if applicable), special lifting instructions, and clearly indicate lifting attachments. The marking shall be in the form of a name tag, name plate, or other permanent marker.

The above requirements do not apply to the existing BTH shown on drawing H-2-99046.

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3.4.4.3 Pump Lifting and Handling

Lifting instructions and lift diagrams shall be provided. The lift diagram must show estimated weight and center of gravity. The lifted item must be level and plumb when suspended. The design shall consider the pump orientation. All lift points, both permanent and temporary (if necessary), shall be identified on the pump assembly.

The Seller shall provide a lift analysis to ensure the fully assembled pump can be lifted without distortion, damage, or exceeding allowable stresses when using the existing crane and BTH lifter or new BTH lifter. Any temporary attachment points on the pump at a location analyzed to prevent pump damage shall be clearly identified.

The Seller shall detail any special handling requirements in the instruction manual to ensure that the pump assembly can be safely lifted and installed without damage to the pump. The plan shall address righting the pump if shipped horizontally. All drawings and procedures required for pump installation/removal and operation shall be included in the manual for quick reference. All lift/attachment points shall be designated in the Shipping and Handling Plan (See Section 6.3).

The pump assembly should be stored and transported vertically to prevent damage. The Seller shall design and provide a stand to allow the pump rotating assembly to be loaded, and off-loaded from a truck trailer via two methods:

A single crane utilizing the lifting yoke (H-2-99046) or BTH lifting device attached to designated lift points.

Single forklift utilizing designated engagement sleeves built into the stand.

The pump assembly shall be shipped in accordance with the applicable DOT standards. Transport and tie-down instructions and diagrams shall be provided. Lift points shall not be used for transport tie-downs. Transport tie-down points shall be identified on the equipment. Calculations to include requirements of 49 CFR 393, Subpart I, Protection Against Shifting and Falling Cargo, shall be required for the design of all transport tie-down attachment points.

3.4.5 Materials

a) All materials shall be consistent with original material selection of installed pump. Alternative materials must be approved by Buyer. Materials must be selected by the Seller based on acceptable performance when subjected to the environmental exposures described in Sections 3.3.2 and 3.3.3 and, as applicable, must meet the following requirement.

b) Material and components shall be new.

c) All metallic portions of assembly in contact with either the pumped fluid or seal water shall be stainless steel of suitable type and grade for the purpose intended except the impeller shall be ASTM A-890, with supplemental requirement S32 (tensile test). Note previous specifications for impeller material specified ASTME A 744 Grade CD4MCU. Seller to provide recommendation for impeller material to be approved by Buyer.

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d) Material selection shall be identified within the design data for Buyer review, and material certification data shall be submitted prior to shipment for Buyer approval. Material identification shall include the applicable ASTM Specification number and any proposed supplementary feature that is listed as optional in the ASTM Specifications. Material certification shall present the results of chemical analysis and physical tests required in applicable ASTM Specifications.

e) Brass, bronze, and copper base materials, if used, shall not come in contact with the pumped waste fluid. The use of aluminum is not acceptable.

f) The materials of construction shall be chosen to prevent differential thermal expansion of the individual pump components (i.e. shaft) from adversely affecting the performance of the pump over the maximum range of operating temperatures.

g) All major pressure boundary and rotating parts shall be furnished to ASTM material Specifications and shall include Certified Material Test Reports (CMTRs).

h) Materials used for other parts shall be clearly identified on the bill of material as to material type and grade; however, CMTR are not required. Materials shall be non-asbestos, non-absorbent and suitable for the chemical and radiation environment in which they are used. All elastomers used shall comply with TFC-ENG- STD-34, Standard for the Selection of Non-Metallic Materials in Contact with Tank Waste.

3.4.6 Welds / Critical Welds

All critical welds on the equipment shall be identified in the design media. For the purpose of this requirement, critical welds are defined as those welds whose failure could result in loss of load or loss of load control. All critical welds on lifting devices shall be full-penetration welds, if possible, and shall be verified by approved NDE.

3.5 DRAWINGS AND MANUALS

a) As-built, detailed, dimensioned assembly drawings shall be submitted to the Buyer for approval. Drafting shall be done according to applicable ASME Y14 series standards (ASME Y14.1, Y14.2M, Y14.3M, Y14.5M and Y14.38). As-built dimensions shall include the following at a minimum:

1. Distance from the bottom of the pump impeller to the base of the pump flange plate (not including the gasket thickness).

2. Distance from the bottom of the pump flange plate (not including the gasket thickness) to the top of the motor.

3. Distance from the end-face and applicable centerlines of each mechanical connection to a single datum to allow the fabrication of future piping spools.

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b) All component parts shall be listed in the bill of materials, referring to the applicable material Specifications or manufacturer and part number or supplier’s fabrication drawing.

c) A manufacturer’s Installation, Operation and Maintenance (IOM) manual shall be supplied with the pump. Instruction manuals shall contain storage, installation/removal, start-up, operation and maintenance instructions for the pump and all associated equipment. As discussed in Section 3.4.4.3, lifting instructions including lift diagrams shall be included in the IOM manual.

3.6 FABRICATION/ASSEMBLY PROCESSES

a) Welding of pump pressure-containing components or any repairs to such parts shall be performed in accordance with ASME B31.1.

b) Welding of structural members, as well as any repairs to such parts, shall be performed in accordance with the applicable AWS welding standard (i.e. AWS D1.1 for steel or AWS D1.6 for stainless steel) for statically loaded structures, as applicable.

c) Machining or grinding of stainless steel shall be done with tools that have never come in contact with materials other than stainless steel. In addition, the following shall apply:

Wire brushing of stainless steel shall be done using stainless steel brushes that have never been used on materials other than stainless steel.

Grinding wheels shall be resin-bonded aluminum oxide. Rotary files shall be faced with tungsten carbide.

d) Metallic material-handling devices used for machining, positioning, supporting, welding, etc. that come in contact with stainless steel shall be made of stainless steel. It is acceptable to use high-strength carbon steel clamping devices such as machine chuck jaws on stainless steel, provided the Seller has a program or procedure for ensuring that the stainless steel has not been contaminated by the carbon steel. This procedure shall be available at the Seller's facility for the Buyer's review.

e) The finish for structural shapes and plate surfaces shall be mill finish, 125 RMS on cut surfaces and machined surfaces shall be 250 micro inches RMS finish or better to achieve function.

3.6.1 Cleaning and Painting

a) Before delivery to the site, the pump and all associated components shall be cleaned with a cleaning procedure or plan prepared by the Seller and submitted to the Buyer for approval prior to use. Pump and all associated components shall be clean to the extent such that extraneous materials, such as those listed below, are not present.

Metallic or other dusts (shop dust), chips, and turnings Abrasive particles or dirt

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Weld splatter Rust and other loose corrosion products Magnetic/liquid penetrant residues, dye check, etc. Foreign material, such as paper, plastic, wood, tape or tape adhesive Cutting oils Excess lubrication grease and oil Marking dyes

b) Cleaning solutions shall not contain halogenated compounds. Solvents and cleaning solutions used on stainless steel shall not exceed 25 ppm for halides and less than 50 ppm for chlorides.

c) Mechanical cleaning tools used on stainless steel shall not have been previously used on carbon steel or any other materials that would contaminate stainless steel surfaces.

d) Exposed carbon steel components shall be protected with an epoxy paint. Powder coating is an approved alternative to paint, color shall be gray or as specified by the Buyer. Thecolor of free nut retainers and bails shall be yellow, and supports for nozzles and brackets shall be a different color than the motor.

e) Stainless steel components do not require painting except as needed for identification or for targeting. Paint used on stainless steel shall be epoxy-phenolic or Buyer approved alternate.

f) The following areas of the pump shall be painted yellow for targeting.

A 1-1/2-inch band around the top of dowel guides/holes or as space permits. Nozzle kick plate. The top portion of lifting bails.

g) Identification shall be painted on the pump as described in Section 3.6.3.

h) Visual direction indicating disk on top of the motor shall be painted half red and half yellow.

3.6.2 Special Tools

a) Special tools and fixtures required to disassemble, assemble, lift, or maintain the pump or associated components shall be included in the quotation and furnished with delivery of the unit.

b) Each tool shall be labeled to indicate its intended use, with instructions in the manual on its use. Any special tooling required shall be supplied by Seller at a minimum of 2 each.

c) The pump is to be placed, secured, and delivered utilizing an appropriate fixture (stand).

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3.6.3 Marking

a) The pump shall have a manufacturer's name plate with information identified Hydraulic Institute Standards. In addition to the information required by Hydraulic Institute Standards, the name plate shall include the assembly weight (dry and wet), this Specification number and revision, and purchase order number.

b) A stainless steel identification tag shall be attached to the pump. The tag shall show the pump number, P-B-1, the Specification Number and the Customer Purchase Order Number.

c) The pump identification number (serial number) shall be as stated in the procurement documentation. The pump identification number, this Specification number and revision, and the weight of the complete pump assembly and of the rotating assembly, shall bepainted on the motor frame or lifting bails. The numbers/letters shall not be less than 1 in.high block type, black on yellow background. The use of a vinyl decal, minimum 3 mil thickness, is acceptable for identifying only the Specification number/revision and weight.

d) Any temporary lifting attachment points on the pump shall be clearly marked.

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4.0 QUALITY ASSURANCE REQUIREMENTS

4.1 QUALITY ASSURANCE PROGRAM

a) The Seller shall comply with the quality assurance requirements stated in the Procurement Documents.

b) The Seller shall have a Quality Assurance Program (QAP) that establishes quality control.

a) Once the Seller's QAP is approved by the Buyer, any deficiency to the approved contract or QAP must be reported to Buyer for evaluation. Reports shall be in writing and submitted within 24 hours of the identification of the deficiency.

b) The QAP shall apply to all activities, including subcontracted activities and work performed for the Buyer.

4.2 QUALIFICATIONS

4.2.1 Welding Personnel and Procedures

Personnel and procedures for welding pressure-retaining components along with attachments thereto, shall have been qualified in accordance with ASME B31.1, paragraph 127.5 prior to the start of welding. Personnel and procedures for welding structural components shall have been qualified in accordance with the applicable AWS welding standard (i.e. AWS D1.1 for steel or AWS D1.6 for stainless steel) prior to the start of welding (welding qualifications and procedures per ASME B&PVC, Section IX are acceptable).

In lieu of qualification of Welder Procedure Specifications (WPSs), Standard Welding Procedure Specifications (SWPS) developed and controlled by the AWS and accepted in Article V of ASME B&PVC Section IX may be utilized within the specific limitations of ASME B31.1 paragraph 127.5.4. The AWS is considered a responsible and recognized organization and prior approval is not required. If utilized, SWPS shall be demonstrated and documented in accordance with ASME B31.3 and ASME IX (QW-100.1, Article V and Appendix E). Document demonstration tests using Form QW-485 (from ASME B&PVC Section IX) or equivalent form. SWPS shall be demonstrated prior to the start of welding. Documentation tests are considered synonymous with qualification of a WPS in accordance with ASME B&PVC Section IX, QW-100.3 and the current edition and mandatory addenda of ASME B&PVC Section IX shall be used.

A copy of welder performance qualification test results and renewal of qualification documentation shall be maintained at the jobsite for the Buyer's evaluation, if desired. A copy of the Weld Procedure Specifications, Procedure Qualification Records, and Supporting Demonstration Records, as applicable, shall be maintained at the jobsite for the Buyer's evaluation, if desired.

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4.2.2 Welding Inspectors and Procedures

Visual weld examinations shall be performed, and appropriate documentation prepared by Certified Welding Inspectors (CWI) who have received certification in accordance with AWS QC1. Certified Associate Welding Inspectors (CAWI), certified in accordance with AWS QC1, may perform examinations when under immediate direction of Certified Welding Inspectors.

Qualification/certifications of CAWI and CWI under whom the examinations were performed, shall be included in the Pump Final Data Package.

Personnel performing nondestructive examination shall be certified in accordance with Seller's written practice, which shall meet 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 nondestructive examination performance procedures as applicable at the fabrication site for Buyer's evaluation, if desired.

4.3 INSPECTIONS AND TESTING

a) The Seller shall develop a fabrication, inspection, and test plan (FIT plan) that sequences the fabrication operations and denotes the Seller’s inspection and test points. The FIT plan shall be reviewed and approved by the Buyer prior to the start of fabrication. At the time of the review of the FIT, the buyer shall specify all applicable witness and hold points.

b) The Buyer reserves the right to witness all tests listed below and shall be given a minimum of ten working days’ written notice prior to each test date. It should be noted that third party inspectors may be required to be present during testing as the representative for the Buyer or an independent representative for the Buyer’s stakeholders. The following includes the witness/hold points for the Buyer and/or their representative for specific points in the fabrication/testing process:

Welding and NDE of pressure retaining components (Section 4.3.1), Megger Testing (Section 4.3.3), Pump Motor Driver Testing (Section 4.3.4), Hydrostatic pressure testing (Section 4.3.5), Pre-pump run-in performance test (Section 4.3.6), Pump sealing system leak check (Section 4.3.8), Pump run-in test (Section 4.3.7). Only the start and finish of the 24-hr run-in test need

to be witnessed to ensure proper operation of the pump assembly, Post-pump run-in performance test (Section 4.3.9).

Any additional witness/hold points for the Buyer and/or their representatives will be specified during their review and approval of the FIT plan.

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c) Prior to the performance of these tests, the Seller shall submit a procedure for each test to the Buyer for review and approval. Test information recorded or calculated shall be documented and submitted to the Buyer.

d) Inspection/examination of the pump assembly shall be in accordance with applicable Hydraulic Institute Standards, or other appropriate standards.

e) Verification shall be performed all on critical dimensions. The Buyer will provide critical as-built dimensions for the existing design and required tolerances to Seller. The Seller is responsible for verifying the location and dimensions that affect interface points of the P-B-1 Pump (See Section 3.2.3) are in accordance with the Buyer approved fabrication drawings.

f) The Seller shall submit all nonconformance reports (NCRs) that specify “Use-As-Is” or “Repair” to the Buyer with a proposed disposition for approval. Work related to that NCR shall not proceed until the NCR disposition is approved by the Buyer.

g) NDE reports and radiographs shall be traceable to the item examined, include all essential examination parameters, and signed and dated by the NDE examiner. These reports and radiographs shall be submitted for approval by the Buyer prior to shipment of completed items.

h) For measuring and test equipment (M&TE) used in examination/inspections and testing, the Seller shall provide legible, reproducible copies of Certificates of Calibration traceable to the National Institute of Standards and Technology or other documented evidence must be submitted stating the basis of the calibration. This is not required for commercial equipment such as timing instruments, rulers, tape measures, and levels, if such equipment provides the required accuracy.

i) Measurement and Testing Equipment used in the tests shall comply with NIST Handbook 143.

j) A pump casing will be furnished by the Buyer. The spare pump casing will be shipped to the Seller to use for testing purposes. The pump casing is shown on Lawrence Pumps Inc. Drawing E25252, sheets 1 and 2.

k) A vertical 2”, 3-way connector (Drawing H-2-32427, Assembly 2) will be supplied by the Buyer to facilitate the Seller's testing that is required.

l) Final test reports shall be submitted with shipment. Pump tests shall be conducted in accordance with Hydraulic Institute Standards (ANSI/HI 14.6). Data and test results shall be obtained and presented as outlined in the standards.

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4.3.1 Weld Inspection and Examination

Piping and containment welds, joints, and attachments thereto shall be examined in accordance with ASME B31.1, paragraph 341.4.1 for normal service. Volumetric examination [radiographic test (RT) or ultrasonic test (UT)] of welds where specified by ASME B31.1 shall be performed where possible (i.e., in-process examination shall not be specified). 100% of RT of pipe butt welds, with the exception of grease lines, per ASME B31.1 shall be performed.

Inspection and examination of structural welds shall be performed in accordance with the applicable AWS welding standard (i.e. AWS D1.1 for steel or AWS D1.6 for stainless steel). Welding qualifications and procedures per ASME B&PVC, Section IX, are acceptable. In accordance with original drawings, 100% liquid penetrant testing on structural welds root and cover passes per applicable AWS standard shall be performed.

All welds shall be visually inspected as a minimum. The seller shall perform 100% visual examination of all root and cover welds for the pump and pipe pressure containment welds. Weld maps shall be prepared and submitted. Non-destructive examinations, including Visual, Penetrant Test, Radiographic Testing, or Magnetic Particle Test examinations, shall be recorded and submitted. Radiographic Testing film shall be included as part weld documentation submittal if Radiographic Testing was performed.

4.3.2 Radiographic Examination of Impeller

The finished propeller shall be given a 100% X-ray examination per ASTM E 446 and E 186 as determined by the thickness of the material examined. The classifications from which to determine the radiographic standards to be used for evaluation of defects shall be:

Under ASTM E 446 Under ASTM E 186

Category Severity Level Category Severity Level

A 5 A 4

B 5 B 4

C 5 All types C 4 All types

D 1 D 1

E 1 E 1

F 1 F 1

G 1

4.3.3 Megger Test

A megger test shall be conducted on the pump motor. Prior to the megger test perform a continuity check between the phases to ensure no shorts exist. The megger test shall be

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conducted between each phase and the ground individually. The acceptable value is greater than or equal to the values MG-1. Measured megger resistances shall be recorded. Resistance measurements shall be corrected for temperature and documented in the test results.

4.3.4 Pump Motor Driver Testing

The motor shall be given the following testing listed below to demonstrate that it is free from mechanical and electrical defects. The testing shall be conducted in accordance with ANSI/IEEE Standard 112.

This testing shall include:

Typical tests on completed assembly motors per NEMA MG-1, Section 12.55. ANSI/IEEE Standard 112, Method B, dynamometer test ANSI/IEEE Standard 112, Locked rotor tests Vibration Tests: For vibration refer to NEMA MG 1 Part 7, IEC 60034-14 [B4], API 541

[B2], or other specified standards as applicable. Vibration displacement, measured at the outer edge of the mounting flange, shall not exceed 0.002 inch under any stable operating condition of the pump.

Test voltage: The commonly specified AC high-potential test voltage for factory testing of new stators is 1000 V plus two times the rated voltage of the machine.

Speed-torque and speed-current curves: The speed-torque characteristic is the relationship between torque and speed, embracing the range from zero to synchronous speed for a motor and from synchronous speed to pull-out speed for an induction generator. This relation, when expressed as a curve, will include maximum (breakdown), pull up or pull out, and locked-rotor torques. A speed-torque and speed-current curve test shall be performed using whichever method the supplier choses.

4.3.5 Hydrostatic Test

a) The pump casing, with rotating assembly installed, shall be hydrostatically tested at a pressure of 50 psig. There shall be no drop in pressure when under test for 4 hours.

b) Water used for hydrostatic and performance testing shall be tested for chlorides if austenitic stainless steel wetted materials are present. The chloride content of the test medium shall not exceed 50 ppm for water temperatures of < 149 °F.

c) A test certification shall be provided with final data submittals.

4.3.6 Pre-Pump Run-In Performance Test

A performance test, performed prior to the pump run-in test, shall be conducted using the fully assembled pump in accordance with Hydraulic Institute Standards (ANSI/HI 14.6). The performance test shall obtain sufficient data points, including rated performance point and run-out, to plot a full performance curve at the rated speed. The following shall be recorded and/or calculated:

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Flow rate Total head Power input Pump efficiency Actual speed (rpm) Motor amperage and voltage (one each phase) Pump Vibration Liquid level.

Following pump testing, the Seller shall prepare a certified correct pump curve reflecting pump performance at the discharge nozzle with water. Information shall include impeller type and size, head/flow curve, and estimates of horsepower @ maximum specific gravity, efficiency, and NPSHR. Information shall include high- and low-end allowable operating regions and any limitations of operation.

4.3.7 Pump Run-in Test

A run-in test shall be performed on the fully assembled pump. The run-in test shall be performed in compliance with Hydraulic Institute Standards, and be conducted for a minimum of 24 hours of continuous operation, with the pump operating at the rated performance point. As a minimum, the following readings shall be determined and recorded every 30 minutes during the test: Flow rate, total dynamic head, NPSH, power input, actual speed (rpm), motor amperage and voltage (on each phase), pump vibration, and liquid level.

4.3.8 Pump Sealing System Leak Inspection

The pump shaft sealing systems shall be inspected for operation and any leakage of the pumped fluid into the barrier fluid. No observable leakage from the main shaft cartridge seal shall be permitted. mechanical seal and assembled seal water supply lines shall be leak tight to 135 psig.

Leak test for the remotable gasket shall be performed at 14 psig. See H-2-99028, Sht. 3, note 4 for details.

4.3.9 Post-Pump Run-In Performance Test

A performance test, performed after to the pump run-in test, shall be conducted using the fully assembled pump. The intention of this test is to validate that the pump run-in has not degraded the performance of the pump. The performance test shall obtain sufficient data points, including rated performance point and run- out, to plot a full performance curve at the rated speed. The following shall be recorded and/or calculated: Flow rate, total head, power input, pump efficiency, actual speed (rpm), motor amperage and voltage (one each phase), and liquid level.

Following pump testing, the Seller shall prepare a certified correct pump curve reflecting pump performance at the discharge nozzle with water. Information shall include impeller type and size, number of stages, head/flow curve, and estimates of bhp @ maximum specific gravity, efficiency, and NPSHR. Information shall include high- and low-end allowable operating regions and any limitations of operation.

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5.0 DOCUMENT SUBMITTAL

Required submittals are identified and listed on the procurement Master Submittal Register (MSR). Table 5-1 provides a summary of these submittals. The MSR identifies the minimum submittals required by this Specification and identifies 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 in accordance with the Subcontractor’s Quality Assurance procedures. The Subcontractor shall attest, in writing, to the accuracy and completeness of the information contained in the final deliverables.

Deliverables shall be subject to approval by the BTR. Deliverables shall comply with this Specification and technical basis documents and other requirements identified herein.

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

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


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Table 5-1. Summary of Submittals

Item Title Purpose When required

1 Schedule Pre Evaluation With Proposal

2 Proposal Data Pre Evaluation With Proposal

3 Quality Assurance Program Certification Approval With Proposal

4 Pump Design Report Approval Prior to Fabrication

5 Fabrication, Inspection, and Test Plan Approval Prior to Fabrication

6 Welder Performance Qualifications Approval Prior to Fabrication

7 WPSs, PQRs, SWPSs, and SWPS Demonstration Records Approval Prior to Fabrication

8 CWI and CAWI Certifications Approval Prior to Fabrication

9 NDE Personnel Certification Records Approval Prior to Fabrication

10 Test Procedures Approval Prior to Testing

11 Certified Test Data and Reports Approval Prior to Shipment

12 Inspections and Examination Results Approval Prior to Shipment

13 Radiography Film & Associated Reader Sheets. Approval Prior to Shipment

14 Certificate of Conformance and Suspect Counterfeit Items Statement

Approval Prior to Shipment

15 Installation, Operation, and Maintenance Manuals Review/Information Prior to Shipment

16 Preservation, Packaging, Shipping, Storage and Lifting Plan


17 Nonconformance reports, if applicable Approval Prior to Shipment

18 Final Pump Data Package with As-Builts and Spare Parts List


5.1 APPROVAL OF SUBMITTALS

All submittals transmitted shall include the designation in the Master Submittal Register (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

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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.

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. Eachdeliverable (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

This list of submittals along with relevant dates shall be kept as part of the MSR.

Identify each submittal by the purchase order number and Seller’s identification number.

1. Schedule.

a. Design/Fabrication Schedule: Submit a schedule showing design, fabrication, assembly, testing and shipment of the equipment after receipt of the order.

2. Proposal Data

a. Work Plan: Submit a work plan showing design & fabrication approach.

3. Quality Assurance Program Certification

4. Pump Design Report. At a minimum, the following information shall be included in the Pump Design Report:

a. Pump Performance Data: Information shall include impeller type and size, predicted head/flow curve, and estimates of bhp @ maximum specific gravity, efficiency, and NPSHR. Information shall include high- and low-end allowable operating regions and any limitations of operation.

b. 3-dimensional computer aided design solid body model of the pump.

c. General arrangement drawing(s): Detailed, dimensioned drawings, including bill of materials, with Specification information.

d. Motor Driver Data, including certified driver outline and dimensional drawings.

e. Cross-Sectional/Outline Drawing(s)

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f. Electrical and instrumentation wiring diagrams, elementaries, and instrumentation data sheets.

g. Seismic Analysis (See Section 3.4.1).

h. Rotor Dynamic Analysis (See Section 3.4.2).

i. Critical Speed Analysis (See Section 3.4.3).

j. Lifting Analysis (See Section 3.4.4).

k. Transportation Calculations (See Section 3.4.4.3).

5. Fabrication, Inspection, and Test Plan which include Welds Maps.

6. Welder Performance Qualifications.

7. Certified Weld Inspector Certifications including current Eye Test.

8. Welding Procedure Specifications and Applicable Procedure Qualification Records.

9. NDE Personnel Certification Records including current Eye Test.

10. Test Procedures. The following information shall be submitted:

a. Megger Test (See Section 3.4.3).

b. Pump Motor Driver Testing (See Section 3.4.4).

c. Hydrostatic Testing (See Section 3.4.5).

d. Pre-Pump Run-in Performance Test (See Section 3.4.6),

e. Pump Run-in Test (See Section 3.4.7).

f. Pump Sealing System Leak Inspection (See Section 3.4.8).

g. Post-Pump Run-in Performance Test (See Section 3.4.9).

11. Certified Test Data and Reports. The test data and reports shall be submitted. Once approved, the test results shall become part of the Final Pump Data Package:

a. Megger Test Results (See Section 3.4.3).

b. Pump Motor Driver Test Results (See Section 3.4.4).

c. Hydrostatic Test Results (See Section 3.4.5).

d. Pre-Pump Run-in Performance Test Results (See Section 3.4.6),

e. Pump Run-in Test Results (See Section 3.4.7).

f. Pump Sealing System Leak Inspection Results (See Section 3.4.8).

g. Post-Pump Run-in Performance Test Results (See Section 3.4.9).

h. Certified Material Test Reports.

12. Inspection and Examination Results, including:

a. Weld Inspection and Examination Results (See Section 4.3.1). See submittal 13 for Radiography Film & Associated Reader Sheets.

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b. M&TE Calibration Reports.

13. Radiography Film & Associated Reader Sheets. A copy of all RT film associated with this procurement shall be sent to Buyer.

14. Certificate of Conformance and Suspect Counterfeit Items Statement

15. Installation, Operation, and Maintenance Manuals

16. Preservation, Packaging, Shipping, Storage and Lifting Plan.

17. Nonconformance Reports, if applicable.

18. Final Pump Data Package, including approved Items 3 through 17, shall include thecomplete documentation and record of P-B-1 Pump. Final Pump Data Package shall include:

a. Final detailed, dimensioned drawings, including bill of materials with Specification information, with all redlines incorporated.

b. 3-dimensional computer aided design solid body model of the pump.

c. Completed FIT Plans.

d. Critical dimension verification.

e. NDE Records/Reports.

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6.0 PREPARATION FOR DELIVERY

6.1 PRESERVATION AND PACKAGING

a) All items shall be dried and cleaned to protect against rust and corrosion.

b) All items shall be protected from dirt, soil, and moisture and packaged for long-term storage in a Level B storage facility (indoors/temperature controlled) as defined by ASME NQA-1-2008 with 2009 Addenda, Quality Assurance Requirements for Nuclear Facility Application.

c) All items shall be packaged, as required, to eliminate damage during 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. Electrical cable ends shall be sealed and secured to prevent moisture entry into cable.

6.2 MARKING

Prior to shipment, all packages shall be clearly and suitably tagged to identify, at a minimum:

The Buyer’s name with destination address The Seller’s name with return address Package numbers showing the Purchase Order Number followed by the packagenumber

and the total number of packages Procurement Specification Number Package contents description Weight of package Center of gravity Parts list (for each package) Handling instructions (e.g., Fragile, Center of Gravity, Keep Dry, This Side Up, Sling

Here, Do Not Freeze) and stacking limitations, as appropriate Special Handling instructions.

6.3 SHIPPING AND HANDLING

The Seller shall submit to the Buyer for review and approval of a Shipping and Handling Plan that includes pump assembly preservation, packaging, shipping, storage, and lifting procedures. 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 entire pump shipping assembly shall be protected by a 3/8 inch, minimum, wall box covering of exterior grade plywood with adequate framing to provide protection for the pump.

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The wrapped and sealed components shall be boxed or crated in a manner to prevent damage during shipment and to permit handling by forklift or hoist while in storage or during installation.

The boxed or crated components shall be blocked and securely fastened to prevent shifting, crushing, or bumping during handling.

All packages shall be suitably marked on the outside to facilitate identification on the purchase order, the package contents, and any special handling instructions. Procedures for marking for shipment shall be included in the Seller's packing plan.

The pump and seal water system shall be protected from freezing during shipment.

Material not shipped in a weatherproof vehicle shall be protected from weather by a second sealed envelope or in a manner acceptable to the Buyer. Shipping procedures shall define the method of protecting components from the weather.

Shipping dunnage, tie-downs, etc., shall be such that the system components cannot be damaged or unduly stressed in any manner from carrier vibration or acceleration-deceleration.

6.4 TRANSPORTATION

The Seller shall be responsible for delivery of the pump to the Hanford on-site storage warehouse to be off-loaded. The Buyer shall be responsible for off-loading of the pumps utilizing the stand designated lifting points provided by the Seller (See Section 3.4.4). The Seller shall recommend the preferred transportation method and provide protection of the equipment during transit. The Seller shall be responsible for all equipment damage which occurs as a result of improper transportation. All components, unless specified otherwise in this section or related sections, shall be compatible with being transported by public roadway to the contract specified destination unless otherwise specified or allowed by equipment specific design documents. Items shall either be self-supporting or provided with packing and dunnage so as to ensure their stability and protection from damage.

The Seller shall provide instructions and diagrams for securing all shipping packages. Transportation tie-down points shall be identified on the equipment. Lift points shall not be used for tie-downs. Calculations will be required for the design of all transport tie-down attachment points (if applicable). Equipment shall be packaged, supported, and secured to the transport vehicle in a manner so it can withstand a 0.8g (forward) hard-braking stop, and rearward or lateral acceleration of 0.5g, as well as, shock and vibration loads associated with transportation. Calculations demonstrating compliance with these requirements shall be provided.

All equipment shall be shipped in accordance with the applicable Department of Transportation standards and in an orientation ready for lifting. Additional handling of the equipment to orientate it for lifting is not acceptable. Load handling instructions shall also be provided with the shipment and made available for the off-loading of the item.

Offloading at The Buyer’s designated delivery site will be performed by the Buyer or a Buyer-designated representative.

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7.0 NOTES

7.1 LIST OF ACRONYMS

ANSI American National Standards InstituteAPI American Petroleum InstituteASCE American Society of Civil EngineersASME American Society of Mechanical EngineersASNT American Society of for Nondestructive TestingASTM American Society for Testing and MaterialsAWS American Welding SocietyBTH below-the-hookCAWI Certified Associate Welding InspectorGFE government furnished equipmentCFR Code of Federal RegulationsCMTR Certified Material Test Reports COR Code of RecordCWI Certified Weld InspectorDOT Department of TransportationFIT fabrication, inspection, and test planHI Hydraulic InstituteIEEE Institute of Electrical and Electronics EngineersIOM Installation, Operation and MaintenanceISO International Organization for StandardizationNCR nonconformance reportsNDE nondestructive examinationNEMA National Electrical Manufacturers AssociationNIST National Institute of Standards and TechnologyNPSH net positive suction headM&TE measuring and test equipmentMSC monitor and control system MSR master submittal reportQAP quality assurance planRT Radiographic examinationSWPS Standard Welder Procedure SpecificationsTEFC totally-enclosed, fan cooledTOC tank operations contractorUT ultrasonic methods for weld testingWPS Welding Procedure Specifications

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7.2 UNITS

“ inch°F degrees Fahrenheit cP centipoiseft. foot or feetg gravityg/L or gm/L gram per litergpm gallon per minuteHP horsepowerHz hertzM molarmol/l moles per literppm parts per millionpsia pounds per square inch absolutepsig pounds per square inch gaugeR/hr Rad/hourrpm rotations per minuteV voltsVol % volume percent

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8.0 APPENDIX A – PUMP CURVE FOR FACILITY PUMP

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Figure 8-1 PUMP CURVE FOR P-B-1 PUMP

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DOCUMENT RELEASE AND CHANGE FORMANSI/HI 14.6, 2011 Rotodynamic Pumps for Hydraulic Performance...

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