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AREVA Federal Services LLC Title: KW Basin Annex Modifications HEPA Filter Housings and Exhaust

Fans Technical Specifications

Document No: 44577-SPEC-M-003 Rev. No: A Page 2 of 402

Project No: 01949.03.P001.48 Project Name: Modified KW Annex Design

REVISION HISTORY

REV. CHANGES

A Preliminary Design.





TABLE OF CONTENTS

1.0 INTRODUCTION ............................................................................................................... 5

2.0 PURPOSE ......................................................................................................................... 5

3.0 REFERENCE DOCUMENTS ............................................................................................ 5

4.0 SCOPE OF SUPPLY ...................................................................................................... 11

5.0 GENERAL PARAMETERS AND SPECIFICATIONS ..................................................... 12

6.0 COMPONENT FEATURES ............................................................................................ 136.1 HEPA Filter Housings .......................................................................................... 136.2 Exhaust Fans ...................................................................................................... 206.3 Dampers .............................................................................................................. 246.4 Backdraft Dampers (ECRT-BDD-501 and ECRT-BDD-503) ............................... 266.5 Duct Spool Piece ................................................................................................. 276.6 Flexible Connections ........................................................................................... 286.7 Vibration Mounts ................................................................................................. 286.8 Fasteners ............................................................................................................ 286.9 Structural Supports .............................................................................................. 296.10 Instrumentation .................................................................................................... 306.11 Protective Coatings ............................................................................................. 316.12 Test Filters ........................................................................................................... 32

7.0 DESIGN and FABRICATION ......................................................................................... 337.1 Industry and Government Standards .................................................................. 337.2 Basic Units of Measurement ............................................................................... 337.3 Calculations ......................................................................................................... 337.4 Drawings ............................................................................................................. 347.5 Human Engineering ............................................................................................. 357.6 Cleanliness and Foreign Material Exclusion........................................................ 377.7 Identification and Marking ................................................................................... 387.8 Document Submittal (Vendor Information) .......................................................... 38

8.0 QUALITY ASSURANCE ................................................................................................. 458.1 General ................................................................................................................ 458.2 Responsibility for Calculations............................................................................. 468.3 Commercial Grade Item Dedication .................................................................... 478.4 Welding ............................................................................................................... 478.5 Personnel and Training ....................................................................................... 538.6 Parts/Materials/Processes ................................................................................... 548.7 Nameplates ......................................................................................................... 568.8 Responsibility for Verification .............................................................................. 578.9 Inspections and Tests ......................................................................................... 578.10 Hold, Witness, and Observation Points ............................................................... 588.11 Source Quality Control ........................................................................................ 59





8.12 Qualification ......................................................................................................... 64

9.0 PREPARATION FOR DELIVERY................................................................................... 679.1 Packaging and Shipping Plan ............................................................................. 679.2 Preservation and Packaging ............................................................................... 679.3 Packing ................................................................................................................ 679.4 Marking ................................................................................................................ 689.5 Handling .............................................................................................................. 689.6 Shipping .............................................................................................................. 68

10.0 NOTES ............................................................................................................................ 6810.1 Definitions ............................................................................................................ 6810.2 Records Maintenance, Control, and Disposition ................................................. 69

11.0 APPENDICES ................................................................................................................. 71A. Drawings ............................................................................................................. 72B. STP-ECRTS Exhaust Ventilation Equipment ASME AG-1a-2009

Compliance Matrix Plan ...................................................................................... 78C. ASME AG-1 Compliance Matrix (Example) ....................................................... 278D. Master Equipment List Preferred Format .......................................................... 384E. Design Requirements Compliance Matrix (DRCM) ........................................... 386




Project No: 01949.03.P001.48 Project Name: Modified KW Annex Design 1.0 INTRODUCTION

A pair of high-efficiency particulate air (HEPA)-filtered exhaust trains are required in the K West Modified Annex (hereafter referred to as KW Annex) to provide redundant HEPA-filtered exhaust. The required design consists of two trains, each containing a 3-high by 1-wide double-HEPA filter bank, complete with prefilter section, aerosol test sections, inlet plenum, discharge plenum, isolation valves, flexible connections, exhaust fan, and backdraft damper. The HEPA-filtered exhaust trains will be located inside the HEPA filter room in the KW Annex. The HEPA-filtered exhaust trains will be designed, fabricated, inspected, and tested in accordance with the requirements of the Code on Nuclear Air and Gas Treatment (ASME1 AG-1a). The KW Annex facility is located near the Columbia River on the northern part of the Hanford Site in Richland, Washington. The discharge from the exhaust fans will interface with the stack breaching, which will be by others.

2.0 PURPOSE

The purpose of this technical specification is to provide the minimum functional, performance, and code requirements allowing prospective Sellers to bid the design, fabrication, inspection, testing, and delivery of the required HEPA-filtered exhaust trains.

3.0 REFERENCE DOCUMENTS

1. 10 CFR 50 (Appendix B), Quality Assurance Criteria for Nuclear Power Plants and Fuel Reprocessing Plants, Code of Federal Regulations, as amended.

2. 10 CFR 830.122, Nuclear Safety Management, Quality Assurance Criteria, Code of Federal Regulations, as amended.

3. 29 CFR 1910, Occupational Safety and Health Standards Code of Federal Regulations, as amended.

4. ABMA 9, Load Ratings and Fatigue Life for Ball Bearings, Anti-Friction Bearing Manufacturers Association, Incorporated, Washington, D.C.

5. ABMA 11, Load Ratings and Fatigue Life for Roller Bearings, Anti-Friction Bearing Manufacturers Association, Incorporated, Washington, D.C.

6. AISC2 325-11, Steel Construction Manual, Fourteenth Edition, American Institute of Steel Construction, Inc, Chicago, Illinois.

1 ASME is a registered trademark of the American Society of Mechanical Engineers. 2 AISC is a registered trademark of American Institute of Steel Construction, Inc.





7. AMCA Standard 99, Standards Handbook, Air Movement and Control Association International, Inc., Arlington Heights, Illinois.

a. 99-0401, Classifications for Spark Resistant Construction. b. 99-2404, Drive Arrangement for Centrifugal Fans. c. 99-2406, Designations for Rotation and Discharge of Centrifugal Fans.

8. AMCA Standard 204, Balance Quality and Vibration Levels for Fans, Air Movement and Control Association International, Inc., Arlington Heights, Illinois.

9. AMCA 210, Laboratory Methods of Testing Fans for Certified Aerodynamic Performance Rating, Air Movement and Control Association International, Inc., Arlington Heights, Illinois.

10. AMCA 211, Certified Ratings Program Product Rating Manual for Fan Air Performance, Air Movement and Control Association International, Inc., Arlington Heights, Illinois.

11. AMCA Standard 300, Reverberant Room Method of Sound Testing of Fans, Air Movement and Control Association International, Inc., Arlington Heights, Illinois.

12. AMCA Standard 301, Methods for Calculating Fan Sound Ratings from Laboratory Test Data, Air Movement and Control Association International, Inc., Arlington Heights, Illinois.

13. AMCA Standard 500-D, Laboratory Methods of Testing Dampers for Ratings, Air Movement and Control Association International, Inc., Arlington Heights, Illinois.

14. ASCE 7-053, Minimum Design Loads for Buildings and Other Structures, American Society of Civil Engineers, Reston, Virginia.

15. ASHRAE4 Standard 52.2, Method of Testing General Ventilation Air-Cleaning Devices for Removal Efficiency by Particle Size, American Society of Heating, Refrigerating, and Air Conditioning Engineers, Inc., Atlanta, Georgia.

16. ASME AG-1, Code on Nuclear Air and Gas Treatment, American Society of Mechanical Engineers, New York, New York.

17. ASME AG-1a, Addenda to Code on Nuclear Air and Gas Treatment, American Society of Mechanical Engineers, New York, New York.

3 ASCE is a registered trademark of the American Society of Civil Engineers. 4 ASHRAE is a registered trademark of the American Society of Heating, Refrigerating, and Air Conditioning Engineers, Inc.





18. ASME B&PV Code, ASME Boiler and Pressure Vessel Code, American Society of Mechanical Engineers, New York, New York.

a. Section II, Materials. b. Section III, Rules for Construction of Nuclear Facility Components. c. Section V, Nondestructive Examination. d. Section IX, Welding and Brazing Qualifications.

19. ASME B18.2.1, Square, Hex, Heavy Hex, and Askew Head Bolts and Hex, Heavy Hex, Hex Flange, Lobed Head, and Lag Screws (Inch Series), American Society of Mechanical Engineers, New York, New York.

20. ASME B18.2.2, Nuts for General Applications: Machine Screw Nuts, Hex, Square, Hex Flange, and Coupling Nuts (Inch Series), American Society of Mechanical Engineers, New York, New York.

21. ASME B30.20, Below-the-Hook Lifting Devices, American Society of Mechanical Engineers, New York, New York.

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

23. ASME B31.3, Process Piping, American Society of Mechanical Engineers, New York, New York.

24. ASME BTH-1, Design of Below-the-Hook Lifting Devices, American Society of Mechanical Engineers, New York, New York.

25. ASME N509, Nuclear Power Plant Air-Cleaning Units and Components, American Society of Mechanical Engineers, New York, New York.

26. ASME N510, Testing of Nuclear Air Treatment Systems, American Society of Mechanical Engineers, New York, New York.

27. ASME NQA-1-2008, Quality Assurance Requirements for Nuclear Facility Applications, American Society of Mechanical Engineers, New York, New York.

28. ASNT-TC-1A, Recommended Practice for Personnel Qualification and Certification in Nondestructive Testing, American Society of Nondestructive Testing, Columbus, Ohio.

29. ASQ5 Q9000-2005, Quality Management Systems Fundamentals and Vocabulary, Third Edition, American Society for Quality, Milwaukee, Wisconsin.

5 ASQ is a registered trademark of the American Society for Quality.





30. ASQC E4, Specifications and Guidelines for Quality Systems for Environmental Data Collection and Environmental Technology Programs, American Society for Quality, Milwaukee, Wisconsin.

31. ASTM6 A 36/A 36M, Standard Specification for Carbon Structural Steel, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

32. ASTM A 53/A 53M, Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

33. ASTM A 106/A 106M, Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service, American Society for Testing and Materials, West Conshohocken, Pennsylvania.

34. ASTM A 182/A 182M, Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

35. ASTM A 193/A 193M, Standard Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

36. ASTM A 194/A 194M, Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure or High Temperature Service, or Both, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

37. ASTM A 240/A 240M, Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and General Applications, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

38. ASTM A 269, Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

39. ASTM A 276, Standard Specification for Stainless Steel Bars and Shapes, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

40. ASTM A 307, Standard Specification for Carbon Steel Bolts and Studs, 60,000 PSI Tensile Strength, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

6 ASTM is a registered trademark of the American Society for Testing and Materials.





41. ASTM A 312/A 312M, Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

42. ASTM A 320/A 320M, Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for Low-Temperature Service, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

43. ASTM A 325, Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 Ksi Minimum Tensile Strength, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

44. ASTM A 354, Standard Specification for Quenched and Tempered Alloy Steel Bolts, Studs, and Other Externally Threaded Fasteners, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

45. ASTM A 403/A 403M, Standard Specification for Wrought Austenitic Stainless Steel Piping Fittings, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

46. ASTM A 490, Standard Specification for Structural Bolts, Alloy Steel, Heat Treated, 150 ksi Minimum Tensile Strength, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

47. ASTM A 500/A 500M, Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

48. ASTM A 563a, Standard Specification for Carbon and Alloy Steel Nuts, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

49. ASTM A 992/A 992M, Standard Specification for Structural Steel Shapes, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

50. ASTM F 436, Standard Specification for Hardened Steel Washers, American Society of Testing and Materials, West Conshohocken, Pennsylvania.

51. AWS7 B2.1/B2.1M-BMG, Base Metal Grouping for Welding Procedure and Performance Qualification, American Welding Society, Miami, Florida.

52. AWS D1.1/D1.1M, Structural Welding Code Steel, American Welding Society, Miami, Florida.

53. AWS D1.3/D1.3M, Structural Welding Code Sheet Steel, American Welding Society, Miami, Florida.

7 AWS is a registered trademark of the American Welding Society.





54. AWS D1.6/D1.6M, Structural Welding CodeStainless Steel, American Welding Society, Miami, Florida.

55. AWS D1.9/D1.9M, Sheet Metal Welding Code, American Welding Society, Miami, Florida.

56. AWS QC1, Standard for AWS Certification of Welding Inspectors, American Welding Society, Miami, Florida.

57. CHPRC-00263, Off-Site Vendor Instructions for Preparation and Control of Engineering Drawings, CH2M HILL Plateau Remediation Company, Richland, Washington.

58. DOE G 414.1-3, Suspect/Counterfeit Items Guide for Use with 10 CFR 830 Subpart A, Quality Assurance Requirements, and DOE 0 414.IB, Quality Assurance, U.S. Department of Energy, Office of Environment, Safety and Health, Washington, D.C.

59. DOE O 414.1C, Quality Assurance, U.S. Department of Energy, Washington, D.C.

60. DOE/RL-92-36, Hanford Site Hoisting and Rigging Manual, U.S. Department of Energy, Richland, Washington.

61. DOE-STD-1189-2008, Integration of Safety into the Design Process, U.S. Department of Energy, Washington, D.C.

62. IBC8, 2006 International Building Code, International Code Council, Inc., Whittier, California.

63. MIL-STD-889B, Dissimilar Metals, U.S. Department of Defense, Washington, D.C.

64. NCIG-01, Visual Weld Acceptance Criteria for Structural Welding at Nuclear Power Plants, Nuclear Construction Issues Group, St. Louis, Missouri.

65. NCSL Z540.3, Requirements for the Calibration of Measuring and Test Equipment, National Conference of Standards Laboratories International, Boulder, Colorado.

66. NEMA MG-1, Motors and Generators, National Electrical Manufacturers Association, Rosslyn, Virginia.

67. NFPA 70, National Electrical Code (NEC)9, National Fire Protection Association, Quincy, Massachusetts.

8 IBC and International Building Code are registered trademarks of the International Code Council, Inc.





68. NFPA 90A, Standard for the Installation of Air-Conditioning and Ventilating Systems, National Fire Protection Association, Quincy, Massachusetts.

69. PRC-PRO-QA-268, Control of Purchased/Acquired Items and Services, Revision 0, Change 3, CH2M HILL Plateau Remediation Company, Richland, Washington.

70. PRC-PRO-QA-301, Control of Inspections, Revision 0, Change 2, CH2M HILL Plateau Remediation Company, Richland, Washington.

71. SAE J429, Mechanical and Material Requirements for Externally Threaded Fasteners, Society of Automotive Engineers, Warrendale, Pennsylvania.

72. SAE J995, Mechanical and Material Requirements for Steel Nuts, Society of Automotive Engineers, Warrendale, Pennsylvania.

73. UL10-Listed, Electrical Appliance and Utilization Equipment Directory, Underwriters Laboratories, Inc., Northbrook, Illinois.

74. UL 586, High-Efficiency, Particulate, Air Filter Units, Underwriters Laboratories, Inc., Northbrook, Illinois.

75. UL 900, Air Filter Units, Underwriters Laboratories, Inc., Northbrook, Illinois.

76. US DOE Drawing H-1-92251, sheets 1 and 2, STP ECRTS Ventilation System Exhaust Filter Assembly, U.S. Department of Energy, Washington, D.C.

77. US DOE Drawing H-1-92252, sheets 1 and 2, STP ECRTS Ventilation System Exhaust Fan Assembly, U.S. Department of Energy, Washington, D.C.

78. US DOE Drawing H-1-92253, STP ECRTS Ventilation System Exhaust System G. A., U.S. Department of Energy, Washington, D.C.

4.0 SCOPE OF SUPPLY

The HEPA-filtered exhaust train assembly Seller shall furnish the following equipment and services:

1. Delivery of two HEPA-filtered exhaust trains as specified herein; 2. Equipment operating and maintenance instructions; 3. Installation drawing with clearance and performance notes such as:

a. Outline dimensions and interface connection locations, b. Component weight list (including component and total assembly), c. Anchorage locations and requirements,

9 NEC and National Electrical Code are registered trademarks of the National Fire Protection Association. 10 UL is a registered trademark of Underwriters Laboratories, Inc.





d. Certified fan curves, and e. Component pressure drops;

4. Recommended spare parts lists; 5. Inspection procedures; 6. Test procedures; 7. Welder qualifications; 8. Welding procedures; 9. Completed ASME AG-1, including ASME N509 and N510, Compliance Matrix; 10. Signed inspection reports; and 11. Signed test reports.

5.0 GENERAL PARAMETERS AND SPECIFICATIONS

Table 1 lists general parameters and specifications required for the HEPA-filtered exhaust trains.

Table 1. Parameters and Requirements. (2 sheets)

General Parameter Specification

Normal Operating Pressure 10-in. w.g., negative pressure. Leak Test Pressure 12.5-in. w.g., negative pressure. Structural Capability Test Pressure 15-in. w.g., negative pressure. Leakage Class Class I, ESF systems in accordance with ASME AG-1a

(Table SA-B-1310). Normal Air Flow 4,100 cfm at 10.3 in. w.g. (dirty filters). Maximum Air Flow 4,500 cfm at 12.4 in. w.g. Wind Load Not applicable, located inside the building. Snow Load Not applicable, located inside the building. Ash Fall Load Not applicable, located inside the building. Live Load Maintenance loads shall be considered. Temperature 65 to 85 F, components are located inside a

conditioned space. Relative Humidity Expected relative humidity will not exceed 70 percent.





Table 1. Parameters and Requirements. (2 sheets)

General Parameter Specification

Seismic Design Parameters All structures, systems, and/or components, including anchorages, shall be designed and evaluated using IBC 2006 and ASCE 7-05 provisions as follows:

Occupancy Category = IV; Seismic Design Category (Site Class) = D; Limit State = C; Rp = 0.8Rp, reduced per DOE-STD-1189 (Appendix A); IBC Soil Classification = D; Importance Factor = 1.5; Mapped spectral accelerations for short periods, Horizontal (SDSH) = 0.458 g; and Mapped spectral accelerations for short period, Vertical (SDSV) = 0.323.

Load Combinations Load combinations, allowable stresses, and strength requirements shall comply with IBC 2006, ASCE 7-05, and ASME AG-1 Service Level A, as applicable. ASME AG-1 confinement boundary structures, systems, and/or components shall be subject to a combination of loading from IBC 2006, ASCE 7-05, and ASME AG-1; allowable stress shall be per ASME AG-1 Service Level A.

Nonstructural Components Adequacy of nonstructural components shall comply with Section 13.2.1 of ASCE 7-05.

ASCE = American Society of Civil Engineers. ASME = American Society of Mechanical Engineers. cfm = cubic feet per minute.

DOE = U.S. Department of Energy. IBC = International Building Code. w.g. = water gauge.

6.0 COMPONENT FEATURES

6.1 HEPA Filter Housings

6.1.1 Provide two HEPA filter housings, one right-hand access (ECRT-HEPA-501) and one left-hand access (ECRT-HEPA-502). Each HEPA filter housing shall be 3-high by 1-wide configuration and shall include an inlet plenum with an 18-in.-diameter isolation valve, a prefilter section, an upstream aerosol test section, HEPA filter section, combination test section, HEPA filter section, outlet plenum section with an 18-in.-diameter isolation valve.

6.1.2 Each HEPA filter train shall require one filter housing inlet plenum section and one filter housing outlet plenum section. The plenum sections shall be fabricated from ASTM A 240/A 240M, Type 300-series stainless steel with a 2-B mill finish. All welded components shall be fabricated from Type 300-series stainless steel, Grade L. The flanges shall be, at a minimum, 1/4-in.- thick Type





300-series stainless steel, Grade L flanges or rolled angles and meet the requirements of ASTM A 240/A 240M or ASTM A 276.

6.1.2.1 Provide inlet and outlet plenums, welded or bolted to the housing.

6.1.2.2 If the plenums are bolted, the spacing shall be the manufacturers standard bolt-hole pattern, not to exceed 4 in. between bolt holes on center.

6.1.3 Each HEPA filter housing assembly shall require a prefilter housing.

6.1.3.1 The prefilter housing shall be a Flanders BF Series11 or Buyer-reviewed equivalent, Type 1, one right-hand and one left-hand access.

6.1.3.2 The prefilter housing shall not exceed a depth of 14 in. in the direction of airflow. The prefilter housing may be combined with the upstream aerosol test section where the housing shall not exceed a depth of 42 in.

6.1.3.3 Provide removable, separate, access doors for each tier of filters. Use solid silicone or neoprene gaskets that seal the door to the housing wall, while maintaining clearance between the bag-out flange and the inside door surface. Provide stainless-steel door latches that pivot away after release and remain attached to the housing or door. Use 300-series stainless-steel bolts with nuts made from a precipitation hardening grade of stainless steel, treated substantially harder than the bolt. Metal pockets for instruction manuals are optional.

6.1.3.4 On the upstream side of each filter position, provide a smooth inlet design with a minimum 3/4-in. deep recess around the upstream perimeter of the prefilter or filter to limit the buildup of contaminants in crevices or filter frames.

6.1.3.5 Filter Locking Mechanism. A toggle or over-center-type filter element clamping assembly or locking tray shall be used to secure the filter elements in the housing. The clamping assembly shall apply a sealing force that is even and uniform across the top and bottom of the filter element. Provide a filter locking mechanism with a replaceable clamping assembly or locking tray.

6.1.3.6 Filter Rails. Provide filter rails in the filter housings, 6 in. deep for the prefilter.

6.1.3.7 Bag-In/Bag-Out. Provide each filter access door with a bag-in/bag-out port inside the access door, which is hemmed on its outer edges to prevent tearing of the bag. Provide two continuous ribs on the outside

11 Flanders BF Series is a trademark of Flanders Corporation.





of the port to hold the bags elastic shock cord and the safety strap during the bag-out operation. The turned edge on the port is not considered a rib. Provide each housing with two, 8 mil, transparent, polyvinyl chloride (PVC) glovebags for each bag-in/bag-out port. Incorporate mittens into the bag. Provide bag with stock number rolled into the hem for easy identification when reordering. Provide bag with a smooth finish to prevent from sticking to itself and provide a nylon safety strap with each bag-in/bag-out port to prevent the bag from slipping off during the bag-out procedure. Provide a cinching strap with each bag-in/bag-out port to tie off the slack in the bag while the exhaust system is operating. Provide a banding kit to facilitate in the secure clamping off of the bag between the housing and the spent filter. Access doors shall include a minimum of four tie-down latches. The latches shall be designed in such a manner as not to impede the bag-in/bag-out process. The latch materials may be the manufacturers standard.

6.1.3.8 Filter Removal Tray. Provide one filter removal tray for each size of prefilter to aid in the change-out operation.

6.1.3.9 Static-Pressure Ports. Locate static-pressure ports on the front or top of the housing upstream and downstream of each filter bank. Provide 1/4-in. national pipe thread ports with cap, Type 304 stainless steel.

6.1.4 Each HEPA filter housing assembly shall require two stages of HEPA filtration separated by a combination test section.

6.1.4.1 Each HEPA filter housing shall accommodate number designation 7 (24-in. by 24-in. by 11-1/2-in.) fluid seal, Type B (Nuclear Grade) HEPA elements in a 1-wide by 3-high array. Filter-to-housing seal shall be affected by means of a knife-edge frame in the housing that engages with a continuous perimeter channel on the face of the filter element that has been filled with a viscous, non-drying fluid. The filter elements shall not require any special attachments or devices to function correctly in the housings.

6.1.4.2 Provide removable, separate, access doors for each tier of filters. Use solid silicone or neoprene gaskets that seal the door to the housing wall, while maintaining clearance between the bag-out flange and the inside door surface. Provide stainless-steel door latches that pivot away after release and remain attached to the housing or door. Use 300-series stainless-steel bolts with nuts made from a precipitation hardening grade of stainless steel, treated substantially harder than the bolt. Metal pockets for instruction manuals are optional.

6.1.4.3 On the upstream side of each filter position, provide a smooth inlet design with a minimum 3/4-in. deep recess around the upstream





perimeter of the filter to limit the buildup of contaminants in crevices or filter frames.

6.1.4.4 Filter Locking Mechanism. A toggle or over-center-type filter element clamping assembly or locking tray shall be used to secure the filter elements in the housing. The clamping assembly shall apply a sealing force that is even and uniform across the top and bottom of the filter element. Provide a filter locking mechanism with a replaceable clamping assembly or locking tray.

6.1.4.5 Filter Rails. Provide filter rails in the filter housings, 12 in. wide for the HEPA filter.

6.1.4.6 Bag-In/Bag-Out. Provide each filter access door with a bag-in/bag-out port inside the access door, which is hemmed on its outer edges to prevent tearing of the bag. Provide two continuous ribs on the outside of the port to hold the bags elastic shock cord and the safety strap during the bag-out operation. The turned edge on the port is not considered a rib. Provide each housing with two, 8 mil, transparent, PVC glovebags for each bag-in/bag-out port. Incorporate mittens into the bag. Provide bag with stock number rolled into the hem for easy identification when reordering. Provide bag with a smooth finish to prevent from sticking to itself and provide a nylon safety strap with each bag-in/bag-out port to prevent the bag from slipping off during the bag-out procedure. Provide a cinching strap with each bag-in/bag-out port to tie off the slack in the bag while the exhaust system is operating. Provide a banding kit to facilitate in the secure clamping off of the bag between the housing and the spent filter. Access doors shall include a minimum of four tie-down latches. The latches shall be designed in such a manner as not to impede the bag-in/bag-out process. The latch materials may be the manufacturers standard.

6.1.4.7 Filter Removal Tray. Provide one filter removal tray for each size of HEPA filter to aid in the change-out operation.

6.1.4.8 Static-Pressure Ports. Locate static-pressure ports on the front or top of the housing upstream and downstream of each filter bank. Provide 1/4-in. national pipe thread ports with cap, Type 304 stainless steel.

6.1.4.9 Each filter housing shall be provided with 1-in., Type 304 or Type 304L stainless-steel drain, piped to outside structural-steel base with a threaded cap installed on the pipe. Piping shall be Schedule 40 and meet the requirements of ASTM A 312/A 312M. All drains shall exit in the orientation as shown on the drawings.





6.1.5 Each HEPA filter housing assembly shall require one upstream aerosol test section and one combination aerosol test section.

6.1.5.1 The inlet test section shall be a Flanders or Buyer-reviewed equivalent test inlet section, compatible with the models selected for the prefilter and HEPA filter sections.

6.1.5.2 The combination test section shall be a Flanders or Buyer-reviewed equivalent, compatible with the models selected for the HEPA filter sections. The combination test section shall be located between the two banks of HEPA filter elements.

6.1.5.3 Construct the test sections in such a manner that adjoining test chambers are isolated from each other to permit individual testing of each HEPA filter and its pressure boundary for its efficiency per ASME AG-1 (Appendix TA-VI).

6.1.5.4 Provide test section with separate aerosol mixing devices, sample ports, and inlet ports to allow individual in-place testing of the HEPA filters per ASME AG-1 (Article FC-5120 and Appendix TA-VI). Upstream sampling sections and downstream sampling sections that require the use of external power (e.g., compressed air) are not acceptable. Provide 1-in., Schedule 40, injection ports and 1/2-in., Schedule 40, sampling ports. Identify each test section with a model number and label all test equipment (i.e., operational handles, injection and sample ports). Provide an aerosol injection manifold and a sampling manifold on a multiple high or wide filter train. Manifold all test sections per stage together, in order that each stage of HEPA filter can be treated as a single unit. Provide a stainless-steel manifold that has valves located to isolate individual HEPA filters in the event the system fails the in-place Hanford testing criteria at the jobsite. Provide one external connection for each manifold and locate 30 to 60 in. above the filter train base. Ship the manifold loose for installation by others. Provide a union at each break point. Position each manifold to allow for the change-out of all filters without causing interference.

6.1.5.5 Aerosol Injection Manifold. Construct the manifold of 1-in., Schedule 40 pipe or 3/4-in. outside diameter tubing and provide a full port ball valve, 1-in. male national pipe thread end, at the inlet port of the manifold.

6.1.5.6 Sampling Manifold. Construct the manifold of 1/2-in., Schedule 40 pipe or 5/8-in. outside diameter tubing and provide a full port ball valve, 1/2-in. male national pipe thread end, at the outlet port of the manifold. Install ball valves on each manifold branch line to allow each HEPA filter to be individually tested.





6.1.5.7 The test sections shall not exceed a nominal depth of 28 in. in the direction of airflow.

6.1.5.8 The test sections shall be constructed in such a manner to allow HEPA filter in-place testing in accordance with the requirements of ASME AG-1 (Article FC-5120), outside the system using apparatus and devices which are supplied as an integral part of the test section. Apparatus and devices shall include, as a minimum:

6.1.5.8.1 Inlet Test Section - challenge aerosol inlets, mixing apparatus (diffusers), and upstream sample outlets.

6.1.5.8.2 Combination Test Section - downstream mixing apparatus (diffusers) and sample outlets for the upstream filter elements, plus challenge aerosol inlets, mixing apparatus (diffusers), and upstream sample outlets for the downstream filter elements.

6.1.5.9 The filter housings and test sections shall be tested for air-aerosol mixing uniformity in accordance with the requirements of ASME AG-1 (Section HA-5700). Qualification testing of sampling manifolds shall be conducted in accordance with ASME AG-1 (Section HA-5800).

6.1.5.10 Qualification testing of challenge aerosol injection manifolds shall be performed in accordance with ASME AG-1 (Section HA-5800). If similar equipment (duplicate in design, layout, and fabrication) has previously been qualified by these tests, the results of this testing may be used to demonstrate manifold and air-aerosol mixing uniformity qualification. Acceptance criteria shall be as provided in ASME AG-1 (Appendix HA-D).

6.1.5.11 Test sections shall have a static pressure drop of a maximum of 0.5-in. water gauge (w.g.) at 1,000 standard cubic feet per minute (scfm) per filter element with the test sections in the test position. With the test sections in the operating mode, the static pressure drop shall be less than 0.05-in. w.g. at 1,000 scfm per filter element.

6.1.5.12 Apparatus and devices that make-up the test sections shall meet the intent of the non-mandatory design guidelines of ASME AG-1 (Appendix HA-C).

6.1.5.13 Apparatus and devices that make-up the test sections shall be designed to allow qualification testing of the apparatus and devices in accordance with ASME AG-1 (Appendix HA-D), as required.





6.1.6 Materials, Inspections, and Testing

6.1.6.1 The HEPA filter housing assembly shall be fabricated from 11 and 14 gauge, ASTM A 240/A 240M, Type 300-series stainless steel with a 2-B mill finish. All welded components shall be fabricated from Type 300-series stainless steel, Grade L.

6.1.6.2 The HEPA filter housing assembly shall be adequately reinforced to withstand the system structural capability pressure as defined in ASME N509 (Section 4.5) and ASME AG-1 (Article AA-4000). ASME AG-1 confinement boundary structures, systems, and/or components shall be subject to a combination of loading from the IBC 2006, ASCE 7, and ASME AG-1; allowable stress shall be per ASME AG-1 Service Level A.

6.1.6.3 All pressure retaining weld joints and seams shall be 100 percent continuously welded. Weld joints and seams shall be wire brushed or buffed after final nondestructive examination (NDE) and inspection as required to remove heat discoloration, oxidation, all burrs, and sharp edges.

6.1.6.4 The HEPA filter housing assemblies shall undergo a structural capability test in accordance with ASME AG-1, on the completed component prior to the final pressure decay leak test.

6.1.6.5 The HEPA filter housing assemblies shall be pressure-decay leak tested before and after HEPA filter elements are installed. Tests shall be conducted to meet the requirements of ASME AG-1. The leak rate shall not exceed 0.1 percent of the housing volume per hour at the system leak test pressure and as defined in Table 1 and ASME AG-1 for Leakage Class I (Table SA-B-1310).

6.1.7 For structural and pressure boundary materials, the Seller shall submit Certified Material Test Reports (CMTRs) to the Buyer for review. All other materials used in the construction of test sections shall be provided with Certificates of Conformance.

6.1.8 Seismic Fabrication Requirements. Fabricate HEPA filter housings, internal mounting frames and attachment to housings, accessories, and other section components with reinforcement strong enough to withstand seismic forces defined in Table 1 of this specification.

6.1.9 Lifting Lugs. Provide Type 304 or Type 304L stainless-steel lifting lugs with a 2-in.-diameter lifting eye. Lifting devices shall be in accordance with DOE/RL-92-36, ASME B30.20, and ASME BTH-1. Each section or subassembly shall be provided with lifting lugs or equivalent.




Project No: 01949.03.P001.48 Project Name: Modified KW Annex Design 6.2 Exhaust Fans

6.2.1 Provide two exhaust fans, top angular up (45 degrees), Arrangement 9, one counterclockwise, motor position W (ECRT-EF-502), and one clockwise, motor position Z (ECRT-EF-503).

6.2.1.1 Description: Factory-fabricated, -assembled, -tested, and -finished, belt-driven fans consisting of housing, flanged outlet, wheel, fan shaft, pulleys, guards, bearings, and inverter-duty motor.

6.2.1.2 Two fans, each with 100 percent system flow capability in accordance with Table 1. Fan shall be selected to provide stable operation at plus or minus 5 percent of air flow and plus or minus 10 percent of total pressure of design conditions as listed in this specification.

6.2.1.3 The fans are required to be in compliance with ASME AG-1 (Section BA), except as noted in Appendix B of this specification.

6.2.1.4 Fan Performance Ratings. Establish flow rate, pressure, power, air density, speed of rotation, and efficiency by factory tests and ratings according to AMCA 210. Fan performance shall be based on AMCA 210, Laboratory Methods of Testing Fans for Certified Aerodynamic Performance Rating, standard air (68 F, 0.075 lbm/ft3). Fans shall be certified as complying with AMCA 210. Submit certified fan curve in accordance with AMCA 210 and AMCA 211, Certified Ratings Program Product Rating Manual for Fan Air Performance.

6.2.1.5 The exhaust fans shall be constructed of nonsparking materials per AMCA Standard 99, Standards Handbook (99-0401).

6.2.1.6 Fan sizing based on aged components and ductwork is not required.

6.2.1.7 Fan Sound Power Level rating shall conform to AMCA 301, Methods for Calculating Fan Sound Ratings from Laboratory Test Data, and shall be the result of tests made with AMCA 300, Reverberant Room Method for Sound Testing of Fans, over the entire operating range. Without taking credit for hearing protection, the design shall prevent workers from being exposed to an 8-hour time weighted average in excess of 80 decibels measured on the A-scale. Label fans with the AMCA-Certified Ratings Seal. Without taking credit for hearing protection, the design shall prevent exposure to impulsive or impact noise from exceeding 85 decibels peak sound pressure level.

6.2.1.8 Belt-Driven Fans. Single-width, single-inlet, multi-blade type, airfoil, or backward curved centrifugal, Arrangement 9 (AMCA Standard 99-2404), with self-aligning, anti-friction bearings with a minimum L-50 life of 100,000 hours per ABMA 9, Load Ratings and Fatigue Life for Ball Bearings or ABMA 11, Load Ratings and Fatigue Life for Roller





Bearings, provide inverter-duty motor installed on an adjustable fan-base mounted on the casing.

6.2.1.9 Fan Housings. Formed panels to make curved-scroll housings with shaped cutoff; with doors or panels to allow access to internal parts and components. Each fan and fan housing shall be constructed from stainless steel. The series of stainless steel shall be determined in accordance with ASME AG-1. Materials for components of the fans shall be in accordance with ASME AG-1 (Article BA-3000, Table BA-3100).

6.2.1.10 The ASME and/or ASTM material numbers and grades shall be identified and shall be provided for the scrolls, housing side sheets, inlet and outlet flanges, side plates, weld-filler metal, and support framing integral to the fan. All material designations shall be indicated on the fabrication drawings and in the material lists.

6.2.1.11 Fan bearing pedestals and motor bases shall be fabricated from structural-steel shapes and plates properly reinforced for maximum rigidity.

6.2.1.12 Bronze, copper, lead, zinc, tin, antimony, cadmium, or other low-melting point metals, their alloys, or materials containing such metals as their basic constituents or molybdenum, and halogens shall not be used in direct contact with stainless steel, with the exception of oil impregnated bronze bearings. This prohibition applies to use of tools, fixtures, paints, coatings and sealing compounds, and any other equipment or materials used by the Seller in handling, assembly, and storage of stainless-steel parts or components.

6.2.1.13 Asbestos and Teflon12 shall not be used in any component of the fans or accessories.

6.2.1.14 Each fan housing shall have a plugged 1-in., Schedule 40, national pipe threaded drain connection at the low point on the fan housing to collect condensation.

6.2.1.15 Each fan shall be equipped with inlet and outlet flanges with standard bolt patterns. Flange faces shall be flat to within a tolerance of plus or minus 1/32 in. All seams and flanges shall be seal welded.

6.2.1.16 Each fan shall be equipped with a factory-installed shaft drive and all-drive components shall be covered with protective guards. Fabricate to comply with Occupational Safety and Health Administration (OSHA13) and Sheet Metal and Air Conditioning Contractors National

12 Teflon is a registered trademark of E.I. Du Pont De Nemours and Company. 13 OSHA is a registered trademark of the Occupational Safety and Health Administration.





Association (SMACNA14) requirements of diamond-mesh wire screen welded to steel-angle frame or equivalent, prime coated. Secure to fan or fan supports without short circuiting vibration isolation. Include provisions for adjustment of belt tension, lubrication, and use of tachometer with guard in place.

6.2.1.17 Seismic Fabrication Requirements. Fabricate fan section, internal mounting frame and attachment to fans, fan housings, motors, casings, accessories, and other fan section components with reinforcement strong enough to withstand seismic forces defined in Table 1 of this specification.

6.2.1.18 Bearings shall be furnished with pressure lubrication fittings that are accessible without disassembly. Bearings and all pressure lubrication fittings shall be located outside of the airstream. A bearing to shaft locking device shall maintain shaft concentric with the bearing housing.

6.2.1.19 Exhaust fan motors shall be National Electrical Manufacturers Association (NEMA) definite-purpose, premium-efficiency, inverter-duty, polyphase motors in conformance with NEMA MG 1 (Part 31) criteria. Motor insulation class shall be selected to ensure that winding temperature rise limits are not exceeded based on an ambient temperature of 115 F (46 C). Motors shall operate on 480-volt, 3-phase, 60-hertz (Hz) electrical power.

6.2.1.20 Motor coupling/drive to fan shall allow for dial indications for in-field run-out checkout. Baseline testing on motors per NEMA MG 1 shall be recorded and provided with complete test reports.

6.2.1.21 The following rotating components are to be balanced in accordance with this section:

6.2.1.21.1 The drive-motor rotating element and

6.2.1.21.2 The fan wheel and shaft assembly.

6.2.1.22 Balancing and vibration criteria shall comply with ASME AG-1. The drive-motor rotating element shall be dynamically balanced, as a minimum, to the requirements of AMCA Standard 204, Balance Quality and Vibration Levels for Fans, for low horsepower, industrial process, or petrochemical applications (6.4-mm/s peak velocity at the outlet flange and 3.8-mm/s peak velocity at the inlet flange). Balancing services may be performed by the component manufacturer or by a Seller selected balancing company. When vibration readings are

14 SMACNA is a registered trademark of Sheet Metal and Air Conditioning Contractors National Association, Inc.





taken, the fan system shall be bolted to a level/flat concrete pad free of major cracks.

6.2.1.23 The natural frequency of the fan rotating assembly (includes shaft, wheel, and coupling hub) shall be determined to ensure that when operating at maximum speed, the assembly is at a minimum of 25 percent below its first resonance modal. The natural frequency of the fan wheel in the axial direction shall be verified to be at least 10 percent below or above the fan frequency over its entire operating speed range. The natural frequency of all portions of the structure shall be well outside the operating frequency of the mechanical equipment.

6.2.1.24 Wheel and shaft shall be statically and dynamically balanced in accordance with ASME AG-1 (Article BA-4162), as an assembly. Fan wheel and shaft shall be statically and dynamically balanced, and vibration levels checked in accordance with the following:

Rotational Speed (rpm) Double Amplitude (mil)

600 3.2

720 2.7

900 2.1

1200 1.6

1800 1.1

3600 0.5

6.2.1.25 The double amplitude of vibration in any plane measured on the bearing cap at the rotational rotor speed shall not exceed the above values. Displacement may be interpolated for other speeds.

6.2.1.26 The fan wheel shall be tested for an over-speed condition of 15 percent above its maximum operating speed for 10 minutes without increased vibration. A visual inspection shall serve to further verify that no deformation or cracks have occurred.

6.2.1.27 The exhaust fan shall be equipped with a method of limiting shaft leakage. The seal arrangement shall be noncontact labyrinth or another suitable method reviewed by the Buyer before ordering the fans or any associated fabrication that deals with the fan assembly.

6.2.1.28 Fan shafting shall be ground and polished to a dimensional tolerance based on the requirements of the selected bearing manufacturer. Seller shall provide the bearing manufacturer data before ordering





shafting for Buyer review of the diametrical tolerance. The shafting shall not exceed 0.0015 in. run-out over the entire length of the shaft. Evidence shall be submitted to demonstrate that shaft run-out inspections performed and are in conformance to the tolerance specified.

6.2.2 Fan Drives:

6.2.2.1 Fan Pulleys. Cast iron or cast steel with split tapered bushing; dynamically balanced at factory.

6.2.2.2 Motor Pulleys. Fixed pitch.

6.2.2.3 Belts. Oil resistant, nonsparking, and nonstatic; matched sets for multiple belt drives.

6.2.2.4 Motor Mount. Adjustable mount for belt tensioning.

6.2.3 Lifting devices shall be in accordance with DOE/RL-92-36, ASME B30.20, and ASME BTH-1.

6.2.4 For structural and pressure boundary materials, Seller shall submit CMTRs to the Buyer for review. All other materials used in the construction of the fan assembly shall be provided with Certificates of Conformance.

6.3 Dampers

6.3.1 Design of dampers shall be in accordance with the requirements of ASME AG-1 (Section DA). Note that per ASME AG-1 (Article DA-1210), valves whose design, manufacture, test, and installation are covered by the ASME B&PV Code (Section III) or ASME B31.1, are excluded from the requirements of ASME AG-1 (Section DA).

6.3.2 Damper rating shall be in accordance with AMCA Standard 500-D, Laboratory Methods of Testing Dampers for Ratings.

6.3.3 Manual Isolation Dampers (ECRT-V-507, ECRT-V-508, ECRT-V-513, and ECRT-V-514):

6.3.3.1 Dampers shall meet the requirements of ASME AG-1 (Section DA). Frame leakage class (zero leakage) and blade leakage class (zero leakage) rating in accordance with ASME AG-1 (Appendix DA-I), with linkage outside the airstream and bearing AMCAs Certified-Ratings Seal for both air performance and air leakage.

6.3.3.2 Dampers shall be designed for a minimum pressure of minus 20-in w.g and plus 20-in. w.g.





6.3.3.3 Frames. Steel Channel, material shall be stainless-steel Type 304 or Type 304L and be listed in ASME AG-1 (Table DA-3110).

6.3.3.4 Blades. Fabricated of the same material as the frame, minimum 1/4-in. thick.

6.3.3.5 Bearings. Grease-lubricated ball bearings mounted outboard of the damper frame.

6.3.3.6 Shaft. Continuous, stainless steel.

6.3.3.7 Shaft Seals. External, adjustable, double-packing gland, shaft seal.

6.3.3.8 Butterfly valves may be used to isolate the filter train assembly from the ducting at the inlet plenum. Isolation valves shall meet the design requirements of ASME B31.1. Butterfly valves, where used, shall be Keystone15 KLOK BFV 362-107, or approved equivalent, with Type 316 stainless-steel lugged body, disc, and stem. Stem packing shall be Teflon and the resilient seat shall be Buna-N16. The stem bushing shall be RFTF/Fiberglass Epoxy.

6.3.3.9 Seller shall submit CMTRs to the Buyer for review of chemical and physical properties of material and hardware for stress components (i.e., frames, blades, and shafts).

6.3.3.10 Inspection and testing of dampers shall be in accordance with ASME AG-1 (Article DA-5000).

6.3.3.11 Seller shall conduct and shall be responsible for the shop testing. Seller shall furnish all facilities necessary for the performance of tests. Inspection and test procedures shall be submitted to the Buyer for review.

6.3.3.12 Seller shall be responsible for establishing the written visual examination procedures and necessary tolerances to ensure that the products are built to the manufacturers drawings.

6.3.3.13 Dampers shall be installed in accordance with the damper manufacturers instructions and applicable codes, which include ASME AG-1 (Article DA-6000) and NFPA 90A.

6.3.3.14 Operators shall be oriented and positioned for accessibility and maintainability.

15 Keystone is a trademark of Tyco Industries. 16 Buna N is a registered trademark of Buna Werke Huls G.m.b.h.





6.3.3.15 All dampers shall be field inspected and tested in accordance with applicable requirements from ASME AG-1 (Section TA).

6.3.3.16 Furnish with manual gear drive operator with position indication and hardware for application of lock and tag devices. Provide chain wheel drives and chains for dampers located more than 6 ft-0 in. above the finished floor.

6.4 Backdraft Dampers (ECRT-BDD-501 and ECRT-BDD-503)

6.4.1 Backdraft dampers shall be of airfoil design, double thickness, minimum 18 gauge fabricated of the same material as the frame.

6.4.2 Backdraft dampers shall meet the requirements of ASME AG-1 (Section DA). Frame leakage class (zero leakage) and blade leakage class II (moderate leakage) rating in accordance with ASME AG-1 (Appendix DA-I), with linkage outside the airstream and bearing AMCAs Certified-Ratings Seal for both air performance and air leakage.

6.4.3 Backdraft dampers shall be designed for a minimum pressure of minus 20-in. w.g and plus 20-in. w.g.

6.4.4 Backdraft damper frames shall be rolled, formed, or fabricated to a channel shape having a minimum width of 4 in., a minimum flange height of 1-1/2 in., and a minimum thickness of 1/8 in. Frame deflection shall not exceed 1/360th of the span in any direction. Frame material shall be stainless-steel Type 304 or Type 304L, minimum 10 gauge.

6.4.5 Shafts shall be of Type 304 stainless-steel material and shall have a minimum diameter of 3/4 in. or square equivalent. Shafts shall be solid and extend the full length of the blade, the blade welded, or through bolted to the shaft in such a manner that the integrity of the attachment can be verified.

6.4.6 Backdraft dampers shall be equipped with an external, adjustable, counter-balance assembly.

6.4.7 Blade, side, and edge seals shall be provided. Seals shall be stainless-steel, ethylene propylene diene monomer (EPDM), or similar materials, mechanically fastened or bonded such that blade action and air velocity shall not destroy the bond.

6.4.8 Bearings. Grease-lubricated ball bearings mounted outboard of the damper frame. Damper materials used shall be in accordance with ASME AG-1 (Article DA-3000).

6.4.9 Seller shall submit CMTRs to the Buyer for review of chemical and physical properties of material and hardware for stress components (i.e., frames, blades, and shafts).





6.4.10 Inspection and testing of backdraft dampers shall be in accordance with ASME AG-1 (Article DA-5000).

6.4.11 Seller shall conduct and shall be responsible for the shop testing. Seller shall furnish all facilities necessary for the performance of tests. Inspection and test procedures shall be submitted to the Buyer for review.

6.4.12 Seller shall be responsible for establishing the written visual examination procedures and necessary tolerances to ensure that the products are built to the manufacturers drawings.

6.4.13 Backdraft dampers shall be installed in accordance with the damper manufacturers instructions and applicable codes which include ASME AG-1 (Article DA-6000) and NFPA 90A.

6.4.14 All backdraft dampers shall be field inspected and tested in accordance with applicable requirements from ASME AG-1 (Section TA).

6.5 Duct Spool Piece

6.5.1 Ductwork shall be designed such that it can be assembled in the field without welding.

6.5.2 The ductwork sections shall be fabricated from ASTM A 240/A 240M, Type 300-series stainless steel with a 2-B mill finish. All welded components shall be fabricated from Type 300-series stainless steel, Grade L.

6.5.3 The ductwork flanges shall be, at a minimum, 1/4-in.-thick plate or rolled angle flanges and meet the requirements of ASTM A 240/A 240M or ASTM A 276.

6.5.4 Ducting shall be capable of withstanding up to 20-in. w.g. positive pressure and 20-in. w.g. negative pressure.

6.5.5 Install a downstream sample port in the duct spool piece between the isolation damper and the fan inlet.

6.5.6 The ductwork assemblies shall undergo a structural capability test in accordance with ASME AG-1, on the completed component before the final pressure decay leak test.

6.5.7 The ductwork assemblies shall be pressure-decay leak tested. Test shall be conducted to meet the requirements of ASME AG-1. The leak rate for ductwork downstream of the filter housing shall not exceed 1.0 percent of the housing volume per hour at the system leak test pressure and as defined in Table 1 and ASME AG-1 for Leakage Class II (Table SA-B-1310).





6.5.8 For structural and pressure boundary materials, Seller shall submit CMTRs to the Buyer for review. All other materials used in the construction of the ductwork shall be provided with Certificates of Conformance.

6.6 Flexible Connections

6.6.1 Manufacturer: Proco, Style 520-EE, 4-in. face-to-face flange dimension.

6.6.2 Round and rectangular flexible duct connections shall meet the requirements of ASME AG-1 (Article SA-4410, Flexible Connections) and NFPA 90A.

6.6.3 Flexible connectors shall be U-type flange connectors of nominal 3/16 in. thickness manufactured with a minimum of one ply of reinforced fabric vulcanized into an EPDM elastomer, 1-1/2-in.-high flanges on both sides. No splices shall be made in the corner areas. Provide connectors with 3/8-in.-thick retainer bars. Maximum pressure rating shall exceed plus or minus 20-in. w.g. Temperature rating shall exceed 250 F.

6.7 Vibration Mounts

6.7.1 Provide captive neoprene mountings complete with steel housing and a captive steel insert embedded in neoprene to prevent contact with the housing and the central threaded insert. Bonded assemblies without mechanical interlocks are not acceptable.

6.7.2 All mountings shall have bolts for rigid attachment to the equipment with adequate base bolting provision. Mountings shall have a minimum static deflection of 0.15 in.

6.7.3 Mountings shall be Type RBA-Black as manufactured by Mason Industries Inc.

6.8 Fasteners

6.8.1 Graded fasteners shall be carefully controlled as defined in the ASME NQA-1-2008, Quality Assurance Requirements for Nuclear Facility Applications.

6.8.2 Fasteners shall exhibit grade marks and manufacturers identification symbols (headmarks).

6.8.3 Fasteners that are on Suspect/Counterfeit Fastener Headmark Lists, or facsimiles thereof, shall be deemed to be unacceptable. Any fasteners supplied with headmarks matching those displayed in PRC-PRO-QA-301, Control of Inspections, or facsimiles thereof, shall be deemed to be unacceptable under the terms of this Purchase Requisition. This procedure describes the process for the identification, prevention, evaluation, notification, and disposition of suspect/counterfeit items.





6.8.4 Seller shall establish the bolt torque requirements for all bolted connections in accordance with ASME AG-1 (Article AA-5400).

6.8.5 Fasteners shall be inspected to verify compliance with the requirements listed on the design drawings or procurement specifications.

6.8.6 Stainless-steel bolts, cap screws, and washers shall be per ASTM A 193/A 193M, Grade B8, and nuts shall be heavy hex nuts per ASTM A 194/A 194M, Grade 8. Bolts and cap screws shall be grade marked.

6.8.7 Carbon-steel bolts shall be per ASTM A307, A325, A354, A490 as specified, and nuts per ASTM A 194/A 194M or ASTM A 563a, as specified.

6.8.8 All graded fasteners shall conform to ASME B18.2.1, ASME B18.2.2, or SAE J429 and SAE J995.

6.8.9 Seller shall select fasteners where they are not specifically called out in this specification using the following guidance:

6.8.9.1 Anti-galling compound (e.g., Neo-Lube17) shall be applied where stainless-steel bolts are used;

6.8.9.2 Stainless-steel bolts, nuts, and washers shall be used when the mating parts are stainless steel; and

6.8.9.3 Carbon-steel bolts, nuts, and washers shall be used where mating parts are not stainless steel.

6.8.10 All fasteners used for structural and pressure boundary applications shall be provided with a manufactures Certificate of Conformance.

6.9 Structural Supports

6.9.1 Carbon steel shall meet the requirements of ASTM A 36/A 36M or ASTM A 992/A 992M.

6.9.2 Structural tubing shall meet the requirements of ASTM A 500/A 500M, Grade B (fy = 46 ksi).

6.9.3 Steel pipe shall meet the requirements of ASTM A 53/A 53M, black steel, Types E or S, Grade B, or ASTM A 106/A 106M, Grade B, standard weight, Schedule 40 and Schedule 80.

6.9.4 Carbon steel-welding material shall meet the requirements of AWS D1.1/D1.1M, carbon-steel E70XX electrodes.

17 Neo-Lube is a registered trademark of Watson Bowman ACME Corporation.





6.9.5 Stainless-steel shapes and bars shall meet the requirements of ASTM A 276, 300-series stainless steel.

6.9.6 Stainless-steel welding material shall meet the requirements of AWS D1.6/D1.6M, stainless-steel E308/ER308 or E309/ER309 electrodes.

6.9.7 Bolts and Fasteners

6.9.7.1 Bolts General Applications: ASTM A 307, Grades A or B.

6.9.7.2 Nuts General Applications: ASTM A 563a, Grade A, heavy hex.

6.9.7.3 Bolts Structural Connections: ASTM A 325 or ASTM A 490.

6.9.7.4 Nuts Structural Connections: ASTM A 563a, Grade DH, heavy hex.

6.9.7.5 Washers: ASTM F 436.

6.9.8 The Seller shall develop structural calculations documenting the maximum forces from each ductwork/pipe, support/anchor, and the maximum stresses on existing building members. These calculations shall be submitted to the Buyer for review.

6.10 Instrumentation

6.10.1 Pressure instrumentation shall have calibration ports and instrument isolation valves to facilitate installed calibration.

6.10.2 All instrumentation with local displays (such as filter differential pressure transmitters) needs to be readily accessible for surveillance readings.

6.10.3 Electronic differential pressure transmitter shall be designed to measure the differential air pressure as indicated on the drawings or as required. The output shall be a 2-wire, 4 to 20-mA, loop-powered device with an input range as indicated in the drawings, but not more than twice the actual measure variable. The accuracy, including linearity, hysteresis, and repeatability, shall be less than plus or minus 2 percent. Provide gauge root valves at all transmitters. Transmitters shall be nationally recognized testing laboratory (NRTL)- approved.

6.10.3.1 HEPA Filter Train Differential Pressure Transmitters (DPT-750-512 and DPT-750-516)

6.10.3.1.1 Wetted Material: Stainless steel.

6.10.3.1.2 Power Requirements: Loop powered.

6.10.3.1.3 Accuracy: Plus or minus 0.2 percent.





6.10.3.1.4 Range: Minus 40 to 40 in. w.g.

6.10.3.1.5 Span: 10 in. w.g.

6.10.3.1.6 Output: HART 4 to 20 mA,

6.10.3.1.7 Process Ports: 1/4-in. female national pipe thread.

6.10.3.1.8 Manufacturer: Yokogawa Model EJA110A Series.

6.10.3.2 HEPA filter train Prefilter Differential Pressure Indicators (DPI-750-511, DPI-750-515)


6.10.3.2.2 Power Requirements: None.


6.10.3.2.4 Range: 0 to 4-in. w.g.


6.10.3.2.6 Manufacturer: Dwyer18 Model 2004-ASF.

6.10.3.3 HEPA filter train HEPA filter Differential Pressure Indicators (DPI-750-512, DPI-750-513, DPI-750-516, DPI-750-517)


6.10.3.3.2 Power Requirements: None.


6.10.3.3.4 Range: 0 to 8 in. w.g.


6.10.3.3.6 Manufacturer: Dwyer: Model 2008-ASF.

6.11 Protective Coatings

6.11.1 Seller shall provide protective coatings, as necessary, to ensure a reasonable life expectancy of 5 years for components supplied by the Seller. Painting and coating shall comply with ASME AG-1 (with the technical justifications for applicability noted in Appendix B of this specification).

18 Dwyer is a registered trademark of Dwyer Instruments, Inc.





6.11.2 All exposed carbon steel shall be coated to prevent environmental degradation. Prepare, prime, and top coat structural steel in accordance with the manufacturers recommendations. The final coat shall be light gray. All coatings shall be applied in such a manner as to produce a uniform smoothness. Special attention shall be paid to crevices, weld lines, carriers, and edges to obtain the required thickness.

6.11.3 Shop Primer. Rust-inhibitive, epoxy-based primer Amerlock19 2 or Amerlock 400.

6.11.4 Finish Coatings and Top Coats. Abrasive-resistant, Aliphatic-Polyurethane or Siloxane Epoxy.

6.11.4.1 Aliphatic Polyurethane. Amershield20.

6.11.4.2 Siloxane Epoxy. PSX 700 by Protective Coatings of Ameron.

6.11.5 Do not apply primer or paint to surfaces within 3 in. of structural-steel welds before welding.

6.12 Test Filters

6.12.1 Seller shall provide the prefilters and HEPA filters for testing purposes only. Buyer will provide and install final filters after acceptance testing is complete. The type of filters provided shall be compatible with the HEPA housings and prefilter housing described above. The filters shall meet the following requirements:

6.12.1.1 Moderate-efficiency filters shall be a dry media-type used as a prefilter for a flowing air cleaning device. Unless noted otherwise, they shall have a minimum efficiency reporting value of MERV 13 (average dust spot efficiency of 80 percent) when tested in accordance with ASHRAE Standard 52.2.

6.12.1.2 Moderate efficiency filters shall be of the rigid-frame-type, size 24 in. by 24 in. by 6 in. deep. Frames shall be fabricated with corrosion-resistant metal.

6.12.1.3 The moderate efficiency filters shall be UL 900, Class 1-listed, VariCel21, or Buyer-reviewed equivalent.

6.12.1.4 High-efficiency filters shall be a dry-media-type used as a HEPA filter for a flowing air cleaning device. Unless noted otherwise, they shall

19 Amerlock is a registered trademark of Ameron Protective Coatings Division 20 Amershield is a registered trademark of Ameron Protective Coatings Division. 21 VariCel is a registered trademark of American Air Filter International.





have an average efficiency of 99.97 percent on 0.3 microns and higher when tested in accordance with UL 586.

6.12.1.5 The high-efficiency filters shall be Flanders filters number designation 7 (24-in. by 24-in. by 11-1/2-in.) GGF Series with fluid seal, Type B (Nuclear Grade), or Buyer reviewed equivalent.

6.12.2 Filter media shall be glass fiber-based material, containing a binder to retain the fibers, with both fiber and binder suitable for the environmental conditions that the equipment will be subjected to.

6.12.3 Filter assembly shall be by pleating the media around the separators, applying the sealant and frame to form a physically stable unit. Filter assembly may be without separators when convoluted filter media specifically designed for this purpose is used.

7.0 DESIGN AND FABRICATION

7.1 Industry and Government Standards

7.1.1 Design guides and codes as listed Section 3.0 shall be used, where applicable. These documents form a part of this specification to the extent specified herein. In the event of conflict between the document referenced herein and the contents of this specification, Seller shall notify the Buyer and obtain review for its disposition. Use the latest edition of the code or standard at the time of contract award, unless otherwise specified.

7.2 Basic Units of Measurement

7.2.1 Given that the existing drawings for the KW Annex Site, uses the inch-pound system. All designs documents (calculations, drawings, specifications, etc.) shall use the inch-pound system for units of measurement. This includes, but is not limited to, inch (in.), feet (ft), pound (lb), British thermal unit (Btu), pounds per square inch (psi), inch water gauge (in. w.g.), and degree Fahrenheit (F).

7.3 Calculations

7.3.1 Seller shall provide, as a minimum, the following listed calculations (the calculations shall be assembled and submitted to the Buyer for review):

7.3.1.1 Skid anchorage calculations showing anchorage and anchorage details that will restrain seismic forces;

7.3.1.2 Structural calculation showing the maximum force from each component, and the maximum force on the existing building members;

7.3.1.3 Calculations showing ducting, pipe hanger, and bolted or clamped connections to structural steel;





7.3.1.4 Component structural capability calculations per ASME AG-1; and

7.3.1.5 Seller shall demonstrate, in the calculations, that the requirements specified are met.

7.3.2 Seller shall submit all calculations to the Buyer for review before or with construction specifications, drawings, or other items requesting review.

7.4 Drawings

7.4.1 New or revised engineering drawings required by this specification shall be submitted in AutoCAD22 (Release 2007 or higher) and shall comply with the requirements of the current revision of CHPRC-00263, Off-Site Vendor Instructions for Preparation and Control of Engineering Drawings.

7.4.2 Bills of Material on drawings shall include quantity, manufacturer, material type, electrical characteristics, size, and general descriptions. All component parts shall refer to applicable material specifications, such as the Military, ASME, ASTM, federal, or other specifications.

7.4.3 As-built drawings for fabrication and installation shall be verified in accordance with the Sellers Quality Assurance Program Controls before submittal, and shall be in accordance with the Buyer-supplied drawing procedures.

7.4.4 Seller shall not place any proprietary legend or stamp on any data produced as a result of this specification.

7.4.5 All shop drawings or other data are the property of the U.S. Department of Energy.

7.4.6 Seller shall provide, as a minimum, the following fabrication drawings and system component assembly outline and detail drawings for each component shall include:

7.4.6.1 The as-shipped configuration of the equipment and instrumentation;

7.4.6.2 Mounting dimensions and information required for the design of supports and foundations;

7.4.6.3 Operating weight of the skid assemblies;

7.4.6.4 The space required for the removal of components;

7.4.6.5 The locations of access doors;

7.4.6.6 The weight of individual components;

22 AutoCAD is a registered trademarks of Autodesk, Inc.





7.4.6.7 The type, size, and location of static pressure taps and plugs;

7.4.6.8 Housing inlet and outlet sizes and interface connection details;

7.4.6.9 The lifting points and the gross weight shall be identified on the drawing, the assembly drawing shall also identify the approximate center of gravity of the assembly for lifting and handling;

7.4.6.10 Labeling and name plate details;

7.4.6.11 The locations and identification of parts that is included in the parts list; and

7.4.6.12 The ASTM, or equivalent, designations for materials.

7.4.7 Seller shall provide, as a minimum, the following construction drawings:

7.4.7.1 System component installation details;

7.4.7.2 Skid and equipment anchorage plan and details.

7.5 Human Engineering

7.5.1 Equipment and controls to be used by personnel shall accommodate human characteristics, including normal variations (left-handed versus right-handed, color blindness, size, task lighting, etc.). Operator controls shall be installed at approximately a 5 ft-0 in. height.

7.5.2 The items included in Table 2 are detailed design considerations for human factors for functional requirements and design criteria for the exhaust system. These considerations are to be included, as a minimum, in the human factors engineering design.

Table 2. Human Factors for the Exhaust System. (3 sheets)

Item Issue 1 Can the equipment be readily assembled and disassembled as designed? 2 Are assembly clearances adequate? 3 Has the design appropriately considered maintenance, operations, and

reliability, including maintenance procedures and techniques, unique maintenance requirements, and frequencies?

4 Can the design and its parts be easily inspected for conformance to engineering specifications and to support in-service inspection?

5 Are optimization methods used [as low as reasonably achievable (ALARA) decision-making methods] to ensure that occupational exposure is maintained ALARA?






Item Issue 6 Does the design avoid, under normal conditions, releases of chemical

vapors, aerosols, or solids to the workplace atmosphere?

7 Are doorways and labyrinths wide enough to permit personnel, component, and equipment passage?

8 Are serviceable components capable of being isolated and drained?

9 Is there adequate provision for rapid removal of equipment?

10 Does the design consider the use of built-in rigging to facilitate component handling?

11 Does the design facilitate flushing and decontamination of components?

12 Are components selected with consideration for the specified service life, ease of removal, and frequency of maintenance?

13 Are serviceable components easily accessible with adequate workspace, lay-down areas, and lighting?

14 Are equipment cover plates hinged or closed with captive quick-opening fasteners to facilitate routine personnel access or maintenance access?

15 Does the design adequately consider life expectancy and reliability in selecting and locating equipment, to minimize the need for personnel access in the area?

16 Are pointed or other sharp projections avoided?

17 Does the design of ducting, piping, fans, stack, and pumps facilitate draining, cleaning, and flushing?

19 Are remotely operated valves used where needed?

20 Are manual valve operators used only for infrequently operated valves?

21 Are instruments and controls grouped functionally?

22 Are instruments selected for the specified service life and low maintenance requirements?

23 Are lifting lugs provided on equipment?






Item Issue 24 Are displays, indicators, switches, and actuators:

a. Arranged and grouped to ensure status and conditions are easily discernible?

b. Arranged to ensure standard conventions of order (e.g., A before or above B), direction and rotation (e.g., clockwise or counterclockwise)?

c. Placed at angles and heights that permit comfortable viewing? d. Properly illuminated and easily visible in all expected normal lighting

conditions? e. Clearly and unambiguously labeled as to function? and f. Easily operated when wearing required personal protective equipment?

25 Are lamp test switches and pushbuttons employed, when appropriate?

26 Is color-coding of alarm and status indicators consistent with existing operational practices?

27 Has the design appropriately considered the use of latching of status and alarm conditions to allow post-event analysis

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