PWS_Chandler_Pump_Overhaul_Revision_2_0003.pdf

PERFORMANCE WORK STATEMENT (PWS)

Bureau of Reclamation

Columbia Cascades Area Office Chandler Turbine and Pump Overhaul

1.0 BACKGROUND:

The United States Bureau of Reclamation’s Columbia Cascades Area Office has a need to overhaul a turbine and pump at its Chandler Pumping Plant, which is located at 47415 Old Inland Empire Hwy, Benton City, WA. The unit that is to be worked on consists of a James Leffel & Co, turbine, and a Worthington Hydrocone, pump.

2.0 SCOPE:

Furnish labor, equipment, and materials to overhaul a James Leffel & Co, turbine, and a Worthington Hydrocone pump. The overhaul will consist of repair work to the pump and modification of a turbine shaft, shaft sleave replacement, installation of turbine runner (new, provided by government) to turbine shaft, fabrication of wearing rings and pump impeller repair. Additionally, there may be a need to refurbish the guide and thrust bearing. The Contractor shall be responsible for all tools, equipment, labor, and materials for the pickup, delivery, rebuild, machining, balancing, and testing of the turbine and pump components as specified in this document. The government will be responsible for the disassembly and installation of the turbine, pump, and their components.

3.0 References

All work shall be performed in accordance with applicable industry standards including, but not limited to:

American Society of Mechanical Engineers (ASME) ASME BPVC-V-2004 Boiler and Pressure Vessel Code - Section V - Non-destructive testing ASME BPVC-VIII-2007 Boiler and Pressure Vessel Code - Section VIII - Division 1, Rules for Construction of Pressure Vessels, UW-51 and UW-52 ASME BPVC-IX-2007 Boiler and Pressure Vessel Code - Section IX - Welding and Brazing Qualifications ASME B18.8.2-2000 Taper Pins, Dowel Pins, Straight Pins, Grooved Pins, and Spring Pins ASTM International (ASTM) ASTM B23-04 Standard Specification for White Metal Bearing Alloys ASTM A36-08 Standard Specification for Carbon Structural Steel American Welding Society (AWS) AWS D.1.1-02 Standard Code for Arc Welding in Building Construction Department of Defense (DOD) DOD-STD-2183 (1991) Bond Testing, Babbitt-Lined Bearings DOD-STD-2188 (1987) Babbitting of Bearings Shells MIL-C-16173D (1993) Corrosion Preventive Compound, Solvent Cutback, Cold-Application Society of Protective Coatings (SSPC)/NACE International (NACE)

SSPC-SP5/NACE 1-00 White Metal Blast Cleaning SSPC-SP6/NACE 3-00 Commercial Blast Cleaning SSPC-SP7/NACE 4-00 Brush-Off Blast Cleaning

This is a listing of associated manufacturer drawings. These drawings are not owned by Bureau of Reclamations and are not available for distribution:

James Leffel & CO drawing numbers:

o 47900-A (Runner) o 54591 (Runner & Shaft Mods Chandler Pump Unit 2 34”LL Vertical Turbine) o 51242 (Wearing Rings-Stationary) o 47946 ( Head Cover) o 47895 (Bottom Ring, Facing Plate and Wearing Ring)

Worthington Pump and Machinery Corp drawing numbers:

o RW-107006 (42-NA-57 T.V. VOL. Pump Sectional Elevation)

4.0 DEFINITIONS

a. NDT: Non-Destructive Testing.

b. NDE: Non-Destructive Examination.

4.0 PERSONNEL QUALIFICATIONS

QUALIFICATION OF WELDERS

1. Welding procedures and welding operators:

a. Welding of principle stress-carrying parts: ASME BPVC-IX.

b. Welding of less important parts: ASME BPVC-IX or AWS D.1.1.

2. Non-Destructive Examination personnel:

a. Qualified in accordance with applicable method of the ASNT SNT-TC-1A or equivalent qualifications.

5.0 GOVERNMENT-FURNISHED EQUIPMENT (GFE) AND MATERIALS:

a. Impeller balancing mandrel for machining and balancing.

b. Runner balancing mandrel for machining and balancing.

c. Stainless-steel turbine runner.

d. Turbine shaft.

e. Ringfeder Rfn 7014 180 x 250 Locking Assembly

f. Impeller wear rings, stationary and rotating.

g. Turbine wear rings, stationary.

6.0 TASKS:

a. PUMP IMPELLER AND ASSOCIATED WEAR RINGS:

1. Remove rotating wearing rings.

2. Sandblast impeller to remove ceramic coatings.

3. Weld up any areas showing erosion or thinning in the casting. This will require the contractor to perform a chemical analysis of the bronze so the proper welding procedure can be used. USBR will be given ownership of chemical analysis results in case of future repairs. Blend welded areas to maintain the contour. Welding procedure is to be reviewed and approved by USBR representative prior to start of welding. Allow up to 10 days for approval of welding procedure.

4. The ceramic coating shall be applied as two or more coats at a thickness of 10 mils minimum per coat as per manufacturer's instructions to a final thickness of 20 mils minimum and 40 mils maximum.

5. Final machine Reclamation supplied stationary rings.

6. Finished wearing ring dimensions are to be taken by the Contractor on finished and installed stationary rings, and dimensions are to be approved by a USBR representative. Machine rotating wearing rings to fit stationary rings with specified clearance. (.026" clearance total).

7. Final machine and install Reclamation supplied rotating wearing rings on pump impeller.

8. Perform balance of impeller.

9. Provided balancing procedure and results to Reclamation.

10. Rough machine a new set of stainless-steel wearing rings to replace the spare set. Rough machining is considered adding approximately 0.150” to the outside diameter (OD) of the rotating rings and to the inside diameter (ID) of the stationary ring’s dimensions for finish machining later.

11. The Reclamation provided set of wearing rings that are to be installed in this overhaul need to have the final machining completed to the required clearance prior to installation.

12. Ship the impeller, and balance arbor equipment (provided by government) to Chandler Power Plant.

13. Government will be responsible for the removal and installation of stationary and rotating wear rings to include the remove and install packing sleeve if replacement is necessary.

b. TURBINE RUNNER, ASSOCIATED WEAR RINGS, AND TURBINE SHAFT:

1. Final machining on integrated rotating wear rings.

2. Finished wearing ring dimensions are to be taken by the Contractor on finished and installed stationary rings, and dimensions are to be approved by a USBR representative. Machine integrated rotating wear rings to fit stationary wear rings with specified clearance.

3. Perform balance of turbine runner

4. Provided balancing procedure and results to Reclamation.

5. Machine alter the existing Unit 1 turbine shaft as required to convert it to a shaft locking type coupling and proper fit for a Ringfeder Rfn 7014 180 x 250 Locking Assembly (supplied by the government) and to place the top of the machined and balanced runner (supplied by the government) at the proper elevation when coupled to the shaft. Government will leave the existing runner attached to the shaft when shipped to the contractor.

6. The machining on the shaft is: A 12 inch length of a steel tapered shaft, starting at an 8 in diameter tapering down to a 7.156 inch diameter would need to be machined to 7.156 inch diameter. As well remove and fill the key/keyway.

7. Match the elevation of the new runner to the existing runner.

8. Prepare the balance arbor equipment (provided by government), make a crate, and ship the items to

Chandler Powerplant.

9. Assemble shaft, Ringfeder, nosecone, and nut, verifying both fit and elevation.

10. Ship the runner, shaft, Ringfeder, nosecone, balance arbor equipment (provided by government), and nut assembly to Chandler Power Plant (Also return of unused shaft locating key from the old shaft design).

11. Contractor will supply two stationary wearing rings to replace existing spare rings. The Material is 410 Stainless steel with a hardness of 20 to 25 Rockwell C. They are to have a finished inside diameter of approximately 3ft 2in. An outside diameter of approximately 3ft 3.2in. And a depth of about 1.75in. Rough machining is considered adding approximately 0.150in to the OD of the rotating rings and 0.150in to the ID of the stationary rings. There shall be a minimum of 0.040” between the rotating and stationary rings, the tolerances shall be +0/-0.003 for the outer diameter of the rotating rings, and +0.003/-0 for the inner diameter of the stationary rings.

12. Remove installed shaft sleeve from turbine runner shaft.

13. Install new shaft sleeve on turbine runner shaft.

14. Government will be responsible for the removal and installation of stationary wear rings.

c. FACE PLATE MANUFACTURING AND WICKET GATE BUSHINGS:

1. Upon approval from the USBR representative, manufacture new set of face plates for scroll case and head cover per, contractor measurements, and drawings (Will be available upon Award). Package face plates for long term storage for use as spares if replacement of installed face plates is not necessary, which shall be determined by USBR representative upon removal and inspection of installed face plates. Face plates shall be manufactured from carbon steel with a Brinell hardness of 200 to 223. These face plates should be supplied with 1/16” stock (minimum) on the faces that are on the wicket gate side; 1/8” stock in the wicket gate bushing bores; 1/8” stock in ID of upper facing plate; and 1/8” stock on the OD of the lower facing plate. Final machining will take place once attached to their respective component (Head Cover and Bottom Ring). The facing plate patch bolt hole locations should be transferred from the Head cover/Bottom Ring once the existing facing plates are removed. The contractor shall supply the facing plates, remove existing facing plates and install newly manufactured plates, complete finish machining which includes skim milling and shop boring, and supply patch bolts, wicket gate bushings, and sand seals in Head cover and Bottom Ring for wicket gate bushings.

2. Manufacture 32 SAE 660 Bronze (or equivalent material) bushings for the wicket gate stems. The size of these bushings are approximately; 3 inch OD, 2.5 inch ID, 2.75 tall, with grease grooves.

More details and manufacture drawings will be available upon Award.

d. BEARINGS:

1. All bearing inspections, testing and repairs or refurbishment will be done in accordance with

Attachment 1 and as approved by Reclamation. The existing bearings shall be tested for bonding by the UT (ULTRASONIC TESTING) method to determine if they can be reused. If USBR representative determines that bearings can be reused based on the findings of the UT testing, contractor may be authorized to machine finish bearings. Contractor will provide report of surface condition and a proposed recommendation as to how much material will need to be removed to achieve required surface finish per drawings. USBR representative will determine if bonding of bearings is acceptable after receiving inspection report and bonding report.

2. Bearings will be inspected for condition and measured for dimension by USBR on site at time of delivery. Bearings will not be accepted prior to USBR final onsite inspection.

3. Additional Bearing information:

a. There are 2 Guide bearings

i. The pump guide bearing and the turbine guide bearing are a split sleeve style journal bearings. The inside diameters of these two bearing are just under 8 inches. They are about 6 inches deep.

b. There is 1 Thust bearing

i. Exact size of the thrust bearing shoes unknown. There are 4 shoes of a tilting pad

Kingsbury design.

c. See attachment titled Bering Rehabilitation for further information.

e. ADDITIONAL TASKS, SIZES, AND INFORMATION:

1. Conduct laser leveling of pump case. This work will be onsite and scheduled by the USBR representative as the pump is available and in ready condition for alignment.

2. Pump Size and Information

a. Approximately a 4-foot diameter, Frances type, bronze, pump impeller.

b. Stainless steel stationary wear rings with approximate OD of 40 inches and 35 inches.

c. Stainless steel rotating wear rings with approximate OD of 38 inches and 33 inches.

d. The government will remove the existing stationary wear rings and install the final machined wear rings.

e. Impeller Rotating Rings: Fabricated from Type 420 stainless steel, or similar stainless steel as approved by the USBR representative with a Rockwell C scale hardness of 30 to 35 and machined to specifications.

f. Impeller Stationary Rings: Fabricated from Type 416 stainless steel with a Rockwell C scale hardness of 40 to 45 and machined to specifications.

g. The impeller wearing rings consist of two rotating rings which include an upper ring and a lower ring, and two stationary rings which include an upper ring, the Elbow Suction ring, and a lower ring, the Stuffing Box Head ring. There shall be a minimum of 0.040” between the rotating and stationary rings, the tolerances shall be +0/-0.003 for the outer diameter of the rotating rings, and +0.003/-0 for the inner diameter of the stationary rings.

h. Impeller welding media used in past overhauls: AMPCO Trode 150 welding rod or wire.

i. Impeller ceramic coating used in past overhauls: 3M Scotchkote Urethane Ceramic Lining FG

514.

j. Balancing Mandril: Approximate weight 800 lbs. The contractor shall be responsible for transportation of the mandrel to and from the Chandler Power and Pumping Plant. Use mandrel to balance to 450 RPM right-hand (clockwise) rotation. Balancing weights shall be added or removed in such a manner that there will be no depressions or projections from finished surfaces.

k. If necessary, manufacture a new impeller packing sleeve from stainless steel as specified by Reclamation.

l. Reclamation will remove and install the impeller packing sleeve if replacement is necessary.

3. Turbine Size and Information

a. Approximately a 3.5-foot diameter, Frances type, stainless, turbine runner.

b. Integrated rotating wear rings.

c. The turbine shaft is approximately 7-foot long with and 8-in diameter.

d. The government will remove the existing stationary wear rings and install the final machined wear rings.

e. The turbine stationary wear rings are to be fabricated from a single piece rolled ring forging from to 410 stainless steel. These are the upper and lower wear rings and shall be made in accordance with Reclamation specifications and are to be 20 to 25 Rockwell C scale hardness. Rings will be rough machined with 0.150" of extra material added on the ID dimensions for later finish machining.

f. Machine the turbine runner shaft sleeve from stainless steel having a Brinell hardness of 250 to 300, an OD of 9.000", and an ID of 8.000" per Reclamation specifications.

7.0 DELIVERY, STORAGE, AND HANDLING (Contractor Requirements)

a. Take every precaution during loading, transportation, and unloading.

b. Protect from corrosion, deformation, and other types of damage.

c. Approximate weight total weight of all components: 5000 lbs. total.

a. Components crated and packaged by the Contractor, will require Contractor to provide adequate packing boxes for shipping to prevent damage to components. Boxes to be retained by Reclamation for future storage after delivery.

e. Pickup and deliver the components to the location.

f. A forklift and operator will be available at the powerplant for loading and unloading the components onto and from the Contractor's common carrier. Request from the USBR representative these services a minimum of 24-hours prior to pick-up and/or delivery.

g. Notify the USBR representative at least five full working days in advance of final delivery to the destination.

I. The Government will store the components in accordance with the manufacturer's recommendations.

8.0 Extra Work and Deficient Conditions

If additional work is required due to unknown conditions identified after inspection and testing, or during repair, the Contractor shall notify the Government immediately. The Contractor shall assess the level of additional work needed and submit a quote with itemized detail. The Government will review the quote and, any approved additional work will be executed with a bilateral modification.

9.0 DELIVERABLES

ITEM CONTRACTOR

REQUIREMENT Deadline Date RECLAMATION

Impeller Spare/New Runner Removed Runner Bearings (Pump Guide, Turbine Guide and Thrust Shoes) Head Cover Turbine runner shaft

Pick-up items Available to Contractor by Nov.

14, 2025

Impeller Report of findings Nov. 25, 2025 USBR to respond no later than Dec.1, 2025

Impeller Repaired and recoated as approved

Feb. 10, 2026 On site and USBR accepted NLT Feb. 12, Runner #1 Spare Scroll case and headcover will be available for wear ring measurements by contractor

Dec. 8, 2025

Runner #1 Spare/New Needed dimensions for final machine

New Packing Sleeve Installed, installed on machined shaft, ready to be shipped

Jan. 15, 2026 On Site and USBR accepted NLT January 21, 2026

Wicket Gate Bushings Manufactured and approved

Jan. 15, 2026 On site and USBR accepted NLT Jan. 21, Runner #2 (removed Runner) Removed from shaft and prepared for shipment back to Chandler.

Jan. 15, 2026 On site and USBR accepted NLT Jan. 21, Bearings Inspected, Tested and a report of findings submitted

Dec. 12, 2025 USBR to respond no later than December 22, 2025

Bearings Completed repair as approved by USBR.

Apr. 1, 2026 On site and USBR accepted NLT April 1, Spare Wear Rings Completed repair as approved by USBR.

Apr. 1, 2026 On site and USBR accepted NLT April 1, Pump case Laser leveling Laser leveling completed Feb. 24, 2026

All other parts Delivered back to plant Apr. 15, 2026 On site and USBR accepted NLT April 15, 2026

10.0 Drawings:

USBR - 566-100-124

11.0 CONTRACTING OFFICER REPRESENTATIVE (COR)

A COR will be appointed by a separate letter. The COR will serve as the point of contact for communication with the contractor. All communication shall go through the COR and CO. The contractor shall coordinate scheduling of repairs with the COR.

12.0 SUBMITTALS

Please see provision 52.212-1 Instructions to Offerors—Commercial Products and Commercial Services for a complete list of items required to be submitted with quotes. Failure to include submittals could result in rejection of quote.

13.0 PERFORMANCE REQUIREMENTS SUMMARY

Desired Outcome: Successfully overhaul turbine and pump to like-new, working condition

Task No. Performance Requirement

Method of Surveillance

Acceptable Quality Level

Performance Standards

Performance Measurement

Services necessary to overhaul turbine and pump

COR

Successful testing and operation of turbine and pump;

contractor will provide all complete deliverables.

Fully Operation of Pump before April 15, 2026

COR report that 100% of task has been achieved.