Attachment_4_Statement_of_Work_Task_Order.pdf

Document No.

140R3019R0001

Document Title Turbine and Generator Hydroelectric Component Manufacturing and Rehabilitation IDIQ

Attachment 4 - Statement of Work Task Order “Field Machining of

Facing Plates, Seal Rings and Wicket Gate Line Boring for unit N1”

Statement of Work Field Machining of Facing Plates, Seal Rings and Wicket Gate Line Boring for unit N1

Task Order

Hoover Dam

1.0 Background

Unit N1 has not had upgrades in the turbine pit area since 1988. Currently, new wicket gates and facing plates have been procured or are in the process of being procured. In order for the new wicket gates to be as efficient as possible, the new facing plates and seal rings must be machined to optimal specifications and the wicket gate bore holes must be corrected of any alignment deficiencies.

2.0 Scope

The general scope of work will require all machining to be performed inside the Hoover Dam Powerhouse. The contractor is required to supply all labor, equipment, materials, transportation, and tools. The government will supply necessary support in the form of cranes, compressed air, and electric power.

3.0 Objectives

It is the intention of field machining operations to return unit N1 back to original equipment manufacturers specifications, or as optimal as possible, in reference to unit plumb, perpendicularity to plumb, and concentricity to centers.

4.0 Requirements

The work required includes:

4.1. Detailed site measurements of ‘As-Found’ conditions

4.2. Field machining

4.3. Facing plates plumb and parallel to each other. The facing plates and associated fasteners will be supplied and installed by the government.

4.4. Upper scroll case flange to plumb

4.5. Upper and lower stationary seal rings to plumb

4.6 Field machining and line boring of wicket gate openings, plumb, perpendicular and concentric to associated centers.

4.6.1. All fumes from welding and machining must be properly ventilated.

4.6.2. Control of all metal chips and debris with cleanup to restore the work area to the condition found at the beginning of work.

Solicitation No. 140R3019R0001

5. Final ‘As-Built’ measurements and drawings to verify conformance as required.

The following illustration outlines areas of concern:

Field machining of the stay ring flange [1], spiral case o-ring surface [2], discharge ring surface [3&3a], main cover plate surface [4&4a], lower seal ring seating surface [5](subject to as-found condition), and upper seal ring seating surface [6](subject to as-found condition).

6. Schedule

Note: The following schedule is subject to change or modification if scheduling, logistical issues, or a combination thereof should be present. The contractor shall provide a cost proposal with supporting documents to substantiate any price adjustments should the need arise.

The work area is within the turbine pit and immediate area for staging equipment. The work area is expected to be available to the contractor 24 hours/day starting at 7:00 A.M. on 12/18/2019. Mobilization of equipment and materials to the site can begin as early as 12/11/2019.

There will be two expected breaks in the schedule:

6.1. There will be an expected break in the schedule due to holiday activities from 5:00 P.M. on 12/24/2019 until 7:00 A.M. on 1/2/2020.

6.2. There will be an expected 2 to 3-day break in the schedule due to installation of facing plates - Exact dates are yet to be determined.

Removal of the headcover facing plates and bottom ring facing plates will be completed by Hoover Dam personnel prior to initiation of machining.

It is estimated that this work will require the headcover to be installed and removed during the course of machining operations. Each headcover removal will require an 8hr shift for Government personnel to accomplish. Proposals shall account for headcover installation and removals in their proposed schedules and cost for the work.

Tasks requiring Government approval may include, but are not limited to, machine setup and final machined dimensions. Government response shall take no longer than three (3) hours once required data or measurements are submitted to the COR.

Hoover Dam personnel shall be notified 72 hours in advance of materials delivery so that staging sites, rigging, and personnel can be prepared for unloading. Hoover Dam receiving hours are 6:30 A.M. to 3:30 P.M. PST, Monday – Friday.

7. Security/Clearances All contractor personnel working on site shall be subject to passing background investigations and be cleared prior to commencement of work. It shall be the contractor’s responsibility to incur costs for the credentialing process.

The contractor will be required to furnish a list of all employees (prime and subcontractors) who have passed background investigations and will be working at the site(s).

The following identifies the requirements:

7.1 Contractor Employee Security Requirements

Operations at Hoover Dam require continuous and effective security measures. In accordance with Homeland Security Presidential Directive-12, all on-site Contractor personnel shall have a Government-issued Personal Identity Verification credential before being allowed access to work at the site.

The cost of initiating the credentialing process, submitting the requisite forms (forms will be provided by the COR to the contractor after award), obtaining fingerprints, travel to a Credentialing Center for card enrollment and activation, and security interviews shall be borne by the Contractor.

The cost of suitability and PIV related background investigations will be borne by the Government.

For each employee who will be working at Hoover Dam, the Contractor shall:

Complete the Request for Initiation of Contractor Background Investigation form and all of the Declaration for Federal Employment Form (OF-306) and Fair Credit Authorization Form.

Failure to complete the forms in a timely fashion may cause delays in processing background investigations.

Promptly mail (do not e-mail or fax) the completed forms to:

Manuel Contreras (LCD-23106) Hoover Dam PO Box 60400 Boulder City, NV 89006-0400

Following the submittal of the above investigation package for each employee, the employee will receive an invitation to provide additional information required for their background investigation through the on-line e-QIP process. The background investigation will be conducted by the Office of Personnel Management, with the results furnished to the Reclamation Office of Security, Safety, and Law Enforcement for final determination of the employee’s suitability to be assigned to a Reclamation facility.

Once a favorable determination has been made, Contractor personnel shall be invited to visit the Reclamation Credentialing Center at:

Lower Colorado Regional Security Office 200 Date Street Boulder City, NV 89005

(702) 293-8008 Contractor personnel may have the option of visiting a more convenient location to complete the enrollment process.

The Contractor shall be responsible for ensuring that its employees comply with all required investigation interviews and established security rules and regulations.

Contract personnel shall not be permitted to enter established or designated restricted areas unless so authorized by the Government. Entry shall be in accordance with and subject to the security regulations established in the area. It shall be the Contractor’s responsibility to ensure that its personnel do not enter these areas unless authorized.

The Personal Identity Verification Card must be obtained from, and returned to, the Hoover Dam Police Department at the completion of on-site work.

8. Technical Point of Contact All technical issues regarding design, deliver and submittals shall be coordinated through the primary Contracting Officer’s Representative (COR) or the Alternate COR (ACOR):

COR: Manuel Contreras (702) 494-2425 ACOR: George Wendt (702) 494-2240

9. Technical Requirements The purpose of this work is to restore critical dimensions of the large components associated with the turbine water passageway and improve operations, maintenance requirements, and efficiency.

It should be noted that all surfaces to be machined under the scope of this work use relative tolerances.

Absolute dimensions are not a requirement as certain components will be manufactured based on the final measurements from the field machining. For example, the horizontal facing surfaces to be machined specify tolerance for maximum material removal, flatness, and level, but do not require that these surfaces be machined to exact elevations to maintain the distributor stack-up height. The distributor height will be addressed by new facing plates that will be supplied after some machining is complete. The new plates will be ground to thickness to accommodate the required distributor height. However, it is desirable that the newly machined surface elevations be symmetrical about the centerline of the unit distributor.

9.1. Stay Ring Flange and O-Ring Surface Refurbishment

The stay ring flange is that feature of the spiral casing with which the main cover plate is attached. The spiral casing is made up of five (5) individual cast steel casing sections (drawing 806-221) that have been bolted together and encased in concrete. This surface ultimately dictates the horizontal plane in which all turbine pit components are aligned and, in the scope of this work, shall be considered to be the primary datum surface “A”. Included in the scope of this refurbishment, the contractor will be required to re-machine the horizontal surface to within 0.010” from true horizontal (normal to gravitational plumb) as measured across the total diameter of the feature.

The extent of the machining to restore this surface to level shall not exceed 0.060” of material removal at any one location unless approved by the Contracting Officer’s representative (COR). It is desired that the machining on this surface approach >90% witness cleanup of the surface; that is to say that at least 90% of the surface shall show material removal. This is consistent with minimizing the necessary material removal to achieve tolerance, in turn minimizing dimensional complication of components or features installed above the head cover elevation (bearing extension, shift ring, etc.).

The primary water seal between the spiral casing and the head cover is located adjacent to the stay ring flange as shown on drawing 45-301-9668, Details “A” and “B”. The original o-ring surface incorporated a “tear-drop” gland design (refer to drawing 806-221, detail “X”) that over the years has deteriorated. The original gland design will not be maintained and shall be modified by machining this surface flat as shown on drawing 45-301-9668 (Note: This portion may not appear for this unit in which case this section will be omitted).

9.2. Discharge Ring Refurbishment

The discharge ring is made from two steel castings that are bolted together and, as an assembly, bolted to the lower stay ring flange (refer to drawings 807-240 and 806-232). The discharge ring and spiral casing are encased in concrete with the discharge ring major cavities filled with grout. The discharge ring serves as the lower face of the main distributor and has attached to its horizontal surface sacrificial facing plates that make up the lower wicket gate sealing surface. The discharge ring also includes the lower wicket gate stem bushings and lower stationary seal ring.

The bottom ring horizontal surface shall be re-machined flat and parallel with datum surface “A” as defined on drawing 45-301-9668 and will define the feature datum surface “B”. The extent of the machining to restore this surface to tolerance shall not exceed 0.080” of material removal at any one location unless approved by the COR. It will be necessary to machine the top 1.25” of the outer stationary seal ring due to a design change that extends the facing plates over the existing outer seal ring.

The lower stationary seal ring mounting surface shall also be machined round and concentric to the turbine centerline (datum surface “Z”). Prior to machining, the as-found diameter, roundness, and concentricity shall be recorded and submitted to the COR for review. It is anticipated that the maximum cut on the radius will be 0.030” to achieve the tolerance specified on drawing 45-301-9668. Once the lower seal machining is complete, the Government requires the dimension of the seat ID to be measured in a timely fashion so that the final machining of the replacement seal ring can be completed by Government forces.

9.3. Main Cover Plate Refurbishment

The main cover plate is made from two steel castings that are bolted together and, as an assembly, bolted to the stay ring flange (refer to drawings 807-240 and 806-227). The main cover serves as the upper face of the main distributor and has attached to its horizontal surface, sacrificial facing plates that make up the upper wicket gate sealing surface.

This horizontal surface shall be re-machined flat and parallel with datum surface “B” as defined on drawing 45-301-9668. The extent of the machining to restore this surface to tolerance shall not exceed 0.080” of material removal at any one location unless approved by the COR. It will be necessary to machine the top 1.25” of the outer stationary seal ring due to a design change that extends the facing plates over the existing outer seal ring.

The upper stationary seal ring mounting surface shall also be machined round and concentric to the turbine centerline (datum surface “Z”). Prior to machining, the as-found diameter, roundness, and concentricity shall be recorded and submitted to the COR for review. It is anticipated that the maximum cut on the radius will be 0.030” to achieve the tolerance specified on drawing 45-301-9668. Once the upper seal machining is complete, the Government requires the dimension of the seat ID to be measured in a timely fashion so that the final machining of the replacement seal ring can be completed by Government personnel.

9.3.1. Materials

The surfaces to be machined under this work scope are of cast steel construction under Federal specification QQ-S-681, Grade 2 – medium anneal.

10. Machine Requirements The machining equipment to be used shall be mounted in such a way that the overall stiffness of the machine is adequate to prevent excessive tool chatter or other poor cutting characteristics. At a minimum, the machine base shall be attached at six (6) equidistant points on the same elevation in the draft tube.

The contractor will be required to submit details as to the mounting requirements, crane access requirements (including overall weights and sizes), and power requirements of the machine. The Government will provide reasonable accommodations for electrical power in the form of 3ph-480V, 60amp service, within a 40’ reach of the work area. The Government will supply the contractor with the necessary mating plug to connect to the available service outlet.

11. Quality Control The contractor will be required to provide accurate measurements in the as-found condition as well as the as-built condition after machining operations are finished. Intermediate measurements will also be required between machining operations as necessary to verify consistency in the machine setup. All measurements/readings shall be submitted to the COR in an electronic format approved by the COR. The contractor shall submit a quality control plan prior to beginning work that includes drawings/diagrams showing measurement locations, equipment used for measurement, and sequence of the measurements to be taken with respect to proposed machining operations.

At a minimum, the following components and features will be measured:

- Stay ring flange flatness and level (8 equidistant locations)

- Spiral Casing concentricity to unit centerline and establishment of Datum “Z”

- Stay ring flange to bottom ring distance (8 equidistant locations)

- O-ring surface run out

- Bottom ring parallelism to stay ring flange

- Bottom ring to main cover plate distance (@ 72 locations)

- Upper and Lower seal ring diameters and runout

- Bottom ring wicket gate bore locality (chordal and radial) for 24 bores

Machining tolerances shall be consistent with ASME Standard Y14.5M, Dimensioning and Tolerancing, with measurement accuracies deviating not more than 0.002” and 0.001” for feature dimensions over 120” and under 120”, respectively.

12. Safety

Safety and Health Requirements

The Contractor will not require any laborer or mechanic employed in the performance of this specification to work under conditions which are unsanitary, hazardous, or dangerous to the laborer’s or mechanic’s health or safety, as determined under Construction Safety and Health Standards promulgated by the Secretary of Labor under section 107 of the Specification Work Hours and Safety Standards Act (40 U.S.C. 327 et seq.), as amended. ”Reference RAR 1452.223-81 Safety and Health-Bureau of Reclamation.”

12.1. RSHS-2009 Reclamation Safety and Health Standards. Available on the internet at http://www.usbr.gov/ssle/safety/RSHS/rshs.html is the reference standard for the USBR.

12.2. A safety program outlining proposed safety precautions must be submitted in accordance with the Reclamation Safety and Health Standards (RSHS) July 2014 Manual.

The Contractor is responsible for being cognizant of and ensuring compliance with the requirements set forth in (a), (b), and (c) above as well as in the Construction Safety and Health Standards promulgated by the Secretary of Labor under section 107 of the Specification Work Hours and Safety Standards Act (40 U.S.C. 327 et seq.), as amended, and “Reclamation Safety and Health Standards,” (Revised 2001) published by the Bureau of Reclamation. Such responsibility will apply to both the Contractor’s operations and those of the Contractor’s subcontractors. When violations of the safety and health requirements contained in these specifications or standards referenced in subparagraph a., b., and c. are called to the Contractor’s attention by the Contracting Officer or the Contracting Officer’s authorized representatives, the Contractor will immediately correct the condition to which attention has been directed. Such notice either oral or written, when served on the Contractor or the Contractor’s representative(s), will be deemed sufficient.

In the event the Contractor fails or refuses to promptly comply with the compliance directive issued under subparagraph b. above, the Contracting Officer or the Contracting Officer’s authorized representative may issue an order to stop all or any part of the work. When satisfactory corrective action is taken, an order to resume work will be issued. The Contractor will not be entitled to any extension of time, or to any claim for Damage or to additional compensation by reason of either the directive or the stop order. Failure of the Contracting Officer or the Contracting Officer’s Representative to order discontinuance of any or all of the Contractor’s operations will not relieve the Contractor of the Contractor’s responsibility for the safety of personnel and property.

The Contractor will maintain an accurate record of, and will report to the Contracting Officer’s authorized representative in the manner prescribed by the Contracting Officer, all cases of death, occupational diseases, or traumatic injury to employees or the public involved, and property Damage in excess of $2,500 per incident to performance of work under this contract.

http://www.usbr.gov/ssle/safety/RSHS/rshs.html

The rights and remedies of the Government provided in this paragraph are in addition to any other rights and remedies provided by law or under this contract.

In the event there is a conflict between the requirements contained in Reclamation’s “Reclamation Safety and Health Standards,” specifications paragraphs, Contractor’s approved safety program, referenced safety and health codes and standards, or the U.S. Department of Labor Construction Safety and Health Standards, promulgated under section 107 of the Specification Work Hours and Safety Standards Act (40 U.S.C. 327 et seq.), as amended, the more stringent requirement will prevail.

The cost of complying with this paragraph will be included in the Schedule prices for other items of work.

13. Special Work Permit The Contractor will be required to sign and abide by the instructions in a special use permit spelling out what areas of the Dam and powerhouse that the Contractor is allowed to be in. This special use permit will also identify any unusual hazards that might exist in the construction areas. The special use permit will also include any clearances required for safe completion of work. In the case of a fire alarm, drill or actual fire, all Contractor personnel working at Hoover will report to the Arizona ramp adjacent to Unit A3 transformer and provide the head counts to the Government Contracting Representative (the inspector).

Personnel will not return to work until the Bureau of Reclamation’s Safety Officer has sounded the “all clear” air horn.

14. Submission of Job Hazard Analysis The Contractor, consulting with the Bureau site representative, will assess the workplace and work activities to determine if hazards are present or are likely to be present. The Contractor will develop a written Job Hazard Analysis (JHA) for the commissioning work per the Section 3.3 Required Safety Program and Section 4.2 of the “Reclamation Safety and Health Standards” (Revised 2001). JHA’s are required prior to engaging potentially hazardous work. Submittals will be in accordance with Paragraph C.1.4 (Submittal Requirements) and Table 1A (List of Submittals).

15. Reference Drawings Unit N1 is a clockwise spinning, Francis Turbine, rated at 175,000 HP. The latest install of the turbine was in 1988 manufactured by Allis Chalmers

Unit N1 Drawings

1. USBR drawing 45-301-9668; In-Place Machining Details (N1 - N4)

2. Allis-Chalmers Corp. drawing 808-294; Plan View of Power House

3. Allis-Chalmers Corp. drawing 808-295; Plan View of Hydraulic Turbine (N1-N4)

4. Allis-Chalmers Corp. drawing 807-240; Sectional View of Hydraulic Turbine (N1-N4)

5. Voith Hydro Corp. drawing 3829-BPK-1; Arrangement of Runner & Seals (N1-N4)

6. Allis-Chalmers Corp. drawing 806-221; Assembly of Casing Sections (N1-N4)

7. Allis-Chalmers Corp. drawing 806-227; Main Cover Plate (N1-N4)

8. Allis-Chalmers Corp. drawing 806-229; Details of Main Cover Plate (N1-N4)

9. Allis-Chalmers Corp. drawing 806-232; Discharge Ring (N1-N4)

10. Allis-Chalmers Corp. drawing 806-241; Cast Steel Draft Tube (N1-N4)

11. Allis-Chalmers Corp. drawing 807-242; Test Ring – INFORMATION ONLY (N1-N4)

12. Allis-Chalmers Corp. drawing 807-254; Details of Pit Liner (N1-N4)

13. Allis-Chalmers Corp. drawing 810-202; Unit Markings (N1-N4)

16. Submittals

- Safety plan

- Machining plan including; equipment details, sequence of machining operations, and estimated requirements for Government support (crane access).

- Quality Control Plan

- Inspection Report(s)

Safety, machining, and quality control plans shall be submitted no later than 15 days after award.

Inspection reports shall be submitted within 24 hrs of occurrences.

RSN Section Submittal Name(s)

Requirement Required date(s)

No. of sets sent to:

CO COR

1 12 Site Specific

Safety Plan Prime and Subcontractor(s)

15 days after award

1 1

2 6 Schedule Prime 15 days after award

1 1

3 11 Quality Control Prime 15 days after award

1 1

4 11 Initial and final measurements

Prime and Subcontractor(s)

Within 14 days of work completion

1 1

5 14 Job Hazard Plan

Prime and Subcontractor(s)

Prior to commencement of work

1 1

6 Performance & Payment Bonds

Prime Within 10 calendar days after award

1 1

7 Insurance Prime Within 10 days after award

1 1

8 clause 52.222-8

Construction Wage Documentation Certified Payroll Reports

Prime One week after the completion of each payroll period.

1 1

9 clause 52.222-11

Labor Standards Data List of Subcontractors and form SF-

Prime Within 14 days of award and within 14 days after award of any subcontract.

1 1

10 clause 52.222-26

Equal Opportunity Form SF-100

Prime Within 30 days following award

1 0

11 clause 1452.204-70

Release of Claims DI-137

Prime After completion of work and prior to final payment

1 0

17.

FAR

52.211-10

Commencement, Prosecution, and Completion of Work

APR 1984

The Contractor shall be required to (a) commence work under this contract within 10 calendar days after the date the Contractor receives the notice to proceed, (b) prosecute the work diligently, and (c) complete the entire work ready for use not later than 32 calendar days after receiving notice to proceed. The time stated for completion shall include final cleanup of the premises.

(End of clause)

18. Magnitude of Construction The magnitude of construction is between $450,000 and $650,000.

Document No.

140R3019R0001

Document Title Turbine and Generator Hydroelectric Component Manufacturing and Rehabilitation IDIQ

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