Amendment 005_0005.pdf

(x)

140R6021R0012 x x copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted ; or (c) By separate letter or electronic communication which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGEMENT TO BE

RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN REJECTION OF YOUR

OFFER. If by virtue of this amendment you desire to change an offer already submitted , such change may be made by letter or electronic communication, provided each letter or electronic communication makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

x

Billings MT 59107

R60

PO Box 36900 Regional Office Great Plains Region Bureau of Reclamation

02/25/20210005

13. THIS ITEM ONLY APPLIES TO MODIFICATION OF CONTRACTS/ORDERS. IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

12. ACCOUNTING AND APPROPRIATION DATA (If required) is not extended.is extended, Items 8 and 15, and returning

Offers must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended , by one of the following methods: (a) By completing

The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offers

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

FACILITY CODE CODE

10B. DATED (SEE ITEM 13)

10A. MODIFICATION OF CONTRACT/ORDER NO.

9B. DATED (SEE ITEM 11)

9A. AMENDMENT OF SOLICITATION NO.

CODE

8. NAME AND ADDRESS OF CONTRACTOR (No., street, county, State and ZIP Code)

7. ADMINISTERED BY (If other than Item 6)CODE 6. ISSUED BY

PAGE OF PAGES

4. REQUISITION/PURCHASE REQ. NO.3. EFFECTIVE DATE2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO. (If applicable)

1. CONTRACT ID CODE

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

01/12/2021

CHECK ONE A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE CONTRACT

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority) appropriation data, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(b).

E. IMPORTANT: Contractor is not is required to sign this document and return __________________ copies to the issuing office.

ORDER NO. IN ITEM 10A.

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)15A. NAME AND TITLE OF SIGNER (Type or print)

15C. DATE SIGNED 16B. UNITED STATES OF AMERICA 15B. CONTRACTOR/OFFEROR 16C. DATE SIGNED

(Signature of person authorized to sign) (Signature of Contracting Officer)

Gerri Voto-Braun

STANDARD FORM 30 (REV. 11/2016)

Prescribed by GSA FAR (48 CFR) 53.243

Previous edition unusable

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

Canyon Ferry Powerplant G1 – G3 Generator Rewinds

Canyon Ferry Unit, Helena-Great Falls Division Pick–Sloan Missouri Basin Program, Montana

See attached for changes:

Except as provided herein, all terms and conditions of the document referenced in Item 9 A or 10A, as heretofore changed, remains unchanged and in full force and effect .

Solicitation# 140R6021R0012

Amendment No. 0005

Description of Changes:

1. Update the due date for proposals on the 1442 to reflect the extension.

2. Insert the following sections that were inadvertently left out of Amendment 004:

• SECTION 02 80 10 - GENERAL REQUIREMENTS FOR COATINGS CONTAINING

HAZARDOUS MATERIALS ABATEMENT

• SECTION 02 83 30 - REMOVAL AND DISPOSAL OF COATINGS CONTAINING

REGULATED METALS

• SECTION 48 13 71 - ARMATURE WINDINGS

• SECTION 48 13 73 - FIELD WINDINGS

• SECTION 51 00 00 - INFORMATION AVAILABLE TO OFFERORS

• SECTION 51 00 10 - GENERATOR LOADING TESTS

• SECTION 51 00 20 - GENERATOR MATERIAL SAMPLING RESULTS

3. In Part 1 – The Schedule, Section F - Deliveries or Performance replace in its entirety with the new Section F – Deliveries or Performance.

4. Contractor Question #42: Section F, Paragraph F.1 states “The Government will evaluate equally, as regards time of delivery, offers that propose delivery of each quantity within the applicable delivery period specified above.” Section L, Paragraph L.20 states “An offeror that can show a shorter, yet reasonable schedule based on the information required as above will receive a more favorable rating.”

a. Is it correct to understand that the Government sees no value in a faster delivery schedule for the supplies, but will evaluate shorter outage schedules more favorably?

b. Is there a minimum / maximum outage duration?

Part a.: Yes, the supply delivery schedule must meet the time frame shown in Section F.1. The schedule anticipates the parts to be onsite just prior to install. There is a shortage of space for storage of the supply. The schedules in F.1 are established in how the site work is sequenced.

However, a shorter outage duration will receive a more favorable rating.

Part b.: Outages will be driven the successful offers proposed schedules as the work under the specifications is placed between. It is the intent of the Government to minimize outage durations.

Acknowledgement: See Block 11 above regarding how to acknowledge this amendment. The

Government must receive the acknowledgement at the place designated for receipt of bids (See Block

10 of the Standard Form 1442).

Closing Date for the Receipt of Proposals- The hour and date for receipt of proposals is hereby not extended.

Third Party: If you have given a copy of the solicitation to someone else, please forward this amendment accordingly.

Canyon Ferry Powerplant G1-G3 Generator Rewinds Canyon Ferry Unit, Helena-Great Falls Division Pick-Sloan Missouri Basin Project, Montana Amendment No. 004

General Requirements for Coatings Containing Hazardous Materials Abatement New 02 80 10 - 1

SECTION 02 80 10

GENERAL REQUIREMENTS FOR COATINGS CONTAINING HAZARDOUS

MATERIALS ABATEMENT

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Cost:

1. Include cost in prices in the Price Schedules for items of work for which General Requirements for Hazardous Materials is required.

1.02 DEFINITIONS

A. AIHA: American Industrial Hygiene Association.

B. Competent Person:

1. Arsenic: 29 CFR Part 1926.1118.

2. Cadmium: 29 CFR Part 1926.1127.

3. Lead: 29 CFR Part 1926.62.

C. OSHA: Occupational Safety and Health Administration.

D. PEL: Permissible Exposure Limit.

E. Regulated Area:

1. Arsenic: 29 CFR Part 1926.1118.

2. Cadmium: 29 CFR Part 1926.1127.

3. Lead: 29 CFR Part 1926.62.

F. TSP: Total Suspended Particulates.

1.03 REFERENCE STANDARDS

A. American Society of Testing and Materials (ASTM)

1. ASTM D6966-18 Collection of Settled Dust Samples Using Wipe Sampling Methods for Subsequent Determination of Metals

B. Code of Federal Regulations (CFR)

1. 29 CFR Part 1926.62 Lead

Pick-Sloan Missouri Basin Project, Montana Amendment No. 004

General Requirements for Coatings Containing Hazardous Materials Abatement New 02 80 10 - 2

2. 29 CFR Part 1926.103 Respiratory Protection

3. 29 CFR Part 1926.1118 Arsenic

4. 29 CFR Part 1926.1127 Cadmium

C. Occupational Safety and Health (OSHA)

1. OSHA ID-125G-02 Metals and Metalloid Particulates in Workplace Atmospheres (ICP Analysis)

2. OSHA ID-1006-05 Arsenic, Cadmium, Cobalt, Copper, Lead, and Nickel

SUBMITTALS

D. Submit the following in accordance with Section 01 33 00 - Submittals.

E. RSN 02 80 10-1, Resumes and Qualifications:

1. Competent Person resume for arsenic, cadmium, and lead.

2. Independent Testing Laboratory, arsenic, cadmium, and lead in Coatings.

a. See Article 1.04.

b. Include name, contact person, address, and telephone number.

F. RSN 02 80 10-2, Worker Protection Plan:

1. Personal Protective Equipment:

a. Respirators.

b. Personal air monitoring equipment.

c. Personal Protective clothing.

2. Compliance Program for Worker Protection:

a. Respirator program as required by 29 CFR Part 1926.103.

b. Medical surveillance program for:

1) Arsenic in accordance with 29 CFR Part 1926.1118.

2) Cadmium in accordance with 29 CFR Part 1926.1107.

3) Lead in accordance with 29 CFR Part 1926.62.

G. RSN 02 80 10-3, Background Results for Arsenic, Cadmium, and Lead:

1. Background Level Test Results:

a. Air monitoring results.

b. Wipe samples results.

c. Map indicating location of each sample.

Pick-Sloan Missouri Basin Project, Montana Amendment No. 004

General Requirements for Coatings Containing Hazardous Materials Abatement New 02 80 10 - 3

H. RSN 02 80 10-4, Working Level Test Results for Arsenic, Cadmium, and Lead:

1. Air monitoring and personal employee exposure results inside and outside of Regulated Area.

2. Competent Person verification that OSHA PEL was not exceeded.

3. Map indicating location of each sample.

I. RSN 02 80 10-5, Air Clearance Results:

1. Air and personal employee exposure sample results inside Regulated Area.

2. Wipe samples results inside and outside of Regulated Area.

3. Compare with pre-construction test results for increased contaminant levels.

Include:

a. Competent Person verification that levels did not exceed OSHA PEL for air samples for arsenic, cadmium, and lead.

b. Competent Person acceptance for wipe sample analytical comparison between pre- and post-construction.

1.04 QUALIFICATIONS

A. Competent Person for arsenic, cadmium, and lead: One year experience in air monitoring and evaluating air monitoring data in similar type projects.

B. Independent Testing Laboratory, AIHA accreditation for OSHA ID-125G and OSHA ID- 1006.

1.05 PROJECT CONDITIONS

A. Existing materials contain regulated metals. See Section 51 02 83 - Hazardous Materials Survey and Analytical Results.

B. Existing equipment may be covered in dust.

1.06 ADMINISTRATIVE REQUIREMENTS

A. Competent Person, Regulated Metals:

1. In accordance with Section 01 35 30 - Contractor's Onsite Safety Personnel.

2. Independent from Coatings Removal Contractor.

3. Be onsite for duration of coatings removal activities.

4. Ensure workers use proper hygiene methods and decontamination procedures.

5. Perform or direct air monitoring and clearance testing accordance with 29 CFR Part 1926.

a. Review results and provide results.

Pick-Sloan Missouri Basin Project, Montana Amendment No. 004

General Requirements for Coatings Containing Hazardous Materials Abatement

New 02 80 10 - 4

b. If PELs are exceeded, notify COR immediately.

6. Available for emergencies.

PART 2 PRODUCTS

Not Used

PART 3 EXECUTION

3.01 WORKER EXPOSURE AND AREA SAMPLING

A. Worker Exposure and Area Sampling:

1. Background:

a. Prior to coatings removal:

1) Collect and analyze air samples for arsenic, cadmium, and lead in accordance with:

a) Area samples: OSHA ID-125G.

b) Personal air samples: OSHA ID-1006.

2) Collect wipe samples from areas to be disturbed, in locations as determined by COR in accordance with ASTM D6966. Analyze wipe samples in accordance with OSHA ID-125G.

b. Submit results to COR.

2. During coatings removal:

a. Collect and analyze air and personal employee exposure samples for arsenic, cadmium, and lead in accordance with 29 CFR Part 1926.1118, 29 CFR Part 1926.62, 29 CFR Part 1926.1127, and OSHA ID-125G.

B. Clearance Testing:

1. Collect and analyze air and personal employee exposure sample results in accordance with OSHA ID-125G for arsenic, cadmium, and lead.

2. Collect wipe samples for surfaces related to area where coatings disturbance of removal occurred in accordance with ASTM D6966. Analyze in accordance with

OSHA ID-125G.

END OF SECTION

Removal and Disposal of Coatings Containing Regulated Metals

New 02 83 30 - 1

SECTION 02 83 30

REMOVAL AND DISPOSAL OF COATINGS CONTAINING REGULATED METALS

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Cost:

1. Include in prices offered in the Price Schedules A, C, E, G, and I for Install and Field Test Stator Core.

1.02 DEFINITIONS

A. Class II Landfill: See ARM Rule 17.50.504(2)(a).

B. Class IV Landfill: See ARM Rule 17.50.504(2)(c).

C. DOT: Department of Transportation.

D. Group IV waste: See ARM Rule 17.50.503(1)(c).

E. Handling: Includes containment, collection, storage, and transportation.

F. Regulated Area: See Section 02 80 10 - General Requirements for Coatings Containing Hazardous Materials Abatement.

G. NELAP: National Environmental Laboratory Accreditation Program.

H. NLLAP: National Lead Laboratory Accreditation Program.

I. QAPP: Quality Assurance Project Plan.

J. RCRA: Resource and Recovery Act.

K. Solid Waste: See ARM Rule 17.50.502.

L. TSDF: See Section 02 80 10 - General Requirements for Coatings Containing Hazardous Materials Abatement.

1.03 REFERENCE STANDARDS

A. American Public Health Association (APHA)

1. Method No. 21101-0170T Methods of Air Sampling and Analysis, Second Edition.

B. American Society for Testing and Materials (ASTM)

New 02 83 30 - 2

1. ASTM MNL42-EB-00 RCRA Waste Management: Planning, Implementation, and Assessment of Sampling Activities

C. Code of Federal Regulations (CFR)

1. 40 CFR Part 50, Appendix B Reference Method for the Determination of Suspended Particulate Matter in the Atmosphere (High-Volume Method)

2. 40 CFR Part 50, Appendix G Reference Method for the Determination of Lead in Suspended Particulate Matter Collected From Ambient Air

3. 49 CFR Chapter I, Subchapter C Hazardous Materials Regulations

D. Administrative Rules of Montana (ARM)

1. ARM Rule 17.8.204 Ambient Air Monitoring

2. ARM Rule 17.8.220 Ambient Air Quality Standards for Settled Particulate Matter

3. ARM Rule 17.8.222 Ambient Air Quality Standard For Lead

4. ARM Rule 17.50, Subchapter 5 Solid Waste Management: Refuse Disposal

5. ARM Rule 17.53 Hazardous Waste Management

E. Environmental Protection Agency (EPA)

1. SW-846 Test Method 1311 Toxicity Characteristic Leaching Procedure

(TCLP)

F. Society for Protective Coatings (SSPC)

1.

2. SSPC Guide 6-15 Containing Surface Preparation Debris Generated During Paint Removal Operations

1.04 SUBMITTALS

A. Submit the following in accordance with Section 01 33 00 - Submittals.

B. RSN 02 83 30-1, Qualifications:

1. General: Include name, contact person, telephone number, and address.

2. Hazardous Waste Transporter: See Article 1.07A.

3. Independent Testing Laboratory: See Article 1.07B.

4. Solid Waste Facility: See 1.07C.

5. TSDF: See Article 1.07D.

New 02 83 30 - 3

C. RSN 02 83 30-2, Coating Removal Debris Abatement Plan:

1. QAPP. See Article 1.08A.3.

2. Plan. See Article 1.08A.

D. RSN 02 83 30-3, Waste Characterization, Handling, and Disposal Plan:

1. See Article 1.08B.

E. RSN 02 83 30-4, Waste Characterization Report.

1. See Article 1.08C.

F. RSN 02 83 30-5, Manifest for BOR Signature.

1. Only required if Waste Characterization Report indicates Hazardous Waste.

2. See Article 1.08E.1.b.1.

G. RSN 02 83 30-6, Manifest from TSDF:

1. Only required if Waste Characterization Report indicates Hazardous Waste.

2. See Article 1.08E.1.b.3 and Article 1.08E.1.c.

H. RSN 02 83 30-7, Bill of Lading:

1. See Article 1.08E.2.

1.05 SAFETY AND HEALTH REGULATIONS

A. See Section 02 80 10 - General Requirements for Coatings Containing Hazardous Materials Abatement.

1.06 PROJECT CONDITIONS

A. Existing coatings may contain hazardous materials. Assume coatings contain RCRA 8 metals (arsenic, barium, cadmium, chromium, lead, mercury, selenium, and silver).

B. Contractor will be considered the co-generator of hazardous waste, in accordance with ARM Rule 17.53.

C. Facility owner EPA Identification number will be provided to Contractor after award.

1.07 QUALIFICATIONS

A. Hazardous Waste Transporter:

1. Approved for hazardous waste transport in accordance with:

a. ARM Rule 17.53, Subchapter 7.

b. 49 CFR Chapter I, Subchapter C.

New 02 83 30 - 4

2. EPA Identification number.

B. Independent Testing Laboratory:

1. Accredited under NELAP to perform:

a. Method No. 21101-0170T or approved equivalent.

b. Air sampling analysis according to EPA Part 50, Appendix B.

c. SW-846 Test Method 1311.

2. Accredited under EPA NLLAP to perform air sampling analysis according to EPA Part 50, Appendix G.

C. Solid Waste Disposal Facility:

1. Licensed as a Class II or Class IV Landfill to accept Group IV waste.

2. EPA Identification number.

D. TSDF:

1. Meets requirements of ARM Rule 17.53.

2. EPA Identification number.

1.08 ADMINISTRATIVE REQUIREMENTS

A. Coatings Removal Debris Abatement Plan:

1. Coatings Removal Method:

a. Containment System for Particulate Creating Removal: Prevent the release of coatings outside of containment during the disturbance and removal in accordance with SSPC Guide 6.

1) Descriptions, detail project drawings, and site layout.

2) Include work site containment area techniques, local exhaust ventilation system locations, decontamination units, temporary waste storage facility, location of temporary utilities, and boundaries of Regulated Areas.

3) Performance criteria for the containment. Emission of dusts, metals, toxic vapors or gases into the plant or surrounding environment are prohibited.

4) Signed by the qualified Design Professional.

5) Emissions Monitoring:

a) Monitoring and reporting reportable releases in accordance with ARM Rule 17.8.204, ARM Rule 17.8.220, and ARM Rule 17.8.222.

New 02 83 30 - 5

b) Sampling and analysis in accordance with 40 CFR Part 50, Appendix B, 40 CFR Part 50, Appendix G, and (Method No. 21101-0170T or approved equivalent).

c) Decontamination of contaminated areas and surfaces.

d) Reportable release monitoring, notification and remediation.

b. Non-particulate Creating Coatings Removal.

1) Localized method to remove coatings such as chemical coating stripper or mechanical cutters or grinders with shrouds attached to dust collection system.

2) Indicate where coatings are to be removed and their location by this method.

2. QAPP in accordance with ARM Rule 17.8.204.

B. Waste Characterization, Handling, and Disposal Plan:

1. Waste Characterization Plan:

a. Sampling in accordance with ASTM MNL-42-EB.

b. Characterize samples in accordance with SW-846 Method 1311.

2. Determine disposal methods for Solid Waste and Hazardous Waste.

a. Hazardous Waste Transporter:

1) Name, contact person, telephone number, and address.

2) EPA Identification number.

b. Solid Waste Disposal Facility:

1) Name, contact person, telephone number, and address.

2) EPA Identification number.

c. TSDF.

1) Name, contact person, telephone number, and address.

2) EPA Identification number.

3) Agreement to accept waste generated under this contract.

3. Spill Plan:

a. Methods to:

1) Prevent releases from wastewater from discharging into open drains.

2) Collect releases and clean area after release.

b. Equipment onsite to contain and collect releases.

New 02 83 30 - 6

c. Personnel training and availability for release response.

d. Immediately notify COR, by phone, of releases; follow up with written report within 24 hours.

C. Waste Characterization Report:

1. Sampling, analyzing, and characterizing samples from coating removal debris.

a. Independent Testing Laboratory name, contact person, telephone number, and address.

b. Include Independent Laboratory quality assurance / quality control information, matrix spikes, matrix spike duplicate data, method detection limits, machine detection limits, dilution factors.

D. Transportation Requirements:

1. General: Obtain required transportation permits.

2. Hazardous Waste:

a. Only required when Waste Characterization shows the presence of Hazardous Waste:

b. Before transporting Hazardous Waste, obtain notice from owner or operator of the TSDF, including documentation that TSDF has required permits and will accept waste to be shipped generated in this section.

3. Solid Waste: Transport in accordance with ARM Rule 17.50.523.

E. Disposal Requirements:

1. Hazardous Waste Manifest, EPA Form 8700-22, required when the Waste Characterization show the presence of Hazardous Waste.

a. Prepare, in accordance with ARM 17.53 and 49 CFR Chapter I, Subchapter C, before transporting Hazardous Waste for offsite treatment, storage, or disposal.

b. Obtain signed manifests and disposal documentation:

1) At time of collection, signed by Transporter and BOR.

2) At time of delivery to TSDF, signed by Transporter.

3) At time of disposal, signed by TSDF.

4) Certificate of Disposal or Notice of Acceptance for Hazardous Waste from TSDF.

c. Acceptance of Hazardous Waste at a the approved TSDF does not meet the definition of final treatment nor final disposal under the contract.

1) Obtain documentation to prove final treatment or final disposal of has been accomplished.

New 02 83 30 - 7

2) Attach documentation to the Certificate of Disposal or Notice of Acceptance.

2. Bills of Lading: From Solid Waste Disposal Facility.

PART 2 PRODUCTS

Not Used

PART 3 EXECUTION

3.01 COATINGS REMOVAL

A. Perform in accordance with approved Coating Removal Debris Abatement Plan.

B. Minimize quantity of coatings to be removed.

C. Perform the following activities using coatings removal methods in approved Removed Coatings Debris Abatement Plan:

1. Coating removal.

2. Surface preparation.

3. Waste and debris containerization.

4. Activities which may spread contamination outside contained area.

3.02 WASTE CHARACTERIZATION, HANDLING AND DISPOSAL

A. Characterize solid waste debris generated from coatings removal operations in accordance with approved Waste Characterization, Handling and Disposal Plan. Presume waste is hazardous until characterized.

B. Hazardous Waste:

1. Comply with ARM Rule 17.53.

2. Do not co-mix different types of hazardous and non-hazardous waste materials.

3. Store coating debris in DOT approved weatherproof, watertight steel containers.

C. Solid Waste:

1. Store in closed containers separate from hazardous waste storage areas.

2. Store then dispose of waste in accordance with the approved Waste Characterization, Handling and Disposal Plan.

D. Transport hazardous waste materials in accordance with Waste Characterization, Handling and Disposal Plan

New 02 83 30 - 8

3.03 REPORTABLE RELEASES

A. In accordance with the approved Coating Removal Debris Abatement Plan.

Armature Windings Revised 48 13 71 - 1

SECTION 48 13 71

ARMATURE WINDINGS

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Furnish and Factory Test Armature Winding:

1. Payment: Lump-sum price offered in Schedules A, B, D, F, and H.

a. Includes:

1) Armature Winding Spare Coils in Schedule A only.

2) Nine (9) extra coils per each generator (total 27) to be dissected by the Government.

B. Install and Field Test Armature Winding:

1. Payment: Lump-sum price offered in Schedules A, C, E, G, and I.

a. Includes: Generator Performance Tests in Schedule A only.

C. Armature Winding Monthly Storage:

1. Measurement: Storage of armature winding per month.

2. Payment: Unit price offered in Schedules J, K, L, and M.

a. Environmentally Controlled.

D. Extended Warranty:

1. Payment: Lump-sum price offered in Schedules A, B, D, F, and H.

a. Includes warranty inspections.

1.02 REFERENCE STANDARDS

A. ASTM International (ASTM)

1. ASTM E376-17 Measuring Coating Thickness by Magnetic- Field or Eddy-Current (Electromagnetic) Examination Methods

2. ASTM E1282-11(2016) Specifying the Chemical Compositions and Selecting Sampling Practices and Quantitative Analysis Methods for Metals, Ores, and Related Materials

B. American Welding Society (AWS)

Revised 48 13 71 - 2

1. AWS A5.8/A5.8M-11 Filler Metals for Brazing and Braze Welding

C. Facilities Instructions, Standards and Techniques (FIST)

1. FIST 3-8 Operation, Maintenance, and Field Test Procedures for Protective Relays and Associated Circuits

D. Institute of Electrical and Electronics Engineers (IEEE)

1. IEEE 43-13 Testing Insulation Resistance of Machinery

2. IEEE 95-02(2012) Insulation Testing of AC Electric Machinery (2300 V and Above) with High Direct Voltage

3. IEEE 115-09 Test Procedures for Synchronous Machines

4. IEEE 286-00 Measurement of Power Factor Tip-Up of Electric Machinery Stator Coil Insulation

5. IEEE 522-04 Guide for Testing Turn Insulation of Form- Wound Stator Coils for Alternating-Current Electric Machines

6. IEEE C50.12-05 Salient-Pole 50 Hz and 60 Hz Synchronous Generators and Generator/Motors for Hydraulic Turbine Applications Rated 5 MVA and Above

7. IEEE C57.13-16 Instrument Transformers

E. National Electrical Manufacturer’s Association (NEMA)

1. NEMA FI1-04 Manufactured Electrical Mica

2. NEMA LI1-11 Industrial Laminated Thermosetting Products

1.03 SUBMITTALS

A. Submit the following in accordance with Section 01 33 00 - Submittals.

B. RSN 48 13 71-1, Approval Drawings:

1. Include bill of materials for each set of drawings:

a. Do not change bill of material reference numbers between delivery orders.

2. Dimensioned sectional views of armature windings and slots including:

a. Total copper cross-sectional area.

b. Bare copper strand dimensions and strand insulation details.

c. Slot fillers, wedging details, and corona suppression system.

Revised 48 13 71 - 3

d. View of overall exterior shape and dimensions of coils.

e. Voltage grading treatment overlap length with slot section outer corona protection, and overall length of the coating. Specify margin between end of voltage grading treatment and any end-winding blocking and bracing, lashing, or ties.

f. Insulating material types and thicknesses.

1) Define the excepted nominal epoxy resin content, and range, for the coil cell section, areas under the voltage grading treatment, and the end arm or end winding areas.

2) Tolerance of groundwall thickness at slot section at straight sides and around corners.

3) Tolerances of coil cross-section outer dimensions.

4) Nominal outer radius at corners of coil plus tolerance.

5) Specified layers of mica tape plus tolerance for acceptable tape layer count when viewed in cross-section.

6) Provide the minimum bending radius for the mica tape layers.

7) Provide the minimum bending radius for tape layers that incur wrinkles, folds, fingers, waves, kinks, etc

3. Winding layout diagram showing:

a. Parallel paths per phase.

b. Views or notes defining slot-numbering system, method of determining slot number in which each coil is located, if it is in front or rear slot position, and location of slot number 1.

c. Detailed listing showing each slot, phase identification of coils, and position of coils with reference to line end of circuit.

d. Slot location of each RTD with confirmation that RTDs are located in slots with same phase coils in top and bottom slot positions.

e. Phasor diagram showing the sequence of positive emf.

f. Winding connection to A, B and C phases.

4. Wedge and spring-type wedge filler assembly details.

5. Plan and sectional views of circuit ring buses, connections between windings and circuit ring buses, and connections between circuit ring buses and main and neutral leads.

6. Plan and sectional views of surge rings and bracing.

7. Plan and sectional views of main and neutral bus, including CT details:

a. CT manufacturer data sheets.

Revised 48 13 71 - 4

8. Resistance Temperature Detectors (RTDs):

a. Manufacturer’s technical data.

b. Plan and sectional views.

c. Wiring diagram

C. RSN 48 13 71-2, Design Data:

1. Furnish after completion of design:

a. Armature winding resistance at 95 degrees C.

b. Armature I2R losses at rated load.

c. Stray load losses at rated load.

d. Maximum temperature rise in degree C above 40 degrees C ambient, at rated load, for armature windings by RTD and for field windings by resistance.

e. Field current and voltage requirements for operation at:

1) Rated generator kVA, rated power factor and rated voltage.

2) Rated generator kVA, unity power factor and rated voltage.

3) Speed no-load, unity power factor and rated voltage.

f. Normal voltage stress per mil (0.001 inch) of ground wall insulation.

g. Total capacitance of each phase of armature winding to ground.

h. Capability curves, (over- and under-excited), based on rated load, reflecting maximum temperature rise of 80 degrees C for both armature and field windings.

i. Maximum forces on coils, both for slots with same phase coils and slots with different phase coils. Furnish formula and calculations.

j. Direct-axis synchronous reactance Xd.

k. Quadrature axis synchronous reactance Xq.

l. Direct axis transient reactance X’du and X’d-sat.

m. Quadrature axis transient reactance X’q.

n. Direct axis sub-transient reactance X"d.

o. Quadrature axis sub-transient reactance X’’q.

p. Direct axis open circuit transient time constant T’do.

q. Direct axis open circuit sub-transient time constant T"do.

r. Quadrature axis open circuit sub-transient time constant T’’qo.

s. Leakage reactance Xl.

Revised 48 13 71 - 5

t. Potier reactance Xp.

u. Spring filler acceptable deflection range during installation and minimum acceptable deflection of spring fillers during operation (end of warranty period).

D. RSN 48 13 71-3, Manufacturing Procedures:

1. Step-by-step description of manufacturing procedures and descriptions of manufacturing techniques.

2. Quality control at each step in the coil production process.

3. Acceptable levels of touch-ups and unacceptable techniques for abnormalities in manufacturing processes.

4. Method of groundwall and end-winding insulation application.

5. Method of looping, spreading, forming, pressing, heating, and curing.

a. Temperatures, pressures, and durations.

E. RSN 48 13 71-4, Factory Test Procedures:

1. Procedures and acceptable test results for each test performed on coils.

2. Provide Government notification of optimal time to witness coil testing and manufacturing.

F. RSN 48 13 71-5, Factory Test Reports:

1. Reports or records for each factory test performed.

2. Permanent record identifying each coil, even if it is not part of final windings or spare parts.

G. RSN 48 13 71-6, Installation Procedures:

1. Step-by-step description including drawings or sketches, photographs, list of materials, descriptive literature of resins and tapes, list and description of tools unique to rewind work, specific storage requirements, handling and use precautions, and other information to clarify procedure.

2. Method of installation of coils including method of interconnecting them, connecting parallel string to ring bus, and insulating connections.

a. Include details for brazing operations of the windings including cooling method and control and prevention of water coming in contact with coil insulation.

b. Method of controlling air quality during brazing operations.

3. Method of installing spring fillers, determining tightness of coils in slots, and measuring initial and future spring filler compression.

Revised 48 13 71 - 6

4. Method of installing and securing wedges to prevent slippage during machine operation.

5. Method of installation of circuit ring buses, surge rings, and main and neutral leads.

6. Description of test methods and equipment used for dielectric tests on installed winding sections during each shift and after installation is complete.

H. RSN 48 13 71-7, Field Test Procedures:

1. Procedures and acceptable test results for each field test performed including performance tests.

I. RSN 48 13 71-8, Field Test Reports:

1. Test reports for field tests excluding performance tests.

2. Summary of test reports, including ripple-spring compression data.

J. RSN 48 13 71-9, Performance Tests:

1. Test reports for performance tests.

K. RSN 48 13 71-10, Warranty Inspection Procedures:

1. Method of checking armature winding, stator core and rotor pole condition. The rotor may or may not be removed until last inspection near end of the 5 year warranty period.

L. RSN 48 13 71-11, Warranty Inspection Reports:

1. Report inspection results.

2. Corrective action plans, implementation, and make additional maintenance recommendations if required for future satisfactory generator operation.

1.04 ADMINISTRATION

A. Final Drawings and Operation and Maintenance Manuals: Submit in accordance with Section 01 78 30 - Project Record Documents.

1.05 DESIGN REQUIREMENTS

A. Provide a complete winding with a full number of un-repaired, operational coils that meets specified generator ratings and temperature limits.

B. Coordinate the armature winding design for the vertical-shaft hydro-generator to fit in the slots of the new stator core.

C. Provide multi-turn coils with strand insulation, dedicated turn insulation, and ground wall insulation; and for top end-winding connection as shown on the attached drawings.

Revised 48 13 71 - 7

D. Design in accordance with the following requirements:

1. Transposed strands in the coil end-winding area or in the leads of the coils to minimize Eddy currents and stray load losses by averaging strand distance from the air gap.

2. End-windings with adequate clearance between coil shoulders to minimize corona and to fit in the space available for the top and bottom end-windings.

3. Top and bottom surge rings with supports for winding alignment and to restrain end-windings during most severe short-circuit conditions the generator could experience.

4. Slot filler materials for a tight fit of the armature coils in the stator core slots.

5. Spring filler for tension behind slot wedges to restrain winding and slot fillers from movement during the operating life of the winding.

6. Main and neutral lead extensions for connection to existing generator bus work.

1.06 DELIVERY, STORAGE, AND HANDLING

A. In accordance with Section 01 60 00 - Product Requirements.

B. Store in designated location.

C. The size and weight of the armature coil crates used for shipping new coils to site shall be accounted for in the design for the work platform loading capacity.

1. The actual weight of each loaded crate shall be clearly labeled on one end and side.

2. If the size or weight of a loaded armature coil crate exceeds the capacity of the powerplant forklift, the Contractor is responsible for providing a properly rated forklift to facilitate off-loading the coil crates at the powerplant and moving them around to support the platform work effort.

1.07 EXISTING CONDITIONS

A. Generator Ratings:

1. Load: 16,666 kilovolt amperes.

2. Power factor: 1.00.

3. Rated Current: 1,395 Amps

4. Overload Rating: 19,200 kVA

5. Voltage: 6.9 kilovolts, 3 phase.

6. Frequency: 60 hertz.

7. Speed: 150 rpm (48 poles).

8. Direction of rotation (viewed from top of unit) G1 through G3: Clockwise.

Revised 48 13 71 - 8

9. Excitation Voltage: 250 Vdc

10. Number of stator slots: 351

11. Number of parallel circuits: 3

12. Coils per parallel circuit: 39

13. Coil/Insulation Type: Multi-turn, GE Asphalt Mica

1.08 EXTRA MATERIALS

A. Furnish with same material and workmanship identical to installed parts of generator and that meet requirements of these specifications.

B. Items intended as spare parts, but used for replacements during installation, shall not deplete number of spare part sets required to be furnished for extended storage.

C. Mark and package spare parts for storage in separate moisture tight wrappings or containers.

D. Spare parts:

1. 50 coils with long leads.

2. Installation materials in quantities to install 50 spare coils:

a. Slot filler materials.

b. Four stator slot RTDs.

c. Blocks, shims, spacers, felt, and bindings.

d. Wedges, ripple springs, and spring fillers.

e. End connectors, jumpers, and fittings.

f. Sil-Fos or other brazing material (ribbon and rod).

g. Mica and other insulating tapes.

h. Glass protective tapes and outer bindings.

i. Detailed list and part numbers of consumables for spare coil installation which have limited shelf life and must be ordered at time of use.

E. Additional coils for dissection analysis:

1. Produce 9 additional coils for each generator.

2. Government will randomly select 3 coils from each of early production, mid-production, and late productions stages.

a. Mark, package, and ship additional coils immediately after manufacturing and final testing has been completed.

Revised 48 13 71 - 9

b. Coils will be dissected and analyzed to compare against the manufacturing drawings and tolerances provided by the contractor in the Approval Drawings submittal.

c. If dissection analysis identifies the randomly selected coils deviate from the manufactures approved drawings and tolerances, all coils manufactured prior to the dissected specimens are subject to rejection. Additionally, further dissections and inspection shall be performed to determine if additional coils fail to meet the manufactures approved drawings and tolerances and additional coils may be rejected.

PART 2 PRODUCTS

2.01 RATINGS

A. Provide complete new armature winding with the following ratings:

1. Load: 19,200 kilovolt amperes.

2. Power factor: 1.00.

3. Voltage: 6.9 kilovolts, 3 phase.

4. Frequency: 60 hertz.

5. Speed: 150 rpm (48 poles)

6. Direction of rotation (viewed from top of unit) G1 through G3: Clockwise.

2.02 TEMPERATURE RISE

A. Defined as degrees C rise above average cooling air temperature, which is maintained by the Government not to exceed 40 degrees C:

1. Comply with IEEE C50.12 for Class F insulation and warrant an armature winding temperature rise limit of 80 degrees C at rated load.

2. Design for service conditions defined in IEEE C50.12.

2.03 ARMATURE WINDING AND INSULATION SYSTEM

A. Provide coils with Class F insulation in accordance with IEEE C50.12, consistent with each other in shape and dimensions.

B. Insulation: Class 155 (Class F) as defined in IEEE C50.12.

C. Provide coils consistent with each other in shape and dimensions.

D. Strands and Strand Insulation:

Revised 48 13 71 - 10

1. Copper strands splice free over entire length of coil and sized to minimize eddy and circulating currents.

2. Annealed copper, free from splinters, flaws, rough spots, or kinks.

3. Insulate with glass, Dacron-glass or mica tape. Strand bonding resin properties must be compatible with ground insulation to prevent bonding failure due to mechanical, thermal and chemical effects.

4. Transpose strands in the coil end-winding are or lead portions of each coil.

Extend uninsulated strands at coil ends for connection to other coils and ring buses.

E. Turns and turn insulation:

1. Insulate with a taping system containing Mica splittings or Mica paper, including glass backing fabrics with binding and filling materials compatible with strand and ground wall insulation.

2. Shape and lay-up the completely insulated turns before application of ground wall insulation to form a dense and void-free structure after ground wall application.

3. Provide unique coil identification. Keep permanent records of coils for Government inspection, even if they are not used for installation or spare sets.

4. Furnish coils with dimensions in the slot section allowing a tight fit in the slots.

5. Provide sufficient end-turn spacing to prevent damaging discharge activity between objects in the end-turn area with significant potential differences.

F. Ground Wall Insulation:

1. Provide taping system consisting of mica splittings or mica paper, including glass backing fabrics with binding and filling materials.

2. Provide Grade C mica insulating materials in accordance NEMA FI1.

3. Apply tape continuously over entire slot portion of coil. Apply tape using an overlap method to eliminate butt joints.

4. Completely impregnate ground insulation with solvent-free epoxy or polyester resin, using vacuum pressure impregnation process, resin-rich "B-staged" epoxy tape, or polyester-impregnated tape curing processes.

5. Finished insulation to be a solid, dense structure with minimal voids and inclusions, and minimum tape waviness or folds (fingers).

6. After ground wall and end winding insulation are cured, do not disturb insulation system other than replacing protective covering with binder or armor tape.

G. Corona Shielding System:

Revised 48 13 71 - 11

1. Provide corona shielding system consisting of semi-conductive treatment in slot area and a voltage grading treatment in areas near core ends to minimize partial discharge.

2. Prevent or minimize general discharge activity during machine operation to minimize ozone generation and electrical degradation of insulation systems during the service life of the winding installation.

3. Resistant to physical damage during handling, installation and normal maintenance and resistant to common cleaning solvents such as trichloromethane, Stoddard solvent, citrus based cleaners, or other commercially available solvents used for cleaning electrical equipment.

4. Semi-conductive Treatment:

a. Continuous semi-conductive coating for slot portion of coils providing a Faraday shield and grounding system to prevent electrical discharge.

b. Completely and permanently bonded to coils. Ensure semi-conductive treatment in slot portion of coil does not adhere to stator core.

c. Extend beyond core ends and overlap with voltage grading treatment. In applying voltage grading treatment over semi-conductive treatment, take precautions to ensure any deteriorating effects, including softening and possible displacement of semi-conductive treatment, do not occur.

d. Combine semi-conductive treatment system with tight coil installation and wedging methods to ensure adequate contact between coils and slot walls is established and maintained, and to ensure electrical charges on coil sides are distributed along contact surface without development of damaging slot corona.

5. Voltage Grading Treatment:

a. Apply voltage grading treatment system to coil ends near core, using pre-saturated grading tape or painted voltage grading treatment equal to pre-saturated tape in adhesion and abrasion resistance.

b. Coordinate voltage grading treatment to overlap semi-conductive coating without chemical or electrical degradation of junction areas.

c. Select the resistance of voltage grading treatment to meet following performance criteria:

1) Free of discharge activity at the junction between voltage grading treatment and semi-conductive slot treatment.

2) Free of discharge activity in the voltage grading treatment area.

3) If multistage grading system is used, match resistances of individual treatments to prevent discharges or heat deterioration at junction areas where treatments overlap.

H. Do not use polyester film (Mylar) backing tapes in permanent installation.

Revised 48 13 71 - 12

2.04 WEDGES AND SLOT FILLER

A. Wedges:

1. Suitable for tightly wedging coils in slots without shrinking, buckling or dislodging from wedge grooves and capable of maintaining adequate pressure in slots to prevent coils from vibrating and slot fillers from migrating during the service life of the winding.

2. Made from glass mat base laminate grade GPO-1, GPO-2, GPO-3, or better in accordance with NEMA LI1.

3. Provide wedges with slots or series of appropriately located holes to be used for measuring spring compression differentially between peaks and valleys.

4. Perform machining of wedges at the factory. On-site modifications of wedges are not permitted.

5. Alternate to Single-Piece Wedge System: Two part, radial-pressure-type wedges.

Include method of measuring amount of spring compression in alternate wedge system.

B. Slot Filler Materials:

1. Provide flat filler strips of semi-conducting material.

2. Provide spring filler material of non-conducting material.

3. Capable of satisfactory operation for entire service life of windings.

2.05 CIRCUIT RING BUS

A. Provide new circuit ring buses of sufficient cross section to prevent abnormal heating at rated machine output and provide adequate insulation. Design for thermal expansion and contraction.

B. Provide blocking and lashing materials, tapes, supports, binding and other materials necessary for complete installation of new armature windings.

C. Provide supports with mounting brackets for ring bus support under normal and short-circuit operations.

D. Provide support structures with structural and dielectric strength equal to or better than corresponding materials used in existing installation.

E. Apply insulation to circuit rings after final shaping.

F. Do not use solvent-type varnish as tape binder on circuit rings, main and neutral leads, and winding interconnections.

Revised 48 13 71 - 13

2.06 SURGE RINGS AND BRACING

A. Provide insulated non-magnetic top and bottom surge rings to aid coil alignment during installation and to prevent damaging movement of end-windings during severe short-circuit conditions.

B. Apply insulation after final shaping and after they are secured.

C. Spacers:

1. Provide phenolic laminate or polyester glass laminate spacers for bracing and binding end turns to surge rings.

2. Cover with a material such as Dacron felt pre-soaked with solvent-free epoxy or polyester resin.

3. Secure in place using lashing material.

2.07 RESISTANCE TEMPERATURE DETECTORS (RTD)

A. Provide 12, dual-element platinum 100-Ohm RTDs, plus/minus 0.5 percent at 0 degrees Celsius.

B. Nominal Temperature Coefficient of Resistance: 0.00385 Ohm/Ohm/degree Celsius.

C. Sensing Element Length: Approximately 5 inches.

D. Leads: 3 conductor, stranded, tinned copper encapsulated in flexible heat-cured compound or protected with acrylic resin-coated fiberglass sleeving.

2.08 MAIN AND NEUTRAL BUS

A. Bus:

1. Provide new copper bus of sufficient cross section to prevent abnormal heating at rated machine output and provide adequate insulation and spacing.

2. Provide supports with adequate dielectric strength and structural support under normal and short-circuit conditions.

3. Main Bus:

a. Provide insulated copper bus bar from circuit ring bus to flex-links.

b. Provide new flexible links and hardware for connection to existing bus.

4. Neutral Bus:

a. Provide copper bus bar from circuit ring bus to wye-point. Provide bus to make wye connection.

b. The neutral bus bar making the wye-point connection cannot be installed at a lower elevation than existing.

Revised 48 13 71 - 14

c. Reuse the existing neutral cable from the neutral grounding transformer.

B. Current Transformers (CT):

1. Generator Metering and Relaying and Excitation CTs (3 per phase, 9 total per unit):

a. Conform to IEEE C57.13.

b. Ratio: 2000:5 amperes.

c. Accuracy class: C800.

d. Class: 600 Volt

2. Wire CTs out to shorting-type terminal blocks in existing generator terminal box.

3. Provide cable and conduit in accordance with Section 26 05 10 – Conductors and Cables and Section 26 05 33 – Electrical Conduit.

2.09 NAMEPLATE

A. Provide nameplate for each generator, same physical size as existing nameplate. Include pertinent information such as rated output, voltage, amperage, power factor, frequency, rpm, insulation class, and maximum temperature rise of rotor and stator.

B. Minimum size of nameplate to match that of existing generator OEM nameplate.

2.10 CONTRACTOR SOURCE QUALITY TESTING

A. General Requirements:

1. Test metals in accordance with ASTM E376, ASTM E1282, and specialized industry practices involving other pertinent and non-conflicting standards.

2. Do not ship materials or equipment until required tests, analyses, and shop inspections are completed and Government gives permission to ship, or inspection at shipping point is waived. Government will give notification of specific tests that will be witnessed by Government.

3. Stop production and notify Government if 2 failures occur within 25 consecutive coils being tested, within the same type of specified test.

4. Identify and correct cause for failures. Notify Government of intent to restart production. Government will concur with plans to restart production only if corrective actions are implemented and verified.

B. Perform manufacturer’s standard tests and include the following:

1. Strand Insulation Test:

a. Test each strand for continuity and strand-to-strand shorts at a minimum voltage of 110 volts, 60 hertz.

2. Dimensional Tests:

Revised 48 13 71 - 15

a. Shape and dimensional checks during manufacturing and on final coils.

b. Visual inspection of each stator coil to observe for abnormal conditions such as irregular shapes, sharp corners, abnormal tape layout, evidence of abrasions, cracks, protrusions, or other abnormalities.

3. Slot Resistance Test:

a. Measure surface resistance of slot corona semi-conductive treatment.

4. Insulation Resistance and Polarization Index test at 5 kVDC and in accordance with IEEE 43.

5. Turn insulation test:

a. High-frequency surge comparison test in accordance with IEEE 522.

6. Ground Wall Dielectric Test:

a. Perform on completely manufactured coils.

b. Alternating Current Test:

1) Test at minimum of 22.2 kV, 60 hertz for 1 minute.

2) Perform this test only after adequate insulation resistance test.

c. Direct Current Test:

1) Perform a 1-minute direct-current high-potential withstand test at a minimum of 25.2 kVdc.

2) Record leakage current after one minute.

3) Perform the dc high-potential test after the ac test.

7. Power Factor Tip-Up Test:

a. Test in accordance with IEEE 286.

b. Test each coil by measuring power factor, expressed in percent, at 1 kVAC and 4 kVAC determine numerical difference in test values. If difference is greater than 1 percent (0.01 power factor), reject coil and do not furnish as part of contract.

8. Dissipation Factor Test:

a. Perform test on every 10th coil of each production batch.

b. Test coils at 20 percent through 200 percent of rated line-to-ground voltage at 20 percent intervals using power factor tip-up test setup.

c. For each coil failing dissipation factor test, test four additional coils. Do not exceed following dissipation factors:

1) 0.0015 for each 20 percent interval between 20 and 60 percent.

2) 0.003 for each 20 percent interval between 60 and 120 percent.

Revised 48 13 71 - 16

3) 0.004 for each 20 percent interval between 120 and 200 percent.

d. To compensate for occasional measurement anomalies, averaging of a single-step value not meeting specified criteria with next higher step is permitted. Different acceptance criteria may also be averaged.

9. Spring Filler Test:

a. Test 2 percent of spring-type filler material to be used in new winding installation. Test samples of each size of spring filler to be used.

b. Pressure required for 80 percent reduction in spring height: At least 110 pounds per square inch.

c. Completely flatten test samples between two plates. Maintain this condition at 120 degrees Celsius for 168 hours.

d. Measure pressure required for 80 percent reduction in spring height after full compression, high-temperature conditioning test.

1) Acceptable pressure not less than 70 pounds per square inch at room temperature.

2) Uncompressed spring height reduction not less than 20 percent.

e. Redesign and retest spring filler that fails test.

PART 3 EXECUTION

3.01 INSTALLATION

A. Verify existing dimensions pertaining to new winding design…