Albeni Falls Blade Seals - Tech Specs.pdf

TECHNICAL SPECIFICATIONS

ALBENI FALLS POWERHOUSE

MAIN UNIT TURBINE BLADE SEALS

1.0 INTENT

The following specifications pertain to the purchase of four (4) sets of seals for Albeni Falls Powerhouse Main Unit Kaplan turbine blades. The turbine runner is a 4-bladed vertical axis Kaplan.

2.0 SCOPE

The successful bidder shall be required to furnish and deliver the Kaplan blade seals and all accessories to Albeni Falls Dam by the date shown in the “Shipment and Delivery section. Contractor shall also provide submittals as stated in these specifications.

3.0 BLADE SEALS FOR MAIN UNITS

The contractor shall furnish four (4) sets of molded Kaplan turbine blade seals. The seals shall be James Walker nitrile back-to-back shallex (chevron style) seals to suit housing dimensions shown in the attached reference drawings. The seals shall be specially designed for Kaplan turbines to assure a long-term leak-free sealing action. The seals sets are to include two header rings, two v-rings, and one center gland ring.

The blade seals shall be press cured in endless form & split for in-place installation. For each set, the two header rings are to be square cut, the two v-rings are to be cut with one scarf joint, and the center gland ring also cut with a scarf joint.

The nominal packing size will have an OD of 44.250 and an ID of 42.750 (0.75-inch wide). The housing ID is 42.750 +/- 0.005 inch (BLH 38993, Piece 6) final dimension after interference fit with trunnion. The housing OD is 44.250 + 0.002/-0.000 diameter bore (BLH 39000, Piece 1).

The seals shall be designed to fit within the existing packing box dimensions as shown on the attached reference drawings. The seals shall be an engineer approved, manufactured product which has been sold for at least ten years.

Provide seal assemblies that have been match‐marked by the manufacturer to provide uniform free stack height within +/‐ 1/32” and appropriate stagger of the splits. The seal assemblies are to be verified by the manufacturer that they are within the tolerance and suitable for the dimensions of the housing. The manufacturer is to have a mock‐up of the housing for final fit‐up and matchmarking. At a minimum, this mock-up for the housing will be two plates set at the packing housing width. Prior to delivery, match mark the set and provide quality assurance documentation in the shipment showing the final measurements.

The blade seals will function against the blade packing sleeve (ID) and the retaining ring (OD). The trunnion (ID blade seal surface) will rotate from 19-34 degrees (15 degrees total) during operation, while the hub (OD blade seal surface) will be stationary. The OD of the blade seal housing is Cast Steel Fed Spec QQ-S-681b Class 2 Med (BLH 39000, Piece 1). The ID of the blade seal housing is ASTM A296- 49T or stainless-steel Type 410 Annealed (BLH 38993, Piece 6).

4.0 SUBMITTED DOCUMENTATION

Submit the following for approval, prior to the shipment of the seals. Manufacturer’s drawings and installation procedures shall be provided for the seals requested.

4.1 Blade Seal Assembly Drawings

Submit for approval prior to manufacturing of new seals. The Government will be taking housing measurements and will confirm with manufacturing the suitability of use. Include the required surface finish of the contact surfaces of the housing on the drawing.

The drawings shall include material, dimension, specifications, vendor name and phone number, and a drawing number that can be referenced for replacement blade packing on future orders. The drawings shall be provided as PDF digital format so it can be added to the existing drawing database. If available, the CADD version of the drawing shall also be provided.

4.2 Blade Seal Installation Instructions

Submit for approval instructions for installing the blade seals into the housing. The instructions are required to reflect installation in place (without removal of the blades) and include details for the specific assembly shown in the attached drawing of the seal assembly (shown in BLH-39002).

4.3 Blade Seal Quality Documentation

Prior to shipment from the manufacturer, submit for approval the quality documentation and photos showing the seals were measured to match tolerances and acceptance criteria shown in the blade seal drawing.

5.0 WARRANTY

All items shall be covered by the manufacture’s standard warranty on all parts, labor, and workmanship from factory defects. Warranty period shall be a minimum of one year.

6.0 PACKAGING

All seal assemblies shall be individually vacuum packed to facilitate long term storage. All seal assemblies and all accessories shall be packaged into a single box or wood crate for storage. This container shall be mounted on a pallet so that it can be handled with a forklift or pallet jack. Include a copy of the final quality documentation and drawing inside the crate. The box or crate shall be clearly labeled on one side and on top with the following description:

Contract Number Turbine Blade Seals for Main Units Contractor’s Company Name Contractor’s Seal Model Name / Part Number Contractor’s Point of Contact Name Contractor’s Point of Contact Phone Number

7.0 SHIPMENT AND DELIVERY

All items shall be delivered free-on-board (FOB) to the project within 14 weeks of contract award. The contractor shall be responsible for packing and shipping the components in a manner that will ensure undamaged and complete arrival to the powerhouse. No shipments are allowed other than normal business hours of Monday-Thursday 7:00 a.m. to 4:00 p.m. PST, excluding federal holidays.

All shipments shall be delivered to:

U.S. Army Corps of Engineers Albeni Falls Dam Warehouse Receiving 2376 E. Highway 2 Oldtown, ID 83822

BID SCHEDULE

MAIN UNIT TURBINE BLADE SEALS

BID ITEM LIST

ITEM DESCRIPTION QUANTITY U/M U/P AMOUNT

Turbine Blade Seals

SET

Total

TECHNICAL SPECIFICATIONS

ALBENI FALLS POWERHOUSE

MAIN UNIT TURBINE BLADE SEALS

1.0 INTENT

The following specifications pertain to the purchase of four (4) sets of seals for Albeni Falls Powerhouse Main Unit Kaplan turbine blades. The turbine runner is a 4-bladed vertical axis Kaplan.

2.0 SCOPE

The successful bidder shall be required to furnish and deliver the Kaplan blade seals and all accessories to Albeni Falls Dam by the date shown in the “Shipment and Delivery section. Contractor shall also provide submittals, drawings, and other documentation as stated in the specifications.

3.0 BLADE SEALS FOR MAIN UNITS

The contractor shall furnish four (4) sets of molded Kaplan turbine blade seals. The seals shall be James Walker model “Solosele KB Hydro OSJ” to suit measured housing dimensions. The seals shall be designed to fit within the existing packing box dimensions as shown on drawings BLH 38996, BLH 39000, and BLH- 39002. The final dimensions will be provided at contract award and may increase a maximum of 0.040-inch, to be confirmed between James Walker engineering and the US Corps of Engineers’ Hydroelectric Design Center.

The nominal packing size will have an OD of 44.250 and an ID of 42.750 (0.75-inch wide). The housing ID is 42.750 +/- 0.005 inch (BLH 38993, Piece 6) final dimension after interference fit with trunnion. The housing OD is 44.250 + 0.002/-0.000 diameter bore (BLH 39000, Piece 1).

The blade seals will function against the blade packing sleeve (ID) and the retaining ring (OD). The trunnion (ID blade seal surface) will rotate from 19-34 degrees (15-degrees total) during operation, while the hub (OD blade seal surface) will be stationary. The OD of the blade seal housing is Cast Steel Fed Spec QQ- S-681b Class 2 Med (BLH 39000, Piece 1). The ID of the blade seal housing is ASTM A296-49T or stainless-steel Type 410 Annealed (BLH 38993, Piece 6).

If the contractor wishes to provide an “approved equal” product, the contractor shall be responsible for submitting all product data sheets and other documentation necessary to prove that the products meets all of the specifications. The design shall incorporate a radially compressed, floating seal set specially designed for Kaplan turbines to assure a long-term leak-free sealing action. The turbine blade seals shall be designed to completely seal out water and seal in turbine oil, requiring no compression in the axial direction of the blade.

The seals shall be an engineer approved equal of standard, commercially available manufactured product which has been sold for at least ten years. The seals shall include a split to allow for field installation and provisions for on-site joining during installation.

3.1 FIELD JOINING KIT

The contractor shall provide four (4) joining kits which includes all tools, materials, and supplies necessary to successfully join all seals in the field. The joining kit shall also be commercially available and normally sold as an accessory to the specified type of seal.

4.0 MATERIAL PROPERTIES

The molded floating lip seals shall be made from nitrile rubber (NBR) with the following physical properties.

The seal material shall be nitrile (NBR) with a fabric reinforced base. The NBR compound shall be made from acrylonitrile/butadiene based synthetic rubber with nominally 36% ACN, reinforced with carbon black and incorporating a Sulphur based cure system.

a. Hardness: 80 IRHD

b. Tensile strength: 17 MPa

c. Elongation at break: 400%

d. Compression Set: 15% after 24 hours @ 100 deg. C

e. Fluid Immersion Testing in Oil (70 hours @ 100 deg. C):

f. Change in hardness: +5 / -10 IRHD

g. Change in tensile strength: +5 / -15 %

h. Change in elongation at break: +0 / -15 %

i. Change in volume: +11 / -2 %

5.0 SUBMITTED DOCUMENTATION

Submit the following for approval, prior to the shipment of the seals. Manufacturer’s drawings and installation procedures shall be provided for the seals requested.

4.1 Blade Seal Assembly Drawings

Submit for approval prior to manufacturing of seals. The Government will be taking housing measurements and will confirm with manufacturing the suitability of use. Include the required surface finish of the contact surfaces of the housing on the drawing.

The drawings shall include material, dimension, specifications, vendor name and phone number, and a drawing number that can be referenced for replacement blade packing on future orders. The drawings shall be provided as PDF digital format so it can be added to the existing drawing database. If available, the CADD version of the drawing shall also be provided.

4.2 Blade Seal Installation Instructions

Submit for approval instructions for installing the blade seals into the housing. The instructions are required to reflect installation in place (without removal of the blades) and include details for the specific assembly shown in the attached drawing of the seal assembly (shown in BLH-39002).

4.3 Blade Seal Quality Documentation

Prior to shipment from the manufacturer, submit for approval the quality documentation and photos showing the seals were measured to match tolerances and acceptance criteria shown in the submitted and approved blade seal drawing.

6.0 WARRANTY

All items shall be covered by the manufacture’s standard warranty on all parts, labor, and workmanship from factory defects. Warranty period shall be a minimum of one year.

7.0 PACKAGING

All seal assemblies shall be individually vacuum packed to facilitate long term storage. All seal assemblies and all accessories shall be packaged into a single box or wood crate for storage. This container shall be mounted on a pallet so that it can be handled with a forklift or pallet jack. Include a copy of the final quality documentation and drawing inside the crate. The box or crate shall be clearly labeled on one side and on top with the following description:

Contract Number Turbine Blade Seals for Main Units Contractor’s Company Name Contractor’s Seal Model Name / Part Number Contractor’s Point of Contact Name Contractor’s Point of Contact Phone Number

8.0 SHIPMENT AND DELIVERY

All items shall be delivered free-on-board (FOB) to the project within 14 weeks of contract award. The contractor shall be responsible for packing and shipping the components in a manner that will ensure undamaged and complete arrival to the powerhouse. No shipments are allowed other than normal business hours of Monday-Thursday 7:00 a.m. to 4:00 p.m. PST, excluding federal holidays.

All shipments shall be delivered to:

U.S. Army Corps of Engineers

Albeni Falls Dam Warehouse Receiving 2376 E. Highway 2 Oldtown, ID 83822

BID SCHEDULE

MAIN UNIT TURBINE BLADE SEALS

BID ITEM LIST

ITEM DESCRIPTION QUANTITY U/M U/P AMOUNT

Turbine Blade Seals

SET

0002 On Site Joining (OSJ) Kit 4 SET $ $

Total