Attachment_01_SOW_N1_Brake_Ring.pdf

N1 Brake Ring

Statement Of Work: N1 Brake Ring

Department of the Interior

Bureau of Reclamation

LCDO - Hoover Dam

SECTION 1 - GENERAL

1.01 BACKGROUND

1.02 SCOPE

1.03 OBJECTIVES

SECTION 2 - TASKS

2.01 GENERAL

2.02 BRAKE PLATES

2.03 FASTENERS

2.04 DRAWINGS

2.05 DELIVERY

SECTION 3 - GOVERNMENT-FURNISHED PROPERTY

3.01 AVAILABLE ELECTRICAL

3.02 CRANE SUPPORT

3.03 OTHER LOCATIONS

SECTION 4 - ONSITE REQUIREMENTS

4.01 GENERAL

4.02 SECURITY

4.03 SAFETY

4.04 PARKING

4.05 USE OF GOVERNMENT LAND

4.06 PROTECTION OF EXISTING INSTALLATIONS

SECTION 5 - PERIOD OF PERFORMANCE

5.01 NOTICE TO PROCEED

SECTION 1 - GENERAL

1.01 BACKGROUND

A. Unit N1 is a 130 MW unit that rotates 180 rpm in a clockwise direction as viewed from above. It was first placed into service in 1936 and total weight of the unit is approximately 630 tons. Recent inspection of the rotor brake ring revealed excessive wear and metal fatigue warranting replacement.

1. The requirement is for replacement of the entire brake ring assembly

2. Manufacture based on drawings and current brake ring segments as templates

1.02 SCOPE

A. The projected work is to replace the brake ring of unit N1 with a newly manufactured brake ring assembly which consists of 10 separate brake plates and associated fasteners.

1.03 OBJECTIVES

A. Replacement of the brake ring assembly shall consist of:

1. The manufacture of 10 new brake plates

2. Removal of the old brake plates

3. Attachment of new brake plates. The contractor shall supply all components required for attaching brake plates to rotor and labor to perform the installation.

4. Warrantied to maintain structural integrity for five years. Brakes engage at 20% of rated speed (36 rpm).

SECTION 2 - TASKS

2.01 GENERAL

A. The rotor of unit N1 will be removed by Hoover Dam personnel and placed in the rotor assembly area located at the upstream side of the Nevada side powerhouse. The contractor will utilize this area for staging equipment if needed, removal of the old brake plates, field modifications as needed, and installation of the newly manufactured brake ring.

B. The contractor shall:

1. Manufacture ten brake plates made from ASTM A588 Grade B Steel.

2. Provide all fasteners, washers, and weldments required to assemble and install the brake ring.

3. Conduct field machining as needed.

4. Assemble and install the new brake ring onto unit N1.

5. Provide all engineering data and drawings to the U.S. Government.

6. Provide all material properties and certifications to the U.S. Government.

2.02 BRAKE PLATES

A. There is a generic drawing available but shall act as a guide only.

B. The contractor shall remove the old brake plates and ship one or more to their facility as templates for machining and final dimensions of new brake plates.

1. Minimum requirements for measurements taken at the contractor facility are manual measurements with a precision of three decimal places, FARO/scanner measurements will be allowed.

2. Surface finish of brake plate at brake-pad-to-brake-plate interface shall be 32 micro-inches or better. Surface finish of other surfaces shall be 125 micro-inches max.

3. Tolerances for machining, unless otherwise specified, shall be as follows:

a. Fractional measurements: ±1/32 inches.

b. Angular measurements: ±0.25 degrees, ±0.5-inch bend.

c. Two place decimals: ±0.02 inches.

d. Three place decimals: ±0.005 inches.

4. Brake plate thickness shall have a tolerance of ±0.002 inches

5. Novel cooling channels and design may be considered provided performance is not degraded and correctly fit the rotor.

6. Brake plate material shall be made of the material specified in section 2.01.B.1. If the specified materials are unavailable, substitute materials shall only be permitted with written approval from the Government.

a. Any substitution shall be equal to or better than the material specified. The contractor shall prove that the proposed substitute material is equal to or better than the material specified.

b. Substitute materials will be reviewed by the COR and CO prior to approval, and the

CO may accept or reject any proposed material substitution at their discretion.

7. Brake plates shall be stress relieved.

8. Drawing T-3695961, Rotor Spider Arms contains a reference to brake plates for rough dimensioning only.

9. Drawing P-5161730, Brake Plate contains references that may be incorrect and require field verification.

2.03 FASTENERS

A. The fasteners and associated lock washers shall be attached based on current conditions of rotor fixation points.

B. Weldment at some areas to be referenced with any drawings.

C. The contractor shall provide all fasteners, shims, and associated plates. Bolts shall be ASTM A193

B7 or equal with 1 ½” - 6 threads per inch.

D. Hoover Dam personnel will re-assembly Unit N1 once the brake ring has been installed.

2.04 DRAWINGS

A. The contractor shall generate new as-built drawings of brake plates and fasteners and submit them to the Government approval. All drawings will become property of the USBR.

B. Minimum information in the title block:

1. Contract number, Contractor’s name, drawing number, “N1”, part name, and as-built changes with revision dates.

2. Allow a space of 3- by 3-inches for review stamps on each drawing.

3. Drawings shall be ANSI D size (22 inches by 34 inches).

4. Draw to scale using computer drafting.

5. Show as-machined changes made during fabrication, including revision dates.

6. Ensure drawings follow ASME Y14.1 and Y14.5 standards where applicable.

7. Submit as both a PDF and an AUTOCAD (.dwg).

a. AUTOCAD files must be compatible with the latest version available during the bidding period for this contract.

2.05 DELIVERY

A. The contractor shall provide all shipping FOB destination:

• Hoover Dam Central Warehouse

• NV State Route 172

• Boulder City, NV 89004

• ATTN: Tyrese Smith

B. Receiving hours are 0730-1530 PST, Monday through Friday, excluding Federal holidays.

C. Notify the COR of inbound shipments at least 72 hours prior to anticipated delivery date.

D. Ship only via freight carriers which possess fleets of sufficient size to ensure the shipment is delayed not more than two days due to breakdown, vehicle or driver unavailability, or any other circumstances, excluding inclement weather.

E. Provide gross weights of loads, project reference, part number(s) and number of pieces in each crate marked on all crates.

F. If the vehicle transporting material is involved in an accident and a reasonable person would consider it prudent to inspect the material for damage before use at Hoover Dam, the Contractor shall arrange for the material to be transported to its shop and inspect the material completely before reshipment to Hoover Dam.

G. All plates shall be protected from inclement weather conditions and packaged to allow for forklift offloading.

H. Contractors must provide the equipment and labor to have all plates transferred into the

Powerhouse.

SECTION 3 - GOVERNMENT-FURNISHED PROPERTY

3.01 AVAILABLE ELECTRICAL

A. 480VAC, 3Φ 60Hz is available for use at the contractors’ discretion. If used, the contractor is responsible for connections and power distribution in the work area.

B. 110VAC, single phase 60Hz is available for use with a limit of 15 amps.

3.02 CRANE SUPPORT

A. Once the rotor is in place at the repair area, the contractor may utilize the dedicated jib crane as needed (Jib crane is rated at 4 tons). If the crane is utilized, the contractor shall provide a certified crane operator for jib crane operations.

B. Overhead bridge crane operations can be provided by the USBR as needs arise.

C. The contractor shall also provide a third-party crane inspection before and after using the jib crane.

3.03 OTHER LOCATIONS

A. Workspace may be limited and the contractor shall contact the COR for accommodation. While every effort will be made to provide other areas, there is no guarantee of availability.

8 N1 Brake Ring

SECTION 4 - ONSITE REQUIREMENTS

4.01 GENERAL

A. Tourism – The area of work is in full view of tourism from approximately 0900hrs – 1645hrs local time every day.

B. Tourists will be taking photos of the work area and workers are reminded they will be in full view of the public tours

4.02 SECURITY

A. In accordance with Homeland Security Presidential Directive 12 (HSPD-12), all on-site

Contractor personnel shall have a Government-issued Personal Identity Verification (PIV) card prior to being allowed access to work at Hoover Dam.

1. The Contractor shall bear the costs of submitting the requisite forms, traveling to a credentialing center, and, if applicable, security interviews.

2. The Government will bear the cost of the background investigation.

B. For each employee who will work at Hoover Dam, complete the following forms:

1. Request for Initiation of Contractor Background Investigation

2. Declaration for Federal Employment

3. Fair Credit Authorization

4. All forms listed within this section shall be provided by the government to the contractor.

C. Promptly mail the completed forms to the COR at the following address:

• Hoover Dam, PO Box 60400

• Boulder City, NV 89005-0400

• TBD

• Engineering Office

• Phone: TBD

• Email: TBD

• You may contact the COR at TBD for any clarifications needed.

D. Following submission of the requisite forms, the employee will receive an email from the

Reclamation Security Office (TBD with instructions to complete the online questionnaire (e-QIP) and to make an appointment at a credentialing center to enroll for a PIV card, be fingerprinted, and have a photo taken.

E. Following completion of the requisite forms, e-QIP, and fingerprinting, the Office of Personnel

Management (OPM) will initiate the background investigation and a preliminary Special Agreement

9 N1 Brake Ring

Check (SAC) will be conducted.

1. If the SAC result is unfavorable, the employee will not be permitted to work at Hoover

Dam.

2. If the SAC result is favorable, the employee will be permitted to work at Hoover Dam.

However, if the official background investigation result is unfavorable, employment will be terminated.

3. If an employee is terminated, the Contractor shall replace the employee with an employee who possesses equivalent technical qualifications and whose SAC is favorable.

F. The PIV card shall be obtained from the Hoover Dam Security Office and returned upon completion of on-site work.

4.03 SAFETY

A. Perform all work in accordance with the applicable standards from OSHA, RSHS, and HECP.

B. Prior to commencement of work requiring Lockout/Tagout:

1. The Contractor’s site superintendent and foremen shall take and in-person facility HECP class and pass the test (estimated 2 hours).

2. The Contractor’s site superintendent shall lock onto the clearance lockbox with a uniquely keyed lock and walk the clearance limits. The lock shall be labeled with the name and primary phone number of the superintendent.

C. Prior to commencement of work requiring Confined Space Entry:

1. Develop and submit a confined space entry program to the COR.

a. Contractors shall be responsible for; bringing and using air monitoring equipment, having a confined space attendant during entry, and providing rescue for contractor employees.

2. Inspect air monitoring equipment for proper function.

D. Prior to commencement of work requiring Fall Protection:

1. Develop and submit a site-specific rescue plan to the COR.

2. Inspect fall protection equipment for proper function.

4.04 PARKING

A. If the worksite is in the Powerhouse, the Contractor may park not more than two company vehicles on the tailrace ramp. All vehicles will be subject to move at a moment’s notice. Vehicles shall be marked with the Company’s logo or display a sign in the driver’s side window which contains the following information:

1. Company’s name.

2. Driver’s name and phone number.

3. COR’s name and phone number.

B. Park all other vehicles at the Hoover Dam Central Warehouse.

1. Parking under the awning by the warehouse is for government employees only,

2. The contractor must contact the Contracting Officer’s Representative (COR) for alternative parking locations.

4.05 USE OF GOVERNMENT LAND

A. The Contractor will be permitted use of Government land, controlled by the Bureau of Reclamation, for field offices, storage yards, and other construction and service facilities required for the work.

Laydown areas will vary depending on location of the worksite. Additional laydown areas are available at the Hoover Dam Central Warehouse. Equipment laydown areas and vehicle parking areas will be designated by the COR. To the extent feasible, the COR will provide dedicated locations for laydown and storage. However, contractor must take appropriate measures to secure and protect contractor- owned/provided materials and equipment, as use of the designated areas may not be exclusive.

B. No charge will be made to the Contractor for the use of Government land for work activities under this contract.

4.06 PROTECTION OF EXISTING INSTALLATIONS

A. In accordance with Federal Acquisition Regulation (FAR) 52.245-1, the Contractor shall take all precautions to safeguard existing buildings, equipment, and vegetation on the Government installation from damage.

B. If the Contractor’s failure to use reasonable care causes damage to any of this property, the

Contractor shall replace or repair the damage at no expense to the Government as the Contracting

Officer directs; or, at the option of the Contracting Officer, any such damaged may be repaired by the Government, and the Contractor will be back charged for the cost thereof.

1. The time and manner permitted for remediation will be determined by the Contracting

Officer.

2. If the Contractor fails or refuses to make such repair or replacement, the Contractor shall be liable for the cost, which may be deducted from the contract price.

SECTION 5 - PERIOD OF PERFORMANCE

5.01 NOTICE TO PROCEED

A. There will be two Notice to Proceeds (NTPs). One NTP for removal of old plates, fabrication, and delivery of new plates and one NTP for Installation.

1. Fabrication: NTP will be issued after all required submittals. Plates shall be delivered for installation by 1 October 2027

2. Installation: Installation shall be accomplished within 30 days of notice from the government. The period of performance is projected to be between 15 November 2027 and

15 February 2028. The NTP will be provided once the rotor has been removed and placed in the rotor assembly area, removal will start in October 2027 and is expected to take 6 weeks.

3. Workdays: Work shall be limited to 0600 – 1600 hrs, local, Monday to Saturday.

4. There will be no work on Sunday or Federal Holidays.

F. The PIV card shall be obtained from the Hoover Dam Security Office and returned upon completion of on-site work.

2. Inspect air monitoring equipment for proper function.