Attachment_1_-_SOW_-_A2___N7_Wide_Head_Turbine.pdf

1 Attachment 1 – Statement of Work

Statement Of Work: A2 & N7 Wide Head Turbine

Department of the Interior

Bureau of Reclamation

LCDO - Hoover Dam

Attachment 1 – Statement of Work

SECTION 1 - GENERAL 4

1.01 SUMMARY 4

1.02 DEFINITIONS 4

1.03 CURRENT EQUIPMENT 5

1.04 SCHEDULE FOR THE WORK 5

1.05 MEASUREMENT AND PAYMENT 6

SECTION 2 - SUBMITTALS 7

2.01 SUBMITTAL REQUIREMENTS 7

2.02 SUBMITTAL PROCEDURES 8

2.03 REVIEW OF SUBMITTALS 9

2.04 TRANSMITTAL ADDRESSES 10

2.05 SHIPPING AND DELIVERY 10

2.06 RECEIVING 10

2.07 SHOP ACCESS 11

2.08 SUBMITTAL ITEMS 11

2.09 LIST OF SUBMITTALS 14

SECTION 3 - RUNNER DESIGN AND ANALYSIS 17

3.01 REFERENCE STANDARDS 17

3.02 CURRENT UNIT RATING AND DATA 18

3.03 UNIT STRESSES 19

3.04 DESIGN AND PERFORMANCE REQUIREMENTS 19

3.05 NON-DESTRUCTIVE TESTING AND INSPECTIONS 19

SECTION 4 - RUNNER MANUFACTURING 24

4.01 MATERIAL REQUIREMENTS 24

4.02 CASTING 24

4.03 RUNNER BLADE TEMPLATES 25

4.04 INTEGRAL SEAL RINGS 26

4.05 ASSEMBLY 26

4.06 WELDING 28

4.07 FINISHING AND TRAILING EDGES 29

4.08 BALANCING 30

4.09 CLEANING AND PASSIVATING 30

SECTION 5 - ASSOCIATED EQUIPMENT 32

5.01 FASTENERS 32

5.02 TURBINE NAMEPLATE 32

5.03 STATIONARY WEAR RINGS 33

5.04 WEAR RING INSTALL AND MACHINING 33

5.05 ROUGHING AIR ADMISSION 33

SECTION 6 - ADDITIONAL REQUIREMENTS 35

6.01 WARRANTY 35

6.02 DELIVERY, STORAGE AND HANDLING 36

6.03 MAINTENANCE 36

6.04 RECOMMENDED CAVITATION REPAIR PROCEDURE 37

SECTION 7 - DRAWINGS 38

7.01 GENERAL 38

7.02 MANUFACTURING AND DETAIL DRAWINGS 38

7.03 ASSEMBLY AND INSTILLATION DRAWINGS 39

7.04 FINAL DRAWINGS 39

7.05 LIST OF PROVIDED DRAWINGS 40

SECTION 8 - ON-SITE REQUIREMENTS 43

8.01 SECURITY 43

8.02 SAFETY 44

8.03 PARKING 44

8.04 USE OF GOVERNMENT LAND 44

8.05 PROTECTION OF EXISTING INSTALLATIONS 45

8.06 GOVERNMENT-SUPPLIED LABOR AND MATERIALS 45

8.07 GOVERNMENT FURNISHED FACILITIES 45

SECTION 9 - APPENDIX 47

9.01 APPENDIX A 47

8.01 APPENDIX B 48

SECTION 1 - GENERAL

1.01 SUMMARY

A. This requirement is being solicited on a sole-source basis pursuant to FAR 6.302-1(a)(2), Only One

Responsible Source. The turbine runners for Units A2 and N7 must be hydraulically and dimensionally identical to the existing Wide-Head runner designs installed in Units A1, N5, and N6.

Compatibility with existing hydraulic performance characteristics, cavitation behavior, structural safety factors, and the Hoover Dam runner interface geometry requires the use of this same design and manufacturing source.

B. The work is located at Hoover Dam and Powerplant, approximately 8 miles northeast of Boulder

City, Nevada and 32 miles from Las Vegas, Nevada in Clark County, Nevada and Mohave County, Arizona.

C. Principal features of the work under this solicitation include:

1. Hydraulic turbine runner manufacturing and delivery of two (2) 196,000 HP turbine runners, one for Unit A2 (counterclockwise) and one for Unit N7 (clockwise), including associated runner cone and coupling bolts.

2. Design and installation of a roughening air system, including the pipework leading into the headcover and a support cone for the pipework in the turbine runner.

3. The supply of two upper and two lower stationary seal rings for the two units (1 upper and 1 lower per unit).

4. In-place machining of the four new stationary seal rings.

5. Providing a contractor engineer to witness performance testing to determine if the newly installed turbine runners meet hydroelectric efficiency guarantees.

a. The cost is to be included in the lump sum schedule prices for each turbine runner.

D. The two new turbine runners shall be identical hydraulically and dimensionally to the turbine runners supplied to the Hoover Dam previously for N5, N6, and A1. N7 shall use the design for

N5/6 (clockwise) and A2 shall use the design for A1 (counterclockwise).

1.02 DEFINITIONS

ASME American Society of Mechanical Engineers.

ASNT American Society for Nondestructive Testing.

ASTM American Society for Testing and Materials International.

AWS American Welding Society

CFD Computational Fluid Dynamics

CLIN Contract Line-Item Number

CO Contracting Officer

COR Contracting Officer Representative

Days Calendar days.

FEA Finite Element Analysis

IEC International Electrotechnical Commission

NDT Non-Destructive Testing

PT Dye Penetrant Testing

Ra Roughness average

RFI Request For Information

RSN Required Submittal Number, identifies items to be submitted together as a complete submittal.

RT Radiographic Testing

SOW Statement of Work, Submittals Includes drawings, data, manuals, certifications, test reports, curves, samples, brochures, and other items furnished by the Contractor for approval, informational, or other purposes.

UT Ultrasonic Testing

1.03 CURRENT EQUIPMENT

A. The Lower Colorado Dams Office (LCDO) currently operates 19 hydro units at Hoover Dam, including 17 large generators (15 with nominal capacity of 130 MW each and 2 with nominal capacity of 60 MW each) and 2 small station service generators with nominal capacity of 3 MW each.

B. The turbine systems for units A2 and N7 were originally supplied by Baldwin Southwark. New replacement turbine runners manufactured by Voest Alpine were installed in 1989 for A2 and 1982 for N7.

1.04 SCHEDULE FOR THE WORK

A. The Government anticipates issuing the sole source award on or about November 30, 2026. All milestone dates below are based on this projected award date and will be adjusted if the award date changes.

B. Milestone Schedule Dates during this contract:

DATE ACTION ITEM

6/09/2026 Issue Solicitation 8/10/2026 Proposal Due date

11/30/2026 Anticipated contract award date 3/28/2027 New stationary seal rings (2 upper and 2 lower) delivered to Hoover 4/27/2027 In-place machining completed on A2 5/27/2027 In-place machining completed on N7

7/26/2027 Air Admission for A2 and N7 completed (excluding turbine component installation)

11/23/2027 New A2 turbine delivered to Hoover 2/21/2028 New A2 turbine performance testing completed 8/19/2028 2nd runner delivered (N7)

11/17/2028 New N7 turbine performance testing completed

C. The dates listed for receipt of submittals listed in Table 1 - List of Submittals are required dates to be met by the contractor under this contract.

1.05 MEASUREMENT AND PAYMENT

A. Cost:

1. Include cost of submittals in prices offered in the schedule for contract line items.

B. Payment:

1. Ten percent (10%) of the payment for contract line items will be withheld until all submittals related to that item are received and approved by the Government.

1.06 PERSONNEL QUALIFICATIONS

A. If the contractor elects to use a sub-contractor, the awardee of the sub-contracted work must have at least 5 years of experience with work in or related to hydro-electric power.

1. Relevant experience can be tabulated by a total of 5 years, but the most recent experience must be no more than 6 months before the award of this solicitation.

2. Experience will be evaluated by the Government prior to mobilization. The contractor is required to provide the government with an advance of 45 business days prior to sub-contractors expected date to be onsite.

3. The government will have 14 business days after receiving sub-contractor experience to evaluate qualifications.

SECTION 2 - SUBMITTALS

2.01 SUBMITTAL REQUIREMENTS

A. In the case where an RSN described in a separate section of this SOW contains different submittal requirements than listed in this section, contractor shall follow the requirements listed there within.

B. General:

1. Identify submittal with contract number, title, and RSN.

2. Submit as an electronic PDF unless otherwise noted.

3. Units: US customary.

C. Drawings:

1. Unless otherwise stated, all drawings included in submittals for this solicitation must meet the requirements listed within section 7.

D. Product Data:

1. Contractor shall mark the manufacturer’s data for commercial products and equipment used in the completion of this contract.

a. Include manufacturer’s name, type, model, size, and characteristics of the product.

b. Providing markings that products meet requirements of specifications and reference standards as applicable.

c. Ensure markings are furnished in a manner that is visible and can be photographed.

d. Strike through any items that do not apply.

E. Certifications:

1. Certifications must be signed and sealed by a registered professional in the subject which the certification pertains to.

2. Manufacturer certifications must be signed by an authorized representative of the manufacturer.

F. Castings

1. Furnish to the CO certificates showing the results of the ladle analysis and material properties.

G. Mill or Shop Orders

1. The Contractor shall send the CO, upon request, a copy of each mill or shop order for material purchased by the Contractor for use in the fabrication of turbine components.

a. The copies of the orders are to state the place at which the material is to be manufactured.

b. All such mill or shop orders are to quote the requirements of the special conditions and drawings for articles, materials, and supplies to be furnished.

H. Manuals:

1. Copies: Provide hard copies (bound and indexed) and one set of electronic copy either in

Word document (.doc) or Adobe Acrobat document (.pdf) format.

2. Contents:

a. Parts identification lists, lists of special tools, and accessories.

b. Detailed instructions for installing, operating, lubricating, and maintaining equipment.

c. As-built drawings and test records or reports required by the specifications.

I. Inlet/Discharge Edge Templates

1. Submit drawings showing positioning of the templates for reference.

J. Photographs and Images:

1. Include contract number, name of equipment, and view title.

2. Digital files shall be submitted in .jpeg format.

3. Photos shall be in 1080p quality or better.

4. Ensure the subject of each photo is visible and photos do not contain blur or camera shake.

2.02 SUBMITTAL PROCEDURES

A. Contractor shall submit complete sets of required materials for each RSN.

B. Provide submittals in accordance with the “No. of sets to be sent to:” column in Table 1 – List of

Submittals. Contact information is provided in section 2.04.

C. Transmittal Letters:

1. Contractor shall provide a transmittal letter in .PDF format with submittals

2. Include the following information in transmittal letters:

a. Contract number and title.

b. RSN for each attached submittal.

c. Primary point of contact.

d. Number of sets for each RSN.

e. Identify submittal as initial or resubmittal.

3. More than one RSN may be submitted under a transmittal letter, provided the point of contact is the same.

i. Submittals not approved:

1. Revise and resubmit for approval.

2. Show changes and revisions with revision date.

a. Resubmitted drawings shall include a revision block with the date of revision.

3. Describe reasons for significant changes in transmittal letter.

4. Resubmit returned submittals within 14 days after receiving the comments, unless otherwise specified.

5. Requirements for initial submittals apply to resubmittals.

6. Resubmittals shall include all items required for the submittal without reference to the original submittal.

7. The contractor shall not change designs without re-approval of the COR after drawings, documentation, and technical data have been approved by the COR.

2.03 REVIEW OF SUBMITTALS

A. Submit all submittals to the COR for review and acceptance.

B. Time Required:

1. Submittal review will be completed within 21 days for each submittal or resubmittal, unless otherwise specified.

2. Time required for review begins after the complete set of materials required for a particular submittal or resubmittal are received by the government.

C. Time in Excess of Specified:

1. The CO may extend the required delivery date for submittals to allow additional time for completing work affected by extended review times.

a. The time extension will be to the extent that extended review time caused a delay to the required contract completion date.

b. Time extension will not exceed time used in excess.

D. Return of Submittals:

1. Return of submittals will be by email or hard copy as applicable.

2. One set of submittals required for approval will be returned either approved, approved subject to identified changes, or not approved.

a. Submittals that are not approved shall be revised and resubmitted for approval.

b. No details of a submittal item may be changed after the submittal has been approved without approval from the CO and review of proposed changes.

c. Exception: Schedules may be accepted, partially accepted, or not accepted.

3. Responses to RFIs shall be provided to contractor within 14 days of receiving the request.

4. Responses to general correspondence with the COR shall be provided within 14 days.

2.04 TRANSMITTAL ADDRESSES

A. Contractor shall provide transmittal letters and RSNs to the following. See Table 1 - List of

Submittals, column: No. of Sets to be Sent to, to determine which address(s) to send the given quantity of transmittal and submittal items to.

B. Information regarding transmittal addresses, including the Contracting Officer and Contracting

Officer Representative, will be provided at the time of award

2.05 SHIPPING AND DELIVERY

A. Deliver shipments to the following address:

• Hoover Dam Central Warehouse

• NV State Route 172

• Boulder City, NV 89004

• ATTN: [name of the COR]

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

C. Notify the COR of inbound shipments at least two business days 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. 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.

2.06 RECEIVING

A. The Government will accept shipments on behalf of the Contractor at the Hoover Dam Central

Warehouse during normal business hours.

1. The Government will not inspect shipments which are accepted on behalf of the Contractor.

The Contractor is responsible for inspection of shipments for any damage incurred in transit.

2. The Government will not transport shipments. The Contractor is responsible for the transportation of shipments from the Hoover Dam Central Warehouse to the worksite.

2.07 SHOP ACCESS

A. If specified in the SOW, the Contractor shall permit the Government access to any facilities where the Contractor is executing work under this contract or is storing material which will be used under this contract at any time when work under this contract is being executed.

2.08 SUBMITTAL ITEMS

A. RSN A-1, Payment Information

1. Information for payment of invoices by Electronic Funds Transfer.

B. RSN A-2, Project Schedules

1. The total project schedule, using Critical Path Method (CPM) techniques and a logic diagram and bar chart showing the major items of work contained in the proposal, their durations, and anticipated start and finish dates. The schedule should show float, material, manpower (shifts and days per week), equipment resources, major submittals required, and the logical relations or interface between activities.

C. RSN 001, Extended Warranty

1. Extended Warranty as required in section 6.01.

D. RSN 002, Approval Drawings and Design Data

1. Detailed drawings of the runner including fabrication details and blade shape, runner cone, coupling bolts, seal rings, and material limits and locations for balancing.

2. Provide the following design data as part of this submittal item.

a. Weight of runner, cone and seal rings.

b. Materials list for runner crown, blades, band, and cone including the chemical composition of all runner components.

c. Materials list and assembly details for turbine runner to turbine shaft coupling bolts.

d. Design clearances between rotating seal surfaces on turbine runner and stationary seal rings. Stepped labyrinth seals shall not be used for the turbine runner or stationary seal design.

e. Maximum downward thrust – both with design seal ring clearances and with 2x design seal ring clearances.

f. Maximum upthrust – both with design seal ring clearances and with 2x design seal ring clearances.

g. Maximum sustained runaway speed at 565 feet of head, various gate positions.

h. Moment of inertia (WR2) of the runner both watered and un-watered.

i. Design calculations and complete information showing the maximum unit stresses used in the design.

j. Operating range for the unit.

3. Inspection plan detailing nondestructive test methods contractor will use for locating casting defects and weld defects of the runner components and fabricated runner and methods to measure Dimensional check of the runner.

a. Inspection requirements are described in section 3.05.

4. Heat treatment procedure.

5. Runner balancing procedure.

6. Cavitation repair procedures including recommended weld rod materials, preparation, weld procedures, post-weld heat treatment, and template locating drawings.

7. Drawings showing the dimensions and positioning of runner blade inlet edge templates and runner blade discharge edge templates.

8. Drawings showing the design and location of the roughening air admission system and all related components.

E. RSN 003, Runner Fabrication Logistics

1. Casting, plate, forging, and fabrication locations.

2. Transportation information.

F. RSN 004, Runner Material Certification

1. Provide certifications for all materials to be used for the turbine runner and associated equipment.

a. Requirements for material certifications are defined in section 4.01.E.

G. RSN 005, Casting Inspection Reports

1. Reports of NDE/NDT of all castings to be used for fabricating the turbine runner and associated equipment prior to assembly.

a. Government approval is required before contractor may begin repair welding.

b. Refer to sections 3.05 and 4.02.C for more details.

H. RSN 006, Initial Dimensional check Inspection Reports

1. Report of the turbine runner Dimensional check after tack welding and trial assembly.

a. Government approval is required before contractor may adjust/relocate components.

b. Refer to sections 3.05 and 4.05.D for more details.

I. RSN 007, Welding Inspection Reports

1. Reports of NDE/NDT of welds made to assembly the turbine runner crown, band, and blades. Inspections shall also include regions affected by the heat during the weld process.

a. Government approval is required before contractor makes repairs to the welds or components with heat affected surfaces.

b. Refer to sections 3.05 and 4.06.G for more details.

J. RSN 008, Balancing Report

1. Final report of runner balancing once assembly is complete.

a. Include in the report a description of changes made and drawings that include the location of balance modifications.

b. Include results from final balance test and the balance quality achieved for government review.

c. Refer to section 4.08 for more details.

K. RSN 009, Final NDT and Dimensional Check Report

1. Final NDT report after assembly and final machining.

a. Refer to sections 3.05 and 4.05.E for final NDT requirements.

2. Final dimensional check inspection report after assembly and final machining.

a. Refer to sections 3.05 and 4.05.D for final dimensional check requirements.

L. RSN 010, Runner Final Data

1. As-built drawings with final runner dimensions and machined weight.

2. Templates and drawings for runner repair as per section 4.03.

a. Submit drawings showing positioning of the templates for reference.

3. As-built drawings with final seal ring dimensions and upstream/downstream and river/canyon clearances.

4. All drawings provided within this submittal shall become property of the government.

M. RSN 011, Seal Ring Material Certification

1. Contractor shall provide certifications of seal ring materials for government review.

a. Refer to section 5.03.A for material requirements.

b. Contractor shall also provide heat treatment procedure, furnace type, and controls for seal rings as part of this submittal.

c. Any material found unsatisfactory will require replacement. Refer to section 4.01.G if specified materials are unavailable.

N. RSN 012, Runner to Shaft Coupling Nut Design Data

1. Provide design drawings or product information for coupling nuts that meet the requirements listed in sections 5.01 and 4.01.B.

O. RSN 013, Associated Equipment As-Built Drawings

1. Provide as-built drawings of the following components:

a. Stationary seal rings machining with final dimensions.

b. Roughing air admission system components:

i. Air admission piping for the turbine pit, headcover, and turbine runner.

ii. Turbine shaft cap.

iii. Air admission support cone.

2. All drawings provided within this submittal shall become property of the government.

P. RSN A-3, Release of Claims Release of Claims (DI-137) against the United States

1. Release of Claims (DI-137) against the United States.

2.09 LIST OF SUBMITTALS

A. Table 1-List of Submittals

RSN Item Primary

POC

Submittals required

No. of sets to be sent to: Due Date or delivery time

CO COR

A-1 Payment Information CO Information for payment of invoices by Electronic Funds

Transfer. Ensure payment data in System for Award

Management database is current, accurate, and complete.

1 1 14 days prior to first payment.

A-2 Project Schedule CO Project baseline schedule updated once per month with actual progress. The initial schedule must be accepted by the Government prior to the start of work.

1 1 Baseline schedule submittal within 30 days of contract award

A-3 Performance and

Payment Bonds

CO Within 14 days of award 2 0 Prior to issue of Notice to

Proceed

A-4 Release of Claims

Against the

Government

CO Release of Claims (DI-137) against the United States

1 0 After completion of the work and prior to final payment.

001 Extended Warranty CO Refer to requirements in 6.01. 2 2 Within 30 days of contract award

002 Approval Drawings and Design Data

COR Provide all relevant design data and information as per

Section 3

2 2 Within 270 days of contract award

003 Runner Fabrication

Logistics

COR Provide logistics for runner component fabrication as described in section 4.01.D.

1 2 Within 30 days prior to casting or fabrication of components

004 Runner Material

Certification

COR Provide material certifications for all materials used for the turbine runner and associated equipment. Refer to section

4.01.E for more details.

1 2 Within 7 days of receipt of materials by primary contractor

005 Casting Inspection

Reports

COR Provide an inspection report for all cast materials. Refer to sections 3.05, and 4.02.C for more details.

1 2 Within 14 days of receipt of cast materials by primary contractor

006 Initial Dimensional

Check Inspection

Reports

COR Provide a report on the turbine runner dimensional check in trial assembly. Refer to sections 3.05 and 4.05.D for more details.

1 2 Within 5 days of tack welding and trial assembly of the turbine runner

007 Welding Inspection

Reports

COR Provide a report on all inspections performed on assembly welds. Refer to sections 3.05 and 4.06.G for more details.

1 2 Within 14 days of completing welding and assembly of the turbine runner.

008 Balancing Report COR Provide a report on the final balance and modifications made to achieve balance.

Refer to section 4.08 for more details.

1 2 Within 7 days of completing balancing.

009 Final NDT and

Dimensional Check

Report

COR Provide an inspection report of the final inspections performed on the runner prior to delivery. Refer to sections

3.05, 4.05.D, and 4.05.E for more details.

2 2 Within 30 days of completing assembly, machining, and balancing.

010 Runner Final Data COR Provide drawings and design data as per section 3, including all machining and adjustments made after assembly, templates for runner repair as described in section 4.03, and details on balancing as per section 4.08.

2 2 7 days prior to planned shipment of runner

011 Seal Ring Material

Certification

COR Provide certification for the materials listed in section 5.03 in addition to seal ring heat treatment logistics.

1 2 Within 7 days of receipt of materials by primary contractor

012 Coupling Nut Design

Data

COR Provide information on coupling nut design selection.

Requirements are described in sections 5.01 and 4.01.B

1 2 Within 14 days prior to purchase/fabrication of coupling nuts

013 Associated

Equipment As-Built

Drawings

COR Provide as-built drawings of the stationary seal rings machining with final dimensions, roughing air admission piping (both in the turbine pit/headcover and turbine runner), shaft cap, and support cone.

1 1 Within 28 days of completing final stationary seal ring machining and installation of air admission system.

SECTION 3 - RUNNER DESIGN AND ANALYSIS

3.01 REFERENCE STANDARDS

A. Unless otherwise specified, all materials that will become a part of the completed work shall be new and will conform to the following standards and be of standard commercial quality.

B. American Society of Mechanical Engineers (ASME)

1. ASME B46.1-2019 Surface Texture (Surface Roughness, Waviness, and Lay)

2. ASME BPVC-2025 Boiler and Pressure Vessel Code

3. ASME Y14.1-2020 Drawing Sheet Size and Format

4. ASME Y14.5-2018 (R2024) Geometric Dimension and Tolerancing

C. American Society for Testing and Materials International (ASTM International)

1. ASTM A193/A193M-25 Standard Specification for Alloy-Steel and Stainless-Steel Bolting for High Temperature or High-Pressure Service and Other Special Purpose Applications

2. ASTM A240/A240M-25a Standard Specification for Chromium and Chromium-Nickel

Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

3. ASTM A743/A743M-21 Standard Specification for Castings, Iron-Chromium, Iron-

Chromium-Nickel, Corrosion Resistant, for General Application

4. ASTM A751 Test Methods and Practices for Chemical Analysis of Steel Products

5. ASTM A802-19 Standard Practice for Steel Castings, Surface Acceptance Standards, Visual Examination

6. ASTM A903/A903M-99(2024) Standard Specification for Steel Castings, Surface

Acceptance Standards, Magnetic Particle and Liquid Penetrant Inspection

7. ASTM A967/A967M-25 Standard Specification for Chemical Passivation Treatments for

Stainless Steel Parts

8. ASTM E164-24 Standard Practice for Contact Ultrasonic Testing of Weldments

9. ASTM E165/E165M-18 Standard Practice for Liquid Penetrant Testing for General

Industry

10. ASTM E1742/E1742M-23 Standard Practice for Radiographic Examination

11. ASTM E186-20 Standard Reference Radiographs for Heavy-Walled (2 to 4 1/2 in. (50.8 to

114 mm)) Steel Castings

12. ASTM E280-21 Standard Reference Radiographs for Heavy-Walled (4 1/2 to 12 in. (114 to

305 mm)) Steel Castings

13. ASTM E390-20 Standard Reference Radiographs for Steel Fusion Welds

14. ASTM E446-20 Standard Reference Radiographs for Steel Castings Up to 2 in. (50.8 mm) in Thickness

15. ASTM E709-21 Standard Guide for Magnetic Particle Testing

D. International Electrotechnical Commission (IEC)

1. IEC 60193 (2019) Hydraulic turbines, storage pumps, and pump-turbines – Model acceptance tests

E. American Welding Society (AWS)

1. AWS D1.1/D1.1M:2020 Structural Welding Code - Steel

2. AWS D1.6/D1.6M-2017 Structural Welding Code - Stainless Steel

3.02 CURRENT UNIT RATING AND DATA

A. General

1. The original turbines are vertical-shaft Francis-type and were installed between 1935 and

1941 by the Baldwin-Lima-Hamilton, Co.

2. The replacement runners for A2 and N7 were supplied by Voest-Alpine Int Corp under specifications DS-7403, awarded January 1980 and installed in 1989 (A2) and 1982 (N7).

3. Existing turbine output for units A2 and N7 with current wicket gates and 9.7” GVO is

157,300 hp at 490 feet, full gate.

4. The Nevada unit N7 rotates at 180 revs/min, clockwise, viewed from above.

5. The Arizona unit A2 rotates at 180 revs/min, counterclockwise, viewed from above.

6. The Hoover generators installed at Units N7 and A2 are currently rated at 133.3 MVA each.

B. Rough Zone

1. Rough zones currently occur at gate openings 25% to 80%.

C. Air Depression System

1. Units A2 and N7 use a system to admit compressed air to the draft tube to depress the water level in the turbine to reduce electrical load during condenser operation.

D. The effective head range on the turbine for power production may vary between 350 and 575 feet.

The expected range is 396 feet to 511 feet net head. The controlling water-surface elevations are as follows:

E. Table 2- Turbine operating conditions

Location Elevation (feet)

Tailwater Minimum 630

Normal Range 639 – 656

Headwater Minimum for generation 1000

Maximum for generation 1229

Casing Centerline 637

3.03 UNIT STRESSES

A. Contractor shall ensure that the turbine runner and associated components provided under this solicitation adhere to the same safety factors used for units A1, N5, N6, and N8.

B. The Contractor shall send the COR, upon request, a copy of each mill or shop order for material purchased by the Contractor for use in the fabrication of turbine components.

1. The copies of the orders shall state the place at which the material is to be manufactured.

2. All such mill or shop orders shall quote the requirements of the special conditions and drawings for articles, materials, and supplies to be furnished.

3.04 DESIGN AND PERFORMANCE REQUIREMENTS

A. The contractor shall manufacture and deliver two turbine runners using the design provided to the

Hoover Dam for units A1, N5, N6, and N8.

1. The first runner, for Unit A2, shall use the counterclockwise design from A1.The second runner, for Unit N7, shall use the clockwise design from N5, N6, and N8.

3.05 NON-DESTRUCTIVE TESTING AND INSPECTIONS

A. Inspection Plan:

1. As per RSN 002, contractor shall provide a plan for inspections including the following:

a. Examination type to be used for each given situation.

b. Equipment to be used for examinations and inspections that meets standards for each method being used. For dimensional checks, describe measurement equipment and accuracy of instrumentation to be used.

c. Details and qualifications of inspection personnel for each examination type to be used.

d. Procedure of inspections and reference standard to be used by the contractor

e. Procedure and details of weld repairs.

i. Include details such as the filler material to be used for certain components and the pre-post heat procedure within the plan.

f. Procedure of component locational adjustment in the case of a failed dimensional check.

B. Personnel Qualifications:

1. Qualified in accordance with the relevant reference standard for the examination type.

2. The minimum qualification level of all NDT personnel shall be Level II for the specific examination type being used.

a. For UT and RT, inspection reports shall be reviewed and signed by someone of

Qualification Level III for UT and/or RT respectively.

C. Equipment Requirements:

1. Contractor must provide the necessary equipment and tools to perform adequate NDT on the runner and associated equipment.

a. Equipment must meet standards as applicable for each inspection method.

2. Contractor shall provide templates and other means, such as 5-axis measuring machinery or templates, to compare dimensions of the runner to drawings to check dimensions.

D. VT, MT, and PT Requirements:

1. VT shall be in accordance with ASTM A609.

a. VT on cast components shall be in accordance with both ASTM E609 and A803.

b. Unless otherwise stated, VT alone will not be sufficient for an inspection and must be performed in addition to another examination method.

2. MT shall be in accordance with ASTM E709.

a. MT on cast components shall be in accordance with both ASTM E709 and A903.

3. PT shall be performed in accordance with ASTM E165.

a. PT on cast components shall be in accordance with both ASTM E165 and A903.

E. RT Requirements:

1. Contractor shall perform RT in accordance with Section V of the ASME BPVC and the following ASTM standards for cast components:

a. ASTM E446 for all castings up to 2 inches in thickness.

b. ASTM E186 for all castings 2 to 4.5 inches in thickness.

c. ASTM E280 for all castings 4.5 to 12 inches in thickness.

i. Components that are 4.5 inches in thickens shall be inspected in accordance with ASTM E280.

2. RT on welds shall be performed in accordance with ASTM E390.

3. For all other components, RT shall be performed in accordance with ASTM E1742.

4. Contractor may use any radiation source listed in the relevant ASTM standard, so long as they specify in the inspection plan what source will be used.

F. UT Requirements:

1. UT on welds shall be in accordance with ASTM E164.

2. UT on other components shall be in accordance with ASTM A609.

3. Note that UT may be used on cast components to determine if a defect has been totally removed during excavation but cannot be used as the primary defect inspection method.

G. Dimensional Checks:

1. Contractor shall take dimensional measurements of the turbine runner and compare them to the dimensions in the design drawings.

H. Inspection Reporting:

1. Contractor shall report all defects with clear defect mapping that indicates the location, size, and depth of all defects.

2. Contractor shall take photos of defects and include images in inspection reports.

a. Photos shall meet the requirements described within section 2.02.F.

b. Photos shall include a scale for relative size of defect.

3. For dimensional checks, contractor shall provide annotated drawings showing the as found measurements taken during the inspection and a copy of the design drawings with dimensions and tolerances that were compared.

a. If adjustments were required to pass the dimensional check contractor shall include in the report indications of which components needed to be adjusted and dimensions before and after said adjustments.

I. Acceptance Criteria:

1. Refer to Table 3A for runner blades, band, crown, band, and welds acceptance criteria.

2. Refer to Table 3B for all other components (bolts, seal rings, etc.) acceptance criteria.

a. For Table 3A and 3B, critical locations shall refer to the following areas:

i. Welds joining the runner blade to the curb/band and crown, including the area within 2 inches beyond the weld of all surfaces.

ii. Leading and trailing edges of the runner blades.

iii. Any location that experiences more than 1/3 of the material yield strength during regular operation as determined by FEA.

3. Dimensional check Criteria:

a. To pass the dimensional check, all measurements must be accurate to the contractor drawings with all the dimensions within design tolerances.

4. Contractor shall base acceptance criteria on whatever measurement/value is the smallest.

J. Table 3A – Acceptance Criteria for Runner Blades, Band, Crown, Band, And Welds.

Method Critical Locations All Other Locations

VT

As per ASTM A802, cast surface discontinuities shall have an Acceptance Level of A1, B1, C2, D1, E3, F1, G1, H1, and J1. For non-cast components any cracks or cavities exceeding 10 percent of the material thickness or 0.5 inches will not be accepted.

As per ASTM A802, discontinuities of cast surfaces shall have an Acceptance Level of A2, B2, C1, D1, E3, F1, G2, H3, and J2. For non-cast components any cracks or cavities exceeding 15 percent of the material thickness or 0.75 inches will not be accepted.

PT

As per ASTM A903, cast components shall be inspected to Acceptance Level 1. For non-cast components any cracks or cavities exceeding 10 percent of the material thickness or 0.5 inches will not be accepted.

As per ASTM A903, cast components shall be inspected to Acceptance Level 2. For non-cast components any cracks or cavities exceeding 15 percent of the material thickness or 0.75 inches will not be accepted.

MT

As per ASTM A903, cast components shall be inspected to Acceptance Level 1. For non-cast components any cracks or cavities exceeding 10 percent of the material thickness or 0.5 inches will not be accepted.

As per ASTM A903, cast components shall be inspected to Acceptance Level 2. For non-cast components any cracks or cavities exceeding 15 percent of the material thickness or 0.75 inches will not be accepted.

UT

Cavities or voids exceeding 10 percent of the material thickness or 0.5 inches will not be accepted.

Cavities or voids exceeding 15 percent of the material thickness or 0.75 inches will not be accepted.

RT

Using the appropriate ASTM standard, cast surfaces with any discontinuity above severity level 1 will not be accepted.

Using the appropriate ASTM standard, cast surfaces with any discontinuity above severity level 2 will not be accepted.

K. Table 3B – Acceptance Criteria for All Other Components

Method Critical Locations All Other Locations

VT

As per ASTM A802, discontinuities of cast surfaces shall have an Acceptance Level of A2, B2, C1, D1, E3, F1, G2, H3, and J2. For non-cast components any cracks or cavities exceeding 15 percent of the material thickness or 0.75 inches will not be accepted.

As per ASTM A802, discontinuities of cast surfaces shall have an Acceptance Level of A3, B4, C3, D2, E3, F1, G3, H4, and J3. For non-cast components, any cracks or cavities exceeding 20 percent of the material thickness or 1 inch will not be accepted.

PT

As per ASTM A903, cast surfaces shall be inspected to Acceptance Level 2. For non-cast components any cracks or cavities exceeding 15 percent of the material thickness or 0.75 inches will not be accepted.

As per ASTM A903, cast surfaces shall be inspected to Acceptance Level 3. For non-cast components, any cracks or cavities exceeding 20 percent of the material thickness or 1 inch will not be accepted.

MT

As per ASTM A903, cast surfaces shall be inspected to Acceptance Level 2. For non-cast components any cracks or cavities exceeding 15 percent of the material thickness or 0.75 inches will not be accepted.

As per ASTM A903, cast surfaces shall be inspected to Acceptance Level 3. For non-cast components, any cracks or cavities exceeding 20 percent of the material thickness or 1 inch will not be accepted.

UT

Cavities or voids exceeding 15 percent of the material thickness or 0.75 inches will not be accepted.

Cavities or voids exceeding 20 percent of the material thickness or 1 inch will not be accepted.

RT

Using the appropriate ASTM standard, cast surfaces with any discontinuity above severity level 2 will not be accepted.

Using the appropriate ASTM standard, cast surfaces with any discontinuity above severity level 3 will not be accepted.

L. Government Witness Inspections

1. Conduct final NDT and dimensional check inspection of the runner with the COR present at a location that is approved for travel by the Department of State (www.travel.state.gov) without additional protective services or safety requirements.

a. If the runner fabrication and inspection location does not meet these requirements, relocate the runner to a machine within the United States, for final inspection.

b. Contractor shall plan to perform both the final NDT and dimensional check inspections within the same time period to be witnessed and examined by the COR during one visit. A report of inspections results as part of RSN 009 is still required.

3.06 PERFORMANCE TESTING

A. Performance testing shall be performed on both units. The government will be responsible for data collection and evaluation. The contractor shall provide an engineer to witness testing.

B. Performance shall be evaluated using the final hill chart from the most recent turbine runner the new units are based upon.

1. A2 shall be compared to the hill chart from unit A1.

2. N7 shall be compared to the hill chart from unit N6.

3. To pass performance testing each tested unit must meet the efficiency as defined within the hill chart in accordance with IEC 60193.

C. If the tested unit(s) do not produce the efficiency as guaranteed the Government has the right to accept the runner or require the contractor to fabricate a new runner that will be subject to the same performance tests.

SECTION 4 - RUNNER MANUFACTURING

Turbine Runner (ref. Dwg. No. 42335, 42343, 42344, 42345, 42390, 42393)

4.01 MATERIAL REQUIREMENTS

A. Turbine runner components shall be made of the following materials:

1. Runner: ASTM A743 grade CF-3 cast components including supplemental requirements S3 through S7 and S12.

2. Nose cone: ASTM A240 UNS S30403/304L stainless steel plate.

3. Integral Seal Rings: Same material as used for the turbine runner crown and band.

B. Unless otherwise specified, materials used in the manufacturing of the equipment shall conform to applicable specifications of ASTM, SAE, or ANSI.

C. The contractor shall submit to the COR, per RSN 003, fabrication logistics including the following:

1. Casting, plate, forging, and fabrication locations.

2. Transportation information.

D. Contractor shall submit to the COR, per RSN 004, material certifications for all materials including the following:

1. Chemical composition of materials determined by ladle analysis.

2. Mill Test Report detailing the physical properties of the material:

a. Ultimate Tensile Strength in KSI.

b. 0.2% Yield in KSI.

c. Percent elongation in 2 inches.

d. Brinell hardness.

e. Records of method used to determine physical properties.

3. Heat treatment records.

E. Show the chemical composition of components in their respective drawings.

F. The contractor shall procure the specified materials. If the specified materials are unavailable, substitute materials shall only be permitted with written approval from the Government.

1. 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.

2. 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.

4.02 CASTING

A. Furnish to the COR certificates showing the results of the ladle analysis and material properties as per ASTM A751. See RSN 004 in Table 1 – List of Submittals.

1. The COR will compare the material composition results from the ladle analysis to the material standard for ASTM A743 Grade CF-3. If any element in the material composition is outside of acceptable range for A743 Grade CF-3 the material will be rejected.

B. Heat-treating procedure as recommended by the contractor in accordance with ASTM A743 and approved by the COR. See RSN 002 in Table 1 – List of Submittals.

C. Perform NDT on all cast components prior to assembly in accordance with section 3.05.

1. Any defect or discontinuity found that does not meet the acceptance criteria defined in section 3.05.I and Tables 3A and 3B must be repaired by the contractor.

a. If any casting has more than 5 defects that fail acceptance the entire casting shall be rejected, and contractor must furnish a new casting.

i. The new casting shall be subject to the same

b. Contractor must first notify the COR and await approval to begin any repairs.

i. Include in the correspondence the extent of defect excavation prior to repair welding.

c. If excavation is required to properly repair a defect, contractor must use UT in accordance with section 3.05.E to ensure the defect is entirely removed.

d. Contractor shall ensure repairs do not reduce the base metal below the design thickness.

e. After repairing the defect contractor shall refinish repaired regions to meet the requirements in section 4.07.

f. After repairs are complete, contractor must repeat NDT on component to ensure all defects have been repaired and no new defects are present.

2. As per RSN 005, contractor shall provide a report of results from the NDT in accordance with section 3.05.H.

3. All inspections and repairs shall be done at the expense of the contractor.

4.03 RUNNER BLADE TEMPLATES

A. As per RSN 010, fabricate and furnish four templates to fit the profile of the runner blade, spaced evenly across the discharge edge, and three templates to fit the profile of the runner blade, spaced evenly across the inlet edge, to aid in runner repair per IEC 60193.

1. Use templates to validate final hydraulic profile.

2. Design all templates for use in the field.

B. Laser-cut to match profile in designated locations, considering allowable tolerances.

C. Stamp to identify relative locations to leading and trailing edges, pressure or suction side and template elevation.

D. Deliver templates along with the turbine runner, coupling nuts, or seal rings to the government.

E. Contractor shall provide a rigid storage case with lockable latches and foam interior with cut-outs to secure templates.

1. Clearly label case with project name, contents, and weight.

4.04 INTEGRAL SEAL RINGS

A. Provide turbine runner with integral upper and lower rotating seal rings as per the design used for

A1, N5, N6, and N8.

1. Machine and finish the turbine runner’s integrated rotating seal rings.

a. Refer to section 4.07.A.3 for requirements on seal ring surface finish.

2. Ensure the seal rings have sufficient base material to allow for seal rehabilitation in the future.

3. Measure the rotating seal diameters of the turbine runner which interfaces with the stationary surfaces.

B. Determine target diameters for each surface and submit the targets to the COR for review before.

any material is removed.

4.05 ASSEMBLY

A. Assemble runner of major components welded together.

1. The band, crown, and blades are considered major components.

2. Details on welding requirements are provided in section 4.06.

B. Cast the crown, band, and buckets or fabricate using steel plate.

C. Perform shaping of the buckets prior to welding between the crown and band by machining using a numerically controlled 5-axis milling machine or by stamping plate material.

D. Perform dimensional check inspections on the turbine runner in accordance with section 3.05.H.

1. Any dimensions found during a dimensional check inspection that does not meet the acceptance criteria defined in section 3.05.I.3. must be adjusted by the contractor.

2. Contractor must first notify the COR and await approval to begin any adjustments.

a. After making necessary adjustments contractor shall reperform dimensional check inspections to ensure dimensions are in tolerance.

b. Regions where tack welds had to be removed and reapplied for adjustments shall have NDT performed to ensure no defects formed during the process.

i. Refer to section 4.06.G for weld inspection guidelines.

3. Dimensional check inspections shall be performed at the following intervals:

a. Initial dimensional check: Perform inspection with all components positioned in trial assembly and tack welded together.

b. Final dimensional check: Perform inspection after assembly, machining, and balancing of the runner is complete and RSN 001 through 008 are submitted and approved.

i. Final dimensional check inspection shall be performed with a government witness. Refer to section 3.05.J for more details.

4. As per RSN 006, contractor shall provide a report of results from the initial dimensional check inspection in accordance with section 3.05.H.

5. As per RSN 009, contractor shall provide a report of results from the final dimensional check inspection in accordance with section 3.05.H.

6. All inspections and adjustments shall be done at the expense of the contractor.

E. Perform final NDT in accordance with section 3.05 on the turbine runner after assembly, machining, and balancing of the runner is complete and RSN 001 through 008 are submitted and approved.

1. This inspection shall be conducted with a government witness. Refer to section 3.05.J for more details.

2. Any defect or discontinuity found that does not meet the acceptance criteria defined in section 3.05.I and Tables 3A and 3B must be repaired by the contractor.

a. Contractor must first notify the COR and await approval to begin any repairs.

i. Include in the correspondence the extent of defect excavation prior to repair welding.

b. If excavation is required to properly repair a defect, contractor must use UT in accordance with section 3.05.F to ensure the defect is entirely removed.

c. Contractor shall ensure repairs do not reduce the base metal below the design thickness.

d. After repairing the defect contractor shall refinish repaired regions to meet the requirements in section 4.07.

e. After repairs are complete, contractor must repeat NDT on components to ensure all defects have been repaired and no new defects are present.

3. As per RSN 009, contractor shall provide a report of results from the final NDT in accordance with section 3.05.H.

4. All inspections and repairs shall be done at the expense of the contractor.

F. Perform trial assembly on runner and runner cone (if applicable) prior to shipment to Government to ensure there is a smooth transition between the crown and nose cone.

4.06 WELDING

A. Perform welding by the electric-arc method by a process that excludes the atmosphere from the molten metal, and where practicable, by automatic machines.

B. All welding work shall be done in accordance with AWS D1.1 and D1.6 where applicable.

C. Welding qualifications

1. Welding operators and procedures must be in accordance with Section IX of ASME BPVC.

D. Contractor shall begin the assembly process with tack welding the turbine runner components after submittal and approval of RSN 001 to 005.

E. Contractor must submit RSN 006 and receive approval before continuing runner assembly welding.

F. Machined surfaces of parts affected by welding shall be machined to final dimensions after welding is complete.

1. In addition, grind and fair weld passes smooth to the specified surface finish as per section

4.07.

G. Design and fabricate welded parts subject to stress from hydraulic pressure and other principal stress-carrying parts in accordance with Part UW of ASME BPVC-VIII, with the following exceptions:

1. Localized stress-relieving is not permitted for shop-welded parts.

2. Where required under ASME BPVC-VIII or under this solicitation, welded joints inspected by a non-destructive method approved by the Government.

H. Contractor shall perform NDT on welds and heat affected zones in accordance with section 3.05.

1. Inspections shall be performed at the following intervals:

a. After fillet welding and initial arc gouging weld ends.

b. After bucket end welding is complete.

c. After welding and contouring are complete.

2. Any defect or discontinuity found that does not meet the acceptance criteria defined in…